Wheel Loader Sl730

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SECTION 1 GENERAL

Group 1 Safety Hints - - - 1-1

Group 2 Specifications - - - 1-10

Group 3 Operational Checkout Record Sheet - - - 1-19

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SECTION 1 GENERAL

FOLLOW SAFE PROCEDURE FOLLOW SAFE PROCEDURE

Unsafe wor k practices are dangerous. Understand service procedure before doing work; Do not attempt shortcuts.

WEAR PROTECTIVE CLOTHING WEAR PROTECTIVE CLOTHING

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

WARN OTHERS OF SERVICE WORK WARN OTHERS OF SERVICE WORK

Unexpected machine movement can cause serious injury.

Before performing any work on the wheel

load-er, attach a 「Do Not OperateDo Not Operate」 tag on the

right side controller lever.

USE HANDHOLDS AND STEPS USE HANDHOLDS AND STEPS

Falling is one of the major causes of personal inju-ry.

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.

GROUP 1 SAFETY HINTS

73031GE01

73032E01 830K1SH03E

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PREPARE FOR EMERGENCIES PREPARE FOR EMERGENCIES Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, a m bu l a n c e s e r v i c e, h o s p i t a l , a n d f i r e department near your telephone.

PROTECT AGAINST FLYING DEBRIS PROTECT AGAINST FLYING DEBRIS

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

PROTECT AGAINST NOISE 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.

WORK IN CLEAN AREA

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. · · · · 73031GE03 73031GE26 73031GE04 73031GE05

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SUPPORT MACHINE PROPERLY 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.

SERVICE COOLING SYSTEM SAFELY 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.

HANDLE FLUIDS SAFELY-AVOID FIRES 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.

PARK MACHINE SAFELY

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 73031GE06 73031GE07

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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.

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 REMOVE PAINT BEFORE WELDING OR HEATING

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.

· ·

73031GE09

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SERVICE MACHINE SAFELY 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.

STAY CLEAR OF MOVING PARTS STAY CLEAR OF MOVING PARTS

Entanglements in moving parts can cause serious injury.

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

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.

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AVOID HIGH PRESSURE FLUIDS 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.

AVOID HEATING NEAR PRESSURIZED

AVOID HEATING NEAR PRESSURIZED FLUID LINES

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.

PREVENT BATTERY EXPLOSIONS PREVENT BATTERY EXPLOSIONS

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

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

Do not charge a frozen battery; It may explode. Warm battery to 16˚C (60˚F).

73031GE14

73031GE15

73031GE16

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USE TOOLS PROPERLY 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.)

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.

Avoid the hazard by:

Filling batteries in a well-ventilated area. Wearing eye protection and rubber gloves. Avoiding breathing fumes when electrolyte is added.

Avoiding spilling of dripping electrolyte. Use proper jump start procedure. If you spill acid on yourself: Flush your skin with water.

Apply baking soda or lime to help neutralize the acid.

Flush your eyes with water for 10-15 minutes. Get medical attention immediately.

If acid is swallowed:

Drink large amounts of water or milk.

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

Get medical attention immediately. 1. 2. 3. 4. 5. 1. 2. 3. 1. 2. 3. 73031GE18 73031GE19

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SERVICE TIRES SAFELY 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.

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.

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LIVE WITH SAFETY LIVE WITH SAFETY

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

REPLACE SAFETY SIGNS REPLACE SAFETY SIGNS

Replace missing or damaged safety signs. See the machine operator's manual for correct safety sign placement.

KEEP ROPS INSTALLED PROPERLY

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.

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GROUP 2 SPECIFICATION

1. MAJOR COMPONENT

830K2SE01E Bucket Boom Bell crank Bucket link Muffler Fuel tank Engine Battery Tire Boom cylinder Bucket cylinder Front axle Head light

Main control valve

Cab

Steering cylinder

Main pump

Transmission Torque converter

Counterweight Raidator Hydraulic tank Air cleaner

Precleaner

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2. SPECIFICATIONS

WITH BOLT-ON CU

WITH BOLT-ON CUTTING EDGE TYPE BUCKETTTING EDGE TYPE BUCKET

1) 1) 5700 4880 3775 G K H J A E D C F I B 4895 40 830K2SE03E

Description Unit Specification

Operating weight kg (lb) 10200 (22490)

Bucket capacity Struck m3 (yd3₎ 1.5 (2.0)

Heaped 1.8 (2.4) Overall length A mm (ft-in) 6830 (22' 5") Overall width B 2450 (8' 1") Overall height C 3235 (10' 7") Ground clearance D 370 (1' 3") Wheelbase E 2850 (9' 4") Tread F 1850 (6' 1") Dump clearance at 45˚ G 2865 (9' 5")

Dump reach (full lift) H 1075 (3' 6")

Width over tires I 2300 (7' 7")

Dump angle J

degree (˚) 45

Roll back angle (carry position) K 49

Cycle time

Lift (with load)

sec

5.2

Dump (with load) 1.2

Lower (empty) 2.7

Maximum travel speed km/hr (mph) 39.5 (24.5)

Braking distance

m (ft-in) 13.1 (43' 0") Minimum turning radius (center of outside tire) 4.90 (16' 1")

Gradeability degree (˚) 30 Travel speed Forward First gear km/hr (mph) 7.4 (4.6) Second gear 13.3 (8.3) Third gear 23.9 (14.9) Fourth gear 39.5 (24.5)

Reverse First gear 9.2 (5.7)

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WITH TOOTH TYPE BUCKET WITH TOOTH TYPE BUCKET 2) 2) 5725 4880 3775 G K H J A E D C F I B 4895 40 830K2SE04E

Description Unit Specification

Operating weight kg (lb) 10200 (22490)

Bucket capacity Struck m3 (yd3₎

1.4 (1.8) Heaped 1.7 (2.2) Overall length A mm (ft-in) 6940 (22' 9") Overall width B 2480 (8' 2") Overall height C 3235 (10' 7") Ground clearance D 370 (1' 3") Wheelbase E 2850 (9' 4") Tread F 1850 (6' 1") Dump clearance at 45˚ G 2790 (9' 2")

Dump reach (full lift) H 1150 (3' 9")

Width over tires I 2300 (7' 7")

Dump angle J

degree (˚) 45

Roll back angle (carry position) K 49

Cycle time

Lift (with load)

sec

5.2

Dump (with load) 1.2

Lower (empty) 2.7

Maximum travel speed km/hr (mph) 39.5 (24.5)

Braking distance

m (ft-in) 13.7 (43' 0") Minimum turning radius (center of outside tire) 4.90 (16' 1")

Gradeability degree (˚) 30 Travel speed Forward First gear km/hr (mph) 7.4 (4.6) Second gear 13.3 (8.3) Third gear 23.9 (14.9) Fourth gear 39.5 (24.5)

Reverse First gear 9.2 (5.7)

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3. SPECIFICATION FOR MAJOR COMPONENTS

ENGINE ENGINE 1) 1) Item Specification Model YC6J125Z-T20

Type 4-cycle turbocharged diesel engine.

Control type Mechanical control

Cooling method Water cooling

Number of cylinders and arrangement 6 cylinders, in-line

Firing order 1-5-3-6-2-4

Combustion chamber type Direct injection type Cylinder bore × stroke 105×125 mm (4.1"×4.9") Piston displacement 6494 cc (396 cu in)

Compression ratio 17.5 : 1

Rated gross horse power 92 kW / 2200 rpm Maximum gross torque at 1400~1600 rpm 500 N·m

Engine oil quantity 16ℓ(4.2 U.S. gal)

Dry weight 650 kg (1430 lb)

High idling speed 2400±50 rpm

Low idling speed 725±50 rpm

Rated fuel consumption (at rated) 215 g/kW·hr

Starting motor 24 V-6 kW

Alternator 28 V-55 Amp

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MAIN CONTROL VALVE MAIN CONTROL VALVE 3)

3)

MAIN PUMP

MAIN PUMP (+steering pump) 2)

2)

Item Specification

Type Fixed displacement gear pump

Capacity 100＋50 cc/rev

Maximum operating pressure 200 kgf/cm2 (2840 psi)

Rated oil quantity 169ℓ/min (44.6 U.S.gpm)

Rated speed 2200 rpm

Item Specification

Type 2 spool

Operating method Mechanical control

Main relief valve set pressure 160 kgf/cm2 _{(2280 psi)}

Overload relief valve set pressure 180 kgf/cm2 _{(2560 psi)}

CYLINDER CYLINDER 4)

4)

Item Specification

Boom cylinder Bore dia×Rod dia×Stroke Ø110×Ø65×785 mm Bucket cylinder Bore dia×Rod dia×Stroke Ø160×Ø80×380 mm Steering cylinder Bore dia×Rod dia×Stroke Ø 70×Ø45×412 mm

DYNAMIC POWER TRANSMISSION DEVICES DYNAMIC POWER TRANSMISSION DEVICES 5)

5)

Item Specification

Transmission

Model YJ315/BS428

Type Converter Single-stage, Single-phase Transmission Mechanical, hydraulic

Gear shift Forward fourth gear, reverse second gear Control Mechanical single lever type

Axle

Drive devices 4-wheel drive Front Front fixed location

Rear Oscillation±12˚ of center pin-loaded

Wheels Tires 17.5-25, 14PR (L3)

Brakes Travel Four-wheel, dry-disc type, pneumatic Parking Disc type brake on transmission

Steering Type Hydraulic, articulated

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4. TIGHTENING TORQUE OF MAJOR COMPONENT

No. Descriptions Bolt size Torque

kgf·m lbf·ft 1

Engine

Engine mounting bolt (2EA) M24×3.0 100 ± 15 723 ± 108 2 Engine mounting bolt (bracket) M12×1.75 10.7 ± 1.6 77.4 ± 11.6 3 Radiator mounting bolt M16×2.0 29.7 ± 4.5 215 ± 32.5 4 Fuel tank mounting bolt M16×2.0 29.7 ± 4.5 215 ± 32.5 5

Hydraulic system

Main pump housing mounting bolt M12×1.75 12.8 ± 3.0 92.6 ± 21.7 6 Main control valve mounting bolt M12×1.75 12.8 ± 3.0 92.6 ± 21.7 7 Steering unit mounting bolt M10×1.5 6.9 ± 1.4 49.9 ± 10.1 8 Steering valve mounting bolt M10×1.5 6.9 ± 1.4 49.9 ± 10.1 9 Brake valve mounting bolt M8×1.25 2.5 ± 0.5 18.1 ± 3.6 10 Control lever mounting bolt M10×1.5 6.9 ± 1.4 49.9 ± 10.1 11 Hydraulic oil tank mounting bolt M16×2.0 29.7 ± 4.5 215 ± 32.5 12

Power train

Transmission mounting bolt M24×3.0 100 ± 15 723 ± 108 13 Transmission mounting bolt (bracket) M18×2.5 32.7 ± 4.9 237 ± 35.4 14 Torque converter housing mounting bolt

M12×1.75 10.7 ± 1.6 77.4 ± 11.6 15 Front axle mounting bolt, nut M30×2.0 200 ± 15 1447 ± 108 16 Tire mounting nut M20×1.5 61 ± 2.0 441 ± 14.5 17 Drive shaft joint mounting bolt, nut 1/2-20UNF 15.5 ± 0.5 112 ± 3.6 18

Others

Counterweight mounting bolt M30×2.0 199 ± 29.9 1439 ± 216 19 Operator seat mounting bolt

M8×1.25 3.4 ± 0.8 24.5 ± 5.8 20 Cab mounting bolt (4EA) M27×3.0 70 ± 10 506 ± 72.3

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5. TORQUE CHART

Use following table for unspecified torque.

Fine thread

Fine thread BOLT AND NUT BOLT AND NUT Coarse thread Coarse thread (1) (1) 1) 1) (2) (2) Bolt size 8T 10T kg·m lb·ft kg·m lb·ft M 6×1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 M 8×1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.7 ~ 29.8 M10×1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60 M12×1.75 7.4 ~ 11.2 53.5 ~ 79.5 9.8 ~ 15.8 71 ~ 114 M14×2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 167 M16×2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247 M18×2.5 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 343 M20×2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482 M22×2.5 48.3 ~ 63.3 350 ~ 457 65.8 ~ 98.0 476 ~ 709 M24×3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832 M30×3.0 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1655 M36×4.0 174 ~ 236 1261 ~ 1703 250 ~ 310 1808 ~ 2242 Bolt size 8T 10T kg·m lb·ft kg·m lb·ft M 8×1.0 2.17 ~ 3.37 15.7 ~ 24.3 3.04 ~ 4.44 22.0 ~ 32.0 M10×1.25 4.46 ~ 6.66 32.3 ~ 48.2 5.93 ~ 8.93 42.9 ~ 64.6 M12×1.25 7.78 ~ 11.58 76.3 ~ 83.7 10.6 ~ 16.0 76.6 ~ 115 M14×1.5 13.3 ~ 18.1 96.2 ~ 130 17.9 ~ 24.1 130 ~ 174 M16×1.5 19.9 ~ 26.9 144 ~ 194 26.6 ~ 36.0 193 ~ 260 M18×1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376 M20×1.5 40.0 ~ 54.0 289 ~ 390 53.4 ~ 72.2 386 ~ 522 M22×1.5 52.7 ~ 71.3 381 ~ 515 70.7 ~ 95.7 512 ~ 692 M24×2.0 67.9 ~ 91.9 491 ~ 664 90.9 ~ 123 658 ~ 890 M30×2.0 137 ~ 185 990 ~ 1338 182 ~ 248 1314 ~ 1795 M36×3.0 192 ~ 260 1389 ~ 1879 262 ~ 354 1893 ~ 2561

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FITTING FITTING

4)

PIPE AND HOSE

PIPE AND HOSE (FLARE type) 2)

2)

PIPE AND HOSE

PIPE AND HOSE (ORFS type) 3)

3)

Thread size (PF) Width across flat (mm) kgf·m lbf·ft

1/4" 19 4 28.9 3/8" 22 5 36.2 1/2" 27 9.5 68.7 3/4" 36 18 130 1" 41 21 152 1-1/4" 50 35 253

Thread size (UNF) Width across flat (mm) kgf·m lbf·ft

9/16-18 19 4 28.9 11/16-16 22 5 36.2 13/16-16 27 9.5 68.7 1-3/16-12 36 18 130 1-7/16-12 41 21 152 1-11/16-12 50 35 253

Thread size Width across flat (mm) kgf·m lbf·ft

1/4" 19 4 28.9 3/8" 22 5 36.2 1/2" 27 9.5 68.7 3/4" 36 18 130 1" 41 21 152 1-1/4" 50 35 253

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6. RECOMMENDED LUBRICANTS

Use only oils listed below or equivalent. Do not mix different brand oil.

Service point Kind of fluid _{ℓ (U.S. gal)}Capacity

Ambient temperature˚C (˚F) -20 (-4) -10 (14) 0 (32) 10 (50) 20 (68) 30 (86) 40 (104)

Engine oil pan Engine oil 16 (4.2)

Transmission Gear oil 40 (10.6)

Axle Gear oil Front : 15 (4.0) Rear : 15 (4.0)

Hydraulic tank Hydraulic oil

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

Fuel tank Diesel fuel 170 (44.9)

Fitting

(grease nipple) Grease As required

Radiator Mixture of antifreeze and water 50 : 50 33 (8.7) SAE 30 SAE 10W SAE 10W-30 SAE 15W-40 SAE 80W-90 ISO VG 32 ISO VG 46 ISO VG 68 ASTM D975 NO.1 ASTM D975 NO.2 NLGI NO.1 NLGI NO.2

Ethylene glycol base permanent type ATF DEXRON Ⅲ SAE 85W-90 ·SAE ·API ·ISO : : :

Society of Automotive Engineers American Petroleum Institute

International Organization for Standardization

: : :

National Lubricating Grease Institute American Society of Testing and Material Auto Transmission Fluid

·NLGI ·ASTM ·ATF

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GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET

·Owner ·Date ·Hours ·Serial No. ·Technician : : : : :

Use this sheet to record operational

Use this sheet to record operational checkout results.

checkout results.

Perform the operational check before Perform the operational check before installing any test equipment.

installing any test equipment.

Item 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 □ □

NOT OK ※

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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 □ □

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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 □ □

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SECTION 2 POWER TRAIN SYSTEM

Group 1 Structure and function - - - 2-1

Group 2 Transmission - - - 2-2

Group 3 Torque converter - - - 2-35

Group 4 Axle - - - 2-40

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GROUP 1 STRUCTURE AND FUNCTION

SECTION 2 POWER TRAIN SYSTEM

POWER TRAIN SYSTEM

Front axle

Ttansmission Upper shaft Torque converter Engine

Front drive shaft Center drive shaft Rear drive shaft Rear axle

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.

1. POWER TRAIN COMPONENT OVERVIEW

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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.

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Figure 1 Structure of transmission 10 9 8 7 6 5 4 3 2 1 11, 12 1 Transmission housing

2 Large end cover

3 Reverse shaft assembly

4 Input shaft flange

5 Input shaft assembly

6 Countershaft assembly

7 Rear output flange

8 Output shaft

9 Range gear sleeve

10 Oil tray

11 Front output flange

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Gear

Lever Gear selector lever High · low speed selector lever

Ⅰ Ⅱ Ⅲ

Forward 1 ● _{Low speed}

2 ● _F 3 ● _{High speed} 4 ● R Reverse 1 ● _F 2 ● _R

2. WORKING OF TRANSMISSION

As enumerated in figure 3, the transmission route is as follows: Forward gear Ⅰ transmission route : 1 - 15 - 7 - 9 - 3 - 11 - 13 - 17 - 4 Forward gear Ⅱ transmission route : 1 - 8 - 10 - 16 - 3 - 11 - 13 - 17 - 4 Forward gear Ⅲ transmission route : 1 - 15 - 7 - 9 - 12 - 17 - 4

Forward gear Ⅳ transmission route : 1 - 8 - 10 - 9 - 12 - 17 - 4

Reverse gear Ⅰ transmission route : 1 - 8 - 6 - 14 - 2 - 5 - 9 - 3 - 11-13 - 17 - 4 Reverse gear Ⅱ transmission route : 1 - 8 - 6 - 14 - 2 - 5 - 9 - 12 - 17 - 4

1 Input shaft

2 Rear gear shaft

3 Countershaft

4 Output shaft

5 Reverse shaft gear wheel

6 Reverse gear pinion

7 First & third gear input shaft

8 Second & forth gear input gear

9 First & third gear countershaft

10 Second & forth gear countershaft 11 Low gear countershaft

12 High gear output shaft 13 Low gear output shaft 14 Reverse gear clutch III 15 First & second gear clutch I 16 Second & forth gear clutch II 17 High & Low gear sliding sleeve

Figure 3 Working of transmission

Gear selector lever

High low speed selector lever . Low speed High speed I II III 830KPT19

(28)

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 kgf·m (661 lbf·ft)

82 kW

Countershaft, constant mesh, hydraulic fork 3.82 2.08 1.09 0.59 3.05 0.87 AFT (DEXRON Ⅲ)

CB32 (no in transmission box) 1.4 ~ 1.6 MPa

100˚C >0.55 MPa

(29)

Figure 4 Schematic diagram of oil system

1 Suction filtering device

2 Transmission pump

3 Transmission pressure valve

4 Overflow valve

5 Transmission control valve

6 Brake relief valve

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.

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.

Control valve Torque converter Cooler Torque converter valve block Lubrication Brake valve T/M part T/C part Oil cooling

(30)

Transmission control valve includes brake relief valve and transmission control valve. Orifice A on the valve body is connected to combined valve of transmission. When transmission valve spool moves, oil under pressure from combined valve of torque converter can flow into orifice C, D or E (C for clutch Ⅰ, D for clutch Ⅱ, E for clutch Ⅲ) to go forth or back for shift. Screw PT1/8” at E on the top of valve body is for connection of output to reverse gear.

When the brake pedal is pressed down, compressed air from the brake master cylinder has an air passage for brake valve spool to push the spool rod, cutting operating oil way (A and B is not connected). At the time, transmission is in neutral to ensure reliable braking.

Figure 5 Transmission control valve ass’y

5. TRANSMISSION CONTROL VALVE

assembly

M22×1.5

(31)

6. MOUNTING

Mount the transmission housing on the frame and fix with bolts. For mounting size, refer to the page 2-12.

CONNECTION CONNECTION

Input flange of transmission is connected with torque conver ter 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 :

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.

Connection screw on the end of brake control valve is connected to the air pipe of brake master cylinder.

Inlet for transmission control is located in Ⅰ-Ⅰ as illustrated in figure 5.

Inlet for spray oil of transmission is located in Ⅱ-Ⅱ.

Inlet for cooling transmission is located in Ⅲ-Ⅲ. (3) and (4) is connected to each correct port on combined valve of torque converter. (5) is connected to oil outlet of radiator. For positions of shift rod of range gear, see attached figure 1. There are three gears. The outside is high gear, the inside low gear, stroke between two adjacent gears is 15

mm. Connection sizes of handle are illustrated in figure 6. _{Figure 6}

1) 1)

USING USING

After mounting the transmission on the frame, add AFT (DEXRON Ⅲ) for about 40 liter from the filler and, 5 minutes after starting the engine, check the oil level for specified position on scale. After each shift work, it’s required to check the oil level of transmission.

During operation of transmission, be careful to check that its operating pressure is within 1.4~1.6 MPa, oil temperature at outlet of torque converter doesn’t exceed 105˚C, and 115˚C in short time, and that in the oil tray of transmission doesn’t exceed 100˚C.

Run in the transmission 12 hours after mounting on the frame, each 2 hours for 6 gears. The load in run-in period should not exceed 70% of the rated value, and frequently check oil temperature, oil level and tightness of bolts. After completion of run-in, clean the oil tray of transmission and oil-filter strainer, and renew oil.

Moving into reverse gear from a forward gear, into a forward gear from reverse gear, or moving between high and low gears must be conducted after parking.

Gear 1 and 2, or gear 3 and 4 can be changed with each other during travel. 2) 2) (1) (2) (3) (4) (5)

(32)

7. MAINTENANCE AND TROUBLESHOOTING

MAINTENANCE MAINTENANCE

Maintenance is carried out after running for 10, 50, 250, 500,1000 and 2000 hours. 10 hours ma

10 hours maintenanceintenance

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. 250

250 hours maintenancehours maintenance

Inspect operation and noise of transmission. Clean the filter.

500 hours mai

500 hours maintenancentenance

Renew oil. 1000 hours

1000 hours maintenancemaintenance

Replace oil filter.

2000 hours maint2000 hours maintenanceenance

Inspect operation, input power, noise, oil temperature, oil leaks, etc.

Clean air vent caps, fasten up screws and pipe fittings.

1) 1) (1) (1) ① ② ③ (2) (2) ① ② (3) (3) (4) (4) ① (5) (5) ① ① ②

(33)

TROUBLESHOOTING TROUBLESHOOTING

Problem Cause Remedy

Too low oil pressure or zero

1. Transmission gear pump does not supply oil 2. Failed reducing valve of torque converter. 3. Stuck brake valve.

4. Oil leaks in oil circuit.

5. Failed piston packing of clutch. 6. Failed O-ring of transmission valve. 7. Seal ring is failed.

8. Emptying valve for clutch has fallen off.

Repair. Repair. Repair. Repair.

Service and repair. Replace.

Replace.

Check and repair. Too high oil pressure 1. Malfunction in overflow valve for torque converter.

2. Clogged oil circuit. 3. Incorrect oil is used.

Repair. Clean. Renew oil. 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 completely.

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

Replace.

Engine runs but vehicle will not move

1. Insufficient oil.

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.

See “Too low oil pressure trouble”.

Reengage gear. Check brake spool. Replace.

Repair. Weak traction 1. Low oil pressure.

2. Clutch friction plate can not be separated completely and dragging.

3. Insufficient oil supply.

See “Too low oil pressure trouble”.

Repair.

Replenish oil.

2) 2)

(34)

NOTES IN REPAIR OPERATION NOTES IN REPAIR OPERATION

Following cares should be taken to reassemble the transmission after disassembly:

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.

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.

3) 3) (1) (2) ① ② ③

(35)

Vie w K F ront Rear Flange C Input flange A Hi-Neutr al-Lo Range Gear le ve r Vie w K Oil retur n por t Output flange B

Pressure oil por

t

Pressure tap

Cooling oil por

t Oil spr a y por t 7. STRUCTURE 7. STRUCTURE

(36)

9 66 62 65 2 3 6 7 5 9 8 15 14 10 1112 16 11 17 9 52 1415 13 8 9 19 18 20 2822 29 26 27 24 23 22 21 7 6 5 4 34 35 31 30 1 4 8 9 13 25 33 32 63 64 1 Housing 2 Name plate 3 Rivet 4 Bracket 5 Hexagon bolt 6 Spring washer 7 Hexagon nut 8 Hexagon bolt 9 Washer 10 End cover 11 Gasket 12 Regulating ring 13 Regulating screw 14 Hexagon bolt 15 Stop plate

16 Input shaft end cover 17 Seal

18 Middle shaft end cover 19 Gasket 20 Regulating ring 21 Nut 22 Washer 23 Connector 24 Washer plate 25 Strainer core 26 Bolt 27 Flange joint 28 Hexagon bolt 29 O-ring 30 Gasket 31 Sump 32 Suction pipe 33 Magnetic 34 Oring 35 Plug 52 Hexagon bolt 62 Housing cover 63 Cover sheet

64 Semi circular rivet

65 Gasket 66 Hexagon bolt 830KPT05 TRANSMISSION HOUSING TRANSMISSION HOUSING (1/2) 2) 2)

(37)

58 57 53 55 54 56 61 60 59 68 48 9 44 46 45 43 67 952 67 52 9 45 67 44 42 43 52 9 46 45 44 43 8 9 50 51 51 49 37 36 39 42 40 38 22 47 41 830KPT06 TRANSMISSION HOUSING TRANSMISSION HOUSING (2/2) 8 Hexagon bolt 9 Washer 22 Washer 36 O-ring 37 Pipe assy 38 Hexagon bolt

39 Pipe & dipstick 40 Seal 41 O-ring 42 Cover 43 Bush 44 Washer 45 Bush

46 Input end cover

47 Dowel pin

48 Socket pin

49 Washer

50 Input sealing cover

51 Input seal 52 Hexagon bolt 53 Air vent 54 Square nut 55 Vent plate 56 Sleeve 57 Plate 58 Sleeve 59 Long screw 60 Casing 61 Gasket 67 Plug 68 Plug

(38)

830KPT07 1 2 3 4 5 6 7 7 9 10 8 11 12 13 14 13 15 16 18 17 17 19 13 20 13 12 11 6 21 5 4 3 2 1 24 2223 OUTPUT SHAFT OUTPUT SHAFT 3) 3) 1 Hexagon bolt 2 Stop pad 3 Pressure plate 4 O-ring 5 Output flange 6 Dust cover 7 Seal output

8 Output rear end cover

9 Hexagon bolt 10 Washer 11 Ball bearing 12 Thrust ring 13 Sliding bearing 14 Ring 15 Gear

16 High-low sliding sleeve

17 Steel ball 18 Output shaft 19 Output gear 20 Ring 21 Brake drum 22 Nut 23 Spring washer 24 Bolt

(39)

830KPT08 1516 17 18 19 21 24 20 28 27 5 29 30 31 32 33 23 22 26 25 1 23 4 5 6 8 9 10 9 8 11 12 13 14 7 INTPUT SHAFT INTPUT SHAFT 4) 4)

1 Small ring nut

2 Stop washer

3 Washer 4 Flange

5 Taper roller bearing

6 Input shaft 7 Plug 8 Hole ring 9 Ball bearing 10 Gear 11 Snap ring

12 Outer end cover

13 External friction disc

14 Internal friction disc

15 Snap ring 16 Spring seat 17 Spring 18 Piston 19 Sealing ring 20 O - ring

21 Clutch case assy

22 Steel ball 23 Valve seat 24 Gear 25 Stop pad 26 Hexagon bolt 27 Pin 28 Bush

29 Inner sealing sleeve

30 Piston ring

31 Shaft end baffle

32 Stop pad

(40)

1 2 3 4 5 6 7 8 9 1011 12 1110 13 14 15 16 1718 19 20 21 22 23 26 29 6 2425 27 28 INTERMEDIATE SHAFT INTERMEDIATE SHAFT 5) 5) 830KPT09 1 Hexagon bolt 2 Stop pad

3 Shaft end baffle

4 Piston ring

6 Roller bearing 7 Gear 8 Plug 9 Intermediate shaft 10 Hole ring 11 Ball bearing 12 Gear 13 Snap ring

14 Outer end cover

17 Snap ring 18 Spring seat 19 Spring 20 Pistion 21 Sealing ring 22 O-ring

23 Clutch case assy

24 Steel ball 25 Valve seat 26 Gear 27 Stop pad 28 Hexagon bolt 29 Pin

(41)

830KPT10 1 2 3 4 5 6 7 8 9 1011 12 1110 13 14 15 16 1718 19 20 21 23 22 26 29 6 25 24 27 28 REVERSE SHAFT REVERSE SHAFT 6) 6) 1 Hexagon bolt 2 Stop pad

3 Shaft end baffle

4 Piston ring

6 Roller bearing 7 Sleeve 8 Plug 9 Reverse shaft 10 Hole ring 11 Ball bearing 12 Gear 13 Snap ring

14 Outer end cover

17 Snap ring 18 Spring seat 19 Spring 20 Piston 21 Sealing ring 22 O-ring

23 Clutch case aasy

24 Steel ball 25 Valve seat 26 Stop pad 27 Hexagon bolt 28 Stop pad 29 Pin

(42)

830KPT11 6 7 13 12 11 10 4 5 2 1 3 8 9

HIGH-LOW SPEED SHIFT FORK

HIGH-LOW SPEED SHIFT FORK 7)

7)

1 Pin

2 Socket screw

3 HIgh-low shift fork

4 Gasket 5 Fork support 6 Washer 7 Hexagon bolt 8 Seal 9 Fork shaft 10 Plug 11 Washer 12 Steel ball 13 Spring

(43)

830KPT12 12 12 11 10 9 13 14 15 16 17 22 23 24 26 25 7 8 5 7 6 1 2 3 4 27 28 11 10 20 21 19 18 9 CONTROL VALVE CONTROL VALVE 8) 8) 1 Screw 2 Washer 3 Spring 4 Steel ball 5 Dust cover 6 Pressure tap 7 Washer 8 Plug 9 Snap ring 10 Seal 11 Regulating washer

12 Control sliding valve

13 Dust cover

14 Plug 15 O-ring 16 Cup

17 Brake sliding valve

18 Spring 19 O-ring 20 Spring seat 21 Plug 22 Valve body 23 Gasket 24 Bottom plate 25 Socket screw 26 Screw 27 Hexagon bolt 28 Washer

(44)

830KPT13 1 2 1 2 3 5 4 3 6 13 14 19 7 7 8 9 10 10 11 12 15 25 26 24 16 17 18 28 29 27 23 14 20 21 22 PARKING VALVE PARKING VALVE 9) 9)

1 Parking brake bracket

2 Cam plate

3 Washer

4 Split pin

5 Axis pin

6 Set screw

7 Set screw spring

8 Set screw spring

9 Washer 10 Nut

11 Nut

12 Hexagon bolt

13 Upper fixed plate

14 Semi circular rivet

15 Lower fixed plate

16 Rivet 17 Friction pad 18 Bracket 19 Steel band 20 Bracket 21 Bolt 22 Iron wire 23 Regulating spring 24 Bracket 25 Bolt 26 Washer 27 Bracket 28 Hexagon bolt 29 Spring washer

(45)

Unscrew the M20×1.5 bolts on the oil pan with a spanner and make drainage fully. 830KTM10 M20×1.5 bolts 830KTM11 830KTM12 M10×30 bolts

8. DISASSEMBLY

DRAINAGE FOR TRANSMISSION DRAINAGE FOR TRANSMISSION

Hoist transmission up and put an oil

container under it.

1) 1) (1)

(2)

OIL PAN OF TRANSMISSION OIL PAN OF TRANSMISSION

Unscrew 20 - M10×30 bolts in sequence on the oil pan with a spanner. As disassembly, two diagonal bolts should be

removed finally to prevent from injury to

people due to falling oil pan.

Be careful of remaining oil in the oil pan when the last two bolts are removed. Put the oil pan removed in a clean place. 2) 2) (1) (2) (3) 830KTM13

(46)

830KTM14 HAND BRAKE ASSY

HAND BRAKE ASSY

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

3) (1)

830KTM15 Remove 4 - M8×25 bolts on the right

bracket of handbrake with a spanner. Pull the total hand brake assy out and put it in a clean place.

(2)

(3)

830KTM16 REMOVING FRONT & REAR OUTPUT

REMOVING FRONT & REAR OUTPUT FLANGE

FLANGE

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

4) 4)

(1)

830KTM17 Remove the bolt lock plate at the rear

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

(47)

830KTM18 REMOVING INPUT FLANGE

REMOVING INPUT FLANGE

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

5) 5) (1)

830KTM19 REMOVING GEAR SHIFT FORK (HI

REMOVING GEAR SHIFT FORK (HI AND LO SPEED

AND LO SPEED)

Put the transmission level, release the set screw lock on the gear shift fork mount and unscrew the M10 set screw with M14 spanner.

Unscrew 4 - M10×30 bolts on the fork mount with a spanner and tap lightly the mount assy out with a copper bar and put it in a clean place.

6) 6) (1) (2) 830KTM20 830KTM21 REMVING OUTER END COVER OF

REMVING OUTER END COVER OF TRANSMISSION

TRANSMISSION

Put the transmission level with the input side up.

Unscrew 4 - M10×25 bolts on the end covers of input shaft, intermediate shaft and reverse shaft with a spanner and then use 2 - M10×25 bolts to push the three end covers out and put them in a clean place.

Unscrew 8 - M10×30 bolts on the rear end cover of output shaft and use 2 M10×30 bolts to push the rear end cover out and put it in a clean place.

7) 7)

(1) (2)

(48)

830KTM22 Turn the transmission for other side and

place it level.

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

(5)

830KTM23

830KTM24 Unscrew 4 - M10×25 bolts on the seal

cap of front output shaft with a spanner and use 2 - M10×25 bolts to push it out and put in a clean place.

(6)

830KTM25 Unscrew 13 - M10×30 socket bolts on the

large end cover with a socket wrench and then use 2 - M10×45 bolts to push it out and put in a clean place.

(49)

830KTM26 REMOVING

REMOVING CLUTCHESCLUTCHES

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.

8) 8) (1)

830KTM27

830KTM28 Set the input parts up as illustrated in the

figure and use a flat chisel to release two bolt locks and then unscrew 2 - M8×16 bolts with a spanner and use a copper bar to tap the input shaft out.

Use a flat taper to release the bolt lock onthe clutch assy and unscrew 8 - M10×25 bolts with a spanner.

Remove the retainer with a screwdriver, and then the outer end cover 6 outer friction plates and 5 inner plates in order. Use a tool to remove 60 retaining ring from clutch case, and then inner spring seat, spring and piston in order.

(2)

(3)

(4)

(5)

(50)

830KTM30 REMOVING OUTPUT SHAFT

REMOVING OUTPUT SHAFT

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.

9) 9) (1)

(51)

9. ASSEMBLY

ASSEMBING INPUT CLUTCH PARTS ASSEMBING INPUT CLUTCH PARTS

Check the clutch valve seat (23) and internal steel ball (22) for looseness.

Use a spanner to screw up 8 - M10×25 bolts to fasten gear I part drive gear (24) to clutch case assy (21).

Put up glue and knock in 2 straight pins (27).

Unscrew 8- M10×25 bolts with a spanner and put up 4 stop plates (25) and fasten up 8 - M10 ×25 bolts and lock up 4 stop plates with flat taper.

Fit the oil seal ring (19) into piston (18) groove with the broken opening toward gear. Fit O-ring (20) into place on clutch case.

Tap the piston assy into the oil cylinder of clutch case with a tool.

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).

Put up 6 outer plates (13) and 5 inner plates (14) alternatively, and assemble outer end cover (12)

and retainer (11) finally.

Knock 2 annular ball bearing into the bore of gear I drive gear (10) and mount two retainer (8) to set.

Mount the gear I drive gear assy into the clutch assy. Insert input shaft (6) into the bore of gear I drive gear assy.

Knock the bearing (5) onto the input shaft with the special tool and mark on the inner and outer ring of the bearing.

Turn and mount sleeve (28) and knock the inner ring of bearing and oil seal (29) onto the input shaft respectively.

Apply glue and knock stop plug (7) in and then assemble end plate (31) and then stop washer (32) and fasten up 2 - M8×16 with a spanner and make the two sides lock of stop washer with a flat taper. (1) (2) (3) (4) (5) (6) (7) (8) (9) 1516 17 18 19 21 24 20 28 27 5 29 30 3132 33 23 22 26 25 1 23 4 5 6 8 9 10 9 8 11 12 13 14 7 830KPT08 (10) (11) (12) (13) (14) (15) 1) 1)

(52)

Check the valve seat (25) of clutch case assy (23) and internal steel ball (24) for looseness. Use a spanner to screw up 8 - M10×25 bolts to fasten gear II drive gear (26) to clutch case assy.

Put up glue and knock in 2 straight pins (29).

Unscrew 8 - M10×25 bolts with a spanner and put up 4 stop plates (27) and fasten up 8 - M10 ×25 bolts and lock up 4 stop plates with flat taper.

Tap the piston assy into the oil cylinder of clutch case with a tool.

Put up 6 outer plates (15) and 5 inner plates (16) alternatively, and assemble outer end cover (14) and retainer (13) finally.

Knock two annular ball bearings (11) into the bore of gear II drive gear (12) and mount two retainers (10) to set.

Mount the gear II drive gear assy into the clutch assy.

Insert intermediate shaft (9) into the bore of gear II drive gear assy.

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. Knock inner seal (5) onto the intermediate shaft with special tool.

Apply glue and knock stop plug (8) in and then assemble end plate (3) and then stop washer (2) (1) (2) (3) (4) (5) (6) (7) (8) (9) 1 2 3 4 5 6 7 8 9 1011 12 1110 13 14 15 16 1718 19 20 2122 23 26 29 6 2425 27 28 830KPT09 (10) (11) (12) (13) (14) (15)

ASSEMBLING INTERMEDIATE SHAFT CLUTCH PARTS ASSEMBLING INTERMEDIATE SHAFT CLUTCH PARTS 2)

(53)

Check the valve seat (25) of clutch case assy (23) and internal steel ball (24) 5 for looseness. Use M16 spanner to screw up 8 - M10×25 bolts to fasten reverse gear reverse gear (26) to clutch

case assy.

Apply glue and knock in 2 straight pins (29).

Unscrew 8-M10×25 bolts with a spanner and put up 4 stop plates (27) and fasten up 8 - M10 ×25 bolts and lock up 4 stop plates with flat taper.

Tap the piston assy into the cylinder of clutch case with a tool.

Put up 6 outer plates (15) and 5 inner plates (16) alternatively, and assemble outer end cover (14)

and retainer (13) finally.

Knock two annular ball bearings (11) into the bore of reverse drive gear (12) and mount two retainers (10) to set.

Mount the reverse drive gear assy into the clutch assy.

Insert reverse gear shaft (9) into the bore of reverse drive gear assy.

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.

Knock inner seal (5) onto the reverse gear shaft with special tool.

Apply glue and knock stop plug (8) in and then assemble end plate (3) and then stop washer (2) and fasten up 2 - M8×16 with a spanner and make the two sides lock of stop washer with a flat taper.

Put 2 piston rings (4) into inner seal groove. (1) (2) (3) (4) (5) (6) (7) (8) (9) 1 2 3 4 5 6 7 8 9 1011 12 1110 13 14 15 16 1718 19 20 21 23 22 26 29 6 25 24 27 28 830KPT10 (10) (11) (12) (13) (14) (15) (16)

ASSEMBLING REVERSE SHAFT CLUTCH PARTS ASSEMBLING REVERSE SHAFT CLUTCH PARTS 3)

(54)

830KTM35 ASSEMBLING OUTPUT SHAFT PARTS

ASSEMBLING OUTPUT SHAFT PARTS Mount four composite bearings to high s p e e d g e a r a n d l o w s p e e d g e a r respectively. 4) 4) (1) 830KTM36 Insert high and low speed sleeve gear,

high speed gear and bearing onto the output shaft.

(2)

830KTM37 ASSEMBLY

ASSEMBLY

Mount the left bracket and right bracket of h a n d b r a k e a t t h e o u t p u t s i d e o f transmission onto the transmission box and set with four M8×25 bolts and M12×30 bolts respectively.

Mount the bearing outer rings into the bearing bore respectively and mark. 5)

5) (1)

(2)

830KTM38 Mount the intermediate shaft assy, reverse

gear shaft assy and output shaft assy into their correct place on the box.

(55)

830KTM39 Mount bearing into the bore for bearing on

the large end cover. (4)

830KTM40 Mount the large end cover into the box

and put up a paper gasket in the middle. Assemble the outer seal into the oil inlet end cover.

Mount the oil inlet end covers in place on the box watching oil orifice position.

(5)

(6)

(7)

830KTM41 Assemble the front output flange and

handbrake assy. (8)

(56)

830KTM43 Assemble the low speed gear assy into

the box. (9)

830KTM44 Assemble the output shaft assy.

(10)

830KTM45 Assemble rear end cover of output shaft

and rear output flange.

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

(11)

(12)

(13)

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

(14) (15)

(57)

830KTM47

830KTM48 Mount the oil pan and set with 20 -

M10×30 bolts. (16)

830KTM49 Mount the control valve assy and top

plate and connect with 8-M10×45 and 4 - M10×35 bolts

(58)

GROUP 3 TORQUE CONVERTER

1. FEATURES AND USE

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

2. WORKING

The pump pulley connects to engine flywheel by a connection wheel and flexible steel board. Driven by mechanical energy from engine, the unit transforms the energy into hydraulic power, which drives the turbine to be transformed into mechanical energy and outputted by power output members. Guide pulley has functions to change direction of operating flow and give a counter torque to the flow to change torque and speed.

The oil inlet valve consists of main pressure valve and an overflow valve. Function of the main pressure valve is to ensure sufficient oil supply to torque converter and that oil pressure range in speed change oil circuit of engine is within 1.30 ~ 1.50 MPa. The function of overflow valve is to build up a compensatory pressure to the system and, by different loading of torque converter and variation of internal pressure of hydraulic oil, automatically control the flow passing through the torque converter to control the heat dissipating capacity of torque converter and provide overpressure protection when the outlet port of torque converter is clogged.

3. TECHNICAL DATA

Limit input torque 69.3 kgf·m (502 lbf·t)

Nominal torque at zero-speed loading 5.8 kgf·m (42.2 lbf·t) Nominal torque at high efficiency loading 6.1 kgf·m (44.1 lbf·t)

Torque ration at zero-speed loading 3.24

Max. efficiency 0.836

Width of high efficiency region 2.032

Net weight 159kg

(59)

4. MOUNTING AND USAGE

MOUNTING MOUNTING

When mounting, ensure that centerline of rotation of torque converter coincide with that of crankshaft of engine (see page 2-39).

USAGE USAGE

Hydraulic torque converter uses AFT (DEXRON Ⅲ). Oil temperature should be within 85~100˚C,

and not exceed 110˚C normally.

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.

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.

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.

It’s required to renew oil for hydraulic torque converter after 30~50 hours of operation and then renew for second time after 500 hours of operation. After that, renew oil in the same time interval. 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.

1) 1) 2) 2) (1) (2) (3) (4) (5) (6)

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5. OIL SUPPLY SYSTEM

Working principle of oil supply system of hydraulic torque converter.

1 Cooler

2 Hydraulic torque converter

3 Main pressure valve Opening pressure 1.3 ~ 1.5 MPa 4 Overflow valve Opening pressure 1.3 ~ 1.5 MPa 5 Flow Q ≥ 50 ℓ/min

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6. TROUBLESHOOTING

Problem Cause Increase engine rpm

I n s u f f i c i e n t power output

Engine rpm drops. Increase engine rpm. Gas exists in hydraulic oil. Check transmission oil level.

Check for tightness of tubing system. Check for deteriorated hydraulic oil. Too high hydraulic oil temperature. Lower oil temperature.

Too low pressure of overflow valve of hydraulic torque converter.

Check for sensitivity of motion of overflow valve and hydraulic oil leaks.

Too high oil temperature

Too long time of operation in low efficiency region.

Decrease external load or increase engine rpm.

Too low oil level in oil tank or gas exists in hydraulic oil.

Add hydraulic oil, check for tightness of the connections of piping, and check for deteriorated oil. Oil does not meet requirements. Use oil as recommended in operator's manual. Too low oil pressure in oil supply

system.

Repair hydraulic valve, increase oil pressure.

Low water level in cooling system. Repair water tank. Insufficient oil supply. Check oil supply system. To o l o w o i l

pressure in oil supply system

Back pressure valve failure. Replace back pressure valve. Clogged oil feed tube. Check oil tubing.

Insufficient oil supply of transmission oil pump.

Check and repair oil pump, or replace.

Damaged or severely worn oil seal inside hydraulic torque converter.

Replace oil seal.

Too low oil level in oil tank. Add hydraulic oil.

Clogged suction filter. Clean or replace the filter. Failed pressure gauge. Replace the pressure gauge. Oil leakage Damaged reinforced oil seal.

Damaged O-ring.

Replace the oil seal. Replace the O-ring.

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7. OUTSIDE VIEW

Ov

erflo

w pressure

Total 3 positions of spline

Opening pressure

Torque con

ve

rter oil supply system diag

ra m Vie w A Vie w A Pressure measur ing por t Lifting hole Oil o verflo w por t To center Oil retur n por t Total 3 spots Oil o verflo w por t Total 3 spots Length of spline To center

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GROUP 4 AXLE

1. 1. OUTLINE

OUTLINE

PRODUCT SURVEY 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.

MAIN PERFORMANCE AND TECHNICAL PARAMETERS MAIN PERFORMANCE AND TECHNICAL PARAMETERS

THE STRUCTURAL CHARACTERISTICS AND WORKING PRINCIPLE THE STRUCTURAL CHARACTERISTICS AND WORKING PRINCIPLE

Main s

Main structural characteristicstructural characteristics

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

Working principle Working principle 1) 1) 2) 3) 3) (1) (1) (2) (2) Axle model

Main technical parameters

Max. load Max. input

torque Total ratio Main ratio

Wheel-end ratio

Braking

moment Oil pressure

ZL30 18500 kg 235 kgf·m

(1700 lbf·ft) 20.26 4.222 4.8

979 kgf

(7080 lbf·ft) 9.8 MPa

Wheel reductor Axle shaft

Final drive Input flange

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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.

Transmiss

Transmission route of drive axle as follows:ion route of drive axle as follows:

Power torque of vehicle → Input flange → Final drive → Differential → Axle shafts → Wheel-end reductors → Wheels.

MAINTENANCE MAINTENANCE

Must lubricate for new drive axle before it is mounted on vehicle. Recommended the lubricant: SAE85W-90.

When refuel oil, should separately refuel it from oil inlets at bowl of the middle of axle housing and at two sides wheel-end.

Oil amount

Front axle : 24ℓ(6.3 U.S.gal) Real axle : 24ℓ(6.3 U.S.gal)

Maintenance per 250 hoursaintenance per 250 hours

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 don’t 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.

Maintenan

Maintenance per 1000 hoursce per 1000 hours

Lubricant in drive axle work per 1000 hours to replace once new oil. Maintenance pe

Maintenance per 2000 hoursr 2000 hours

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. 4) 4) (1) (2) (2) · ① ② ③ (3) (3) (4) (4) ① ② ③ ④