Wheel Loader Sl730

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.

830K1SH03E

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.

KEEP ROPS INSTALLED PROPERLY (option) Make certain all parts are reinstalled correctly if the roll-over protective structure (ROPS) is loosened or removed for any reason. Tighten mounting bolts to proper torque. The protection offered by ROPS will be impaired if ROPS is subjected to structural damage, is involved in an overturn incident, or is in any way altered by welding, bending, drilling, or cutting. A damaged ROPS should be replaced, not reused.

73031GE22

1-9

GROUP 2 SPECIFICATION 1. MAJOR COMPONENT

Bucket

Boom

Bell crank

Bucket link

Tire

Boom cylinder

Bucket cylinder

Front axle

Head light

Hydraulic tank

Main control valve

Cab

Main pump

Battery

Air cleaner

Raidator

Counterweight

Precleaner

Muffler Engine

Steering cylinder Transmission Torque converter Rear axle Fuel tank 830K2SE01E

1-10

2. SPECIFICATIONS

J H C

40

4880 3775 G

F I

B

1) WITH BOLT-ON CUTTING CUTTING EDGE TYPE BUCKET

K D

48 570 95 0

E A 830K2SE03E

Description Operating weight Struck

Bucket capacity

Unit

Specification

kg (lb)

10200 (22490)

m3 (yd3)

Heaped

1.5 (2.0) 1.8 (2.4)

Overall length

A

6830 (22' 5")

Overall width

B

2450 (8' 1")

Overall height

C

3235 (10' 7")

Ground clearance

D

370 (1' 3")

Wheelbase

E

Tread

F

1850 (6' 1")

Dump clearance at 45˚

G

2865 (9' 5")

Dump reach (full lift)

H

1075 (3' 6")

Width over tires

I

2300 (7' 7")

Dump angle

J

Roll back angle (carry position)

K

mm (ft-in)

degree (˚)

Lift (with load) Cycle time

sec km/hr (mph)

Maximum travel speed Braking distance

m (ft-in)

Minimum turning radius (center of outside tire)

degree (˚)

Gradeability

1.2 39.5 (24.5) 13.1 (43' 0") 4.90 (16' 1") 30

First gear

7.4 (4.6)

Second gear

13.3 (8.3)

Third gear

km/hr (mph)

Fourth gear Reverse

49

2.7

Lower (empty)

Travel speed

45 5.2

Dump (with load)

Forward

2850 (9' 4")

23.9 (14.9) 39.5 (24.5)

First gear

9.2 (5.7)

Second gear

29.0 (18.0)

1-11

40

J H C

4880 3775 G

F I

B

2) WITH TOOTH TYPE BUCKET

K D

48 572 95 5

E A 830K2SE04E

Description Operating weight Struck

Bucket capacity

Unit

Specification

kg (lb)

10200 (22490)

m3 (yd3)

Heaped

1.4 (1.8) 1.7 (2.2)

Overall length

A

6940 (22' 9")

Overall width

B

2480 (8' 2")

Overall height

C

3235 (10' 7")

Ground clearance

D

370 (1' 3")

Wheelbase

E

Tread

F

1850 (6' 1")

Dump clearance at 45˚

G

2790 (9' 2")

Dump reach (full lift)

H

1150 (3' 9")

Width over tires

I

2300 (7' 7")

Dump angle

J

Roll back angle (carry position)

K

mm (ft-in)

degree (˚)

Lift (with load) Cycle time

sec km/hr (mph)

Maximum travel speed Braking distance

m (ft-in)

Minimum turning radius (center of outside tire)

degree (˚)

Gradeability

1.2 39.5 (24.5) 13.7 (43' 0") 4.90 (16' 1") 30

First gear

7.4 (4.6)

Second gear

13.3 (8.3)

Third gear

km/hr (mph)

Fourth gear Reverse

49

2.7

Lower (empty)

Travel speed

45 5.2

Dump (with load)

Forward

2850 (9' 4")

23.9 (14.9) 39.5 (24.5)

First gear

9.2 (5.7)

Second gear

29.0 (18.0)

1-12

3. SPECIFICATION FOR MAJOR COMPONENTS 1) ENGINE Item

Specification

Model

YC6J125Z-T20

Type

4-cycle turbocharged diesel engine.

Control type

Mechanical control

Cooling method

Water cooling

Number of cylinders and arrangement

6 cylinders, in-line

Firing order

1-5-3-6-2-4

Combustion chamber type

Direct injection type

Cylinder bore × stroke

105×125 mm (4.1"×4.9")

Piston displacement

6494 cc (396 cu in)

Compression ratio

17.5 : 1

Rated gross horse power

92 kW / 2200 rpm

Maximum gross torque at 1400~1600 rpm

500 N·m

Engine oil quantity

16ℓ(4.2 U.S. gal)

Dry weight

650 kg (1430 lb)

High idling speed

2400±50 rpm

Low idling speed

725±50 rpm

Rated fuel consumption (at rated)

215 g/kW·hr

Starting motor

24 V-6 kW

Alternator

28 V-55 Amp

Battery

2×12 V×120 Ah

1-13

2) MAIN PUMP (+steering pump) Item

Specification

Type

Fixed displacement gear pump

Capacity

100＋50 cc/rev

Maximum operating pressure

200 kgf/cm2 (2840 psi)

Rated oil quantity

169ℓ/min (44.6 U.S.gpm)

Rated speed

2200 rpm

3) MAIN CONTROL VALVE Item

Specification

Type

2 spool

Operating method

Mechanical control

Main relief valve set pressure

160 kgf/cm2 (2280 psi)

Overload relief valve set pressure

180 kgf/cm2 (2560 psi)

4) CYLINDER Item

Specification

Boom cylinder

Bore dia×Rod dia×Stroke Ø110×Ø65×785 mm

Bucket cylinder

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

Steering cylinder

Bore dia×Rod dia×Stroke Ø 70×Ø45×412 mm

5) DYNAMIC POWER TRANSMISSION DEVICES Item

Specification

Model

Transmission

Axle

Wheels Brakes

Steering

Type

YJ315/BS428 Converter

Single-stage, Single-phase

Transmission

Mechanical, hydraulic

Gear shift

Forward fourth gear, reverse second gear

Control

Mechanical single lever type

Drive devices

4-wheel drive

Front

Front fixed location

Rear

Oscillation±12˚ of center pin-loaded

Tires

17.5-25, 14PR (L3)

Travel

Four-wheel, dry-disc type, pneumatic

Parking

Disc type brake on transmission

Type

Hydraulic, articulated

Steering angle

40˚ to both right and left angle, respectively

1-14

4. TIGHTENING TORQUE OF MAJOR COMPONENT No.

Descriptions

Bolt size

Torque kgf·m

lbf·ft

Engine mounting bolt (2EA)

M24×3.0

100 ± 15

723 ± 108

Engine mounting bolt (bracket)

M12×1.75

10.7 ± 1.6

77.4 ± 11.6

Radiator mounting bolt

M16×2.0

29.7 ± 4.5

215 ± 32.5

4

Fuel tank mounting bolt

M16×2.0

29.7 ± 4.5

215 ± 32.5

5

Main pump housing mounting bolt

M12×1.75

12.8 ± 3.0

92.6 ± 21.7

6

Main control valve mounting bolt

M12×1.75

12.8 ± 3.0

92.6 ± 21.7

Steering unit mounting bolt

M10×1.5

6.9 ± 1.4

49.9 ± 10.1

Steering valve mounting bolt

M10×1.5

6.9 ± 1.4

49.9 ± 10.1

2.5 ± 0.5

18.1 ± 3.6

1 2 3

Engine

7 8

Hydraulic system

9

Brake valve mounting bolt

10

Control lever mounting bolt

M10×1.5

6.9 ± 1.4

49.9 ± 10.1

11

Hydraulic oil tank mounting bolt

M16×2.0

29.7 ± 4.5

215 ± 32.5

12

Transmission mounting bolt

M24×3.0

100 ± 15

723 ± 108

13

Transmission mounting bolt (bracket)

M18×2.5

32.7 ± 4.9

237 ± 35.4

Torque converter housing mounting bolt

M12×1.75

10.7 ± 1.6

77.4 ± 11.6

Front axle mounting bolt, nut

M30×2.0

200 ± 15

1447 ± 108

16

Tire mounting nut

M20×1.5

61 ± 2.0

441 ± 14.5

17

Drive shaft joint mounting bolt, nut

1/2-20UNF

15.5 ± 0.5

18

Counterweight mounting bolt

M30×2.0

199 ± 29.9

1439 ± 216

3.4 ± 0.8

24.5 ± 5.8

70 ± 10

506 ± 72.3

14 15

19 20

Power train

Others

M8×1.25

Operator seat mounting bolt

M8×1.25

Cab mounting bolt (4EA)

M27×3.0

1-15

112 ± 3.6

5. TORQUE CHART Use following table for unspecified torque. 1) BOLT AND NUT (1) Coarse thread 8T Bolt size

10T

kg·m

lb·ft

kg·m

lb·ft

M 6×1.0

0.85 ~ 1.25

6.15 ~ 9.04

1.14 ~ 1.74

8.2 ~ 12.6

M 8×1.25

2.0 ~ 3.0

14.5 ~ 21.7

2.73 ~ 4.12

19.7 ~ 29.8

M10×1.5

4.0 ~ 6.0

28.9 ~ 43.4

5.5 ~ 8.3

M12×1.75

7.4 ~ 11.2

53.5 ~ 79.5

9.8 ~ 15.8

71 ~ 114

M14×2.0

12.2 ~ 16.6

88.2 ~ 120

16.7 ~ 22.5

121 ~ 167

M16×2.0

18.6 ~ 25.2

135 ~ 182

25.2 ~ 34.2

182 ~ 247

M18×2.5

25.8 ~ 35.0

187 ~ 253

35.1 ~ 47.5

254 ~ 343

M20×2.5

36.2 ~ 49.0

262 ~ 354

49.2 ~ 66.6

356 ~ 482

M22×2.5

48.3 ~ 63.3

350 ~ 457

65.8 ~ 98.0

476 ~ 709

M24×3.0

62.5 ~ 84.5

452 ~ 611

85.0 ~ 115

615 ~ 832

M30×3.0

124 ~ 168

898 ~ 1214

169 ~ 229

1223 ~ 1655

M36×4.0

174 ~ 236

1261 ~ 1703

250 ~ 310

1808 ~ 2242

39.8 ~ 60

(2) Fine thread 8T Bolt size

10T

kg·m

lb·ft

kg·m

lb·ft

M 8×1.0

2.17 ~ 3.37

15.7 ~ 24.3

3.04 ~ 4.44

22.0 ~ 32.0

M10×1.25

4.46 ~ 6.66

32.3~48.2

5.93 ~ 8.93

42.9 ~ 64.6

M12×1.25

7.78 ~ 11.58

76.3 ~ 83.7

10.6 ~ 16.0

76.6 ~ 115

M14×1.5

13.3 ~ 18.1

96.2 ~ 130

17.9 ~ 24.1

130 ~ 174

M16×1.5

19.9 ~ 26.9

144 ~ 194

26.6 ~ 36.0

193 ~ 260

M18×1.5

28.6 ~ 43.6

207 ~ 315

38.4 ~ 52.0

278 ~ 376

M20×1.5

40.0 ~ 54.0

289 ~ 390

53.4 ~ 72.2

386 ~ 522

M22×1.5

52.7 ~ 71.3

381 ~ 515

70.7 ~ 95.7

512 ~ 692

M24×2.0

67.9 ~ 91.9

491 ~ 664

90.9 ~ 123

658 ~ 890

M30×2.0

137 ~ 185

990 ~ 1338

182 ~ 248

1314 ~ 1795

M36×3.0

192 ~ 260

1389 ~ 1879

262 ~ 354

1893 ~ 2561

1-16

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

Width across flat (mm)

kgf·m

lbf·ft

1/4"

19

4

28.9

3/8"

22

5

36.2

1/2"

27

9.5

68.7

3/4"

36

18

130

1"

41

21

152

1-1/4"

50

35

253

Thread size (UNF)

Width across flat (mm)

kgf·m

lbf·ft

9/16-18

19

4

28.9

11/16-16

22

5

36.2

13/16-16

27

9.5

68.7

1-3/16-12

36

18

130

1-7/16-12

41

21

152

1-11/16-12

50

35

253

Thread size

Width across flat (mm)

kgf·m

lbf·ft

1/4"

19

4

28.9

3/8"

22

5

36.2

1/2"

27

9.5

68.7

3/4"

36

18

130

1"

41

21

152

1-1/4"

50

35

253

3) PIPE AND HOSE (ORFS type)

4) FITTING

1-17

6. RECOMMENDED LUBRICANTS Use only oils listed below or equivalent. Do not mix different brand oil. Service point

Kind of fluid

Capacity ℓ (U.S. gal)

Ambient temperature˚C(˚F) -20 (-4)

-10 (14)

0 (32)

10 (50)

20 (68)

30 (86)

40 (104)

SAE 30 SAE 10W Engine oil pan

Engine oil

16 (4.2) SAE 10W-30 SAE 15W-40

Transmission

Gear oil

40 (10.6)

Axle

Gear oil

Front : 15 (4.0) Rear : 15 (4.0)

Hydraulic tank

Hydraulic oil

ATF DEXRON Ⅲ

SAE 80W-90 SAE 85W-90

ISO VG 32

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

ISO VG 46 ISO VG 68

ASTM D975 NO.1 Fuel tank

Diesel fuel

170 (44.9) ASTM D975 NO.2 NLGI NO.1

Fitting (grease nipple)

Grease

Radiator

Mixture of antifreeze and water 50 : 50

As required NLGI NO.2

Ethylene glycol base permanent type

33 (8.7)

·NLGI : National Lubricating Grease Institute ·SAE : Society of Automotive Engineers ·ASTM : American Society of Testing and Material ·API : American Petroleum Institute ·ISO : International Organization for Standardization ·ATF : Auto Transmission Fluid

1-18

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.

830K1CH01

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

□

□

·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 SYSTEM Group Group Group Group

1 2 3 4

Structure and function --------------------------------------------------------------------------------------Transmission -----------------------------------------------------------------------------------------------------Torque converter -----------------------------------------------------------------------------------------------Axle ---------------------------------------------------------------------------------------------------------------------

2-1 2-2 2-35 2-40

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

Ttansmission

Upper shaft

Torque converter

Engine

Front axle

Front drive shaft

Center drive shaft Rear drive shaft

Rear axle 830KPT01E

The power train of the following components: · Transmission · Front, center, rear and upper drive shafts · Front and rear axles Engine power is transmitted to the transmission through the torgue converter. The transmission is a hydraulically engaged four speed forward, two speed reverse countershaft type power shift transmission. A disc type parking brake is located on the transmission. The Transmission outputs through universal joints to three drive shaft assemblies. The front drive shaft is a telescoping shaft which drives the front axle. The front axle is mounted directly to the loader frame. The rear axle is mounted on an oscillating pivot. The power transmitted to front axle and rear axle is reduced by the pinion gear and ring gear of differential. It been passes from the differential to the sun gear shaft (axle shaft) of final drive. The power of the sun gear is reduced by a planetary mechanism and is transmitted through the planetary hub to the wheel.

2-1

GROUP 2 TRANSMISSION 1. STRUCTURE AND WORKING PRINCIPLE OF TRANSMISSION As illustrated in the page 2-3, figure 1, the transmission consists of transmission housing (1), large end cover (2), reverse shaft assembly (3), input shaft assembly (5), countershaft assembly (6), output shaft (8), range gear sleeve (9) and shoe brake (12). A hydraulic clutch is attached each to reverse shaft assembly (3), input shaft assembly (5) and countershaft assembly (6). As illustrated in figure 2, a hydraulic clutch consists of clutch driving shaft (1), clutch housing (2), piston (3), exterior friction plate (4), interior friction plate (5), return spring (6) and clutch emptying valve (7). When flow of hydraulic oil enters head end of cylinder, piston is pushed to move forward pressing drive and driven friction plate to make driving shaft and gear to rotate, cut off hydraulic oil, and thus clutch emptying valve opens automatically to press spring (6) to return. As illustrated in figure 2, the hydraulic clutch consists of 6 clutch drive plates and 5 driven plates. The driven plate has a 0.5 mm crown and the crown side should face piston. Gap-clearance of piston ring should be ground and its width within 0.05~0.1 mm.

Figure 2 Structure of hydraulic clutch

2-2

10 9 8 11, 12

7

6

5

4

3 2 1

Figure 1 Structure of transmission

1 2 3 4

Transmission housing Large end cover Reverse shaft assembly Input shaft flange

5 6 7 8

Input shaft assembly Countershaft assembly Rear output flange Output shaft

2-3

9 10 11 12

Range gear sleeve Oil tray Front output flange Shoe brake

2. WORKING OF TRANSMISSION As enumerated in figure 3, the transmission route is as follows: Forward gear Ⅰ transmission route : 1 - 15 - 7 - 9 - 3 - 11 - 13 - 17 - 4 Forward gear Ⅱ transmission route : 1 - 8 - 10 - 16 - 3 - 11 - 13 - 17 - 4 Forward gear Ⅲ transmission route : 1 - 15 - 7 - 9 - 12 - 17 - 4 Forward gear Ⅳ transmission route : 1 - 8 - 10 - 9 - 12 - 17 - 4 Reverse gear Ⅰ transmission route : 1 - 8 - 6 - 14 - 2 - 5 - 9 - 3 - 11-13 - 17 - 4 Reverse gear Ⅱ transmission route : 1 - 8 - 6 - 14 - 2 - 5 - 9 - 12 - 17 - 4

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

Input shaft Rear gear shaft Countershaft Output shaft Reverse shaft gear wheel Reverse gear pinion First & third gear input shaft Second & forth gear input gear First & third gear countershaft Second & forth gear countershaft Low gear countershaft High gear output shaft Low gear output shaft Reverse gear clutch III First & second gear clutch I Second & forth gear clutch II High & Low gear sliding sleeve

Figure 3 Working of transmission

Gear

Lever Gear selector lever High · low speed selector lever Ⅰ Ⅱ Ⅲ

Forward 1

●

3 4

High speed

Low speed ●

2

High.low speed selector lever

Low speed

F

●

Gear selector lever

High speed ●

R

Reverse 1

●

F

2

●

R

II

I III

2-4

830KPT19

3. TECHNICAL DATA Max. input speed Max. input torque Max. input power Type of transmission housing Transmission ratio Forward gear 1 gear 2 gear 3 gear 4 Reverse gear 1 gear 2

2500 rpm 91.4 kgf·m (661 lbf·ft) 82 kW Countershaft, constant mesh, hydraulic fork 3.82 2.08 1.09 0.59 3.05 0.87

Oil for transmission Oil pump Operating pressure Allowable oil temperature of oil tray Operating pressure of brake relief valve

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

2-5

4. WORKING AND CONSTRUCTION OF HYDRAULIC OPERATING SYSTEM Working of hydraulic operating system is as illustrated in figure 4. The right half of double dot dash line is torque converter while the left half incorporates transmission control valve, hydraulic cylinder (clutch), filter and tank (including a tank and a tray). When charging pump of torque converter runs, pump (2) is driven by driving gear, sucking oil from tank to output hydraulic oil, which enters combined valve of torque converter. Combined valve block of torque converter consists of a reducing valve (3) and an overflow valve (4). The flow that enters the combined valve will ensure supply in priority for transmission control by reducing valve (3) and then for torque converter via reducing valve.

Torque converter T/M part

T/C part

Brake valve

Cooler

Control valve Torque converter valve block

Lubrication Oil cooling

Figure 4 Schematic diagram of oil system

1 2 3

4 5 6

Suction filtering device Transmission pump Transmission pressure valve

Overflow valve Transmission control valve Brake relief valve

Transmission oil pressure and inlet oil pressure of torque converter are controlled by reducing valve (3) and overflow valve (4) respectively. Set pressure of reducing valve is 1.4~1.6 MPa while that of overflow valve is 0.5~0.65 MPa. When inlet pressure of torque converter becomes higher than the set value of overflow valve (4), the valve opens to overflow spray oil for transmission. The flow from outlet is directed to transmission lubricating system after cooling. High pressure oil delivered from pump is controlled to 1.4~1.6 MPa by reducing valve, which then enters transmission control valve (5) via brake relief valve (6) to control gear shift clutch.

2-6

5. TRANSMISSION CONTROL VALVE

M22×1.5

M22×1.5

M22×1.5

Figure 5 Transmission control valve assembly ass’y

Transmission control valve includes brake relief valve and transmission control valve. Orifice A on the valve body is connected to combined valve of transmission. When transmission valve spool moves, oil under pressure from combined valve of torque converter can flow into orifice C, D or E (C for clutch Ⅰ, D for clutch Ⅱ, E for clutch Ⅲ) to go forth or back for shift. Screw PT1/8” at E on the top of valve body is for connection of output to reverse gear. When the brake pedal is pressed down, compressed air from the brake master cylinder has an air passage for brake valve spool to push the spool rod, cutting operating oil way (A and B is not connected). At the time, transmission is in neutral to ensure reliable braking.

2-7

6. MOUNTING Mount the transmission housing on the frame and fix with bolts. For mounting size, refer to the page 2-12. 1) CONNECTION Input flange of transmission is connected with torque converter by driving shaft. Front and rear flange of transmission is connected to driving shaft and front & rear axle respectively. 5 connections of transmission control valve are : (1) Mounting sizes of transmission control valve lever are as illustrated in the figure 5. After the lever is pulled to the most outside gear, Neutral, gear I and gear II are gained in order by moving inside. The sizes are Lmax=51 mm, Lmin=15 mm and stroke per gear = 12 mm. (2) Connection screw on the end of brake control valve is connected to the air pipe of brake master cylinder. (3) Inlet for transmission control is located in Ⅰ-Ⅰ as illustrated in figure 5. (4) Inlet for spray oil of transmission is located in Ⅱ-Ⅱ. (5) Inlet for cooling transmission is located in Ⅲ-Ⅲ. (3) and (4) is connected to each correct port on combined valve of torque converter. (5) is connected to oil outlet of radiator. For positions of shift rod of range gear, see attached figure 1. There are three gears. The outside is high gear, the inside low gear, stroke between two adjacent gears is 15 mm. Connection sizes of handle are illustrated in figure 6.

Figure 6

2) USING After mounting the transmission on the frame, add AFT (DEXRON Ⅲ) for about 40 liter from the filler and, 5 minutes after starting the engine, check the oil level for specified position on scale. After each shift work, it’s required to check the oil level of transmission. During operation of transmission, be careful to check that its operating pressure is within 1.4~1.6 MPa, oil temperature at outlet of torque converter doesn’t exceed 105˚C, and 115˚C in short time, and that in the oil tray of transmission doesn’t exceed 100˚C. Run in the transmission 12 hours after mounting on the frame, each 2 hours for 6 gears. The load in run-in period should not exceed 70% of the rated value, and frequently check oil temperature, oil level and tightness of bolts. After completion of run-in, clean the oil tray of transmission and oil-filter strainer, and renew oil. Moving into reverse gear from a forward gear, into a forward gear from reverse gear, or moving between high and low gears must be conducted after parking. Gear 1 and 2, or gear 3 and 4 can be changed with each other during travel.

2-8

7. MAINTENANCE AND TROUBLESHOOTING 1) MAINTENANCE Maintenance is carried out after running for 10, 50, 250, 500,1000 and 2000 hours. (1) 10 hours maintenance maintenance ① Check oil level in transmission. ② Check transmission for normal operation and driving gear for noise. ③ Check the bolts and nuts for good tightness and check for oil leaks. (2) 250 hours maintenance ① Inspect operation and noise of transmission. ② Clean the filter. (3) 500 hours maintenance maintenance ① Renew oil. (4) 1000 hours maintenance ① Replace oil filter. (5) 2000 hours maintenance maintenance ① Inspect operation, input power, noise, oil temperature, oil leaks, etc. ② Clean air vent caps, fasten up screws and pipe fittings.

2-9

2) TROUBLESHOOTING Problem

Cause

Remedy

Too low oil pressure or 1. Transmission gear pump does not supply oil zero 2. Failed reducing valve of torque converter. 3. Stuck brake valve. 4. Oil leaks in oil circuit. 5. Failed piston packing of clutch. 6. Failed O-ring of transmission valve. 7. Seal ring is failed. 8. Emptying valve for clutch has fallen off.

Repair. Repair. Repair. Repair. Service and repair. Replace. Replace. Check and repair.

Too high oil pressure

Repair. Clean. Renew oil.

1. Malfunction in overflow valve for torque converter. 2. Clogged oil circuit. 3. Incorrect oil is used.

Too high oil temperature 1. Clogged oil cooler. 2. Water has gotten into the oil circuit. 3. Insufficient oil amount. 4. Incorrect gear selection in operation. 5. Hand brake can not be normally released or

Clean. Renew oil. Replenish oil. Change to low gear. Adjust.

braking drag. 6. Clutch friction plate can not be separated Replace. completely. Engine runs but vehicle 1. Insufficient oil. will not move 2. Incorrect range gear selector fork position. 3. Brake spool has not response. 4. Clutch friction plate collision. 5. Malfunction in control valve for transmission. Weak traction

1. Low oil pressure.

See “Too low oil pressure trouble”. Reengage gear. Check brake spool. Replace. Repair.

See “Too low oil pressure trouble”. 2. Clutch friction plate can not be separated Repair. completely and dragging. 3. Insufficient oil supply. Replenish oil.

2-10

3) NOTES IN REPAIR OPERATION Following cares should be taken to reassemble the transmission after disassembly: (1) Paper gasket and large end cover paper gasket must be of 0.5 mm, or too much axial clearance of bearing may be formed to lead to damaged gear. (2) Adjustment of bearing clearance for input shaft, countershaft and reverse shaft. Axial clearance must be readjusted when reassembling input shaft, countershaft and reverse shaft after disassembly. Perform adjustment as followings: ① If clearance of input shaft is too little, thickness of paper gasket may be increased or that of shaft bushing decreased. ② For adjustment of clearance for countershaft and reverse shaft, you may first loosen stop plate, and fasten adjusting screw, and then loosen a lock groove position (back for 0.125 mm axial clearance) and lock up the lock plate. ③ Normal axial play of input shaft, countershaft and reverse shaft Normal axial play of input shaft, countershaft and reverse shaft should be 0.1~0.13 mm.

2-11

Input flange A

Flange C

Hi-Neutral-Lo

Range Gear lever

Rear Front

Output flange B

Oil return port

View K

2-12

Cooling oil port

Oil spray port

1) OUTSIDE VIEW

Pressure tap

Pressure oil port

View K

7. STRUCTURE

2) TRANSMISSION HOUSING (1/2) 66 9

3

4

2 62

6

65

7

5 11

63

12 64

10 8

9

1

21 22

13

15 14 17

23 24

11 9

8 27

25

6

16

7

29 4

30 26 28

32 33

20

13 22

19 18

15 14 8

5 31

9 52 34

9

35 830KPT05

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

Housing Name plate Rivet Bracket Hexagon bolt Spring washer Hexagon nut Hexagon bolt Washer End cover Gasket Regulating ring Regulating screw Hexagon bolt

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

Stop plate Input shaft end cover Seal Middle shaft end cover Gasket Regulating ring Nut Washer Connector Washer plate Strainer core Bolt Flange joint Hexagon bolt

2-13

29 30 31 32 33 34 35 52 62 63 64 65 66

O-ring Gasket Sump Suction pipe Magnetic Oring Plug Hexagon bolt Housing cover Cover sheet Semi circular rivet Gasket Hexagon bolt

TRANSMISSION HOUSING (2/2)

67 54 56

53

57 39

59 60 61 22

36

9

46 55

9

67

45

44

48

52

43 68

58 42

9

52

45

41 40

38

43

44 67

42 47

37

9

52

46 45 44 43 51 51

9

8

50 49

830KPT06

8 9 22 36 37 38 39 40 41 42 43

Hexagon bolt Washer Washer O-ring Pipe assy Hexagon bolt Pipe & dipstick Seal O-ring Cover Bush

44 45 46 47 48 49 50 51 52 53 54

Washer Bush Input end cover Dowel pin Socket pin Washer Input sealing cover Input seal Hexagon bolt Air vent Square nut

2-14

55 56 57 58 59 60 61 67 68

Vent plate Sleeve Plate Sleeve Long screw Casing Gasket Plug Plug

3) OUTPUT SHAFT 7

18

7 6

17

5

16 17

2

3

4

15

1

13

3

14

2

1

4

13

5

12 11

21

8

6 9

24

11

10 12 13 20 13 19

22

23

830KPT07

1 2 3 4 5 6 7 8

Hexagon bolt Stop pad Pressure plate O-ring Output flange Dust cover Seal output Output rear end cover

9 10 11 12 13 14 15 16

Hexagon bolt Washer Ball bearing Thrust ring Sliding bearing Ring Gear High-low sliding sleeve

2-15

17 18 19 20 21 22 23 24

Steel ball Output shaft Output gear Ring Brake drum Nut Spring washer Bolt

4) INTPUT SHAFT

13

12 11

8

8

9

10 9

6

25 26

7 4 12

14

5

30

32 31

33

29 5

23 22

28

3 27 24 21 20 19

15

16

17

18

830KPT08

1 2 3 4 5 6 7 8 9 10 11

Small ring nut Stop washer Washer Flange Taper roller bearing Input shaft Plug Hole ring Ball bearing Gear Snap ring

12 13 14 15 16 17 18 19 20 21 22

Outer end cover External friction disc Internal friction disc Snap ring Spring seat Spring Piston Sealing ring O - ring Clutch case assy Steel ball

2-16

23 24 25 26 27 28 29 30 31 32 33

Valve seat Gear Stop pad Hexagon bolt Pin Bush Inner sealing sleeve Piston ring Shaft end baffle Stop pad Hexagon bolt

5) INTERMEDIATE SHAFT

15

14 13 11

10

12 10

16

11

9 7

28

8

27

6

25 24

5 1

2

3

4 6 29 26 23 21

22

20 19 17

18 830KPT09

1 2 3 4 5 6 7 8 9 10

Hexagon bolt Stop pad Shaft end baffle Piston ring Inner sealing sleeve Roller bearing Gear Plug Intermediate shaft Hole ring

11 12 13 14 15 16 17 18 19 20

Ball bearing Gear Snap ring Outer end cover External friction disc Internal friction disc Snap ring Spring seat Spring Pistion

2-17

21 22 23 24 25 26 27 28 29

Sealing ring O-ring Clutch case assy Steel ball Valve seat Gear Stop pad Hexagon bolt Pin

6) REVERSE SHAFT

15

14 13 16 12

10

11

10

11 27

9 6

7

28

25 24

8

6

5 1

23

29

4 26 23 22 21 18 17

19

20

830KPT10

1 2 3 4 5 6 7 8 9 10

Hexagon bolt Stop pad Shaft end baffle Piston ring Inner sealing sleeve Roller bearing Sleeve Plug Reverse shaft Hole ring

11 12 13 14 15 16 17 18 19 20

Ball bearing Gear Snap ring Outer end cover External friction disc Internal friction disc Snap ring Spring seat Spring Piston

2-18

21 22 23 24 25 26 27 28 29

Sealing ring O-ring Clutch case aasy Steel ball Valve seat Stop pad Hexagon bolt Stop pad Pin

7) HIGH-LOW SPEED SHIFT FORK

1

2

3 4

5 6 7

8 12 10

13

11 9

830KPT11

1 2 3 4 5

Pin Socket screw HIgh-low shift fork Gasket Fork support

6 7 8 9 10

Washer Hexagon bolt Seal Fork shaft Plug

2-19

11 12 13

Washer Steel ball Spring

8) CONTROL VALVE

12

9 10

12 11 1 2 7 8 13 14

15

5

27

3 4

6 7

28

16 17

18

22

19 11 10

23

9 24 21 26

20 25

830KPT12

1 2 3 4 5 6 7 8 9 10

Screw Washer Spring Steel ball Dust cover Pressure tap Washer Plug Snap ring Seal

11 12 13 14 15 16 17 18 19 20

Regulating washer Control sliding valve Dust cover Plug O-ring Cup Brake sliding valve Spring O-ring Spring seat

2-20

21 22 23 24 25 26 27 28

Plug Valve body Gasket Bottom plate Socket screw Screw Hexagon bolt Washer

9) PARKING VALVE

5 3 2 4

1 2 1

22 21

19 20 14 13 3

14

6 18 27

7

16

23

17

11

7

28 29

8 9 10

15 24

12

10

25 26

830KPT13

1 2 3 4 5 6 7 8 9 10

Parking brake bracket Cam plate Washer Split pin Axis pin Set screw Set screw spring Set screw spring Washer Nut

11 12 13 14 15 16 17 18 19 20

Nut Hexagon bolt Upper fixed plate Semi circular rivet Lower fixed plate Rivet Friction pad Bracket Steel band Bracket

2-21

21 22 23 24 25 26 27 28 29

Bolt Iron wire Regulating spring Bracket Bolt Washer Bracket Hexagon bolt Spring washer

8. DISASSEMBLY 1) DRAINAGE FOR TRANSMISSION (1) Hoist transmission up and put an oil container under it.

830KTM10

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

830KTM11

2) OIL PAN OF TRANSMISSION (1) Unscrew 20 - M10×30 bolts in sequence on the oil pan with a spanner. As disassembly, two diagonal bolts should be removed finally to prevent from injury to people due to falling oil pan. (2) Be careful of remaining oil in the oil pan when the last two bolts are removed. (3) Put the oil pan removed in a clean place. 830KTM12

M10×30 bolts

830KTM13

2-22

3) HAND BRAKE ASSY (1) Remove 4 - M12×30 bolts on the left bracket of hand brake with a spanner.

830KTM14

(2) Remove 4 - M8×25 bolts on the right bracket of handbrake with a spanner. (3) Pull the total hand brake assy out and put it in a clean place.

830KTM15

4) REMOVING FRONT & REAR OUTPUT FLANGE (1) Remove the bolt lock plate at the front output flange with a screwdriver and unscrew 2 - M10×25 bolts inside the front output flange with a spanner. After taking the pressure plate and O-ring out, pull the front output flange assy out and place it in a clean place. 830KTM16

(2) Remove the bolt lock plate at the rear output flange with a screwdriver and unscrew 2 - M10×25 bolts inside the rear output flange with a spanner. After taking the pressure plate and O-ring out, pull the rear output flange assy out and place it in a clean place.

830KTM17

2-23

5) REMOVING INPUT FLANGE (1) Release the lock of stop plate on the input shaft with a screwdriver and use a special tool or iron piece to remove M - 20×1.5 round nut. After taking the pressure plate out, pull the input flange (flange assy) out and put it in a clean place.

830KTM18

6) REMOVING GEAR SHIFT FORK (HI AND LO SPEED) SPEED (1) Put the transmission level, release the set screw lock on the gear shift fork mount and unscrew the M10 set screw with M14 spanner. (2) Unscrew 4 - M10×30 bolts on the fork mount with a spanner and tap lightly the mount assy out with a copper bar and put it in a clean place.

830KTM19

830KTM20

7) REMVING OUTER END COVER OF TRANSMISSION (1) Put the transmission level with the input side up. (2) Unscrew 4 - M10×25 bolts on the end covers of input shaft, intermediate shaft and reverse shaft with a spanner and then use 2 - M10×25 bolts to push the three end covers out and put them in a clean place. (3) Unscrew 8 - M10×30 bolts on the rear end cover of output shaft and use 2 M10×30 bolts to push the rear end cover out and put it in a clean place.

830KTM21

2-24

(4) Turn the transmission for other side and place it level. (5) Unscrew 5 - M10×30 bolts on the oil inlet end cover of gear I, gear II and reverse gear with a spanner and then use 2M10×30 bolts to push the three end cover out and put them in a clean place.

830KTM22

830KTM23

(6) Unscrew 4 - M10×25 bolts on the seal cap of front output shaft with a spanner and use 2 - M10×25 bolts to push it out and put in a clean place.

830KTM24

(7) Unscrew 13 - M10×30 socket bolts on the large end cover with a socket wrench and then use 2 - M10×45 bolts to push it out and put in a clean place.

830KTM25

2-25

8) REMOVING CLUTCHES (1) Take 3 sets of clutch par ts out of transmission box and put them in a clean place and mark outer ring of bearing to prevent from miss assembly.

830KTM26

830KTM27

(2) Set the input parts up as illustrated in the figure and use a flat chisel to release two bolt locks and then unscrew 2 - M8×16 bolts with a spanner and use a copper bar to tap the input shaft out. (3) Use a flat taper to release the bolt lock onthe clutch assy and unscrew 8 M10×25 bolts with a spanner. (4) Remove the retainer with a screwdriver, and then the outer end cover 6 outer friction plates and 5 inner plates in order.

830KTM28

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

830KTM29

2-26

9) REMOVING OUTPUT SHAFT (1) Use a copper bar to tap on to the front end of transmission to make the front end output shaft to fall out from front bearing, and then take the output shaft parts out and put in a clean place.

830KTM30

830KTM31

2-27

9. ASSEMBLY 1) ASSEMBING INPUT CLUTCH PARTS 13

12 11 9

10 8

8

9

6

25 26

7 4 12

14

5

30

32 31

33

29 5

23 22

28

3 27 24 21 20 19

15

16

17

18

830KPT08

(1) Check the clutch valve seat (23) and internal steel ball (22) for looseness. (2) Use a spanner to screw up 8 - M10×25 bolts to fasten gear I part drive gear (24) to clutch case assy (21). (3) Put up glue and knock in 2 straight pins (27). (4) Unscrew 8- M10×25 bolts with a spanner and put up 4 stop plates (25) and fasten up 8 - M10 ×25 bolts and lock up 4 stop plates with flat taper. (5) Fit the oil seal ring (19) into piston (18) groove with the broken opening toward gear. (6) Fit O-ring (20) into place on clutch case. (7) Tap the piston assy into the oil cylinder of clutch case with a tool. (8) Assemble the spring (17) and spring seat (16) onto the shaft of the clutch case and use the special tool to mount the circlip for shaft (6). (9) Put up 6 outer plates (13) and 5 inner plates (14) alternatively, and assemble outer end cover (12) and retainer (11) finally. (10) Knock 2 annular ball bearing into the bore of gear I drive gear (10) and mount two retainer (8) to set. (11) Mount the gear I drive gear assy into the clutch assy. (12) Insert input shaft (6) into the bore of gear I drive gear assy. (13) Knock the bearing (5) onto the input shaft with the special tool and mark on the inner and outer ring of the bearing. (14) Turn and mount sleeve (28) and knock the inner ring of bearing and oil seal (29) onto the input shaft respectively. (15) Apply glue and knock stop plug (7) in and then assemble end plate (31) and then stop washer (32) and fasten up 2 - M8×16 with a spanner and make the two sides lock of stop washer with a flat taper. 2-28

2) ASSEMBLING INTERMEDIATE SHAFT CLUTCH PARTS 15

14 13 11

10

12 10

16

11

9 7

28

8

27

6

25 24

5 1

2

3

4 6 29 26 23 21

22

20 19 17

18 830KPT09

(1) Check the valve seat (25) of clutch case assy (23) and internal steel ball (24) for looseness. (2) Use a spanner to screw up 8 - M10×25 bolts to fasten gear II drive gear (26) to clutch case assy. (3) Put up glue and knock in 2 straight pins (29). (4) Unscrew 8 - M10×25 bolts with a spanner and put up 4 stop plates (27) and fasten up 8 - M10 ×25 bolts and lock up 4 stop plates with flat taper. (5) Fit the oil seal ring (21) into piston (20) groove with the broken opening toward gear. (6) Fit O-ring (22) into place on clutch case. (7) Tap the piston assy into the oil cylinder of clutch case with a tool. (8) Assemble the spring (19) and spring seat (18) onto the shaft of the clutch case and use the special tool to mount the circlip for shaft (9). (9) Put up 6 outer plates (15) and 5 inner plates (16) alternatively, and assemble outer end cover (14) and retainer (13) finally. (10) Knock two annular ball bearings (11) into the bore of gear II drive gear (12) and mount two retainers (10) to set. (11) Mount the gear II drive gear assy into the clutch assy. (12) Insert intermediate shaft (9) into the bore of gear II drive gear assy. (13) Push gear II idler gear (7) onto the spline of intermediate shaft and knock the bearing onto the intermediate shaft with the special tool and mark on the inner and outer ring of the bearing. (14) Knock inner seal (5) onto the intermediate shaft with special tool. (15) Apply glue and knock stop plug (8) in and then assemble end plate (3) and then stop washer (2) and fasten up 2 - M8×16 with a spanner and make the two sides lock of stop washer with a flat taper. (16) Put 2 piston rings (4) into inner seal groove. 2-29

3) ASSEMBLING REVERSE SHAFT CLUTCH PARTS

15

14 13 16 12

10

11

10

11 27

9 6

7

28

25 24

8

6

5 1

23

29

4 26 23 22 21 18 17

19

20

830KPT10

(1) Check the valve seat (25) of clutch case assy (23) and internal steel ball (24) 5 for looseness. (2) Use M16 spanner to screw up 8 - M10×25 bolts to fasten reverse gear reverse gear (26) to clutch case assy. (3) Apply glue and knock in 2 straight pins (29). (4) Unscrew 8-M10×25 bolts with a spanner and put up 4 stop plates (27) and fasten up 8 - M10 ×25 bolts and lock up 4 stop plates with flat taper. (5) Fit the oil seal ring (21) into piston (20) groove with the broken opening toward gear. (6) Fit O-ring (20) into place on clutch case. (7) Tap the piston assy into the cylinder of clutch case with a tool. (8) Assemble the spring (19) and spring seat (18) onto the shaft of the clutch case and use the special tool to mount the circlip for shaft (9). (9) Put up 6 outer plates (15) and 5 inner plates (16) alternatively, and assemble outer end cover (14) and retainer (13) finally. (10) Knock two annular ball bearings (11) into the bore of reverse drive gear (12) and mount two retainers (10) to set. (11) Mount the reverse drive gear assy into the clutch assy. (12) Insert reverse gear shaft (9) into the bore of reverse drive gear assy. (13) Push reverse gear sleeve (7) onto the reverse gear shaft and knock the bearing onto the reverse gear shaft with the special tool and mark on the inner and outer ring of the bearing. (14) Knock inner seal (5) onto the reverse gear shaft with special tool. (15) Apply glue and knock stop plug (8) in and then assemble end plate (3) and then stop washer (2) and fasten up 2 - M8×16 with a spanner and make the two sides lock of stop washer with a flat taper. (16) Put 2 piston rings (4) into inner seal groove. 2-30

4) ASSEMBLING OUTPUT SHAFT PARTS (1) Mount four composite bearings to high speed gear and low speed gear respectively.

830KTM35

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

830KTM36

5) ASSEMBLY (1) Mount the left bracket and right bracket of handbrake at the output side of transmission onto the transmission box and set with four M8×25 bolts and M12×30 bolts respectively. (2) Mount the bearing outer rings into the bearing bore respectively and mark. 830KTM37

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

830KTM38

2-31

(4) Mount bearing into the bore for bearing on the large end cover.

830KTM39

(5) Mount the large end cover into the box and put up a paper gasket in the middle. (6) Assemble the outer seal into the oil inlet end cover. (7) Mount the oil inlet end covers in place on the box watching oil orifice position.

830KTM40

(8) Assemble the front output flange and handbrake assy.

830KTM41

830KTM42

2-32

(9) Assemble the low speed gear assy into the box.

830KTM43

(10) Assemble the output shaft assy.

830KTM44

(11) Assemble rear end cover of output shaft and rear output flange. (12) Mount the output shaft rear end cover and oil seal (45×62×12) on the box and then input flange, and adjust the bearing gap at the input side to meet requirements. (13) Mount the intermediate shaft end cover and reverse gear shaft end cover and fasten up the screws and set the stop plate.

830KTM45

(14) Mount the fork shaft in the fork bracket. (15) Mount the fork bracket assy through the holes on the box and fasten with 4 M10×30 bolts. Mount the for k for high-low shift speed by inserting the fork shaft into the fork hole and adjust the p o s i t i o n o f fo r k s h a f t t o k e e p i t perpendicularly and drill hole to match assembly. 830KTM46

2-33

830KTM47

(16) Mount the oil pan and set with 20 M10×30 bolts.

830KTM48

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

830KTM49

2-34

GROUP 3 TORQUE CONVERTER 1. FEATURES AND USE Hydraulic torque converter is a single stage, single phase radial turbine hydraulic converter. In addition to the structural features of general hydraulic torque converter, this product features three output shafts and thus it can drive three different models of hydraulic pump or other components to meet the requirements of engine.

2. WORKING The pump pulley connects to engine flywheel by a connection wheel and flexible steel board. Driven by mechanical energy from engine, the unit transforms the energy into hydraulic power, which drives the turbine to be transformed into mechanical energy and outputted by power output members. Guide pulley has functions to change direction of operating flow and give a counter torque to the flow to change torque and speed. The oil inlet valve consists of main pressure valve and an overflow valve. Function of the main pressure valve is to ensure sufficient oil supply to torque converter and that oil pressure range in speed change oil circuit of engine is within 1.30 ~ 1.50 MPa. The function of overflow valve is to build up a compensatory pressure to the system and, by different loading of torque converter and variation of internal pressure of hydraulic oil, automatically control the flow passing through the torque converter to control the heat dissipating capacity of torque converter and provide overpressure protection when the outlet port of torque converter is clogged.

3. TECHNICAL DATA Limit input torque

69.3 kgf·m (502 lbf·t)

Nominal torque at zero-speed loading

5.8 kgf·m (42.2 lbf·t)

Nominal torque at high efficiency loading

6.1 kgf·m (44.1 lbf·t)

Torque ration at zero-speed loading

3.24

Max. efficiency

0.836

Width of high efficiency region

2.032

Net weight

159kg

Dimensions

470×530×530 mm

2-35

4. MOUNTING AND USAGE 1) MOUNTING When mounting, ensure that centerline of rotation of torque converter coincide with that of crankshaft of engine (see page 2-39). 2) USAGE (1) Hydraulic torque converter uses AFT (DEXRON Ⅲ). Oil temperature should be within 85~100˚C, and not exceed 110˚C normally. (2) Before staring hydraulic torque converter, check each rotating part for smooth rotation and that if there is seizure and collision. Mount the hydraulic torque converter on the vehicle and add a suitable amount of hydraulic oil to the tank. (3) Start the engine and make the hydraulic torque converter to run for 1~2 minutes at low speed. Add oil to the tank again. Oil level should reach indicator line in running of hydraulic torque converter. Keep in mind to bleed air for the oil supply system when adding oil. (4) After starting hydraulic torque converter, run it in low speed and moderate speed in sequence, then under load. Frequently watch its running and check if there is abnormal noise. Immediately stop and check if abnormal. During operation, frequently check for variation of oil pressure and temperature and ensure that are within normal range. When the hydraulic torque converter is in use, be sure to check it at least once a week and, if oil level is below the line, add adequate amount of oil promptly. (5) It’s required to renew oil for hydraulic torque converter after 30~50 hours of operation and then renew for second time after 500 hours of operation. After that, renew oil in the same time interval. (6) For mechanic transmission, the driver should make timely gear shift to prevent the engine from dying by sound heard during operation. No engine dying will occur if transmission of hydraulic torque converter is matched rationally. However, the driver still needs to change gear timely by oil temperature readings to prevent from overheated oil in low efficiency region of torque converter that may cause damage to sealing pack.

2-36

5. OIL SUPPLY SYSTEM Working principle of oil supply system of hydraulic torque converter.

1 2 3 4 5

Cooler Hydraulic torque converter Main pressure valve Overflow valve Flow

Opening pressure 1.3 ~ 1.5 MPa Opening pressure 1.3 ~ 1.5 MPa Q ≥ 50 ℓ/min

2-37

6. TROUBLESHOOTING Problem

Cause

Increase engine rpm

I n s u f f i c i e n t Engine rpm drops. power output Gas exists in hydraulic oil.

Increase engine rpm. Check transmission oil level. Check for tightness of tubing system. Check for deteriorated hydraulic oil.

Too high hydraulic oil temperature.

Lower oil temperature.

Too low pressure of overflow valve of Check for sensitivity of motion of overflow valve and hydraulic torque converter. hydraulic oil leaks. Too high oil Too long time of operation in low Decrease external load or increase engine rpm. temperature efficiency region. Too low oil level in oil tank or gas exists Add hydraulic oil, check for tightness of the in hydraulic oil. connections of piping, and check for deteriorated oil. Oil does not meet requirements.

Use oil as recommended in operator's manual.

Too low oil pressure in oil supply Repair hydraulic valve, increase oil pressure. system. Low water level in cooling system.

Repair water tank.

Insufficient oil supply.

Check oil supply system.

To o l o w o i l Back pressure valve failure. Replace back pressure valve. pressure in oil Clogged oil feed tube. Check oil tubing. supply system Insufficient oil supply of transmission oil Check and repair oil pump, or replace. pump. Damaged or severely worn oil seal Replace oil seal. inside hydraulic torque converter.

Oil leakage

Too low oil level in oil tank.

Add hydraulic oil.

Clogged suction filter.

Clean or replace the filter.

Failed pressure gauge.

Replace the pressure gauge.

Damaged reinforced oil seal. Damaged O-ring.

Replace the oil seal. Replace the O-ring.

2-38

2-39

Pressure measuring port

Opening pressure

View A

er ent c To

Lifting hole

ter cen o T

Opening pressure

Overflow pressure

Torque converter oil supply system diagram

Oil overflow port

Total 3 spots

Oil return port View A

Total 3 spots

Total 3 positions of spline

Length of spline

Oil overflow port

7. OUTSIDE VIEW

GROUP 4 AXLE 1. OUTLINE 1) PRODUCT SURVEY The axle has two stages reduction structure. It has rational design structure, reliable use performance, long duration of life, etc. It adopts caliper disc brake by pneumatic braking. Braking moment is large and braking is stable and reliable. 2) MAIN PERFORMANCE AND TECHNICAL PARAMETERS Main technical parameters Axle model

ZL30

Max. load

Max. input torque

Total ratio

Main ratio

Wheel-end ratio

Braking moment

Oil pressure

18500 kg

235 kgf·m (1700 lbf·ft)

20.26

4.222

4.8

979 kgf (7080 lbf·ft)

9.8 MPa

3) THE STRUCTURAL CHARACTERISTICS AND WORKING PRINCIPLE (1) Main structural structural characteristics The drive axle is two stages reduction transmission device. The first grade device adopts spiral bevel gear to transmit. Drive axle bears large input torque and has capability of high transmission efficiency and stable working. The second grade device adopts planetary reduction transmission structure (NGW) type. Rigidity of whole movement of drive axle is well and output speed is smooth. Between two grades device, we adopt full-floating axle shaft to connect and transmit power. The structure has overcome that axle housing in the course of working distortion brings the influence to axle shaft transmission. (2) Working principle Wheel reductor

Axle shaft

Final drive

Input flange 830K2AX100

2-40

Power torque of vehicle is inputted by drive shaft from input flange of drive axle. Final drive changes rotary direction to drive driven spiral bevel gear and differential case to rotate after it does reduction and differential. Differential case drives cross pin and planet bevel gears to transmit power to axle shaft gears. Axle shaft gears transmit power to two sides wheel-end reductors by axle shafts, finally transmit power to planet carriers after wheel-end reductors do reduction, thereby drive wheels to roll ahead. Transmission route of drive axle as follows: Transmission Power torque of vehicle → Input flange → Final drive → Differential → Axle shafts → Wheel-end reductors → Wheels. 4) MAINTENANCE (1) Must lubricate for new drive axle before it is mounted on vehicle. Recommended the lubricant: SAE85W-90. When refuel oil, should separately refuel it from oil inlets at bowl of the middle of axle housing and at two sides wheel-end. · Oil amount Front axle : 24ℓ(6.3 U.S.gal) Real axle : 24ℓ(6.3 U.S.gal) (2) Maintenance aintenance per 250 hours ① Inspect wear condition of braking discs and whether there are destructive wear on them. ② Inspect wear condition of braking plates. When the grooves on friction lining have been worn down and don’t meet the requirement, should immediately replace. ③ Inspect whether oil level at axle housing meets the requirement. If oil level lowers, should refuel oil in time. (3) Maintenan Maintenance ce per 1000 hours Lubricant in drive axle work per 1000 hours to replace once new oil. (4) Maintenance pe perr 2000 hours Should disconnect drive axle to inspect when it has worked for 2000 hours. ① Inspect spiral bevel gear pair backlash, mesh and wear condition of final drive. ② Inspect wear condition of differential gears and bevel gear washers. ③ Inspect wear condition of wheel-end gears. ④ Inspect wear condition of wheel-end planet gear needle rollers and bearings.

2-41

(6) Requirement of inspection and debugging projects in the course of use ① Spiral bevel gear pair backlash is 0.2~0.3 mm. Mesh is >50% both face width and tooth depth. Mesh is at teeth middle. Mesh leans to little end at empty load. Backlash and mesh are adjusted by adding and reducing adjust shims at bearing seat and by adjust nuts at two sides bearings of differential. ② Adjustment of bearing clearance on wheel-end hub: Turn locknut tight until hub only rotates with difficulty, then reverse locknut 1/10 turn. Here, hub can rotate freely without jammed phenomenon, obvious axial clearance and oscillatory phenomenon, turn locknut tight with screw last.

2-42

5) TROUBLESHOOTING Parts names Final drive and differential

Wheel-end reductions

Brake

Problem

Cause

Remdy

Loud noise

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

Adjust gear backlash. Replace bearing.

Housing body early heats

L u b r i c a t i o n i s b a d . N o Refuel lubricant to oil level. lubricant or lubricant is excessive.

Periodic unusual sound

1 . G e a r a p p e a r s t o o t h Replace gear. breakage. 2. There is eyewinker inside. Bleed the oil port to inspect. 3. Fasteners loose. Turn fasteners tight.

Differential failure

Cross pin breakage.

Leakage

1. Oil seal ages and wears. Replace oil seal. 2. Sealant loses its efficiency. Scrape off old sealant and smear afresh. 3. Fasteners loose Turn fasteners tight.

Wheel-end doesn't rotate

1. Axle shaft breakage. 2. Differential system failure.

There is unusual sound

1 . G e a r a p p e a r s t o o t h Replace gear. breakage. 2. There is eyewinker inside. Bleed the oil port to inspect.

Housing body early heats

L u b r i c a t i o n i s b a d . N o Refuel lubricant to oil level. lubricant or lubricant is excessive.

Braking failure

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

Replace cross pin.

Replace axle shaft. Adjust and replace differential system.

Connect or replace oil line. Replace O-ring. Replace brake. Inspect oil pump and exhaust gas in oil line.

Friction lining doesn't 1. Piston seal ring ages and Replace seal ring. wears. release 2. Oil inlet joint looses. Turn oil inlet joint tight. 3. There is casting defect on Replace brake body and repair. brake body.

6) TRANSPORTATION AND DEPOSIT (1) Strictly prohibit to deposit drive axle in the open air. It should be deposited in the room with good ventilation. If lubricant has molded and deteriorated, when use drive axle, should replace new oil. (2) Can’t knock and savagely handle drive axle in the course of carry and turnover.

2-43

8) STRUCTURE (1) Drive axle assembly

1

4

2

3 5 7

6

18

9 8

14

16

17

15

10 11

12 13 830KPT14

1 2 3 4 5 6

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

7 8 9 10 11 12

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

2-44

13 14 15 16 17 18

Nut Washer Bolt Bolt Washer Disc brake assy

(2) Wheel-end reductor

20 18 12 11

16 1314 15

19

17

10 89 5 3 4

6 7

1 2

28

30 31

10 37

37

35 36

23 32

33 34

29 26 24 21

27

22

28

25 830KPT15

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

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

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

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

2-45

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

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

(3) Final drive assembly

19

20 2221 21 24 23 25

33 32 31 30 26

29 28

27

33

30

18

29

17 16

40 42

13 12 7

1

4 23

8

40 42

38

11 10

39

29

30

32 31

33

28 36

15 14

6

41 42 40

9 1011

40

39 38 37

5

35 34

43

44 45 46

830KPT16

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

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

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

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

2-46

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

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

(4) Brake assembly

3 4

4 3

6

2

8

9

1

10 11

2 3

12 4 5 5

11 4

12

3

11 13

6

14 7 8

13 9

10

14 11 12 830KPT17

1 2 3 4 5

Outside brake Piston Square seal ring Dust shroud Braking plate

6 7 8 9 10

O-ring Inside brake Washer Joint Exhaust plug

2-47

11 12 13 14

Washer Bolt Split pin Bolt pin

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

SECTION 3 BRAKE SYSTEM GROUP 1 STRUCTURE

3

6

3 1

7

5

2 4

830KBS01

1 2 3 4

5 6 7

Air brake valve Air tank Air booster Oil and water separator

3-1

Safety valve Front axle Rear axle

GROUP 2 AIR BRAKE CIRCUIT

FRONT AXLE

REAR AXLE

E/G AIR COMPRESSOR

830KBS01A

1 2 3 4

5 6 7 8

Air brake valve Air tank Air booster Oil and water separator

3-2

Safety valve Auto water drain Brake lamp air pressure switch Pressure switch and sensor

GROUP 3 COMPONENTS SPECIFICATION AND FUNCTION 1. BRAKE VALVE 1) USE AND STRUCTURE As a main device of foot brake, this unit adopts high technology and can be applied to single circuit braking system of machines. 2) WORKING PRINCIPLE When the brake pedal (2) is pressed, the rod (3) presses the equalizing spring (4) to produce a pressure, which then pushes the piston (6) to move down to make intake valve (7) to open allowing compressed air to flow from inlet to outlet port. When brake pedal (2) is released, return spring (5) pushes the piston (6) to move up to make intake valve to return to original position to close air flow between inlet and outlet. Remaining pressure at outlet is vented through exhaust port. 3) TECHNICAL DATA (1) Operating air pressure : 784 kPa (2) Working temperature : -30 ~ +80˚C (3) Working medium : air 4) MOUNTING AND CONNECTION SIZE (1) Connection screw : M22×1.5 (3EA) (2) Mounting : 4-ø9 (3) Dimensions : 136×136×335 5) CORRECT USE AND MAINTENANCE (1) Notes in using ① Before mounting, remove the plugs for inlet and outlet, and be sure to have the pedal and valve body are securely assembled. Valve clearance should be adjusted properly with adjusting screw (pressure of surplus for the roller to press the rod should be less than 0.5 mm) and fasten up the nut. ② Insert M8 bolts through 4-ø9 holes to make secure assembly. ③ When connecting with piping, distinguish inlet port from outlet. Marking “1” means, inlet, “2” means outlet and “3” exhaust port. (2) Notes in Maintenance ① There should be water draining and filtering devices in air circuit to secure a clean air source. Anti-rust process is required for the brake tubes and air cylinder. ② A space should be secured for freely moving of the pedal. ③ When replacing a wearing part, use a part same with the worn, the damaged fastening pieces (such as stop ring, bolt) must also be replaced. All parts should be assembled in correct position securely and no other part be damaged. After replacing, do not assemble to the machine before completing test. ④ The moving part of air brake valve should be served grease. If the brake doesn’t grip properly or grips weakly, check the wearing parts of air brake valve and braking system.

3-3

6) TROUBLESHOTTING Trouble

Cause

Remedy

Air leaks under no work.

Worn rubber.

Replace rubber or assembly.

Air leaks under work.

Worn rubber.

Replace rubber or assembly.

Unsmooth exhaust.

Seizing of piston.

Replace the assembly.

Improper adjustment of pedal roller and rod.

Adjust the adjusting screw manually to the extent that pedal roller is just contacting the rod. (Pressure of surplus for the roller to press the rod should be less than 0.5 mm)

7) STRUCTURE AND MOUNTING SIZE

View A

Air outlet

Air intlet

Air outlet

850KBS10

1 2 3

Bolt Pedal Rod

4 5 6

Equalizing spring Spring Piston

3-4

7

Intake valve

2. SAFETY RELIEF VALVE 1) USE AND STRUCTURE Safety relief valve automatically drains condensate inside the air cylinder of brake line and manual drainage is also available. 2) WORKING PRINCIPLE Safety relief valve is used to automatically drain condensate inside the air cylinder of brake line by variation of air pressure (air pressure drops 0.03~0.1 MPa) and manual drainage is also available after parking for fast drainage. 3) TECHNICAL DATA (1) Rated operating air pressure : 800 kPa (2) Working temperature : -30 ~ +80˚C (3) Weight : 0.1 kg 4) MOUNTING AND CONNECTION SIZE (1) M22×1.5 (2) Exhaust port down. 5) STRUCTURE AND MOUNTING SIZE To connect air cylinder

Manual drainage button Exhaust port 850KBS13

3-5

3. SAFETY VALVE 1) USE AND STRUCTURE Safety valve is used to ensure that charge pressure of air brake line does not exceed 900 kPa. 2) WORKING PRINCIPLE Compressed air flows in through air inlet and, when the pressure at inlet exceeds 850 kPa, the safety valve A is actuated for air relief to protect the air brake line. 3) TECHNICAL DATA (1) Safety operating pressure : 850~900 kPa (2) Working temperature : -40 ~ +80˚C 4) MOUNTING AND CONNECTION SIZE Inlet M16×1.5 is connecting screw. 5) NOTES IN USING Adjusting bolt of safety valve has been already set as delivery and user is not permitted to adjust or remove the part as his/her wish. 6) TROUBLESHOOTING Problem Leaks at valve port

Cause

Remedy

Damaged rubber of safety valve stem assy.

Replace safety valve assy

7) STRUCTURE AND MOUNTING SIZE

Adjusting bolt

Air outlet

Air inlet 850KBS14

3-6

4.OIL AND WATER SEPARATOR 1) STRUCTURE Oil and water separator combined valve is applicable to brake system. This device features automatic control of working pressure in brake system and auto drainage of oil and water after filtering. Since the unit has a built-in protector, safe pressures can be guaranteed. 2) WORKING PRINCIPLE Air under pressure from compressor flows into the valve through air inlet and water and impurities can be filtered off through a strainer. After filtering, the compressed air reaches the outlet through one-way valve to charge the cylinder. When the pressure inside cylinder reaches opening pressure, air that enters into top head overcomes resistance of pressure spring to push control valve assy to move upward to open the exhaust valve at the lower part to discharge the air along with filtered impurities and water into atmosphere and compressor becomes idle state. When the pressure inside air cylinder drops to exhaust stop value and the air inside cavity of top head can not overcome the pressure spring, control valve moves down, and the exhaust valve moves up by the action of spring to stop exhaust valve and air supply to cylinder is restarted. 3) TECHNICAL DATA (1) Opeing pressure : 784±20 kPa (2) Exhaust stop pressure : 685 ~ 750 kPa (3) Working temperatures : -30 ~ +100˚C (4) Weight : 1.8 kg 4) MOUNTING AND CONNECTION SIZE (1) Mounting size : 2-M8×40 double end stud (2) Connection size : Inlet (M22×1.5), outlet (M22×1.5) (3) Dimensions : 150.5×128.5×220 MAINTENANCE AINTENANCE 5) CORRECT USE AND M (1) Notes in using ① Before mounting, remove the plugs for inlet and outlet. ② Mount the unit on the mount plate with outlet down. ③ Pressure regulator screw and safety valve have been set as delivery and user is not permitted to adjust or remove by his/her self. (2) Notes in maintenance ① The length of pipe from air compressor to combined valve should not be less than 2 m, aperture not less than ø12 to ensure fully cooling of hot air and condensing moisture in air. ② If severely worn wearing part or air leaks is found, immediately replace the wearing part. ③ When replacing a wearing part, use a part same with the worn, the damaged fastening pieces (such as bolt and nut) must also be replaced. All parts should be assembled in correct position securely and no other part be damaged. After replacing, do not assemble to the machine before completing test.

3-7

6) TROUBLESHOOTING Problem Leaks eaks at exhaust port.

Leaks eaks at top head vent

Cause

Remedy

Polluted exhaust valve.

Clean pipe line.

Damaged exhaust valve.

Replace exhaust valve.

Damaged diaphragm.

Clean pipe line.

Damaged control piston O-ring.

Replace control piston O-ring.

7) STRUCTURE AND MOUNTING SIZE

Air outlet Air inlet

850KBS16

3-8

SECTION 4 STEERING SYSTEM Group Group Group Group

1 2 3 4

Hydraulic circuit --------------------------------------------------------------------------------------------------- 4-1 Structure and function ----------------------------------------------------------------------------------------- 4-5 Operational check and troubleshooting ------------------------------------------------------------ 4-18 Test and adjustments ------------------------------------------------------------------------------------------ 4-24

SECTION 4 STEERING SYSTEM GROUP 1 HYDRAULIC CIRCUIT 1. STEERING CIRCUIT 5

L

R

P

T

7

MCV

B

6 T A

1 T/C

10 11 8

9

830K3HC03E

1 5 6

Main pump Steering cylinder Streering valve

7 8 9

Steering unit Return filter Bypass valve

4-1

10 11

Air breather Hydraulic tank

2. NEUTRAL

5

7

R

L

G

P

MCV

T

B

6 T

A

1 T/C

10 11 8

9

830K3HC34

The steering wheel is not being operated so control spool (G) does not move. The oil from the steering pump enters port P streeing unit (7) and returns to hydranlic tank through the spool (G).

4-2

3. LEFT TURN 5

7

R

L

G

H

P

MCV

T

B

6 T

A

1 T/C

10 11 9

8

830K3HC35

When the steering wheel is turned to the left, the spool (G) within the steering unit (7) connected with steering colurm turns in left hand direction. At this time, the oil discharged from the steering pump flows into the spool (G) of the steering unit (7) and flows into the gerotor (H). Oil flow from the gerotor flows back into the spool (G) where it is directed out the left work port (L) to the respective chamber of the steering cylinders (5). Oil returned from left and right cylinder returns to hydraulic tank through the spool (G) of the steering unit. When the above operation is completed, the machine turns to the left. 4-3

4. RIGHT TURN

5

R

L

7

G

H

P

MCV

T

B

6 T

A

1 T/C

10 11 8

9

830K3HC36

When the steering wheel is turned to the right, the spool (G) within the steering unit (7) connected with steering colurmn turns in right hand direction. At this time, the oil discharged from the steering pump flows into the spool (G) of the steering unit (7) and flows into the gerotor (H). Oil flow from the gerotor flows back into the spool (G) where it is directed out the right workport (R) to the respective chamber of the steering cylinders (5). Oil returned from left and right cylinder returns to hydraulic tank through the spool (G) of the steering unit. When the above operation is completed, the machine turns to the right. 4-4

GROUP 2 STRUCTURE AND FUNCTION 1. STEERING PUMP

LOADER PUMP

10 11

1

2

3

4

5

6

12

14 13

9 7 8

23 19 20

24

21 22

18 17 16 15

STEERING PUMP

830KSE15E

1 2 3 4 5 6 7 8

Snap ring Oil seal Front cover Snap ring Bearing Bushing Seal Seal

9 10 11 12 13 14 15 16

Side plate Drive gear Driven gear Seal Seal Middle body Seal Shaft

4-5

17 18 19 20 21 22 23 24

Pump body Rear cover Decal Rivet Washer Bolt Seal Bolt

2. STEERING UNIT 1) STEERING GEAR

850KSE12

1 2 3 4 5 6 7 8 9

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

10 11 12 13 14 15 16 17 18

X-ring O-ring Front cap Spring washer Bolt Cap screw Washer Bar End cap

4-6

19 20 21 22 23 24 40 41

Spacer O-ring Gerotor Gerotor Drive Plate Pin Ball

2) OVERLOAD VELVE

850KSE13

25 26 27 29 30

Plug O-ring Housing Spool Spring

31 32 33 34 35

Spring seat Plug (adjusting screw) Plug Plug O-ring

4-7

36 37 38 39

Spool Ball Poppet Spring

3) INSTRUCTION FOR USE OF STEERING GEAR AND COMBINED OVERLOAD VALVE ■ ·

·

STEERING STEERIN G GEAR When the cycloid rotary valve and non reaction type steering gear, the oil inlet and return port are interconnected and two cavities of hydraulic cylinder are in close state. External force applied to hydraulic cylinder is transmitted to steering wheel but driver will not feel shaking from rough road. Partial parameters of steering gear: Max. operating pressure : 16 MPa Max. counter pressure : 6.3 MPa Constant counter pressure : ≤ 2.5 MPa

(1) Structure of steering gear For structure of steering gear, refer to page 4-6. The components of the system are as follows. ① Rotary follow-up valve consisting of spool, sleeve and valve body Controls direction of oil flow and its spool is directly connected with steering wheel and column. ② Cycloidal Cycloidal gear pair (a stator and a rotor) Detects motor to keep direct proportion between flow entering into steering cylinder and steering wheel angle as power steering and be the equal of hydraulic pump as manual steering. ③ Intermediate shaf shaftt and yoke linking rotor and valve sleeve Works to keep the valve sleeve synchronous with rotor as power steering while to transmit torque as manual steering. ④ Spring Spring leaf Ensures the follow-up valve to return to center when not in steering. ⑤ One-way val valve ve between inlet and return port As manual steering is made, this device allows the oil inside a chamber of steering cylinder to be pressed into another chamber through return port by the cycloidal gear pair while, as power steering is made, the device ensures that oil does not directly flow from P port into T port. Port A and B are connected to two chambers of steering cylinder and port P connected to hydraulic pump and port T to oil tank. (2) Working principle of steering gear When steering gear is on center, the valve spool and sleeve are located in center by action of spring leaf. Flow from pump is directed to spool through two rows of small holes in valve sleeve and the end of valve spool and then is backed to oil tank through port T. When the wheel is turned to right (or left), the spool is driven to turn to right (or left). Since there is a max. 10.5° turn between valve spool and sleeve, the spool has an angle of turn in reference to the sleeve, and the oil groove of spool is connected to oil inlet of sleeve. The flow from pump goes through valve sleeve, oil groove of spool, and further to rotor and stator from the sleeve to push the rotor to turn in reference to stator and, at the same time, the flow from rotor and stator goes through valve sleeve and is directed to a chamber of steering cylinder via port A (or B) to cause the piston rod extending (contracting) to push the steering wheel to turn to right (or left), while the flow in the other chamber of cylinder is directed to valve sleeve via port B (or A) and goes through the return groove of spool and then return groove of sleeve to return to oil tank through port T. Oil circuit becomes current from approx. 1.5˚ of relative angle between valve spool and sleeve and rotation of the rotor causes oil to flow into cylinder. Oil amount is in direct proportion with angle of steering wheel. 4-8

Manual steering : Manual When engine stops or steering pump is malfunctioned, this type of steering gear allows turning of steering wheel manually by static pressure. When the steering wheel is turned to right (left), the valve spool turns for 10.5˚ to drive the sleeve, intermediate shaft and rotor by yoke. At the time, the stator and rotor work together as a pump. Rotation of rotor sucks oil out from port T and the flow goes through one-way valve, valve sleeve and spool, into inlet cavity of rotor pump. Manual turning of rotor pump pressurizes oil to make the flow to be directed to a chamber of steering cylinder to extend the piston rod (contract) causing the wheels to turn to right (left). Flow in another chamber goes via port B (A) through valve sleeve, spool, then is directed from the sleeve to inlet cavity of rotor pump through one-way valve, being constantly supplied to large (small) chamber to realize steering. To guarantee realization of manual steering, the steering gear should not be mounted in a position 0.5 m higher than oil level of oil tank for better oil suction effect. (3) Using, disassembly and assembly · Using steering gear ① Mounting When mounting steering gear, be sure to keep in line with steering column (coaxial), and there should be a clearance axially to prevent the valve spool to become stuck. After assembly, check the steering wheel can return smoothly. Oil line should be laid by marking of four ports: P is connected to pump, T to tank, A and B to left and right chamber of steering cylinder respectively. ② Test operation a. Before operation, clean the oil tank and refill to the max. level, loosen the steering cylinder screw connector, run oil pump in slow speed to bleed to the extent no foam is seen in out flowing oil. b. Disconnect piston rod from steering arm, turn steering wheel to the left and right extremes (do not stop at two extremes) and refill oil into tank to the max. level again. c. Fasten up all the screw connections (do not fasten under hydraulic pressure), connect piston rod to steering arm, check that system pressure meets the specified value as piston reaches extremes, check steering system works normally in any operating conditions and, when steering is not smooth, find out the reasons carefully, do not turn the wheel forcibly, nor disassemble the steering gear in a hurry to prevent parts to be damaged. Using and Maintenance ③ Check oil leaks daily, oil level in tank and operation, replace filter element and drawing liquid. When any problem is found, never turn the steering wheel by two people together.

4-9

· Disassembly of steering gear ① Typically, there are two kinds of orders for disassembling a steering gear, i.e. solution A and solution B. a. Front cover → small snap ring → bearing → large snap ring → valve spool & sleeve → yoke → spring leaf, rear cover → stop → stator → rotor → intermediate shaft → partition disc → steel ball → valve body. b. Rear cover → stop → stator → rotor → intermediate shaft → partition disc → steel ball → valve spool & sleeve → yoke → spring leaf → small snap ring → bearng → large snap ring → front cover → valve body. ② Notes in disassembly Be careful not to make the working or end surface of any part to be damaged or scratched when disassembling. Do not put the rubber rings disassembled in gasoline to prevent from deformation or deterioration due to reaction with gasoline. · Assembly of steering gear ① Order of assembly: Valve spool → valve sleeve → yoke → spring leaf → large snap ring → bearing → small snap ring → valve body → front cover → steel ball → partition disc → intermediate shaft → rotor → stator → stop → rear cover. ② Notes when assembling a. Clean all parts with gasoline or kerosene before assembling (except for rubber ring). Paint on junction surfaces should be cleaned with acetone. Never use cotton fabrics or cloth to clean the parts, but use soft brush or silk. It’s the best to use compressed air to blow clean. After assembling steering gear, add 50~100 ml hydraulic oil via the oil filler, turn the valve spool to left and right and check if there is problem before assembling to the machine. b. Junction surface of valve body, partition disc, stator and rear cover must be highly clean and there should no scratches or damages. c. There is a mark each on the stator and shaft end and be careful to make correct assembly in the matching positions of shaft notch and internal hole of spline. d. Conforming washer must be used for rear cover bolt. e. When fastening 7 bolts for rear cover, fasten in order and every other two bolts, fasten up gradually to a torque of 4.1 ~ 5.1 kgf·m (29.7 ~ 36.9 Ibf·ft). f. Port of P, T, A, B should must be connected in one-to-one correspondence.

4-10

6) TROUBLESHOOTING Problem Oil leaks

Cause

Remedy

Damaged O-ring at journal Replace O-ring. and overflow valve. Oil leaks at connections of Clean off dirt on junction surface, grind valve body, partition disc, scratches, and fasten up screws stator and rear cover. according to notes in assembly.

Steering is light under no load (or Pressure of overflow valve is Adjust the pressure of overflow valve l i g h t l o a d ) b u t h e a v y w h e n lower than that of steering to a specified value, or clean the increasing load system or overflow valve is overflow valve. clogged. Steering is light as slowly turning Insufficient oil supply of Select a suitable pump. Check hydraulic while heavy as fast hydraulic pump. pump for normal operation ad check if the volumetric efficiency is too little. Steering is heavy as fast or slowly Malfunction of one -way If steel ball is missing, load ø8 steel turning and no steering pressure. valve inside the valve body. ball. If steel ball is stuck by dirt, clean. Foam is in oil, irregular sound is Air in steering system. heard, cylinder moves and stops from time to time Steering is heavy

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

Oil tank is not full, or oil Refill oil to specified level. viscosity too high. Use recommended fluid.

Severe steering deviation. Cylinder Malfunction in t wo -way Clean two-way buffer valve, or replace will not move as turning steering buffer valve (steel ball is spring. wheel (or moves slowly) seized due to dirt, or spring failure). Disordered oil distribution. Steering Reversed locations of rotator Reassemble referring to notes in wheel turns itself or shakes and intermediate shaft. assembly. Obvious increase in vibration by Broken or deformed yoke, Replace yoke, replace intermediate pressure. Further, the wheel could broken or deformed opening shaft. Substitution with other object is not turn of intermediate shaft. forbidden. Steering wheel could not return to Steering column and valve Troubleshoot after finding out the cause. center. Steering gear could not spool are not coaxial. unload when steering wheel stops Steering column has pushed turning the valve spool to be stuck. Too much steering column rotating resistance. Broken or deformed spring leaf. Steering cylinder moves little at first Too low oil level in oil tank Refill oil to specified level. and then will not as manual steering (oil in cylinder has returned to oil tank). As power steering, cylinder piston Too much radial or axial Replace rotor and stator. If axial reaches the ex treme and driver clearance at rotor and stator clearance has become too large, grind could not feel the extreme clearly. due to long time of use. the end surface of stator. Steering cylinder will not move as manual steering No manual steering

Too high oil viscosity.

4-11

Use recommended oil.

■

OVERLOAD VALVE (1) Overview The overload valve is a combined valve for full hydraulic steering gear, and can be directly assembled to four port flanges of steering valve body to become integrated one. (2) Structure and working principle The overload valve consists of a one-way valve, overflow valve and two-way buffer valve, which guarantee stable steering performance, safety and reliability. · Featu Features res ① Compact design, easy installation, space efficiency. ② Flexible pressure regulation, no leaks. ③ Combined valve can simplify hydraulic system and has low costs. Structure ure · Struct ① One-way valve has a taper structure, consists of a valve seat, spool and spring and is fitted to inside of oil inlet of valve body. This valve features light resistance and good sealing. High pressure oil from hydraulic pump must pass through one-way valve to reach steering valve body. This one-way valve is designed to prevent operation of hydraulic system from being broken due to deflection of steering wheel because of return of oil to pump due to oil pressure in cylinder being higher than operating oil pressure that is caused by obstruction to steering wheel in special situations. One-way valve needs not adjustment in normal use, but reverse oil leaks should be prevented. ② Overflow valve is of differential and direct-acting type consisting of a differential valve seat, spool, spring, pressure regulating bolt and locking bolt. This device is attached to oil inlet and return port of overflow valve body featuring simple structure and stable operation. Its function is to prevent from overload, control pressure difference between inlet and return side to assure stable pressure. This device has also the function to unload and overflow and is called as safety valve. This valve also features regulation by loosening locking bolt and turning regulating bolt. After regulating pressure, fasten the locking bolt. ③ Two-way buffer valve includes two direct-acting overflow valves and consists of a spring, two ball valve seats and two steel balls. This device is attached to the valve body to the each port of two chambers of steering cylinder. The ports are connected to return port. The product features simple structure and easy manufacture and repair, and functions as two safety valves to unload and make oil returning when pressure in a chamber of cylinder increases as speedy steering or vehicle travel encounters sudden variation in resistance to protect the oil circuit between steering cylinder and steering gear, assuring safe and reliable steering. Opening pressure of the valve is 5~6 MPa higher than operating pressure of steering gear. (3) Installation and requirements in using ① Installation Be sure to make correct connection of four ports, i.e., P, T, A and B when installing the valve block on the flange at the steering gear side. Be careful to keep clean junction surface of flange and prevent dirt from entering into the system. Four O-seal rings in between valve block and steering gear flange should be laid flat, two screws fastened at even fastening torque, 40~50 N.m. Be sure that valve block is not twisted.

4-12

4) TROUBLESHOOTING Problem

Cause

Remedy

Steering is light under no Pressure of overflow valve inside valve Regulate the pressure in overflow load (or little load) but block is lower than required steering valve. heavy as load is increased. pressure. Overflow valve is seized by dirt, or Clean overflow valve, replace spring or spring or oil seal failed. seal ring. Vehicle travel is deflected, Failed two-way buffer valve (steel ball Clean two-way buffer valve, replace or cylinder will not move (or is stuck by dirt or spring failed), failed spring or seal ring. slowly) when turning wheel. seal ring. P r e s s u r e c o u l d n o t b e Broken spring. Replace spring. r e g u l a t e d ( i n c r e a s e o r Poor sealing at valve port causes valve Set the spool and seat, or replace part. decrease). constant open. Valve spool is stuck due to burr or oil Remove, inspect and repair. stain. Unstable pressure, with Poor contact between valve spool and Set the valve spool and seat, or f r e q u e n t n o i s e a n d seat. replace part. vibration. Poor spool motion. Check valve spool for being stuck by dirt. Bent or too weak spring.

Replace spring.

Dirty oil, clogged damping hole

Change fluid, clean damping hole

Flow exceeds specified value.

Replace with a larger flow valve.

4-13

3. STEERING VALVE

850KSE14

1 2 3

Body Snap ring Spool

4 5 6

O-ring Spring Spring seat

4-14

7 8

Plug Damping plug

1) OVERVIEW The steering valve is used for full hydraulic steering gear to ensure a stable fluid flow for steering gear in case fluid flow from the pump and load of hydraulic system fluctuate and to meet the requirements for steering performance and stable steering. In addition to above features, this valve also divert a current of hydraulic oil to other hydraulic devices and, consequently, the system can delete an oil pump and simple design is also available. 2) STRUCTURE AND WORKING PRINCIPLE The steering valve consists of valve body, a spool, a spring and a damping plug. The steering valve just works in one-way and extra oil than supply for steering system and overflow from safety valve all returns to oil tank through port T. 3) REQUIREMENTS IN USING (1) Installation : The steering valve should be mounted such that the axis of valve spool is level as far as possible. (2) After setting pressure, do not loosen the safety valve. Adjusting washer/shim of safety valve should not be altered as user wishes. When change of washer/shim is required for variation, test must be performed on a test bed. (3) Difference of pressure between before and after constant orifice is already set as delivery, and do not alter the valve spool spring optionally. If change of difference of pressure is required, be sure to make adjustment on a test bed for setting min. constant flow. (4) Nominal flow of oil pump supporting the steering valve is 1~3 times of that of steering valve. To secure normal operation of vehicle and steering system, the flow of oil pump as low speed operation should not be less than nominal flow of the steering valve. (5) Return piping of steering valve should be short as far as possible. Inside diameter of return piping should be relatively large.

4-15

4) TROUBLESHOOTING Problem Decrease in nominal stable flow is less than the flow required for steering gear for 60 turn/min

Cause

Remedy

Volumetric efficiency of supporting Replace or repair pump. pump has increased, or the pump delivers a flow less than nominal stable flow as low speed operation. Hydraulic oil is not clean. The spool of Clean the filter element and change steering valve or safety valve is stuck hydraulic oil. due to impurities. Broken or deformed spool spring or Replace spring. safety spring. Improper spool clearance of steering Repair or replace. valve and increased inside leaks. Damaged seal ring at safety valve Replace seal ring. seat.

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

The spool of steering valve is stuck Clean the filter element and change due to impurities. hydraulic oil. Poor compression of spool spring of Check condition of assembly. steering valve. Clogged damping hole of valve spool.

Clean the filter element and change hydraulic oil.

Pressure of safety valve is Improper setting of opening pressure Under stable nominal flow, regulate the on the low side or too high of safety valve. pressure of safety valve. Add or subtract pressure regulating washer/ shim. Compression of safety valve spring is Check the spring the mounting size. on the low side or over compressed. Safety valve spool and seat are not in Replace part. close contact. Oil seeps & leaks

Damaged O-ring

Replace O-ring.

4-16

4. STEERING CYLINDER 25 6 7

24 3 23

2

1

5

4

21

22 15 14

1 9

8 15 26

13 30

27 16

29 12 11 28 10 830KSE15A

1 2 3 4 5 6 7 8 9

Dust seal Rod wiper O-ring Rod seal Buffer ring O-ring Snap ring Washer Nut

10 11 12 13 14 15 16 21 22

O-ring Piston ring Wear ring Screw Joint bearing Snap ring O-ring Rod assy Bushing

4-17

23 24 25 27 28 29 30

Cylinder head Bushing Back up ring Clamp Piston Nut Tube assy

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

4-18

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

Description

Steering unit check

Run engine at low idle.

Service action OK Check completed.

B

A

Turn steering wheel until frames are at maximum right (A) and NOT OK then left (B) positions. Go to next check. LOOK : Frames must move smoothly in both directions. When steering wheel is stopped, frames must stop. FEEL : Excessive effort must not be required to turn steering wheel. NOTE : It is normal for steering to drift from stops when steering wheel is released.

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

Right

Turn steering wheel rapidly until OK Check completed. frames are against stops. Hold approximately 2kgf on NO NOT T OK steering wheel. Do steering system leakage test in group 3 to Count steering wheel revolutions isolate the leakage. for 1 minute. Repeat test in opposite direction. LOOK : Steering wheel should rotate less than 5rpm. NOTE : Use good judgment; Excessive steering wheel rpm does not mean steering will be affected.

4-19

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

Slow or hard steering

Cause

Remedy

Low oil level.

Add recommended oil.

Restricted suction line.

Check.

Failed hydraulic pump.

Remove and inspect return filter for metal pump particles.

Stuck steering valve spool.

Remove and inspect steering valve spool.

Relief valve in steering unit stuck open.

Do relief cartridge leakage test.

Failed hydraulic lines.

Check.

Too much friction in the mechanical Lubricate bearings and joints of frame parts of the machine. or cylinders or repair if necessary. Check steering column installation. Cold oil.

Warm the hydraulic oil.

Worn hydraulic pump.

Do hydraulic pump performance check.

Low system relief valve setting.

Test and adjust if necessary.

Low overload relief valves setting.

Test and adjust if necessary.

4-20

Problem

Cause

Remedy

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

Check for foamy oil. Do steering system leakage check.

Worn steering unit.

Do steering unit neutral leakage test in group 4.

Spring without spring force or broken.

Replace springs.

Spring in overload relief valve broken.

Replace overload relief valve.

Gear wheel set worn.

Replace gear wheel set.

Cylinder seized or piston seals worn.

Replace defects parts.

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

Do steering system leakage check.

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

Do steering system leakage check.

Do steering unit leakage check.

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

Erratic steering

Spongy or soft steering

Leakage in steering system.

Do steering system leakage test in group 4.

Air in oil.

Check for foamy oil.

Low oil level.

Add recommended oil.

Loose cylinder piston.

Remove rod to inspect piston.

Damaged steering unit.

Remove and inspect.

Air in oil.

Check for foamy oil.

Low oil level.

Add recommended oil.

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

Tighten. Inspect.

Steering unit binding or B i n d i n g i n s t e e r i n g c o l u m n o r Inspect. steering wheel does not misalignment of column. immediately return to High return pressure. Check for a pinched or damaged return neutral when released line. Contamination in steering unit.

4-21

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. Worn or damaged steering unit.

Repair or replace steering unit.

Abrupt steering wheel Improperly timed gerotor gear in steering Time gerotor gear. oscillation unit. Steering wheel turns by Lines connected to wrong port. itself Worn or damaged steering unit.

Reconnect lines.

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

Align the steering column with steering unit.

Steering column and steering unit out of line.

Repair or replace steering unit.

Too little or no play between steering Adjust the play and, if necessary, column and steering unit input shaft. shorten the splines journal. Pinching between inner and outer spools. Contact the nearest service shop.

"Motoring" effect. Leaf springs are stuck or broken and Replace leaf springs. The steering wheel can have therefore reduced spring force. turn on its own Inner and outer spools pinch, possibly Clean steering unit or contact the due to dirt. nearest service shop. Return pressure in connection with the Reduce return pressure. reaction between differential cylinder and steering unit too high. Backlash

Cardan shaft fork worn or broken.

Replace cardan shaft.

Springs without spring force or broken.

Replace springs.

Worn splines on the steering column.

Replace steering column.

4-22

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.

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

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

Fill with clean oil and bleed the system.

Replace worn parts.

Replace or repair cylinder. Replace gear wheel set.

Spacer across cardan shaft forgotten.

Install spacer.

Steering wheel can be One or both anticavitation valves are Clean or replace defect or missing turned slowly in one or leaky or are missing in overload relief valves. both directions without the valves. steered wheels turning One or both overload relief valves are Clean or replace. leaky. Steering is too slow and Insufficient oil supply to steering unit, Replace pump or increase number of heavy when trying to turn pump defective or number of revolutions revolutions. quickly too low. Relief valve setting too low.

Adjust valve to correct setting.

Relief valve sticking owing to dirt.

Clean the valve.

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

Contact authorized man or shop.

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

Let machine run until oil is warm.

Too little steering force

Correct pump pressure.

Pump pressure too low.

4-23

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.

4-24

5) Start the filter caddy. Check to be sure oil is flowing through the filters. Operate filter caddy approximately 10 minutes so oil in hydraulic oil tank is circulated through filter a minimum of four times. ※ Hydraulic oil tank capacity 95ℓ(25.0 U.S. gal). Leave filter caddy operating for the next steps. 6) Start the engine and run it at high idle. ※ For the most effective results, cleaning procedure must start with the smallest capacity circuit then proceed to the next largest capacity circuit. 7) Operate all functions, one at a time, through a complete cycle in the following order: clam, steering, bucket, and boom. Also include all auxiliary hydraulic functions. Repeat procedure until the total system capacity has circulated through filter caddy seven times, approximately 30 minutes. Each function must go through a minimum of three complete cycles for a through cleaning for oil. ※ Filtering time for machines with auxiliary hydraulic functions must be increased because system capacity is larger. 8) Stop the engine. Remove the filter caddy. 9) Install a new return filter element. 10) Check oil level in hydraulic oil tank ; Add oil if necessary.

4-25

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

4-26

3. STEERING SYSTEM RESTRICTION TEST · SPECIFICATION Oil temperature 45±5˚C (113±9˚F) Engine speed High idle Maximum pressure 3.0MPa (30 bar, 430psi) at steering unit · GAUGE AND TOOL Gauge 0~7 MPa (0~70 bar, 0~1000 psi) 2EA · This test will check for restrictions in the steering system which can cause overheating of hydraulic oil. 1) Install temperature reader. (see temperature reader installation procedure in this group).

P

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

A

3) Connect fitting (A) and install gauge. Do not operate steering or loader functions or test gauge may be damaged. 4) Run engine at specification and read pressure gauges. If pressure is more than specification at the steering unit, inspect steering unit. 850KSE37

4-27

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 5-33). 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. Safety lock bar

6) Leakage is greater than specifications, repair or replace steering unit. 830KSE38

4-28

5. STEERING UNIT PRESSURE TEST · SPECIFICATION Oil temperature 45±5˚C (113±9˚F) Engine speed High idle Oil pressure 16 MPa (160 bar, 1160 psi) · GAUGE AND TOOL Gauge 0~35 MPa (0~350 bar, 0~5000 psi) Temperature reader 1) Connect gauge to test port. 2) Install temperature reader (see installation procedure in this group).

Test port

3) Install frame locking bar. Steering cylinder

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

Relief valve

5) Run engine at specifications and turn steering wheel rapidly hold approximately 22N (5lb force) pressure on wheel with frames locked. ※ If steering wheel is turned slowly, it will continue to with the frames locked. This will give an incorrect pressure reading. If steering wheel continues to turn rapidly with the frames locked, steering system leakage is indicated.

A

B

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

Safety lock bar

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

830KSE39

4-29

SECTION 5 WORK EQUIPMENT Group Group Group Group

1 2 3 4

Hydraulic circuit --------------------------------------------------------------------------------------------------Structure and function ---------------------------------------------------------------------------------------Operational checks and troubleshooting ---------------------------------------------------------Test and adjustments ------------------------------------------------------------------------------------------

5-1 5-8 5-21 5-31

SECTION 5 WORK EQUIPMENT GROUP 1 HYDRAULIC CIRCUIT 1. HYDRAULIC CIRCUIT 4

3

5

L

R

P

T

7 2 B2 A2 Boom

B1 A1

Bucket

B

6 T T

P

A

1 T/C

10 11 8

9

830K3HC01E

1 2 3 4

Main pump Main control valve Boom cylinder Bucket cylinder

5 6 7 8

Steering cylinder Steering valve Steering unit Return filter

5-1

9 10 11

Bypass valve Air breather Hydraulic tank

2. WORK EQUIPMENT HYDRAULIC CIRCUIT

4

3

2 B2 A2 Boom

B1 A1

Bucket

T

P

Steering system

1 T/C

10 11 8

9

830K3HC02E

1 2 3 4

8 9 10 11

Main pump Main control valve Boom cylinder Bucket cylinder

5-2

Return filter Bypass valve Air breather Hydraulic tank

1) WHEN THE BOOM CONTROL LEVER IS IN THE RAISE POSITION

4

3

2 B2 Boom

A2 B1

Bucket A1

T

P

Steering system

1 T/C

10 11 8

9

830K3HC21

· When the boom control lever is pulled back, the boom spool is moved to raise position. · The oil from main pump (1) flows into main control valve (2) and then goes to the large chamber of boom cylinder (3). · The oil from the small chamber of boom cylinder (3) returns to hydraulic oil tank (11) through the boom spool at the same time. · When this happens, the boom goes up.

5-3

2) WHEN THE BOOM CONTROL LEVER IS IN THE LOWER POSITION

4

3

2 B2 Boom

A2 B1

Bucket A1

T

P

Steering system

1 T/C

10 11 8

9

830K3HC22

· When the boom control lever is pushed forward, the boom spool is moved to lower position. · The oil from main pump (1) flows into main control valve (2) and then goes to small chamber of boom cylinder (3). · The oil returned from large chamber of boom cylinder (3) returns to hydraulic tank (11) through the boom spool at the same time.

5-4

3) WHEN THE BOOM CONTROL LEVER IS IN THE FLOAT POSITION

4

3

2 B2 A2 Boom B1 Bucket A1

T

P

Steering system

1 T/C

10 11 8

9

830K3HC23

· When the boom control lever is pushed further forward from the lower position, then the boom spool is moved to floating position. · The work ports (A2), (B2) and the small chamber and the large chamber are connected to the return passage, so the boom will be lowered due to it's own weight. · In this condition, when the bucket is in contact with the ground, it can be move up and down in accordance with the shape of the ground.

5-5

4) WHEN THE BUCKET CONTROL LEVER IS IN THE DUMP POSITION

4

3

2 B2 Boom

A2 B1

Bucket A1

T

P

Steering system

1 T/C

10 11 8

9

830K3HC24

· If the bucket control lever is pushed forward, the bucket spool is moved to dump position. · The oil from main pump (1) flows into main control valve (2) and then goes to the small chamber of bucket cylinder (4). · The oil at the large chamber of bucket cylinder (4) returns to hydraulic tank (11). · When this happens, the bucket is dumped.

5-6

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

4

3

2 B2 Boom

A2 B1

Bucket A1

T

P

Steering system

1 T/C

10 11 8

9

830K3HC25

· If the bucket control lever is pulled back, the bucket spool is moved to roll back position. · The oil from main pump (1) flows into main control valve (2) and then goes to the large chamber of bucket cylinder. · The oil at the chamber of bucket cylinder (4) returns to hydraulic tank (11). · When this happens, the bucket roll back.

5-7

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

LOADER PUMP

10 11

1

2

3

4

5

6

12

14 13

9 7 8

23 19 20

24

21 22

18 17 16 15

STEERING PUMP

830KSE15E

1 2 3 4 5 6 7 8

Snap ring Oil seal Front cover Snap ring Bearing Bushing Seal Seal

9 10 11 12 13 14 15 16

Side plate Drive gear Driven gear Seal Seal Middle body Seal Shaft

5-8

17 18 19 20 21 22 23 24

Pump body Rear cover Decal Rivet Washer Bolt Seal Bolt

2) MOUNTING REQUIREMENTS FOR GEAR PUMP (1) Before mounting the gear pump, check its normal rotating direction and for being suitable to whole system. (2) Entry of gear pump should keep clean and no pollution. Interfacing surface of entry and discharge should not be damaged and good sealing with O-ring seal should be guaranteed. (3) Check if the depth of mounting hole for gear pump is longer than the length of the shaft of pump so to prevent potential impact to the shaft and gear pump from burning out. Key shaft should be assembled normally. 3) NOTES IN USING (1) It’s strictly prohibited for user to disassemble the product, or the manufacturer will not guarantee the performance of product. (2) Viscosity of oil is dependant to temperature. When oil temperature increases, its viscosity decreases. Therefore, oil temperature should be maintained under 80˚C. To secure the gear pump working normally under different operating temperature, selected oil should feature little change by variation of temperature, and have good chemical durability and foam resistance. Use of ISO VG46 (ISO VG32, ISO VG68) anti-wear hydraulic oil is recommended. (3) No impurities from machine and corrosive substance should be in oil. There should be filtering devices with a precision of 25 µm in the system where the gear pump is working for. (4) For transmission of gear pump, the manners that may produce radial force to pump (such as direct geared and pulley transmission) are not permitted. Shaft bushing or elastic coupling can be used. Requirements for concentricity: not more than 0.05 mm for shaft bushing type, no more than 0.1 mm for coupling type. Axial force is not permitted. (5) The entry and discharge of gear pump should be assembled securely and sealing be reliable. Or air may be included and oil leaks caused to lower the performance of gear pump. (6) Max. pressure and max. rate of gear pump means momentary peak values permitted during operation. Long time of continued use of gear pump may shorten its life span. (7) Check if the depth of mounting hole for gear pump is longer than the length of the shaft of pump so to prevent potential impact to the shaft and gear pump from burning out. (8) Before mounting the gear pump, check the rotating direction of pump meets requirement.

5-9

4) TROUBLESHOOTING Problem Noise in pump

Cause

Remedy

Air in system.

Fasten up all the connectors.

Insufficient oil supply.

Refill oil to an adequate level.

Cold oil.

Run slowly.

Contaminated suction filter.

Clean or replace the filter.

Too thin suction pipe.

Use a larger pipe.

Suction pipe is clogged.

Remove the obstruction.

Clogged air filter in oil tank.

Clean or replace the air filter.

Poor concentricity of pump and Inspect. input shaft. Severe resonance with tank, Check piping, elements and bolts for peripheral parts of piping. being securely fastened. Pump lags in response or no response

High oil temperature

Foam forms in oil

Insufficient oil supply.

Refill oil to an adequate level.

Improper pressure setting of Regulate the pressure of relief valve. relief valve. Worn or damaged pump.

Repair or replace.

Worn, leaking or stuck valve.

Repair or replace.

Too low pressure setting at overflow valve.

Regulate pressure of overflow valve.

Too low viscosity of hydraulic oil.

Use recommended hydraulic oil.

Too low oil level.

Refill oil to an adequate level.

Small tank.

Add an oil cooler or replace with larger tank.

Worn or damaged pump.

Repair or replace.

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

Use recommended oil.

Too low oil level.

Refill oil to an adequate level.

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

5-10

Problem Insufficient nsufficient flow of pump or pressure

Leaks occur even after replacing lip seal for main shaft

Cause

Remedy

Damaged side plate.

Replace side plate.

Air has entered into the system.

Fasten up all the connectors.

Too high viscosity of oil.

Use recommended oil.

Contaminated oil.

Change all the oil.

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

Replace seal ring.

5) NOTICE IN PLACING ORDER TURN RIGHT (CLOCKWISE)

TURN LEFT (COUNTER CLOCKWISE)

850K3HC52

5-11

2. MAIN CONTROL VALVE 1) STRUCTURE

16 17

15 12

13

18

19 20

14

11 10 9 8 7

21

6 5

22

4

23

3 2 1

29 28

34

33

32

31

27 15 14

12

26

25

24

13

30

830KSE17E

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

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

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

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

5-12

27 28 29 30 31 32 33 34 35 36 37

O-ring kit Plug Body Spool Spacer Spring Ball Spool positioner Washer Ring Snap ring

SAFETY RELIEF VALVE

20

2

21

19

22

18

3

17

23

4

16

24

15

5

6

14

25

13

12

1 11

850KSE18

1 2 3 4 5 6 11

Seal Lock nut Seal O-ring Seal Seal Seat

12 13 14 15 16 17 18

Back up seal Spring seat Spring seat Poppet Spring Housing Nut

5-13

19 20 21 22 23 24 25

Adjust screw Cap Body Washer Spring seat Spring seat Spring

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 DFS - XX -XX Product code Inner diameter Series code 4) TECHNICAL DATA Item

Unit

Specification

ℓ/min

160

Nominated pressure

MPa

16

Pressure regulating range

MPa

8 ~ 20

Center

MPa