Hyundai SL733S Wheel Loader Repair Manual 2023 - PDF DOWNLOAD

CONTENTS SECTION 1 GENERAL Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10 Group 3 Operational Checkout Record Sheet --------------------------------------------------------------- 1-18

SECTION 2 POWER POWER TRAIN SYSTEM Group 1 Structure and Function -------------------------------------------------------------------------------------- 2-1 Group 2 Transmission ------------------------------------------------------------------------------------------------------ 2-2 Group 3 Torque Converter ----------------------------------------------------------------------------------------------- 2-19 Group 4 Axle --------------------------------------------------------------------------------------------------------------------- 2-25

SECTION 3 BRAKE SYSTEM Group 1 Structure ------------------------------------------------------------------------------------------------------------- 3-1 Group 3 Components Specification and Function -------------------------------------------------------- 3-2

SECTION 4 STEERING SYSTEM Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------- 4-1 Group 2 Structure and Function -------------------------------------------------------------------------------------- 4-2 Group 3 Operational Checks and Troubleshooting ------------------------------------------------------- 4-17 Group 4 Test and Adjustments ---------------------------------------------------------------------------------------- 4-23

SECTION 5 WORK EQUIPMENT Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------- 5-1 Group 2 Structure and Function -------------------------------------------------------------------------------------- 5-3 Group 3 Operational Checks and Troubleshooting ------------------------------------------------------- 5-15 Group 4 Test and Adjustments ---------------------------------------------------------------------------------------- 5-25

SECTION 6 ELECTRICAL SYSTEM Group 1 Component Location ----------------------------------------------------------------------------------------- 6-1 Group 2 Electrical Circuit ------------------------------------------------------------------------------------------------- 6-3 Group 3 Monitoring System --------------------------------------------------------------------------------------------- 6-4 Group 4 Connector ----------------------------------------------------------------------------------------------------------- 6-11

FOREWORD 1. STRUCTURE This service manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This service manual mainly contains the necessary technical information for operations performed in a service workshop.

For ease of understanding, the manual is divided into the following sections.

Structure and function This group explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.

Operational checks and troubleshooting This group explains the system operational checks and troubleshooting charts correlating problem to remedy.

Tests and adjustments This group explains checks to be amide before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.

Disassembly and assembly This group explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.

The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your Hyundai distributor for the latest information.

0-1

2. HOW TO READ THE SERVICE MANUAL Distribution and updating Any additions, amendments or other changes will be sent to HYUNDAI distributors.

Get the most up-to-date information before you start any work.

Revised edition mark (①②③…)

When a manual is revised, an edition mark is recorded on the bottom outside corner of the pages.

Revisions Revised pages are shown at the list of revised pages on the between the contents page and section 1 page.

Filing method 1. See the page number on the bottom of the page.

File the pages in correct order.

2. Following examples shows how to read the page number.

Example 1 3-3 Section number (3. Power train system) Consecutive page number for each section.

3. Additional pages : Additional pages are indicated by a hyphen(-) and number after the page number. File as in the example.

10 - 4 10 - 4 - 1 10 - 4 - 2 10 - 5

Symbols So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols.

Symbol

Item

Remarks Special safety precautions are necessary when performing the work.

Safety Extra special safety precautions are necessary when performing the work because it is under internal pressure.

Added pages

※

0-2

Special technical precautions or other precautions for preserving Caution standards are necessary when performing the work.

3. CONVERSION TABLE Method of using the Conversion Table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below.

Example 1. Method of using the Conversion Table to convert from millimeters to inches Convert 55 mm into inches.

(1) Locate the number 50 in the vertical column at the left side, take this as ⓐ, then draw a horizontal line from ⓐ.

(2) Locate the number 5in the row across the top, take this as ⓑ, then draw a perpendicular line down from ⓑ.

(3) Take the point where the two lines cross as ⓒ. This point ⓒ gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.

2. Convert 550 mm into inches.

(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm.

(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.

(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value.

This gives 550 mm = 21.65 inches. ⓑ

Millimeters to inches 0 0

ⓐ

1mm = 0.03937 in

1

2

3

4

5

6

7

8

9

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

10

0.394

0.433

0.472

0.512

0.551

0.591

0.630

0.669

0.709

0.748

20

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

30

1.181

1.220

1.260

1.299

1.339

1.378

1.417

1.457

1.496

1.536

40

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

50

1.969

2.008

2.047

2.087

2.126

ⓒ 2.165

2.205

2.244

2.283

2.323

60

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

70

2.756

2.795

2.835

2.874

2.913

2.953

2.992

3.032

3.071

3.110

80

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

90

3.543

3.583

3.622

3.661

3.701

3.740

3.780

3.819

3.858

3.898

0-3

Millimeters to inches 0 0

1mm = 0.03937in

1

2

3

4

5

6

7

8

9

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

10

0.394

0.433

0.472

0.512

0.551

0.591

0.630

0.669

0.709

0.748

20

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

30

1.181

1.220

1.260

1.299

1.339

1.378

1.417

1.457

1.496

1.536

40

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

50

1.969

2.008

2.047

2.087

2.126

2.165

2.205

2.244

2.283

2.323

60

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

70

2.756

2.795

2.835

2.874

2.913

2.953

2.992

3.032

3.071

3.110

80

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

90

3.543

3.583

3.622

3.661

3.701

3.740

3.780

3.819

3.858

3.898

Kilogram to Pound 0 0

1kg = 2.2046lb

1

2

3

4

5

6

7

8

9

2.20

4.41

6.61

8.82

11.02

13.23

15.43

17.64

19.84

10

22.05

24.25

26.46

28.66

30.86

33.07

35.27

37.48

39.68

41.89

20

44.09

46.30

48.50

50.71

51.91

55.12

57.32

59.5.

61.73

63.93

30

66.14

68.34

70.55

72.75

74.96

77.16

79.37

81.57

83.78

85.98

40

88.18

90.39

92.59

94.80

97.00

99.21

101.41

103.62

105.82

108.03

50

110.23

112.44

114.64

116.85

119.05

121.25

123.46

125.66

127.87

130.07

60

132.28

134.48

136.69

138.89

141.10

143.30

145.51

147.71

149.91

152.12

70

154.32

156.53

158.73

160.94

163.14

165.35

167.55

169.76

171.96

174.17

80

176.37

178.57

180.78

182.98

185.19

187.39

189.60

191.80

194.01

196.21

90

198.42

200.62

202.83

205.03

207.24

209.44

211.64

213.85

216.05

218.26

0-4

Liter to U.S. Gallon 0 0

1ℓ = 0.2642 U.S.Gal

1

2

3

4

5

6

7

8

9

0.264

0.528

0.793

1.057

1.321

1.585

1.849

2.113

2.378

10

2.642

2.906

3.170

3.434

3.698

3.963

4.227

4.491

4.755

5.019

20

5.283

5.548

5.812

6.6076

6.340

6.604

6.869

7.133

7.397

7.661

30

7.925

8.189

8.454

8.718

8.982

9.246

9.510

9.774

10.039

10.303

40

10.567

10.831

11.095

11.359

11.624

11.888

12.152

12.416

12.680

12.944

50

13.209

13.473

13.737

14.001

14.265

14.529

14.795

15.058

15.322

15.586

60

15.850

16.115

16.379

16.643

16.907

17.171

17.435

17.700

17.964

18.228

70

18.492

18.756

19.020

19.285

19.549

19.813

20.077

20.341

20.605

20.870

80

21.134

21.398

21.662

21.926

22.190

22.455

22.719

22.983

23.247

23.511

90

23.775

24.040

24.304

24.568

24.832

25.096

25.631

25.625

25.889

26.153

Liter to U.K. Gallon 0 0

1ℓ = 0.21997 U.K.Gal

1

2

3

4

5

6

7

8

9

0.220

0.440

0.660

0.880

1.100

1.320

1.540

1.760

1.980

10

2.200

2.420

2.640

2.860

3.080

3.300

3.520

3.740

3.950

4.179

20

4.399

4.619

4.839

5.059

5.279

5.499

5.719

5.939

6.159

6.379

30

6.599

6.819

7.039

7.259

7.479

7.969

7.919

8.139

8.359

8.579

40

8.799

9.019

9.239

9.459

9.679

9.899

10.119

10.339

10.559

10.778

50

10.998

11.281

11.438

11.658

11.878

12.098

12.318

12.528

12.758

12.978

60

13.198

13.418

13.638

13.858

14.078

14.298

14.518

14.738

14.958

15.178

70

15.398

15.618

15.838

16.058

16.278

16.498

16.718

16.938

17.158

17.378

80

17.598

17.818

18.037

18.257

18.477

18.697

18.917

19.137

19.357

19.577

90

19.797

20.017

20.237

20.457

20.677

20.897

21.117

21.337

21.557

21.777

0-5

kgf·m to lbf kgf lbf·ftft 0

1kgf·m = 7.233lbf·ft

1

2

3

4

5

6

7

8

9

7.2

14.5

21.7

28.9

36.2

43.4

50.6

57.9

65.1

10

72.3

79.6

86.8

94.0

101.3

108.5

115.7

123.0

130.2

137.4

20

144.7

151.9

159.1

166.4

173.6

180.8

188.1

195.3

202.5

209.8

30

217.0

224.2

231.5

238.7

245.9

253.2

260.4

267.6

274.9

282.1

40

289.3

396.6

303.8

311.0

318.3

325.5

332.7

340.0

347.2

354.4

50

361.7

368.9

376.1

383.4

390.6

397.8

405.1

412.3

419.5

426.8

60

434.0

441.2

448.5

455.7

462.9

470.2

477.4

484.6

491.8

499.1

70

506.3

513.5

520.8

528.0

535.2

542.5

549.7

556.9

564.2

571.4

80

578.6

585.9

593.1

600.3

607.6

614.8

622.0

629.3

636.5

643.7

90

651.0

658.2

665.4

672.7

679.9

687.1

694.4

701.6

708.8

716.1

100

723.3

730.5

737.8

745.0

752.2

759.5

766.7

773.9

781.2

788.4

110

795.6

802.9

810.1

817.3

824.6

831.8

839.0

846.3

853.5

860.7

120

868.0

875.2

882.4

889.7

896.9

904.1

911.4

918.6

925.8

933.1

130

940.3

947.5

954.8

962.0

969.2

976.5

983.7

990.9

998.2

10005.4

140

1012.6

1019.9

1027.1

1034.3

1041.5

1048.8

1056.0

1063.2

1070.5

1077.7

150

1084.9

1092.2

1099.4

1106.6

1113.9

1121.1

1128.3

1135.6

1142.8

1150.0

160

1157.3

1164.5

1171.7

1179.0

1186.2

1193.4

1200.7

1207.9

1215.1

1222.4

170

1129.6

1236.8

1244.1

1251.3

1258.5

1265.8

1273.0

1280.1

1287.5

1294.7

180

1301.9

1309.2

1316.4

1323.6

1330.9

1338.1

1345.3

1352.6

1359.8

1367.0

190

1374.3

1381.5

1388.7

1396.0

1403.2

1410.4

1417.7

1424.9

1432.1

1439.4

0-6

kgf/cm2 to lbf/in2 0

1kgf / cm2 = 14.2233lbf / in2

1

2

3

4

5

6

7

8

9

14.2

28.4

42.7

56.9

71.1

85.3

99.6

113.8

128.0

10

142.2

156.5

170.7

184.9

199.1

213.4

227.6

241.8

256.0

270.2

20

284.5

298.7

312.9

327.1

341.4

355.6

369.8

384.0

398.3

412.5

30

426.7

440.9

455.1

469.4

483.6

497.8

512.0

526.3

540.5

554.7

40

568.9

583.2

597.4

611.6

625.8

640.1

654.3

668.5

682.7

696.9

50

711.2

725.4

739.6

753.8

768.1

782.3

796.5

810.7

825.0

839.2

60

853.4

867.6

881.8

896.1

910.3

924.5

938.7

953.0

967.2

981.4

70

995.6

1010

1024

1038

1053

1067

1081

1095

1109

1124

80

1138

1152

1166

1181

1195

1209

1223

1237

1252

1266

90

1280

1294

1309

1323

1337

1351

1365

1380

1394

1408

100

1422

1437

1451

1465

1479

1493

1508

1522

1536

1550

110

1565

1579

1593

1607

1621

1636

1650

1664

1678

1693

120

1707

1721

1735

1749

1764

1778

1792

1806

1821

1835

130

1849

2863

1877

1892

1906

1920

1934

1949

1963

1977

140

1991

2005

2020

2034

2048

2062

2077

2091

2105

2119

150

2134

2148

2162

2176

2190

2205

2219

2233

2247

2262

160

2276

2290

2304

2318

2333

2347

2361

2375

2389

2404

170

2418

2432

2446

2460

2475

2489

2503

2518

2532

2546

180

2560

2574

2589

5603

2617

2631

2646

2660

2674

2688

200

2845

2859

2873

2887

2901

2916

2930

2944

2958

2973

210

2987

3001

3015

3030

3044

3058

3072

3086

3101

3115

220

3129

3143

3158

3172

3186

3200

3214

3229

3243

3257

230

3271

3286

3300

3314

3328

3343

3357

3371

3385

3399

240

3414

3428

3442

3456

3470

3485

3499

3513

3527

3542

0-7

TEMPERATURE Fahrenheit-Centigrade Conversion.

A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse is to enter the accompanying table in the center or boldface column of figures.

These figures refer to the temperature in either Fahrenheit or Centigrade degrees.

If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.

If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.

˚C

˚F

˚C

˚F

˚C

˚F

˚C

˚F

-40.4 -37.2 -34.4 -31.7 -28.9

-40 -35 -30 -25 -20

-40.0 -31.0 -22.0 -13.0 -4.0

-11.7 -11.1 -10.6 -10.0 -9.4

11 12 13 14 15

51.8 53.6 55.4 57.2 59.0

7.8 8.3 8.9 9.4 10.0

46 47 48 49 50

114.8 116.6 118.4 120.2 122.0

27.2 27.8 28.3 28.9 29.4

81 82 83 84 85

117.8 179.6 181.4 183.2 185.0

-28.3 -27.8 -27.2 -26.7 -26.1

-19 -18 -17 -16 -15

-2.2 -0.4 1.4 3.2 5.0

-8.9 -8.3 -7.8 -6.7 -6.7

16 17 18 20 20

60.8 62.6 64.4 68.0 68.0

10.6 11.1 11.7 12.8 12.8

51 52 53 55 55

123.8 125.6 127.4 131.0 131.0

30.0 30.6 31.1 32.2 32.2

86 87 88 90 90

186.8 188.6 190.4 194.0 194.0

-25.6 -25.0 -24.4 -23.9 -23.3

-14 -13 -12 -11 -10

6.8 8.6 10.4 12.2 14.0

-6.1 -5.6 -5.0 -4.4 -3.9

21 22 23 24 25

69.8 71.6 73.4 75.2 77.0

13.3 13.9 14.4 15.0 15.6

56 57 58 59 60

132.8 134.6 136.4 138.2 140.0

32.8 33.3 33.9 34.4 35.0

91 92 93 94 95

195.8 197.6 199.4 201.2 203.0

-22.8 -22.2 -21.7 -21.1 -20.6

-9 -8 -7 -6 -5

15.8 17.6 19.4 21.2 23.0

-3.3 -2.8 -2.2 -1.7 -1.1

26 27 28 29 35

78.8 80.6 82.4 84.2 95.0

16.1 16.7 17.2 17.8 21.1

61 62 63 64 70

141.8 143.6 145.4 147.2 158.0

35.6 36.1 36.7 37.2 51.7

96 97 98 99 125

204.8 206.6 208.4 210.2 257.0

-20.0 -19.4 -18.9 -18.3 -17.8

-4 -3 -2 -1 0

24.8 26.6 28.4 30.2 32.0

-0.6 0 0.6 1.1 1.7

31 32 33 34 35

87.8 89.6 91.4 93.2 95.0

18.9 19.4 20.0 20.6 21.1

66 67 68 69 70

150.8 152.6 154.4 156.2 158.0

40.6 43.3 46.1 48.9 51.7

105 110 115 120 125

221.0 230.0 239.0 248.0 257.0

-17.2 -16.7 -16.1 -15.6 -15.0

1 2 3 4 5

33.8 35.6 37.4 39.2 41.0

2.2 2.8 3.3 3.9 4.4

36 37 38 39 40

96.8 98.6 100.4 102.2 104.0

21.7 22.2 22.8 23.3 23.9

71 72 73 74 75

159.8 161.6 163.4 165.2 167.0

54.4 57.2 60.0 62.7 65.6

130 135 140 145 150

266.0 275.0 284.0 293.0 302.0

-14.4 -13.9 -13.3 -12.8 -12.2

6 7 8 9 10

42.8 44.6 46.4 48.2 50.0

5.0 5.6 6.1 6.7 7.2

41 42 43 44 45

105.8 107.6 109.4 111.2 113.0

24.4 25.0 25.6 26.1 26.7

76 77 78 79 80

168.8 170.6 172.4 174.2 176.0

68.3 71.1 73.9 76.7 79.4

155 160 165 170 172

311.0 320.0 329.0 338.0 347.0

0-8

SECTION 1 GENERAL Group 1 Safety Hints --------------------------------------------------------------------------------------------------------1-1 Group 2 Specifications -----------------------------------------------------------------------------------------------------1-10 Group 3 Operational Checkout Record Sheet ---------------------------------------------------------------1-18

SECTION 1 GENERAL GROUP 1 SAFETY HINTS FOLLOW SAFE PROCEDURE Unsafe wor k practices are dangerous.

Understand service procedure before doing work.Do not attempt shortcuts.

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

73031GE01

WARN OTHERS OF SERVICE WORK Unexpected machine movement can cause serious injury.

Before performing any work on the wheel loader, attach a 「Do Do Not Operate Operate」 tag on the right side controller lever.

850S1SH03

USE HANDHOLDS AND STEPS Falling is one of the major causes of personal injury.

When you get on and off the machine, always maintain a three point contact with the steps and handrails and face the machine. Do not use any controls as handholds.

Never jump on or off the machine. Never mount or dismount a moving machine.

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

73032E01

1-1

PREPARE FOR EMERGENCIES Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance ser vice, hospital, and fire department near your telephone.

73031GE03

WORK IN CLEAN AREA Before starting a job : · Clean work area and machine. · Make sure you have all necessary tools to do your job. · Have the right parts on hand. · Read all instructions thoroughly; Do not attempt shortcuts.

73031GE26

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

73031GE04

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

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

73031GE05

1-2

PARK MACHINE SAFELY Before working on the machine: · Park machine on a level surface. · Lower bucket to the ground. · Turn the flameout swich to stop engine.

Remove key from switch. · Turn the hydraulic safety lock to locked position. · Allow engine to cool.

73031GE23

SUPPORT MACHINE PROPERLY Always lower the attachment or implement to the ground before you work on the machine. If you must work on a lifted machine or attachment, securely support the machine or attachment.

Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load.

Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.

73031GE06

SERVICE COOLING SYSTEM SAFELY Explosive release of fluids from pressurized cooling system can cause serious burns.

Shut off engine. Only remove filler cap when cool enough to touch with bare hands.

73031GE07

HANDLE FLUIDS SAFELY-AVOID FIRES Handle fuel with care; It is highly flammable.

Do not refuel the machine while smoking or when near open flame or sparks. Always stop engine before refueling machine.

Fill fuel tank outdoors.

73031GE08

1-3

Store flammable fluids away from fire hazards.

Do not incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris.

Do not store oily rags ; They can ignite and burn spontaneously.

73031GE09

BEWARE OF EXHAUST FUMES Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.

If you must operate in a building, be positive there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.

REMOVE PAINT BEFORE WELDING OR HEATING Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.

Do all work outside or in a well ventilated area.

Dispose of paint and solvent properly.

Remove paint before welding or heating: · If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. · If you use solvent or paint stripper, remove stripper with soap and water before welding.

Remove solvent or paint stripper containers and other flammable material from area.

Allow fumes to disperse at least 15 minutes before welding or heating.

73031GE10

1-4

ILLUMINATE WORK AREA SAFELY Illuminate your work area adequately but safely.

Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

73031GE11

SERVICE MACHINE SAFELY Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing or necklace when you work near machine tools or moving parts.

If these items were to get caught, severe injury could result.

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

73031GE12

STAY CLEAR OF MOVING PARTS Entanglements in moving parts can cause serious injury.

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

73031GE13

1-5

AVOID HIGH PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serious injury.

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

Search for leaks with a piece of cardboard.

Protect hands and body from high pressure fluids.

73031GE14

If an accident occurs, see a doctor immediately.

Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

73031GE15

AVOID HEATING NEAR PRESSURIZED FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.

Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area.

Install fire resisting guards to protect hoses or other materials.

73031GE16

PREVENT BATTERY EXPLOSIONS Keep sparks, lighted matches, and flame away from the top of battery. Battery gas can explode.

Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.

Do not charge a frozen battery; It may explode.

Warm battery to 16˚C (60˚F).

73031GE17

1-6

PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

1. Avoid the hazard by: 2. Filling batteries in a well-ventilated area.

3. Wearing eye protection and rubber gloves.

Avoiding breathing fumes when electrolyte is added.

4. Avoiding spilling of dripping electrolyte.

5. Use proper jump start procedure.

1. If you spill acid on yourself: 2. Flush your skin with water.

Apply baking soda or lime to help neutralize the acid.

3. Flush your eyes with water for 10-15 minutes.

Get medical attention immediately.

1. If acid is swallowed: 2. Drink large amounts of water or milk.

Then drink milk of magnesia, beaten eggs, or vegetable oil.

3. Get medical attention immediately.

73031GE18

USE TOOLS PROPERLY Use tools appropriate to the work. Makeshift tools, parts, and procedures can create safety hazards.

Use power tools only to loosen threaded tools and fasteners.

For loosening and tightening hardware, use the correct size tools. Avoid bodily injury caused by slipping wrenches.

73031GE19

Use only recommended replacement parts.

(See Parts catalogue.)

1-7

SERVICE TIRES SAFELY Explosive separation of a tire and rim parts can cause serious injury or death.

Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job.

Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure.

Never weld or heat a wheel and tire assembly.

The heat can cause an increase in air pressure resulting in a tire explosion.

Welding can structurally weaken or deform the wheel.

When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and not in front of or over the tire assembly. Use a safety cage if available.

Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.

73031GE24

USE PROPER LIFTING EQUIPMENT UIPMENT Lifting heavy components incorrectly can cause severe injury or machine damage.

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

73031GE25

DISPOSE OF FLUIDS PROPERLY Improperly disposing of fluids can harm the environment and ecology. Before draining any fluids, find out the proper way to dispose of waste from your local environmental agency.

Use proper containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

73031GE20

DO NOT pour oil into the ground, down a drain, or into a stream, pond, or lake. Observe relevant environmental protection regulations when disposing of oil, fuel, coolant, brake fluid, filters, batteries, and other harmful waste.

1-8

REPLACE SAFETY SIGNS Replace missing or damaged safety signs.

See the machine operator' s manual for correct safety sign placement.

73031GE21

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

1-9

GROUP 2 SPECIFICATION 1. MAJOR COMPONENT Bucket

Tire

Head light

Hydraulic tank

Boom cylinder

Main control valve

Bell crank

Bucket cylinder

Cab

Bucket link

Front axle Steering cylinder

Boom

Main pump

Air cleaner

Battery

Radiator

Counterweight

Precleaner

Muffler Engine

Transmission Torque converter Rear axle Fuel tank

733S2SE01

1-10

2. SPECIFICATIONS

J H C

38

4885 3770 G

F I

B

WITH TOOTH TYPE BUCKET

K D

49 577 50 0

E A 733S2SE04

Description Operating weight Struck

Bucket capacity

Unit

Specification

kg (lb)

10200 (22490)

m3 (yd3)

Heaped

1.4 (1.8) 1.7 (2.2)

Overall length

A

6965 (22' 10")

Overall width

B

2475 (8' 1")

Overall height

C

3215 (10' 7")

Ground clearance

D

370 (1' 3")

Wheelbase

E

Tread

F

1850 (6' 1")

Dump clearance at 45˚

G

2790 (9' 2")

Dump reach (full lift)

H

1150 (3' 9")

Width over tires

I

2295 (7' 6")

Dump angle

J

Roll back angle (carry position)

K

mm (ft-in)

degree (˚)

Lift (with load) Cycle time

sec

Lower (empty) Braking distance

m (ft-in)

Minimum turning radius (center of outside tire)

degree (˚)

Forward Travel speed

1.3 40.0 (24.9) 13.7 (43' 0") 4.95 (16' 3") 30

First gear

7.5 (4.7)

Second gear

13.4 (8.3)

Third gear Fourth gear

Reverse

43

3.0 km/hr (mph)

Gradeability

45 5.4

Dump (with load)

Maximum travel speed

2750 (9' 0")

km/hr (mph)

24.2 (15.0) 40.0 (24.9)

First gear

9.3 (5.8)

Second gear

29.4 (18.3)

-

3. SPECIFICATION FOR MAJOR COMPONENTS 1) ENGINE Item

Specification

Model

YC6J125Z-T20

Type

4-cycle turbocharged diesel engine.

Control type

Mechanical control

Cooling method

Water cooling

Number of cylinders and arrangement

6 cylinders, in-line

Firing order

1-5-3-6-2-4

Combustion chamber type

Direct injection type 105×125 mm (4.1"×4.9")

Piston displacement

6494 cc (396 cu in)

Compression ratio

17.5 : 1

Rated gross horse power

92 kW / 2200 rpm

Maximum gross torque at 1400~1600 rpm

500 N·m

Engine oil quantity

16ℓ(4.2 U.S. gal)

Dry weight

650 kg (1430 lb)

High idling speed

2400±50 rpm

Low idling speed

725±50 rpm

Rated fuel consumption (at rated)

215 g/kW·hr

Starting motor

24 V-6 kW

Alternator

28 V-55 Amp

Battery

2×12 V×120 Ah

1-12

2) MAIN PUMP (+steering pump) Item

Specification

Type

Fixed displacement gear pump

Capacity

100.8 cc/rev

Maximum operating pressure

200 kgf/cm2 (2840 psi)

Rated oil quantity

221ℓ/min (58.4 U.S.gpm)

Rated speed

2200 rpm

3) MAIN CONTROL VALVE Item

Specification

Type

2 spool

Operating method

Mechanical control

Main relief valve set pressure

173 kgf/cm2 (2460 psi)

Overload relief valve set pressure

193 kgf/cm2 (2750 psi)

4) CYLINDER Item

Specification

Boom cylinder

Bore dia×Rod dia×Stroke Ø110×Ø65×800 mm

Bucket cylinder

Bore dia×Rod dia×Stroke Ø160×Ø80×380 mm

Steering cylinder

Bore dia×Rod dia×Stroke Ø 70×Ø45×293 mm

5) DYNAMIC POWER TRANSMISSION DEVICES Item

Specification

Model

Transmission

Axle

Wheels Brakes

Steering

Type

YJ315LH/BD08XD Converter

Single-stage, Single-phase

Transmission

Mechanical, hydraulic

Gear shift

Forward fourth gear, reverse second gear

Control

Mechanical single lever type

Drive devices

4-wheel drive

Front

Front fixed location

Rear

Oscillation±11˚ of center pin-loaded

Tires

17.5-25, 14PR (L3)

Travel

Four-wheel, dry-disc type, pneumatic

Parking

Mechanical type brake on transmission

Type

Hydraulic, articulated

Steering angle

38˚ to both right and left angle, respectively

-

4. TIGHTENING TORQUE OF MAJOR COMPONENT No.

Descriptions

Bolt size

Torque kgf·m

lbf·ft

Engine mounting bolt (4EA)

M18×2.5

30.4 ± 4.6

220 ± 33.3

Engine mounting bolt (bracket)

M12×1.5

9.03 ± 1.8

65.3 ± 13.0

Radiator mounting bolt

M12×1.75

9.03 ± 1.8

65.3 ± 13.0

4

Fuel tank mounting bolt

M16×2.0

21.9 ± 3.3

158 ± 23.9

5

Main pump housing mounting bolt

M12×1.75

9.03 ± 1.8

65.3 ± 13.0

6

Main control valve mounting bolt

M12×1.75

9.03 ± 1.8

65.3 ± 13.0

Steering unit mounting bolt

M10×1.5

5.0 ± 1.0

36.2 ± 7.2

Steering valve mounting bolt

M10×1.5

5.0 ± 1.0

36.2 ± 7.2

9

Brake valve mounting bolt

M8×1.25

2.5 ± 0.5

18.1 ± 3.6

10

Control lever mounting bolt

M10×1.5

5.0 ± 1.0

36.2 ± 7.2

11

Hydraulic oil tank mounting bolt

M16×2.0

21.9 ± 3.3

158 ± 23.9

12

Transmission mounting bolt

M16×2.0

21.9 ± 3.3

158 ± 23.9

13

Transmission mounting bolt (bracket)

M12×1.75

9.03 ± 1.8

65.3 ± 13.0

14

Torque converter housing mounting bolt

M10×1.5

5.0 ± 1.0

36.2 ± 7.2

Front axle mounting bolt, nut

M24×2.0

79.9 ± 12.0

578 ± 86.8

Rear axle mounting bolt, nut

M24×2.0

79.9 ± 12.0

578 ± 86.8

17

Tire mounting nut

M20×1.5

60.7 ± 5.6

439 ± 40.5

Drive shaft joint mounting bolt, nut

M14×1.5 18

21.0 ± 3.1

152 ± 22.4

M12×1.25

13.3 ± 2.7

96.2 ± 19.5

19

Counterweight mounting bolt

M24×3.0

100 ± 15

723 ± 108

Operator seat mounting bolt

M8×1.25

3.4 ± 0.8

24.5 ± 5.8

Cab mounting bolt (4EA)

M27×3.0

70 ± 10

506 ± 72.3

1 2 3

Engine

7 8

15 16

20 21

Hydraulic system

Power train

Others

-

5. TIGHTENING TORQUE Use following table for unspecified torque.

1) BOLT AND NUT (1) Coarse thread 8T Bolt size

10T

kg·m

lb·ft

kg·m

lb·ft

M 6×1.0

0.85 ~ 1.25

6.15 ~ 9.04

1.14 ~ 1.74

8.2 ~ 12.6

M 8×1.25

2.0 ~ 3.0

14.5 ~ 21.7

2.73 ~ 4.12

19.7 ~ 29.8

M10×1.5

4.0 ~ 6.0

28.9 ~ 43.4

5.5 ~ 8.3

39.8 ~ 60

M12×1.75

7.4 ~ 11.2

53.5 ~ 79.5

9.8 ~ 15.8

71 ~ 114

M14×2.0

12.2 ~ 16.6

88.2 ~ 120

16.7 ~ 22.5

121 ~ 167

M16×2.0

18.6 ~ 25.2

135 ~ 182

25.2 ~ 34.2

182 ~ 247

M18×2.5

25.8 ~ 35.0

187 ~ 253

35.1 ~ 47.5

254 ~ 343

M20×2.5

36.2 ~ 49.0

262 ~ 354

49.2 ~ 66.6

356 ~ 482

M22×2.5

48.3 ~ 63.3

350 ~ 457

65.8 ~ 98.0

476 ~ 709

M24×3.0

62.5 ~ 84.5

452 ~ 611

85.0 ~ 115

615 ~ 832

M30×3.0

124 ~ 168

898 ~ 1214

169 ~ 229

1223 ~ 1655

M36×4.0

174 ~ 236

1261 ~ 1703

250 ~ 310

1808 ~ 2242

(2) Fine thread 8T Bolt size

10T

kg·m

lb·ft

kg·m

lb·ft

M 8×1.0

2.17 ~ 3.37

15.7 ~ 24.3

3.04 ~ 4.44

22.0 ~ 32.0

M10×1.25

4.46 ~ 6.66

32.3~48.2

5.93 ~ 8.93

42.9 ~ 64.6

M12×1.25

7.78 ~ 11.58

76.3 ~ 83.7

10.6 ~ 16.0

76.6 ~ 115

M14×1.5

13.3 ~ 18.1

96.2 ~ 130

17.9 ~ 24.1

130 ~ 174

M16×1.5

19.9 ~ 26.9

144 ~ 194

26.6 ~ 36.0

193 ~ 260

M18×1.5

28.6 ~ 43.6

207 ~ 315

38.4 ~ 52.0

278 ~ 376

M20×1.5

40.0 ~ 54.0

289 ~ 390

53.4 ~ 72.2

386 ~ 522

M22×1.5

52.7 ~ 71.3

381 ~ 515

70.7 ~ 95.7

512 ~ 692

M24×2.0

67.9 ~ 91.9

491 ~ 664

90.9 ~ 123

658 ~ 890

M30×2.0

137 ~ 185

990 ~ 1338

182 ~ 248

1314 ~ 1795

M36×3.0

192 ~ 260

1389 ~ 1879

262 ~ 354

1893 ~ 2561

- 5

2) PIPE AND HOSE (FLARE type) Thread size (PF)

Width across flat (mm)

kgf·m

lbf·ft

1/4"

19

4

28.9

3/8"

22

5

36.2

1/2"

27

9.5

68.7

3/4"

36

18

130

1"

41

21

152

1-1/4"

50

35

253

3) PIPE AND HOSE (24 cone type with O-RING) Thread size (UNF)

Width across flat (mm)

kgf·m

lbf·ft

1/4"

19

1.6

11.6

3/8"

22

3.7

26.8

1/2"

27

4.7

34.0

3/4"

36

11.8

85.3

1"

41

13.9

100.5

1-1/4"

50

23.1

167

Thread size

Width across flat (mm)

kgf·m

lbf·ft

1/4"

19

4

28.9

3/8"

22

5

36.2

1/2"

27

9.5

68.7

3/4"

36

18

130

1"

41

21

152

1-1/4"

50

35

253

4) FITTING

- 6

6. RECOMMENDED OILS Use only oils listed below or equivalent.

Do not mix different brand oil.

Kind of Service point fluid

Capacity ℓ (U.S. gal) -50 -30 (-58) (-22)

Ambient temperature˚C(˚F) -20 (-4) ★1

-10 (14)

0 (32)

10 (50)

20 (68)

30 40 (86) (104)

SAE 5W-40 SAE 30

Engine oil pan

Engine oil

SAE 10W

16 (4.2)

SAE 10W-30 SAE 15W-40

Transmission

Gear oil

Axle

Gear oil

Hydraulic

43 (11.4)

AFT DEXRON III

Front : 18 (4.8)

SAE 80W-90

Rear : 18 (4.8)

SAE 85W-90 ★1

Tank; 90 (23.8)

ISO VG 15

Hydraulic tank

ISO VG 46 oil

System; 160 (42.3)

ISO VG 68 ★1

Fuel tank

Diesel fuel

ASTM D975 NO.1

155 (40.9) ASTM D975 NO.2 ★1

Fitting (grease nipple)

Grease

NLGI NO.2

Mixture of Radiator antifreeze (reservoir tank) and soft water★2 Brake (air booster)

NLGI NO.1

As required

Brake oil

Ethylene glycol base permanent type (50 : 50) 34 (9.0)

★1

Ethylene glycol base permanent type (60 : 40)

Front : 1.0 (0.3) Rear : 1.0 (0.3)

DOT-3 synthetic brake fluid

SAE : Society of Automotive Engineers API : American Petroleum Institute ISO : International Organization for Standardization NLGI : National Lubricating Grease Institute ASTM : American Society of Testing and Material UTTO : Universal Tractor Transmission Oil

-

★1 Cold region

Russia, CIS, Mongolia ★2 Soft water City water or distilled water

GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET : ·Owner : ·Date : ·Hours ·Serial No. : ·Technician : ※ Use this sheet to record operational checkout results.

Perform the operational check before installing any test equipment.

830S2SE03

OK

NOT OK

· Gauge check

□

□

· Battery check

□

□

· Cluster indicator circuit check

□

□

· Cluster turn signals and warning indicator check

□

□

□

□

· Cluster display and alternator output checks

□

□

· Transmission temperature gauge check

□

□

· Transmission oil pressure gauge check

□

□

· Brake air pressure gauge check

□

□

· Engine coolant temperature gauge check

□

□

Item

1. Cluster indicator and gauge checks (engine OFF)

2. Transmission checks · Transmission control lever and neutral

3. Cluster indicator and gauge checks (engine running)

1-18

Comments

4. Brake system and clutch cut off checks · Park brake capacity check

□

□

· Park brake transmission lockout check

□

□

· Service brake capacity check

□

□

· Brake system leakage check

□

□

· Service brake pedal check

□

□

· Service and park brake system drag check

□

□

·Transmission noise check

□

□

·1st and 2nd speed clutch pack drag check

□

□

·Transmission pressure, pump flow and leakage check

□

□

·Torque converter check

□

□

·Engine power check

□

□

·Hydraulic system warm up procedure

□

□

·Hydraulic pump performance check

□

□

·Control lever boom float check

□

□

·Bucket rollback circuit relief valve check

□

□

Low pressure check

□

□

High pressure check

□

□

□

□

·Steering unit check

□

□

·Steering system leakage check

□

□

5. Driving checks

6. Hydraulic system checks

·Bucket dump circuit relief

·Boom and bucket cylinder drift check

7. Steering system checks

1-19

8. Accessory checks ·Operating lights check

□

□

·Work light check

□

□

·Brake light check

□

□

·Cab light check

□

□

·Horn circuit check

□

□

·Windshield washer and wiper check

□

□

·Defroster blower check

□

□

·Heater/Air conditioner blower check

□

□

·Heater functional check

□

□

·Air conditioner functional check

□

□

·Cab door latch check

□

□

·Cab door hold, open latch check

□

□

·Cab door release button check

□

□

·Cab door lock check

□

□

·Cab door window check

□

□

·Cab window latch check

□

□

·Seat and seat belt check

□

□

·Air intake filter door check

□

□

·Side door check

□

□

·Frame locking bar check

□

□

·Service decal check

□

□

9. Cab components and vandal protection checks

1-20

SECTION 2 POWER TRAIN SYSTEM Group 1 Structure and function --------------------------------------------------------------------------------------- 2-1 Group 2 Transmission ------------------------------------------------------------------------------------------------------ 2-2 Group 3 Torque converter ------------------------------------------------------------------------------------------------ 2-19 Group 4 Axle --------------------------------------------------------------------------------------------------------------------- 2-25

SECTION 2 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND FUNCTION 1. POWER TRAIN COMPONENT OVERVIEW Ttansmission

Torque converter

Engine

Front axle

Front drive shaft

Center drive shaft Rear drive shaft

The power train of the following components:

Rear axle

830SPT01

· Transmission and torque converter · Front, center and rear drive shafts · Front and rear axles Engine power is transmitted to the transmission through the torgue converter.

The transmission is a hydraulically engaged four speed forward, two speed reverse countershaft type power shift transmission. A disc type parking brake is located on the transmission.

The Transmission outputs through universal joints to three drive shaft assemblies. The front drive shaft is a telescoping shaft which drives the front axle. The front axle is mounted directly to the loader frame.

The rear axle is mounted on an oscillating pivot.

The power transmitted to front axle and rear axle is reduced by the pinion gear and ring gear of differential. It been passes from the differential to the sun gear shaft (axle shaft) of final drive.

The power of the sun gear is reduced by a planetary mechanism and is transmitted through the planetary hub to the wheel.

2-1

GROUP 2 TRANSMISSION 1. FEATURES AND USE This transmission features simple structure, stable operation, easy operation and high efficiency.

This transmission is used for transmission of four-wheel drive type wheel loaders which need frequent change of load and speed after mounting a hydraulic torque converter.

2. TECHNICAL DATA Maximum input

2500 rpm

Maximum input torque

950 N.m

Maximum input power

74 kW

Torque ratio of torque converter

3.0~3.6

Type

Countershaft, constant mesh, power shifting transmission

Ratio

Forward I 3.82 II 2.08 III 1.09 IV 0.59 Backward I 3.05 II 0.87

Fluid

AFT (DEXRON III )

Pump

CB32 (Not accompanying with transmission)

Operating pressure

1.2~1.5 Mpa

Allowable pan oil temperature

100˚C

Brake relief valve operating pressure

>0.55 Mpa

2-2

1) WORKING PRINCIPLE OF TRANSMISSION SYSTEM The transmission has four shafts and five shifting clutches, which transmission principle is illustrated in figure 2, see page 2-4.

When first hydraulic clutch is engaged with low clutch, the power from torque converter is transmitted in following course: 1-7-9-3-11-13-4, which is first gear.

When second hydraulic clutch is engaged with low clutch, the power is transmitted in following course: 1-8-10-3-11-13-4, and second gear is gained.

Other shifting gears can be obtained by analogy referencing table as below.

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

Input shaft Reverse gear shaft Countershaft Output shaft Reverse rack Reverse pinion Input shaft I, III gear Input shaft II, IV gear Countershaft I, III gear Countershaft II, IV gear Countershaft low gear Output shaft high gear Output low gear

Figure 1

Transmission system diagram Gear Forward

Clutch

I

II

Backward

Low gear

High gear

I II III IV

Reverse

I II

Remarks : Each gear needs two clutches engaged, separating either of which will be neutral gear. Low and high gear can’t be engaged simultaneously while they can be separated simultaneously.

2-3

TRANSMISSION DIAGRAM

F

F

A

Input

Input

G

Output

I

Output D Output

Forward I gear

Output

Output D Output

J

I J

Forward IV gear

C

I

Output D Output

C

Reverse I gear

J

Reverse II gear

Figure 2 Transmission diagram (The illustration is a view from input side)

F G H

Reverse clutch IV I, III clutch I II, IV clutch II

I J

2-4

Low gear clutch High gear clutch

B

I

H

Output D Output

J

A G

B

H

C D Output

J

Input

G

B

I

F

A

Input

G

B

Forward II gear

F

A

H

H

C

Forward III gear

F Input

I

A G

B

H

C

J

Input

G

B

H

F

A

C D Output

Figure 3 Structure of transmission

1 2 3 4

Casing Reverse clutch pack Reverse shaft Flange of input shaft

5 6 7 8

Input shaft Intermediate shaft Flange High low sliding tooth set

2-5

9 Oil pan 10 Parking brake 11 Flangel 12 Control valve

(1) Hydraulic clutch

to

Transmission’s input shaft assembly, countershaft assembly and reverse shaft assembly have similar construction, each of which has a key unit, hydraulic clutch, with the same construction.

Figure 4 is a diagram of hydraulic clutch. This unit consists of drive shaft (1), clutch case (2), piston (3), powder metallurgy friction plate (4), friction plate (5), return spring (6), drain valve (7).

Hydraulic oil from transmission’s control valve is directed to the tube inside the case and large end cover, then into the way (8) of drive shaft (1), then piston cavity, pushing the piston forward to press the active and passive plate (4) and (5). Therefore, drive shaft (1) rotates along with gear (9), hydraulic oil is cut off, drain valve opens, the piston quickly returns by the force of spring (6), active and passive plate part, and gear (9) idles.

1

2

3

7

10

8

9

4

5

6

11

Figure 4 Diagram of hydraulic clutch

Active plate is made of copper-based metal powder, total 6 pcs. Passive plate is made of 65Mn, total 5 pcs. Concavity is 0.5 mm, convexity should face piston side as assembling. After assembly, turn the friction plate with hand to check and, if you feel tight, the spacing is too small and you need to change with a thinner one.

Poor installation of piston ring (10) and (11) and wear appeared in use adversely affects sealing condition and further operation of clutch. Therefore, it’s required to pay attention in installation of packing ring.

2-6

0.05~0.1

When the compression ring of compressor is used in the clutch, a 50 degree bevel is on the outer side of the groove on the shaft (figure 5). That would result in pressure difference between T1 and T2 of two sides of the ring, by which a small ring near point A is pressed tightly to to achieve oil sealing, and relative rotation and friction near point A occurs. The outer annulus of piston ring receives tension force from piston ring to apply pressure on the inside surface of ring.

Before setting the piston ring, be sure to grind its opening making the width of opening being within 0.05~0.1 mm. Piston ring with too small opening is vulnerable and may be broken as fitting while the too large allows too much oil leakage to result in low pressure.

T1

A

T2

Hydraulic oil

T1

T2 A

Figure 5 Piston sealing diagram

(2) High low sliding sleeve When the high low sliding sleeve is down in figure 3, it's low gear I , II and reverse I gear. It is high gear III , IV and reverse II gear. There is no output in intermediate position.

Its control lever is as shown in figure 1. There are three places for staying, high, empty and low.

The shift of high low sliding sleeve must be taked in neutral case and after the parking of machine.

Otherwise the impact will occur.

2-7

3) WORKING PRINCIPLE AND CONSTRUCTION OF CONTROL SYSTEM Working principle of control system for hydraulic transmission is illustrated in figure 6. The components on the right to the double dot dash line in the figure are configured with torque converter. The left part consists of transmission control valves, cylinder (clutch), strainer and oil tank (consists of pan and case)

Part of torque converter

From brake master cylinder

Part of transmission

Control valves

Torque converter Radiator

Transmission combination valve

Spraying

Lubrication

Figure 6 Oil way system schematic diagram

1 2 3

Oil suction filter Main oil pump Shift pressure valve

4 5 6

Outlet pressure valve Oil inlet pressure valve Shift valve

7

Brake relief valve

When torque impeller runs, the drive gear drives oil pump (2) to operate, sucking in hydraulic fluid, which is then directed to torque converter’s combination valve. Torque converter’s combination valve consists of pressure control valve (3), input pressure valve (5) and baffle. Transmission pressure valve (3) assures supply of hydraulic fluid in combination valve for control use in priority, which then is directed to torque converter via transmission pressure valve (3). Control pressure and torque converter inlet pressure of fluid is controlled by transmission pressure valve (3) and inlet pressure valve (5). The pressure is 1.1~1.5 Mpa and 0.3~0.6 Mpa, respectively (torque converter inlet pressure is 0.1~0.2 Mpa as shifting). When torque converter’s inlet pressure exceeds the set value of inlet pressure valve (5), the valve opens and fluid flows out to be supplied to transmission and torque converter. Torque converter’s outlet pressure valve (4) controls its outlet pressure to be 0.05~0.15 Mpa. The fluid leaving outlet pressure valve (4) runs through radiator and then is directed to transmission lubricating system.

2-8

4) CONTROL VALVES

cooling reverse

breake valve

Figure 7 Control valve body

Control valve includes brake relief valve and shift valve. Orifice A on the valve body is connected to combination valve of transmission. When the shift spool of moved, the fluid from torque converter is directed to orifice D, E or F, respectively to allow shifting of transmission forward or backward.

When brake pedal is pressed, a part of fluid from brake master cylinder is directed to brake spool pushing the spool stem to cut off oil way to make transmission in idle to ensure reliable braking.

2-9

3. MAINTENANCE AND REPAIR 1) MAINTENANCE Five levels of maintenance service including daily service (approx. 8h), weekly service (approx.

50h), month service (approx. 200h), quarterly service (approx. 500h), yearly service (approx.

2400h) should be performed. · Daily Service : Check oil level in transmission, operation of clutches, noise of gear, bolt-nut fastening. · Weekly service : Check oil level and control unit of transmission. · Monthly service : Check operation of transmission and noise, clean strainer. · Quarterly service : Change oil, replace strainer. · Yearly service : Check operation, input power, noise, oil temp and oil leaks, clean vent cap, and fasten up each screw and tube joints.

2) REPAIR Problem

Cause

Remedy

Too low oil pressure or Insufficient oil, air entered zero Clogged strainer Failed gear pump Failed shift pressure valve of bypass valve Stuck control valve spool Broken oil seals of transmission or piston of oil inlet has caused oil leaks Clutch drain valve steel ball is missing

Replenish Clean, replace Replace Repair Check, repair Replace

Too high oil pressure

Oil distributor failure Impurities in oil way, blocked oil way Incorrect oil is used

Repair Clean Change oil

Too high oil temperature

Oil cooler is blocked Water entered into oil way Insufficient oil in transmission Inappropriate gear selection Handbrake can’t be released well Scuffing friction plate of clutch or incomplete oil separation

Clean Change oil Replenish oil Select low gear Adjust Replace

Engine runs but vehicle Too low oil pressure will not travel Gear is not engaged in place Brake valve spool has not returned

Weak traction force

Repair

Scuffing friction plate Control valve failure

See “Too low oil pressure” Re-engage Check brake valve spool Replace Repair

Too low oil pressure Transmission clutch does not disengage completely Lacking oil

See “Too low oil pressure” Repair Replenish oil

2-10

4. STRUCTURE 1) OUTPUT SHAFT ASSEMBLY

1 2 3 4 5 6 7 8

Bolt Lock washer Press plate O-ring Output flange Output flange Oil seal Back cover

9 Bolt 10 washer 11 Bearing 12 Thrust ring 13 Bush 15 Gear 16 High sliding gear sets 18 Output shaft

2-11

19 21 22 23 24

Gear Hand brake hub Nut Spring washer Bolt

2) INPUT SHAFT ASSEMBLY

1 2 3 4 5 6 7 8 9 10 11

Nut Washer Washer Input flange Bearing Input shaft Plug Snap ring Bearing Gear Snap ring

12 Outside cover 13 Friction disc 14 Friction disc 15 Snap ring 16 Spring retainer 17 Spring 18 Piston 19 Spacer ring 20 O-ring 21 Clutch shell assembly 24 Gear

2-12

25 26 28 29 30 31 32 33

Lock washer Bolt Shaft sleeve Inner cover Piston ring Retaining part Lock washer Bolt

3) INTERMEDIATE SHAFT ASSEMBLY

1 2 3 4 5 6 7 8 9 10

Bolt Lock washer Retaining part Piston ring Inner cover Bearing Gear Plug Intermediate shaft Snap ring

11 12 13 14 15 16 17 18 19 20

Bearing Gear Snap ring Outside cover Friction disc Friction disc Snap ring Spring retainer Spring Piston

2-13

21 22 23 26 27 28

Spacer ring O-ring Clutch shell assembly Gear Lock washer Bolt

4) REVERSE SHAFT ASSEMBLY

1 2 3 4 5 6 7 8 9 10

Bolt Lock washer Retaining part Piston ring Spacer ring Bearing Shaft sleeve Plug Shaft Snap ring

11 12 13 14 15 16 17 18 19 20

Bearing Gear Snap ring Outside cover Friction disc Friction disc Snap ring Spring retainer Spring Piston

2-14

21 22 23 26 27 28

Spacer ring O-ring Clutch shell assembly Gear Lock washer Bolt

5) CONTROL VALVE ASSEMBLY

1 2 3 4 5 6 7 8 9 10

Screw Washer Spring Steel ball Dust cover Test connector Washer Plug Snap ring Oil seal

11 12 13 14 15 16 17 18 19 20

Adjust washer Control slide valve Dust cover Plug O-ring Cup Break slide valve Spring O-ring Spring seat

2-15

21 22 23 24 25 26 27 28

Plug Valve body Gasket Bottom plate Socket bolt Gasket Bolt Washer

6) PARKING BRAKE 5

6

3 7

4

1 8 2

10 13

12 11

14

9 16

15 10

17

9

18

1 2 3 4 5 6

Brake disc Pin Brake pad Bracket Adjust bolt Return spring

7 Fixed shaft 8 Bracket 9 Bolt 10 Washer 11 Support 12 Brake pad

2-16

13 14 15 16 17 18

Pull shaft Pin-split Bracket Spring Pulling Nut

7) HIGH-LOW SPEED SHIFT FORK

1 2 3 4 5

Iron wire Screw High-low speed shift fork Gasket Forkt bracket

6 Washer 7 Bolt 8 Oil seal 9 Fork shaft 10 Plug

2-17

11 12 13

Washer Steel ball spring

8) T/M HOUSING

1 Housing 2 Mark 3 Rivet 4 Bracket 5 Bolt 6 Spring washer 7 NUT 8 Bolt 9 Wsher 10 Cover 11 Gasket 12 Adjustment ring 13 Adjustment screw 14 Bolt 15 Stopper pad 16 Input shaft cover 17 Oil seal

18 Cover 19 Gasket 20 Gesr oil cap adjust ring 21 Nut 22 Washer 23 Connector 24 Gasket 25 Fillter 26 Bolt 27 Flange connector 28 Bolt 29 O-ring 30 Gasket 31 Oil pan 32 Suction pipe 33 Permanent magent 34 O-ring

35 Plug 36 O-ring 37 Tube assembly 38 Bolt 39 Pipe cover assembly 40 Gasket 42 Cover 43 Bush 44 GASKET 45 Outer oil seal cap 46 Cover 47 Pin 48 Socket bolt 49 Front output shaft shims 50 Fr output shaft seal oil cap 51 Oil seal 52 Bolt

2-18

53 Ventilation cover 54 Nut 55 Ventilation tablet 56 Copper cover 57 Maze tablet 58 copper spacer 59 Long screw 60 Housing 61 Gasket 62 Cover 63 Gear oil cap 64 Rivet 65 Gasket 66 Bolt 67 Plug 68 Plug

GROUP 3 TORQUE CONVERTER 1. FEATURES AND USE Hydraulic torque converter is a single stage, single phase radial turbine hydraulic converter. This hydraulic torque converter features advanced structure, reliable operating, easily matching with engine, and convenient maintenance. It can be combined with an engine with rated rpm 2000~2400 and rated power approximately 80kW. In addition to the structural features of general hydraulic torque converter, this product features two output shafts and thus it can drive a hydraulic pump and another unit to meet the requirements of engine.

1) CONSTRUCTION AND OPERATING PRINCIPLE Hydraulic torque converter is a single stage, single phase and three components hydraulic converter.

This series of torque converter consists of energy converting components (pump pulley, turbine and guide pulley), power input and output components (elastic plate, cover wheel, turbine shaft and output flange), supporting component (casing), hydraulic components and other accessories. · Operating principle The pump pulley (1) connects to engine flywheel by power input components. Driven by mechanical energy from engine, the unit transforms the energy into hydraulic power MB by centrifugal force. The fluid does not only turn around the supporting shaft in high velocity, but also make a circulating current along circulating way consisting of the ways of pump pulley (1), turbine (3) and guide pulley (2), which drives the turbine (3) to be transformed into mechanical energy MT and outputted by power output members (7). The flow out from turbine (3) drives the guide pulley (2), which has functions to change direction of operating flow to direct it again to pump pulley (1). Since the guide pulley is fixed, the flow receives a counter torque MD from the guide pulley as it effects onto the guide pulley, which drives the turbine (3) to change the value of torque of turbine, therefore the output torque will be MT=MB+MD. 1 2 3 4 6 7

5

7352PT10

1 2 3

Pump pulley Guide pulley Turbine

4 5 6

Guide pulley seat Elastic plate Turbine shaft

2-19

7

Output flange

The function of oil inlet valve is to compensate pressure for the system, and automatically control the flow passing through the torque converter in line with working status and varying internal fluid pressure of torque converter, to control heat dissipating capacity of torque converter and, at the same time, to protect the torque converter against overpressure as the outlet of it is clogged. The function of return valve is to ensure entire the hydraulic system being in required operating state.

With such special construction and functions, hydraulic torque converter has following benefits as a transmitting component in comparison with mechanism: (1) With automatic torque control feature of a hydraulic torque converter, the machine can well adapt to sudden changes in load from outside, preventing from engine stall due to sudden increase of external load, to meet operating needs of operating equipment.

(2) Since the unit uses liquid as operating medium, it can decrease and isolate vibration, saving the life of engineering machine. According to statistic data, the unit may increase the life of engine by 47%, and that of transmission box by 400%.

(3) Trafficability and adaptability of vehicle can be enhanced.

(4) Operating system of vehicle can be simplified.

2. TECHNICAL DATA Item

Specification

Diameter of circular circle

315 mm

Nominal torque at zero-speed loading

5.8±0.29 kgf·m (42.0±2.1 lbf·ft)

Nominal torque at high efficiency loading

6.1±0.3 kgf·m (44.1±2.2 lbf·ft)

Torque ration at zero-speed loading

3.0±0.15

Max. efficiency

83%

Rated input

2200 rpm

Weight

179 kg

Dimensions

470×530×530 mm

2-20

3. USAGE AND MAINTENANCE 1) Before starting hydraulic torque converter, check each rotating part for smooth rotation and that if there is seizure and collision. Mount the hydraulic torque converter on the machine and add a suitable amount of hydraulic oil to the tank.

2) Start the engine and make the hydraulic torque converter to run for 1~2 minutes at low speed. Add oil to the tank again. Oil level should reach indicator line in running of hydraulic torque converter.

Keep in mind to bleed air for the oil supply system when adding oil.

3) After starting hydraulic torque converter, run it in low speed and moderate speed in sequence, then under load. Frequently watch its running and check if there is abnormal noise. Immediately stop and check if abnormal. During operation, frequently check for variation of oil pressure and temperature and ensure that are within normal range. When the hydraulic torque converter is in use, be sure to check it at least once a week and, if oil level is below the line, add adequate amount of oil promptly.

4) It’s required to renew oil for hydraulic torque converter after 100 hours of operation. After that, renew oil in the interval of 500 hours.

5) For mechanic transmission, the driver should make timely gear shift to prevent the engine from dying by sound heard during operation. No engine dying will occur if transmission of hydraulic torque converter is matched rationally. However, the driver still needs to change gear timely by oil temperature readings to prevent from overheated oil in low efficiency region of torque converter that may cause damage to sealing pack.

2-21

4. OIL SUPPLY SYSTEM In hydraulic torque converter, to prevent from adverse effect from cavitation corrosion and continued increase of temperature of operating fluid due to hydraulic loss which will result in too high fluid temperature and fluid leakage loss during compensating the torque converter, and to always ensure sufficient operating fluid inside hydraulic torque converter, it’s required to use a make-up pump and continuously lead the fluid out of the torque converter for cooling. Then, the make-up pump needs to deliver the operating fluid again to the circulating circle at a certain pressure to prevent from decrease of pressure in the circulating circle due to fluid leakage loss, and deteriorated torque transmission performance of the torque converter due to air penetration through the sealings.

Opening pressure 1.3~1.4 Mpa

2

Q = 80 lpm

3 1 4 Opening pressure 0.6~0.65 Mpa

7352PT11

Schematic diagram for fluid supply system 1 Cooler 2 Hydraulic torque converter

3 4

2-22

Main pressure valve Overflow valve

5. TROUBLESHOOTING The hydraulic torque converter may encounter various malfunctions during operation, which may cause serious accident if not remedied timely. Therefore, you need to be careful to any abnormal situation occurring during use, and make through analysis to the malfunctions, then take appropriate actions to remedy with reference to below table.

Problem Insufficient power output

Cause

Remedy

Engine rpm drops.

Increase engine rpm.

Gas exists in hydraulic oil.

Check transmission oil level.

Check for tightness of tubing system.

Check for deteriorated hydraulic oil

Too high hydraulic oil temperature.

Lower oil temperature

Too low pressure of inlet/outlet valve of Check for sensitivity of motion of each hydraulic torque converter. valve and hydraulic oil leaks.

Too high oil temperature

Too long time of operation in low Decrease external load or increase efficiency region engine rpm.

Too low oil level in oil tank or gas exists Add hydraulic oil, check for tightness of in hydraulic oil. the connections of piping, and check for deteriorated oil.

Oil does not meet requirements.

Use oil as recommended in operator's manual.

Too low oil pressure in oil supply Repair hydraulic valve, increase oil system. pressure.

Low water level in cooling system.

Repair water tank.

Insufficient oil supply.

Check oil supply system.

Too low oil pressure in oil Back pressure valve failure. supply system Clogged oil feed tube.

Replace back pressure valve.

Check oil tubing.

Insufficient oil supply of transmission Check and repair oil pump, or replace. oil pump.

Damaged or severely worn oil seal Replace oil seal. inside hydraulic torque converter.

Too low oil level in oil tank.

Add hydraulic oil.

Clogged suction filter.

Clean or replace the filter.

Failed pressure gauge.

Replace the pressure gauge.

Oil leakage

Damaged reinforced oil seal.

Damaged O-ring.

Replace the oil seal.

Replace the O-ring.

Aluminum dust exits in fluid

Damaged bearing

Replace bearing.

2-23

6. OUTSIDE VIEW

PF 1/4 Pressure regulator

Driving oil pump A

M16

M24 1.5 Oil inlet PF1/8 Oil level

Driving oil port B

Driving oil port A

2-24

PF3/4 Oil inlet PF 3/8 Hydraulic oil inlet

PF1 Oil inlet

Driving oil port B

7352PT12

GROUP 4 AXLE 1. OUTLINE 1) PRODUCT SURVEY The axle has two stages reduction structure. It has rational design structure, reliable use performance, long duration of life, etc. It adopts caliper disc brake by pneumatic braking. Braking moment is large and braking is stable and reliable.

2) MAIN PERFORMANCE AND TECHNICAL PARAMETERS Main technical parameters Axle model

ZL30

Max. load

Max. input torque

Total ratio

Main ratio

Wheel-end ratio

Braking moment

Oil pressure

18500 kg

235 kgf·m (1700 lbf·ft)

20.26

4.222

4.8

979 kgf (7080 lbf·ft)

9.8 MPa

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

(2) Working principle

830K2AX100

2-25

Power torque of vehicle is inputted by drive shaft from input flange of drive axle. Final drive changes rotary direction to drive driven spiral bevel gear and differential case to rotate after it does reduction and differential. Differential case drives cross pin and planet bevel gears to transmit power to axle shaft gears. Axle shaft gears transmit power to two sides wheel-end reductors by axle shafts, finally transmit power to planet carriers after wheel-end reductors do reduction, thereby drive wheels to roll ahead.

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

4) MAINTENANCE (1) Must lubricate for new drive axle before it is mounted on vehicle.

Recommended the lubricant: SAE85W-90.

When refuel oil, should separately refuel it from oil inlets at bowl of the middle of axle housing and at two sides wheel-end. · Oil amount Front axle : 18ℓ(4.8 U.S.gal) Real axle : 18ℓ(4.8 U.S.gal) (2) Maintenance per 250 hours ① Inspect wear condition of braking discs and whether there are destructive wear on them. ② Inspect wear condition of braking plates. When the grooves on friction lining have been worn down and don’t meet the requirement, should immediately replace. ③ Inspect whether oil level at axle housing meets the requirement. If oil level lowers, should refuel oil in time.

(3) Maintenan Maintenance ce per 1000 hours Lubricant in drive axle work per 1000 hours to replace once new oil.

(4) Maintenance per per 2000 hours Should disconnect drive axle to inspect when it has worked for 2000 hours. ① Inspect spiral bevel gear pair backlash, mesh and wear condition of final drive. ② Inspect wear condition of differential gears and bevel gear washers. ③ Inspect wear condition of wheel-end gears. ④ Inspect wear condition of wheel-end planet gear needle rollers and bearings.

2-26

(6) Requirement of inspection and debugging projects in the course of use ① Spiral bevel gear pair backlash is 0.2~0.3 mm. Mesh is >50% both face width and tooth depth.

Mesh is at teeth middle. Mesh leans to little end at empty load. Backlash and mesh are adjusted by adding and reducing adjust shims at bearing seat and by adjust nuts at two sides bearings of differential. ② Adjustment of bearing clearance on wheel-end hub: Turn locknut tight until hub only rotates with difficulty, then reverse locknut 1/10 turn. Here, hub can rotate freely without jammed phenomenon, obvious axial clearance and oscillatory phenomenon, turn locknut tight with screw last.

2-27

5) TROUBLESHOOTING Parts names Final drive and differential

Wheel-end reductions

Brake

Problem

Cause

Remedy

Loud noise

1. Gear backlash is oversize 2. Bearing is worn.

Adjust gear backlash.

Replace bearing.

Housing body early heats

Lubrication is bad. No Refuel lubricant to oil level. lubricant or lubricant is excessive.

Periodic unusual sound

1. Gear appears tooth Replace gear. breakage.

2. There is eyewinker inside. Bleed the oil port to inspect.

3. Fasteners loose.

Turn fasteners tight.

Differential failure

Cross pin breakage.

Leakage

1. Oil seal ages and wears.

Replace oil seal.

2. Sealant loses its efficiency. Scrape off old sealant and smear afresh.

3. Fasteners loose Turn fasteners tight.

Wheel-end doesn't rotate

1. Axle shaft breakage.

2. Differential system failure.

There is unusual sound

1. Gear appears tooth Replace gear. breakage.

2. There is eyewinker inside. Bleed the oil port to inspect.

Housing body early heats

Lubrication is bad. No Refuel lubricant to oil level. lubricant or lubricant is excessive.

Braking failure

1. Oil line disconnects or is clogged.

2. Piston O-ring ages and wears.

3. Piston and piston cylinder jam.

4. Hydraulic pressure isn't enough.

Replace cross pin.

Replace axle shaft.

Adjust and replace differential system.

Connect or replace oil line.

Replace O-ring.

Replace brake.

Inspect oil pump and exhaust gas in oil line.

Friction lining doesn't 1. Piston seal ring ages and Replace seal ring. release wears.

2. Oil inlet joint looses.

Turn oil inlet joint tight.

3. There is casting defect on Replace brake body and repair. brake body.

6) TRANSPORTATION AND DEPOSIT (1) Strictly prohibit to deposit drive axle in the open air. It should be deposited in the room with good ventilation. If lubricant has molded and deteriorated, when use drive axle, should replace new oil.

(2) Can’t knock and savagely handle drive axle in the course of carry and turnover.

2-28

8) STRUCTURE (1) Drive axle assembly

830KPT14

1 2 3 4 5 6

Wheel-end reductor Axle housing assy O-ring Screw plug Exhaust plug O-ring

7 8 9 10 11 12

Screw plug Screw plug O-ring Final drive assy Double end studs Washer

2-29

13 14 15 16 17 18

Nut Washer Bolt Bolt Washer Disc brake assy

(2) Wheel-end reductor

830KPT15

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

Screw plug O-ring Bolt Washer Cover Retaining plate Adjusting mainstay Screw plug O-ring Rim nut Planetary carrier O-ring

13 14 15 16 17 18 19 20 21 22 23 24

Steel ball Washer Needle roller Spacer Planetary pin Planetary gear Washer Short axle shaft Criclip Sun gear Screw Lock nut

2-30

25 26 27 28 29 30 31 32 33 34 35 36 37

Ring gear Bearing Hub Rim bolt Straight pin Washer Bolt Bearing O-ring Braking disc Washer Bolt Oil seal

(3) Final drive assembly

830KPT16

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

Cover Nut Washer Baffle plate O-ring Input flange Oil seal Oil seal Thrust washer Bolt Washer Bolt Bearing Adjust shim Spacer Bearing seat

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Bearing Adjust shim Adjust nut Bearing Nut Lock plate Lock plate Lock plate Differential case Driven bevel gear Bolt Diff bearing cap Left differential case Bolt Lock plate Lock plate

2-31

33 34 35 36 37 38 39 40 41 42 43 44 45 46 46

Bolt Adjust nut Bearing Bolt Right differential case Thrust washer Axle shaft gear Thrust washer Cross pin Planetary bevel gear Final drive housing Criclip Bearing Driving gear Driving gear

(4) Brake assembly

830KPT17

1 2 3 4 5

Outside brake Piston Square seal ring Dust shroud Braking plate

6 7 8 9 10

O-ring Inside brake Washer Joint Exhaust plug

2-32

11 12 13 14

Washer Bolt Split pin Bolt pin

SECTION 3 BRAKE SYSTEM Group 1 Structure ------------------------------------------------------------------------------------------------------------- 3-1 Group 2 Components specification and function ----------------------------------------------------------- 3-2

SECTION 3 BRAKE SYSTEM GROUP 1 STRUCTURE

1 3

6

5 3 2

7

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

5 Safety valve 6 Front axle 7 Rear axle

4

GROUP 2 COMPONENTS SPECIFICATION AND FUNCTION 1. BRAKE VALVE 1) USE AND STRUCTURE As a main device of foot brake, this unit adopts high technology and can be applied to single circuit braking system of machines.

2) WORKING PRINCIPLE When the brake pedal (2) is pressed, the rod (3) presses the equalizing spring (4) to produce a pressure, which then pushes the piston (6) to move down to make intake valve (7) to open allowing compressed air to flow from inlet to outlet port. When brake pedal (2) is released, return spring (5) pushes the piston (6) to move up to make intake valve to return to original position to close air flow between inlet and outlet. Remaining pressure at outlet is vented through exhaust port.

3) TECHNICAL DATA (1) Operating air pressure : 784 kPa (2) Working temperature : -30 ~ +80˚C (3) Working medium : air 4) MOUNTING AND CONNECTION SIZE (1) Connection screw : M22×1.5 (3EA) (2) Mounting : 4-ø9 (3) Dimensions : 136×136×335 5) CORRECT USE AND MAINTENANCE (1) Notes in using ① Before mounting, remove the plugs for inlet and outlet, and be sure to have the pedal and valve body are securely assembled. Valve clearance should be adjusted properly with adjusting screw (pressure of surplus for the roller to press the rod should be less than 0.5 mm) and fasten up the nut. ② Insert M8 bolts through 4-ø9 holes to make secure assembly. ③ When connecting with piping, distinguish inlet port from outlet. Marking “1” means, inlet, “2” means outlet and “3” exhaust port.

(2) Notes in Maintenance ① There should be water draining and filtering devices in air circuit to secure a clean air source.

Anti-rust process is required for the brake tubes and air cylinder. ② A space should be secured for freely moving of the pedal. ③ When replacing a wearing part, use a part same with the worn, the damaged fastening pieces (such as stop ring, bolt) must also be replaced. All parts should be assembled in correct position securely and no other part be damaged. After replacing, do not assemble to the machine before completing test. ④ The moving part of air brake valve should be served grease. If the brake doesn’t grip properly or grips weakly, check the wearing parts of air brake valve and braking system.

３－２

6) TROUBLESHOTTING Trouble

Cause

Remedy

Air leaks under no work.

Worn rubber.

Replace rubber or assembly.

Air leaks under work.

Worn rubber.

Replace rubber or assembly.

Unsmooth exhaust.

Seizing of piston.

Replace the assembly.

Improper adjustment of pedal roller and rod.

Adjust the adjusting screw manually to the extent that pedal roller is just contacting the rod.

(Pressure of surplus for the roller to press the rod should be less than 0.5 mm)

7) STRUCTURE AND MOUNTING SIZE

View A

Air outlet

Air intlet

Air outlet

850KBS10

1 2 3

Bolt Pedal Rod

4 5 6

Equalizing spring Spring Piston

3-3

7

Intake valve

2. SAFETY RELIEF VALVE 1) USE AND STRUCTURE Safety relief valve automatically drains condensate inside the air cylinder of brake line and manual drainage is also available.

2) WORKING PRINCIPLE Safety relief valve is used to automatically drain condensate inside the air cylinder of brake line by variation of air pressure (air pressure drops 0.03~0.1 MPa) and manual drainage is also available after parking for fast drainage.

3) TECHNICAL DATA (1) Rated operating air pressure : 800 kPa (2) Working temperature : -30 ~ +80˚C (3) Weight : 0.1 kg 4) MOUNTING AND CONNECTION SIZE (1) M22×1.5-6g (2) Exhaust port down.

5) STRUCTURE AND MOUNTING SIZE To connect air cylinder

Manual drainage button Exhaust port

3-4

3. SAFETY VALVE 1) USE AND STRUCTURE Safety valve is used to ensure that charge pressure of air brake line does not exceed 900 kPa. 2) WORKING PRINCIPLE Compressed air flows in through air inlet and, when the pressure at inlet exceeds 850 kPa, the safety valve A is actuated for air relief to protect the air brake line.

3) TECHNICAL DATA (1) Safety operating pressure : 850~900 kPa (2) Working temperature : -40 ~ +80˚C 4) MOUNTING AND CONNECTION SIZE Inlet M16×1.5 is connecting screw.

5) NOTES IN USING Adjusting bolt of safety valve has been already set as delivery and user is not permitted to adjust or remove the part as his/her wish.

6) TROUBLESHOOTING Problem Leaks at valve port

Cause

Remedy

Damaged rubber of safety valve stem assy.

7) STRUCTURE AND MOUNTING SIZE

Adjusting bolt

Air outlet

Air inlet

3-5

Replace safety valve assy

4.OIL AND WATER SEPARATOR 1) STRUCTURE Oil and water separator combined valve is applicable to brake system. This device features automatic control of working pressure in brake system and auto drainage of oil and water after filtering. Since the unit has a built-in protector, safe pressures can be guaranteed.

2) WORKING PRINCIPLE Air under pressure from compressor flows into the valve through air inlet and water and impurities can be filtered off through a strainer. After filtering, the compressed air reaches the outlet through one-way valve to charge the cylinder. When the pressure inside cylinder reaches opening pressure, air that enters into top head overcomes resistance of pressure spring to push control valve assy to move upward to open the exhaust valve at the lower part to discharge the air along with filtered impurities and water into atmosphere and compressor becomes idle state. When the pressure inside air cylinder drops to exhaust stop value and the air inside cavity of top head can not overcome the pressure spring, control valve moves down, and the exhaust valve moves up by the action of spring to stop exhaust valve and air supply to cylinder is restarted.

3) TECHNICAL DATA (1) Opeing pressure : 784±20 kPa (2) Exhaust stop pressure : 685 ~ 750 kPa (3) Working temperatures : -30 ~ +100˚C (4) Weight : 1.5 kg 4) MOUNTING AND CONNECTION SIZE (1) Mounting size : 2-M8×40 double end stud,distance of bolt :70±0.2 (2) Connection size : Inlet (M55×1.5-6g), outlet (M22×1.5-6H) (3) Dimensions : 150.5×128.5×220 MAINTENANCE AINTENANCE 5) CORRECT USE AND M (1) Notes in using ① Before mounting, remove the plugs for inlet and outlet. ② Mount the unit on the mount plate with outlet down. ③ Tires should be inflated joint outward, easy inflated operation ④ Pressure regulator screw and safety valve have been set as delivery and user is not permitted to adjust or remove by his/her self.

(2) Notes in maintenance ① The length of pipe from air compressor to combined valve should not be less than 2 m, aperture not less than ø12 to ensure fully cooling of hot air and condensing moisture in air. ② If severely worn wearing part or air leaks is found, immediately replace the wearing part. ③ When replacing a wearing part, use a part same with the worn, the damaged fastening pieces (such as bolt and nut) must also be replaced. All parts should be assembled in correct position securely and no other part be damaged. After replacing, do not assemble to the machine before completing test.

3-6

6) TROUBLESHOOTING Problem Leaks eaks at exhaust port.

Leaks eaks at top head vent

Cause

Remedy

Polluted exhaust valve.

Clean pipe line.

Damaged exhaust valve.

Replace exhaust valve.

Damaged diaphragm.

Clean pipe line.

Damaged control piston O-ring.

Replace control piston O-ring.

7) STRUCTURE AND MOUNTING SIZE

Air outlet Air inlet

3-7

SECTION 4 STEERING SYSTEM Group 1 Hydraulic circuit --------------------------------------------------------------------------------------------------Group 2 Structure and function ----------------------------------------------------------------------------------------Group 3 Operational check and troubleshooting -----------------------------------------------------------Group 4 Test and adjustments ------------------------------------------------------------------------------------------

4-1 4-2 4-16 4-22

SECTION 4 STEERING SYSTEM GROUP 1 HYDRAULIC CIRCUIT

HL830S4SE01

1

Main pump

6 7

Priority valve Steering unit

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

GROUP 2 STRUCTURE AND FUNCTION STEERING 1. S T EERING UNIT

1 15 2 16 3

24

4

17 18

5 6

19

7 20 25 8 21

9

26

22

10 11

23

12 13 14

1 2 3 4 5 6 7 8 9

Spool Centering spring Sleeve Seal Bearing Seal O-ring Housing O-ring

HL830S4SE02

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

19 20 21 22 23 24 25 26

O-ring Gerotor O-ring Drive Plate Pin Orifice Plug

OVERLOAD VALVE(FKBR)

31

27

28

32 33

29

34

30 35

36 29 37

28

36 27

29 33 38 33 29 36 37 36 32

HL830S4SE03

31

27 Ball retainer 28 Washer 29 Ball 30 Body

31 Plug 32 O-ring 33 Poppet 34 Plug

35 O-ring 36 O-ring 37 Spool 38 Spring

2. STREERING UNIT STRUCTURE AND FUNCTION 1) STRUCTURE 3

Load port

850S4SE02

1 Coupler

7

Snap ring

13

Rear cover

19

2 Front cover

8

Bearing

14

Bolt

20 Stop bolt

3 Screw

9

Slip ring

15

Stopper

21

O-ring

4 Spring washer

10 O-ring

16

Drive

22

Spring

5 O-ring

11 Plate

17

Spool-sleeve

23

Pin

6 X-ring

12 Stator-rotorunit

18

Body

24

FK combination valve

4-4

Ball

2) PRINCIPLE (1) This steering unit has the function of flow amplification as well as load sensing. Besides flow amplification, this unit works in a same manner as normal load-sensing unit, com-bined with priority valve, consistute the load-sensing system. Once the steering wheel is turned, the spool of priority valve would be pushed due to a pressure signal from sensor, which would open new oil channel to steering unit and realize the function of turning. When the steering wheel is not being operated, oil would not flow into steering unit at all.

(2) When the power steering system is applied, the pressure oil would partially flow into the stator-rotor unit with a certain ratio (flow amplification) and drive the rotor rotating along with the wheel column, the oil would correspondingly be pushed into a certain chamber of cylinders by this stator-rotor unit.

When the mechanical steering system is applied, the stator-rotor unit plays a role as a pump, which would push the oil in steering cylinders from one chamber to another. The mechanical steering system provides limited turning torque.

(3) FK combination vavle struture

1 Plug 2 Washer 3 Body 4 Plug 5 Spring 6 Safety

7 Plug 8 Washer 9 Overload-vavle base 10 seal 11 Spring 12 Overload fill valve

4-5

13 Base 2 14 O-ring 15 Port check valve 16 Nut-lock

3) SPECIFICATION Maximum system pressure

172 bar

Maximum operating back-pressure

21 bar

Maximum operating temperature

93˚C

Maximum allowable temperature diff from system

28˚C

Power steering torque (6.3 bar back-pressure)

1.7~2.8 NM

Magnification

1.6

Maximum torque allowable for mechanical-steering

136 NM

Recommended hydraulic oil

ISO VG32, 46, 68

FK combination valve pressure

Depend on system requirement

4) INSTALLATION (1) Layout

1 Tank 2 Steering pump

3 Steering unit 4 Steering cylinder

5 Priority valve

(2) Installation requirements Keep clean and avoid contaminating steering unit and hydraulic system.

Keep clean of couplings, do not seal them with thread tapes.

Make sure the ports are correctly paired.

Avoid axial load on input end of unit when installing.

4-6

(3) Troubleshooting Problem

Phenomenon

Leakage Junction leakage

Heavy steering

Cause

Remedy

Junctions polluted.

Check junctions and clean them up.

Front cover leakage

Seals worn out.

Replace seals.

Bolts (plugs) leakage

Insufficient pre-tightening torque.

Tighten bolts (plugs).

Heavy steering when quick Insufficient flow. steering Spool of priority valve was stuck.

Check pump and circuit.

Check priority valve.

Cylinder crawling Foam in fluid Sounding

Air in the system.

Release the air.

Check air leakage of pump.

Heavy steering, no reactions of steering cylinders

Damage on check valve of mechanical steering.

Check existence of steel ball.

Check whether the check valve is stucked by dirt.

No reactions of steering Leakage on overload valve of Check internal leakage. cylinders combination valve.

Replace combination valve.

Internal leakage of cylinders.

Easy steering on light load Safety valve gasket leak or valve. Check and clean the safety valve in Heavy steering on heavy spring failure. the priority valve. load Heavy steering

High viscosity of fluid.

Streering Spool cannot move back Invalid spring. doesn't to neutral when not being work operated

Replace spring.

Severe pressure wave, Pin bended or fracture. even malfunction Damage on slot of coupler.

Replace pin or coupler.

Counter-steering or sway

Dislocation of shaft and rotor.

Reassemble.

Drifting and no reaction

Two-way overload valve stucked Check overload valve. by dirt.

Invalid spring.

No reaction

Priority valve stucked, no oil flows into steering unit through port "CF".

4-7

2. FKBR VAVLE STRUCTURE AND CHARACTERISTIC 1) STRUCTURE AND WORKING PRINCIPLE (1) Structure

(2) Working principle The FKBR valve consists of a one-way valve and two-way buffer valve.

① One-way valve has a taper structure, consists of a valve seat, spool and spring and is fitted to inside of oil inlet of valve body. This valve features light resistance and good sealing. High pressure oil from hydraulic pump must pass through one-way valve to reach steering valve body.

This one-way valve is designed to prevent operation of hydraulic system from being broken due to deflection of steering wheel because of return of oil to pump due to oil pressure in cylinder being higher than operating oil pressure that is caused by obstruction to steering wheel in special situations. One-way valve needs not adjustment in normal use, but reverse oil leaks should be prevented.

Two-way buffer valve includes two direct-acting overflow valves and consists of a spring, two ball valve seats and two steel balls. This device is attached to the valve body to the each port of two chambers of steering cylinder. The ports are connected to return port. The product features simple structure and easy manufacture and repair, and functions as two safety valves to unload and make oil returning when pressure in a chamber of cylinder increases as speedy steering or vehicle travel encounters sudden variation in resistance to protect the oil circuit between steering cylinder and steering gear, assuring safe and reliable steering. Opening pressure of the valve is 5~6 MPa higher than operating pressure of steering gear.

2) INSTALLATION AND REQUIREMENTS IN USEING (1) Installation

Be sure to make correct connection of four ports, i.e., P, T, A and B when installing the valve block on the flange at the steering gear side.

Be careful to keep clean junction surface of flange and prevent dirt from entering into the system.

Four O-seal rings in between valve block and steering gear flange should be laid flat, two screws fastened at even fastening torque, 40~50 N.m. Be sure that valve block is not twisted.

4-8

(2) Oil temperature range : -20 ~ 80˚C

Normal oil temperature : 30 ~ 60˚C Hydraulic oil in high temperature for long time causes the oil to be prematurely deteriorated.

(3) Oil selection: Viscosity index of 17~33cst at normal temperature and viscosity index of over 100

are suitable and N32,N46 oil is recommended.

(4) Filtering : Maintain clean operating fluid and have filtering precision of system not less than 30

µm.

(5) Pressure of two-way buffer valve is already set as delivery and, if adjustment is required, be

sure to make on a test bed.

3) TROUBLESHOOTING Problem

Cause

Remedy

Steering is light under no Pressure of overflow valve inside valve Regulate the pressure in overflow load (or little load) but block is lower than required steering valve. heavy as load is increased. pressure.

Overflow valve is seized by dirt, or Clean overflow valve, replace spring or spring or oil seal failed. seal ring.

Vehicle travel is deflected, Failed two-way buffer valve (steel ball Clean two-way buffer valve, replace or cylinder will not move (or is stuck by dirt or spring failed), failed spring or seal ring. slowly) when turning wheel. seal ring.

P r e s s u r e c o u l d n o t b e Broken spring.

Replace spring. r e g u l a t e d ( i n c r e a s e o r Poor sealing at valve port causes valve Set the spool and seat, or replace part. decrease). constant open.

Valve spool is stuck due to burr or oil Remove, inspect and repair. stain.

Unstable pressure, with Poor contact between valve spool and Set the valve spool and seat, or f r e q u e n t n o i s e a n d seat. replace part. vibration.

Poor spool motion.

Check valve spool for being stuck by dirt.

Bent or too weak spring.

Replace spring.

Dirty oil, clogged damping hole

Change fluid, clean damping hole

Flow exceeds specified value.

Replace with a larger flow valve.

4-9

3. PRIORITY VALVE 1) INTRODUCTION The priority valve can, in accordance with the requirement of the oil circuit, allocate and prioritize the flow in full amount, no matter how high the load pressure is and how fast the steering disc speed is, so the steering movement is constantly smooth and reliable.

The flow from the oil pump will partially be distributed to the steering oil circuit, so as to maintain its norma l operation needs, and the remaining part may be supplied all to the auxiliary oil circuit, thereby counteracting the power loss due to the excessive flow to the steering oil circuit and improving the system efficiency.

When the oil for hydraulic steering system is supplied by the load sensing pump, the output flow and pressure of the pump can match with the load requirement, which ensures a higher system efficiency.

2) Working principle Seeting this graphic system as an example to explain the working principle of load sensing steering system.

The steering body LS port

inclued in the priority valve spool

priority vavle LS

inclued in the priority valve spool

Spool Intermediate position

End

inclued in the priority valve spool Spool Hydraulic schematics

Steering

Priority vavle needs to be used in conjunction with the diverter.In this system,priority valve is adifferentical pressure relief element. Weather load pressure and pump fuel supply has changed. Priority valve can maintain to port C1 at both ends of the pressure difference within the therestrictor is basically unchanged. Keep a supply of the product is always equal to theflow speed the steering wheel and steering engines.

4-10

(1) When steering unit don't work, if engine stop, the oil pump don't supply the oil, the priority valve spool move to right by control spring , CF port (Steering unit port) will be connected.

Now the oil can't flow.

If engine start, the hydraulic oil flow from gear pump to priority valve, littler hydraulic oil flow from CF port to LS port through dynamic signal throttle. Pre-heater and maintain the system neutral state, Meanwhile, the pressure of dynamic signal throttle will push the priority valve spool to the pilot position, the oil flow to the steering unit, and the other oil flow to the attachment through EF port.

(2) When the steering system is started ,oil of load sensing steering connect to LS system through the load sensing steering throttle port. The oil flow to steering control valve and steering cylinder at the same time, it enter the working state, at this point, the difference pressure on the both end of priority spool push the spool to the required flow because the pressure of load sensing steering is falling. The oil which is used for the steering unit control into the distributor. Residual hydraulic oil flow to the other hydraulic system.

If the steering wheel rotation speed is accelerated, the required flow is increase, the pr-essure of supply oil is reduced. So the dynamic signal control valve spool move to right.

CF port open more. There is more oil into the load sensing steering unit. In order to co-mpensate the requirement of the pressure difference.

(3) When the steering system don't working , one liter oil into the steering unit, the other hy-draulic oil flow to the other system.

(4) When the spool of load sensing steering in the median, if engine flameout, the oil pump can't supply the oil, the spring of dynamic signal priority control valve push the spool to the left , the EF port is connected , the steering unit is on the waiting state.

(5) When the steering cylinder arrive at the terminal, if you continue turn the steering wheel , the steering cylinder can't work, so the pressure rise ,the differential pressure on the both end of priority spool is decreased, when the steering oil pressure is more than the setting pressure. Steering relief valve is opened, at the moment, the priority valve spool move to the left because of difference pressure, oil through the steering unit is reduced, and more oil flow to the other system through EF port.

(6) When the engine flame out and hydraulic pump have some troubles , the driver can use steering metering pump to supply the oil to steering system as a manual pump. In order to achieve human steering.

4-11

3) THE STRUCTURE OF PRIORITY VALVE

8 9 7 10

6

15

5

11

12

4

13 14

3

2 1 HL830S4SE04

1 2 3 4 5

Plug O-ring Spool Body Spring

6 7 8 9 10

O-ring Valve block Poppet seat O-ring Poppet

4-12

11 12 13 14 15

Spring Sleeve Adjust shim Plug Spring

4. TROUBLESHOOTING FOR LOAD SENSING STEERING SYSTEM WHICH FORMED WITH Bzz5(TLF1) AND YXL PRIORITY VAVLE 1) HARD STEERING (1) Hard and stiff steering : Turn the steering wheel with engine off and then release immediately to check the wheel for returning. If no, you have a stuck valve in steering column. You can unscrew the bolt connecting steering rod and steering gear and add washer. The principle is that the structure of steering column must guarantee no transmission of axial load to input shaft of steering gear. Assembly of steering rod must ensure that the steering gear can return to neutral position after completion of operation.

(2) Clogged orifice by dirt, stuck stem or deformed main spring of priority valve : Clean the orifice and stem of priority valve.

(3) Safety valve pressure of steering system is on the low side : Light steering while travelling normally and heavy steering while parked means low pressure of safety valve (increase the pressure of safety valve properly).

(4) Decreased oil pump efficiency or lacking of oil supply : Diagnosis is made by throttle position and hot or cold hydraulic fluid.

(5) Steering wheel will not move (fallen out steel ball or spool of one-way valve has, stuck input port, or clogged oil way) : Check the steel ball for existing, and the one-way spool at P port of valve block for fallen out and caused the oil way blocked, and check the system tubing for normal flow.

(6) Premature opening of safety valve on the priority valve (stuck by impurities) : Open the return way of safety valve on the priority valve to check the safety valve for premature opening before steering to the dead point. If open, steering will be hard. Normally, the safety valve should open after steering to the dead point and hydraulic fluid flowing out. In case of premature opening, you need to clean the safety valve on the priority valve or replace the safety valve assy.

(7) Troubles such as worn hydraulic oil pump : Repair or replace the oil pump.

2) STOPPING POINT IS NOT SENSED (1) Two-way buffer valve pressure is on the low side : Safety valve pressure can be increased to a proper value.

(2) Too high pressure value set for safety valve of steering system : Pressure set for safety valve on the priority valve can be increased to a proper value.

(3) Return tube of priority valve is blocked : Disassemble the return tube of safety valve and steer to the dead point. No returning oil means blocked oil tube.

(4) Low pretightening force on the bolt at the end of steering gear : Increase the pretightening force properly.

(5) Too much wheel play : Replace the stator/rotator or grind the end surface of stator to decrease the play between the rotator and stator.

4-13

3) NO SENSING OF STOPPING POINT ON ONE SIDE (1) One cavity pressure of two-way buffer valve is too low : Increase the two-way buffer valve pressure properly.

(2) Buffer valve port is clogged by dirt : Clean the port of buffer valve.

4) STEERING WHEEL TURNS BY ITSELF (1) Axially stuck steering gear and steering lever shaft : Diagnose by referring to the first item of hard steering.

(2) Valve malfunction due to dirt in oil : Clean the valve.

(3) Too hot oil causing malfunction of valve : Clean the valve.

(4) Broken spring : Replace the spring piece.

5) STEERING WHEEL SHIMMY (1) Too low two-way buffer valve pressure: Increase two-way buffer valve pressure properly.

(2) Weak or broken spring piece: Broken spring piece and noncentering valve spool and sleeve. Replace spring piece.

6) STEERING PULL (1) Weak or broken spring piece : Weak or broken spring piece and noncentering valve spool and sleeve. Replace spring piece.

(2) Too low pressure in one cavity of two-way buffer valve : Broken or deformed spring. Replace spring. Increase the pressure for two-way buffer valve.

7) WHEEL WON’T TURN, STEERING WHEEL DOES (1) Lack of oil in oil tank : Add oil in oil tank.

(2) Worn steering cylinder : Replace steering cylinder.

(3) Too much play between stator and rotator due to wear : Replace stator and rotator pair or grind the stator to decrease the play.

4-14

5. STEERING CYLINDER 11 12 10 4 3 7 5 8

6

9

2

20

19 21

20

22

1

18

17 16 15 13 14

1 2 3 4 5 6 7

Tube assy Rod assy Gland DU bushing Rod seal Back up ring Buffer ring

8 Dust wiper 9 Snap ring 10 O-ring 11 O-ring 12 Back up ring 13 Piston 14 O-ring

4-15

15 16 17 18 19 20 21 22

Piston seal Wear ring Lock nut Set screw Pin bushing Dust seal Bearing Retaining ring

GROUP 3 OPERATIONAL CHECKS AND TROUBLESHOOTING This procedure is designed so the service man can make a quick check of the steering system using a minimum amount of diagnostic equipment. If you need additional information, prefer to structure and function in group 2.

A location will be required which is level and has adequate space to complete the checks.

The engine and all other major components must be at operating temperature for some checks.

Locate system check in the left column and read completely, following this sequence from left to right.

Read each check completely before performing.

At the end of each check, if no problem is found (OK), that check is complete or an additional check is needed. If problem is indicated (NOT OK), you will be given repair required and group location.

If verification is needed, you will be given next best source of information : Chapter 2 : Troubleshooting Group 4 : Tests and adjustments

4-16

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

Item

Description

Steering unit check

Run engine at low idle.

Service action OK Check completed.

B

A

Turn steering wheel until frames are at maximum right (A) and NOT OK then left (B) positions.

Go to next check.

LOOK : Frames must move smoothly in both directions.

When steering wheel is stopped, frames must stop.

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

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

Steering system leakage check Heat hydraulic oil to oper- Left ating temperature.

Run engine at high idle.

Right

Turn steering wheel rapidly until OK frames are against stops.

Check completed.

Hold approximately 2kgf on NOT NOT OK steering wheel.

Do steering system leakage test in group 3 to Count steering wheel revolutions isolate the leakage. for 1 minute.

Repeat test in opposite direction.

LOOK : Steering wheel should rotate less than 5rpm.

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

4-17

2. TROUBLESHOOTING ※ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely, more difficult to verify. Remember the following steps when troubleshooting a problem : Step 1. Operational check out procedure (see group 3 in section 1) Step 2. Operational checks (in this group) Step 3. Troubleshooting Step 4. Tests and adjustments (see group 4) Problem No steering

Slow or hard steering

Cause

Remedy

Low oil level.

Add recommended oil.

Restricted suction line.

Check.

Failed hydraulic pump.

Remove and inspect return filter for metal pump particles.

Stuck steering valve spool.

Remove and inspect steering valve spool.

Relief valve in steering unit stuck open.

Do relief cartridge leakage test.

Failed hydraulic lines.

Check.

Too much friction in the mechanical Lubricate bearings and joints of frame or cylinders or repair if necessary. parts of the machine.

Check steering column installation.

Cold oil.

Warm the hydraulic oil.

Worn hydraulic pump.

Do hydraulic pump performance check.

Low system relief valve setting.

Test and adjust if necessary.

Low overload relief valves setting.

Test and adjust if necessary.

4-18

Problem

Cause

Remedy

Constant steer ing to Air in system. maintain straight travel Leakage in steering system.

Check for foamy oil.

Do steering system leakage check.

Worn steering unit.

Do steering unit neutral leakage test in group 4.

Spring without spring force or broken.

Replace springs.

Spring in overload relief valve broken.

Replace overload relief valve.

Gear wheel set worn.

Replace gear wheel set.

Cylinder seized or piston seals worn.

Replace defects parts.

S l ow s t e e r i n g w h e e l Leakage in steering system. movement will not cause Worn steering unit gerotor. any frame movement

Do steering system leakage check.

Steering wheel can be Leakage in steering system. turned with frames against steering stop

Do steering system leakage check.

Do steering unit leakage check.

Steer ing wheel tur ns Broken steering column or splined of Remove and inspect. with no resistance and steering unit. causes no frame Lack of oil in steering unit.

Star t engine and check steering movement operation.

Erratic steering

Spongy or soft steering

Leakage in steering system.

Do steering system leakage test in group 4.

Air in oil.

Check for foamy oil.

Low oil level.

Add recommended oil.

Loose cylinder piston.

Remove rod to inspect piston.

Damaged steering unit.

Remove and inspect.

Air in oil.

Check for foamy oil.

Low oil level.

Add recommended oil.

Free play at steering Loose steering wheel nut. wheel Worn or damaged splines on steering column or valve.

Tighten.

Inspect.

Steering unit binding or B i n d i n g i n s t e e r i n g c o l u m n o r Inspect. steering wheel does not misalignment of column. immediately return to High return pressure.

Check for a pinched or damaged return neutral when released line.

Contamination in steering unit.

4-19

Inspect hydraulic filter for contamination.

Repair cause of contamination. Flush hydraulic system.

Problem Steering unit locks up

Cause

Remedy

Large particles of contamination in Inspect hydraulic filter for contamination.

Repair cause of contamination. Flush steering unit. hydraulic system.

Worn or damaged steering unit.

Repair or replace steering unit.

Abrupt steering wheel Improperly timed gerotor gear in steering Time gerotor gear. oscillation unit.

Steering wheel turns by Lines connected to wrong port. itself Worn or damaged steering unit.

Reconnect lines.

Neutral position of steering wheel cannot be obtained, i.e. there is a tendency towards "motoring"

Align the steering column with steering unit.

Steering column and steering unit out of line.

Repair or replace steering unit.

Too little or no play between steering Adjust the play and, if necessary, column and steering unit input shaft. shorten the splines journal.

Pinching between inner and outer spools.

Contact the nearest service shop.

"Motoring" effect.

Leaf springs are stuck or broken and Replace leaf springs.

The steering wheel can have therefore reduced spring force. turn on its own Inner and outer spools pinch, possibly Clean steering unit or contact the due to dirt. nearest service shop.

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

Backlash

Cardan shaft fork worn or broken.

Replace cardan shaft.

Springs without spring force or broken.

Replace springs.

Worn splines on the steering column.

Replace steering column.

4-20

Problem

Cause

Remedy

Air in the steering cylinder.

"Shimmy" effect The steered wheels vibrate (Rough tread on tires Mechanical connections or wheel gives vibrations.) bearings worn.

Bleed cylinder.

Find and remove the reason for air collection.

Steering wheel can be Oil is needed in the tank. turned the whole time Steering cylinder worn. without the steered wheels moving Gear wheel set worn.

Fill with clean oil and bleed the system.

Replace worn parts.

Replace or repair cylinder.

Replace gear wheel set.

Spacer across cardan shaft forgotten.

Install spacer.

Steering wheel can be One or both anticavitation valves are Clean or replace defect or missing turned slowly in one or leaky or are missing in overload relief valves. both directions without the valves. steered wheels turning One or both overload relief valves are Clean or replace. leaky.

Steering is too slow and Insufficient oil supply to steering unit, Replace pump or increase number of heavy when trying to turn pump defective or number of revolutions revolutions. quickly too low.

Relief valve setting too low.

Adjust valve to correct setting.

Relief valve sticking owing to dirt.

Clean the valve.

"Kick back" in steering Fault in the system. wheel from system Kicks from wheels

Contact authorized man or shop.

H e a v y k i c k - b a c k i n Wrong setting of cardan shaft and gear- Correct setting. steering wheel in both wheel set. directions Turning the steering wheel Hydraulic hoses for the steering Connect lines to correct ports. activates the steered cylinders have been switched around. wheels opposite Hard point when starting Oil is too thick (cold). to turn the steering wheel

Let machine run until oil is warm.

Too little steering force

Correct pump pressure.

Pump pressure too low.

4-21

GROUP 4 TESTS AND ADJUSTMENTS 1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY ※ Service equipment and tool. ·Portable filter caddy ·Two 3658 mm (12 ft) × 1" I.D. 100R1 hoses with 3/4 M NPT ends ·Quick disconnect fittings ·Discharge wand ·Various size fittings and hoses ※ Steering system uses oil from hydraulic oil tank. Flush all lines in the steering system.

Disassemble and clean major components for steering system.

Steering components may fail if steering system is not cleaned after hydraulic oil tank contamination.

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

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

3) To minimize oil loss, pull a vacuum in hydraulic oil tank using a vacuum pump.

Connect filter caddy suction line to drain port at bottom of hydraulic oil tank using connector. Check to be sure debris has not closed drain port.

4) Put filter caddy discharge line into hydraulic oil tank filter hole so end is as far away from drain port as possible to obtain a through cleaning of oil.

4-22

5) Start the filter caddy. Check to be sure oil is flowing through the filters.

Operate filter caddy approximately 10 minutes so oil in hydraulic oil tank is circulated through filter a minimum of four times. ※ Hydraulic oil tank capacity 95ℓ(25.0 U.S. gal).

Leave filter caddy operating for the next steps.

6) Start the engine and run it at high idle. ※ For the most effective results, cleaning procedure must start with the smallest capacity circuit then proceed to the next largest capacity circuit.

7) Operate all functions, one at a time, through a complete cycle in the following order: clam, steering, bucket, and boom. Also include all auxiliary hydraulic functions.

Repeat procedure until the total system capacity has circulated through filter caddy seven times, approximately 30 minutes.

Each function must go through a minimum of three complete cycles for a through cleaning for oil. ※ Filtering time for machines with auxiliary hydraulic functions must be increased because system capacity is larger.

8) Stop the engine. Remove the filter caddy.

9) Install a new return filter element.

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

4-23

2. TEST TOOLS 1) CLAMP-ON ELECTRONIC TACHOMETER INSTALLATION · Service equipment and tools Tachometer A : Clamp on tachometer.

Remove paint using emery cloth and connect to a straight section of injection line within 100 mm (4in) of pump.

Finger tighten only-do not over tighten.

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

C : Red clip (+). Connect to transducer.

D : Tachometer readout. Install cable.

B

C

D A

75795SE32

2) DIGITAL THERMOMETER INSTALLATION · Service equipment and tools Digital thermometer A : Temperature probe.

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

B : Cable.

C : Digital thermometer.

A C B

75795SE33

4-24

3. STEERING SYSTEM RESTRICTION TEST · SPECIFICATION Oil temperature 45±5˚C (113±9˚F) Engine speed High idle Maximum pressure 3.0MPa (30 bar, 430psi) at steering unit · GAUGE AND TOOL Gauge 0~7 MPa (0~70 bar, 0~1000 psi) 2EA · This test will check for restrictions in the steering system which can cause overheating of hydraulic oil.

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

P

2) Heat hydraulic oil to specifications. (see hydraulic oil warm up procedure at page 5-27).

A

3) Connect fitting (A) and install gauge.

Do not operate steering or loader functions or test gauge may be damaged.

4) Run engine at specification and read pressure gauges.

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

850KSE37

4-25

4. STEERING UNIT LEAKAGE TEST · SPECIFICATION Oil temperature 45±5˚C (113±9˚F) Engine speed High idle Maximum leakage 15ℓ/min (4 gpm) · GAUGE AND TOOL Temperature reader Measuring container (approx. 20ℓ) Stop watch

Cap fitting T L R

1) Install frame locking bar to prevent machine from turning.

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

3) Heat hydraulic oil to specifications. (see hydraulic oil warm up procedure at page 5-27).

4) Disconnect return hose from fitting.

Install cap fitting.

5) Run engine at specifications. Rotate steering wheel against locking bar using approximately 1.2 kgf·m of force.

Measure oil flow from return hose for 1 minute.

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

Safety lock bar

830KSE38

4-26

5. STEERING UNIT PRESSURE TEST · SPECIFICATION Oil temperature 45±5˚C (113±9˚F) Engine speed High idle 16 MPa Oil pressure (160 bar, 1160 psi) · GAUGE AND TOOL Gauge 0~35 MPa (0~350 bar, 0~5000 psi) Temperature reader 1) Connect gauge to test port.

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

Test port

3) Install frame locking bar.

Steering cylinder

4) Heat hydraulic oil to specifications (see hydraulic oil warm up procedure at page 5-27).

Relief valve

5) Run engine at specifications and turn steering wheel rapidly hold approximately 22N (5lb force) pressure on wheel with frames locked. ※ If steering wheel is turned slowly, it will continue to with the frames locked.

This will give an incorrect pressure reading.

If steering wheel continues to turn rapidly with the frames locked, steering system leakage is indicated.

A

B

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

7) If pressure in not to specification, remove the plug (A) from steering unit. Turn adjusting screw (B) in relief cartridge using a hex head wrench to adjust pressure.

Safety lock bar

If pressure cannot be adjusted to specification, disassemble and inspect steering unit.

830KSE39

4-27

SECTION 5 WORK EQUIPMENT Group 1 Hydraulic circuit --------------------------------------------------------------------------------------------------- 5-1 Group 2 Structure and function ---------------------------------------------------------------------------------------- 5-3 Group 3 Operational checks and troubleshooting ---------------------------------------------------------- 5-15 Group 4 Test and adjustments ------------------------------------------------------------------------------------------ 5-25

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

HL830S5WE01

1 2 3 4 5 6

Main pump Main control valve Boom cylinder Bucket cylinder Steering cylinder Priority valve

7 8 9 10 11

Steering unit Return filter Bypass valve Air breather Hydraulic tank

2. WORK EQUIPMENT HYDRAULIC CIRCUIT

Steering system Steering system

HL830S5WE02

1 2 3 4

Main pump Main control valve Boom cylinder Bucket cylinder

8 9 10 11

Return filter Bypass valve Air breather Hydraulic tank

GROUP 2 STRUCTURE AND FUNCTION 1. MAIN PUMP 1) STRUCTURE

HL830S5WE03

1 2 3 4 5 6

Snap ring Oil seal Rolling bearing Seal Front cover Bearing

7 Seal 8 Gasket 9 Seal 10 Seal 11 Side plate 12 Drive gear

5-3

13 14 15 16 17

Driven gear Rivet Decal Rear cover body Bolt

2) MOUNTING REQUIREMENTS FOR GEAR PUMP (1) Entry of gear pump should keep clean and no pollution. Interfacing surface of entry and discharge should not be damaged and good sealing with O-ring seal should be guaranteed.

(2) Check if the depth of mounting hole for gear pump is longer than the length of the shaft of pump so to prevent potential impact to the shaft and gear pump from burning out. Key shaft should be assembled normally.

3) NOTES IN USING (1) It’s strictly prohibited for user to disassemble the product, or the manufacturer will not guarantee the performance of product.

(2) Viscosity of oil is dependant to temperature. When oil temperature increases, its viscosity decreases. Therefore, oil temperature should be maintained under 80°C. To secure the gear pump working normally under different operating temperature, selected oil should feature little change by variation of temperature, and have good chemical durability and foam resistance. Use of LHM46 (GB11118.1-94) anti-wear hydraulic oil is recommended.

(3) No impurities from machine and corrosive substance should be in oil. There should be filtering devices with a precision of 25 µm in the system where the gear pump is working for.

(4) For transmission of gear pump, the manners that may produce radial force to pump (such as direct geared and pulley transmission) are not permitted. Shaft bushing or elastic coupling can be used. Requirements for concentricity: not more than 0.5 mm for shaft bushing type, no more than 0.1 mm for coupling type. Axial force is not permitted.

(5) The entry and discharge of gear pump should be assembled securely and sealing be reliable. Or air may be included and oil leaks caused to lower the performance of gear pump.

(6) Max. pressure and max. rate of gear pump means momentary peak values permitted during operation. Long time of continued use of gear pump may shorten its life span.

(7) Check if the depth of mounting hole for gear pump is longer than the length of the shaft of pump so to prevent potential impact to the shaft and gear pump from burning out.

(8) Before mounting the gear pump, check the rotating direction of pump meets requirement.

(9) Installation position of the pump as possible the pump oil inport below the oil tank level, if the oil inport installed must be above the oil level, it should not exceed the height difference is generally 0.5m, pump inlet velocity should not exceed 2.5m / s, inport pressure: -0.05 ~ +0.1 Mpa, connection the outlet of the pump inlet tank, if neel to install filters, strainers installed only allowed 50 or less, otherwise it will cause early damage to the pump.

5-4

4) TROUBLESHOOTING Problem Noise in pump

Cause

Remedy

Air in system.

Fasten up all the connectors.

Insufficient oil supply.

Refill oil to an adequate level.

Cold oil.

Run slowly.

Contaminated suction filter.

Clean or replace the filter.

Too thin suction pipe.

Use a larger pipe.

Suction pipe is clogged.

Remove the obstruction.

Clogged air filter in oil tank.

Clean or replace the air filter.

Poor concentricity of pump and Inspect. input shaft.

Severe resonance with tank, Check piping, elements and bolts for peripheral parts of piping. being securely fastened.

Pump lags in response or no response

High oil temperature

Foam forms in oil

Insufficient oil supply.

Refill oil to an adequate level.

Improper pressure setting of Regulate the pressure of relief valve. relief valve.

Worn or damaged pump.

Repair or replace.

Worn, leaking or stuck valve.

Repair or replace.

Too low pressure setting at overflow valve.

Regulate pressure of overflow valve.

Too low viscosity of hydraulic oil.

Use recommended hydraulic oil.

Too low oil level.

Refill oil to an adequate level.

Small tank.

Add an oil cooler or replace with larger tank.

Worn or damaged pump.

Repair or replace.

Air has entered into oil tank Fasten up all the connectors. through suction pipe.

Incorrect selection of oil.

Use recommended oil.

Too low oil level.

Refill oil to an adequate level.

Tank baffle design is unreasonable

Correction baffle design

Return pipe above the oil level

The return pipe installed under the oil level

Worn or damaged lip seal for Replace the lip seal for main shaft. main shaft.

5-5

Problem Insufficient flow of pump or pressure

Leaks occur even after replacing lip seal for main shaft

Cause

Remedy

Damaged side plate.

Replace side plate.

Overload valve failure

Replace the overload valve

Air has entered into the system.

Fasten up all the connectors.

Too high viscosity of oil.

Use recommended oil.

Contaminated oil.

Change all the oil.

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

Worn or damaged seal ring.

Replace seal ring.

5) NOTICE IN PLACING ORDER TURN RIGHT (CLOCKWISE)

TURN LEFT (COUNTER CLOCKWISE)

5-6

2. MAIN CONTROL VALVE 1) STRUCTURE

HL830S5WE04

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

Bolt End cover Stopper Spring retaine Spring Spring retaine Spacer O-ring kit Spool Relief valve Overload valve Plug O-ring

14 15 16 17 18 19 20 21 22 23 24 25 26

Spring Poppet Plug O-ring kit Spring Poppet Bolt Dust seal End cap O-ring kit Pin Plug O-ring

7

27 28 29 30 31 32 33 34

O-ring kit Plug Body Spool Spacer Spring Ball Spool positioner

2) OVERVIEW The valve has the following characteristics, 1. T he ultra-low leakage to prevent excessive sedimentation.

2. Reduce the deformation of the stem of high temperature and high pressure and reduce the operating force and avoid hydraulic clamping.

3. Valve body structure design more optimized to increase the capacity to accept the pressure.

4. Lower pressure loss.

Multi-way directional valve is of integrated slide valve structure which includes 2 spools valve (bucket and boom spool) and triple multi-way valve (service spool, bucket spool, boom spool). Oil ways include parallel and series connection. Multi-way valve has also various service valves (overflow valve, overload valve, makeup valve) attached. As a hydraulic device for main equipment of large and medium loader, the valve features compact structure, reliable functions, high performance, good sealing, and convenient repair.

3) MODEL IDENTIFICATION AND TECHNICAL DATA (1) Model identification G

DF

- XX

XX Product code Inner diameter Series code Product number

(2) Technical data GDF-25 Series

Product series Nominated flow L / min

160

Nominated pressure Mpa

20

Pressure regulating range Mpa

8-20

Pressure regulating range of overload valve Mpa

8-25

4) STRUCTURE AND WORKING PRINCIPLE (1) Structure See figure 1 in the next page. ((2) 2) Working Principle This valve is designed with serial-parallel conception (figure 2). It changes the directions of flow to control bucket cylinder and boom cylinders or leave the specific components at a certain position so that it can fullfil the basic requirement of construction equipment.

8

Lift Neutral Lower Float Retract (roll back) Neutral Dump

Pressure taps

Port

Port

Figure 1 Connection and size

9

Figure 2 Hydraulic circuit

Boom spool has 4 positions and 6 ways . It can realize the function of raising, holding, lowering and floating.

Main relief valve control the whole pressure of the system. Once the pressure exceeds the rated pressure, the valve would open a way direct to tank to protect the system against over pressure.

In the multi-way directional valve, port P is flow inlet , T is flow return. A1 and B1 connect to the large chamber and small chamber of bucket cylinder respectively. A2 and B2 connect to the large chamber and small chamber of boom cylinders respectively. Check valve is used to prevent pressure oil flowing back to the tank so that fix the “nodding” problem.

(1) Neutral position: When bucket spool and boom spool are at neutral positions, oil from pump returns to tank directly through port P. (2) Boom raising: When the boom spool is pulled out, the oil way from P to T is closed. Fluid flows directly to A2 which is connected to the large chamber of boom cylinders. The oil in the small chamber would return to tank through B2.Then the boom raises.

(3) Boom lowering: When the boom spool is pushed in at the first position, the oil way from P to T is closed too.

Fluid flows directly to B2 which is connected to the small chamber of the boom cylinders. The oil in the large chamber would return to tank through A2. Then the boom lowers.

(4) Boom floating: When the boom spool is pushed in further more, all the inlet port P and large chamber and small chamber of boom cylinders are connected to tank. The cylinders become floating by the weight of equipment and bearing the force from ground.

(5) Bucket roll back: When the bucket spool is pulled out. The oil way from P to T is closed. Fluid flows directly to A1 which is connected to the large chamber of bucket cylinder. The oil in the small chamber would return to tank through B1. Then the bucket rolls back.

(6) Bucket dumping: When the bucket spool is pushed in. The oil way from P to T is closed too. Fluid directly to B1 which is connected to the small chamber of bucket cylinder. The oil in the large chamber would return to tank through A1. Then the bucket dumps.

10

When the external force is not applied to the bucket spool. The spring would push or pull the spool back to the neutral position.

(7) Overload-make-up valve: Overload and make-up valves are applied in both side of bucket cylinder.(Based on requirement). It would keep the system safety when the bucket receives external impact or interfered with by other mechanisms. Besides, it would make up oil for cylinder to prevent a chamber to be evacuated.

5) MOUNTING AND USING (1) When transporting, mounting, and storing the product, be careful that the product does not receive impacts that may damage the machined surface or flange face.

(2) Mounting plate should be level, mounting screws fastened in even torque.

(3) Never disassemble the product in dust before assembling to machine to prevent dust from entering.

(4) Operating fluid should be clean, cleanliness meeting ISO4406 19/16 or NAS1638 11 grade and up.

(5) The oil viscosity index V>9%, the best viscosity for work(recommended) is 20-30m ㎡/S. (6) The user without pressure detection conditions, it is strictly prohibited to adjust the safety valve and overload valve pressure.

6) TROUBLESHOOTING No.

Problem Insufficient operating pressure

Cause

Remedy

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

2. Spool of main relief valve is stuck.

1

2. Remove and clean, or replace valve spool.

3. Damaged pressure regulating 3. Replace with new product. spring.

4. Too much pressure loss in system 4. Replace piping, or regulate line. pressure of main relief valve within the allowable range of pressure.

Insufficient operating flow

1. Oil supply to system is insufficient.

Check oil source and repair oil pump.

2. Too much leaks inside valve. a. Too high oil temperature, low a. Take measures to reduce oil temperature. viscosity

2

b. Improper hydraulic oil.

b. Change hydraulic oil.

c. Too much clearance between c. Replace slide valve to keep a reasonable clearing. slide valve and valve body.

Malfunction in return.

3

1. Damaged or deformed return 1. Replace with new product. spring.

2. Reset parts have different concentricity

2.Reassemble，remain concentricity

3. Dirt between valve lever and valve 3. Clean part. body.

11

No.

Problem

4

External seeps and leaks 5

Cause

Remedy

1.Overload valve is stuck with dirt.

1.Clean and install.

2.Oil is not clean.

2.Change oil.

3.Damaged O - ring.

3.Replace with new product.

4.Leak of cylinder.

4.Check and repair cylinder.

1. Damaged seal ring.

1. Replace with new product.

2. Poor sealing on flange surface.

2. Check fastening and sealing of related parts.

3. Loose fastening pieces.

3. Fasten related fastening piece.

7) NOTES IN DISASSEMBLY (1) Keep clean field for assembly. Dust and dirt shall be strictly prevented.

(2) Never clean rubber sealing pieces with gasoline.

(3) To prevent from damage to part, never knock a part with an iron object when disassembling.

(4) Be sure to clean all the parts with kerosene or cleaner before assembling.

(5) After assembling, be sure to perform test and only passed product can be used.

５－12

3. BOOM CYLINDER

14 13 17 15 16 18

19

1 25

22 21

26 23

22 2

25 24 27 29 28

10

26

9 7 6

8

3 12 11

20

5 4

HL830S5WE05

1 2 3 4 5 6 7 8 9 10

Tube assy Rod assy Cylinder head Bushing Snap ring Snap ring Snap Buffer ring Dust seal Snap ring

11 12 13 14 15 16 17 18 19 20

O-ring Snap Piston O-ring Piston ring Wear ring Dust seal Nut Screw Hexagon screw

3

21 22 23 24 25 26 27 28 29

Bushing Dust seal Pipe assy - R Pipe assy - B O-ring Hexagon screw Clamp Bolt Spring Washer

4. BUCKET CYLINDER

22 21

2

22

10 9 7 6 8

17

3

13 12

15

11

14 16

19

4 5

18

1 22

21

22

23

24 26 28 27

25 HL830S5WE06

1 2 3 4 5 6 7 8

Tube assy Rod assy Cylinder head Bushing Snap ring Snap ring Snap ring Buffer ring

9

Dust seal

10 11 12

Snap ring O-ring Snap ring

13 14 15 16

Piston Piston ring Dust seal Wear ring

17 18

O-ring Nut

19 20 21 22 23 24 25 26 27 28

4

Screw Hexagon screw Bushing Dust seal Base pipe assy O-ring Hexagon screw Clamp Bolt Washer

GROUP 3 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS This procedure is designed so the mechanic can make a quick check of the system using a minimum amount of diagnostic equipment. If you need additional information, read structure and function, Group 2.

A location will be required which is level and has adequate space to complete the checks.

The engine and all other major components must be at operating temperature for some checks.

Locate system check in the left column and read completely, following the sequence from left to right.

Read each check completely before performing.

At the end of each check, if no problem is found (OK), that check is complete or an additional check is needed. If problem is indicated (NOT OK), you will be given repair required and group location.

If verification is needed, you will be given next best source of information: ·Chapter 2 : Troubleshooting ·Group 4 : Tests and adjustments

5-15

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

Item Hydraulic system warm-up procedure Run engine at high idle.

Refer to page 5-27.

Description

Service action

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

Periodically cycle all hydraulic functions to distribute warm oil.

Repeat procedure until oil is at operating temperature.

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

Hydraulic pump performance check Heat hydraulic oil to operating temperature.

Run engine at high idle.

With bucket flat on ground, OK actuate boom raise. Time how Check completed. long it takes to raise boom to full NOT OK height.

C h e ck t h e hy d r a u l i c LOOK : Boom must raise to full pump. height in less than 6~7 seconds.

IF OK Do steering system leakage check at page 4-21.

IF OK Do main hydraulic pump flow test at page 5-28.

Control valve lift check Run machine at low idle.

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

NOT OK Slowly move boom control lever Repair lift checks in to boom lower position. loader control valve.

Slowly move bucket control lever to bucket dump position.

LOOK : Boom must not raise before moving down.

Bucket must not rollback before dumping.

5-16

Item

Description

Bucket rollback circuit relief valve check

Service action

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

Check complete.

Engage transmission in 2nd NOT OK speed forward.

Replace boom lower check valve.

LOOK : Bucket angle must not change.

Bucket dump circuit relief valve low pressure check

Raise front of machine which OK bucket at 45˚ angle.

Go to next check.

Backdrag with bucket while NOT OK observing bucket angle.

Do loader system and circuit relief valve test at LOOK : Bucket must not rollback page 5-29.

Boom cylinder and bucket cylinder drift check

S e t t h e b o o m a n d bu cke t OK horizontal, then stop the engine. Check complete.

H e a t hy d r a u l i c o i l t o operating temperature.

Stop the engine, wait for 5 NOT OK minutes, then start measuring.

Go to next check.

B

A

Measure the amount the lift and dump cylinder rods retract during 15 minutes. (unloaded bucket) A : Retraction of boom cylinder rod B : Retraction of bucket cylinder rod Boom cylinder must drift less than 36 mm

B

A

Bucket cylinder must drift less than 33 mm

5-17

Item Boom cylinder leakage check H e a t hy d r a u l i c o i l t o operating temperature.

Description

Service action

Dump bucket until teeth or cutting OK edge is perpendicular to the Drift is approximately the ground. same between first and second measurement.

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

Repair loader control Stop engine. Measure drift from valve or circuit relief valve. tooth or cutting edge to ground NOT OK for 1 minute.

If drift is considerably less Wait 10 minutes. on second measurement, Measure drift from tooth or repair cylinder. cutting edge to ground for 1 minute.

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

Bucket cylinder leakage check H e a t hy d r a u l i c o i l t o operating temperature.

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

Drift is approximately the same between first and Stop engine. Place a support second measurement. under boom.

Measure drift from tooth or Repair loader control cutting edge to ground for 1 valve or circuit relief valve minute. at page 5-30.

Wait 10 minutes.

NOT OK Measure drift from tooth or Drift is considerably less cutting edge to ground for 1 on second measurement. minute.

Repair cylinder.

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

Check valve of safety valve leakage check

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

H e a t hy d r a u l i c o i l t o operating temperature.

Place a piece of tape on cylinder NOT OK rod at least 51 mm (2 in) from rod Check or replace safety guide. valve.

Run engine at low idle in safetyrelease position.

LOOK : Bucket must not drift up.

Control lever check

Stop engine. Turn key switch to OK Check completed.

OFF position.

Move bucket control lever to roll NOT OK back, dump positions and then Repair bucket control release. lever.

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

5-18

Item Cycle time check

Description Function

H e a t hy d r a u l i c o i l t o Boom raise operating temperature.

Run engine at high idle.

Boom lower

Operating condition.

Service action Maximum cycle time

Bucket flat on ground to full 5.4 sec height.

Full height to level ground.

2.7 sec

Bucket dump

Boom at full height.

1.1 sec

Bucket rollback

Boom at full height.

1.5 sec

Steering [No. of Frame stop to frame stop. turns]

3.4 turns OK Check complete.

NOT OK Go to slow hydraulic functions in group 3.

5-19

※ MEASURING BOOM AND BUCKET CYCLE TIME 1) MEASUREMENT CONDITION ·Coolant temperature : Inside operating range ·Steering position : Neutral ·Hydraulic temperature : 40~50˚C ·Bucket : Unloaded ·Engine speed : High idling 2) MEASU MEASURING RING TOOL · Stop watch (1EA)

3) MEASURIN MEASURING G PROCEDURE (1) Lifting time of boom Set the bucket near the maximum tilt back position and at the lowest position on the ground. Raise the bucket and measure the time taken for bucket to reach the maximum height of the boom.

Lifting time of boom

HL830S5WE07

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

Lowering time of boom

HL830S5WE08

(3) Dumping time of bucket Raise the boom to the maximum height and measure the time taken for the bucket to move from the maximum tilt back position to the maximum dump position

Dumping time of bucket Rollback time of bucket

(4) Roll back time of bucket Raise the boom to the maximum height and measure the time taken for the bucket to reach the maximum tilt back position.

HL830S5WE09

5-20

2. TROUBLESHOOTING ※ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely, more difficult to verify. Remember the following steps when troubleshooting a problem : Step 1. Operational check out procedure (see section 1) Step 2. Operational checks (see group 3) Step 3. Troubleshooting Step 4. Tests and adjustments (see group 4) Problem Noisy hydraulic pump

No or Slow hydraulic functions

Cause

Remedy

Low oil supply or wrong viscosity.

Fill reservoir with recommended oil.

Plugged or pinched suction line.

Clean or replace line.

Air in oil.

Check for foamy oil.

Tighten connections.

Replace O-rings and or lines.

Plugged suction line.

Inspect and clean suction line.

Loose or missing hydraulic line clamps.

Tighten or replace clamps.

Hydraulic lines in contract with frame.

Inspect and repair.

Worn or damaged pump.

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

Failed or worn hydrualic pump.

Do performance check.

Cold oil.

Warm oil up.

Slow engine speed.

Adjust engine speed.

Check high idle speed.

Suction line air leak.

Check for foamy oil.

Low oil supply.

Add recommended oil.

Wrong oil viscosity.

Use recommended oil.

Oil leaking past cylinders or control valve.

Check cylinder drift in group 3.

Blocked or damaged line.

Inspect lines.

Binding loader control valve (MCV) spool.

Inspect valve.

5-21

Cause

Problem

Remedy

No steering or hydraulic function

Low oil level.

Add recommended oil.

Failed hydraulic pump.

Remove and inspect return filter for metal pump particles.

No hydraulic functions steering normal

Failed hydraulic pump.

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

Stuck open port relief valve.

Replace relief valve.

Boom float function does not work

Loader control valve (MCV) spool Do pressure reducing valve pressure binding in bore. test.

One hydraulic function does not work.

Stuck open port relief valve.

Replace relief valve.

Oil leaking past cylinder packings.

Do boom and bucket cylinder leakage test in group 4.

Blockage in oil lines or valve.

Inspect lines for damage.

Disconnect and inspect lines for internal blockage.

Loader control valve (MCV) spool stuck Inspect and repair valve. in bore.

Low hydraulic power

Leakage within work circuit.

Do cylinder drift check in group 3.

Low system relief valve (main relief Do loader system and port relief valve valve) setting. pressure test in group 4.

Low port relief valve setting.

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

Leaking system relief valve.

Remove and inspect valve.

Worn hydraulic pump.

Do hydraulic pump performance check in group 3.

5-22

Cause

Problem Function drifts down

Remedy

Leaking cylinders.

Do cylinder leakage checks in group 4.

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

Boom drifts up

Leaking loader control valve (MCV).

Repair or replace valve section.

Leakage in boom down spool.

Remove and inspect boom down spool.

Boom down does not MCV spool stuck. work (engine off)

Inspect and repair valve.

Oil overheats

Low oil viscosity in hot weather.

Use recommended oil.

Excessive load.

Reduce load.

Holding hydraulic system over relief.

Reduce load.

Leakage in work circuit.

Do boom and bucket cylinder leakage test in group 4.

Plugged fins in oil cooler.

Inspect and clean oil cooler.

Internally plugged oil cooler.

Do hydraulic oil cooler restriction test.

Incorrect system or circuit relief valve setting.

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

Restriction in oil lines or loader control Inspect for dented or kinked lines. valve (MCV).

Hydraulic oil foams

Malfunctioning steering unit.

Do hydraulic system restriction test in group 4.

Leaking system main relief valve.

Do hydraulic system restriction test in group 4.

Remove and inspect valve and seals.

Worn hydraulic pump (internal leakage).

Do hydraulic pump performance check in group 3.

Low oil level.

Add recommended oil.

Wrong oil.

Change to recommended oil.

Water in oil.

Change oil.

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

5-23

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

1) Every structure has its limit of strength and durability. The relief valve is installed to limit the pressure on the hydraulic equipment and protect various parts of the wheel loader from possible damage. Therefore, never change the preset pressure of the relief valve unless absolutely necessary.

2) Since the hydraulic equipment is built with precision, the presence of only the slightest amount of dust and / or other particles in the hydraulic circuit might cause wear and/or damage, resulting in unstable functions and/or damage, resulting in unstable functions and/or unexpected accidents.

Therefore, always keep hydraulic oil clean. Periodically, check the filter in the return circuit and replace the element as necessary.

3) Extract about 200cc of hydraulic oil from the tank as a sample every 6 months. If possible, have it analyzed by a specialist to confirm that the oil can still be used. Never extract the oil for sampling until the oil temperature has become the normal operating temperature. Since the replacement period varies depending on operating conditions, refer to Operator's Manual and change oil.

4) Should the equipment get damaged due to the presence of metal particles and/or foreign matter in the circuit drain out the hydraulic oil and carry out flushing. Also, replace the filter element and clean the hydraulic tank. Change the hydraulic oil entirely.

5) When checking the filter, if found metal particles in the element, drain out the hydraulic oil entirely, flush the whole circuit, and then fill with new oil. The presence of metal particles may indicate internal damage to the equipment. In such a case, check carefully before flushing, and repair or replace as required.

6) To add and/or change the hydraulic oil, always use recommended oil. (Refer to the list of lubricants. Never mix oil of recommended oils and lubricants at page 1-17, Recommended lubricants.) different makes of kinds.

7) To change the hydraulic oil, use a clean vessel and funnel for pouring it into the tank. Never use cloth because it might cause the presence of lint in the circuit.

8) When removing the hydraulic equipment, be sure to put plugs or caps on hoses, tube lines and ports. Also, enter mating marks for later identification.

9) Disassemble and/or assemble the hydraulic equipment only in a clean place free of dust. When disassembling, be careful about the interchangeability of parts, and clean the disassembled parts with pure and clean mineral cleansing oil. Clean the internal passages as well. After the parts have dried, wipe them off with a clean lint-free cloth.

10) When overhauling the hydraulic equipment replace all O-rings, backup rings, etc. with new ones.

Assemble O-rings with grease or vaseline applied.

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

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

5-24

GROUP 4 TESTS AND ADJUSTMENTS 1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY ※ Service equipment and tool ·Portable filter caddy ·Two 4000 mm × 1in 100R1 Hoses ·Quick disconnect fittings. ·Discharge wand ·Various size fittings. ※ Flush all lines in the steering system and cut off system. Disassemble and clean major components for steering system.

Steering components may fail if steering system is not cleaned after hydraulic oil tank contamination.

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

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

3) To minimize oil loss, pull a vacuum in hydraulic oil tank using a vacuum pump.

Connect filter caddy suction line to drain port at bottom of hydraulic oil tank using connector. Check to be sure debris has not closed drain port.

4) Put filter caddy discharge line into hydraulic oil tank filler hole so end is as far away from drain port as possible to obtain a thorough cleaning of oil.

5-25

5) Start the filter caddy. Check to be sure oil is flowing through the filters.

Operate filter caddy approximately 10 minutes so oil in hydraulic oil tank is circulated through filter a minimum of four times. ※ Hydraulic oil tank capacity : 90ℓ(23.8 U.S. gal) Leave filter caddy operation for the next steps.

6) Start the engine and run it at high idle. ※ For the most effective results, cleaning procedure must start with the smallest capacity circuit then proceed to the next largest capacity circuit.

7) Operate all functions, one at a time, through a complete cycle in the following order : Steering, bucket, and boom. Also include all auxiliary hydraulic functions.

Repeat procedure until the total system capacity has circulated through filter caddy seven times, approximately 30 minutes.

Each function must go through a minimum of three complete cycles for a through cleaning for oil. ※ Filtering time for machines with auxiliary hydraulic functions must be increased because system capacity is larger.

8) Stop the engine. Remove the filter caddy.

9) Install a new return filter element.

10) Check oil level in reservoir; Add oil if necessary.

5-26

2. TEST TOOLS 1) CLAMP-ON ELECTRONIC TACHOMETER INSTALLATION ·Service equipment and tools Tachometer A : Clamp on tachometer.

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

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

C : Red clip (+). Connect to transducer.

D : Tachometer readout. Install cable.

B

C

D A

75795SE32

2) DIGITAL THERMOMETER INSTALLATION ·Service equipment and tools Digital thermometer A : Temperature probe.

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

B : Cable.

C : Digital thermometer.

A C B

75795SE33

3. HYDRAULIC OIL WARM UP PROCEDURE 1) Install temperature reader (see temperature reader installation procedure in this group).

2) Run engine at high idle.

3) Hold a hydraulic function over relief to heat the oil.

4) Periodically cycle all hydraulic functions to distribute warm oil.

5) Heat oil to test specification (approx. 45˚C).

5-27

4. MAIN HYDRAULIC PUMP FLOW TEST · SPECIFICATION Oil temperature 45±5˚C (113±9˚F) Engine speed 2200±25 rpm Test pressure 173±5 bar (2461 psi) Maximum pump flow 221ℓ/min (58.4 gpm) · FLOW METER AND TOOL Flow meter 300ℓ/min (79.3 gpm) Temperature reader

Flow meter

1) Make test connections.

To MCV

2) Install temperature reader. (see temperature reader installation procedure in this group) 3) Heat hydraulic oil to specifications. (see hydraulic oil warm up procedure in this group) 4) Run engine at test specifications.

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

Main pump

6) Read flow meter.

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

830KWE33

5-28

5. LOADER L ADER SYSTEM AND PORT RELIEF VALVE PRESSURE TEST · SPECIFICATION Oil temperature (40~50˚C) Relief valve Engine speed

Relief pressure

System (M)

Low

173±5 kg/cm2 (2461±70 psi)

Bucket rollback (R)

Low

203±5 kg/cm2 (2887±70 psi)

Bucket dump (D)

Low

122±5 kg/cm2 (1740±70 psi)

M

Bucket Boom

· Gauge and tool Gauge 0~35 MPa (0~350 bar, 0~5000 psi) M : System (main) relief valve R : Bucket rollback relief D : Bucket dump relief

D

R

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

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

3) Heat hydraulic oil to specifications. (see hydraulic oil warm up procedure in this group) 4) To check the system relief (M), run engine at low idle. Lower boom to bottomed position.

Slowly activate boom down function while watching pressure gauge. If pressure is not to specification, loosen lock nut on system relief valve (M) and adjust to specification.

Hyd tank

※ Do not adjust the system relief valve above 173 kg/cm2 (2461 psi). Damage to the pump will result from excessive pressure settings.

830KWE34

5-29

6. HYDRAULIC SYSTEM RESTRICTION TEST · SPECIFICATION Oil temperature 45±5˚C (113±9˚F) Engine speed High idle Maximum pressure 3 MPa (30 bar, 43 psi) at steering unit Maximum pressure at main control valve 1 MPa (10 bar, 145 psi) · GAUGE AND TOOL Gauge 0~7 MPa (0~70 bar, 0~1000 psi) 2EA This test will check for restrictions in the hydraulic system which can cause overheating of hydraulic oil.

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

T

Steering unit

2) Heat hydraulic oil to specifications. (see hydraulic oil warm up procedure in this group) 3) Connect fitting and gauge to steering valve.

4) Connect fitting and gauge to main control valve.

Do not operate steering or loader functions or test gauge may be damaged.

MCV

5) Run engine at specification and read pressure gauges.

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

If pressure is more than specification at the steering unit, inspect neutral condition of the steering unit and priority valve for a stuck spool. Make sure orifice plugs are installed in ends of priority valve spool.

Check for plugged orifice in priority valve LS port and dynamic signal orifice on the spool of priority valve.

830KWE42

5-30

7. LOADER CYLINDER DRIFT TEST · SPECIFICATION Oil temperature Boom horizontal Bucket horizontal Bucket unloaded Item

45±5˚C (113±9˚F)

Standard value

Retraction of boom cylinder rod Retraction of bucket cylinder rod

8

mm

8

B mm

GAUGE E AND TOOL · GAUG Stop watch Temperature reader Put the safety lock lever in the lock position.

Do not go under the work equipment.

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

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

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

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

7577AWE31

5-31

8. BOOM AND BUCKET CYLINDER LEAKAGE TEST · SPECIFICATION Oil temperature 45±5˚C (113±9˚F) Engine speed Low idle Maximum leakage 15 mℓ/min (1/2 oz/min) · GAUGE AND TOOL Temperature reader Stop watch Measuring container 1) Fasten temperature sensor to head end port of cylinder to be tested. Cover sensor with a shop towel.

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

Never work under raised equipment unless it is supported with a hoist or support stands.

3) Full extend the cylinder to be tested. If testing the boom cylinders, restrain boom in the fully raised position using a hoist or a stand. ※ Check cylinders for leakage in the fully extended position only. In the retracted position contacts the end of the cylinder and seals off piston seal leakage.

4) Remove and plug cylinder rod end hose or line.

5) Run engine at slow idle. Activate control lever to extend cylinder for 1 minute over relief while measuring leakage for open port.

If leakage is within specification, excessive cylinder drift is caused by leakage in the loader control valve or circuit relief valve.

(770-3ATM) 6-56

5-32

9. CYCLE TIME TEST · SPECIFICATION Oil temperature Engine speed

45±5˚C (113±9˚F) High idle

Function

Operating conditions

Maximum cycle time (seconds)

Boom raise

Bucket flat on ground to full height

5.4

Boom lower (float)

Full height to ground level

2.7

Bucket dump

Boom at full height

1.1

Bucket rollback

Boom at full height

1.5

Steering (number of turns)

Frame stop to stop

3.4 turns

5-33

10. HYDRAULIC OIL FILTER INSPECTION PROCEDURE 1) Lower the bucket to the ground, stop the engine, move the control lever back and forth several times, and clean all over the upper surface of the hydraulic oil tank.

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

3) Remove the spring and bypass valve.

4) Remove the filter element from the tank.

Cover O-ring Spring By-pass valve

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

Return filter

(1) Clean the inside of the filter case.

(2) Place new element in the proper positions inside the filter case.

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

(4) Install the O-ring and filter case covers.

Tighten them with bolt. Replace the O-ring with new one if damaged.

830KWE40

5-34

SECTION 6 ELECTRICAL SYSTEM Group 1 Component Location ----------------------------------------------------------------------------------------- 6-1 Group 2 Electrical Circuit -------------------------------------------------------------------------------------------------- 6-3 Group 3 Monitoring System --------------------------------------------------------------------------------------------- 6-4 Group 4 Connectors --------------------------------------------------------------------------------------------------------- 6-11

SECTION 6 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 1. LOCATION 1 1 3

9

12 11

2 13

10

45

6

7 8

830S3CD02

1 2 3 4 5

Head lamp switch Work lamp switch Beacon switch (option) Gear selector lever Hazard switch

6 Dashboard 7 Multi function switch 8 Horn button 9 Electric fan 10 Radio and MP3 player

6-1 6-2

11 Aircon and heater switch 12 Starting Switch 13 Engine stop switch

2. LOCATION 2 5

4

6

4

1

3

2

7

8

12 9

10

11

830S6EL01

1 2 3 4 5

Head lamp Horn Multi function switch Work lamp Beacon lamp

6 7 8 9 10

Electric fan Coolant temperator sensor Engine oil pressure sensor Reverse warning tone Battery

6-2

11 Power switch 12 Rear combi lamp

GROUP 2 ELECTRICAL CIRCUIT

6-3

GROUP 3 MONITORING SYSTEM 1. CLUSTER The gauges panel consists of gauges and monitors as shown below, to warn the operator in case of abnormal machine operation or conditions for the appropriate operation and inspection. ·Gauges : Indicate operating status of the machine. ·Warning lamp : Indicate abnormality of the machine. ·Pilot lamp : Indicate operating status of the machine. ※ The monitor installed on this machine does not entirely guarantee the condition of the machine. Daily inspection should be performed according to chapter 6, Maintenance. ※ When the monitor provides a warning immediately check the problem, and perform the required action.

Hour meter

Parking brake warning lamp

High beam pilot lamp

Right turning pilot lamp

Left turning pilot lamp Battery charging warning lamp Brake air pressure warning lamp

Engine oil pressure warning lamp

Engine coolant temperature gauge T/M oil pressure gauge T/M oil temperature gauge

Brake air pressure gauge

850S3CD02

6-4

HOUR METER This gauge indicates the working time of engine. It's reading can be used as repair and maintenance basis.

850S3CD03

ENGINE COOLANT TEMPERATURE GAUGE This gauge indicates the temperature of coolant.

Red range : Above 100˚ C

Operating range Red 60 50

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

100 115

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

850K3CD05

If the indicator is in the red range, keep idling engine at low speed for 5 minutes, turn off the engine and check the radiator and engine.

TRANSMISSION OIL TEMPERATURE GAUGE This gauge indicates the temperature of transmission oil.

Red range : Above 120˚C

Operating range Red

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

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

850K3CD07

If the indicator is in the red range, it means the transmission is overheated. Be careful that the indicator does not move into the red range.

TRANSMISSION OIL PRESSURE GAUGE g tin ra ge e Op ran

This gauge indicates the pressure of transmission oil.

Red

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

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

850K3CD08

-

5) BRAKE AIR PRESSURE GAUGE Oper ating range Red

(1) This gauge indicates the air pressure of service brake. · Red range : Below 0.4 MPa (2) If the indicator is in operating range, it is normal.

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

850K3CD06

6) DIRECTION PILOT LAMP (1) This lamp flashes when the signal indicator lever is moved.

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

77073CD10

7) HIGH BEAM PILOT LAMP (1) This lamp works when the illuminating direction is upward.

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

77073CD12

8) PARKING BRAKE WARNING LAMP (1) When the parking brake is actuated, the lamp lights ON. ※ Check the lamp is OFF before driving.

77073CD13

9) BRAKE AIR PRESSURE WARNING LAMP (1) The lamp lights ON when the air pressure of service brake drops below the normal range.

(2) When the lamp is ON, stop the engine and check for its cause. ※ Do not operate until any problems are corrected.

850K3CD16

6-6

10) ENGINE OIL PRESSURE WARNING LAMP (1) In the oil pump pressure supply every part will be lubrication at the same time. This lamp is comes ON after starting the engine because of the low oil pressure.When the engine starts normally will automatically turn off the lamp.

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

77073CD18

11) BATTERY CHARGING WARNING LAMP (1) This lamp is ON when key ON, it is turned OFF after starting the engine.

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

77073CD22

6-7

2. SWITCHES Beacon switch (option) Main light switch Work lamp switch Engine stop switch Starting switch

Horn button Multi function switch Hazard switch

733S3CD04

STARTING SWITCH There are three positions, OFF, ON and START. · (OFF) : None of electrical circuits activate. · (ON) : All the systems of machine operate. · (START) : Use when star ting the engine. Release key immediately after starting.

77073CD41

6-8

2) HAZARD SWITCH OFF ON

(1)Use for parking, or roading machine.

(2) Both turn signal lights will flash simultaneously. ※ If the switch is left ON for a long time, the battery may be discharged.

77073CD42

3) WORK LAMP SWITCH (1)This switch use to operate the front and rear work lamps by two step. ·First First step : Front work lamp located on the cab comes ON. ·Second Second step : Rear work lamp located on the cowl comes ON.

77073CD46

4) MAIN LIGHT SWITCH (1)The switch use to operates the clearance lamp and head light by two step. ·First First step : Clearance lamp and cluster illumination lamp comes ON. Also, all indicator lamp of switches come ON. ·Second Second step : Head light comes ON. 77073CD45

5) BEACON SWITCH (option) (1)This switch turns ON the rotary light on the cab.

77073CD50

6) HORN BUTTON Horn button

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

830K3CD28A

-

7) CAB LAMP SWITCH (1) This switch turns ON the cab room lamp.

(2) Press ON or OFF can control the lamp.

73033CD24

8) MULTI FUNCTION SWITCH (1) Front wiper and washer switch

OⅠⅡ

II I 0

① When placed in Ⅰ or Ⅱ position, the wiper moves continuously. ② If you press a button at the end of the lever, washer liquid will be sprayed and the wiper will be activated 2-3 times.

7613CD33

Up

Down 733S3CD51

Left turning

Right turning

※ Check the quantity of washer liquid in the tank. If the level of the washer liquid is LOW, add the washer liquid (In cold, winter days) or water. The capacity of the tank is 2.5 liter.

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

(3) Turning switch ① This switch is used to warn or signal the turning direction of the machine to other vehicles or equipment. ② Push the lever up for turning left, pull the lever down for turning right.

7613CD50

9) ENGINE STOP SWITCH (1) If the switch is pressed, the engine stops immediately.

830K3CD37

-

GROUP 4 CONNECTOR 1. MAIN HARNESS Connector number

Type

CN-35 CN-36

No. of pin

Destination

3 J/C

CN-37

10

Connector part no.

DJ7031-7.8-11

TO FUSE BOX

12

DJ7101-6.3-11 DJ7121-6.3-11

CS-2

KET

6

START SWITCH

MG610335

CN-171

J/C

2

SERVICE SOCKET

DJ7028-6.3-21

J/C

5

FUSE BOX

DJJ7051-6.3-21

CR-11

J/C

2

FLASHER UNIT RELAY

DJJ7058A-6.3-21

CN-26

TYW

2

WARNING BUZZER

174198-1

CN-1

J/C

3

REAR FRAME SIDE 1

DJ7031-7.8-11

CN-2

J/C

14

REAR FRAME SIDE 2

DJ141-6.3-21

CN-3

J/C

8

REAR FRAME SIDE 3

DJ7081-6.3-21

CN-11

J/C

8

HEATER SIDE

DJ7021A-7.8-21

EARTH4

J/C

2

-

CN-9A

J/C

10

TO FRONT HARNESS

DJ7021A-7.8-21

CN-7

J/C

8

TO CAB HARNESS

DJ7081-6.3-21

CN-4

TYCO

16

TO DASHBOARD HARNESS

368047-1

CN-5

TYCO

15

TO DASHBOADR HARNESS

85223-1

CR-3 CR-40 CR-2 CR-26 CR-27 CR-30 CR-55 CR-63 CR-79 CR-56

CN-21 CS-36 CS-79

Y10-10

ILL & HEAD LAMP SWF

10

WORK LAMP DIODE

6-11

SWF593757

2. CAB HARNESS Connector number

Type

No. of pin

Destination

Connector part no.

CN-7

J/C

8

TO MAIN HARNESS

DJ7081-6.3-11

CL-7

TYCO

2

BEACON

174198-1

CN-23 CN-24

KET

2

SPEAKER

7123-1520

CL-1

J/C

2

ROOM LAMP

DJ7021-6.3-21

CN-27

-

16

RADIO & MP3 player

PK145-16017

CL-5

J/C

2

WORK LAMP, FRONT-LH

DJ7021-1.5-20

CL-6

J/C

2

WORK LAMP, FRONT-RH

DJ7021-1.5-20

CL-23

SWF

10

BEACON SWITCH

593757

EARTH

J/C

1

RING TERMINAL

DJ431-10

AC-3

J/C

2

FAN

DJ7021-6.3-10

CL-22

J/C

2

WORK LAMP,REAR-LH

DJ7021-1.5-20

AC-3

J/C

2

WORK LAMP,REAR-RH

DJ7021-1.5-20

3. DASHBOARD HARNESS Connector number

Type

No. of pin

Destination

Connector part no.

CS-11

J/C

8

TURN LEVER

DJ70818-6.3-21

CN-21

J/C

6

FRONT WIPER

DJ7061-6.3-21

CS-41

SWF

10

HAZARD SWITCH

593757

CN-56

TYCO

16

GAUGE BOARD SIDE

368047-1

CN-4

TYCO

16

TO MAIN HARNESS

368050-1

CN-5

TYCO

15

TO MAIN HARNESS

2-85262-1

CS-35

SWF

10

WIPER SWITCH

593757

CS-36

SWF

10

WORK LAMP SWITCH

593757

CS-45

J/C

2

BACK-UP SWITCH

DJ7021-6.3-21

J/C

1

RING TERMINAL

Y10-10

CN-9A

J/C

8

TO MAIN HARNESS

DJ7081-6.3-11

CD-4

J/C

1

STOP LAMP HARNESS

CS-26

J/C

3

PARKING LEVER

DJ7031-6.3-21

CS-12

J/C

6

TURN LEVER

DJ70658-6.3-11

CN-9

J/C

8

TO FRONT HARNESS

DJ7081-6.3-21

EARTH1 EARTH2

6-12

DJ431-5

4. REAR FRAME HARNESS Connector number

Type

No. of pin

Destination

Connector part no.

CD-49

J/C

1

TM TEMP

DJ431-5

CD-48

KSC 2620

1

TM OIL PRESSURE

R1.25-4

CD-3

J/C

1×2

AIR PRESSURE

DJ431-5

EARTH2

J/C

1

RING TERMINAL

Y10-10

GROMMET

HHI

-

-

21LB-34020

CN-65

DEUTSCH

2

BACK BUZZER

DT06-2S

CL-16A CL-16B CL-15A CL-15B

3

J/C

2 3

J/C

2

REAR COMBI-RH

REAR COMBI-LH

DJ7031-1.5-21 DJ7031-1.5-21 DJ7031-1.5-21 DJ7031-1.5-21 03.21000

CN-95

MTA

-

-

03.01080 03.21210

HHI PARTS

-

-

21LM-03180

CN-1

J/C

3

-

DJ7031-7.8-11

CN-2

J/C

14

-

DJ7141-6.3-21

CN-3

J/C

8

-

DJ7081-6.3-11

CN-12

J/C

12

-

DJ7021-6.3-21

CN-74

J/C

1×2

MASTER SWITCH

KET

4

POWER RELAY

CR-1A DR-1B

Y10-10 MG612017

5. FRONT HARNESS Connector number

Type

No. of pin

Destination

Connector part no.

CN-9

J/C

8

FRONT FRAME SIDE

DJ7081-6.3-11

CL-3

TYCO

3

COMBI-FRONT, LH

174200-1

CL-24

TYCO

2

HEAD LIGHT, LH

174198-1

CN-20

MOLEX

2

HORN-LOW

36825-0211

CN-25

MOLEX

2

HORN-HIGH

36825-0211

CL-4

TYCO

3

COMBI-FRONT, RH

174200-1

CL-25

TYCO

2

HEAD UGHT, RH

174198-1

EARTH3

J/C

1

RING TERMINAL

DJ431-10

6-13

6. ENGINE HARNESS Connector number

Type

No. of pin

Destination

Connector part no.

CN-79

J/C

2

ENGINE STOP SOLENOID

DJ70217-6.3-20

CD-18

KSC 2620

1

ENGINE OIL PRESSURE

R1.25-4

CD-8

KSC 2620

1

COOLANT TEMP

R1.25-4

CN-45

KSC 2620 KET

1 1

STARTER

R14-8 ST710197

CN-74

KSC 2620 KSC 2620

1 1

ALTERNATOR

R14-8 R1.25-4

CN-96

KSC 2620 KSC 2620

1 1

POWER EARTH

R2.0-4 R2.0-12

CN-12

J/C

12

ENGINE SIDE

DJ7121-6.3-11

CN-97

KSC 2620

1

FAN CLUTCH

282080-1

EARTH 6

KSC 2620

1

EARTH

R3.0-14

RS-1

-

2

-

21Z2-30160

6-14

8. CONNECTION TABLE FOR CONNECTORS 1) 58-L TYPE CONNECTOR No. of pin

Receptacle connector (female)

Plug connector (male) 1

1

1

S813-030100

1

2

S813-130100

1

2

2

S813-030200

6-15

S813-130200

2) PA TYPE CONNECTOR No. of pin

Receptacle connector (female)

Plug connector (male)

2

5

1

3

1

3

2

5

5

S811-005002

S811-105002

3

7

1

4

1

4

3

7

7

S811-007002 4

9

S811-107002

1

5

4

9

9

1

5 S811-009002

S811-109002

5

11

1

6

1

6

5

11

11

S811-011002

6-16

S811-111002

No. of pin

Receptacle connector (female)

Plug connector (male)

6

13

1

7

1

7

6

13

13

S811-013002

S811-113002 1

9

9 S811-017002

8

17

10 1

21

1

11

1

11

1 10

21

8

17

1

17

S811-117002

21

S811-021002

6-17

S811-121002

3) J TYPE CONNECTOR No. of pin

Receptacle connector (female)

Plug connector (male)

1

2 1

2

12

2

S816-002001

S816-102001 3

2

1

3

3

1

2

S816-003001

S816-103001

3

1

4

2

4

2

3

1

4

S816-004001 6

3 1

8

5 2

S816-104001 8

5 2

6

3 1

8

S816-008001

6-18

S816-108001

4) SWP TYPE CONNECTOR No. of pin

Plug connector (male)

Receptacle connector (Female)

1

1

1

S814-001000

S814-101000

2

1

1

2

2

S814-002000

S814-102000

3

1

2 1

23

S814-003000

S814-103000

3

2

4

1

3

1

3

2

4

4

S814-004000

6-19

S814-104000

No. of pin

Receptacle connector (female)

Plug connector (male)

3

6

1

4

1

4

3

6

6

S814-106000

S814-006000 4

8

1

5

1

5

4

8

8

S814-008000 4

12

1

9

S814-108000 1

9

4

12

12

S814-012000

S814-112000

3

14

1

11

1

11

3

14

14

S814-014000

6-20

S814-114000

5) CN TYPE CONNECTOR No. of pin

Receptacle connector (female)

Plug connector (male)

1

1

1

S810-001202

S810-101202

2

2

2

1

1 S810-002202

S810-102202

3

2

3

1

2

3

1

S810-003202

S810-103202

2

4

1

3

1

3

2

44

4

S810-004202

6-21

S810-104202

No. of pin

Receptacle connector (female) 3

Plug connector (male) 1

6

4

6

1

4 S810-006202

3

6 S810-106202

4

8

1

5

1

5

4

8 S810-108202

8

S810-008202

6-22

6) ITT SWF CONNECTOR No. of pin

Receptacle connector (female)

Plug connector (male)

2 10 10

1 9

SWF593757

7) MWP NMWP CONNECTOR No. of pin

Receptacle connector (female)

Plug connector (male)

1 1

NMWP01F-B

6-23

8) DEUTSCH DT CONNECTORS DT 06 - 3S - ★★★★ Modifications (see below) Number of contacts (P : Pin, S : Socket) 04 : Receptacle, 06 : Plug Deutsch connetors ※ Modification E003 : Standard end cap - gray E004 : Color of connector to be black E005 : Combination - E004 & E003 EP04 : End cap EP06 : Combination P012 & EP04 P012 : Front seal enhancement - connectors color to black for 2, 3, 4 & 6pin No. of pin

Receptacle connector (female)

1

Plug connector (male)

2

2

1

2

DT06-2S

2

1

DT04-2P

1

2

3

3

3 DT06-3S

DT04-3P

4

1

1

4

3

2

2

3

4

DT06-4S

6-24

DT04-4P

No. of pin

Receptacle connector (female)

Plug connector (male)

6

1

1

6

4

3

3

4

6

DT06-6S

4

5

1

8

DT04-6P

5

4

8

1

8

DT06-8S

DT04-8P

6

7

7

6

1

12

12

1

12

DT06-12S

6-25

DT04-12P

9) ECONOSEAL J TYPE CONNECTORS No. of pin

Receptacle connector (female)

Plug connector (male)

1

S816-101002

S816-001002

1

2

2

1

2

S816-002002

S816-102002

S816-003002

S816-103002

S816-004002

S816-104002

3

4

6-26

No. of pin

Receptacle connector (female)

Plug connector (male)

6

S816-006002

S816-106002

S816-008002

S816-108002

S816-010002

S816-110002

S816-012002

S816-112002

8

10

12

6-27

No. of pin

Receptacle connector (female)

Plug connector (male)

15

2-85262-1

368301-1

10) KET 090 CONNECTOR No. of pin

2

Receptacle connector (female)

Plug connector (male)

1

2 MG610070

6-28

11) KET 090 WP CONNECTORS No. of pin

2

Receptacle connector (female)

Plug connector (male)

1

2 MG640605

2

1

2 MG640795

12) CHINA CONNECTORS No. of pin

Receptacle connector (female)

2

Plug connector (male)

2

1

1

4

4

3 DJ7041-6.3-11

3

4 DJ7041-6.3-21

1 8

4 5

8

6-29

DJ7081-6.3-21

13) TYCO CONNECTOR No. of pin

Receptacle connector (female)

Plug connector (male)

2

2

1 282080-1

1

2

2 174198-1

5

11

1

6

11

172497-1

6-30