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Shop Manual

SERIAL NUMBER

WA115H30051 AND UP

VEBM120100

WHEEL LOADER

WA115-3

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CONTENTS

00 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-3

01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-1

10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . .10-1

20 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . .20-1

30 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . will be issued later

90 APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90-1

No. of page

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SAFETY

Safety notice . . . . . . . . . . . . . . . . . . . . . . . . . . 00-4

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-8

How to read the shop manual . . . . . . . . . . . . 00-9

Volumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-9

Distribution and updating . . . . . . . . . . . . . . . . . 00-9

Filing method . . . . . . . . . . . . . . . . . . . . . . . . . . 00-9

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-10Hoisting instructions . . . . . . . . . . . . . . . . . . 00-11

00

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Safety notice SAFETY

Safety notice

Important Safety Notice

Proper service and repair is extremely important for safe

machine operation. Some of the described service and re-

pair techniques require the use of tools specially designed

by Komatsu for the specific purpose.

To prevent injury to workers, the symbol is used tomark safety precautions in this manual. The cautions ac-

companying these symbols must always be followed care-

fully. If any dangerous situation arises or may possibly

arise, first consider safety, and take the necessary actions

to deal with the situation.

General Precautions

Mistakes in operation are extremely dangerous. Read the

OPERATION AND MAINTENANCE MANUAL carefully before

operating the machine! Always follow the safety rules valid

in your country carefully!

1. Before carrying out any greasing or repairs, read all the pre-cautions given on the decals which are fixed to the machine.

2. When carrying out any operation, always wear safety shoes

and helmet. Do not wear loose work clothes, or clothes with

buttons missing.

Always wear safety glasses when hitting parts with a

hammer.

Always wear safety glasses when grinding parts with a

grinder, etc.

3. If welding repairs are needed, always have a trained, experi-

enced welder carry out the work. When carrying out welding

work, always wear welding gloves, apron, glasses, cap and
http://wf550_safety.pdf/http://wf550_safety.pdf/

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SAFETY Safety notice

5. Keep all tools in good condition and learn the correct way to

use them.

6. Decide a place in the repair workshop to keep tools and re-

moved parts. Always keep the tools and parts in their correct

places. Always keep the work area clean and make sure

that there is no dirt or oil on the floor. Never smoke while

working. Smoke only in the areas provided for smoking.

Preparations for work

1. Before adding oil or making any repairs, park the machine

on hard, level ground, and block the wheels or tracks to pre-

vent the machine from moving.

2. Before starting work, lower blade, ripper, bucket or any other

work equipment to the ground and install the safety bar on

the frame. If this is not possible, insert the safety pin or use

blocks to prevent the work equipment from falling. In addi-

tion, be sure to lock all the control levers and hang warning

signs on them.

3. When disassembling or assembling, support the machine

with blocks, jacks or stands before starting work.

4. Remove all mud and oil from the steps or other places used

to get on and off the machine. Always use the handrails, lad-

ders or steps when getting on or off the machine. Never

jump on or off the machine. If it is impossible to use the

handrails, ladders or steps, use a stand to provide safe foot-

ing.

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Safety notice SAFETY

Precautions during work

1. When measuring hydraulic pressure, check that the measur-ing tool is correctly assembled before taking any measure-

ments.

2. When removing the oil filler cap, drain plug or hydraulic

pressure measuring plugs, loosen them slowly to prevent

the oil from spurting out.

Before disconnecting or removing components of the oil,

water or air circuits, first remove the pressure completely

from the circuit.

3. The water and oil in the circuits are hot when the engine is

stopped, so be careful not to get burned.

Wait for the oil and water to cool before carrying out any

work on the oil or water circuits.

4. Before starting work, remove the leads from the battery. Al-

ways remove the lead from the negative (-) terminal first.

5. When raising heavy components, use a hoist or crane.

Check that the wire rope, chains and hooks are free from

damage.

Always use lifting equipment which has ample capacity.

Install the lifting equipment at the correct places. Use a hoist

or crane and operate slowly to prevent the component from

hitting any other part.

Do not work with any part still raised by the hoist or crane.

6. When removing covers which are under internal pressure or

under pressure from a spring, always leave two bolts in po-

sition on opposite sides. Slowly release the pressure, then

slowly loosen the bolts to remove.

7. When removing components, be careful not to break or

damage the wiring. Damaged wiring may cause electrical

fires.

8. When removing piping, stop the fuel or oil from spilling out. If

any fuel or oil drips onto the floor, wipe it up immediately. Fu-

el or oil on the floor can cause you to slip, or can even start

fires.

9. As a general rule, do not use gasoline to wash parts. In par-

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SAFETY Safety notice

11. When installing high pressure hoses, make sure that they

are not twisted.

Damaged tubes are dangerous, so be extremely careful

when installing tubes for high pressure circuits. Also, check

that connecting parts are correctly installed.

12. When aligning two holes, never insert your fingers or hand.

Be careful not to get your fingers caught in a hole.

13. When assembling or installing parts, always use the speci-

fied tightening torques. When installing protective parts suchas guards, or parts which vibrate violently or rotate at high

speed, be particularly careful to check that they are installed

correctly.

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Foreword SAFETY

Foreword

General

This shop manual has been prepared as an aid to improve the

quality of repairs by giving the service personnel an accurate un-

derstanding of the product and by showing them the correct way

to perform repairs and make judgements. Make sure you under-

stand the contents of this manual and use it to full effect at every

opportunity.

This shop manual mainly contains the necessary technical infor-

mation for operations performed in a service workshop. For

ease of understanding, the manual is divided into the following

chapters; these chapters are further divided into the each main

group of components:

Structure and function

This section explains the structure and function of each compo-nent. It serves not only to give an understanding of the structure,

but also serves as reference material for troubleshooting.

Testing and adjusting

This section explains checks to be made before and after per-

forming repairs, as well as adjustments to be made at comple-

tion of the checks and repairs. Troubleshooting charts

correlating "Problems" to "Causes" are also included in this sec-tion.

Disassembly and assembly

This section explains the order to be followed when removing,

installing, disassembling or assembling each component, as

well as precautions to be taken for these operations.

Maintenance standard

This section gives the judgement standards when inspecting dis-

assembled parts.

NOTE

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SAFETY How to read the shop manual

How to read the shop manual

Volumes

Shop manuals are issued as a guide to carrying out repairs.

Distribution and updating

Any additions, amendments or other changes will be sent to Ko-matsu distributors.

Get the most up-to-date information before you start any work.

Filing method

1. See the page number on the bottom of the page. File the

pages in correct order.

2. Following examples show how to read the page number.

Example 1 (Chassis volume):

3. Additional pages: Additional pages are indicated by a point

(.) and number after the page number. File as in the exam-

ple.

Example:

10 - 3

Item number (10. Structure and Function)

Consecutive page number for each item

10-410-4.110-4.210-5

Added Pages

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How to read the shop manual SAFETY

Symbols

So that the shop manual can be of ample practical use, impor-tant safety and quality portions are marked with the following

symbols:

Symbol Item Remarks

Safety Special safety precautions are necessary when performing the work.

CautionSpecial technical precautions or other precautions for preserving standards are necessary

when performing the work.

WeightWeight of parts of systems.

Caution necessary when selecting hoisting wire, or when working posture is important, etc.

Tightening torque Places that require special attention for the tightening torque during assembly.

Coat Places to be coated with adhesives and libr icants, etc.

Oil, water Places where oil, water or fuel must be added, and the capacity.

Drain Places where oil or water must be drained, and quantity to be drained.

!

4

3

2

5

6

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SAFETY Hoisting instructions

Hoisting instructions

Heavy parts (25kg or more) must be lifted with a

hoist, etc. In the DISASSEMBLY AND ASSEMBLY

section, every part weigthing 25 kg or more is in-

dicated clearly with the symbol:

If a part cannot be smoothly removed from the machine by hoist-

ing, the following checks should be made:

1. Check for removal of all bolts fastening the part to the rela-

tive parts.

2. Check for existence of another part causing interference

with the part to be removed.

Wire ropes

1. Use adequate ropes depending on the weight of parts to be

hoisted, refering to the table below:

The allowable load in tons, is given by vertical tensible

force.

The allowable load value is estimated to be one-sixth or

one-seventh of the breaking strength of the rope used.

Wire ropes:

(Standard "Z" or "S" twist ropes without galvanizing)

Rope diameter (mm) Allowable load (tons)

10 1.0

11.2 1.4

12.5 1.6

14 2.2

16 2.8

18 3.6

20 4.4

4

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Hoisting instructions SAFETY

2. Sling wire ropes from the middle portion of the hook.

Slinging near the edge of the hook may cause the rope toslip off the hook during hoisting, and a serious accident can

result. Hooks have maximum strength at the middle portion.

3. Do not sling a heavy load with one rope alone, but sling with

two or more ropes symmetrically wound onto the load.

Slinging with one rope may cause turning of the load during

hoisting, untwisting of the rope, or slipping of the rope from

its original winding position on the load, which can result in

a dangerous accident.

4. Do not sling a heavy load with ropes forming a wide hanging

angle from the hook.

When hoisting a load with two or more ropes, the force sub-

jected to each rope will increase with the hanging angles.

The table below shows the variation of allowable load (kg)

when hoisting is made with two ropes, each of which is al-

lowed to sling up to 1000 kg vertically, at various hanging

angles.

When two ropes sling a load vertically, up to 2000 kg of total

weight can be suspended. This weight becomes 1000 kg

when two ropes make a 120 hanging angle. On the other

hand, two ropes are subjected to an excessive force as

large as 4000 kg if they sling a 2000 kg load at a lifting angle

of 150

100% 88% 79% 71% 41%

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GENERAL

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 01-2

Dimensions, weights and operating data . . 01-3

Weight table . . . . . . . . . . . . . . . . . . . . . . . . . . 01-4

Lubricants and operating mediums . . . . . . . 01-5

Basic procedures of maintenance . . . . . . . . 01-6

Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7

Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7

Storing oil and fuel . . . . . . . . . . . . . . . . . . . . . . 01-7

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8

Biodegradable hydraulic oils and lubricants . . . 01-8

Outline of electric system . . . . . . . . . . . . . . . . . 01-8

Torque list screws and nuts . . . . . . . . . . . . 01-9

01

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Specifications GENERAL

Specifications

Machine model WA115-3

Serial No. WA115H30051 and up

Engin

e

Model

Type

No. of cylinders - bore/stroke [mm]

Piston displacement [cm]

S4D106-1HC

4-cycle Diesel naturally aspirated

4 - 106 / 125

4,412

Flywheel horsepower

[kw (PS/HP)]

Maximum torque [Nm at rpm]

Starting motor

Alternator

Battery

65 (88.4/87.2)

366 /1500

12V - 23.0 kw

12V - 80 A

12V - 92 Ah

Powertrain Reduction gear

Differential

Drive type

2-stage

Limited slip differential, locking value 45%

Front-, rear-wheel drive

Axle,wheel Tire

Turning radius 40

455/70 R24

Over tires 4.635 mm

Over bucket 5.100 mm

Over rear frame 4.635 mm

Brakes Service brake

Parking brake

Wet-type disc brake in the rear axle (acting on all 4 wheels)

Wet-type disc brake in the rear axle (acting on all 4 wheels)

Steering

system Type

Structure

articulated steering

hydrostatic

Hydraulicsystem

Main pump

Delivery [cm/1 revolution]

Gear pump

52.4

Controlva

lve Operating pressure

[bar]

Steering pressure

[bar]

3-spool type

210

Orbit-roll valve type

175

linder Boom cylinder No. - bore stroke [mm]

Tilt cylinder No. - bore stroke[mm]

2 - 95 702

1 - 70 660

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GENERAL Dimensions, weights and operating data

Dimensions, weights and operating data

Dimensions, operating data

Bucket type m UniversalMulti

purposeMulchgrab

Sidedump

Stockpile

Highdump

Lightmaterial

Bucket capacity as per ISO 7546 1.3 1.2 1.3 1.5 1.7 2.2

Dumping weight t/m 1.8 1.8 1.6 1.6 1.0 1.0

Bucket weight without teeth kg 554.5 808 804 885 601 1.224 876

Stat. tipping load, straight kg 6.064 6.547 5.601 5.230 6.116 4.604 5.393

Stat. tipping load, 40 articulated kg 5.307 5.752 4.876 4.385 5.353 3.981 4.672

Break-out force hydraulic kN 73,3 71.5 72.0 57.4 67.5 44.0 53.0

Lifting capability hydr. at ground level kN 76.7 76.9 76.0 58.4 77.0 60.0 74.0

Operating weight kg 7.456 7.736 7.720 7.800 7.560 8.120 7.800

Turning radius at corner of tyres mm 4.520 4.520 4.520 4.520 4.520 4.520 4.520

Turning radius at bucket edge mm 4.915 4.950 4.920 4.985 4.930 5.200 5.100

a Reach at 45 mm 815 810 885 995 860 1.420 1.055

b Dumping height at 45 mm 2.774 2.770 2.697 2.585 2.722 4.020 2.460

A

B

H

d

c

b

C

D

E e

f

F

a

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Weight table GENERAL

Weight table

This weight table is a guide for use when transporting or

handling components.

Components Weight [kg] Components Weight [kg]

Engine 306 Boom cylinder

Radiator 45 Bucket cylinder

Drive shaft 29 Engine hood

Front axle 273 Engine hood carrier

Rear axle with reduction gear 404 Front frame 655

Steering valve 4.5 Rear frame 777

PPC valve 5.2 Quick-coupler 140

Steering cylinder 39 Bellcrank 52

Variable-displacement motor

Motor A6VM 80

Motor A6VM 107

34

47

Boom (including bushing) 326

Bucket see page 01-3

Counterweight 1011

Variable-displacement pump 50 Battery 27.1

Hydraulic pump 17.3 Floor, Cab assembly

Main control valve Operator's seat 32

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GENERAL Lubricants and operating mediums

Lubricants and operating mediums

WA115-3

LUBRICANTS, FUELS AND FILLING CAPACITIES

Lubricants,

fuel etc.BI code **) Quality grades

Tempera-

ture ranges

Viscosity

ranges

Approx. filling

capacity in

litres

Engine Engine Oil EO

EO 1540 A

EO 1030 A

NRS

CCMC D4 or, if not

available:

API CE or

API CF -4 )

-25 to 45C

-20 to 30C

-15 to 20C

SAE 15W-40 *)

SAE 10W-30

SAE 05W-30

14

Transfer Gear Box

Standard Type

High Speed Version

Gear Oi GO GO 90 LS

API-GL5 +LS

or

MIL-L-2105D +LS

SAE 90 LS

1.6

1.0

Front Axle Gear Oi GO GO 90 LS

API-GL5 +LS

or

MIL-L-2105D +LS

SAE 90 LS *)

SAE 85W-90 LS

SAE 80W-90 LS

Planet Gear:

2 1.5

Differential: 4.5

Rear Axle Gear Oi GO GO 90 LS

API-GL5 +LS

or

MIL-L-2105D +LS

SAE 90 LS *)

SAE 85W-90 LS

SAE 80W-90 LS

Planet Gear:

2 1.5

Differential: 4.5

Hydraulic system,

steering, brakes

Hydraulic Oil

HYD

HYD 0530

HYD 1030

HYD 1540

HVLP, HVLP D

-15 to 20C

-20 to 30C

-15 to 45C

ISO VG 46 *)

ISO VG 68

ISO VG 100

85or Engine Oil

EO

EO 1540 A

EO 1030 A

NRS

CCMC D4 or, if not

available:

API CE or

API CF -4 )

-15 to 20C

-20 to 30C

-15 to 45C

SAE 15W-40 *)

SAE 10W-30

SAE 05W-30

or

Hydraulic OilBIO-E-HYD

BIO-E-HYD

0530

HEES

(acc. to VDMA fluidtechnology) -15 to 20C ISO VG 46

Service Brake

Automatic

Transmission

Gear Oil

AFTAFT, Type A

Suffix A 0.7

Cooling systeLong-Time

CoolantSP-C

Antifreeze and Cor-

rosion Protection

Proportion of Mixture:

50% Coolant : 50% Water

Min. Freeze Proofing: -34 C

15.0

Fuel tank Diesel fuel)

CFPP class BCFPP class D

CFPP class E

CFPP class F

DIN-EN 590

up to 0Cup to -10C

up to -15C

up to-20C

120

Grease nipples,

central lubrication

Multi-purpose

grease MPG on

a lithium base

MPG-A KP2N-20 NLGI 2

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Basic procedures of maintenance GENERAL

Basic procedures of maintenance

Oil

Fuel

The oil in the engine and in the hydraulic system is subject to extreme conditions (high temperatures, high

pressures). Therefore, the oil quality will decrease with extended operation.

Always use oils prescribed for the works and temperatures indicated in the operating and maintenance man-

ual. Always observe the prescribed oil change intervals.

Always handle oils with extreme care so that they are not contaminated.When storing or refilling oil, make

sure that it is not contaminated. The majority of all malfunctions is caused by the penetration of dirt and other

contaminations.

Never mix oil of different brands or types.

Always refill the prescribed oil quantity. Too little or excessive oil may cause malfunctions.

If the oil in the hydraulic system is not clear (milky), water or air is propably introduced into the circuit. In such

cases, call your Komatsu dealer.

Upon each oil change, the related filter must be replaced as well.

We recommend to have an oil analysis carried out in regular intervals in order to check the machine condi-

tion. Customers who desire such an oil analysis should contact their Komatsu dealer.

The fuel pump is a precision instrument; if fuel containing water or dirt is used, it cannot work properly.

Be extremely careful not to let impurities penetrate when storing or adding fuel.

Always use the fuel specified in the Operation and Maintenance Manual. Fuel may congeal depending on the

temperature (particularly at low temperatures below -15C), so change to a fue matching this temperature.

To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel

tank after completing the day's work.

Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment and water

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GENERAL Basic procedures of maintenance

Coolant

Grease

Storing oil and fuel

River water contains large amounts of calcium and other impurities, so if it is used, scale will stick to the en-gine and radiator causing a defective heat exchange and overheating.

Do not use water that is not suitable for drinking.

When using anti-freeze, always observe the precautions given in the Operation and Maintenance Manual.

Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is

shipped. This anti-freeze prevents corrosion in the cooling system. The anti-freeze can be used continuouslyfor two years or 4000 hours. Therefore, it can be used as it is even in hot areas.

Anti- freeze is flammable, so be extremely careful not to expose it to open flame or fire.

The proportion of anti-freeze to water differs according to the ambient temperature. For details of the mixing

ratios, see Operation Manual: CLEANING THE INSIDE OF THE COOLING SYSTEM".

If the engine overheats, wait for the engine to cool before adding coolant.

If the coolant level is low, it will cause overheating and corrosion due to the air in the coolant.

Grease is used to prevent twisting and noise at the joints.

The nipples not included in the maintenance section are nipples for overhaul, so they need not be lubricated.

If any part becomes stiff after being used for a long time, add grease.

Always wipe off all of the old grease that is pushed out when greasing. Be particularly careful to wipe off the

old grease in places where sand or dirt in the grease would cause the rotating parts to wear.

Keep oil and fuel indoors to prevent any water, dirt or other impurities from penetrating.

When keeping barrels for a long period, lay down the barrel on its side so that the filler port is at the side (to

prevent moisture from being sucked in).

If barrels have to be stored outside cover them with a waterproof sheet or take other measures to protect

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Basic procedures of maintenance GENERAL

Filters

Biodegradable hydraulic oils and lubri-cants

Outline of electric system

Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from enteringimportant equipment and causing problems.

Replace all filters periodically. For details, see the Operation and Maintenance Manual.

However, when working under severe conditions, it is necessary to consider replacing the filters at shorter in-

tervals according to the oil and fuel (sulfur content) being used.

Never try to clean the filters (cartridge type) and use them again. Always replace with new filters.

When replacing oil filters, check if any metal particles are stuck to the old filter. If any metal particles arefound, please contact your Komatsu distributor.

Do not open packs of spare filters until just before they are to be used.

Always use original Komatsu filters.

The use of biodegradable hydraulic oils and lubricants on the basis of synthetic esters for Komatsu ma-

chines is permitted. For information on the products cleared for use and best suited for your application con-

tact our authorized service workshops.

If the wiring gets wet or the insulation is damaged, the electric system leaks resulting in hazardous malfunc-

tions of the machine.

Maintenance work at the electric system includes:

1. Check fan belt tension,

2. Check damage or wear to the fan belt,

3. Check battery fluid level.

Never remove or disassemble any electric components installed in the machine.

Never install any electric components other than those specified by Komatsu.

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GENERAL Torque list screws and nuts

Torque list screws and nuts

Unless otherwise specified, tighten the metric bolts and nuts

to the torque shown in the table.

The tightening torque is determined by the width across flats

of the nut and bolt.

If it is necessary to replace any nut or bolt, always use a Ko-

matsu genuine part of the same size as the part that was re-

placed.

NOTE

When tightening panels or other parts having tightening fixtures

made of plastic, be careful not to use excessive tightening torque:

doing so will damage the plastic parts.

Metric Thread 10.9

Thread diameter

[mm]

(a)

Width across flat [mm]

(b)

Steel Aluminium-Cast

Nm kpm Nm kpm

M 6 10 14 1.4 7.7 0.77

M 8 13 35 3.5 19 1.9

M 10 17 (15) 70 7 37 3.7

M 12 19 115 11.5 64 6.4

M 14 22 185 18.5 101.5 10.15

M 16 24 280 28 158 15.8

M 18 27 390 39 218 21.8

M 20 30 560 56 306.5 30.65

M 22 32 750 75 416 41.6

M 24 36 960 96 528.5 52.85

M 27 41 1400 140 774 77.4

M 30 46 1900 190 1053 105.3

M 33 50 2600 260

M 36 55 3300 330

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Torque list screws and nuts GENERAL

Metric Fine Thread 10.9

Thread Diameter [mm]

(a)

Width across Flat[mm]

(b)

Steel Aluminium-Cast

Nm kpm Nm kpm

M 8 1 13 35 3.5 20 2

M 10 1 17 (15) 75 7.5 42 4.2

M 10 1,25 17 (15) 70 7 39 3.9

M 12 1,25 19 125 12.5 70 7

M 12 1,5 19 120 12 67 6.7

M 14 1,5 22 200 20 110 11

M 16 1,5 24 300 30 167.5 16.75

M 18 1,5 27 440 44 243 24.3

M 18 2 27 420 42 230 23

M 20 1,5 30 620 62 338.5 33.85

M 20 2 30 322.5 32.25

M 22 1,5 32 820 82 454.5 45.45

M 22 2 32 436 43.6

M 24 1,5 36 1090 109 596 59.6

M 24 2 36 1040 104 573 57.3

M 27 2 41 1500 150 832 83.2

M 30 2 46 2120 212 1158 115.8

M 33 2 50 2800 280

M 36 3 55 3500 350

M 39 3 60 4600 460

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STRUCTURE AND FUNCTION

Powertrain 20 km/h . . . . . . . . . . . . . . . . . . . 10-3

Powertrain 35 km/h . . . . . . . . . . . . . . . . . . . 10-4

Closed circuit . . . . . . . . . . . . . . . . . . . . . . . . . 10-5

Hydraulic drive system 20 km/h . . . . . . . . 10-6

Hydraulic drive system 35 km/h . . . . . . . . 10-8

Variable displacement pump . . . . . . . . . . . 10-10

Regulating valve . . . . . . . . . . . . . . . . . . . . . . . 10-13

Charge pressure limiting valve . . . . . . . . . . . . 10-13

Control cylinder . . . . . . . . . . . . . . . . . . . . . . . 10-14

4/3 Way valve with direction control solenoids 10-14

Pressure cut-off valve . . . . . . . . . . . . . . . . . . 10-15

Safety-/charge valve . . . . . . . . . . . . . . . . . . . 10-15

Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16

Variable displacement motor . . . . . . . . . . . 10-17

Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-51

Axle mounting front and rear axle . . . . . . 10-52

Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53

Rear axle with distributor box 20 km/h . . 10-54

Rear axle with distributor box 35 km/h . . 10-55

Distributor box, single stage 20 km/h . . . 10-56

Distributor box, double stage 35 km/h . . 10-57

Limited slip differential

(locking value 45%), front and rear axle . . 10-58

Wheel hub, front and rear axle . . . . . . . . . . 10-60

Service and parking brake, rear axle . . . . . 10-65

Sevice brake scheme 20 km/h . . . . . . . . . 10-67

Sevice brake scheme 35 km/h . . . . . . . . . 10-67Parking brake scheme 20 km/h . . . . . . . . 10-68

Parking brake scheme 35 km/h . . . . . . . . 10-68

Inch-brake pedal 20 km/h . . . . . . . . . . . . . 10-69

Inch-brake pedal 35 km/h . . . . . . . . . . . . . 10-70

Steering cylinder . . . . . . . . . . . . . . . . . . . . .10-103

Lifting with quick-coupler . . . . . . . . . . . . . .10-104

Bucket positioner . . . . . . . . . . . . . . . . . . . .10-105

Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-106

Operation of proximity switch . . . . . . . . . . . . .10-106

Adjusting the bucket positioner . . . . . . . . . . .10-107

Monitor display . . . . . . . . . . . . . . . . . . . . . .10-111

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-112

Engine oil pressure sensor . . . . . . . . . . . . . .10-112

Fuel level sensor . . . . . . . . . . . . . . . . . . . . . .10-113

Engine coolant temperature sensor . . . . . . . .10-114

Brake oil reservoir sensor . . . . . . . . . . . . . . .10-115

Ribbon heater temperature sender unit . . . . .10-116

Ribbon heater . . . . . . . . . . . . . . . . . . . . . . . .10-117

Engine stop/start/preheating circuit . . . . .10-120

Driver's cab . . . . . . . . . . . . . . . . . . . . . . . . .10-122

Fuses (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-122

Relais (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-122

Wiring diagrams . . . . . . . . . . . . . . . . . . . . . .10-131

Wiring diagram Fig. 1 . . . . . . . . . . . . . . . . .10-132



Wiring diagram Fig. 4 . . . . . . . . . . . . . . . . .10-139Wiring diagram Fig. 5 . . . . . . . . . . . . . . . . .10-140

Air conditioner (option) . . . . . . . . . . . . . . . .10-151

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . .10-151

Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-152

Installation of air conditioner . . . . . . . . . . . . .10-158

Safety when handling coolants . . . . . . . . . . .10-159

Operating the air conditioner . . . . . . . . . . . . .10-161

Maintenance of the air conditioner . . . . . . . . .10-162Instructions for filling . . . . . . . . . . . . . . . . . . .10-165

Exchange of magnetic clutch . . . . . . . . . . . . .10-168

Exchange of compressor . . . . . . . . . . . . . . . .10-169

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . .10-171

10

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Blank for technical reason

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STRUCTURE AND FUNCTION Powertrain 20 km/h

Powertrain 20 km/h

Outline

The engine power is transmitted to the drive axles through ahydrostatic system. The system consists of a variable dis-

placement pump mounted on the engine and a variable dis-

placement motor mounted on the rear axle transmission

distribution box. Power is transmitted from the variable dis-

placement motor through the distribution box to the front and

1. Rear axle 4. Displacement pump

2. Hydrostatic Transmission 5. Displacement motor

3. Front axle

1 2 3

45

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Powertrain 35 km/h STRUCTURE AND FUNCTION

Powertrain 35 km/h

1. Rear axle 4. Front axle

2. Hydrostatic Transmission 5. Displacement pump

3. Displacement motor 2 6. Displacement motor 1

Outline

The engine power is transmitted to the drive axles through a hydrostatic system. The system consists of a vari-

able displacement pump (5) mounted on the engine, a variable displacement motor 1 (6) and variable displace-

ment motor 2 (3), mounted on the rear axle transmission distribution box.

High speed not active:

Range 1 switched on:

Range 2 swichted on:

0 - 5.5 km/h

0 - 5.5 km/h

5.6 . 15 km/h

motor 1 and 2 maximum swashangle.

motor 1 and 2 maximum swashangle;

motor 1 swivels back to minimum swashangle, motor 2 swivels back to

0 swashangle (no drive).

High speed active:

Range 1 activ: 0 15 km/h motor 1 on macimum swashangle motor 2 at 0 swashangle (no drive)

1 2 3

56

4

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STRUCTURE AND FUNCTION Closed circuit

Closed circuit

Outline

A hydraulic system is described as closed when the hydrau-

lic fluid is returned from the user direct to the pump.

There is a high pressure and a low pressure side, depend-

ing on the direction of load (take-off torque at the user).

The high pressure side is protected by pressure relief

valves, which unload to the low pressure side. The hydraulicfluid remains in the circuit. Only the continuous leakage from

pump and motor (dependent on operating data) must be re-

placed.

This fluid is replenished by an integrated auxiliary pump

(normally), which delivers a continuous, adequate supply of

fluid (boost fluid) via a check valve into the low pressure side

of the closed circuit. Any surplus flow of the boost pump

which operates in open circuit, is returned via a boost pres-

sure relief valve to the tank. The boosting of the low pres-

sure side enhances the pump operating characteristics.

Typical features of the closed circuit for axial piston units

are:

directional control valves - small sizes for pilot operation

filter/cooler - small sizes

tank size - small, dimensioned to suit boost pump flow

and volume of system

arrangement/mounting position - flixible/optional

load maintained via the drive motor

feedback of braking power

Installation step by step

Basic system with variable pump and variable motor.

Single pump input drive direction. Motor power take-

off in both directions. The pump can be swivelled

smoothly over centre, i.e. the direction of flow is

reversible.

Pressure relief valves - one each for the high and lowpressure sides - prevent the maximum permissible

pressure form being exeeded.

The leakage from pump and motor is led back to a

DBV

DBV

max

max

oil tankleckageoil

pump

motor

a max

a max

a max

a min

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Hydraulic drive system 20 km/h STRUCTURE AND FUNCTION

Hydraulic drive system 20 km/h

Rear axle

Front axle

8

9

10

12

1

3

14

15

16

17

18

19

M

3

M2

11

M1

STRUCTURE AND FUNCTION H d li d i t 20 k /h

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STRUCTURE AND FUNCTION Hydraulic drive system 20 km/h

1. Inch-brake valve2. Check valve (2 bar)

3. Variable displacement pump

4. 4/3 way valve with electric direction preselection (forward - neutral - reverse)

5. Safety valve with charge valve

6. Control cylinder

7. Regulating valve (Rpm-dependent)

8. Charge pressure relief valvent)

9. Hydraulic travel pressure cut-off valve

10. Charge pump

11. Steering and working hydraulic pump

12. Shuttle flushing valve

13. Throttle check valve

14. Electrical override valve (energized in forward)15. Check valve

16. Control piston

17. Control valve

18. Variable displacement motor

19. Suction and return filter

M1. Control pressure check point (no check nipple installed)

M2. Forward travel pressure check point

M3. Reverse travel pressure check point


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Hydraulic drive system 35 km/h

Rear axle

Front axle

M2

M3

10

9

M1

11

12

13

14

15

16

17

18.1

18.2

17

16

13

14

15


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1. Inch-brake valve2. Check valve (2 bar)

3. Variable displacement pump

4. 4/3 way valve with electric direction preselection (forward - neutral - reverse)

5. Safety valve with charge valve

6. Control cylinder

7. Regulating valve (Rpm-dependent)

8. Charge pressure relief valvent)

9. Hydraulic travel pressure cut-off valve

10. Charge pump

11. Steering and working hydraulic pump

12. Shuttle flushing valve


14. Electrical override valve (energized in forward)15. Check valve

16. Control piston

17. Control valve

18.1 Variable displacement motor A6VM 107

18.2 Variable displacement motor A6VM 80

19. Suction and return filter

M1. Control pressure check point (no check nipple installed)

M2. Forward travel pressure check point

M3. Reverse travel pressure check point

Variable displacement pump STRUCTURE AND FUNCTION

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p p p

Variable displacement pump

1 2 3 4 5 6

1. Drive shaft

2. Swivel bearing

3. Screw plug

4. Swash plate

5. Adjusting lever, adjusting cylinder-swash plate

6. Screw plug

7 8 9

7. Adjusting cylinder

8. Adjusting screw for mechanical 0-position of wash plate

9. 4/3 way valve with electric forward reverse direction prese-

lection

STRUCTURE AND FUNCTION Variable displacement pump

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12 14

10 11 12 13

10. Hydraulic travel pressure cut-off valve11. Orifice

12. Safety-/charge valve

13. Regulating valve

14. Charge pressure relief valve

15

15. Charge pump


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Function

The swash plate drive unit is a displacement pump, where

the displacement pistons are mounted axialy parallel to the

drive shaft. They react against the swash plate.

The drive shaft is rotated by the engine. The drive shaft is

splined to the cylinder head.

The cylinder head rotates with the drive shaft. The pistons(2) are mounted in the cylinder head. The pistons are

mounted in guide shoes; these glide over the swash plate

and cause an axial displacement in the cylinder head. The

guide shoes are held with spring pressure against the swash

plate.

During rotation the pistons move between bottom dead cen-

tre and top dead centre and back to the start position. In

moving between the dead centres (here the piston changesits linear direction) the piston completes a stroke. Because

of this oil is sucked in over the inlet port and displaced

through the outlet port. The oil volume displaced depends

on the piston area an length of stroke.

1. Drive shaft2. Pistons

3. Piston area

4. Piston displacement

5. Swash plate

6. Operating angle

7. Cylinder head

8. Drive shaft

9. Control plate

10. Top dead centre

11. Bottom dead centre

12. Inlet port (rotation as shown)

13. Outlet port (rotation as shown)


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Regulating valve

Charge pressure limiting valve

1

8

7

9

10

11

12

13

14

15

R

P

Psp

Pst

2

3

4

5

6

1. Spring cup

2. Pressure spring

3. Housing

4. Nut

5. Ring

6. Piston7. Throttle

8. Seal nut

9. Screw

10. Circlip

11. O-ring

12. Coller

13. Circlip

14. Regulating cylinder

15. Circlip

P = from pump

Pst = Control pressure

Psp = Boost pressureR = Return to tank

R

Psp

1 2 3

1. Valve housing

2. Spring cup

3. Pressure spring

4 O i


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Control cylinder

4/3 Way valve with direction control sole-noids

1

7 8 9 10 11

AB

2 3 4 5 6

1. O-ring

2. Pressure spring

3. Pressure spring

4. Control cylinder

5. Distance ring

6. Circlip7. Collet

8. Ring, variable

9. Spring cup

10. Spring cup

11. Rod

1 2 3

4 5 6 7 8 9

1. Grub screw

2. Control piston

3. O-ring

4. Plug connector

5. Pressure spring

6. Spring cup

7. Valve housing

8. Direction control solenoid

9. Plug connector


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Pressure cut-off valve

Safety-/charge valve

1

Pa

Pst

R

Pb

2

3

4

5

6

7

8

9

10

11

12

1. Seal nut

2. Spring cup

3. O-ring

4. Pressure spring

5. O-ring

6. Adjusting screw7. Cap screw

8. Control piston

9. Valve bush

10. Piston

11. Control piston

12. Valve seat

Pa = Travel pressure

Pb = Travel pressure

R = Return oil to tank

Rst = Control pressure

1

6

7

8

9

1. Cap screw

2. Pressure spring

3. Screw

4. Valve stem guide

5. Valve cup

6. Adjusting screw


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Towing

Function

Machines with hydrostatioc drives should only be towed

when a connection is made in the drive pump between the

high pressure and low pressure sides. To enable this, the

high pressure safety valves in the pump have a by-pass

function. That means, when screw (1) is turned the valve

tension is released and the oil can flow between the high

pressure and low pressure sides.

Bypass function

Release the locknut and srew in the screw (1) until the top of

the screw is level with the locknut.

Tighten the locknut.

To prevent damage to the hydrostatic drive system do nottow faster than 2 km/h or further than 1 km. Because the

feed pump is not working, the system will loose oil.

Care should be taken that the system does not overheat.

After towing screw (1) should be returned to its original position.

The setting of the high pressure control valve is not changed.

Valve Function

Release the locknut and screw out the screw (1) until the

screw reaches the end of its stroke.

Tighten the locknut.

1

1

1

STRUCTURE AND FUNCTION Variable displacement motor

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Variable displacement motor

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

14

15

16

17

18

19

202122

26

23

25

24

27

28

29

1. Output shaft

2. Retaining ring with washer

3. Retaining ring

4. Tapered roller bearing

5. Adjusting shim

6. Tapered roller bearing

7. Cone piston with piston rings, 7 units

8. Center pin

9. Cylinder

10. Adjusting screw for minimum swivel angle (max. speed)

11. Control lens

12. Control piston cover with throttle check valve (26)

13. Control piston

14. Swivel pin clamping screw

15. Swivel pin

16. Adjusting shim

17. Control piston

18. Adjusting screw for travel change over pressure

19. Control valve solenoid, 12 Volt,

Energized = max. swivel angle = 1st range

De-energized = min. swivel angle = 2nd range

20. Adjusting screw for max. swivel angle (min. speed)

21. Adjusting shim

22. Shaft seal

23. Safety valve

24. Flushing valve

25. Check point for travel change over pressure


27. Check valve

Variable displacement motor STRUCTURE AND FUNCTION

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Function

The drive motor is the opposite working principle to the drive

pump. In this case oil under pressure is sent to the drive mo-

tor. Oil enters the motor through thje control plate into the

cylinders. Four or five cylinders are in connection through

the kidney shaped inlet port with oil under pressure. The

other cylinders are connected through the kidney shaped

outlet port to the oil return side.

At least one cylinder is closed at the top or bottom dead cen-tre. The oil pressure forces the piston out, the guide shoes

slide on the swash plate and causes the cylinder head to ro-

tate. The cylinder turns through the action of the nine pis-

tons and so drives the output shaft. The torque required is

dependent on the drive pressure and is transmitted to the

drive shaft through the pistons in the cylinder head. The oil

volume determins the drive speed.

The drive torque is created directly at the drive shaft fromthe pistons in the cylinder head.

A change in the swing angle is achieved by a radial mov-

ment of the swash plate with the control piston.

1. Drive shaft2. Pistons

3. Piston area

4. Piston displacement

5. Swash plate

6. Operating angle

7. Cylinder head

8. Control plate

9. Top dead centre

10. Bottom dead centre

11. Inlet port (rotation as shown)

12. Outlet port (rotation as shown)

STRUCTURE AND FUNCTION Variable displacement motor

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Pages

10-19 to 10-50

skipped for technical reason

Variable displacement motor STRUCTURE AND FUNCTION

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Pages

10-19 to 10-50


STRUCTURE AND FUNCTION Drive shaft

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Drive shaft

1 2

5 6 5

3 4

1. Front axle 3. Distribution box 5. Universal joint

2. Drive shaft 4. Rear axle 6. Sliding joint

Axle mounting front and rear axle STRUCTURE AND FUNCTION

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Axle mounting front and rear axle

1. Nut

2. Washer

3. U-screw

1

2

3

STRUCTURE AND FUNCTION Front axle

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Front axle

Y

X

X

X - X Y

1

32

4 5 6

7

Rear axle with distributor box 20 km/h STRUCTURE AND FUNCTION

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Rear axle with distributor box 20 km/h

Y - Y

K

Y

1 12 3 4

5

9

Y

7

6

8

10

11 1212 11

X

STRUCTURE AND FUNCTION Rear axle with distributor box 35 km/h

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Rear axle with distributor box 35 km/h

Z

K

K

Y

Y

Y

1 12

3 4

98

5

7

6

Distributor box, single stage 20 km/h STRUCTURE AND FUNCTION

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Distributor box, single stage 20 km/h

1. Output gear 10. Breather

2. Cover 11. Bearing

3. Drain plug 12. Input flange

4. Output pinion 13. Input gear

5. Bearing 14. Housing

6. Cover 15. Bearing

9

11

12

13

8

7

6

5

1615

3

4

17

2

1

14

10

STRUCTURE AND FUNCTION Distributor box, double stage 35 km/h

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Distributor box, double stage 35 km/h

1. Output shaft 8. Cover

2. Housing 9. Input gear 35 km/h

3. Bearing 10. Cover

4. Cover 11. Plug

5. Drive shaft flange 12. Oil drain plug

6. Flange nut 13. Breather

7

8

12

11

6

5

4

3

1

13

2

910

Limited slip differential (locking value 45%), front and rear axle STRUCTURE AND FUNCTION

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Limited slip differential (locking value 45%), front and rear

axle

1 2 3

4

5

6

7

8

9

19

17,5 0,1 17,5 0,1

STRUCTURE AND FUNCTION Limited slip differential (locking value 45%), front and rear axle

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Function

Because of the nature of their work, 4-wheel drive loaders

have to work in places where the road surface is bad.

In such places, if the tires slip, the ability to work is reduced.

The torque proportioning selflocking differential is installed

to overcome this problem.

Operation

The self locking effect depends on the internal friction of the

differential. It is produced by two multi-disc brakes, which

are arranged symmetrically in the differential cage. With aconventional differential, one wheel can be stopped or

slowed down without any difficulty when the vehicle is

jacked up when driving.

The other wheel will then revolve correspondingly faster.

With the selflocking differential this process is rendered

more difficult due to the multi-disc brakes, in fact it will be-

come increasingly more difficult with increasing torque.

The crown wheel (4) is mounted on the differential housing

(1) and transmits the drive torque to the pins (2). The pins

carry the planet gears (3) and transmit the drive torque to

the sun gears (5).

If one drive wheel starts to lose traction with the ground the

planet gears (3) turning on the pins (2) start to rotate around

the sun gears (5). This takes place because the other drive

wheel now turns slower than the wheel that is slipping.

The reaction to this movement acts on the sun gears (5).

These can move axially. This causes pressure to be applied

to the disc pack (6) and the difference in turning speed be-

tween the two drive wheels is limited.

1 2 3 4 5 6

17,5 0,1 17,5 0,1

Wheel hub, front and rear axle STRUCTURE AND FUNCTION

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Wheel hub, front and rear axle

1 2 3

4 5 6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

2122

23242526

1-2 mm

STRUCTURE AND FUNCTION Wheel hub, front and rear axle

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Pages

10-61 to 10-64


Wheel hub, front and rear axle STRUCTURE AND FUNCTION

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Pages

10-61 to 10-64


STRUCTURE AND FUNCTION Service and parking brake, rear axle

S i d ki b k l

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Service and parking brake, rear axle

Service brake

The service brakes are two multi disc wet type

units (1) with 8 inner discs (3) and 8 outer discs

(4), operating in the rear axle.

Function When pressing the brake pedal the inch valve

opens and the servo oil in the variable displace-

ment pump flows to the tank. At same time the

brake master cylinder is operated. The oil from

Parking brake

The parking brake is a negative brake (7) operat-

ing in the rear axle. An electrical switch on the

parking brake lever prevents the machine from

being driven when the parking brake is applied.

Function

When the parking brake lever is applied, the

parking brake valve opens the negative brake

circuit and the hydraulic oil flows back into the

3

4

5

1

2

6

6

7

98

Service and parking brake, rear axle STRUCTURE AND FUNCTION

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STRUCTURE AND FUNCTION Sevice brake scheme 20 km/h

Sevice brake scheme 20 km/h

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1. Brake cylinder 4. Pedal

2. Brake pressure switch 5. Rear axle

3. Expansion tank 6. Displacement pump

Hydrostatic Inching

Parking brake scheme 20 km/h STRUCTURE AND FUNCTION

Parking brake scheme 20 km/h

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1. Handbrake valve 4. Rear axle

2. Brake pressure switch 5. Hydraulic pump

3. Hydraulic accumulator

Hydraulic tank

STRUCTURE AND FUNCTION Inch-brake pedal 20 km/h

Inch-brake pedal 20 km/h

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Function

The inch valve in the variable displacement pump allows, in-

1 Pedal 5 Brake pipe to service brake

2 Adjusting screw for pedal 6 Inch pipe to variable displacement pump

3 Bracket for pedal and brake master cylinder 7 Brake master cylinder

4 Brake light switch 8 Master cylinder push rod

6

5

4

3

7

Inch-brake pedal 35 km/h STRUCTURE AND FUNCTION


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1 Pedal 7 Brake master cylinder

2 Adjusting screw for pedal 8 Return flow pipe to hydraulic tank

3 Bracket for pedal and brake master cylinder 9 Servo brake pipe from distributor piece

4 Brake light switch 10 Distributor piece

5 Brake pipe to service brake 11 Meassure point 20 bar

6 Inch pipe to variable displacement pump 12 Master cyilinder push rod

1

12

11

10

9

8 7

6

5

4

3

2

STRUCTURE AND FUNCTION Inch-brake pedal 35 km/h

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Pages

10-71 to 10-80


Inch-brake pedal 35 km/h STRUCTURE AND FUNCTION

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Pages

10-71 to 10-80


STRUCTURE AND FUNCTION Steering scheme

Steering scheme

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g

1. Steering cylinder, right 5. Return folwsuction filter

2. Priority valve 6. Orbitrol

3. Work and steering pump 7. Steering cylinder, left

4. Oil tank

7 6 5 4

321

Steering scheme STRUCTURE AND FUNCTION

Priority valve

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Outline

The priority valve serves to ensure that in a steering opera-

tion oil is supplied to the steering system as a matter of pri-

ority; the residual quantity of oil is fed to the loader hydraulic

system. When no steering takes place, all the oil is passed

to the loader hydraulic system.

1 2 3 4 5 6 7

LS

EF CF

P Inlet from steering and working hydraulics pump


Orbit-roll-valve

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Outline

The orbit-roll is connected to the steering wheel through the

steering column. The orbit-roll controls the oil flow from the

steering pump to the steering cylinder and sets the steering

angle. The amount of oil delivered is proportional to the

amount the steering wheel is turned.

The control spool (4) and the control sleeve (6) form the

steering control valve. In normal working condition the oil

displacement system, made up of rotor (2) and stator (1) op-erates as a hydraulic pump. In an emergency steering situa-

tion the unit operates as a hand pump.

Structure

The control spool (4) is directly connected to the steering

wheel column and is connected to the control sleeve (6) by

the centre pin (7) and the centring springs (5).

The control spool (4) and the control sleeve (6) do not have

contact with each other in the neutral position.

The drive shaft (3) is meshed with the centre pin (7), and

forms one unit with the control sleeve (6). The other end of

the drive shaft (3) is meshed with the splines of the rotor (2)

of the girotor.

There are four ports in the valve body (8). They are connect-ed to the steering pump, to the tank and to the steering cyl-

inders. There is a check valve (9) mounted between the

pump port and the tank port. If the steering pump or the en-

gine fail, oil for the emergency steering can be drawn for the

girotor through the check valve (9).

In the orbit-roll, between the steering cylinder and the orbit-

roll, are mounted shock valves (10) these prevent damage

to the system from outside shocks.

R P

LT

1

2

7

8

3

4

5

6

9 10

Steering scheme STRUCTURE AND FUNCTION

Steering relief valve

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Function

The steering relief valve (2) is inside the orbit-roll valve (1),and sets the maximum circuit pressure of the steering circuit

when the orbit-roll valve is actuated. When the orbit-roll

valve is being actuated, if the steering circuit goes above the

set pressure of this valve, oil is relieved from this valve.

R P

L T

3

2

1

4

5

6

7

8

9

10

1. Orbit-roll valve

2. Pressure limiting valve

3. Valve seat (spool)

4. O-ring

5. Backup ring

6. Pressure spring

7. Distance bush

8. Clamping screw

9. Sealing ring

10. Screw plug


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Pages

10-85 to 10-89


PPC-Valve STRUCTURE AND FUNCTION

PPC-Valve

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PPC-valve port identification

1. Connection boom lower/float - with detent 4. Connection dump

2. Connection tilt 5. Connection 3rd control unit - with detent

3. Connection tilt 6. Connection 3rd control unit

V Travel direction switch forward

R Travel direction switch reverse

V

R

A

A

STRUCTURE AND FUNCTION PPC-Valve

Operation of PPC-valve

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Function

The PPC-valve controls the oil comming from the feed

pump. Depending on how the PPC-valve lever is moved, oil

is sent to the servo face of one or other of the main control

valve spools.

The oil pressure acts on this spool face and moves the

spool.

Operation

With the engine running the operating lever is in the neutral

position. The PPC system is supplied with oil from the vari-

able displacement drive feed pump.

The pressure builds up and is controlled by the feed pump

pressure control valve. Excess oil not required in the system

is allowed to return to the tank, so that this system is protect-

ed.

The steering and working hydraulic pump supplies oil

through a priority valve to the steering and hydraulic sys-

tems.

If the steering is not used, the complete oil flow is sent to the

working hydraulic system. It flows through the main control

valve to the tank.

If the PPC control lever is moved to the boom lower position,

servo oil flows to the main control valve boom lower spool.

The spool is moved to the position boom lower and oil from

the main pump is diverted. The non-return valve (pressure

holding valve) opens and oil is allowed to flow into the boom

lower circuit.

The rod side of the boom lift piston is supplied with oil under

pressure and the piston moves out until it reaches the end

stop. The rising pressure is controlled by the main valve

pressure regulating valve.

If the PPC control lever is moved through the boom lower


Servo pressure regulating valve

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Function

The servo pressure regulating valve is in the drive pump.

Apart from limiting the drive system feed pressure it also lim-

its the PPC servo pressure.If the PPC valve is not used the

servo pressure regulating valve protects the PPC and the

drive feed pressure system.

Operation

The regulating valve is mounted in the end housing of thevariable displacement drive pump.

When the oil pressure rises above the spring (2) preset

pressure, the valve piston (3) compresses the spring and

the seat lifts. the valve piston moves to the left and the oil

can release to the tank.

R

R

Psp

Psp

1 2

3 1 4

Psp Feed pump oil pressure

R Return to tank


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Control circuit for tilt-in/tilt-out(cross section)

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( )

Connection identification on the main control valve

1. Shock and anti cavitation valve for tilt back 6. Spool stopper (max. stroke)

2. Pressure holding valve 7. Springs (inner and outer)

3. Shock and anti cavitation valve for dump 8. Bucket spool

4. Screw 9. Housing

5. Spring cap 10. End cap (empty)

PB2 PA2

A2

P

1 32

4 5 6 7 8 9 10

B2

P Pump inlet channelA2 Connection dump, piston side of the bucket cylinder

B2 Connection tilt back, piston rod side of the bucket cylinder

PA2 - PP2 Connections PPC valve


Pressure regulating valve

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Function

The pressure regulating valve is mounted in the inlet port of

the main control valve.When the operating pressure reaches

a pre-set maximum, the valve opens and so prevents further

increase in pressure by directing the access oil back to the

tank.

Shock-anticavitation valve

Function

The shock-anticavitation valve is mounted in the main con-

trol valve between the spool and the operating cylinder. If

1 2 3 4 5

6

1. Piston

2. Cartridge

3. Spring

4. Locknut

5. Adjusting screw

6. Seal ring set

1 2 3 4 5 6 7 8

10 9

1. Valve piston

2. Cartridge

3. Piston

4. Spring

5. Spring

6. Ring

7. Locknut

8. Adjusting screw

9. Circlip

10. Seal ring set


Anticavitation valve

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Function

The anticavitation valve opens when there is a possibilitythat cavitation can take place in the system.

1 2

3 4

1. Cartridge

2. Ball valve

3. Seal ring set

4. Pin


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Pages

10-97 to 10-100



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Pages

10-97 to 10-100


STRUCTURE AND FUNCTION Lift cylinder

Lift cylinder

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Dimensions

Tightening torque

Pressures

2

6

3

3

3

4

5

7

9

8

1

Mounting length 1095 1mm

Stroke 702 1.5 mm

Piston rod 50 mm

Piston 95 mm

Guide bush 390 - 430 Nm

Operating pressure 210 bar

Shock pressure 320 bar

1. Piston

2. Piston rod

3. O-ring

4. Seal

5. Bearing

6. Wiper ring

7. Rod guide ring

8. Piston seal

9. Piston guide ring

Dump cylinder STRUCTURE AND FUNCTION

Dump cylinder

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Dimensions

Tightening torque

Pressures

7

6

5

3

3

4

2

1

Mounting length 1660 1.5 mm

Stroke 660 1.5 mm

Piston rod 70 mm

Piston 130 mm




1. Piston

2. Piston seal

3. O-ring

4. Rod guide ring

5. Seal

6. Wiper ring

7. Piston rod

STRUCTURE AND FUNCTION Steering cylinder

Steering cylinder

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Dimensions

Tightening torque

Pressures

1

2

3

4

5

8

9

10

6

7

Mounting length 665 2 mm

Stroke 395 2 mm

Piston rod 32 mm

Piston 57 mm




1 Plug

2 Headless setscrew

3 Pistion seal

4 O-ring

5 Guide ring

6 Pistion

7 Pistion rod

8 O-ring

9 Bearing ring

10 Seal

11 Retaining ring

12 Bearing

13 Wiper ring

Lifting with quick-coupler STRUCTURE AND FUNCTION

Lifting with quick-coupler

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1. Tilt rod 5. Lift arm

2. Tilt arm 6. Quick coupler cylinder

3. Tilt cylinder 7. Lift cylinder Bucket

4. Lift cylinder

1 2 3

4567

STRUCTURE AND FUNCTION Bucket positioner

Bucket positioner

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Bucket positioner STRUCTURE AND FUNCTION

Function

The bucket positioner is an electrically actuated system

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which is used to set the bucket to the desired angle whenthe bucket is moved from the DUMP position to the TILT po-

sition.

When the bucket reaches the desired position, the bucket

lever is returned from the TILT position to the HOLD posi-

tion, and the bucket is automatically set to the suitable dig-

ging angle.

Detector (2) is secured to bucket cylinder rod (3) by bolts. In

addition, proximity switch (1) fixed to the cylinder by bolts.

When the bucket is moved from the DUMP position to the

TILT position, the bucket cylinder rod moves to the left, and

at the same time, detector (2) also moves to the left. Proxim-

ity switch (1) separates from detector (2) at the desired posi-

tion, and the bucket lever is returned to neutral.

Operation of proximity switch

When the bucket is lower than the set position for the auto-

leveler (bucket tilted further), the detector is not above the

detection surface of the proximity switch, so electric current

flows in the proximity switch load circuit.

When the bucket lever is moved to the TILT position, (until it

engages), the control lever is held in the TILT position by amagnet.

When the set digging angle is reached, the sensor surface

of the proximity switch is released, the circuit interrupted and

Proximity switch Detector

STRUCTURE AND FUNCTION Bucket positioner

Adjusting the bucket positioner

1. Lower the bucket to the ground and set the bucket to the de-

sired digging angle Set the bucket lever to HOLD stop the

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sired digging angle. Set the bucket lever to HOLD, stop the

engine and adjust as follows:

2. Loosen two bolts (1) and adjust mounting bracket (4) of the

proximity switch so that the rear tip of detector (2) is in line

with the center of the sensing surface of proximity switch (3).

Then tighten the bolts to hold the bracket in position.

3. Loosen two nuts (5) of the proximity switch and adjust to

make a clearance of 6 to 8 mm (0.12 to 0.20 in) between de-

tector (2) and the sensing surface of proximity switch (3).

Then re-tighten the nuts.

Tightening torque: 15 - 20 Nm

4. After the adjustment, start the engine and raise the lift arm.

Operate the bucket lever to the DUMP position, then oper-

ate it to the TILT position and check that the bucket lever is

automatically returned to HOLD when the bucket reaches

the desired angle.

Action of proximity switch

GK100299

2

1

3

4

5

"

PositionWhen detector is in position at detection

surface of proximity switch

When detector is separated from detec-

tion surface of proximity switch

Proximity switch load circuit

(relay switch circuit) Current flows Current is shut off

Relay switch load circuit

(solenoid circuit)Current flows Current is shut off

Bucket positioner STRUCTURE AND FUNCTION

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Pages

10-108 to 10-110


STRUCTURE AND FUNCTION Monitor display

Monitor display

Display group Symbol System Operation Display type

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Display

Working flood lights When switched on Display lightens up.

ALS-electronics

(Option)When switched on

Display lightens up, when the ALS-

electronics is switched on and when

the machine drives faster than 5 km/h.

Rear windscreen

heaterWhen switched on Display lightens up.

Air intake pre-heaterWhen pre-heater is switched

on

When the display lightens up the igni-

tion is switched on. Duration depends

on the ambient temperature.

Turning lights

(left - right)When switched on Display lightens up.

Travel direction

(forward, reverse)

When drivingDisplay lightens up when the forward/

reverse lever is not in NEUTRAL.

Parking brakeWhen the parking brake is

applied

Display lightens up and an acoustic

warning is heard if the forward/

reverse lever is not in NEUTRAL.

Headlight When switched on Display lightens up.

Dipped headlights When switched on Display lightens up.

High-Speed - 35 km/h

(Option)When switched on

Display lightens up if the high-speed

gear is switched on.

Counter Working hours Engine working time in hours

Shows the current working time in

hours, when the engine generator is

charging.

Analogue display

Engine water tempera-

ture6-point display

Display lightens up and shows the cur-rent engine working temperature. By

temperatures over 105C, there also is

an acoustic warning.

Sensors STRUCTURE AND FUNCTION

Sensors

Sensor detection item Sensor method When normal When abnormal

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Engine oil pressure sensor

Function

This sensor is installed to the engine block and the dia-

phragm (4) detects the oil pressure. If the pressure goes be-

low the specified pressure, the switch is turned ON.

This makes the monitor flash to warn of the abnormality. At

the same time the alarm buzzer is actuated to warn of the

abnormality.

Eng. oil pressure Contact ON OFF

Engine coolant temperature Resistance 25C (42.7 k) 106C (3.157 k)

Fuel level Resistance FULL (2.2 k) EMPTY (88.5 k)

Air filter negative pressure Contact OFF ON

Brake oil level Contact OFF ON

61 2 3 4 5

Structure of circuit

1. Plug

2. Contact ring

3. Contact

4. Diaphragm

5. Spring

6. Terminal

STRUCTURE AND FUNCTION Sensors

Fuel level sensor

61 2 3 4 5

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Function

The fuel level sensor is mounted and secured in the top ofthe tank. The float (9) moves up and down according to the

fuel level.

The contact spring (13), which is mounted on the float,

moves up and down the two parallel resistance wires (15).

The contact spring (13) connects the two resistance wires

(15) and gives a resistance proportional to the position of

the float.

The measured resistance is sent to the monitor as an elec-

trical signal and shows the fuel level.

7

8

9

10

1112

13

14

15

16

171. Connector

2. Rivet

3. Seal ring

4. Isolator

5. Spring

6. Flange

7. Centre rod

8. Outer pipe

9. Float

10. Lock ring

11. Inlet

12. Isolator

13. Contact spring

14. Guide

15. Resistance wire

16. Solder connection

17. Wire holder

9

13

15

+12V

10A Monitor


Engine coolant temperature sensor

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Function

This sensor is installed to the engine cylinder block. The

change in the temperature changes the resistance of the

thermistor, and a signal is sent to the monitor to display thetemperature.

When the display on the monitor reaches the specified level,

the caution lamp and alarm buzzer are also actuated at the

same time to warn of the abnormality.

1. Connector

2. Plug

3. Thermistor

2 31

2

1

12


STRUCTURE AND FUNCTION Sensors

Brake oil reservoir sensor

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Function

The sender unit is mounted in the screw cap. When the oil

level falls under a minimum the float sinks down until the

switch contacts close (ON position).

This lights the warning lamp to inform the driver that the

brake oil level is low.

1. Contacts

2. Screw cap

3. Float

4. Brake pipe connection

5. Mounting



Ribbon heater temperature sender unit

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Function

The housing of the temperature sender unit has a hexagon

head and a screw thread. The isolation bush (1) is fitted in

the top of the sender unit and isolates the connection from

chassis.

The temperature transmitter (7) is mounted at the bottom of

the sender unit and is held in position by the pressure spring

(4). The disc (6) ensures that the spring presses evenly on

the temperature transmitter (7) and the housing to chassis.

Because of the insolator (5) the pressure spring (4) and the

disc (6) have no connection to chassis.

The air intake temperature influences the temperature trans-

mitter (7) resistance. The resistance changes according to

the air intake temperature and sets the electrical current for

the in series connected monitor. The monitor then controlls

th h t ti f th ibb h t

1

2

3

4

5

6

7

1. Isolation bush

2. Seal ring

3. Housing

4. Pressure spring

5. Isolator

6. Disc

7. Temperature transmitter


STRUCTURE AND FUNCTION Ribbon heater

Ribbon heater

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Function Operation

Electrical ribbon

heater

Current supply

(pin 15)

Start signal

(pin 50a)

Preheat/warning light

Relationship between ambient temperature and preheat time

ON

OFF

ON

OFF

ON

OFFt

20

30

10

0-25 -20 -15 -10 -5 0

t (s)

T (C)

Ambient temperature

Preheat time

Ribbon heater STRUCTURE AND FUNCTION

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Pages

10-118 to 10-119


STRUCTURE AND FUNCTION Ribbon heater

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Pages

10-118 to 10-119


Engine stop/start/preheating circuit STRUCTURE AND FUNCTION

Engine stop/start/preheating circuit

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STRUCTURE AND FUNCTION Engine stop/start/preheating circuit

Engine stop/ start/ preheating circuit

Section Description Sect. Description

9 S 43 Start-switch 8 K 158 Relay, starter

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12 S 58 Battery, main switch 7 K 167.1 Time relay for motorstop

8 G 10 Generator 4 K 238 Relay, preheating

12 G 57 Battery 5 K 320 Relay, motorstop

10 M 9 Starter 5 H 28 Warning lamp, alternator

6 P 21 Working hour gauge 4 H 76 Preheat warning lamp

2 P 426 Main control panel 7 H 439.1 Warning lamp travel direction V

6 V 1 Diode 7 H 439.2 Warning lamp travel direction R

3 R 12 Flame plug 2 B 14 Temp. sender, preheat

10 K 106 Relay, battery 5 Y 320 Solenoid, engine stop

Connectors

X L Connector platform X J Connector main control panel

X M Connector motor X A Connector axle

X C Connector cabinX 47 Connector socket

X F Connector front frame

Fuses

F... Fuse

Engine start

Voltage flows in the following circuit: Starting mo-

tor (M9) - terminal 30, BAT Alternator, battery re-

lay (K106) terminal 30 and starting switch

terminal 30. When the starting switch is turned

(terminal 15) relay (K106) is activated. Now ter-

minal 15 in the machine is switched on, the en-

gine stop solenoid (Y320) is activated, the

controll circuit for the preheating system is also

on.

When the starting key in the starter switch is

turned to position 50a, current flows to the neu-

tral position starter relais (K208). The neutral po-

Preheating

Current flows to the starter motor (M9)-terminal

30, BAT generator, terminal 30, preheat relay

(K283) terminal 30 battery relay (K106), and to

the starting switch terminal 30.

When the starting switch is switched on terminal

15 activates the battery relay (K106). Now termi-

nal 15 in the machine is on, the stop solenoid

(Y320) and the controll circuit for the preheat

system is activated.

The preheat time depends on temperature and is

controlled over the main monitor and tempera-

t d (B14)

Driver's cab STRUCTURE AND FUNCTION

Driver's cab

Fuses (1)

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( )

Relais (2)

1 Starter stop magnet, socket 20A Solenoid valves gear unit 10A

2 Inside lighting, radio 10A Direction indicator, horn 10A

3 Hazard flasher 10A Instrument lighting 10A

4 Windscreen wiper and windscreen washer front and rear 20A Working light 20A

5 Brake light, reversing warning system, warning beacon 10A Side lamp left, lamp registration number 10A

6 Fan, ventilation, heating 20A Side lamp right 10A

7 Heated rear windscreen 20A High beam 10A

8Tank sensor, solenoid valves high-speed motor, ALS

(option)10A Low beam 10A

(2)

STRUCTURE AND FUNCTION Driver's cab

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Pages

10-123 to 10-130


Driver's cab STRUCTURE AND FUNCTION

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Pages

10-123 to 10-130


STRUCTURE AND FUNCTION Wiring diagrams

Wiring diagrams

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Wiring diagrams STRUCTURE AND FUNCTION

Wiring diagram Fig. 1

NOTE

See wiring diagram 1 in chapter 90 "APPENDIX", page 10-133

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Sect. Description Sect. Description

1 P426 Instrument paneel 15 S439 Travel direction switch

2 B14 Sender preheat temperature 16 K373.2 Relay for parking brake "R"

3 H76 Air preheater pilot lamp 17 S173 Sender for 3rd control circuit

3 K238 Relay for suction air preheater 17 K385 Relay for backup alarm

3 R12 Suction air preheater 16 Y236 Solenoid valve forward

4 K320 Relay for engine stop 17 Y237 Solenoid valve reverse

4 Y320 Solenoid for engine stop 18 S261 Drive range switch

5 P21 Working hour gauge 18 K167.2 Time relay 0.8 sec.

5 H28 Alternator pilot lamp 18 H379 Drive range pilot lamp

5 V118 Diode 20 Y235 Drive range solenoid valve

6 H439.1 Travel direction "F" pilot lamp 22 R97 Fuel level sender

6 H439.2 Travel direction "R" pilot lamp 22 P96 Fuel level gauge

6 K167.1 Time relay for engine stop 22 R97 Cooling water temperaturee gauge

7 G10 Alternator 23 P25 Cooling water temperature sender

8 S43 Starting switch 23 B13 Air filter pilot lamp

8 K158 Relay for starter motor 24 H263 Air filter depression sender

9 M9 Starter motor 24 B262 Engine oil pressure pilot lamp

9 K106 Reay for battery 25 H30 Engine oil pressure sender

11 G57 Battery 25 B19 Brake oil level sender

11 S58 Battery cutoff key 26 B304 Brake oil level pilot lamp

14 H126 Parking brake pilot lamp 26 H288 Speedometer gauge

14 Y127 Parking brake solenoid valve 27 P384 ALS-rotation switch

14 K373.1 Relay for parking brake "F" 27 K314 Speed sender

14 S127 Parking brake switch 27 B228 Travel direction switch

15 B127 Parking brake pressure switch

Connectors


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NOTE


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Sect. Description Sect. Description

29 K67 Blinker unit 41 E68.1 Tail lamp left

30 H31 Blinker pilot lamp 42 E69.1 Tail lamp right

30 E68.2 Blink lamp rear RH 42 V118 Diode

30 E5 Blink lamp front LH 43 S70 Brake light switch

30 P426 Instrument paneel 43 E68.3 Brake light left

31 S331.1 Blinker steering arm switch 44 E69.3 Brake light right

33 E6 Blink lamp front LH 46 S51 Working head light switch

33 E69.2 Blink lamp rear RH 46 H51 Working head light pilot lamp

34 S101 Anti-collision light switch 46 E3 Working head light front LH

34 H101 Anti-collision light pilot lamp 47 E4 Working head light front rH

36 S331.2 Head light steering arm switch 49 E60 Working head light rear LH

36 E1 Head light left 50 E61 Working head light rear RH

36 K56.1 Relay for head light 53 S331.3 Horn steering arm switch

38 E2 Head light right 51 E123 Cabin light

38 K56.2 Relay for bright light 53 B8 Horn

40 H29.1 Bright light pilot lamp 54 X47 Socket

40 H29.2 Head light pilot lamp

Connectors

X J Instrument paneel connector X M Engine connector

X L Plattform connector X F Front frame connector

X C Cabin connector

Fuses

F... Fuse



NOTE


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Sect. Description Se

WA115-3_VEBM120100

Documents

Transcript of WA115-3_VEBM120100