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Doosan DISD SD 310, Shop Manual

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Doosan DISD SD 310 Shop Manual Download Page 503

Reference 

Number 

Description 

Reference 

Number 

Description 

1 

M27

³

2-05 NUT 

22-1 

SHIM 

2 

WASHER, LOCK 

22-2 

SHIM 

3 

BOLT 

22-3 

SHIM 

4 

CASE,MAIN REDUCTION 

23 

NUT,ADJUSTING 

5 

RING,RETAINING 

24 

BEARING,TAPER ROLLER 

6 

BEARING,ROLLER 

25 

M16

³

1.5-10 NUT 

7 

PINION 

26 

WASHER, PLAIN 

8 

BEARING,TAPER ROLLER 

27 

CASE,DIFFERENTIAL 

9 

SLEEVE   

28 

PIN 

10-1 

SHIM 

29 

WASHER 

10-2 

SHIM 

30 

GEAR,DIFFERENTIAL 

10-3 

SHIM 

31 

SPIDER 

10-4 

SHIM 

32 

GEAR,DIFFERENTIAL 

11 

NUT 

33 

WASHER 

12 

WASHER, PLAIN 

34 

BOLT 

13 

FLANGE,ASSY 

35 

GEAR,HELICAL 

14 

CAP,DUST 

36 

CASE,DIFFERENTIAL 

15 

SEAL 

37 

WASHER 

16 

M14

³

60-8.8 BLOT 

38 

M16

³

1.5-10 NUT 

17 

14WASHER, SPRING 

39 

M16

³

1.5

³

150-10.9 BLOT 

18 

HOLDER

，

OIL SEAL 

40 

PLATE,FIXED 

19 

BEARING,TAPER ROLLER 

41 

10WASHER,SPRING 

20 

GASKET,FLANGE 

42 

M10

³

1

³

20-8.8BOLT 

21 

SUPPORT,BEARING 

 

 

 

 

 

 

 

 

 

 

 

 

 

Rear  Axle                                                                                                                                                        SPC000010 

Page 9 

Summary of Contents for DISD SD 310

Page 1: ... 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 represe...

Page 2: ......

Page 3: ...C000005 Engine and Drive Train Engine SPC000006 Transmission and Torque Converter SPC000007 Front Axle SPC000009 Rear Axle SPC000010 Hydraulics Cylinders SPC000011 Main Pump SPC000012 Steer Pump SPC000013 Main Control Valve SPC000014 Feed Unit SPC000015 Priority Valve SPC000016 Steering Unit SPC000017 Motor SPC000018 Hydraulic Oil Tank SPC000019 Hydraulic Schematic SPC000020 Brake Brake System SPC...

Page 4: ...Electrical System Air Conditioner SPC000024 Electrical System SPC000025 Electrical Schematic SPC000027 Attachments Table of Contents Page 2 ...

Page 5: ...1SAFETY ...

Page 6: ......

Page 7: ...anual 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 MODEL SERIAL NUMBER RANGE ALL MODELS ALL MODELS Copyright 2011 DISD November 2011 Wheel Loader Safety S0103010K Page 1 ...

Page 8: ...neral Safety Essentials 6 Location of Safety Labels 6 Unauthorized Modifications 6 General Hazard Information 7 Before Starting Engine 15 Machine Operation 18 Maintenance 25 Battery 33 Towing 35 Shipping and Transportation 36 S0103010K Wheel Loader Safety Page 2 ...

Page 9: ...se respect the importance of taking responsibility for your own safety and that other people who may be affected by your actions Safety information on the following pages is organized into the following topics 1 General Safety Essentials on page 6 2 Location of Safety Labels on page 6 3 Unauthorized Modifications on page 6 4 General Hazard Information on page 7 5 Before Starting Engine on page 15 ...

Page 10: ...ly to intended uses of the machine If you use your machine for any unintended uses that are not specifically prohibited you must be sure that it is safe for any others In no event should you or others engage in prohibited uses or actions as described in this manual DISD delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped If this m...

Page 11: ...ce WARNING This word is used on safety messages and safety labels and indicates potential of a hazardous situation that if not avoided could result in serious injury or death It may also be used to alert against a highly unsafe practice DANGER This word is used on safety messages and safety labels and indicates imminent hazard of a situation that if not avoided is very likely to cause death or ext...

Page 12: ...the warning signs are legible Clean the warning signs or replace the warning signs if you cannot read the words Replace the illustrations if the illustrations are not visible When you clean the warning signs use a cloth water and soap Do not use solvent gasoline or other harsh chemicals to clean the safety signs Solvents gasoline or other harsh chemicals could loosen the adhesive that secures the ...

Page 13: ...ith a person on work site traffic duty be sure that all personnel know the nature of the work and understand all hand signals that are to be used Always observe strictly any other rules related to safety SAFETY FEATURES Be sure that all guards and covers are installed in their proper position Have guards and covers repaired immediately if damaged Be sure that you understand the method of use of sa...

Page 14: ...bjects such as flammable or explosive items into the operator s cab To ensure safety do not use the radio or music headphones when operating the machine There is danger that this may lead to a serious accident When operating the machine do not put your hands or head out of the window When standing up from the operator s seat always place transmission neutral lock lever in the LOCK position and set...

Page 15: ...ne or component with the wind at your back whenever possible Always observe any rules and regulations related to the work site and working environment MOUNTING AND DISMOUNTING Before getting on or off the machine if there is any oil grease or mud on the handrails steps or track shoes wipe it off immediately Always keep these parts clean Repair any damage and tighten any loose bolts Never get on or...

Page 16: ...in constant contact with the neck of the fuel filling nozzle to provide a ground Keep fuel and other fluid reservoir caps tight and do not start the engine until caps have been secured PRECAUTIONS WHEN HANDLING FLUIDS AT HIGH TEMPERATURE Immediately after operations are stopped the coolant engine oil and hydraulic oil are at high temperature and the radiator and hydraulic tank are still under pres...

Page 17: ...e mounted in the cab Check and service the fire extinguisher at regular intervals and make sure that all work site crew members are adequately trained in its use Provide a first aid kit in the storage compartment and keep another at the work site Check the kit periodically and make any additions if necessary Know what to do in case of injury from fire Keep emergency numbers for doctor ambulance se...

Page 18: ...relocating fasteners Any serious impact or damage to system requires a complete integrity reevaluation Reinstallation recertification and or replacement of system may be necessary INSTALL ADDITIONAL SAFETY EQUIPMENT IF CONDITIONS REQUIRE Laminate glass protection for the front side or rear windows may also be recommended depending upon particular site conditions Contact your DISD distributor for a...

Page 19: ...on and Maintenance Manual The accumulator is charged with high pressure nitrogen gas so it is extremely dangerous if it is handled in the wrong way Always observe the following precautions Do not drill or make any holes in the accumulator or expose it any flame fire or heat source Do not weld on the accumulator or try attaching anything to it When carrying out disassembly or maintenance of the acc...

Page 20: ...sent a potential hazard or cause the operator to react suddenly and cause an accident Use a spotter or signal person working near bridges phone lines work site scaffolds or other obstructions Minimum levels of insurance coverage work permits or certification physical barriers around the work site or restricted hours of operation may be mandated by governing authorities There may also be regulation...

Page 21: ... position If any abnormalities are found in the above checks carry out repairs immediately ENGINE STARTING Walk around your machine before getting in operator s cab Look for evidence of leaking fluid loose fasteners misaligned assemblies or any other indications of possible equipment hazard All equipment covers and machinery safety guards must be in place to protect against injury while machine is...

Page 22: ...ing the problems it may lead to unexpected injury or failure Clear all personnel from directly around machine and from the area Clear all obstacles from the machine s path Beware of hazards Be sure that all windows are clean Secure the doors and the windows in the open position or in the shut position Adjust the rear view mirrors for best visibility close to the machine Make sure that the horn the...

Page 23: ... not twist out of seat if job activity behind you or to the side requires your attention Use a spotter or signal person if you cannot see clearly and something is happening behind you Replace damaged safety labels and lost or damaged operator s manuals Do not let anyone operate machine unless they ve been fully and completely trained in safety and in operation of the machine SEAT BELTS SHOULD BE U...

Page 24: ... traveling on rough ground travel at low speed and avoid sudden changes in direction Always keep to the permissible water depth When traveling over bridges or structures on private land check first that the bridge or structure can withstand the weight of the machine When traveling on public roads check with the local authorities and follow their instructions SLOPING TERRAIN REQUIRES CAUTION Dig ev...

Page 25: ...ectly and work out a safety plan with them BEFORE STARTING TO DIG CONTACT AUTHORITIES Below ground hazards also include natural gas lines water mains tunnels and buried foundations Know what s underneath work site before starting to dig BE AWARE OF HEIGHT OBSTACLES Any type of object in vicinity of boom could represent a potential hazard or cause operator to react suddenly and cause an accident Us...

Page 26: ...ws STAY ALERT FOR PEOPLE MOVING THROUGH WORK AREA When loading a truck you should always know where the driver is Avoid loading over the cab of a truck even if the driver is in a safe spot Someone else could have gone inside for any number of reasons Avoid working where unseen passersby might be Slow down work cycle and use slower travel speeds in congested or populated areas Use a commonly unders...

Page 27: ...s main purpose Using it for other purposes will cause failures To ensure an ample view do as follows When working in dark areas attach working lights and front lights to the machine If necessary set up lighting at the work site Stop operations when the visibility is poor such as in fog mist snow and rain Wait for the visibility to improve to a level which causes no problems for the operation Keep ...

Page 28: ... in very cold temperatures Reducing work cycle rate and work load may be necessary When the temperature rises frozen road surfaces become soft so the machine travel becomes unstable In cold weather do not touch metal surfaces with your bare hands If you touch a metal surface in extremely cold weather your skin may freeze to the metal surface PARKING MACHINE Avoid making sudden stops or parking mac...

Page 29: ...ipment that may have been installed on machine IMPORTANT When hydraulic system maintenance or service work must be performed be aware that accumulators in system store fluid under pressure after system has been shut down To release hydraulic pressure in accumulators operate control with engine OFF until accumulator pressure is completely dissipated NEVER LET ANYONE RIDE ON ATTACHMENT Never let any...

Page 30: ...p and injure yourself When washing the machine do the following Wear shoes with nonslip soles to prevent yourself from slipping and falling on wet places Wear safety glasses and protective clothing when washing the machine with high pressure steam Take action to prevent touching high pressure water and cutting your skin or having mud fly into your eyes Do not spray water directly on electrical com...

Page 31: ...lled onto hot surfaces or onto electrical components can cause a fire Store all fuels and all lubricants in properly marked containers and away from all unauthorized persons Store oily rags and other flammable material in a protective container Do not smoke while you refuel the machine or while you are in a refueling area Do not smoke in battery charging areas or in areas the contain flammable mat...

Page 32: ...ling system Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Remove the hydraulic tank filter plug only after the engine has been stopped Make sure that the hydraulic tank filter plug is cool before you remove it with your bare hand Remove the hydraulic tank filter plug slowly to relieve pressure Relieve all pressure in the hydraulic o...

Page 33: ...uids Do not flame cut on pipes or on tubes that contain flammable fluids Before you weld on pipes or on tubes or before you flame cut on pipes or on tubes clean the pipes or tubes thoroughly with a nonflammable solvent If heat is applied directly to rubber hoses or piping under pressure they may suddenly break so cover them with a fireproof covering Wear protective clothing Make sure there is good...

Page 34: ...ction cover open but not locked there is danger that it may suddenly close and cause injury if there is a gust of wind CRUSHING PREVENTION AND CUTTING PREVENTION You should always have at least two people working together if the engine must be run during service One person needs to remain in the operator s seat ready to work the controls or stop the machine and shut off the engine Unless you are i...

Page 35: ...irm level ground and lower all equipment before shutting down and switching OFF controls When engine lube oil gearbox lubricant or other fluids require change wait for fluid temperatures to decrease to a moderate level before removing drain plugs NOTE Oil will drain more quickly and completely if it is warm Do not drain fluids at temperatures exceeding 95 C 203 F however do not allow full cool dow...

Page 36: ...e lines Do not strike high pressure lines Do not install lines tubes or hoses that are bent or damaged Make sure that all clamps guards and heat shields are installed correctly to prevent vibration rubbing against other parts and excessive heat during operation If any of the following conditions are found replace the part Damage or leakage from hose end Wear damage cutting of covering or exposure ...

Page 37: ...TROLEUM BASED OILS AND FLUIDS PROPERLY Physical contact with used motor oil may pose a health risk Wipe oil from your hands promptly and wash off any remaining residue Used motor oil is an environmental contaminant and may only be disposed of at approved collection facilities To prevent pollution of the environment always do the following Never dump waste oil in a sewer system rivers etc Always pu...

Page 38: ...an damp cloth Never use gasoline thinner or any other organic solvent or detergent Tighten the battery caps securely Explosive battery gas can be set off by sparks from incidental contact or static discharge Turn OFF all switches and engine when working on batteries Keep battery terminals tight Contact between a loose terminal and post can create an explosive spark If the battery electrolyte is fr...

Page 39: ...tions are made 24 volt battery units consisting of two series connected twelve volt batteries have a cable connecting one positive terminal on one of the 12 volt batteries to a negative terminal on the other battery Booster or charger cable connections must be made between the nonseries connected positive terminals and between the negative terminal of the booster battery and the metal frame of the...

Page 40: ...low these signals correctly If the engine on the problem machine will not start or there is a failure in the brake system always contact your DISD distributor Never go between the towing machine and the towed machine during the towing operation It is dangerous to carry out towing on slopes so select a place where the slope is gradual If there is no place where the slope is gradual carry out operat...

Page 41: ...Refer to the section Transportation section of operation manual SUMMARY OF SAFETY PRECAUTIONS FOR LIFTING WARNING Improper lifting can allow load to shift and cause personal injury or damage to the machine To make safe lifts the following items must be evaluated by operator and work site crew Condition of ground support Wheel loader configuration and attachments Weight lifting height and lifting r...

Page 42: ...S0103010K Wheel Loader Safety Page 36 ...

Page 43: ...1SPECIFICATIONS ...

Page 44: ......

Page 45: ...se 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 MODEL SERIAL NUMBER RANGE SD310 010001 and Up Copyright 2012 DISD July 2012 Specifications for SD310 SPC000001 Page 1 ...

Page 46: ...neral 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 Figure 1 identifies the location of major machine components Figure 1 SPC000001 Specifications for SD310 Page 4 ...

Page 49: ... Fan Motor 7 Tire 27 Oil Tank 8 Axle Hub 28 Priority Valve 9 Cooling Pipe line 29 Bucket Cylinder 10 Main Pipe line 30 Steering Unit 11 Steering Pipe line 31 Joystick 12 Front Combined Lamps 32 Pilot Filter 13 Battery 33 Engine 14 Rear Combined Lamps 34 Transmission 15 Console 35 Radiator 16 Cabin 36 Axle 17 Engine Cover 37 Shaft 18 Front Fender 38 Tire 19 Ladder 39 Fuel Tank 20 Platform Specifica...

Page 50: ...ed 1 2 3 4 km h mph Forward 6 4 4 0 11 8 7 3 23 8 14 8 39 0 24 2 Reverse 6 5 4 0 11 9 7 4 24 1 14 9 Steering Angle 40 Min Tire Turning Radius Tire Center 5 500 mm Max Tractive Effort 17 260 kg 38 051lb Max Breakout Force 16 100kg 35 494 lb Bucket Rise Time 5 8 Seconds Bucket Dump Time 1 4 Seconds Bucket Descent Time 3 5 Seconds Working Range Dump Height at 45 w cutting edge 3 230 mm 10 7 Dump Reac...

Page 51: ...Specifications for SD310 SPC000001 Page 7 ...

Page 52: ...ENGINE PERFORMANCE CURVES SPC000001 Specifications for SD310 Page 8 ...

Page 53: ...300 rpm 92 kg m 1 300 rpm 666 ft lb 1 300 rpm Fuel Consumption 156 g ps h Performance Standard SAE J1349 gross NOTE Barometric Pressure 760 mm 30 Mercury Temperature 20 C 68 F W O Cooling Fan Driven by hydraulic fan motor Alternator 24 V 6kw Exhaust System Complete attached Air Cleaner Installed Specifications for SD310 SPC000001 Page 9 ...

Page 54: ...A 8 220 mm 26 11 Dump Height to tooth H 3 110 mm 10 2 Overall Width B 3 004 mm 9 10 Dump Distance to Bucket Edge I 1 158 mm 3 9 Overall Height C 3 468mm 11 4 Dump Height to Bucket Pivot K 4 160 mm 13 8 Wheel Base E 3 190 mm 10 5 Max Dump Angle at Fully Raised a 48 Tread F 2 152 mm 7 1 Max Tilt Angle at Carry b 49 Ground Clearance G 424 mm 1 5 Tire Size 23 5 25 16 PR L3 SPC000001 Specifications for...

Page 55: ... cubic meter cubic yard of many types of workload materials APPROXIMATE WEIGHT OF WORKLOAD MATERIALS MATERIAL LOW WEIGHT OR DENSITY 1 100 KG M 3 1 850 LB YD 3 OR LESS MEDIUM WEIGHT OR DENSITY 1 600 KG M 3 2 700 LB YD 3 OR LESS HIGH WEIGHT OR DENSITY 2 000 KG M 3 3 370 LB YD 3 OR LESS Charcoal 401 kg m 3 695 lb yd 3 Coke blast furnace size 433 kg m 3 729 lb yd 3 Coke foundry size 449 kg m 3 756 lb ...

Page 56: ...arth DRY packed 1 522 kg m 3 2 565 lb y d 3 Earth WET muddy 1 762 kg m 3 2 970lb yd3 Gypsum calcined heated powder 961kg m 3 1 620 lb yd 3 Gypsum crushed to 3 inch size 1 522 kg m 3 2 565 lb y d 3 Gravel DRY packed fragments 1 810 kg m 3 3 051 lb y d 3 Gravel WET packed fragments 1 522 kg m 3 3 240 lb y d 3 Limestone graded above 2 1 282 kg m 3 2 160 lb y d 3 Limestone graded 1 1 2 or 2 1 362 kg m...

Page 57: ... 3 2 565 lb yd 3 Sand WET packed 1 922 kg m 3 3 240 lb yd 3 Shale broken 1 362 kg m 3 2 295 lb y d 3 Sulphur broken 529 kg m 3 891 lb yd 3 IMPORTANT Weights are approximations of estimated average volume and mass Exposure to rain snow or ground water settling or compaction due to overhead weight and chemical or industrial processing or changes due to thermal or chemical transformations could all i...

Page 58: ...SPC000001 Specifications for SD310 Page 14 ...

Page 59: ...11GENERAL MAINTENANCE ...

Page 60: ......

Page 61: ...e 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 MODEL SERIAL NUMBER RANGE ALL MODELS ALL RANGES Copyright 2011 DISD July 2011 General Maintenance Procedures S0302000 Page 1 ...

Page 62: ...enance 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 6 Cleaning and Inspection 7 General Guidelines 7 Bearing inspection 8 S0302000 General Maintenance Procedures Page 2 ...

Page 63: ...rocedures and equipment If repairs are performed incorrectly structural weakening or other damage to the machine that is not always readily visible could be caused Always consult DISD After Sales Service before welding on integral components loader arm frames car body track frames turntable attachment etc of the machine It is possible that some types of structurally critical repairs may require Ma...

Page 64: ...replace damaged components Hoses that are inadvertently switched during disassembly inlet for outlet and vice versa air introduced into the system or assemblies that are low on oil due to neglect or careless maintenance could all produce sufficient fluid loss to cause damage When starting the engine particularly after long layoff or storage intervals make sure that all hydraulic controls and opera...

Page 65: ...tion and darkening of the fluid Visible accumulations of dirt or grit could be an indication that filter elements are overloaded and will require more frequent replacement or that disintegrating bearings or other component failures in the hydraulic circuit may be imminent or have already occurred Open the drain plugs on the main pump casings and check and compare drain oil in the pumps Look for ev...

Page 66: ...or other fluids to mix with the oil in the system Use clean oil to flush any traces of solvent or other residue before reassembly If metal or rubber fragments are found in the system flush and replace all fluid in the system and troubleshoot the circuit to identify the source of contamination IMPORTANT Make sure that cleaning solvents will be compatible with rubber materials used in the hydraulic ...

Page 67: ...o dry bearings use moisture free compressed air Be careful to direct air stream across bearing to avoid spinning bearings that are not lubricated DO NOT SPIN BEARINGS WHEN DRYING bearings may be rotated slowly by hand to facilitate drying process 3 Carefully inspect all bearing rollers cages and cups for wear chipping or nicks to determine condition Do not replace a bearing cone or cup individuall...

Page 68: ...of its components for wear and damage Once the bearing is removed clean all parts thoroughly using a suitable cleaning solution If the bearing is excessively dirty soak the bearing assembly in a light solution and move the bearing around until all lubricants and or foreign materials are dissolved and the parts are thoroughly clean When drying bearings moisture free compressed air can be used Be ca...

Page 69: ... 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 General Maintenance Procedures S0302000 Page 9 ...

Page 70: ...ing away of material usually at roller spacing Replace bearings check seals and check for proper lubrication Misalignment Outer race misalignment due to foreign object Clean related parts and replace bearing Make sure races are properly seated Indentations Surface depressions on race and rollers caused by hard particles of foreign materials Clean all parts and housings check seals and replace bear...

Page 71: ...aring 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 lubrication Replace bearings check seals Abrasive Roller Wear Pattern on races and rollers caused by fine abrasives Clean all parts and housings check seals and bearings and replace if leaking rough or noisy General Maintenance Proced...

Page 72: ...page caused by poor fitting lubrication overheating overloads or handling damage Replace bearings clean related parts and check for proper fit and lubrication Replace shaft if damaged Frottage Corrosion set up by small relative movement of parts with no lubrication Replace bearing Clean all related parts Check seals and check for proper lubrication S0302000 General Maintenance Procedures Page 12 ...

Page 73: ...ut metal whereas a file drawn over a hard part will glide readily with no metal cutting Replace bearing if over heating damage is indicated Check seals and other related parts for damage Stain Discoloration Discoloration can range from light brown to black caused by incorrect lubrication or moisture if the stain can be removed by light polishing or if no evidence of overheating is visible the bear...

Page 74: ...S0302000 General Maintenance Procedures Page 14 ...

Page 75: ...se 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 MODEL SERIAL NUMBER RANGE ALL MODELS ALL RANGES Copyright 2011 DISD July 2011 Standard Torque S0309000 Page 1 ...

Page 76: ... 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 9 Other Uses for Torque Wrench Extension Tools 10 Tightening Torque Specifications Metric 10 S0309000 Standard Torque Page 2 ...

Page 77: ... 66 M14 x 1 5 4 10 29 65 4 30 31 10 6 60 47 73 5 70 41 22 8 30 60 03 7 50 54 24 11 10 80 28 12 50 90 41 13 00 94 02 18 50 11 26 22 00 158 12 M16 x Std 5 60 40 50 6 00 43 39 9 00 65 09 8 00 57 86 11 50 83 17 10 50 75 94 15 50 112 11 17 90 129 47 18 50 133 81 26 00 188 05 31 00 224 22 M16 x 1 5 6 20 44 84 6 50 47 01 9 70 70 16 8 60 62 20 12 50 90 41 11 30 81 73 17 00 122 96 19 50 141 04 20 00 144 66...

Page 78: ... thread surfaces are clean and lubricated with SAE 30 engine oil See Note 2 Joints are rigid that is no gaskets or compressible materials are used 3 When reusing nuts or bolts use minimum torque values NOTE Multiply the standard torque by 0 65 when finished jam nuts are used 0 70 when Molykote white lead or similar mixtures are used as lubricants 0 75 when parkerized bolts or nuts are used 0 85 wh...

Page 79: ...4 1 8 1 14 1 1 8 7 1 1 8 12 1 1 4 7 1 1 4 12 1 3 8 6 1 3 8 12 1 1 2 6 1 1 2 12 1 3 4 5 2 4 1 2 6 7 13 15 24 27 38 42 58 65 84 93 115 130 205 240 305 334 455 510 610 685 860 955 1130 1290 1400 1690 2370 3550 8 9 18 20 33 37 52 57 79 88 114 126 156 176 278 312 414 454 617 691 827 929 1166 1295 1532 1749 2034 2291 3213 4813 9 11 18 21 34 38 54 60 82 90 120 132 165 185 290 320 455 515 695 785 990 1110...

Page 80: ... following 1 Phosphate coated bolts used in tapped holes in steel or gray iron 2 Phosphate coated bolts used with phosphate coated prevailing torque nuts nuts with distorted threads or plastic inserts 3 Phosphate coated bolts used with copper plated weld nuts Markings on bolt heads or nuts indicate material grade ONLY and are NOT to be used to determine required torque NOMINAL THREAD DIAMETER STAN...

Page 81: ... TYPE AND SIZE TORQUE RADIATOR AIR CLEANER BOOTS ETC HYDRAULIC SYSTEM KILOGRAM METER kg m INCH POUNDS in lb KILOGRAM METER kg m INCH POUNDS in lb T Bolt Any Diameter Worm Drive Under 44 mm 1 3 4 in Open Diameter Worm Drive Over 44 mm 1 3 4 in Open Diameter Worm Drive All Ultra Tite 0 68 0 72 0 2 0 3 0 5 0 6 0 6 0 7 59 63 20 30 40 50 50 60 0 5 0 6 0 5 0 6 40 50 40 50 Standard Torque S0309000 Page 7...

Page 82: ...nd or bolts which may cause leakage FLANGE SIZE BOLT SIZE BOLT TORQUE KILOGRAM METER kg m INCH POUNDS in lb 1 2 3 4 1 1 1 4 1 1 2 2 2 1 2 3 3 1 2 5 16 3 8 3 8 7 16 1 2 1 2 1 2 5 8 5 8 2 1 2 5 3 0 3 7 3 7 4 8 4 8 6 2 6 4 8 0 7 6 9 0 10 9 12 6 19 1 20 7 16 2 18 4 15 18 22 27 27 35 35 45 46 58 55 65 79 91 138 150 117 133 Inside diameter of flange on end of hydraulic tube or hose fitting NOTE Values s...

Page 83: ... the torque wrench doubles the tightening force on the bolt It also halves the indicated reading on the scale or dial of the torque wrench To accurately adjust or convert indicated scale or dial readings use the following formula I A x T A B where I Indicated force shown on the torque wrench scale or dial T Tightening force applied to the nut or bolt actual Torque A Length of the torque wrench bet...

Page 84: ...embly or mechanism to accept a torque wrench welding a nut or other adapter on the end of a linkage shaft or other leverage point will allow turning the shaft or assembly manually TIGHTENING TORQUE SPECIFICATIONS METRIC For coated threads prelubricated assemblies CAUTION Disassembly overhaul and replacement of components on the machine installation of new or replacement parts and or other service ...

Page 85: ...Setup 545 No filler non clog formula for high pressure hydraulic systems Over application will not restrict or foul system components Purple Hand tools 4 Hours or 1 2 hour with Locquic T Primer 656 Solvent resistant higher viscosity tapered thread sealer White Hand tools 4 Hours or 1 2 hour with Locquic T Primer III Loctite gasket flange sealer Product Application Color Notes 518 Gasket eliminator...

Page 86: ...es to 232 C 450 F Green Same as 609 above 680 For high strength bonds and tight clearance gaps to 0 00008 mm 0 002 Green Same as 609 above V Loctite Adhesives Product Application Color Notes 380 Black Max instant adhesive for shock and vibration resistant bonds Black May take 120 hours to reach full cure strength 454 Adhesive for porous surfaces Clear Full strength in 24 hours 480 Increased streng...

Page 87: ...1FFRAME ...

Page 88: ......

Page 89: ...se 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 MODEL SERIAL NUMBER RANGE SD310 010001 and Up Copyright 2012 DISD July 2012 Counterweight SPC000003 Page 1 ...

Page 90: ...TABLE OF CONTENTS Specifications 3 Counterweight 3 SPC000003 Counterweight Page 2 ...

Page 91: ... and Up Counterweight 1 Parts list Fig 1 Reference Number Description Reference Number Description 1 COUNTERWEIGHT 9 PIN SPLIT 2 BOLT 10 WASHER PLAIN 3 WASHER HARDEN 11 PIN 4 PIN 12 NUT 5 COVER R H 13 WASHER PLAIN 6 COVER L H 14 RUBBER STOPPER 7 LOCK 15 HINGE 8 PLATE Counterweight SPC000003 Page 3 ...

Page 92: ...2 TORQUE Fig 2 NOTE 1 Tighten bolt to torque value list in the following table SD310 100 kg m 726 ft lb SPC000003 Counterweight Page 4 ...

Page 93: ...se 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 MODEL SERIAL NUMBER RANGE SD310 010001 and Up Copyright 2012 DISD July 2012 Center Joint Articulation Joint SPC000005 Page 1 ...

Page 94: ...TABLE OF CONTENTS General Description 3 Maintenance Standard 4 SPC000005 Center Joint Articulation Joint Page 2 ...

Page 95: ...ing 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 Before trying to service the loader make sure to set frame lock plate Prior to moving traveling the loader make sure the frame lock plate is set to original position Center Joint Articulation Joint SPC000005 Page 3 Figure 1 ...

Page 96: ...Maintenance Standard Figure 2 SPC000005 Center Joint Articulation Joint Page 4 LOWER HINGE BEARING UPPER HINGE BEARING ...

Page 97: ...ge 80 0 0 434 0 36 0 453 0 019 0 36 8 Clearance between front frame and spacer large 95 0 0 307 0 22 0 394 0 087 0 22 9 Clearance between lower hinge bearing and rear frame 140 0 0 0 04 0 02 0 02 0 04 10 Height of lower hinge spacer small 31 5 0 0 1 0 11 Height of lower hinge spacer large 56 0 0 1 0 12 Shim thickness for lower hinge and cap rear frame 0 5 1 0 13 Shim thickness for upper hinge and ...

Page 98: ...SPC000005 Center Joint Articulation Joint Page 6 ...

Page 99: ...1ENGINE AND DRIVE TRAIN ...

Page 100: ...SPC000006 ...

Page 101: ...ntained 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 MODEL SERIAL NUMBER RANGE SD310 010001 and Up Copyright 2012 DISD July 2012 5ton Diesel Engine SPC000006 Page 1 ...

Page 102: ...tenance 13 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 MAINTENANCE OF MAJOR COMPONENTS 90 4 1 Cooling System 90 4 2 Lubrication System 94 4 3 Fuel Injection Pump 97 4 4 Turbocharger 110 5 SPECIAL TOOL LIST 119 APPENDIX SPC000006 5ton Diesel Engine Page ...

Page 103: ...tion Cleaning Disassembly Pay close attention Important Reassembly Tighten to specified torque Align the marks Use special tools of manufatur s Directional Indication Lubricate with oil Inspection Lubricate with grease Measurement 5ton Diesel Engine SPC000006 Page 3 ...

Page 104: ...vary in hardness and design depending on position of installation 8 Clean the parts before inspection or reassembly Also clean oil ports etc using compressed air to make certain they are free from restrictions 9 Lubricate rotating and sliding faces of parts with oil or grease before installation 10 When necessary use a sealer on gaskets to prevent leakage 11 Carefully observe all specifications fo...

Page 105: ...very low level of hazardous exhaust gases such as smoke nitrogen oxide hydrocarbon or carbon monoxide and thus ensure high performance and low fuel consumption 1 2 3 Oil gallery cooling type piston DE08TIS Oil gallery cooling is used for the piston of DE08TIS diesel engine When thermal loading is high piston cooling by means of an oil gallery in the crown is normally necessary to prevent crown cra...

Page 106: ...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: ...00006 5ton Diesel Engine Page 8 REVOLUTION rpm ISO 1585 SAE J1349 Performance 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 FUEL CONSUMPTION g ps h POWER OUTPUT PS TORQUE kg m ...

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: ...ank shaft pulley 21 Crank shaft gear 22 Vibration damper 23 Oil pump 24 Oil suction pipe 25 Oil pan 26 Crank shaft 2 Piston 11 Cylinder block 3 Air compressor 4 Intake valve 12 Push rod 14 Ring gear 15 Tappet 16 Cam shaft 17 Fly wheel 18 Oil seal Rear 5 Exhaust valve 6 Breather 7 Cylinder head cover 8 Exhaust valve spring 9 Cylinder head 13 Flywheel housing ...

Page 111: ... charger 1 Fuel injection pipe 2 Fuel filter 10 Fuel injection pump 3 Fuel injection nozzle 4 Intake manifold 11 Timing gear case 12 Oil filler cap 5 Air heater 6 Rocker arm 13 Connecting rod 7 Rocker arm bracket 14 Oil spray nozzle 8 Exhaust manifold 15 Oil filter 16 Oil cooler ...

Page 112: ...ction pump 13 Starter 22 Crankshaft pulley 5 Air pipe From air cooler to intake manifold 14 Oil filler cap 23 Mounting bracket 6 Oil filter 15 Oil cooler 24 Cylinder head cover 7 Drain plug 16 Alternator 25 Cylinder head 8 Oil pan 17 Air compressor 26 Cylinder block 9 Air pipe From turbocharger to air cooler 18 Lifting hook Front 27 Flywheel SPC000006 5ton Diesel Engine Page 12 ...

Page 113: ...SAN 60 99901 0038 The density of antifreezing solution and additive for rust prevention is able to be confirmed by the cooling water test kit DOOSAN 60 99901 0038 How to use the cooling water test kit 1 When the cooling water temp of engine is in the range of 10 55 C loosen the plug for cooling water discharge and fill the plastic cup about a half Note In taking the cooling water sample if the wat...

Page 114: ...a fan belt of specified dimensions and replace if damaged frayed or deteriorated Check the fan belt for belt tension If belt tension is lower than the specified limit adjust the tension by relocating the alternator specified deflection 10 15 mm when pressed down with thumb 2 1 3 Engine oil Check oil level with the oil level gauge and replenish if necessary Check the oil level with the engine coole...

Page 115: ...cessary Change the oil filter cartridge simultaneously at every replacement of engine oil 2 1 5 Fuel filter Drain water in cartridge with loosening the cock under filter manually 6 from time to time 2 1 6 Air cleaner In case that elements are deformed damaged or if the air cleaner has a crack replace it By the definite interval the elements must be cleaned and replaced 5ton Diesel Engine SPC000006...

Page 116: ... air systems like air filter element are worn or polluted 2 1 8 Valve clearance adjust procedure After letting the 1 cylinder s piston come at the compression top dead center by turning the crankshaft adjust the valve clearances Loosen the lock nuts of rocker arm adjusting screws and push the feeler gauge of specified value between a rocker arm and a valve stem and adjust the clearance with adjust...

Page 117: ...of 1 cylinder 3 Rotating the crankshaft by one revolution 6 cylinder become the compression state of top dead center 4 Thereafter adjust the valve clearances corresponding to of lower figure 5 After reinsuring the valve clearances retighten if necessary No 1 cylinder is located at the side where flywheel was installed 2 1 9 Cylinder compression pressure Stop the engine after warming up and take ou...

Page 118: ...normal 2 1 11 Fuel injection pump Check the housing crack damage etc and replace it if abnormal Check if the idle operation and speed regulating lever s sealing is removed The adjustment and testing of fuel injection pump should necessarily be done at the test bench 2 1 12 Battery Inspect for any leakage of electrolytic solution owing to battery crack and replace the battery in case of poor condit...

Page 119: ...efully for nut or foreign material not to get in Periodic inspection should be applied on the compressed air and exhaust gas pipes For leaking air will bring the overheat engine an immediate repair must be done During the operation that is surrounded by the dust and oil mixed air frequent cleaning must be done on the impellers Tear down the impeller casing attention be careful not to bend and must...

Page 120: ... following description summarizes the probable cause of and remedy for generall failure by item Immediate 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: ...epair 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 For the analogous parts not the original parts are poor in qualities and gives illl performances it may rather bring early engine failure 5ton...

Page 130: ...order 3 1 2 Oil level gauge Pull out the oil level gauge 3 1 3 Cooling water Remove the radiator cap Open the drain plug at the radiator lower part to drain the coolant as the right figure Caution When removing radiator filler cap while the engine is still hot cover the cap with a rag then turn it slowly to release the internal steam pressure This will prevent a person from scalding with hot steam...

Page 131: ...fixing bolts then take off the flange and cooling fan 3 1 6 Belt Loosen the tension adjusting bolts of the alternator and the idle pulley and take off the belts 3 1 7 Thermostat Loosen the rubber hose connected to the cooling water pipe and remove the thermostat Remove the rubber hose of the bypass line 5ton Diesel Engine SPC000006 Page 31 ...

Page 132: ...ber hose Remove fuel filter fixing bolts and disassemble the fuel filter If the fuel filter is of cartridge type disassemble the cartridge element only 3 1 10 Breather Loosen the clamp screw to remove the rubber hose 3 1 11 Intercooler D1146TI DE08TIS Tear down the various hoses and air pipes from the inter cooler Remove the intercooler fixing bolts and tear it down SPC000006 5ton Diesel Engine Pa...

Page 133: ...e it Remove the oil cooler fixing bolts and take off the oil cooler 3 1 14 Oil filter Remove the oil filter assembling bolts and disassemble the oil filter assembly 3 1 15 Power steering pump Remove the oil hose between power steering oil pump and control unit of the vehicle Unscrew the power steering oil pump fixing bolts and remove the power steering pump 5ton Diesel Engine SPC000006 Page 33 ...

Page 134: ...dle pulley Unscrew the idle pulley fixing bolts and take off the idle pulley 3 1 18 Water pump Unclamp the rubber hose connected to the oil cooler Unscrew the water pump fixing bolts from the cylinder block and take off the water pump 3 1 19 Cylinder head cover Remove the head cover fixing bolts and lift the cylinder head cover SPC000006 5ton Diesel Engine Page 34 ...

Page 135: ...cylinder head and discard it 3 1 21 Turbo charger D1146TI DE08TIS Remove the oil supply pipe and oil return pipe between the turbo charger and the cylinder block Unclamp the rubber hose connected the intercooler and air cleaner Unscrew the turbo charger fixing nuts and take off the turbo charger from the exhaust manifold 3 1 22 Exhaust manifold Unscrew the exhaust manifold fixing nuts and remove t...

Page 136: ...do not come into the cooling water passage 3 1 25 Rocker arm Remove the rocker arm bracket fixing bolts in reverse order zigzag method of assembling and disassemble the rocker arm Take out the push rod upwards Disassembly of rocker arm assembly Remove the snap ring from the both ends of rocker arm shaft by means of a plier Remove the washer rocker arm bracket and spring from the rocker arm shaft i...

Page 137: ...ad each other Take out the cylinder head gasket and scrap it Remove the foreign residues from the cylinder head surface and block surface Caution Try not to make any damage on the contact surfaces Disassembly of cylinder head Place the cylinder head on a individual shelf As pressing the valve spring with a special tool remove the cotter pin valve spring Take out the intake and exhaust valves For r...

Page 138: ... damper assembly 3 1 29 Timing gear case cover Disassemble the oil seal using an oil seal removing jig Remove the cover fixing bolts and disassemble the cover from the timing gear case 3 1 30 Oil pump Unscrew the bracket fixing bolts of the oil suction pipe Unscrew the pipe fixing bolt of oil pump and disassemble the suction and supply oil pipe Unscrew the oil pump fixing bolts and disassemble the...

Page 139: ...irection of oil pan toward cylinder head disassemble the piston assembly The disassembled piston assembly should be handled to prevent bumping each other and stored as the cylinder s order In order for connecting rod cap not to be swapped temporarily assemble to the corresponding connecting rod Disassembly of piston 1 Remove the snap rings by means of a plier 2 Heat the piston with a electric heat...

Page 140: ...2 Cylinder liner Diassemble 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 Unscrew the camshaft gear fixing bolts and remove the camshaft gear SPC000006 5ton Diesel Engine Page 40 ...

Page 141: ... injection pump flange Unscrew the injection pump fixing bolts and remove the injection pump by lifting it up Remove the bracket fixing bolts of injection pump and disassemble by pulling the injection pump backward 3 1 35 Water chamber cover Unscrew the fixing bolts and remove the water chamber cover Remove the remnant gasket thoroughly 5ton Diesel Engine SPC000006 Page 41 ...

Page 142: ...mble the flywheel housing Disassemble the oil seal of flywheel housing 3 1 38 Injection pump drive gear Unscrew the drive gear housing fixing bolts and remove the drive gear assembly 3 1 39 Timing gear case Remove the timing gear case assembling bolts By tapping lightly with a urethane hammer the right and left back of timing gear case s connecting part disassemble the timing gear case SPC000006 5...

Page 143: ...revented from bends or damage put it on the special lathe and store Disassemble the metal bearings in turn and store them Note Do not mingle with the metal bearings and bearing caps randomly To prevent mixing temporarily assemble the metal bearings to the corresponding bearing caps in turn 3 1 42 Camshaft and tappet In order for camshaft not to be damaged disassemble turning it In order for the di...

Page 144: ...3 1 43 Oil spray nozzle D1146TI DE08TIS only Remove the valve screws of oil spray nozzle and disassemble it SPC000006 5ton Diesel Engine Page 44 ...

Page 145: ...f about 4kg cm2 to intake port and soak it in water for about 1 minute to check if there is any leakage Water temperature 70 C 3 2 2 Cylinder head 1 Cylinder head assembly disassembly 1 Disassemble the cylinder assembly and put it on the shelf for assembly or clean lathe Caution Prevent any damage to gasket s contact surface of the cylinder head 2 Disassemble the cotter pin spring spring seat push...

Page 146: ...inder head s distortion at 6 directions with horizontal ruler and clearance gauge If the measured value is beyond the limit value correct it by means of the fine grinding paper or grinding machine If it is beyond the max allowable value replace the cylinder head 3 Flatness Check the flatness of the installing surface of cylinder head s intake and exhaust manifolds with horizontal ruler and clearan...

Page 147: ... the valve seat contact surface for any crack and wear and if necessary correct with grinding paper and if excessive replace it Valve head thickness Measure the thickness of valve head and if beyond the limit value replace the valve 2 Valve guide Insert a valve into cylinder head and measure the clearance between valve guide and valve by valve movement If the clearance is excessive measure the val...

Page 148: ...f the contact surface with intake valve seat and exhaust valve seat If beyond the limit value replace the valve seat Assemble the valve at the valve seat of the cylinder head and check the amount of depression of the valve from the lower portion of the cylinder head using a dial gauge If the amount of depression is beyond the specified limit replace the valve seat SPC000006 5ton Diesel Engine Page...

Page 149: ... valve seat and lap the valve seat by turning it until it is seated in position then wipe out the lapping compound 4 Valve spring Visual check Check the appearance of valve spring and if necessary replace the spring Valve spring free length Use a vernier caliper to measure the valve spring free length If the measured value is less than the specified limit the valve spring must be replaced Valve sp...

Page 150: ...ide of cylinder head Coat engine oil to valve stem and valve guide and assemble the valve However be careful for the damage of valve stem seal Install the lower seat of valve spring to the valve guide of cylinder head After putting inner outer springs install the spring upper seat on it Assemble the valve by inserting the valve cotter pressing the valve spring with a special tool After installing ...

Page 151: ... with a bench press to correct the run out Replace the shaft if the measured value exceeds the limit Rocker arm shaft diameter With an outside micrometer measure the rocker arm shaft diameter at the point where the rocker arms have been installed Replace the rocker arm if the amount of wear is beyond the specified limit 2 Rocker arm Visual check Visually check the face of the rocker arm in contact...

Page 152: ...nce of the tappet and tappet holes of the cylinder block If the value is beyond the specified limit replace tappets Visual check of tappet Visually check the face of the tappets in contact with the cam for pitting scores or cracks and replace if severely damaged If the amount of cracks or pitting is small correct with an oil stone or grinding paper Outside diameter of tappet With an outside microm...

Page 153: ...g things should be heeded Check the oil supply hole of rocker arm shaft for any clog and clean thoroughly Be careful not to occur any swap of position and reverse assembly 3 2 4 Camshaft 1 Camshaft end play Push the thrust plate toward the cam gear With a feeler gauge measure the clearance between the thrust plate and camshaft journal If the end play is excessive replace the thrust plate 2 Cam Cam...

Page 154: ...nd camshaft bush With an outside micrometer measure the camshaft journal diameter Measure the inside diameter of the camshaft bushing on the cylinder block using a cylinder bore indicator and compare the measured value with the camshaft outside diameter to determine the clearance Replace the bushing if the measured value is beyond the specified limit Run out Support the camshaft on two V blocks an...

Page 155: ...ompare the measured values to determine the amount of wear If the amount of wear is beyond the limit have the crankshaft ground and install undersize bearings However if the amount of wear is within the limit you can correct the wear using an oil stone or oiled grinding paper of fine grain size Be sure to use grinding paper which has been immersed in oil In case that pin s wear is more than the li...

Page 156: ... and keep in mind to remove any jaws or coarse surface absolutely 3 Crankshaft run out Support the crankshaft on V blocks Turn the crankshaft with a dial indicator placed on the surface plate and take the amount of crankshaft run out 2 Crankshaft bearing and connecting rod 1 Visual check Visually check the crankshaft bearing and connecting rod bearing for scores uneven wear or damage 2 Oil clearan...

Page 157: ...iates from the specified range have the crankshaft journals and pins ground and install undersize bearings 3 Oil clearance between crankshaft and bearing Method 2 plastic gauge Assemble the crankshaft on the cylinder block and put plastic gauge on the journal and pin of crankshaft and then after assembling bearing cap tighten the bolts at the specific torque Again after disassembling the bearing c...

Page 158: ... to specified torque unscrew out one bolt completely then measure the clearance between the bearing cap and cylinder block using a feeler gauge Connecting rod bearing crush Install the bearing and cap in the connecting rod big end retighten the bolts to specified torque unscrew out one bolt completely then measure the clearance between the bearing cap and connecting rod big end using a feeler gaug...

Page 159: ...ion to the ring groove 2 Clearance between the piston and cylinder liner With an outside micrometer measure the piston outside diameter at a point 13mm away from the lower end of piston skirt in a direction at a right angle to the piston pin hole Using a cylinder bore gauge measure cylinder liner inside diameter at 3 points cylinder top ring contacting face middle and oil ring contacting face on B...

Page 160: ...d 2 Piston ring gap Insert the piston ring into the upper portion of the cylinder liner bore so that it is held at a right angle to the cylinder liner wall Measure the piston ring gap with a feeler gauge Replace piston rings with new ones if the gap is beyond the limit 3 Piston ring side clearance Fit the compression ring and oil ring in the piston ring groove With a feeler gauge measure side clea...

Page 161: ...ver damaged more if the measured value is beyond the limit 3 Condition check Check the engaged condition of the piston and piston pin If it is possible to force the pin into the piston heated with piston heater the piston is normal When replacing the piston be sure to replace the piston pin together 5 Connecting rod inspection 1 Distorsion Check the connecting rod for distortion As shown in the fi...

Page 162: ...de clearance using a feeler gauge Assemble the connecting rod to the piston and measure connecting rod small end side clearance If the measured values are beyond the limit replace the connecting rod 3 2 7 Fuel injection nozzle projection DE08TIS Insert a seal ring on the cylinder head and assemble the injection nozzle Measure the clearance between the cylinder head bottom and nozzle tip If the mea...

Page 163: ...reassembled Check the bolts for looseness after reassembly After completing the engine reassembly operation check if there is missing parts or shortage of parts Keep your hands clean during the working 3 3 2 Cylinder block Cover the floor of the workshop with wood plate or thick paper to prevent damage to the cylinder head and place the cylinder block with the head fitting surface facing downward ...

Page 164: ...em while turning the camshaft Caution Be careful not to generate a damage to camshaft and bush Check to see that the camshaft rotates smoothly 3 3 5 Crankshaft Install the main bearing refer to assemble sequence right figure machined with two holes in the cylinder block so that the key is aligned with the key groove then apply oil to the bearing surface SPC000006 5ton Diesel Engine Page 64 ...

Page 165: ...h sides of the crankshaft apply engine oil to journals and pins then assemble the crankshaft with the cylinder block by tightening the fixing bolts Caution Coat engine oil to the pin and journal of crankshaft Install the oiled thrust washers with the oil groove facing outward Install the bearing and thrust washers to the bearing cap and apply oil to the bearing and thrust washers 5ton Diesel Engin...

Page 166: ...s 3 Third stage With impact wrench tighten up to about 15 kg m 4 Fourth stage With torque wrench tighten up to about 25 kg m 5 Fifth stage By means of torque wrench tighten finally in the specified torque 30 kg m Tighten the bearing cap in the sequence of 4 3 5 2 6 1 7 Check to see that the assembled crankshaft turns smoothly with hand 3 3 6 Flywheel housing Temporarily install the guide bar on th...

Page 167: ...nd adjust 3 3 7 Oil seal Rear side Apply lubricating oil to the outside of the oil seal and flywheel housing inside diameter and fit them over the crank shaft then assemble the oil seal using an oil seal fitting jig 3 3 8 Flywheel Installation of flywheel ring gear With a gas burner heat the ring gear evenly until heat expansion takes place then install it using a hammer Caution Do not allow the t...

Page 168: ... the hole where the guide bar had been inserted According to the order of tightening tighten the fixing bolts using a torque wrench in a diagonal sequence to specified torque 3 3 9 Magnetic pick up sensor Move the lock nut to hexagonal side of sensor completely Rotate Clockwise the pick up sensor on fly wheel housing until the end of it reach on fly wheel ring gear Then rotate Counter clockwise th...

Page 169: ...wheel faces downward Thoroughly clean the liner flange fitting surface and bore inside with compressed air to prevent the entry of foreign substances After the cleaning operation make the cylinder liner dried up and push it into the cylinder block by hand Wet the liner inside diameter with engine oil 3 3 12 Piston and connecting rod Use a piston heater to heat the piston approximately 100 C 212 F ...

Page 170: ...curely assembled Install the piston ring in the piston using piston ring pliers Identify the mark Y or TOP on the ring end to prevent the top and bottom of the piston ring from being interchanged and make the marked portion face upward The surface marked as Y is upper surface Adjust the angle among individual piston ring gaps to 90 and fit a piston assembling jig onto the piston Use care not to ma...

Page 171: ...ng rod cap and connecting rod big end are identical and install the connecting rod cap by aligning it with dowel pin Wet the fixing bolts with engine oil semi tighten them with hand tighten them to the specified torque using a torque wrench as follows Tightening order 1 First stage Coat engine oil over bolts 2 Second stage Temporary bolt screwing about 1 2 threads 3 Third stage With torque wrench ...

Page 172: ...pin and then assemble it by tapping lightly with an urethane hammer to the right and left Particularly around dowel pin Tighten the bolts for assembling to the specified torque However in case of tightening the bolts tighten primarily the bolts of both end parts and then do the rest 3 3 14 Timing gear and idle gear pin Install the oil pump idle gear onto the No 7 bearing cap Install a thrust washe...

Page 173: ... Check and adjust the amount of backlash between gears using a feeler gauge 3 3 15 Injection pump flange After assembling the fuel injection pump gear to the idle gear tighten the assembling bolts of the injection pump flange Mount gasket by aligning the bolt holes with the pin holes on the bearing housing Turning the flywheel adjust the pointer to the position of the engraved scale After adjustin...

Page 174: ...ection of engine rotation Disassemble the fuel injection pipe that connect the fuel injection pump and 1 injection nozzle Disassemble the f el injection pump delivery valve holder and after removing the valve and valve spring again assemble the valve holder and then on it assemble the pipe of U shape on it Operating the priming pump of supply pump turn the crankshaft slowly in the direction of eng...

Page 175: ...plunger at the rate of a drop for 6 8 sec tighten the driving gear fixing bolt of fuel pump After the adjustment of injection timing disassemble the U shape pipe the delivery valve and the valve spring Turn the coupling until the notch mark of the indicator plate attached to the fuel injection pump is aligned with the notch mark of the coupling Tighten the coupling fixing bolts and nuts to specifi...

Page 176: ...ing bolt holes with those on the gasket Align the dowel pin with the cover pin hole then install the cover with light tap Tighten the fixing bolts beginning with the oil pan fitting face Caution In the assembling be careful not to be damaged by the crankshaft 3 3 19 Front oil seal Apply lubricating oil to the outside of the oil seal and the oil seal hole of the timing gear case cover Put the new o...

Page 177: ...tightening the assembling bolts at the specified tightening torque according to bolt tightening order refer to right figure 3 3 22 Oil pan Remove the gaskets thoroughly that project at the timing gear case case cover of cylinder block and the contacting part of flywheel housing by means of a scraper Caution Be careful for the gasket pieces not fall into the engine during the work Coat the silicone...

Page 178: ... filter Install the oil filter onto the cylinder block and tighten the fixing bolts Apply engine oil to the oil filter cartridge o ring and assemble the cartridge using a filter wrench 3 3 24 Oil cooler Install the gasket on the cylinder block Assemble the oil cooler by tightening the assembling bolts Connect the cooling water pipe with the cooling water pump and tighten a hose clamp 3 3 25 Starte...

Page 179: ...all the cotter pin Tap the valve stem lightly with a rubber hammer to check that the valve is assembled correctly 3 3 27 Cylinder head Blow the bolt holes of cylinder block with a compressed air and remove the foreign matter Clean the head gasket contact surface thoroughly Caution However be careful for the foreign material not to enter into the combustion chamber Assemble the new head gasket by a...

Page 180: ...hten in proper sequence to the specified torque according to bolt tightening order refer to the figure However before tightening bolts the side parallel degree between cylinder heads should be adjusted Tightening order of bolts by steps 1 First stage Coat the bolts with engine oil 2 Second stage Tighten 1 2 threads with hands 3 Third stage Tighten at about 6 kg m with a wrench 4 Fourth stage Tight...

Page 181: ...the described sequence Install the rocker arm and bracket in the same direction Adjust the valve clearance as following guide Guide for valve clearance adjustment By turning the crankshaft when the intake and exhaust of 6 cylinder the sixth cylinder from the flywheel overlap that is when 1 cylinder s piston come at the compression top dead center OT adjust the valve clearances by mark indicated Af...

Page 182: ...n in cold Caution 1 Crankshaft revolution is done by hands without using a starting motor 2 Turn it to the direction of engine rotation but do not use the installing bolts at the turn 3 The cylinder no and the order of intake and exhaust can be determined from the crank shaft pulley Adjust valve clearance with a feeler gauge and tighten the fixing nuts to specified torque 3 3 29 Intake manifold Pu...

Page 183: ... from the middle to left and right alternately Caution For upper and lower bolts differ in the length so use the correct bolts 3 3 31 Turbocharger D1146TI DE08TIS Fit a new gasket over the stud bolts of the exhaust manifold before tightening those turbocharger fixing nuts Install the oil supply pipe and return pipe Tighten the clamps of rubber hose that is connected air pipe to the intercooler 3 3...

Page 184: ...driving dog engaged Insert the O ring coated with grease into the oil outlet of the air compressor Place the air compressor on the mounting bracket carefully and tighten the fixing bolts to the specified torque Carefully damage the O ring Assemble the oil feed pipe 3 3 35 Alternator Install the alternator mounting bracket and supporter to the cylinder block then tighten the fixing bolts Install th...

Page 185: ... the cylinder head As aligning the ball of nozzle with a groove in the nozzle hole Insert the nozzle into the cylinder head and tighten the nozzle 3 3 38 Fuel injection pipe Semi assemble a nut at both ends of the fuel injection pipe and tighten them up one by one to specified torque Assemble the fuel return pipe on the nozzle holder Connect the injection pump lubricating oil pipe with a hollow sc...

Page 186: ... breather and breather hose Fit the oil filler cap on the cylinder head cover 3 3 40 Cooling fan Install the flange to the water pump pulley then assemble the cooling fan to the pulley by tightening the fixing bolts 3 3 41 Belt Install the V belt on the crank pulley alternator pulley and water pump pulley Adjust the V belt tension using the tension adjusting support SPC000006 5ton Diesel Engine Pa...

Page 187: ...oints with the pulley T 0 015 X S about 1 5 mm per 100mm 3 3 42 Oil level gauge Apply sealant Locktite 262 to the bottom side of the guide tube Then assemble the guide tube and oil level gauge on the oil pan 3 3 43 Others Assemble by connecting the other oil and fuel hoses 5ton Diesel Engine SPC000006 Page 87 ...

Page 188: ...ded High speed operation with no load should be prevented Abrupt start and stop of the engine should be avoided Engine speed must be under 70 of its maximum speed Maintenance and inspection must be accomplished thoroughly 3 4 3 Check points for break in During the break in the initial running of the engine period be particularly observant as follows a Check engine oil level frequently Maintain oil...

Page 189: ...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 Refer to following table If long oil change intervals are to be used ACEA E3 oil must be used 5ton Diesel Engine SPC000006 Page 89 ...

Page 190: ...bing 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 opening temperature At the radiator the heat absorbed in the coolant is radiated to cool down and the coolant re...

Page 191: ...is closed and the water passage to the radiator is opened so that the coolant is forced to flow into the radiator Caution There are 3 kinds of thermostats according to surrounding and operating conditions One is named by 71 C 79 C type and the other is 83 C Inspecting 1 Check the wax pallet and spring for damage 2 Put the thermostat in a container of water then heat the water slowly and check temp...

Page 192: ...llet type thermostat Therefore to avoid a sharp rise of coolant temperature it is essential to idle the engine sufficiently before running it In cold weather do not run the engine at overload or overspeed it immediately after starting off 2 When draining out or replenishing coolant do it slowly so that air is bled sufficiently from the entire cooling system 3 Replacing thermostat If the thermostat...

Page 193: ...4 1 4 Diagnostics and troubleshooting 5ton Diesel Engine SPC000006 Page 93 ...

Page 194: ...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 Specifications Diagram of lubricating system SPC000006 5ton Diesel Engine Page 94 ...

Page 195: ...disassemble the oil pump cover The oil pump cover is fixed with the two dowel pins 3 Disassemble the drive gear and driven gear Inspection and correction 1 With steel rule and feeler gauge measure the axial end play of the oil pump gear Replace if the measured value is beyond the limit 2 With a feeler gauge measure the amount of backlash between the oil pump drive gear and driven gear Replace if t...

Page 196: ...s 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 Reassembly 1 For reassembly reverse the disassembly sequence 4 2 3 Diagnostics and troubleshooting SPC000006 5ton Diesel Engine Page 96 ...

Page 197: ...ng 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 Make sure that servicing should be performed at the professional maintenance shop as authorized by Bosch or Zexel Company For adjustment of fuel injection volume refer to the Specifications of fuel injection pu...

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: ... is driven by the push rod and tappet via the camshaft of injection pump and performs reciprocating operation to control the suction and delivery of fuel When the cam reaches the Bottom Dead Center as shown in the figure the fuel is drawn in through the check valve on the inlet side The fuel pressurized as the cam rotates on flows through the check valve on the outlet side as shown in B If the fee...

Page 203: ...ing 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 In addition a strainer is fitted into joint bolt on the inlet side of the fuel feed pump to filtrate any foreign substances possibly mixed in fuel 5ton Diesel Engine SPC000006 Page 103 ...

Page 204: ...ke off the tappet 10 and push rod 1 3 Inspection If the check valve is damaged or scored on its seat face replace it with a new one Inspect the piston and tappet for damage Replace the push rod if excessively worn and replace together with the pump housing if required The inspection for wear should be performed in the same procedure as for suction pressure test described below 4 Reassembly Reassem...

Page 205: ...eck to see if fuel is drawn in and delivered for 40 seconds or so 2 Delivery test Make a test with the feed pump mounted on a pump tester as illustrated Operate the pump at the rate of 1 000 rpm and check to see if the pump delivery is more than 405 cc 15 seconds 3 Sealing test Plug up the delivery port on the feed pump and apply compressed air of 2 kg cm2 into the inlet side Submerge the feed pum...

Page 206: ...ctive engine performance 2 Construction 3 Disassembly Clamp the nozzle assembly and remove the nozzle holder Remove the nozzle nut and components inside 4 Inspection Visually inspect the disassembled components for damage 5 Reassembly After removing carbon deposit submerge the nozzle in diesel oil and clean it Replace all the seal rings with new ones Assemble the parts and tighten them to specifie...

Page 207: ...sure to the standard pressure by spring tension shims After adjusting the injection pressure tighten the cap nut to specified torque Re check the injection pressure and see if the spray pattern is normal Spray pattern should be uniform and free of spattering 7 Testing With the nozzle assembled to a nozzle tester and specified pressure applied check the nozzle for fuel leakage 5ton Diesel Engine SP...

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: ...el completely should be supplied into the cylinders Therefore the engine output is determined substantially by the cylinder capacity and a greater volume of compressed air is charged into cylinders of given capacity the greater engine output can be obtained as a greater volume of air charged into the cylinders burns so much more fuel As explained the compressing of air to supply into the cylinders...

Page 213: ... is delivered to the intake stake This is the operating principle of the compressor 3 Bearings 1 Thrust bearing The turbine wheel creates thrust force Therefore exercise care so that the shaft is not deviated from its the original position due to this thrust 2 Journal bearing This journal bearing of floating type forms a dual oil film on both the inside and outside of the bearing so that the beari...

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: ...ixing portions etc lowers charging effect As such components as turbine chamber that becomes red hot during operation use heat resisting steel nuts do not interchange these nuts with ordinary steel nuts In addition apply anti seizure coating to fixing nuts on the portions as designated 3 Fuel system If the full load stopper regulating the maximum injection volume and the maximum speed stopper regu...

Page 216: ...sing and increase the engine revolutions slowly If a high pitch sound is heard continuously it means that the rotor assembly is not normal In this case as the metal bearing and rotor are likely to be in abnormal conditions the turbocharger should be replaced or repaired 2 Guide for checking rotor end play Disassemble the turbocharger from the engine then check the rotor axial play and radial play ...

Page 217: ...ne inject new oil in the oil inlet port and lubricate the journal and thrust bearings by rotating them with hand Clean not only the pipes installed between the engine and oil inlet port but also the oil outlet pipe and check them for damage or foreign matters Assemble each joint on oil pipes securely to prevent oil leaks 2 Intake system Check the inside of the intake system for foreign matters Ass...

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 Tightening torque for major parts Tightening torque for fuel injection pump system 5ton Diesel Engine SPC000006 Page 121 ...

Page 222: ...imit value for bolt elasticity 2 Tension is calculated by multiplying tensile strength by cross section of thread 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 Tightening torque for hollow screw 4 hole Adopted in DOOSAN engine SPC000006 5ton Diesel Engine Page 122 ...

Page 223: ... Maintenance 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: ...se 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 MODEL SERIAL NUMBER RANGE SD310 010001 and Up Copyright 2012 DISD July 2012 Transmission and Torque Converter SPC000007 Page 1 ...

Page 230: ...ews 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 ELECTRO HYDRAULIC GEARBOX CONTROL 12 2 TORQUE CONVERTER 75 3 GEARBOX 86 4 RETARDER 166 5 AXLE DELCLUTCH 179 6 AXLE DIFFERENTIAL 190 7 POWER TAKE OFF CONTROLLABLE UNDER LOAS 211 SPC000007 Transmission and Torque Converter Page 2 ...

Page 231: ...l The Service Stations established by the Zahnradfabrik Friedrichshafen all over the world offer you I Constantly trained personnel 2 Prescribed installations e g Special Tools 3 Genuine ZF Spare Parts according to the latest phase of development Here all operations are carried out for you with utmost care and realibity Repair operations carried out by ZF Service Stations arc covered additionally ...

Page 232: ...st be checked by the skilled Serviceman He will decide if the parts can be reused For the heating of bearings etc hot plates rod healers or heating furnaces must be used Never heat parts directly with the flame An auxiliary solution would be to immerse the bearing in a vessel filled with oil which is then heated with the flame In this way damage to the bearings could be avoided Ball bearings cover...

Page 233: ...ules 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 The proper Repair of these ZF Products requires especially trained personnel The Repairer himself is obliged to provide for the training Transmission and Torque Converter SPC000007 Page 5 ...

Page 234: ... Conversion Bemerkungen Note Note Masse Mass Mass m kg Kilogramm kg Kraft Force Force F N Neweton Kp 1 kp 9 81 N Arbeit Work Travail A J Joule kpm 0 102 kpm 1J Nm Leistung Power Puissance P KW Kilowatt PS DIN 1 PS 0 7355 KW 1 KW 1 36 PS Drehmoment Torque Couple T Nm kpm Newtonmeter 1 pkm 9 81 Nm T Nm F N r m Kraftmoment Moment Force Moment Fore M Nm kpm Newtonmeter 1pkm 9 81Nm M Nm F N l m Druck U...

Page 235: ...456 Liter 1 Liter 3 785 Liter 1609 344 m 0 C Celsius 0 C Celsius 1 in inch 2 205 lb poubds 7 233 ibf x ft pound force foot 1 Ibf x ft pound force foot 5 560 lb in pound per inch 14 233 psi pound force per squar inch IbfTin 1 psi Ibf in 0 264 Gallon Imp 1 Gallon Imp 0 220 Gallon US 1 Gallon US 1 Mile Landmeile 32 F Fahrenheit 273 15Kelvin Transmission and Torque Converter SPC000007 Page 7 ...

Page 236: ... 670 960 1120 M27 1000 1400 1650 M30 1350 1900 2250 M33 1850 2600 3000 M36 2350 3300 3900 M39 3000 4300 5100 Metric ISO Fine Tread DIN 13 Page 13 Abmessung 8 8 10 9 12 9 M8X1 24 6 36 43 M9X1 36 53 62 M10X1 52 76 89 M10X1 25 49 72 84 M12X1 25 87 125 150 M12X1 5 83 122 145 M14X1 5 135 200 235 M16X1 5 205 300 360 M18X1 5 310 440 520 M18X2 290 420 490 M20X1 5 430 620 720 M22X1 5 580 820 960 M24X1 5 76...

Page 237: ...he ZF Torque Converter NOTES REGARDING THE SPARE PARTS ORDERS When ordering genuine ZF Spare Parts please indicate 1 Gearbox type 2 Serial No See Model Identification Plate 3 ZF Parts List No 4 Mark and type of vehicle 5 Denomination of the spare part 6 Spare parts No 7 Way of transport When all of the above required indications are considered errors in the delivery of spare part order can be avoi...

Page 238: ...eedometer connection 12 Inter axle differential 13 Axle drive flange mounted 14 Multi disc clutch for 4 5 and 6 speed version 15 Emergency steering pump 16 PTO unit engine driven 17 Transmission control 18 Steering column switch SG 4 S G 6 19 Console switch SG 4 SG 6 20 Rotary reversing switch DW 1 21 Automatic control unite EST 2 22 Inching valve 23 Dual pressure control valve 24 Pressure cut out...

Page 239: ...ils SAE 20 W 20 SAE 15 W 40 SAE 10 W 10 W 30 10 W 40 ATF 10 C 15 2 0 C 30 C 5 C 0 C 5 C 10 C The minimum oil temperature for starting the vehicle moving can be achieved by at least 20 minutes warm up m Neutral setting preheating At greasing points use a multi purpose grease with the following properties lithium soap drop point above 170 NLGI Class 2 The grease must be anti corrosive water resistan...

Page 240: ...be carried out without agreement of ZF Therefore the repair of gearbox control units should be carried out by ZF Service stations only The relative shop equipment of our Service stations gearbox control resp transmission test benches as well as constantly trained personnel ensure a professional repair The following Disassembly and Reassembly Instructions Page 1 01 1 73 will therefore be useful onl...

Page 241: ...F Filling time Δ t1 Modulation time Δ t3 Modulation time in dependence with 2 stage pressure control valve Diagram 2 Basic diagram Pressure control curve WK p Modulation start p Modulation end t1 Filling time t2 Modulation time ATTENTION The pressure control curve is different according to the Transmission Version resp the vehicle type and will be adjusted by means of corresponding shims and diaph...

Page 242: ...rbox control e g 4 magnets Measuring points for pressure oil 65 Central measuring point for system pressure control pressure 53 Clutch KV 55 Clutch KR 55 Clutch KR in case of 5 mangnet Version 56 Clutch K1 57 Clutch K2 58 Dutch K3 60 Clutch K4 60 Clutch K4 in case of 5 magnct Version L3 Aluminium die cast gearbox control Measuring points for pressure oil 65 Central measuring point for system press...

Page 243: ...et head screws install two adjusting screws Arrows and remove shift control housing Now remove gaskets and intermediate plate S Adjusting screws M8 5870 204 011 Now remove gaskets and intermediate plate Remove delivery lines Loosen socket head screws and separate channel plate as well as gaskets and intermediate plate from the gear case Transmission and Torque Converter SPC000007 Page 15 Figure 1 ...

Page 244: ...crews and fix shift control housing provisionally using Special Tool S Now loosen the remaining hex head screws and separate cover is spring loaded from the valve body by uniform loosening of the nuts S S Adjusting screws M5 5870 204 036 with nut S Adjusting screws M6 5870 204 049 with nut SPC000007 Transmission and Torque Converter Page 16 Figure 6 Figure 7 Figure 4 Figure 5 ...

Page 245: ...nd 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 Transmission and Torque Converter SPC000007 Page 17 Figure 10 Figure 8 Figure 9 ...

Page 246: ...or 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 Install stop plate 5 NOTE Pay attention to the installation position of the various stop plates see Figure on the right SPC000007 Transmission and Torque Converter Page 18 Figure 15 ...

Page 247: ...14 Install two adjusting screws S and mount flat gasket Place cover against shoulder using nuts S Now fasten cover by means of 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 Install components 1 Valve body 2 Spring L 72 5 mm 3 Spool 3 control surfaces 4 Spring L 72 5 mm 5 Spool 5 control surfaces 6 Spring L 72 5 mm 7 Spool ...

Page 248: ... position of the solenoid valves see Figure 21 Install cable harness mount new gaskets fasten ground cable and connect solenoid valves Figure 20 NOTE Pay attention to the location of the plug nose see Arrow Figure 21 Mount new O Ring 164 2 x 5 7 and fix cover by means of clamping collar SPC000007 Transmission and Torque Converter Page 20 Figure 19 Figure 20 Figure 21 Figure 22 ...

Page 249: ... additionally by means of center punch Now clean diaphragm from Loctite residues by means of compressed air Install diaphragm for the backfeed Position see Arrow 2 accordingly Insert thread plug 3 with Loctite Type No 270 Employ new sealing ring for connecting plug 4 and screw plug Position see Arrow 5 and install them Insert the two check valves composed of balls and springs in the channel plate ...

Page 250: ...on to a correct position of the ball seat valves Pay attention to the position of the various screws see corresponding Spare Parts List Assemble 1st gasket NOTE Pay attention to the different gaskets see Figure 28 and 29 Install intermediate plate and 2nd gasket SPC000007 Transmission and Torque Converter Page 22 Figure 27 Figure 28 Figure 29 Figure 26 ...

Page 251: ...8 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 delivery lines see Perspective Illustrations in the corresponding Spare Parts List Transmission and Torque Converter SPC000007 Page 23 Figure 30 ...

Page 252: ...SPC000007 Transmission and Torque Converter Page 24 ...

Page 253: ...Transmission and Torque Converter SPC000007 Page 25 ...

Page 254: ...DISASSEMBLY Remove delivery line S Adjusting screws M8 5870 204 011 Relax spring clip and remove cover Pull oil cable shoes and remove cable harness Loosen socket head screws and remove solenoid valves Remove components see Figure on the right SPC000007 Transmission and Torque Converter Page 26 Figure 36 Figure 37 Figure 38 Figure 35 ...

Page 255: ...l housing is spring loaded from the valve body by uniform loosening of the nuts S S Adjusting screws M5 5870 204 036 with nut S Adjusting screws M6 5870 204 049 with nut Dismantle pressure control valve Remove components Remove stop plates Arrows and demount detent blocks 2x Transmission and Torque Converter SPC000007 Page 27 Figure 39 Figure 41 Figure 42 Figure 40 ...

Page 256: ...il components prior to the reassembly Close the bores by means of balls 8 pieces Φ 4 50 mm Introduce detent blocks 1 and 2 into the bores and fix them by means of stop plates 3 and 4 Install detent block 5 NOTE Pay attention to the installation position Install components 1 Spool total length 86 00 mm 2 Spring Lo 53 40 mm NOTE L o Length of the unloaded spring SPC000007 Transmission and Torque Con...

Page 257: ...l components 1 Spring Lo 78 60 mm 2 Spring Lo 65 40 mm 3 Disk s empirical value s 3 00 mm 4 Disk s empirical value s 1 00 mn NOTE ps is deter mind by the disks 3 and 4 pay attention to Notes Page 12 14 Pre assemble 2 stage pressure control valve Figure 51 53 Install diaphragm optional NOTE Wet thread of diaphragm with Loctite Type No 270 Δ t1 is determined by the diaphragm pay attention to Notes P...

Page 258: ...ttention to Notes Page 12 14 Close the bore by means of ball Φ 5 mm s e e Arrow Install components and fix them by means of socket head screws and flat washers Figure 54 and 55 1 Gasket 2 Housing assembly 3 Ring optional 4 Spool 5 Gasket 6 Cover 7 O Ring 8 Screw plug NOTE Δ t3 is determined by the ring 3 pay attention to Notes Page 12 14 Torque limit M5 8 8 5 5 Nm S Adjusting screws M5 5870 204 03...

Page 259: ...the solenoid valves and fix them by means of retaining plate and socket head screws Torque limit M5 8 8 5 5 Nm Insert the solenoid valves and fix them by means of retaining plate and socket head screws Torque limit M5 8 8 5 5 Nm NOTE Pay attention to the radial installation position of the solenoid valves see Figure 59 Install cable harness NOTE Mount new gaskets Pay attention to the location of t...

Page 260: ... to the gearshift Version different channel plate variants are possible Pay attention to the Perspective Illustration of the corresponding Spare Parts List The following Reassembly Instruction is treating the Version with diaphragm for the backfeed without control diaphragm Wet thread of diaphragm with Loctite Type No 270 install diaphragm Position see Arrow 1 and secure it additionally by means o...

Page 261: ...n to the installation position of the components see corresponding Spare Parts List Install two adjusting screws Assemble housing gasket intermediate plate and gasket S Adjusting screws M8 5870 204 011 Assemble channel plate and fasten it by means of socket head screws Torque limit 20 Nm NOTE Pay attention to the installation position of the different socket head screws see corresponding Spare Par...

Page 262: ...s List 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 the Spare Parts List NOTE Mount new sealing rings SPC000007 Transmission and Torque Converter Page 34 Figure 68 Figure 67 ...

Page 263: ...Transmission and Torque Converter SPC000007 Page 35 ...

Page 264: ...SPC000007 Transmission and Torque Converter Page 36 ...

Page 265: ...hed WK Valve 1 2 2 1 DISASSEMBLY Relax spring clip and remove cover Pull off cable shoes Loosen socket head screws and remove solenoid valves Remove components Transmission and Torque Converter SPC000007 Page 37 Figure 75 Figure 76 Figure 77 Figure 78 ...

Page 266: ...nd separate shift control housing is spring loaded from the valve body by uniform loosening of the nuts S S Adjusting screws M5 870 204 036 with nut S Adjusting screws M6 5870 204 049 with nut Remove components Remove stop plates see Arrows and demount the remaining components SPC000007 Transmission and Torque Converter Page 38 Figure 79 Figure 80 Figure 81 Figure 82 ...

Page 267: ... spool 2 and spring 3 Lo 51 3 mm and fix them by means of the stop plate 5 Install spool 6 spring 7 Lo 53 4 mm and detent block 8 and fix them by means of the stop plate 9 Insert detent block 10 NOTE Pay attention to the installation position of the different stop plates see Figure on the right Gearshift valve Install components 1 Spring Lo 53 40mm 2 Spool Reset spool Install components 1 Spool 2 ...

Page 268: ...e and attach shift control housing WK Figure 89 92 Close the two bores by means of balls and install diaphragm 1 Bail Φ 4 50 mm 2 Diaphragm optional 3 Ball Φ 7 00 mm NOTE Secure diaphragm by means of Loctite Type No 270 Now clean diaphragm from Loctite residues by means of compressed air I t2 Modulation time WK is determined by the diaphragm 2 pay attention to Notes Page 12 14 Install two adjustin...

Page 269: ... with O Ring NOTE p2 is determired by the disk 6 pay attention to Notes Page 12 14 I Install components 1 Shift control housing 2 Spring Lo 51 30 mm 3 Spool 4 Spool 5 Spring Lo 37 10 mm 6 Spool fixing retaining plate and socket head screw 7 Spring Lo 53 40 mm 8 Spool 9 Retaining plate and socket head screw 10 Solenoid valves 5x NOTE Pay attention to the installation position of the solenoid valves...

Page 270: ...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 32 34 Pay attention to the Perspective Illustration of the corresponding Sparc Parts List S Adjusting screws M8 5870 204 011 SPC000007 Transmission and Torque Converter Page 42 Figure 96 Figure 95 Figure 97 ...

Page 271: ...Transmission and Torque Converter SPC000007 Page 43 ...

Page 272: ...SPC000007 Transmission and Torque Converter Page 44 ...

Page 273: ...MBLY S Adjusting screws 5870 204 011 Relax spring clip and remove cover Pull off the cable shoes loosen socket head screws and remove cable harness Loosen socket head screws and demount solenoid valves Transmission and Torque Converter SPC000007 Page 45 Figure 100 Figure 102 Figure 101 ...

Page 274: ... see Figure on the right Loosen two socket head screws and fix the shift control housing provisionally using a Special Tool S Now loosen the remaining socket head screws and separate cover is spring loaded from the valve body by uniform loosening of the nuts S S Adjusting screws M6 5870 204 049 with nut SPC000007 Transmission and Torque Converter Page 46 Figure 104 Figure 106 Figure 105 Figure 103...

Page 275: ...e right Remove stop plate and demount spring as well as spool NOTE Installation position of the stop plate see Arrow Remove diaphragm and check valves Transmission and Torque Converter SPC000007 Page 47 Figure 108 Figure 109 Figure 107 ...

Page 276: ...pieces and install them Install check valves and diaphragm optional NOTE Mount new O Rings Fasten O Ring 6 x 1 5 mm Arrow with grease on the end face of the diaphragm makes the reassembly easier Use only oil soluble grease for the reassembly Δ t1 is determined by the diaphragm pay attention to Notes Page 12 14 Torque limit Screw plug Ml10x 1 20 Nm Screw plug Ml8x1 5 35 Nm Diaphragm 20 Nm Close the...

Page 277: ...7 10 mm 4 Disk 5 Disk s optional 6 Displacement spool NOTE Install disk with the countersinking facing the compressison spring P1 is determined by the disk 5 pay attention to Notes Pages 12 14 Reversing valve Install components 1 Reversing spool 2 Spring L0 5 6 3 0 mm Control spool KV Install components 1 Spool total length 55 50 mm 2 Spring L0 51 30 mm Transmission and Torque Converter SPC000007 ...

Page 278: ...nnecting piece NOTE Install detent block 7 with the countersinking facing the spring p2 is determined by the disk 5 pay attention to Notes Page 12 14 Install two adjusting screws and assemble flat gasket Arrow Fasten shift control housing and cover by means of socket head screws mount flat washers Torque limit M6 8 8 9 5 Nm S Adjusting screws M6 5870 204 049 with nut Mount new O Rings Arrows and f...

Page 279: ...length 52 50 mm Insert 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 disks mount between valve body and retaining plate see Arrow Pay attention to the radial installation position of the solenoid valves see also Figure 124 Install cable harness Torque limit M6 8 8 9 5 Nm NOTE ...

Page 280: ...le and attach channel plate Figure 126 129 Mount connecting pipe 1 and screw plug 2 Install two adjusting screws and assemble housing gasket NOTE Pay attention to the different gaskets see Figure 127 and 128 S Adjusting screws M8 5870 204 011 SPC000007 Transmission and Torque Converter Page 52 Figure 125 Figure 126 Figure 127 Figure 124 ...

Page 281: ...Use only socket head screws M8 x 35 DIN 6912 with low head Position of screws see Arrows Attach gearbox control Figure 130 132 Assemble 1st gasket NOTE Pay attention to the different gaskets see Figure 130 and 131 Assemble intermediate plate and 2nd gasket Transmission and Torque Converter SPC000007 Page 53 Figure 129 Figure 130 Figure 131 Figure 128 ...

Page 282: ...1 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 the corresponding Spare Parts List SPC000007 Transmission and Torque Converter Page 54 Figure 132 ...

Page 283: ...Transmission and Torque Converter SPC000007 Page 55 ...

Page 284: ...SPC000007 Transmission and Torque Converter Page 56 ...

Page 285: ...e Figure on the right 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 S Adjusting screws M6 5870 204 049 with nut Transmission and Torque Converter SPC000007 Page 57 Figure 135 Figure 136 Figure 137 Fi...

Page 286: ...p plate and demount spool as well as spring Dismantle pressure control valve see Figure on the right Remove diphragm and check valves SPC000007 Transmission and Torque Converter Page 58 Figure 139 Figure 140 Figure 141 Figure 142 ...

Page 287: ...nal NOTE Mount new O Rings Fasten O Ring 6x1 5 mm Arrow with grease on the end face of the diaphragm makes the reassembly easier Δ t 1 is determined by the diaphragm pay attention to Notes Page 12 Torque limit Screw plugs Ml0x1 20 Nm Screw plugs Ml8x1 5 35 Nm Diaphragm 20 Nm Close the bores by means of ball 10 pieces Φ 4 50 mm Control pressure valve Install components 1 Spring Lo 96 20 mm 2 Disk s...

Page 288: ...sk 2 pay attention to Notes Page 12 14 Install components 1 Control spool total length 55 50 mm 2 Spring Lo 51 30 mm NOTE Pay attention to the installation position of the spool see Figure Pre assemble and attach 2 stage pressure control valve Figure 149 157 Close the bores by means of balls 4 pieces Φ 4 50 mm SPC000007 Transmission and Torque Converter Page 60 Figure 148 Figure 147 Figure 146 Fig...

Page 289: ...y means of nuts S against shoulder and fasten it subsequently by means of socket head screws mount flat washers Torque limit M6 8 8 9 5 Nm S Adjusting screw M6 5870 204 049 with nut Introduce spool 2 and spring 1 preload and fix them by means of stop plate 3 1 Spring L0 51 30 mm 2 Control spool total length 3 9 5 0 mm 3 Stop plate Install components 1 Spring Lo 51 30 mm 2 Control spool total lengt...

Page 290: ...l cable harness NOTE Mount new gaskets Pay attention to the location of the plug nose see Arrow Connect the solenoid valves according to the Illustration on the right Mount new O Ring see Arrow and fix the cover by means of clamping collar NOTE The Reassembly of the channel plate as well as the attachment of the gearbox control arc treated on Page 52 54 Pay attention to the Perspective Illustratio...

Page 291: ...Transmission and Torque Converter SPC000007 Page 63 ...

Page 292: ...tage pressure control valve 1 3 3 1 DISASSEMBLY Relax spring dip and remove cover Pull off the cable shoes and remove cable harness Loosen socket head screws and remove solenoid valves SPC000007 Transmission and Torque Converter Page 64 Figure 161 ...

Page 293: ...y 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 S Adjusting screws M6 5870 204 049 with nut Remove components of the WK Valve as well as of the 2 stage pressure control valve Transmission and Torque Converter SPC000007 Page 65 Figure 163 Figure 164 Figure 165 Figure 166 ...

Page 294: ...e components see Figure on the right Remove stop plate Arrow and spool as well as spring Remove diaphragm and check valves SPC000007 Transmission and Torque Converter Page 66 Figure 167 Figure 168 Figure 169 ...

Page 295: ... 3 Screw plugs Install components according to the Illustration on the right NOTE Employ new O Rings for all screw plugs Figure 171 shows the positions of the O Rings on the diaphragm 2 Fasten O Ring 6 x 1 5 mm Arrow 2 with grease Δ t l is determined by the diaphragm 2 pay attention to Notes Page 12 14 Torque limit Screw plug M10x 1 20 Nm Screw plug Ml8x1 5 35 Nm Diaphragm 20 Nm Close the bores by...

Page 296: ...sure control valve Install components 1 Control spool 2 Spring Lo 124 10 mm 3 Spring Lo 77 10 mm 4 Displacement spool Reversing valve Install components 1 Spool 2 Spring Lo 56 30 mm Control spool KV Install components 1 Spool total length 55 50 mm 2 Spring Lo 51 30 mm SPC000007 Transmission and Torque Converter Page 68 Figure 173 Figure 174 Figure 175 Figure 176 ...

Page 297: ...eter 7 50 mm 1 piece Ball diameter 6 00 mm Screw diaphragm wet thread with Loctite Type No 270 into the bore Arrow and fix it additionally by means of center punch Now clean the diaphragm from Loctite residues by means of compressed air NOTE t2 is determined by the diaphragm pay attention to Notes Page 12 14 Transmission and Torque Converter SPC000007 Page 69 Figure 177 Figure 178 Figure 179 Figur...

Page 298: ...semble new O Ring Torque limit M10x 1 20 Nm 2 stage Pressure control valve Figure 183 and 184 Install components 1 Spool 2 Disk s optional 3 Spring Lo 70 90 mm 4 Screw plug 5 Needle roller 6 Ring s total thickness s 5 00mm empirical value 7 Spool 8 Screw plug NOTE Mount new O Rings see Arrows Δ t3 is determined by the disk 2 p3 is determined by the ring 6 pay attention to Notes Page 12 14 SPC00000...

Page 299: ... socket head screws Torque limit M5 8 8 5 5 Nm Assemble control spool K4 KR and compression spring Lo 51 30 mm and fix them by means of stop plate NOTE Position of stop plate see Arrow Install components 1 Spring Lo 51 30 mm 2 Control spool K4 KR 3 Spring Lo 51 30 mm 4 Control spool K1 K2 K3 5 Spool 6 Spring Lo 3 7 1 0 mm 7 Retaining plate 8 Socket head screws 9 Spring Lo 51 30 mm 10 Pilot spool t...

Page 300: ...arness Torque limit M6 8 8 9 5 Nm NOTE Mount new gaskets Pay attention to the location of the plug nose see Arrow Connect solenoid valves according to the illustration on the right Mount new O Ring Arrow and fix cover by means of clamping collar NOTE The reassembly of the channel plate as well as the attachment of the gearbox control are treated on Page 52 54 Pay attention to the Perspective Illus...

Page 301: ...Transmission and Torque Converter SPC000007 Page 73 ...

Page 302: ...SPC000007 Transmission and Torque Converter Page 74 184 ...

Page 303: ... tilting device 5870 350 000 S Basic support 5870 350 014 S Support 5870 350 036 S Set of eye bolts 5870 204 002 Loosen screwed connection Install hex head screw tap impeller wheel loose and separate it from converter impeller cover see Figure Loosen hex head screws and remove impeller wheel flange Transmission and Torque Converter SPC000007 Page 75 Figure 1 Figure 2 Figure 3 Figure 4 ...

Page 304: ...tor and remove released components Squeeze out snap ring Press free wheel outer ring out of the stator Separate turbine wheel from converter impeller cover SPC000007 Transmission and Torque Converter Page 76 Figure 5 Figure 6 Figure 7 Figure 8 ...

Page 305: ... converter impeller cover by means of compressed air S Rubber cap 5870 509 009 Press profiled bush out of the converter impeller cover NOTE The profiled bush is axially fixed by means of a snap ring which will be destroyed at the pressing out Transmission and Torque Converter SPC000007 Page 77 Figure 9 Figure 10 Figure 11 Figure 12 ...

Page 306: ...anded by means of the profiled bush S f thus allowing the reassembly of the drive dog S Profiled bush 5870 345 073 Install the two rectangular rings see Arrows Oil piston bearing surfaces as well as rectangular rings and insert piston in the converter impeller cover until contact is obtained NOTE Expand the inner rectangular ring 140 x 149 x 2 mm slightly to ensure a correct contact in the piston ...

Page 307: ...st followed by one inner plate and one outer plate as last plate Check Clearance WK 0 4 0 6 mm Figure 19 Example A Determine Dimension I from the straightedge to the outer plate DimensionⅠ e g 44 0 mm S Straightedge 5870 200 022 S Digital depth gauge 5870 200 072 Determine Dimension II from the straightedge to the contact surface of the backing plate DimensionⅡ e g 43 5 mm Transmission and Torque ...

Page 308: ...upwards and fasten it by means of hex head screws Torque limit M8x25 10 9 34 Nm S Adjusting screw M8 5870 204 011 Fasten turbine wheel hub by means of hex head screws mount flat washers Torque limit M8xl8 8 8 23 Nm NOTE Secure hex head screws with Loctite Type No 270 Heat the ball bearing and mount it against shoulder until contact is obtained SPC000007 Transmission and Torque Converter Page 80 Fi...

Page 309: ... hub and grease it Thread up pro assembled turbine wheel until the inner plates have been received Heat stator and insert free wheel outer ring until contact s obtained Fix free wheel outer ring by means of snap ring Transmission and Torque Converter SPC000007 Page 81 Figure 24 Figure 25 Figure 26 Figure 27 ...

Page 310: ...7 and 6 according to the Illustration on the left with grease into the bores of the free wheel hub Place ball bearing 2 on the long hub side 24 mm against shoulder install thrust washer 3 s 1 5 mm and press free wheel inner ring against shoulder Press spring caps by means of guide plate S into the free wheel ring until the cylindrical roller pairs 5 can be installed NOTE The second roller pair has...

Page 311: ...onal e g s 0 5 mm and shaft washer 60x85x4 75 NOTE The end play of the stator is determined by means of shim 10 e g s 0 5 mm empirical value However a later check Figure 39 Example B is absolutely essential Mount housing washer 62x85x4 75 mm and axial needle bearing 60x85x3 mm Transmission and Torque Converter SPC000007 Page 83 Figure 32 Figure 33 Figure 34 Figure 35 ...

Page 312: ...m NOTE Pay attention to the radial installation position Secure hex Head screws with Loctite Type No 270 Check end play Stator max 0 2 mm Figure 39 Example B Mount flat gasket Arrow Determine DimensionⅠ from the flange mounted surface gasket to the plane surface impeller wheel flange Dimension Ⅰ e g 88 05 mm S Straightedge 5870 200 022 S Gauge blocks 5870 200 066 S Digital depth Gauge 5870 200 072...

Page 313: ... is illustrated on Figure 34 Screw two adjusting screws into the converter impeller cover and mount flat gasket Place impeller wheel against shoulder and fasten it by means of hex head screws Torque limit M8x32 8 8 23 Nm NOTE Install flat washers Pay attention to the radial position see markings S Adjusting screw M8 5870 204 011 Squeeze the rectangular ring into the annular groove Arrow and engage...

Page 314: ... hollow screw and remove delivery line Loosen screwed connection Figure 2 and separate engine connecting case from gear case by means of pry bars Figure 3 Loosen hollow screw and remove delivery line SPC000007 Transmission and Torque Converter Page 86 Figure 1 Figure 2 Figure 3 Figure 4 ...

Page 315: ...nge 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 Loosen hex head screws and separate pump from oil supply flange Transmission and Torque Converter SPC000007 Page 87 Figure 5 Figure 8 Figure 7 Figure 6 ...

Page 316: ...sure pump Figure 11 14 Remove the two straight pins by means of striker Figure 11 loosen hex head screws and remove cover Figure 12 S Striker 5870 650 001 NOTE If traces of wear should be encountered in the pump case or on the housing cover the complete pump has to be renewed SPC000007 Transmission and Torque Converter Page 88 Figure 9 Figure 10 Figure 11 Figure 12 ...

Page 317: ...x the straight pins axially by means of caulkings 2x and tighten hex head screws finally Remove converter relief valve ball and spring Squeeze out circlip S Set of external 5870 900 016 snap ring pliers Press drive shaft in direction of Arrow until the spur gear is released Transmission and Torque Converter SPC000007 Page 89 Figure 13 Figure 14 Figure 15 Figure 16 ...

Page 318: ...corresponding Spare Parts List Remove ball bearing and drive shaft Pull roller bearing out of the bore S Internal puller 5870 300 014 S Back up tool 5870 300 003 Remove temperature connection SPC000007 Transmission and Torque Converter Page 90 Figure 17 Figure 18 Figure 19 Figure 20 ...

Page 319: ...ing spool and valve sleeve Remove drive side inductive transmitter 3 1 2 COAXIAL POWER TAKE OFF mechanical control Loosen clamping screw and remove lever Arrow Remove Woodruff key and shift lever Transmission and Torque Converter SPC000007 Page 91 Figure 21 Figure 22 Figure 23 Figure 24 ...

Page 320: ...socket head screws and remove housing Loosen hex head screws and lift complete power take off housing out of the bore S Set of eye bolts 5870 204 002 SPC000007 Transmission and Torque Converter Page 92 Figure 25 Figure 26 Figure 27 ...

Page 321: ...tion of Arrow NOTE For this step an assistant is absolutely necessary S Circlip pliers 5870 900 026 Squeeze out snap ring Figure 29 tap the drive dog loose and drive it out of the spur gear resp housing bore Figure 30 NOTE Pay attention to the released components Transmission and Torque Converter SPC000007 Page 93 Figure 28 Figure 29 Figure 30 ...

Page 322: ...ller out of the ball bearing resp spur gear and remove released spur gear S Internal puller 5870 300 006 S Back up tool 5870 300 003 Expand snap rings align them centrically tap the ball bearing loose and drive it out of the housing bore NOTE Assistant necessary SPC000007 Transmission and Torque Converter Page 94 Figure 31 Figure 32 Figure 33 Figure 34 ...

Page 323: ...3 1 4 REMOVE EMERGENCY STEERING PUMP Loosen hex nuts and separate emergency steering pomp from gear case Transmission and Torque Converter SPC000007 Page 95 Figure 35 ...

Page 324: ...ce out of the clutch resp gear case S Puller 5870 000 069 Lift clutch out of the gear case and deposit it NOTE Use lifting device Remove clutch KR K2 accordingly In the case of clutch K4 K3 push the lower spacing washer to the rear Only then the clutch can be removed S Lifting device 5870 350 041 3 1 6 REMOVE COUNTERSHAFT ASSEMBLY Remove closing cover SPC000007 Transmission and Torque Converter Pa...

Page 325: ... screw Pull axle by means of Special device out of the housing bore resp spur gear bearing S Puller 5870 000 0S3 Remove spur gear and disk Transmission and Torque Converter SPC000007 Page 97 Figure 44 Figure 45 Figure 46 ...

Page 326: ...1 and demount components Squeeze out snap ring Remove plate pack Preload compression spring squeeze out circlip and remove components S Assembly jig 5870 345 028 SPC000007 Transmission and Torque Converter Page 98 Figure 50 Figure 51 Figure 52 Figure 53 ...

Page 327: ... 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 5870 300 003 Transmission and Torque Converter SPC000007 Page 99 Figure 54 Figure 55 ...

Page 328: ...n hex head screws Pry output flange off the shaft S Pry bar 5870 345 065 Tilt gear case 180 Loosen hex head screws Separate brake drum from output flange S Crow bar 5870 345 071 SPC000007 Transmission and Torque Converter Page 100 Figure 60 Figure 61 Figure 62 Figure 63 ...

Page 329: ...e shaft S Two leg puller 5370 970 004 Unhook return springs and remove brake shoes S Brake spring pliers 5870 900 006 Pry shaft seed out of the housing bore S Crow bar 5870 345 071 Transmission and Torque Converter SPC000007 Page 101 Figure 64 Figure 65 Figure 66 Figure 67 ...

Page 330: ...00 021 Loosen the two closing covers by central tapping and remove them Loosen the two hex head screws and remove them along with flat washers Remove upper oil retainer SPC000007 Transmission and Torque Converter Page 102 Figure 68 Figure 69 Figure 70 Figure 71 ...

Page 331: ...be removed prior to the disassembly of the output shaft S Puller 5870 023 017 S Puller 5870 023 026 S Striker 5870 650 001 Remove output gear and plate Squeeze out circlip and remove brake cam S Set of external 5870 900 013 snap ring pliers Drive the pin out of the housing bore and remove it Transmission and Torque Converter SPC000007 Page 103 Figure 72 Figure 73 Figure 75 Figure 74 ...

Page 332: ...the housing bore Figure 77 S Puller device 5870 000 066 Tilt gear case 180 Pry shaft seal out of the housing bore Squeeze out circlip and remove spacing washer S Circlip pliers 5870 900 021 SPC000007 Transmission and Torque Converter Page 104 Figure 76 Figure 77 Figure 78 Figure 79 ...

Page 333: ...Illustration on the right shows the components of the brake cam Pre assemble brake cam according to Figure 91 and insert it in the housing bore until contact is obtained Now tighten hex head screw until the brake cam has got contact on the housing without play and pressure NOTE Secure hex head screw with Loctite Type No 270 Grease O Ring Arrow Figure 92 Transmission and Torque Converter SPC000007 ...

Page 334: ...900 021 Lay shim 2 e g s 0 7 mm empirical value and roller bearing 3 upon circlip 1 NOTE The end play of the output shaft bearing is determined by means of shim 2 However a later check of the end play Figure 104 to Example A is absolutely essential SPC000007 Transmission and Torque Converter Page 106 Figure 93 Figure 94 Figure 95 ...

Page 335: ...y it over the roller bearing 3 Heat bearing inner race 5 and assemble it until contact is obtained Position spur gear 6 see Draft Position oil retainer 7 see Draft Transmission and Torque Converter SPC000007 Page 107 Figure 98 Figure 96 Figure 97 Figure 99 ...

Page 336: ...irclip 8 S Clamping pliers 5870 900 021 Press the speedometer drive worm against shoulder NOTE In case of a Version without mechanical speedometer a spacer has to be installed instead of the speedometer drive worm Thread up output shaft 9 until contact is obtained SPC000007 Transmission and Torque Converter Page 108 Figure 103 Figure 102 Figure 100 Figure 101 ...

Page 337: ...ine DimensionⅡ from the end face output shaft to the upper plane surface of the circlip Dimension II e g 79 10 mm Example A Dimension I 79 60 mm Dimension II 79 10 mm Difference End play 0 50 mm NOTE In case of deviations from the required end play correct by means of a corresponding shim 2 see Figure 95 Press ball bearing against shoulder Transmission and Torque Converter SPC000007 Page 109 Figur...

Page 338: ...ling surface with spirit If not use sealing compound Curil T Grease sealing lip S Driver 5870 048 067 The Figure on the right shows a Version with two 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 given by application of the prescribed driver 1 NO...

Page 339: ... 260 002 Install brake shoes and engage return springs Insert hex head screws in the bores of the output flange and press retaining plate Arrow against shoulder Heat output flange and assemble it until contact is obtained Transmission and Torque Converter SPC000007 Page 111 Figure 112 Figure 111 Figure 113 Figure 114 ...

Page 340: ...at washers Torque limit Ml0 10 9 68 Nm S Adjusting screws MI0 5870 204 007 Tilt gear case 180 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 If the outer diameter of the shaft seal is rubberized wet the sealing surface with spirit If not use sealing compound Curil T Grease sealing lip S D...

Page 341: ...of upper and lower sealing lip with grease S Driver 5870 048 067 Insert hex head screws in the bores heat the output flange and assemble it until contact is obtained Fasten output flange by means of disk and hex head screws NOTE Wet contact areas of disk and screw heads with sealing compound Torque limit M10 8 8 46 Nm Fix hex head screws means of lock plate S Driver 5870 057 009 S Handle 5870 260 ...

Page 342: ...Press drive gear flat against the end face speedometer drive shaft Introduce speedometer drive shaft and fix it by means of straight pin Guide installer S over the speedometer drive shaft and install shaft seal Arrow with the sealing lip facing the oil chamber S Driver 5870 048 072 SPC000007 Transmission and Torque Converter Page 114 Figure 124 Figure 123 Figure 125 Figure 126 ...

Page 343: ...y means of hex Head screws Torque limit M8 8 8 23 Nm In case of the Version without speedometer close the bore by means of cover Arrow NOTE Wet sealing surfaces with Loctite Type No 270 Transmission and Torque Converter SPC000007 Page 115 Figure 126 Figure 127 ...

Page 344: ...wards to the drift S Drift 5870 506 055 Check operation of the bleeder valves NOTE Ball may not stick if necessary clean it by means of compressed air or renew it Insert the profiled sealing rings Arrows in the recesses of the piston with the sealing lip facing the pressure chamber NOTE Pressure side Oil profiled sealing rings and insert piston until contact is obtained NOTE Use installer s S Inst...

Page 345: ...upper spring guide 3 Mount guide ring 4 and circlip 5 Figure 137 preload compression spring and fix the components by means of circlip Figure 138 Assembly jig 5870 345 028 Transmission and Torque Converter SPC000007 Page 117 Figure 136 Figure 137 Figure 138 ...

Page 346: ...lation Ball Bearing Disc carrier 1 1 420 434 436 0501 309 014 4644 308 115 4644 308 014 4644 308 115 Coupling KV O Clutch Disc I Clutch Disc O Clutch Disc S 2 0 S 1 5 8 7 1 1 440 442 450 452 456 0501 309 541 0501 312 283 4644 308 329 4644 308 330 4644 308 329 4644 308 330 Coupling K1 O Clutch Disc O Clutch Disc I Clutch Disc I Clutch Disc I Clutch Disc S 2 0 S 2 5 7 1 3 3 1 1 Assembly Note Assembl...

Page 347: ...te 1 1 5 or 2 0 1 5 or 2 0 4644 308 115 4644 308 014 No of friction surfaces 14 Plate clearance 2 2 2 4 Plate installation No 13 WG 180 bis 201 Truck crane without WK Outer plate 8 2 0 16 0501 309 330 Inner plate 7 2 5 17 5 4644 308 330 Inner plate Compensating plate Inner plate 1 1 5 or 2 0 1 5 or 2 0 4644 308 115 4644 308 014 No of friction surfaces 14 Plate clearance 2 2 2 4 Plate installation ...

Page 348: ...1 314 388 Compensating plate Inner plate 1 2 0 or 2 5 2 0 or 2 5 0501 314 389 0501 314 388 No of friction surfaces 14 Plate clearance 2 2 2 4 Clutch K3 Type of plate Quantity n S mm n s mm ZF No Plate installation No 30 Standard WG 180 to 201 Outer plate 10 2 0 20 05051 309 329 Inner plate 1 1 5 1 5 4642 308 330 Inner plate 6 2 0 12 4642 308 332 Inner plate 1 2 5 2 5 4642 308 331 Compensating plat...

Page 349: ...642 308 332 4642 308 331 No of friction surfaces 18 Plate clearance 2 2 2 4 Plate installation No 41 WG 200 Graphite plate loader version Outer plate 9 2 0 18 0501 314 310 Inner plate 4 1 5 6 0501 314 387 Inner plate 2 2 0 4 0501 314 385 Inner plate 1 2 5 2 5 0501 314 386 Compensating plate Inner plate 1 1 5 or 2 0 or 2 5 1 5 or 2 0 or 2 5 0501 314 387 0501 314 385 0501 314 386 No of friction surf...

Page 350: ...arting with the piston side the first plate must be one double sided coated outer plate Standard Version Exception A In case of Plate installation No 22 31 and 41 the first plate must be one one sided coated outer plate and in this case the plate must be always installed with the uncoated side facing the piston Exception B In case of Plate installation No 12 and 13 the first plate must be one doub...

Page 351: ... of the different clutches can be taken from the Table Page 119 122 In case of Plate installation No 40 e g 2 0 2 4 mm Measure Dimension Ⅰ from the end face of the plate carrier to the backing plate Dimension Ⅰ e g 5 3 mm Place backing plate against snap ring until contact is obtained upwards and determine Dimension Ⅱ Dimension Ⅱ e g 3 2 mm Transmission and Torque Converter SPC000007 Page 123 Figu...

Page 352: ...ings are possible see corresponding Spare Parts List as well as Figures 143 and 144 Spur Rear K4 Version A Figure 143 1 Thrust plate 5 Spur gear 2 Thrust washer 6 Bearing inner race 3 Collar shim 7 Shim 4 Roller cage 2x Spur gear K4 Version Figure 144 1 Thrust plate 2 Thrust washer 3 Spur gear U Needle cage 5 Thrust washer 6 Thrust washer 7 Compensating plate optional Install components 2 6 Figure...

Page 353: ...until all inner plates arc received NOTE Make thrust washer 2 and cylindrical rollers 5 adhere with grease 3 2 3 6 Install clutch K4 K3 Adjust end play of clutch 0 1 0 3 mm Figure148 to Example E Determine Dimension I from the flange mounted surface axle to the plane surface housing Arrow DimensionⅠe g 251 15 mm NOTE In case of spur gear bearing K4 Version B Figure 144 lay forked washer and thrust...

Page 354: ...drical rollers to the surface plate Dimension Ⅲ e g 227 20 mm Example D for the determination of the installation dimension Dimension Ⅲ e g 227 20 mm End play e g 0 20 mm gives installation dimension Clutch 227 40 mm Example E for the determination of the shim Housing dimension e g 230 15 mm Installation dimension Clutch 227 40 mm Difference Shim e g 2 75 mm Insert clutch K4 KR by means of lifting...

Page 355: ...alled Now align the complete clutch as well as the shim by means of drift again and fix it NOTE In case of spur gear bearing K4 Version A without forked washer and thrust washer Figure 153 In case of spur gear bearing K4 Version MB another forked washer as well as one thrust washer have to be installed in addition to the shim ATTENTION Pay attention to the radial installation position of the forke...

Page 356: ... stud bolts see Arrows NOTE Secure the stud bolts with Loctite Type No 270 Heat housing bores about 90 C S Hot air blower 220 V 5870 221 503 S Hot air blower 110 V 5870 221 501 Thread up axle compl until contact is obtained SPC000007 Transmission and Torque Converter Page 128 Figure 155 Figure 156 Figure 157 Figure 158 ...

Page 357: ...etic base 5870 200 055 S Dial indicator 5870 200 057 S Crow bar 5870 345 071 Check operation of the clutches KH and K3 by means of compressed air NOTE If the components are correctly installed the closing resp opening of the clutches is clearly audible Transmission and Torque Converter SPC000007 Page 129 Figure 159 Figure 160 Figure 161 ...

Page 358: ...d condition the marking must be facing the drive side upwards Insert shim and pre assembled spur gear Figure 163 NOTE Pay attention to the installation position of the collar shim Arrow radius on the inner diameter must show upwards Heat bearing bores and bearing inner race about 90 C S Hot air blower 220 V 5870 221 500 S Hot air blower 110 V 5870 221 501 Insert axle until contact is obtained SPC0...

Page 359: ...KR K2 NOTE The pre assembly of the plate carrier KR K2 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 Plate carrier KR K2 in the zone X without oil hole Figure 168 Plate carrier KV K1 in the zone X with oil hole Figure 169 Transmission and Torque Converter SPC000007 Page 131 Figure 166 Figure 167 F...

Page 360: ...hrust plate 7 Thrust washer 2 Thrust washer 8 Forked washer 3 Needle cage 9 Shim optional 4 Spur gear 5 Plate 6 Hex head screws NOTE Secure hex head screws M6 8 8 9 5 Nm with Loctite Type No 270 Spur gear bearing KR Version B Fig 172a 1 Thrust plate 2 Thrust washer 3 Roller bearing compl 4 Spur gear 5 Plate 6 Hex head screw 7 Shim optional NOTE Secure hex head screws M6 8 8 9 5 Nm with Loctite Typ...

Page 361: ... thrust plate 1 Arrow and thread up spur gear until all inner plates are received NOTE Make thrust washers and cylindrical rollers adhere with grease 3 2 5 3 Plate pack K2 Install plate pack and check clearance NOTE Plate arrangement see Plate installation Page 118 122 3 2 5 4 Pre assemble and install spur gear K2 NOTE According to the Transmission Version resp operating conditions different spur ...

Page 362: ...angle rings are always facing the bearing rollers Make thrust washer 2 adhere with grease Spur gear bearing K2 Version B Fig 176 1 Thrust plate 2 Thrust washer 3 Spur gear 4 Needle cage 5 Ring 6 Roller cage NOTE pay attention to the installation position of the roller cage 5 the larger inner diameter of the brass cage is showing outwards Arrow In case of an equal inner diameter the installation po...

Page 363: ...o the thrust washer DimensionⅠ e g 252 20 mm Now remove forked washer and thrust washer again NOTE In case of spur gear bearing KR Version B Figure 172 a measure up to the plane surface housing without forked washer and thrust washer Measure Dimension II from the butting face bearing rollers to the flange mounted surface DimensionⅡ e g 22 55 mm Example F for the determination of the housing dimens...

Page 364: ...0 mm gives Installation Dimension Clutch e g 227 85 mm Example H for the determination of the shim Housing dimension e g 229 65 mm Installation dimension Clutch e g 227 85 mm Difference Shim e g s 1 80 mm Insert clutch KR K2 in the housing using lifting device NOTE The installation of the shims and the fixing of the clutch has to be done along with the clutch KV K1 S Lifting device 5870 350 041 SP...

Page 365: ...84 and 185 Spur gear bearing KV Version A Fig 184 1 Thrust plate 2 Thrust washer 3 Roller bearing 4 Spur gear 5 Plate 6 Hex head screws M6 8 8 9 5 Nm 7 Shim optional NOTE Secure hex head screws 5 with Loctite Type No 270 Pay attention to the installation position of the bearing inner races oil grooves see Arrows Spur gear bearing KV Version B Fig 185 1 Thrust plate 8 Spur gear 2 Disk 9 Plate 3 Thr...

Page 366: ...arrangement see Plate installation Page 118 122 3 2 6 4 Pre assemble and install spur gear K 1 NOTE According to the Transmission Version resp operating conditions different spur gear bearings arc possible see corresonding Spare Parts List as well as the following Figures 188 190 Spur gear bearing K1 Version A Fig 188 1 Thrust plate 2 Thrust washer 3 Needle cage 4 Spur gear 5 Sleeve 6 Ball bearing...

Page 367: ... Version C K1 Fixing Figure 190 and 191 1 Thrust plate 2 Thrust washer 3 Needle cage 4 Spur gear 5 Sleeve 6 Ball bearing 7 Disk optional 8 Circlip NOTE Make thrust washer adhere with grease Pay attention to he installation position of the sleeve Figure 190 Adjust ball bearing 6 free of play by means of disk Figure 191 shows the fixing of the spur gear after the installation of the clutch 1 Clutch ...

Page 368: ...m NOTE In case of spur gear bearing KV Version B Figure 185 lay forked washer and thrust washer upon the plane surface of the housing and measure up to the thrust washer Measure Dimension II from the butting face bearing rollers to the flange mounted surface DimensionⅡ e g 27 00 mm Example J for the determination of the housing dimension DimensionⅠ e g 254 40 mm DimensionⅡ e g 27 00 mm Difference ...

Page 369: ...m Installation dimension Clutch e g 224 00 mm Difference Shim e g s 3 40 mm Insert clutch KV K1 by means of lifting device in the housing and position it ATTENTION For different Transmission variants the output gear of the lateral power take off must be installed prior to the installation of the clutch axles KV K1 and KR K2 narrow installation space If necessary handle steps of Figure 216 219 firs...

Page 370: ...Figure 200 can be installed Now align the complete clutch as well as the shims again using drift and fix them NOTE Shim thickness for KV KI and KR K2 see corresponding Examples 1 Install thrust washer plastic facing the spur gear Pay attention to a correct fixing of the forked washer Tilt gear case in a vertical position 90 and place the complete clutches in direction of Arrow against shoulder Now...

Page 371: ... and align them centrically Heat housing bore about 90 C S Hot air blower 220 V 5870 221 500 S Hot air blower 110 V 5870 221 501 Thread up axle compl until contact is obtained Fasten axle by means of hex nuts Torque limit M8 8 23 Nm Transmission and Torque Converter SPC000007 Page 143 Figure 202 Figure 203 Figure 205 Figure 204 ...

Page 372: ... KV KI accordingly as KR K2 Figure 202 206 The illustration on the left shows the components 1 Clutch axle 2 Rectangular rings 3 pieces 3 Ball 2 pieces 4 O Ring 5 Cylindrical roller 2 pieces 6 Set screw 2 pieces Squeeze in and engage rectangular rings Install O Ring Insert the two balls with grease in the bores Arrow NOTE Cylindrical rollers and set screws will be installed later Heat housing bore...

Page 373: ... must be lifted at the uniform tightening of the two set screws in direction of the Arrow Insert set screws with Loctite Type No 241 Check operation of the clutches K1 and KV by means of compressed air NOTE If the components are correctly installed the closing resp opening of the clutches is clearly audible I Check end play of the clutches 0 1 0 3 mm again and correct if necessary Transmission and...

Page 374: ...d grease it Insert studs 4 pieces with Loctite Type No 241 and assemble emergency steering pump until contact is obtained NOTE Pay attention to the radial installation position A slight rotation on the final drive makes the threading up easier Fasten emergency steering pump by means of hex nuts Torque limit M8 8 23 Nm SPC000007 Transmission and Torque Converter Page 146 Figure 213 Figure 214 Figur...

Page 375: ... 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 S Expanding ring 5870 345 038 Position spur gear with the long hub side showing downwards Transmission and Torque Converter SPC000007 Page 147 Figure 216 Figure 217 Figure 218 Figure 219 ...

Page 376: ...the driving shaft Heat ball bearing Figure 221 and introduce driving shaft until contact is obtained Figure 222 Fix driving shaft by means of circlip Arrow SPC000007 Transmission and Torque Converter Page 148 Figure 220 Figure 221 Figure 222 Figure 223 ...

Page 377: ...e facing the drift upwards S Drift 5870 506 060 Install two adjusting screws mount flat gasket and place pump flange against shoulder S Adjusting screws M8 5870 200 011 Fasten pump flange by means of socket head screws Torque limit M8 8 8 DIN 6912 16 Nm Install oil supply power take off NOTE Use new sealing rings Transmission and Torque Converter SPC000007 Page 149 Figure 224 Figure 225 Figure 226...

Page 378: ... 3 Spool 4 Valve sleeve 5 O Ring 6 Screw plug 7 Connecting piece temperature 8 O Ring Thread up disk spring spool and the valve sleeve NOTE Pay attention to the radial installation position of the valve sleeve Install connecting piece NOTE Pay attention to the installation position see Figure 229 SPC000007 Transmission and Torque Converter Page 150 Figure 228 Figure 229 Figure 230 Figure 231 ...

Page 379: ...p 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 Press bearing outer race firmly against shoulder Transmission and Torque Converter SPC000007 Page 151 Figure 232 Figure 233 Figure 234 Figure 235 ...

Page 380: ... up drive shaft and oil supply flange by means of Assembly aid S Assemble disk according to the Version with or without NOTE The exact installation position of the drive shaft is determined by means of the Assembly aid S Assembly aid 5870 345 032 SPC000007 Transmission and Torque Converter Page 152 Figure 236 Figure 237 Figure 238 Figure 239 ...

Page 381: ...aring 3 Shim optional 4 Pump 5 Ball bearing 6 Circlip 7 Rectangular ring 8 Output shaft 9 Adjusting spring Squeeze in circlip Arrow Press ball bearing against circlip until contact is obtained NOTE Pay attention to the installation position of the ball bearing closed bearing side is facing the circlip upwards Transmission and Torque Converter SPC000007 Page 153 Figure 240 Figure 241 Figure 242 Fig...

Page 382: ...of shim e g s 0 8 mm Press ball bearing against shoulder with the closed side showing upwards Squeeze in circlip Check end play 0 2 0 4 mm between circlip and bearing inner race using feeler gauge NOTE In case of deviations from the required end play correct by means of shim Figure 245 SPC000007 Transmission and Torque Converter Page 154 Figure 244 Figure 245 Figure 246 Figure 247 ...

Page 383: ...he drive shaft bearing 0 2 0 4 mm Figure 250 Example M Determine DimensionⅠ from the flange mounted surface to the contact area ball bearing DimensionⅠ e g 7 10 mm Replace gasket and measure Dimension II from the end face ball bearing to the gasket flange mounted surface Dimension 11 e g 6 05 mm Transmission and Torque Converter SPC000007 Page 155 Figure 248 Figure 249 Figure 250 Figure 251 ...

Page 384: ...ere with grease Install two adjusting screws mount flat gasket and install converter relief valve ball and spring S Adjusting screws M8 5870 204 011 Place pre assembled pump against oil supply flange and fasten it by means of hex Head screws Torque limit M8 8 8 23 Nm SPC000007 Transmission and Torque Converter Page 156 Figure 252 Figure 253 Figure 254 ...

Page 385: ...n ports and pressure ports with Loctite Type No 221 Install two adjusting screws Install flat gasket Arrow and thread up oil supply flange until contact is obtained S Adjusting screws M8 5870 204 011 ATTENTION For different Transmission Versions one O Ring must be installed instead of the flat gasket Installation position of the O Ring see Arrow Figure 257 Transmission and Torque Converter SPC0000...

Page 386: ... one end face At the pressing in the marking must be facing the drift upwards The exact installation position is obtained by application of the prescribed Special Tool Wet shaft seal outer diameter with sealing compound S Driver 5870 058 058 S Driver 5870 055 022 S Handle 5870 260 002 Install two adjusting screws and mount flat gasket Assemble bearing cap and fasten it by means of hex head screws ...

Page 387: ...essing in the marking must be facing the drift S S Drift 5870 506 060 Squeeze the two snap rings into the annular groove of the housing Assemble roller cage and collar shim and fix them by means of circlip NOTE Pay attention to the installation position of the roller cage annular groove Transmission and Torque Converter SPC000007 Page 159 Figure 263 Figure 264 Figure 265 Figure 266 ...

Page 388: ...e dog into the housing until the first snap ring engages in the annular groove of the roller bearing The illustration on the left shows the installation position of the snap rings see Arrow Locate snap ring finally thus fixing the spur gear SPC000007 Transmission and Torque Converter Page 160 Figure 267 Figure 268 Figure 269 Figure 270 ...

Page 389: ...Loctite Type No 242 Thread up pre assembled power take off and fasten it by means of hex head screws and hex nuts Torque limit M8 8 8 23 Nm Install shaft seal Arrow flush mounted with the sealing lip showing inwards S Driver 5870 048 074 Transmission and Torque Converter SPC000007 Page 161 Figure 271 Figure 272 Figure 273 Figure 274 ...

Page 390: ...r S S Installer 5870 651 018 Thread up locking device composed of pin and two compression springs and fix it by means set screw NOTE Insert the set screw with Loctite Type No 242 Assemble shim s 1 5 mm and install adjusting spring Install shift lever free of pressure a small end play is permitted and fix it by means of hex head screw SPC000007 Transmission and Torque Converter Page 162 Figure 275 ...

Page 391: ...ies and components in relation to a specific Transmission Variant Deviating steps of other possible Versions can be carried out without difficulty by trained personnel In this connection see also the Perspective Illustration of the corresponding Spare Parts Lists Thread up torque converter by means of lifting device until contact is obtained S Set of eye bolts 5870 204 002 Mount edge protection Ar...

Page 392: ...uction pipe NOTE Install new gaskets Install oil level pipe NOTE Install new gaskets as well as baffle plate Install compl cover plate NOTE Install new gaskets SPC000007 Transmission and Torque Converter Page 164 Figure 284 Figure 285 Figure 282 Figure 283 ...

Page 393: ...necessary align the spur gear accordingly Remove measuring pin and measure Dimension A from the end face measuring pin to the circlip see Figure 286 Dimension A e g 26 00 mm Determine Dimension B from the contact surface inductive transmitter to the contact area see Figure 286 Dimension B e g 27 10 mm Example N Dimension A 26 00 mm required gap e g 0 60 mm Difference Adjustment dimension 25 40 mm ...

Page 394: ...ad screws and remove retarder valve Demount temperature sensor and the two connecting pieces see Arrows Loosen hex head screws remove the two covers and demount components SPC000007 Transmission and Torque Converter Page 166 Figure 1 Figure 2 Figure 3 Figure 4 ...

Page 395: ...ete retarder can be separated from the converter compartment by loosening the screwed connection Figure 8 Loosen screw plug Loosen first hex head screw and remove it by means of magnetic rod Remove the remaining hex head screws accordingly Loosen screwed connection Transmission and Torque Converter SPC000007 Page 167 Figure 5 Figure 6 Figure 7 Figure 8 ...

Page 396: ...ment using lifting device S Set of eye bolts 5870 204 002 Loosen socket head screws Separate cover from stator S Set of eye bolts 5870 204 002 Remove rectangular ring SPC000007 Transmission and Torque Converter Page 168 Figure 9 Figure 10 Figure 11 Figure 12 ...

Page 397: ... connection and remove thrust ring Remove stator ring NOTE Pay attention to the released components Squeeze out circlip and remove shim Transmission and Torque Converter SPC000007 Page 169 Figure 13 Figure 14 Figure 16 Figure 16 ...

Page 398: ...Remove shaft seal S Pry bar 5870 345 065 Drive 4 point bearing out of the bore SPC000007 Transmission and Torque Converter Page 170 Figure 17 Figure 18 ...

Page 399: ...isk 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 NOTE The exact installtion position is obtained by application of the prescribed driver S Driver 5870 048 068 Install stator ring Transmission and Torque Converter SPC000007 Page 171 Figure 20 Figure 21 Figure 22 Figure 23 ...

Page 400: ... according to Figure 25 and 26 NOTE Pay attention to the installation dimension B l 6 mm Ref Figure 23 and 26 1 Guide pin 2 Cup spring packs 8 packs with 6 cup springs each 3 Spring guide 4 Compression spring 5 Spring guide Install pre assembled dampers see Arrows SPC000007 Transmission and Torque Converter Page 172 Figure 24 Figure 25 Figure 26 Figure 27 ...

Page 401: ... of 3 straight pinsΦ 6 mm Assembly aid Figure 28 and29 3x Straight pin 0631 306 178 Oil rectangular ring slide rotor into the stator case until contact is obtained and remove straight pins again Transmission and Torque Converter SPC000007 Page 173 Figure 28 Figure 29 Figure 30 ...

Page 402: ...Install two adjusting screws and insert cover until contact is obtained NOTE Pay attention to the radial installation position oil duct see Arrow 2 S Adjusting screws M8 5870 204 011 Now remove guide pin Assembly aid again and fasten cover by means of socket head screws mount flat washers NOTE Secure socket head screws with Loctite Type No 640 Torque limit M8 I0 9 34 Nm SPC000007 Transmission and ...

Page 403: ... Ⅰ e g 12 00 mm S Straightedge 5870 200 022 S Gauge blocks 5870 200 046 S Digital depth gauge 5870 200 072 Determine Dimension Ⅱ from the flange mounted surface drive flange to the bearing inner race Dimension Ⅱ e g 10 65 mm EXAMPLE A Dimension Ⅰ 12 00 mm Dimension Ⅱ 10 65 mm Difference 1 35 mm Required gap Rotor Stator ring e g 1 20 mm gives Shim s 0 15 mm Assemble shim e g s 0 15 mm Transmission...

Page 404: ...ct is obtained and fasten it by means of hex head screws Torque limit M10 8 8 46 Nm Fasten rotor at the drive flange NOTE Tighten hex head screws uniformly 180 displaced and secure them with Loctite Type No 241 Torque limit M10 8 8 46 Nm Install the two screw plugs see Arrows NOTE Install new O Rings SPC000007 Transmission and Torque Converter Page 176 Figure 39 Figure 40 Figure 41 Figure 42 ...

Page 405: ...ents according to the Figure on the right 1 Case 2 Hex head screw 3 Cover 4 Gasket 5 Compression spring 6 Spool 7 Spool 8 Grooved rings NOTE Install grooved rings 8 with the sealing lip facing the pressure chamber Fasten the two connecting pieces by means of socket head screws Install temperature sensor Arrow NOTE Install new O Rings Torque limit M8 8 8 23 Nm Install screw plug Arrow NOTE Install ...

Page 406: ...nst shoulder and fasten it 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 right 1 To the Retarder 2 Converter exit 3 Return to Sump 4 To the Lubrication NOTE Install new O Rings SPC000007 Transmission and Torque Converter Page 178 Figure 47 Figure 48 Figure 49 ...

Page 407: ...d separate axle declutch from gear case S Pry bar 5870 345 065 Remove lock plate loosen hex head screws and remove disk Pull flange from output shaft S Three leg puller 5870 971 003 Transmission and Torque Converter SPC000007 Page 179 Figure 1 Figure 2 Figure 3 ...

Page 408: ...Pry shaft seal out of the bore S Crowbar 5870 345 071 Squeeze out circlip Press output shaft out of the housing SPC000007 Transmission and Torque Converter Page 180 Figure 6 Figure 4 Figure 5 ...

Page 409: ...t shaft If necessary separate shift lever from gearshift shaft mark radial installation position Demount locking device and remove shift fork Squeeze out circlip and remove shim s Transmission and Torque Converter SPC000007 Page 181 Figure 9 Figure 7 Figure 8 Figure 10 ...

Page 410: ...Demount sleeve and disk Remove needle bearing SPC000007 Transmission and Torque Converter Page 182 Figure 11 Figure 12 ...

Page 411: ...ined by application of the prescribed driver S If the outer diameter of the shaft seal is rubberized wet the sealing surface with spirit If not use sealing compound Curilt T Grease sealing lip S Driver 5870 048 057 Insert shaft seal until contact is obtained NOTE Wet rubberized outer diameter with spirit Grease sealing lip S Driver 5870 048 031 Transmission and Torque Converter SPC000007 Page 183 ...

Page 412: ... sliding blocks Arrow I position shift fork and fix by means of gearshift shaft NOTE Pay attention to the installation position of the sliding blocks see Figure Realize the overlapping of the gearshift shaft countersinkings Arrow 2 Figure 20 and the tapped holes of the shift fork and install the two set screws NOTE Secure set screws with Loctite Type No 242 Insert disk SPC000007 Transmission and T...

Page 413: ...mpirical value the sliding collar will be adjusted free of pressure Figure 26 Secure socket head screw with Loctite Type No 242 Cheek the pressureless condition of the sliding collar NOTE In a pressureless condition a small tilting play on the sliding collar can be noted If necessary correct by means of shim Figure25 Transmission and Torque Converter SPC000007 Page 185 Figure 23 Figure 24 Figure 2...

Page 414: ...igure 19 The Illustration on the left shows the components of the locking screw 1 Spring bush 2 Sealing ring 3 Compression spring 4 Ball Fix the ball by indents 3 x 120 on the end face of the spring bush see Arrow Figure28 Insert compression spring and ball in the spring bush and preload them in a vise Assemble new sealing ring and install locking screw SPC000007 Transmission and Torque Converter ...

Page 415: ...row until contact is obtained and fix it by slight central tapping NOTE Wet sealing surfaces with Loctite Type No 270 Insert socket head screws Arrow in the housing bores Insert hex head screws in the bores of the output flange heat output flange and assemble it until contact is obtained NOTE Pay attention to a correct contact If necessary press it against shoulder see Figure 34 Transmission and T...

Page 416: ...m Fix hex head screws by means of lock plate S Driver 5870 057 011 S Handle 5870 260 002 Install disk and assemble driving bush NOTE Pay attention to the installation position of the driving bush see Figure Fix driving bush free of play by means of shim s and circlip SPC000007 Transmission and Torque Converter Page 188 Figure 35 Figure 36 Figure 37 Figure 38 ...

Page 417: ...s and assemble flat gasket S Adjusting screws MI0 5870 204 021 Place axle declutch assembly against housing until contact is obtained and fasten it by means of socket head screws Torque limit M10 8 8 46 Nm Transmission and Torque Converter SPC000007 Page 189 Figure 39 Figure 40 ...

Page 418: ...Loosen socke head screws and separate axle declutch unit from gear case by means of pry bar S Pry bar 5870 345 065 Remove hollow shaft Loosen the two socket head screws and remove them along with disk SPC000007 Transmission and Torque Converter Page 190 Figure 1 Figure 2 Figure 3 Figure 4 ...

Page 419: ...t of the housing Demount locking screw and shift lever and remove sliding collar NOTE Mark the radial installation position of the shift lever Loosen the two set screws Transmission and Torque Converter SPC000007 Page 191 Figure 5 Figure 6 Figure 7 Figure 8 ...

Page 420: ...shift fork Remove disk Fasten housing in a vise use protecting jaws and pry shaft seal out of the housing bore Remove sleeve and squeeze circlip out SPC000007 Transmission and Torque Converter Page 192 Figure 9 Figure 10 Figure 11 Figure 12 ...

Page 421: ...ft seal with the sealing lip lacing the oil chamber NOTE By application 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 If not use a sealing compound Grease sealing lip S Driver 5870 048 134 Transmission and Torque Converter SPC000007 Page 193 Figure 13 Figure 15 Figure 16 Figure 17 ...

Page 422: ...ly essential see Figure 25 Install sliding blocks Arrows 1 position shift fork and fix it by means of gearshift shaft NOTE Pay attention to the installation position of the sliding blocks chamfered end face is showing to the rear Realize the overlapaping of the gearshift shaft countersinkings Arrow Figure 20 and the tapped holes of the shift fork and install the two set screws NOTE Secure set scre...

Page 423: ...iding 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 NOTE If the required end play 0 1 0 2 mm is not obtained correct with corresponding shims see Figure 19 Now remove hollow shaft again Transmission and Torque Converter SPC000007 Page 195 Figure 22 Figure 23 Figure 24 Figure 25 ...

Page 424: ...s condition NOTE In case of a correct adjustment a slight tilting play on the sliding collar can be noted If necessary correct it by means of shim Arrow Figure 26 The Illustration on the right shows the components of the locking screw 1 Spring bush 2 Sealing ring 3 Compression spring 4 Ball Insert compression spring and ball in the spring bush and preload them in a vise Fix the ball by indents 3 x...

Page 425: ... the markings Insert closing cover Arrow until contact is obtained and fix it by slight central tapping NOTE Wet sealing surfaces with Loctite Type No 270 Insert disk and assemble sleeve NOTE Pay attention to the installation position of the sleeve Fix sleeve by means of disk and socket head screws Torque limit M10 8 8 DIN 6912 32 Nm NOTE Secure socket head screws with Loctite Type No 270 Transmis...

Page 426: ... puller 5870 300 010 Tilt gear case 180 Loosen hex head screws and pull output flange from the shaft s Clamping yoke 5870 240 025 Pry shaft seal out of the housing bore S Pry bar 5870 345 071 Remove circlip and shim S Clamping pliers 5870 900 021 SPC000007 Transmission and Torque Converter Page 198 Figure35 Figure 36 Figure 37 Figure 38 ...

Page 427: ...re Drive output shaft by means of striker out of the housing bore S Striker 870 650 001 Squeeze circlip out and remove shim Pull roller bearing out of the housing bore S Puller 5870 300 010 Transmission and Torque Converter SPC000007 Page 199 Figure 39 Figure 40 Figure 41 Figure 42 ...

Page 428: ...h flat washers Figure 44 Now take cover plate out of the gear case Figure 45 Loosen socket head screws and remove supporting tube NOTE Socket head screws are secured with Loctite S Allen screw A F 8 5870 290 001 SPC000007 Transmission and Torque Converter Page 200 Figure 43 Figure 44 Figure 45 Figure 46 ...

Page 429: ...tion 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 Take supporting plate out of the gear case Transmission and Torque Converter SPC000007 Page 201 Figure 47 Figure 48 Figure 49 Figure 50 ...

Page 430: ...carrier is ensured Take the output gear out of the gear case Drive roll pins carefully in until contact is obtained Press planetary shafts out of the bores and remove released components SPC000007 Transmission and Torque Converter Page 202 Figure 51 Figure 52 Figure 53 Figure 54 ...

Page 431: ...e installation position of the thrust washer 4 smaller inner diameter see Arrow Insert needle rollers 7 with grease in the planetary gear Position planetary gear as well as thrust washers and align them centrically Undercool planetary shafts introduce and fix them by means of roll pin Install the remaining planetary gears accordingly NOTE Pay attention to the installation position of the planetary...

Page 432: ...r with the long hub side showing downwards into the internal gear Lay supporting plate upon the output gear Figure 61 and fix it by uniform tightening of the socket head screws Figure 62 Torque limit Ml0 10 9 68 Nm NOTE Secure socket head screws with Loctite Type No 241 SPC000007 Transmission and Torque Converter Page 204 Figure 59 Figure 60 Figure 61 Figure 62 ...

Page 433: ...870 100 035 Introduce supporting tube and fasten it by means of socket head screws Torque limit Ml0 10 9 68 Nm NOTE Secure socket head screws with Loctite Type No 241 S Allen screw A F 8 5870 290 00I Insert roller bearing until the supporting tube is received NOTE In order to ensure a possible disassembly the roller bearing must be installed with the open cage side showing outwards on top The exac...

Page 434: ...ure hex head screws with Loctite Type No 241 Tilt gear case 180 Insert roller bearing until contact is obtained NOTE Pay attention to the installation position open cage side of roller bearing is showing outwards on top Insert sleeve Arrow flush mounted in the hollow shaft SPC000007 Transmission and Torque Converter Page 206 Figure 67 Figure 70 Figure 68 Figure 69 ...

Page 435: ...limit Ml0 8 8 DIN 7984 32 Nm S Adjusting screws MI0 5870 204 007 Tilt gear case 180 Drive differential assembly by careful tapping upon the roller bearing downwards until the exact contact of the lower roller bearing Figure 69 on the shift control housing Figure 72 is ensured Adjust end play of the differential 0 4 0 6 mm Figure 74 76 Squeeze in circlip S Clamping pliers 5870 900 021 Transmission ...

Page 436: ...50 mm Difference Shim e g s 1 00 mm Install shim e g 1 00 mm see Example A and squeeze circlip in Insert needle bush 1 flush mounted in the bore of the output shaft 2 Press ball bearing 3 against shoulder until contact is obtained NOTE Install needle bush with the reinforced shell facing the pressing tool S Driver 5870 058 023 S Handle 5870 260 002 SPC000007 Transmission and Torque Converter Page ...

Page 437: ...the outer diameter of the shaft seal is rubberized wet the sealing surface with spirit If not use a sealing compound Grease sealing lip S Driver 5870 048 150 Assemble up output flange and fasten it by means of disk and hex head screws NOTE Wet contact surface of disk and screw heads with sealing compound Torque limit M10 8 8 46 Nm Now fix hex head screws with lock plate S Clamping yoke 5870 240 02...

Page 438: ...ad screws and mount screw plug Arrow NOTE In tall new flat gasket as well as O Ring Torque limit Hex head screws M8 8 8 23 Nm Torque limit Screw plug M22x1 5 60 Nm Assemble flat gasket and fasten speedometer compl by means of hex head screws on the gear case Torque limit M8 8 8 23 Nm SPC000007 Transmission and Torque Converter Page 210 Figure 82 Figure 83 Figure 84 ...

Page 439: ...Remove components according to the Illustration on the right Loosen socket head screws and remove solenoid valve Loosen hex head screws and pull the output flange from the output shaft using puller S Clamping yoke 5870 240 025 Transmission and Torque Converter SPC000007 Page 211 Figure 1 Figure 2 Figure 3 Figure 4 ...

Page 440: ...rews and pull complete clutch out of the housing Squeeze circlip out and remove backing plate as well as plate pack S Clamping pliers 5870 900 021 Remove rectangular ring SPC000007 Transmission and Torque Converter Page 212 Figure 5 Figure 6 Figure 7 Figure 8 ...

Page 441: ...ve released components S Assembly jig 5870 345 028 Remove piston S Clamping pliers 5870 900 007 Squeeze out circlip Press output shaft compl out of the ball bearing Transmission and Torque Converter SPC000007 Page 213 Figure 9 Figure 10 Figure 11 Figure 12 ...

Page 442: ... ball bearing out of the cover Preload circlip Arrow align it centrically and squeeze it out Press drive shaft out of the housing bore SPC000007 Transmission and Torque Converter Page 214 Figure 13 Figure 14 Figure 15 Figure 16 ...

Page 443: ...clip out Press ball bearing from the drive shaft Pull needle bush out of the drive shaft bore S Internal puller 5870 300 004 S Back up tool 5870 300 003 Transmission and Torque Converter SPC000007 Page 215 Figure 17 Figure 18 Figure 19 Figure 20 ...

Page 444: ...inst shoulder until contact is obtained Insert needle bush in the drive shaft bore until contact is obtained NOTE Install needle bush with the reinforced shell facing the pressing tool S Driver 5870 058 013 S Handle 5870 260 002 Fix ball bearing by means of circlip SPC000007 Transmission and Torque Converter Page 216 Figure 21 Figure 22 Figure 23 Figure 24 ...

Page 445: ... and align them centrically Press drive shaft into the housing bore until contact is obtained Preload circlip align centrically and squeeze it into the annular groove of the housing Transmission and Torque Converter SPC000007 Page 217 Figure 25 Figure 26 Figure 27 ...

Page 446: ...lip type sealing rings and insert piston carefully until contact is obtained S Clamping pliers 5870 900 007 Install compression spring and disk NOTE Install disk with the reduced plane surface facing the compression spring Preload compression spring by means of assembly jig S and fix it by means of circlip Arrow S Assembly jig 5870 345 028 SPC000007 Transmission and Torque Converter Page 218 Figur...

Page 447: ... Oil plate pack prior to the installation Mount backing plate and fix plate pack by means of circlip S Clamping pliers 5870 900 021 Check operation of the clutch by means of compressed air Squeeze rectangular ring into the annular groove Arrow and engage it Transmission and Torque Converter SPC000007 Page 219 Figure 32 Figure 33 Figure 34 Figure 35 ...

Page 448: ...xact installation position is obtained If the outer diameter of the shaft seal is rubberized wet the sealing surface with spirit If not use a sealing compound Crease scaling lip S Driver 5870 055 05 S Handle 5870 260 002 Support the bearing inner race of the ball bearing and press cover against shoulder until contact is obtained SPC000007 Transmission and Torque Converter Page 220 Figure 36 Figure...

Page 449: ... Insert hex head screws with Loctite Type No 241 S Clamping yoke 5870 240 025 Install two adjusting screws and replace flat gasket Grease rectangular ring Figure 35 align it centrically and introduce the complete clutch until contact is obtained S Adjusting screws M8 5870 204 011 Fasten clutch by means of hex head screws Torque limit M8 8 8 23 Nm Transmission and Torque Converter SPC000007 Page 22...

Page 450: ...leeve 7 Spool 8 O Ring 9 Cover 10 Hex head screw Torque limit M6 8 8 9 5 Nm NOTE Pay attention to the installation position of the spool 2 Install disk 5 with the chamfering facing the sleeve Install two adjusting screws and assemble flat gasket as well as shift control housing Now fasten shift control housing by means of hex head screws use flat washers Torque limit M8 8 8 23 Nm S Adjusting screw...

Page 451: ...se 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 MODEL SERIAL NUMBER RANGE SD310 010001 and Up Copyright 2012 DISD July 2012 Front Axle SPC000009 Page 1 ...

Page 452: ...B DRIVE AXLE 6 MAIN DRIVE ASSEMBLY 8 DRIVE AXLE BRAKE ASSEMBLY 10 SCHEDULED MAINTENANCE 11 EVERY MONTH MAINTENANCE 11 EVERY HALF YEAR MAINTENANCE 11 EVERY YEAR MAINTENANCE 11 GENERAL DISASSEMBLY AND REASSEMBLY INSTRUCTIONS 12 AXLE DISASSEMBLY 13 DISASSEMBLY OF DRIVE AXLE 13 ASSEMBLY DISMANTLING 18 AXLE REASSEMBLY 27 AXLE ASSEMBLY 27 ASSEMBLY PARTS ASSEMBLING 33 SPC000009 Front Axle Page 2 ...

Page 453: ...ue and make wheels at both sides having speed difference Besides it also plays the role of bearing and transmitting Drive axle assembly of loader is mainly composed of shell main drive including differential mechanism semiaxis hub reduction gear brake caliper assembly and other parts Of which the parts having reduction and differential function is main driver and hub reduction gear power transmiss...

Page 454: ...C 2 HOUSING ASSY AXLE 12 D10 30 PIN 3 COVER ASSY 130 REDUCER ASSY MAIN 4 8 WASHER PLAIN 14 16 WASHER SPRING 5 8 WASHER SPRING 15 M16 1 5 40 8 8 BOLT 6 M8 20 8 8 BOLT 16 PLETE NAME 7 BREATHER 17 RIVET 8 BRAKE UNIT 18 WASHER SEAL 9 20 WASHER SPRING 10 M20 1 5 55 10 9 BOLT SPC000009 Front Axle Page 4 Figure 2 ...

Page 455: ...HOUSING ASSY AXLE Reference Number Description Reference Number Description 1 CAP DUST 3 PLATE MOUNTINGA 2 SPINDLE DRIVE AXLE 4 HOUSING AXLE Front Axle SPC000009 Page 5 Figure 3 ...

Page 456: ...Hub drive axle assembly SPC000009 Front Axle Page 6 Figure 4 ...

Page 457: ...ER ROLLER 6 PLUG MAGNETIC 23 HUB 7 BOLT HUB 24 20 WASHER SPRING 8 CARRIER PLANETARY GEAR 25 M20 1 5 8 NUT 9 RING O 26 GASKET 10 WASHER 27 BEARING TAPER ROLLER 11 SPACER 28 SLEEVE 12 GEAR PLANET 29 SEAL 13 BEARING NEEDLE 30 HOLDER OIL SEAL 14 STEEL BALL 31 M8 20 10 9BOLT 15 SHAFT 32 DISK BRAKE 16 SHAFT AXLE 33 M20 1 5 50 8 8 BOLT 17 RING RETAININ 34 WASHER SEAL Front Axle SPC000009 Page 7 ...

Page 458: ...Main drive assembly SPC000009 Front Axle Page 8 Figure 5 ...

Page 459: ... DIFFERENTIAL 9 SLEEVE 28 PIN 10 1 SHIM 29 WASHER 10 2 SHIM 30 GEAR DIFFERENTIAL 10 3 SHIM 31 SPIDER 10 4 SHIM 32 GEAR DIFFERENTIAL 11 NUT 33 WASHER 12 WASHER PLAIN 34 BOLT 13 FLANGE ASSY 35 GEAR HELICAL 14 CAP DUST 36 CASE DIFFERENTIAL 15 SEAL 37 WASHER 16 M14 60 8 8 BLOT 38 M16 1 5 10 NUT 17 14WASHER SPRING 39 M16 1 5 150 10 9 BLOT 18 HOLDER OIL SEAL 40 PLATE FIXED 19 BEARING TAPER ROLLER 41 10W...

Page 460: ...umber Description 1 EXTERIOR BRAKE 9 20 1 6 O RING 2 PISTON 10 SUPPORT DEFLATING VALVE 3 RECTANGULAR SEAL 11 DEFLATING VALVE 4 DUST CASE 12 WASHER 5 BLOCK RING 13 BOLT 6 BRAKE DISK 14 SPLIT PIN 7 20 2 4 O RING 15 PIN 8 INNER BRAKE SPC000009 Front Axle Page 10 Figure 6 ...

Page 461: ...r 2 Check abrasion condition of differential mechanism gear 3 Check abrasion condition of hub gear 4 Check abrasion condition of needle bearing of hub planetary gear 5 Requirements of installation and debugging items after overhaul checking 1 After assembling axle shaft gear and bevel gear shall move flexibly with hand touching rather than locking The Min gear backlash of gear is 0 18 0 23mm Tooth...

Page 462: ... clean shop and should be as dust free as possible 5 Make sure tools and equipment are at hand 6 When reassembling Daewoo strongly recommends to replace the following parts with new Seal Rings O rings Gaskets Threaded rings with notched collar Any component damaged during disassembly 7 When mounting heat fitted components make sure of their proper position and direction of assembly after they have...

Page 463: ...tc same as following situation which will not state again 3 Dismantle brake caliper assembly Loosen the connection bolts between brake caliper and brake caliper support dismantle brake caliper assemble 4 Release gear oil from Loosen hub oil releasing drain plug and shell oil releasing drain plug turn on slowly with hands to avoid oil spilling Note Store gear oil with clean container Front Axle SPC...

Page 464: ...le end cap 7 Dismantle locating block Take down locating block with hands Note If it is tight when taking down please use assistant tools to pry out 8 Dismantle stop collar Dismantle stop collar from semiaxis with stop collar pincers Note Before dismantling stop collar pull out a section of semiaxis from shell Note It must clamp firmly when using stop collar pincers to avoid safety hazard when it ...

Page 465: ...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 12 O Ring Dismantle O ring from planet carrier Front Axle SPC000009 Page 15 Figure 15 Figure 16 Figure 17 Figure 18 ...

Page 466: ...embly 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 16 Dismantle spacer bush Take out spacer bush Remark Dismantle all parts at the other side with the same method SPC000009 Front Axle Page 16 Figure 19 F...

Page 467: ...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 parts inside are knocked again during suspending and dismantling process Front Axle SPC000009 Page 17 Figure 23 ...

Page 468: ...net carrier assembly 1 Put planet carrier on working platform horizontally 2 Take out planet axle with tools 3 Take out steel balls 4 Take out planet wheel and gasket SPC000009 Front Axle Page 18 Figure 24 Figure 25 Figure 26 Figure 27 ...

Page 469: ...ler from inside of planet wheel Dismantle hub assembly 1 Put hub assembly on working platform 2 Loosen connection bolts between brake disc and hub 3 Take out brake disc Front Axle SPC000009 Page 19 Figure 28 Figure 29 Figure 30 Figure 31 ...

Page 470: ... seat and asbestos gasket 5 Take out bearing Dismantle main drive assembly 1 Put main drive assembly input flange upward horizontally and fixed on supporting 2 Dismantle thrust bolts SPC000009 Front Axle Page 20 Figure 32 Figure 33 Figure 34 Figure 35 ...

Page 471: ...ange 5 Dismantle connection bolts between sealing cover and bearing sleeve take out sealing cover 6 Turn main drive for 180 dismantle bolts of Fastening lock plate take out lock plate Front Axle SPC000009 Page 21 Figure 36 Figure 37 Figure 38 Figure 39 ...

Page 472: ...ack to original position during assembling 8 Dismantle connection bolts of bearing seat and take out bearing seat 9 Dismantle adjusting nuts 10 Dismantle bearing outer ring SPC000009 Front Axle Page 22 Figure 40 Figure 41 Figure 42 Figure 43 ...

Page 473: ...ctive spiral bevel gear assembly and bracket with jackscrew Dismantle differential assembly 1 Put differential assembly vertically on working platform and guarantee it is stable 2 Dismantle bearing on left and right shell of differential mechanism Front Axle SPC000009 Page 23 Figure 44 Figure 45 Figure 46 Figure 47 ...

Page 474: ... connection screws of left and right shell separate shell of differential mechanism Note Before taking out driven spiral bevel gear please checkor mark assembling sign first so that it can be placed back to the original position 5 Take out semiaxis gear gasket and semiaxis gear 6 Take out joint cross and differential gear together take out differential gear gasket and gear from joint cross SPC0000...

Page 475: ...bearing sleeve clamp down on thread end of active spiral bevel gear assembly with down device Note Do not clamp too much to avoid damaging flange pull out bearing sleeve from active spiral bevel gear assembly 2 Reverse bevel gear assembly and take out inner bearing ring 3 Take out bearing block Front Axle SPC000009 Page 25 Figure 52 Figure 53 Figure 54 Figure 55 ...

Page 476: ...4 Take out adjusting gasket 5 Take out spacer bush SPC000009 Front Axle Page 26 Figure 56 Figure 57 ...

Page 477: ... thread sealant 2 Spacer bush Overturn shell and install bearing spacer bush Chamfered side of the spacer faced axle hump 3 Wheel hub assembly Coat lubrication grease on hub supporting axle of shell assembly assembly wheel hub assembly on both sides of supporting axle of shell assembly Assembly bearing inner ring on the larger side of wheel hub Front Axle SPC000009 Page 27 Figure 58 Figure 59 Figu...

Page 478: ...tion is not within the range of 160 10N adjust tightness degree of round bolts according to the indication until it is within the range of 160 10N In the end coat Letai 262 thread fastening sealant for 5 6 from the second thread hole of internal gear form a liquid level at 1 3 circle of thread then fasten bolts and fix round nuts Note Before dynamometry rotate hub wheel for more than 5 times Letai...

Page 479: ... wheel hub with rim bolts gaskets and nuts Note fastening torque 500 10Nm 8 Assemble semiaxis Install semiaxis assembly with sun gear on hub pay attention to semiaxis multiple spline and gear assembly 9 Assemble sun gear Assemble sun gear at one side of semiaxis with baffle ring groove Front Axle SPC000009 Page 29 Figure 65 Figure 66 Figure 67 Figure 68 ...

Page 480: ...l ball 12 Assemble end cap Assemble end cap Note Fasten all screws according to symmetrical and crossing principle Fastening torque 110 130Nm Letai Silicone Rubber 598 planar sealant Letai 262 thread fastening sealant 13 Assemble brake caliper assembly Assemble disc brake on brake caliper supporting fix with bolts and gaskets Note Fastening torque 550 40Nm Coat Letai 262 thread fastening sealant a...

Page 481: ...ore than ten minutes Note Letai 598 silicon rubber surface sealant 16 Assemble main drive Hand up main drive assembly with overhead crane put main drive at main drive shell of the axle assemble locating pin 17 Assemble bolts Coat proper Letai 262 threat fastening sealant on bolts the coating position is 15mm length at thread end Fasten main drive assembly and shell assembly with bolts and gaskets ...

Page 482: ...aerobic type pipe threat sealant Fastening torque 175 235 Nm 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 SPC000009 Front Axle Page 32 Figure 77 Figure 78 ...

Page 483: ...er ring 2 turn over to keep the small end of hub upward and assemble bearing outer ring 3 Bearing inner ring assembled 4 Check completeness of oil seal Coat lubrication oil in oil seal seat evenly and assemble oil seal in oil seal seat Front Axle SPC000009 Page 33 Figure 79 Figure 82 Figure 80 Figure 81 ...

Page 484: ...ake disc on hub and fasten with bolts and gaskets Note Fastening torque 360 20Nm Fasten all screws according to symmetrical and crossing principle Assemble planet carrier assembly 1 Stick lubrication grease quill roller 27 units each on walls of inner holes of planet gears assemble baffle ring in the middle of quill roller 2 Assemble gaskets at both sides of planet gear SPC000009 Front Axle Page 3...

Page 485: ...e of planet gear and gasket and assemble on planet carrier After assembly planet gear shall rotate flexibly there is no blocking Install of main drive assembly 1 Assemble rolling bearing on bear neck of the terminal with pressure machine rotate to the left on active spiral bevel gear front axle and rotate to the right side 2 Assemble circlip Front Axle SPC000009 Page 35 Figure 88 Figure 89 Figure ...

Page 486: ... into rolling bearing with press ure machine at the other side 4 Turn over gear and assemble outer ring of gear 5 Install spacer bush 6 Install gaskets SPC000009 Front Axle Page 36 Figure 91 Figure 92 Figure 93 Figure 94 ...

Page 487: ...ill accelerate abrasion of taper rolling bearing Press with P 5420 kg pressure at the top side of inner ring of rolling bearing grapple Φ14 5 hole with pull and push ergometer pull ergometer along with tangential direction indication of ergometer when pushing shall be 17 34 30 06N if the indication is not within the range of 17 34 30 06N increase or reduce thickness of spacer shim repeat the above...

Page 488: ...ition of left shell terminal of differential mechanism 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 5 Install semiaxis gear SPC000009 Front Axle Page 38 Figure 100 Figure 101 Figure 102 Figure 99 ...

Page 489: ...fferential mechanism align Note Coat proper Letai 262 thread fastening sealant at the thread bottom within 12mm length Note After assembling semiaxis gear and taper gear can be rotated manually without blocking 8 Install driven spiral bevel gear Aim at assembling mark fasten driven spiral bevel gear Rotate to the left for rear axle rotate to the right for front axle with bolts gaskets and nuts and...

Page 490: ...l the assembled active sprial bevel gear assembly in bracket 3 Coat sealant line with diameter 2 4mm at the small end refer to the picture for sealant line sealant line and diameter of bearing sleeve the other side of gasket shall be done according to the above requirements 4 Assemble sealing cover Press oil seal in sealing cover Note Coat a layer of proper lubrication oil when assembling oil seal...

Page 491: ...nect with bracket with bolts and gaskets Note Screw fastening torque 145 5Nm 6 Install input flange 7 Coat sealant on one end face of gasket the surface with sealant is downward install gasket Note Letai 598 sealant 8 Install round screws and fasten Note Screw fastening torque 320 400 Nm Note Letai 598 sealant Front Axle SPC000009 Page 41 Figure 111 Figure 112 Figure 113 Figure 114 ...

Page 492: ...read end surface of bolts 11 Adjust spiral bevel gear Adjustment of spiral bevel gear mesh condition refers to adjustment of mesh zone and back lash when adjusting back lash of spiral bevel gear pair dial gauge can be used to touch the gear surface of large side edge of driven spiral bevel gear then rotate driven spiral bevel gear to measure back lash directly the clearance shall be 0 2 0 35mm Adj...

Page 493: ...th height smaller than the small end on teeth length direction Increasing preload of differential bearing after adjusting back lash of spiral bevel gear well it shall guarantee the clearance between taper rolling bearing at both sides of differential mechanism is 0 Following is the adjusting methods Adjustment of contact zone and back lash when installing spiral bevel gear Contact zone of driven s...

Page 494: ... 5 10mm length at the end surface of fixing bolt Note Coat Letai 262 thread fastening sealant 13 Install thrust bolts Overturn carrier press copper cover into the side with thrust bolts twist into the center of carrier make copper contact with the back of driven spiral bevel gear of differential assembly reverse for 1 6 1 4 circles fasten with nuts and lock plate Note Letai 598 sealant 14 Bend one...

Page 495: ...se 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 MODEL SERIAL NUMBER RANGE SD310 010001 and Up Copyright 2012 DISD July 2012 Rear Axle SPC000010 Page 1 ...

Page 496: ...B DRIVE AXLE 6 MAIN DRIVE ASSEMBLY 8 DRIVE AXLE BRAKE ASSEMBLY 10 SCHEDULED MAINTENANCE 11 EVERY MONTH MAINTENANCE 11 EVERY HALF YEAR MAINTENANCE 11 EVERY YEAR MAINTENANCE 11 GENERAL DISASSEMBLY AND REASSEMBLY INSTRUCTIONS 12 AXLE DISASSEMBLY 13 DISASSEMBLY OF DRIVE AXLE 13 ASSEMBLY DISMANTLING 17 AXLE REASSEMBLY 26 AXLE ASSEMBLY 26 ASSEMBLY PARTS ASSEMBLING 32 SPC000010 Rear Axle Page 2 ...

Page 497: ...d make wheels at both sides having speed difference Besides it also plays the role of bearing and transmitting Drive axle assembly of loader is mainly composed of shell main drive including differential mechanism semiaxis hub reduction gear brake caliper assembly and other parts Of which the parts having reduction and differential function is main driver and hub reduction gear power transmission b...

Page 498: ...ER ASSY WHEEL 11 REDUCER ASSY MAIN 2 HOUSING ASSY AXLE 12 16 WASHER SPRING 3 BREATHER 13 M16 1 5 40 8 8 BOLT 4 BRAKE UNIT 14 WASHER SEAL 5 20 WASHER SPRING 15 6 M20 1 5 55 10 9 BOLT 16 7 PLUG MAGNETIC 17 8 PLETE NAME 18 9 RIVET 10 D10 30 PIN SPC000010 Rear Axle Page 4 Figure 2 ...

Page 499: ...HOUSING ASSY AXLE Reference Number Description Reference Number Description 1 CAP DUST 4 HOUSING AXLE 2 SPINDLE DRIVE AXLE 5 SEAT 3 PLATE MOUNTINGA Rear Axle SPC000010 Page 5 Figure 3 ...

Page 500: ...Hub drive axle assembly SPC000010 Rear Axle Page 6 Figure 4 ...

Page 501: ...ER ROLLER 6 PLUG MAGNETIC 23 HUB 7 BOLT HUB 24 20 WASHER SPRING 8 CARRIER PLANETARY GEAR 25 M20 1 5 8 NUT 9 RING O 26 GASKET 10 WASHER 27 BEARING TAPER ROLLER 11 SPACER 28 SLEEVE 12 GEAR PLANET 29 SEAL 13 BEARING NEEDLE 30 HOLDER OIL SEAL 14 STEEL BALL 31 M8 20 10 9BOLT 15 SHAFT 32 DISK BRAKE 16 SHAFT AXLE 33 M20 1 5 50 8 8 BOLT 17 RING RETAININ 34 WASHER SEAL Rear Axle SPC000010 Page 7 ...

Page 502: ...Main drive assembly SPC000010 Rear Axle Page 8 Figure 5 ...

Page 503: ... DIFFERENTIAL 9 SLEEVE 28 PIN 10 1 SHIM 29 WASHER 10 2 SHIM 30 GEAR DIFFERENTIAL 10 3 SHIM 31 SPIDER 10 4 SHIM 32 GEAR DIFFERENTIAL 11 NUT 33 WASHER 12 WASHER PLAIN 34 BOLT 13 FLANGE ASSY 35 GEAR HELICAL 14 CAP DUST 36 CASE DIFFERENTIAL 15 SEAL 37 WASHER 16 M14 60 8 8 BLOT 38 M16 1 5 10 NUT 17 14WASHER SPRING 39 M16 1 5 150 10 9 BLOT 18 HOLDER OIL SEAL 40 PLATE FIXED 19 BEARING TAPER ROLLER 41 10W...

Page 504: ...umber Description 1 EXTERIOR BRAKE 9 20 1 6 O RING 2 PISTON 10 SUPPORT DEFLATING VALVE 3 RECTANGULAR SEAL 11 DEFLATING VALVE 4 DUST CASE 12 WASHER 5 BLOCK RING 13 BOLT 6 BRAKE DISK 14 SPLIT PIN 7 20 2 4 O RING 15 PIN 8 INNER BRAKE SPC000010 Rear Axle Page 10 Figure 6 ...

Page 505: ...r 2 Check abrasion condition of differential mechanism gear 3 Check abrasion condition of hub gear 4 Check abrasion condition of needle bearing of hub planetary gear 5 Requirements of installation and debugging items after overhaul checking 1 After assembling axle shaft gear and bevel gear shall move flexibly with hand touching rather than locking The Min gear backlash of gear is 0 18 0 23mm Tooth...

Page 506: ... clean shop and should be as dust free as possible 5 Make sure tools and equipment are at hand 6 When reassembling Daewoo strongly recommends to replace the following parts with new Seal Rings O rings Gaskets Threaded rings with notched collar Any component damaged during disassembly 7 When mounting heat fitted components make sure of their proper position and direction of assembly after they have...

Page 507: ...support dismantle brake caliper assemble 3 Release gear oil from Loosen hub oil releasing drain plug and shell oil releasing drain plug turn on slowly with hands to avoid oil spilling Note Store gear oil with clean container 4 Release gear oil from shell Turn on oil releasing bolts axle end cap to release gear oil Note Store gear oil with clean container Rear Axle SPC000010 Page 13 Figure 7 Figure...

Page 508: ...t when taking down please use assistant tools to pry out 7 Dismantle stop collar Dismantle stop collar from semiaxis with stop collar pincers Note Before dismantling stop collar pull out a section of semiaxis from shell Note It must clamp firmly when using stop collar pincers to avoid safety hazard when it is popup 8 Dismantle sun gear Dismantle semiaxis from sun gear SPC000010 Rear Axle Page 14 F...

Page 509: ...dismantle planet carrier assembly Note Please slowly loosen planet carrier to avoid safety hazard resulted from dropping of planet carrier assembly 11 O Ring Dismantle O ring from planet carrier 12 Dismantle round bolts Pry up wire of bolt loosen the clamp bolt of round nuts then dismantle round nuts Rear Axle SPC000010 Page 15 Figure 15 Figure 16 Figure 17 Figure 18 ...

Page 510: ...rocess 15 Dismantle spacer bush Take out spacer bush Remark Dismantle all parts at the other side with the same method 16 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 a...

Page 511: ...anet carrier assembly 1 Put planet carrier on working platform horizontally 2 Take out planet axle with tools 3 Take out steel balls 4 Take out planet wheel and gasket Rear Axle SPC000010 Page 17 Figure 23 Figure 24 Figure 25 Figure 26 ...

Page 512: ...ller from inside of planet wheel Dismantle hub assembly 1 Put hub assembly on working platform 2 Loosen connection bolts between brake disc and hub 3 Take out brake disc SPC000010 Rear Axle Page 18 Figure 27 Figure 28 Figure 39 Figure 30 ...

Page 513: ...l seat and asbestos gasket 5 Take out bearing Dismantle main drive assembly 1 Put main drive assembly input flange upward horizontally and fixed on supporting 2 Dismantle thrust bolts Rear Axle SPC000010 Page 19 Figure 31 Figure 32 Figure 33 Figure 34 ...

Page 514: ...ange 5 Dismantle connection bolts between sealing cover and bearing sleeve take out sealing cover 6 Turn main drive for 180 dismantle bolts of Fastening lock plate take out lock plate SPC000010 Rear Axle Page 20 Figure 35 Figure 36 Figure 37 Figure 38 ...

Page 515: ...ack to original position during assembling 8 Dismantle connection bolts of bearing seat and take out bearing seat 9 Dismantle adjusting nuts 10 Dismantle bearing outer ring Rear Axle SPC000010 Page 21 Figure 39 Figure 40 Figure 41 Figure 42 ...

Page 516: ...active spiral bevel gear assembly and bracket with jackscrew Dismantle differential assembly 1 Put differential assembly vertically on working platform and guarantee it is stable 2 Dismantle bearing on left and right shell of differential mechanism SPC000010 Rear Axle Page 22 Figure 43 Figure 44 Figure 45 Figure 46 ...

Page 517: ...n connection screws of left and right shell separate shell of differential mechanism Note Before taking out driven spiral bevel gear please checkor mark assembling sign first so that it can be placed back to the original position 5 Take out semiaxis gear gasket and semiaxis gear 6 Take out joint cross and differential gear together take out differential gear gasket and gear from joint cross Rear A...

Page 518: ... bearing sleeve clamp down on thread end of active spiral bevel gear assembly with down device Note Do not clamp too much to avoid damaging flange pull out bearing sleeve from active spiral bevel gear assembly 2 Reverse bevel gear assembly and take out inner bearing ring 3 Take out bearing block SPC000010 Rear Axle Page 24 Figure 51 Figure 52 Figure 53 Figure 54 ...

Page 519: ...4 Take out adjusting gasket 5 Take out spacer bush Rear Axle SPC000010 Page 25 Figure 55 Figure 56 ...

Page 520: ... thread sealant 2 Spacer bush Overturn shell and install bearing spacer bush Chamfered side of the spacer faced axle hump 3 Wheel hub assembly Coat lubrication grease on hub supporting axle of shell assembly assembly wheel hub assembly on both sides of supporting axle of shell assembly Assembly bearing inner ring on the larger side of wheel hub SPC000010 Rear Axle Page 26 Figure 57 Figure 58 Figur...

Page 521: ...ation is not within the range of 160 10N adjust tightness degree of round bolts according to the indication until it is within the range of 160 10N In the end coat Letai 262 thread fastening sealant for 5 6 from the second thread hole of internal gear form a liquid level at 1 3 circle of thread then fasten bolts and fix round nuts Note Before dynamometry rotate hub wheel for more than 5 times Leta...

Page 522: ...n wheel hub with rim bolts gaskets and nuts Note fastening torque 500 10Nm 8 Assemble semiaxis Install semiaxis assembly with sun gear on hub pay attention to semiaxis multiple spline and gear assembly 9 Assemble sun gear Assemble sun gear at one side of semiaxis with baffle ring groove SPC000010 Rear Axle Page 28 Figure 64 Figure 65 Figure 66 Figure 67 ...

Page 523: ...l ball 12 Assemble end cap Assemble end cap Note Fasten all screws according to symmetrical and crossing principle Fastening torque 110 130Nm Letai Silicone Rubber 598 planar sealant Letai 262 thread fastening sealant 13 Assemble brake caliper assembly Assemble disc brake on brake caliper supporting fix with bolts and gaskets Note Fastening torque 550 40Nm Coat Letai 262 thread fastening sealant a...

Page 524: ...in drive shell of the axle assemble locating pin 16 Assemble bolts Coat proper Letai 262 threat fastening sealant on bolts the coating position is 15mm length at thread end Fasten main drive assembly and shell assembly with bolts and gaskets Note Fastening torque 180 210Nm Letai 262 threat fastening sealant Fasten all screws according to symmetrical and crossing principle 17 Add oil Add 17L 85W 90...

Page 525: ...wing 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 Rear Axle SPC000010 Page 31 Figure 76 ...

Page 526: ...er ring 4 turn over to keep the small end of hub upward and assemble bearing outer ring 3 Bearing inner ring assembled 4 Check completeness of oil seal Coat lubrication oil in oil seal seat evenly and assemble oil seal in oil seal seat SPC000010 Rear Axle Page 32 Figure 77 Figure 80 Figure 78 Figure 79 ...

Page 527: ...ake disc on hub and fasten with bolts and gaskets Note Fastening torque 360 20Nm Fasten all screws according to symmetrical and crossing principle Assemble planet carrier assembly 1 Stick lubrication grease quill roller 27 units each on walls of inner holes of planet gears assemble baffle ring in the middle of quill roller 2 Assemble gaskets at both sides of planet gear Rear Axle SPC000010 Page 33...

Page 528: ...le of planet gear and gasket and assemble on planet carrier After assembly planet gear shall rotate flexibly there is no blocking Install of main drive assembly 1 Assemble rolling bearing on bear neck of the terminal with pressure machine rotate to the left on active spiral bevel gear Rear Axle and rotate to the right side 2 Assemble circlip SPC000010 Rear Axle Page 34 Figure 86 Figure 87 Figure 8...

Page 529: ... into rolling bearing with press ure machine at the other side 4 Turn over gear and assemble outer ring of gear 5 Install spacer bush 6 Install gaskets Rear Axle SPC000010 Page 35 Figure 89 Figure 90 Figure 91 Figure 92 ...

Page 530: ...will accelerate abrasion of taper rolling bearing Press with P 5420 kg pressure at the top side of inner ring of rolling bearing grapple Φ14 5 hole with pull and push ergometer pull ergometer along with tangential direction indication of ergometer when pushing shall be 17 34 30 06N if the indication is not within the range of 17 34 30 06N increase or reduce thickness of spacer shim repeat the abov...

Page 531: ...osition of left shell terminal of differential mechanism 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 5 Install semiaxis gear Rear Axle SPC000010 Page 37 Figure 98 Figure 99 Figure 100 Figure 97 ...

Page 532: ...ifferential mechanism align Note Coat proper Letai 262 thread fastening sealant at the thread bottom within 12mm length Note After assembling semiaxis gear and taper gear can be rotated manually without blocking 8 Install driven spiral bevel gear Aim at assembling mark fasten driven spiral bevel gear Rotate to the left for rear axle rotate to the right for front axle with bolts gaskets and nuts an...

Page 533: ...ll the assembled active sprial bevel gear assembly in bracket 3 Coat sealant line with diameter 2 4mm at the small end refer to the picture for sealant line sealant line and diameter of bearing sleeve the other side of gasket shall be done according to the above requirements 4 Assemble sealing cover Press oil seal in sealing cover Note Coat a layer of proper lubrication oil when assembling oil sea...

Page 534: ...nnect with bracket with bolts and gaskets Note Screw fastening torque 145 5Nm 6 Install input flange 7 Coat sealant on one end face of gasket the surface with sealant is downward install gasket Note Letai 598 sealant 8 Install round screws and fasten Note Screw fastening torque 320 400 Nm Note Letai 598 sealant P002343 Rear Axle Page 40 Figure 109 Figure 110 Figure 111 Figure 112 ...

Page 535: ...read end surface of bolts 11 Adjust spiral bevel gear Adjustment of spiral bevel gear mesh condition refers to adjustment of mesh zone and back lash when adjusting back lash of spiral bevel gear pair dial gauge can be used to touch the gear surface of large side edge of driven spiral bevel gear then rotate driven spiral bevel gear to measure back lash directly the clearance shall be 0 2 0 35mm Adj...

Page 536: ...th height smaller than the small end on teeth length direction Increasing preload of differential bearing after adjusting back lash of spiral bevel gear well it shall guarantee the clearance between taper rolling bearing at both sides of differential mechanism is 0 Following is the adjusting methods Adjustment of contact zone and back lash when installing spiral bevel gear Contact zone of driven s...

Page 537: ...n 5 10mm length at the end surface of fixing bolt Note Coat Letai 262 thread fastening sealant 13 Install thrust bolts Overturn carrier press copper cover into the side with thrust bolts twist into the center of carrier make copper contact with the back of driven spiral bevel gear of differential assembly reverse for 1 6 1 4 circles fasten with nuts and lock plate Note Letai 598 sealant 14 Bend on...

Page 538: ...SPC000010 Rear Axle Page 44 ...

Page 539: ...1HYDRAULICS ...

Page 540: ......

Page 541: ...se 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 MODEL SERIAL NUMBER RANGE SD310 010001 and Up Copyright 2012 DISD July 2012 Cylinder SPC000011 Page 1 ...

Page 542: ...TABLE OF CONTENTS GENERAL DESCRIPTION 3 WORKING PRINCIPLE 3 DETAILED LIST OF SPARE PARTS 4 DISASSEMBLING AND ASSEMBLING STEPS 5 SPC000011 Cylinder Page 2 ...

Page 543: ...raight line movement of output force and piston effective area and the pressure difference at both sides It is used to change hydraulic energy into mechanic energy The input of cylinder is flow rate and pressure of fluid the output is speed and force of straight line movement Piston of cylinder can finish straight line alternating motion the output straight line displacement is limited Cylinder is...

Page 544: ...Dust ring 13 SPGO 3 Obturating ring 14 Piston 4 Support ring 15 Socket head cap screw 5 Cushion seal 16 Port protecting cover 6 Support ring 17 Hole protecting cover 7 Four fluorine block circle 18 Oil cup 8 O RING 19 Cylinder end bush 9 Guide sleeve 20 bush 10 Cylinder block 21 Bolt 11 O RING 22 Washer SPC000011 Cylinder Page 4 ...

Page 545: ...ylinder 1 Put the cylinder on special supporting vertically screw down bolts of cylinder cover with pneumatic wrench or torque wrench refer to figure 3 2 Hang piston rod assembly out from cylinder and put it on special protective support refer to figure 4 3 Twist piston lock screw with special tools refer to figure 5 Cylinder SPC000011 Page 5 Figure 4 Figure 3 Figure 5 ...

Page 546: ...iston tightening tool and jackhammer refer to figure 6 5 Dismantle piston and cylinder cover assembly refer to figure 7 6 Dismantle sealing parts with special tools refer to figure 8 SPC000011 Cylinder Page 6 Figure 6 Figure 7 Figure 8 ...

Page 547: ... 1 Install sealing parts of cylinder refer to figure 9 2 Install cylinder cover assembly refer to figure 10 3 Install piston with special tools refer to figure 11 Cylinder SPC000011 Page 7 Figure 9 Figure 10 Figure 11 ...

Page 548: ...s with special tools refer to figure 12 5 Put piston rod in cylinder barrel refer to figure 13 6 Screw down bolts of cylinder cover and cylinder barrel refer to figure 14 SPC000011 Cylinder Page 8 Figure 12 Figure 13 Figure 14 ...

Page 549: ...se 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 MODEL SERIAL NUMBER RANGE SD310 010001 and Up Copyright 2012 DISD July 2012 Main Pump SPC000012 Page 1 ...

Page 550: ...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: ...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 At the other oil outlet side the size is smaller because of gear mesh hydraulic oil is squeezed out gear keeps rotating gear teeth keeps squeezing out hydraulic oil to enter into work oilway and realize constant oil supplying of the system Figure 1 Mai...

Page 552: ...PARTS LIST Figure 2 SPC000012 Main Pump Page 4 ...

Page 553: ...d and broken 3 Castings front cover pump body and rear cover 3 1 If there is flaw on castings and sealing zone has chip rust deformed pin hole then replace castings 3 2 Replace pump body when one of the following conditions happens oil mouth is broken pump body is broken and rusty when bore depth of pump body 0 08mm 4 Round pin round pin must be replaced when the matching does not comply with requ...

Page 554: ...ation impact and the constant running time at the highest pressure on main machine total working time of main pump and reason for returning for maintenance etc 4 Make sure the production is released from the factory as a whole and it is not disassembled after releasing otherwise it is not maintained 5 If there is external leaking do gas tightness checking to the entire pump and find out leaking po...

Page 555: ... by sharp endge of shaft 3 Take out snap ring with proper tool and Remove 2 shaft seal with screwdriver Take out the shaft seals only needed Shaft seals disassembled from the mounting flange is not reusable 4 Remove the pressure plate with prearranged parts O ring back up ring from the working section and examine it carefully Take out square O ring from the groove on the body Be careful not to giv...

Page 556: ...ssembly pressure plates for 1st working section 1 pressure plates for 1st working section Smear clean grease on pressure plate groove Locate O ring into the grove on the aluminum pressure plate Locate back up ring upon the O ring working body 2 Smear clean grease on the square groove Insert square rings into the groove and 4 alignment pins SPC000012 Main Pump Page 8 Figure 7 Figure 9 Figure 8 ...

Page 557: ...prearranged 4 prepare cleaned 2 nd body prearranged guard pins and square O ring Insert a pressure plate prearranged O ring back up ring inside of body Opened area of O ring should face to suction side And O ring side should face to the body Main Pump SPC000012 Page 9 Figure 12 Figure 10 Figure 11 ...

Page 558: ...ble mounting flange to the body use proper tools in order to avoid any damage on the shaft seals by sharp edge of shaft Smear clean grease on the lips of shaft seals before assembling 7 Assemble the bolts and tighten the bolts with in a crisscross pattern to a torque value of 280 Nm SPC000012 Main Pump Page 10 Figure 13 Figure 14 Figure 15 ...

Page 559: ...se 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 MODEL SERIAL NUMBER RANGE SD310 010001 and Up Copyright 2012 DISD July 2012 Steer Pump SPC000013 Page 1 ...

Page 560: ...F 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: ...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 At the other oil outlet side the size is smaller because of gear mesh hydraulic oil is squeezed out gear keeps rotating gear teeth keeps squeezing out hydraulic oil to enter into work oilway and realize constant oil supplying of the system Figure 1 Ste...

Page 562: ...PARTS LIST Figure 2 SPC000013 Steer Pump Page 4 ...

Page 563: ... 5 Driven Gear 21 Sleeve Bearing 6 Screw TCEI 22 Upper Sleeve Bearing 7 Screw TE 23 Sleeve Bearing MB 8 Grub Screw 24 HUB 9 Washer 10 25 Dowel Pin 10 Washer 14 26 Steel Bushes 11 Seal PL K20 27 Driven Gear 12 Seal FP KP HD30 28 Thrust Plate 13 Upper Seal 29 Body PL20 14 Standard Seal 30 Body PL30 15 Seal PL20 31 Upper Thrust Plate 16 Shaft Seal 32 Drive Shaft Steer Pump SPC000013 Page 5 ...

Page 564: ... bearing must be replaced bearing surface is scratched painting coat sheds or copper basement is exposed 6 Secondary sealing ring replace with new parts when there is inner diameter abrasion end face abrasion thickness is milled deformed surface is coarse 7 Non metal sealing parts all non metal sealing parts must be replaced 8 Outboard bearing replace with new parts when parts are worn and rusty 9...

Page 565: ...sen and remove the assembling bolts and washers from the 2 nd pump 2 Remove the complete 2 nd working section Remove through hub 3 Loosen and remove the assembling bolts and washers from the 1 st pump Steer Pump SPC000013 Page 7 Figure 3 Figure 4 Figure 5 ...

Page 566: ... by sharp edge of shaft 5 Take out snap ring with proper tool and Remove 2 shaft seal with screwdriver Take out the shaft seals only needed Shaft seals disassembled from the mounting flange is not reusable 6 Remove the pressure plate with prearranged parts O ring back up ring from the working section and examine it carefully Take out square O ring from the groove on the body Be careful not to give...

Page 567: ...side 8 Remove the pressure plate with prearranged parts O ring back up ring from the working section and examine it carefully Pull out driving gear driven gear keeping gears as straight as possible 9 Remove rear cover and other pressure plate at rear side with same way for front side Steer Pump SPC000013 Page 9 Figure 9 Figure 11 Figure 10 ...

Page 568: ... Assembling of front cover assembly 1 Smear clean grease on pressure plate groove Locate O ring into the grove on the aluminum pressure plate Locate back up ring upon the O ring 2 repeat same procedure SPC000013 Steer Pump Page 10 Figure 13 Figure 12 Figure 14 ...

Page 569: ... 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 5 Smear clean grease on the square grooves insert square rings into the grooves Steer Pump SPC000013 Page 11 Figure 15 Figure 16 Figure 17 ...

Page 570: ...pressure plates 7 Locate shaft seal inside shaft hole to the end insert snap ring and locate it into the groove prearranged 8 Assemble mounting flange to the body use proper tools in order to avoid any damage on the shaft seals by sharp edge of shaft Smear clean grease on the lips of shaft seals before assembling SPC000013 Steer Pump Page 12 Figure 18 Figure 19 Figure 20 ...

Page 571: ...lue of 140 Nm 10 insert a through shaft to the 1 st working section locate 2nd working section to the rear of 1st working section 11 Assemble the bolts and tighten the bolts with in a crisscross pattern to a torque value of 45 Nm Steer Pump SPC000013 Page 13 Figure 21 Figure 22 Figure 23 ...

Page 572: ...12 Check that the pump rotates freely when the drive shaft is turned by hand if not a possible plate seal may be pinched SPC000013 Steer Pump Page 14 Figure 24 ...

Page 573: ...ose 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 MODEL SERIAL NUMBER RANGE SD310 010001 and Up Copyright 2012 DISD July 2012 Main Control Valve SPC000014 Page 1 ...

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: ...eering machines 3 Characteristics a Adopt decompression type pilot valve to control which reduce reversing operating force greatly b Improve jogging feature of multi way valve greatly c Relief valve overload valve oil compensating valve and check valve adopt plug in mounting which has good generality and easy for maintenance d Four floating is easily realized on the basis of three main valves whic...

Page 576: ...Detailed list of spare parts Figure 2 SPC000014 Main Control Valve Page 4 ...

Page 577: ...12x30 14 Make up valve O Ring 45x3 1 15 Overload valve Bolt M10x45 16 Relief valve O Ring 44x3 5 17 Spring Rivet 2x4 Disassembly and assembly steps When repairing the entire valve put multi way valve at a flat and clean place clean all parts after disassembly and then assemble 1 Dismantle and assemble overload valve and relief valve do not loosen locknut when dismantling put wrench at cartridge va...

Page 578: ...or deformed when installing spring and valve rod the clearance between return spring and spring seat when spring is at free state is around 2 5mm 4 Dismantle and assemble check valve Dismantle three end caps of check valve with inner hexagon screw mark on each end cap with chalk check if the check valve is leaking by checking if the spring is deformed and surface normal line of check valve is good...

Page 579: ...e is too high viscosity decreases a Take measures to reduce oil temperature b Selection of oil is improper b Replace oil c Clearance between slide valve and valve is too large c Replace slide valve according to reasonable clearance Fault of relief valve Repair relief valve ３ Resetting does not work Resetting spring is damaged or deformed Replace new ones There is pollutant between valve rod and va...

Page 580: ...SPC000014 Main Control Valve Page 8 ...

Page 581: ...se 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 MODEL SERIAL NUMBER RANGE SD310 010001 and Up Copyright 2012 DISD July 2012 Feed Unit SPC000015 Page 1 ...

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 Work principle Figure 1 Feed Unit SPC000015 Page 3 ...

Page 584: ...DETAILED LIST OF SPARE PARTS Figure 2 Reference Number Description Reference Number Description 1 Reducing Valve 3 Accumulator 2 Solenoid Valve 4 Plug SPC000015 Feed Unit Page 4 ...

Page 585: ...Disassembly and assembly steps Figure 3 Feed Unit SPC000015 Page 5 ...

Page 586: ...SPC000015 Feed Unit Page 6 ...

Page 587: ...se 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 MODEL SERIAL NUMBER RANGE SD310 010001 and Up Copyright 2012 DISD July 2012 Priority Valve SPC000016 Page 1 ...

Page 588: ... 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 8 SPC000016 Priority Valve Page 2 ...

Page 589: ...h multiway valve LS mouth is control mouth connected with load sensing mouth of steering gear T is load discharging mouth connected with oil tank When the load does lifting work oil from steering pump goes through P mouth and a hole and reaches right side of priority valve spool it will overcome control pressure of priority valve spring with the effect of pressure oil pushes priority spool moving ...

Page 590: ... spool 12 O Ring 28X2 65 3 O Ring 26 5X2 65 13 Priority Valve Spring 4 PlugⅠ 14 Priority Valve Gasket 5 Check Valve Spring 15 Priority Spool 6 Relief ValveⅠ 16 O Ring 11 8X2 1 7 O Ring 15X1 8 17 Plug 8 Relief ValveⅡ 18 Check Valve 9 Relief Valve seat 19 PlugⅡ 10 Bolt M10X50 20 Relief Valve Spring SPC000016 Priority Valve Page 4 ...

Page 591: ...rom the left side take out check valve spring check valve and screw out plug from the right side Tools torque electric wrench m27 sleeve m6 inner hexagonal spearhead 3 Screw off relief valve I and relief valve seat on the left take out priority spring priority spool and screw out plug I from the right side Tools torque electric wrench m27 sleeve m22 sleeve and m16 sleeve Priority Valve SPC000016 P...

Page 592: ...y pay attention to protect valve body hole plug combination surface and thread from damaging 3 Check if O ring is deformed trimmed and aged after disassembling usually O ring cannot be used again after disassembling 4 After disassembling valve body and spool shall be cleaned with 32 hydraulic oil check if spool surface has obvious scratch do not use spool and valve body if there is scratch SPC0000...

Page 593: ...e and m16 sleeve 2 Install relief valve I check valve spring check valve and plug into valve body from left to right Tools torque electric wrench m27 sleeve m6 inner hexagonal spearhead 3 Install plug I load discharging valve spring load discharging valve spool and plug II into valve body from left to right Tools torque electric wrench m27 sleeve Priority Valve SPC000016 Page 7 Figure 6 Figure 7 F...

Page 594: ... spool surface and sharp corner slightly with find abrasive paper reclean the valve 3 Avoid to damage trim of O ring when screwing on screw plug it is better to coat grease on the surface before installation Tools for disassembly and assembly Main tools for disassembly and assembly are Torque wrench Electric wrench M27 sleeve M22 sleeve M16 sleeve M6 inner hexagonal spearhead SPC000016 Priority Va...

Page 595: ...s 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 MODEL SERIAL NUMBER RANGE SD310 010001 and Up Steering Unit SPC000017 Page 1 ...

Page 596: ...L DESCRIPTION 3 W ORK PRINCIPLE 3 DETAILED LIST OF SPARE PARTS 4 DISASSEMBLY STEPS OF STEERING UNIT 5 ASSEMBLY STEPS OF STEERING UNIT 11 MATTERS NEED ATTENTION FOR DISASSEMBLING STEERING UNIT 14 SPC000017 Steering Unit Page 2 ...

Page 597: ...through oil mouth B or A returns oil groove through spool and goes back to oil tank through T oil mouth from valve bush The relative rotation angle of spool and valve bush is 1 5 oil way is connected and rotation of rotor makes oil connects with cylinder oil supplying quantity and rotation angle of steering wheel become direct ratio When steering wheel turns right or left for an angle and keeps th...

Page 598: ...ator 2 Front cover 13 O Ring 3 Valve body 14 Spacer Plate 4 Spring lamination 15 Steel Ball 5 Pin 16 Big Baffle Rring 6 Valve bush 17 Thrust Ball Bearing 7 Valve spool 18 Small Baffle Ring 8 Linkage Shaft 19 O Ring 9 Rotor 20 X Ring 10 Limited Post 20 O Ring 11 Rear Cover SPC000017 Steering Unit Page 4 Figure 2 ...

Page 599: ...Disassembly steps of steering unit 1 Take out link block 2 Take out front cover 3 Take out multi roll bearing Steering Unit SPC000017 Page 5 Figure 3 Figure 4 Figure 5 ...

Page 600: ...4 Take out bolts of rear cover 5 Take out rear cover 6 Dismantle stator 7 Dismantle O RING SPC000017 Steering Unit Page 6 Figure 6 Figure 7 Figure 8 Figure 9 ...

Page 601: ...8 Dismantle rotor 9 Take out limitation block 10 Take out link axle 11 Take out clapboard Steering Unit SPC000017 Page 7 Figure 10 Figure 11 Figure 12 Figure 13 ...

Page 602: ...12 Take out valve bush and spool assembly 13 Take out pin 14 Take out spring lamination 15 Take out valve spool SPC000017 Steering Unit Page 8 Figure 14 Figure 15 Figure 16 5 Figure 17 ...

Page 603: ...16 Dismantle valve block 17 Take out check valve 18 Take out oil return throttle valve 19 Take out oil inlet throttle valve Steering Unit SPC000017 Page 9 Figure 18 Figure 19 Figure 21 Figure 20 ...

Page 604: ...20 Take out oil compensating valve 4EA SPC000017 Steering Unit Page 10 Figure 22 ...

Page 605: ... 1 Keep four bolt holes of valve body upward 2 Install valve spool valve bush spring lamination and pin 3 Install well assembled valve spool and valve bush into valve body Steering Unit SPC000017 Page 11 Figure 23 Figure 24 Figure 25 ...

Page 606: ...ller thrust bearing and small baffle ring 5 Install front cover with well assembled sealing ring 6 Keep fourteen holes of steering unit upward 7 Install sealing ring SPC000017 Steering Unit Page 12 Figure 26 Figure 27 Figure 28 Figure 29 ...

Page 607: ...cture 9 Install spacer plate and align the holes 10 Install couple axle stop dial pin with linkage shaft 11 Install turn stator vice note mark on linkage shaft shall align with groove on rotor Steering Unit SPC000017 Page 13 Figure 30 Figure 31 Figure 32 Figure 33 ...

Page 608: ...achines turn around spool install in machine for test if everything is normal 2 Combination surface of valve body spacer plate stator and rear cover must be highly clean do not knock or scratch 3 There is spot mark on end surface of rotor and linkage shaft that is teeth of linkage shaft groove shall align with multiple spline groove inside rotor teeth bottom pay attention to the relative position ...

Page 609: ...se 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 MODEL SERIAL NUMBER RANGE SD310 010001 and Up Copyright 2012 DISD July 2012 Motor SPC000018 Page 1 ...

Page 610: ... 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: ...izione 2 Body 15 Shaft Seal BA 3 Front Cover 16 Shaft Seal G 4 Rear Cover 17 Ring 30 5 Thrust Plate 18 Ring 20 6 Drive Gear 19 Antiextrusion 7 Driven Gear 20 Key 8 Ball Bearing 21 Flange 9 Nut 22 HUB 10 Washer B14 23 Back up Washer 11 Washer 10 24 Support Shaft 12 Seal PL20 25 Dowel Pin 13 Standard Seal PL20 26 Screw ...

Page 613: ...ck if the surface has chip and rust 2 Check model and factory releasing number on nameplate if there is no nameplate on motor check factory releasing number at seam allowance of front cover 3 Fill in relative information on motor returned for maintenance card before disassembling such as manufacturer applicable machine model applicable working condition motor model factory releasing number factory...

Page 614: ...g nut and washer key from the shaft 2 Loosen and remove the assembling bolts and washers from the motor 3 Loosen and remove the valves from the cover follow step 3 4 only when you need to change O rings of the plugs or valves SPC000018 Main Motor Page 6 Figure 3 Figure 4 Figure 5 ...

Page 615: ... and other components remain position 5 Remove shaft seal with screwdriver and take out snap ring with proper tool and shaft seal again Take out the shaft seals only needed Shaft seals disassembled from the mounting flange is not reusable 6 Take out 2nd flange bearing assembled Main Motor SPC000018 Page 7 Figure 7 Figure 6 Figure 8 ...

Page 616: ...s process only for changing bearing or shaft 8 Remove the pressure plate with prearranged parts O ring back up ring from the working section and examine it carefully Pull out driving gear driven gear keeping gears as straight as possible 9 Remove other pressure plate on rear side with same way for front side SPC000018 Motor Page 8 Figure 9 Figure 10 Figure 11 ...

Page 617: ...while moving 2 insert square rings into the grooves Shape of square ring is different depend on direction of body Smear clean grease on the square rings to fix their position while moving 3 Locate O ring first and fix the position with grease Insert bearing shaft assembly Use small hammer to fit the bearing into the flange be careful not to give any damage to the bearing Motor SPC000018 Page 9 Fig...

Page 618: ...and fix the position with grease 5 Load working body on the rear cover 6 Insert pressure plate until it its face meet the rear cover Locate driving gear and driven gear keeping as straight as possible during assembling 7 Locate one of pressure plates prepared Insert through shaft into driving gear SPC000018 Main Motor Page 10 Figure 17 Figure 15 Figure 16 Figure 18 ...

Page 619: ...ls before assembling 9 Assemble the bolts and tighten the bolts with in a crisscross pattern to a torque value of 45 Nm 10 Locate a key on the shaft and load washer and nut Check that the pump rotates freely when the drive shaft is turned by hand if not a possible plate seal may be pinched Main Motor SPC000018 Page 11 Figure 20 Figure 22 Figure 19 Figure 21 ...

Page 620: ...SPC000018 Main Motor Page 12 ...

Page 621: ...se 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 MODEL SERIAL NUMBER RANGE SD310 010001 and Up Copyright 2012 DISD July 2012 Hydraulic Oil Tank SPC000019 Page 1 ...

Page 622: ...TABLE OF CONTENTS General Description 3 Parts List 3 Specifications 4 SPC000019 Hydraulic Oil Tank Page 2 ...

Page 623: ...nce Number Description Reference Number Description 01 Oil Tank 07 Return pipe 02 Filter 08 Drain Plug 03 Filter 09 Cover 04 Spring 10 Level Gauge 05 O ring 11 Flange 06 Return Filter 12 Adapter Hydraulic Oil Tank SPC000019 Page 3 Figure 1 ...

Page 624: ...eal 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 Filter rating 12μ Pressure drop 0 045 MPa 800L min SPC000019 Hydraulic Oil Tank Page 4 ...

Page 625: ...se 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 MODEL SERIAL NUMBER RANGE SD310 010001 and Up Copyright 2012 DISD July 2012 Hydraulic Schematic SD310 SPC000020 Page 1 ...

Page 626: ...TABLE OF CONTENTS GENERAL DESCRIPTION 3 SCHEMATIC DIAGRAM 3 SPC000020 Hydraulic Schematic SD310 Page 2 ...

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 632: ......

Page 633: ...ose 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 MODEL SERIAL NUMBER RANGE SD310 010001 and Up Copyright 2012 DISD July 2012 Brake System SPC000021 Page 1 ...

Page 634: ...ING 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 8 SYSTEM MAINTENANCE AND FAILURES ANALYSIS 9 SPC000021 Brake System Page 2 ...

Page 635: ...ontrol valve When air pressure in air tank reaches the highest braking pressure usually around 0 784MPa of brake system pressure control valve will close the exit going to air tank open load discharging mouth and discharge the compressed air from air compressor to the air directly When compressed air in air tank reaches the lowest pressure usually around 0 71MPa of brake system pressure control va...

Page 636: ...PARTS LIST 2 Structure Chart of Brake System 3 SPC000021 Brake System Page 4 Figure 2 ...

Page 637: ... SEAL RING 38 PIPE 10 VALVE 39 TEE 11 PLUG 40 PIPE 12 VALVE 41 ACCUMULATOR 13 HOSE 42 BOLT 14 HOSE 43 SEAL RING 15 PIPE BRAKE ASSY 16 ADAPTER 101 VALVE BRAKE PEDAL 17 WASHER PLAIN 102 WASHER PLAIN 18 HOSE 103 BOLT 19 ADAPTER 110 SWITCH LAMP 20 HOSE 111 SEAL RING 21 WASHER PLAIN 112 ADAPTER 22 BOLT 117 ADAPTER 23 CLIP 118 BOLT 24 HOSE 25 CLAMP 26 VALVE 27 BOLT 28 BOLT 29 NUT Brake System SPC000021 ...

Page 638: ... 9 RELIEF VALVE ASS Y 2 REGULATING VALVE 10 ORIFICE PLUG 3 EAR DRUM 11 ONE WAY VALVE 4 STEM 12 FILTER ASS Y 5 REGULATING SPRING 13 OIL COLLECTOR 6 UPPER COVER 14 AIR BLEEDING PISTON 7 REGULATING SCREW 15 LOWER SHELL 8 CONTROLING PISTON ASS Y 16 AEROFIOL NUT SPC000021 Brake System Page 6 Figure 3 ...

Page 639: ...rence Number Description 1 MANDRIL 7 VALVE BODY 2 PEDAL ASS Y 8 INTAKE VALVE ASS Y 3 ANTIDUST COVER 9 VALVE ASS Y 4 BALANCING SPRING 10 OUTLET VALVE ASS Y 5 PISTON ASS Y 11 SEALING FIN 6 PISTON FOUR SPRING 12 SPRING SEAT Brake System SPC000021 Page 7 Figure 4 ...

Page 640: ... CYLINDER 8 PISTON 2 Y SEAL RING 9 BREAKING PUMP 3 PISTON 10 AIR OUTLET SCREW 4 RELEASING SPRING 11 PUSHING BORER 5 ENDPLATE 12 MAIN PUMP FUR BOWL 6 STORAGE CUP 13 X SEAL RING 7 PUTTING SEAT SPECIAL TOOLS AND MATERIALS LUBRICANTS SEALANTS AND OIL SPC000021 Brake System Page 8 Figure 5 ...

Page 641: ...is no moving distance which cause braking power is not enough compensation hole of brake pump is blocked by dirt brake fluid cannot go into ante chamber of piston and oil in brake oilway is not enough Brake lags behind 1 Air in brake system is not evacuated air is compressed when braking air resets when releasing brake which affects returning of friction plate 2 Brake air pressure is not enough 3 ...

Page 642: ... special tool shall be used to add brake fluid Replacement of brake fluid and Notes Technicians shall guide clients to use and replace brake fluid strictly when following conditions appear all brake fluid must be replaced immediately 1 When brake fluid is mixed with mineral substance such as gas oil and diesel 2 When vehicle is travelling normally brake is light and heavy 3 When brake fluid in the...

Page 643: ...ose 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 MODEL SERIAL NUMBER RANGE SD310 010001 and Up Copyright 2012 DISD July 2012 Parking System SPC000022 Page 1 ...

Page 644: ...TABLE OF CONTENTS GENERAL DESCRIPTION 3 STRUCTURE OF PARKING BRAKE 3 WORKING PRINCIPLE OF PARKING BRAKE 3 PARTS LIST 4 ASSEMBLY STRUCTURE CHART 4 SPC000022 Parking System Page 2 ...

Page 645: ...brake chamber and store energy The other part goes into the small chamber of stop valve of variable speed control valve and connects with shift gear oilway When emergency and parking brake are needed emergency and parking brake valve is controlled to stop compressed air brake chamber compressed air in stop valve chamber will be discharged into air through quick release valve shift gear oilway is s...

Page 646: ...PARTS LIST Assembly structure chart SPC000022 Parking System Page 4 Figure 1 ...

Page 647: ...umber Description 1 ACCUMULATOR 9 WASHER 2 WASHER 101 VALVE CONTROL 3 ADAPTER 102 WASHER 4 BRACKET 103 ADAPTER 5 ADAPTER 104 HOSE AIR 6 WASHER SPRING 105 HOSE AIR 7 WASHER PLAIN 106 WASHER 8 ADAPTER 107 ADAPTER Parking System SPC000022 Page 5 ...

Page 648: ...SPC000022 Parking System Page 6 ...

Page 649: ...1ELECTRICAL SYSTEM ...

Page 650: ......

Page 651: ...ose 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 MODEL SERIAL NUMBER RANGE SD310 010001 and Up Copyright 2012 DISD July 2012 Air Conditioner SPC000024 Page 1 ...

Page 652: ...TABLE OF CONTENTS GENERAL DESCRIPTION 3 CIRCULATION OF REFRIGERATION AGENT 4 CONTROL PANEL 6 AC SYSTEM CIRCUIT DIAGRAM 7 MAINTENANCE 8 TROUBLE SHOOTING 10 SPC000024 Air Conditioner Page 2 ...

Page 653: ...ontrol panel room at the right of control platform to control indoor temperature AC of the machine has three functions of refrigeration heating and natural wind Reference Number Description Reference Number Description 1 Compressor 4 Evaporator 2 Condenser 5 Control Panel 3 Receiver Drier Air Conditioner SPC000024 Page 3 4 1 2 5 3 Figure 1 AC system schematic diagram ...

Page 654: ...Circulation of refrigeration agent SPC000024 Air Conditioner Page 4 Figure 2 Refrigeration agent circulation schematic diagram ...

Page 655: ...ced too The result is refrigeration agent absorbs heat from surrounding air to create refrigeration effect refrigeration agent is changed from gas state to liquid state Refrigeration agent flows into compressor in gas state again and repeat the above process 7 CAUTION Refrigeration agent is compressed and sealed in AC system Special protective measures are needed when injecting or releasing refrig...

Page 656: ...ontrol switch Control specifications Rotation speed control of air blower CLOSE switch LOW SPEED switch INTERMEDIATE SPEED switch HIGH SPEED switch Compressor control Temperature sensor SPC000024 Air Conditioner Page 6 Figure 3 AC control panel diagram ...

Page 657: ...ence Number Description Reference Number Description 1 Fuse Box 5 Temperature Sensor 2 Blower Switch 6 LED 3 Blower 7 Press Cut Off Switch 4 Thermistor 8 Compressor Air Conditioner SPC000024 Page 7 Figure 4 AC system circuit diagram ...

Page 658: ...ed checking method of belt tightness degree put about 10kg force on middle of belt force is downward descending amplitude of belt is about 10 15mm it cannot be too high or too low maintenance standard check once a week in summer 5 Check if there is refrigeration agent in the system Checking method check Freon injection mouth of compressor head refer to the picture screw off plastic plug poke with ...

Page 659: ...glass state of reservoir and trouble analysis Liquid sight glass state Trouble analysis Liquid sight glass is lacte bubbles can be seen at the moment of turning on and turning off AC and bubbles become transparent suddendly Freon charging quantity is proper Few bubbles flowing compressor head is hot refrigeration output is not enough high and low pressure of the system are both very low Freon char...

Page 660: ...s lower than 4º Temperature sensing detector is open circuit or not connected AC temperature control switch relay is broken 3 Evaporation fan rotates condensation fan rotates compressor does not absorb Coil of compressor clutch is broken High low pressure switch is broken Freon is leaked Circuit from high low pressure switch to compressor is open 4 Evaporation fan does not run condensation fan run...

Page 661: ...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 MODEL SERIAL NUMBER RANGE SD310 010001 and Up Copyright 2012 DISD July 2012 Electrical System SPC000025 Page 1 ...

Page 662: ...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 Windshield Wiper 21 Lighting System 23 Electric Detent System 25 Electric return Circuit 25 Swing arm lifting limitation system 26 Automatic bucket laid flat system 26 Proximity Switch 26 Electric Speed Control System 27 SPC000025 Electr...

Page 663: ...entire rectifier Wire harness of the system can be distinguished by different insulation colour Each colour symbol used for electrical system is listed below Electric Wire Color Symbol Color Symbol Color W White R Red G Green Gr Gray Or Orange P Pink B Black Y Yellow L Blue Br Brown Lg Light Green V Violet NOTE RW Red wire with White stripe R Base Color W Stripe Color NOTE 0 85G Nominal sectional ...

Page 664: ...light power supply terminal 6 General stop electromagnet power input terminal 7 Generator terminal B 8 Preheat relay power input terminal When switch of keys is at ON and START position electric current flows to fusible wire from storage battery reaches key switch terminal B BR through fuse box and reaches storage battery relay control terminal through guide line activate storage battery relay coi...

Page 665: ...ence Number Description 1 Disconnect Switch 6 Starter Switch 2 Battery 7 Fuse 3 Starter 8 Battery Relay 4 Starter Relay 9 Alternator 5 Diode 10 Saftey Start Relay Electrical System SPC000025 Page 5 Figure 1 Power supply circuit diagram ...

Page 666: ... then other contact terminals B and PP are connected active gear of starter 3 is propelled to contact ring gear of flywheel and connect with contact terminal of starter Electric current comes out from storage battery 2 goes through terminal B and PP of starter relay 4 and arrives at starter 3 terminal 50 Operation After Start Process Once generator is started the belt will drive AC generator 9 to ...

Page 667: ...n Reference Number Description 1 Disconnect Switch 6 Starter Switch 2 Battery 7 Fuse 3 Starter 8 Battery Relay 4 Starter Relay 9 Alternator 5 Diode 10 Saftey Start Relay Electrical System SPC000025 Page 7 Figure 2 Starter circuit ...

Page 668: ...temperature Rt resistivity is smaller than 800Ω controllor 7 is not at preheating state preheating indicator light 12 is off 10 When water temperature of engine is lower than 25 water temperature Rt resistivity is smaller than 800Ω controllor 7 is at preheating state preheating time is related with water temperature 11 When preheating time T1 is up preheating indicator light 12 is off if ignition ...

Page 669: ...iption 1 Disconnect Switch 7 Preheat Controller 2 Battery 8 Preheat Relay 3 Alternator 9 Pre heater 4 Starter Switch 11 Water Temperature Sensor 5 Fuse 12 Preheat Indicator Electrical System SPC000025 Page 9 Figure 3 Control circuit of preheating system ...

Page 670: ...are connected Electric current goes through insurance of electrical box 3 from positive pole of storage battery 2 and terminals B and C of key switch flameout relay 5 coil is power on and works flameout electromagnet 6 terminal 85 is power on pulls in coil and works fuel injection pump is opened and lever is closed Then key switch will be back to ON gear automatically pulling in coil is broken whi...

Page 671: ... Number Description Reference Number Description 1 Disconnect Switch 4 Starter Switch 2 Battery 5 Engine Stop Relay 3 Fuse 6 Engine Stop Motor Electrical System SPC000025 Page 11 Figure 4 Engine stalling system ...

Page 672: ... generator 5 earth connected and forms a circuit charging indication light 8 is on to warn and supplies excitation electric current for generator 5 After engine is started generator 5 starts charging Electric current comes from terminal B of generator 5 goes through fuse box 4 and reaches storage battery 2 Charging indication light 8 is off Generator 5 also supplies power to other electrical parts...

Page 673: ...Reference Number Description 1 Disconnect Switch 6 Battery Relay 2 Battery 7 Diode 3 Starter Switch 8 Charge Indicator 4 Fuse Box 9 Resistor 5 Alternator Electrical System SPC000025 Page 13 Figure 5 Charging system circuit diagram ...

Page 674: ...ng device etc Reference Number Description Reference Number Description 1 Gauge Panel 6 Fuel Sensor 2 Battery 7 Sensor 3 Alternator 8 Temperature Sensor 4 Rocker Switch 9 Back Buzzer Switch 5 Switchgroup Monitoring system will process information collected from all sensors the instrument panel will indicate all data and warning signals SPC000025 Electrical System Page 14 2 8 1 3 4 5 6 7 9 Figure 6...

Page 675: ... Converter Oil Temperature Meter 16 Turn and Hazard Warning Light 6 Engine Coolant Temperature Gauge 17 Turn and Hazard Warning Light 7 Hour meter 18 Water temperature too high warning light 8 Speedometer 19 Charging Warning Light 9 Odometer 20 Brake low pressure warning light 10 Engine oil pressure meter 21 TM Oil pressure too low warning light 11 Neutral position indicator 22 Electrical System S...

Page 676: ...on Input Terminal Input Specification Air Pressure Meter CN 29 0 1MPa 0 9V 0 4MPa 2 1V 0 6MPa 2 9V 0 7MPa 3 3V 0 8MPa 3 7V Fuel Gauge CN 03 0 80 欧姆 1 2 32 欧姆 F 8 欧姆 Tachometer CN 10 12 66 脉冲 转 Voltage meter CN 11 SPC000025 Electrical System Page 16 ...

Page 677: ...98 96KΩ 60 2 476KΩ 80 1 25KΩ 100 0 6744KΩ 120 0 4071KΩ Engine Coolant Temperature Gauge CN 02 0 98 96KΩ 40 5 312KΩ 60 2 476KΩ 80 1 25KΩ 100 0 6744KΩ 120 0 4071KΩ Hour meter Speedometer Odometer CN 04 CN 27 Engine oil pressure meter CN 08 0 1MPa 0 9V 0 2MPa 1 3V 0 3MPa 1 7V 0 4MPa 2 1V Electrical System SPC000025 Page 17 ...

Page 678: ...ltage reduces to 24V Under normal condition light is on when starting light is off when engine starts working Headlights on full beam CN 25 The light is on when headlight on full beam is turned on The Max terminal input is 24V Oil pressure of gear box CN 17 The light is on when pressure decreses to 1 1Mpa Preheat CN 01 The light is on when preheating system is working Parking brake CN 18 The light...

Page 679: ...re than 103 the lamp is lit Nertral position CN 06 When control handle in a neutral position the lamp is lit filter CN 20 When pressure vacuum reach 6KPa lamp is lit Brake pressure CN 29 When pressure is reduced to 0 4 MPa the lamp is lit Electrical System SPC000025 Page 19 ...

Page 680: ... temp Switch 4 Fuse Box 15 Eng Oil Pressure Switch 5 Alternator 16 Air Pressure Alarm Switch 6 Starter Relay 17 Empty filter jams switch 7 Park press switch 18 Combination Switch 8 Gauge Panel 19 Relay 9 Water Temperature Sensor 20 Excitation resistance 10 Fuel Sensor 21 Blinker Unit 11 Transmission Temp Sensor SPC000025 Electrical System Page 20 Figure 8 Schematic diagram of monitoring system ...

Page 681: ...3 reaches terminal 1 and 4 of combination switch 2 and connects with earth Through the rocket switch 7 control rear window wiper blade and scrubber 1 Single windshield wipers gear not automatic reset When Wiper blade in the running gear the current from the fuse box 1 through the windscreen wiper motor 5 into line terminal to rocket switch 7 terminal 4 2 then grounding 2 The windshield wipers and ...

Page 682: ...er Description Reference Number Description 1 Fuse Box 5 Rear Wiper 2 Combination Switch 6 Rear Washer 3 Wiper 7 Rocker switch 4 Washer SPC000025 Electrical System Page 22 Figure 9 Circuit diagram of windshield wiper ...

Page 683: ... turned to right handed rotation its terminal 13 and 12 are connected electric current from fuse box 1 goes through flasher 7 combination switch 2 and reaches right turning lamp of front combination lamp 13 and rear combination lamp 15 When brake switch 3 works electric current from fuse box 1 reaches brake lamp of rear combination lamp 14 and rear combination lamp 15 brake lamp works When pressin...

Page 684: ...witch 13 Front Combination Lamp R 4 Room Lamp 14 Rear Combination Lamp L 5 High Lamp Relay 15 Rear Combination Lamp R 6 Low Lamp Relay 16 Hazard Switch 7 Blinker Unit 17 Position Lamp Switch 8 Rear Lamp 18 Front Lamp Switch 9 Working Lamp 19 Back Relay 10 Working Lamp Switch SPC000025 Electrical System Page 24 Figure 10 Lighting system circuit diagram ...

Page 685: ...aid flat system Electric return circuit Reference Number Description Reference Number Description 1 Fuse Box 5 Float Magnet 2 Raise Relay 6 Return to Dig Magnet 3 Return to Dig Relay 7 Proximity Switch 1 4 Raise Magnet 8 Proximity Switch 2 Electrical System SPC000025 Page 25 Figure 11 Electric detent system circuit ...

Page 686: ... flating position swing arm will descend with effect of dead weight At this moment the driver can operate other items such as flat bucket with the right hand thus working efficiency is improved Push swing arm operation handle to floating position during slicking bucket will rise along with rising of ground and will not damage the road Automatic bucket laid flat system When bucket is at material di...

Page 687: ...rough the transmission control valve Y1 Y5 action combination decided to gear state Magnet under Voltage Forward Reverse Neutral Speed 1 2 3 4 1 2 3 1 2 3 4 M1 M2 M3 M4 M5 Clutch KV KV KV K4 KR KR KR K3 Clutch K1 K2 K3 K3 K1 K2 K3 Electrical System SPC000025 Page 27 ...

Page 688: ...TO MANU SW 2 VALVE ASS Y 9 SAFETY START RELAY 3 T M SELECTOR SWITCH 10 T M CUT OFF SW 4 DIAGNOSE 11 BRAKE AIR PRESS SW 5 SENSOR 12 DOWN SHIFT SW KD 6 SENSOR 13 PARK PRESS SW 7 FUSE 14 BACK BUZZER RELAY SPC000025 Electrical System Page 28 Figure 11 Variable speed control system ...

Page 689: ...ed 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 Copyright 2012 DISD July 2012 Electrical Schematic SD310 SPC000027 Page 1 ...

Page 690: ...TABLE OF CONTENTS General Description 3 SD310 4 SPC000027 Electrical Schematic SD310 Page 2 ...

Page 691: ...agram 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 Electrical Schematic SD310 SPC000027 Page 3 Figure 1 ...

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 ...

Page 696: ......

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