Fiatallis Service Manual FW60 FW80 Wheel Loaders (76589732) - PDF DOWNLOAD

----.-. ....... .,.....

FIATALLIS®

WHEEL LOADERS SERVICE MANUAL

FW60 SIN 300 55-UP

FW80 SIN 302 57-UP

76589732 ISSUE 1

76589732

IReprinted I

AVOID ACCIDENTS Most accidents, whether they OCCur In Industry, on the farm, at home or on the highway, are caused by the failure of some individual to follow simple and fundamental safety rules or precautions. For this reason MOST ACCIDENTS CAN BE PREVENTED by recognizlng the real cause and doing something about it bators the accident occurs.

Regardless of the care used in the design and construction of any type of eqUipment there are conditions that cannot be completely safeguarded against without Interfering with reasonable accessibility and effiCient operation.

A carelul operator is the best insurance against an accident.

The complete observance of ono simple rule would prevent many thousand serious injuries each year.

That rule is:

Never attempt to clean, oil or adjust a machine while it is in motion.

WARNING On machines having hydraulically. mechanically, andror cable controlled equipment (such as shovels, loaders, dozers, scrapers, etc.) be certain the equipment is lowered to the ground before servicing. adjusting andror repairing. If It is necessary to have the hydraulically, mechanlcally, andror cable controlled equipment pertially or fully raised to gain access to certain items, be sure the equipment Is suitably supported by means other than the hydraulic lift cylinders, cable andror mechanical devices used for controlling the equIpment

CAUFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

COPYRIGHT BY FIATAllfS

• All rights reserved. Reproduction of text and Illustrations In whole or In part, is strictly prohibited.

TABLE OF CONTENTS FW60, FW80 WHEEL LOADERS Group ~O-Servicing material, sealing kits, lubricants Group 01-Engine Group 08-Fuellines Group 20-Frame Group 22-Hydrostatic drive Group 23-Front axle Group 24-Brakes Group 26-Rear Axle Group 27-Steering Group 33-Electrical system Group 34-Cab Group 36-Hydraulic system Group 41-Cab heating Please note; Model references of '220' is the 'FW60' and '420' is the 'FW80'.

Controls

perator compartment 220 1320 1420 (Typ 300 55/301 56 1302 57)

~e=:"compartment 220 1320 142~~Y~~55/301 56/302 57) Roof

41

Lever - steering wheel angle and height adjustment

1

Sun visor

42

Steering wheel

2 3 4

Roof fixture for sun visor

43

Fuse box

Windscreen fixture for sun visor

44

5 6 7

Steering ootumn combination control lever - indicators, fron!

Operator compartmenl1ype label

wiper with intermittent wipe, front washer, horn, headlight

Interior Ught

flasher, main beam/dipped beam

Roof hatch lock

45

Brake fluid tank

Rear wiper

46

Washer fluid tank - windscreen and rear window washer

Front instrument panel

system

8

notuseci

47

Inching/service brake pedal

9

not used

48

Accelerator pedal

10

not used

49

Comrollever -loader unit (raising -lowering - tilting in -

11

Rocker switch - rear wiper with washer switch

dumping OUI)

12

Rocker switch - bounce control (SO)

50

13

Rocker switch -lights

51

14

Switch (red) - steering synchronisation

Pushbutton - differential lock Comrollever with lock - implements and quickhitch facility (3rd control circuit)

15

Rocker switch - steering (SO)

52

Look for loader unit and implements

16

Rocker switch - rotating beacon (SO)

53

Cornrollever console

17

Rocker switch - working light

54

Lever - parking brake Operator seat

18

Rooker switch - hazard warning light

19

Telltale (green) - four wheel steering

55

Height adjustment

20

Telltale (green) - front axle steering

56

Handle - horizontal adjustment of complete seat

21 22

Telltale (red) - generatorJbattery monitoring

57

Lever - weight setting

Telltale (red) - engine oil pressure

58

Handle - horizontal adjustment of upper part of

23

noiused

59

Lever - backrest adjustment

24 25 26

Telltale (red) - parking brake

60

Seat belt

Telltale (yellow) - brake pad wear

61

Armrest

Telltale (red) - hydraulic reflux filter

62

Twist knob - arm rest angle

27 28

Telltale (yellow) - air filter

63

Operator seat

29 30

Telltale (green)- indicators

64

Storage area - operation manual

Telltale (yellow) - cold starter

65

Toolbox

(green) - dilferentiallook

66

Storage area/emergency

32 33 34 35

Ternperature gauge - engine and cooling oil

67

Preheating start switch

Temperature gauge - hydraulio oil

68

Rotary switch - 3 level heater blower

Speedometer with hour metar (high speed SO)

69

Rotary switch - heater blower temperature regulation

Hour meter

70

Rotary switch - fresh airfrecirculated air

36

Voltmeter - Satlery

71

Dummy cover - radio (SO)

37

Fuellevet indicator

72

Cigarette lighter/socket

Front controlS

73

Rotary switch - vehicle heater (SO)

Side and rear controls

Telltale (blue) - main beam

38 39

Front wiper

74

Drink holder

Air nozzle - windscreen

75

Door locks

40

Steering column oontrollever - hydrostatic drive and driving direction 302s0001.fm4

pecifications wheel loader 220 (model 300 55) Frame

Power train

Sturdy U-section frame, rubber-mounted operator cab, rubber-mounted engine

Hydrostatic power train with drive aulomanc and permanent four wheel drive.

Engine

Hydraulic pump:

IDirect flanged to !he engine, !Model: MVG28DA

Product:

Deutz diese! engine

Model:

Cylinder arrangement:

@

Displaoement:

128 cm3trev maximum

KHD F3L 1011 ' P

Max. service pressure

1440 bar

In line

(Ap): Starting RPMs;

I1.150 rpm, 50 bar HP

Droop:

2.300 t l00 rpm, 260 bar HP

Nominal bore and stroke:

Boost pump:

DisplacementS.l cm3frev Charging pressure:25 bar, 1,500 rpm

Compression ratio:

Control:

Speecl-sensitive hydraulic feed volume adjustment with pressure out·off

Number of cylinders:

Oulput:

kW [ 39.4 HP, 2,500 rpm (DIN ISO 3046)

_D_riv_e_d_ireo1 _ io_"_:_ _ _ Electrohydraul_c.COO i __tr_OI_ _ _ _ __ _

Rated engine torque:

Inching:

Max. engine torque: Fuel consumption:

±SO

gfKWh minimum with single pumps

Fuel injection syste

controlled via master

Hydraulic motor:

Attached to Ihe rear axle transler gearbox

Variable displacement motor

Model A6VM80DAl63

Injection pressure:

250 bar

Firing order:

1-2 - 3

17.8 cm3/rev minimum

Star! of delivery:

14" before top dead centre

aocm3Jrev maximum

Starting aid:

Healer plug (preheating time 1 minule)

Oil lubrication of engine max. lateral inclination left/right 58158 % is ensured up to the fo!- max. inclination upwardJdownward: 84147 % lowing inermd positions: Observe tilting fimi! of the machinel ------~

Oil pressure:

minimum, 2,500 rpm

Inlet 0.30 mm Oulle! 0.5 mm engine at cold temperature respectively a. Minimum time for engine to coo! down '" 30 millU!l!S; oil temperature be· low 80" C

Control: Drive speed:

Traction force:

ISpeed-related controller I1st position fol1li'afd • reverseD· 5 !cpo 2nd position Iforward - reverseD · 20 !cph

I

Specifications wheel loader 220 (model 300 55) Axles

Steering

Front axle

Fully hydraulic four wheel steering wfth emergency steering fea1Ures.

model PLT steering and drive axle (portal-type); gear reductions in

the wheel hubs; with central brake disc at axle input and 100% differentia! lock; rigid screw connection wiff1 frame.

Track wid!h:

1375mm

Camber:

1"

King-pin ["cHnation:

10'

Rear axle model PLT sleering and drive axles (portal-type) wiff1 oscillation; gear retiucllons in the wheel hubs; disc brake (high speed version) and multidisc dtfferentiallock.; flange-mounted hydrostatic motor with axle transfer gearbox.

Oscillation:

i±9°

Track width:

11.375 mm

Camber.

1·

King-pin incHnation:

10·

Steering modes:

Four wheel steering

Components:

Hand pump; hydraulic pump; 1 steering ram per axle; safety valves; solenoid valve for steeI ring synchronisation, priority valve.

Hand pump:

Eaton 5erYostal Dispiacemenl120 cm 3trev Service pressure172 bar

Hydraullc pump:

Gear pump (priority valve) Displacement28 cm3trev

Maximum sleering angle:

45'

Work hydraulics Hydraulic pump

Gear pump Dispiacement28 cm3trev 70 Itt/min maximum Service pressure175 bar

Axle load

Conlrol valve:

Nordhydrauiik 3-fold pilot control

Front and rear 3,750 kg maximum

Secondary safety:

TIttram

--

..

rod side200 bar bottom side120 bar

Brakes Pilot control Service brake:

Disc brake al front axle input

Components:

Masler brake cylinder, pressure difference valve, brake calliper, differential lock (inching valve on power train)

Pilot control pump = Displacement S,1 cWlrev boosl pump of hydraulic pump Charging pressure25 bar, 1,500 rpm

8takefluid:

Isee Lubricants and engine/machine fluids on

Pilot valve (Joystick):

Four-way lever - centro! of lift and tilt rams

Pilot centrol unit (sim-

Control of lock ram and implements

[page A-24

0

Additional brake force via the hydrostatic drive!

pie): Ball-type slop cock:

Parking brake:

I~echanical disc brake installed on rear axle,

Brake disc outer 0:

10270mm

Lock against unitrtentional actuation (for longhau! travel)

acting to both axles via propshafl

3OOs!XXl2.fm4

Specifications wheel loader 220 (model 300 55) Loader unit

Weights

Bucket capacity

heaped as per SAEO,58 m3

Kerb weighl

Tipping load

2.800 kg

Gross weight rating

Payload

1.400 kg (tipping load x 0.5)

Front axle weight rating 3.750 kg

lJit load at max, height

2,365 kg

Rear axle weighl rating

3.750 kg

Maximum authorized load for towing facility

5.500 kg

Bucket width

~~--~-~~------~--

14,600 kg (daN)'

Ts.sooig

• Values indicated are valid for machines equipped with standard bucket.

Noise levels Breakout force

Payload on pallet fo

[Wd8{A)

Noise level in the cab

i79 dBtA)

(;l Noise measurement in accordance with EC guidelines 84/532

L.!.J EEC, 79{113 EEC and 86!662 EEC.

Tipping load (DIN 24 094) Payload

Sound power level

Factor 125 Factor 1,67

Vibration

Movable payload in

transport position Fador 125 2230 kg

Effective acceleration value for the upper

extremities of the;;body;;;:I~5;~---------1

Electrical system Alternator Starter Battery

Socket

Tyres Tyre size

<2,5 mls'l

Wheal rims sel

l00mm

tOOmm 100mm

OOmm • Increase lyre pressure by 0'.5 bar during pallet forks operation!

Specifications wheel loader 220 (model 300 55) capacities

Tightening torques

Fuel tank

90 Itr.

Hydraulic oil tank

511tr.

Dieselengille (engine oil)

10.SItr.

Gearbox and rear axle differential

Itr.

Front axle ------------~----Front and rear axle final 1.25 Itr. drives each

Brake system

0.51tr.

Windsc!een washing system Rear washing system

2.SItr.

Diesel fuel as per DIN 51601 for oil changes, incl. filter HD-C 15W40 (MIL-L-2104C) (API CDJCEK)F4; CCMC 04)

PM

us M6

SAE 90, Gosoa MlL-L-2105S; API- GL4

M8 Ml0

SAE 90, Gosoa .

MIL-L-2105B; API· GU

Cleaning agent

sa

M14

137

196

M16

211

300

358

M18

290

412

147 235

M20

518

490 696

M22

785 1000

1200

M24

a. Abbreviation for lubricanlS (Hauptverba.nd dtr Deut<;chen Bauinduslrie e.V. - Gelman construction engineering associlIIion)

Dimensions

M12

942

M27

1480

1774

Mao

2010

2400

• These values are valid for SCftIW$ with untreated, norHubric:atec:I surS.OOOmm

faces.

2.645mm

Specific tightening torques

1.750mm

Wheel nut

Outer track cilded a. with standard bucket b. with standan:l tytes c. with FOPS sc.neen plus 295 mm d. with 4 wheel steering

3O(}:20Nm

casue nut -1Iack rod (steering ram)

200Nm

Axle mounting

380Nm

Specifications wheel loaders 320/420 (models 301 56/302 57) Frame Sturdy U-section frame, rubber-mounted operator cab, rubber-mounted engine

Engine 320 (301 56)

Engine 420 (302 57)

(DIN ISO 3046) Rated engine torque:

Max. engine torque:

1,600 - 2,000 rpm

--------~-----------

Fuel consumption: Fuel injection system:

iDirect fuel injection with single pumps

Injection pressure:

1250 bar

Firing order:

11-3-4-2

Start of delivery: Starting aid:

I

, 14· before top dead centre

IHeater plug (preheating time 1 minute) I I

Oil lubrication of engine max. lateral inclination !eftlright 5815S % is ensured up to the 101- max. inclination upwardldownward: 84147 % lowing inclined positions: I' ,Observe lilting limit of the mechine!

Oil pressure:

Varve tip cJearance$:

Oil lubrication of engine is ensured up to the fol- max. iodination upwardldownward: 84141 % lowing incHned positions: I Observe tilting limit of the machine!

I ------Oil pressure:

i Inlet 0,30 mm

Inlet 0.30 mm OUlfet 0.5 mm engine at cold temperature respeclively

a. Minimum time for engine to cool down 0: 30 minutes; oil tellIpemlUre below 80·C

t minute)

2,500 rpm

- -'------ --

: Outlet 0,5 mm

Iengine at cold temperature respectively a. Minimum time for engine to cool down =30 milllltes; oil temperatme below 8(F C

-ications wheel loaders 320/420 (models 301 56/302 57) Power train

Rear axle

Hydrostatic power train with drive automatic and permanent four wheel drive. High speed gearbox available as an option

model PLT steering and drive axles (portal-type) with oscillation; gear reductions in the wheel hubs; multidisc differential lock; high speed version with disc brake; flange-mounted hydrostatic motor wrth axle transfer gearbox.

Hydraulic pump:

- ----Displacement:

±9"

Direct flanged to the engine.

Mode!: MVG40DA

Track:

1,440mm

Gamber: King-pin inclination:

Max. service t)l'es~>ure (Ap): Starting APMs:

Axle load

Droop:

Front and rear 3,750 kg maximum

Boost pump:

Brakes Control:

lume adjust-

Inching:

Hydraulic inching valve, cootrof1ed via: master brake cylinder

Hydraulic motor:

Attached to the rear axle transfer gearbox

Variable cflSplacement motor

IModel: ASVM107uA/63

Ision: also on rear axle)

Components:

1Master brake cylinder, pressure difference

Capacity:

27.1 cm3lrev minimum 107 cm3/revrnaximum

Control:

Speed-related controller

Drive speed:

1st position forward reverseo - 5 kph I2nd posilion .forward - reverseo • 20 kIlh

I

«

High speed (opticn) via: ,1st position the mechanical stand- forward - reverseO • 9,5 kph 2nd position still transfer gearbox forward - reverseO - 39 kph Traction force:

[valve, brake caliper, differential lock (inching valve on power train)

----------------------

I

4O.4kN

Axles Front axle mode! PLT steering and drive axle (portafolype); gear reductions in the wheel hubs; wrth central brake disc at axle input and 100% aifferentlal klck; rigid scraw connection with frame.

IDisc brake at front axle input (high speed ver-

Service brake: Drive direction:

Brakeffuid:

o

see Lubricents and engine/machine fluids On IpageA-24 I

Additional brake force via: the hydrostatic drive!

Parking brake:

Mechanical disc brake installed on front axle, acting to both axles via: propshaft

Brake disc outer 0:

0270mm

....:---- --

cifications wheel loaders 320/420 (models 301 56/302 57) Steering

Loader unit 320

Fully hydraulic four wheel steering with emergency steering features.

Bucket capacity

.heaped as per SAEO.7 m3

IFour wheel steering

Tipping load

2,970 kg

tn 2nd speed of high speed version, front axle steering only!

--~----------~--

Steeling modes:

------------+--~~~---------------

Components:

Hand pump; hydraulic pump; 1 steering ram per axle; safety valves; solenoid vatve for steering synchronisation, priority valve.

Hand pump:

Eaton servostat Disp!acement120 cmslrev Service pressure172 bar

-------Hydraulic pump:

Payload

1,485 kg (tipping load x 0.5)

Lilt load at max. height

2,910 kg ~-----------

Tipping load (DIN 24 (94)

2,375 kg

~-------------

ump (priority valve) ems/rev

Maximum steering

angle:

Work hydraulics Hydraulic pump

pump I,Gear Dispiacement28 emsirev

Payload

70 !trimin maximum Service pressure210 bar

Movable payload in transport position Factor 1.25 2,450 kg

Control valve:

Nortihydraufik 3-1old piio! control

Secondary safety:

Tilt ram

rod side240 bar bottom side120 bar

Factor 1.25 1,900 kg Factor 1.67 1,420 kg

Loader unit 420 Bucket capacity

Pilot control

TIPping load

I

PHot control pump = DisplacementS,4 ems/rev boost pump 01 hydraulic pump Charging pressure25 bar, 1,500

Pilot vaWe (Joystick):

IFour-way lever - control of lift and Uti rams

Pilot control unit (simple):

Control of lock ram and implements

Bali-type stop cock:

Lock against unintentional actuation (for longhaul travel)

Payload

x 0.5)

Lilt load at max. height Bucket width Dumping height Dumping reach Scraping depth

Payload

Factor Factor

Movabfe payload in transport .position Factor 1.25

cifications wheel loaders 320/420 (models 301 56/302 57) Weights Kerb weight 320 420

Gross weight rating

Battery

IE. g. for cigarette lighter; 15 A maximum

Socket

Front axle weight rating Rear axle weight rating Maximum authorized

Tyres 320 Tyre size

, Tyre pressure (bar)'1 front

rear

5,500 kg

• Values indicated are valid for machines equipped with standard bucket.

Wheel rims Wheel rim

Noise levels 12.5-18 MPT T632-1 0 PR

67mm

12.5-18 MPT E91 -2 PR

67mm

1Sound power level

!

98dB(A) 97 dB(A)

Noise level in the cab

75 dB(A}

67mm 67mm 61mm

• increase tyre pressure by 0.5 bar during pallet forks operation!

Vibration Effec!lve acceleration

Tyres 420 iyre pressure (bar)'

front

Wheel rims

rear

Wheel rim

I

off,i Whee! set

11 x

2.5

2.0

12.5-18 MPT 3O-810PR I 2..25

2.0

11 x18

67mm

12.5-18 MPTTG32-10 PR

2.5

2.0

11>: 18

67mm

12.5-18 MPT E91-2-·8 PR

2.5

12.5-18 Super TL-l0 PR

2..25

12.5-20 MPT E5810 PR

2.0

15.5-55 R18 SPPG 7 14PR

3.25

335180 R18 XM27 132G

2.25

335180 R20 SPT9136B

2.5

365170 Ri8 SPT9 1358

2.75

12.5-18 MPT NB38 10PR

Noise measurement in accordance with EC guidelines 841532

EEC, 791113 EEe and 86/662 EEe.

67mm

365170R18 S

Tyre size

CD

I

67mm mm 2.25

67mm

• Increase tyre pressure by 0.5 bar during pallet forks operation!

320 420

<2.5 mfsZ

Specifications wheel loaders 320/420 (models 301 56/302 5 Capacities

Tightening torques dimensions

M5

Gearbox and rear axle differentia!

M10 M12 M14

1.116 1.118

M24

Dimensions OveraIllengthi

• These values are vatid for screws wiIh untreated, I1OI1-Iubricate surfaces.

Specific tightening torques Wheel nut 320 420 castle nut • track rod (steering ram)

Frontlrear track width Wheelbase

OUter 1lJming radius<' OUter 1rack circlet a. with S1anclard bucket a.lld S1anclard tyres i>. with FOPS screen plus 295 _ c. with 4 wheel steering

320 and 420

Axle mounting

Maintenance plan 220 (model 300 55) vaUd from serial no. 300 55 0001 and 320 (model 301 56) valid up to serial no. 301 560129

,

L_ __-,

Work description For 5C!'1CC and mamtelWlce work on !he diesel engute/mlplement. we also refer 10 the opera-I Main_ ...,. , lion and maintenance manual of !he engineI'''''l'lemenl manuflill:tllr¢t. ! daily

Maintenance planllservice hours

,

Function8l ehedr ( ? ): Che.:k the flU>Clion of the folJov.'itlg assemblies/components. Rerufy if ~ • $er\'ice and parking bral:e

Cbeck pipe and flexible lint$. as well as screw connections of the fd!lo'.>ing poncntS for tightness. leakage and cha.!l:ngs. Rerufy if n=swy:

:._ :.. _A:!:i~ line (air CUter -~)

1;

Work If) be ~wt (m(;e oo.ty Wt the: fu,U 100 ~ce boI:n. Tha mAi~ ~ ~oo wort:row 'be am~ out by & c!cakrm~.orlWlo'p fur ~ dai:ns 'In be ~

... ~_>f1"'tb<:!inIII\OO..,.,;..,....,.(2odi~_be"""""'_""._ •• _~ft>: .._cl>ims"'b<_Iedgal.

l:

_

),

~5Jwl="_b!'!b:tclIt:ik"''''''_-''''''''''''''''''''''''l''2

"S,

~t .. """"",,· ... -_ -·_ .. """"""Y"'-"'-""'~· _ . ~_b<lt"""l'4SOO

......... 11OO _ _.

Annex

18

~ 19

/17

8

Lubrication plan

25 tl:A .:;ooS$~ to· jjm4

26

MQ~13OOIi5

valid from lIertall1o. 300 55 0001

A·23

AIIlIC~

17

18

16

Lubrication plan 320 Model 301 ee valid from 8erllli no. 301 ee 0001 up to 3001 ee 129 !JAlO. J6/lQ;l'lBfJ.MbJl;.6J/ra4

A·2,S

f.O ,...

\

Maintenance plan 220 (300 55) from serial no. 300 55 0001 Maintenance plan 320 (301 56) up to serial no. 301 56 0129 Lubricants and engine/machine fluids Component/application

SAE grade i Enginelmachine fluid II Specification

Diesel engine

Engine oirZ

Season! temperature

I SAE 10W;

! Capacities1

below·SoC

I E0103

ISAE 2OW20; E0203

-10" upto+10"C

!SAE30;

S"C up to 3O"C

!, E0303

10.Sltr.

i HD·C 10W-40; E01040B3

year-round

HD-C 15W-40;

EOl540Ss Rear axle differential and gearbox

Gearbox oif4

SAE90 G0903

Rear axle final drives

I Gearbox oil4

SAE90

I

Go903

Fronl axle differential

year-round I

year-round

Front axle final drives Hydraufic oil tank

Grease nipples

5.0Itr.

Ir

1.25 Itr. each 4.25Itr. 1.25 Itr. each

Hydraulic oij:ATF SIO SIO

ATF66M(ATP) AVIA Synlofluid 46 PANOLIN HLP Synth 46

year-round

about 57 Itr.

Muttipurpose grease

lithium-saponified brandname grease MPG-A3

year-round

as required

Battery terminals

IAcid-proof grease

SP-B3

year-round

as required

Mounting of pins, shafts, etc.

Special grease

Optimoly paste orAQ

year-round

as required

Fuel tank

Diesel fuel

DIN 51601 , min 45 Cetan,

90.0Itr.

Brake system

Brake fluid

SAEJ 1703 DOT 3,4, SP-A3

0.5 Itr.

i

1, The capacities indicated are approximative values; the oil level check alone is relevant for the correct oil level 2. MIL-L-2104C; API-CDfCEJCF4; CCMC-D4 3. Abbrevialion for lubricants (Hauplverband der Deulschen Bauindustrje e.V. • German construction engineering association) 4. MIL-L-2105B; API · Gl4 5. 250 gr tubeOrder no.: 000441 32 10

Notes:

Delivery inspection - valid for all vehicles

Check the following material. Refill if necessary: • Engine oil • Hydraulic oil • Brake fluid • Gearbox oil in the front and rear axle differential/gearbox • Gearbox oil in the front and rear planetary drives, left and right Check screWS and nuts or screw connections for tightness on the following assemblies/components.

Retighten if necessary: • Engine and engine bearing • • • •

10, 11 6, 9

4 20,22 24

Steering system Hydraulic system Axle mounting. axle suspension Fastening screws of the propshafts

• Micel nuts Check fuel filter cartridge. Replace if necessary Clean dust valve on air filter housing V -belt: Check condition and pretension. Retighten or replace if necessary

13 18 17

Tyre check (air pressnre)

Lubrication service; Lubricate tbe following assemblies/components: • •

Rear axle osc:il1ating bearing Front and rear axle final drive beating, left and right

•

Loader unit: - Lift frame bearing - Lift ram bearing - Tilt lever bearing - Tilt rod bearing - Tilt ram bearing - Quickhitch frame (lock pins, lift frame bearing)

27

26 2 2

2 2 2 1

Delivery inspection - valid for all vehicles

of the followlllg assemblies/components. Rectify if necessary: •

Service and parking brake

• • •

Steering system Hydraulic system Hydrostatic drive/gearshift

•

Light system

•

Electrical

(heater blower, horn, windscreen

etc.)

Leakage check: Check pipe and flexible lines, as well as screw connections of the following assemblies/components for rightness, leakage and chafings. Rectify if necessary:

• •

Air intake line (air filter - engine) Engine lubrication (engine - filter)

• •

Fuel feed lines Cooling system

• •

Brake system Steering system

•

Hydraulic system

Leakage check of the following hydraulic rams. Rectify if necessary:

•

Front and rear axle steering rams

•

Loader unit:

- Liftram - Tiltram - Control ram on quickhitch frame 1. For service and maintenance work on the diesel engine we also refer to the operation and maintenance manual of the engine manufacturer.

2. Reference number for the lubrication plan

Maintenance plan 320 (model 301 56) valid from serial no. 301 560130 and 420 (model 30257) valid from serial no. 3112 570170

1: 2: 3: 4:

s:

Worl::m~wr:i¢d~~~a!ttt::bt6ml00~Mtw,'l'hd·_~acdi~~~~~oo:by ' ~Ol'~~~!Ot<q.-nmtY~Wk.~ ~_ _ .".~_,*""'5<s!600_""""f.!I>d_j""",,,,..-,,,,,by._,,,_~f"'_""""l''''''''''''''_lodi«L ~5lI<:r-""""""'by"",-"",-~-""",,-""'Y (Z"",_",l200_MIm.

~l'n!~Pd4u.st~00:c." i~~b-t~tuclt:liA~~1DllI't~> ~~"",...."4500_,"",,,.

Annex

17

18

16

Lubrication plan 320/420 MocI4Il 301 sa I 302 87

valid from

BA3<ll5IJIl/lr;:..-;..-;-:.-:,;;,;--------------------

1m'" no. 301 68 0130

and 302 57 0110 A·2S

Maintenance plan 320 (301 56) from serial no. 301 56 0130 Maintenance Ian 420 302 5 from serial no. 302 570170 Lubricants and engine/machine fluids Component!

I SAE grade Engine/machine fluid I application

Diesel engine

i Specification

Season! temperature

Capacities 1

Englneol[2

10.5 Jtr

i HD-C 10W-4n;

IE01040eJ Rear axle differential and gearbox

I Gearbox oi~

Rear axle final drives

Gearbox oirl

SAE90

year-round

year-round

5.0 Itr.

year-round

1.25 ilL each

Gogo!!

Front axle differential

425ltr.

125 itt. each

Front axle final drives Hydraulic oil tank

Hydrau!ic oil:ATF

510 SIO Grease nipples

Multipurpose grease

Battery terminals

Acid·proof grease

ATF 66 M {ATF3) AVIA Syntofluid 46 PANOLIN HLP Synth 46

year-round

about 57 11r.

lithium-saponified bnandname grease MPG-A3

year-round

as required

year-round

as required

year-round

Mounting of pins, shafts, etc.

Special grease

Fuel tank

: Diesel fuel

DIN 51601, min 45 Catan,

Brake system

Brake lluid

SAEJ 1703 DOT 3-4, SP·A3

1. The capacities indicated are approximative values; the oil level check alone is relevant for the correct oil level 2. MIL-L-2104C; APi-CDfCElCF4; CCMC-D4 3. Abbreviation for lubricants (Hauptveroand der Deutschen Bauindusirie e.V. • German construction engineering asscciaoon) 4. MIL-L·2105B; API· GL4 5.250 grfubeOrder no.: 000 4413210

Notes:

Maintenance plan 420 (model 302 57) valid up to serial no. 30257 0169 'Noli< description For ~ and maintenan<:e wcrk on tire diesel cnglndimpl_, we IlOO refer !l) the operodon and mai","""""" ~ of !he engineIlmpk_nt =tXt"""'_

l'

Wuri:tobt:eoL"ricdoot~oo.tyll.fUJt=am tOOW"'i"U~ "t'hd~m$'~OO-wuH~bt~O\:Itboya~<x~~for-~~l»bo::~

~

_""'~

,:

~f.,,'=#j""''''''''by''''-'''''~l'"'''il-'''-'''''''Y 12_",'200"",*_ ~1I··""""",""'_<006"-~_"_ _d>e _ _ ~, __

""

_ _ ""fiM600"",* _ _ i"""""')"""""eam.d_1Iy._w_....,.,..",*"........",<w...., .. oclarow~

~_"'''''''l'4S00

..

Anne'X

17

18

16

1'3

1'0

1'2

lubrication plan 420 Model30251

valid from ..rIel no. 302 61 0IIII'l up 10 ••rlal no. 302 61 0169 OMltnn -•

••• J!.fm4

1.·25

Maintenance plan 420 (302 57) up to serial no. 301 560169 lubricants and engine/machine fluids Component! i Engine/machine fluid I SAE grade application

Diesel engine

i

, Specification

Engine oif!

I Season!

itemperature

SAE 10W;

Capacities1

below -5OC

10.SItr.

E0103 SAE 2OW20; E0203

-100 up to +10·C

SAE30;

5°C up to 3O"C

E0303 HD-C 1OW-40;

year-round

E01040Ss HD-C 15W-40;

E01540S3 Rear axle differential and gearbox

Gearbox oil"

SAE90

year-round

5.0 Itr.

year-round

1.25 Itr. each

G0903 Rear axle fina! drives

SAE90

Goooa

Front axle differential Front axle final drives Hydraulic oil tank

Hydraulic oi!:ATf BIO BIO

Grease nipples

Multipurpose grease

ATf 66 M(ATFs) AVIA Syntofluid 4S PANOUN HLP Synth 46

4,251tr.

i

1.25 Itr. each year-round

about 571tr.

year-round

as required

I

year-round

as required

I

year-round

as required

lithium-saponified bran(\.

name grease ! MPG-A3 Battery terminals

Acid-proof grease

I SP-sS

Mounting of pins, shafts, etc.

Special grease

Optimoty paste "TA.s

Fuel tank

~

! DIN 51 601 , min 45 Celan,

1. The capacities indicated are approximative values; the oil level check alone is relevant for the correct oil level 2. MIL-L-2104C; API-CCICO or CDISE or COISF , 3. Abbreviation for lubricants (Hauptverband dar Deutschen Bauinduslrie e.V. - German construction engineering association) 4. MIL-L-2105B; API - GL4 5. 250 gr tubeOrder no.: 000441 32 10

90.0 Itr.

Engine

00 Oeutz diesel engine single pumps

00.1 Specifications firing order:

00.1.1 Overview of engine 220 (300 55)

Start of deHl/ery.

14" before top dead centre

Dew diesel engine

Starting aid:

Iheater plug (preheating time 1 min

KHD F3L 1011 'P'

Max. lateral indination !aft/right: 58/58 % Oil lubrication oj engine is ensured up Max. inclination upward/downward: 84147 % to the foliowing incli- iObserve tilting limit of the ned position: imachine!

!

I

minimum, 2500 rpm

Oil pressure:

I Inlet 0.3 mm

Compression ratio:

Output

Valve tip clearance1:

!18.5

129 kW /39.4 HP, 2500 rpm

0utlet: 0.5 mm lEngine at cold temperature in each case

I(DlNIISO 3048)

Rated engine torque: 1110 Nm

00.1.3 Overview of engine 420 (302 57)

Max. engine torque: 1120 Nm, 1800 rpm t fuel injection with single pumps

Product

IDew diesel engine

Mode!:

:KHD BF4L 1011 FT"KRS"

Cylinder arrangement: lin line Number 01 cylinders: 1 4, oil-to-air cooled

12732 cc i Max. lateral inclination tetllright 58158 % Oil lubrication of engine is ensured up Max. inclination upward/downward: 84147 % to the following incH- Observe tilting limit of the ned positions: machine!

Oil pressure:

2.3 bar minimum. 2500 rpm

Va!vetip clearance 1:

Inlet 0.3 mm Outiet 0.5 mm Engine at cold temperature in each case

injection with single pumps firing order.

00.1.2 Overview of engine 320 (301 56) Product

iDeutz diesel engine

Model:

KHD F4L 1011 F "KFW

kW! 53 HP, 2500 rpm

SH 302 57 - E<fitiOn Xt.O· 302s0100.fm4· geanCertZ!l.02.9€, 16;14

Start of delivery:

3-4-2

• before top dead centre

Starting aid:

Heater plug {preheating time 1

onlubrication of engine is ensured up to the following inclined posilions:

Max. latera! inclination left/right 58158 % Max. inclination upward/downward: 84147 % Observe tilting limit of the machine!

Oil pressure:

2.3 bar minimum, 2500 rpm Inlet: 0.3 mrn Outlet 0.5 mm Engine at cold temperature in each case

01-1

Engine

00.1.4 Engine serial number and rating plate

00.1.6 Direction of rotation

The engine serial number is stamped on the rating plate and on one side 01 the crankcase.

In addition to the engine serial number, the rating plate also provides information on the engine type.

As viewed onto the flywheel, the crankshaft rotates anticiockwise,

SF 4 L1011 I TIE

H Turbocharged F H High-speed four-stroke engine 4 H Number of cylinders L H Air cooled 10 H Model series 11 H Piston stroke in c:m

00.1.7 Firing order •

F2L 1011: 1 • 2

•

F3L 1011: 1 - 2 • 3

•

F4l 1011: 1 - 3 • 4 - 2

B

T E Fig,l:

H Ughtly turbocharged H External cooling system

Type designation Oeutz engine

Since 1989, engine power outputs on rating plates have been represented in a new form. This new form is based on ECE Regu!ation 881 195 in conjunction with ECE-R24103 and ISO 1885 for automotive engines. It differentiates between three power ratings: •

G-Rating: The engine is equipped wtth a controlled blower that does not operate at the time when the power is taken off.

•

S-Rating: The engine is equipped with an uncontrolled blower.

•

W·Rating: The maximum net brake power avai!able at flywheel when an additional cooler is mounted.

00.1.8 Permissible inclinations The Fl 1011 engines in the standard configuration allow inclinations of 30 degrees to all sides - see Specifications on page 01-1.

00.1.9 Cold start Cold-starting ability is ensured as follows: •

To -10 ·C without starting aid

•

To -20 'C with cold-starting aid

•

To -30 'c with special ether cold-starting equipment

Reliable engine operation is ensured under extreme temperature conditions.

/4s the engines are equipped with an uncontrolled blower, the S-rating is applicable.

00.1.5 Numbering of cylinders The numbering of cylinders begins at flywheel end.

Without starting aid 12V rger battery 12 V and electric heating coil larger battery, heating coil and larger starter motor 24V, 4kW

·20·C

·SO"C

for use at outside temperatures of Fig . S:

Cold-starting ability

00.1.10 Bolted joints Tightening specifications All bolted joints of the engines must be tightened to specified torques and angle degrees. The values applicable to the individual botts are given in the Speclfication Data.

Fig. 2:

01-2

Numbering of cylil1ders

SH 302 57 - Edltion X1 ,0 • 302s0100.fm4 • geandert 29,02.96, 15:14

Engine

Tightening

IType

angles

Main bearing_ca.-...:.p-s-------------j--~

Idler puHeyN-baH pulley Idler pulley/toothed belt Injection pump fastening

Me

Oil pump fastening 1

M8x30 M8x45 M6x35Z

Blower carrier

Me

Rocker chamber cover

1st step

Oil intake housing Air intake manifold t Exhaust manifold Injection lines 011 drain plug Injector fastening1

55::!:5

20±2

Injector clamping nut Air intake manifold 3·1101e flange 1

M8x35Z20

Oil filter bracket 1

M8x20

145±5 8.8 8.8

i22±2 122±2

1. rOFlx screws

2. WIth L.OCTf'I'E 3. With NEVER SEIZE PASTE Fig. 4:

Table with tightening specifioations

SH 302 57 _ Editioo Xl.O· 302s0100.fm4 • ge.:!n<le.'t; 29.oz.%, 16:14

01-3

Engine

00.2 Engine construction

For fitting the dry slip-fit liner the cast-in liner must be bored out As is shown in Fig. 6, a shoulder is cut into the liner rim for locating the liner.

00.2.1 Crankcase with integrated cylinder liners Crankcase and cylinder liners form an integrated unit; it is made of ductile cast iron.

00.2.2 Cylinder liners The cylinder liners integrated in the crankcase are open at the top (open-deck type).

Fig. 6:

Slip-fit liner

The liner is then fitted in dry condition (slip fit), with liner rim protruding a little beyond the cylinder head seating surface. This is necessary for proper location of the liner. No reworking of cylinder liner working surfaces is required, as the slip-fit liner is honed to nomina! size.

Fig . 5:

Open-deck type cylinder liners

Thus the coolant is fed down to below the block-type cylinder. This improves the cooling effect in the area of the liner rim and in the cylinder head.

00.2.3 Block-type cylinder head The engines have block-type cylinder heads, made of GG-25, with integrated valve guides and shrink-fit valve seat inserts.

Valves and valve seat inserts

Cylinder repair If a cylinder is damaged, the engine must be removed from the equipment. In-situ repair is not possible. A dry slip-fit liner is inserted into the defective cylinder. This method offers the following advan-

The engines have one iniet and one exhaust valve per cylinder. To reduce oil consumption and hydrocarbon emissions, the valves are provided with valve stem seals.

tages: •

The monobloc crankcase may be reconditioned repeatedly simply by fltling dry liners without changing the standard piston size.

•

individual cylinders can be repaired without having to use different repair size pistons in the engine.

1Valve 2 Valve collet 3 Valve head Fig. 7:

4 Valve stem seal 5 Valve guide 6 Valve spring

Vallie stem seal

Prior to assembly. the valve stem seals 4 must be dipped into oil.

Then slipped over the stem afterwards, a fitting sleeve must be used to protect the sealing lip from getting damaged by the sharp-edged valve collet splines.

014

SH 302 57· Edition X1.0· 302s0100.fm4' geandert: 29-\12.96.15:14

Engine The inlet valves are made ot alloyed chrome-nickel steel, the exhaust valves of silicon-chrome steel. The valve seat inserts are made oj a different material than the cylinder heads because of the high thermal and mechanical stress loads they have to withstand.

They are undercooled in fiquid nitrogen and then shrunk in place to get the necessary interference-fit.

On the naturally aspirated engine version oil fumes from the crankcase breathing system are used lor lubrication to minimise wear 01 valves and valve seat inserts. For this purpose, the block-type cylinder head is provided with a transverse oil bore with the outlet port ending in the intake duct.

In this way, the engine fumes from the crankcase are also routed back into the intake system. On the turbocharged version, the flow from the crankcase breathing system enters upstream the air compressor inlet

Check/acijust the valve clearances at an engine oil temperature of less than eo°c. The specified valve clearance values for Fl 1011 engines are: • Inlet valves = 0.3 mm • Exhaust valves::: 0.5 mm After initial assembly or renewal of cylinder head gasket • •

Inlet valves = 0.4 mm Exhaust valves::: 0.6 mm

A feeler blade of the respective size must just go between rocker

arm tappet and valve stem, with a slight resistance being felt.

If the gap is too large or too narrow for the feeler blade to be jnser~ ted, the valve clearance must be re-adjusted: I!ii.W To adjust the valve clearance, relax locknut 1 with a wrench by 2 to 3 tums.

I!ii.W Adjust the set screw 2 by means of an allen wrench so that the feeler blade can just be slipped in and pulled out with a slight drag, with the locknut having been pulled tight

2--~~

~-----3

r .......IC!'""--.;-.

1

Fig. 8:

Valve sea! lubrication

00.2.4 Maintenance and repair work on block-type cylinder head Valves In order to find out whether a used valve is suitable for re-use, the foliowing measurements need to be taken:

l loclmut 2 Setscrew 3 Rocker arm

On the removed valve:

Diameter 01 valve stem • Width of vaWe seat (contact area)

•

• •

Diameter of valve head Thickness 01 valve head face

On the installed valve:

• •

Valve stem clearance Valve recess (cleananoe between valve head centre and cylinder head sealing surface)

Fig. 9:

Valve clearance

AJways check/adjust the clearances on all vawes!

Specified values and permissible wear tolerances are iisted in the Workshop Manual under 'Specification Data",

Valve clearance Insufficient or excessive valve clearance may result in severe engine damage as it causes mechanical and thermal overload. Valve clearanees must therefore be checked, and adjusted as necessary, at regular imervals {see Workshop Manual).

SIi 3rul57 - Edition )(1,0 • 302s01oo.fm4 • geandoo:: 29.02.96.1 6:1 4

01-5

Engine

Adjusting valve clearance according to the diagram below Irrespective of the number of cylinders installed, the valve clearance is adjusted in two crankshaft positions: •

Fig. 11:

Cylinder head gasket

The different thicknesses of the cylinder head gasket are identified by notches.

A :: not ready for adjustment

• B= ready for adjustment

D

i

3 (t x 1,60mm ' o.os)

f Fig. 10:

Oiagram for vallie clearance adjustfMnt

Crankshaft position 1: Tum crankshaft in direction of engine rotation until both valves of cylinder no. 1 are in overlap (i.e. exhaust valve about to close, inlet valve about to open).

The schematic for valve clearance adjustment shows under crankshaft position 1 which valves can be adjusted.

Crankshaft position 2: Tum crankshaft by another revolution (360°). Now the other valves are ready for adjustment To ease work, put a chalk mark 1 on the valves which have been adjusted.

Lubrication of rocker arms: Lubrication oil from the oil cooling circuit circulates the block-type cylinder head and feeds the rocker arm brackets. Transverse oil bores a!low Ihe oil to flow on to the rocker arm bearings. The oil retums to the sump through the push rod bores in the crankcase.

Fill. 12:

Identification of cylinder head gasket

Measuring piston projection To measure the piston projection you wi!! need a dial gauge and a fIXture: •

Dial gauge

• •

Bridge Two plane-parallel. ground spacer plates

Valve springs No particular direction of installation need be observed for the vaJve springs.

Adjusting the piston crown clearance Selecting the appropriate cylinder head gasket

Fill. 13:

Measuring piston projection

The illustration at the centre shows the location of the gauge points on the piston. From the values measured at these gauge points the mean value is taken tor each piston.

Hiustration A shows how to dial is set to "{}" on the sealing surface of the crankcase, B shows how to proceed with the measurement.

The measurement must be carried out on all pistons. Then the obtained maximum "S~ value is compared with the table in Fig. 11 and the appropriate cylinder head gasket is selected.

01--6

SH 3C2 57 - Edilion Xl .0· 3C2s0100.Jm4· geiindert: 29.02.96, 16;14

Engine

Mountingthe block-type cylinder head Proceed as follows:

•

Clean threads in the crankcase.

•

Check sealing surfaces on cylinder head and engine block lor damage.

•

Clean sealing surfaces (when renewing cylinder head gasket, fully remove old cylinder head gasket without damaging the sealing surfaces).

• •

Fit new cylinder head gasket in place.

Cautiously poSition block-type cylinder head on engine block (paying attention to dowel sleeves!).

•

Check cylinder head studs for cleanliness and wet with oil.

•

Tum in cylinder head studs and tighten according to specification. The tightening specification indicates tightening order, torques and tightening angles.

i

Tightening order block-type cylinder head tor 4-cylinder engine

CYL. HEAD TIGHTENING SPEC.

6

2

_--__.0

Fig- 16:

,..o_ _S_O_c:=,) .....

[ 30Nm

1

[ SONm

I

[ 160Nm

t

[110DEG. !

Fig, 17:

1

5

3

Tightening Qrder block-type cylinder head for 2-cylinder engine

Fig, 14:

7

3

5

1

FIg, 15:

Cylinder head stud tightening specifications

4

6

Tightening order block·type cylinder head for 3-cylinder

engine

SH 302 57· Edrtion Xl,Q' 302s0100Jm4 ' geaooert: 29,Q2,S<;. 16:14

01-7

Engine

00.2.5 Camshaft and valve timing Camshaft

The toothed beit tension is to be checked every 1000 running hours.

A special measuring device is required for checking and adjusting the toothed belt tension.

The camshafts are made from semi-finished forgings. Bearings and cams are induction-hardened. Calculate the number of the bearings as follows:

Number of bearings:: number of cylinders + 1

One inlet and one exhaust cam as well as one injection pump cam are provided for each cylinder unit. There is a bore in bearing 1 receiving the adjusting pin that is used to fix the camshaft in position for setting the valve timing when mounting the toothed belt The camshafts of naturally aspirated and turbocharged engines dilfer in their inlet and exhaust cam profiles. The camshaft of the turbocharged model is easily recognised by the flattened tip of the exhaust cam lobe.

5

Fig . 15:

'@,

5 Camshaft driving gear 6 Thrust plate 7 Bore for adjusting pin

Camshaft

Valve timing The camshaft is driven via toothed be~.

1 Toothed belt 2 Crankshaft gear 3 Idler Fig. 19:

01-8

Toothed belt drive

Toothed belt tension measuring device

The measuring device is handled as follows: • Take up the instrument as shown in Fig. 20, press the grips together and hold in this position.

• Press down the locking button with the thumb of the other hand and keep button depressed.

~.

1 Exhaust cam 2 Injection pump cam 3 Inlet cam 4 Camshaft bearing

Fig. 20:

• Relax the hold on the grips, The measuring device is now tensioned and locked and thus ready for checking the toothed belt tension.

• Slide the measuring device onto the toothed belt. While doing this, pay attention that the rollers are flush and make good contact with the fiat side of the beft and that the tension sensing finger engages between two teeth.

•

Irrespective of the belt width, always slide the measuring device up to the edge of the belt. Tnen by swiftly pressing together the grips, release the lock, and then let go quickly.

Before reading off the scale, check that the instrument is freely attached to the toothed belt and does not touch any other components.

Repeat the measuring process by pressing together and then swiftly releasing the grips, in order to rule out any doubt To assure that the basic settings of crankshaft and camshaft do not get changed when mounting the toothed belt, both shafts are locked in position by screwing in the adjusting pins.

40il pump 5 Camshaft gear Fig. 2\:

Locking crankshatt in position

SH 302 57 - Edition Xt.O· 302s0100.fm4 - geaooert: 29.02.96. 16:14

Engine

Aid for determining top dead centre position with block-type cylinder head mounted in position

•

Retain multipower tool and tighten central bolt to 210·.

•

Depress detent knob. Unload mu!tipower tccL

Remove the blanking plug from the crankcase. Now, using a bright light, the machined thrust face on the crank web is visible when looking through the adjusting pin bore - see Fig. 22,

•

Remove mullipower toollrom doHy,

•

Remove doily.

Fig. 22:

Locking crankshaft in position

Additionally, the injector of the foremost cylinder can be removed.

This ma.kes it possib!e to make out the TOC position by means of a lead wire.

The adjusting pin is screwed in as far as it will go, then the cranks· haft is tumed in direction of engine rotation until the stop and kept in this position white mounting !he toothed belt.

Mounting toothed belt with central camshaft gear bolt relaxed (basic toothed belt setting) Crankshaft toothed bett drive

•

Slide on crankshaft toothed belt driving gear.

Nota!

Ali connecting surfaces must be clean and free from oil!

• Fit connecting flange in the centre mark.

• Start and lightly tighten central bo~.

• •

Screw in adjusting pin for crankshaft as far as it will go.

Tum crankshaft in clockwise direction against stop.

Note!

Piston at front cover is in TOC position!

•

Preload centra! bolt to 130 Nm.

•

Fit dolly and tighten.

•

Frt multipower tool and socket to dolly.

Note!

Use bolt belonging 10 multipower tool!

SH 302 57· Edition XU)' 3OZs0100,lm4' :leandert: 29.02,00. 16:14

01-9

Engine

01.3 Fuel system 01.3.2 Fuel injection pump The fuel injection pumps are driven by the engine camshaft.

:J 4

1 Fuel injector 2 Fuel injection line 3 Individual fuel injection pump 4 Fuel feed pump 6 Fuel tank 5 Fuel filter 7 Back leakage Hne Fig. 23:

5-

l ow· and high·pressure fue l system

The fuel coming from the tank 6 is delivered by feed pump 4 to the filter 5, flows on to the inlet ports of the individual injection pumps 3 which feed the fuel to the injectors 1 through short injection lines 2. Excess fuel is collected together with the nozzle leakage fuel and returned to the tank through back leakage line 7.

A restriction is fitted in the back leakage line of the injection pumps at flywheel end, in order to obtain the necessary fue! supply pressure for the injection pumps.

Bleeding of the fuel system is not necessary, as this system is self· bleeding.

01.3.1 Fuel feed pump

1 Delivll!)' valve holder 11 Reliefvalve 2 O-ring 12 Pump element 3 Spring for blanking plug 13 Locating pin 4 Blanking plug 14 Bush 5 Washer l So-sea!

6Adapler 16 Grub screw 781ind plug (cavitatkln guard) SShim 17 cavitation guard 9 Valve spring 18 Sealing ring 10 Sealing ring 19 Dished plug Fig. 25 :

20 Eccentric !>ott 210-seat 22 Housing 2SGuard ring 24 Control sleeve 25 Valve spring cap (top) 2£ Plunger retum spring 27 Valve spring cap (bottom) 28 Roller tappet

Fuel injection pump construction details

Mounting the individual fuel injection pump For mounting the individual injection pump, position the roller tappet on the base circle of the driving cam (see Fig. 26).

The fuel feed pump is of diaphragm-type, equipped with two oneway valves. It is directly driven by the engine camshaft and delivers fuel under a pressure of 0.4 bar. This pump cannot be repaired.

When installing the pump, take care that the pump tappet is properiy located on the base circle of the delivery cam.

Fl1011

X(mm)

~ 1800 rpm

57.3

> 1801 rpm

56.8

BF4l10111T

I I

~36oo rpm

sao

1 Paper gasket 2 Roller tappet Fig. 26:

Immersed depth of roller tappet

Then measure the installation dimension of the pump This is the distance (x) between contact suriace of the pump on crankcase with fitted paper gasket and upper contact surface of roller tappet Add 0.1 mm to the measured dimension or place a paper gasket on the contact surface for measuring. Fit an appropriate number of 0.2 mm aluminium shims, if necessary, to obtain the required installation dimension.

Fig . 24:

01-10

Fuel teed pump

SH 302 57 - Edition Xl .0 • 302s0110.fm4 • geandert: 29.02.96. 16:19

Engine The control rod is inside the crankcase, the grooves for ti'le adjusting sleeve pin are neither visible nor accessible. To ensure correct assembly, control rod and injection pump plunger must be fixed in position.

Fig. 27 shows the locating pin for the control rod and how it must be fitted.

Note!

Be sure to remove the injection pump kicating pin prior to engine start as IT blocks the injection pump at.d makes engine shutdown impossible.

01.3.3 Fuel injection line The fuel injection line has an outer diameter 0\ 4 mm and an inner diameter of 1.5 mm. The injection Iines used for the naturally aspIrated and the turbocharged engines are identical.

01.3.4 Fuel injector FiS. 27:

The fuel injector consists of injection nozzle and nozzle holder. A cap nut keeps both parts together.

Locating control rod

Fig. 28 and Fig. 29 show how to locate the injection pump plun· ger, and the locating pin provided for that purpose.

I

2

I i

I

The correct opening pressure of 250 +8 bar is adjusted by means of shims.

1

~~ I J

1Shim

1 Blanking plug 2 Locating pin

Fig, 28;

Fig. 29:

2 Pressure spring 3TI1rust bolt 4 locating device 5 Injection nozzle and needle L-._______________________6 Cap nut

Injection pump plunger locating pin Fig, 30:

Construction details of fuel Injector

Fig . 31:

Fue! injector

Locating injection pump plunger

To introduce the locating pin, first remove the blanking plug 1. After completed assembty. fit blanking plug back in place to protect the bore against dirt and dust.

SH 302 57· Ed'rtion Xl.0· 302s0110.fm4· seaM",\: 29,02.9£.16:19

01·11

Engine

01.4 Lubrication and cooling oil system

Design details and operating principle of the rotor type pump

The oil pump delivers oil for lubrication -1/3 of the delivery volumeand for cooling - 213 of the delivery volume,

01.4.1 Lubrication system The engines have forced-feed circulation lubrication. The maximum oil pressure is 6 bar. Diagram of the lubrication circuit:

10il inlel 2 Rotor ring 3 Rotor 4 Oil outlet

1

Fig. 34:

Rotor type oil pump

The rotor 3 turns inside the rotor ring 2. The rotor has one cam less than the rotor ring. This ensures that there is always only one cam of the rotor in full engagement with the rotor ring. The other rotor cams pass by the ring cams, positively sealing off the spaces and preventing the oil from flowing back.

... Oil is drawn into the pump, as the rotor cams pass by and over the rotor ring cams.

- Oil is forced out, as the rotor cams engage with the recesses of the rotor ring.

The engine oil pump is mounted outside the oil sump and is also driven by the timing toothed belt This ensures easy access in case of repair.

01.4.2 Air/oil cooling system

10i!pump 2 Full-liow oil niter

Two thirds of the total oil flow serve to coo! the cylinders and lubri· cate the valve timing gear.

3 Crankshaft 4 camShaft Fig. 32:

Lubrication system

The oil delivered by oil pump and safety valve 1 is pumped from the sump through the fuII·flow oil filter 2 and on to the crankshaft 3 and camshaft 4. The oil for lubricating valves and rocker arms is branched off the cooling oil circuit.

1 Cylinder 2camshatt 3 Crankshaft

Engine type

IImin

4 ORpU!11p 5 FulHlow oH fitter 6 Thermostat housing

F2L 1OO11E

60

F3L 1011/E

60

F4L 1011/2

as

BF4L lOWE, F4L 1011 special power rating Fig, 33:

01-12

Fig . 35:

Cooling oil system

I

r I I

100

Engine type delivery rate oloi! pump

SH 302 fi7 - Edition X1 .0 · 302s0110Jm4' geal'Klert: 29.02.95. 16:1 9

Engine

01.5 Renewing toothed belt for camshaft drive

~ Proceed as foHows:

Special tools required: • •

Adjusting pin Toothed belt tension gauge

Commercial tools required: • •

V-be~ tension gauge

Crowfoot spanner SW 13

Used symbols:

IIRemove

+

Iobstructing parts

Remove air cowling.

•

Undo injection lines at injectors.

•

Remove V-belt idler pulley, V-belt, cableterminai box and V-belt puUey.

l

Cf

Special tool Mark

G) C)

fB

•

before disassembly, observe marks when reassembling

Ii Reinstall - Remount parts which had obstructed disassembly

1f

Check - Adjust e.g. torque, dimensions, pressures, etc.

Tighten - CI.a mp ~

<l ~

e.g. tightening a clamping device

Check - fnspect Visual inspection j

IRenew at each reassembly

SH 302 57 - Edition X1 .0· 302s0120.fm.4 • geanoert: 2l.W2.9t. 16:22

01-1 3

Engine

•

Remove toothed bett guard.

•

Remove retaining bracket

•

Tum out camshaft screw plug.

•

•

Rotate crankshaft in direction oj engine rotation so as to make camshaft bore and crankcase bore coincide.

•

Tum in camshaft adjusting pin as far as it will go.

•

Tum in crankshaft adjusting pin as far as it will go.

Tum out crankshaft screw plug.

01-14

•

Remove idler pulley.

•

Take off toothed belt.

SH 30257 - Edition Xl.0· 302s0120J m4 * geanden: 2~M)2.96 . 16:22

•

Hold crankshaft in position against stop.

•

Position neW toothed belt.

•

Tum out camshatl and crankshaft adjustingpins.

•

Mount toothed beit tension gauge so that the ful! belt width can be covered without that contact is made with any other component.

•

Tension toothed beit.

•

Tum idler pulley anticlockwise so as to attain a scale reading between 5.5 and 6.0.

•

Tighten toothed belt idler puliey fastening bolt to 45 ±4 Nm.

Note!

When positioning the new toothed belt lake care that the beit portion between crankshaft gear and camshaft gear is tight

• •

Fit idler pulley.

Correct toothed belt posttion so as to attain a uniform distance of 8 to 9 mm from the front cover.

SH 302 57· Edition X1.0· 302s0120.!m4· gearldsr!: 2$,02.00,15:22

01-15

Engine

•

Remove toothed belt tension gauge.

oC)

• •

Fit toothed belt tension gauge. Take toothed belt tension.

Specified scale reading: 6.5 to 9.5.

1f 1 +1

•

Mark camshaft gear and opposite boll

o C)

•

if the measured tension differs from the specified scale reading, readjust bett tension by means of idler pulley.

•

Remove belt tension gauge.

Checking valve timing

•

Tum crankshaft over four times in direction of engine rotation so that the marks coincide.

01-16

•

Tum crankshaft in direction of engine rotation so as to make camshaft bore and crankcase bore coincide.

•

Screw in adjusting pin until it makes contact

SH 302 57 - Edition X1.0 · 3Oes01ZOJm4 • gearn:!ert: 2$.02.%. 1522

Engine

Note!

If it is not possible to screw the adjusting pm into the crankcase to the specified depth, although al! instructions had been observed, the basic camshaft setting as described in the WOIkshop Manual has to be repeated.

•

Tighten centra! bolt to 40 Nm by means of torque spanner.

•

Then graduaUy unload torque spanner again.

• •

•

•

Remove crankshaft and camshaft adjusting pins.

•

Insert camshaft and crankshaft screw plugs, using new copper gaskets, and lock tight

•

Remove retaining bracket.

•

Mount toothed belt guard and cable terminal box.

Screw in crankshaft adjusting pin until it has slight contact with crankshaft.

Marl< this position with chalk on the adjusting pin.

The setting is correct when the adjusting pin can still be screwed in10 the crankcase by another 0.75 to 2.25 tums up to stop.

SH 30257· Edition Xl.0· 302s0120.lm4· geiindert: 29.02.96. 1$:22

01-17

Engine

• •

Fit V-bett pulley.

Tighten bolts to 42 ±4 Nm,

• •

Tension V-belt.

Tighten V-belt idler fastening bolts to 40 ±4 Nm.

•

Fit V-batt idler pulley.

•

Check V-belt tension by means of tension gauge (Krikit) and correct as necessary.

Note!

Lightly screw in botts.

•

Position V-belt.

0'1-18

V-belt tensioning data: •

Initial tension: approx. 400 Nm,

•

Retension after about 15 minutes to between 200 and 300 Nm.

• Connect injection lines at injectors and lock tight to between 15 and 16.5 Nm.

SH 302 f)/- Editioo X1 .0 · 302s0120.fm4 - g"andert: 2:9.02.96, 16:22

Engine

Notes

•

At the cover back on.

SrI 30:2 57 - Editioo Xl.!)' 302s0120.1iM • ~aooert: 29.02.96. 1622

01·19

Engine Notes

01-20

Sll' 302 57 - Edition Xl.o '3()2s01201m4' geij.- "icn; 1902,%, 16;22

Group Fuel lines

08

.,

"

Fuel feed system 220/320/420 wheel loaders (models 30055/301 56/302 57~

---,.

-

I

-~-

Diesel tank about in right-hand side apcess ~ ~

Diesel prefilter

36EH0800)so

30250801 ,al

Group Frame

20

,...

o(If)

.......

It) It)

o

o(If)

tn

( I)

"C

o E "'-'" tn

"(I)

"C CO

--o

CD CD

.c

o== ~ ....... o N

(If)

....... o N N

~

tn

CO

CI)

E

«S "-

U.

/

~~"

----...~ ......~~'''----~~/

~~

iI

/

,----------- --.

::

~' \

I I

I I I

I I I

I I I I

I I I I

I I I

I

I I I I I

I I !

I I I I

I I I

I I I

I I I I I

I I

I I

I I I

I

I I I I I I I I I

I I I I I

,

I I I I

'------------4>------

~J

, I

, I I I I

I I

I I

I I I I I I

,

I I

/

I

/

/

. w)

~

<])-

I I I I I I I I I I

Hydrostatic drive 320 I 420 wheel loaders (models --. 301 561 302 57) ~-y

Return flow control valve/steering

.WI'!

Diff lock front axle Dlff lock rear axle

Pressure difference valve brake 8 + 1 bar adjusted

Inch line

Control line

//."

Control tine

~~-~

~--~'

•

Hydrostatic drive 320 I 420 wheel loaders (models 301 561 302 57) Pressure

loader unit steering

HP

High pressure

Boost pressure valve

Transposition screw

reverse Control press. Zero position

Boost pressu

Pump loader unit steering

Control cartridge

HD

Pressure cut-off 320-420

Brake/i nching line 302S2212.a i

Hydrostatic drive 220 wheel loader (model 300 55) Pressure loader unit steering

HP

Boost pressure valve

Transposition screw Control press. Zero position

Boost pressu

Pump loader unit steering

Control cartridge HD

Brake/inching line 300S2203.11i

Hydrostatic drive

22 Hydrostatic drive for Notes: wheel loaders 220/320 1420 (type 300 55/301 56/302 57) 22.1 Name 22.1.1 Pump 28...

=

tn 220 (type 300 55)

' A 4 V G 40 DAD .......

- -

-

t f f

Speed-dependent adjustment in 320 1420 with pressure cut-off

:

,

in 320 1420 (type 301 55 / 302 57)

f

1 l

i i i

i

1

Capacity in wrev

I

Newverston

i i

Variable swivl!i angle

1 i

l i

i i

ii

11-----'•

Axial

Series 32 is fitted in 220/ 320 / 420 (type 300 55 ! 301 56 / 302 57)

22.1.2 Hydraulic motor I

In 220 1320 1420 IA 6 V M 80 DA 3 -......- - - (type 300 55 / 301 55 ! 302 57)

Electric driving direction detection

I

Speed-dependent goveming Capacily in cc/fev

Variable

•

There are two series: 61 and 63. Series 63 has a slop screw for Qmax and Qmin' Installation in machines with the following chassis numbens:

Loader (type)

Series 61

IFrom 300 55 0001

220 (300 55)

320 (30156) 420 (302 57)

ISeries 63

301 56 0419

From 301 56 0420

IFrom 302 57 0330 22-1

Hydrostatic drive

L2.2

Description

22.2.1 Hydraulic pump •

~

I

•

Check the slJction line and suction line filter to the boost pump in case of malfunctions.

•

Orifices" O.S mm are fitted in the valve controlling driving direction in connection T (tank):

i:

~, '

The forwards (FW) and reverse (RV) high pressure cartridges (secondary valves) shouki be set approx. 10 % higher than the pressure clJ!-off of the 32 (301 56) and 420 (302 57}>

I

/

:

'

Pump shut

The !WIst screw can bE!lJmed between the 12 and 6 o'C!ookpcsitons TwlstSCfew

The !WIst screw is rormaJly set to tM :3 o'clock position

.. The orifices may be contaminated if the venicle changes direction too sluggishly because the control pressure cannot dissipate quickly enough. .. Check the diameter of the throttle if the vehicle changes direction too abruptly.

Hydr. resiSt. CUM [barJ

When setting the control initiation, note the pressure on the FW pressure gauge on the pump:

400

the pressure in the positioning chamber from the drive motor drops abruptly is the control initiation pressure.

.. A i mm shim corresponds 10 approx. 4 bar increase in pressure.

•

100

Note the following when dismantling the boost pump: fl41i" Fit the chamfered side of the gear towards the end cover

If the pressu re cut-off judders:

/'

I

/

/

J./

t::> 1000

when re-assembling it.

•

f

200

• Set the boost pressure valve using shims:

.J ():a o'clock '-.'-/

/

500

The temperature of the system will be raised during the first 50 operating hours until the bearings have run in.

Hytil$lOC resistance / C\lNe, set on test rig

/

450

.. The pressure shown on the FW high pressure gauge when

•

/

500

/

....

I 1500

2000

2500 Speed [rpmlmin]

Notes:

.. There may be air trapped in the pressure cut-of! system. fl41i" Bleed the system using a minimess hose connected to the

FW measurement connection> •

The pump does not deflect fully if the control pressure is not reached: .. The piston in the engine valve may not be closing so the control pressure passes into the retum flow.

•

The pressure cut-off valve must be neutralised by screwing it in completely when setting the FW and RV high pressure or secondary valves in the 320! 420 (301 56 f

30257).

•

Swivel angle of pump: ± 20 •

•

The characteristic of the hydraulic resistance curve is set on the twist screw.

•

It the twist screw is set to the 6 o'clock position: .. The high pressure rise is flatter (more !eisurely driving style).

•

If the twist screw is set to the 12 o'clock position: .. The high pressure rise is steeper (more brisk driving style).

22-2

SH 302 57· Edition X l.O· 3tt2s2200J'm4' gw.am; 29.02.96, 16:32

Hydrostatic drive •

Towing away 220 (300 55) •

Piloted high pressure or secondary valves are fitted in the 28 cc pump in the 220 (300 55), Consequently. proceed as foflows:

Retum the high pressure valves to their original setting betore taking the loader back into operation! Ths involves unscrewing each allen screw 3 up to its stop and securing it with a locknut 2.

Notes:

•

Changeover both high pressure relief valves on the hydraulic pump. Do this as follows: ~ Secure hexagon nut 1 ~ Unscrew hexagon nut 2 through maximum two rotations

(one rotation corresponds to approx, 290 bar).

•

Run the engine at idling speed if possible when towing the vehicle away,

•

Retum the high pressure valves to their original setting before taking the loader back into operation! This involves tightening each hexagon nut 2 to a tightening torque of 60 Nm,

Towing away 320 1420 (301 56/302 57) Directly controlled high pressure or secondary valves are fitted in the 40 ex: pump in the 320 (30t 56) and 420 (302 57), Consequently, proceed as follows when towing the vehicle away:

•

!

3~ 1,

~

~--''''~ ' = '.:;:- ' ~

' ::,::::' .

.

'I

--

~ .

~\

LJ ~',:~ \1 2~ . ' "~.J ,/, ' ' ;, ' 3~ ~.. .

•

}

. I

Changeover high pressure relief valves 1 on the hydraulic pump, Do this as follows: ~ Unscrew hexagon locknuts 2 on both high pressure valves, ~ Screw in allen screws 3 on both high pressure valves 1 until

they are flush with locknut 2, ~ Secure allen screws 3 on both high pressure valves 1 with

locknuts 2, •

Run the engine at idling speed if possible when towing the vehicle away,

SH 302 57 - Edition Xl.O ' 3(J2s22OOJ'm4 ' J',ciln<im, 29.02.96, 16:32

22-3

Hydrostatic drive

~.2.2

•

Hydraulic motor

When taking the machine into operation for the first time, brake the vehicie and drive it against hydraulic resistance: _ Output shaft and bearings are brought to the initial position.

•

The connecting plate from the old motor (series 61) is sealed with a paper seal: .. Note the thickness of the seal during assembly.

•

The connecting plate on the new motor (series 63) is sealed with an O-ring:

.. Pay attention to the piston rings during assembly due to the risk of a piston ring projecting.

•

If the new motor (series 63) does not generate the required tractive effort:

-

Check if the Qmax and Qmln stop screw has been screwed into the hydraulic motor.

The solenoid valve on the hydraulic motor for the driving direction signal sends the pump and motor the signal for forwards driving direction and downhill driving: .. The motor and pump do not return to the same control setting straight away.

•

SWivel angle of the motor. 5 0 • 25 0

•

The motor is deflected by the control pressure and returned by the high pressure.

•

Shuttle throttles must be fitted so deflection from a large to a small angle takes place quickly, Throttling takes place when changing from a small to a large swivel angle.

•

Shuttle throttie in series 61 (old): " 6 q> Point must face outwards towards the measurement connection.

Shuttle throttle in series 63 {new):" 4 q> Point must face inwards.

22-4

Notes:

Hydrostatic drive 220 (300 55) •

22.3 Adjustment work 220 (300 55)

Use shims to set the boost pressure valve to 25 bar. ~ Unscrew and remove the complete valve (WAF 27) and fit

the shim(s) to do this.

Note!

Run the vehicle to warm it up before taking the measurement so the hydraulic system reaches its optimum operating temperature of 60C e!

Notes:

The vehicle must be braked using the service brake when the measurement is taken. Consequently. unscrew the brake-inching line from the hydraulic pump and fit a dummy coven Only adjust the valves when they are depressurised!

Tools required: •

High pressure gauge (600 bar, 2 pes.)

•

Pressure gauge (60 bar, 2 pes.)

•

Rev counter

22.3.1 Starting speed Starting speed: approx. 50 bar high pressure, 1050 - 1150 rpm

Adjust the control cart· ridge WAF 131allen key 4 CcnIroI~

HP

I

~~g

I

I

•

Jack up the vehicle.

•

Push the steering column control lever tor hydrostatic drive and driving direction forwards = driving direction forwards.

•

Slowly increase the revs.

•

Set the starting speed on the control cartridge: ~ Screw in the control cartridge:

.. Starting later ~ Unscrew the control cartridge:

.. Starting sooner

sa 300 SS ~ Edition XLO • 300s.22031m4 • gelln<k..-,; 29.02.%, 16:36

22-1

Hydrostatic drive 220 (300 55)

12.3.2 Hydraulic resistance curve (characteristic curve) of the pump Hyde resist. curve [bar]

/'

/

500

/

450 400

/

300

f

200

J

I

HyJ!aU!ic resistance CUM!, set on test rig

SO'clock

. /'

-

12o'cmd<

100

- Connect rev

1000

counter

1500

2000

2500

Q'Set the twist screw towards 12 o'clock: .. Curve becomes flatter (= vehicle reacts more smoothly).

CD

Note!

The twist screw is set to the 9 o'clock =0 (position indicated by slot in screw)!

Correct the hydraulic resistance curve if necessary by tuming the

Q'Set the twist screw towards 6 o'clock: .. Curve becomes steeper (= vehicle reacts more abruptly).

Notes:

twist screw to a setting between 6 and 12 o'dock!

Warning!

We recommend you contact the Kramer customer service department before modifying the hydraulic resistance curve!

Measurement • •

Jack up the vehicle.

Push the steering column control lever for hydrostatic drive and driving direction forwards = driving direction forwards, 1st gear.

•

Increase the revs and drive against the hydraulic resistance. .. FW high pressure must be at least 400 bar at 2000 rpm.

22-2

SH 300 55· Edition Xl.O • :300>2203.fm4 • ~~: 29.02.%. 16:}6

Hydrostatic drive 220 (300 55)

22.3.3 Pump power

Notes:

Measurement • •

Jack up the vehicle.

Push the steering column control lever for hydrostatic drive and driving direction forwards:: driving direction forwards, 1st gear.

• •

Set maximum revs.

Brake the vehicle until the high pressure reaches 260 bar. . . The droop speed must be 2250 - 2350 rpm.

In case of excessive engine droop: •

Check the air filter and fuel system.

•

Unscrew and remove the complete control caJilidge (WAF 22) and check the orifice in the control cartridge for contamination (the orifice is secured using a Seeger ring).

SH 300 55 · Edition Xl.o · 3QOs2203.fm4· gdn""": 29.02.%. 16:36

22-3

Hydrostatic drive 220 (300 55)

1!2.3.4 Control initiation on hydraulic

Notes:

motor

- Connect FW high

pressure gauge 600 bar

HP

• Jack up the vehicle.

•

Push the steering column control lever for hydrostatic drive and driving direction forwards ::: driving direction forwards, 2nd gear.

•

Set maximum reys (FW high pressure is at approx.

100 bar).

• Slowly brake the vehicle. _ Pressure on pressure gauge (FW high pressure) and in control piston slowly rises.

Note!

The FW high pressure must be approx. 270 bar when the pressure in the control piston falls rapidly!

1AdjUSll'llentWAF 101a11el1 r;ey 3 Screw in " pressure mcrease Unscrew" resSeure reduCllQn

22-4

SH 30055· Editioo XIJ)' 3OOs2203im4 ' gcliz:rl",,: W.OZ .96, 16: 36

Hydrostatic drive 220 (300 55)

Brake-inching

22.3.5 High pressure

-\

. ~ Neutral position

-~ fitIe

Set screw on botIoMJnserew: Screw in: inching valVe brake-inching br'ake-inching WAF10/allenkey3sooner later i

Note!

The wheel loader 220 type 300 55 does not have pressure cut-off (operational pressure is set on the high pressure cartridge!).

I

•

Jack up the vehicle.

•

Connect the FW high pressure gauge (600 bar).

•

Connect the pressure gauge for forwards high pressure.

•

•

Push the steering column selector !ever for hydrostatic drive and driving direction forwards = driving direction forwards, 1st gear.

Push the steering column selector lever for hydrostatic drive and driving direction forwards =driving direction forwards, 2nd gear.

•

Set maximum revs.

•

Drive the vehicle against hydraulic resistance (use the service brake as wer! if necessary).

•

Brake the vehicle slightly until the wheels stop turning. .... The high pressure must briefly rise by about 30 - 50 bar when you do this.

a" Adjust the high pressure cartridge.

Note!

~ Adjust the bottom inching valve 0NAF 10/allen key 3).

Pressure cut-off meens:

Note!

High pressure is maintained. Pump deflects back to reduced delivery -> device feed is reduced!

Speed is measured by the speed of the wheels!

•

Measure the speed of the wheels when the diesel engine is running at 2500 rpm.

Q'See inspection report.

•

Connect the brake-inching line again after taking the measure-

ments.

•

Bleed the brake at the hydraulic pump through the bleed valve.

Notes:

SH 30055· Edition Xl.O. 300s2203.im4· gd~dtn: 29.02.96. 16:36

22-5

Hydrostatic drive 220 (300 55)

22.3.6 Inspection report 220 type 300 55 Chassis number

Hydr. pump - fact. no.: Hydr. motor -fact. no.:

Actual

Nominal

Settings

Set

.at oil temperature 60°C: .

23 - 25 bar 1050 - 1150 rpm

HP hydraulic resistance curve at 2000 rpm. 1st gear

min. 400 bar

Power test at 260 bar Enginespeed in 1st gear Brake-inching disconnected

2.250 - 2350 rpm

High pressure/control piston evenly in on-road range atter braking

250-290 bar

High pressure

460-480 bar

Tractive effort (check value only)

3150kp

HP rise: 1st gear fut! acceler.

Brake-inching connected (check value only)

30-40 bar

Speed of wheels at nominal engine speed n = 2500 rpm

115 - 135 rpm

20 kph Implement and steering hydraulics: Implement hydraulics

165 -180 bar

Tilt ram pressure

115-135bar

Steering pressure

160 -180 bar

I i I

l owering speed of loading Unit (011 temperature 60°C, pressure In ram p =100 bar, time t =10 mmutes)

Lift ram Tilt ram

I

max. 14 mm max 15mm

Remarks:

22-6

Hydrostatic drive 320 ! 420 (301 56 / 302 57)

22.4 Adjustment work 320 1420 (301 56/302 57)

• Set the starting speed on the control cartridge: ~ Screw in the control cartridge:

.. Starting later ~ Unscrew the control cartridge:

Note!

Run the vehicle to warm it up before taking the measurement so the hydraulic system reaches its optimum operating temperature of 6O"C!

.. Starting sooner •

Use shims to set the hoost pressure valve to 25 bar. ~ Unscrew and remove the complete valve (WAF 27) and fit

the shim(s) to do this.

The vehicle must be hraked uSing Ihe service brake when taking the measurement Consequently, unscrew the brake-inching line from the hydraulic pump and fit a dummy coverl

Notes:

Only adjust the valves when they are depressurisedl

Tools required: •

High pressure gauge (600 bar, 2 pes.)

•

Pressure gauge (60 bar, 2 pes.)

•

Rev counter

22.4.1 Starting speed Starting speed: approx. 50 bar high pressure, 1050 - 1150 rpm

Adjust the control cartridge , WAF 131allen ! key 4 CoM»! otttrIdg< !

•

Jack up the vehicle.

•

Push the steering column control lever for hydrostatic drive and driving direction forwards = driving direction forwards.

•

Slowly increase the revs.

SH 302 57· Edition X 1.0 • 302s2203.fm4 ' gd!:tldcn: 29.02.96,14:38

22-1

Hydrostatic drive 320 I 420 (301 56 ! 302 57)

.t2.4.2 Hydraulic resistance curve (characteristic curve) of the pump _~

H?

=. .l'O=p_.=-=

Hydr. resiSt.

curve fbar]

/

500

WAr\7i

400

f

HydIauliC resistance

I

450

alIenl<ay5

! C:;(W, set onll9:st rig

/

i.

/

i

i i

gO'clOCk

I

i i

I

I . /

I

,

I-Connect 600 bar ~

/

J/ /

100

./

/

pressure gall

'I

, -Connect rev counter

I

1000

1500

2000

2500 Speed [lJl!1lj

HI'

o

Q'Sel the twist screw towards 12 o'clock:

... Curve becomes flatter (= vehicle reacts more smoothly).

Note!

Q'Set the twist screw towards 6 o'clock:

The twist screw is set to 9 o'clock :::() (position indicated by slot in screw)!

... Curve becomes steeper (= vehicle reacts more abruptly).

Notes:

Correct the hydraulic resistance curve if necessary by turning the twist screw to a setting between 6 and 12 o'clock!

Attention!

We recommend you contact Ihe Kramer customer service '~partment before modifying the hydraulic resistance curve!

Measurement •

Jack up the vehicle,

•

Push the steering column control lever for hydrostatic drive and driving direction forwards:: driving direction forwards, 1st gear.

•

Increase the revs and drive against the hydraulic resistance. .. FW high pressure must be al least 400 bar at 2000 rpm.

22-2

Sf{ 302 57· Editioo Xl.O· 302s2203.fm4. gel:ld<;':; 2)\,0::.96. ]4;,S

Hydrostatic drive 320 ! 420 (301 56 ! 302 57) Notes:

22.4.3 Pump power

- Adjustment WAF141 allen key 4

preS$Ure gauge - Connect rev counter

J/ HP

~Cil!-Of!

3201420

~

.,.

Measurement •

Jack up the vehicle.

•

Push the steering column control lever for hydrostatic drive and driving direction forwards = driving direction forwards, 1st gear.

•

Set maximum revs.

•

Brake the vehicle until the high pressure reaches 260 bar. .. The compression speed must be 2250 - 2350 rpm.

In case of excessive motor compression: •

Jack the air filter and fill system.

•

Unscrew and remove the complete control cartridge IJiAF 22) and check the orifice in the control cartridge for contamination (the orifice is secured using a Seeger ring).

SH 302 57 • Edition Xl.O ' 3Q2s2203im4 • geilnde.'t: 2'i.02.%, 14:38

22-3

Hydrostatic drive 320 / 420 (301 58 J302 57)

aa.4.4 Control initiation on hydraulic motor

- Connect FW nigh pre$Sure gauge 600 bar

• •

Jack up the vehicle.

Push the steering column OOI1trol !ever fer hydrostatic drive and driving directioo forwards", driving direc!ton tClWards, 2nd gear.

• Set maximum re\lS (FW high pressure is at approx. 100 bar).

•

Slowly brake the vehicle. .. Pressure on pressure gauge (FW high pressure) and control piston slowly rises.

Note!

The high pressure forwards must be approx. 270 bar when the pressure in the control piston falls rapidly!

t

Adjustment WAf 10!anen kay 3 , - Screw in " pressure increase

Unscrew" pressure reiluctkm

22-4

Notes:

Hydrostatic drive 320 / 420 (3Q1 56 ! 302 57)

22.4.5 High pressure

Secondary valves forwards - reverse Measurement Note!

Pressure setting of the secondary valves: approx. 40 bar higher than the pressure cut-ofH •

Tum the pressure cut-oft to block.

•

Connect the FW and RV high pressure gauges.

•

Drive the vehicle against hydraulic resistance.

•

Adjustment see section 22.1.5.

•

Reset the pressure cut-off after taking the measurements: 470 bar CNAF 13!allen key 4).

•

Remove valve 2 completely.

....- - Unscrew allen key 3

Note!

Clamp on spring retainer

The pressure cut-ofi corresponds to the hydraulic pressure measured at the FW and RV high pressure measurement points!

• •

Engage 1sl or 2nd gear.

Push the steering column selector lever for hydrostatic drive and driving direction forwards = driving direction forwards.

•

Drive the vehicle against hydraulic resistance (use the service brake as weI! IT necessary).

•

Lead off the pressure on the FW high pressure gauge.

•

Adjust the pressure on the pressure cut-off (WAF 131allen key 4).

Adjust here (WAF 8) 1 rotation approx. 40 bar

302S2214,ai

Valve muit be completely removed (WAF 32)

Ili.ii" Screw in the pressure cut-off:

.... Pressure increase ~ Unscrew the pressure cut-off:

.... Pressure reduction

SH 302 57 • Edition XLO • 302s2203.fm4 • geand"!t; :!9 ,0:.'016. ;4 :38

22-5

Hydrostatic drive 320 I 420 (301 56 / 302 57)

Notes:

drake-inching Boos:

p..-.. H? !\We"'" 1<i9/\ p'OSW'" eoo.:"",..ur. High!l"'$$urt TIriS! """" c._, No""," .......

10__ _ .. post"'" ,

- Connect FW blgh

pressure gauge 600 bar

Setscrew onbotlom inc:hing VIM WAF 10 I allen key 3

• Jack up the vehicle.

• Connect the FW high pressure gauge (600 bar).

•

Push 1he steering column selector lever for hydrostatic drive and driving direction forwards = driving direction forwards, 2nd gear.

• Set maximum revs.

•

Brake the vehicle slightly unnl the wheels stop tuming. .. The high pressure must briefiy rise by about 30 - 50 bar when you do this.

IJ3' Adjust the bottom inching valve 0NAF 10!allen key 3).

Notel Speed is measured by the speed of the wheets!

•

Measure the speed of the wheels when the diesel engine is running at 2500 rpm.

IE'ii" See rnspection report.

•

Connect the brake-inching line again after taking the measurements.

•

Bleed the brake at the hydraulic pump through the bleed valve.

22-6

SH 302 57· Edition XLO' 302s..."203.!m4· g~~"": 29.02 .96. 14:38

Hydrostatic drive 320 I 420 (301 56 ! 302 57)

22.4.6 Inspection report 320/420 type 301 561302 57 Chassis number

pump

no.:

Hydr. motor-fact. no.: Nominal

Settings at oil temperature 60°C:

I

Set

Actual

1

Hydraulic pump' 23·25 bar

Boost pressure min.

Starting speed at 50 bar HP

1050-115Orpm

HP hydraulic resistance curve at

min. 400 bar

2000 rpm, 1st gear Power test at 260 bar Engine speed in 1sf gear Brake-inching disconnected

2200 - 2400 rpm

High pressure/control piston evenly in on-road range after braking

250-290 bar

High pressure

I I

450 - 470 bar

Tractive effort (check va!

4000kp

HP rise: 1st gear full acceleration brake-inching connected (check value only)

30-40 bar

!

Speed of wheels at nQmmal engIne speed n =2500 rpm 20kph

110 - 130rpm

30kph

157 ,) 77 rpm

37kph

207 • 227 rpm

Implements and steering hydrauhcs: Implement hydraulics

Tilt ram pressure Steering pressure

I I

205·220 bar 115- 135 bar 160 -180 bar

Lowering speed of loading unit (oil temperature 6O"C, pressure in ram p = 100 bar, time t = 10 minutes)

Remarks:

SH 302 57· Edition Xl.O« 302s22D3.fm4 • gefultkrt: 29.02.96. 14:38

22-7

Group Front axle

23

v~· _ ·· _ · ,,", ··. _ ·· ···

Front and rear axle final drive 220/320/420 wheel loaders (models 300 55/301 56/302 57) Adjustment of

Clrclip

taper roller bearings as with 312 Sl

Sealing ring with three sealing lubrication point upper final drive bea .

\\,>," " » "., , <l

, ri ndi Sea I'"9 Extraction thread M

1Q..-------~~~~

Lubrication point lower final drive

Rec~ss in casting for exchanging wheel bolts

bearing The king pin bearing needs no longer to be adjusted (calculated)!

Shim always same dimension

.......•__ _ ..~ _ _ _ _ _._ _ _ _~_ _ _ _ _ _ _ _ _ _ _ _ _ _~_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _. 30252302,81

Front and rear axle final drive 220 1 3201 420 wheel loaders (models 300 55/301 56/302 57 ___~ :: -=1-+-__• I...

dimension 1 -

dimension2

= dimension 3

!".

+

'I

0.10 mm

----HII ---.'- ..... = shim H

, 2

II

~~""'" '~~)~ 38e26040Jso ,

"-

.~

I _ ' ~

!

...

- ,

dimension 1 - dimension 2 = dimension 3 + 0.12 mm • = shim

3Q2S2303,ai

Front and rear axle final drive 220 1320 I 420 wheel loaders models (300 55/301 56/302 57

A

97,1 mm

59,0 mm

B

59,Omm

302$2304.a i

Front and rear axle final drive 220 1320 1 420 wheel loaders (models 300 55/301 56/302 57 A:

97.1 - 59.0 = 38.1

B:

(straight edge)

9.0

+ 15.0

(measuring shim)

=24.0

15.0 mm

C:

59.0 - 24.0 =35.0

(straight edge) (result 8)

0:

38.1 - 35.0 = 3.1 + 0.12 = 3.22

(result A) (result C) (initial stress)

Ie differential 220 I 320 I 420 wheel loaders (models 300 55/301 56/302 57) ~_.~~ .

v _ ·· _ ··· _~ ····· ~~ ··· · ·,··

Shift sleeve

When working on the differentia or the cylinder of the lock, completely flange the left half of the axle wi.t h the final drive

(100 % locking effect) Clamping sleeve for centring the piston Ram cylinder

+--rPiston ~~~~~\

Needle bearing Piston ring } S~aling of piston

r-.......;-_ _ Piston ring

Gear drive assy

O-ring sealing Ram cylinder to the axle bod Rotary shaft Compression spring (sets back the shift sleeve) Output flange

Circllp for cardan shaft screws

~ ~''''

Brake calliper with wear indication of the pads

,<;

Brake disc for service brake

and parking brake (20 kph);

40 kph version: extra brake disc on the gearbox Castle nut with split pin .. .. ~

~ . --."-.-~'""-

..

~,,-------.

302$2301 .81

I Front and rear axle final drive 220/320/420 wheel loaders (models 300 55/301 56/302 57)

r

~ i1 1 :1 I

29.0 -26.4

rl

0,· _ ···-

= 2.6 + 0.1 = 2.7

I I

t I

:I : II

, I

I

I I

I:

I

I

: II

26.4 mm

I

J I

I I

I I

d.-b,

I

I

29.0mm

302S2306.at

Front and rear axle final drive 220/320/420 wheel loaders (models 300 55/301 56/302 57)

//

Measuring appliance for final drive

/'/'

~<~

" ',

"-,

",_ 170 '...

" 135 ",

'-

~y/

'.>,

,

"'//

5

. </ .~, "'.....

-'-,-

'-,

"', -"-.., .....

,

',~

, _" 200 "', "'-..

'"'"

360

" " '" ."-

" "' / /

250 '''.

~-,

,.

-"

"~.

//

, ~//

v"/ '

_ _ _~..W ·. . . _ _ _ _ _ _ _~~_ _ _•

302$2307.81

Group Brakes

24

Brake calliper 220/320/420 wheel loaders (models 300 55/301 56/30257)

Wear indicator

~

Brake pads

/'

".

" .",,~\ ~ >'>,~1)'1 ," '----- Piston ~,

(~\

Breather valve

~

il~)

...

Dirt scraper

//'\

(~A'>~

~~" "'~~~<'v~7/ "'" " . ~ ~"~ '\c,,, \ ") ~<\ / \

"',

, r",.

"~,~

\ (

/ \

~'... ~. ",,~(,//'

U~rlng

B,ake call1pe'

~';:;.~~-

380112400.1$0

302S2403.81

Brake 220/ 320 / 420 wheel loaders (models 300 55/ 301 56/ 302 57) Brake pedals (coupled)

Master brake cylinder

Brake light switch

o

!

Fill and anticavitation line

Pressure difference valve Breather valve

Adjusting screw 8 :I:: 1 bar

'-@J\,~,~

Breather valve Inch valve Adjusting screw

Brake diagram 420 wheel loader (model 302 57) Air bleed

z;-r-I--L_

CD

8 &.

J

~ !Xl

Air bleed

"-

8.

~r ~_~_1_ _---.l!>--__~

Front axle

IT

Rear axle

2 Pedals

302bmms.aJ

no contact pressure passage

Group Rear axle

26

Front and rear axle differential lock circuit (high speed version)

220 1320 1420 wheel loaders (models 300 55/301 56/302 57) • Both axles are locked when the button on the Joy-stick is pressed.

Switch 10 high spee

../'

• Rear axle Is locked when the brake pedal is pressed.

Label

Rocker

1

at standstill only

r'·~[~r(::::::~.

{

High speed

10~

!

Fr. axle Pilot control / ' •. ",.

Re. axle 10~~~ ;:C~ / ~ ~/ c;P •

• w

1f.;. ,no; ~ /§~., "t'>...

Solenoid

-

'

~,

" c (T\ ',~

'\

high sp.e . .ed ; ( . .

/~

\\.A~~~ikIV

'"

/

-\

Suction line to boos.t pump

".'

:~ ....J~~. .

A:J

I)~, / ~i. ~ W ~}

"j. "

(",..Bv - -".' ..'.' 1

I

,,_,

"~."" '-'-HP tank !) ).w' / I

\tl.r XJ ,~f

\Reflux

Reflux

~

';;':;\Y~JJ"'<;~ y 1

to pilot control Reflux

1

'

I!

Feed and' r.e,.fIUX .'

to ram

J.. .

high speed versio ~

A

{fiJI

---~-~20 hAr' "

J/' /' .. . /

/

Actuating ram high speed

Boost pump

,

Measuring port boost pressure

Pressure line to accessory consumers 302S2605.al

I Rear axle differential 220 1320 1 420 wheel loaders (models 300 55/301 56/ 302 5 Piston guide pin In the ram

Multidisc differential lock Is locked every time

Bushing (ram cylinder in rlght~hand side axle carrier)

Piston seal

the brakes are applied

/

. .A" l'::~,~.,-<;,'«,~ ~."'

•.J'<§~ ""'<lr7r

.<.

....

A 7 ,r " .~:', '. " "'>.. ~~>

~ \: "f~~

'"

, l ~' I r

" "",, ....'. >.. ~,,--',

Piston seal

~-'~

'.'

.

LLdL "

Insert the roUer bearing with grease when fitting it in

:lO ~26000 , I SO

') ,,~j

When working on the differen-

Inner discs O-ring seal from ram cylinder to axle carrier

"\

Sliding sleeve

wheel

Outer discs

tial or the ram of the djff lock flange the right half of the axle complete with the final drive 302S2602,al

Rear axle differential 220 1320 1 420 wheel loaders (models 300 55/301 56 1 302 57) Differential lock

When removing the gear housing cover hold with screw M10

When working on the differential or on the rear axle differential lock flange the right half of the axle complete with the final drive

Bronze bushing oscillating bearing

Driving bushing

Hydraulic motor

302S2603,al

Rear axle 220 I 320 I 420 wheel loaders (models 300 551 301 561 302 57) ~.--------------------~~

- Oscillating pin can be pulled out to the front (M 16 thread), use a ram - Lower the axle with help of the mounting - Renew the bushings and assemble the axle

~¥

Lube line oscillating bearing passed through the frame

Hydraulic motor direct flanged to the rear axle

a-ring seal

Solenoid 1st + 2nd speed 38026000.190

,_,._ .._ .. ________

30232604.11; ,

Rear axle 220 I 320 I 420 wheel loaders (models 300 55 I 301 56 I 302 57) Oscillating tube with bronze bushing

Adjust as with 312 SL

Sealing ring with three sealing lips

Oil drain plug

lube point Upper final drive bearing

When working on the differential or The king pin shim needs no longer the cylinder of the differential lock, to be calculated (constant dimension) completely flange one half of the axle with the final drive Lube point Lower final drive bearing

Hexagon head WS 32 cast onto the set nut 3Q2S2601.ai

Group Steering

27

._.__,--

,.---~-~----~-"-" '~- " -'~-' "

...

Steering ram 220 I 320 I 420 wheel loaders (models 300 55 I 301 56 I 302 57)

For sealing work loosen the counternut WS 17 and unscrew the spherical head (take measure oft the spherical head)

Check compact plug when troubleshooting

cad02099J,o

Adhesive fixing and caulking of piston

Caution

Bleed after removing a steering ram (see Instruction)!

h~

t-~~

Air bleed valve no longer used In future

.. ~...- .., / L....._ _ _ __

_ __ __ __ __ __ _ _ _ _ ,,_ _ _ •.•.._ ,,_ . _ .••.,,~._.••• _ . _ _ _

_ __ ,_. _.~_ ._ 3l)~§~03 ,aj

23 Steering 220 1 320 1 420 (300 55 I 301 56 1302 57) 23.1 Technical data Hydraulic four whee! power steering with emergency features, Steering modes:

Four whee! steering Front axle steering: In version with high speed, only front axle steering is possible in ,2nd gear!

Assemblies:

Hand pump; hydraulic pump; 2 steering rams integrated in the axles; safety valves; isolenoid vatve for synchronising the steel ring; priority vahle

Hand pump:

' Eaton servostat Displacement Operating pressure

120 cc/rev

110 bar

Hydraulic pump:

3ear pump (priority valve) )isplacement 28 cc/rev

Hydraulic rams

Kramer rams

Max. steering angle

±45

0

23.2 Synchronising the steering

The follOwing applies to all vehicle versions:

Only the 1st range can be engaged during the steering synchronisatiOn process When switch 14 is flashing, You can use steering column control lever 40 to select the 2nd range. but the shift into second range is delayed until the synchronisation process has been completed, The following applies to vehicles with high speed

(40 kph): The synchronisation process functions according to the procedure described above. In addition: •

Front axle steering is selected alrtomatically when high speed is engaged by pressing rocker switch 15 (with the vehicle at a standstill and steering column control lever 40 in neutral). However, high speed is not engaged until the rear axle has been set to straight ahead. Telltale 20 flashes until the shift is completed.

•

Four wheel steering is selected automatically when high speed is disengaged (with the vehicle at a stands and steering column control lever 40 in neutral), In this case, the shift is not perfonmed until the front axle has been set to straight ahead, Telltale 19 flashes until the shift is completed,

23.3

Bleeding the steering system

Select front Wheel steering and steer from lock to lock at least 3 times in both directions, •

Switch to four Wheel steering and steer from lock to lock once. .. Wheels in crab steering position

•

Press in the left-hand half of the synchronisation switch and hold IT there, select front Wheel steering and tum the steering Wheel until the wheels reach the four whee! steering position at the maximum steering angle,

•

Release the synchronisation switch and steer from lock to lock at least 3 times in both directions in four Wheel steering mode,

•

Check for synchronisation of the steering changeover.

R" Proceed as follows in order to synchronise the steering:

• • • •

CDi

Check that high speed is disengaged (with the vehicle at a standstill!), Drive at walking pace on level ground and press switch 14, Continue driving, tuming the steering wheel to the left and right Carry out a functional check of the steering system, Although the steering electronics automaticalfy synchronise the front and rear axles, the synchronisation process is not complete until the steering rams have passed through the straight ahead position from both directions, The telftale in synchronisation switch 14 goes out

SH 300 S5 • Au,S''''' Xl.O • 3OQsZ700.fm4 • £,e.:wden: 29 .02.%, ; 6:42

-1

Steering circuit 220 13201 420 wheel loaders (models 300 55/301 56/302 57) Non-return valves 0.5 bar 10 bar

Steering valve Front wheel, 4 wheel steering HP pump steering and work hydraulics

Rear axle steering ram

.•.. , ~,

steering ram

Servostat (Eaton) 3Ao2700{Us()

Steering pressure setting 170 bar Setting 1. Unscrew hose WS 19

Measuring ports for troubleshooting

2 .Unscrew screw connection with int.er-

Priority valve

mediate piece WS 19 3. Set pressurewith hexagon socket 7/32 4 .Fit parts and check pressure

Annex . ~

... .. ~

-

. ~

..

~

....

Ref: .I1£- Desc!i£lion 81 Senwr (front axle centre position) 82 SenWf (rear ..1. centre posillon) 63 PI",II.vel Sensor Temperature sensor (engine and cooling B4 011) a5 Tempernture scow, (hydraulic oll) 00 Hom D1 Steering electronics ELE4 Instrument panelligltl~ PLP6 Rw Ught (left) Eli 1$6 Pront parking light (left) £;7 Pront parking lighl (right) E6 Rear light (risht) El).l'12 Switdllights SS,S12.SI3.SI7 E13 Rear w"rhng light E14 Interior light with switch EIS High beam, dippOO heam (left) E16 Hlgb beam, dipped beam (right) E17 Cigat.ll. lighter FLF27 Puses (rentral electrics) A!9.. f31 Poses (power supply) 01 Generalor with elUTent regulator G2 Battery HI Telltale· synchronisation f« Telltale - parking brake H5 Telllllle . preheating HE! Telltale· hydmuUe 011 filter H7 Telltale,· oil pre.~sure (engine) HE! Telltale · brake pad wear H9 Telltale - coolanllevcl HlO Telltale · air filter 1-111 Telltale .... not assigned HI2 Telltale - generator charge funetion HI3 Telltale· tum indieMors HI. Tcllmlc · differential lock HIS Telltale - high beam Hie Tum indlcal!Jf (frout left) HI7 Tum Indicator (front right) HIe 1\un IndicatvT (r_ letl) H19 Tum Indicator (rear right) H2O,1121 Brake IIght~ (left, right) Kl Switching relay (starling interlock) K2,I<3 SwitchIng relay (driving direclion) Switciting relay (differen!iallock K4

K5

Ke K7

K6 K9

2 2

3

3 3

4

"

phase)

Kll

2

K12

3 5

Starling relay Pulse generator (SO speedometer) K13 Hazard light Indicator KI4 Pulse generator (intern1lttenl wiper) KIS TIme-lag relay (telltale check) K16 SwHehi»g relay (drMllg interlock) 1<17.K16 Hlgh .current relay Mt Slarlet M2 I'mnl wiper motol 1.13 Pront washer fluid pump 1M Rear washer fluid pump M5 Reat wiper "M", Me Pan motor for cooling (2 speeds) M1 Fan motor for heati ng (3 ,peed.)

PI

P2 1'3

P. 1'5

1'6 1

fl1

2

SI

3 3

82 S3 S'

3

Temperature indleator (engine & COOling oil) Tempe"'t"'" indkator (hydraulic oil) SpeOOorneter (option) Ilotlfmeter Voltmeter Heater plug filament Preheater and starter switch

PMUng brake switch (NOC) Drive switch (steering eolnom left) Push hullon . synchronisMI""

$5

Switch ~ bounce control

3

S6

3 3 3 3 3 3 3

87 S6 SO

Switch - dlfrerentiallock PrCSlU.fC switch · oil return flow flIlrr OJI pressure switch (engille) CAntact wire In brake pad Pressure switch air filter Ught switch Swll"h • working light Multifunction switch (steering column

911 $12

$13 St4

<•••

515

Hnurd warning light .wilch wi th telltale

5

SIS

Dntke tighf swit.ch ~ service brake

5 5

2

&

6 6

Swllch - rear window wlperlwnsher Temperature switch hydmuhc 0\1 2nd SIS cooling stage S19 SWilCh - fan (hcater blower) $2{) Pres,ure switch (differential lock) 821 Switch - steerlnglhigh speed VI V 0 Suppressor diode (in solenoid valve , I plug) Vll Blocking diode V12"Vt9 Blocking diode (telltale cheek) V20. V21 Blocking diode (differentinllock) S17

Xl _X2

X3

phase)

S·pole plug (.Ieering e.lectronic.)

8,pole plug (high speed .witeh) 3-po1e plug (numberplale lights) 2. pole plug (switch lightS)

2

2

X4

2

)(5.),9

2

1

Xl0 XII

2

XI2

e

X13

I·pole plug (radiO)

6

XI4

?I -pole plug (cab - frame) 2.pole plug (."lerm!d . high speed) 8·pole plug (speedometer .Ignal .mpll· fier} 8-pole plug (working light switch)

XIS

XIS

XU

Svpolt plug (mhitlng l.xmcon swildl)

I·pole plug (ro.. ilng be.con bracket) t ' PQIe plug (2nd rotating bencon)

&

5

3 2

3

)(18 )('9 2 ~pole ph!!: (a.dditional front wOrldng

)(20

3

3

)(21

3 3

)(22

2 2

X23

X2'

2 2 2 2

3 3 3 4

dthl)

5

I'-','-"

a

Fucl level lndleator

a

brakes) Switching relay (difrcrentialiock) Switching relay (wiper. 200 speed) Switching relay (wiper, lSI speed) SwitchIng relay (separation . SlarlJng

Kl0 'Swilchiilg'retayi2nd

5

light) 2-pole plug (additi<::nnl rettt working Ught) 2 ~po1c phjg: (compre~sor .seal aqjuSly

ment)

4 pole plug (4 -pole socket) 8.pole plug (4th centrol circuit .witch) 8·pole plug (4~1 control cirelli! push button)

)(25

Relay bracket

X26

2·pole plug (additional healing)

&

2· pole plug (telltale 4 wheel steering) 2·pole plug (telltale front wheel stccring) VI Solenoid - (high pressure switchover) Y2 Solenoid - (reverse driving) ya Solenoid - (forward driving) Y4 Solenoid - (ht/ 2nd gear) Y5 Solenoid - (4 wheel.teedng) Y6 Solenoid - (fmnt wheel steering) n. Y8 SQlenoid .•. (bounce rontrol) Y9 Cutoff .olenoid YIO Differential lOCK (rear) X21 X2~

VII

2

2

Differential lock (front)

6

7

5

FUMIlze3:

50A = 1'29, F3!l. F31 40A = F22 lSA = PI. Fl, 1'26 lOA ~ I'S, 1'6. 1'15, 1'17, Pl9, F20, 7.5A ~ F3. F4, Fl. rl!. F9. 1'10. I'll.

2

2.3

1'18, F23. 1'24 f'14.1'28 ~ diode sockels

2

Switching relay ("'parnl\Qn . starting

L_........

A,l<

RAJiltlMJm"

Bili!lQ.1~·@Jru4

Annex

_ion 81

SenSOr (fron! axJe centre position) 82 Sensor (rear axle centre position) Fuel level senSor f» Temperature sensor (engin. and cooling a4 oil) as Temperature sensor (hydraulic oil) so Hom Ot Steering electronics I:1..E4 Instrument jlllnelllghts PL..P6 Ell Rear I\ght (left) Ee From parking Ught (left) 107 I'ront parking light (right) EO Rear ligh. (right) EH12 Switch lights S5,SI1,SI3.SI7 E13 Rcar working light E14 Interior light with switch E15 High beam. dipped beam (lel'l) E16 fIlgb beam. dipped beam (right) E17 Cigar.lle lighter Fl .. F21 Puses (central electrics) f29 .. F31 I'Ilses (power supply) Ot Generator with ClllTent regulator (J.~

K5

KG K7

K8 1<0

A·2'

2

3

5 2

A '.'_~~ V _ ·· "

ReLno. Des<:ription s;;;;iiebi~g;cl~y (2nd cooling stage)'" Kl0 KlI Starting relay K12 Putse generator (SO speedometer) 1\13 Hazard light indicalor K.4 Pulse generator (Intermittent wiper) K15 Tlme·lag relay (telltale che.ck) K16 Switching relay (driving interlock) KH, K16 High·current relay 1.11 SUlrter 1.12 Front wiper motor

4

X.5

Rt S1

Healer plug filament

)(23

Prcbeater and starter gwHch

)(24

8~polc plug (4th control circuit push but~

PS

82 $:I 84

85

86 87 88 3

89

3

8\1 812

3

813

3 5

$1.

5

515

S.6 $17

SIS

Parking brake switch (NOC) Drive switch (steering columl11el'l) Push button· synchronisalion Switch · bounce control Switch dif[crentJallock Pressu.re switch ~ oil return flow filter Oil preSSure switch (engine) Contsel wire in brake pad Pressure switch ... air filler Light.witch Swi.ch . working lighl Multifunction switch ('Ieering column

8

6 6

6

2 2 2

2·pole Illug (solenoid · high ,!",.cd) 8-pul. plug (speedometer signal runpliXI6 fier} )(17 a-pole plug (working light swHch) XI8 XI9 2·polc I'lug (additional front working . light) ' ·pole plug (additional rear working X2C light)

)(21

3

3

3 3

3

right)

Haurd warning light switch with telltale Urnkc light .witch . service brake Switch ~- rear window wiper/washer Tempemure $wilch . hydraulic oil 2l1d

X22

ton) X25 Relay bracket )(26 2-pul" plug (additional heating) )(21 2 ' 1'010 plug (tcHUlI. 4 wheel Sleering) )(28 2-pol. plug (telltnle front wheel atC<lring) '11 Solenoid . .. (high pressure 8witchnver) '(2 Solenoid - (reverse driving) '(3 Solenoid .. · (forward driving) '14 Solenoid - (lst/2nd gear) '15 Solenoid - (4 wheel steering) VB Solenoid ,.. (fron. wheel steering) '17, V8 Solenoid ... (bounce control) '19 OMIT solenoid Yl0 Dlffcrenliallock (rcar) VII Differcnti.llock (front)

6 6

8

6 2 2

2

cooling stage Fuse 81.1.$8:

S19

brakes) Switching relay (differential lock) Switching relay (wiper. 2nd speed) Switching relay (wiper. I st speed) Switching reJay (s<:paratlon . stlll1lng phase) Switching relay (separati"" ' .Hrting

3

6

va

P4

5

21·polc plug (cab - frame)

2-pcle plug (compre-ssnf -sea. adJu~i:l . mem) 4·pule plug (4·pule socket) 3·pok plug (4th ccnuot circuit.witch)

r.a

3

)(14

Rear Wll,hcr fluid pump Rear wiper motOr Fan motor for cooling (2 speerls) Pan motor for heating (3 speed.)

Puellevel indicator Temperl\lure Indicator (engine & rooling oil) 'Temperature indlcntor (hydraulic oil) Speedometer (option) Hour meier Voltmeter

P3

3

8

6

1 2

1.14

M7 PI

2

6

a·pole plug (steering electronics) a·pole plug (high speed .wilch) X. 3·polc plug (numberplMc lights) )(5 .. X9 2·pole plug (switch lights) XtO 8.pol. plug (mUlling beac()n switch) XII J ·pole plug (m.ating beaco" braekel) , .pule plug (2nd rotating beacon) )('2 X13 I-pole plug (radio) Xl ,X2 X3

Front washer fluid pump

1.1&

8

s~~

1.13 1.15

a.Hory

Telltale - synchronililliion H4 Telltale - parking brake H5 Telll.le - preheating H6 Telltale · hydraulic oil titter H7 l'e.lItale - oll pressure (engine) H6 Telltale · brake pad wear H9 l'elllllle· coolant level HtO Telltale .. air filter Hll Telltale - not assigned HI2 TeUwle - generator cbarge fllnctlon HI3 Tellt.le . lurn indicators Telliale - dlff.ronttallock HI' H\5 Telltale - high belUTl HIe Turn lndical<lf (front lel'l) HI? Turn Indicator (front right) H18 Tvrn Indicator (rear left) H19 Turn Indicator (reM right) 1120, H21 Drake Ughls (left, right) Kl Switching relay (starling interlock) K2.K3 Switching: rday (drl,ing dire<:tion) Switching rclay (difrerential lock ..

HI

K4

2

Switch - f•.ll (heater blower) S20 Press",,, .wilch (diffcrentiallock) 821 Swllch - steeringlhigh speed Ifl .,VlO Suppressor dinde (In solenoid valve ph;g) 1/1 j Blocking diode r 1/12..1119 Blocking diode (teiliale check) 11M, V21 Blockingdiodc(dlffcrentiaI lock) 1122. \/?3,11.1""kine dinde (driyin~ interlock)

5 2

I

2,3

50A " P29, P30, 1'31 40/\ " P22 15/\ = Fl. 1'2.1'26 10/\" 1'5,1'6,1'15. Fl'!, 1'19, nO. I'2 I.r'ZS, £'27 7,5A " 1'3,1'4. F1. 1'8, 1'9. PIO, I'll. 1'12, PlJ, 1'16.

PI S, 1'23. 1'24 Pl4 . 1'2& " diode sockets

2

.... ph.se) OM )1.))" "41o"" 1.1 • S9.im4

~ <:

Q N N

In In

...g E

C; ~ 8~ .., ~

10 ",

...tn ::e~ 8 8 ·8 g~ :c ~ III

..

III

iii

0

1: U <1/

W

..

to

e

,g ~ "iii ,.

~

..., ~

Annex Ref. flO. Description 61 Sensor (fron! axle centre position) Sensor (rear rude centre position) 62 D3 I'uellevel sensor Temperature sensor (engine and cooling 94 oil) Temperature: sensor (hydnmllc oil) !lS B6 Horn 01 Steering electronics EI..E4 Instrel!\ent panel Ugbu; P 1...P6 116 Rear light (Iel\) Ell 117 Ell

_loIt 2 2

3 2 3

From parking lighl (lef\) Fronl parking lighl (right) Rear ligh! (right)

4

K9

A -]<

Switching relay (scparal,on - &!luting

2 3 3 3 3

3 3 3 3 3

5

6

2

M2

Front wIper moior Front washer fluid pump Rear washer !luid pump

6

Rear wiper motor

6 1

P2 P3

P5 PO f\ 1 ij 1

62 83 S. 86

56 87 S& $9 5t t 812 813

$14 5

5

Starter

P4

01

phase) 3

MI

Pl

F29 •. mt Fuses (power supply)

phase)

Starting relay Pulse generator (SO speedometer) 1(13 Hazard light indicator Kl' Pulse generator (interm!!tcnt wiper) KI5 llmc·lall ,elay (telltale cheek) Kia Switching relay (driving interlock) KIl. K'6 HI&h~ct,rrenl relay

M5 M6 !.IT

8

3..,,,,,,

Switching relay (2nd cooling stage)

KII K12

1.14

E13

Generator with current regul.tor 02 Battery HI Telltale - synchronisation 114 Telltale - parking brake 115 Telltale - preheating 116 Telltale - hydraulic oil filter Hl Telltale - oil preasure (engine) H& Thlltale - htake pad we..H9 Telltale - coolant level HI!) Telltale - alr filter Hll Tellta!e - not a$Signed HI2 Telltat" - generator charge function H13 Telltale - lum indicalors HI. Thlllllle - differentJallock HIS Telltale - high beam Hill Turn indicator (from len) Hil Turn irnJicator (frOnl right) HIll Turn Indicator (rear left) HI9 Turn indicator (rear right) H2I), Hal Brake lights (left, right) Kl Switching relay (starting imerlock) K2,K3 Switching relay (driving direction) K4 Switching relay (dlfferentlallock brakes) K5 Swltdtlng relay (differential lock) K6 Switching relay (wiper, 2nd speed) K7 SwltchJng relay (wiper, 1st speed) K6 Switching relay (scp1ltatlon starting

KIO

Ml

E9-EI2 Switch lights 55,S 12.S !J,S 11

Rear working light 1114 Interior light with switch 1115 High beam. dipped beam (left) 1116 High beam, dipped beam (right) 1111 Cigarette lighter F1..F27 Fu,e, (centra! deemcs)

Ref. no:" oe;;;ripiion~~---'~-~

Fan motor for cooling (2 speeds) Fan motor for heating (3 speeds) Fuel level indicator

Temperature indicator (engine & COOling 011)

Temperature Indicator (hydraulic oil) Speedometer (option) Hour meter Voltmeter Heater plug filament Prehea.ter and statler switch

Parking brake switch (NOCl Drive swilch (steering column len) Push bUtion - synchronbalion Switch - bounce control Switch - differential lock Pressure switch· oil return flnw filter Oil pressure switch (ellgine) Conlact wire in brake pad Pressure switch - air filt.s Light.wilch Switch - working light Multifunction switch (steering column

817

right) Hazard warning IIght.witch with telltale Brake light switch - se,vloe brake Switch - rear window wiper/washer

StS

Tem.perature swilch ~ hydraulic oil 2nd

819

Switch

820 52 t

Preasure switch (differential lock)

SI5 SIt)

&

3

g-pole plug (steering electronics) S,polc plug (high 'pood switch) X3 X4 3-rol. plug (numberplate tights) X5, .)(9 2·polc plug (s",itch lights) 8-pole plug (minting bencon swlleh) )('0 )(11 I "pele plug (rotating beacon bracket)

)(1. )(2

)(12

I-pole plug (2nd rotating beacon) j-poleplug (Iadio) 21·pole plug (cab - frame) 2,polo plug (solenoid · high speed) 8-pole plug (speedometer signal amplifier) a-pole plug (working light switch) 2-polc plug (addillonal front working llgh!)

2-polc plug (additional renr working light) 2·polc plug (""mprcssor scat adju$!'

3

meat)

2

4 pole plug (4·pol. socket) S-polc plug (4th control circuit.witch) g·pole plug (41h control circ"it push but ton)

Relay bracket 2-pole plug (additional heating) l -pele plug (telltale 4 wheel Sleeting) 2-I,ole plug (telltale front wheel steeting)

Solenoid - (high prc~~ure switchover) Solcnoiu- (reverse driving) "

2

2

4

5

5

8 3 ~

8

8 6 8

3 7 ~

2 2

SolenOid - (forward driving)

2

Solenoid · (hi 12nd gear) Solcnold - (4 wheel <leering) Solenoid - (f.ont wheel Sleering)

2 2

2

Solenoid - (bounce ""nlrol) Cutoff solenoid Olffe.rentiallock (rear) OiffercntL"li lock. (front)

cooltoll stage

6 6

8

at• • :

fan (healer blower)

1'29, 1'30, Il3I 1'22

Switch - siccringihigh speed

Vt ,.VIO Suppressor d\odr: (in solenoid valve plug) VII mocking diooe VtV/19 Blocking diode (telltale cheek) VllO. V2' Blocking diodr: (diffcrcntiallock)

FI. 1'2, 1'26

2.3

£IS, F6. PIS, FI? Fl9, 1'20, 1'21, 1'25.1'27 F3. 1'4, 1'7, FS, F9, FlO, I' ll, F12, 1'13. F16.

1'18,1'23,1'24 1'28 " diooe sockets

~~~,.~~.3_..!l. I"""!~~I.i<><le~ (~ri.v.i!'!;irr.t~'.I.",,k) ....

phase) fMJOI Y>Jm~"''''· o e&tkJ..n. ,1:.5Um4

Elektronics box 220 1320 1 420 wheel loaders (models 300 551 301 56/302 57) 8 _ _"

· -10 1 __- 56

9 _~ 11 ~' 12 -~ "'-.

13 _ 14

Cable no. assignment

- 4 - 3

15

No.

2

18 ~

FunctIon

mm2

1

Flat plug sleeve

Flat plug

2 4

Input · Rear sensor

Earthing connectIon

Ftont whool steering 0 1stspood 0 Rear sensor 0

~ ~O""ut<h"k

10

0 4 wheel stoorlng

12

0 SynchronisatIon 0 1Magnet 1st spood 0 Front sensor

14

0 I Magnet 4 wheel

/ Input check

16

Input · Telltale 4 wheel steering

1,0

o I Magnet front axle

o I Lamp asynchronous o I Lamp 4 wheel steering Booper for

JIf@

o I Lamp front wheel steering

malfunction

302$3303.al

Anne.

11l.."!:.!",·..~!,!iOo~•.. m _ .._ ••_ .m.m.. ___~ B1 B2

B5 118

Sensor (frool axle centre positiun) Sensor (rear alle centre position) Fuel level sensor TcmperalUre <COst" (engille and cooli.lIg oil) Tcmpemture sensor (I1ydreulic oil) Horn

01

StecMns eJectronics

BJ

114

3 3 3

Kl1 K12 K13 KI. KI5 KI6

Starting relay Pulse generator (SO speedomewr) Halanllight indicator Pulse generator (intermiHcnt wiper) Time·lag relay (tellt"le check) Switching relay (driving Interlock)

. -', · o v phase) Xl, X2 S·polc plug (st.~fin& electronics) 1<) S-polc plug (high speed switch) )(4 j·pnle plug (numherplatc lights) X5. ,X9 2 , pole plug (switch light.) )(10 Spnle plug (rotaling he.CO" switch)

3

l ~ polc plug (fO(;Hing beacon brookel)

5-

Starlet

2

)(12

s

6 6

Xt3 XI4

I.polc plug (2nd rotatiog heacon) I.~pole plug (radio)

21-po\cl'lug (cab· frame)

3

XI.

2· pnlc plug (solenoid - high speed)

ES E6

Rear light (left) Pront plldcing \ight (1.1\)

1.12 1.13

Front wiper motor Front w&£her fluid pump

£7

Front parking light (right)

M4

Rear washer flu id pump

~~~~

~'EI2 SWItch lights S5,SI2,813,SI7 E'3 Rear working light £14 Interior light with switch E 15 High heam, dipped henm (left) E16 High heam, dipped beam (right) E17 Cigarette lighter FLJ'27 FUll•• (central electrics) F29"F31 I'uses (power supply) Gt Generator wilh current regulator 02 Battery HI Telltale · synchronllUllion H4 Telltale· parking brake liS Tellta.ie • preheating He Telltale · hydmulic oilliHcr Ht Telltale - oil preuure (engine) He Telltale · broke pad wear He Telltale · coolant level Hl0 Telltale· air flIta Hll Telltale - nOI assigned H12 Telltale - generator charge function Hla Telltale - Ium indicators HI. Telltale . differenlia! lock H15 Telltale . high beam H1a Turn indicator (front len) HI7 Turn indicalor (/ronl right) HIS Tumindicalor (rear left) HIS Turn indicator (rear right) H2O, H21 Brake lights (letl, right) 1(1 Swllcblng mlay (statting interlock) 1(2$3 Switching relay (driving direction) 1<4 Switching relay (dlfferenllal lock · brakes) 1(5 Switching relay (d.lffercntiallockl KG Switching relay (wiper, 2nd speed) K7 Switching relay (wiper, 1st speed)

~~~-

Me

1.11 PI

8

P5

S' 52 S3

3

84

3 3 3 3 3

55 sa 57 S8 80 911 512 513

2 2 2 6 6

.

phase)

K9

Switching relay (separalion Marting

PO III

I 2 3 3

Fud level lndicotor Temperalure indic.tor (engine & woling

3

oll)

3 3

Temperature indicator (hydranlic oil) Speedometer (not ror model 300 51) !lour meter Voltmeter Heater plug Ilhtment Preheal"r and starter switch Parking brake switch (NOCl Orive .witch (steering column left) Push bullon . synchronisation Switch . hounee control Switch . differential lock Prcssure switch _oil relurn flow filter

2 2 2 2 2 2 3

on pressure switch (engine)

:I

Contact wire in brake pad

3 3

Pres,ure switch", air filler Ught switch Switch _ worklng light Multifunction switch (steering cotUlltn 514 right) SIS HllZard warning light switch wilh lelll.le 916 Br:akelighl.wi1ch. ~ ..!Vic. brake $11 Switch - rear window wiper/w.sher 518 Temperature switch· hydrnulic oil 2nd coolm8 siage 519 Switch fun (heater blower) 920 Pres,ure switch (differenllallock) S21 Switch ", siccringfhigll speed VI 'Ito Suppressor dIode (in solenoid valve.

8

3 3

4 s 6

Blocking diode

V20, V2t Blocking diode (differential lock)

I I

ncr) S-pnle plug (working light switch) 2-polo plug {addition.' front working Xt8. )(19 light) 2-pole plug (additiona.. rcar working X20 light) X2t 2' poie plug (compressor """tadjust·

3

X17

menl)

3 X22.

2)(23

"plug) 1/11

6

XW~~~-~~

ran motor for cooling (2 speeds) Pan motor for heating (3 speeds)

V12" V19 HI ock'lUg d'lvue . ,,' (IeIIh"e _. check)

Switching relay (scparoll"" - slattIng

~8

P2 P3 P4

3 3 a 5

S

X11

Ml

K17, K18 High--currcnt relay

ELI!4 InslnJment panclllglJl! PLP6

2,3

4·pole plug (4"pole socket) a·pole plug (4th conlrol circuil switch) )(24 3-pole plug (4th conlrol circllit push but· Ion) )(25 Relay bracket XZ6 2·pule plug (additional healing) X27 2-pnle plug (telltale 4 whecl steering) )(28 2.pol" plug (wlllal. fmut wheel .t<:<1ringl YI Solenoid ", (high pre",,,rc switchover) Y2 Solenoid - (reverse driving) Y3 Solenoid", (forwnrd driving) '14 Solenoid (lsi/2nd gear) Y5 Solenoid .. · (4 wheel Sleering) '16 Soicnoid .. (front wheel'leering) '17, '18 Solenoid ~ (hounce c"olml) YO Cutoff solenoid Y'C Differenlial lock (rear) VII Uiffcrcnllallock(front)

2 2 2 2

2 2

~~ :1:;9 1'10 F3!

40A ~ 1"'22' - , 15A ~ I'l , F2, F26 lOA ~ F5. £'6. PIS, 1'17, 1'19, no, 1'21, F25, F27 I,SA ~ P3, 1'4, 1'7, 1'8, 1'9, 1'10, I'l l, 1'12, F13, F16, Fla, F23. £124 FI4 ' 1'28 ; diode & sockets ~ S5, Yr. ¥e, 117 V8 01

~~~ k2<

BA 300S)"

"&1iM IO'SUm4

Wiring harnesses 220 I 320 I 420 wheel loaders (models 300 55 1 301 561 302 57 Horn

Restriction indicator Temperature switch Battery Air filter Fan 1st & 2nd speed \

Fuse box with distributor 3 x 50 A

Solenoid Steering synchronisation

re

Solenoid

It/peed

Pressure differ~ ence valve

Master brake cylinder Rev sensor with brake light switch Speedometer

Sorenoid 1st & 2nd speed

Temperature sensor Hydraulic oil In instrument panel

Solenoid foreward/reverse 3028330 I ,Ill

Subdivision of wiring harnesses 220/320/420 wheel loaders (models 300 55/301 56/30~ 57) Wiring harness 8ssy CD Drive automatics

Ii5l, ~ ~= -==(e2"''''' ~' '''''''''''1fF§j,PlUgS Plug housing

38330031.150

Wiring harness 8SSY @ ~ Differential lock ~ High spseed (option)

~ ~III,

Wiring harness easy ® - Bounce control

•

·~

~ Steering valve

Z~

~=Q]~"''''''''----PIU9S , /'

Plug housing

~~

- -('1f(l ",

,~. _'_' M_ t: _~Il;j

~/ '

38330051.100

Plugs

'PlUg housIng 302s3302,al

Group Cab

34

/

Removing the front wiper motor 220/3201 420 wheel loaders (models 300 55/301 56/30~j7) - Remove the wiper arm WS 13 - Unscrew the nuts fixing the motor (WS 221WS 24) - Remove the upper instrument panel (4 countersunk screws) - Remove the supporting sheet-metal panel for the steering column (remove screw on steering column WS 17) - Remove the supporting sheet-metal panel upwards - Remove the lining on the right of the steering column (countersunk screws) - Separate the compact plug and the earthing cable through the lateral opening - Remove the wiper motor upwards through the opening of the instrument panel (wiring harness in the instrument panel Is sufficiently long)

E765303,iso

•. . A·"_'<UH<_."~"""-'~_'

~.·

o __

,~~~~2:l~!J

Group Hydraulic system

36

Annex

IRer. no. IJmt'lpnOn Sleering Servo.tat 2 3

t<ramcr steering rams Priorll;, valve

4 5

Master brakcr cylinder Pressure dlffcrenee valve

6

Expansion fank

7

Front lillie dlffcrcnlln! lock

8 9

Rear a.1e differenliallock Hydrostatic drive

II}

Variable d15p!ncement PUInll - drive (MVG40DA) Variable displllCemenf motor - drive (MVMI07DA)

II

12 13

Press",e cut-off Radialor

14

Return flow filler for hydraulic oil

15

23

Tank v,,"m.Hon Hydraulic oil tonk Control vaIve for loader unit Look fer long. haul "avcl Control ram for quickhileh facility Uftram Tiltrllln Bounce control SO 1393/08, 09 .. 3·fold control valve with

24

float JlO.,h ion SO 1367101 - h.lgh speed version

16

17 18

19 20 21

n

A<t5

5!1: WI $61 J(I~ $1 'Dl ' &ti~lM ~ ·19.t:m4

An.Rex

(1)r - --~!·.· · ·--··· ·.· · ·=·-~l .JJ9.~

r j~. n~ :'l I ,

i

i

I I[~I II III I i ~~L _'

ct-J

__ '

Il,,. L

-\~).­ ~.~

- ...

1

dl~o(i~)

(Ii} ;

r---"'

0.5 be,

f fi - · _· · ..lumlino ldiff...mJ!Ji·1J '1' nhxlo (!j f!L ~t,!! .. !!i. . . - FJ!.- ~-.....- r ......

4!

....... ____ . ~

,

(8) [lJl .

--

~ff;; "

-I • . ••• . • • • • • • ••• • w

•• • •

,~~ £!!!!P"~~<e~~~~t~~.'?9 .

~f*_~

r' ""1$1trli(:$.-) ' • .,.. . ,~ .. _~ .. _~_- .... ~t-m"" --1

(~

Hydraulics diagram 320/420 Modol301 56130257- Slandord equipment valid from oorllli 110. 301 58 0130 8.nd 302 57 0170 33001 00 2Sb II 1.9<

BAWl $Of"

! . B4i1if)~.1.. • 79.rIM

A-26

Anne",

2

Kramer steering rams

3

Priority valve

4 5

Master braker cylinder l'Iessure dllferCl1Cc vah-e

(;

El.panslon tank

1 8 9 10

Front rude dlffcrenliallock Rear axle diffcrcnliul lock Hydrostatic drive Variable displacement pump drive (MV(l4(lPA)

IJ

Varioble displacement motor - drive (A6VMI07PA)

lZ

Pres.ure cut-off

13 14 15 16

Radiator Return flow flUer for hydraulic oll Tank vcntUallO" Hydmullc 011 tank

11 19 20

Control valve for loader unit Lock for long-haul I'-live I Control ram for quickhitch facility Liftran\

21

Tilt ram

22 23

Bounce control SO 1393108.09 -. 3 -fold control valve with float po.ition SO 1367101 - high specJ version

13

24

A ..:25

OM JOl S1 , BdHoo U « JUHl4

Annex.

~~

=..sJ [J

.I...,,,..

Ii ' t

1

I. I

!~,~.~ .~.

'ronl a~la

fa

o:-lt0

4 .~ .~

Cay

0"~It ';AJ~:ful0" ··· · · "~ rl M-~

. . ····"tl .. P!!!~~~~Jp~~.~ .

Pl!~pa1O!i#

@

r' ~~._!tt ~

Jie>Oi«t ... ·.t....

@

Hydraulics diagram 420 Mo~1 302 57- Standard equipment

valid from serlol no. 302 57 0001 up to .... rlal no. 302 57 0169 3800I0025b/lUJ<1-

OM 30111-

.1 t"JUm4

M6

Allne~

2: 3

Kramer .steering rantS Priority valye

4 6

Master braker cyUnder ProSSll,e difference valve Expan,;o" tank

1

Fmnl axle differential lock

B

Rear axle differential lock

9 10

Hydroslatic drive Variable displacement pump - drive {A4VG40DA) Variable displacement molor • drive (1\6VM 100DA) Prossure cut-ofr Radbllor Return flow IlIter for hyd.rnullc on

S

II

12 13 14 15 16

Tank vcnfilal.iofl

11

Control valve for loader unit

Hydraulic olltnnk

18

lAck for long-haul travel

19

Control ram for quickhl!ch facility

20 21

22

Liftf.m 1111 ram Bounce control

l3

SO 1393108, ()'} - 3·[old control valve wllh

24

SO 1367/01 - high spoed version

l10al posilion

A-25

IlA)QJ,56fW157En · fAffioox'iHm4

Annex

CDr---i i I

i !

I

i

L

Ir, +lf[~-r

~",~.~

I;r

m ~H .· ")o !* ","

~~

!

(~)

Hydraulics diagram 320 Model 301 56 • Standard equipment valid from serial no. 30t 56 0001 up to 301 56 129 3800' 00 25bl 11.94

SA 301\6,.

t ' E&!!oa " *11 J're4

A·26

Annex

Ref. no, uescnpuon I Steering Servo..., 1.

Kramer steering mIn' 3 Priority valve

4 S

Masler braker cylinder

Pressure difference valve

6

flxpansiun tank

7 8

Front axle differential lock Rear axle dHftrentlallock HydrostMic drive Variable displacement pump - drive (MVGZ80A) Variable displacement motor - drive (A6VM80DA)

<}

IQ 11 12

nQl 355IJ!1l00

13 14

Return now fill.cr for hydrauHc oil

lS

J6 17 IS 19 20

1.1 1.2 23

Radiator Tank ventilation Hydraulic oil tank Control valve for loader unit Loci< ro, long-haul ""vel Control ram ror quick.hirch raeilily Liftrilm Tilt ram

flollnee control SO 1393 f 08, 09 - 3-fold <"Quol valve with

float position

A,25

BlI 100 " &' FAll.!tm 1£ -14.f1M

"nne. (~12

xle

(

om ... ~ ;;rt4""' tlT'f! c.,i!j .... j ...... E .' ') 1m" l{fI~-

7 ... '

""",",""

P!~:!~~!'~ (pkt t>:;\~~1.L __ ___~~

~. PIt~

200'"

I

Hydraulics diagram 220 (2~)

Model 300 55 • Standard equipment velld from oorlol no. 300 55 0001 31 001 00 25 J ro:fm

8A 10055£

~

lJl ~ 16}m4

A·26

..... o

(W)

.......

It) It)

g (W)

-

U)

CD

"eo

........

!CD

"!

--z ;= ,s;.

o

N

~

.......

o N

(W)

....... o N N

...,

--::s

.

C

Q)

"io ..J

....o

(l')

........

It)

an

o o (l')

-en

CD "tJ

o

E

---en ~

CD "tJ

as

-o

CD CD &:.

~

o

~ o

........

N

(l')

........

o

N N CD

E

....l! &:.

(.) ....,

--.c ~ (.)

.-:::s

"

Tilt ram 220/320/420 --_ wheel loaders (models 300 55/301 56/30257) . . ........ ~

~,.,-,.

Securing screw Hexagon socket" 3

'" 38036070.150

Torque 1100 Nm Removal

- Remove securing screw (hexagon socket" 3) - Turn off the cover with a chain spanner - Pull out the piston rod complete with cover, guide bushing and piston - Unscrew the self-locking nut - Fit the complete sealing kit - Assembly in the reverse order

self-securing nut and securing screw are included in the s ealing kit

302S3!l 11,ai

Quickhitch ram 220 1320 1 420 wheel loaders (models 300 551 301 56 1 302 57) --,-..

- - " , ' ' ' - ' ' ' '......

-~--------.

Torque 90 Nm

38a31lO00Jso

Removal

- Remove the circlip - Pull out the piston rod complete with the guide bushing and the piston - Unscrew the self-locking nut - Fit the complete sealing kit - Assembly in the reverse order

self-securing nut and securing screw are included In the sealing kit

30253612,al

------------------"-.-"'- " ~-' -

Pilot valve 3rd control circuit 220/3201 420 wheel loaders (models 300 55/301 56/302 157) -.- , --,-----~-."-------------------I

Lock 3rd control circuit

,.--.-I.--l"---"

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Bellows

Cpl guide sleev;

Cpl pilot valve

36036110.180

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Lift ram 220/320/420 wheel loaders (models 300 55/301 56/302 57) Securing screw Hexagon socket 0 3

"" Torque 1100 Nm Removal:

- Remove securing screw (hexagon socket 0 3) - Turn off the cover with a chain spanner - Pull out the piston rod complete with cover, guide bushing and piston - Unscrew the self-locking nut - Fit the complete sealing kit

- Assembly in the reverse order

self-securing nut and securing screw are included in the sealing kit

302S3BtO,ai

Pilot valve 220 I 320 I 420 wheel loaders (models 300 55 I 301 56 I 302 57)

Cpl control lever with bellows and cable for diff lock Universal Joint

cpr pilot valve

Pressure Insert

O-ring between individual segments

3!!e36120Jso

30253607,al

Pilot valve with float position 220 1320 1420 wheel loaders (models 300 55/301 56/302 57) Button diff lock

Cpt control lever with bellows and cable for dlff lock /

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X1

X2

T

Bellows

Universal joint

Y1

Y2

~ Set screw

Lock .....-- Float position Guide sleeve

Pressure insert

Cable diff lock

O-ring between individual

segments 302S350B,ai

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Pilot control 220 I 320 I 420 wheel loaders (models 300 55 I 301 561 302 57)

Y2 Y1 X Y X1 X2

Lift & lower

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3rd control circuit

Lock for long-haul travel

Solenoid valves for lock

20 ba.r " D

.........>7" ~

3 8 0360 50'''''

Pressure accumulator for emergency lowering 30253005.01

t control with float position 220/3201 420 wheel loaders (models 300 55/301 56/302 57) lock for long-haul travel (pitot pressure is interrupted)

Lift & lower Froat position

Y2 Y1

X

Y

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X1 X2

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Boost pump

Pressure accumulator for

emergency lowering

302S3606,ai

Hydraulic tank 220 I 320 I 420 wheel loaders (models 300 55 1 301 56/302 57)

Coarse sieve

Filler inlet

Air bleed filter 0.2 bar pretension

Combined suction and reflux filter

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Sight glass for hydraulic oil level »~~ »~ -- »~»~.

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Work hydraulics 420 wheel loader (model 302 57)

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Reflux line

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LS CF EF

Pv ", 20bar

T~~~1r ~~:":lj Priority valve

!,Plug

170 bar

' Socket

P Pressure line priority valve

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from cooler

Temperature sensor 'Irev in

1(40

~ '" 2.5~ - :PT p-"" """" -P3:,~

Drive

Suction line

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'''0.2 bar

Pilot control element ---,

total", 77 t

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0,5 bar 01 to differential lock

Reflux line

-5iifim,mtiai lock

Reflux line control valve Reflux line ollot control Pressure line pilot control 302arbei.ai

302S3604.al

Hydraulic system 220/320/420 wheel loaders (models 300 55/301 56/30257 1 st section - 3rd circuit control 2nd section - Lift circuit 3rd section - Tilt circuit dump out 120 bar dump In 240 bar (320, 420) 200 bar (220)

Control valve

HP 210 bar (320, 420) 175 bar (220)

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Se condary

Dum • pin 240 bar

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Measuring port I

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service work

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Pilot pres' Reflux sure msert 5 bar

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Priority valve Hydraulics I steering

Solenoid Bounce control

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,--------- --,-~ - ,

HP valve Steering

Pressure accu. p = 20 bar

Pump Hydraulics I steering 28 cm3/rev

Hydraulic system 220/320/420 wheel loaders (models 300 55/301 56/30257

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38 e 36 000, ISO

Control line from Servostat Steering

The set screw for the steering pressure is located In the T-port 30283602.al

Group Cab heating

41

Heating 220 1 320 1 420 wheel loaders (models 300 55/301 56/302 57) Rotary switch ball-type cock (oil feed) Windscreen air nozzles

FanSWit~

.......----- Fresh air rotary switch

Air flap cable pull

\ Air distributor

Air flap

Heater

Feed

Reflux

1011 Deutz on~to-air cooled

F series heating ports 220/320/420 wheel loaders (models 300 55/301 56/302 57) F series engines fitted as of serial no.: 220 (300 55) as of 300 55 0001 320 (301 56) as of 301 560130 420 (302 57) as of 302 57 0170

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Valve Insert (port not assigned) Feed line to heating

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Valve Insert (port not assigned) Reflux from heat exchanger

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3(1)e0112.iso

302S4102.ai

Heating 220/320/420 wheel loaders (models 300 55/301 56/30257)

Ball-type cock

3 speed radial fan

Heat exchanger

Air flap

Replace pollen filter as required, Included in maintenance kit "0" (1200 service hours) 30284103.al