Hyundai SL765S Wheel Loader Repair Manual 2023 - PDF DOWNLOAD

CONTENTS FOREWORD -------------------------------------------------------------------------------------------------------------------------- 0-1 SECTION 1 GENERAL Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10 Group 3 Operational Checkout Record Sheet --------------------------------------------------------------- 1-19

SECTION 2 POWER POWER TRAIN SYSTEM Group 1 Structure and Function -------------------------------------------------------------------------------------- 2-1 Group 2 Transmission ------------------------------------------------------------------------------------------------------ 2-2 Group 3 Axle --------------------------------------------------------------------------------------------------------------------- 2-23

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

SECTION 4 STEERING SYSTEM Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------- 4-1 Group 2 Structure and Function -------------------------------------------------------------------------------------- 4-5 Group 3 Operational Checks and Troubleshooting ------------------------------------------------------- 4-16 Group 4 Test and Adjustments ---------------------------------------------------------------------------------------- 4-22

SECTION 5 WORK EQUIPMENT Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------- 5-1 Group 2 Structure and Function -------------------------------------------------------------------------------------- 5-2 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 ----------------------------------------------------------------------------------------------------------- 6-8

0-9

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 ---------------------------------------------------------------1-19

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.

警

告

禁止

启动

850S1SH01

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 key switch to OFF to stop engine.

Remove key from switch. · Move pilot control shutoff lever 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 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

Boom

Bell crank

Bucket link

Fuel tank

Head light

Tire

Boom cylinder Main control valve

Bucket cylinder

Front axle

Cab

Air cleaner

Battery

Precleaner

Main pump

Transmission

Steering cylinder

Raidator

Counterweight

Muffler Engine

Rear axle

Hydraulic tank 850S2SE01

1-10

2. SPECIFICATIONS

J H

5370 4100 G

K

35

D

C

F I

B

WITH TOOTH TYPE BUCKET

62 713 00 0

A

E

850S2SE02

Description Operating weight Struck

Bucket capacity

Heaped(Filled)

Unit

Specification

kg (lb)

16500 (36380)

3

m3 (yd )

2.6 (3.4) 3.0 (3.9)

Overall length

A

7900 (25' 11")

Overall width

B

2980 (9' 9")

Overall height

C

3420 (11' 3")

Ground clearance

D

410 (1' 4")

Wheelbase

E

Tread

F

2250 (7' 5")

Dump clearance at 45˚

G

3100 (10' 2")

Dump reach (full lift)

H

1240 (4' 1")

Width over tires

I

2845 (9' 4")

Dump angle

J

Roll back angle (carry position)

K

mm (ft-in)

degree (˚)

Dump (with load)

5.6 sec

Lower (empty) Braking distance

m(ft-in)

Minimum turning radius (center of outside tire)

Travel speed

Forward Reverse

First gear Second gear

39.0 (24.2) 12.5 (41' 0") 6.2 (20' 4")

degree (˚)

Gradeability

1.1 3.5

km/hr (mph)

Maximum travel speed

45 49

Lift (with load) Cycle time

3200 (10' 6")

30 10.6 (6.6)

km/hr (mph)

First gear

39.0 (24.2) 14.5 (9.0)

1-11

3. SPECIFICATION FOR MAJOR COMPONENTS 1) ENGINE Item

Specification

Model

Weichai Power WD10G220E23

Type

4-cycle turbocharged diesel engine.

Control type

Mechanical control

Cooling method

Water cooling

Number of cylinders and arrangement

6 cylinders, in-line

Firing order

1-5-3-6-2-4

Combustion chamber type

Direct injection type

Cylinder bore × stroke

126×130 mm (5.0"×5.1")

Piston displacement

9726 cc (594 cu in)

Compression ratio

17 : 1

Rated gross horse power

162 kW / 2000 rpm

Maximum gross torque at 1300~1500 rpm

900 N·m

Engine oil quantity

20ℓ(5.3 U.S. gal)

Dry weight

1000 kg (2200 lb)

High idling speed

2200±20 rpm

Low idling speed

750±20 rpm

Rated fuel consumption (at rated)

208 g/kW·hr

Starting motor

24 V-8.1 kW

Alternator

24 V-55 Amp

Battery

2×12 V×120 Ah

1-12

2) MAIN PUMP Item

Specification

Type

Gear pump

Capacity

100 cc/rev

Maximum operating pressure

230 kgf/cm2

Rated oil quantity

200l/min

Rated speed

2000 rpm

3) STEERING PUMP + PILOT PUMP Specification Steering pump

Pilot pump

Gear pump

Type Capacity

8 0cc/rev

1 0cc/rev

Maximum operating pressure

2 0 0kgf/cm2

3 0kgf/cm2

Rated oil quantity

2 0 0ℓ/min

2 3 . 5 ℓ/min

4) MAIN CONTROL VALVE Item

Specification

Type

2 spool

Operating method

Mechanical control

Main relief valve set pressure

180 kgf/cm2

Overload relief valve set pressure (bucket in)

200 kgf/cm2

5) CYLINDER Item

Specification

Boom cylinder

Bore dia×Rod dia×Stroke

mm

Bucket cylinder

Bore dia×Rod dia×Stroke

mm

Steering cylinder

Bore dia×Rod dia×Stroke

mm

1-13

6) DYNAMIC POWER TRANSMISSION DEVICES Item

Specification

Model

Transmission

Axle

Wheels Brakes

Steering

Type

ZL50 Converter

Double-stage, Double-phase

Transmission

Mechanical, hydraulic

Gear shift

Forward second gear, reverse first gear

Control

Mechanical single lever type

Drive devices

4-wheel drive

Front

Front fixed location

Rear

Oscillation ±11˚ of center pin-loaded

Tires

23.5-25, 16PR (L3)

Travel

Single line gas oil caliper disc brake

Parking

Drum type brake on transmission, mechanicall control

Type

Hydraulic, articulated

Steering angle

35˚ to both right and left angle, respectively

1-14

. TORQUE CHART 、 Use following table for unspecified torque.

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

5

5

kgfÂm

lbfÂft

kgfÂm

lbfÂft

. Ý

~

~

~

~

. Ý

~

~

~

~

. Ý

~

~

~

~

. Ý

~

~

~

~

. Ý

~

~

~

~

. Ý

~

~

~

~

. Ý

~

~

~

~

. Ý

~

~

~

~

. Ý

~

~

~

~

. Ý

~

~

~

~

. Ý

~

~

~

~

. Ý

~

~

~

~

(2) Fine thread Bolt size

5

5

kgfÂm

lbfÂft

kgfÂm

lbfÂft

. Ý

~

~

~

~

. Ý

~

~

~

~

. Ý

~

~

~

~

. Ý

~

~

~

~

. Ý

~

~

~

~

. Ý

~

~

~

~

. Ý

~

~

~

~

. Ý

~

~

~

~

. Ý

~

~

~

~

. Ý

~

~

~

~

. Ý

~

~

~

~

1-15

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

Width across flat ( mm

kgf m

lbf ft

Width across flat (mm

kgf m

lbf ft

Width across flat mm

kgf m

lbf ft

3) PIPE AND HOSE (ORFS type) Thread size (UNF)

4) FITTING Thread size

1-16

5. TIGHTENING TORQUE OF MAJOR COMPONENT No.

Descriptions

Bolt size

kgf·m

Engine mounting bolt (2EA)

M18×2.5

30.4 ± 4.6

Engine mounting bolt (bracket)

M12×1.5

9.03 ± 1.8

Radiator mounting bolt

M16×2.0

21.9 ± 3.3

4

Fuel tank mounting bolt

M16×2.0

21.9 ± 3.3

5

Main pump housing mounting bolt

M12×1.5

9.03 ± 1.8

6

Main control valve mounting bolt

M12×1.75

12.3 ± 2.5

Steering unit mounting bolt

M10×1.5

5.0 ± 1.0

Steering valve mounting bolt

M10×1.5

5.0 ± 1.0

9

Brake valve mounting bolt

M8×1.25

2.5 ± 0.5

10

Control lever mounting bolt

M10×1.5

5.0 ± 1.0

11

Hydraulic oil tank mounting bolt

M16×2.0

21.9 ± 3.3

12

Transmission mounting bolt

M24×3.0

73.5 ±11.0

13

Transmission mounting bolt (bracket)

M18×2.5

32.7 ± 4.9

Torque converter mounting bolt

M12×1.75

9.03 ± 1.8

Front and rear axle mounting bolt, nut

M30×2.0

161 ± 24.2

16

Tire mounting nut

M22×1.5

79 ± 2.5

17

Drive shaft joint mounting bolt, nut

M12×1.25

13.3 ± 2.7

Counterweight mounting bolt

M30×3.5

199 ± 29.9

Cab mounting bolt

M27×3.0

70 ± 10

1 2 3

Engine

7 8

14 15

18 19

Hydraulic system

Power train

Others

1-17

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

20 (5.3)

SAE 10W-30 SAE 15W-40

Transmission

Gear oil

Axle

Gear oil

Hydraulic

60 (15.9)

AFT DEXRON III

Front : 29 (7.7)

SAE 80W-90

Rear : 29 (7.7)

SAE 85W-90 ★1

Tank; 170 (44.9)

ISO VG 15

Hydraulic tank

ISO VG 46 oil

System; 230 (60.8)

ISO VG 68 ★1

Fuel tank

Diesel fuel

ASTM D975 NO.1

260 (68.7) 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) 44 (11.6)

★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

1-18

★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.

850K1CH01

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)

1-19

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

□

□

· Clutch cut off 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

1-20

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

□

□

·Engine side panels check

□

□

·Radiator cap access door check

□

□

·Frame locking bar check

□

□

·Service decal check

□

□

9. Cab components and vandal protection checks

1-21

SECTION 2 POWER TRAIN SYSYTEM Group 1 Structure and Function -------------------------------------------------------------------------------------- 2-1 Group 2 Transmission ------------------------------------------------------------------------------------------------------- 2-2 Group 3 Axle ---------------------------------------------------------------------------------------------------------------------- 2-

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

Transmission

Engine Engine

Front axle

Front drive shaft

Center drive shaft

Rear drive shaft

Rear axle 851S2PT01

The power train consists of the following components: ·Transmission ·Front, center and rear drive shafts ·Front and rear axles Engine power is transmitted to the transmission through the torque converter.

The transmission is a hydraulically engaged two speed forward, one speed reverse countershaft type power shift transmission. A drum 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 then 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. OUTSIDE VIEW

2-2

2. STRUCTURE

2

1

12 Intermediate input shaft 13 Large overrunning clutch roller 14 Large overrunning clutch cam 15 Outer-ring gear, large over- running clutch 16 Sun gear 17 Recerse gear planet shelf assembly 18 A block planet shelf assembly 19 Cover 20 Three shaft assembly 21 Four shaft assembly 22 Oil pan

1 Working pump 2 Variable speed pump 3 First-stage input gear 4 Input second-stage gear 5 Shaft gear 6 Guide pulley seat 7 Second-stage turbine 8 First-stage turbine 9 Guide pulley 10 Pump pulley 11 Transfer gear

2-3

3. TECHNICAL DATA Rated input power Rated input speed Torque converter type Torque converter model Torque ratio when zero speed Transmission Type Mechanical Gear Ratio; Gear I Gear II Reverse Hydraulic oil pressure Inlet oil pressure, torque converter Outlet oil pressure, torque converter Lubricating oil pressure Max. permissible tempeture at outlet of torque converter

2-4

162 kW 2000 rpm Single-stage, two-phase, four-element YJSW315-8A 4±0.20 Two forward and one reverse gears, hydraulic shift, planetary structure 2.155 0.578 1.577 1.10 ~ 1.40 MPa 0.30 ~ 0.45 MPa 0.20 ~ 0.30 MPa 0.10 ~ 0.20 MPa 120˚C

4. OPERATION 1) HYDRAULIC TORQUE CONVERTER Torque converter is designed as single-stage, two-phase and four elements. Its construction is as shown in figure 2 (page 2-3).

Torque converter consists mainly of pump pulley (10), first-stage turbine (8), second-stage turbine (7) and guide pulley (9). The pump pulley connects to engine flywheel by a flexible steel board.

When the pump pulley turns, oil in torus is driven and has certain kinetic energy. Then the oil drives the first- and second-stage turbines, and drives the transmission running. Since turbines’ torque and speed would change by variation of load, the torque converter possesses the functions of automatic torque- and speed-changing. The guide pulley is fixed on housing of torque converter by a guide pulley seat (6).

When hydraulic transmission has a small load or high speed, the second-stage turbine works individually; however, when the load increases and the speed decreases (at the moment the speed of motor is basically unchanged), two turbines automatically work together.

2) MECHANICAL TRANSMISSION Power of the second-stage turbine (7) is transferred to intermediate input shaft (12) via input second-stage gear (4), and that of the first-stage turbine to input first-stage gear (3), then to outerring gear of large overrunning clutch (15). When external load is comparatively small, speed of intermediate input shaft (12) is higher than that of outer-ring gear of large overrunning clutch (15), thus making large overrunning clutch roller (13) racing. At this time the second-stage turbine works individually.

When external load is increasing, speed of intermediate input shaft (12) is caused to descend gradually. If speed of the intermediate input shaft (12) is lower than that of outer-ring gear of large overrunning clutch (15), the roller (13) is to be wedged. Power from the first-stage turbine is transferred to large overrunning clutch cam (14) via the roller (13). Since the cam (14) and the intermediate input shaft (12) are connected with bolts, the first- and the second-stage turbines work together at the time. Mechanical transmission has two forward gears and one reverse gear.

Transmission route and power flow chart of each gear are as shown in figure 4, 5 and 6.

← Hydraulic oil

← Hydraulic oil ← Hydraulic oil

Figure 4 Power flow chart of forward gear I

Figure 5 Power flow chart of forward gear II

2-5

At the bottom of the transmission, there is a front and rear axle release device (see to figure 2), which can control single- or dual-axle drive. Pull the control rod outward for single-axle drive and push inside for dual-axle drive. Generally, use single-axle drive in long-distance transport with light load to reduce loss from power recycling; and use dual-axle drive when operating under heavy load on slushy roads or crossing bridges.

Hydraulic oil →

Hydraulic oil →

Figure 6 Diagram of reverse gear power flow chart

3) HYDRAULIC SYSTEM

Safety valve (0.3~0.45 MPa)

Pressure reducing valve (P=1.1~1.4 MPa) Mpa) (P=1.1~1.4 Small hole

Check valve Bypass valve

Filter

Torque converter

Clutch lockup cutoff valve Gear pump

Cooler

Shift lever

Gear I clutch Lubricant removal circuit

Reverse gear clutch

Gear II clutch

Sump

Diagram of hydraulic system of hydraulic transmission

2-6

Gear II Gear I Neutral Reverse gear

Lubricant pressure regulator valve (0.1~0.2 MPa)

Main oil circuit (P main=1.1~1.4MPa) Gear shift oil way Torque converter inlet circuit Torque converter outlet circuit Sump Valve spool, valve rod

850KPT51

5. APPLICATION AND INSTALLATION 1) INSTALLATION AND CONNECTION (1) Connection to engine Surface of torque converter casing is directly connected to that of engine flywheel casing by bolts. Through the connection between flexible steel board of converter and engine flywheel by stud bolts and nuts, power is transferred. Head of centering shaft at front end of pump pulley cover inserts flywheel centering hole as centering.

When installing, screw stud bolts into flywheel, open a chock on torque converter, lift the transmission and make hole on flexible steel board and centering hole lining up, screw end-face bolts and tighten the nuts through square holes at lower side of the chock, at last, cover the chock. ※ Difference between the plane of flywheel casing and that of flywheel 0.50 mm.

(2) Connection to oil pump Working oil pump and steering oil pump are directly mounted onto PTO1 and PTO2 of transmission. (Shaft head length 60~65 mm, key connection useful length 40 mm). ※ Connection parameter must be correct.

(3) Installation on vehicle Had better apply three- or four-point flexible supporting installation. There is each one V-block at both sides of transmission for installation and it’s required to weld corresponding V-blocks on the vehicle body, too. Between two V-blocks insert a rubber plate of 10~12 mm as elastic layer, avoiding stress from vehicle chassis being transmitted to transmission housing directly.

(4) Selection and assembly of filter Select filter meeting parameter as follows : Min. filter flow: 120ℓ/min Filter accuracy not less than 150 mesh/inch. Use sintered filter as far as possible.

The installation height of filter and oil pipes must not be higher than that of the oil pipe connector of housing.

(5) Selection and assembly of cooler Calculate cooling capacity required on the basis of an ambient temperature 30, which should be 35~40% of the rated power of engine. Normal flow must be assured.

Cooler for transmission should be located at cool water end of the cooling system.

Diameter of oil pipe and thread connector for cooler and filter should be more than 20, and when oil pipe exceeds 1m in length, the value increases by 20%. ※ The system maker is liable for correct installation.

2) APPLICATION REQUIREMENTS (1) After installation of hydraulic transmission, fill in about AFT (DEXRON Ⅲ) from the oil hole.

Check the oil level again after 5min running from starting engine, which should reach the height of oil-level plug. During checking, be sure to take safety measures to avoid vehicle moving or rolling.

(2) Oil level should be checked before each shift operating.

(3) When the transmission works, the hydraulic oil pressure should be kept within 1.1~1.4 MPa. In case of the value is lower than 1 MPa or higher than 1.6 MPa, stop and check to avoid damaging the parts inside.

2-7

(4) The oil temperature should be lower than 120˚C. When it exceeds, keep the engine speed within 1200~1500 rpm and make the transmission at neutral, then the oil temperature should decrease to a normal value in 2~3 min. If not, it shows there are problems in the system, which must be resolved before operation.

(5) Reduce machine speed before transmission changing down. And stop before reversing.

(6) The shifting lever should be at neutral position when starting the engine.

(7) Stop when control by using the axle releasing device.

After installation of a new T/M, keep running in for twelve hours under a load less than 70%, four hours for each of three gears. Check the oil temperature, oil pressure and the tightness of bolts.

After running in, clean the sump strainer of transmission and then renew oil.

3) MAINTENANCE Maintenance is carried out after running for 50, 250, 1000 and 2000 hours.

(1) 50 hours maintenance : ① check oil level ② Inspect the control system.

(2) 250 hours maintenance : Clean filter and clean sump.

(3) 500 hours maintenance : Change oil.

(4) 1000 hours maintenance : Replace filter.

(5) 2000 hours maintenance : Dismantle and inspect the transmission and the torque converter, replace easily-worn parts, regulate or replace parts when necessary.

2-8

6. MAIN FAILURES AND REMEDIES Main Failures

Remedies

The engine rotating, but machine can not run 1. Did not in any gears 2. Hydraulic oil level too low 3. Brake rod of shift valve can not return 4. Insufficient oil supply due to shifting oil pump damaged or oil seals broken

1. Put into gear or check if it correct 2. Add oil 3. Dismantle and check the brake rod 4. Replace oil pump or oil seals

Insufficient driving force 1. Low oil pressure at inlet of torque converter 2. Clutch sliding 3. Insufficient engine speed

1. Check oil level; clean sump strainer and filter; check the pressure regulating valve of torque converter 2. Inspect clutch oil pressure and piston oil seal 3. Inspect the engine

Variable speed oil pressure too low 1. Misalignment of reducing valve 2. Obstructed oil filter 3. Damaged oil pump 4. Serious oil leakage in clutch oil seal

1. Realignment 2. Clean oil filter 3. Replace oil pump 4. Replace oil seals

Oil temperature in torque converter too high 1. Oil level in transmission too low or too high 2. Clutch sliding 3. Long-time, heavy load operation

1. Fill oil acc. to specified 2. Check oil pressure of clutch 3. Stop to cool

Can not put into gear after emergent braking 1. Misalignment limit screws of air brake valve pedal 2. Choked piston of air brake valve. Return is unavailable after release of brake.

3. Choked brake valve rod

1. Realign the limit screws of pedal so that air brake valve can return completely.

2. Clean and repair the piston 3. Dismantle and check brake valve rod

2-9

7. DISASSEMBLY AND ASSEMBLY 1) DISASSEMBLY (1) Use a M16 socket wrench to unscrew 6-M10×60 bolts on the interface between oil pump and casing. Use a copper bar to lightly knock on the outside of oil pump and remove the oil pump.

850KTM01

(2) When assebmling, set a paper washer on the surface of oil pump with grease, set 6-M10×60 bolts and fasten up one by one.

850KTM02

850KTM03

850KTM04

2-10

(3) Use a M16 socket wrench to fasten up 10-M10×70 and 1-M10×65 bolts on the control valve.

850KTM05

(4) When assembling, set a paper washer on the surface of casing with grease and mount the control valve. First set a bolt, then insert 10-M10×70 and 1-M10×65 bolts in sequence and fasten up. Be sure that the bolts are fastened from inside to outside not to have the water paper broken.

850KTM06

(5) Use a M16 socket wrench to unscrew 26-M10×30 and 5-M10×70 jointing the torque converter and transmission. Use 3-M10×70 art bolts to disassemble the torque from the casing.

850KTM07

850KTM08

2-11

(6) Dismount the bearing seat and torque converter respectively.

1 Bearing seat

1 850KTM09

850KTM10

(7) Disassemble the input first and second g e a r s f r o m t h e t o r q u e c o nve r t e r respectively.

1 Input first gear 2 Ball thrust bearing 3 Ball bearing (55×120×29)

1

2

3 850KTM11

4 Input second gear 5 Oil seal (45×53×5)

4

5 850KTM12

2-12

(8) Use a M16 socket wrench to unscrew 26-M10×30 and 5-M10×70 jointing the torque converter and transmission. Use 3-M10×70 art bolts to disassemble the torque from the casing.

1 Ball bearing (55×100×21) 2 Steering oil pump driving shaft 3 Steering oil pump drive gear Flat key (14×35) Ball bearing (50×90×20)

1

2

3 850KTM13

4 Ball bearing (60×95×18) 5 Gear shaft 6 Ball bearing (50×90×20)

4

5

6 850KTM14

(9) Disasemble biaxial assy.

850KTM15

850KTM16

2-13

(10) Put the transmission in level position and use a M16 wrench to unscrew 8-M10×30 bolts of end cover. Set two eye bolts into screw hole and remove the end cover.

1 End cover

1 850KTM17

2 Casing

2

850KTM18

(11) Use two M12 eye bolts to sling the direct gear assy out.

1 Direct gear assy

1

850KTM19

(12) Use a M22 socket wrench to unscrew 8-M14×40 bolts on the mid-cover to remove it.

1 Mid-cover

1 850KTM20

2-14

(13) Remove the parts of the planetary gear sets inside transmission, gear I cylinder assy, 15 spring pins, springs, friction discs (4 sets), gear I planet carrier, isolator assy, friction discs (4 sets), reverse gear planet carrier assy and reverse gear piston in sequence.

850KTM21

850KTM22

(14) Remove 2 rings 130 at two sides of the casing and knock out the output shaft forward from the rear side.

850KTM23

850KTM24

2-15

2) ASSEMBLY (1) Clean the transmission case, put it in level position, and assemble the reverse gear piston.

850KTM25

1 Reverse gear piston

1 850KTM26

(2) Assemble reverse planetary gear.

850KTM27

850KTM28

2-16

(3) Assemble 4 sets of reverse driven disc and driving disc in sequence.

1 Reverse driving disc 2 Reverse driven disc

1

2 850KTM29

850KTM30

(4) Assemble friction disc isolator assy.

1 Friction disc isolator assy

1

850KTM31

850KTM32

2-17

(5) Assemble gear I planet gear carrier assy.

1 Pinion carrier 2 Reverse ring gear 1

2 850KTM33

850KTM34

(6) Assemble gear I ring gear and 4 sets of driving disc and driven disc.

1 Gear I ring gear

1 850KTM35

2 Driven disc 3 Driving disc 2

3 850KTM36

2-18

(7) Insert 15 springs and spring pins, and put the gear I cylinder body assy.

850KTM37

1 Gear I cylinder body

1

850KTM38

(8) Put the mid-cover and use a M22 socket wrench to fasten up 8-M14M0 bolts on the mid-cover.

1 Mid-cover 1

850KTM39

850KTM40

2-19

(9) Assemble direct gear assy, end cover, and use a M16 wrench to fasten up 8-M 10×30 bolts.

1 Direct gear assy 1

850KTM41

850KTM42

(10) Assemble steering oil pump driving shaft and gear shaft assy into the torque converter.

850KTM43

1 Gear shaft

1 850KTM44

2-20

(11) Assemble the 1st/2nd stage gear input and bearings into torque converter.

850KTM45

850KTM46

(12) Assemble the biaxial assy into the transmission box.

850KTM47

850KTM48

2-21

(13) Joint the torque conver ter to the transmission and set 2-A10×30 pin and then use a M16 socket wrench to fasten 26-M10×30 and 5-M10×70 to combine the torque converter with transmission box.

850KTM49

850KTM50

(14) Assemble the control valve and oil pump.

850KTM51

850KTM52

2-22

GROUP 3 AXLE 1. OVERVIEW 1) FEATURES IN STRUCTURE As the main part of chassis transmission system, driving axle has the functions of increasing the torque from engine, distributing it to the left and right side driving wheels, and allowing the wheels to have differential feature. In addition, driving axle also receives various forces from road and chassis.

The axle is a two stage transmission device and consists mainly of driving axle housing assembly, main reductor assembly, planetary reductor assembly and brake assembly. The first stage device is main reductor assembly driven by gleason bevel gear, which is large in input torque, high in efficiency, sand table in work.

The second stage device is planetary reductor assembly with planetary reduction driving structure with four planetary wheels (NGW type) which is high in overall running rigidity and stable in output speed.

2) PRINCIPLE The inputting flange inputs the torque from engine, through the main reductor, the power will reach planetary reductor system via differential axle. Then the power is driven to planetary carrier, it makes the tire to move.

The work line is: engine torque→input flange→the main reductor→differential axle→planetary reductor system→Tire. (figure 1, 2)

Tire

Differential Planetary axle reductor

Main reductor

Input flange Figure 1

2-23

Tire

Planetary reductor

Differential Axle housing axle

Figure 2

2-24

Main reductor

Flange

3) MAIN PERFORMANCE PARAMETERS Model

ZL50K (front and rear axle)

Max. Load

27000 kg

Assembling dimensions

2248 mm 890×260×400

Fixing dimensions with chassis (mm)

Speed Ratio

Resultant gear ratio

22.847

Main speed ratio

4.625

Speed ratio of planetary reductor

4.94

Max. torque

520 kgf·m (3760 Ibf·ft)

Brake torque

1330 kgf·m (9625 Ibf·ft) 11 MPa

Oil pressure of braking

2-25

4) TROUBLESHOOTING Names of the parts

Problem

The main re- Large noise ductor and the differential gear Early-stage heat of the housing

Cause The gaps of the gears are oversized.

The rolling bearing is abraded.

Remedy Adust the gaps of the gears.

Exchange the bearing.

The lubrication is bad, no lubrica- Refuel to the normal oil level. tion oil or excessive lubricating oil.

Periodical abnormal The gears are cut.

Exchange the gears. noise There are foreign bodies inside.

Drain the oil to inspect.

The stening piece becomes loose. Fasten the fastening piece.

M a l f u n c t i o n o f t h e The cross axle is broken. differential gear

Exchange the cross axle.

Oil leakage

Exchange the oil seal.

Scrap the used glue, and smear afresh.

Fasten the fastening piece.

The oil seal is aged and abraded.

The sealing glue becomes ineffective.

The fastening piece becomes loose.

T h e w h e e l Non-rotation of the The semi-axle is twisted off.

Exchange the semi-axel. reductor wheel The differenrial system doesn't A d j u s t a n d ex c h a n g e t h e work. differential system.

Abnormal noises

The gears are cut.

There are foreign bodies.

Exchange the gears.

Drain the oil to inspect.

Early-stage heat of the The lubrication is bad, i.e, no Refuel the lubricating oil to the oil housing lubr icating oil or excessive level. lubricating oil.

Non-returning of the The sealing ring of the piston is Exchange the sealing ring. friction plate aged and abraded.

The oil inlet nozzle beomes loose. Screw the oil inlet nozzle.

The casting of the grip is defective. Exchange or repair the breaking grip.

2-26

5) STRUCTURE (1) Front and rear axle 1

3 4

2

5

6 7

8 Axle housing oil level plug

9 10 12

11 850KAX110

1 2 3 4 5 6

Planetary reduction assy Driving axle shell Brake assy Washer Bolt Deflation valve

7 8 9 10 11 12

2-27

Seal Plug Main reductor Pin Washer Bolt

(2) Planetary reductor

1 2

21 22

3 4

23

5

24 25

6 7 8

9 10

26 27

11

12

Plug Washer Bolt Washer Cover Snap ring Plug Seal Nut Bolt Planetary gear carrier Seal ring Adjusting pin Washer

14 15

16

17

18 19

14

20

28 29

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

13

15 16 17 18 19 20 21 22 23 24 25 26 27 28

30

31 32

33

Roller needle Space bushing Planetary gear Steel ball Planetary gear shaft Shaft Snap ring Sun gear Spacer Iron wire Fastening bolt Slot nut Set Internal gear assy

2-28

34

35

29 30 31 32 33 34 35 36 37 38 39 40

36

37

38

Bearing Rim Washer Nut Bearing Washer Snap ring Oil seal Oil seal Brake disk Washer Bolt

39

40

(3) Main reductor

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

Lock nut Washer O-ring Flange Bolt Washer Oil seal Oil seal Sealing gland Bearing Bearing bushing Adjusting washer Shaft bushing Bearing Adjusting washer

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Adjusting nut Bearing Differential bolt Nut Differential cage Driven bevel gear Bolt Washer Differential crossing Bevel gear Bearing seat Bolt Lock plate Washer Bolt

2-29

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

Iron wire Nut Cage Pin Thrust washer Axle shaft gear Differential cage Bolt Lock plate Nut Bearing Stop ring Bevel gear Washer Bolt

(4) Brake assembly

1 2 3 4 5

Exterior brake Piston Rectangular seal Dust case Block ring

6 7 8 9 10

Brake disk O-ring Inner brake Washer Connecting

2-30

11 12 13 14 15

Deflating valve Washer Bolt Washer Bolt pin

2. SPECIAL TOOL

25

13

The special tool is used to unfasten the main reductor lock nut.

70

Quenching hardness 50HRD

18

25

8.5

85

+0.2 0

65

Unit : mm 850KAX104

2-31

3. DISASSEMBLY 1) Put the driving axle to disassemble on a secure support. Have a wide working area with good light, the ground being clean and free from dust, and preventing from wind that may carry dust. ※ Clean all surfaces of driving axle before disassembly.

2) Remove the oil plugs at axle bottom and two wheel sides to drain gear oil from axle housing. ※ Use a clean container for containing gear oil. Clean container allows easy estimation of used oil. Worn off metal, distinct deterioration or pollution of oil in the used oil shows the condition of axle.

850KAX08

850KAX09

3) Removing brake caliper assembly. Use a torque spanner to unscrew M20 bolts (4 bolts for each brake caliper) and remove the brake caliper.

850KAX10

2-32

4) Removing each end cover at both sides of axle. Use a torque spanner to unscrew M12×1.25 bolt (8 bolts each side) and then push off the end cover with bolt through screw hole and remove it.

850KAX11

850KAX12

5) Pulling out the sun gear and differential axle. Remove the adjusting pin from the exterior end of differential axis and use a spring outside caliper to remove retainer ring at the same time and then remove the sun gear.

850KAX13

850KAX14

2-33

6) Removing main reductor assembly. Use a spanner to unscrew M16 bolts (total 14 pcs) and push the assembly off the axle housing with the bolt through screw hole, then move out with a hoisting equipment or manpower. ※ Step 5) must be performed before removing main reductor assembly. I.e, the differential axle must be pulled out in advance, otherwise it will catch axle shaft gear to cause removal of main reductor unavailable.

850KAX15

850KAX16

7) DISASSEMBLY AND INSPECTION OF MAIN REDUCTOR (1) Fix the assembly on a rotary table.

(2) First remove the thrust bolt.

850KAX17

(3) Make the assembly’s larger side upward, and remove wire, M12 bolts and lock washers on the block.

850KAX18

2-34

(4) Remove bearing block and adjustment nut. ※ Be mindful to make marking for the bearing block, adjustment nut and case for each side not to be confused when reassembling.

(5) Remove the differential assembly. ※ Be careful not to be confused with bearing outer race of two sides.

850KAX19

(6) Removing conical bearing. Unscrew driven crown gear bolts and nuts, total 12 sets, then remove the crown gear (driven) off the differential case.

850KAX20

850KAX21

2-35

(7) Turn the assembly over. First use a chisel or a sharp object to strip the locking por tion of lock nut and then use a specialized tool to remove the lock nut.

For specialized tool, refer to page 2-18.

850KAX22

(8) Remove the washer and O-ring and remove the flange.

850KAX23

(9) Remove the bolt on sealing gland and then remove the sealing gland. ※ When removing sealing gland, be careful not to scratch oil seal.

850KAX24

850KAX25

2-36

(10) Reassemble the flange and lock nut and use a bolt to push whole the driving gear off through the thread hole. ※ When removing a bearing block, be careful not to make the adjusting washer damaged or missing.

(11) Unfasten the lock nut and remove the flange, bearing bushing, shaft bushing and washer and so on in order. ※ When removing a bearing bushing, be careful to keep the shaft bushing and adjusting washer well. ※ Drive and driven gear form a pair and, when anyone is damaged, whole the pair should be replaced. ※ If three bearing inner rings to the drive gear are damaged or worn, a pulling tool can be used to pull out. Take care not to make bearing installing surface on the drive gear damaged.

850KAX26

850KAX27

8) DISASSEMBLY AND INSPECTION OF DIFFERENTIAL DEVICE (1) Remove the bolts, nuts (8 sets) of differential device and small differential cage. ※ When removing small cage of differential device, check if there is matching marks on the holes of differential crossing of large and small cage. If no, make marks.

850KAX28

(2) Remove differential crossing, bevel gear and its washer, axle shaft gear and its washer. ※ If a bearing at two sides of differential device is damaged or worn severely, forcible removal is available (use a chisel to knock out).

Be careful not to have the bearing fitting surface on the differential cage damaged.

850KAX29

2-37

9) DISASSEMBLY AND INSPECTION OF PLANETARY REDUCTOR (1) Remove the bolts for rim.

850KAX30

(2) Push the planetary carrier off with bolt through the thread hole (There are two thread holes on a planetary carrier) and O-ring on the hub.

850KAX31

(3) Remove the inner hexagon nut and lock washer on final drive axle.

850KAX32

(4) Remove the taper bushing (Use a copper bar to shock out).

850KAX33

2-38

(5) Pull the ring gear carrier out.

850KAX34

(6) Pull the hub and brake disc out (can be removed as one body). ※ When pulling the hub and brake disc out, be careful to keep balance as being hung in the air not to make the spline on the shaft to scratch oil seal.

850KAX35

(7) Remove the bolts from brake disc to separate the brake disc from hub.

850KAX36

850KAX37

2-39

10) DISASSEMBLY AND INSPECTION OF PLANETARY CARRIER (1) Place the planetary carrier on a platform, with its large side upward. Use a pressing machine or manpower to press the planetary carrier out. ※ Take out the locking ball at the other side as the planetary shaft is pushed out for about 15mm or it might be lost.

850KAX38

(2) After removing four shafts, remove the planetary gear and washer. ※ Be careful not make the needle, ring or washer of planetary gear to fall down or be lost.

850KAX39

4. CLEANING AND INSPECTION 1) Examine each element and fine surface and determine if there is over wear.

2) Before reassembly, each part should be cleaned with kerosene and blown dry.

3) Specially for the positions where there was a damaged part, such as the inside of axle housing, main reductor or planetary carrier housing, the residue (iron and copper chippings) must be removed.

4) All the oil sealing elements should be replaced and reuse is not permitted once removed.

2-40

5. REASSEMBLY 1) Reassembly of the driving axle should be made in the reverse procedure of above disassembly.

(1) Place the cleaned large and small differential cages on a platform, set the axle shaft gear washer in the large differential cage, then fit the axle shaft gear. Set the planetary bevel gear and washer with ball face on to the four journals of differential crossing, which is then inserted into four corresponding holes in the large differential cage.

Assemble another axle shaft gear, washer and small differential cage. ※ When assembling small differential cage, be careful to align the holes of differential crossing of large and small differential cage with the markings.

850KAX40

850KAX41

(2) After assembly of differential device, use the bolts applied thread locking glue to joint, and fasten up with M16×1.5 nuts.

Tightening torque should be 19.7~26.2 kgf·m (142~190 Ibf·ft).

850KAX42

(3) Assemble the driven spiral bevel gear onto the flange of large differential cage, use the bolts applied thread locking glue to joint, and fasten up with M16×1.5 nuts.

Tightening torque should be 19.7~26.2 kgf·m (142~190 Ibf·ft).

850KAX43

2-41

(4) Use a specialized tool to push the preheated bearing inner race into two sides of differential device.

The gear backlash of axle shaft gear and bevel gear is 0.18-0.23 mm and, after assembly, the gears should facilely rotate and has no deactivation.

850KAX44

2) REASSEMBLY OF DRIVE GEAR ASSEMBLY (1) Push the bearing inner race onto the journal of drive spiral bevel gear and then fit the outer race. Then, fit the shaft bushing and adjusting washer, assemble the bearing bushing fitted with bearing, bearing inner race, flange and main reductor lock nut.

850KAX45

850KAX46

2-42

※ The lock nut should be only fastened up, not locked with thread locking glue. Apply a force of 35~40 kgf·m (253~289 Ibf·ft) to the lock nut for main reductor and then use a tension gauge to hook in the fitting hole of bearing bushing and pull the gauge in tangential direction. The torque should be OK if the readings of the gauge is within 1.32~1.97 kgf·m (2.91~4.34 Ibf·ft) as the bearing bushing starts to turn.

850KAX47

(3) Take a bearing and push its inner race into drive spiral bevel gear journal and assemble a snap ring onto the outer ring.

850KAX48

3) REASSEMBLY OF MAIN REDUCTOR (1) Fix the case of main reductor on a rotary table with its small side upward, apply sealant onto the adjusting washer and fit it onto the small side, then assemble drive gear assembly, and fasten up with two M14×1.5×55 bolts with a torque of 12.6~16.8 kgf·m (91.1~122 Ibf·ft). ※ When assembling drive gear assembly, be careful to make the oil passage hole on bearing bushing aligning with that of casing.

850KAX49

(2) Turn the case for 180˚ to make large side upward and fit the differential assembly in.

850KAX50

2-43

(3) Fit the bearing block and adjustment nut.

Assuring a certain backlash between drive and driven gears (apprx. 0.25-0.40 ), fasten the adjustment nut at a side to the extent that the driven gear can be turned with difficulty and then turn the nut back 1/5~1/10 turn to keep the axial clearance of bearing within 0.1~0.18, to secure a certain pre-tight strength between two tapered bearings.

850KAX51

(4) Precisely adjust the back lash between drive and driven spiral bevel gears to be within 0.25~0.40, its variable less than 0.1.

Be sure that, when the nut at one side is turned back, the other side nut is fastened for the same extent, to secure the pretight strength as adjusted under above item (figure 850KAX52).

(5) By marking test, the contact face should be near to the small side along tooth length, mesh mark ≥1/2 of tooth length, and the contact face at the middle of gear surface. Mesh mark should meet the requirements of figure 850KAX55.

Otherwise, the number of adjusting washer (shim) can be added or subtracted, or loosen the nut at one side and fasten that at other side for the equal amount to make adjustment (figure 850KAX55).

After completing this step of adjustment, be sure to inspect the back lash again as d e s c r i b e d i n a b o v e s t e p. I f t h e requirements as correct mesh mark and back lash can not be met simultaneously, the pair of drive & driven spiral bevel gear or main reductor case must be replaced.

(6) Fasten up the bolts for main reductor with torque of 75.5~89.7 kgf·m (546~649 Ibf·ft), lock the locking washer with M10×20 bolts with torque of 4.6~6.0 k g f·m ( 3 3 . 3 ~ 4 3 . 4 I b f·f t ) ( f i g u r e 850KAX53).

(7) Fasten up the bolts for main reductors, locking washer and bolt M10×20-8.8 and bind with wire (figure 850KAX54).

850KAX52

850KAX53

850KAX54

2-44

※BACKLASH CHECK AND ADJUSTMENT Driven spiral bevel gear

Contact position on driven gear face Forward

Backward Method of adjustment

Gear moving direction

Drive face Move the driven gear to get close to drive gear. Move the drive gear outward if the back lash is too small.

Driven face

Drive spiral bevel gear

Move the driven gear away from drive gear. Move the drive gear inward if the back lash is too large.

Drive face

Move the drive gear to get close to driven gear. Move the driven gear outward if the back lash is too small.

Move the drive gear away from driven gear. Move the driven gear inward if the back lash is too large.

Driven face

Figure 850KAX55

(8) Clean the bore of seal gland, and apply a certain amount of grease and push the oil seal B80×100×10, FB80×100×10 into seal gland in order. Then apply lithium bisulfide grease into the gaps of two oil seals. ※ For the order of two oil seals, FB type oil seal should be at outside and the seals be pressed level.

850KAX56

2-45

(9) Place case with its small side upward, remove the flange and two M14 bolts, apply sealant on the end surface of bearing bushing, and fit up the seal gland with oil seal, apply thread lock glue to M12×1.5×55-10.9 and M14×1.5×5510.9, then assemble along with grower washer, fasten diagonally.

850KAX57

Fastening torque for M12×1.5×55-10.9 should be 8.2~10.2 kgf·m (59.3~73.8 Ibf·ft), that for M14×1.5×55-10.9 be 12.6~16.8 kgf·m (91.1~122 Ibf·ft). ※ When fitting sealing gland, be careful not to make the spline to scratch oil seal.

850KAX58

(10) Install the flange on to the spline of drive spiral bevel gear, then fit the O-ring, washer and lock nut, with fastening torque to the lock nut at 76.5~81.6 kgf·m (553~590 Ibf·ft) (lock up the lock nut after checking there is no error in assembly). ※ Check if the surface of flange to contact with oil seal is smooth and without cracks.

850KAX59

850KAX60

2-46

(11) Turn the bracket for 90˚, insert the thrust bolt applied sealant, turn it into position, and then turn back for 1/4 turn, and fit lock washer and M27×22 nut, turn with fastening torque at 45.9~54 kgf·m (332~391 Ibf·ft) to lock up the lock washer.

850KAX61

4) REASSEMBLY OF PLANETARY CARRIER ASSEMBLY (1) After cleaning the bore of planetary gear, apply a right amount of lithium grease, and insert the selected needles and space bushing of planetary gear into the bore. Be careful that needles selection should be matching, with the difference between max. and min. diameter less than 0.003 mm.

850KAX62

(2) Fix planetary gear and washer.

850KAX63

(3) Push the planetary gear shaft into the planetary carrier, put a ø3/8 steel ball in the hemispherical hole to prevent the planetary gear shaft to turn.

850KAX64

2-47

5) REASSEMBLY OF HUB ASSEMBLY (1) Place the hub on a table with its small side upward, apply a right amount of grease on the inner surface of the bore of hub and then push a bearing outer ring into small side, put up the inner race, and push the oil seal spacing bush into the bore. Use a specialized tool to push oil seal B150×180×15 and FB150×180×15 into the bore of hub in order.

850KAX65

850KAX66

(2) Assemble the brake disc and fasten with brake disc bolts M20×1.5 and grower washer with a torque at 51~60 kgf·m (369~434 Ibf·ft).

(3) Tur n over the hub with brake disc assembled with its large side upward, apply a right amount of grease on the inner surface of the bore on the large side of hub, and push the outer ring of bearing 32026 in.

(4) Fit the O-ring onto the rabbet of ø384 hub.

850KAX67

850KAX68

2-48

6) REASSEMBLY OF AXLE (1) Clean the axle housing assembly and put it on a support, insert the preheated gasket to wheel side supporting axle thermally securing the end surface of gasket to be perpendicular with axle center and the parallelism with support is controlled within 0.1 mm.

(2) Mount the hub assembly at the both sides of axle. ※ When assembling hub and brake disc, ke e p t h e m i n g o o d b a l a n c e a n d suspending to prevent the oil seal from being scratched by spline.

(3) Preheat the inner race of bearing and fit it into the small side of ring carrier assembly welded and align the female spline of ring carrier with the spline of wheel side supporting axle to assemble.

850KAX69

850KAX70

(4) Fit taper bushing.

850KAX71

2-49

(5) Turn the inner hexagon nut to the thread onto the wheel side supporting axle (apply thread lock glue on the thread of nut) and fasten to give a certain pre-tight strength to the bearing and turn the hub at the same time to make two bearings into correct positions. Apply a twisting force of 11.9~16.1 kgf·m (86.0~116 Ibf·ft) to the rim bolts and at the time, just moving of hub means the pre-tight strength of taper bearing is OK. Put up a locked spacer and make its claw to get in the locking groove of nut and then fasten up the lock nut (inner hexagon nut, locking glue applied on the thread) at outside with a torque of 35.7~40.8 kgf·m (258~295 Ibf·ft) making its locking claw to get in the locking groove of outside nut.

850KAX72

850KAX73

(6) Assemble planetary carrier.

850KAX74

(7) Assemble rim bolts and nuts, and fasten up with a torque spanner with a torque of 43.8~47.9 kgf·m (317~346 Ibf·ft). ※ Take care to check if the O-ring is fit up for rim when fixing planetary carrier.

850KAX75

2-50

7) When mounting main reductor, first locate three stop dowels on the mounting surface of axle housing and apply a coat of silicone adhesive uniformly between the main reductor and axle housing and align the main reductor to its mounting position to assemble and fasten up with main reductor bolts M14×1.5×35 with a torque of 1 2 . 6 ~ 1 6 . 8 kgf·m ( 9 1 . 1 ~ 1 2 2 Ibf·ft) (M16×1.5×35 and 19.7~26.2kgf·m (142~190 Ibf·ft).

850KAX76

850KAX77

8) Set the sun gear at the side of differential axle with locating groove and set the snap ring and push into axle housing securing correct mesh between sun gear and the planetary gear inside the planetary carrier.

After that two people can turn the wheel side at two different sides in reverse direction and smooth rotation should be secured.

850KAX78

9) Select suitable adjusting pin and end cover for the two sides of axle and secure a 1-2 mm clearing between the adjusting pin and stop block after assembly. Apply some silicone adhesive on the end cover and fix it on the planetary carrier with M12×1.25 bolts wrapped with tape and fasten up with a torque of 7.1~9.2 kgf·m (51.4~66.5 Ibf·ft).

850KAX79

2-51

10) Mount the brake caliper and fasten up with brake caliper bolts with a torque of 51~59.1 kgf·m (369~427 Ibf·ft).

11) Insert the plug at the axle bottom and fix.

Supply oil into the axle housing (differential gear) and wheel side (planetary gear). ·Oil amount Front axle : 29ℓ(7.7 U.S. gal) Rear axle : 29ℓ(7.7 U.S. gal) Supply oil unit is it overflows from the oil filler, then install the plug.

Recommended oil is SAE 85W-90.

2-52

6. GENERAL TROUBLES AND TROUBLESHOOTING Since the loader features great torque and complex structure, failure to observe repair and working standards may cause troubles. Followings are description of troubles, causes, symptoms and measures.

1) ABNORMAL NOISE FROM DRIVING AXLE Complex noise is produced from driving axle and defective parts, incorrect assembly and adjustment of main transmission system and excessive wear during using cause noise in travelling and operation. Generally, noise increases by increase of vehicle speed.

(1) Noise due to inappropriate backlash between drive and driven gears. ① Symptoms and causes. ·Too much backlash between two gears causes arrhythmic gear knocking sound, clunking. ·Too little backlash causes gears to jam and overheat. ·Uneven backlash causes rhythmic rattle noise and further causes the driving axle to sway. ② Measures. ·Remove the main reductor and adjust the back lash between drive and driven gears.

(2) Noise due to improper fit of incorrect bearing clearance ① Symptom and cause. ·Too little clearance causes noise sounds like continued “M---!” and excessive clearance like "Hara---Hara!" ② Measures. ·Remove main reductor and add or subtract washer/shim to readjust bearing clearance. ·Replace with new bearing, if damaged, and readjust the clearance.

(3) Periodic abnormal noise ① Symptom and cause. ·Gears are cut, or there are foreign objects inside sounding like clatter. ② Measures. ·Replace the damaged gear or clear the foreign objects.

(4) Abnormal noise in differential device ① Symptom and cause. ·When planetary gear and differential crossing are jammed, cracking sound is made, specially as cornering. ·Poor mesh gears make complex noise such as sounding "M---" as machine travel in straight line and plus clicking as cornering. ② Measures. ·Remove main reductor to replace differential crossing, or planetary gear and differential gear.

2) DRIVING AXLE HOUSING OVERHEAT (1) Symptom and cause.

After a period of time of travelling or operation, touch the axle housing with hand and, when you feel hot and can not sustain, the axle housing is determined overheat. Overheat of axle housing is mainly due to too little bearing clearance, too little back lash of drive and driven gears, choked deflection valve on the axle, or insufficient lubricant.

(2) Measures.

First check the deflection valve for being choked, and insufficient lubricant and, if no problem with these factors, remove main reductor, and check and adjust bearing clearance or back lach between drive and driven gears.

2-53

3) OIL LEAKS (1) Symptom and cause.

Gear oil leaks at junction between main reductor and axle housing, junction between main reductor flange and sealing gland, and inside planetary reductor. Oil leaks at junction between main reductor and axle housing is mainly due to loose bolt or deteriorated sealant and that at junction between main reductor flange and sealing gland and inside planetary reductor is mainly due to aged and worn oil seal or O-ring.

(2) Measures.

Reapply sealant and fasten up bolts, replace sealing gland or O-ring.

4) WEAK DRIVING FORCE (1) Symptom and cause.

Weak scraping and shearing force of loader under normal oil temperature of transmission.

One cause may be broken differential axis.

(2) Measures.

First determine which of the differential axle of front axle or rear axle is broken. Turn down the bucket to make the front wheels to rise away from the ground and then change to reverse gear and step on it gradually to observe whether the loader can travel or not. If the loader can not travel and rear driving axle turns, the rear differential axle may be broken.

2-54

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

6

3 4

5

7

1 2 3 4

Air brake valve Air tank Air booster Oil and water separator

5 6 7

3-1

Safety valve Front axle Rear axle

2

GROUP 2 COMPONENTS SPECIFICATION AND FUNCTION 1. BRAKE VALVE 1) USE AND STRUCTURE As a main device of foot brake, this unit intruduced high technology from CAT (USA) and can be applied to single circuit 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 (2) Working temperature : -30 ~ +80 (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) Wearing parts ITEM

PART NAME

P/N

QUANTITY

O-RING SEE DRAWING O-RING

6) 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

3-2

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.

7) 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)

3-3

STRUCTURE AND MOUNTING SIZE

STRUCTURE AND MOUNTING SIZE

View A

Air outlet

Air intlet

Air outlet

1 2 3

Bolt Pedal Rod

4 5 6

Equalizing spring Spring Piston

3-4

7

Intake valve

2. 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 M16×1.5-6g is connecting screw.

5) Wearing parts PART NAME

P/N

SAFETY VALVE ASSY

SEE DRAWING

QUANTITY

6) 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.

7) TROUBLESHOOTING Problem Leaks at valve port

Cause

Remedy

Damaged rubber of safety valve stem assy.

3-5

Replace safety valve assy

STRUCTURE AND MOUNTING SIZE

Adjusting bolt

Air outlet

Air inlet

3-6

3. 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.It can be used to charge the tyre when unscrew the nut. 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 : 1.8 kg 4) MOUNTING AND CONNECTION SIZE (1) Mounting size : 2-M8×40 double end stud,spacing is 70± 0.2 (2) Connection size : Inlet (M22×1.5-6g), outlet (M22×1.5-6H) Dimensions : 150.5×128.5×220 5) Wearing parts

ITEM

PART NAME

P/N

O-RING

SEE DRAWING

Control Piston O-RING

SEE DRAWING

Diaphragm

SEE DRAWING

Drain Valve

SEE DRAWING

QUANTITY

MAINTENANCE 6) CORRECT USE AND MAINTENANCE (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 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.

3-7

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.

7) 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.

Replace diaphragm.

Damaged control piston O-ring.

Replace control piston O-ring.

3-8

STRUCTURE AND MOUNTING SIZE

3-9

SECTION 4 STEERING SYSTEM Group 1 Hydraulic circuit -------------------------------------------------------------------------------------------------- 4-1 Group 2 Structure and function --------------------------------------------------------------------------------------- 4-5 Group 3 Operational Checks and Troubleshooting ------------------------------------------------------- 4-16 Group 4 Tests and Adjustments -------------------------------------------------------------------------------------- 4-22

SECTION 4 STEERING SYSTEM GROUP 1 HYDRAULIC CIRCUIT 1. STEERING CIRCUIT

9

L

R

5

MCV

6

P

T

CF

LS

LS

EF

P

T1

Return line

T

15 RCV

2

14

12

1

11

13

7614SE01

1 2 5 6

Main pump Steering and pilot pump Steering unit Steering valve

9 11 12 13

Steering cylinder Hydraulic tank Air breather Return filter

4-1

14 15

Oil cooler Orifice fitting

2. NEUTRAL

9

L

R

5

G

MCV

P

6

LS

T

CF

LS

EF

D P

Return line

T

T1

Priority valve

15 RCV

2

14

12

1

11

13

7614SE02

The steering wheel is not being operated so control spool (G) does not move.

The oil from the steering pump (2) enters port P of priority valve in steering valve (6) and the inlet pressure oil moves the spool (D) to the right.

The pump flow goes to the loader system (main control valve) through the EF port.

4-2

3. LEFT TURN

9

L

R

5

G

H

6

P

T

CF

LS

MCV

LS

EF

D P

T1

Return line

T

Priority valve

15 RCV

2

14

12

1

11

13

7614SE03

When the steering wheel is turned to the left, the spool (G) within the steering unit (5) connected with steering colurm turns in left hand direction.

At this time, the oil discharged from the steering pump (2) flows into the spool (G) of the steering unit (5) through the spool (D) of priority valve in steering valve (6) and flows into the gerotor (H).

Oil flow from the gerotor flows back into the spool (G) where it is directed out the left work port (L) to the respective chamber of the steering cylinders (9).

Oil returned from left and right cylinder returns to hydraulic tank (11) through the spool (G) of the steering unit (5).

When the above operation is completed, the machine turns to the left.

4-3

4. RIGHT TURN

9

L

R

5

G

H

6

P

T

CF

LS

MCV

LS

EF

D P

T1

Return line

T

Priority valve

15 RCV

2

14

12

1

11

13

7614SE04

When the steering wheel is turned to the right, the spool (G) within the steering unit (5) connected with steering colurmn turns in right hand direction.

At this time, the oil discharged from the steering pump (2) flows into the spool (G) of the steering unit (5) through the spool (D) of priority valve in steering valve (6) and flows into the gerotor (H).

Oil flow from the gerotor flows back into the spool (G) where it is directed out the right work port (R) to the respective chamber of the steering cylinders (9).

Oil returned from left and right cylinder returns to hydraulic tank (11) through the spool (G) of the steering unit (5).

When the above operation is completed, the machine turns to the right.

4-4

GROUP 2 STRUCTURE AND FUNCTION 1. STEERING PUMP

1 2 3 4 5 6 7 8 9 10 11

Shaft end cover Cover Drive gear Idler gear Connecting shaft Thrust plate Snap ring Outboard bearing Seal Bushing Plug

12 13 14 15 16 17 18 19 20 21 22

Dowel pin O-ring seal Seal Back up ring Stud Hexagon nut Hardened washer Cover Gear housing Drive gear Idler gear

4-5

23 24 25 26 27 28 29 30 31

Thrust plate Bushing Dowel pin Seal Seal Back up ring Stud Hardened washer Relief valve

2. STEERING UNIT 1) STRUCTURE

3 1

2

4

5

6

7

8

9

10

11

12

13 14 15 16

17 18 21

23

22

24

19

20

Load port

850S4SE02

1 2 3 4 5 6 7 8

Coupler Front cover Screw Spring washer O-ring X-ring Snap ring Bearing

9 10 11 12 13 14 15 16

Slip ring O-ring Plate Stator-rotor unit Rear cover Bolt Stopper Drive

4-6

17 18 19 20 21 22 23 24

Spool-sleeve Body Ball Stop bolt O-ring Spring Ping FK combination valve

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, combined 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 statorrotor 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) Combination valve is available as an option for different systems depending on the requirements (some kind of systems are not required). This valve is used to integrate different kind of valves together such as safety valve, two-way overload valve, two-way oil fill valve and port check valve.

The below figure shows the structure of combination valve.

B B-B

B

14

15 850S4SE03

4-7

16

1

13

2

3

12

11

4

10

9

5

8

7

6

850S4SE04

1 2 3 4 5 6

Plug Washer Body Plug Spring washer Safety valve

7 8 9 10 11 12

Plug Washer Overload-valve base1 Seal Spring Overload and oil fill valve

13 14 15 16

Base 2 O-ring Port check valve Nut-lock

3) SPECIFICATION Maximum system pressure

175 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

4-8

(4) 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".

4-9

Problem

Phenomenon

Cause

Remedy

Wheel column cannot Pressure loss at neutral Steering column and spool Determined case by rotate back to neutral position without unloading. are not co-axial. case. automatically Steering column stuck spool at axial direction.

Too much resistant torque for steering wheel.

Can't reach maximum Cannot reach maximum Low relief pressure of safety Raise relief pressure of turning angle turning angle and heavy valve. safety valve. steering.

Endless

Slightly move can be applied Low relief pressure of with hard turn to wheel even overload valve. the cylinder have reached the maximum angle.

Steering weakness

No stop feeling at limiting Big clearance between Replace stator-rotorunit. stator and rotor at axial or postion for power steering.

Malfunction for mechanical radial direction. sterring.

4-10

Raise relief pressure of overload valve.

3. STEERING VALVE 1) STRUCTURE 11

12 13 14 15 16 6

10

17

18

9 8 7

19 2 5

5 2 4 3 2 1 763S4WE25

1 2 3 4 5 6 7

Screw plug O-ring Unload valve spring Unload valve spool Screw Valve body Check valve

8 9 10 11 12 13 14

Spring Safety valvel Safety valve Bolt Shim Safety valve seat O-ring

4-11

15 16 17 18 19

Spring Washer Hex socket plug Damping plug Priority valve spool

2) OVERVIEW Steering valve is a control element of steering system. Upon supply of fluid for steering system in priority, excess fluid in steering system can be automatically relieved in a low pressure in case of a work condition with high pressure and small flow. Load relief pressure can be adjusted through pressure relief valve considering work condition to make up for deficiency of priority valve, reduce power loss, and decrease temperature rise in the system.

Steering valve features simple structure, reliable performance, and easy repair.

3) PRODUCT MODEL AND TECHNICAL DATA (1) Product model : YSF 25 X (2) Technical Data Item

Unit

Specification

Nominal pressure

MPa

20

Nominal flow

ℓ/min

160

Nominal internal diameter

mm

25

Nominal pressure of steering relief valve

MPa

16

Nominal pressure of load relief valve

MPa

14

Control pressure

MPa

1.1

4-12

4) PRINCIPLE OF CIRCUIT AND CONNECTION SIZE (1) Principle of circuit ① This valve is mounted on steering circuit, between steering pump and load sensor hydraulic steering control unit. P is inlet port connecting to steering pump. CF is steering port connecting to flow inlet of steering gear, EF is service port connecting to main control valve of working system, LS is control port connecting to load sensor port of steering gear, and T is load relief valve connecting to tank.

1 3

2

2 4

CF

LS EF

3

3 P

T

T1

② When loader is in raising work, the flow from steering pump is directed to P port, orifice (a) through to the right end of priority spool. The pressure fluid will resist the control pressure from spring to push the priority spool to move to the left to make the flow from steering pump to open check valve which is then directed to EF port and then to working system by combination of flow, to meet requirement for a large quantity of flow. When loader is under high pressure and small flow working condition as excavating, high pressure fluid in EF port causes load relief valve to open and control fluid is directed to way (b) through to the left end of spool, then to orifice (c) and T. The difference in pressure formed in the process causes load relief spool to resist the force of spring of load relief valve to move to the right, and fluid in P is relieved directly through load relief port T. ③ When loader is in steering operation, the flow from steering pump is directed to CF, supplied to steering gear in priority. At the time, LS port receives load feedback signal of steering gear and, when the load is too much, steering relief valve opens, causing priority spool to move to the left, and the flow from steering pump is directed to check valve, EF port, main control valve and then relieved.

Item

Size

1

Torque

Quantity

kgf·m

lbf·ft

M10

4.5~5.9

32.5~42.8

4

2

M18×1

4.1

29.5

1

3

M30×1.5

9.7~12.7

70.1~92.2

4

4

M14×1.5

2.0

14.8

2

4-13

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.

(2) Never disassemble the product in a dusty place before assembling to machine to prevent dust from entering.

(3) Before using the product, check there is no scratch or rust on the joint surface.

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

(5) Allowable oil temperature range : -20 ~ 110˚C. 6) TRUOBLESHOOTING Problem

Cause

Remedy

Too low steering pressure 1. Damaged steering relief valve. or heavy steering 2. Dirt fluid has caused stuck spool.

1.Clean or replace with new relief valve.

2.Change fluid, and disassemble and clean the valve.

Insufficient flow in working 1. Damaged load relief valve

1.Clean or replace with new relief valve.

system

2.Change fluid, and disassemble and clean the valve.

3.Clean the orifice.

2. Dirt fluid has caused stuck spool.

3. Orifice a is clogged

Too high fluid temperature 1. Dirt has made the priority spool stuck.

2. Damaged priority spool spring.

1.Remove and clean, and then replace.

2.Replace with a good spring.

3. Dirt has made the load relief valve stuck. 3.Remove and clean, and then replace.

Leakage

1. Damaged or deteriorated O-ring.

2. Poor sealing at flange joining port.

4-14

1.Replace with good O-ring.

2.Check the sealing and make it even.

4. STEERING CYLINDER 10 11 4 12 3 7 5 6 8 9

2

19 19 20 20 1

18

17 16 15 13 14

1 2 3 4 5 6 7

Tube assy Rod assy Gland Bushing Rod seal Back up ring Buffer ring

763S4SE20

8 9 10 11 12 13 14

Dust wiper Snap ring O-ring Back up ring O-ring Piston O-ring

4-15

15 16 17 18 19 20

Piston seal Wear ring Lock nut Set screw 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 Run engine at low idle.

A

Steering unit check

Service action OK Check completed.

B

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 operating temperature.

Run engine at high idle.

Right Left

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 4 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.

Priority valve in steering valve low pressure check

Park machine on a hard surface.

Hold brake pedal down.

OK Check completed.

NOT OK Do steering system leakSteer machine to the right and age test in group 4 to left as far as possible. isolate the leakage.

Run engine at high idle.

LOOK : Machine must turn at least half way to the right and left stops.

Priority valve in steering va l ve h i g h p r e s s u r e check Run engine at high idle.

Steer to steering stop and OK release wheel.

Check completed.

Roll bucket back and hold over NOT OK O relief and observe engine rpm.

Do steering valve pressure test in group 4.

Turn wheel to steering stop and hold, observe engine rpm.

LOOK : Steering stall engine rpm must be higher than hydraulic stall rpm.

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 priority valve spool.

Remove and inspect priority valve spool.

Broken priority valve spring.

Remove and inspect spring.

Relief valve in priority valve stuck open.

Do relief cartridge leakage test.

Failed hydraulic lines.

Check.

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

Check steering column installation.

Cold oil.

Warm the hydraulic oil.

Low priority valve pressure setting.

Do priority valve pressure test.

Worn hydraulic pump.

Do hydraulic pump performance check.

Sticking priority valve spool.

Remove and inspect.

Broken priority valve spring.

Remove and inspect.

Pinched or restricted LS line.

Inspect line. Do priority valve LS port flow test in group 4.

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.

Worn steering unit.

Check for foamy oil.

Do steering system leakage check.

Do steering unit neutral leakage test in group 4.

Leaf spring without spring force or Replace leaf springs. broken.

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.

Sticking priority valve spool.

Remove and inspect spool.

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. steering unit.

Repair cause of contamination. Flush hydraulic system.

★ Thermal shock

Do priority valve LS port flow test in group 5. This oil flow provides a warmup flow to steering unit when not using the steering.

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.

Vibration in steer ing High priority valve setting. system or hoses jump

Do priority valve pressure test.

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

Steering column and steering unit out of line.

Repair or replace steering unit.

Align the steering column with 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 Contact the nearest service shop. spools.

"Motoring" effect.

Leaf springs are stuck or broken and The steering wheel can have therefore reduced spring force. turn on its own Inner and outer spools pinch, possibly due to dirt.

Replace leaf springs.

Clean steering unit or contact the 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.

Leaf springs without spring force or Replace leaf springs. broken.

Jerky steering

Worn splines on the steering column.

Replace steering column.

LS port orifice missing.

Inspect orifice.

Orifice in top end of priority valve spool

Disassemble and inspect.

missing.

★ Thermal shock is caused by a large temperature differential (Approx 30˚C, 50˚F) between the steering unit and hydraulic oil. If the steering is not operated for a long period of time and the orifice in the bottom of the priority valve spool is plugged, the steering unit may bind up when the steering is operated if the hydraulic oil is hot enough.

4-20

Problem

Cause

Remedy

"Shimmy" effect Air in the steering cylinder.

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

High priority valve setting pressure.

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.

Bleed cylinder.

Find and remove the reason for air collection.

Replace worn parts.

Set pressure as regular value.

Fill with clean oil and bleed the system.

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.

Spool in priority valve sticking owing to Clean the valve, check that spool moves dirt. easily without spring.

Too weak spring in priority valve.

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

Replace spring by a stronger.

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 Spring force in priority valve too weak. to turn the steering wheel Air in LS.

Too little steering force

Replace spring by a stronger.

Bleed LS line.

Clogged orifices in LS in priority valve.

Clean orifices in spool and in connecting plugs for LS.

Oil is too thick (cold).

Let machine run until oil is warm.

Pump pressure too low.

Correct pump pressure.

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 170ℓ(44.9 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).

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

P

3) Connect fitting (A) and install gauge.

A

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 valve for a priority valve spool. Make sure orifice plugs installed in ends of priority valve spool in steering valve.

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.

Ssfety lock bar

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

850KSE38

4-26

5. STEERING VALVE PRESSURE TEST · SPECIFICATION Oil temperature 45±5˚C (113±9˚F) Engine speed High idle Oil pressure 16 MPa

T1 T EF

(160 bar, 1160 psi)

LS CF

· GAUGE AND TOOL Gauge 0~35 MPa (0~350 bar, 0~5000 psi) Temperature reader

Adjusting nut

P

Steering valve

1) Connect gauge to test port.

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

3) Install frame locking bar.

Test port

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

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.

Steering cylinder

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

7) If pressure in not to specification, turn adjusting nut 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 valve.

7614SE10

4-27

SECTION 5 WORK EQUIPMENT Group 1 Hydraulic circuit --------------------------------------------------------------------------------------------------- 5-1 Group 2 Structure and function ---------------------------------------------------------------------------------------- 5-2 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

a3 b3 a2 b2

P

3

a1 b1 1A

B3

R/BACK

8

2B

3A

3B

R/BACK

D/FLOAT

UP

b1

A1

2-LEVER TYPE(OPT)

a1 BOOM

P

T

DOWN FLOATING

UP

B2

7

2A

DUMP

B1

5

PLUG 2C

a3

BUCKET

L

DUMP

b3

A3

R

1B

4

AUX

9

b2

A2

a2

T

4

1A

1B

R/BACK

DUMP

T

P

LS

CF

LS

P1

T1

2B

2A

3A

3B

UP

D/FLOAT

16 P

JOYSTICK TYPE(STD)

P2

EF

P

2C

10

P3

6

PLUG

T

L

15

T

14 12 2

1

11 13

615HC01

1 2 3 4 5 6

Main pump Steering and pilot pump Main control valve Remote control valve Steering unit Steering valve

7 8 9 10 11 12

Boom cylinder Bucket cylinder Steering cylinder Pressure select valve Hydraulic tank Air breather

5-1

13 14 15 16

Return filter Oil cooler Orifice fitting Safety valve

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

1 2 3 4 5 6

Front cover Pump body Drive gear Driven gear Side plate Spring ring

7 8 9 10 11 12

Bearing Seal Bearing seal Blocking screw Pin O-ring

5-2

13 14 15 16

E-ring E-retain ring Bolt Washer

2) Mounting requirement and note in use (1) For tansmissions of gear pump, the manner that may produce radial or axial force to pump (such as direct geared and pulley transmission) are not permitted. Requirements for concentricity: no more than 0.05mm for shaft bushing type, no more tahn 0.1mm for coupling type, for universal coupling, shaft angel deviation from drive shaft shouldn't exceed 1 degree.

(2) Before mounting the gear pump , check its normal rotating direction be suiting the system. Push Push the gear into the pump body slightly. Koncking or compacting by screws are not permitted.

(3) Sufficient oil is required. The entry of gear pump should be assembled securely and sealing be reliable. Proper section area of suction pipe is required. To keep the vacuum degree under 0.02 Mpa, suction port shouldn't be 0.5m higher than the oil level.

(4) Check the oil frequently. No impyreities from machine and corrosive substance should be in the oil.

(5) Control the equipment under high system pressure or overload condition. Keep the pressure of gear pump below the rated prssure 21 Mpa. (6) If the oil temperature is low, please start the pump at a low speed until the temperature exceed normal.

(7) Sudden acceleration is not permitted. Acceleration should be smooth.

5-3

3) Troubleshooting Problems

Cause

Shaft fracture

① Incorrect assembly of shaft and connections which produces

Body fracture

① Overload,sudden increasing of pressure, clogged pipe or invalid

radial force. ② Connections are not coaxial with shaft or too big clearance. (more than 0.05 mm) between mounting hole and connect plate. ③ Overload,sudden increasing of pressure, clogged pipe or invalid relief valve produced large deformation which result in severe touch between shaft and body. ④ Mismatching between path area of discharging pipe or other components and flow quantity of pump. ⑤ Fatigue or poor quality of shaft. relief valve produced large deformation which result in severe touch between shaft and body. ② Mismatching between path area of discharging pipe or other components and flow quantity of pump. ③ No safety protecting deviece is applied. ④ If the straight cracks are not lacerated, poor quality lead to the fracture.

Leakage form shaft end ① Incorrect assembly of shaft and connections which produces radial force. ② Connections are not coaxial with shaft or too big clearance. (more than 0.05 mm) between mounting hole and connect plate. ③ Great negtive pressure in the system result in invalid sealing. ④ Clogged air breather produces negtive pressure in tank. ⑤ Assembled with reversed direction of rotating.

Leakage form pump body

① Bolts to fasten pump body become loose or they are streched

due to the long-time over pressure working. ② High temperature damage the seals. ③ Poor quality in pump assembling.

Leakage form ports

① Bolts become loose or screws mismatched. ② Interface surfaces are not parallel. Damage in the surfaces. ③ Unreliabel sealing or small deflection of seals.

Noise and vibration

① Wrong connection between transmission parts ② Insufficient oil in tank. Polluted oil. High viscosity of oil. ③ Air in the system. ④ Small path area or low strength or poor resistance of

pressure of suction pipe. ⑤ Unreliable sealing of suction pipe.

No reactions or slow reactions

① No pwer outputs. ② No hydraulic oil or insufficient oil. ③ Main relief valve is stucked or worn out. ④ Different rotaing direction between pump and power source.

Serious side shaft splines indentation

① Shaft loose fitting with connectors.

5-4

Touch between shaft and body (1) Touch between shaft and body (2)

Touch area more than one third of the gear hole: overload, sudden increasing pressure result in high deformation of shaft.

Touch area less than one third of the gear hole: normal abrasion.

grinding burn of gear

No hydraulic oil or insufficient oil.

Impressions on gear shaft

① Long-time overload working.

Grinding burn of side plates.

Side plates fall off.

Uneven wear.

① No hydraulic oil or insufficient oil.

Clear impression or abrasion on one side of the side plate

Insufficient depth of hole for assembling drive shaft so that it produces axial force.

Flashes on seals

① High temperature of pump, bad cooling. ② Bolts to fasten pump body become loose or they are streched

② Normal abrasion.

② Dirty oil. ③ Poor quality if copper coating fall off without burn phenomenon.

due to the long-time over pressure working.

Scratches in the front plate.

Components connected with shaft have such a long length and might ead to shaft fracture or leakage from shaft end.

5T\

5) NOTICE IN PLACING ORDER

TURN LEFT (COUNTER CLOCKWISE)

TURN RIGHT (CLOCKWISE)

850K3HC52

5-6

2. MAIN CONTROL VALVE 1) STRUCTURE

P,A,T port size

5-7

2) OVERVIEW 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 G - DF - XX -XX Product code Inner diameter Series code Product grade 4) TECHNICAL DATA Item

Unit

Specification (GDF-32)

Nominated flow

ℓ/min

250

Nominated pressure

MPa

20

Pressure regulating range

MPa

8 ~ 20

Pressure regulating range of overload valve

MPa

8 ~ 25

5-8

(2) Working Principle

763S5WE21

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.

5-9

(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.

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 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.

5-10

8) TROUBLESHOOTING No.

Problem

Insufficient operating pressure

Cause

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

Remedy

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 viscosity temperature.

2

b. Improper hydraulic oil.

b. Change hydraulic oil.

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

3. Main relief valve failure.

Malfunction in return 3

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

2. Dirt between valve lever and valve 2. Clean part. body.

External seeps and leaks

1. Damaged seal ring.

1. Replace with new product.

2. Loose fastening pieces.

2. Fasten related fastening piece.

3. Too high oil temperature, low 3. Takes measures to reduce oil viscosity. temperature.

4

Bucket dumping 5

3. Repair or replace the main relief valve.

4. Poor sealing on flange surface.

4. Check fastening and sealing of related parts.

1. Overload valve is stucked.

1. Clean and reassemble.

2. Dirty fluid.

2. Change fluid.

3. Damaged O-ring.

3. Replace O-ring.

4. Internal leakage of cylinder.

4. Inspect cylinder.

5-11

9) 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

1 19 29 28

29

25 27 26

2 10

23 22

9

7

6

8

24

3 12 11 4

20

5

23 21 24

25

27 26 763S5WE22

1 2 3 4 5 6 7 8 9 10

Tube assembly Rod assembly Gland Bushing Snap ring Rod seal Back up ring Buffer ring Dust wiper Snap ring

11 12 13 14 15 16 17 18 19 20

O-ring Back up ring Piston O-ring Piston seal Wear ring Dust ring Lock nut Set screw Socket bolt

5-13

21 22 23 24 25 26 27 28 29

Pipe assembly Pipe assembly O-ring Socket bolt Pipe clamp Hexagon bolt Spring washer Pin bushing Dust seal

4. BUCKET CYLINDER 25 24

2

25 10 9

7 6 8

14

3 4

13

5

17

12 11

20

15 16

19 18

1

25 24

25 21 26

23

27 28

22

1 2 3 4 5 6 7 8 9 10

Tube assembly Rod assembly Gland DU bushing Snap ring Rod seal Back up ring Buffer ring Dust wiper Snap ring

11 12 13 14 15 16 17 18 19 20

O-ring Back up ring Piston O-ring Piston seal Wear ring Dust ring Lock nut Set screw Socket bolt

5-14

21 22 23 24 25 26 27 28

Pipe assembly Socket bolt O-ring Pin bushing Dust seal Pipe clamp Spring washer Hexagon bolt

763S5WE23

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 5-33.

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 7 seconds.

IF OK Do steering system leakage check at page 4-26.

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 5 minutes. (unloaded bucket) A : Retraction of boom cylinder rod B : Retraction of bucket cylinder rod Boom cylinder must drift less than 4 mm Bucket cylinder must drift less than 6 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 for 1 minute.

NOT OK 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 Drift is approximately the ground with bucket level. 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 at page 5-34. minute.

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 OFF position.

Check completed.

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 5.3 sec height.

Full height to level ground.

3.5 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]

4.4 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

850KWE35

(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

850KWE36

(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.

850KWE37

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 strainer.

Inspect and clean strainer in reservoir.

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

Problem

Cause

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

Problem Function drifts down

Cause

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 1-18, 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 : 170ℓ(44.9 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 180±5 bar (2610 psi) Maximum pump flow 366ℓ/min (96.7 gpm)

Flow meter

· FLOW METER GAUGE AND TOOL Gauge 0~35 MPa (0~350 bar, 0~5000 psi) Temperature reader

To MCV

1) Make test connections.

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

Steering valve EF port

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.

763G5WE10

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

180±5 kg/cm2 (2610±70 psi)

Bucket rollback (R)

Low

200±5 kg/cm2 (2840±70 psi)

Bucket dump (D)

Low

130±5 kg/cm2 (1850±70 psi)

M

· 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

Bucket Boom

R

D

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 180 kg/cm2 (2610 psi). Damage to the pump will result from excessive pressure settings.

850KWE34

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 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.

T

5) Run engine at specification and read pressure gauges.

MCV

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.

850KWE42

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

4 mm

Retraction of bucket cylinder rod

6 mm

B

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 Function

45±5˚C (113±9˚F) High idle Operating conditions

Maximum cycle time (seconds)

Boom raise

Bucket flat on ground to full height

5.3

Boom lower (float)

Full height to ground level

3.5

Bucket dump

Boom at full height

1.1

Bucket rollback

Boom at full height

1.5

Steering (number of turns) Frame stop to stop

4.4 turns

5-33

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 ------------------------------------------------------------------------------------------------------------ 6-8

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

1

9

1 2 3 4

Head lamp switch Work lamp switch Beacon switch Gear selector lever

6

5 6 7 8

12

2

10

45

3

7 8

Hazard switch Cluster Multi function switch Horn button

6-1

9 10 11 12

Electric fan Radio and MP3 player Aircon and heater switch Starting Switch

11

2. LOCATION 2 6

4

5

4

1 2

3

9

11 12

7,8 10

13

851S7EL01

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

6 Fan 7 Coolant temperature sensor 8 Engine oil pressure sensor 9 Work lamp 10 Battery

6-2

11 Rear combi lamp 12 Back buzzer 13 Battery relay

2. ELECTRICAL CIRCUIT

6-3

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 in operator's manual. ※ 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

BRAKE AIR PRESSURE GAUGE Oper ating range Red

This gauge indicates the air pressure of service brake.

Red range : Below 0.4 MPa If the indicator is in operating range, it is normal.

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

850K3CD06

DIRECTION PILOT LAMP

This lamp flashes when the signal indicator lever is moved.

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

This lamp works when the illuminating direction is upward.

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

77073CD10

HIGH BEAM PILOT LAMP

77073CD12

PARKING BRAKE WARNING LAMP

When the parking brake is actuated, the lamp lights ON. ※ Check the lamp is OFF before driving.

77073CD13

BRAKE AIR PRESSURE WARNING LAMP

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

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

850K3CD16

6-6

ENGINE OIL PRESSURE WARNING LAMP

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

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

77073CD18

BATTERY CHARGING WARNING LAMP

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

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

77073CD22

6-7

4. CONNECTOR 1. MAIN HARNESS Conector

Type

CN-35 CN-36

Pin counts

Destination

3 J/C

12

DJ7031-7.8-11 TO FUSE BOX

10

CN-37

Part number

DJ7121-6.3-11 DJ7101-6.3-11

CS-2

KET

6

START SWITCH

MG615330

CN-171

J/C

2

SERVICE SOCKET

DJ7028-6.3-21

CR-3

HIGH BEAM

CR-40

LOW BEAM

CR-2

HORN RELAY

CR-26 CR-27

J/C

5

CR-11

J/C

5

FLASHER UNIT RELAY

DJJ7058A-6.3-21

CN-26

TYCO

2

WARING 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

2

HEATER SIDE

DJ7021A-7.8-21

EARTH4

J/C

1

-

CN-9

J/C

8

TO FRONT

DJ7126-6.3-21

CN-7

J/C

8

TO CABIN

DJ7081-6.3-21

CN-4

TYCO

16

TO DASH

368047-1

CN-5

TYCO

16

TO DASH

368050-1

SWF

10

DJJ7051-6.3-21

CR-30 CR-55 CR-63 CR-96 CR-58 CR-5 CR-41 CR-42

CS-21 CS-36

Y10-10

WORK LAMP ILL & HEAD LAMP

6-8

SW593757

2. CAB HARNESS Conector

Type

Pin counts

J/C

Destination

Part number

TO MAIN

J/C

J/C J/C

J/C J/C

3. DASHBOARD HARNESS Conector

Type

Pin counts

Destination

J/C

Part number DJ70818-6.3-11

J/C

CN-9A

DJ7126-6.3-11

12

CN-46

DJ7021-6.3-11

NEUTRAL

DJ7021-6.3-21

J/C CN-9

J/C

DJ7126-6.3-21

12

J/C J/C CS-12

DJ7065B-6.3-11

J/C

6-9

4. REAR FRAME HARNESS Conector

Type

Pin counts

Destination

Part number

J/C

J/C DJ7021-1.5-20 DJ7021-1.5-20

J/C

J/C

21LM-03280

21LM-03280

J/C J/C J/C J/C J/C

J/C

5. FRONT HARNESS Conector

Type J/C

J/C

Pin counts

Destination

Part number DJ7121-6.3-11

Conector

Type

Pin counts

CN-100

TYCO

3

BOOM KICK OUT

174359-2

CN-100A

TYCO

3

PLUG

174357-2

CN-101

TYCO

3

BUCKET LEVEL

174359-2

CN-101A

TYCO

3

PLUG

174357-2

Destination

Part number

6.GAUGE HARNESS Conector

Type

Pin counts

Destination

Part number DJ431-3A

-

8SQZ570.001

AMP

7. ENGINE HARNESS Conector

Type

Pin counts

Destination

Part number

J/C

ST710289-2

J/C

282080-1

282104-1

6-11