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 Not Operate tag on the Do Operate 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. 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.

73031GE14

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 16C (60F).
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. 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. Use only recommended replacement parts. (See Parts catalogue.)

73031GE18

73031GE19

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. 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.
73031GE24

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. 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.
73031GE20

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

Tire

Head light

Hydraulic tank

Air cleaner

Raidator

Boom

Boom cylinder

Main control valve

Battery

Counterweight

Bell crank

Bucket cylinder

Cab

Main pump

Precleaner

Muffler Engine

Bucket link

Front axle

Steering cylinder Transmission Torque converter Rear axle Fuel tank

830K2SE01E

1-10

2. SPECIFICATIONS
1) WITH BOLT-ON CUTTING EDGE TYPE BUCKET CUTTING

F I

4880 3775 G

J H K D C E A
830K2SE03E

Operating weight Bucket capacity Overall length Overall width Overall height Ground clearance Wheelbase Tread Dump clearance at 45 Dump reach (full lift) Width over tires Dump angle Roll back angle (carry position) Cycle time Maximum travel speed Braking distance Minimum turning radius (center of outside tire) Gradeability First gear Forward Travel speed Reverse Second gear Third gear Fourth gear First gear Second gear Struck Heaped A B C D E F G H I J K Lift (with load) Dump (with load) Lower (empty)

40
48 570 95 0

Description

Unit kg (lb) m3 (yd3)

Specification 10200 (22490) 1.5 (2.0) 1.8 (2.4) 6830 (22' 5") 2450 (8' 1") 3235 (10' 7") 370 (1' 3")

mm (ft-in)

2850 (9' 4") 1850 (6' 1") 2865 (9' 5") 1075 (3' 6") 2300 (7' 7") 45 49 5.2 1.2 2.7 39.5 (24.5) 13.1 (43' 0") 4.90 (16' 1") 30 7.4 (4.6) 13.3 (8.3) 23.9 (14.9) 39.5 (24.5) 9.2 (5.7) 29.0 (18.0)

degree ()

sec km/hr (mph) m (ft-in) degree ()

km/hr (mph)

1-11

2) WITH TOOTH TYPE BUCKET

F I

4880 3775 G

J H K D C E A
830K2SE04E

Operating weight Bucket capacity Overall length Overall width Overall height Ground clearance Wheelbase Tread Dump clearance at 45 Dump reach (full lift) Width over tires Dump angle Roll back angle (carry position) Cycle time Maximum travel speed Braking distance Minimum turning radius (center of outside tire) Gradeability First gear Forward Travel speed Reverse Second gear Third gear Fourth gear First gear Second gear Struck Heaped A B C D E F G H I J K Lift (with load) Dump (with load) Lower (empty)

40
48 572 95 5

Description

Unit kg (lb) m3 (yd3)

Specification 10200 (22490) 1.4 (1.8) 1.7 (2.2) 6940 (22' 9") 2480 (8' 2") 3235 (10' 7") 370 (1' 3")

mm (ft-in)

2850 (9' 4") 1850 (6' 1") 2790 (9' 2") 1150 (3' 9") 2300 (7' 7") 45 49 5.2 1.2 2.7 39.5 (24.5) 13.7 (43' 0") 4.90 (16' 1") 30 7.4 (4.6) 13.3 (8.3) 23.9 (14.9) 39.5 (24.5) 9.2 (5.7) 29.0 (18.0)

degree ()

sec km/hr (mph) m (ft-in) degree ()

km/hr (mph)

1-12

3. SPECIFICATION FOR MAJOR COMPONENTS

1) ENGINE
Item Model Type Control type Cooling method Number of cylinders and arrangement Firing order Combustion chamber type Cylinder bore stroke Piston displacement Compression ratio Rated gross horse power Maximum gross torque at 1400~1600 rpm Engine oil quantity Dry weight High idling speed Low idling speed Rated fuel consumption (at rated) Starting motor Alternator Battery YC6J125Z-T20 4-cycle turbocharged diesel engine. Mechanical control Water cooling 6 cylinders, in-line 1-5-3-6-2-4 Direct injection type 105125 mm (4.1"4.9") 6494 cc (396 cu in) 17.5 : 1 92 kW / 2200 rpm 500 Nm 16(4.2 U.S. gal) 650 kg (1430 lb) 240050 rpm 72550 rpm 215 g/kWhr 24 V-6 kW 28 V-55 Amp 212 V120 Ah Specification

1-13

2) MAIN PUMP (+steering pump)

Item Type Capacity Maximum operating pressure Rated oil quantity Rated speed Specification Fixed displacement gear pump 10050 cc/rev 200 kgf/cm2 (2840 psi) 169/min (44.6 U.S.gpm) 2200 rpm

3) MAIN CONTROL VALVE

Item Type Operating method Main relief valve set pressure Overload relief valve set pressure 2 spool Mechanical control 160 kgf/cm2 (2280 psi) 180 kgf/cm2 (2560 psi) Specification

4) CYLINDER
Item Boom cylinder Bucket cylinder Steering cylinder Specification

Bore diaRod diaStroke 11065785 mm Bore diaRod diaStroke 16080380 mm Bore diaRod diaStroke 7045412 mm

5) DYNAMIC POWER TRANSMISSION DEVICES

Item Model Type Gear shift Control Drive devices Axle Front Rear Wheels Brakes Tires Travel Parking Type Steering angle Converter Transmission YJ315/BS428 Single-stage, Single-phase Mechanical, hydraulic Forward fourth gear, reverse second gear Mechanical single lever type 4-wheel drive Front fixed location Oscillation12 of center pin-loaded 17.5-25, 14PR (L3) Four-wheel, dry-disc type, pneumatic Disc type brake on transmission Hydraulic, articulated 40 to both right and left angle, respectively Specification

Transmission

Steering

1-14

4. TIGHTENING TORQUE OF MAJOR COMPONENT

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Others Power train Hydraulic system Engine Descriptions Engine mounting bolt (2EA) Engine mounting bolt (bracket) Radiator mounting bolt Fuel tank mounting bolt Main pump housing mounting bolt Main control valve mounting bolt Steering unit mounting bolt Steering valve mounting bolt Brake valve mounting bolt Control lever mounting bolt Hydraulic oil tank mounting bolt Transmission mounting bolt Transmission mounting bolt (bracket) Torque converter housing mounting bolt Front axle mounting bolt, nut Tire mounting nut Drive shaft joint mounting bolt, nut Counterweight mounting bolt Operator seat mounting bolt Cab mounting bolt (4EA) Bolt size M243.0 M121.75 M162.0 M162.0 M121.75 M121.75 M101.5 M101.5 M81.25 M101.5 M162.0 M243.0 M182.5 M121.75 M302.0 M201.5 1/2-20UNF M302.0 M81.25 M273.0 Torque kgfm 100 15 10.7 1.6 29.7 4.5 29.7 4.5 12.8 3.0 12.8 3.0 6.9 1.4 6.9 1.4 2.5 0.5 6.9 1.4 29.7 4.5 100 15 32.7 4.9 10.7 1.6 200 15 61 2.0 15.5 0.5 199 29.9 3.4 0.8 70 10 lbfft 723 108 77.4 11.6 215 32.5 215 32.5 92.6 21.7 92.6 21.7 49.9 10.1 49.9 10.1 18.1 3.6 49.9 10.1 215 32.5 723 108 237 35.4 77.4 11.6 1447 108 441 14.5 112 3.6 1439 216 24.5 5.8 506 72.3

1-15

5. TORQUE CHART
Use following table for unspecified torque. 1) BOLT AND NUT (1) Coarse thread
Bolt size kgm M 61.0 M 81.25 M101.5 M121.75 M142.0 M162.0 M182.5 M202.5 M222.5 M243.0 M303.0 M364.0 0.85 ~ 1.25 2.0 ~ 3.0 4.0 ~ 6.0 7.4 ~ 11.2 12.2 ~ 16.6 18.6 ~ 25.2 25.8 ~ 35.0 36.2 ~ 49.0 48.3 ~ 63.3 62.5 ~ 84.5 124 ~ 168 174 ~ 236 lbft 6.15 ~ 9.04 14.5 ~ 21.7 28.9 ~ 43.4 53.5 ~ 79.5 88.2 ~ 120 135 ~ 182 187 ~ 253 262 ~ 354 350 ~ 457 452 ~ 611 898 ~ 1214 1261 ~ 1703 kgm 1.14 ~ 1.74 2.73 ~ 4.12 5.5 ~ 8.3 9.8 ~ 15.8 16.7 ~ 22.5 25.2 ~ 34.2 35.1 ~ 47.5 49.2 ~ 66.6 65.8 ~ 98.0 85.0 ~ 115 169 ~ 229 250 ~ 310 lbft 8.2 ~ 12.6 19.7 ~ 29.8 39.8 ~ 60 71 ~ 114 121 ~ 167 182 ~ 247 254 ~ 343 356 ~ 482 476 ~ 709 615 ~ 832 1223 ~ 1655 1808 ~ 2242 8T 10T

(2) Fine thread

Bolt size kgm M 81.0 M101.25 M121.25 M141.5 M161.5 M181.5 M201.5 M221.5 M242.0 M302.0 M363.0 2.17 ~ 3.37 4.46 ~ 6.66 7.78 ~ 11.58 13.3 ~ 18.1 19.9 ~ 26.9 28.6 ~ 43.6 40.0 ~ 54.0 52.7 ~ 71.3 67.9 ~ 91.9 137 ~ 185 192 ~ 260 lbft 15.7 ~ 24.3 32.3~48.2 76.3 ~ 83.7 96.2 ~ 130 144 ~ 194 207 ~ 315 289 ~ 390 381 ~ 515 491 ~ 664 990 ~ 1338 1389 ~ 1879 kgm 3.04 ~ 4.44 5.93 ~ 8.93 10.6 ~ 16.0 17.9 ~ 24.1 26.6 ~ 36.0 38.4 ~ 52.0 53.4 ~ 72.2 70.7 ~ 95.7 90.9 ~ 123 182 ~ 248 262 ~ 354 lbft 22.0 ~ 32.0 42.9 ~ 64.6 76.6 ~ 115 130 ~ 174 193 ~ 260 278 ~ 376 386 ~ 522 512 ~ 692 658 ~ 890 1314 ~ 1795 1893 ~ 2561 8T 10T

1-16

2) PIPE AND HOSE (FLARE type)

Thread size (PF) 1/4" 3/8" 1/2" 3/4" 1" 1-1/4" Width across flat (mm) 19 22 27 36 41 50 kgfm 4 5 9.5 18 21 35 lbfft 28.9 36.2 68.7 130 152 253

3) PIPE AND HOSE (ORFS type)

Thread size (UNF) 9/16-18 11/16-16 13/16-16 1-3/16-12 1-7/16-12 1-11/16-12 Width across flat (mm) 19 22 27 36 41 50 kgfm 4 5 9.5 18 21 35 lbfft 28.9 36.2 68.7 130 152 253

4) FITTING
Thread size 1/4" 3/8" 1/2" 3/4" 1" 1-1/4" Width across flat (mm) 19 22 27 36 41 50 kgfm 4 5 9.5 18 21 35 lbfft 28.9 36.2 68.7 130 152 253

1-17

6. RECOMMENDED LUBRICANTS
Use only oils listed below or equivalent. Do not mix different brand oil.
Service point Kind of fluid Capacity (U.S. gal) Ambient temperatureC(F) -20 (-4) -10 (14) 0 (32) 10 (50) 20 (68) SAE 30 SAE 10W Engine oil pan Engine oil 16 (4.2) SAE 10W-30 SAE 15W-40 30 (86) 40 (104)

Transmission

Gear oil

40 (10.6)

ATF DEXRON

Axle

Gear oil

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

SAE 80W-90 SAE 85W-90

Hydraulic tank

Hydraulic oil

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

ISO VG 32 ISO VG 46 ISO VG 68

ASTM D975 NO.1 Fuel tank Diesel fuel 170 (44.9) ASTM D975 NO.2 NLGI NO.1 Grease As required NLGI NO.2 Mixture of antifreeze and water 50 : 50

Fitting (grease nipple)

Radiator

33 (8.7)

Ethylene glycol base permanent type

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

Item

OK

NOT OK

Comments

1. Cluster indicator and gauge checks (engine OFF)

Gauge check Battery check Cluster indicator circuit check Cluster turn signals and warning indicator check

2. Transmission checks
Transmission control lever and neutral

3. Cluster indicator and gauge checks (engine running)

Cluster display and alternator output checks Transmission temperature gauge check Transmission oil pressure gauge check Brake air pressure gauge check Engine coolant temperature gauge check

1-19

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

5. Driving checks
Transmission noise check 1st and 2nd speed clutch pack drag check Transmission pressure, pump flow and leakage check Torque converter check Engine power check

6. Hydraulic system checks

Hydraulic system warm up procedure Hydraulic pump performance check Control lever boom float check Bucket rollback circuit relief valve check Bucket dump circuit relief Low pressure check High pressure check Boom and bucket cylinder drift check

7. Steering system checks

Steering unit check Steering system leakage check

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

9. Cab components and vandal protection checks

Cab door latch check Cab door hold, open latch check Cab door release button check Cab door lock check Cab door window check Cab window latch check Seat and seat belt check Air intake filter door check Engine side panels check Radiator cap access door check Frame locking bar check Service decal check

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

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

9 10 11 12

Range gear sleeve Oil tray Front output flange Shoe brake

2-3

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

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

Gear

Lever Gear selector lever High low speed selector lever

Low speed

High.low speed selector lever High speed

Forward 1 2 3 4 Reverse 1 2

Low speed F High speed R F R

II I

Gear selector lever

III

830KPT19

2-4

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 Oil for transmission Oil pump Operating pressure Allowable oil temperature of oil tray Operating pressure of brake relief valve 2500 rpm 91.4 kgfm (661 lbfft) 82 kW Countershaft, constant mesh, hydraulic fork 3.82 2.08 1.09 0.59 3.05 0.87 AFT (DEXRON ) CB32 (no in transmission box) 1.4 ~ 1.6 MPa 100C >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 Brake valve T/C part Cooler

Control valve Torque converter valve block

Lubrication Oil cooling

Figure 4 Schematic diagram of oil system

1 2 3

Suction filtering device Transmission pump Transmission pressure valve

4 5 6

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

M221.5

M221.5

M221.5

Figure 5 Transmission control valve assembly assy

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 , D for clutch , E for clutch ) 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 - as illustrated in figure 5. (4) Inlet for spray oil of transmission is located in -. (5) Inlet for cooling transmission is located in -. (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 ) 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, its 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 doesnt exceed 105C, and 115C in short time, and that in the oil tray of transmission doesnt exceed 100C. 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 Check oil level in transmission. Check transmission for normal operation and driving gear for noise. Check the bolts and nuts for good tightness and check for oil leaks. (2) 250 hours maintenance Inspect operation and noise of transmission. Clean the filter. (3) 500 hours maintenance maintenance Renew oil. (4) 1000 hours maintenance Replace oil filter. (5) 2000 hours maintenance maintenance Inspect operation, input power, noise, oil temperature, oil leaks, etc. Clean air vent caps, fasten up screws and pipe fittings.

2-9

2) TROUBLESHOOTING
Problem Cause Remedy Repair. Repair. Repair. Repair. Service and repair. Replace. Replace. Check and repair. Repair. Clean. Renew oil. Clean. Renew oil. Replenish oil. Change to low gear. Adjust.

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. Too high oil pressure 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

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: If clearance of input shaft is too little, thickness of paper gasket may be increased or that of shaft bushing decreased. For adjustment of clearance for countershaft and reverse shaft, you may first loosen stop plate, and fasten adjusting screw, and then loosen a lock groove position (back for 0.125 mm axial clearance) and lock up the lock plate. Normal axial play of input shaft, countershaft and reverse shaft Normal axial play of input shaft, countershaft and reverse shaft should be 0.1~0.13 mm.

2-11

7. STRUCTURE

View K

1) OUTSIDE VIEW

Rear Front Range Gear lever

Oil return port Hi-Neutral-Lo

2-12
Flange C Output flange B Pressure oil port

View K

Input flange A

Oil spray port

Pressure tap

Cooling oil port

2) TRANSMISSION HOUSING (1/2)

66 9

3 2 62 7 65 63 64 1

6 5 11 10 8 21 22 23 24 8 27 25 29 9 9 15 14 12

13

17 11 16 6

30 26 28 13 22 15 14 8 9 18 19 20 9 52 34 35 32 33 31 5

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

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

2-13

TRANSMISSION HOUSING (2/2)

67 54 56 57 39 59 60 61 22 38 42 47 46 53 55 58 42 41 40 43 9 48 43 68 44 45 9

52 67 52

9 45 44 67

36

37

9 46 45 44 43

52

51 51 8

9 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

55 56 57 58 59 60 61 67 68

Vent plate Sleeve Plate Sleeve Long screw Casing Gasket Plug Plug

2-14

3) OUTPUT SHAFT
7 7 6 5 3 4 13 14 13 12 11 8 21 5 4 15 3 2 16 17 2 1 1

18 17

6 9 10 12 13 20 13 19 22 23 11 24

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

17 18 19 20 21 22 23 24

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

2-15

4) INTPUT SHAFT

13

12 11 9 8 14

10 8 6 7 4 12 3 5 23 22 9

25 26 29 5 28 27 24 21

30

32 31

33

20 19 16 17 18

15

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

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

2-16

5) INTERMEDIATE SHAFT

15

14 13 11 12 10 9 7 6 5 1 2 3 4 6 29 26 23 21 20 19 17 18
830KPT09

10 16

11

8 25 24

28 27

22

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

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

2-17

6) REVERSE SHAFT

15

14 13 16 12 11 27 25 24 29 26 23 22 21 18 17 19 20 28 11 10

10 9 6 5 1 23 4 7 8

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

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

2-18

7) HIGH-LOW SPEED SHIFT FORK

1 3

2 4

5 6 7

8 12 10 11 9 13

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

11 12 13

Washer Steel ball Spring

2-19

8) CONTROL VALVE

12

9 10 11 1 2 7 8 13 14 15 16 17 22 23 24 21 26 25 20 18 19 11 10 9 5 6 7 3 4 27 12

28

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

21 22 23 24 25 26 27 28

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

2-20

9) PARKING VALVE

5 3 2 1 2 1 19 20 14 13 3 6 18 27 16 11 28 29 8 9 10 10 17 23 14 21 22 4

7 7

15 12 25 26 24

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

21 22 23 24 25 26 27 28 29

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

2-21

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

830KTM10

(2) Unscrew the M201.5 bolts on the oil pan with a spanner and make drainage fully. M201.5 bolts

830KTM11

2) OIL PAN OF TRANSMISSION (1) Unscrew 20 - M1030 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. M1030 bolts
830KTM12

830KTM13

2-22

3) HAND BRAKE ASSY (1) Remove 4 - M1230 bolts on the left bracket of hand brake with a spanner.

830KTM14

(2) Remove 4 - M825 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 - M1025 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 - M1025 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 - 201.5 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 - M1030 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 - M1025 bolts on the end covers of input shaft, intermediate shaft and reverse shaft with a spanner and then use 2 - M1025 bolts to push the three end covers out and put them in a clean place. (3) Unscrew 8 - M1030 bolts on the rear end cover of output shaft and use 2 M1030 bolts to push the rear end cover out and put it in a clean place. 2-24

830KTM21

(4) Turn the transmission for other side and place it level. (5) Unscrew 5 - M1030 bolts on the oil inlet end cover of gear I, gear II and reverse gear with a spanner and then use 2M1030 bolts to push the three end cover out and put them in a clean place.

830KTM22

830KTM23

(6) Unscrew 4 - M1025 bolts on the seal cap of front output shaft with a spanner and use 2 - M1025 bolts to push it out and put in a clean place.

830KTM24

(7) Unscrew 13 - M1030 socket bolts on the large end cover with a socket wrench and then use 2 - M1045 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 - M816 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 M1025 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. (5) Use a tool to remove 60 retaining ring from clutch case, and then inner spring seat, spring and piston in order.
830KTM28

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 8 14

10 8 6 7 4 12 3 5 23 22 9

25 26 29 5 28 27 24 21

30

32 31

33

20 19 16 17 18

15

830KPT08

(1) Check the clutch valve seat (23) and internal steel ball (22) for looseness. (2) Use a spanner to screw up 8 - M1025 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- M1025 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 - M816 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 12 10 9 7 6 5 1 2 3 4 6 29 26 23 21 20 19 17 18
830KPT09

10 16

11

8 25 24

28 27

22

(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 - M1025 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 - M1025 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 - M816 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 11 27 25 24 29 26 23 22 21 18 17 19 20 28 11 10

10 9 6 5 1 23 4 7 8

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 - M1025 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-M1025 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 - M816 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 M825 bolts and M1230 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 (456212) 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 M1030 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 M1030 bolts.

830KTM48

(17) Mount the control valve assy and top plate and connect with 8-M1045 and 4 - M1035 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 Nominal torque at zero-speed loading Nominal torque at high efficiency loading Torque ration at zero-speed loading Max. efficiency Width of high efficiency region Net weight Dimensions 69.3 kgfm (502 lbft) 5.8 kgfm (42.2 lbft) 6.1 kgfm (44.1 lbft) 3.24 0.836 2.032 159kg 470530530 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 ). Oil temperature should be within 85~100C, and not exceed 110C 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) Its 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 /min

2-37

6. TROUBLESHOOTING
Problem Cause Increase engine rpm Increase engine rpm. Check transmission oil level. Check for tightness of tubing system. Check for deteriorated hydraulic oil. Lower oil temperature.

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

Too high hydraulic 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. Insufficient oil supply. Repair water tank. 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. Too low oil level in oil tank. Clogged suction filter. Failed pressure gauge. Oil leakage Damaged reinforced oil seal. Damaged O-ring. Add hydraulic oil. Clean or replace the filter. Replace the pressure gauge. Replace the oil seal. Replace the O-ring.

2-38

7. OUTSIDE VIEW

Lifting hole

Total 3 spots

Length of spline

Oil return port View A

er ent oc T
Total 3 positions of spline

Total 3 spots

2-39
Oil overflow port

Opening pressure

Pressure measuring port

ter cen To

Oil overflow port

View A

Overflow pressure

Opening pressure Torque converter oil supply system diagram

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 Max. load Max. input torque 235 kgfm (1700 lbfft) Total ratio Main ratio Wheel-end ratio Braking moment 979 kgf (7080 lbfft) Oil pressure

ZL30

18500 kg

20.26

4.222

4.8

9.8 MPa

3) THE STRUCTURAL CHARACTERISTICS AND WORKING PRINCIPLE (1) Main structural characteristics structural 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 Transmission route of drive axle as follows: 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 : 24(6.3 U.S.gal) Real axle : 24(6.3 U.S.gal) (2) Maintenance per 250 hours aintenance Inspect wear condition of braking discs and whether there are destructive wear on them. Inspect wear condition of braking plates. When the grooves on friction lining have been worn down and dont meet the requirement, should immediately replace. Inspect whether oil level at axle housing meets the requirement. If oil level lowers, should refuel oil in time. (3) Maintenance per 1000 hours Maintenance Lubricant in drive axle work per 1000 hours to replace once new oil. (4) Maintenance per 2000 hours per Should disconnect drive axle to inspect when it has worked for 2000 hours. Inspect spiral bevel gear pair backlash, mesh and wear condition of final drive. Inspect wear condition of differential gears and bevel gear washers. Inspect wear condition of wheel-end gears. Inspect wear condition of wheel-end planet gear needle rollers and bearings.

2-41

(6) Requirement of inspection and debugging projects in the course of use 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. 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 Problem Loud noise Housing body early heats Periodic unusual sound Cause 1. Gear backlash is oversize 2. Bearing is worn. Remdy Adjust gear backlash. Replace bearing.

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. 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. Cross pin breakage. Replace cross pin.

Differential failure 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. 1. Axle shaft breakage. 2. Differential system failure. Replace axle shaft. Adjust and replace differential system.

Wheel-end reductions

Wheel-end doesn't rotate

There is unusual sound Housing body early heats

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. 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. 1. Oil line disconnects or is clogged. 2. Piston O-ring ages and wears. 3. Piston and piston cylinder jam. 4. Hydraulic pressure isn't enough. Connect or replace oil line. Replace O-ring. Replace brake. Inspect oil pump and exhaust gas in oil line.

Brake

Braking failure

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) Cant knock and savagely handle drive axle in the course of carry and turnover.

2-43

8) STRUCTURE (1) Drive axle assembly

4 3 5 7 6

18

9 8 10 11 12 13

14

16 15

17

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

13 14 15 16 17 18

Nut Washer Bolt Bolt Washer Disc brake assy

2-44

(2) Wheel-end reductor

20 18 12 11 10 89 5 3 4 6 7 16 1314 15 17 19

1 2 10

28

30 31

37 23 32 29 26 24 21 22 25 27 28 35 36 33 34

37

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

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

2-45

(3) Final drive assembly

19

20 2221 21 24 23 25 30 26 27 18 29 28

33 32 31

30 29

33

17 16 13 12 7 4 23 6 9 1011 5 44 45 46 43 8 11 10 15 14 42 40 38 39 40 42 40 42 29 28 36 41 40 39 38 37 35 34 30 32 31 33

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

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

2-46

(4) Brake assembly

3 4

4 3 2 6 8 1 2 3 4 5 5 4 3 6 7 8 9 10 11 12
830KPT17

10 11 12

11 12 11 13 14 13 14

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

11 12 13 14

Washer Bolt Split pin Bolt pin

2-47

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 1

2 4

830KBS01

1 2 3 4

Air brake valve Air tank Air booster Oil and water separator

5 6 7

Safety valve Front axle Rear axle

3-1

GROUP 2 AIR BRAKE CIRCUIT

FRONT AXLE

REAR AXLE

E/G AIR COMPRESSOR

830KBS01A

1 2 3 4

Air brake valve Air tank Air booster Oil and water separator

5 6 7 8

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

3-2

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 ~ +80C (3) Working medium : air 4) MOUNTING AND CONNECTION SIZE (1) Connection screw : M221.5 (3EA) (2) Mounting : 4-9 (3) Dimensions : 136136335 5) CORRECT USE AND MAINTENANCE (1) Notes in using Before mounting, remove the plugs for inlet and outlet, and be sure to have the pedal and valve body are securely assembled. Valve clearance should be adjusted properly with adjusting screw (pressure of surplus for the roller to press the rod should be less than 0.5 mm) and fasten up the nut. Insert M8 bolts through 4-9 holes to make secure assembly. When connecting with piping, distinguish inlet port from outlet. Marking 1 means, inlet, 2 means outlet and 3 exhaust port. (2) Notes in Maintenance There should be water draining and filtering devices in air circuit to secure a clean air source. Anti-rust process is required for the brake tubes and air cylinder. A space should be secured for freely moving of the pedal. When replacing a wearing part, use a part same with the worn, the damaged fastening pieces (such as stop ring, bolt) must also be replaced. All parts should be assembled in correct position securely and no other part be damaged. After replacing, do not assemble to the machine before completing test. The moving part of air brake valve should be served grease. If the brake doesnt grip properly or grips weakly, check the wearing parts of air brake valve and braking system.

3-3

6) TROUBLESHOTTING
Trouble Air leaks under no work. Air leaks under work. Unsmooth exhaust. Cause Worn rubber. Worn rubber. Seizing of piston. Improper adjustment of pedal roller and rod. Remedy Replace rubber or assembly. Replace rubber or assembly. Replace the assembly. 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

Intake valve

3-4

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 ~ +80C (3) Weight : 0.1 kg 4) MOUNTING AND CONNECTION SIZE (1) M221.5 (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 ~ +80C 4) MOUNTING AND CONNECTION SIZE Inlet M161.5 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 Damaged rubber of safety valve stem assy. Remedy 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 : 78420 kPa (2) Exhaust stop pressure : 685 ~ 750 kPa (3) Working temperatures : -30 ~ +100C (4) Weight : 1.8 kg 4) MOUNTING AND CONNECTION SIZE (1) Mounting size : 2-M840 double end stud (2) Connection size : Inlet (M221.5), outlet (M221.5) (3) Dimensions : 150.5128.5220 MAINTENANCE 5) CORRECT USE AND MAINTENANCE (1) Notes in using Before mounting, remove the plugs for inlet and outlet. Mount the unit on the mount plate with outlet down. Pressure regulator screw and safety valve have been set as delivery and user is not permitted to adjust or remove by his/her self. (2) Notes in maintenance The length of pipe from air compressor to combined valve should not be less than 2 m, aperture not less than 12 to ensure fully cooling of hot air and condensing moisture in air. If severely worn wearing part or air leaks is found, immediately replace the wearing part. When replacing a wearing part, use a part same with the worn, the damaged fastening pieces (such as bolt and nut) must also be replaced. All parts should be assembled in correct position securely and no other part be damaged. After replacing, do not assemble to the machine before completing test.

3-7

6) TROUBLESHOOTING
Problem Leaks at exhaust port. eaks Cause Polluted exhaust valve. Damaged exhaust valve. Leaks at top head vent eaks Damaged diaphragm. Damaged control piston O-ring. Remedy Clean pipe line. Replace exhaust valve. Clean pipe line. 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

MCV
T

6
A

1
T/C

10 11 9 8

830K3HC03E

1 5 6

Main pump Steering cylinder Streering valve

7 8 9

Steering unit Return filter Bypass valve

10 11

Air breather Hydraulic tank

4-1

2. NEUTRAL

MCV
T

6
A

1
T/C

10 11 9 8

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

MCV
T

6
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

MCV
T

6
A

1
T/C

10 11 9 8

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

14 13

10 11 5 6 9 7 8

12

23 19 20 18 17 16 15 21 22

24

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

17 18 19 20 21 22 23 24

Pump body Rear cover Decal Rivet Washer Bolt Seal Bolt

4-5

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

19 20 21 22 23 24 40 41

Spacer O-ring Gerotor Gerotor Drive Plate Pin Ball

4-6

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

36 37 38 39

Spool Ball Poppet Spring

4-7

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

STEERING STEERING 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. 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. Cycloidal gear pair (a stator and a rotor) Cycloidal Detects motor to keep direct proportion between flow entering into steering cylinder and steering wheel angle as power steering and be the equal of hydraulic pump as manual steering. Intermediate shaft and yoke linking rotor and valve sleeve shaft Works to keep the valve sleeve synchronous with rotor as power steering while to transmit torque as manual steering. Spring leaf Spring Ensures the follow-up valve to return to center when not in steering. One-way valve between inlet and return port valve 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 Manual steering : When engine stops or steering pump is malfunctioned, this type of steering gear allows turning of steering wheel manually by static pressure. When the steering wheel is turned to right (left), the valve spool turns for 10.5 to drive the sleeve, intermediate shaft and rotor by yoke. At the time, the stator and rotor work together as a pump. Rotation of rotor sucks oil out from port T and the flow goes through one-way valve, valve sleeve and spool, into inlet cavity of rotor pump. Manual turning of rotor pump pressurizes oil to make the flow to be directed to a chamber of steering cylinder to extend the piston rod (contract) causing the wheels to turn to right (left). Flow in another chamber goes via port B (A) through valve sleeve, spool, then is directed from the sleeve to inlet cavity of rotor pump through one-way valve, being constantly supplied to large (small) chamber to realize steering. To guarantee realization of manual steering, the steering gear should not be mounted in a position 0.5 m higher than oil level of oil tank for better oil suction effect. (3) Using, disassembly and assembly Using steering gear 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. 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 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 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. 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 Order of assembly: Valve spool valve sleeve yoke spring leaf large snap ring bearing small snap ring valve body front cover steel ball partition disc intermediate shaft rotor stator stop rear cover. Notes when 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. Its 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 kgfm (29.7 ~ 36.9 Ibfft). 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 8 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. Use recommended oil.

4-11

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. Features Features Compact design, easy installation, space efficiency. Flexible pressure regulation, no leaks. Combined valve can simplify hydraulic system and has low costs. Structure Structure One-way valve has a taper structure, consists of a valve seat, spool and spring and is fitted to inside of oil inlet of valve body. This valve features light resistance and good sealing. High pressure oil from hydraulic pump must pass through one-way valve to reach steering valve body. This one-way valve is designed to prevent operation of hydraulic system from being broken due to deflection of steering wheel because of return of oil to pump due to oil pressure in cylinder being higher than operating oil pressure that is caused by obstruction to steering wheel in special situations. One-way valve needs not adjustment in normal use, but reverse oil leaks should be prevented. Overflow valve is of differential and direct-acting type consisting of a differential valve seat, spool, spring, pressure regulating bolt and locking bolt. This device is attached to oil inlet and return port of overflow valve body featuring simple structure and stable operation. Its function is to prevent from overload, control pressure difference between inlet and return side to assure stable pressure. This device has also the function to unload and overflow and is called as safety valve. This valve also features regulation by loosening locking bolt and turning regulating bolt. After regulating pressure, fasten the locking bolt. Two-way buffer valve includes two direct-acting overflow valves and consists of a spring, two ball valve seats and two steel balls. This device is attached to the valve body to the each port of two chambers of steering cylinder. The ports are connected to return port. The product features simple structure and easy manufacture and repair, and functions as two safety valves to unload and make oil returning when pressure in a chamber of cylinder increases as speedy steering or vehicle travel encounters sudden variation in resistance to protect the oil circuit between steering cylinder and steering gear, assuring safe and reliable steering. Opening pressure of the valve is 5~6 MPa higher than operating pressure of steering gear. (3) Installation and requirements in using 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. Dirty oil, clogged damping hole Flow exceeds specified value. Replace spring. Change fluid, clean damping hole 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

7 8

Plug Damping plug

4-14

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 24 3 23 4 5 7

1 22

21

15 14

1 9 8 15 26 13 30 29 12 11 28 10
830KSE15A

27 16

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

23 24 25 27 28 29 30

Cylinder head Bushing Back up ring Clamp Piston Nut Tube assy

4-17

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 Steering unit check A Description Run engine at low idle. Service action OK Check completed.

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 NOT OK NOT 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 Low oil level. Restricted suction line. Failed hydraulic pump. Stuck steering valve spool. Relief valve in steering unit stuck open. Failed hydraulic lines. Slow or hard steering Cause Remedy Add recommended oil. Check. Remove and inspect return filter for metal pump particles. Remove and inspect steering valve spool. Do relief cartridge leakage test. Check.

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. Worn hydraulic pump. Low system relief valve setting. Low overload relief valves setting. Warm the hydraulic oil. Do hydraulic pump performance check. Test and adjust if necessary. Test and adjust if necessary.

4-20

Problem

Cause

Remedy Check for foamy oil. Do steering system leakage check. Do steering unit neutral leakage test in group 4. Replace springs. Replace overload relief valve. Replace gear wheel set. Replace defects parts. Do steering system leakage check. Do steering unit leakage check. Do steering system leakage check.

Constant steer ing to Air in system. maintain straight travel Leakage in steering system. Worn steering unit. Spring without spring force or broken. Spring in overload relief valve broken. Gear wheel set worn. Cylinder seized or piston seals worn. 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 Steering wheel can be Leakage in steering system. turned with frames against steering stop

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. Leakage in steering system. Erratic steering Air in oil. Low oil level. Loose cylinder piston. Damaged steering unit. Spongy or soft steering Air in oil. Low oil level. Free play at steering Loose steering wheel nut. wheel Worn or damaged splines on steering column or valve. Do steering system leakage test in group 4. Check for foamy oil. Add recommended oil. Remove rod to inspect piston. Remove and inspect. Check for foamy oil. Add recommended oil. 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. Inspect hydraulic lter for contamination. Repair cause of contamination. Flush hydraulic system.

4-21

Problem Steering unit locks up

Cause

Remedy

Large particles of contamination in Inspect hydraulic lter 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. Neutral position of steering wheel cannot be obtained, i.e. there is a tendency towards "motoring" Steering column and steering unit out of line. Reconnect lines. Repair or replace steering unit. Align the steering column with steering unit.

Too little or no play between steering Adjust the play and, if necessary, column and steering unit input shaft. shorten the splines journal. Pinching between inner and outer 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. Springs without spring force or broken. Worn splines on the steering column. Replace cardan shaft. Replace springs. Replace steering column.

4-22

Problem

Cause

Remedy Bleed cylinder. Find and remove the reason for air collection. Replace worn parts. Fill with clean oil and bleed the system. Replace or repair cylinder. Replace gear wheel set. Install spacer.

"Shimmy" effect Air in the steering cylinder. The steered wheels vibrate (Rough tread on tires Mechanical connections or wheel gives vibrations.) bearings worn. 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. Spacer across cardan shaft forgotten.

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. Relief valve sticking owing to dirt. "Kick back" in steering Fault in the system. wheel from system Kicks from wheels Adjust valve to correct setting. Clean the valve. 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 Too little steering force Pump pressure too low. Let machine run until oil is warm. Correct pump pressure.

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 95(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.

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 455C (1139F) Engine speed High idle Maximum pressure 3.0MPa (30 bar, 430psi) at steering unit GAUGE AND TOOL Gauge 0~7 MPa (0~70 bar, 0~1000 psi) 2EA This test will check for restrictions in the steering system which can cause overheating of hydraulic oil. 1) Install temperature reader. (see temperature reader installation procedure in this group). 2) Heat hydraulic oil to specifications. (see hydraulic oil warm up procedure at page 5-33). 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 455C (1139F) Engine speed High idle Maximum leakage 15/min (4 gpm) GAUGE AND TOOL Temperature reader Measuring container (approx. 20) Stop watch 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 kgfm of force. Measure oil flow from return hose for 1 minute.
Safety lock bar

Cap fitting
T L R

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

830KSE38

4-28

5. STEERING UNIT PRESSURE TEST

SPECIFICATION Oil temperature 455C (1139F) 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). 3) Install frame locking bar. 4) Heat hydraulic oil to specifications (see hydraulic oil warm up procedure at page 5-33). 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. 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. If pressure cannot be adjusted to specification, disassemble and inspect steering unit.
Safety lock bar

Test port

Steering cylinder Relief valve

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 3 4 5

7 2
B2 A2 Boom B1 A1 P Bucket T P T A B T

1
T/C

10 11 9 8

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

9 10 11

Bypass valve Air breather Hydraulic tank

5-1

2. WORK EQUIPMENT HYDRAULIC CIRCUIT

2
B2 A2 Boom B1 A1 Bucket

1
T/C

Steering system

10 11 9 8

830K3HC02E

1 2 3 4

Main pump Main control valve Boom cylinder Bucket cylinder

8 9 10 11

Return filter Bypass valve Air breather Hydraulic tank

5-2

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

2
B2 Boom A2 B1 Bucket A1

1
T/C

Steering system

10 11 9 8

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

2
B2 Boom A2 B1 Bucket A1

1
T/C

Steering system

10 11 9 8

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

2
B2 A2 Boom B1 Bucket A1

1
T/C

Steering system

10 11 9 8

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

2
B2 Boom A2 B1 Bucket A1

1
T/C

Steering system

10 11 9 8

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) POSITION (retract)

2
B2 Boom A2 B1 Bucket A1

1
T/C

Steering system

10 11 9 8

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

14 13

10 11 5 6 9 7 8

12

23 19 20 18 17 16 15 21 22

24

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

17 18 19 20 21 22 23 24

Pump body Rear cover Decal Rivet Washer Bolt Seal Bolt

5-8

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) Its 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 80C. 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 m 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 Air in system. Insufficient oil supply. Cold oil. Contaminated suction filter. Too thin suction pipe. Suction pipe is clogged. Clogged air filter in oil tank. Remedy Fasten up all the connectors. Refill oil to an adequate level. Run slowly. Clean or replace the filter. Use a larger pipe. Remove the obstruction. 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 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. Worn, leaking or stuck valve. High oil temperature Too low pressure setting at overflow valve. Too low viscosity of hydraulic oil. Too low oil level. Small tank. Worn or damaged pump. Foam forms in oil Repair or replace. Repair or replace. Regulate pressure of overflow valve. Use recommended hydraulic oil. Refill oil to an adequate level. Add an oil cooler or replace with larger tank. Repair or replace.

Air has entered into oil tank Fasten up all the connectors. through suction pipe. Incorrect selection of oil. Too low oil level. Use recommended oil. 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 flow of pump or nsufficient pressure

Cause Damaged side plate. Air has entered into the system. Too high viscosity of oil.

Remedy Replace side plate. Fasten up all the connectors. Use recommended oil. Change all the oil.

Leaks occur even after replacing lip seal for main shaft

Contaminated 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

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

16 17

18

19 20

21 22 23

29 28

27 15 14

12 13

26

25

24

34

33

32

31

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

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

5-12

SAFETY RELIEF VALVE

20

21

22

23

24

25

19

18

17

16

15

14

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

19 20 21 22 23 24 25

Adjust screw Cap Body Washer Spring seat Spring seat Spring

5-13

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 Nominated flow Nominated pressure Pressure regulating range Pressure loss Center Direction change Unit /min MPa MPa MPa MPa MPa Specification 160 16 8 ~ 20 <0.3 <0.6 8 ~ 25

Pressure regulating range of overload valve

5-14

5) STRUCTURE AND WORKING PRINCIPLE (1) Structure

Dump Neutral Retract (roll back) Bucket Boom Float Lower Neutral Lift

850K3HC51

(2) Working Principle

B2 A2 Boom

B1 A1

Bucket

Hydraulic circuit
830K3HC50

The Multi-way directional valve has boom control lever and bucket control lever. The bucket lever has three positions, i.e. neutral, roll back and dump. Boom lever has four positions, i.e., hold, raise, lower and float. Port P is flow inlet, T is flow return port and port A1 and B1 are connected to large and small chamber bucket cylinder respectively, and port A2 and B2 are to large and small chamber of boom cylinder.

5-15

 Neutral position When bucket control lever and boom control lever are in neutral positions, the flow from pump returns from inlet port P to tank through middle oil way. Bucket roll back and dump When bucket control lever is shifted to back, the flow from pump opens one-way valve, and is directed to A1 cavity, then to large chamber of bucket cylinder to make the bucket roll back, while the flow in small cavity returns through cavity B1. Similarly, when bucket lever is shifted to forward, the flow from pump opens one-way valve, and is directed to cavity B1, then to small chamber of bucket cylinder to make the bucket dump, while flow in large chamber return through cavity A1. Float of Boom When the boom control lever is shifted to back, the flow from pump opens one-way valve, and is directed to cavity A2, then to large chamber of boom cylinder to make the boom to raise, while the flow in small chamber returns through cavity B2. Likewise, when the boom control lever is shifted to forward, the flow from pump opens one-way valve, and is directed to cavity B2, then to small chamber of boom cylinder to make the boom to lower, while the flow in large chamber returns through cavity A2. When the control lever of boom is in lower, move it further to forward to get in float position. At the time, all of inlet port P and large and small chambers of cylinder are connected to return way, and become under low pressure, and the cylinder is floating by the weight of working equipment and bearing force of ground. Function of main relief valve, overload valve and makeup valve Main relief valve controls pressure in system. When pressure in system exceeds rated pressure, the main relief valve opens and the flow returns to tank to protect the hydraulic system against over pressure. When the bucket receives external impact or is interfered with by other mechanism, overload valve opens for safety. Makeup valve functions to make up oil for cylinder to prevent a chamber to be evacuated. AND 6) MOUNTING AND USING (1) When transporting, mounting, and storing the product, be careful that the product does not receive impacts that may damage the machined surface or flange face. (2) Never disassemble the product in dust before assembling to machine to prevent dust from entering. (3) Check that rated pressure, sliding function, oil-way type and other features conform to system requirements. (4) Mounting plate should be level, mounting screws fastened in even torque, and the valves should be in good alignment. (5) Operating fluid should be clean, cleanliness meeting NAS 1638 10 grade and up. (6) Allowable oil temperature range: -20 ~ 80C, normal oil temperature 505C. (7) Connect each port correctly and piping shall not be too thin, too long. (8) Our company offers three-guarantees to the product for one year from delivery for any malfunctions resulted from problem in workmanship in case the user would have observed the provisions given with regard to storage, use, installation and transportation.

5-16

7) TROUBLESHOOTING
No. Problem Insufficient operating pressure Cause Remedy

1. Pressure of main relief valve is on 1. Regulate pressure of main relief low side. valve. 2. Spool of main relief valve is stuck. 2. Remove and clean, or replace valve spool.

3. Damaged pressure regulating 3. Replace with new product. spring. 4. Too much pressure loss in system 4. Replace piping, or regulate line. pressure of main relief valve within the allowable range of pressure. Insufficient operating flow 1. Oil supply to system is insufficient. 2. Too much leaks inside valve. a. Too high oil temperature, low a. Take measures to reduce oil viscosity temperature. Check oil source and repair oil pump.

b. Improper hydraulic oil.

b. Change hydraulic oil.

c. Too much clearance between c. Replace slide valve to keep a slide valve and valve body. reasonable clearing. 3. Main relief valve failure. Malfunction in return. 3 3. Repair or replace the main relief

1. Damaged or deformed return 1. Replace with new product. spring. 2. Dirt between valve lever and valve 2. Clean part. body.

External seeps and leaks 4

1. Damaged seal ring. 2. Loose fastening pieces.

1. Replace with new product. 2. Fasten related fastening piece.

3. Too high oil temperature, low 3. Takes measures to reduce oil viscosity temperature. 4. Poor sealing on flange surface. 4. Check fastening and sealing of related parts.

5-17

8) NOTES IN DISASSEMBLY (1) Keep clean field for assembly. Dust and dirt shall be strictly prevented. (2) Never clean rubber sealing pieces with gasoline. (3) To prevent from damage to part, never knock a part with an iron object when disassembling. (4) Be sure to clean all the parts with kerosene or cleaner before assembling. (5) After assembling, be sure to perform test and only passed product can be used.

5-18

3. BOOM CYLINDER
6 28 8 7 8 29

9 10 12 11

30 13 31 25 13

21

27 26 14 10 27 12 11

1 2 3 22 4 16 15 23 24 5

830KWE20

1 2 3 4 5 6 7 8 9

Rod wiper Rod seal Buffer ring O-ring Snap ring O-ring Piston ring Wear ring Screw

10 11 12 13 14 15 16 21 22

O-ring Hexagon screw Washer Dust seal Bolt Washer Hexagon screw Rod assy Cylinder head

23 24 25 26 27 28 29 30 31

Back up ring Bushing Pipe assy - R Clamp Pipe assy - B Piston Nut Tube assy Bushing

5-19

4. BUCKET CYLINDER
17 31 17 21

1 2 3 12 13 22 4 7 28 29 8 29 30 6 11 26 10 24 25 5

14 15 9 14 15 10 11 27

16 23

34 33 32 17 31

6 17
830KWE21

1 2 3 4 5 6 7 8 9 10 11

Rod wiper Rod seal Buffer ring O-ring Snap ring O-ring O-ring Piston ring Screw Hexagon screw Washer

12 13 14 15 16 17 21 22 23 24 25

Hexagon screw Washer Nut Washer Bolt Dust seal Rod assy Cylinder head Tube assy Back up ring Bushing

26 27 28 29 30 31 32 33 34

Rod pipe assy Base pipe assy Piston Wear ring Nut Bushing Pipe band Clamp Pipe band

5-20

GROUP 3 OPERATIONAL CHECKS AND TROUBLESHOOTING

1. OPERATIONAL CHECKS
This procedure is designed so the mechanic can make a quick check of the system using a minimum amount of diagnostic equipment. If you need additional information, read structure and function, Group 2. A location will be required which is level and has adequate space to complete the checks. The engine and all other major components must be at operating temperature for some checks. Locate system check in the left column and read completely, following the sequence from left to right. Read each check completely before performing. At the end of each check, if no problem is found (OK), that check is complete or an additional check is needed. If problem is indicated (NOT OK), you will be given repair required and group location. If verification is needed, you will be given next best source of information: Chapter 2 : Troubleshooting Group 4 : Tests and adjustments

5-21

 Hydraulic oil must be at operating temperature for these checks.

Item Hydraulic system warm-up procedure Run engine at high idle. Refer to page 5-33. Description Service action

Hold a hydraulic function over OK relief to heat oil (don't keep relief Check completed. condition over 5 seconds at a time). Periodically cycle all hydraulic functions to distribute warm oil. Repeat procedure until oil is at operating temperature. FEEL : Hydraulic reservoir must be uncomfortable to hold your hand against. (approximately 40 ~50C)

Hydraulic pump performance check Heat hydraulic oil to operating temperature. Run engine at high idle.

With bucket flat on ground, OK actuate boom raise. Time how Check completed. long it takes to raise boom to full NOT OK height. C h e ck t h e hy d r a u l i c LOOK : Boom must raise to full pump. height in less than 6~7 seconds. IF OK Do steering system leakage check at page 4-24. IF OK Do main hydraulic pump flow test at page 5-34.

Control valve lift check Run machine at low idle.

With bucket partially dumped, OK lower boom to raise front of Check complete. machine. NOT OK Slowly move boom control lever Repair lift checks in to boom lower position. loader control valve. Slowly move bucket control lever to bucket dump position. LOOK : Boom must not raise before moving down. Bucket must not rollback before dumping.

5-22

Item Bucket rollback circuit relief valve check

Description

Service action

Position bucket at a 45 angle OK against an immovable object. Check complete. Engage transmission in 2nd NOT OK speed forward. Replace boom lower check valve. LOOK : Bucket angle must not change.

Bucket dump circuit relief valve low pressure check

Raise front of machine which OK Go to next check. bucket at 45 angle. Backdrag with bucket while NOT OK observing bucket angle. Do loader system and circuit relief valve test at LOOK : Bucket must not rollback page 5-36.

Boom cylinder and bucket cylinder drift check H e a t hy d r a u l i c o i l t o operating temperature.

B

S e t t h e b o o m a n d bu cke t OK horizontal, then stop the engine. Check complete. Stop the engine, wait for 5 NOT OK minutes, then start measuring. Go to next check. Measure the amount the lift and dump cylinder rods retract during 15 minutes. (unloaded bucket) A : Retraction of boom cylinder rod B : Retraction of bucket cylinder rod
B

Boom cylinder must drift less than 36 mm

A

Bucket cylinder must drift less than 33 mm

5-23

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

Description

Service action

Dump bucket until teeth or cutting OK edge is perpendicular to the Drift is approximately the ground. same between first and second measurement. Raise boom until cutting edge is about 1 m (3 ft) above ground. Repair loader control Stop engine. Measure drift from valve or circuit relief valve. tooth or cutting edge to ground for 1 minute. NOT OK If drift is considerably less Wait 10 minutes. on second measurement, Measure drift from tooth or repair cylinder. cutting edge to ground for 1 minute. LOOK : Compare the drift rate between the first measurement and the second measurement.

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

Raise bucket about 1 m (3 ft) off OK ground with bucket level. Drift is approximately the same between first and Stop engine. Place a support second measurement. under boom. Measure drift from tooth or Repair loader control cutting edge to ground for 1 valve or circuit relief valve minute. at page 5-36. Wait 10 minutes. NOT OK Measure drift from tooth or Drift is considerably less cutting edge to ground for 1 on second measurement. minute. Repair cylinder. LOOK : Compare the drift rates between the first measurement and the second measurement.

Check valve of safety valve leakage check H e a t hy d r a u l i c o i l t o operating temperature.

Put bucket level and position OK about 1.2 m (4 ft) above ground. Check complete. Place a piece of tape on cylinder NOT OK rod at least 51 mm (2 in) from rod Check or replace safety guide. valve. Run engine at low idle in safetyrelease position. LOOK : Bucket must not drift up.

Control lever check

Stop engine. Turn key switch to OK OFF position. Check completed. Move bucket control lever to roll NOT OK back, dump positions and then Repair bucket control release. lever. LOOK : Lever must return to neutral when released from roll back, dump positions.

5-24

Item Cycle time check Function

Description Operating condition.

Service action Maximum cycle time

H e a t hy d r a u l i c o i l t o Boom raise operating temperature. Run engine at high idle. Boom lower Bucket dump Bucket rollback

Bucket flat on ground to full 5.1 sec height. Full height to level ground. Boom at full height. Boom at full height. 3.0 sec 1.1 sec 1.5 sec 6.1 turns OK Check complete. NOT OK Go to slow hydraulic functions in group 3.

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

5-25

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

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

Lifting time of boom

830KWE35

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

Lowering time of boom

830KWE36

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

Dumping time of bucket Rollback time of bucket

830KWE37

5-26

2. TROUBLESHOOTING Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely, more difficult to verify. Remember the following steps when troubleshooting a problem : Step 1. Operational check out procedure (see section 1) Step 2. Operational checks (see group 3) Step 3. Troubleshooting Step 4. Tests and adjustments (see group 4)
Problem Noisy hydraulic pump Cause Low oil supply or wrong viscosity. Plugged or pinched suction line. Air in oil. Remedy Fill reservoir with recommended oil. Clean or replace line. Check for foamy oil. Tighten connections. Replace O-rings and or lines. Inspect and clean suction line. Tighten or replace clamps. Inspect and repair. Do hydraulic pump performance check in group 3. Do hydraulic pump flow test in group 4. Do performance check. Warm oil up. Adjust engine speed. Check high idle speed. Check for foamy oil. Add recommended oil. Use recommended oil. Check cylinder drift in group 3. Inspect lines. Inspect valve.

Plugged suction line. Loose or missing hydraulic line clamps. Hydraulic lines in contract with frame. Worn or damaged pump.

No or Slow hydraulic functions

Failed or worn hydrualic pump. Cold oil. Slow engine speed. Suction line air leak. Low oil supply. Wrong oil viscosity. Oil leaking past cylinders or control valve. Blocked or damaged line. Binding loader control valve (MCV) spool.

5-27

Problem No steering or hydraulic function Low oil level.

Cause

Remedy Add recommended oil. Remove and inspect return filter for metal pump particles. Remove and inspect return filter for metal pump particles, or replace the pump. Replace relief valve.

Failed hydraulic pump. Failed hydraulic pump.

No hydraulic functions steering normal

Stuck open port relief valve. Boom float function does not work One hydraulic function does not work.

Loader control valve (MCV) spool Do pressure reducing valve pressure binding in bore. test. Stuck open port relief valve. Oil leaking past cylinder packings. Replace relief valve. Do boom and bucket cylinder leakage test in group 4. Inspect lines for damage. Disconnect and inspect lines for internal blockage.

Blockage in oil lines or valve.

Loader control valve (MCV) spool stuck Inspect and repair valve. in bore. Low hydraulic power Leakage within work circuit. Do cylinder drift check in group 3.

Low system relief valve (main relief Do loader system and port relief valve valve) setting. pressure test in group 4. Low port relief valve setting. Do loader system and port relief valve pressure test in group 4. Remove and inspect valve. Do hydraulic pump performance check in group 3.

Leaking system relief valve. Worn hydraulic pump.

5-28

Problem Function drifts down

Cause Leaking cylinders.

Remedy Do cylinder leakage checks in group 4.

Leaking seals in circuit relief valve (port Inspect seals. Replace relief valve. relief valve) or valve stuck open. Leaking loader control valve (MCV). Boom drifts up Leakage in boom down spool. Repair or replace valve section. Remove and inspect boom down spool. Inspect and repair valve. Use recommended oil. Reduce load. Reduce load. Do boom and bucket cylinder leakage test in group 4. Inspect and clean oil cooler. Do hydraulic oil cooler restriction test. Do loader system and circuit relief valve pressure test in group 4.

Boom down does not MCV spool stuck. work (engine off) Oil overheats Low oil viscosity in hot weather. Excessive load. Holding hydraulic system over relief. Leakage in work circuit. Plugged fins in oil cooler. Internally plugged oil cooler. Incorrect system or circuit relief valve setting.

Restriction in oil lines or loader control Inspect for dented or kinked lines. valve (MCV). Malfunctioning steering unit. Leaking system main relief valve. Do hydraulic system restriction test in group 4. Do hydraulic system restriction test in group 4. Remove and inspect valve and seals. Do hydraulic pump performance check in group 3. Add recommended oil. Change to recommended oil. Change oil.

Worn hydraulic pump (internal leakage). Hydraulic oil foams Low oil level. Wrong oil. Water in oil.

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

5-29

 Followings are general precautions for the hydraulic system and equipment. 1) Every structure has its limit of strength and durability. The relief valve is installed to limit the pressure on the hydraulic equipment and protect various parts of the wheel loader from possible damage. Therefore, never change the preset pressure of the relief valve unless absolutely necessary. 2) Since the hydraulic equipment is built with precision, the presence of only the slightest amount of dust and / or other particles in the hydraulic circuit might cause wear and/or damage, resulting in unstable functions and/or damage, resulting in unstable functions and/or unexpected accidents. Therefore, always keep hydraulic oil clean. Periodically, check the filter in the return circuit and replace the element as necessary. 3) Extract about 200cc of hydraulic oil from the tank as a sample every 6 months. If possible, have it analyzed by a specialist to confirm that the oil can still be used. Never extract the oil for sampling until the oil temperature has become the normal operating temperature. Since the replacement period varies depending on operating conditions, refer to Operator's Manual and change oil. 4) Should the equipment get damaged due to the presence of metal particles and/or foreign matter in the circuit drain out the hydraulic oil and carry out flushing. Also, replace the filter element and clean the hydraulic tank. Change the hydraulic oil entirely. 5) When checking the filter, if found metal particles in the element, drain out the hydraulic oil entirely, flush the whole circuit, and then fill with new oil. The presence of metal particles may indicate internal damage to the equipment. In such a case, check carefully before flushing, and repair or replace as required. 6) To add and/or change the hydraulic oil, always use recommended oil. (Refer to the list of recommended oils and lubricants at page 1-18, Recommended lubricants.) Never mix oil of lubricants. different makes of kinds. 7) To change the hydraulic oil, use a clean vessel and funnel for pouring it into the tank. Never use cloth because it might cause the presence of lint in the circuit. 8) When removing the hydraulic equipment, be sure to put plugs or caps on hoses, tube lines and ports. Also, enter mating marks for later identification. 9) Disassemble and/or assemble the hydraulic equipment only in a clean place free of dust. When disassembling, be careful about the interchangeability of parts, and clean the disassembled parts with pure and clean mineral cleansing oil. Clean the internal passages as well. After the parts have dried, wipe them off with a clean lint-free cloth. 10) When overhauling the hydraulic equipment replace all O-rings, backup rings, etc. with new ones. Assemble O-rings with grease or vaseline applied. 11) After installing the equipment, add more hydraulic oil to make up for that lost during disassembly. 12) Tighten joints correctly. Loose joints will cause the hydraulic oil to leak. If the oil leaks, the tank oil level drops and air gets sucked in, so the pump will break down. Also loose joints in suction lines will take air in and might cause abnormal noise, malfunction or damage to pumps.

5-30

GROUP 4 TESTS AND ADJUSTMENTS

1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY
Service equipment and tool Portable filter caddy Two 4000 mm 1in 100R1 Hoses Quick disconnect fittings. Discharge wand Various size fittings. Flush all lines in the steering system and cut off system. Disassemble and clean major components for steering system. Steering components may fail if steering system is not cleaned after hydraulic oil tank contamination. 1) If hydraulic system is contaminated due to a major component failure, remove and disassemble steering cylinders to clean debris from cylinders. 2) Install a new return filter element. Inspect filter housing before installing new element. For a failure that creates a lot of debris, remove access cover from hydraulic oil tank. Drain and clean hydraulic oil tank of fill the specified oil to hydraulic oil tank through upper cover. 3) To minimize oil loss, pull a vacuum in hydraulic oil tank using a vacuum pump. Connect filter caddy suction line to drain port at bottom of hydraulic oil tank using connector. Check to be sure debris has not closed drain port. 4) Put filter caddy discharge line into hydraulic oil tank filler hole so end is as far away from drain port as possible to obtain a thorough cleaning of oil.

5-31

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

5-32

2. TEST TOOLS
1) CLAMP-ON ELECTRONIC TACHOMETER INSTALLATION Service equipment and tools Tachometer A : Clamp on tachometer. Remove paint using emery cloth and connect to a straight section of injection line within 100 mm (4 in) of pump. Finger Tighten only-do not over tighten. B : Black clip ( - ). Connect to main frame. C : Red clip (+). Connect to transducer. D : Tachometer readout. Install cable.

D A

75795SE32

2) DIGITAL THERMOMETER INSTALLATION Service equipment and tools Digital thermometer A : Temperature probe. Fasten to a bare metal line using a tie band. Wrap with shop towel. B : Cable. C : Digital thermometer.

A C B

75795SE33

3. HYDRAULIC OIL WARM UP PROCEDURE

1) Install temperature reader (see temperature reader installation procedure in this group). 2) Run engine at high idle. 3) Hold a hydraulic function over relief to heat the oil. 4) Periodically cycle all hydraulic functions to distribute warm oil. 5) Heat oil to test specification (approx. 45C).

5-33

4. MAIN HYDRAULIC PUMP FLOW TEST

SPECIFICATION Oil temperature Engine speed Test pressure Maximum pump flow 455C (1139F) 220025 rpm 1605 bar (2280 psi) 169/min (44.6 gpm)

FLOW METER AND TOOL Flow meter 300/min (79.3 gpm) Temperature reader 1) Make test connections. 2) Install temperature reader. (see temperature reader installation procedure in this group) 3) Heat hydraulic oil to specifications. (see hydraulic oil warm up procedure in this group) 4) Run engine at test specifications. 5) Close flow meter loading valve to increase pressure to test specifications. 6) Read flow meter. 7) If flow is below specifications, check suction line and suction pressure for abnormality before removing pump.
To MCV

Flow meter

Main pump

830KWE33

5-34

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

SPECIFICATION Oil temperature (40~50C)
Relief valve Engine speed System (M) Bucket rollback (R) Bucket dump (D) Low Low Low Relief pressure 1605 kg/cm2 (228070 psi) 1805 kg/cm2 (256070 psi) 1205 kg/cm2 (171070 psi)
Bucket Boom

Gauge and tool Gauge 0~35 MPa (0~350 bar, 0~5000 psi) M : System (main) relief valve R : Bucket rollback relief D : Bucket dump relief 1) Install fitting and pressure gauge to test port in pump delivery line. 2) Install temperature reader. (see temperature reader installation procedure in this group) 3) Heat hydraulic oil to specifications. (see hydraulic oil warm up procedure in this group) 4) To check the system relief (M), run engine at low idle. Lower boom to bottomed position. Slowly activate boom down function while watching pressure gauge. If pressure is not to specification, loosen lock nut on system relief valve (M) and adjust to specification. Do not adjust the system relief valve above 160 kg/cm2 (2280 psi). Damage to the pump will result from excessive pressure settings.
MCV

Hyd tank

830KWE34

5-35

6. HYDRAULIC SYSTEM RESTRICTION TEST

SPECIFICATION Oil temperature 455C (1139F) Engine speed High idle Maximum pressure 3 MPa (30 bar, 43 psi) at steering unit Maximum pressure at main control valve 1 MPa (10 bar, 145 psi) GAUGE AND TOOL Gauge 0~7 MPa (0~70 bar, 0~1000 psi) 2EA This test will check for restrictions in the hydraulic system which can cause overheating of hydraulic oil. 1) Install temperature reader. (see temperature reader installation procedure in this group) 2) Heat hydraulic oil to specifications. (see hydraulic oil warm up procedure in this group) 3) Connect fitting and gauge to steering valve. 4) Connect fitting and gauge to main control valve. Do not operate steering or loader functions or test gauge may be damaged. 5) Run engine at specification and read pressure gauges. If pressure is more than specification at the loader control valve, check for a kinked, dented or obstructed hydraulic line. Check loader control valve for a binding spool. If pressure is more than specification at the steering unit, inspect neutral condition of the steering unit and priority valve for a stuck spool. Make sure orifice plugs are installed in ends of priority valve spool. Check for plugged orifice in priority valve LS port and dynamic signal orifice on the spool of priority valve.
T

Steering unit

MCV

830KWE42

5-36

7. LOADER CYLINDER DRIFT TEST

SPECIFICATION Oil temperature Boom horizontal Bucket horizontal Bucket unloaded
Item Retraction of boom cylinder rod Retraction of bucket cylinder rod

455C (1139F)

Standard value 36 mm

B
33 mm

GAUGE GAUGE AND TOOL Stop watch Temperature reader Put the safety lock lever in the lock position. Do not go under the work equipment. 1) Set the boom and bucket horizontal, then stop the engine. 2) Stop the engine, wait for 5 minutes, then start measuring. 3) Measure the amount the boom and bucket cylinder rods retract during 5 minutes.

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

7577AWE31

5-37

8. BOOM AND BUCKET CYLINDER LEAKAGE TEST

SPECIFICATION Oil temperature 455C (1139F) Engine speed Low idle Maximum leakage 15 m/min (1/2 oz/min) GAUGE AND TOOL Temperature reader Stop watch Measuring container 1) Fasten temperature sensor to head end port of cylinder to be tested. Cover sensor with a shop towel. 2) Heat hydraulic oil to specifications (see hydraulic oil warm up procedure in this group). Never work under raised equipment unless it is supported with a hoist or support stands. 3) Full extend the cylinder to be tested. If testing the boom cylinders, restrain boom in the fully raised position using a hoist or a stand. Check cylinders for leakage in the fully extended position only. In the retracted position contacts the end of the cylinder and seals off piston seal leakage. 4) Remove and plug cylinder rod end hose or line. 5) Run engine at slow idle. Activate control lever to extend cylinder for 1 minute over relief while measuring leakage for open port. If leakage is within specification, excessive cylinder drift is caused by leakage in the loader control valve or circuit relief valve.

(770-3ATM) 6-56

5-38

9. CYCLE TIME TEST

SPECIFICATION Oil temperature Engine speed
Function Boom raise Boom lower (float) Bucket dump Bucket rollback Steering (number of turns)

455C (1139F) High idle

Operating conditions Bucket flat on ground to full height Full height to ground level Boom at full height Boom at full height Frame stop to stop Maximum cycle time (seconds) 5.1 3.0 1.1 1.5 6.1 turns

5-39

10. HYDRAULIC OIL FILTER INSPECTION PROCEDURE

1) Lower the bucket to the ground, stop the engine, move the control lever back and forth several times, and clean all over the upper surface of the hydraulic oil tank. 2) Remove the bolts and take out the filter case cover and O-ring. 3) Remove the spring and bypass valve. 4) Remove the filter element from the tank. 5) Check the element and the filter case bottom for debris. Excessive amounts of brass and steel particles can indicate a failed hydraulic pump or a pump failure in process. A rubber type of material can indicated cylinder packing or other packing failure. The hydraulic oil filter in the filter case of the hydraulic oil tank should be replaced every 1000 operating hours or more often. When the filter element is replaced, please keep as follows. (1) Clean the inside of the filter case. (2) Place new element in the proper positions inside the filter case. (3) Install the bypass valve and spring. Make sure the element stand upright, and check for complete contact of the element bottom with the filter case bottom. (4) Install the O-ring and filter case covers. Tighten them with bolt. Replace the O-ring with new one if damaged.
Cover O-ring Spring By-pass valve Return filter

830KWE40

5-40

SECTION 6 ELECTRICAL SYSTEM

Group Group Group Group 1 2 3 4 Component location -------------------------------------------------------------------------------------------Electrical circuit ---------------------------------------------------------------------------------------------------Monitoring system ----------------------------------------------------------------------------------------------Connector -----------------------------------------------------------------------------------------------------------6-1 6-3 6-4 6-11

SECTION 6 ELECTRICAL SYSTEM

GROUP 1 COMPONENT LOCATION
1. LOCATION 1

9 Cab ceiling(LH)
1

Front

10 11
C A B R O O F

78 5 3 2 64 14 12 13 15

830K7EL02E

1 2 3 4 5 6

Beacon switch Work lamp switch Front wiper/washer switch Gear selector lever Hazard switch Cluster

7 8 9 10 11 12

Multi function switch Horn button Electric fan Aircon and heater switch Radio and MP3 player Starting Switch

13 14 15

Battery volt meter and hour meter Cigar lighter Engine stop switch

6-1

2. LOCATION 2
4 5 4 4 6

4 1 2 3

8 7

9 10

15 11

10 11

14

13

12
830K7EL02-1

1 2 3 4 5

Head lamp Horn Multi function switch Work lamp Beacon lamp

6 7 8 9 10

Electric fan Coolant temperator sensor Engine oil pressure sensor Work lamp Battery

11 12 13 14 15

Rear combi lamp Fuel sender Back buzzer Battery relay Air tank pressure switch

6-2

FRONT WIPER WORK LAMP SW WIPER SW

-

HAZARD SW
CN-56
+ 1 8 7 2 8 9 9

TURN LEVER
M
(6) 30 (5) H 862
U LED

CN-55 (1) L 6 BARO METER (11) R 751H 862 ROr 284D G15J CN-53
-

I 0 B E Pf Hi Lo

0,
3 6 5 6 4 2 3 1 5 10 6 4 2 1 5 3 3 7 3 7 10 10 9 9 2 6 2 6 1 4 5 8 1 4 5 8 10

BACKING

CN-171 SERVICE 2 1 SOCKET

I
0 I 10 1 4 3 9 6 4 5 8 B R 7 2

7 5 9 2

(7) 57/58

CS-36

CS-35

CS-41

CN-21

10

Gr

L B Y B R R W

ROr 892
B

Or

ROr

ROr

VOr

VOr

TC TEMP GAUGE

BrW

BrW

Or B

U LED

L
56b (8) 56a (9)
8 5 9 1 1 2

H
LP (10)

751G 892 W 284C G15I CN-54

363

362

261 352 360 G26 290C 261

311

301

293

226

234

211

211

360

362

352

G26

G26

G25

290F

500 G06

G30 G06 G03 G02 G01 10 11

CS-45
4 6 3 2

CS-11

1 7

GROUP 2 ELECTRICAL CIRCUIT

EARTH4
878 15 Y WB B GY ROr R VW Y BrW Or

FUEL LEVEL GAUGE

751H 878 Or 284B G15G

U LED

CN-22 B
226 343 251 261 333 325 211 234 351 G26
1 361 G02

CN-4
361 Gr 1 223 913 1 363

FRONT WASHER
M 2 Gr

CL-51A

CR-30
86 30

87a

TURN LH CHARGE
CL-51B CL-52A

11

1 2 1 2

85 87

223 Y G15F B 913A RW 751E

320 Y 2 325

85 87 87a

86 30

8R
4 20A 5 30A 6 20A 7 30A 8 20A 9

8R
11 10A

HIGH BEAM
B V Y ROr G01 321 320 250A 3

323

V B 872 10 Y R Y

CR-40
86 30

HIGH BEAM BRAKE LOW PRESSURE

CL-52B 472 16 CL-DL 1 2 13 CL-26A

1 2 1 2

87a

250 ROr 3 4 5 293 333 251 VW ROr 330 290

85 87
85 87 87a

CN-56

323 G15D 751E 872

86 30

LOW BEAM
B GW VW ROr G01A 331 330 250

PARKING

1 2 1 2

CR-2
86 30

87a 85 87 VW GY W 350A 340 341 B G01B

472 VW 751D 572 573

CL-26B 233 4 CL-53A

340 GY W 6 7 352 211 8 343 350

1 4 5 6 7 9 10 11 12 13 15 16

HORN RY
85 87 87a

86 30

TURN RH
933 5

CR-11
G
B 85 E 86 B G01C R 225 L 87 BrW 210

233 Or G15C 751D 933 G

1 2 1 2

ENGINE OIL
CL-53B

GAUGE BOARD SIDE

FLASHER UNIT
210 BrW

226 234 934 863 893 883 873 914 904 924 879 473 324 285 752 V LW R

Y Or G ROr W LW Y RW Gr Br Or VW

3 14 2

8R 600

CN-52
-

CN-37
20A 1 20A 2 20A 3 20A

WORK LMAP_FRONT WORK LMAP_REAR STOP LAMP HEAD LAMP WIPER & BACK BUZZER AIR-CON/HEATER

ENGINE COOLENT TEMP

G26

12 14 8 2

903 284 G15 751 923 9

751A 903 Gr 284A LW G15A CN-51

U LED -

GW Gr R ROr W 2R 100 150 200 250 350 400

285 234 752 261 324 473 879 873 863 883 893 914 904 934 924 450 311 301 351 226 G25 G26 Or

CIGAR SERVICE POWER1 COWL OPEN

TM OIL PRESSURE

FRONT DASH SIDE

U LED

R RL 500 530
B B G L VW Or Y ROr LW W RW Gr G Br WB Y 256 266 13 14 15 16 10 11 12 14 15 12 11 16 13 10 9 ROr W

751 923 284 G15

R Br LW

20A 10 20A

ILL LAMP BEACON LAMP SPARE1 SPARE2 SPARE3

4 5 6 7 8 9

2 3

12 10A 13 10A 14 30A 15 30A 16 10A

SPEAKER LH

CN-4

CN-5
R

SPEAKER RH

Or

LW

WB

ROr V VW Or Y

ROr LW W RW Gr G Br

IGNITION SWITCH POWER RELAY ROOM LAMP, RADIO(+)

BEACON

FUSE BOX
2Or 2Gr 650 680 310 300 354 220
17 10A 18 20A 19 30A 20 30A 21 10A 22 10A 23 20A 24 20A 25 20A 26 5A 27 5A 28

230

Y 700
G04 G01 225 425 R L

280

750

321 471 876

871 861 881 891 912 902 932 922

260

TURN LAMP AIRCON(+) SPARE4 SPARE5 GAUGE 24V RADIO(IG) SPARE6 SPARE7 SPARE8 ILLUMINATION 1 ILLUMINATION 2

10 10 9

3 2 1

7 6 4 5

CS-23

CN-24

1 L

CN-23

LW

RW

GY

OR W

RH CONSOLE SIDE

R G 750 800

CN-7
267 8

G14

283

704

703

267

702

705

111

CN-7
400 R 1
111 RW

LW 280 ROr 290

800 280C G LW 160 R 2 3

CL-7
G13A B 2 1

BEACON

Br 270 670
550

2Br
3R

801 2 5

801 G14 703

CN-27 G B GY 702 L 1 2 3 4 5 6 701 Y 7 8 283 704 ACC ILLNC SPK FRT RHSPK FRT LHTEL MUTE ANT 12V BACK UP+

4 5 6 8 7

700 266 110

Y W RW

MP3 PLAYER

CR-35
86 30

87a 85 87 B G01H 670 657 680

POWER RELAY
2Br
R
85 87 87a

86 30

701 283 6 3

LW
OR

2Gr

9 10 11 12 705 13 W G14A B 14 15 16

ILL+ NC SPK FRT RH+ REMOCON+ REMOCON GND SPK FRT LH+ NC GND

POWER CONNECT

CR-21
86 30

87a 85 87 86 30

85 87 87a

Br R ROr

G01I 270 260 256 290A 341 ROr VW

CLEARLENCE LAMP CR-3

86 30

CN-9
7 3

87a 85 87 RW G 300 100 GW 110 86 30 B G01J

701A

CL-1
Y

ROOM LAMP

G14 8

2 1

85 87 87a

AC-3 321 280C 230 V LW Or 331 220 GW Y 411 1 5

411 R G14 B 2 1

FAN

CAB CHASSIS SIDE

WORK LAMP FRONT CR-55

86 30

2 6

87a 85 87 R L Gr 150 310 160 86 30 B G01K

111 7 4 1

111

RW G13A B

CL-5
2 1

85 87 87a

WORK LAMP REAR CR-63

86 30

CS-79
1 Or 650 2 87a 85 87
85 87 87a

111A

RW G13B B

CL-6
2 1 3

WORK LAMP FRONT

ENGINE STOP SW

H0 I

START SWITCH

BR ACC

ST C

3 AC 24V 3 4 5 6 7 8 Y L NC 4

2R 400

5 AC CONTROLLER B+ AC COMP AC CONDENSOR FAN ILLUMINATION 6 7 8

425 448

CN-48 750

BW 445 ROr 290

CR-7
86 30

87a 85 87 86

1 2 3 4 5 6 7 8

ROr 447 LW 446 R

85 87 87a

448 447 446

650 G15 657 660 R 30

G15B 912 RW 750

HRM(-) KEYSWITCH NC NC GND HRM(+) 24V NC 400 400 444 471 G02 657 G02 871 G02

1.2B

1.2R

1.2Or

1.2R

CR-33
Y B R B VW B
86 30

87a 85 87
85 87 87a

HORN LOW

BW

445
3

CS-26

86 30

CN-125

BrW 444 R 400 R 400

877 Or ROr 860 Y 870 LW 880 W 890 RW 911 Gr 901 G 931 Br 921

EARTH5

CN-83
665 291 221 201 202 204 661 664 281 231 352 551 601 531 440 441 443 449
M

449 G25

BrW B

CN-79

CN-12
G10 2B 2B G08

CN-29

INLET MOTOR(FRE)

INLET M/ACT

880 Pa 920 930

WK

LW Br G

TEMP M/ACT(PBR)

MODE M/ACT(M+)

900

Gr

Gr 4

901

MODE M/ACT(M-) MODE M/ACT(PBR)

10 11

TEMP M/ACT

666

BLOWER RELAY(M2)

14

CN-74

BLOWER RELAY(HI)

15

ST

CONDENSER FAN

17

STARTER CN-45

AC & HEATER CONTROLLER

910

BW

CD-4
201 202
G29 B 442 VW 1

BATTERY(+) ILLUMINATION

4 5

MODE(VENT)

LW

G08A 443 5 10

DUCT SENSOR(+)

CN-28

REVERSE FAN SIG

10

Pa

860 870

ROr Y

NC NC NC

12 13 14

RESISTOR

AIR PRESSURE

AC-2
CD-49
552 3R

DUCT SENSOR

TM TEMP

EARTH6

890
601 551 669 8R 3R R

G09 1 2 531

CN-71
1 3 B RL 2 6

7A
5

MASTER SWITCH

COWL OPEN SWITCH

CN-95 FUSIBLE LINK

661 G06B
661A G06C

G25 G27 G09 G08 G07 G28 0.85 2.0 EARTH2

352

12

G WK

NC

11

10

11

14

13

REAR FRAME SIDE

AIR-CON COMP

CD-3

DUCT SENSOR(GND)

OrW 52

GW 40

STOP LAMP SWITCH

NC

BW

41

7 6

R G

Pa

POWER IG

42

43

BW

911

BATTERY(+)

RW

44

BW 910

GND

RW

45

15 R

5Y

GND

5L

BrW 46

ALTERNATOR 24V, 35A

18 D+ B+ W

MODE(D/FOOT)

BrW 47

18

12

17

~3

COMPRESSOR(DPS)

16

23

16

11

LW

24

15

YW

25

14

6
U
G

664

BLOWER RELAY(M1)

13

BOr 26

13

COOLENT TEMP

BLOWER RELAY(LO)

12

YW

27

12

LW

28

11

29

10

LW

30

CD-8 C

MODE M/ACT(FOOT)

WOr 31

ENGINE OIL PRESS

TM OIL PRESS SWITCH

MODE M/ACT(DEF)

BW

32

1 3

Br G

921 931

Pa

MOTOR ACT(REF)

GY

33

34

FUEL CUT OFF SOL

CD-18

TEMP MOTOR ACT(-)

35

CD-48

TEMP MOTOR ACT(+)

BOr 36

37

AIR-CON PRESS

662

9 8 2

665

INLET MOTOR(REC)

BW

38

ENGINE SIDE

SWITCH

440 441

Y ROr

1 2

AC-1 Pa
WOr 39

6 5

2 2

BLOWER MOTOR GND

G30 G30

1 1

AC CONTROLLER GND

663

2W

CN-11

3 2

660

WARNING BUZZER

6-3
86 30

4 1 5 5

STOP LAMP
Br G R G01L 203 205 200B

667

161

CL-22
4
6 2 7 8 6 G13A B 290E ROr 2 1

CR-58
86 30

87a 85 87 86 30

CL-23
9 G02 B 161 10 R G13B B G02 290E 450 B 2

9 10

WORK LAMP REAR

WB L 354 380 350 W

BACK-UP BUZZER
85 87 87a

CL-2
ROr
Or

G14 CIGAR G13

CN-26
1 2 R 200A Y 871

EARTH7

650

2Or

CS-2
0, I
B

A E
B+
BATTERY
EARTH1

332A GW 322 V G12B B

CL-3
2 1 3

Y Lo R Hi B

CN-9
2 1 LW Y 282 222 282
222

CHINA

LW
Y

1 2

Br /Gr

HOURMETER & VOLTMETER

AIR-CON COMP RELAY AIRCON CONDENSOR FAN RELAY

B E G T CL-24
G12A B

CN-20
1

8
1 2 1 87 30 86 87a 85 3 4 1 2

342A VW

CR-79

G11B B

CN-25
876 861 871 881 891 912 902 932 922
87a 87

HORN HIGH

GPS CONN.

FRONT FRAME SIDE

600

550 3R 8R

448 447 446 444

530

667 290 220A 200 205 203 R ROr Y R G Br

657 663 280 230A 380 R 2W LW Or L RL

3
30

VW
2 4 1 3
85 86

342

342

1 VW 2

CL-4
332 GW

CN-125A

Or ROr Y LW W RW Gr G Br

Y ROr LW BrW

4 5 3 4 5 6 7 8
R 668

GW V

332 322

322

CN-2

CN-3

ENGINE STOP BUZZER

PARKING LEVER

CN-1
1 2 3R 8R

G11

13 15 1 2

14

9 10 11 12

668

Y Lo R Hi B 2 8 1 3 11 4 12 14 15 5 6 7 9 10 13 R 2W LW Or L RL R ROr Y R G Br G11 G12 ROr Y ROr LW BrW 7 6 Or 292 232 292

232

CHINA

ROr
G11A B Or

1 2

Br /Gr

B E G T

AC COND FAN

1 2

CL-25 EARTH3

AC-11
1 WB 15 16 BW

2 1

2 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 BW 16 LR BG GL Y GW BG WR LB YB LG YBr BG YB LW LY 3 4 5 6 15 17 20 WB LR Y 7

M
7 1

1 2 3 18 19 9A BG GL GB 4 5 6 7 1

4 2 5 7 3

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

21

GW

2 3 4 5

M
CR-1 BATT RY DO-2

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

BR

BR

22 23 20A

BG WR Y

6 7

1 2 3 24 25 BrR 9B 26 35 27 36A LG YW YBr L LB YB GB 4 5 6

1 2 RW 3 RW 4 G 5 RY 6

2 5 7

8 GB 9 GB 10

7 1 2 3 4 Lo 1 MH 3 ML 2 Hi 4

AC-22
1 2

29 1.25LgB 1.25G 9 8 33 6B 36

YB R RY L

1 2 3 4

RELAY(HI)

28 1 2

BG

RELAY(M2)

1,2 32 6 10 33 30 31 5
G LY 2B

33A 6A 35 2R RY BR LW RW 32

R RY YW 2B

1 2 3 4
1 36 7 8 6 2 5 4 3 1 L 2

CS-74

BLOWER M

CN-11

4 1

NO.
1 2 3 4 5 6 7 8

231

291

COWL OPEN

AIR CON

204A

877 G27

204

221 G28 B Br Y

281 G28 B Br LW Or

G28 L B

Or B

ROr

R B 1 3 2 1

1 2

3 2

CD-2

CN-65

CL-16

DESTINATION

GND(CONTROLLER) GND(BLOWER) FUSE(IG) MCU FUSE(Battery) DPS(COMPRESSOR) CONDENSOR FAN ILLUMINATION

FUEL LEVEL SENSOR

REAR COMBI RH CL-15

DIODE
2

E S

BACK BUZZER

REAR COMBI LH

830K7EL10

GROUP 3 MONITORING SYSTEM

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

Fuel gauge High beam pilot lamp

Parking brake warning lamp Right turning pilot lamp

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

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

830K3CD02K

6-4

1) FUEL GAUGE (1) This gauge indicates the amount of fuel in the fuel tank. (2) Fill the fuel when the indicator moves 0 point, refuel as soon as possible to avoid running out of fuel. If the gauge indicates below 0 point even though the machine is on the normal condition, check the electric device as that can be caused by the poor connection of electricity or sensor.

850K3CD04

2) ENGINE COOLANT TEMPERATURE GAUGE

Operating range Red

(1) This gauge indicates the temperature of coolant. Red range : Above 100C (219F) (2) If the indicator is in operating range, it is normal. (3) Keep idling engine at low speed until the indicator is in the operating range.

850K3CD05

(4) If the indicator is in the red range, turn OFF the engine, check the radiator and engine. 3) TRANSMISSION OIL TEMPERATURE GAUGE
Operating range Red

(1) This gauge indicates the temperature of transmission oil. Red range : Above 120C (225F) (2) If the indicator is in operating range, it is normal. (3) Keep idling engine at low speed until the indicator is in the operating range.

850K3CD07

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

4) TRANSMISSION OIL PRESSURE GAUGE

g tin era ge Op ran

(1) This gauge indicates the pressure of transmission oil.

Red

(2) If the indicator is in operating range, it is normal. (3) If the indicator is in the red range, stop the engine and check the transmission system.

850K3CD08

6-5

5) BRAKE AIR PRESSURE GAUGE

Oper ating range Red

(1) This gauge indicates the air pressure of service brake. Red range : Below 0.4 MPa (2) If the indicator is in operating range, it is normal. (3) If the indicator is in the red range, keep idling engine at low speed until the operating range indicates.

850K3CD06

6) DIRECTION PILOT LAMP (1) This lamp flashes when the signal indicator lever is moved. (2) When the lamp lights up, the alarm (50 dB) sounds.

77073CD10

7) HIGH BEAM PILOT LAMP (1) This lamp works when the illuminating direction is upward. (2) This lamp comes ON when the dimmer switch is operated, e.g., when passing another vehicle.

77073CD12

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

77073CD13

9) BRAKE AIR PRESSURE WARNING LAMP (1) The lamp lights ON when the air pressure of service brake drops below the normal range. (2) When the lamp is ON, stop the engine and check for its cause. Do not operate until any problems are corrected.

850K3CD16

6-6

10) ENGINE OIL PRESSURE WARNING LAMP (1) This lamp is comes ON after starting the engine because of the low oil pressure. (2) If the lamp comes ON during engine operation, shut OFF engine immediately. Check oil level.

77073CD18

11) BATTERY CHARGING WARNING LAMP (1) This lamp is ON when key ON, it is turned OFF after starting the engine. (2) Check the battery charging circuit when this lamp comes ON during engine operation.

77073CD22

6-7

2. SWITCHES

Front Cab celing (LH) Beacon switch

Horn button Multi function switch Hazard switch Front wiper/washer switch Work lamp switch

Starting switch Engine stop switch

Engine cover switch

830K3CD29E

1) STARTING SWITCH (1) There are three positions, OFF, ON and START. (OFF) : None of electrical circuits activate. (ON) : All the systems of machine operate. (START) : Use when star ting the engine. Release key immediately after starting.
77073CD41

6-8

2) HAZARD SWITCH
OFF ON

(1) Use for parking, or roading machine. (2) Both turn signal lights will flash simultaneously. If the switch is left ON for a long time, the battery may be discharged.

77073CD42

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

77073CD46

4) FRONT WIPER AND WASHER SWITCH (1) The switch use to operate the front wiper and washer by two step. First step : The front wiper operates. Second step : The washer liquid is sprayed and the front wiper is operated only while pressing. If release the switch, return to the first step position.
77073CD47

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

77073CD50

6) HORN BUTTON
Horn button

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

850K3CD28A

6-9

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

73033CD24

8) MULTI FUNCTION SWITCH (1) Dimmer switch This switch is used to turn the head lights direction. Switch positions Up : To flash for passing Middle : Head lights low beam ON Down : Head lights high beam ON If you release the switch when it's in up position, the switch will return to middle

Up M Down
850K3CD30

(2) Turning switch

Left turning

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

Right turning
850K3CD31

9) ENGINE COVER SWITCH (1) This switch is used to open or close the engine cover. (2) Turn the staring switch to the ON position, press the button. Green button : Open the engine cover Red button : Close the engine cover

Green Red

830K3CD46

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

830K3CD37

6-10

GROUP 4 CONNECTOR
1. MAIN HARNESS
Connector number CL-2 HES Type No. of pin 1 CIGAR Destination Connector part no. S810-001202 S822-014000 S822-114000 S814-006000 DJ7041-6.3-21 DJ7041-6.3-11 174198-1 174200-1 174200-1 MG640605 8JA003526-001

CS-2 CN-125 CN-125A CN-171 CS-26 CS-79 CN-22 CR-55 CR-3 CR-40 CR-2 CR-63 CR-35 CR-21 CR-30 CR-33 CR-7 CR-58 CR-11 CR-79 CN-37 CN-26 CN-1 CN-2 CN-3 CN-11 EARTH4 CN-9 CN-7 CN-4 CN-5 CN-48

HES CHINA CHINA TYCO TYCO SWF HELLA

6 4 4 2 3 10 2 5

START SWITCH GPS GPS SERVICE SOCKET PARKING BRAKE LEVER ENGINE STOP SWITCH FRONT WASHER WORK LAMP (FR) RELAY WORK LAMP (RR) RELAY LOW BEAM RELAY HORN RELAY STOP LAMP RELAY POWER RELAY CLEARANCE LAMP RELAY HIGH BEAM RELAY AIRCON CONDENSOR FAN RELAY AIRCON COMPRESSOR RELAY BACK UP BUZZER RELAY FLASHER UNIT RELAY ENGINE STOP BUZZER

TYCO HES TYCO TYCO DEUTSCH KSC 2620 CHINA CHINA TYCO TYCO MOLEX

20 2 2 15 15 8 1 8 8 16 15 8

FUSE BOX WARNING BUZZER REAR FRAME SIDE 1 REAR FRAME SIDE 2 REAR FRAME SIDE 3 HEATER SIDE TO DASH TO DASH HOURMETER & VOLTMETER

21N8-20041 174198-1 S813-130200 368301-1 2-85262-1 DT06-8S R8-10 DJ7081-6.3-21 DJ7081-6.3-21 368047-1 85223-1 39-01-2085

6-11

2. CAB HARNESS
Connector number CN-7 CL-7 CN-23 CN-24 CL-1 CN-27 CL-5 CL-6 CL-22 CL-23 CS-23 EARTH7 AC-3 CHINA TYCO KET DEUTSCH DEUTSCH DEUTSCH DEUTSCH SWF KSC 2620 Type No. of pin 8 2 2 3 16 2 2 2 2 10 1 2 Destination CAB CHASSIS SIDE BEACON SPEAKER ROOM LAMP RADIO & MP3 player WORK LAMP, FRONT WORK LAMP, FRONT WORK LAMP, REAR WORK LAMP, REAR BEACON SWITCH RING TERMINAL FAN Connector part no. DJ7081-6.3-11 174198-1 7123-1520 MG651032 PK145-16017 DT06-2S DT06-2S DT06-2S DT06-2S 593757 R3-10 DJ7021-6-3-10

3. DASHBOARD HARNESS
Connector number CS-11 CN-21 CS-41 CN-56 CN-4 CN-5 CS-35 CS-36 CS-45 TYCO TYCO SWF TYCO TYCO TYCO SWF SWF SWF Type No. of pin 11 6 10 16 16 15 10 10 2 Destination TURN LEVER FRONT WIPER HAZARD SWITCH GAUGE BOARD SIDE TO MAIN TO MAIN WIPER SWITCH WORK LAMP SWITCH BACK-UP SWITCH Connector part no. 172497-1 936257-1 593757 368047-1 368050-1 2-85262-1 593757 593757 MATING WITH DJ7021-6.3-10

6-12

4. REAR FRAME HARNESS

Connector number CD-49 CD-48 CD-3 CD-4 CN-65 CL-16 CL-15 CN-29 CN-83 CN-95 KET KET KET KET DEUTSCH HES HES KUM HES DO-2 CR-1 EARTH2 CN-1 CN-2 CN-3 CN-12 CN-71 CD-2 CS-74 HES KSC 2620 HES TYCO TYCO CHINA CHINA Type No. of pin 1 1 12 12 2 4 4 2 2 2 2 2 2 12 1 2 15 15 12 2 2 1 1 TM TEMP TM OIL PRESSURE AIR PRESSURE STOP LAMP SWITCH BACK BUZZER REAR COMBI-RH REAR COMBI-LH AIRCON PRESSURE SWITCH FAN FUSIBLE LINK FUSIBLE LINK DIODE DIODE BATTERY RELAY RING TERMINAL MASTER SWITCH (IF EQUIPPED) MASTER SWITCH (IF EQUIPPED) Destination Connector part no. 710197 710197 710197 710197 DT06-2S S814-004000 S814-004000 MG 640795 PB625-02027 S813-130200 21EA-40171 S816-002002 21EA-50550 S820-104002 R5-10 S813-030200 2-85262-1 368301-1 DJ7041-6.3-21 DJ7041-6.3-21 S814-002000 S820-205000 ST710287-2

5. FRONT HARNESS
Connector number CN-9 CL-3 CL-24 CN-20 CN-25 CL-4 CL-25 EARTH3 CHINA TYCO TYCO MOLEX MOLEX TYCO TYCO KSC 2620 Type No. of pin 8 3 2 2 2 3 2 1 Destination FRONT FRAME, SIDE COMBI-FRONT, LH HEAD LIGHT, LH HORN-LOW HORN-HIGH COMBI-FRONT, RH HEAD UGHT, RH RING TERMINAL Connector part no. DJ7081-6.3-11 174200-1 174198-1 36825-0211 26825-0211 174200-1 174198-1 R3-10

6-13

6. GAUGE HARNESS
Connector number CN-55 CN-53 CN-54 CN-52 CN-51 CL-51 A,B CL-52 A,B CL-26 A,B CL-53 A,B CN-56 Type No. of pin Destination BARO METER TC TEMP GAUGE FUEL LEVEL GAUGE ENGINE COOLANT TEMP TM OIL PRESSURE TURN-LH, CHARGE HIGH BEAM, BRAKE LOW PRESSURE PARKING TURN-RH, ENGINE OIL PRESSURE GAUGE BOARD Connector part no.

SWF KSC2620

2 13

913328 R 1.25-4

CHINA

22

DJ702256-6.3-21

TYCO

16

368050-1

7. ENGINE HARNESS
Connector number CN-79 CD-18 CD-8 CR-23 HES KSC 2620 TYCO KET KSC 2620 KET KSC 2620 KSC 2620 TYCO KSC 2620 KSC 2620 Type No. of pin 3 1 1 22 1 1 1 1 12 1 1 Destination FUEL CUT OFF SOL ENGINE OIL PRESSURE COOLANT TEMP START RELAY Connector part no. S818-020311 Rl.25-4 Rl.25-4 ST710384-2 ST710589-2 R14-12 ST710246-2 R14-8 Rl.25-4 DJ7121-6.3-11 NMWP01F-B Rl.25-10

CN-45

STARTER

CN-74

ALTERNATOR

CN-12

ENGINE SIDE

CN-28

COMPRESSOR

6-14

8. CONNECTION TABLE FOR CONNECTORS 1) 58-L TYPE CONNECTOR

No. of pin Receptacle connector (female) 1 Plug connector (male) 1

S813-030100

S813-130100

S813-030200

S813-130200

6-15

2) PA TYPE CONNECTOR
No. of pin Receptacle connector (female) Plug connector (male)

3 S811-005002

5 S811-105002

4 S811-007002

7 S811-107002

5 S811-009002

9 S811-109002

11

11

6 S811-011002

11 S811-111002

6-16

No. of pin

Receptacle connector (female) 6 13

Plug connector (male) 1 7

13

7 S811-013002

13 S811-113002 1 9

17

17

1 10 1

9 S811-017002 21

17 S811-117002

11

21

11 S811-021002

1 10

21 S811-121002

6-17

3) J TYPE CONNECTOR
No. of pin Receptacle connector (female) 1 Plug connector (male) 2 1

2 S816-002001 2

1 2 S816-102001 3 1

1 S816-003001

2 S816-103001 4 2

2 S816-004001

1 S816-104001

3 1

5 2

5 2 S816-008001

3 1 S816-108001

6-18

4) SWP TYPE CONNECTOR

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

S814-001000 2

S814-101000 1

1 S814-002000 3

2 S814-102000 1

2 1 S814-003000 2 4

23 S814-103000 1 3

S814-004000

S814-104000

6-19

No. of pin

Receptacle connector (female) 3 6

Plug connector (male) 1 4

6 S814-106000

S814-006000 4 8 1

8 S814-108000

S814-008000
4 12 1

12

12

S814-012000
3 14
1

S814-112000
11

14

11

14

S814-014000

S814-114000

6-20

5) CN TYPE CONNECTOR
No. of pin Receptacle connector (female) Plug connector (male)

1 S810-001202

1 S810-101202

1 S810-002202 3

1 S810-102202 2

2 S810-003202

3 S810-103202 1 3

3 S810-004202

4 4 S810-104202

6-21

No. of pin

Receptacle connector (female)

3 6

Plug connector (male)

1 4

4 S810-006202 8 1

6 S810-106202 5

S810-008202

8 S810-108202

6-22

6) ITT SWF CONNECTOR

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

2 10 1 9 SWF593757 10

7) MWP NMWP CONNECTOR

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

1 1

NMWP01F-B

6-23

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

Receptacle connector (female)

Plug connector (male)

1 2

DT06-2S

DT04-2P

2 3

3 DT06-3S

3 DT04-3P

4 4 3

2 DT06-4S

3 DT04-4P

6-24

No. of pin

Receptacle connector (female)

Plug connector (male)

6 6

3 DT06-6S

4 DT04-6P

4 8

8 DT06-8S

1 DT04-8P

12

12 DT06-12S

12

1 DT04-12P

6-25

9) ECONOSEAL J TYPE CONNECTORS

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

S816-001002

S816-101002

1 2

S816-002002

S816-102002

S816-003002

S816-103002

S816-004002

S816-104002

6-26

No. of pin

Receptacle connector (female)

Plug connector (male)

S816-006002

S816-106002

S816-008002

S816-108002

10

S816-010002

S816-110002

12

S816-012002

S816-112002

6-27

No. of pin

Receptacle connector (female)

Plug connector (male)

15

368301-1

2-85262-1

10) KET 090 CONNECTOR

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

2 MG610070

6-28

11) KET 090 WP CONNECTORS

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

2 MG640605

2 MG640795

12) CHINA CONNECTORS

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

3 DJ7041-6.3-11

4 DJ7041-6.3-21

1 8 5 4

DJ7081-6.3-21

6-29

13) TYCO CONNECTOR

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

1 282080-1

2 174198-1

5 11

11

6 172497-1

6-30