Doosan DISD SD 310 Shop Manual

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SD 310

Shop Manual

950106-01386

Serial Number 010001 and Up (Tier II)

July 2012

DISD reserves the right to improve our products in a continuing process to provide the

best possible product to the market place. These improvements can be implemented at

any time with no obligation to change materials on previously sold products. It is

recommended that consumers periodically contact their distributors for recent

documentation on purchased equipment.

This documentation may include attachments and optional equipment that is not available

in your machine's package. Please call your distributor for additional items that you may

require.

Illustrations used throughout this manual are used only as a representation of the actual

piece of equipment, and may vary from the actual item.

950106-01386 Shop Manual

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Summary of Contents for Doosan DISD SD 310

Page 1 SD 310 Shop Manual 950106-01386 Serial Number 010001 and Up (Tier II) July 2012 DISD reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products.
Page 3 TABLE OF CONTENTS Safety Wheel Loader Safety ..................S0103010K Specifications Specifications for SD310 ................SPC000001 General Maintenance General Maintenance Procedures..............S0302000 Standard Torques.................... S0309000 Frame Counterweight....................SPC000003 Center Joint (Articulation Joint)..............SPC000005 Engine and Drive Train Engine....................... SPC000006 Transmission and Torque Converter …………..........SPC000007 Front Axle .....................SPC000009 Rear Axle ....................SPC000010 Hydraulics...
Page 4 Electrical System Air Conditioner....................SPC000024 Electrical System ..................SPC000025 Electrical Schematic ...................SPC000027 Attachments Table of Contents Page 2...
Page 5 1SAFETY...
Page 7 S0103010K 2WHEEL LOADER SAFETY WHEEL LOADER SAFETYS0103010K CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load.
Page 8: Table Of Contents
TABLE OF CONTENTS To the Operator of a DISD Wheel Loader ................3 General Safety Essentials ....................6 Location of Safety Labels ....................6 Unauthorized Modifications....................6 General Hazard Information ....................7 Before Starting Engine ...................... 15 Machine Operation ......................18 Maintenance........................
Page 9: To The Operator Of A Disd Wheel Loader
TO THE OPERATOR OF A DISD WHEEL LOADER DANGER! Unsafe use of the wheel loader could lead to serious injury or death. Operating procedures, maintenance and equipment practices or traveling or shipping methods that do not follow the safety guidelines on the following pages could cause serious, potentially fatal injuries or extensive damage to the machine or nearby property.
Page 10 WARNING! Improper operation and maintenance of this machine can be hazardous and could result in serious injury or death. Operator and maintenance personnel should read this manual thoroughly before beginning operation or maintenance. Keep this manual in the storage compartment to the rear of the operator’s seat, and have all personnel involved in working on the machine periodically read the manual.
Page 11 SAFETY ALERT SYMBOL Be Prepared - Get to Know All Operating and Safety Instructions This is the Safety Alert Symbol. Wherever it appears - in this manual or on safety signs on the machine - you should be alert to potential for personal injury or accidents. Always observe safety precautions and follow recommended procedures.
Page 12: General Safety Essentials
GENERAL SAFETY ESSENTIALS ACCESSORY APPLICATIONS This wheel loader has been designed primarily for moving earth with a bucket. For use as a grapple or for other object handling, contact Daewoo. Lifting-work applications are permitted in approved lift configuration, to rated capacity only, with no side-loading (unless prohibited by local regulation). Do not use machine for activities for which it was not intended.
Page 13: General Hazard Information
GENERAL HAZARD INFORMATION SAFETY RULES Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. Do not operate the machine if you are not feeling well, if you are taking medication that makes you feel sleepy, if you have been drinking, or if you are suffering from emotional problems.
Page 14 INSIDE OPERATOR'S COMPARTMENT When entering the operator's compartment, always remove all mud and oil from the soles of your shoes. If you operate the accelerator and brake pedals with mud or oil stuck to your shoes, your foot may slip and this may cause a serious accident.
Page 15 BREATHING MASKS, EAR PROTECTION MAY BE REQUIRED Do not forget that some risks to your health may not be immediately apparent. Exhaust gases and noise pollution may not be visible, but these hazards can cause disabling or permanent injuries. ASBESTOS DUST HAZARD PREVENTION Asbestos dust can be HAZARDOUS to your health if it is inhaled.
Page 16 FUEL, OIL AND HYDRAULIC FLUID FIRE HAZARDS Fuel, oil and antifreeze will catch fire if it is brought close to a flame. Fuel is particularly flammable and can be hazardous. Always strictly observe the following. Add fuel, oil, antifreeze and hydraulic fluid to the machine only in a well-ventilated area.
Page 17 INJURY FROM WORK EQUIPMENT Do not enter or put your hand, arm or any other part of your body between movable parts, such as between the work equipment and cylinders, or between the machine and work equipment. If the control levers are operated, the clearance between the machine and the work equipment will change and this may lead to serious damage or personal injury.
Page 18 PROTECTION FROM FALLING OR FLYING OBJECTS On work sites where there is danger that falling objects or flying objects may hit the operator's cab select a guard to match the operating conditions to protect the operator. Work in mines, tunnels, deep pits or on loose or wet surfaces could produce danger of falling rock, roll over hazardous...
Page 19 ATTACHMENT PRECAUTIONS Options kits are available through your dealer. Contact DISD for information on available one-way (single- acting) and two-way (double-acting) piping / valving / auxiliary control kits. Because DISD cannot anticipate, identify or test all attachments that owners may wish to install on their machines, please contact DISD for authorization and approval of attachments and their compatibility with options kits.
Page 20: Before Starting Engine
BEFORE STARTING ENGINE WORK SITE PRECAUTIONS Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. Check the terrain and condition of the ground at the work site, and determine the best and safest method of operation.
Page 21 CHECKS BEFORE STARTING ENGINE Every day before starting the engine for the first time, carry out the following checks. If these checks are not carried out properly, there is danger of serious injury. • Completely remove all wood chips, leaves, grass, paper and other flammable materials accumulated in the engine compartment and around the battery.
Page 22 BEFORE OPERATING MACHINE If checks are not carried out properly after starting the engine, it may result in a delay in discovering abnormalities in the machine, and this may lead to personal injury or damage to the machine. Carry out the checks in an open area where there are no obstructions. Do not let anyone near the machine when carrying out the checks.
Page 23: Machine Operation
MACHINE OPERATION IMPORTANT If you need more information or have any questions or concerns about safe operating procedures or working the wheel loader correctly in a particular application or in the specific conditions of your individual operating environment, please consult your local DISD representative. OPERATE WHILE SEATED AT OPERATOR’S STATION ONLY Never reach in through a window to work a control.
Page 24 TRAVEL PRECAUTIONS When traveling, wheel loader always keeps lights on; make sure that you are in compliance with all state and local regulations concerning warning flags and signs. Never turn the starter switch to the "O" (OFF) position when traveling. It is dangerous if the engine stops when the machine is traveling.
Page 25 AVOID HIGH-VOLTAGE CABLES Serious injury or death can result from contact or proximity to high-voltage electric lines. The bucket does not have to make physical contact with power lines for current to be transmitted. Use a spotter and hand signals to stay away from power lines not clearly visible to operator.
Page 26 USE SOLID SUPPORT BLOCKING Never rely on lift jacks or other inadequate supports when work is being done. Block wheels fore and aft to prevent any movement. DIGGING BENEATH OVERHANGS Digging beneath an overhang is dangerous. Overhand could collapse on top of operator and cause serious injury or death.
Page 27 NEVER USE ETHER STARTING AIDS An electric-grid type manifold heater is used for cold starting. Glowing heater element can cause ether or other starting fluid to detonate, causing injury. Figure 19 OBSERVE GENERAL SAFETY RULES Only trained and authorized personnel, with a good knowledge and awareness of safe procedures, may be allowed to operate or perform maintenance or service on wheel loader.
Page 28 KEEP "PINCH POINT" AREAS CLEAR – USE CAUTION IN REVERSE Use a signal person in high traffic areas and whenever operator‘s view is not clear, such as when traveling in reverse. Anyone standing near wheels, working assemblies of the attachment, is at risk of being caught between moving parts of machine.
Page 29 SHUTDOWN CONTROL FUNCTIONS After bucket has been lowered to overnight storage position, move all switches and controls to "OFF" position. Pull parking brake knob to "APPLIED" position. This will apply parking brake. Move pilot cutoff switch to "LOCK" position. This will disable pilot control valve lever (joystick). Move key in starter switch to "OFF"...
Page 30: Maintenance
MAINTENANCE USE WARNING TAG DURING SERVICE Alert others that service or maintenance is being performed and tag operator‘s cab controls - and other machine areas if required - with a warning notice. Warning tags for controls are available from DISD distributors;...
Page 31 PROPER TOOLS Use only tools suited to the task. Using damaged, low qualify, faulty, or makeshift tools could cause personal injury. There is danger that pieces from, chisels with crushed heads, or hammers, may get into your eyes and cause blindness. Figure 24 USE OF LIGHTING When checking fuel, oil, battery electrolyte, or...
Page 32 BURN PREVENTION When checking the radiator coolant level, shut down engine, let the engine and radiator cool down, then check the coolant recovery tank. If the coolant level in the coolant recovery tank is near the upper limit, there is enough coolant in the radiator. Loosen the radiator cap gradually to release the internal pressure before removing the radiator cap.
Page 33 WELDING REPAIRS When carrying out welding repairs, carry out the welding in a properly equipped place. The welding should be performed by a qualified worker. During welding operations, there is the danger of, generation of gas, fire, or electric shock, so never let an unqualified worker do welding. The qualified welder must do the following;...
Page 34 PRECAUTIONS WHEN WORKING ON MACHINE When carrying out maintenance operations on the machine, keep the area around your feet clean and tidy to prevent you from falling. Always do the following; • Do not spill oil or grease. • Do not leave tools laying about. •...
Page 35 DO NOT RUN ENGINE IF REPAIRS OR WORK ARE BEING PERFORMED ALONE You should always have at least two people working together if engine must be run during service. One person needs to remain in operator‘s seat, ready to work controls or stop machine and shut "OFF" engine. ALWAYS USE ADEQUATE EQUIPMENT SUPPORTS AND BLOCKING Do not allow weight or equipment loads to remain suspended.
Page 36 PRECAUTIONS WITH HIGH PRESSURE LINE, TUBES AND HOSES When inspecting or replacing high-pressure piping or hoses, check that the pressure has been released from the circuit. Failure to release the pressure may lead to serious injury. Always do the following; •...
Page 37 USE CORRECT REPLACEMENT FASTENERS TIGHTENED TO PROPER TORQUE Refer to "General Maintenance" section of Shop Manual for information on tightening torques and recommended assembly compounds and always use correct part. Poor or incorrect fastener connections can dangerously weaken assemblies. SAFETY-CRITICAL PARTS MUST BE REPLACED PERIODICALLY Replace following fire-related components as soon as they begin to show any sign of wear, or at regular periodic intervals, whether or not deterioration is visible: •...
Page 38: Battery
BATTERY HAZARD PREVENTION Battery electrolyte contains diluted sulfuric acid and batteries generate hydrogen gas. Hydrogen gas is highly explosive, and mistakes in handling them can cause serious injury or fire. To prevent problems, always do the following; • Do not smoke or bring any flame near the battery. •...
Page 39 USE LOW HEAT PORTABLE LIGHTING Hot surfaces on trouble lights or portable work lights can set off fuel or battery explosive gases. BOOST STARTING OR CHARGING ENGINE BATTERIES If any mistake is made in the method of connecting the booster cables, it may cause an explosion or fire. Always do the following;...
Page 40: Towing
TOWING PRECAUTIONS WHEN TOWING If any mistake is made in the method of selecting or inspecting the towing wire or in the method of towing, it may lead to serious personal injury. Always do the following; • Always use the method of towing given in this Operation and Maintenance Manual. Do not use any other method.
Page 41: Shipping And Transportation
SHIPPING AND TRANSPORTATION OBEY STATE AND LOCAL OVER-THE-ROAD REGULATIONS Check state and local restrictions regarding weight, width and length of a load before making any other preparation for transport. Hauling vehicle, trailer and load must all be in compliance with local regulations governing intended shipping route.
Page 42 S0103010K Wheel Loader Safety Page 36...
Page 43 1SPECIFICATIONS...
Page 45 SPC000001 1SPECIFICATIONS FOR SD310 CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
Page 46 TABLE OF CONTENTS Component Locations ....................4 General Specifications ....................6 Engine Performance Curves ..................8 Working Range and Dimensions.................10 Working Capacities .....................11 Bucket Capacity ....................11 Tipping Load ......................11 Material Weight ......................11 Approximate Weight of Workload Materials ............11 SPC000001 Specifications for SD310 Page 2...
Page 47 Specifications for SD310 SPC000001 Page 3...
Page 48: Component Locations
COMPONENT LOCATIONS Figure 1 identifies the location of major machine components. Figure 1 SPC000001 Specifications for SD310 Page 4...
Page 49 Reference Reference Description Description Number Number Frame Seat E/G and T/M Ass`y Boom Cylinder Fuel Tank Steer Cylinder Oil Tank Steer Pump Axle and Driving shaft Main Pump Axle and Driving shaft Fan Motor Tire Oil Tank Axle Hub Priority Valve Cooling Pipe line Bucket Cylinder Main Pipe line...
Page 50: General Specifications
Vehicle Weight 17,350 kg (38,250 lb) Engine Type Doosan DE08TIS Rated power (SAE J 1995 gross) 218 ps @ 2,000 rpm (215 hp @ 2,000 rpm) 92 kg•m / 1,300 rpm (666 ft lb @ 1,300 rpm) Max. Torque (SAE J 1995 gross)
Page 51 Specifications for SD310 SPC000001 Page 7...
Page 52: Engine Performance Curves
ENGINE PERFORMANCE CURVES SPC000001 Specifications for SD310 Page 8...
Page 53 Serial Number 010001 and Up Engine Type DE08TIS Rated Power (217 hp @ 2,000 rpm) 218ps @ 2,000 rpm (214 hp @ 2,200 rpm) 92 kg•m @ 1,300 rpm (666 ft lb @ 1,300 rpm) Maximum Torque (666 ft lb @ 1,300 rpm) Fuel Consumption 156 g / ps.h Performance Standard...
Page 54: Working Range And Dimensions
WORKING RANGE AND DIMENSIONS Figure 3, illustrates exterior machine dimensions and working range of machine when it is equipped with a standard bucket. Figure 3 Category Dimension Category Dimension 8,220 mm (26‘ 11") 3,110 mm (10‘ - 2") Overall Length (A) Dump Height, to tooth (H) 3.004 mm (9‘...
Page 55: Working Capacities
WORKING CAPACITIES BUCKET CAPACITY Standard toothed bucket has a capacity of 3.0 m (3.9 yd ). An optional bucket equipped with a cutting edge and no teeth has a capacity of 3.2 m (4.2 yd ), and 2.9 m3(3.8 yd3),V-Type of 2.7 m3(3.5 yd3) rock bucket and 4.0 m3(5.2 yd3) big bucket.
Page 56 LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR DENSITY 1,100 KG/M DENSITY 1,600 KG/M DENSITY 2,000 KG/M MATERIAL (1,850 LB/YD (2,700 LB/YD (3,370 LB/YD OR LESS OR LESS OR LESS Cement, Portland, DRY 1,506 kg/m --------------------- --------------------- granular (2,583 lb/yd Cement, Portland, DRY 1,362 kg/m ---------------------...
Page 57 LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR DENSITY 1,100 KG/M DENSITY 1,600 KG/M DENSITY 2,000 KG/M MATERIAL (1,850 LB/YD (2,700 LB/YD (3,370 LB/YD OR LESS OR LESS OR LESS 929 kg/m Salt --------------------- --------------------- (1,566 lb/yd 529 kg/m Snow, light density --------------------- ---------------------...
Page 58 SPC000001 Specifications for SD310 Page 14...
Page 59 11GENERAL MAINTENANCE...
Page 61 S0302000 GENERAL MAINTENANCE PROCEDURES CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
Page 62 TABLE OF CONTENTS Welding Precautions and Guidelines .................. 3 Hydraulic System - General Precautions ................4 Maintenance Service and Repair Procedure ..............5 General Precautions ..................... 5 Hydraulic System Cleanliness and Oil Leaks..............6 Maintenance Precautions for Hydraulic System Service ..........6 Oil Leakage Precautions....................
Page 63: Welding Precautions And Guidelines
WELDING PRECAUTIONS AND GUIDELINES IMPORTANT To avoid accidents, personal injury and the possibility of causing damage to the machine or to components, welding must only be performed by properly trained and qualified personnel, who possess the correct certification (when required) for the specific welding fabrication or specialized repair being performed.
Page 64: Hydraulic System - General Precautions
CAUTION! Observe the following safety precautions: 1. Use extra caution and adequate safety shielding when welding near fuel and oil tanks, batteries, hydraulic piping lines or other fire hazards. 2. Never weld when the engine is running. Battery cables must be disconnected before the welding procedure is started.
Page 65: Maintenance Service And Repair Procedure
IMPORTANT Hydraulic system operating conditions (repetitive cycling, heavy work loads, fluid circulating under high pressure) make it extremely critical that dust, grit or any other type of contamination be kept out of the system. Observe fluid and filter change maintenance interval recommendations and always pre-clean any exterior surface of the system before it is exposed to air.
Page 66: Hydraulic System Cleanliness And Oil Leaks
HYDRAULIC SYSTEM CLEANLINESS AND OIL LEAKS MAINTENANCE PRECAUTIONS FOR HYDRAULIC SYSTEM SERVICE Whenever maintenance, repairs or any other type of troubleshooting or service is being performed, it‘s important to remember that the hydraulic system - including both the interior and exterior surfaces of assemblies, and every drop of operating fluid - must be protected from contamination.
Page 67: Cleaning And Inspection
NOTE: Grease lip seals before assembly. CLEANING AND INSPECTION GENERAL GUIDELINES All parts must be clean to permit an effective inspection. During assembly, it is very important that no dirt or foreign material enters unit being assembled. Even minute particles can cause malfunction of close fitting parts such as thrust bearing, matched parts, etc.
Page 68: Bearing Inspection
scratching. Curling under of any seal lip will seriously impair its efficiency. Apply a thin coat of Loctite #120 to outer diameter, of metal casing, on oil seals to assure an oil tight fit into retainer. Use extreme care not to get Loctite on lips of oil seals. If this happens, that portion of the seal will become brittle and allow leakage.
Page 69 Normal Bearing Smooth even surfaces with no discoloration or marks. Bent Cage Cage damage due to improper handling or tool usage. Replace bearing. Galling Metal smears on roller ends due to over heat, lubricant failure or overload. Replace bearing - check seals and check for proper lubrication.
Page 70 Abrasive Step Wear Pattern on roller ends caused by fine abrasives. Clean all parts and housings, check all parts and housings, check seals and bearings and replace if leaking, rough or noisy. Etching Bearing surfaces appear gray or grayish black in color with related etching away of material usually at roller spacing.
Page 71 Fatigue Spalling Flaking of surface metal resulting from fatigue. Replace bearing - clean all related parts. Brinelling Surface indentations in raceway caused by rollers either under impact loading or vibration while the bearing is not rotating. Replace bearing if rough or noisy. Cage Wear Wear around outside diameter of cage and roller pockets caused by abrasive material and inefficient...
Page 72 Cracked Inner Race Race cracked due to improper fit, cocking or poor bearing seat. Replace all parts and housings, check seals and bearings and replace if leaking. Smears Smearing of metal due to slippage caused by poor fitting, lubrication, overheating, overloads handling damage.
Page 73 Heat Discoloration Heat discoloration can range from faint yellow to dark blue resulting from overload or incorrect lubrication. Excessive heat can cause softening of races or rollers. To check for loss of temper on races or rollers, a simple file test may be made. A file drawn over a tempered part will grab and cut metal, whereas a file drawn over a hard part will glide readily with no metal cutting.
Page 74 S0302000 General Maintenance Procedures Page 14...
Page 75 S0309000 1STANDARD TORQUES CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
Page 76 TABLE OF CONTENTS Torque Values for Standard Metric Fasteners ..............3 Torque Values for Standard U.S. Fasteners ............... 4 Type 8 Phosphate Coated Hardware .................. 6 Torque Values for Hose Clamps..................7 Torque Values for Split Flanges................... 8 Torque Wrench Extension Tools..................9 Torque Multiplication .....................
Page 77: Torque Values For Standard Metric Fasteners
TORQUE VALUES FOR STANDARD METRIC FASTENERS NOTE: The units for the torque values are kg•m (ft lb). Grade Dia. x 10.9 12.9 Pitch (mm) (4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K) 0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48...
Page 78: Torque Values For Standard U.s. Fasteners
TORQUE VALUES FOR STANDARD U.S. FASTENERS S.A.E. BOLT HEAD TYPE DESCRIPTION GRADE MARKING WILL HAVE NO MARKINGS IN THE CENTER OF THE HEAD. 1 OR 2 Low or Medium Carbon Steel Not Heat Treated. WILL HAVE THREE RADIAL LINES. Quenched and Tempered Medium Carbon Steel. WILL HAVE 6 RADIAL LINES.
Page 79 The following General Torque Values must be used in all cases where SPECIAL TORQUE VALUES are not given NOTE: TORQUE VALUES LISTED THROUGHOUT THIS MANUAL ARE LUBRICATED (WET) THREADS; VALUES SHOULD BE INCREASED 1/3 FOR NONLUBRICATED (DRY) THREADS. HEAT TREATED MATERIAL GRADE 5 AND GRADE 8 GRADE 5 GRADE 8 THREAD SIZE...
Page 80: Type 8 Phosphate Coated Hardware
TYPE 8 PHOSPHATE COATED HARDWARE This chart provides tightening torque for general purpose applications using original equipment standard hardware as listed in the Parts Manual for the machine involved. DO NOT SUBSTITUTE. In most cases, original equipment standard hardware is defined as Type 8, coarse thread bolts and nuts and thru hardened flat washers (Rockwell "C"...
Page 81: Torque Values For Hose Clamps
TORQUE VALUES FOR HOSE CLAMPS The following chart provides the tightening torques for hose clamps used in all rubber applications (radiator, air cleaner, operating lever boots, hydraulic system, etc.). TORQUE RADIATOR, AIR CLEANER, HYDRAULIC SYSTEM BOOTS, ETC. CLAMP TYPE AND SIZE KILOGRAM KILOGRAM INCH POUNDS...
Page 82: Torque Values For Split Flanges
TORQUE VALUES FOR SPLIT FLANGES The following chart provides the tightening torques for split flange connections used in hydraulic systems. Split flanges and fitting shoulders should fit squarely. Install all bolts, finger tight and then torque evenly. NOTE: Over torquing bolts will damage the flanges and/or bolts, which may cause leakage. BOLT TORQUE FLANGE BOLT...
Page 83: Torque Wrench Extension Tools
TORQUE WRENCH EXTENSION TOOLS Very large diameter, high grade fasteners (nuts, bolts, cap screws, etc.) require a great deal of turning force to achieve recommended tightening torque values. Common problems that could occur as a result are: • Recommended torque exceeds the measuring capacity of the torque wrench. •...
Page 84: Other Uses For Torque Wrench Extension Tools
OTHER USES FOR TORQUE WRENCH EXTENSION TOOLS Torque wrench extensions are sometimes made up for reasons other than increasing leverage on a fastener. For example, a torque wrench and extension can be used to measure adjustment "tightness" of a linkage or assembly.
Page 85 I. "Loctite" Fastener Adhesives Break-away Cure Strength Product Application Color Removal (in lb) of Sealer Alone Low strength for 6 mm (1/4") or smaller Purple Hand tools fasteners. 242 or Medium strength for 6 mm (1/4") and Blue Hand tools larger fasteners.
Page 86 IV. "Loctite" retaining compounds Product Application Color Notes For bushings, sleeves, press-fit bearings, Use Locquic "N" primer for increased splines and collars. For gaps to 0.0002 mm Green bond strength cold (0.005"), temperatures to 121° C (250° F). temperature applications. For high temperatures to 232°...
Page 87 1FFRAME...
Page 89 SPC000003 1COUNTERWEIGHT CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
Page 90 TABLE OF CONTENTS Specifications ......................3 Counterweight ......................3 SPC000003 Counterweight Page 2...
Page 91 Specifications NOTE: Weight Model Weight Serial Number Range SD310（ZF T/M） 1650 kg (3,638 lb) 010001 and Up Counterweight 1. Parts list Fig. 1 Reference Reference Description Description Number Number COUNTERWEIGHT PIN;SPLIT BOLT WASHER;PLAIN WASHER;HARDEN COVER(R,H) WASHER;PLAIN COVER(L,H) RUBBER;STOPPER LOCK HINGE PLATE Counterweight SPC000003...
Page 92 2. TORQUE Fig. 2 NOTE: 1) Tighten bolt to torque value list in the following table. SD310 100 kg²m (726 ft lb) SPC000003 Counterweight Page 4...
Page 93 SPC000005 1CENTER JOINT (ARTICULATION JOINT) CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
Page 94 TABLE OF CONTENTS General Description ..................... 3 Maintenance Standard ................... 4 SPC000005 Center Joint (Articulation Joint) Page 2...
Page 95 General Description The loader frame is an articulated type: the front frame is joined to the rear frame with two hinge pins around which the loader pivots for steering. CAUTION! When the loader is steered, the area near center hinge pins becomes so narrow that you may get caught between front and rear frames.
Page 96 Maintenance Standard (UPPER HINGE BEARING) (LOWER HINGE BEARING) Figure 2 SPC000005 Center Joint (Articulation Joint) Page 4...
Page 97 UNIT : mm Check item Criteria Remedy Standard Tolerance Standard Clearance size Clearance limit Clearance between upper hinge pin and rear frame +0.174 0.1-0.193 -0.019 +0.1 Clearance between upper -0.015- hinge pin and bearing 0.019 -0.019 -0.015 Clearance between bearing -0.035- and front frame -0.018...
Page 98 SPC000005 Center Joint (Articulation Joint) Page 6...
Page 99 1ENGINE AND DRIVE TRAIN...
Page 100 SPC000006...
Page 101 5ton Diesel Engine CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
Page 102 TABLE OF CONTENTS 1. GENERAL INFORMATION………………………………………………………………1 1.1 General Repair Instructions…………………………………………………………1 1.2 Engine Specific Character……………………………………………………………2 1.3 Engine Specifications…………………………………………………………………4 1.4 Engine Assembly……………………………………………………………………8 2. MAJOR MAINTENANCE…………………………………………………………………13 ……………………………………………………………13 2.1 Preventive Maintenanc 2.2 Diagnosis and Remedy……………………………………………………………20 2.3 Engine Inspection……………………………………………………………………29 3. MAINTENANCE…………………………………………………………………………30 3.1 Engine Disassembly………………………………………………………………30 3.2 Inspection and Measurement………………………………………………………45 3.3 Engine Reassembly…………………………………………………………………63 3.4 Breaking In on Major Parts…………………………………………………………88 4.
Page 103 DESCRIPTION OF THE ILLUSTRATION MARKS Removal Adjustment Installation Cleaning Disassembly Pay close attention-Important Reassembly Tighten to specified torque Use special tools of Align the marks manufatur‘s Directional Indication Lubricate with oil Inspection Lubricate with grease Measurement 5ton Diesel Engine SPC000006 Page 3...
Page 104: General Information
4. The use of proper tools and special tools where specified is important to efficient and reliable service operation. 5. Use genuine DOOSAN parts necessarily. 6. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts should be discarded and new ones should be prepared for installation as normal function of the parts can not be maintained if these parts are reused.
Page 105 1.2.2 OMEGA combustion bowl The OMEGA combustion bowl is a unit designed to perform high efficiency, low emission combustion. As the rim around the combustion bowl port of the upper of the piston has been machined in a smaller size than the interior of the combustion bowl, strong swirl is produced in the combustion bowl and strong squish flow makes the fuel be mixed more sufficiently with air.
Page 106: 1.3 Engine Specifications
1.3 Engine Specifications 1.3.1 Specification SPC000006 5ton Diesel Engine Page 6...
Page 107 1.3.2 Engine power Production tolerance : ±5% 5ton Diesel Engine SPC000006 Page 7...
Page 108 1.3.3 Performance curve (DE08TIS - 225PS) TORQUE (kg POWER OUTPUT (PS) FUEL CONSUMPTION (g/ps REVOLUTION (rpm) Performance ISO 1585 (SAE J1349) Output (max.) 160 kW (225PS) / 2,000 rpm Torque (max.) 902 N.m (92 kg.m) / 1,300 rpm Fuel consumption (min.) 213 g/kW.h (156 g / PS.h) SPC000006...
Page 109 PERFORMANCE ISO 1585 (SAE J1349) Output (max.) 160 kW (217.6PS) / 2,000 rpm Torque (max.) 902 N.m (92 kg.m) / 1,300 rpm Fuel consumption (min.) 213 g/kW.h (156 g / PS.h) 5ton Diesel Engine SPC000006 Page 9...
Page 110: 1.4 Engine Assembly
1.4 Engine Assembly 1.4.1 Engine sectional view (longitudinal) 1. Water pump 10. Intake valve spring 19. Oil seal (Front) 2. Piston 11. Cylinder block 20. Crank shaft pulley 3. Air compressor 12. Push rod 21. Crank shaft gear 4. Intake valve 13.
Page 111 1.4.2 Engine sectional view (cross) 1. Fuel injection pipe 9. Turbo charger 2. Fuel filter 10. Fuel injection pump 3. Fuel injection nozzle 11. Timing gear case 4. Intake manifold 12. Oil filler cap 5. Air heater 13. Connecting rod 6.
Page 112 1.4.3 Engine assembly views 1. Flywheel housing 10. Turbocharger 19. Breather 2. Fuel filter 11. Exhaust pipe 20. Thermostat 3. Intake pipe 12. Lifting hook (Rear) 21. Water pump 4. Fuel injection pump 13. Starter 22. Crankshaft pulley 5. Air pipe (From air cooler to 14.
Page 113: Major Maintenance
²Since DE08TIS diesel engine cylinder liner is dry type, particularly the cooling water control should be applied thoroughly by the cooling water test kit. (DOOSAN 60.99901-0038) ²The density of antifreezing solution and additive for rust prevention is able to be confirmed by the cooling water test kit.
Page 114 (6) The brown at the middle of test paper and the lower pink color indication represent the additive state for rust prevention, and the proper range is that the meeting numerical value of brown (vertical) and pink color (horizontal) locates in the range of 0.3 to 0.8 at the color list of label on the test paper storage bottle.
Page 115 ²The following oils are also recommended. * If long oil change intervals are to be used, ACEA-E3 oil must be used. 2.1.4 Oil filter ² Check for oil pressure and oil leaks, and repair or replace the oil filter if necessary. ²Change the oil filter cartridge simultaneously at every replacement of engine oil.
Page 116 2.1.7 Intercooler The intercooler is air to air type and has a large cooling fan capacity. The intercooler life and performance depends on the intake air condition greatly. Fouled air pollutes and clogs the air fins of intercooler. As a result of this, the engine output is decreased and engine malfunction is occurred.
Page 117 (1) Rotate the crankshaft to overlap the intake and the exhaust valves of #6, then #1 cylinder become the compression state of top dead center. (2) Therefore adjust the valve clearance corresponding to ― ―of lower figure. At this time there are no force on the push rods of #1 cylinder. (3) Rotating the crankshaft by one revolution, #6 cylinder become the compression state of top dead center.
Page 118 ²Install the special tool (compression gauge adapter) at the nozzle holder hole, and connect the compression pressure gauge there. * Condition: Water temperature 20° C, Engine rotation 200rpm (10 rotations) 2.1.10 Injection nozzle ²Install a nozzle on the nozzle tester. ²If the inspected injection pressure is less than the specified value, adjust using the adjusting shims.
Page 119 2.1.13 Air removal of fuel system The suction room of fuel injection pump has the function of air removal continuously during the operation through a relief valve. In case that the suction room lacks fuel at all, for instance, in case of new installation of injection pump, after loosening the air removing screws of cartridge filter respectively, remove the air by operating the manual pump of fuel supply pump until bubble will disappear.
Page 120: 2.2 Diagnosis And Remedy
2.2 Diagnosis and Remedy ²The following description summarizes the probable cause of and remedy for generall failure by item. ²Immediate countermeasures should be taken before a failure is inflamed if any symptom is detected. SPC000006 5ton Diesel Engine Page 20...
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Page 129: 2.3 Engine Inspection
2.3 Engine Inspection 2.3.1 Stopping engine After checking the engine for any unusual condition at the idling speed, then turn the key switch to stop the engine. 2.3.2 General engine inspection cycle 2.3.3 Use of original parts for repair and replacement For engine is being mechanically harmonized with many parts, only when the original parts that the manufacture recommends to use is used, the engine trouble would be preventively maintained and capable to keep up the maximum performances.
Page 130: Maintenance
3 MAINTENANCE 3.1 Engine Disassembly 3.1.1 Heed at disassembly ²Before disassembly, the part shelf should be prepared for various tools and repair parts. ²When assembling, clean empty hand should be used and clean environment maintained. ²In case of storing the disassembled parts, each part should not touch each other. ²In case of disassembly, the parts should be laid in order.
Page 131 3.1.4 Engine oil ²Remove the oil drain plug of oil pan and pour the engine oil into the prepared vessel. 3.1.5 Cooling fan ²Remove the flange fixing bolts, then take off the flange and cooling fan. 3.1.6 Belt ²Loosen the tension adjusting bolts of the alternator and the idle pulley, and take off the belts.
Page 132 3.1.8 Starter ²Unscrew the starter fixing nuts and remove the starter being careful not to damage its gears. 3.1.9 Fuel filter ²Remove the hollow screws of filter and tear down fuel supply and discharge rubber hose. ²Remove fuel filter fixing bolts and disassemble the fuel filter.
Page 133 3.1.12 Alternator ²Remove the alternator assembling bolt and disassemble the alternator. 3.1.13 Oil cooler ²Loosen the cooling water pump and the rubber hose clamps of connected pipes, and disassemble it. ²Remove the oil cooler fixing bolts and take off the oil cooler.
Page 134 3.1.16 Air compressor ²Remove the oil pipe between cylinder block and air compressor. ²Unscrew the air compressor fixing bolts and take off the air compressor. 3.1.17 Idle pulley ²Unscrew the idle pulley fixing bolts and take off the idle pulley. 3.1.18 Water pump ²Unclamp the rubber hose connected to the oil cooler.
Page 135 3.1.20 Fuel injection nozzle ²Unscrew the fuel injection pipe between the injection pump and nozzle and take off the pipe. ²Install a special jig on the nozzle holder, and then pull out the nozzle as striking the hammer of the jig backwardly.
Page 136 3.1.23 Intake manifold ²Unscrew the intake manifold fixing bolts and remove the intake manfold from the cylinder head. ²Disassemble the intake manifold gasket and discard it. 3.1.24 Cooling water pipe ²Unscrew the cooling water pipe fixing bolts and remove the cooling water pipe from the cylinder head. ²Remove the cooling water pipe gasket and finish the surface with a scraper.
Page 137 3.1.26 Cylinder head ²Remove the cylinder head bolts in the reverse order of tightening but remove it step by step. First step : Loosen 1 ~ 2 threads Second step : Remove by loosening fully. ²However, remove the total bolts simultaneously by the step of 1 and 2.
Page 138 3.1.27 Oil pan ²Unscrew the oil pan fixing bolts and remove the oil pan. ²Remove the oil pan gasket and discard it. 3.1.28 Vibration damper ²Unscrew the vibration damper fixing bolts in reverse sequence of installing sequence and remove the vibration damper assembly.
Page 139 3.1.31 Piston and connecting rod ²Remove the connecting rod cap bolts in the reverse order of assembling but do same as the cylinder head bolt removal. ²Disassemble the upper/lower of connecting rod caps by tapping lightly with urethane hammer, and remove the bearing.
Page 140 (3) Remove the piston ring with a plier. (4) Clean the piston thoroughly. 3.1.32 Cylinder liner ²Diassemble the cylinder liner with a special tool or hand but be careful not to generate any damage at cylinder block. 3.1.33 Cam shaft gear and idle gear ²Unscrew the camshaft gear fixing bolts and remove the camshaft gear.
Page 141 ²Unscrew two bolts fixing the idle gear, then remove the idle gear and its pin. 3.1.34 Fuel injection pump ²Disassembly the oil hose for lubrication. ²Remove the bolts and nuts of injection pump flange. ²Unscrew the injection pump fixing bolts and remove the injection pump by lifting it up.
Page 142 3.1.36 Fly wheel ²Remove the flywheel fixing bolts and disassemble it. ² The bolt removal is done by the reverse order of assembling and by the steps. 3.1.37 Fly wheel housing ² Remove the flywheel housing fixing bolts disassemble the flywheel housing. ²Disassemble the oil seal of flywheel housing.
Page 143 3.1.40 Bearing cap ²Remove the bearing cap assembling bolts by the step in the reverse order of assembling, and disassemble the bearing cap. (Remove by the same way as the cylinder head bolts‘ removal.) ²Disassembled bearing caps are kept laid in order. 3.1.41 Crankshaft ²...
Page 144 3.1.43 Oil spray nozzle (D1146TI, DE08TIS only) ² Remove the valve screws of oil spray nozzle and disassemble it. SPC000006 5ton Diesel Engine Page 44...
Page 145 3.2 Inspection and Measurement on Major Parts 3.2.1 Cylinder block ²Clean the cylinder block thoroughly, and check for any crack or damage. ²If there is any crack or severe damage, replace it and if there is minor one, correct it. ²Check for any clogging or corrosion in the oil passage and water passage.
Page 146 2) Inspection of cylinder head (1) Check for the cylinder head. ²Remove carbon from the cylinder head lower surface, and then should be careful not to scratch the surface. ²Check any crack or damage that can not found by naked eyes through the hydraulic or magnetic particle test.
Page 147 3) Inspection of valve and valve guide (1) Valve After cleaning valve with fuel, check it. ²Valve stem outer diameter Measure the valve stem outer diameter at 3 positions (top, middle, and bottom), and check for any wear and if beyond the limit value, replace the valve. ²Valve seat contacting faces Check the valve seat contact surface for any crack and wear, and if necessary, correct with grinding...
Page 148 ²Assemble the valve at cylinder head‘s valve guide and see if it is centered with the valve seat using a special tool. 3) Valve seat ²Contacting face amount As for the valve seat‘s wear, measure the width of the contact surface with intake valve seat and exhaust valve seat.
Page 149 ²For the disassembling of valve seat, by welding the welding bead to a valve seat rotating tool or valve seat, pull it out with a special tool. ²For the assembling of a new valve seat, by putting it among the dry ices of an ice box previously for about 2 hours for the cold shrinkage, and press it in the cylinder head by a special tool.
Page 150 ²Valve spring tension Use a spring tester to measure the valve spring tension if the measured value is less than the specified limit, the valve spring must be replaced. 5) Assembling cylinder head ²Clean the cylinder head thoroughly. ²Replace the valve stem seal with new one, and by means of a special tool, press the stem seal into the valve guide of cylinder head.
Page 151 3.2.3 Rocker arm assembly 1) Disassembly (1) Disassemble the snap rings that are located at both ends of rocker arm shaft by a plier. (2) Disassemble in the order of washer, rocker arm bracket, rocker arm spring, rocker arm. 2) Inspection of rocker arm assembly (1) Rocker arm shaft ²Rocker arm shaft run-out Place the rocker arm shaft on two V blocks and...
Page 152 ²Rocker arm bushing diameter Measure the inside diameter of the rocker arm bushing with an inside micrometer or vernier calipers, and compare the measured values with the rocker arm shaft diameter. If the clearance exceeds the limit, replace either bushing or shaft, whichever worn more. (3) Tappet and push rod ²Clearance Measure the clearance of the tappet and tappet holes...
Page 153 ²Push rod run-out Use a feeler gauge to measure the push rod run-out. Roll the push rod along a smooth flat surface as shown in the figure. (4) Reassembling rocker arm assembly Reassembling can be done in the reverse order of disassembling and following things should be heeded.
Page 154 Use a micrometer to measure the cam lobe height and journal diameter. If the measured number is less than the specified limit, the camshaft must replaced. ²Cam surface Inspect the cam face for scratch or damage. Slight step wear or damage on the cam face may be corrected with oil stone or oiled grinding paper.
Page 155 3.2.5 Crankshaft 1) Inspection of crankshaft (1) Defect check ²By naked eyes, check for any scratch or damage on the crankshaft journal and crank pin. ²By means of magnetic particle test and color check, check the crankshaft for any crack and if found, replace (2) Wear measuring ²With an outside micrometer measure the diameter of the crankshaft journals and pins in the directions as...
Page 156 <Undersize bearings available> ²Standard ²0.25 (Inside diameter is 0.25 mm lesser than the standard size.) ²0.50 (Inside diameter is 0.50 mm lesser than the standard size.) ²0.75 (Inside diameter is 0.75 mm lesser than the standard size.) ²1.00 (Inside diameter is 1.00 mm lesser than the standard size.) Undersize bearings are available in 4 different sizes as indicated above, and the crankshaft can be reused through the regrinding as described above.
Page 157 outside diameters of crankshaft journals to determine the oil clearance. ²Connecting rod bearing clearance Install the connecting rod bearing in the connecting rod bearing cap, tighten the connecting rod cap bolts to the specified torque, then measure the inside diameter. Compare values obtained...
Page 158 (4) Bearing spread and crush ²Inspection Check to see that the bearing requires a considerable amount of finger pressure at reassembly operation. ²Crankshaft bearing crush Install the bearing and cap in the cylinder block, retighten the bolts to specified torque, unscrew out one bolt completely, then measure the clearance between the bearing cap and cylinder block using a feeler gauge.
Page 159 (5) Crank shaft end play ²Assemble the crankshaft to the cylinder block. ²With a dial gauge, measure crankshaft end play. 3.2.6 Piston assembly 1) Disassemby of piston assembly Disassemble piston according to the disassembly process. 2) Piston inspection (1) Visual check Visually check the pistons for cracks, scuff or wear, paying particular attention to the ring groove.
Page 160 ²The clearance is computed by subtracting the piston outside diameter from the cylinder liner inside diameter. Replace either piston or cylinder liner, whichever damaged more, if the clearance is beyond the specified limit. 3) Piston rings (1) Visual check Replace the piston rings with new ones if detected worn or broken when the engine is overhauled.
Page 161 (4) Piston ring tension With a tension tester, measure piston ring tension. Replace the piston ring if the measured value is beyond the limit. 4) Piston pin inspection (1) Wear Measure the amount of wear on the piston pin at the points as shown.
Page 162 (2) Holes alignment (parallelism) Measure the alignment of the connecting rod piston pin bushing holes with connecting rod big end holes. At this time also, use both connecting rod tester and feeler gauge. (3) Wear ²Assemble the connecting rod to the crankshaft and measure connecting rod big end side clearance using a feeler gauge.
Page 163 3.3 Engine Reassembly 3.3.1 General precautions ²Clean all the disassembled parts, particularly oil and water ports, using compressed air, then check that they are free from restrictions. ²Arrange the general and special tools in order for engine assembly operation. ²To wet each sliding part, prepare the clean engine oil. ²Prepare service materials such as sealant, gaskets, etc.
Page 164 ²Apply engine oil to the entire face of the tappets and slide them into the tappet holes on the cylinder block. ²Wet the cam bush inside diameter and camshaft with oil, and carefully assemble them while turning the camshaft. Caution: Be careful not to generate a damage to camshaft and bush.
Page 165 ²Heat the crankshaft gear for at least 10 minutes to 120° C, then apply sealant (Loctite # 641) to the inside wall of the heated crankshaft gear evenly before inserting it to the end of crankshaft. ²Semi-tighten a bolt at both sides of the crankshaft, apply engine oil to journals and pins, then assemble the crankshaft with the cylinder block by tightening the fixing bolts.
Page 166 ²Install the bearing cap by matching the cylinder block No. with the bearing cap No. ²Apply oil to the entire part of the bearing cap bolts, then tighten in tightening sequence to specified torque. ²After semi-tightening both bolts evenly, tighten them diagonally to the specified torque using a torque wrench as follows.
Page 167 Caution: When the bolts are tightened, remove the guide bar. ²The flywheel housing is assembled after the new oil seal was pressed (Coat engine oil over the outside of oil seal) before in the housing by a press. ²If any peripheral scar was generated due to oil seal at the oil seal contact surface of crankshaft, after inserting about 1 mm shim or thereabout in front of oil seal (Direction toward crankshaft.), measure and adjust.
Page 168 ²Install a guide bar into a bolt hole on the crank shaft, and lift the flywheel to align the dowel pin with the pin hole on the flywheel for temporary assembly operation. ²Coat the adhesive (#271 Loctite) over the assembling bolts and install bolts in the remaining holes.
Page 169 3.3.10 Water chamber cover ² Coat the adhesive over the water chamber cover (Particular around bolt holes) and after attaching the gasket, assemble it to the cylinder block using the bolts for assembling. ²As for tightening of bolts, after primarily tightening the bolts located at the both ends of cover (4ea at both sides) and middle bolts (Upper, lower 2ea) , tighten the rest.
Page 170 ²Nothing the direction of the piston, make the longer side(machined with key groove on the bearing) of the connecting rod big end. ² On the piston head surface, the longer side connecting rod big end is in opposite direction from the valve seating surface as well as in the same direction with the narrow margin of the combustion chamber.
Page 171 ²Position the valve seating surface toward the tappet hole and insert the piston with hand. Caution: Use care not to damage the cylinder liner and piston, and slightly lift and insert the piston into the cylinder so that the ring may not be damaged by the fillet of the liner.
Page 172 ² When the connecting rod bearing cap bolts are tightened, check the connecting rod end play to the right and left with hand. If no end play is found, remove and reinstall or replace the connecting rod bearing cap. 3.3.13 Timing gear case ²Mount a new gasket using dowel pin on the cylinder block.
Page 173 ²With the oil port on the idle gear pin facing the cylinder block, install the idle gear pin. ² Idler gear pin with oil hole is assembled toward cylinder block. ²Install the idle gear by coinciding the marks impressed on the crank gear, cam gear, fuel injection pump drive gear, and idle gear.
Page 174 3.3.16 Fuel injection pump ²Install the injection pump bracket in the cylinder block. ² After measuring the amount of run-out with an alignment setting jig, disassemble the bracket, adjust the shims, then reassemble it. ²Mount the top/bottom adjusting shims in the bracket and then mount the fuel injection pump.
Page 175 (1) As above adjusting method, Please coincide the indication point at the flywheel housing‘s inspection hole with the flywheel‘s inspection angle. (2) Loosen the drive gear fixing bolt of injection pump a bit. (3) After turning slowly the coupling of injection pump until the fuel will drop from #1 plunger at the rate of a drop for 6 ~ 8 sec., tighten the driving gear fixing bolt of fuel pump.
Page 176 3.3.17 Oil pump and oil pipe ² Install a dowel pin in the No.7 bearing cap, then assemble the oil pump by tapping lightly with urethane hammer. ²Tighten the assembling bolts with specified torque. ²Assemble the oil suction pipe with the delivery pipe to oil pump by the bolts.
Page 177 3.3.20 Water pump ²Mount a new gasket. ² Install the water pump on the cylinder block and tighten the assembling bolts with specified torque. ²Connect water pipes and by-pass pipe to the water pump. ²Connect a water pipe to the expansion tank. 3.3.21 Vibration damper ²...
Page 178 ² Assemble the oil pan by tightening the oil pan assembling bolts, and when tightening bolts, primarily tighten the bolts (4ea) at the both ends, and then tighten the rest bolts to specified torque. Caution: Align the bolt holes with gasket holes to prevent damage to the gasket and tighten.
Page 179 3.3.26 Intake and exhaust valves ²Identify the marks of ―IN‖ and ―EX‖ impressed on the valve head before assembling the valve with the valve head. ²With a valve stem seal fitting jig, assemble the valve stem seal on the valve guide. ²After installing valve springs and spring retainer, press the retainer with a jig, then install the cotter pin.
Page 180 ²Check the inside of combustion chamber for foreign substances, and carefully mount the cylinder head assembly in the block by aligning the dowel pin with the dowel pin hole. Caution: Be careful not to damage the cylinder head gasket. If the dowel pin is not in alignment, lift the cylinder head again and then remount it.
Page 181 3.3.28 Rocker arm assembly ²Apply lubricating oil to the rocker arm bush and shaft, and assemble the intermediate bracket with the rockerarm (rocker arm assembly) on the cylinder block using fixing bolts. In tightening the bolts, it must be done at the specified value using zigzag method.
Page 182 ²To adjust the clearance, loosen the locknuts of rocker arm adjusting screws and push the feeler gauge of specified value between a rocker arm and a valve stem (to measure the clearance of the valve and rocker arm contacting part) and adjust the clearance with adjusting screw respectively and then tighten with the lock nut.
Page 183 3.3.30 Exhaust manifold ²Install the exhaust manifold gasket over the stud bolts by aligning the gasket with the exhaust port on the cylinder head so that the face and back of the gasket can be positioned correctly. ²Semi-assemble the exhaust manifold and install the heat resisting plate.
Page 184 3.3.33 Idle pulley ²Assemble the air compressor mounting bracket on the timing gear case. ²Install the idle pulley on the air compressor mounting bracket and tightening the fixing bolt. 3.3.34 Air compressor & power steering pump ² Couple the power steering oil pump to the air compressor with the driving dog engaged.
Page 185 3.3.36 Fuel filter ²Assemble the fuel filter with the intake manifold. ²Assemble the fuel feed hose according to the direction of an arrow impressed on the fuel filter head so that fuel can be fed in the sequence of FUEL FEED PUMP FUEL FILTER FUEL INJECTION PUMP.
Page 186 3.3.39 Cylinder head cover ²Attach a new gasket on the cylinder head cover. ²Assemble the cylinder head cover to the cylinder head by tightening the cap bolts for fixing the cylinder head cover. ²Assemble the breather and breather hose. ²Fit the oil filler cap on the cylinder head cover. 3.3.40 Cooling fan ²...
Page 187 Poly belt will be properly tensioned if the deflection force ―F‖ is applied midway between the belt‘s tangent points with the pulley. T = 0.015 X S (about 1.5 mm per 100mm) 3.3.42 Oil level gauge ²Apply sealant (Locktite #262) to the bottom side of the guide tube.
Page 188 3.4 BREAKING IN 3.4.1 Preparations for breaking-in Fill of new engine oil through the oil filler cap. ²When measuring the oil level with the oil level gauge with the engine mounted, the oil level must indicate about 10mm above the max. line. ²Connect water hoses and fill up cooling water.
Page 189 c) Watch the engine water temperature gauge and be sure there is proper water circulation. The water temperature gauge needle will fluctuate if water level in expansion tank is too low. At the end of the break-in period, remove break-in oil and replace the oil filter. Fill oil pan with recommended engine oil.
Page 190 4 MAINTENANCE OF MAJOR COMPONENTS 4.1 Cooling System 4.1.1 General information This engine is water-cooling type. Heat from the combustion chamber and engine oil heat are cooled down by coolant and radiated to the outside, resulting in the normal operation of the engine. The water absorbing the oil heat and combustion chamber heat goes on to the thermostat through the water pipe, and circulates to the water pump if water temperature is lower than the valve opening temperature on the thermostat, while circulating to the radiator at water temperature higher than the valve...
Page 191 4.1.3 Thermostat ²General descriptions and main data The thermostat maintains a constant temperature of coolant and improves thermal efficiency of the engine by preventing heat loss. Namely, when the temperature of coolant is low, the thermostat valve is closed to make the coolant bypass to directly enter the water pump;...
Page 192 ²Replacing thermostat and precautions for handling (1) Precautions for handling The wax pallet type thermostat does not react as quickly as bellows type one to a variation of temperature of coolant. Such relatively slow reaction is mainly due to the large heat capacity of the wax pellet type thermostat.
Page 193 4.1.4 Diagnostics and troubleshooting 5ton Diesel Engine SPC000006 Page 93...
Page 194 4.2 Lubricating System 4.2.1 General descriptions and specifications ²General descriptions All the engine oil pumped up from the oil pan by the gear type oil pump is filtrated through the oil cooler and oil filter, and this filtrated oil is forced through the main oil gallery in the cylinder block from where it is distributed to lubricate the various sliding parts, and fuel injection pump in order to ensure normal engine performance.
Page 195 4.2.2 Oil pump ²Disassembly (1) Disassembly of oil pump drive gear a. Unscrew the screw and disassemble the oil relief valve. b. Unfold the washer for the oil pump drive gear fixing nut and remove the nut. c. Disassemble the drive gear. (2) Remove the oil pump cover fixing nuts and disassemble the oil pump cover.
Page 196 (3) Measuring clearance between drive shaft and bushing a. Measure the outside diameters of the drive shaft and driven shaft, and replace if the measured values are less than the limit (N16.95mm) b. Measure the inside diameter of the pump body bushing to determine the clearance between the bushing and shaft, and compare the measured value with the standard value to determine whether to replace or not.
Page 197 4.3 Fuel Injection Pump 4.3.1 General information of fuel system The fuel system consists of the fuel tank, injection pump, injection nozzle, fuel filter, and fuel lines such as pipes and hoses necessary to connect those components. 4.3.2 Injection pump The components relating to the injection pump should be serviced at regular intervals as the plunger and delivery valve may be worn after a given length of time for use and cause the deterioration of the engine.
Page 198 1) DE08TIS (225PS) SPC000006 5ton Diesel Engine Page 98...
Page 199 (7) Governor adjustment (DE08TIS-225PS) 5ton Diesel Engine SPC000006 Page 99...
Page 200 2) DE08TIS (240PS) SPC000006 5ton Diesel Engine Page 100...
Page 201 (7) Governor adjustment (DE08TIS-240PS) 5ton Diesel Engine SPC000006 Page 101...
Page 202 4.3.4 Fuel feed pump 1) General descriptions and construction The P-type injection pump is mounted with K-ADS or KP type feed pump. These pumps have the same basic construction and operation, and the general descriptions of the KP type pump are given below: The figures show its construction (right figure) and operation (below figure).
Page 203 This feed pump is mounted with a priming pump designed to permit manual feeding of fuel from the fuel tank with the injection pump mounted in the engine. During the manual feeding operation, air must be bled from the fuel lines. When using the priming pump, fix it securely to prevent the possible entry of moisture or other foreign substances in the inside of feed pump.
Page 204 2) Disassembly ²Clamp the feed pump with a vise and disassemble the hollow screw (30, 32), strainer (31) and seal ring (35, 36). ²Take off the priming pump (25), plug (16), both seal rings (18), spring (15), and check valve (14). ²Take off the plug (7), seal ring (8), spring (6), and piston (5) on the piston side.
Page 205 5) Testing (1) Suction capacity test Connect one end of a hose to the inlet side of the feed pump and immerse the other end of it into the fuel tank as illustrated. Hold the feed pump in position about 1 m above the level of fuel in the fuel tank.
Page 206 4.3.5 Injection nozzle 1) General descriptions Pressurized fuel delivered from the fuel injection pump is sprayed into the combustion chamber past the injection nozzle at proper spray pressure and spray angle, then burnt completely to achieve effective engine performance. 2) Construction 3) Disassembly ²Clamp the nozzle assembly and remove the nozzle holder.
Page 207 6) Adjustment ²After reassembly, install the nozzle on a tester. ²With the adjusting screw loosened, operate the nozzle 2 ~ 3 times to bleed it. ²Operate the nozzle tester lever at the specified rate. ²Adjust the injection pressure to the standard pressure by spring tension shims.
Page 208 4.3.6 Diagnostics and troubleshooting SPC000006 5ton Diesel Engine Page 108...
Page 209 5ton Diesel Engine SPC000006 Page 109...
Page 210 4.4 Turbocharger (D1146TI, DE08TIS) 4.4.1 Main data and specifications 1) Main data and specifications 2) Construction SPC000006 5ton Diesel Engine Page 110...
Page 211 3) Construction 5ton Diesel Engine SPC000006 Page 111...
Page 212 3) Operating principle The turbocharger is a system designed to make use of the engine exhaust gas energy to charge high- density air into the cylinders, thereby to increase the engine output. 4.4.2 General descriptions The engine output is determined by the fuel delivery volume and engine efficiency. To burn the supplied fuel completely to change into effective power for the engine, the volume of air enough to burn the fuel completely should be supplied into the cylinders.
Page 213 4.4.3 Functions 1) Turbine Exhaust gas discharged from the combustion chamber distributes its own energy to the turbine blades while passing the inside of the turbine housing, with the result that the turbine shaft can get rotating force. This is the operating principle of ‗turbine‘, which is mounted with seal rings and heat protector to prevent exhaust gas from affecting the bearings adversely.
Page 214 4.4.4 Precautions for operation 1) Precautions for operation of engine The following precautions should be observed when starting, operating, or stopping the engine: SPC000006 5ton Diesel Engine Page 114...
Page 215 4.4.5 Walk-around check and servicing As the condition of turbocharger depends greatly on how well the engine is serviced, it is very important to maintain the engine in accordance with the specified maintenance procedure. 1) Intake system Pay particular attention to the air cleaner when servicing the intake system. In the case of wet-type air cleaner, if the level of oil surface is lower than specified, cleaning effect is poor;...
Page 216 4.4.6 Periodical checking and servicing Make it a rule to check the turbocharger assembly for condition and contamination periodically. 1) Guide for checking the rotor for rotating condition The inspection of the rotor assembly for rotating condition should be performed by the degree of unusual sound.
Page 217 (3) If the measured axial and radial plays are beyond the limit of wear, replace or repair the turbocharger. 3) Guide for disassembling/cleaning and checking the turbocharger First, disassemble the turbocharger from the engine and clean/check it with the oil inlet and outlet plugged with tape and so on.
Page 218 4.4.7. Diagnostics and troubleshooting SPC000006 5ton Diesel Engine Page 118...
Page 219 5 SPECIAL TOOL LIST 5ton Diesel Engine SPC000006 Page 119...
Page 220 SPC000006 5ton Diesel Engine Page 120...
Page 221 APPENDIX ²Tightening torque for major parts ²Tightening torque for fuel injection pump system 5ton Diesel Engine SPC000006 Page 121...
Page 222 3. Special screws should be tightened to 85% or so of the standard value. For example, a screw coated with MoS2 should be tightened to 60% or so of the standard value. ²Tightening torque for hollow screw (4-hole) *: Adopted in DOOSAN engine SPC000006 5ton Diesel Engine...
Page 223 ²Maintenance specification table 5ton Diesel Engine SPC000006 Page 123...
Page 224 SPC000006 5ton Diesel Engine Page 124...
Page 225 5ton Diesel Engine SPC000006 Page 125...
Page 226 SPC000006 5ton Diesel Engine Page 126...
Page 227 5ton Diesel Engine SPC000006 Page 127...
Page 228 SPC000006 5ton Diesel Engine Page 128...
Page 229 SPC000007 1Transmission and Torque Converter CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
Page 230 TABLE OF CONTENTS Preface…………………………………………………………………………………………3 General Working Instructions…………………………………………………………………4 Important Labour Safety Instructions………………………………………………………5 Denomination of Legal Standards……………………………………………………………6 Conversion Table for Dimensional Units……………………………………………………7 Torque limits for screws………………………………………………………………………8 Inscriptions on the Model Identification Plate and Instructions for Spare Parts Order…9 Possible versions Additional equipment…………………………………………………10 List of lubricants TE-ML 03…………………………………………………………………11 1.
Page 231: Preface
PREFACE This documentation has been developped for the skilled Serviceman, trained by the Zahnradfabrik Passau for the Repair and Maintenance operations on ZF-Units. Treated is a ZF-Serial product according to the design stage of the date of Edition. However, due to further technical developments of the product, the repair of the unit at your disposal could require differents steps as well as other adjustment and testing specifications.
Page 232: General Working Instructions
GENERAL WORKING INSTRUCTIONS During all operations, pay attention to cleanliness and skilled working. Therefore, Transmissions, removed from the vehicle, must be cleaned prior to open them We assume that the Special Tools, specified by ZF, will be used. The Special Tools have a 10-digh Subject-No. and are available from ZF-Passau. After the disassembly, all components must be cleaned, especially corners, cavities and recesses of housing and covers.
Page 233 IMPORTANT INSTRUCTIONS CONCERNING THE LABOUR SAFETY In principle, Repairers of ZF-Units are themselves responsible for the labour safety. The observance of all valid Safety Regulations and Legal Rules is a precondition to prevent damage to individuals and products during the Maintenance and Repair operations Before starting the work, the Repairers have to make themselves familiar with these Regulations.
Page 234 BEZEICHNG DER GESETZLICHEN EIHEITEN PENOMINATION OF STANDARD DIMENSIONS DENMINATION DES DIMENSIONSST AND ARDISEES Hinwels : langenbezogene MaBe in kg/m. flacbenbezogene MaBe in t/m2 Note : linear density in kg/m. areal density in t/m2 Note ; Density lineaire en kg/m, Density superficiolle t/m2 Begriff Formetrcichen Umrechnung...
Page 235 VERGLEICHSTABELLE FOR MASSEINHEITEN CONVERSION TABLE TABLEAU DE CONVERSION 25.4MM 1 in (inch) 1 kg ( Kilogramm ) 2,205 lb(poubds) 9,81 Nm( 1 kpm) 7,233 ibf x ft( pound force foot) 1,356 Nm( 0,138 kpm) 1 Ibf x ft ( pound force foot) 1 k g / cm 5,560 lb / in ( pound per inch ) 1 bar ( 1,02 kp/cm²...
Page 236: Torque Limits For Screws
TORQUE LIMITS FOR SCREWS (IN Nm) ACCORDING TO ZF-STANPARDS 148 Coefficient of friction: μ total = 0,12 for screws and nuts without after treatments as well as for phosphates nuts. Tighten by hand! Torque limits, of not exspecially, can be taken from the following list: Metric ISO-Standard Thread DIN 13, Page 13 Size 10.9...
Page 237 INSCRIPTIONS ON A ZF-MODEL IDENTIFICATION PLATE FOR ZF-HYDROMEDIAREVERSING- TRANSMISSIONS: 1 =Gearbox type 2= Gearbox-No. ZF-Parts List-No. 4 =Total ratio of the Gearbox 5 =Value for the control pressure 6 =ZF-Parts List-No. of the Torque Converter 7 =Type of the ZF-Torque Converter NOTES REGARDING THE SPARE PARTS ORDERS: When ordering genuine ZF-Spare Parts, please indicate: 1.
Page 238 Optional versions and additional equipment for the transmissions of the WG range 1 Converter housing for direct 10 Parking brake 20 Rotary reversing switch DW 1 installation 11 Speedometer connection 21 Automatic control unite EST 2 2 Torque converter 12 Inter-axle differential 22 Inching valve 3 Lock-up clutch 13 Axle drive, flange-mounted...
Page 239: List Of Lubricants Te-Ml 03
Torque converter transmissions for off-road vehicles and machinery (construction plant, special vehicles, lift trucks) List of Lubricants TE-ML 03 Transmission Approved lubricants Engine oils WG 80/81/53/85 API CD/ CE/CF/ SF/ SG WO 100 MIL-L-2104 O -D/ -E WG 120/121 MILL-46152C/-D/-E •...
Page 240: Electro-Hydraulic Gearbox Control
I. ELECTRO-HYDRAULIC GEARBOX CONTROL ATTENTION : In case of malfunctions of the Transmission because of a defective gearbox control, we recommend the replacement of the complete gearbox control. The pressure-control curve of the replacement-gearbox control (see corresponding Spare Parts List) has been accordingly adapted to the Transmission Version, resp.
Page 241 Note regarding the pressure control: Diagram 1 (Basic diagram) Pressure-control curve gear case p = Pressure in box t - Time in seconds p1 =Modulation start p2 =Modulation end p3= Modulation start only in dependence with 2-stage pressure control valve ps =Control pressure Δ...
Page 242 Note: In the following Disassembly and Reassembly Instructions are three different gearbox control Variants treated. 1.1 Cast-iron gearbox control 1.2 Aluminium sand-casting gearbox control 1.3 Aluminium die-cast gearbox control with WK-Valve 1.2 Aluminium sand-casting gearbox control With the help of the following Figures, the coordination of the single gearbox control variants can be visually identified because of the different casting contours! 1.1 Cast-iron gearbox control Measuring points for pressure oil:...
Page 243 1.1 CAST-IRON GEARBOX CONTROL 1 . 1 . 1 Version 1: Standard Version (without WK and 2-stage pressure control valve) 1.1.1.1 DISASSEMBLY Separate shift-control housing and channel plate from gear case (Figure 1 ...3). Loosen socket head screws, install two adjusting screws (Arrows) and remove shift-control housing.
Page 244 Relax spring clip and remove cover. Figure 4 Pull off cable shoes, loosen the socket head screws and remove solenoid valves. Figure 5 Remove components, see Figure on the right! Figure 6 Loosen two hex. head screws and fix shift-control housing provisionally, using Special Tool ( S ).
Page 245 Remove components, see Figure on the right ! Figure 8 Remove stop plates (Arrows) and demount detent blocks. NOTE ; The use o f two spools in order to fix the detent block provisionally axially (Figure 10), avoids the tilting of the detent blocks, thus facilitating the disassembly ! Figure 9 Figure 10...
Page 246 1.1.1.2 REASSEMBLY see also illustrated Tables, Page 26 ! NOTE : Check all components for damage and renew if necessary ! Check free travel of the moving parts in the housing prior to the installation ! Spools can be exchanged individually ! Oil components prior to the reassembly ! Introduce detent blocks (1 and 2) into the bores and fix them by means of stop plates (3 and 4).
Page 247 Install components : 1 = Valve body 2 = Spring (L = 88,6 mm) 3 = Spring (L = 52,0 mm) 1 = Disk (optional) 5 = Spacer 6 = Spool 7 = Sleeve 8 = Spool 9 = Spring (L =81,7 mm) 10 = Spool 11 = Spool Figure 16...
Page 248 Preload detent block and install solenoid valve. Install remaining solenoid valves accordingly. NOTE ; Employ new O-Rings for solenoid valves ! Pay attention to the radial installation position of the solenoid valves, see Figure 21 ! Install cable harness (mount new gaskets), fasten Figure 19 ground cable and connect solenoid valves (Figure 20).
Page 249 Pre-assemble channel plate (Figure 23 and 24) NOTE : According to the gearshift Version, different channel plate variants are possible ! Pay attention to the Perspective Illustrations in the corresponding Spare Parts List ! The following Reassembly Instruction is treating the Standard Version (with control diaphragm and diaphragm for the backfeed) ! Wet thread of control diaphragm with Loctite (Type-...
Page 250 Install intermediate plate and 2nd gasket. Figure 26 Assemble channel plate and fasten it by means of socket head screws. Torque limit (M8/8.8) 23 Km NOTE ; Pay attention to a correct position of the ball seat valves ! Pay attention to the position of the various screws, see corresponding Spare Parts List ! Figure 27 Assemble 1st gasket.
Page 251 Place gearbox control assembly against shoulder and fasten it by means of socket head screws. Torque limit (M8/8.8) 23 Nm NOTE : Pay attention to the position of the different screws (lengths) ! Employ new sealing rings for the screw plugs (see Arrows) and install them ! Now, install...
Page 252 SPC000007 Transmission and Torque Converter Page 24...
Page 253 Transmission and Torque Converter SPC000007 Page 25...
Page 254: Gearbox
ALUMINIUM SAND-CASTING GEARBOX CONTROL 1.2.1 VersionⅠ : With 4 Solenoid valves and attached 2-stage pressure control valve ! 1.2.1.1 DISASSEMBLY Remove delivery line. Figure 35 ( S ) Adjusting screws (M8) 5870 204 Relax spring clip and remove cover. Figure 36 Pull oil cable shoes and remove cable harness.
Page 255 Loosen two socket head screws and fix shiftcontrol housing provisionally, using a Special Tool ( S ). Now, loosen the remaining socket head screws and separate shift-control housing (is spring-loaded) from the valve body by uniform loosening of the nuts ( S ).
Page 256 1 . 2 . 1 . 2 REASSEMBLY see also Illustrated Tables, Page 1.26 and 1.27 ! NOTE : Check all components for damage and renew if necessary ! Check free travel of the moving parts in the housing prior to the installation ! Spools can be exchanged individually ! Oil components prior to the reassembly ! Close the bores by means of balls (8 pieces Φ...
Page 257 Reset valve： Install components. 1 = Spool 2 = Disk(s) (optional) 3 = Spring = 58,00 mm) 4 = Spring = 65,40 mm) NOTE: p2 is determined by the disk 4 Figure 48 (pay attention to Notes, Page 12 ... 14) ! Pressure control valve : Install components.
Page 258 Install components ： 1 = Intermediate plate 2 = Valve 3 = Compression spring = 29,90 mm) 4 = Straight pin 5 = Roller 6 = Spool 6a = Disk (s = 2,5 mm/empirical value) Figure 52 7 = Spring = 70,90 mm) 8 = Disk(s) 9 = Screw plug...
Page 259 Install components ： 1 = Spring = 33,40 mm) 2 = Spool 3 = Spring = 53,40 mm) 4 = Spool 5 = Spool (reducing valve) 6 = Spring = 37,10 mm) 7 = Retaining plate 8 = Socket head screw 9 = Spring = 53,40 mm) 10 = Spool...
Page 260 Connect solenoid valves according to the Illustration on the right. Mount new O-Ring (164,2 x 5,7 mm), see Arrow and Figure 59 fix cover by means of clamping collar. Intall delivery line 1, control pressure sender 2 (according to the Version) as well as screw plug. NOTE : Figure 60 Mount new sealing rings and O-Rings !
Page 261 Install connecting pipe (1) and screw pljg (Arrow). NOTE : Mount new O-Rings ! Insert the two check valves (composed of balls and Figure 63 springs) with grease in the countersinking of the channel plate (see Arrows). NOTE : Use only oil soluble grease ! Attach channel plate and gearbox control (Figure 65 ...
Page 262 Assemble 1st gasket, intermediate plate and 2nd gasket. NOTE : attention various gaskets, corresponding Spare Parts List ! Figure 67 Place control unit against shoulder until contact is obtained and fasten it by means of hex. head screws (mount flat washers). Torque limit 20 Nm Install deliver/ lines according to the Illustration in...
Page 263 Transmission and Torque Converter SPC000007 Page 35...
Page 264 SPC000007 Transmission and Torque Converter Page 36...
Page 265 1.2.2 Version II : With 5 Solenoid valves and attached WK- Valve 1.2.2.1 DISASSEMBLY Relax spring clip and remove cover. Figure 75 Pull off cable shoes. Figure 76 Loosen socket head screws and remove solenoid valves. Figure 77 Remove components. Figure 78 Transmission and Torque Converter SPC000007...
Page 266 WK-Valve : Remove components. Loosen two socket head screws and fix shiftcontrol housing provisionally, using a Special Tool ( S ). Figure 79 Now, loosen the remaining socket head screws and separate shift-control housing (is spring-loaded) from the valve body by uniform loosening of the nuts ( S ).
Page 267 1.2.2.2 REASSEMBLY also Illustrated Tables, Page 1.35and1.37 ! NOTE: Check all components for damage and renew if necessary ! Check free travel of the moving parts in the housing Figure 83 prior to the installation ! Spools can be exchanged individually ! Oil components prior to the reassembly ! Close the bores by means of balls (10 piecesΦ...
Page 268 Pressure control valve : Install components, 1 = Spool 2 = Disk (optional) 3 = Spring = 76,70 mm) 4 = Spring = 132,40 mm) 5 = Spool NOTE ; P1 is determined by the disk 2 (pay attention to Notes, Page 12 ... 14) ! Figure 87 Control pressure valve : Install components.
Page 269 Pull shift-control housing by means of threaded bushings ( S ) against shoulder. Now, fasten lousing by means of socket head screws. Torque limit (M5/8.8) 5,5 Nm ( S ) Adjusting screws (M5) 5870 204 036 with nut ( S ) Adjusting screws (M6) 5870 204 049 with nut...
Page 270 Connect solenoid valves according to the Illustration on the right.. Figure 95 Mount new O-Ring (164.2 x 5.7) and fix cover by means of clamping collar. Figure 96 Install screw plugs as well as control pressure sender (according to the Version). NOTE : The Reassembly of the channel plate as well as the attachment of the gearbox control is treated on...
Page 271 Transmission and Torque Converter SPC000007 Page 43...
Page 272 SPC000007 Transmission and Torque Converter Page 44...
Page 273 1.3 ALUMINIUM DIE-CAST GEARBOX CONTROL 1.3.1 Version 1 : With WK-Valve 1.3.1.1 DISASSEMBLY ( S ) Adjusting screws 5870 204 011 Relax spring clip and remove cover. Pull off the cable shoes, loosen socket head screws Figure 100 and remove cable harness. Loosen socket head screws and demount solenoid valves.
Page 274 Remove components, see Figure on the right! Figure 103 Remove and dismantle WK-Valve : Loosen socket head screws and disassemble solenoid valve. Figure 104 Separate WK-Shift-control housing from the valve body and dismantle it, see Figure on the right ! Loosen two socket head screws and fix the shift- control housing provisionally, using a Special Tool Figure 105...
Page 275 Remove components, see Figure on the right ! Figure 107 Remove stop plate and demount spring as well as spool. NOTE : Installation position of the stop plate, see Arrow! Figure 108 Remove diaphragm and check valves. Figure 109 Transmission and Torque Converter SPC000007 Page 47...
Page 276 1.3.1.2 REASSEMBLY see also Illustrated Tables, Page 55and 56 ! NOTE : Check all components for damage and renew if necessary ! Check free travel of the moving parts in the housing prior to the installation ! Spools can be exchanged individually ! Oil components prior to the reassembly ! Employ new O-Rings for all screw plugs (8 pieces) and install them.
Page 277 Control pressure valve : Install components. 1 = Spring = 96,20 mm) 2 = Disk(s) (optional) 3 = Spool NOTE : ps is determined by the disk (pay attention to Notes, Page 12 ... 14) ! Figure 112 Pressure control valve : Install components.
Page 278 Install two adjusting screws ( S ) and assemble fat gasket (Arrow). Now, pull cover against shoulder, using nuts ( S ) and fix it provisionally by means of socket head screws (4 pieces, see Figure 118). ( S ) Adjusting screws (M6) 5870 204 049 with nut...
Page 279 Introduce control spool (K4/KR) and compression spring (Lo = 51.30 mm), and fix them by means of stop plate. NOTE : Position of the stop plate, see Arrow ! Install components (1 ... 10) : 1 = Spring = 51.30 mm) Figure 120 2 = Control spool K4/KR 3 = Spring...
Page 280 Connect solenoid valves according to the Figure on the right. Mount new O-Ring (Arrow) and fix cover by means Figure 124 of clamping collar. Pre-assemble and attach channel plate (Figure 126 ... 129) ; Figure 125 Mount connecting pipe (1) and screw plug (2). Install two adjusting screws and assemble housing gasket.
Page 281 Install intermediate plate and 2nd gasket. Assemble channel plate and fasten by means of Figure 128 socket head screws (mount flat washers). Torque limit 20 Nm NOTE : Use only socket head screws, M8 x 35, DIN 6912 (with low head) ! Position of screws, see Arrows ! Figure 129 Attach gearbox control (Figure 130 ...
Page 282 Assemble gearbox control and fasten it by means of socket head screws (8 pieces M8 x 65, 11 pieces M8 x 35 and I piece M8 x 63mm). Torque limit 20 Nm NOTE : Mount flat washers ! Position of the socket head screw M8 x 63 mm, see Arrow ! Install delivery lines, see Perspective illustration in Figure 132...
Page 283 Transmission and Torque Converter SPC000007 Page 55...
Page 284 SPC000007 Transmission and Torque Converter Page 56...
Page 285 1.3.2 Version 11 : With 2-stage pressure control valve 1.3.2.1 DISASSEMBLY Relax spring clip and remove cover. Figure 135 Pull off cable shoes, loosen the socket head screws and demount solenoid valves. Remove components, see Figure on the right. Figure 136 Loosen two socket head screws and fix shiftcontrol housing provisionally, using a Special Tool ( S ).
Page 286 Remove components. Remove stop plate and demount spool as well as spring. Figure 139 Dismantle pressure control valve, see Figure on the Figure 140 right. Remove diphragm and check valves. Figure 141 Figure 142 SPC000007 Transmission and Torque Converter Page 58...
Page 287 1.3.2.2 REASSEMBLY see also Illustrated Tables, Page 63 ! NOTE : Check all components for damage and renew if necessary ! Check free travel of the moving parts in the housing prior to the installation ! Spools can be exchanged individually ! Oil components prior to the reassembly ! Employ new O-Rings for all screw plugs and install them.
Page 288 Install components : 1 = Control spool 2 = Spring (Lo =124.10 mm) 3 = Spring (Lo = 77.10 mm) 4 = Displacement spool Figure 146 Install components : 1 = Reversing spool 2 = Disk(s) (optional) 3 = Spring (Lo = 56,30 mm) NOTE ;...
Page 289 Install components ; 1 = Shift-control housing 2 = Spool 3 = Spring = 70,90 mm) 4 = Screw plug 5 = Cylindrical roller (6 x 32 mm) 6 = Ring(s) (optional) 7 = Spool 8 = Screw plug 9 = Spring = 70,90 mm) 10 = Spool Figure 150...
Page 290 Insert the solenoid valves and fix them by means of disks, retaining plates and socket head screws. Torque limit (M5/8.8) 5,5 Nm NOTE : Pay attention to the installation position of the disk (mount between valve body and retaining plate), see Arrow ! Pay attention to the radial installation position of the solenoid valves, see Figure 156 !
Page 291 Transmission and Torque Converter SPC000007 Page 63...
Page 292 Version Ⅲ : With WK-Valve and 1.3.3 variable 2-stage pressure control valve. 1.3.3.1 DISASSEMBLY Relax spring dip and remove cover. Pull off the cable shoes and remove cable harness. Figure 161 Loosen socket head screws and remove solenoid valves SPC000007 Transmission and Torque Converter Page 64...
Page 293 Remove components, see Figure on the right. Figure 163 Loosen socket head screws and remove solenoid valve (2-stage pressure control valve). Figure 164 Loosen two socket head screws and fix shift control housing provisionally, using a Special Tool ( S ). Now, loosen the remaining socket head screws and separate shift-control housing (is spring-loaded) from the valve body by uniform loosening of the nuts...
Page 294 Remove components, see Figure on the right! Figure 167 Remove stop plate (Arrow) and spool as well as spring. Figure 168 Remove diaphragm and check valves. Figure 169 SPC000007 Transmission and Torque Converter Page 66...
Page 295 1.3.3.2 REASSEMBLY see also illustrated Table, Page 73 and 74 ! NOTE : Check all components for damage and renew if necessary ! Check free travel of the moving parts in the housing prior to the installation ! Spools can be exchanged individually ! Oil components prior to the reassembly ! Ref.
Page 296 Control pressure valve : Install components ; 1 = Spring (Lo = 96,20 mm) 2 = Disk(s) (optional) 3 = Spool NOTE : ps is determined by the disk 2 (pay attention to Notes, Page 12 ... 14) ! Figure 173 Pressure control valve : Install components : 1 = Control spool...
Page 297 Pre-assemble shift-control housing pressure control valve) (Figure 177 ... 184); Close the bores according to Figures 177 ... 179 by means of balls, sec Arrows ! 6 pieces = Ball diameter 4,50 mm 2 pieces = Ball diameter 7,50 mm 1 piece = Ball diameter 6,00 mm Figure 177 Figure 178...
Page 298 WK-Valve : Install components ; 1 = Spool 2 = Disk(s) (optional) 3 = Spring (L o = 53,40 mm) 4 = Detent block 5 = O-Ring 6 = Connecting piece Figure 181 NOTE ; Install detent Mock with the countersinking facing the spring ! p2 (WK) is determined by the disk 2 (pay attention to Notes, Page 12 ...
Page 299 Install two adjusting screws ( S ) and assemble flat gasket (Arrow). Pull shift-control housing against shoulder, using nuts ( S ). Now, fasten shift-control housing by means of socket head screws (mount flat washers). Torque limit (M6/8.8) 9,5 Nm ( S ) Adjusting screws (M6) 5870 204 049...
Page 300 Insert solenoid valves and fix them by means of disks, retaining plates and socket head screws. Torque limit (M 5/8.8) 5,5 Nm NOTE : Pay attention to the installation position of the disks (mount between valve body and retaining plate), see Arrow ! Pay attention to the installation position of the Figure 189...
Page 301 Transmission and Torque Converter SPC000007 Page 73...
Page 302 SPC000007 Transmission and Torque Converter Page 74...
Page 303 TORQUE CONVERTER Version： With converter connecting clutch (WK) DISASSEMBLY Separate complete converter from transmission by means of lifting device. (S) Assembly car compl. with tilting device 5870 350 000 Figure 1 (S) Basic support 5870 350 014 (S) Support 5870 350 036 (S) Set of eye bolts 5870 204 002 Loosen screwed connection.
Page 304 Press free wheel inner ring out of the stator and remove released components. Figure 5 Squeeze out snap ring. Figure 6 Press free wheel outer ring out of the stator. Figure 7 Separate turbine wheel from converter impeller cover. Figure 8 SPC000007 Transmission and Torque Converter Page 76...
Page 305 Loosen hex. head screws, remove backing plate and plate pack. Figure 9 Remove cup spring and demount all driving pins (Arrow). Figure 10 Separate piston from converter impeller cover by means of compressed air. ( S ) Rubber cap 5870 509 009 Figure 11 Press profiled bush out of the converter impeller cover.
Page 306 2.2 REASSEMBLY Squeeze snap ring into the annular groove (Arrow) of the converter impeller cover. NOTE : Grease and align snap ring radially prior to reassemble the profiled bush (Figure 14) ! Figure 13 Install O-Ring (Arrow) and grease it. Thread up profiled bush ( S ) and press the drive dog in until the snap ring engages in the annular groove.
Page 307 Insert cup spring , with the concave side showing upwards (see draft , fig 17). Figure 17 Install alternating outer and inner plates (2 pieces each), starting with one outer plate. NOTE ; In case of Versions with three outer and one inner plate, two outer plates have to be installed at first, followed by one inner plate and one outer plate as last plate !
Page 308 Example "A" : DimensionⅠ 44,0 mm DimensionⅡ - 43,5 mm Difference = Clearance = 0.5 mm NOTE : Carry corrections means corresponding pistons (s = 9,2 mm, 9,8 mm and 10,5 mm) ! Assemble backing plate with the chamfering (Arrow) showing upwards and fasten it by means of hex, head screws.
Page 309 Squeeze in rectangular ring (Arrow 1) and engage Insert O-Ring (Arrow 2) in the recess of the turbine wheel hub and grease it. Figure 24 Thread up pro-assembled turbine wheel until the inner plates have been received. Figure 25 Heat stator and insert free wheel outer ring until contact s obtained.
Page 310 The Illustration on the left shows the components of the stator. 1 = Shim (constant, s = 1,0 mm) 2 = Ball bearing 3 = Thrust washer (s = 1,5 mm) 4 = Free wheel inner ring 5 = Cylindrical rollers (28 pieces) 6 = Spring cap (28 pieces) Figure 28 7 = Compression spring (28 pieces)
Page 311 Mount thrust washer (3) s = 1,5 mm and press bearing against shoulder. Figure 32 Install shim (1) s = 1,0 mm and shaft washer (60x85x4,75). Figure 33 Opposite side : Install shim (I) s = 1,0 mm, shim (10) (optional e.g. s = 0,5 mm) and shaft washer (60x85x4,75).
Page 312 Insert stator with the reduced plane surface (Arrow) showing upwards until contact is obtained. Figure 36 Install axial roller bearing and housing washer (62x85x4,75 mm). Mount new flat gasket and fasten flange by means Figure 37 of hex. head screws (mount flat washers) on the impeller wheel.
Page 313 Measure Dimension Ⅱ from the flange-mounted surface (converter impeller cover) to the housing washer. Dimension Ⅱ e.g. 87,95 Example "B" Dimension Ⅰ 88,05 mm Dimension Ⅱ - 87,95 mm Figure 40 Difference s End play 0,10 mm NOTE: In case of deviations from the permitted end play (max.
Page 314 3. GEARBOX 3.1 DISASSEMBLY 3.1.1 CONVERTER CHARGE PUMP and CONTROL PRESSURE PUMP Loosen hollow screw and remove delivery line. Figure 1 Loosen screwed connection (Figure 2) and separate engine connecting case from gear case by means of pry bars (Figure 3). Figure 2 Figure 3 Loosen hollow screw and remove delivery line.
Page 315 Loosen hex. head screws. Figure 5 Tap loose and remove bearing cap. Figure 6 Fasten puller device at the oil supply flange by means of hex. head screws. Pull converter charge pump and control pressure pump (complete) out of the housing bore. (S) Back-off device 5870 000 062 Figure 7...
Page 316 Remove rectangular ring (I) and circlip (2). (S) Set of external 5870 900 016 snap ring pliers Figure 9 Press shaft out of the pump case. Figure 10 Check converter charge pump and control pressure pump (Figure 11 ... 14): Remove the two straight pins by means of striker (Figure 11), loosen hex.
Page 317 Install rotor set, fix cover provisionally by means of hex. head screws and insert the straight pins (with the tapped hole showing upwards) until contact is obtained. Figure 13 Fix the straight pins axially by means of caulkings (2x) and tighten hex. head screws finally. Figure 14 Remove converter relief valve (ball and spring).
Page 318 Remove disk and spur gear. NOTE : According to the Version, with or without disk see corresponding Spare Parts List! Figure 17 Remove ball bearing and drive shaft. Figure 18 Pull roller bearing out of the bore. (S) Internal puller 5870 300 014 (S) Back-up tool 5870 300 003...
Page 319 Loosen screw plug and remove converter control valve, composed of disk, compression spring, spool and valve sleeve. Figure 21 Remove drive side inductive transmitter. Figure 22 3.1.2 COAXIAL POWER TAKE-OFF (mechanical control) Loosen clamping screw and remove lever (Arrow). Figure 23 Remove Woodruff key and shift lever.
Page 320 Remove locking device. Figure 25 Loosen socket head screws and remove housing. Figure 26 Loosen hex. head screws and lift complete power take-off housing out of the bore. (S) Set of eye bolts 5870 204 002 Figure 27 SPC000007 Transmission and Torque Converter Page 92...
Page 321 Fasten power take-off in a vise. Expand the two snap rings, align them centrically and drive the drive dog provisionally about 5 ... 10 mm ahead (direction of Arrow). NOTE: For this step, an assistant is absolutely necessary! (S) Circlip pliers 5870 900 026 Figure 28 Squeeze out snap ring (Figure 29), tap the drive dog...
Page 322 3.1.3 LATERAL POWER TAKE-OFF Loosen socket head screws and remove pump flange. Figure 31 Squeeze out circlip (housing interior). Figure 32 Pull drive dog, by means of internal puller out of the ball bearing, resp. spur gear and remove released spur gear.
Page 323 3.1.4 REMOVE EMERGENCY STEERING PUMP Loosen hex. nuts and separate emergency steering pomp from gear case. Figure 35 Transmission and Torque Converter SPC000007 Page 95...
Page 324 3.1.5 REMOVE MULTI-DISK CLUTCHES NOTE; In case of Versions with Spur Rear fixing K1, the two set screws (Arrows) have to be removed prior to the disassembly of the axle, see Figure on the right! Figure 40 Loosen hex. nuts and pull axle by means of Special device out of the clutch, resp.
Page 325 Loosen socket head screw. Figure 44 Pull axle by means of Special device out of the housing bore, resp. spur gear bearing. (S) Puller 5870 000 0S3 Figure 45 Remove spur gear and disk. Figure 46 Transmission and Torque Converter SPC000007 Page 97...
Page 326 3.1.7 DISMANTLE MULTI-DISK CLUTCH Remove spur gear K1 and demount components. Figure 50 Squeeze out snap ring. Figure 51 Remove plate pack. Figure 52 Preload compression spring, squeeze out circlip and remove components. (S) Assembly jig 5870 345 028 Figure 53 SPC000007 Transmission and Torque Converter Page 98...
Page 327 Remove piston by means of clamping pliers. (S) Clamping pliers 5870 900 007 Figure 54 Pull needle bush out of the bore, using internal puller. NOTE: The disassembly of the clutch KV, KR/K2 and K4/K3 has to be carried out accordingly. (S) Internal puller 5870 300 014 (S) Back-up tool...
Page 328 3.1.8 FINAL DRIVE - VERSION WITH DRUM BRAKE Remove lock plate and loosen hex. head screws. Figure 60 Pry output flange off the shaft. (S) Pry bar 5870 345 065 Figure 61 Tilt gear case 180° . Loosen hex. head screws. Figure 62 Separate brake drum from output flange.
Page 329 Remove lock plate and loosen hex. head screws. Figure 64 Pull output flange from the shaft. (S) Two-leg puller 5370 970 004 Figure 65 Unhook return springs and remove brake shoes. (S) Brake spring pliers 5870 900 006 Figure 66 Pry shaft seed out of the housing bore.
Page 330 Squeeze out circlip and remove shim. (S) Circlip pliers 5870 900 021 Figure 68 Loosen the two closing covers by central tapping and remove them. Figure 69 Loosen the two hex. head screws and remove them along with flat washers. Figure 70 Remove upper oil retainer.
Page 331 Drive output shaft by means of striker out of the output gear and remove it. ATTENTION ： In case of the Version with a mechanical speedometer, speedometer-drive shaft (complete) has to be removed prior to the disassembly of the output shaft ! ( S ) Puller 5870 023 017 ( S ) Puller...
Page 332 Loosen hex. lead screws (Figure 76) and pull pin by means of Special device out of the housing bore (Figure 77). ( S ) Puller device 5870 000 066 Figure 76 Tilt gear case 180° . Figure 77 Pry shaft seal out of the housing bore. Squeeze out circlip and remove spacing washer.
Page 333 3.2 REASSEMBLY 3.2.1 Final drive - Version with Drum brake Install O-Ring (Arrow), insert pin until contact is obtained and fasten by means of housing washer, flat washer and hex. head screw. NOTE : Secure hex. head screw with Loctite (Type-No. 270) ! Figure 90 Illustration on the right shows the components of the...
Page 334 NOTE: For the following steps pay attention to the Draft (Figure 93) ! Figure 93 Squeeze in circlip 1. Tilt gear case 180°. ( S ) Clamping pliers 5870 900 021 Lay shim 2 (e.g. s = 0,7 mm/empirical value) and roller bearing 3 upon circlip 1.
Page 335 Introduce plate 4 through the large housing bore and lay it over the roller bearing 3. Heat bearing inner race 5 and assemble it until contact is obtained. Figure 96 Position spur gear 6, see Draft ! Figure 97 Position oil retainer 7, see Draft ! Figure 98 Figure 99 Transmission and Torque Converter...
Page 336 Fasten both plates by means of hex, head screws (install flat washers). Torque limit (M8/8.8) 23 Nm NOTE : Secure hex. head screws with Loctite (Type-No. 270). Figure 100 Squeeze in circlip 8. ( S ) Clamping pliers 5870 900 021 Press the speedometer-drive worm against shoulder.
Page 337 Cheek end play of the output shaft bearing = 0,3 ... 0,5 mm (Figure 104 ... Example "A"): Measure Dimension I from the end face/output shaft to the contact face (ball bearing). Dimension I e.g. 79,60 mm ( S ) Digital depth gauge 5870 200 072 Figure 104 Determine DimensionⅡ...
Page 338 Heat housing bore and thread up output shaft until contact is obtained. Figure 107 Fix ball bearing free of play by means of shim and circlip. ( S ) Clamping pliers 5870 900 021 Install shaft seal with the sealing lip facing the oil chamber.
Page 339 Install the two closing covers. NOTE ; Wet sealing surfaces with Loctite (Type-No. 270) ! ( S ) Driver 5870 057 015 ( S ) Handle 5870 260 002 Install brake shoes and engage return springs Figure 111 Insert hex. head screws in the bores of the output flange and press retaining plate (Arrow) against Figure 112 shoulder.
Page 340 Fasten output flange by means of disk and hex. head screws. NOTE : Wet the contact surface of disk and screw heads with sealing compound ! Torque limit (Ml0/8.8) 46 Nm Figure 115 Fix hex. head screws means of lock plate. ( S ) Driver 5870 057 009 ( S ) Handle...
Page 341 Figure 119 shows a Version with 2 shaft seals (Version with fording ability). Installation position : Sealing lip of inner shaft seal is facing the oil chamber ! Sealing lip of outer shaft seal is showing outwards. The installation depth is obtained by application of the prescribed driver ! NOTE : Fill space of upper and lower sealing lip with grease !
Page 342 3.2.2 Speedometer The Illustration on the left shows the components. 1 = Speedometer-drive gear 2 = Speedometer-drive shaft 3 = Straight pin 4 = Speedometer connecting piece 5 = Shaft seal Figure 123 Press drive gear flat against the end face/ speedometer-drive shaft.
Page 343 Assemble flat gasket and fasten pre-assembled speedometer by means of hex. Head screws. Torque limit (M8/8.8) 23 Nm Figure 126 In case of the Version without speedometer. close the bore by means of cover (Arrow). NOTE : Wet sealing surfaces with Loctite (Type-No.270) ! Figure 127 Transmission and Torque Converter SPC000007...
Page 344 3.2.3 CLUTCH K4/K3 3.2.3.1 Pre-assemble plate carrier K4/K3 NOTE : The following steps (Figure 132 ... 138) have to be carried out on both sides of the plate carrier ! The needle bush is marked on one end face. Press needle bush carefully against shoulder, using drift ( S ).
Page 345 Assemble lower spring guide (1), compression spring (2) and upper spring guide (3). Mount guide ring (4) and circlip (5) (Figure 137), Figure 136 preload compression spring and fix the components by means of circlip (Figure 138). Assembly jig 5870 345 Figure 137 Figure 138 Transmission and Torque Converter...
Page 346 PLATE INSTALLA TION Ⅰ Determine Plate installation-No. (Page 118) Ⅱ Table for plate installation (Page 119 ... 121) Ⅲ. Example with Draft (Page122) Ref.Ⅰ; Determine Plate installations-No. with the aid of the corresponding Spare Parts List. The following List shows the abstract from a Spare Parts List. A = Transmission Parts List B = Group 151, Clutch KV/K1 C = Assembly Note - Plate installation...
Page 347 Ⅱ Table for Plate installation Clutch KV to KR Type of plate Quantity(n) S(mm) n s (mm) ZF-No. Outer plate 0501 309 330 Inner plate 4644 308 329 Inner plate 4644 308 330*） Compensating plate 4644 308 329 (Inner plate) or 2,5 or 2,5 4644 308 330...
Page 348 Clutch K1 to K2 Type of plate Quantity(n) S(mm) n s (mm) ZF-No. 0501 309 330 Outer plate 4642 308 329 Inner plate 4642 308 330*） Inner plate 4642 308 329 Compensating plate or 2,5 or 2,5 4642 308 330 (Inner plate) No.
Page 349 Clutch K4 Type of plate Quantity(n) S(mm) n s (mm) ZF-No. Outer plate 0501 309 329 Inner plate 4642 308 330 Inner plate 4642 308 332 Inner plate 4642 308 331*) Compensating plate 4642 308 330 (Inner plate) or 2,0 or 2,0 4642 308 332 or 2,5...
Page 350 III. EXAMPLE FOR PLATE INSTALLATION The following Draft shows the plate installation of the Clutch KV and K1 ! Ref. Draft : A = Clutch KV (Plate installation-No. e.g. 12) B = Clutch KI (Plate installation-No. e.g. 22) 1 = Plate carrier 2 = Backing plate 3 = Piston 4 = Outer plates...
Page 351 3.2.3.2 Install plate pack Install plate pack and replace backing plate. NOTE : Plate arrangement, see Plate installation, Page 118 ... 122! Fix plate pack by means of snap ring. Figure 139 Check plate clearance (Figure 141 to Example ―B‖) NOTE : The plate clearance of the different clutches can be Figure 140...
Page 352 Example "B" : DimensionⅠ 5,3 mm DimensionⅡ - 3,2 mm Difference = Plate clearance 2,1 mm NOTE : In case of deviations from the required plate clearance, correct by means of corresponding compensating plates. The pre-assembly of the remaining clutches (K3, KV/K1 and KR/K2) has to be carried out accordingly.
Page 353 3.2.3.4 Install plate pack K3 Install plate pack and check clearance. NOTE ; Plate arrangement, see plate installation, Page 119 ... 122 ! 3.2.3.5 Pre-assemble and install spur gear K3 Figure 146 1 = Thrust plate 2 = Thrust washer 3 = Needle cage 4 = Spur gear 5 = Cylindrical rollers...
Page 354 Ⅱ Measure Dimension from butting face/bearing rollers to the flange-mounted surface. DimensionⅡ e.g. 21,00 mm Example "C", for the determination of the housing dimension Dimension Ⅰ e.g. 251,15 mm Dimension Ⅱ e.g. - 21,00 mm Difference = Housing dimension e.g. 230,15 mm Place clutch on a suitable surface plate and Figure 149...
Page 355 Align clutch by means of drift and fix it provisionally. ( S ) Drift 5870 345 025 For the moment, tilt gear case 90° and push the compl. clutch opposite to the drive side against shoulder until contact is obtained. Now, tilt gear case forward in the horizontal position.
Page 356 Squeeze in and engage rectangular rings (1). Install O-Ring (2). NOTE ; Crease and align rectangular rings centrically. Figure 155 Install stud bolts, see Arrows ! NOTE : Secure the stud bolts with Loctite (Type-No. 270) ! Figure 156 Heat housing bores (about 90° C). ( S ) Hot-air blower 220 V 5870 221 503...
Page 357 Fasten axle by means of hex. nuts. Torque limit (M8/ 8.8) 23 Nm Check end play of the clutch 0,1 ... 0,3 mm again Figure 159 and correct if necessary. ( S ) Magnetic base 5870 200 055 ( S ) Dial indicator 5870 200 057 ( S ) Crow bar 5870 345 071...
Page 358 3.2.4 Pre-assemble install countershaft assembly The illustration on the left shows the components. 1 = Closing cover 2 = Socket head screw 3 = O-Ring (installation position, see Arrow) 4 = Axle 5 = Shim 6 = Roller bearing 7 = Spur gear Figure 162 NOTE : The countershaft gear is marked on the end face.
Page 359 Fix the axle by means of socket head screw. Torque limit (Ml2/10.9, DIN 7984) 80 Nm NOTE : Secure socket head screw with Loctite (Type-No. 242). Figure 166 Install closing cover. NOTE ; Wet contact areas with Loctite (Type-No.270). 3.2.5 Clutch KR/K2 NOTE : Figure 167 The pre-assembly of the plate carrier KR/K2 has to...
Page 360 3.2.5.1 Plate pack KR Install plate pack and check clearance. NOTE : Plate arrangement, see Plate installation, Page 118 ... 122 ! 3.2.5.2 Pre-assemble and install spur gear KR NOTE : According to the Transmission Version, resp. Figure 170 operating conditions, different spur gear bearings arc possible, see corresponding Spare Parts List, as well as Fig.171, 172a and 172b ! Spur gear bearing KR, Version "A"...
Page 361 Spur gear bearing KR, Version ―C" Fig. 172 b) 1 = Thrust plate 8 = Spur gear 2 = Thrust washer 9 = Plate 3 = Thrust washer 10 = Hex. head scrcws 4 = Cylindrical rollers(short) 11 = Thrust washer 5 = Disk 12 = Forked washer 6 = Cylindrical rollers(long) 13 = Shim (optional)
Page 362 Spur gear bearing K2, Version "A" Fig. 175 1 = Thrust plate 2 = Thrust washer 3 = Angle ring 4 = Spur gear 5 = Roller cage (long) 6 = Angle ring 7 = Angle ring 8 = Roller cage (short) NOTE : Figure 175 Pay attention to the installation position of the roller...
Page 363 Install components 2 ... 8 (Figure 175), resp. 2 ... 6 (Figure 176). Replace thrust plate 1 (Arrow) and thread up spur gear until all inner plates arc received. NOTE : Make thrust washer adhere with grease ! 3.2.5.5 Install clutch KR/K2 Adjust end play of the clutch 0,1 ...
Page 364 Put the clutch on a suitable surface plate and determine Dimension from face/cylindrical rollers to the surface plate, see Figures 180 and 181 ! DimensionⅢ e.g. 227,65 mm Figure 180 Example "G" for the determination of the installation Figure 181 dimension DimensionⅢ...
Page 365 3.2.6 Clutch KV/K1 NOTE : The pre-assembly of the plate carrier KV/K1 has to be carried out accordingly like that of the plate carrier K4/K3, see Page 116 and 117. ATTENTION ; Pay attention to the different plate carriers, see Figure 148 and 169 ! 3.2.6.1 Plate pack KV Install plate pack and check clearance.
Page 366 Install components 2 ... 6 (Figure 180), resp. 2 ... 10 (Figure 185). Replace thrust plate 1 and thread up spur gear until all inner plates arc received. NOTE : Make thrust washers as well as cylindrical rollers adhere with grease. Figure 186 3.2.6.3 Plate pack K1 Install plate pack and check clearance.
Page 367 Spur gear bearing K1, Version "B" Fig. 189 1 = Thrust plate 2 = Thrust washer 3 = Spur gear 4 = Angle ring 5 = Roller cage 6 = Circlip (2x) 7 = Ball bearing 8 = Disk (optional) NOTE : Figure 189 Make thrust washer (2) adhere with grease.
Page 368 Install components according to Figure 188, 189, resp. 190. Replace thrust plate (1) and thread up spur gear until all inner plates are received. 3.2.6.5 Install clutch KV/K1 Figure 192 Adjust end play of clutch 0,1 ... 0,3 mm Determine Dimension Ⅰ from the flange-mounted surface/axle to the plane surface/housing.
Page 369 Place clutch on a suitable surface plate and determine Dimension III from the end face of the bearing inner race to the surface plate. Dimension Ⅲ e.g. 223,80 mm Example ―K‖, for the determination of the installation housing dimension . Dimension Ⅲ...
Page 370 Install thrust washer, locked washer and shim, resp. shim (according to the Version)(Figure 198 ... 201) For the moment, tilt housing 90 °and place the complete clutches in direction of Arrow against shoulder. Now, tilt gear case forward in the horizontal position. Pull drift downwards until the thrust washer, forked Figure 198 washer and shim (Figure 199), resp.
Page 371 Install axle KR/K2 (Figure 202 ... 205) Squeeze in rectangular rings (1) and engage them. Install O-Ring (2). NOTE ; Grease rectangular rings and align them centrically ! Figure 202 Heat housing bore (about 90° C). ( S ) Hot-air blower 220 V 5870 221 500 ( S ) Hot-air blower 110 V 5870 221 501...
Page 372 Check operation of clutches KR and K2 by means of compressed air. NOTE : If the components are correctly installed, the closing, resp. opening of the clutches is clearly audible ! Install axle KV/KI (Figure 207 ... 210) NOTE : The following steps (Figure 207 ...
Page 373 Fasten axle by means of hex. nuts (2 pieces). Torque limit (M8/8) 23 Nm Figure 209 Insert cylindrical rollers with the conical surface showing downwards in the bores (Arrows), and fix them by means of set screws. Torque limit 10 Nm NOTE : To ensure the correct fixing of the spur gear, the spur gear K1 must be lifted, at the uniform...
Page 374 3.2.7 Emergency steering pump Squeeze in circlip (4), assemble spur gear (3) until contact is obtained and fix it free of play by means of disk (2) and circlip (1). Introduce O-Ring into the annular groove (Arrow) and grease it. Figure 213 Insert studs (4 pieces) with Loctite (Type-No.
Page 375 3.2.8 Lateral power take-off Squeeze the two snap rings into the groove of the lower housing bore. Figure 216 Lay expanding ring ( S ) upon the snap rings and mount ball bearing, with the recess showing upwards (Figure 217). Now, tap and drive ball bearing in, until the upper snap ring engages in the ball bearing groove (Figure 218).
Page 376 Squeeze snap ring into the annular groove (Arrow) of the driving shaft. Figure 220 Heat ball bearing (Figure 221) and introduce driving shaft until contact is obtained (Figure 222). Figure 221 Figure 222 Fix driving shaft by means of circlip (Arrow). Figure 223 SPC000007 Transmission and Torque Converter...
Page 377 Press needle bush (Arrow) by means of drift into the pump flange until contact is obtained and fix it by engaging the snap ring. NOTE ; The needle bush is marked on one end face. At the pressing in, the marking must be facing the drift (upwards).
Page 378 Fasten shield by means of hex. head screw (mount flat washer). Torque limit (M8/8.8) 23 Nm NOTE : Secure hex. head screw with Loctite (Type-No. 241) ! Figure 228 3.29 Converter control valve Components : 1 = Disk 2 = Spring 3 = Spool 4 = Valve sleeve 5 = O-Ring...
Page 379 Install screw plug. Figure 232 Mount closing cover until it is flush. NOTE ; Wet sealing surface with Loctite (Type-No.270). Figure 233 3.2.10 Converter charge pump and control pressure pump Squeeze rectangular rings into the annular grooves of the drive shaft and engage them. Insert the two roll pins (1,5x5 and 2,5x5 mm) flush-mounted in the bore (Arrow).
Page 380 Thread up drive shaft. Figure 236 Install bearing inner race. Figure 237 Position spur gear with the long hub side (Arrow) showing upwards (facing the ball bearing). Figure 238 Back up drive shaft and oil supply flange by means of Assembly aid ( S ). Assemble disk (according to the Version with or without).
Page 381 Press ball bearing against shoulder. Figure 240 Squeeze circlip into the annular groove of the drive shaft. The Illustration on the right shows the output shaft Figure 241 along with bearing as well as the pump. 1 = Circlip 2 = Ball bearing 3 = Shim (optional) 4 = Pump 5 = Ball bearing...
Page 382 Install adjusting spring (Arrow). Figure 244 Install shim s = 0,8 mm (empirical value) and press output shaft against shoulder. NOTE : The end play of the output shaft of 0,2…0,4 mm is adjusted by means of shim (e.g.s = 0,8 mm) ! Figure 245 Press ball bearing against shoulder, with the closed side showing upwards.
Page 383 Relax the output shaft bearing by tapping. NOTE ; Use plastic hammer ! Figure 248 Squeeze in rectangular ring (Arrow) and engage it. Now, grease rectangular ring and align it centrically. Figure 249 Adjust the end play of the drive shaft bearing 0,2 ... 0,4 mm (Figure 250 ...
Page 384 Example "M" ; Dimension I 7,10 mm Dimension II - 6,05 mm Difference 1,05 mm Required end play e.g. - 0,30 mm gives Shim e.g. s = 0,75 mm Make shim (e.g. s = 0,75 mm) adhere with grease. Figure 252 Install two adjusting screws, mount flat gasket and install converter relief valve (ball and spring).
Page 385 Relax the output shaft bearing by tapping and check the free movement of the spur gear. Figure 255 Heat housing bore. ( S ) Hot-air blower 220 V 5870 221 500 ( S ) Hot-air blower 110 V 5870 221 501 ( S ) Pre-heating sleeve 5870 801 003 Figure 256...
Page 386 NOTE ; To ensure an exact sealing of the suction ports and pressure ports, resp. to avoid the breaking away of the Loctite, fix oil supply flange by a provisional installation of the two outer roll pins (10x50 mm) as well as hex.
Page 387 Mount oil line (Arrow). NOTE ; Use new sealing rings ! 3.2.12 Coaxial power take-off Figure 263 (controllable) Install snap rings and needle bush. NOTE : The needle bush is marked on one end face. At the pressing in, the marking must be facing the drift ( S ) ! ( S ) Drift 5870 506 060...
Page 388 Position spur gear and thread up drive dog until the snap ring is located. Figure 267 Expand the two snap rings, align them centrically and tap drive dog into the housing until the first snap ring engages in the annular groove of the roller bearing.
Page 389 Relax the bearing by tapping. Figure 271 Insert stud (Arrow 1), install two adjusting screws and assemble flat gasket (Arrow 2). NOTE ; Insert stud with Loctite (Type-No. 242) ! Figure 272 Thread up pre-assembled power take-off and fasten it by means of hex. head screws and hex. nuts.
Page 390 Install two adjusting screws and assemble flat gasket. Place housing against shoulder and fasten it by means of socket head screws. Torque limit (M8/I0.9) 34 Nm Figure 275 Install shim (s = 3,0 mm), see Arrow and thread up shift fork. NOTE ;...
Page 391 Insert O-Ring (Arrow), assemble pump flange and fasten it by means of socket head screws. Torque limit (Ml2/8.8 DIN 7984) 55 Nm NOTE : Pay attention to the radial installation position of the pump flange ! Install sliding collar and sliding block prior to the reassembly of the pump ! ATTENTION ;...
Page 392 Install screw plug (Arrow 1) and breather (Arrow 2). Mount suction pipe. Figure 282 NOTE ; Install new gaskets Install oil level pipe. Figure 283 NOTE ; Install new gaskets as well as baffle plate. Install compl. cover plate. Figure 284 NOTE ;...
Page 393 3.2.1.3 Inductive transmitter Adjust required gap 0,50 mm between the contact area/inductive transmitter and the spur gear (tooth tip). Figure 286 to Example "N". Ref. Figure 286 ; 1 = Inductive transmitter 2 = Shim 3 = Measuring pin( S ) Measuring pin ( S ) 5870 200 040 Figure 286...
Page 394 4. RETARDER 4.1 DISASSEMBLY Loosen hose lines. Figure 1 Loosen hex. head screws and remove retarder valve. Figure 2 Demount temperature sensor connecting pieces (see Arrows). Loosen hex. head screws, remove the two covers Figure 3 and demount components. Figure 4 SPC000007 Transmission and Torque Converter Page 166...
Page 395 Tilt gear case 90°. Remove lock plate. Loosen hex. head screws and pull off output flange. NOTE ; If only operations on the transmission are necessary, the complete retarder can be separated from the converter compartment by loosening the screwed connection (Figure 8)! Figure 5 Loosen screw plug.
Page 396 Separate the complete retarder from the converter compartment, using lifting device. ( S ) Set of eye bolts 5870 204 002 Figure 9 Loosen socket head screws. Figure 10 Separate cover from stator. ( S ) Set of eye bolts 5870 204 002 Figure 11 Remove rectangular ring.
Page 397 Remove rotor. Figure 13 Loosen screwed connection and remove thrust ring. Figure 14 Remove stator ring. NOTE : Pay attention to the released components ! Squeeze out circlip and remove shim. Figure 16 Figure 16 Transmission and Torque Converter SPC000007 Page 169...
Page 398 Remove shaft seal. ( S ) Pry bar 5870 345 065 Drive 4-point bearing out of the bore. Figure 17 Figure 18 SPC000007 Transmission and Torque Converter Page 170...
Page 399 4.2 REASSEMBLY 4.2.1 Pre-assemble and attach Retarder Heat bearing bore and insert 4-point bearing firmly against shoulder. Figure 20 Adjust the 4-point bearing free of play by means of disk (optional) and circlip. NOTE : Pay attention that the two bearing inner races are present ! If necessary, insert upper bearing inner race and intall shaft seal.
Page 400 Fasten thrust ring by means of hex. Head screws. Torque limit (M8/8.8) 23 Nm NOTE : Secure hex. head screws with Loctite (Type-No. 241) ! Pre-assemble dampers (3 pieces) according to Figure 25 and 26. Figure 24 NOTE ; Pay attention to the installation dimension B = l,6 mm ! Ref.
Page 401 Slide rectangular ring into the recess of the rotor and preload it by means of 3 straight pinsΦ 6 mm (Assembly aid) (Figure 28 and29). (3x) Straight pin 0631 306 178 Figure 28 Figure 29 Oil rectangular ring, slide rotor into the stator case until contact is obtained and remove straight pins again.
Page 402 Slide second rectangular ring into the recess (Figure 31). Make the bore of the rectangular ring as well as of the rotor overlap and fix rectangular ring by means of suitable pin (Φ 1 mm) (Figure 32). Figure 31 Insert O-Ring in the annular groove of the cover Figure 32 (ArrowⅠ) and grease it.
Page 403 Fasten oil slinger by means of countersunk screws. NOTE ; Wet thread of countersunk screws with Loctite (Type-No. 640) ! Adjust gap between Rotor and Stator ring = 0,8 … Figure 35 1,6 mm (Figure 36 ... 38) : Measure Dimension Ⅰ from the contact surface (4- point bearing) to the flange-mounted surface.
Page 404 Heat bearing inner race and place it against shoulder. NOTE ; Pay attention to the installation position, ball running surface is showing upwards ! Mount flat gasket, assemble the retarder until Figure 39 contact is obtained and fasten it by means of hex. head screws.
Page 405 Assemble drive flange and fasten it by means of disk and hex. head screws. NOTE : Wet contact area of disk with sealing compound ! Torque limit (M8/10.9) 34 Nm Now, fix hex. head screws by means of lock plate. ( S ) Driver 5870 057 010 ( S ) Handle...
Page 406 Install two adjusting screws. Assemble first gasket, intermediate plate and second gasket. ( S ) Adjusting screws (M8) 5870 204 011 Place retarder valve against shoulder and fasten it Figure 47 by means of hex. head screws. Torque limit (M8/8.8) 23 Nm 4.2.3 Install delivery lines Install delivery lines according to the Draft on the...
Page 407 5. AXLE DECLUTCH 5.1 DISASSEMBLY Loosen socket head screws and separate axle declutch from gear case. ( S ) Pry bar 5870 345 065 Figure 1 Remove lock plate, loosen hex. head screws and remove disk. Pull flange from output shaft. Figure 2 ( S ) Three-leg puller 5870 971...
Page 408 Pry shaft seal out of the bore. ( S ) Crowbar 5870 345 071 Squeeze out circlip. Figure 4 Press output shaft out of the housing. Figure 5 Figure 6 SPC000007 Transmission and Torque Converter Page 180...
Page 409 Remove sliding collar. Figure 7 Loosen the two set screws and remove gearshift shaft. If necessary, separate shift lever from gearshift shaft - mark radial installation position ! Figure 8 Demount locking device and remove shift fork. Squeeze out circlip and remove shim(s). Figure 9 Figure 10 Transmission and Torque Converter...
Page 410 Demount sleeve and disk. Figure 11 Remove needle bearing. Figure 12 SPC000007 Transmission and Torque Converter Page 182...
Page 411 5.2 REASSEMBLY Press ball bearing in until contact is obtained. Figure 15 Adjust ball bearing free of play by means of disk and circlip. Figure 16 Install shaft seal (Arrow) with the sealing lip facing the oil chamber. NOTE : The exact installation position is obtained by application of the prescribed driver ( S ) ! If the outer diameter of the shaft seal is rubberized,...
Page 412 Insert shim (1) and straight pin (2) in the housing bore (Arrow). NOTE : The overlapping of the locating bore to the countersinking-shift fork is determined by means of shim(s), e.g. s = 0,50 mm (empirical value) I However, a later check (Figure 27) is absolutely Figure 19 essential ! Install sliding blocks (Arrow I), position shift fork and...
Page 413 Thread up sliding collar. Figure 23 Thread up output shaft and press it against shoulder. Figure 24 Assemble shim(s), e.g. s = 2,00 mm and mount socket head screws. Torque limit (M10/8.8, 7984) 32Nm NOTE : By means of shim, e.g. s = 2,00 mm (empirical value), the sliding collar will be adjusted free of pressure (Figure 26) ! Secure socket head screw with Loctite (Type- No.
Page 414 Bring shift fork, in direction of Arrow, to the upper stop position (final drive is engaged). In this position, the countersinking of the shift fork must be centric to the tapped hole of the housing. If necessary, correct by means of corresponding shims (Figure 19) ! Figure 27 The Illustration on the left shows the components of...
Page 415 Assemble shift lever flush-mounted to the end face of the shaft and fix it by means of clamping screw. NOTE : Radial installation position of the shift lever according to the Indications of the Manufacturer of the vehicle, resp. according to the markings ! Figure 31 Insert closing cover (Arrow) until contact is obtained and fix it by slight central tapping.
Page 416 Fasten output flange by means of disk and hex. head screws. NOTE : Wet contact area of the disk and the screw heads with sealing compound ! Torque limit (M8/10.9) 34 Nm Figure 35 Fix hex. head screws by means of lock plate. ( S ) Driver 5870 057 011 ( S ) Handle...
Page 417 Insert needle ring (Arrow) in the output shaft bore. Install two adjusting screws and assemble flat gasket. ( S ) Adjusting screws (MI0) 5870 204 021 Figure 39 Place axle declutch assembly against housing until contact is obtained, and fasten it by means of socket head screws.
Page 418 AXLE DIFFERENTIAL SHIFT-CONTROL HOUSING 6.1.1 DISASSEMBLY Pull off output flange. Figure 1 Loosen socke head screws and separate axle declutch unit from gear case by means of pry bar. ( S ) Pry bar 5870 345 065 Figure 2 Remove hollow shaft. Figure 3 Loosen the two socket head screws and remove them along with disk.
Page 419 Pull sleeve from the output shaft. Figure 5 Press output shaft out of the housing. Figure 6 Demount locking screw and shift lever, and remove sliding collar. NOTE : Mark the radial installation position of the shift lever ! Figure 7 Loosen the two set screws.
Page 420 Demount gearshift shaft and remove the shift fork. Figure 9 Remove disk. Figure 10 Fasten housing in a vise - use protecting jaws and pry shaft seal out of the housing bore. Figure 11 Remove sleeve and squeeze circlip out. Figure 12 SPC000007 Transmission and Torque Converter...
Page 421 Press ball bearing out of the housing bore. Figure 13 6.1.2 REASSEMBLY Press ball bearing against shoulder until contact is obtained. Figure 15 Fix ball bearing by means of circlip and lay sleeve upon it. Figure 16 Install shaft seal with the sealing lip lacing the oil chamber.
Page 422 Insert shaft seal until contact is obtained. NOTE : Wet rubberized outer diameter with spirit ! Grease sealing lip ! ( S ) Driver 5870 048 031 Figure 18 Insert shims (1) and straight pin (2) in the housing bore (Arrow). NOTE : The shifting travel is adjusted with the shims, total thickness s = 0,6 mm (empirical value) !
Page 423 Insert disk and assemble sliding collar. Figure 22 Introduce output shaft and press it against shoulder until contact is obtained. Figure 23 Assemble the hollow shaft in order to check the shifting travel. Figure 24 Place sliding collar by means of gearshift lever into the upper stop position (direction of Arrow) and determine the play between sliding collar and plane surface-hollow shaft.
Page 424 Assemble shim(s) e.g. s = 2.00 mm and install socket head screw. Torque limit (Ml0/8.8 DIN 7984) 32 Nm NOTE : The sliding collar is adjusted free of pressure by the shim s = 2,00 mm (empirical value) (Figure 27) ! Secure socket head screw with Loctite (Type-No.
Page 425 Assemble new sealing ring and install locking screw (Arrow I). Assemble gearshift lever (Arrow 2) flush mounted and fix it by means of hex. Head screw. NOTE : Radial installation position of the gearshift lever according to the Indications of the Manufacturer of the vehicle, resp.
Page 426 DIFFERENTIAL 6.2.1 Remove and dismantle differential Pull roller bearing by means of puller device out of the housing bore. ( S ) Internal puller 5870 300 010 Figure35 Tilt gear case 180° . Loosen hex. head screws and pull output flange from the shaft (s) Clamping yoke 5870 240 025...
Page 427 Loosen hex. head screws and pull complete speedometer drive out of the housing bore. Figure 39 Drive output shaft by means of striker out of the housing bore. ( S ) Striker 870 650 001 Figure 40 Squeeze circlip out and remove shim. Figure 41 Pull roller bearing out of the housing bore.
Page 428 Loosen closing cover by central tapping and remove Figure 43 Loosen hex. head screws and remove them along with flat washers (Figure 44). Now, take cover plate out of the gear case (Figure 45). Figure 44 Figure 45 Loosen socket head screws and remove supporting tube.
Page 429 Tilt gear case 180° . Take cover plate out of the housing. Figure 47 Loosen the screw connection (Figure 48) and separate the supporting plate by means of back-off screw (M8) from the output gear (Figure 49). ( S ) Back-off screws (M8) 5870 204 008 Figure 48 Figure 49...
Page 430 Displace output gear in direction of arrow until the removal of the planetary carrier is ensured. Figure 51 Take the output gear out of the gear case. Figure 52 Drive roll pins carefully in until contact is obtained. Figure 53 Press planetary shafts out of the bores and remove released components.
Page 431 6.2.2Pre-assemble install differential The Illustration on the left shows the com-ponents of the planetary carrier. 1 = Planetary carrier 2 = Thrust washer 3 = Sun gear 4 = Thrust washer (small inner diameter) Figure 55 5 = Thrust washer 6 =Planetary gear 7 = Needle rollers (replace in sets only) 8 = Roll pin...
Page 432 Insert output gear in the housing and displace it in direction of Arrow, to make the later reassembly of the planetary carrier possible. Figure 59 Introduce planetary carrier with the long hub side showing downwards, into the internal gear. Figure 60 Lay supporting plate upon the output gear (Figure 61) and fix it by uniform tightening of the socket head screws (Figure 62).
Page 433 Lay cover plate upon the supporting plate (Figure 63). Now, tilt gear case 180°. ATTENTION: Differential is not fixed! Figure 63 Squeeze in the first snap ring, press needle bearing against shoulder and fix it by means of second snap ring.
Page 434 Insert cover plate in the gear case. Position the two cover plates and fasten them by Figure 67 means of hex. head screws (install flat washers). Torque limit (M8/8.8) 23 Nm NOTE: Secure hex. head screws with Loctite (Type-No. 241) ! Figure 68 Tilt gear case 180°...
Page 435 Introduce hollow shaft until contact is obtained. Install two adjusting screws, replace 11a: gasket Figure 71 and place compl. shift-control housing against gear case until contact is obtained. Fasten shift-control housing by means of socket head screws and install output flange (Arrow). Torque limit (Ml0/8.8 DIN 7984) 32 Nm ( S ) Adjusting screws (MI0)
Page 436 Push circlip in direction of Arrow against shoulder and determine play between circlip and end face/bearing outer race, using feeler gauge. Dimension Ⅰ e.g. 1,50 mm EXAMPLE "A" : Dimension I e.g. 1,50 mm required end play (0,4 ... 0,6 mm) Figure 75 –...
Page 437 Introduce pre-assembled output shaft until contact is obtained. NOTE: Pay attention to the exact contact of the ball bearing! Figure 78 Fix ball bearing free of play by means of shim and circlip. Install shaft seal with the sealing lip facing the oil chamber.
Page 438 Install the two closing covers. NOTE: Wet sealing surfaces with Loctite (Type-No.270)! ( S ) Driver 5870 057 015 ( S ) Handle 5870 260 002 Figure 82 Fasten closing covers by means of hex. Head screws and mount screw plug (Arrow). NOTE: In tall new flat gasket as well as O-Ring ! Torque limit...
Page 439 7. POWER TAKE-OFF CONTROLLABLE UNDER LOAD 7.1 DISASSEMBLY Loosen hex. head screws and remove shift-control housing Figure 1 Remove components according to the Illustration on the right. Loosen socket head screws and remove solenoid Figure 2 valve. Figure 3 Loosen hex. head screws and pull the output flange from the output shaft, using puller.
Page 440 Pry shaft seal out of the housing bore. Figure 5 Loosen hex. head screws and pull complete clutch out of the housing. Figure 6 Squeeze circlip out and remove backing plate as well as plate pack. ( S ) Clamping pliers 5870 900 021 Figure 7 Remove rectangular ring.
Page 441 Preload compression spring, squeeze circlip out and remove released components. ( S ) Assembly jig 5870 345 028 Figure 9 Remove piston. ( S ) Clamping pliers 5870 900 007 Figure 10 Squeeze out circlip. Press output shaft (compl.) out of the ball bearing. Figure 11 Figure 12 Transmission and Torque Converter...
Page 442 Squeeze circlip out. Figure 13 Press ball bearing out of the cover. Figure 14 Preload circlip (Arrow), align it centrically and squeeze it out. Figure 15 Press drive shaft out of the housing bore. Figure 16 SPC000007 Transmission and Torque Converter Page 214...
Page 443 Squeeze out snap rings (3 pieces). Figure 17 Squeeze circlip out. Figure 18 Press ball bearing from the drive shaft. Figure 19 Pull needle bush out of the drive shaft bore. ( S ) Internal puller 5870 300 004 ( S ) Back-up tool 5870 300 003 Figure 20 Transmission and Torque Converter...
Page 444 7.2 REASSEMBLY Close the two bores by means of set screws see Arrows ! NOTE: Insert set screws with Loctite (Type-No.270). Figure 21 Mount circlip and press ball bearing against shoulder until contact is obtained. Figure 22 Insert needle bush in the drive shaft bore until contact is obtained.
Page 445 Squeeze in and engage snap rings (3 pieces). Now, grease snap rings and align them centrically. Figure 25 Press drive shaft into the housing bore until contact is obtained. Figure 26 Preload circlip, align centrically and squeeze it into the annular groove of the housing. Figure 27 Transmission and Torque Converter SPC000007...
Page 446 Install radial lip-type sealing rings according to the Figure on the left. 1 = Piston 2 = Radial lip-type sealing ring (internal) 3 = Radial lip-type sealing ring (external) 4 = Pressure side NOTE : Sealing lip facing the pressure side ! Figure 28 Oil radial lip-type sealing rings and insert piston carefully until contact is obtained.
Page 447 Assemble outer and inner plates alternately, starting with one outer plate. NOTE ; Quantity outer inner plates, corresponding Spare Parts List ! Oil plate pack prior to the installation ! Figure 32 Mount backing plate and fix plate pack by means of circlip.
Page 448 Press ball bearing against shoulder until contact is obtained. Figure 36 Fix ball bearing by means of circlip. Figure 37 Install shaft seal with the sealing lip facing the oil chamber (downwards). NOTE : By appliation of the prescribed driver, the exact installation position is obtained ! If the outer diameter of the shaft seal is rubberized, wet the sealing surface with spirit !
Page 449 Heat output flange and press it against shoulder until contact is obtained. Fix output flange by means of disk and hex. head Figure 40 screws. Torque limit (M8/8.8) 23 Nm NOTE : Wet contact surface of disk as well as of the screw heads with sealing compound ! Insert hex.
Page 450 Make O-Ring (26 x 3 mm, see Arrow) adhere with grease in the countersinking Of the housing. Introduce solenoid valve until contact is obtained and fasten it by means of socket head screws. Torque limit (M 5/8.8) 5,5 Nm NOTE ; Employ new O-Rings for the solenoid valve ! Figure 44 Install components according to the Illustration on...
Page 451 SPC000009 FRONT AXLE CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
Page 452 TABLE OF CONTENTS GENERAL DESCRIPTION ........................3 STRUCTURE CHART ..........................3 BASIC PARAMETERS OF DRIVEG AXLE ..................3 INTERNAL STRUCTURE OF DRIVE AXLE ..................3 PARTS LIST ..............................4 ASSEMBLY ..............................4 HOUSING ASSEMBLY AXLE ........................ 5 ASSEMBLE OF HUB DRIVE AXLE ....................
Page 453: General Description
GENERAL DESCRIPTION Structure chart Figure 1 1.EDGE REDUCER ASS‘Y 2.BRAKE CLAMP ASS‘Y 3.SHELL 4.MAIN REDUCER ASS‘Y 5.HUB ASS‘Y Basic parameters of drive axle: Type Spiral bevel gear grade one reduction Main drive Reduction ratio 4.625 Type Grade one planet reduction Hub reduction gear Reduction ratio 4.94...
Page 454: Parts List
PARTS LIST Figure 2 Reference Number Description Reference Number Description REDUCER ASSY,WHEEL PLUG,MAGNETIC HOUSING ASSY, AXLE D10³30 PIN COVER ASSY REDUCER ASSY,MAIN 8 WASHER,PLAIN 16 WASHER, SPRING 8 WASHER, SPRING M16³1.5³40-8.8 BOLT M8³20-8.8 BOLT PLETE,NAME BREATHER RIVET BRAKE UNIT WASHER,SEAL 20 WASHER, SPRING M20³1.5³55-10.9 BOLT SPC000009...
Page 455 HOUSING ASSY, AXLE Figure 3 Reference Number Description Reference Number Description CAP,DUST PLATE,MOUNTINGA SPINDLE,DRIVE AXLE HOUSING,AXLE Front Axle SPC000009 Page 5...
Page 456: Assembly
Hub drive axle assembly Figure 4 SPC000009 Front Axle Page 6...
Page 457 Reference Reference Description Description Number Number M10³30-8.8 BOLT GEAR，SUN 10 WASHER, SPRING BLOT CAP,END NUT,ADJUSTING GEAR,RING STEEL BALL BEARING,TAPER ROLLER PLUG,MAGNETIC BOLT，HUB 20 WASHER,SPRING CARRIER,PLANETARY GEAR M20³1.5-8 NUT RING,O GASKET WASHER BEARING,TAPER ROLLER SPACER SLEEVE GEAR,PLANET SEAL BEARING,NEEDLE HOLDER,OIL SEAL STEEL BALL M8³20-10.9BOLT SHAFT...
Page 458: Main Drive Assembly
Main drive assembly Figure 5 SPC000009 Front Axle Page 8...
Page 459 Reference Reference Description Description Number Number 22-1 SHIM M27³2-05 NUT WASHER, LOCK 22-2 SHIM 22-3 BOLT SHIM CASE,MAIN REDUCTION NUT,ADJUSTING RING,RETAINING BEARING,TAPER ROLLER BEARING,ROLLER M16³1.5-10 NUT PINION WASHER, PLAIN BEARING,TAPER ROLLER CASE,DIFFERENTIAL SLEEVE 10-1 SHIM WASHER 10-2 SHIM GEAR,DIFFERENTIAL 10-3 SHIM SPIDER 10-4...
Page 460: Drive Axle Brake Assembly
Drive axle brake assembly Figure 6 Reference Reference Description Description Number Number 20³1.6 “O” RING EXTERIOR BRAKE PISTON SUPPORT,DEFLATING VALVE RECTANGULAR SEAL DEFLATING VALVE DUST CASE WASHER BLOCK RING BOLT BRAKE DISK SPLIT PIN 20³2.4 “O” RING INNER BRAKE SPC000009 Front Axle Page 10...
Page 461: Scheduled Maintenance
SCHEDULED MAINTENANCE Oil of new drive axle must be replaced after working for 15 days (about 100 working hours), oil shall be replaced once after working for every six months (about 1200 working hours) in following days. Every month maintenance： 1．Check abrasion condition of brake disc, if there is disruptive abrasion;...
Page 462: General Disassembly And Reassembly Instructions
Never use gasoline, solvents, or other flammable fluids to clean components. Only use approved commercial solvents that are nonflammable and nontoxic. IMPORTANT Use only GENUINE DOOSAN SPARE PARTS to warrant proper operations and prevent interchangeability problems. GENERAL INSTRUCTIONS 1. Thoroughly clean and dry axle before disassembly.
Page 463: Axle Disassembly
AXLE DISASSEMBLY Drive axle disassembly 1. Put drive axle on supporting and make sure main driver assembly is upward. Figure 7 2. Dismantle brake caliper dust cover Loosen bolts of dust cover with tools of relative specifications (such as sleeve, open end wrench, etc, same as following situation, which will not state again).
Page 464 5. Release gear oil from shell Turn on oil releasing bolts axle end cap to release gear oil. Note：Store gear oil with clean container. Figure 11 6. Dismantle end cap Loosen connection bolts between planet carrier and end cap, then get end cap from hub reducer assembly with jackscrew, dismantle end cap.
Page 465 9. Dismantle sun gear Dismantle semiaxis from sun gear. Figure 15 10. Dismantle semiaxis Take semiaxis from shell slightly. Figure 16 11. Hub reducer First loosen rim bolts with relative tools, then loosen rim from planet carrier with jackscrew and dismantle planet carrier assembly.
Page 466 13. Dismantle round bolts Pry up wire of bolt, loosen the clamp bolt of round nuts ,then dismantle round nuts. Figure 19 14. Dismantle internal gear Take internal gear out by slightly rocking. Figure 20 15. Dismantle wheel hub assembly Take wheel hub assembly from supporting axle.
Page 467 17. Dismantle main drive assembly Dismantle connection bolts between main drive and shell assembly, take out main drive with jackscrew, and suspend main drive assembly. Note: When suspending main drive assembly, guarantee suspending and dismantling tools are at the above of main drive assembly to avoid spare Figure 23 parts inside are knocked again during suspending and dismantling process.
Page 468: Assembly Dismantling
Assembly dismantling Dismantle planet carrier assembly 1. Put planet carrier on working platform horizontally. Figure 24 2. Take out planet axle with tools. Figure 25 3. Take out steel balls. Figure 26 4. Take out planet wheel and gasket. Figure 27 SPC000009 Front Axle Page 18...
Page 469 5. Take out baffle ring and quill roller from inside of planet wheel. Figure 28 Dismantle hub assembly 1. Put hub assembly on working platform. Figure 29 2. Loosen connection bolts between brake disc and hub. Figure 30 3. Take out brake disc. Figure 31 Front Axle SPC000009...
Page 470 4. Loosened bolt of oil seal seat ,Take out oil seal seat and asbestos gasket. Figure 32 5. Take out bearing. Figure 33 Dismantle main drive assembly 1. Put main drive assembly (input flange upward) horizontally and fixed on supporting. Figure 34 2.
Page 471 3. Dismantle locknut and washer. Figure 36 4. Take out input flange. Figure 37 5. Dismantle connection bolts between sealing cover and bearing sleeve, take out sealing cover. Figure 38 6. Turn main drive for 180° ,dismantle bolts of Fastening lock plate, take out lock plate. Figure 39 Front Axle SPC000009...
Page 472 7. Mark with signs so that they can be back to original position during assembling. Figure 40 8. Dismantle connection bolts of bearing seat and take out bearing seat. Figure 41 9. Dismantle adjusting nuts. Figure 42 10. Dismantle bearing outer ring. Figure 43 SPC000009 Front Axle...
Page 473 11. Hang out differential mechanism assembly. Note: Keep balance when hanging out to avoid safety hazard. Figure 44 12. Separate active spiral bevel gear assembly and bracket with jackscrew. Figure 45 Dismantle differential assembly 1. Put differential assembly vertically on working platform, and guarantee it is stable.
Page 474 3. Loosen connection nuts between driven spiral bevel gear and right shell of differential mechanism, dismantle driven spiral bevel gear. Note: Check or mark sign before dismantling driven spiral bevel gear so that it can be assembled to original position. Figure 48 4.
Page 475 7. Take out semiaxis gear gasket and gear. Figure 52 Dismantle active spiral bevel gear assembly 1. Put active spiral bevel gear assembly on working platform, support flange of bearing sleeve, clamp down on thread end of active spiral bevel gear assembly with down device.
Page 476 4. Take out adjusting gasket. Figure 56 5. Take out spacer bush. Figure 57 SPC000009 Front Axle Page 26...
Page 477: Axle Reassembly
AXLE REASSEMBLY Axle assembly 1． Shell Clean shell and suspend with special supporting. Fasten gummed plug screw at oil inlet and oil filler. ： Note: Plug screw fastening torque 175 ~ 235 Nm Note: Letai 262 taper thread sealant. Figure 58 2.
Page 478 4. Internal gear Assemble internal gear of drive axle at multiple spline at the end of supporting bearing. Figure 61 5. Round nuts (1)Assemble round nuts and fasten. Knock internal gear slightly with copper stick to make internal gear in place. Figure 62 Note: Grapple theΦ22.5 hole on wheel hub with push and pull ergometer, pull ergometer along with...
Page 479 6. Assemble O sealing ring Assemble O sealing ring on hub assemble. Figure 65 7. Install planet carrier assembly Assemble planet carrier assembly and O sealing ring on wheel hub with rim bolts, gaskets and nuts. ： Note: fastening torque 500±10Nm Figure 66 8.
Page 480 10. Assemble baffle ring Assemble baffle ring with baffle ring used for axle. Note: It must be clamped firmly when using baffle ring pincer to avoid safety hazard when it is popping out during assembling process. Figure 69 11. Assemble locating block Stake steel ball on locating block, it can rotate flexibly after staking steel ball.
Page 481 14. Assemble dust cover on brake caliper tighten bolts of the dust cover with appropriate tooling. ： ± Note: Fastening torque 5 Nm, Figure 73 15. Assemble main drive assembly Coat Letai 598 silicon rubber surface sealant at the joint surface between shell and bracket, coatφ3～φ6 glue soluting ring with sealing surrounding inside of thread hole at the large end of shell.
Page 482 18. Add oil Add 17L 85W/90 GL-5 gear oil (GB13895-1992) in axle bag of shell and fasten plug screws. Note: use 85W/90 GL-5 gear oil Anaerobic type pipe threat sealant ： Fastening torque 175 ~ 235 Nm Figure 77 Inject 5L (subject to overflowing from planet carrier) 85W/90 GL-5 gear oil (GB13895-1992) into two hub reducers and fasten plug screws.
Page 483: Assembly Parts Assembling
Assembly parts assembling Install hub assembly 1. Keep the large end of hub upward, assemble bearing outer ring . Figure 79 2． turn over to keep the small end of hub upward and assemble bearing outer ring. Figure 80 3. Bearing inner ring assembled. Figure 81 4.
Page 484 5. Assemble asbestos gasket before oil seal on the small side of hub,then screw the bolts tight ： Note: Fastening torque 40 ~ 10Nm Letai 262 threat fastening sealant Fasten all screws according to symmetrical and crossing principle. Figure 83 6.
Page 485 3. Assemble the planet gear with quill roller to the seat hole of planet carrier. Figure 87 4. Assemble steel balls in holes of planet gear shaft, steel ball shall aim at semi circle of planet carrier, go through the inner hole of planet gear and gasket and assemble on planet carrier.
Page 486 3. Press inner ring into rolling bearing with press ure machine at the other side Figure 91 4. Turn over gear and assemble outer ring of gear Figure 92 5. Install spacer bush Figure 93 6. Install gaskets Figure 94 SPC000009 Front Axle Page 36...
Page 487 7. Install bearing sleeve Figure 95 8. Press inner ring of antifriction bearing in the end. Note: when assembling main reducer, taper rolling bearing shall have certain tightness that is on the basis of eliminating bearing clearance and give certain preload. The purpose is to reduce axial force caused during transmission process which will result in axial displacement, improve supporting rigidity, and guarantee normal mesh of bevel gear pair.
Page 488 2. Assemble rolling bearing at the bearing position of left shell terminal of differential mechanism. Figure 99 3. Assemble pins at the position of left shell terminal of differential mechanism. Figure 100 4. Assemble semiaxis gear Assemble semi axis gear gasket in left shell of differential mechanism Note: the side of gasket with groove shall toward to the direction of joint cross...
Page 489 6. Assemble joint cross assembly Assemble bevel gear (internal of small terminal) and bevel gear gasket on four axles of joint cross. Note: Lubricate with grease when assembling bevel gear and bevel gear gasket Figure 103 7. Differential mechanism shell Assemble joint cross in right shell of differential mechanism to make bevel gear and semiaxis gear mesh, turn over left shell assembly of differential...
Page 490 Install main reducer 1. Assemble bracket. copper gasket on Apply a small amount of sealant on upper and lower sides of the gasket and smooth. Note: Make 3 rectangle hole of the copper gasket aimed 3 oil port of the bracket. Note: Coat proper Letai 598 fastening sealant Figure 107 2.
Page 491 5. Install input flange Put gasket on the end face of bracket, install sealing cover assembly (coat lubrication grease on oil seal according to common requirements of drive axle), and connect with bracket with bolts and gaskets. ± Note: Screw fastening torque 145 Figure 111 6.
Page 492 9. Install differential assembly Turnover tracket, install differential assembly in bracket. Figure 115 10. Install bearing seat with gaskets and bolts (bolts shall be a little bit tight). Install adjustable nuts. Note: Two bearing seats cannot be exchanged. Note: Coat proper thread sealant on the length ～...
Page 493 to twist adjusting nuts to change position of driven spiral bevel gear (when it is necessary, move active spiral bevel gear assembly to adjust). If the clearance is larger than the regulated value, approach active spiral bevel gear from driven spiral bevel gear; otherwise be away from it. In order to keep the adjusted preload of taper rolling bearing of differential mechanism, twisting numbers of adjusting nuts at one side shall be equal to twisting numbers of adjusting nuts at the other side.
Page 494 12. Install locking plate Fasten the fixed bolts on bearing seat, fastening torque is 410 ~ 510Nm. Put locking plate at the right position, fix it on bearing seat with bolts and gaskets, and fasten fixing bolts of locking plate. 460±50Nm 、...
Page 495 SPC000010 REAR AXLE CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
Page 496 TABLE OF CONTENTS GENERAL DESCRIPTION ........................3 STRUCTURE CHART ..........................3 BASIC PARAMETERS OF DRIVEG AXLE ..................3 INTERNAL STRUCTURE OF DRIVE AXLE ..................3 PARTS LIST ..............................4 ASSEMBLY ..............................4 HOUSING ASSEMBLY AXLE ........................ 5 ASSEMBLE OF HUB DRIVE AXLE ....................
Page 497: General Description
GENERAL DESCRIPTION Structure chart Figure 1 1.EDGE REDUCER ASS‘Y 2.BRAKE CLAMP ASS‘Y 3.SHELL 4.MAIN REDUCER ASS‘Y 5.HUB ASS‘Y Basic parameters of drive axle: Type Spiral bevel gear grade one reduction Main drive Reduction ratio 4.625 Type Grade one planet reduction Hub reduction gear Reduction ratio 4.94...
Page 498: Parts List
PARTS LIST Figure 2 Reference Number Description Reference Number Description REDUCER ASSY,MAIN REDUCER ASSY,WHEEL HOUSING ASSY, AXLE 16 WASHER, SPRING BREATHER M16×1.5×40-8.8 BOLT BRAKE UNIT WASHER,SEAL 20 WASHER, SPRING M20×1.5×55-10.9 BOLT PLUG,MAGNETIC PLETE,NAME RIVET D10×30 PIN SPC000010 Rear Axle Page 4...
Page 499 HOUSING ASSY, AXLE Figure 3 Reference Number Description Reference Number Description CAP,DUST HOUSING,AXLE SEAT SPINDLE,DRIVE AXLE PLATE,MOUNTINGA Rear Axle SPC000010 Page 5...
Page 500 Hub drive axle assembly Figure 4 SPC000010 Rear Axle Page 6...
Page 501 Reference Reference Description Description Number Number M10³30-8.8 BOLT GEAR，SUN 10 WASHER, SPRING BLOT CAP,END NUT,ADJUSTING GEAR,RING STEEL BALL BEARING,TAPER ROLLER PLUG,MAGNETIC BOLT，HUB 20 WASHER,SPRING CARRIER,PLANETARY GEAR M20³1.5-8 NUT RING,O GASKET WASHER BEARING,TAPER ROLLER SPACER SLEEVE GEAR,PLANET SEAL BEARING,NEEDLE HOLDER,OIL SEAL STEEL BALL M8³20-10.9BOLT SHAFT...
Page 502: Main Drive Assembly
Main drive assembly Figure 5 SPC000010 Rear Axle Page 8...
Page 503 Reference Reference Description Description Number Number 22-1 SHIM M27³2-05 NUT WASHER, LOCK 22-2 SHIM 22-3 BOLT SHIM CASE,MAIN REDUCTION NUT,ADJUSTING RING,RETAINING BEARING,TAPER ROLLER BEARING,ROLLER M16³1.5-10 NUT PINION WASHER, PLAIN BEARING,TAPER ROLLER CASE,DIFFERENTIAL SLEEVE 10-1 SHIM WASHER 10-2 SHIM GEAR,DIFFERENTIAL 10-3 SHIM SPIDER 10-4...
Page 504: Drive Axle Brake Assembly
Drive axle brake assembly Figure 6 Reference Reference Description Description Number Number 20³1.6 “O” RING EXTERIOR BRAKE PISTON SUPPORT,DEFLATING VALVE RECTANGULAR SEAL DEFLATING VALVE DUST CASE WASHER BLOCK RING BOLT BRAKE DISK SPLIT PIN 20³2.4 “O” RING INNER BRAKE SPC000010 Rear Axle Page 10...
Page 505: Scheduled Maintenance
SCHEDULED MAINTENANCE Oil of new drive axle must be replaced after working for 15 days (about 100 working hours), oil shall be replaced once after working for every six months (about 1200 working hours) in following days. Every month maintenance： 1．Check abrasion condition of brake disc, if there is disruptive abrasion;...
Page 506 Never use gasoline, solvents, or other flammable fluids to clean components. Only use approved commercial solvents that are nonflammable and nontoxic. IMPORTANT Use only GENUINE DOOSAN SPARE PARTS to warrant proper operations and prevent interchangeability problems. GENERAL INSTRUCTIONS 1. Thoroughly clean and dry axle before disassembly.
Page 507: Axle Disassembly
AXLE DISASSEMBLY Drive axle disassembly 1. Put drive axle on supporting and make sure main driver assembly is upward. Figure 7 2. Dismantle brake caliper assembly Loosen the connection bolts between brake caliper and brake caliper support, dismantle brake caliper assemble.
Page 508 5. Dismantle end cap Loosen connection bolts between planet carrier and end cap, then get end cap from hub reducer assembly with jackscrew, dismantle end cap. Figure 11 6. Dismantle locating block Take down locating block with hands. Note：If it is tight when taking down, please use assistant tools to pry out.
Page 509 9. Dismantle semiaxis Take semiaxis from shell slightly. Figure 15 10. Hub reducer First loosen rim bolts with relative tools, then loosen rim from planet carrier with jackscrew and dismantle planet carrier assembly. Note: Please slowly loosen planet carrier to avoid safety hazard resulted from dropping of planet carrier assembly.
Page 510 13. Dismantle internal gear Take internal gear out by slightly rocking. Figure 19 14. Dismantle wheel hub assembly Take wheel hub assembly from supporting axle. Note: During hanging and dismantling process, please keep axis of wheel hub assembly is in line with axis of hub reduction supporting axle to avoid scratching oil surface and internal spare parts during dismantling process.
Page 511: Assembly Dismantling
Assembly dismantling Dismantle planet carrier assembly 1. Put planet carrier on working platform horizontally. Figure 23 2. Take out planet axle with tools. Figure 24 3. Take out steel balls. Figure 25 4. Take out planet wheel and gasket. Figure 26 Rear Axle SPC000010 Page 17...
Page 512 5. Take out baffle ring and quill roller from inside of planet wheel. Figure 27 Dismantle hub assembly 1. Put hub assembly on working platform. Figure 28 2. Loosen connection bolts between brake disc and hub. Figure 39 3. Take out brake disc. Figure 30 SPC000010 Rear Axle...
Page 513 4. Loosened bolt of oil seal seat ,Take out oil seal seat and asbestos gasket. Figure 31 5. Take out bearing. Figure 32 Dismantle main drive assembly 1. Put main drive assembly (input flange upward) horizontally and fixed on supporting. Figure 33 2.
Page 514 3. Dismantle locknut and washer. Figure 35 4. Take out input flange. Figure 36 5. Dismantle connection bolts between sealing cover and bearing sleeve, take out sealing cover. Figure 37 6. Turn main drive for 180° ,dismantle bolts of Fastening lock plate, take out lock plate. Figure 38 SPC000010 Rear Axle...
Page 515 7. Mark with signs so that they can be back to original position during assembling. Figure 39 8. Dismantle connection bolts of bearing seat and take out bearing seat. Figure 40 9. Dismantle adjusting nuts. Figure 41 10. Dismantle bearing outer ring. Figure 42 Rear Axle SPC000010...
Page 516 11. Hang out differential mechanism assembly. Note: Keep balance when hanging out to avoid safety hazard. Figure 43 12. Separate active spiral bevel gear assembly and bracket with jackscrew. Figure 44 Dismantle differential assembly 1. Put differential assembly vertically on working platform, and guarantee it is stable.
Page 517 3. Loosen connection nuts between driven spiral bevel gear and right shell of differential mechanism, dismantle driven spiral bevel gear. Note: Check or mark sign before dismantling driven spiral bevel gear so that it can be assembled to original position. Figure 47 4.
Page 518 7. Take out semiaxis gear gasket and gear. Figure 51 Dismantle active spiral bevel gear assembly 1. Put active spiral bevel gear assembly on working platform, support flange of bearing sleeve, clamp down on thread end of active spiral bevel gear assembly with down device.
Page 519 4. Take out adjusting gasket. Figure 55 5. Take out spacer bush. Figure 56 Rear Axle SPC000010 Page 25...
Page 520: Axle Reassembly
AXLE REASSEMBLY Axle assembly 3． Shell Clean shell and suspend with special supporting. Fasten gummed plug screw at oil inlet and oil filler. ： Note: Plug screw fastening torque 175 ~ 235 Nm Note: Letai 262 taper thread sealant. Figure 57 2.
Page 521 4. Internal gear Assemble internal gear of drive axle at multiple spline at the end of supporting bearing. Figure 60 5. Round nuts (1)Assemble round nuts and fasten. Knock internal gear slightly with copper stick to make internal gear in place. Figure 61 Note: Grapple theΦ22.5 hole on wheel hub with push and pull ergometer, pull ergometer along with...
Page 522 6. Assemble O sealing ring Assemble O sealing ring on hub assemble. Figure 64 7. Install planet carrier assembly Assemble planet carrier assembly and O sealing ring on wheel hub with rim bolts, gaskets and nuts. ： Note: fastening torque 500±10Nm Figure 65 8.
Page 523 10. Assemble baffle ring Assemble baffle ring with baffle ring used for axle. Note: It must be clamped firmly when using baffle ring pincer to avoid safety hazard when it is popping out during assembling process. Figure 68 11. Assemble locating block Stake steel ball on locating block, it can rotate flexibly after staking steel ball.
Page 524 14. Assemble main drive assembly Coat Letai 598 silicon rubber surface sealant at the joint surface between shell and bracket, coatφ3～φ6 glue soluting ring with sealing surrounding inside of thread hole at the large end of shell. The coated sealant cannot be in the air for more than ten minutes. Note: Letai 598 silicon rubber surface sealant Figure 72 15.
Page 525 Inject 5L (subject to overflowing from planet carrier) 85W/90 GL-5 gear oil (GB13895-1992) into two hub reducers and fasten plug screws. Note: 85W/90 GL-5 gear oil Anaerobic type pipe threat sealant Fastening torque：175 ~ 235 Nm Figure 76 Rear Axle SPC000010 Page 31...
Page 526: Assembly Parts Assembling
Assembly parts assembling Install hub assembly 1. Keep the large end of hub upward, assemble bearing outer ring . Figure 77 4． turn over to keep the small end of hub upward and assemble bearing outer ring. Figure 78 3. Bearing inner ring assembled. Figure 79 4.
Page 527 5. Assemble asbestos gasket before oil seal on the small side of hub,then screw the bolts tight ： Note: Fastening torque 40 ~ 10Nm Letai 262 threat fastening sealant Fasten all screws according to symmetrical and crossing principle. Figure 81 6.
Page 528 3. Assemble the planet gear with quill roller to the seat hole of planet carrier. Figure 85 4. Assemble steel balls in holes of planet gear shaft, steel ball shall aim at semi circle of planet carrier, go through the inner hole of planet gear and gasket and assemble on planet carrier.
Page 529 3. Press inner ring into rolling bearing with press ure machine at the other side Figure 89 4. Turn over gear and assemble outer ring of gear Figure 90 5. Install spacer bush Figure 91 6. Install gaskets Figure 92 Rear Axle SPC000010 Page 35...
Page 530 7. Install bearing sleeve Figure 93 8. Press inner ring of antifriction bearing in the end. Note: when assembling main reducer, taper rolling bearing shall have certain tightness that is on the basis of eliminating bearing clearance and give certain preload. The purpose is to reduce axial force caused during transmission process which will result in axial displacement, improve supporting rigidity, and guarantee normal mesh of bevel gear pair.
Page 531 2. Assemble rolling bearing at the bearing position of left shell terminal of differential mechanism. Figure 97 3. Assemble pins at the position of left shell terminal of differential mechanism. Figure 98 5. Assemble semiaxis gear Assemble semi axis gear gasket in left shell of differential mechanism Note: the side of gasket with groove shall toward to the direction of joint cross...
Page 532 6. Assemble joint cross assembly Assemble bevel gear (internal of small terminal) and bevel gear gasket on four axles of joint cross. Note: Lubricate with grease when assembling bevel gear and bevel gear gasket Figure 101 7. Differential mechanism shell Assemble joint cross in right shell of differential mechanism to make bevel gear and semiaxis gear mesh, turn over left shell assembly of differential...
Page 533 Install main reducer 1. Assemble bracket. copper gasket on Apply a small amount of sealant on upper and lower sides of the gasket and smooth. Note: Make 3 rectangle hole of the copper gasket aimed 3 oil port of the bracket. Note: Coat proper Letai 598 fastening sealant Figure 105 2.
Page 534 5. Install input flange Put gasket on the end face of bracket, install sealing cover assembly (coat lubrication grease on oil seal according to common requirements of drive axle), and connect with bracket with bolts and gaskets. ± Note: Screw fastening torque 145 Figure 109 6.
Page 535 9. Install differential assembly Turnover tracket, install differential assembly in bracket. Figure 113 10. Install bearing seat with gaskets and bolts (bolts shall be a little bit tight). Install adjustable nuts. Note: Two bearing seats cannot be exchanged. Note: Coat proper thread sealant on the length ～...
Page 536 to twist adjusting nuts to change position of driven spiral bevel gear (when it is necessary, move active spiral bevel gear assembly to adjust). If the clearance is larger than the regulated value, approach active spiral bevel gear from driven spiral bevel gear; otherwise be away from it. In order to keep the adjusted preload of taper rolling bearing of differential mechanism, twisting numbers of adjusting nuts at one side shall be equal to twisting numbers of adjusting nuts at the other side.
Page 537 12. Install locking plate Fasten the fixed bolts on bearing seat, fastening torque is 410 ~ 510Nm. Put locking plate at the right position, fix it on bearing seat with bolts and gaskets, and fasten fixing bolts of locking plate. 460±50Nm 、...
Page 538 SPC000010 Rear Axle Page 44...
Page 539 1HYDRAULICS...
Page 541 SPC000011 CYLINDERS CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
Page 542 TABLE OF CONTENTS GENERAL DESCRIPTION..............3 W ORKING PRINCIPLE..............3 DETAILED LIST OF SPARE PARTS................. 4 DISASSEMBLING AND ASSEMBLING STEPS..............5 SPC000011 Cylinder Page 2...
Page 543: General Description
General Description Working principle It is usually composed of cylinder body, piston rod and sealing parts, intertal of cylinder body is divided into two parts and connect with a oil hold respectively. Since compression of liquid is very small, when oil coming into one oil hole, piston will be propelled to m ake oil going out from another oil hole, piston drives piston rod stretching (compressing), on the contrary as before.
Page 544: Detailed List Of Spare Parts
Detailed list of spare parts Figure 2 Reference Reference Description Description Number Number Cylinder rod Support ring Dust ring SPGO Obturating ring Piston Support ring Socket head cap screw Cushion seal Port protecting cover Support ring Hole protecting cover Four fluorine block circle Oil cup O-RING Cylinder end bush...
Page 545: Disassembling And Assembling Steps
Disassembling and assembling steps Disassembling steps Prepare a container which can store all hydraulic oil of the maintained cylinder, hydraulic oil will flow out from cylinder. 1. Put the cylinder on special supporting vertically, screw down bolts of cylinder cover with pneumatic wrench or torque wrench (refer to figure 3).
Page 546 4. Dismantle piston with special piston tightening tool and jackhammer (refer to figure 6). Figure 6 5. Dismantle piston and cylinder cover assembly (refer to figure 7). Figure 7 6. Dismantle sealing parts with special tools (refer to figure 8). Figure 8 SPC000011 Cylinder...
Page 547 Assembling steps 1. Install sealing parts of cylinder (refer to figure 9). Figure 9 2. Install cylinder cover assembly (refer to figure 10). Figure 10 3. Install piston with special tools (refer to figure 11). Figure 11 Cylinder SPC000011 Page 7...
Page 548 4. Screw down piston bolts with special tools (refer to figure 12). Figure 12 5、Put piston rod in cylinder barrel (refer to figure 13). Figure 13 6. Screw down bolts of cylinder cover and cylinder barrel (refer to figure 14). Figure 14 SPC000011 Cylinder...
Page 549 SPC000012 Main Pump CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
Page 550 TABLE OF CONTENTS GENERAL DESCRIPTION....................3 WORK PRINCIPLE......................3 DETAILED LIST OF SPARE PARTS................. 4 PARTS REPLACEMENT PRINCIPLES................5 PREPARATION BEFORE DISASSEMBLING..............6 DISASSEMBLY AND ASSEMBLY STEPS.................6 SPC000012 Main Pump Page 2...
Page 551 GENERAL DESCRIPTION Work principle When active gear 4 rotates with clockwise direction, driven gear 10 rotates with anti-clockwise direction, partial vaccum is formed when teeth of two gears are away from the area in oil in side (left area shown in the figure), with effect of atmospheric pressure, hydraulic oil enters oil suction chamber of oil pump and fills in teeth area.
Page 552 PARTS LIST Figure 2 SPC000012 Main Pump Page 4...
Page 553 Reference Number Description Reference Number Description Thrust Palte Ring Drive Shaft Back-up Ring Driven Gear Sleeve Bearing Grub Screw Steel Bushes Washer Screw Seal Body Parker Ring Front Cover Shaft Seal Parts replacement principle If main pump needs to be repaired to reach the original performance index, parts replacement principle must be followed to replace parts, following is the detailed replacing rules: 1．...
Page 554 Preparation before disassembling 1．Clean the surface of pump, and check if the surface has chip and rust. 2． Check model and factory releasing number on nameplate, if there is no nameplate on pump, check factory releasing number at seam allowance of front cover. 3．Fill in relative information on main pump returned for maintenance card before disassembling, such as manufacturer, applicable machine model, applicable working condition, pump model, factory releasing number, factory releasing date, head and marks of fabricator, working parameters (pressure, rotation, impact...
Page 555 2. ① Remove mounting flange taking care to keep it as straight as possible during removal. Tap around the edge with rubber mallet in order to break away from the body. ☞Ensure that while removing it, the drive shaft and other components remain position.
Page 556 7. ① Pull out driving gear & driven gear keeping gears as straight as possible. ② Remove other pressure plate on rear side with same way for front side Figure 7 Assembly process Assembling of sealing framework assembly pressure plates for 1st working section 1.
Page 557 3. ① Locate shaft seal inside shaft hole to the end. ② insert snap ring and locate it into the groove prearranged. Figure 10 4. ① prepare cleaned 2 body prearranged guard pins and square O- ring. ② Insert a pressure plate prearranged O-ring & back-up ring inside of body.
Page 558 5. ① Locate driving gear and driven gear keeping as straight as possible during assembling. ② Locate one of pressure plates pre-assembled. Figure 13 6. ① Assemble mounting flange to the body, use proper tools in order to avoid any damage on the shaft seals by sharp edge of shaft.
Page 559 SPC000013 Steer Pump CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
Page 560 TABLE OF CONTENTS GENERAL DESCRIPTION....................3 WORKING PRINCIPLE...................... 3 DETAILED LIST OF SPARE PARTS................. 4 PARTS REPLACEMENT PRINCIPLE................6 PREPARATION BEFORE DISASSEMBLING..............6 DISASSEMBLY AND ASSEMBLY STEPS.................7 SPC000013 Steer Pump Page 2...
Page 561 GENERAL DESCRIPTION Work principle When active gear 4 rotates with clockwise direction, driven gear 10 rotates with anti-clockwise direction, partial vaccum is formed when teeth of two gears are away from the area in oil in side (left area shown in the figure), with effect of atmospheric pressure, hydraulic oil enters oil suction chamber of oil pump and fills in teeth area.
Page 562 PARTS LIST Figure 2 SPC000013 Steer Pump Page 4...
Page 563 Reference Number Description Reference Number Description Rear Cover Ring Cover Antiextrusion PL-K20 Thrust Plate Antiextrusion Ring Drive Gear Upper Antiextrusion Ring Driven Gear Sleeve Bearing Screw TCEI Upper Sleeve Bearing Screw TE Sleeve Bearing MB Grub Screw Washer 10 Dowel Pin Washer 14 Steel Bushes Seal PL-K20...
Page 564 Parts replacement principle If main pump needs to be repaired to reach the original performance index, parts replacement principle must be followed to replace parts, following is the detailed replacing rules: 1．Side plate: replace side plate when it is scratched, there is pit, spray and finishing layer sheds, burnt, deformed and cavitati on corrosion.
Page 565 Disassembly and assembly steps Disassembly steps 1. ①Loosen and remove the assembling bolts and washers from the 2 pump. Figure 3 2. ①Remove the complete 2 working section. ②Remove through hub Figure 4 3. ① Loosen and remove the assembling bolts and washers from the 1 pump.
Page 566 4. ① Remove mounting flange taking care to keep it as straight as possible during removal. Tap around the edge with rubber mallet in order to break away from the body. ☞Ensure that while removing it, the drive shaft and other components remain position.
Page 567 7. ① Pull out driving gear & driven gear keeping gears as straight as possible. ② Remove other pressure plate on rear side with same way for front side Figure 9 8. ①Remove the pressure plate with prearranged parts, O-ring & back up ring from the working section and examine it carefully.
Page 568 10. ①Take out two square rings from the body. Figure 12 Assembling steps Assembling of front cover assembly 1. ① Smear clean grease on pressure plate groove ②Locate O-ring into the grove on the aluminum pressure plate. ③Locate back-up ring upon the O-ring. Figure 13 2.
Page 569 3. ①Smear clean grease on the square groove ②Insert square rings into the groove and 4 alignment pins. Figure 15 4. ①put one of preassembled pressure plates into the body and locate two gears, then load another plate upon the gears. ☞...
Page 570 6. ①put one of preassembled pressure plates into the body and locate two gears, then load another plate upon the gears. ☞ pay attention the positions of gears and directions of pressure plates. Figure 18 7. ① Locate shaft seal inside shaft hole to the end. ②...
Page 571 9. ① Assemble the bolts and tighten the bolts with in a crisscross pattern to a torque value of 140 Nm. Figure 21 10. ① insert a through shaft to the 1 working section. ② locate 2nd working section to the rear of 1st working section Figure 22 11.
Page 572 12. ① Check that the pump rotates freely when the drive shaft is turned by hand, if not a possible, plate seal may be pinched. Figure 24 SPC000013 Steer Pump Page 14...
Page 573 SPC000014 Main Control Valve CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
Page 574 TABLE OF CONTENTS GENERAL DESCRIPTION....................3 SCHEMATIC DIAGRAM....................3 DETAILED LIST OF SPARE PARTS................4 DISASSEMBLY AND ASSEMBLY STEPS..............5 BASIC FAULTS AND OVERCOMING................7 SPC000014 Main Control Valve Page 2...
Page 575: General Description
General description Source: the hydraulic multi-way directional valve is domestic assorting parts for 950B, 966D and 980S wheel loaders introduced in from abroad. 2. Purpose: the valve is combined with DJS pilot valve, mainly used for ZL40, ZL50, ZL60 and other medium and large size loaders, it can also be used for hydraulic system of bulldozers and other medium and large size engineering machines.
Page 576: Detailed List Of Spare Parts
Detailed list of spare parts Figure 2 SPC000014 Main Control Valve Page 4...
Page 577: Disassembly And Assembly Steps
Reference Number Description Reference Number Description Cover Check valve Boom Valve spool Cover Valve body Name Plate Check valve Spool joint ① Cover O-Ring 50x3.1 ② Spring seat O-Ring 20x2.4 ③ Spring O-Ring 60x3.1 ④ Spring Gasket2 ⑤ Spring gasket Bolt M12x20 ⑥...
Page 578 Dismantle both sides with innerhexagon screw, check if sealing ring is good. Pull out valve rod from long end cap; check if the valve rod and valve surface is impacted; install valve rod to valve when it is moving smoothly and there is no blockage, put O ring in oil seal groove of end cap, keep end cap connection oil mouth upward when installing end Figure 4...
Page 579: Basic Faults And Overcoming
Basic faults and overcoming Faults Reasons Overcoming methods Pressure relief valve Adjust pressure of relief valve regulated too low Slide valve of relief valve is Dismantle, clean and assemble again blocked Working pressure is not １ Pressure regulation spring enough Replace with new one broken Replace pipeline or regulate pressure...
Page 580 SPC000014 Main Control Valve Page 8...
Page 581 SPC000015 Feed Unit CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
Page 582 TABLE OF CONTENTS GENERAL DESCRIPTION....................3 WORK PRINCIPLE......................3 DETAILED LIST OF SPARE PARTS................... 4 DISASSEMBLY AND ASSEMBLY STEPS.................5 SPC000015 Feed Unit Page 2...
Page 583: General Description
GENERAL DESCRIPTION Work principle Figure 1 Feed Unit SPC000015 Page 3...
Page 584: Detailed List Of Spare Parts
DETAILED LIST OF SPARE PARTS Figure 2 Reference Number Description Reference Number Description Reducing Valve Accumulator Solenoid Valve Plug SPC000015 Feed Unit Page 4...
Page 585: Disassembly And Assembly Steps
Disassembly and assembly steps Figure 3 Feed Unit SPC000015 Page 5...
Page 586 SPC000015 Feed Unit Page 6...
Page 587 SPC000016 Priority Valve CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
Page 588 TABLE OF CONTENTS GENERAL DESCRIPTION................3 W ORK PRINCIPLE...................3 DETAILED LIST OF SPARE PARTS...............4 DISASSEMBLY STEPS OF PRIORITY VALVE ........... 5 MATTERS NEED ATTENTION FOR DISASSEMBLING PRIORITY VALVE……....6 ASSEMBLY STEPS OF PRIORITY VALVE..........7 MATTERS NEED ATTENTION FOR ASSEMBLING PRIORITY VALVE......8 TOOLS FOR DISASSEMBLY AND ASSEMBLY............
Page 589: General Description
General Description Work principle YSF25 steering control valve is control valve parts of steering system, its premise is to guarantee oil supplying to steering system preferentially, when the loader is working under high pressure and small flowrate, the extra oil of steering system can discharge load automatically under lower pressure. Load discharging pressure can be regulated by relief valve according to working conditions, this makes up the shortage of priority valve, reduces power consumption and reduce temperature rising of the system.
Page 590: Detailed List Of Spare Parts
Detailed list of spare parts Figure2 Reference Number Description Reference Number Description Valve body Gasket 10 Valve spool O-Ring 28X2.65 O-Ring 26.5X2.65 Priority Valve Spring PlugⅠ Priority Valve Gasket Check Valve Spring Priority Spool Relief ValveⅠ O-Ring 11.8X2.1 O-Ring 15X1.8 Plug Relief ValveⅡ...
Page 591: Disassembly Steps Of Priority Valve
Disassembly steps of priority valve 1. Screw off screw plug I on the left, take out load discharging spool, load discharging spring, screw out plug II from the right side. Tools: torque (electric) wrench, m27 sleeve Figure 3 2. Open relief valve I from the left side, take out check valve spring, check valve, and screw out plug from the right side.
Page 592: Matters Need Attention For Disassembling Priority Valve
Matters need attention for disassembling priority valve 1. Plug of pressure mouth is only screwed out when testing pressure; it does not belong to disassembling range (same principle for assembling). 2. Pull out valve spool slowly, pay attention to protect valve body hole, plug combination surface and thread from damaging.
Page 593 Assembling steps of priority valve 1. Install relief valve II, relief valve seat, priority spring, priority spool and plug I into valve body from left to right. Tools: torque (electric) wrench, m27 sleeve, m22 sleeve and m16 sleeve Figure 6 2.
Page 594: Matters Need Attention For Assembling Priority Valve
Matters need attention for assembling priority valve 1. Keep all parts clean before assembling. 2. During installation, all spools shall be installed slowly and guarantee they can slide flexibly, if there is blockage, grind spool surface and sharp corner slightly with find abrasive paper, reclean the valve. 3.
Page 595 SPC000017 Steering Unit CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
Page 596 TABLE OF CONTENTS GENERAL DESCRIPTION...................3 W O R K P R I N C I P L E ..............3 DETAILED LIST OF SPARE PARTS............4 DISASSEMBLY STEPS OF STEERING UNIT ............
Page 597 General description Work principle When steering unit is in the middle, spool and valve bush is at meso-position with the effect of spring lamination, oil from oil pump will enter spool from two rows of holes of valve bush and spool, then returns to oil tank throug T oil mouth.
Page 598 Detailed list of spare parts Figure 2 Reference Number Description Reference Number Description Cross Link block Stator Front cover O-Ring Valve body Spacer Plate Spring lamination Steel Ball Big Baffle Rring Valve bush Thrust Ball Bearing Valve spool Small Baffle Ring Linkage Shaft O-Ring Rotor...
Page 599 Disassembly steps of steering unit 1. Take out link block. Figure 3 2. Take out front cover. Figure 4 3. Take out multi-roll bearing Figure 5 Steering Unit SPC000017 Page 5...
Page 600 4. Take out bolts of rear cover. Figure 6 5. Take out rear cover. Figure 7 6. Dismantle stator Figure 8 7. Dismantle O-RING Figure 9 SPC000017 Steering Unit Page 6...
Page 601 8. Dismantle rotor. Figure 10 9. Take out limitation block Figure 11 10. Take out link axle Figure 12 11. Take out clapboard Figure 13 Steering Unit SPC000017 Page 7...
Page 602 12. Take out valve bush and spool assembly Figure 14 13. Take out pin Figure 15 14. Take out spring lamination Figure 16 15. Take out valve spool Figure 17 SPC000017 Steering Unit Page 8...
Page 603 16. Dismantle valve block Figure 18 17. Take out check valve Figure 19 18. Take out oil return throttle valve Figure 20 19. Take out oil inlet throttle valve Figure 21 Steering Unit SPC000017 Page 9...
Page 604 20. Take out oil compensating valve (4EA) Figure 22 SPC000017 Steering Unit Page 10...
Page 605 Assembly steps of steering unit 1. Keep four bolt holes of valve body upward. Figure 23 2. Install valve spool, valve bush, spring lamination and pin. Figure 24 3. Install well assembled valve spool and valve bush into valve body Figure 25 Steering Unit SPC000017...
Page 606 4. Install big baffle ring, needle roller thrust bearing and small baffle ring Figure 26 5. Install front cover with well assembled sealing ring Figure 27 6. Keep fourteen holes of steering unit upward Figure 28 7. Install sealing ring Figure 29 SPC000017 Steering Unit...
Page 607 8. Put Φ8mm steel balls into the thread holes as shown in the picture Figure 30 9. Install spacer plate and align the holes. Figure 31 10. Install couple axle, stop dial pin with linkage shaft Figure 32 11. Install turn stator vice (note: mark on linkage shaft shall align with groove on rotor) Figure 33 Steering Unit...
Page 608 12. Install upper limitation column and sealing ring Figure 34 13. Install rear cover, combined gasket, bolts, the position shown in the picture by arrow is cotter bolt. Figure 35 Matters need attention during assembling 1. Clean all parts (except rubber ring) with gasoline or kerosene before assembling. If there is paint on combination surface, clean with acetone, it is forbidden to clean parts with cotton yarn or cloth, soft banister brush or silk shall be used to clean parts, it is better to blow with compressed air, after steering unit is installed well, add 50-100ml hydraulic oil before install in machines, turn around spool, install in...
Page 609 SPC000018 Motor CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
Page 610 TABLE OF CONTENTS GENERAL DESCRIPTION....................3 WORK PRINCIPLE DIAGRAM..................3 DETAILED LIST OF SPARE PARTS................4 PARTS REPLACEMENT PRINCIPLES................5 PREPARATION BEFORE DISASSEMBLING..............5 DISASSEMBLY AND ASSEMBLY STEPS................6 SPC000018 Motor Page 2...
Page 611 GENERAL DESCRIPTION Work principle diagram Figure 1 Motor SPC000018 Page 3...
Page 612 PARTS LIST Figure 2 Reference Number Description Reference Number Description Guarnizione Valve Shaft Seal BA Body Shaft Seal G Front Cover Ring 30 Rear Cover Ring 20 Thrust Plate Antiextrusion Drive Gear Driven Gear Flange Ball Bearing Back-up Washer Washer B14 Support Shaft Washer 10 Dowel Pin...
Page 613 Parts replacement principle 1. Check immediately that any spare parts you receive have not been damaged in shipment. 2. Always work in a clean environment. 3. Wash all components in solvent and blow dry with compressed air before refitting. 4. Take care not to damage rubber seals. 5.
Page 614 Disassembly and assembly steps Disassembly steps 1. Loosen and remove the locking nut and washer, key from the shaft. Figure 3 2. ①Loosen and remove the assembling bolts and washers from the motor. Figure 4 3. ①Loosen and remove the valves from the cover. ☞...
Page 615 4. ① Remove mounting flange taking care to keep it as straight as possible during removal. ☞Ensure that while removing it, the drive shaft and other components remain position. Figure 6 5. ① Remove shaft seal with (-) screwdriver and take out snap ring with proper tool and shaft seal again.
Page 616 7. ① Take out bearing & shaft assembly from the flange. ☞Only when the O-ring inside should be changed. ② Remove snap ring, then take out shaft to rear side. ☞ following this process only for changing bearing or shaft. Figure 9 8.
Page 617 Assembly process Assembling of sealing framework assembly 1. ① Locate O-ring into the grove on the aluminum pressure plate. ② Locate back-up ring upon the O-ring. ③ Smear clean grease on the O-ring & back-up ring to fix their position while moving. Figure 12 2.
Page 618 4. ① Insert shaft seal & backup washer. ② Insert snap ring and push it until to reach it to the groove. ③ Insert last shaft seal into the flange inside out. ④ Locate O-ring first and fix the position with grease.
Page 619 8. Load pre-assembled bearing flange on the working body. Figure 19 8. ① Load pre-assembled mounting flange on the bearing flange. ☞ Smear clean grease on the lips of shaft seals before assembling Figure 20 9. ① Assemble the bolts and tighten the bolts with in a crisscross pattern to a torque value of 45 Nm.
Page 620 SPC000018 Main Motor Page 12...
Page 621 SPC000019 HYDRAULIC OIL TANK CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
Page 622 TABLE OF CONTENTS General Description......................3 Parts List ........................3 Specifications......................... 4 SPC000019 Hydraulic Oil Tank Page 2...
Page 623 GENERAL DESCRIPTION PARTS LIST Figure 1 Reference Number Description Reference Number Description Oil Tank Return pipe Filter Drain Plug Filter Cover Spring Level Gauge O-ring Flange Return Filter Adapter Hydraulic Oil Tank SPC000019 Page 3...
Page 624 SPECIFICATIONS SD310 Type Pressure seal Volume (system) 177 L Oil filter Opening pressure 0.035 MPa Oil suction filter Filter rating 100μ Pressure drop 0.05 MPa @1000L/min Oil return filter 12μ Filter rating Pressure drop 0.045 MPa @800L/min SPC000019 Hydraulic Oil Tank Page 4...
Page 625 SPC000020 Hydraulic Schematic (SD310) CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
Page 626 TABLE OF CONTENTS G E NE RA L DE S CRI P T IO N..............3 SCHEMATIC DIAGRAM......................
Page 627 General description Schematic diagram Hydraulic Schematic (SD310) SPC000020 Page 3...
Page 628 SPC000020 Hydraulic Schematic(SD310) Page 4...
Page 629 Hydraulic Schematic(SD310) SPC000020 Page 5...
Page 630 SPC000020 Hydraulic Schematic(SD310) Page 6...
Page 631 BRAKE...
Page 633 SPC000021 BRAKE SYSTEM CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
Page 634 TABLE OF CONTENTS GENERAL DESCRIPTION…………………………………………………..…………………..3 STRUCTURE OF TRAVELLING BRAKE ................3 WORKING PRINCIPLE OF TRAVELLING BRAKE ............3 PARTS LIST ........................4 STRUCTURE CHART OF BRAKE SYSTEM ..............4 OIL-WATER SEPARATOR ....................6 PNEUMATIC BRAKE VALVE .................... 7 BOOSTER PUMP ....................... 8 SPECIAL TOOLS AND MATERIALS ................
Page 635: General Description
General Description Structure of Travelling Brake: It usually includes air compressor, oil-water separation combination valve (oil-water separator, pressure control valve), air tank, pneumatic brake valve, air booster pump and caliper disc brake. If it is equipped with emergency braking function, it usually also includes emergency and stopping brake control valve, brake air chamber, quick release valve.
Page 636: Parts List
PARTS LIST Structure Chart of Brake System Figure 2 SPC000021 Brake System Page 4...
Page 637 Reference Number Description Reference Number Description PIPE CLIP BRACKET HOSE, BOLT BOLT WASHER;PLAIN WASHER;PLAIN HOSE HOSE PLATE PUMP BOLT ADAPTER O-RING PLATE PIPE SEAL RING VALVE PLUG PIPE VALVE ACCUMULATOR HOSE BOLT HOSE SEAL RING PIPE BRAKE ASSY ADAPTER VALVE,BRAKE PEDAL WASHER;PLAIN WASHER;PLAIN HOSE...
Page 638: Oil-Water Separator
2. Oil-water separator Figure 3 Reference Reference Description Description Number Number SHELL ASS’Y RELIEF VALVE ASS’Y REGULATING VALVE ORIFICE PLUG EAR DRUM ONE-WAY VALVE FILTER ASS’Y STEM REGULATING SPRING OIL COLLECTOR UPPER COVER AIR BLEEDING PISTON REGULATING SCREW LOWER SHELL CONTROLING PISTON AEROFIOL NUT ASS’Y...
Page 639: Pneumatic Brake Valve
3. Pneumatic brake valve Figure 4 Reference Reference Description Description Number Number MANDRIL VALVE BODY PEDAL ASS’Y INTAKE VALVE ASS’Y VALVE ASS’Y ANTIDUST COVER OUTLET VALVE ASS’Y BALANCING SPRING PISTON ASS’Y SEALING FIN PISTON FOUR SPRING SPRING SEAT Brake System SPC000021 Page 7...
Page 640: Booster Pump
4. Booster pump Figure 5 Reference Reference Description Description Number Number PISTON STRENGTH CYLINDER BREAKING PUMP Y-SEAL RING AIR OUTLET SCREW PISTON PUSHING BORER RELEASING SPRING MAIN PUMP FUR BOWL ENDPLATE X-SEAL RING STORAGE CUP PUTTING SEAT SPECIAL TOOLS AND MATERIALS LUBRICANTS, SEALANTS AND OIL SPC000021 Brake System...
Page 641: System Maintenance And Failures Analysis
System Maintenance and Failures Analysis Brake caliper is locking The so called ―locking‖ failure refers to brake caliper does not return to the original position, that is one of the common failures of brake system. There are many reasons causing such kind failures, such as brake caliper is blocked, booster pump is blocked or brake caliper valve is blocked.
Page 642 Storage and usage of brake fluid 1. Brake fluid belongs to inflammable goods; please pay Note to avoid evaporation and fire during usage and storage. 2. Brake fluid shall be stored in warehouse or other assigned place, but it cannot be stored in open air and close to hot source to avoid deteriorating and become invalid.
Page 643 SPC000022 PARKING SYSTEM CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
Page 644 TABLE OF CONTENTS GENERAL DESCRIPTION ........................STRUCTURE OF PARKING BRAKE ..................WORKING PRINCIPLE OF PARKING BRAKE ..............PARTS LIST ........................... ASSEMBLY STRUCTURE CHART ..................SPC000022 Parking System Page 2...
Page 645 General Description Structure of parking brake： Brake is located at the front end of output axle of gearbox. Driven method is pneumatic control. Pneumatic control usually has emergency brake function. When brake pressure is lower than safe pressure, the system can stop loader automatically. Working principle of parking brake: When the loader is driven normally, emergency and parking brake control valve are normally open.
Page 646 PARTS LIST Assembly structure chart Figure 1 SPC000022 Parking System Page 4...
Page 647 Reference Number Description Reference Number Description ACCUMULATOR WASHER WASHER VALVE;CONTROL ADAPTER WASHER BRACKET ADAPTER ADAPTER HOSE ,AIR WASHER;SPRING HOSE ,AIR WASHER;PLAIN WASHER ADAPTER ADAPTER Parking System SPC000022 Page 5...
Page 648 SPC000022 Parking System Page 6...
Page 649 1ELECTRICAL SYSTEM...
Page 651 SPC000024 2AIR CONDITIONER CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
Page 652 TABLE OF CONTENTS GENERAL DESCRIPTION................3 CIRCULATION OF REFRIGERATION AGENT……………………..…………..4 C O N T R O L P A N E L … … … … … . . … … … … … … … … … … ......6 AC SYSTEM CIRCUIT DIAGRAM……………………………..….……....7 MAINTENANCE………….….........
Page 653: General Description
GENERAL DESCRIPTION Heater and AC evaporator share one air blower, and it is loacted at the front side of driving cab. When it is necessary, the driver can install it in control panel room at the right of control platform to control indoor temperature.
Page 654: Circulation Of Refrigeration Agent
Circulation of refrigeration agent Figure 2. Refrigeration agent circulation schematic diagram SPC000024 Air Conditioner Page 4...
Page 655 • Refrigeration agent (R134a) is compressed to 15kg/cm2（213psi）within sight view. • Compressed refrigeration agent flows into condenser under high temperature (about 80℃（176° F）). • Refrigeration agent of condenser is cooled down by condensation fan to about 60℃. At the same time, refrigeration agent is changed from gas state to liquid state, even if the temperature is reduced from 80°...
Page 656: Control Panel
Control panel Figure 3. AC control panel diagram Control specifications Control item Control switch Control specifications CLOSE‖ switch ―LOW SPEED‖ switch Rotation speed ―INTERMEDIATE control of air blower SPEED‖ switch HIGH SPEED‖ switch Compressor control Temperature sensor SPC000024 Air Conditioner Page 6...
Page 657: Ac System Circuit Diagram
AC system circuit diagram Figure 4. AC system circuit diagram Reference Number Description Reference Number Description Fuse Box Temperature Sensor Blower Switch Blower Press. Cut Off Switch Thermistor Compressor Air Conditioner SPC000024 Page 7...
Page 658: Maintenance
Maintenance 3. AC outdoors radiator-―condenser‖ must be cleaned regularly; refer to figure 5. Treatment method: dismantle condensing fan, condenser is completely exposes, wash with water, but do not use high water pressure to avoid lodging of condenser fan and affect radiation effect;...
Page 659 Power on checking of the entire machine Open AC control panel, turn III gear switch to H gear and check if there is wind coming from evaporator and if wind is big enough. Turn on temperature control switch on AC control panel and turns to the maximum clockwisely, check if indication light is on, at the same time, Figure 8...
Page 660: Trouble Shooting
Trouble shooting Following is the common troubles and reasons 1. The entire AC system is power off • Reason analysis Fuse of AC is burnout. Wiring harness of AC power is not connected. 2. Evaporation fan is running, after turning on temperature control switch, indication light is not on, condensation fan and compressor do not work.
Page 661 SPC000025 2ELECTRICAL SYSTEM (SD310) CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
Page 662 TABLE OF CONTENTS Overview ........................3 Electric Wire Color ………………………………………………......3 Electric Supply System.....................4 Engine Starting Circuit....................6 Operation During Start Process………………………………………………………6 Operation After Start Process…………………………………………………..……6 Engine Preheating System..................8 Principle of Operation……………………………………………….…………………8 Engine Stop System....................10 Working process before engine is started ……………………………………...….10 Work process of engine flameout..…………………………………………..…10 Charging System.....................12 Monitoring System....................14 Instrument panel……………………….……………………………………………..15...
Page 663: Overview
OVERVIEW Voltage of electrical system of the machine is DC 24V, the rated voltage of all electrical parts is 24V. Electrical cable wire adopts single wire system, and negative earth is adopted. Electrical system includes two serial 12V storage batteries and three phase DC generator with entire rectifier. Wire harness of the system can be distinguished by different insulation colour.
Page 664: Electric Supply System
ELECTRIC SUPPLY SYSTEM Power circuit supplies electric current to each electrical part. It is composed of storage battery, gnerator, fusible line and fuse box. Negative electrode of storage battery is earth connected and connects with balance weight. Even if keys switch is at ―OFF‖ position, when the general power is switched off, storage battery stil supplies electric current to following parts, and returns back to fuse box through fusible link.
Page 665 Figure 1. Power supply circuit diagram Reference Number Description Reference Number Description Disconnect Switch Starter Switch Battery Fuse Starter Battery Relay Starter Relay Alternator Diode Saftey Start Relay Electrical System SPC000025 Page 5...
Page 666: Engine Starting Circuit
ENGINE STARTING CIRCUIT Operation During Start Process Turn key switch (6) to ―ON‖ position, connect terminal ―B‖ and ―BR‖, output electric current starts power relay (8), then fuse box is power on. Make control handle gear in neutral position，relay（10）is power on and “87a”and“30”...
Page 667 Figure 2. Starter circuit Reference Number Description Reference Number Description Disconnect Switch Starter Switch Battery Fuse Starter Battery Relay Starter Relay Alternator Saftey Start Relay Diode Electrical System SPC000025 Page 7...
Page 668: Engine Preheating System
Engine Preheating System Engine preheating system is Intake preheating system, its main functions are: heat air inlet temperature through Heating air intake to solve the problem that engine is difficult to be started in winter resulted from low temperature. Main parts include: temperature sensor (11), preheating controller (7), preheating indicator (12), preheating relay (8), and preheating plug (9).
Page 669 Figure 3. Control circuit of preheating system Reference Number Description Reference Number Description Disconnect Switch Preheat Controller Battery Preheat Relay Alternator Pre heater Starter Switch Water Temperature Sensor Fuse Preheat Indicator Electrical System SPC000025 Page 9...
Page 670: Engine Stop System
ENGINE STOP SYSTEM Engine stopping system is composed of key switch (4), flameout electromagnet (6) and flameout relay (5). There are two kinds of work process: before engine is started and engine flameout. Working process before engine is started: When key switch (4) is turned to ―ON‖ gear, its terminal ―ACC‖ and ―B‖ is connected. Electric current goes through security of electrical box (3) through positive pole of storage battery (2) and ―B‖...
Page 671 Figure 4. Engine stalling system Reference Number Description Reference Number Description Disconnect Switch Starter Switch Battery Engine Stop Relay Fuse Engine Stop Motor Electrical System SPC000025 Page 11...
Page 672: Charging System
Charging System Turn key switch (3) to ―ON‖ position, its terminals ―BR‖ and ―B‖ are connected, power relay (6) acts, electric current coming from storage battery (2) goes through fuse box (4), power relay (6), charging indication light (8) and excitation resistance (9) and reaches ―D+‖ terminal of generator (5), earth connected and forms a circuit, charging indication light (8) is on to warn and supplies excitation electric current for generator (5).
Page 673 Figure 5. Charging system circuit diagram Reference Number Description Reference Number Description Disconnect Switch Battery Relay Battery Diode Starter Switch Charge Indicator Fuse Box Resistor Alternator Electrical System SPC000025 Page 13...
Page 674: Monitoring System
Monitoring System Monitoring system of the equipment includes all kinds of oil pressure gauges, oil pressure sensor plug, water temperature gauge, water temperature sensor plug, voltmeter, barometer and low pressure warning device, etc. Figure 6. Monitoring system Reference Number Description Reference Number Description Gauge Panel...
Page 675: Instrument Panel
Instrument panel Figure 7. Instrument panel arrangement plan Reference Reference Description Description Number Number Air filter plugging warning indicator Air Pressure Meter Fuel Gauge Preheat Indicator Tachometer High Beam Indicator Voltage meter Parking Brake Indicator Torque Converter Oil Temperature Turn and Hazard Warning Light Meter Engine Coolant Temperature Gauge Turn and Hazard Warning Light...
Page 676 Instruments Sensor Specification Function Display Input Terminal Input Specification 0.1MPa——0.9V 0.4MPa——2.1V Air Pressure CN-29 0.6MPa——2.9V Meter 0.7MPa——3.3V 0.8MPa——3.7V 0——80 欧姆 1/2——32 欧姆 CN-03 Fuel Gauge F——8 欧姆 12.66 脉冲/转 CN-10 Tachometer Voltage meter CN-11 SPC000025 Electrical System Page 16...
Page 677 Sensor Specification Function Display Input Terminal Input Specification 0℃——98.96KΩ 60℃——2.476KΩ Torque 80℃——1.25KΩ Converter Oil CN-09 Temperature 100℃——0.6744KΩ Meter 120℃——0.4071KΩ 0℃——98.96KΩ 40℃——5.312KΩ 60℃——2.476KΩ Engine Coolant Temperature CN-02 80℃——1.25KΩ Gauge 100℃——0.6744KΩ 120℃——0.4071KΩ Hour meter CN-04 Speedometer CN-27 Odometer 0.1MPa——0.9V Engine oil 0.2MPa——1.3V pressure CN-08 0.3MPa——1.7V...
Page 678 Indication light 功能显示输入端子操作备注 The light is on when Turn left and turning left signal or dangerous CN-24 dangerous warning light indication light is turned on (the Max. terminal input is 24V) The light is on when Turn right and turning right signal or dangerous...
Page 679 功能显示输入端子操作备注 When the engine water CN-02 temperature more than temperture. 103 ℃, the lamp is lit, When control handle in a Nertral CN-06 neutral position, the lamp position is lit, When pressure vacuum filter CN-20 reach 6KPa, lamp is lit...
Page 680 Schematic diagram of monitoring system Figure 8. Schematic diagram of monitoring system Reference Number Description Reference Number Description Disconnect Switch Speed Sensor Battery T/M Oil Pressure Switch Starter Switch Water temp. Switch Fuse Box Eng. Oil Pressure Switch Alternator Air Pressure Alarm Switch Starter Relay Empty filter jams switch Park press switch...
Page 681: Windshield Wiper
Windshield Wiper Windshield wiper can be operated by combination switch (2). 1. Low speed wiper (I gear) When wiper is running with low speed, electric current comes from fuse box (1), goes through wire inlet terminal and terminal ―L‖ of wiper motor (3), reaches terminal ―6‖ and ―4‖ of combination switch (2) and connects with earth.
Page 682 Figure 9. Circuit diagram of windshield wiper Reference Number Description Reference Number Description Fuse Box Rear Wiper Combination Switch Rear Washer Wiper Rocker switch Washer SPC000025 Electrical System Page 22...
Page 683: Lighting System
Lighting System Lamping system includes big lamp, position lamp, turning signal lamp, dangerous lamp, parking lamp, working ligh and switches of all lamps. When indoor lamp (4) is turned on, electric current goes to indoor lamp from fuse box (1), indoor lamp is Press front lamp switch (18), combination switch (2) is turned to passing lamp, terminal ―8‖...
Page 684 Figure 10. Lighting system circuit diagram Reference Number Description Reference Number Description Fuse Box Rear Lamp Switch Combination Switch Front Combination Lamp(L) Stop Lamp Switch Front Combination Lamp(R) Room Lamp Rear Combination Lamp(L) High Lamp Relay Rear Combination Lamp(R) Low Lamp Relay Hazard Switch Blinker Unit Position Lamp Switch...
Page 685: Electric Detent System
Electric Detent System Electric detent system includes swing arm lifting limitation system and cylinder automatic laid flat system. Electric return circuit Figure 11. Electric detent system circuit Reference Number Description Reference Number Description Fuse Box Float Magnet Raise Relay Return to Dig Magnet Return to Dig Relay Proximity Switch 1 Raise Magnet...
Page 686: Swing Arm Lifting Limitation System
Swing arm lifting limitation system 1. Swing arm lifting limitation When swing arm operation handle is pulled to the rear limitation position, swing arm operation handle will be gripped by swing arm lifting electromagnet (4) (swing arm operation handle will not return to meso position after loosening hands), swing arm will keep lifting;...
Page 687: Electric Speed Control System
Electronic speed control system According to the input signal through the transmission control valve Y1 ~ Y5 action combination, decided to gear state; ●Magnet under Voltage Forward Reverse Neutral Speed ● ● ● ● ● ● ● ● ● ● ●...
Page 688 Figure 11. Variable speed control system Reference Number Description Reference Number Description CONTROLLER AUTO/MANU SW VALVE ASS'Y SAFETY START RELAY T/M SELECTOR SWITCH T/M CUT OFF SW DIAGNOSE BRAKE AIR PRESS SW SENSOR DOWN SHIFT SW (KD) SENSOR PARK PRESS SW FUSE BACK BUZZER RELAY SPC000025...
Page 689 SPC000027 Electrical SCHEMATIC (SD310) WHEEL LOADER SAFETYS0103010K CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load.
Page 690 TABLE OF CONTENTS General Description....................3 SD310……………………..................4 SPC000027 Electrical Schematic (SD310) Page 2...
Page 691 General Description Schematic diagram shown in this section is shown in folio page. The overlapped edge has been considered for convenient copy, a complete schematic diagram can be formed when they are put together. Figure 1 Electrical Schematic (SD310) SPC000027 Page 3...
Page 692 SD310（ZF） SPC000027 Electrical Schematic (SD310) Page 4...
Page 693 Electrical Schematic (SD310) SPC000027 Page 5...
Page 694 SPC000027 Electrical Schematic (SD310) Page 6...
Page 695 1ATTACHMENTS...

Doosan DISD SD 310 Shop Manual

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