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HELI gleen Series Operation & Service Manual

6 to 8 ton engint powered tractor
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6 to 8 ton ngine Powered Tractor
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Summary of Contents for HELI gleen Series

  • Page 1 6 to 8 ton ngine Powered Tractor...
  • Page 2 It has excellent performance, for instance, great traction, easy steering system and long life. Domestic advanced turbocharged engine (CA6110/125ZT), HELI special transmission box and matched high quality spare parts are assembled on the truck; The steel plate of the tractor body is of welded structure and the rear part has casted counterweight which can improve its stability and traction.

  • Page 3: Table Of Contents

    CONTENT FORWARD 1. Driving and Operation of the Tractor .................... 1 2. Main Technical Parameters ......................8 3. Structure, Priciple, Regulation and Maintenance of the Main Parts ........... 13 3.1 Main Parts Distribution ..................... 13 3.2 Dynamic System ....................... 14 3.3 Transmission System ......................

  • Page 4: Driving And Operation Of The Tractor

    1. Driving and Operation of the Tractor The driver and keeper of the tractor must bear in mind that “Safety First”, and operate following this manual. 1.1 Transport of the Tractor Notice following when transporting by container or automobile:  Pull up hand brake to make the tractor stop. ...
  • Page 5 1.4 Running-in period of the new tractor Proper operation during the running-in period has a positive effect on prolonging the service life, improve the reliability and economy.  Clean the vehicle and check the connection and tightness of the parts before running-in period;...
  • Page 6 after running 200km during the running-in period;  Check if there is air or oil leakage in the joints of the brake system and steering system during the running-in period;  Maintain the tractor when the running-in period is over. 1.5 Operation of the Tractor ...
  • Page 7 when checking the battery or oil lever;  Put the gear on the neutral, stop the engine or disconnect the power when leave the truck; pull up the parking brake and wedge the wheels if it will stop for a long time;...
  • Page 8 1.7 Oil, grease and anti-freeze liquid for the tractor Table 1-1 Oil, grease and anti-freeze liquid for the tractor Oil grade Oil adding Oil adding parts Oil type Oil grade(domestic) Notes (overseas) volume JISK2204 、 2# according （ normal operation manual of the environment）...
  • Page 9 Joints of the brake pedal, steering Lubricating 3#li-base lubricating grease JISK-2220、1#、 Proper cylinder, drive grease (dropping point 170) amount axle other moving members Long-effective rust proof －－－ Radiator FD-2type -35℃ anti-fre liquid 1.8 Lubricating chart See figure 1-1.
  • Page 10 Figure 1-1 Lubricating chart...

  • Page 11: Main Technical Parameters

    2. Main Technical Parameters 2.1 Profile Drawing of the Tractor Figure 2-1 Profile Drawing of the Tractor 2.2 Main parameters...
  • Page 12 ITEM UNIT QYCD60-WX QYCD70-WX QYCD80-WX Max. drawbar pull Max. travelling speed without load km/h 30/30 (forward/backward) Gradeability（unloaded） Min. turning radius 4800 Service weight(oil included) 9000 10980 11610 Front axle 1900 2390 2390 Axle load Rear axle 7100 8590 9220 Fuel tank capacity 4055(without front traction seat)，4230(with front Outlin Length...
  • Page 13 Pressure Specification 9.00-20-14PR rear Pressure Model CA6110/125ZT-HL10 Cylinder bore× stroke 6-φ110×125 Rated power kW/rpm 110/2200 Rated torque 560/1400-1600 N· m/rpm 2.3 Performance and Parameters of the Parts 2.3.1 Engine Model: Xichai CA6110/125ZT-HL10 Type: in-line, six-cylinder, water-cooling, turbocharging Cylinder number-cylinder bore × stroke： 6-110 mm×...
  • Page 14 Lubrication system: forced splash 2.3.2 Transmission box P82D3-80011 Model: Type: stepless speed change; two gears: forward and backward Operation mode: postposition concentrated handle operation Forward Ⅰ/backward Ⅰ:1.621 Forward Ⅱ /backward Ⅱ: 0.526 Speed ratio: 2.3.3 Steering unit Model: BZZ-80 Type: cycloid rotary entirely hydraulic redirector Max.
  • Page 15 2.3.8.1 Service brake Type: foot pedal; brake with four wheels Structure: front wheel: disc type; rear wheel: brake shoe; powered brake 2.3.8.2 Parking brake Type: manual; mechanical type Structure: acts on the output shaft of the transmission box 2.3.9 Frame Type: box-shape girder welding structure 2.3.10 Traction pin...

  • Page 16: Structure, Priciple, Regulation And Maintenance Of The Main Parts

    3. Structure principle, regulation and maintenance of the main parts 3.1 Main parts distribution Serial Name Content Engine, air inletting system, exhausting system, cooling Dynamic system system, fuel system, torque converter and hydraulic system are included. Transmission Torque converter, transmission box, speed changing system devices, drive shaft, and brake unit are included.

  • Page 17: Dynamic System

    3.2 Dynamic system Engine, air inletting system, exhausting system, cooling system, fuel system, torque converter and hydraulic system are included. Refer to figure 3-1. Fuel system Cooling system 燃油系统 冷却系统 Torque converter cooling system 变矩器冷却系统 Exhausting system Air intaking system 排气系统...
  • Page 18 b. Drop engine oil to the filter seals and then assemble it. Tighten for 2/3 circle after connecting the body. c. Replace it every 600 hours or three months. (3) Water tank and secondary water tank a. Inspect the cooling liquid lever of the secondary water tank Inspect the cooling liquid lever of the secondary water tank.

  • Page 19: Transmission System

    too loose; (4) Pump oil Press the hand manual pump and let the oil into the fuel injection pump. Press another 5-10 times if it is heavy. (5) Air exhausting Fire extinguishing cover is assembled at the end of the air exhausting system in that case there is no spark in the exhausting air.
  • Page 20 (1) Inching valve is assembled on the truck to improve the inching effect and thus tractor has good inching performance in any working condition. (2) Hydraulic-powered clutch has great durability; (3) One-way clutch which has high transmission efficiency is applied in the torque converter.
  • Page 21 Figure 3-3 Hydraulic-powered transmission box 1-Operation valve 2-Oil-charging pump 3-Ball bearing 4-Axis 5-Ball bearing 6-Torque converter 7-Ball bearing 8-Gear (30 teeth) 9-Parking brake 10-Oil tank 11-Speedometer gear (45 teeth) 12-Gear (32 teeth) 13-Ball bearing 14-Axis 15-Bearing cover 16-Output shaft 17-Oil seal 18-Ball bearing 19-Gear (47 teeth) 20-Clutch parts of reverse gear 21-Clutch parts of forward gear 22-Spring plate 23-Transmission output shaft 3.3.2 Torque converter...
  • Page 22 along the blades because of the centrifugal effect. Liquid flows into the blades of turbine wheel and transmits the torque to output shaft. Liquid flows into pump wheel with the best angle. At the same time, a counteractive torque is produced to push the guide wheel, so that the output torque is larger than input torque.
  • Page 23 Figure 3-4 Torque converter structure 1-Oil-drain plug 2-Pump wheel 3-Turbine wheel 4-Guide wheel 5-Ball bearing 6-Snap ring 7-One-way clutch 8-Spring plate 9-Thrust bearing 10-Ball bearing 11-Guide wheel support 3.3.3 Hydraulic powered clutch In the transmission case there fixes the hydraulic powered clutch. The driving gear on the side of the clutch meshes with the corresponding driven gear.
  • Page 24 1. Ball bearing 2. Thrust shim 3. Needle bearing 4. Gear (57 gears) 5. Bushing 6. End plate 7. Clutch disc 8. Piston ring 9. Piston 10. Stopper spring 11. Snap ring 12. Gear 13. Gear 14. Seal ring Figure 3-5 Forward gear clutch Figure 3-6 Backward gear clutch 3.3.4 Operating valve, relief valve and inching valve Operation valve is fixed on the top side of the transmission box case with gear...
  • Page 25 clutch will be reduced temporarily and clutch is loosen. Refer to figure 3-7 for operating valve. Figure 3-7 Operating valve 3.3.5 Oil circuit of the torque converter After starting the engine, oil-charging pump begins to work. The torque converter oil is pressed from the transmission case bottom to operation valve through the oil-charging pump by filter.
  • Page 26 because of the regulating valve. The oil pressure increases gradually from the clutch begins to work until it joins entirely. When the accumulator is filled with oil, the oil pressure increases rapidly to make the hydraulic clutch entirely meshes. When the forward or reverse clutch works, the other clutch separates.
  • Page 27 (2)Abnormal oil temperature increasing (refer to table 3-4) (3)Loud noise (refer to table 3-5) (4) Low transmission efficiency (refer to table 3-6) (5) Oil leakage (refer to table 3-9)
  • Page 28 Table 3-3 Insufficient power Part Reason Inspection method Remedy A. Low oil pressure (1) Oil level is low Inspect oil level Add oil Tighten Inspect the connector and (2) Take in the air connector pipe replace seal Replace (3) Filter is blocked Dismantle and inspect clean Torque...
  • Page 29 Table 3-4 Abnormal oil temperature increasing Part Reason Inspect method Remedy (1) Oil level is low Inspect oil level Add oil Replace and (2) Filter is blocked Dismantle and inspect clean Take out little oil and (3) Flywheel damages or inspect whether it is Replace collides with other parts...
  • Page 30 Table 3-6 Low transmission efficiency Remove Part Reason Inspect method method Inspect working noise at low (1) Spring plate breaks Replace speed (2) Oil level is low Inspect oil level Add oil Torque Driving system Dismantle and inspect Replace converte oil-charging pump fails (4) Axis breaks Dismantle and inspect...

  • Page 31: Brake System

    3.4 Brake system Refer to the table 3-8 for main specifications of the brake system. On rear wheel, Type inner-expand, with supercharger Service Master pump diameter 31.75 brake Sub pump diameter 47.52 Inner diameter of the brake drum 438.15 Quantity Piece Mechanical, Type...
  • Page 32 system diagram. Brake pump (valve) Steering wheel Brake pedal Accumulator Steering cylinder Brake Figure 3-9 brake system principle diagram...
  • Page 33 Brake pedal Brake caliper Brake Accumulator assembly assembly Brake valve Body center line Brake Brake assembly caliper assembly Figure 3-10 System diagram 3.4.2 Brake pedal The brake pedal is fixed on the left of vehicle by bracket. It pushes the piston by the connecting pole, so the force of stepping can be transmitted with oil pressure.
  • Page 34 piston 5 is pulled left by spring 8, and also return spring 6 is pressed to the left. b)The sliding valve moves to close A, and disconnect the connection of control oil pressure chamber with tank. B opens to connect the control oil pressure chamber with pump.
  • Page 35 stepping on the brake pedal, A opens and B is closed by the motion of sliding valve. Oil of pump connector enters the control oil pressure chamber to make the oil pressure of brake sub-pump increase. (3)Motion of accumulator The motions that pump stops are same as the opening motion and safety motion except following points: a)In the condition of 1-(b), oil pressure of brake sub-pump does not increase because there is no pressure in pump connector.
  • Page 36 The pump oil pressure increases, piston moves to touch limitation, so the accumulator has much power, and the oil pressure is controlled by overflow valve. Combine spring O-ring snap ring O-ring safety valve one-way valve Piston alarming switch Figure 3-12 Accumulator 3.4.5 Service Brake Figure 3-13 Service brake 1-Main brake shoe 2-Return spring 3-Sub-pump 4-Bowl 5-Piston...
  • Page 37 Refer to figure 3-13. Outside the brake shoe there is friction piece. One end of shoe is connected with piston head. The regulator regulates the clearance of shoe and brake drum. 3.4.6 Parking brake The parking brake is inner expanding and mechanical type. See figure 3-3 (item 9).
  • Page 38 3.4.7 Troubleshooting (refer to table 3-9) Table 3-9 Troubleshooting of the brake system Fault Causes Remedy Fluid leaks from the brake system Repair Improper adjustment of the friction Check piece Brake overheating Check for dragging Poor contact between brake drum and Adjust Poor braking friction piece...

  • Page 39: Oil Throttle And Operation Devices

    3.5 Oil throttle and operation devices Refer to figure 3-15 for the oil throttle operating devices. Oil throttle pedal fixed on the floor board is used to control the engine speed. Oil throttle pedal is connected to engine through oil throttle operation bracket and cable. Button assembled on the meter is used to turn off the engine which is connected to the engine through cable.
  • Page 40 Table 3-10 Steering system parameters Type Wholly hydraulic dynamic steering Steering unit type Cycloidal wholly hydraulic dynamic steering unit Steering unit model BZZ-80 Type Double action piston type Cylinder diameter 70mm Steering Piston pole cylinder 50mm diameter Stroke 86mm Rated pressure 6.3MPa Hand steering wheel diameter 360mm...
  • Page 41 Figure 3-16 Steering system 1. Adjust knob 2. Hand steering wheel 3. Steering column 4. Gimbal 5. Steering bracket 6. Wholly hydraulic steering unit 3.6.2 Cycloidal wholly hydraulic steering unit Refer to figure 3-17 for wholly hydraulic steering unit. It can transmit the pressured oil from steady flow valve to steering cylinder according to the turning back angle of the hand steering wheel.

  • Page 42: Troubleshooting

    Figure 3-17 Cycloidal wholly hydraulic steering unit 1. Stopper 2. Valve body 3. Valve element 4. Linking shaft 5. Spring piece 6. Linking block 7. Rotor 8. Stator 9. Valve sleeve 3.6.3 Inspection after reassembling (1)Rotate the steering wheel left and right to see whether the force and rotation are even.
  • Page 43 check the oil seal. Refer to figure 3-18 and 3-19 for the hydraulic system oil circuit. Brake sub pump Powered brake system Steering unit Double gear pump Breather Figure 3-18 Hydraulic system principle diagram...

  • Page 44: Drive Axle

    Figure 3-19 Hydraulic system oil circuit (standard equipment of 1L powered steering oil tank is showed in the figure) 1. High pressure pipeline 2. Joint 3. Powered steering oil tank 4. Low pressure pipeline 5. Double gear pump 6. Sealing gasket 3.8 Drive axle Refer to table 3-12 for drive axle main specifications.
  • Page 45 Type Spiral bevel gear Differential Reduction ratio 6.33 Type Planetary gear type Terminal reduction Reduction ratio 3.75 Differential Oil tank capacity Terminal reduction 4.5L（each side） Total reduction ratio 23.75 3.8.1General description Drive axle consists of differential, terminal reduction, service brake and so on. Refer to figure 3-20, drive axle is connected to the frame through steel plate spring while the steel plate spring is connected to the drive axle through U-bolts.
  • Page 46 Figure 3-20 Drive axle 1. Brake assembly 2. Brake drum and shell assembly 3. Rim assembly 4. Tyre 5. Oil Seal 6. Tapper roller bearing (small bearing) 7. Rim bolt 8. Shell 9. Tapper roller bearing (big bearing) 10. Lock nut (inner) 11.
  • Page 47 Figure 3-21 Differential 1-Regulating nut 2-Bearing cover 3-Lock board 4-Taper roller bearing 5-Left differential case 6-Semi-shaft gear 7-Planet gear 8-Gear ring 9-Cross shaft 10-Shim 11-Right differential case 12- Semi-shaft gear 13-Shim 14-Roller bearing 15-Main decelerator shell 16-Locknut 17-Regulating nut 18-Driving small gear shaft 19-Taper roller bearing 20-Bearing base 21-O-ring...
  • Page 48 Inner gear ring Sun gear Semi shaft Planet gear Figure 3-22 Terminal reduction gear When the sun gear rotates (that is semi-shaft rotating), power transmits to inner gear ring and planet gear. But because the inner gear ring is fixed on the driving shaft shell, the planet gear rotates around the sun gear and self-rotates simultaneously.

  • Page 49: Steering System

    Table 3-14 Maintenance data of the drive axle Reference Part Item value(mm) Thickness of bearing base spacer 0.1,0.2,0.5 Match diameter of flange and oil cover 69.95-70 Spline clearance of flange and driving small gear 0.036-0.067 (shaft) Clearance of driving small gear and tooth ring 0.20-0.30 Pre-load of driving small gear 2.5-3.5(N.m)
  • Page 50 Figure 3-23 Steering axle 1-left linking 2-Steering axle assembly 3-Steering cylinder 4-Right steering knuckle assembly 5-Pushing bearing 6-Needle bearing 7-Steering knuckle main pin 8-Hub 9-Tyre 10-Hub bolt 11-Hub nut 12-Rubber seal 13-Bearing 14-Bearing 15-Hub cover 16-Steering 17-Brake plate 18-O-ring 19-Rustproof cover 20-Left steering knuckle assembly 21-Right linking rod 22-Lubrication nipple 23-Brake caliper assembly...

  • Page 51: Body System

    grease regularly. The knuckle assembly and main pins are fixed by lock pins. Steering cylinder 3.9.3 The steering cylinder is of double-action piston type. The seal unit consists of the supporting ring and o-ring seal, YX-ring seal is adopted between the cylinder cover and piston rod.

  • Page 52: Hanging System

    Figure 3-25 Body system 1. Frame 2. Engine hood 3. Seat 4. Balance weight 5. Front adjusting weight 6. Battery cover 7. Rear adjusting weight assembly (for 8t tractor) 3.11 Hanging system The front and rear hanging is both rectangle steel plate spring, not absolute hanging system.
  • Page 53 device is easy, light, easy to assembling and disassembling and can prolong the work life of spring. (See figure 3-26) (a) Front hanging (b) Rear hanging Figure 3-26 Hanging device 1. Steel plate spring pin 2. Steel plate spring 3. Stopper 4.
  • Page 54 Often inspect the tightness of riding bolt of steel plate spring. Please tight it with over load if it is loose. Or the steel plate spring may break in the middle, central bolt breaks, and bracket and axis are misplaced. The shock absorber can decrease the shock of trailer, increase the stabilization of tractor and prolong the work life of steel plate spring, tractor body and bracket etc.

  • Page 55: Electric System

    3.12 Electric system The electric system of the tractor adopts 24V single electric circuit and cathode ground connection. It is mainly made up of charging system, starting system, combined instrument, lamps and battery and so on. Refer to figure 3-29, for the electric system diagram and appendix I for principle diagram.
  • Page 56 9. Neutral gear (reversing gear) switch 10 Body harness 11. Backward buzzer 12. Rear combined light 13. Brake switch JK205 14. Steering light switch 15. Light switch JK211 16. Preheating starting switch 17. Integrated panel switch 18. Integrated panel harness 19.
  • Page 57 during the working of the engine, it means that the oil pressure of the engine is low and the lubrication is poor. Stop the tractor and check. 3.12.3.2 Charging indication light Before starting the engine, turn the start switch to the lever with electricity and the signal will light up.
  • Page 58 Lights, signals, horn and buzzer are included. Front lamp: 55W; Front combined light (Steering light/ width light):21W/5W; Rear combined light (steering light/ width light/backward indicator/ brake light):21W/5W/10W/21W; Alarming light (optional): 21W; NOTE: Electrical horn should not be used continually for a long time or its service life may be affected.

  • Page 59: Brief Instruction Of Operation

    4. Brief Instruction on Operation 4.1 Start (1) Before starting the engine, put the shift gears at zero first. (2) Turn the start switch clockwise to first gear-lever with electricity to switch on the instrument and ignition power supply. (3) Step on the clutch, turn the start switch clockwise to second gear-starting, start the engine.

  • Page 60: Operation Notes

    5. Operation Notes 5.1 Following this manual to carry out the regulation, maintenance and lubrication. 5.2 The new tractor must go through running-in course. 5.3 The service life of tractor has more relation with the original work condition. In order to prolong the work life of tractor, first work of 50h is running-in period.
  • Page 61 cold starts in winter, first turn the key to preheat position to preheat the system 15-30 seconds, then start the engine. (4) After starting the engine, loosen the key switch immediately to make it go back to work position. If starting three times, the interval between every time should be over 20 seconds.
  • Page 62 running fast is not permitted. ● Drive at limited speed in running-in period. ● Do not run the engine violently. ● Do not drive on rough road. ● Often inspect the temperature of brake hub and wheel hub and regulate it if necessary.
  • Page 63 prolong the work life of every part, do not drive at high speed continuously in the following 10h.

  • Page 64: Maintenance

    6. Maintenance To prolong the work life of tractor, carry out the maintenance by following steps: 6.1 Daily Maintenance (1) Inspect whether the oil, water and brake oil are enough, whether there is leakage, and the antifreeze in winter. (2) Inspect the air pressure of tires and the tightness of wheels. (3) Inspect the noise of engine when running.
  • Page 65 6.4 Maintenance Every Running 300h (1) Inspect the redirector and electrical brush. (2) Clean the oil filter. (3) Take out the plug at the bottom of oil tank and remove the sediment. (4) Inspect whether the vent of transmission case and rear shaft are blocked. (5) Inspect the tightness parts.

  • Page 66: Appendix 1 Electric System Priciple Diagram

    Appendix 1: Electric system principle diagram...
  • Page 67 S200-1:2015...

This manual is also suitable for:

Gleen qycd60-wxGleen qycd70-wxGleen qycd80-wx

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