Mir w270 - Inglese [PDF]

Zitiervorschau

MODELS

Service Manual

W270

W270 WHEEL LOADER

Service Manual Print N° 604.02.247 English Updating 01 october

THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY. Read and heed carefully the safety instructions listed and follow the precautions recommended to avoid potential risks and to safeguard your health and your safety. You will find this symbol in the text of this Manual referred to the following key words:

WARNING - Cautions directed to avoid improper repair interventions involving potential consequences for the operator’s safety. DANGER - These warnings qualify specifically potential dangers for the safety of the operator or other persons directly or indirectly involved.

IMPORTANT NOTICE All maintenance and repair interventions explained in this Manual must be performed exclusively by the Service Organization of the Manufacturer, observing strictly the instructions explained using, whenever necessary, the recommended specific tools. Whoever performs the operations reported without following exactly the precautions is responsible on his own, for the damages that may result. Neither the Factory nor any Organizations in its Distribution Network, including but not limited to national, regional or local distributors, are responsible for any liability arising from any damage resulting from defects caused by parts and/or components not approved by the Factory for use in maintaining and/or repairing products manufactured or merchandized by the Factory. In any case, no warranty of any kind is made or shall be imposed with respect to products manufactured or merchandized by the Factory, when failures are caused by the use of parts and/or components not approved by the Factory.

AVOID ACCIDENTS Most accidents and injuries occurring in industry, on the farm, at home or on the road, are caused by the failure of some individual to follow simple and fundamental safety rules or precautions. For this reason, MOST ACCIDENTS CAN BE PREVENTED by recognizing the real cause and taking the necessary precautions, before the accident occurs. Regardless of the care used in design and construction of any type of equipment, there may be conditions that cannot be completely safeguarded against without interfering with reasonable accessibility and efficient operation. A careful operator is the best insurance against accidents. The complete observance of one simple rule would prevent many thousands serious injuries each year. This rule is: Never attempt to clean, lubricate or adjust a machine while it is in motion.

WARNING On machines having hydraulically, mechanically and/or cable controlled equipment (such as showels, loaders, dozers, scrapers etc.) be certain the equipment is lowered to the ground before servicing, adjusting and/or repairing. If it is necessary to have the equipment partially or fully raised to gain access to certain items, be sure the equipment is suitably supported by means other than the hydraulic lift cylinders, cable and/or mechanical device used for controlling the equipment.

S U M M A RY

SAFETY RULES ............................................................................................. pag. 1 SPECIFICATIONS .......................................................................................... pag. 8 FLUIDS AND CAPACITY TABLE ................................................................... pag. 10 UNITS OF MEASURE USED IN THE MANUAL ............................................. pag. 11 TIGHTENING TORQUES .............................................................................. pag. 12

ENGINE................................................................. Section 1 TRANSMISSION ................................................... Section 2 BRAKING SYSTEM .............................................. Section 3 STEERING SYSTEM ............................................ Section 4 BUCKET BOOM AND FRAME ............................. Section 5 ATTACHMENT HYDRAULIC SYSTEM ................. Section 6 ELECTRICAL SYSTEM ........................................ Section 7 CAB ...................................................................... Section 8

W270

0-1

SAFETY RULES GENERALITIES Read this Manual carefully before starting, operating, maintaining, fuelling or servicing the machine. Read and comply with all safety precautions before any intervention. Do not allow unauthorised personnel to operate or service this machine. Do not wear rings, wrist watches, jewellery, loose or hanging garments, such as ties, torn clothing, scarves, unbuttoned or unzipped jackets that can get caught in moving parts. Wear certified safety clothes such as: hard hat, noslip footwear, heavy gloves, ear protection, safety glasses, reflector vests, respirators. Ask your employer about specific safety equipment requirements. Keep the operator’s compartment, step plates, grab-rails and handles clean and clear of foreign objects, oil, grease, mud or snow to minimize the danger of slipping or stumbling. Remove mud or grease from your shoes before attempting to mount or operate the machine. Do not jump on or off the machine. Always keep both hands and one foot, or both feet and one hand in contact with steps and grab rails. Do not use controls or hoses as hand holds when climbing on or off the machine. Hoses and controls are movable parts and do not provide solid support. Besides, controls may be inadvertently moved and cause unexpected movement of the machine or its attachments. Never operate the machine or its attachments from any position other than sitting in the driver’s seat. Keep head, body, limbs, hands and feet inside the operator’s compartment at all times to reduce exposure to external hazards . Be careful of possible slippery conditions of the steps and hand rails as well as of the ground around the machine. Do not leave the machine until it is has come to a complete stop. Check the seat safety belt at least twice per year and replace it if it shows signs of wear, fraying or other weakness that could lead to failure.

Ensure that nobody is in the machine operating range before moving off or operating the attachment. WALK COMPLETELY AROUND the machine before mounting. Sound the horn. Before starting machine, check, adjust and lock the driver's seat for maximum comfort and control of the machine. Fasten your seat belts(when fitted). Obey all flag signals and signs. Due to the presence of flammable fluids on the machine, never check or fill fuel tanks or accumulator batteries near fires, open flames, or sparks. REMEMBER THAT SPECIAL STARTING FLUIDS ARE FLAMMABLE. Scrupolously follow recommendations printed on the containers and in this Manual. DO NOT PUNCTURE OR BURN CONTAINERS. Containers must be stored in fresh, well ventilated places and out of the reach of unauthorised persons. Strictly follow the instructions provided by the Manufacturer. Never use these products near fires, open flames, or sparks.

OPERATING Check wheel and rim retainers before each working shift. If necessary, tighten to the torque specified. Do not run the engine of this machine in closed buildings without proper ventilation capable to remove harmful exhaust gases. Roll Over Protective Structures (ROPS) are required on wheel or crawler loaders, dozers, or graders. NEVER OPERATE the machine if such protective structure is removed. Keep the operator’s compartment free of foreign objects, especially if not firmly secured. Never use the machine to transport objects, unless proper securing points are provided. DO NOT CARRY RIDERS ON THE MACHINE Study and familiarize with escape routes alternate to normal exit routes.

STARTING NEVER START OR OPERATE A FAILED MACHINE. Before operating the machine, always ensure that any unsafe condition has been satisfactorily corrected. Check brakes, steering and attachment controls before moving off. Report any malfuctioning part or system to the maintenance managers for proper action. Ensure all protective guards and panels as well as all safety devices provided are in place and in good operating condition.

According to law provisions, seat belts must be fitted with Roll Over Protection Structures or cabs. Keep safety belts fastened during operation. For your personal safety, do not climb on or off the machine while it is in motion. Make sure that bystanders are clear of the machine operating range before starting the engine and operating the attachment. Sound the horn. Obey all indications provided by flags, signs and signals. DO NOT COAST OR FREEWHEEL down hills. Engage the most suitable gear speed to keep the machine under control.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0-2

W270 SAFETY RULES

Do not operate the machine if you are extremely tired or feel ill. Be especially careful towards the end of the working shift.

ground is loose or soft since overturn or loss of machine control could result.

Do not operate a machine with misadjusted brakes. Operate the machine at low speed which can ensure complete control at all times.

If noise level is high and continuosly exceeds 90 dBA over 8 hours at the operator's ear, wear approved ear protection in compliance with local regulations.

Travel slowly over very rough terrain, slopes or near dropoffs, in congested areas or on frozen or slippery surfaces.

Where counterweights are provided, do not operate the machine if they have been removed.

When backing, always look to where the machine is to be moved. Be alert of the position of bystanders. Should someone enter the work area, STOP THE MACHINE.

When transporting a loaded bucket, keept it as rolled-back and low as possible for maximum visibility, stability and safety of there machine. Ground speed should be adequate to the load and ground conditions.

Maintain a safe distance from other machines or obstacles to ensure required visibility conditions. Give way to loaded machines. Maintain a clear vision of the surroundings of the travel or work area at all times. Keep cab windows clean and repaired. When machines are operating in tandem, the pusher (rear) must be equipped with the appropriate deflectors to protect the front unit driver against the air stream coming from the blower fan.

The load must always be properly arranged in the bucket; move with extreme care when transporting oversize loads. Use only the type of bucket recommended for the machine and the materials to be handled. Follow the recommendations concerning loading capacity, arrangement of the materials, characteristics of the ground and job to be performed.

When pulling or towing through a cable or chain, do not start suddenly at full throttle. Take-up slack carefully.

Do not lift and move loads overhead where persons are standing or working, nor downhill when working crosswise on slopes. In this case, the bucket should be unloaded on the uphill side, whenever possible.

Carefuly inspect the towing items for flaws or problems before proceedig.

Start and stop the machine carefully when the bucket is full. Do not move off without first reducing engine speed.

Avoid kinking or twisting chains or cables. Do not pull through a kinked chain or cable as the high stresses existing in this condition may induce failures. Always wear heavy gloves when handling chains or cables.

Overtaking manoeuvres should be performed only when absolutely necessary and unavoidable. Beware possible uneven terrains, poor visibility, presence of other machinery or persons out of sight.

Chains and cables should be securely anchored. Anchor points should be strong enough to withstand the expected load. Keep anyone clear of anchor points and cables or chains.

Operate the machine at a speed adequate to the working site conditions and in any case slow enough to ensure complete control at all times.

DO NOT PULL UNLESS THE OPERATOR’S COMPARTMENTS OF THE MACHINES INVOLVED ARE PROPERLY PROTECTED AGAINST POSSIBLE BACKLAS IN CASE OF CABLE OR CHAIN FAILURE OR DETACHMENT. Be alert of soft ground conditions close to newly constructed walls. The fill material and machine weight may cause the wall to collapse. In darkness, check area of operation carefully before moving in with the machine. Use all lights provided. Do not move into low visibility areas. If the engine tends to stall for whatever reason under load or at idle, immediately report this problem to the maintenance managers for proper action. Do not operate the machine until this condition has been corrected. On machines fitted with suction radiator fans, regularly check the engine exhaust system for leaks, as exhaust fumes expelled towards the operator are toxic. Operators must know thoroughly the performances of the machine they are driving. When working on slopes or near sudden level drops in the terrain, avoid areas where

Check instruments at start-up and frequently during operation. Stop the machine immediately should any malfunction be signalled. Never use the bucket as a man lift or to carry riders. Never use the machine as a work platform or scaffolding, nor for other improper use (such as pushing railway cars, trucks or other machines). Pay attetion to people within the machine operating range. Load trucks from the driver’s side whenever possible. Prior to operating the machine, check which obstacles and/or difficulties you will encounter, such as narrow streets, overhead doors, cables, piping, as well as ground, bridges, paving and ramps bearing load limitations. In case of road transfers, find out beforehand what conditions are likely to be encountered, such as size restrictions, heavy traffic, paving type, etc. . Beware fog, smoke or dust that obscure visibility. When crossing gullies or ditches, move at an angle with reduced speed after ensuring ground conditions will permit a safe traverse. Always inspect the working area to identify potential risks

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

0-3 SAFETY RULES

such as: inclines, overhangs, trees, demolition rubble, fires, ravines, steep slopes, rough terrain, ditches, crowns, ridge trenches, heavy traffic, crowded parking and service areas, closed ambients. In such conditions, proceed with extreme care. Whenever possible, avoid going over obstacles such as very rough terrain, rocks, logs, steps, ditches, railroad tracks. When obstructions must be crossed, do so with extreme care and at an angle, if possible. Slow down and select a lower gear. Ease up to the break-over point, pass the balance point slowly and ease down the other side. In steep down-hill operation, do not allow the engine to over-speed. Select the proper gear before starting down grade. Avoid crosswise hill travel, whenever possible. Drive up and down the slope. Should the machine start slipping sideways when going uphill, steer and turn machine front immediately downhill. The gradient you may attempt to overcome is limited by factors such as ground conditions, load being handled, machine type and speed, and visibility. There is no substitute for good judgement and experience when working on slopes. Avoid operating the attachment too close to an overhang or high wall, either above or below the machine. Beware of caving edges, falling objects and landslips. Remember that such hazards are likely to be concealed by bushes, undergrowth and such. When pushing-over trees, the machine must be equipped with proper overhead guards. Never drive a machine up the roots, particularly while the tree is being felled. Use extreme care when pushing over any tree with dead branches. Avoid faggots, bushes, logs and rocks.

Always remember to move the gearshift lever to the neutral position and engage the control lever lock for safety purposes. Apply the parking brake (if fitted). NEVER LEAVE THE MACHINE UNATTENDED with the engine running. Prior to leaving the operator’s seat,and after making sure that all people are clear of the machine, always slowly lower the attachment until resting it safely to the ground Park the machine in a non-operating and no-traffic area. Park on firm level ground. If this is not possible, position the machine at a right angle to the slope, making sure there is no danger of uncontrolled sliding. Apply the parking brake. If parking in traffic lanes cannot be avoided, provide appropriate flags, barriers, flares and signals as required to adequately warn the oncoming drivers. Keep head, body, limbs, hands and feet clear of the dozer, arms, bucket or ripper when raised. Always switch off the battery isolator switch before servicing the machine in whatever manner (i.e., cleaning, repairing, maintaining, etc.). Do the same when the machine is to remain parked for prolonged periods of time to avoid accidental or unauthorized starting. Never lower the attachments other than sitting in the operator’s seat. Sound the horn. Make sure that nobody is within the machine operating range. Lower the attachment slowly. DO NOT USE FLOAT POSITION in case of hydraulic controls. Securely block the machine and lock it every time you leave it unattended. Return keys to authorized security. Perform all necessary operations as detailed in the Operation and Maintenance Instruction Manual. Apply the parking brake (if fitted) every time you leave the machine.

NEVER DRIVE OVER THEM, nor over any other surface irregularities that discontinue adherence or traction with the ground, especially near slopes or drop-offs. Be alert to avoid changes in traction conditions that could cause loss of control. AVOID driving on ice or frozen ground when working on steep slopes or near drop-offs. Working in virgin rough terrains is characterized by the presence of all the perils and risks listed above. In these conditions, it is emphasised the danger represented by large tree limbs (possibly falling on the machine), large roots (which may act as a leverage under the machine when up-rooted and cause the unit to overturn), etc.

MAINTENANCE GENERALITIES Before operating or performing any intervention on the machine: - carefully read all the norms contained in this Manual; - read and observe all safety plates and instructions located on the machine. Do not allow unauthorized personnel to service the machine. Do not carry out any maintenance work without prior authorization. Follow all recommended maintenance and service procedures.

STOPPING When the machine is to be stopped for whatever reason, do so following the instructions given in chapters “Stopping the machine” and “Shutting off the engine" in the Operation and Maintenance Instruction Manual.

Keep the operator’s compartment free of loose objects that are not properly secured. Do not wear rings, wrist watches, jewellery, loose or hanging garments, such as ties, torn clothing, scarves,

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0-4

W270 SAFETY RULES

unbuttoned or unzipped jackets that can get caught in moving parts. Wear certified safety clothes such as: hard hat, no-slip footwear, heavy gloves, ear protection, safety glasses, reflector vests, respirators. Ask your employer about specific safety equipment requirements. Never service the machine with someone sitting in the driver's seat, unless this person is an authorized operator assisting in the maintenance being carried out. Keep the operator’s compartment, step plates, grab rails and handles clear of foreign objects, oil, grease, mud or snow to minimize the danger of slipping or stumbling. Clean mud or grease from your shoes before climbing on the machine or driving it. Never attempt to operate the machine or its attachments from any position other than sitting in the operator’s seat. Never stand under the boom. Should it be necessary to move the attachment through the hydraulic controls for maintenance purposes, remember that this should be done while sitting in the operator’s seat. Before starting the machine or moving its attachment, apply the brakes, sound the horn and call that you are about to manoeuvre. Raise the attachment slowly. Always lock machine arms or any other parts that must be lifted for maintenance purposes using adequate external means. Do not allow anyone to pass near or even below a raised yet unlocked attachment. If you are not absolutely sure about your safety, do not stay under a raised attachment, even if it is locked. Do not place body, limbs, or fingers near articulated cutting edges of uncontrolled machine parts or deprived of the necessary guards, unless they are suitably and safely locked. Never perform any work on the machine with the engine running, except when this is specifically required. Do not wear loose clothing, jewellery or such near moving parts.

The fuel filler pipe nozzle must be constantly kept in contact with the filler neck. Keep this contact from the beginning to the end of the fuelling operation to avoid possible generation of sparks due to static electricity. Tow the machine only from the attaching points provided. Use care in making connections and ensure pins and/or bolt are firmly secured before pulling. Stay clear of drawbars, cables or chains under load. To move a failed machine, use a trailer or a low platform truck, if available. In case towing is needed, use all necessary signals required by local regulations, and follow directions provided in this Manual. Load/unload the machine from transporter on firm level ground providing safe support to the wheels of the truck or trailer. Use strong access ramps, with adequate height and angle. Keep the loading platform free of mud, oil or slippery materials. Tie the machine securely to the platform of the truck or trailer and opportunely wedge machine wheels or tracks as required. Never align holes or slots using your fingers; always use appropriate aligning tools. Remove all sharp edges and burrs from re-worked parts. Use only approved and effectively grounded auxiliary power sources for heaters, battery chargers, pumps and similar equipment to reduce electrical shock hazard. Lift and handle heavy components using hoisting devices of appropriate capacity. Ensure the sling has been correctly applied. Use lifting eyes if provided. Pay attention to bystanders. Never pour gasoline or diesel fuel into open, wide and low containers. Never use gasoline, solvents or other flammable fluids to clean parts. Use proprietary certified nonflammable, non-toxic solvents only.

When service or maintenance require access to areas that cannot be reached from the ground, use a ladder or step platform conforming to regulations in force. If such means are not available, use machine grab rails and steps. Always perform all service or maintenance work with the greatest care and attention.

When using compressed air to clean parts, wear safety glasses with side shields. Limit pressure to max 2 bars, in accordance with local safety regulations in force.

Shop and/or field service platforms or ladders should be manufactured in accordance with safety regulations in force.

Do not smoke, use open flames or produce sparks nearby while refuelling the unit or handling highly flammable materials.

Disconnect batteries and label all controls to warn that service work is in progress. Block the machine and all attachments to be raised.

Do not use any flame as a light source during maintenance work or to look for leaks anywhere on the machine.

Do not check or fill fuel tanks, batteries and accumulators, nor use the starting liquid if you are smoking or near open flames. These fluids are flammable! BRAKES ARE INOPERATIVE when manually released for servicing. Provisions must be made to maintain control of the machine using suitable blocks or other means.

Do not run the engine in closed buildings without proper ventilation capable to remove lethal fumes.

Make sure that all tools provided are in good condition at all times. NEVER USE tools with mushroomed or damaged heads. Always wear eye protections. Move with extreme care when working under the machine, its attachments, and even on or near them. Always wear protective safety equipment as required, such as hard hat, goggles, safety shoes, and ear plugs.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

0-5 SAFETY RULES

In case tests during which the engine should be kept runinng, a qualified operator must sit in the driver’s seat with the mechanic in sight at all times. Place the transmission in neutral, apply and lock the brakes. KEEP HANDS OFF MOVING PARTS. In case of field service, move machine to level ground, if possible, and block it. If work on an incline cannot be advised, block the machine and its attachments securely. Move damaged to level ground as soon as possible. Do not trust worn and/or kinked chains and cables. Never use them for lifting or pulling. Always wear heavy gloves to handle chains or cables. Be sure chains and cables are firmly fastened and that anchor points are strong enough to withstand the expected load. Nobody should stay near the anchor points, cables or chains. DO NOT PULL OR TOW UNLESS THE OPERATOR’S COMPARTMENTS OF THE MACHINES INVOLVED ARE FITTED WITH THE PROPER GUARDS AGAINST BACKLASH IN CASE OF CABLE OR CHAIN FAILURE OR DETACHMENT. Keep the area where maintenance is carried out CLEAN and DRY at all times. Clean immediately all water and oil spillages.

Metal cables get frayed after prolonged use. Always wear appropriate protections (heavy gloves, goggles, etc.) while handling them. Handle all parts carefully. Keep hands and fingers away from gaps, gears, and similar. Always use and wear the appropriate protections. Water can build up in pneumatic systems from condensate moisture due to changes in atmospheric conditions. If necessary, drain such deposits following instructions. Before carrying out any maintenance work or service, lock the machine articulated frame modules using the appropriate safety device. Remember to remove and store it properly at the end of work. If the machine is equipped with hydraulic brakes, make sure that the reservoir is always filled up to the correct level. Always block all wheels, front and rear, before bleeding the braking system or disconnecting control hoses and/or cylinders.

Do not pile up oily or greasy rags as they represent a major fire hazard. Always store them in closed metal containers. Before starting the machine or its attachment, check, adjust and lock the operator’s seat. Also ensure that nobody is within the machine operating range. Sound the horn.

STARTING Do not run the engine in closed buildings without proper ventilation capable to remove lethal exhaust fumes.

Rust inhibitors are volatile and flammable. Use them only in well ventilated areas. Keep open flames away - DO NOT SMOKE - Store containers in a cool well ventilatedplace where they could not be reached by unauthorised people.

Do not place head, body, limbs, feet, hands or fingers near rotating fans or belts.

Do not carry loose objects in your pockets that might fall unnoticed into open compartments. Wear safety glasses with side shields, hard hat, safety shoes, heavy gloves when metal particles or similar may be ejected and hit you.

REMEMBER THAT THE STARTING FLUID IS HIGHLY FLAMMABLE. Follow recommendations provided in this Manual and printed on the containers. Containers must be stored in a cool, well ventilated place out of the reach of unauthorised persons. DO NOT PUNCTURE OR BURN CONTAINERS.

Wear appropriate protective equipment such as dark safety glasses, hard hat, protective clothing, special gloves and footwear while welding. Nearby persons should also wear dark safety glasses even if they are not welding. DO NOT LOOK THE WELDING ARC WITHOUT PROPER EYE PROTECTION.

ENGINE

Become acquainted with all your jacking equipment and its capacity. Remember that the jacking point on the machine should be appropriate for the load applied. Also, be sure the support area of the jack at the machine and on the ground is appropriate and stable. Any load supported by a jack represents a possible hazard. Always transfer the load onto appropriate support means according to local or national safety requirements before proceeding with service or maintenance work.

Be especially careful near blower fans.

Loosen the radiator cap very slowly to relieve system pressure before removing it. Always top-up coolant level with the engine off. Avoid that flammable materials could touch exhaust parts. If not possible, provide necessary protections. Do not refuel with the engine running, especially if hot, as this increases fire hazard. Never attempt to check or adjust fan belt tensions when

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0-6

W270 SAFETY RULES

the engine is running. Do not adjust the fuel pump when the machine is motion. Do not lubricate the machine with the engine running. Do not run the engine with air intakes, door or guards open.

ELECTRICAL SYSTEM Always disconnect the batteries prior to any intervention on the machine or its electrical system (cleaning, repair, maintenance). Should booster batteries be used, remember to connect ends of the booster cables in the proper manner: (+) to (+) and (-) to (-). Do not short-circuit terminals. Thoroughly follow instructions given in this Manual.

to any intervention, install all safety devices according to current regulations. In case the attachment is to be operated through the machine hydraulic system for maintenance purposes, remember to do so only while sitting in the driver's seat. Make sure that nobody is within the machine operating range. Before operating the attachment, alert people by sounding the horn and by voice. Raise the attachment slowly. Do not use the machine to transport loose objects, unless proper devices to this purpose are provided. Clutches and brakes of this machine as well as auxiliary devices and attachments (such as drive cylinder or winch control valves) should always be properly adjusted in accordance with the instructions provided by the Manufacturer. Never perform adjustments with the engine running, except when this is specifically required by the relevant procedures.

Before any intervention, make sure that the battery isolator switch is off. BATTERY GAS IS HIGHLY FLAMMABLE. Leave the battery compartment open during recharging to improve ventilation. Never check battery charge by placing metal objects across the posts. Keep sparks or open flames away from batteries. Do not smoke near the battery to prevent explosion hazard. Before any intervention, make sure that there are no fuel or electrolyte leakages. If any, correct prior to proceeding with further work. Do not recharge batteries in confined spaces. Ensure proper ventilation is provided to avoid accidental explosions due to build-up of gas released during charging.

TYRES AND WHEELS Make sure that the tyre inflation pressure corresponds to specifications issued by the Manufacturer. Regularly check inflation pressure. Should pressure be changed, do this while staying on the tyre side and at a safe distance. Pressure checks should always be carried out with the machine unloaded and cold tyres. Never use reconditioned tyre rims, since possible weldings, incorrect heat-treatments or repairs can weaken the wheels and cause damages or failures. Do not cut, nor weld rims with inflated tyres installed.

HYDRAULIC SYSTEM Pressure fluid escaping from a very small hole can be almost invisible and still have sufficient force to penetrate the skin. Always check any suspected pressure leaks using a piece of cardboard or wood. DO NOT USE HANDS. If injured by escaping fluid, obtain medical attention immediately or serious infection or reaction may develop. Stop the engine and relieve all system pressure before removing panels, housings, caps, plugs or covers. Always use gauges of adequate capacity (end-of-scale reading) and follow recommended procedures.

The spare tyre should be inflated only enough to keep the rim components assembled. Remember that when not installed on the disc, a tyre inflated to maximum pressure can explode. Therefore, maximum care must be taken when handling a fully inflated tyre. Before servicing tyres, block all wheels, front and rear. After jacking up the machine, block it in the raised position using suitable stands conforming to current safety regulations. Deflate the tyre before removing objects from the tyre tread. Never inflate tyres with flammable gas: explosions and severe bodily injuries may result. When starting your work shift, check for loose wheel or rim bolts and brackets and retighten to correct torque as necessary.

TOOLS Always keep head, body, limbs, feet, or hands away from bucket, blade, or ripper when in the raised position. Prior

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

0-7 SAFETY RULES

DECOMMISSIONING THE MACHINE WARNING For the decommissioning of the machine, the availability of particular tooling (hoists, hydraulic presses. containers for liquids etc.) is required as well as specific tools listed in the Repair Manuals, available from FIAT-HITACHI Dealers. This has the purpose of avoiding that during disassembly operations, dangerous situations may arise both for the personnel involved and the environment. In the machine are present: • Fluids under pressure (hydraulic system, cooling system etc.) • Gases (air conditioning system and accumulator, if installed) • Mechanical devices mounted under pressure (track tensioner etc.) • Heavy machine components (frames, blades, buckets etc.)

• The decommissioning of the machine must be performed exclusively by personnel trained, qualified and authorised to perform such operation. • Start the disassembly of hydraulic components only after the same, the hydraulic oil and lubricants have fully cooled-off and after all residual pressures have been released, as described by the Repair Instruction Manual. • Prior to proceeding with disassembly operations, comply with the GENERAL SAFETY RULES and drain each components of the machine filled with fluids, both in the reservoirs and the relevant systems.

WARNING Ensure that the attachment is safely resting on to the ground before repairing,adjusting, or servicing machines fitted with hydraulically, mechanically or cable controlled attachments (such as excavators, loaders, dozers, scrapers, etc.). Should it be necessary to partially or fully raise the hydraulically, mechanically, or cable controlled attachment to gain access to certain items, make sure the attachment is adequately retained in the raised position by means other than the hydraulic lift cylinders, cable and/or mechanical devices used for controlling it.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0-8

W270

SPECIFICATIONS - WHEEL LOADER W270 IDENTIFICATION - 2678.260.00.1 MARKING: W270 ENGINE Make and model .......................... CUMMINS M11C Net power at the flywheel ........................... 199 kW Maxi power speed ................................... 2100 rpm Max torque .......................................... 128.5 daNm Max torque speed .................................... 1300 rpm Diesel type, 4 stroke, direct injection, turbocharged Number of cylinders .............................................. 6 Bore x stroke .................................... 125 x 147 mm Total displacement ................................ 10800 cm3 Valve/rocker operation lash: - intake ..................................................... 0.35 mm - exhaust .................................................. 0.70 mm Firing order ........................................... 1-5-3-6-2-4 Minimum starting temperature: ..................... - 20°C Engine coolant high temperature sender setting ..... .............................................................. 101 + 2 °C Engine oil low pressure switch setting .................... .................................... 0,5 ± 0,1 bar (at idle speed)

ENGINE SPEEDS Minimum idle speed (no load) .................... 720 rpm Maximum idle speed (no load) ................. 2310 rpm Converter stall speed ....................... 2200 ± 50 rpm Steering stall at idle speed > ...................... 600 rpm Attachment stall ............................... 2250 ± 50 rpm Full stall ......................................... 1990 ± 100 rpm

TORQUE CONVERTER Type: Niigata 13.5" (MS370) single-stage, singlephase Main converter pressure ................................... bar Converter safety valve pressure .................. 7.2 bar

TRANSMISSION Maximum ground speeds (forward/reverse) in kph (with 26.5 R25 XHA tyres): Forward speed st

1 2nd 3rd 4th

kph 7.58 13.81 22.12 37.14

Reverse speed st

1 2nd 3rd 4th

Oil pump flow rate (at 2100 rpm) ............................ ..................................................... Front 84.2 lt/min. ..................................................... Rear 92.7 lt/min. Main pressure on the control valve ....... 21 ÷ 24 bar Transmission disengagement sensor ..... 15 ± 1 bar Transmission induction sensors to gear teeth adjust clearance ........................................... 0.5 ÷ 0.8 mm Transmission oil high temperature sensor setting ... ............................................................... 122 ± 3°C

AXLES Axles complete with disc brakes in oil bath. Self-locking differentials. Planetary final drives. Stiff front axle, support structure type - reduction ratio ...................................... 1 : 25.381 Oscillating rear axle, support structure type - reduction ratio ...................................... 1 : 25.381

TYRES Type .................................. 26.5 R25 XHA tubeless Inflating pressure - Work: front = 4.25 bar rear = 2.75 bar - Transfer: front = 2.00 bar rear = 2.00 bar Wheel tightening torque ......................... 78.8 daNm

BRAKES Delivery brakes pump at nominal speed .. 29.7 lt/min. Accumulator recharge start pressure ...... 80 ± 5 bar Accumulator recharge end pressure ..... 110 ± 5 bar Accumulator pre-charge pressure (1.4 lt) ..... 45 bar Transmission disengagement pressure switch setting ........................................................... 15 bar Brake oil low pressure sensor setting ........... 60 bar Brake lights pressure switch setting ............ 1.8 bar Parking brake applied pressure switch setting ........ ON 10 bar - OFF 15 bar

kph 8.16 14.85 23.66 38.62

STEERING SYSTEM Cylinders ........................................ 2 double-acting - bore x stroke ................................... 80 x 542 mm Stand-by/main priority valve setting ............ 206 bar

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

0-9

ATTACHMENT HYDRAULIC SYSTEM Sealed type with anti-cavitation and safety valves. - Pump flow rate at rated speed ............. 193 lt/min. 2 or 3 spool control valve Piloted control Hydraulic double-acting cylinders: - Boom control ..................................................... 2 - Bore x stroke ................................ 170 x 920 mm

Three-position control switch as follows: Position 0: disengaged Position 1: LTS engaged with speeds exceeding 7 kph Position 2: (to be used only for maintenance or repair) LTS engaged at all times. - Accumulator safety valve setting .............. 120 bar

-

ELECTRICAL SYSTEM Operating voltage ............................................ 24 V Batteries in series ................................... 2 - 160 Ah - maintenance - free type DELCO starter motor Rated power ........................ 42MT - 24V - 7.8 kW DELCO alternator with voltage regulator .................................................... 21SI - 24V - 70A

Bucket control cylinder Bore x stroke ................................ 210 x 570 mm Pressure relief valve setting ..................... 206 bar Lift safety valve setting ......................... ...274 bar Bucket roll-back safety valve setting (A1) 230 bar Bucket roll-out safety valve setting (B1) ... 186 bar

OPTIONS Electronic anti-pitch LTS (Load Travel Stabilizer) system.

WEIGHT Loader weight with 26.5 R25 tyres, 4 m3 bucket, fully filled with fluids and operator 22000 kg.

MAIN DIMENSIONS Dimensions taken with machine with the loader fitted with 26.5 R25 XHA tyres and 4 m3 load capacity bucket. Notes: Dimensions in mm Toothed bucket

3050

6800

40°

3500 30

1070

° 48

530 570

2965

1275

4360

5770

45°

1700 3400

2230 2960

8860

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0 - 10

W270

FLUIDS AND CAPACITY TABLE

Component to Capacity (lts) be filled

Fluids and Lubricants

Engine

34

AMBRA - Super Gold

Cooling system

77

Transmission

35

front rear

Lubrication of pivot points Fuel tank

API CF-4/SG, CCMCD4, MIL-L-2104E, NH 324 G NH 900 A

Viscosity Temperature of operation (°C) (SAE) 15W-40 10W-30

-10 +50 -30 +20 -38 +50

-

(Mixed with water at 50%))

Hydraulic and brake system Axles

AMBRA - Agriflu

Technical data and classification

AMBRA - Super Gold

API CF-4/SG, CCMCD4, MIL-L-2104E, NH 324 G

15W-40 10W-30

-10 +50 -20 +50

AMBRA - Hi Tech 46

ISO VG46, DIN 51524 Part 1 e 2, QFH583/HD

-

-20 +50

48 48

AMBRA TX Fluid

API GL5, QFH 586 TR

85W-90

-

AMBRA - MG2

QFH 585 GR, NLGI 2

-

-

-

220

320

-

The capacity are intended as "total"

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

-20 +50

-40 +50 -

W270

0 - 11

UNITS OF MEASURE Units of measure used in this manual are those adopted by the International System which replace the units previously used by the M.K.S. system. Force:

decanewton (daN) replaces kilogram (kg)

Pressure:

bar, replaces kg/cm2

Torque:

decanewton x meter (daNm) replaces kgm

CLASSIFICATION OF STANDARD COMPONENTS TO DETERMINE THE TIGHTENING TORQUES

Note - In case, in the different sections, the tightening torque is not listed, refer to the table “TIGHTENING TORQUES”, only after identifying exactly the component.

The latter is identified by a coded eight digit number, allowing a complete description of the item.

The following tables is to be used to convert units of measure: Example: multiply

by

Force

kg

0.9807

daN

Pressure

kg/cm2

0.9807

bar

Torque

kgm

0.9807

daNm

to obtain

Note - For current service use, the following equivalences can be considered to be valid: kg = daN; kg/cm2 = bar; kgm = daNm.

I / a

b

c

d

e / f

g

I - Standard index digit It is always represented by the digit 1. This number indicates that the item can be fabricated in a number of versions differing for material and coating.

a - b - c - d - e - Standard base digits It is a number always composed of five digits identifying dimensional specifications of the item.

f - Material index digit This digit indicates the material used for a defined item. Its meaning is indicated in the table that follows.

g - Coating index digit It indicates the coating applied to a defined item.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

0 - 12

W270

Resistance class and material Material index (f)

FIAT

UNI

DIN

0

R 40

4D - 4S - 4A

1

R50

5S - 6S

2

R80

3

R100

4 5

Aluminium

6

Copper

BSI

1

A

42

P

56

5

T

80

3

8G

Brass

SAE

BNA

100

10K

8

V

100

Brass

Messing

Brass

Brass

Laiton

Aluminium Aluminium Copper

7

Kupfer

Aluminium

Aluminium Aluminium

Copper

Copper

Cuivre

Blank for other metallic materials

WARNING

TORQUE TABLES

- Lubricate all hardware until 24 dia., with engine oil. Use grease for larger diameters.

If correct torque is not specifically indicated in the relevant pages, refer to the following tables.

- Tolerance on torque: ± 5% - Resistance classes R80, R100, R120 must be understood as follows:

10.9 replaces R100 for screws 12.9 10

"

R120

replaces R80 for nuts

12

"

R100

CDT= cadmed; FOSF= phosphated; ZNT= galvanised.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

0 - 13

NUTS (ZNT)

SCREWS (ZNT/DEIDR)

Strength grade: 10 (R80)

Strength grade: 10.9 (R100)

Diameter and pitch

normal

low type

with polyamide ring

mm

daNm

daNm

normal daNm

low type daNm

M6 x 1

1.3

1.2

-

-

M8 x 1.25

3.2

2.6

3.9

M10 x 1.25

7.2

5.2

M10 x 1.5

6.5

M12 x 1.25

Diameter and pitch

normal ZNT

self-locking ZNT

mm

daNm

daNm

M6 x 1

1.3

-

3.2

M8 x 1.25

1.3

3.5

8.2

6.2

M10 x 1.25

7.1

7.9

5

7.7

6

M10 x 1.5

6.5

7

13

8.7

14.5

10.2

M12 x 1.25

12.7

13.9

M12 x 1.75

11

8.1

12.9

9.6

M12 x 1.75

11

12

M14 x 1.5

19.5

13

21.6

15

M14 x 1.5

20

22

M14 x 2

18

12.5

20

14.6

M14 x 2

18

19

M16 x 1.5

30

17

34

20

M16 x 1.5

30

33

-

-

-

-

-

-

M18 x 1.5

45

25

50

29

M18 x 1.5

45

48

M18 x 2.5

-

-

-

-

M18 x 2.5

-

-

M20 x 1.5

60

30.5

64.5

35

M20 x 1.5

60

65

M20 x 2.5

-

-

-

-

M20 x 2.5

-

-

M22 x 1.5

80

41

-

-

M22 x 1.5

80

90

M22 x 2.5

-

-

-

-

M22 x 2.5

-

-

M24 x 2

100

47

108

52.5

M24 x 2

100

110

M24 x 3

-

-

-

-

M24 x 3

-

-

M27 x 2

95

40.1

-

-

M27 x 2

100

-

M30 x 2

130

49.4

-

-

M30 x 2

140

-

M33 x 2

170

-

-

-

M33 x 2

190

-

M36 x 3

220

-

-

-

M36 x 3

240

-

M16 x 2

M16 x 2

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

SECTION 1

ENGINE TABLE OF CONTENTS

PARAGRAPH

SUBJECT

PAGE

1.1

IDENTIFICATION DATA ........................................................................................... 1

1.2

GENERAL SPECIFICATIONS OF SERIES “M11” ENGINE .................................... 2

1.3

ENGINE SUPPORTS ............................................................................................. 5

1.4

DIAGRAMS OF SERIES “M11” ENGINES .............................................................. 6

W270

ENGINE

1-1

1.1 IDENTIFICATION DATA Data plates of series M11 engine The engine identification plate provides specific information for your engine. Note: the Engine Data plate must not be replaced without approval by Cummins Engine Company Inc.

The identification plate is located on the injection pump side of the engine, on the rocker arm cover side. 1. Engine serial number (ESN) 2. Model 3. Engine power and speed

Fig. 1-1

Fig. 1-2

Data plate of fuel injection pump The data plate for fuel injection pump is located on the upper side of the pump itself. It provides information relative to the calibration of the pump.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1-2

ENGINE

W270

1.2 GENERAL SPECIFICATIONS OF “M11” SERIES ENGINE Engine General Data

Power (please refer to the engine identification plate) Engine speed at maximum power : Rated setting ... .................................................................................................................. 2100 rpm Bore and stroke .... ......................................................................... 125 x 147 mm [4.921 x 5.787 in] Displacement . ........................................................................................................... 10.8 lt [661 C.I.D.] Firing order ........................................................................................................................... 1-5-3-6-2-4 Engine weight (with standard accessories) Weight dry: ............................................................................................................. 929 kg [2045 lbs] Weight supplied (with engine fluids) . ..................................................................... 981 kg [2160 lbs] Engine rotation (seen from front side of engine): ................................................................... Clock wise

Fuel system For the performances and the fuel delivery values, please refer to the engine data sheet or the fuel pump code for the specific models involved.

Maximum restriction of fuel feeding pump inlet Clean fuel filter ................................................................................................. 102 mm Hg [4 in Hg] Dirty fuel filter .. ............................................................................................... 204 mm Hg [8 in Hg] Maximum restriction of fuel discharge piping Without check valves ...................................................................................... 63 mm Hg [2.5 in Hg] With check valves . ...................................................................................... 165 mm Hg [6.5 in Hg] Maximum fuel inlet temperature .. ...................................................................................... 71°C [160°F] Minimum engine starting speed .................................................................................................150 rpm

Lubrication system

Oil pressure: At idle speed (minimum allowed) ............................................................... 0.69 bar (70 kPa) [10 psi] At 1200 rpm or Torque Peak (minimum allowed) ............................................ 2 bar (207 kPa) [30 psi] Oil capacity of standard engine Filter combination . .............................................................................................. 2.6 lt [0.7 U.S. gal] Oil sump (high - low) .................................................................................. 34 - 26.5 lt [9 -7 U.S. gal]

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

ENGINE

1-3

Cooling system

Cooling capacity (engine only - Aftercooled) ............................................................ 12.9 lt [3.4 U.S. gal] Thermostat range ........................................................................................... 82 - 93°C [180° to 200°F] Coolant pressure in cylinder block (pressure cap removed): Minimum Thermostat closed - 1800 rpm - no load . ........................................... 1,37 bar (138 kPa) [20 psi] Maximum Thermostat closed ............................................................................ 2.75 bar (275 kPa) [40 psi] Maximum allowed operating temperature .. ...................................................................... 100°C [212°F] Minimum recommended operating pressure ....................................................................... 71°C [160°F] Maximum allowed de-aeration time .. ........................................................................................... 35 min Maximum recommended cap pressure ............................................................... 0.42bar (48 kPa) [7 psi]

Intake system

Maximum temperature increase between ambient and engine intake air: (ambient temperature higher than 0 °C - 32 °F) ..................................................................... 17°C [63°F] Maximum intake restriction (air cleaner element clean) .................................... 254 mm H2O [10 in H2O] Maximum intake restriction (air cleaner element clean) .................................... 635 mm H2O [25 in H2O]

Exhaust system

Maximum counterpressure from piping to silencer (combined): Hg ................................................................................................................................ 76 mm [3 in ] H2O ......................................................................................................................... 1016 mm [40 in ] Dimension of exhaust pipe (normally acceptable inner diameter) . ................................... 102 mm [4 in ]

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1-4

W270

ENGINE

Electrical system

Voltage of system

Ambient temperature 0°C (32°F)

-18°C (0°F) Cold starting Amp

12 Volt 24 Volt

1800 90

Reserve 1

Cap. Amp

Cold starting Amp

640 320

1280 640

1. The quantity of plates for a certain dimension of batteries determines the capacity. The reserve capacity derives from the length of the time the starting is operated. 2. The CCA specifications are based upon two 12 Volt batteries in series.

Batteries (Specific gravity)

Specific gravity at 27°C [80°F]

State of the charge

1.260 - 1.280 1.230 - 1.250 1.200 - 1.220 1.170 - 1.190 1.110 - 1.130

100% 75% 50% 25% Discharged

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Reserve Cap.1 Amp

480 240

W270

1-5

ENGINE

1.3 ENGINE SUPPORTS bolted on elastic pads and on the rear, by plates bolted to the engine and supported by elastic pads as well.

The engine is mounted on the rear module of the frame in four points: frontally, by the transmission-torque converter group, that in turn, is supported by brackets

2

1 2

4

1

3

5 9 10

3

6 11

7 1

12

8

14 13

4

Fig. 1-3 Engine supports Notes - 1

22.4 daNm

3

19.5 daNm

4

22.4 daNm

. 2

1. 2. 3. 4. 5.

6 daNm

SCREW M10x1.5x110 WASHER LEFT REAR SUPPORT SCREW M16x2x110 UPPER PAD

6. 7. 8. 9. 10.

PLATE WASHER NUT LOWER PAD SCREW M16x2x45

11. 12. 13. 14.

LEFT FRONT SUPPORT SCREW M16x2x110 WASHER SCREW M16x2x45

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1-6

W270

ENGINE

1.4 SERIES "M11" ENGINE DIAGRAMS The illustrations here below contain information relative to the engine components, the location of the filters, the draining points and the access positions for the instrumentation and controls of the engine.

The illustrations and the configuration of the components illustrated in these diagrams are of a general nature. The locations of some components change, depending upon the application and installation.

For the disassembly, check, overhaul and reassembly of the engine, please refer to the specific CUMMINS Manuals.

Fume recirculation port

Oil pressure check point Fuel return to reservoir

Engine serial number and data plate STC oil feeding piping

Fuel delivery piping to injectors

Fuel inlet Fuel filter

STC oil distributor

STC fuel pressure pickup piping

Power steering pump arrangement

Flywheel ring gear sensor

Starter motor Fuel pump

Arrangement for oil sump heater

Fig. 1-4 Side wiew of STC fuel pump

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

1-7

ENGINE

Coolant temperature pick-up point

Turbo charger

Coolant temperature sender

Engine breather (coolant)

Heater delivery

Partialiser Fan sensor Alternator

Arrangement for coolant heating

Heater return

Coolant filter

Radiator return piping Jacobs motor brakes oil delivery

Engine oil filter Oil side draining Dipstick Oil filler neck

Fig. 1-5

Coolant inlet

Oil draining

Exhaust side view

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

SECTION 2

TRANSMISSION TABLE OF CONTENTS

PARAGRAPH

SUBJECT

PAGE

2.1

GENERAL DESCRIPTION ....................................................................................

1

2.2

TORQUE CONVERTER - TRANSMISSION ...........................................................

2

2.3

TORQUE CONVERTER .........................................................................................

8

2.4

TRANSMISSION - TORQUE CONVERTER PUMP ................................................

10

2.5 2.5.1 2.5.2

TRANSMISSION ................................................................................................... Power train diagram ............................................................................................... Transmission control valve .....................................................................................

11 15 17

2.6

AUTOMATIC TRANSMISSION CONTROL SYSTEM .............................................

32

2.7

TRANSMISSION SELECTOR ...............................................................................

39

2.8

OIL CIRCUIT .........................................................................................................

44

2.9

DISASSEMBLY TRANSMISSION ..........................................................................

46

2.10

REASSEMBLY TRANSMISSION ...........................................................................

73

2.11

TROUBLESHOOTING GUIDE ...............................................................................

100

2.12

MAINTENANCE REFERENCE VALUES ...............................................................

103

2.13

TIGHTENING TORQUES .......................................................................................

107

2.14

PROP SHAFTS .....................................................................................................

108

2.15 2.15.1 2.15.2 2.15.3

FRONT AND REAR AXLES .................................................................................. Description of axles ............................................................................................... Description of differential ....................................................................................... Description of final drives ......................................................................................

110 110 115 117

2.16

DISASSEMBLY OF AXLES ...................................................................................

119

2.17

REASSEMBLY OF AXLES ....................................................................................

130

2.18

TROUBLESHOOTINGS .........................................................................................

150

2.19

STANDARD VALUES FOR MAINTENANCE ..........................................................

151

2.20

TIGHTENING TORQUE VALVE FOR MAIN BOLTS ...............................................

152

2.21 2.21.1

WHEELS ............................................................................................................... Tyres......................................................................................................................

153 153

W270

TRANSMISSION

2-1

2.1 GENERAL DESCRIPTION The transmission power train is made of a drive group (torque converter and transmission), prop shafts, front and rear axles and tires. The engine power is driven to the converter-transmission group, where the r.p.m. are reduced and the torque

is increased. The power driven to each axle reaches, through the wheels, the tires, thus driving the loader. Here below a diagram of the transmission power train is provided.

Front axle Engine

Torque converter

Front wheel

Transmission Rear axle

Rear wheel

: Prop shaft

Tire and wheel assembly Torque converter Rear axle Prop shaft

Transmission

Front axle

Fig. 2-1 Composition of transmission power train

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

TRANSMISSION

2-2

W270

2.2 TORQUE CONVERTER - TRANSMISSION

TORQUE CONVERTER - Designation .................................................................................... TCM 678-25 (NIIGATA 13.5" MS370) - Type ............................................................................................ 3 elements, single stage, single phase - Radiator ................................................................................... Water cooled, with multiple radiating fins - Minimum operation pressure ........................................................................................... 2.8 bar (40 psi)

TRANSMISSION PUMP - Designation ............................................................................................................................. SDB 4044

TRANSMISSION - Control .................................................................................................................... Manual or automatic - Type .................................................. Controlled by solenoid valves, full power-shift with constant mesh gears with controlled modulation - Speeds .............................................................................................................. 4 forward and 4 reverse

CLUTCHES (TRANSMISSION) - Type ...................................................................................................................... Oil bath, multiple disc - Operation ................................................................................................................................. Hydraulic - Setting pressure ............................................................................................ 21 ÷ 24 bar (299 ÷ 341 psi) - Oil capacity.................................................................................................................. 40 l (6.6 U.S. gal) - Weight (converter - transmission) ............................................................................... 838 Kg (1850 lbs)

GENERAL DESCRIPTION The control group of the transmission is made of a combination of the torque converter and the transmission, in a single body. The power train system is connected to the engine and is installed on the rear frame.

The engine power is driven to the transmission unit by the flywheel and the converter. The engine and the torque converter - transmission group are connected by means of a splined flange.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

TRANSMISSION

Transmission - Torque converter Countershaft power-shift type with 6 clutch packs for 4 forward and 4 reverse speeds. The torque converter is mounted are the transmission housing and is a 3 element type, single stage, single phase. The hydraulic circuit has: - The lubrication fo the shaft with the directional clutches assured by a section of the feed pump. - The second speed clutch engagement modulation is assured by an accumulator and a no-return valve with an orifice. The hydraulic circuit is feed by a two-section gear type pump. The first section feeds the clutch engagement circuit, the torque converter and assure the lubrication of the shafts with the speed clutch packs. The second section assures the lubrication of the directional clutch packs. On the second speed shaft is installed the multiple disc parking brake. It is disengaged by hydraulic pressure and engaged by spiral type springs. The control is assured by means of a steel cable actuated by a control knob placed on the dashboard and operating an hydraulic control valve. The selection of the various speeds is obtained through a control valve incorporating all the valves, such as, the spools, the main pressure regulating valve and the modulating valves. Totally there are 4 solenoids that are controlled by a speeds selector installed on steering wheel support. The only valves placed outside the control valve are the torque converter inlet safety valve and the modulating valve with accumulator for the engagement of the second speed. To avoid traction losses during shifting operations from second to first speed, a non-return valve with orifice and accumulator is fitted or the second speed supply retarding the disengagement of the clutch pack. As a result there will be a temporary pressure overload in the first and second clutch packs (also of the third clutch pack as a result of the system arrangement) with partial engagement of the two clutch packs. In this way the machine is not moving backward during shifting from second to first speed in uphill operations. The emergency pump is connected to the output shaft through on idler gear placed on 3rd and 4th gear shaft. The transmission disassembly does not reguire particular cautions, there are no adjustment either for clutch packs or shafts. All shafts are rotating on ball bearings. The only caution to be observed regards the removal of the torque converter that must be removed together with thee transmission front cover to which it is connected with screws mounted on the inside.

2-3

Besides for the removal of the parking brake, it is necessary to compress the engagement springs by means of a screw placed on it. This operation must be carried out each time the machine must be moved with a dead engine.

Transmission control The gear shifting is completely electric and there are various gearshifting modes: - Normal working phase in automatic and manual modes. - Kick-down function. - Shift-down function (only for automatic mode). - Transmission disengagement when braking. All the components are located inside the cab. the gear selector located on the steering column, a switch located under the throttle pedal and a switch located at the base of the bucket control for "Kick-down" function, a series of relays and fuses located in the main electric board and the transmission electronic unit located behind the seat the main difference between a machine with automatic transmission and one with manual transmission is given by the fact that all functions described above are in an automatic transmission controlled by the electronic unit, while in the manual transmission the sames are controlled by the relays and fuses console.

Advantages of automatic transmission: - Confort. - Modulation. - Less gearshifting requirements. - Less noise (two to medium low no-load engine speeds during gearshifting). - No loads on transmission. - Optimized use of power-train components (engine, transmission, axles). - No possibility of incorrect operation. - Performance and production. - Maximum use of engine output. - Overall efficiency of torque converter. - Less fuel consumption. - Reduction in travel times. - Increased production. - Easy and safe driving. - More operator concentration on production.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

TRANSMISSION

2-4

W270

1 1

4

10

2

3

5

3

7

9

1

6 2

1

Fig. 2-2

Note -

1. 2. 3. 4. 5. 6.

8

Supports of the transmission-torque converter group

1

20 daNm

ENGINE TRANSMISSION-TORQUE CONVERTER GROUP TRANSMISSION FEED PUMP ENGINE SUPPORT TO FRAME SECURING SCREW UPPER AND LOWER SUPPORT PAD SUPPORT BRACKET FOR TRANSMISSIONENGINE

2

5 daNm

3

18 daNm

7. 8.

SECURING SCREWS FOR BRACKET ON ENGINE SECURING SCREWS FOR BRACKET ON TRANSMISSION 9. SECURING SCREW FOR TRANSMISSION SUPPORT TO FRAME 10. ENGINE SUPPORT

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2-5

TRANSMISSION - TORQUE CONVERTER GROUP OF MODEL W270

Clutch engagement oil pressure: 21 - 24 bar (299 - 342 psi) Opening pressure of safety valve: 7.2 bar (102 psi) daNm Value of tightening torque

Pressure test point

1.

From HEAT EXCHANGER

2.

OIL FILLER HOLE

3.

PARKING BRAKE DISENGAGEMENT PRESSURE

4.

To HEAT EXCHANGER

5.

From FILTER

11.

REVERSE CLUTCH 21 - 24 bar PRESSURE PORT

12.

FORWARD CLUTCH 21 - 24 bar PRESSURE PORT

13.

1st SPEED CLUTCH 21 - 24 bar PRESSURE PORT

Section A-A View from G

Note - For sections D-D, E-E, J-J, please refer to the page to follow.

14.

2nd SPEED CLUTCH 21 - 24 bar PRESSURE PORT

15.

3rd SPEED CLUTCH 21 - 24 bar PRESSURE PORT

16.

4th SPEED CLUTCH 21 - 24 bar PRESSURE PORT

17.

PRESSURE SWITCH MOUNTING PORT

18.

TEMPERATURE SENSOR MOUNTING PORT

19.

CONVERTER OUTPUT PRESSURE PORT

31.

TRANSMISSION PUMP

32.

SUCTION PIPE

33.

STRAINER

34.

OIL LEVEL

35.

CONTROL VALVE

36.

HOSE

37.

BREATHER

38.

SPRING

39.

PLUNGER (SAFETY VALVE)

40.

MOUNTING FOR EMERGENCY STEERING PUMP

41.

MOUNTING FOR EQUIPMENT-STEERING/BRAKES PUMP

Fig. 2-3 Transmission - torque converter group of model W270 (1)

Note:

Threaded part : LOCTITE 572

1 2

Energizing table of transmission control valve solenoid valves

( : Energized) sol. FWD. sol. REV. th

4 FWD. 3rd FWD. 2nd FWD. 1st FWD. N 1 REV. st

2nd REV. 3rd REV. 4th REV.

• • • • • • • •

sol. A

• • • •

sol. B

• • • •

2-6

TRANSMISSION

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

2-7 2

TRANSMISSION -TORQUE CONVERTER GROUP OF MODEL W190 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

POWER PUMP PUMP SLEEVE PUMP DRIVE GEAR BEARING SUPPORT TORQUE CONVERTER TURBINE TORQUE CONVERTER HOUSING IDLE GEAR IDLE GEAR COVER 1ST - 2ND SPEED CLUTCHES SHAFT FLANGE OIL SEAL PLUG SEAL RETAINING COVER

15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.

DRAINING PLUG REVERSE GEAR SHAFT OIL DISTRIBUTION COVER FOR/REV CLUTCHES SHAFT GEAR 1ST-2ND SPEED GEAR PARKING BRAKE DISC HUB PLUG PARKING BRAKE RELEASE SCREW OIL BAFFLE REAR TRANSMISSION HOUSING TRANSMISSION HOUSING GEAR

29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41.

OIL CONTROL VALVE COVER 3RD - 4TH SPEED CLUTCHES SHAFT 5TH - 4TH SPEED GEAR PLATE SPEED SENSOR (FOR SPEEDOMETER) PISTON MOUNTING BRAKE MOUNTING INNER TOOTHED DISCS OUTER TOOTHED DISC COVER PISTON SPRING FINAL DISC HOLDING PLATE

Torque converter housing connection flange : LOCTITE FMD-127

Note - 1 2

Threaded part: LOCTITE 262

3

Threaded part: LOCTITE 572

4

Outer diameter: LOCTITE 572

5

Setting of gap E: after bringing the sensor against the gear, move it away, by loosening it, 1.5 turn.

3

Note - procedure for the installation of seals Seal outer diameter (metal): LOCTITE 262 Seal lip: Grease 2

Bevel and sliding surface of connection flanges: Grease 4

Green

Black

35 3

1

5

34 38

3

39 40

2

41 36 37 Section J-J

Section E-E

Section D-D

Fig. 2-4 Transmission - torque converter group of model W270 (2)

Detail area Z

TRANSMISSION

2-8

W270

2.3 TORQUE CONVERTER The torque converter consists of a torque converter group, an hydraulic pumps drive gear and a turbine shaft. The torque converter group is composed of a pump wheel and a turbine wheel, positioned one in front of the other, with an intermediate stator, located inside

the torque converter housing, filled with oil. The hydraulic pumps drive actuates the transmission power pump, the equipment pump and the steering pump, through the drive gear, mounted on the pumps drive hub.

1

1

9

2

10

3

11

4

2

5

12

3

1

13

6

3

7 8

14 15

Fig. 2-5

Nota -

1. 2. 3. 4. 5. 6. 7. 8.

Torque converter group

1

4.0 ÷ 4.6 daNm (29 ÷ 33 ft-lbs)

2

5.2 ÷ 6.0 daNm (38 ÷ 43 ft-lbs)

TAPER PLUG PUMP WHEEL COVER COUPLING GEAR TURBINE PUMP HUB INPUT GUIDE STATOR HUB STATOR

3

9. 10. 11. 12. 13. 14. 15.

Align the arrows with the oil outlet grooves in the stator holder and the stator hub

IMPELLER COVER PUMP WHEEL PUMP DRIVE GEAR STATOR RETAINER TURBINE SHAFT SEAL SEAL

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

TRANSMISSION

Power train The engine power is transmitted through the engine flywheel, the disc joint or the coupling gear, the front cover, the pump wheel, the turbine and the transmission.

Oil flow (see fig. 2.5) The oil of the torque converter coming from the transmission control valve enters the torque converter wheel through the duct in the stator support. As soon as the engine starts, the pump wheel rotates, throwing oil from the vanes of the blades of the wheel (under the effect of centrifugal force), towards the vanes of the turbine wheel blades. The oil flow hits the turbine with an angle such that, in turn, the turbine shafts rotates. The reaction torque produced by the oil flow which hits the turbine blades, represents the output torque provided by the turbine shaft. The stator diverts the oil flow coming from the turbine vanes, directing it into the pump vanes, thus creating an increase of the torque. Part of the oil contained by the torque converter wheel is directed into the heat exchanger through the appropriate duct in the stator suppor t. In correspondence with the oil inlet into the torque converter, a safety valve is mounted, which discharges excess oil into the torque converter housing.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2-9

TRANSMISSION

2 - 10

2.4

W270

TORQUE CONVERTER PUMP

The pump is mounted on the torque converter cover. It powers, through the control valve, the forward-reverse and

speed clutches, it provides lubrication to the inner components of the transmission, feeds the torque converter. 3

4

Pump main data: Type: ................................. 2 sections, gear Drive: .................................................. gear Delivery front sect. at 2100 rpm: . 84.2 l/min Delivery rear sect. at 2100 rpm: .. 92.7 l/min Engine/pump speed ratio: ............. 1 : 1.018

1

2

5 1. 2. 3. 4. 5.

TRANSMISSION CONVERTER-TRANSMISSION GROUP TORQUE CONVERTER PUMP SLEEVE PUMP SECURING SCREW TORQUE CONVERTER

Fig. 2-6

Installation of pump on transmission-torque converter group

5

13

11-12

11-12

13 7 8 10

Z

6

14

3 2

15 16

17 View from Z

18 1 9 16

16

4 16 Fig. 2-7 1. 2. 3. 4. 5.

Composition of transmission-torque converter pump FRONT COVER PUMP BODY GEAR GEAR SIDE PLATE

6. 7. 8. 9. 10.

PLATE BODY GEAR GEAR TOP COVER

11. 12. 13. 14. 15.

SUPPORT SEAL SEAL SCREW WASHER

16. 17. 18.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

BUSHING S SEAL SNAP RING

W270

TRANSMISSION

2 - 11

2.5 TRANSMISSION

DIRECTION CLUTCHES SHAFT

The transmission changes the speeds and the travel direction.

The direction clutches allow the engagement or discugagement of power, under load, no matter what speed is engaged.

The transmission includes three clutch shaft groups, one inverter gear, one output shaft, a parking brake and a control valve.

1

2

3

4

5

6

1

8

7

9

11

10

FORWARD

12

16

13

1

REVERSE 14

Detail A

Fig. 2-8

Nota -

1. 2. 3. 4. 5. 6.

15

Detail B

Typical configuration of directional clutch packs shaft

1

Sliding surfaces: grease. (Pay attention to the mounting direction. Please refer to the enlarged views shown above).

SHAFT AND DRUM GEAR INNER TOOTHED DISC RETURN SPRING OUTER TOOTHED DISC SPACER

7. 8. 9. 10. 11. 12.

DISCHARGE VALVE SEALING RING (OUTER) O-RING SEALING RING (INNER) PISTON END DISC

13. 14. 15. 16.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

GEAR SEALING RING PLUG SPRING

TRANSMISSION

2 - 12

W270

(Forward/reverse shaft)

REV.

FORW.

(1st/2nd speed shaft)

2a

1a

(3rd/4th speed shaft)

4a

3a

Q.ty

FW.-R.

1st - 2nd

3rd - 4th

Discs (inner toothed)

13 - 13

17 - 10

17 - 10

Discs (outer toothed)

13 - 13

17 - 10

17 - 10

Fig. 2-9 Clutch shafts

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

TRANSMISSION

2 - 13

OPERATION The clutch is engaged by the oil under pressure flowing from the transmission control valve. Pressurized oil flows through the distribution cover and the ducts in the clutch shaft reaching the rear side of the clutch piston, moving it.

1

2

3

4

Then the clutch piston compresses the outer and inner disc fully, thus holding the clutch shaft with the clutch hub, allowing the driving of the power through the output shaft of the transmission.

5 Pressurized oil

From transmission control valve

1. 2. 3. 4. 5.

CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH

SHAFT PISTON INNER DISC OUTER DISC HUB

Fig. 2-10 Clutch engagement When pressurized oil from the control valve is cut-off, the return spring moves the clutch piston backward, freeing the clutch inner and outer disc pack, allowing

1

2

3

4

5

6

the clutch shaft and the clutch hub to rotate independently, thus avoiding the transmission of power to the output shaft of the transmission.

1. 2. 3. 4. 5. 6.

CLUTCH SHAFT CLUTCH PISTON CLUTCH INNER DISC RETURN SPRING CLUTCH OUTER DISC CLUTCH HUB

To transmission control valve

Fig. 2-11

Clutch disengagement

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

TRANSMISSION

2 - 14

W270

2nd SPEED CLUTCH ACCUMULATOR

7

8

9

From control valve

1 2 3

2 nd speed clutch

4 5

6

Fig. 2-12 1. 2. 3. 4. 5.

1st - 2nd speed oil distribution cover

PLUG ADAPTER SPRING BALL 1.0 mm (0.039 in) ORIFICE

6. 7. 8. 9.

The accumulator comes into action when a sudden pressure drop accours in the actuating clutch packs as it happens for example when passing from 2nd to 1st speed with a full bucket on step gradient. The accumulator therefore releases pressure to prevent the rolling backward of the machine when using the "Down-Shift System" that is the automatic selection of lower speeds. Clutch pressure t1

1 t2

2

In graph of fig. 2.21, it is possible to note how the pressure changes with and without accumulator. The engagement time of 1st speed t2 is distinctly lower then time t1 without accumulator. This translates into an almost constant availability of the power during gearshifting, preventing unwanted backing of the machine, under the operating conditions described above. The accumulator operates, also, in the same manner during normal gearshifting (from 2nd to 1st, from 2nd to 3rd).

Operation

1

1st speed engagement pressure

2

2nd speed engagement pressure (without accumulator) 2nd speed engagement pressure (with accumulator)

Fig. 2-13

COVER PLUG SPOOL SPRING

Clutch engagement oil pressure

2

2

To reservoir

Time

Graph of accumulator operation

1. When the 2nd gear is engaged, pressurised oil flowing out the control valve flows through the check valve, to the 2nd speed clutch pack and into the accumulator. 2. When from the 2nd gear the operator shifts to another speed, pressurised oil is discharged through an orifice, so that the oil pressure in the 2nd speed clutch decreases gradually.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

TRANSMISSION

2 - 15

2.5 .1 POWER TRAIN DIAGRAM (4th forward - 4th reverse) 1. Gearshift lever in neutral

2. Gearshift lever in forward

When both the forward and reverse clutches are disengaged, the power driven from the torque converter rotates the forward-reverse clutches shaft, without driving the speed clutches.

When both the forward and reverse clutches are disengaged, the power driven from the torque converter rotates the forward-reverse clutches shaft, without driving the speed clutches.

FWD.

REV

A

C

- - - - - - - - - - 1st forward speed – – – – – – – 2nd forward speed

2a

rd

B

1a D

–– – –– – –– 3 forward speed –– – – –– – 4th forward speed

A

C

4a

3a D B

Fig. 2-14

Power train diagram in forward speed

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

TRANSMISSION

2 - 16

W270

3. Transmission gearshift lever in reverse reach the transmission output shaft through the forward clutch and the clutch of the speed selected.

When the gearshift lever is in any of the four reverse gears, the power driven from the torque converter can

FWD.

REV.

A

C

- - - - - - - - - - 1st reverse speed

2a

1a D

– – – – – – – 2nd reverse speed

B

–– – –– – –– 3rd reverse speed –– – – –– – 4th reverse speed

A

C

4a

3a D

Fig. 2-15

B

Power train diagram in reverse speed

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

TRANSMISSION

2 - 17

2.5.2 TRANSMISSION CONTROL VALVE The transmission control valve allows the selection of the clutches receiving oil at the engagement pressure to shift direction and speed of the loader. The control valve includes a body and 4 solenoid valves that are energised and de-energized by the transmission gearshift selector (control lever), to move

the distribution spools regulating the oil under pressure.

The control valve is equipped, also, with a modulation device operating distinctly, depending upon the speed engaged. If the electrical system fails, it is possible to operate manually the control valve.

1

A

A

D

B

B

C

C

3

4

2

D

Fig. 2-16 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Transmission control valve

PLATE (FOR MANUAL OPERATION) COVER COVER COVER SOLENOID VALVE CONNECTION BLOCK CONTROL VALVE BODY (LOWER) FORW./REV. SELECTOR SPOOL ADAPTER SPRING SPOOL (A) SELECTOR SPOOL SPRING SPOOL (B) SELECTOR SPOOL SPRING ORIFICE 0.8 mm (0.031 in) diam. (for SOLENOID VALVE)

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.

ORIFICE [W] ACCESS PLUG ORIFICE [Z] ACCESS PLUG see note ORIFICE [Y] ACCESS PLUG ORIFICE [X] ACCESS PLUG CONTROL VALVE BODY (UPPER) SPRING FLOW VALVE SPRING PIN ROD INNER SPRING INTERMEDIATE SPRING OUTER SPRING LOAD PLUNGER (H) PRESSURE REGULATING VALVE PLUNGER

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

TRANSMISSION

2 - 18

W270

5 7

15

8

sol IND.

9 10

sol AV.

(W)

11 12

A sol

(Z) (X)

13 14

B sol

(Y)

Sezione A-A 6

16 17 18

19

Vista da B-B

20

30

21 31

22

39

32

23 24

33

25

34

26

35

27

36

28

29

38

Section D-D

37

Section C-C

Fig. 2-17 Transmission control valve Note - Orifices diam. in mm (inches)

32. 33. 34. 35. 36.

Feeding orifice [W]

1st / 2nd orifice [X]

2nd orifice [Y]

3rd / 4th orifice [Z]

6.0 (0.24)

0.9 (0.035)

0.9 (0.035)

1.5 (0.059)

OUTER SPRING INNER SPRING MODULATING SPOOL INNER SPRING INTERMEDIATE SPRING

37. 38. 39.

OUTER SPRING LOAD PISTON L MANUAL SPOOL (FOR EMERGENCY MOVEMENTS)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

TRANSMISSION

2 - 19

1

÷

4 , FWD. , REV. : Clutches

Accumulator FOR./REV selector spool

1 AV.

IND.

2

One way restriction

3 4 sol. REV. sol. B sol. FWD. to torque converter

Spool B Manual spool sol. A Spool A

Pressure regulating valve

(Y) (W)

(Z) (X)

Flow valve Modulating valve from Pump Accumulator (load plunger)

Fig. 2-18 Transmission control valve - Hydraulic circuit diagram

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

TRANSMISSION

2 - 20

W270

OPERATION The modulating valve of this control valve changes the time required to increase the oil pressure up to the clutch engagement value, modifying the pressure increment curve, in accordance with the transmission speed, allowing a smother gearshifting.

The intervention of the modulating valve is represented in the diagram by points A - E. The intervention of the solenoid valves and the manual spool (emergency travel spool) is explained in the pages to follow.

Speed

A

D

Oil pressure

2nd speed 3rd/4th speed

E

C 1st speed

B 0

Time

Fig. 2-19 Variation curves of clutches engagement oil pressure

3rd speed in Neutral (Point A of fig. 2-19) 1. The oil delivered by the transmission pump to the pressure regulating valve through duct (1) of the control valve, flows through a small calibrated hole “a”: filling chamber (2) behind the spool, moving it leftward, as in the figure. The oil, which pressure is regulated at the value of engagement of the clutch, travels circuit (3) to reach the circuit of modulation valve (5). Oil in excess is discharged into the torque converter, through circuit (4). 2. The oil in circuit (5) flows through the gap left open by the chamfer of the modulating valve plunger, reaching circuit (6), communicating, through orifice [W] with the circuits of the gear shift spool (8), of flow valve (9) and forward/reverse selector spool (12). 3. The oil sent into circuit (8) reaches, through passages (8) → (16) → (17) → (18) to the piston chamber of the 3rd speed clutch. The other clutches

are connected with the discharge. 4. The oil in circuit (8) flows through the axial hole of spool A, reaching circuit (19). Then, the oil goes through orifice [Z] and joins chamber (20) of the accumulator. In this chamber there are two load plungers, one for low pressure, the other for high pressure. After the movement of the low pressure plunger moves to contact the rod, the high pressure plunger starts moving. 5. The oil in circuit (12) is stopped by the FORW./ REV. selector spool. Both the forward and reverse clutches are disengaged (neutral). 6. All solenoid valves are in “OFF” (not energized) condition, thus the oil reaching them through the relevant orifices is discharged.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

PUMP

FILTER

SAFETY VALVE

HEAT EXCHANGER

TORQUE CONVERTER

To TRANSMISSION (LUBRICATION)

MANUAL SPOOL

FORW. N REV.

“OFF” sol. IREV.

4

1

5

2

a

FORW./REV. 12 SELECTION

PRESSURE RELIEF VALVE

“OFF” sol. FWD.

TRANSMISSION CONTROL VALVE

3

SUCTION AND DRAIN OIL

MODULATOR

6

w

REV.

“OFF” sol. A

“OFF” sol. B

SPOOL B

Z

ACCUMULATOR

Fig. 2-20 3rd speed in Neutral

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual) CONVERTER LUBRICATION OIL

BLOW PRESSURE

FLOW VALVE

9

19

X

Y

TRANSMISSION

PRESSURE OIL

20

8

17 16

2

3

18

1

4

SPOOL A

CLUTCH

HIGH PRESSURE

FWD. CLUTCH

W270 2 - 21

TRANSMISSION

2 - 22

W270

Transmission gearshifting with 1st in Forward (Point B) 1. Solenoid valves AV and A are energized. 2. With solenoid valve AV energized, the oil discharge is closed, so the oil flow coming from the pressure relief valve is forced to move toward circuit (26) where the FORW./REV. selector spool is located. The pressure created by this oil flow moves the FORW./REV. selector spool rightward, as shown in the figure.

5. The pressure difference between circuits (9) and (22) moves the flow valve plunger rightward, as indicated in the figure, discharging the oil of accumulator (20). 6. The modulating valve plunger moves rightward, as shown in the figure, as a consequence of the pressure drop in circuit (25), letting only the quantity of oil due to circuits (5, 6) go through.

3. In the same manner, with solenoid valve A energized, spool A moves rightward, as shown in the figure. 4. After the FORW./REV. selector spool movement, the oil from circuit (12) can reach circuit (21) where the FORW. clutch is located. During the oil filling of the FORW. clutch piston chamber, a pressure differential is created between the circuits (6 for modulating valve, 22 for the left side-flow valve) upstream, and the downstream circuits (8 of gearshifting selection spool A, 9 for the right sideflow valve, 12 for FORW./REV. selection spool), with respect to orifice [W]. The upstream circuit have a higher pressure).

Speed

A

D

Oil pressure

2nd speed 3rd/4th speed

E

C 1st speed

B 0

Time

Variation curves of clutches engagement oil pressure

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Fig. 2-21

PUMP

FILTER

HEAT EXCHANGER

SAFETY VALVE

TORQUE CONVERTER

To TRANSMISSION (LUBRICATION)

MANUAL SPOOL

FORW. N REV.

“OFF” sol. FWD.

26

PRESSURE RELIEF VALVE

“ON” sol. REV.

F

TRANSMISSION CONTROL VALVE

1

5

6

Transmission in 1st Forward

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

25

HIGH PRESSURE

MODULATOR

w

12

SUCTION AND DRAIN OIL

FORW./REV. SELECTION

21

IND.

REV.

A

“ON” sol. A

“OFF” sol. B

PRESSURE OIL

20

9

CLUTCH

LOW PRESSURE

22

CLUTCH

17 16

CONVERTER LUBRICATION OIL

ACCUMULATOR

FLOW VALVE

SPOOL A 8

SPOOL B

Z

X

Y

VARIABLE PRESSURE OIL

2

3

18

1

4

W270 TRANSMISSION 2 - 23

TRANSMISSION

2 - 24

W270

Engagement of clutches - 1st speed Forward (Point C) 1. When the clutches selected have been filled with oil, the pressure differential before and after orifice [W] is eliminated, thus the plunger of the flow valve moves leftward, as shown in the figure, pushed by the spring, thus closing the oil discharge. The oil in circuit (23) flows through the axial hole of spool A, enters circuit (24), then goes through orifice [X] and enters chamber (20) of the accumulator. 2. At the same time, the oil flows through the gaps (5, 6) of the modulating valve and the holes in the plunger of the valve itself, moving into chamber (7) behind the plunger. Consequently, the plunger of the modulating valve moves gradually leftward for the combined effect of the oil pressure in chamber (25) and the spring, increasing gradually the engagement pressure of the clutch. 3. When the clutch engagement pressure reaches the pre-established value, the load plunger in chamber (20) of the accumulator stops against the rod.

Speed

A

D

Oil pressure

2nd speed 3rd/4th speed

E

C 1st speed

B 0

Time

Variation curves of clutches engagement oil pressure

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Fig. 2-22

PUMP

FILTER

SAFETY VALVE

HEAT EXCHANGER

TORQUE CONVERTER

To TRANSMISSION (LUBRICATION)

MANUAL SPOOL

FORW. N REV.

“OFF” sol. REV.

PRESSURE RELIEF VALVE

“ON” sol. FWD.

TRANSMISSION CONTROL VALVE

5

7

6

FORW./REV. SELECTION

w

SUCTION AND DRAIN OIL

MODULATOR

25

REV.

“ON” sol. A

“OFF” sol. B

20

Engagement of clutches (1st forward)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

23

Z

ACCUMULATOR

LOW PRESSURE

FLOW VALVE

SPOOL A

X

24

2

3

SPOOL B

1

4

CONVERTER LUBRICATION OIL

CLUTCH

Y

TRANSMISSION

PRESSURE OIL

HIGH PRESSURE

FWD. CLUTCH

W270 2 - 25

TRANSMISSION

2 - 26

W270

After the engagement of the clutches - 1st speed Forward (Point D) 1. When the packs of clutches FOR. and 1st speed are both engaged, the pressure in chamber (20) of the accumulator tends to raise, forcing the load plunger to move, until it touches the stop rod (maximum load). At the same time, the pressure increases also in chamber (25) of the modulating valve, until it balances the pressure existing on the other side (7) of the modulating valve plunger, which, in any case, moves leftward, thanks to the combined action of pressure and spring. At this point, the pressure has reached its maximum value, corresponding to the setting pressure of the relief valve.

Speed

A

D

Oil pressure

2nd speed 3rd/4th speed

E

C 1st speed

B 0

Time

Variation curves of clutches engagement oil pressure

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

POMPA

FILTRO

SAFETY VALVE

HEAT EXCHANGER

TORQUE CONVERTER

To TRANSMISSION (LUBRICATION)

MANUAL SPOOL

FORW. N REV.

“OFF” sol. REV.

PRESSURE RELIEF VALVE

“ON” sol. FWD.

TRANSMISSION CONTROL VALVE

7

w

FORW./REV. SELECTION

SUCTION AND DRAIN OIL

MODULATOR

25

REV

HIGH PRESSURE

sol. A

“ON”

sol. B

“OFF”

X

2

3

Z

1

4

Fig. 2-23 Conditions with clutches engaged (1st Forward)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual) CONVERTER LUBRICATION OIL

LOW PRESSURE

Y

VARIABLE PRESSURE OIL

ACCUMULATOR

FLOW VALVE

SPOOL A

SPOOL B

20

CLUTCH

TRANSMISSION

PRESSURE OIL

FWD. CLUTCH

W270 2 - 27

TRANSMISSION

2 - 28

W270

Engagement of the clutches Forward and 2nd speed (Point E) 1. Solenoids A and B are energized, transmission spools A and B move rightward, as shown in the figure. 2. The oil arriving into circuit (8) of gearshifting spool A flows into circuit (23). Thus it goes to power, through the holes drilled in the spool, circuit (24) from which, a portion of the oil flow is directed through calibrated orifice X to chamber (20) of the accumulator. At the same time, the other portion passes from circuit (24) to circuit (27) of gearshifting spool b. From circuit (27) the oil passes through circuit (28) and calibrated orifice Y of circuit (29) flowing into chamber (20) of the accumulator. Thus, when the control lever is shifted into 2nd speed, the oil flows through calibrated orifices X, Y causing a fast increment of the pressure, with an immediate engagement of the clutch packs of the 2nd speed, with respect to the selection of the 1st speed.

Speed

A

D

Oil pressure

2nd speed 3rd/4th speed

E

C 1st speed

B 0

Time

Variation curves of clutches engagement oil pressure

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Fig. 2-24

CONVERTER

TORQUE

To TRANSMISSION (LUBRICATION)

PUMP

FILTER

SAFETY VALVE

HEAT EXCHANGER

“ON” sol. FWD.

PRESSURE RELIEF VALVE

MANUAL SPOOL

FORW. N REV.

“OFF” sol. REV.

TRANSMISSION CONTROL VALVE

MODULATOR

SUCTION AND DRAIN OIL

w

FORW./REV. SELECTION

REV

“ON”

sol. A

“ON”

sol. B

Engagement of clutches (2nd speed Forward)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual) PRESSURE OIL

HIGH PRESSURE

FWD. CLUTCH

20

SPOOL A

SPOOL B

8

Z

CONVERTER LUBRICATION OIL

LOW PRESSURE

X

29

24

Y

VARIABLE PRESSURE OIL

ACCUMULATOR

23

27

2

3

28

1

4

FLOW VALVE

CLUTCH

W270 TRANSMISSION 2 - 29

TRANSMISSION

2 - 30

W270

Operation of the solenoid valves

Solenoid valve not-energized

Four solenoid valves are mounted on the control valve. When selecting speeds, an electric signal is transmitted to the solenoid valves of the control valve. For each speed selected, a combination of solenoid valves are energized (see tables here below) which have the purpose of controlling the selecting spools “FOR and REV “A and B”.

Oil at the pressure controlled by the pressure relief valve, flows constantly through the calibrated orifice and enters the solenoid valve. When the solenoid is not energized, the oil flows through it and discharges to tank. The oil pressure in point B is 0 bar.

sol. FOR sol. REV 4a a

3 FOR

2a 1a

a

1

a

2 REV

3a 4a

• • • •

sol. A

sol. B

•

• • • •

• • • •

•

NOT ENERGIZED "OFF"

P CALIBRATED ORIFICE

•

FROM PRESSURE RELIEF VALVE

Fig. 2-26

•

Solenoid valve energized

1

5

2

IND.

When the solenoid valve is energized, the oil passage inside it is closed and the oil is prevented from discharging. The oil pressure in point P becomes equal to the pressure set by the pressure relief valve. The travel direction and speed control is actuated by the action of FOR/REV spool and gearshifting spools A and B.

6 AV. 3 7 A 4

8 B

ENERGIZED "ON"

P

Fig. 2-25 1. Transmission control valve body - 2. FOR/REV spool 3. Spool A - 5. Spool B - 5. Solenoid valve (Reverse) 6. Solenoid valve (Forward) - 7. Solenoid valve (A) 8. Solenoid valve (B).

FROM PRESSURE RELIEF VALVE

Fig. 2-27

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

TRANSMISSION

2 - 31

Operation of manual spool (emergency travel) Should the solenoid valves fail to operate correctly due to a cut-off electrical connection or any other electrical fault, it is possible to actuate the transmission control valve in 3rd forward or reverse, using this spool. It is recommended that this spool is used when the loader has to be moved away from a traffic area or to be repaired.

3

4

5

1

2

WARNING

Ensure that the engine is not running prior to operate the manual spool. Should the spool actuated when the engine is running, the loader could move suddenly, causing accidents.

Fig. 2-28 Tansmission control valve 1.Control valve - 2. Solenoid valves 3. Screw - 4. Spools retainer plate - 5. Manual spools

FOR. CLUTCH

“OFF” Sol. REV.

“OFF” Sol. FOR.

REV.

26

FOR. N. REV.

MANUAL SPOOL

FORW./REV. SELECTOR SPOOL

32 31 33

Drain oil Pressure oil

From MODULATING VALVE

From PRESSURE RELIEF VALVE

Fig. 2-29 Angaged forward gear by means of manuals spool

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

TRANSMISSION

2 - 32 Transmission in 3rd Forward

To shift into 3rd forward, pull-out the manual spool about 10 mm (0.39 in). 1. The oil, at the pressure set by the relief valve, goes through the orifices and reaches the circuits of the manual spool (31, 32). Since circuit (31) is blocked by the spool, the oil is diverted from circuit (33) into circuit (26) of the FORW./REV. selector spool, moving it rightward, as indicated in the figure, so that the oil pressure in the FORW. clutch increases.

W270

2.6 AUTOMATIC TRANSMISSION CONTROL SYSTEM The entire control system of the transmission is managed by the ATC electronic unit, which receives all the signals of each component of the transmission, controlled by solenoid valves in the transmission control valve, the oil passages flowing to the clutches of each speed and travel direction of the machine.

2. The oil of circuit (32) goes through the spool and the REV. solenoid valve to be discharged.

The control system is composed of the following items: - transmission control selector; - switch for actuation of automatic shifting; - Kick-down and Shift-down button.

3. Being both solenoid valves A and B of the gearshift spools not energized, the pressure in the 3rd speed clutch increases (refer to Fig. 2-24). Consequently, the loader will travel in 3rd forward.

Note - the connection of the wires on the ATC with the system energised could result in damaging the electronic components of the unit with the subsequent zeroing of all the ATC functions.

b. Transmission in 3rd reverse To shift into 3rd reverse, push-in the manual spool about 10 mm (0.39 in). The operation principle is the same as in the case of 3rd forward.

Fig. 2-30 WIRING DIAGRAM OF THE AUTOMATIC TRANSMISSION 1. ATC control unit 2. Transmission control selector 3. Brake pedal valve pressure switch 4. Proximity sensor 5. Parking brake pressure switch 6. Solenoid valves AV - IND - A - B 7. Shift-down and Kick-down button 8. Automatic engagement switch 9. Speed engaged indicator 10. Tachometer 11. Parking brake indicator 12. Back-up relay 13. Back-up alarm 14. Solenoid relay 15. Starter key 16. Switch 1-2 17. Resistor 18. Transmission sensor 19. Capacitor F5A - F6A - F8B - F10A Fuses

Numbered wires are located outside the cab. Coloured wires are located inside the cab. Colours of wires: A: B: C: D: E: F: G: N: R: S: V: Z:

Light blue White Orange Yellow Grey Blue Brown Black Red Pink Green Violet

Connectors B-G-M-D-E-P-C-N-S Connectors C-D-B Transmission selector wire Connectors Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

TRANSMISSION

W270

2 - 33

"ACC" 15

14 3

974

18

D38

S37

B16

FB9 B6

B20

M8

D15

OUT

C1

16 SW1-3

10

3

2

SW1-4

1

D14

D3

P8

C5

D3

E17

E11 E4

E13 SW1-2

1

G1

E15

G17

E9

G18

E8

G15

E7

G14

E6

D17

E1

M-B 2 M-N

9

3 M-V 4

C20

E10

P10

D10

D43

D42

E14

N9

N11

CN1-9

ATC

B16

CN2-10

MAN - OFF AUT - ON

8

N7

N8

S3

+30

RELE' SERVIZI S2

CN2-15 CN2-14

CN2-4 CN2-3

+VC2

CN1-13 CN1-7 CN1-5 CN1-11 CN2-7 CN2-8 CN2-9 CN2-6

F7A N2

N6

12

N3

SW2/3 07 1 1

SW2-1

+VC

D27

033

3 B10

P6

CN2-16

1

06

7

D30

P7

CN2-17

E2

DSS

C17

CN1-2

CN2-11

N1 H-L

C16

D29

H-L B-N

B

E12

E3

CN1-4 CN1-3 CN2-13 CN2-12 CN2-1 CN2-2

P5

A

D32

D28

D31

F7

SW1-1

C19

E16

C15

6 IND

AV

D6

C4

C21

6

Q5

5 C3

19

C24

11

D19

4

+ C2

C8

C4

FB11A

PARKING

D10

D17

D9

R9 P9

17 D11

D10

05

D33

O2

O3

SW2/4 04

MV3

2

2

2

M3

M14

M4

B10

B12

B12

3 4

R

1

2 Fig. 2-31Transmission electric diagram

N F

13

VC2

TRANSMISSION

2 - 34

W270

2.6.1 Electronic unit atc for automatic transmission control Operation Rotating the starting key on the ON position: 1) Are under control: the warning lamps, the solenoid circuits, the solenoids A and B of the speeds, the rev sensors and the L.T.S. circuit. 2) The solenoids F and R (forward and reverse) are controlled when actuated. 3) If during the check a malfunction is noticed the situation is indicated by the flashing of one of the warning lamps. AT/MAN switch in manual mode: 1) The logic of gear shifting depends on the position of the selector. 2) With the Kick-down button it is possible to shift down from 2nd to 1st speed both in forward or reverse without limitation values. 3) The disengagement of the Kick-down is obtained by moving the selector either in neutral position or in another speed. 4) The L.T.S. operates in all speeds, it engages at 7 km/h and disengages at 5 km/h.

2) The gear shifting depends on the speed and is actuated accroding to three different logics: same direction of travel, inversion of direction, use of Kickdown button. 3) The gear up shifting it is possible only with the throttle pedal pressed down. The hold function is possible only when the foot releases the accelerator. 4) The Kick-down function is automatically released when the travel speed reaches a certain value. 5) The electronic unit reads the signal in H3 sent by two sensors located in transmission. 6) The two sensors read the same signal on the same gear. A malfunction of a sensor is indicated as error. The L.T.S. (Load Travelling System) operates in all speeds. It engages at 7 km/h and disengages at 5 km/h.

The switch AT/MAN in automatic mode: 1) The logic of gear shifting is controlled by the electronic unit according to the following table.

Selector

1st 2nd 3rd 4th

Operating onditions

Speeds engaged

With kick-down

loading loading and travel travel

1st only 2nd only 2nd → 3rd aut. nd 2 - 3rd - 4th aut.

1st 1st nd 2 - 1st rd 3 - 2nd - 1st

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

TRANSMISSION

W230

2 - 35

7

F A

6

8

F

1 2 3 4

N R

R 9 F/R C

H

C

H OIL TRAM

COOLANT

1

2

3

4

E\G OIL

BRAKE PRESS

COOLANT TEMP

T\M OIL TEMP

20

12

F

E

CHARGE

30 ENG STE

10 40 50

FUEL

13

1\10 h

HOUR METER

PARKING GENERAL WARNING

km\h

10

5

CN1

4

3

11

ATC

2

1 CN2

14

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Fig. 2-31 Arrangement of the automatic transmission devices on the machine

ELECTRONIC UNIT LOGIC BOARD L.T.S. SOLENOID VALVE (OPTIONAL) SENSOR UNDER THE THROTTLE PEDAL (FOR FUNCTION HOLD) BUTTON FOR "KICK DOWN" FUNCTION INTERRUTTORE INSERIMENTO L.T.S. L.T.S. ENGAGEMENT SWITCH TRANSMISSION PILOT VALVE SPEED ENGAGED INTICATORS TACHOMETER ENGAGEMENT SOLENOID VALVES ON TRASMISSION CONTROL VALVE DIRECTION REVERSER AUXILIARY SWITCH CONTROL BUTTON "FORWARD/REVERSE" FUNCTION SWITCH "FORWARD/REVERSE" CONTROL UNIT

2 - 36

TRANSMISSION

BIANCA

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

TRASMISSIONE

W230

2 - 37

CN1-4 CN1-3 CN2-13 CN2-12 CN2-1

Fig. 2-32 Auxiliary reverser electric diagram

ATC

CN2-2

"ST" CN1-2

CN2-11

ATC UNIT SAFETY SWITCH OR FORW./REV. AUXILIARY DIVERTER FORW./REV. AUXILIARY DIVERTER FORW./REV. MICRO CONTROLLER TRANSMISSION PILOT CONTROL FORW./REV. AUXILIARY DIVERTER ARRANGEMENT ON "SINGLE LEVER EQUIPMENT CONTROL"

B1

CN2-17

M

CN2-16

1

CN2-10

F4A

CN2-15

F4B

CN2-14

CN2-4

R5

CN2-3

07 CN1-13 CN1-7 CN1-5 CN1-11 CN2-7 CN2-8 CN2-9 CN2-6 937

033

022

R4

N1

N2

D37 SW2-3

06

N3

N6

033 H13

SW2-4

07

03

04

05

02

C1

01

H5

F7A

S-G

A-R

C-B

A-V

C-V

C-H

R-N

R7 C3

D27

M14 B11

L-B

B2

R-G A-V R-V C-N R-N

B3 B4 B5 B7 B6

L-B B-R G-R A-B R-V C-N R-N

3

1

2

3 3

2

4

1

2 N

2

R

F

5

ACC

D10

R

G/V

A-V

A-V

H-L

G/R

B

N

2

G1

3 5 8 10 9 12 13 2 6

0

1

1

9

1

3

R

7 11 1 4

R-G

L-B

S-G

C-B

F11A

A-B

1. 2. 3. 4. 5. 6.

CN1-9

3

G1 G3 G5 G2 G4 G6

6 4

5

10

R

D

R

2 - 38

TRANSMISSION

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270

2.7

TRANSMISSION

2 - 39

TRANSMISSION SELECTOR

CONNECTIONS X1

WIRE

TERMINAL

COLOUR

1 2

VP E

RED YELLOW

3

F

PINK

4

G

GREY

X2

1 1

B C

WHITE BROWN

X3

2

D

GREEN

3

A

BLUE

4

H

VIOLET ND

X1

4 3 2 1

X2

1

TABLE OF ENERGIZED SOLENOID VALVES AS A FUNCTION OF THE SPEED ENGAGED BY THE SELECTOR FORWARD A

SOLENOIDS B FORW.

REV.

1st

1

0

1

0

2nd

1

1

1

0

3rd 4th

0 0

0 1

1 1

0 0

NEUTRAL

RELAY NEUTRAL

SOLENOID VALVE 1

REVERSE

SOLENOID VALVE A

B

FORW.

REV.

1st

1

0

0

1

2nd 3rd

1 0

1 0

0 0

1 1

4th

0

1

0

1

(1) SOLENOID VALVE ENERGIZED (0) SOLENOID VALVE NOT ENERGIZED

Speed selected

A CD

1 = 1st speed nd

2 = 2 speed

1

2 3

B F (REV.) E (FORW.)

G (F.) REV.

4

3 = 3rd speed 4 = 4th speed H

VP

Transmission selector electrical system

Fig. 2-33

Transmission control selector

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

F.

FORW.

TRANSMISSION

2 - 40

W270

TRANSMISSION CONTROL LEVER

AUTOMATIC GEARSHIFTING

The speeds and the inversion of directions are choosen by a transmission control selector located on the left side of the steering column, under the steering wheel (see figure). The knob of the selector incorporates a horn button; the speeds which can be selected are eight (four forward and four reverse). A particular feature distinguishing machines equipped with “Automatic Power-shift” is to have available both gearshifting modes, in automatic and manual.

Forward ("F") Push the button of the transmission automatic system (on the right panel) to engage the automatic mode, rotate the knob to position 3 or 4 and move the gearshift lever to forward (“F”). In this position the transmission ratios are changed automatically as a function of the speed of the machine, from second to third respectively or from second to forth. The display indicating the transmission, shows the ratio being used. When the gearshift lever is in this position and the machine is at a standstill, the second gear is automatically engaged (the first being not enabled). The following gears (third and fourth) will be engaged as you accelerate. Dowhshifting from fourth to third to second occurs automatically as the loader ground speed decreases. However, when moving on steep slopes, the machine does not change the gear ratio even if the throttle is fully released. This is due to the action of a sensor located under the throttle pedal, which will be described in detail further on. Transition from the automatic to the manual mode is always possible, while it is necessary to reduce engine rpm and machine ground speed adequately to change the direction of travel.

MANUAL GEARSHIFTING Forward ("F") When the lever is moved to the forward position (“F”) the machine moves forward. Rotate the knob to positions 1, 2, 3, and 4 to select the first, second, third, and fourth gear ratios, respectively. The gear ratio selected will be displayed on the dashboard display (automatic gearshift option only).

Neutral ("N") When the gearshift lever is in the middle position (“N”), the trasmission is in neutral. In practise, the second gear is maintained as it is the “basic ratio”, i.e. the one to which the transmission always returns when no specific control is provided.

Reverse ("R") When the gearshift lever is in this position, the machine can move only rearwards, with the possibility to select the first, sescond, third or fou rth gears. Change of direction is always possible independently of the gear selected. For example, if you are working using the second forward and reverse the direction of travel by moving the gearshift lever to the “R” position, the transmission will automatically switch from second forward to second reverse.

Automatic transmission switch

Fig. 2-34

Kick-Down button to downshift

Neutral ("N") When the gearshift lever is moved to the middle position (“N”), the transmission is in neutral. The second gear, however, remains engaged as it is the basic ratio.

Reverse ("R") When the gearshift lever is in this position, the machine can move only rearwards and the gears change automatically according to the the ground speed. Operation modes and gear selection are same as for forward travel. “HOLD” function When operating on steep ramps or downhill, it is easy overheating the brakes while slowing down continuously the machine, to prevent a galloping speed under the effect of the automatic shifting to higher speeds. The HOLD function provides that, when the foot releases the accelerator, the transmission keeps the speed engaged, without allowing the shifting into higher speeds. In the event the speed of the machine results to be too high, it is possible to slow-down further, without using the brakes, with the function described below.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270 2.7.1

TRANSMISSION Shift-Down device (down-shifting button)

The Shift-Down device is actuated by the automatic transmission button engaged, on the right console. This function allows, under steep gradient situations, the down-shifting by simply pressing button A located between the equipment control levers. The device is composed of a down-shifting button and two relays. 2.7.2

Kick-Down” Function (with manual and automatic gearshift) Whit this device, it is possible, by actuating button “A”, to change from the 2nd to 1st ratio. This is particularly useful, as an example, under all circumstances when it is necessary to change frequently from 1st to 2nd speed and viceversa. To zero the Kick-Down, reverse the motion or, with an automatic transmission, to increase the speed, move the selector to neutral. 2.7.3

Forward/reverse function switch (variant)

A

2 - 41

Operation of Kick-Down device When the loader start digging operations in 2nd speed forward, actuating the Kick-Down device, the transmission is automatically shifted in 1st speed by the action of the downshifting relay, allowing power to be transfered to the inmplement. When the control lever is shifted in reverse after loading or digging operations, the transmission ratio is automatically returned in 2nd speed to have an increased travel speed in reverse. In other words, with the Kick-Down device, it is possible to control both the bucket break-out force, or the travel speed of the loader. To activate this direction reversing auxiliary function, it is necessary that the gearshifting lever is in neutral and the reverser auxiliary switch neutraliser button (fig. 2-39) is engaged. Switch pressed forward: forward speed Switch pressed backward: reverse speed In the event, during the use of the function, the gearshifting lever is moved, the device is cut-off. To re-engage it, return the gearshifting lever into neutral and press the neutraliser button again. REVERSE FORWARD NEUTRAL

Fig. 2-35 Kick-Down button to downshift Fig. 2-36 "FORWARD/REVERSE" function on "piloted single lever" on equipment control (variant)

Engine starting safety system in Neutral The engine starting safety system in neutral prevents the starting of the engine in the event the pilot valve is not in neutral. This allows avoiding that the loader is suddenly moving, when the starter key is moved to START. Make sure that the pilot valve is in neutral, prior to starting the engine. The engine starting safety system in neutral is incorporated in the circuit of the engine starting system. Operation 1. When the key is moved into START with the pilot valve lever in neutral, the neutral relay is closed, allowing electric power to go through the safety relay, thus powering the starter motor of the engine. 2. When the starter key is moved to START with the pilot valve not in neutral, the neutral relay stays open, preventing the power from crossing the safety relay. The engine cannot be started. Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

TRANSMISSION

2 - 42

W270

Operation of the electrical system of the KickDown device Gearshift lever in 2nd forward

Actuating the Kick-Down device

1. When the gearshift lever is moved into 2nd speed, solenoid valve AV is energized by power “a”, whereas relay 1 is actuated by power “b”.

1. When the Kick-Down device is actuated, relay 2 is activated by power “e”, that in turn, cuts-off power “d” to solenoid valve B, de-energizing solenoid valve B. Thus, the transmission shifts to 1st speed.

2. Solenoid valve A is energized by power “c” whereas solenoid valve B is energized by power “d”. Consequently, the transmission engages the 2nd forward.

––

––

––

–– Relay 1 e

Relay 1 b

13

b

13

Kick-down button

Relay 2

e

Kick-down button “ON”

Relay 2

14

14

d Solenoid valve A

Solenoid valve A

1a 2a 3a 4a 14

Solenoid valve B d

d

a Solenoid valve REV

13 b

FOR. F. REV.

Solenoid valve FOR 11

9

13

FOR. F. REV.

Solenoid valve REV 9

15

Fig. 2-37

e

d

Solenoid valve FOR 11

Transmission selector

d

14

c Solenoid valve B

Transmission selector 1a 2a 3a 4a

d

e

15

Fig. 2-38

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

TRANSMISSION

2. At the same time, power “f” appears, allowing relay 2 to remain self energized, thus it stays activated also after the Kick-Down button device is released. Consequently, the transmission stays in 1st speed after the Kick-Down device is de-activated.

2 - 43

Transmission in reverse direction 1. When the gearshift lever is moved to reverse, power “b” is zeroed, thus relay 1 is de-activated. This causes the cut-off of power “f” at relay 2 causing also the opening of relay 2. 2. Power “d” energizing solenoid valve B is re-established, thus shifting into 2nd speed.

+

–– Relay 1

3. Also, solenoid valve “REV.” is energized by power “g” to engage the transmission in 2nd reverse.

13 Relay 2

Kick-down button “OFF”

f

14

f

Transmission selector

Solenoid valve A

––

––

1a 2a 3a 4a

Relè 1

b

14

b

Solenoid f valve B

13 Kick-down button

Relè 2

14 Solenoid valve FOR 11

Solenoid valve REV

13

f FOR. F. REV.

d Solenoid valve A

Transmission selector

d

1a 2a 3a 4a 14

9 15

Solenoid d valve B d 13

Solenoid valve FOR

Fig. 2-39

11

Solenoid valve REV

b

FOR. F. REV.

g

g 9 15

Fig. 2-40

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

TRANSMISSION

2 - 44

W270

2.8 OIL CIRCUIT General description The oil drain by the rear pump passes, with the oil leaving the converter, into the heat excharger to be cooled. After leaving the heat exchanger, the oil lubricates and cools all the speed clutch packs, prior to returning into the sump of the transmission housing.

The oil used to engage the clutches is taken from the transmission housing. As soon as the engine starts, the dual power pump sucks the oil from the sump of the transmission housing, through the mesh filter. The oil sucked by the front pump flows through the delivery filter, to the transmission control valve. The control valve divides the oil flow into two parts: one for the operation of the torque converter and the other for the actuation of the transmission clutches.

2

Note - The heat exchanger is located inside the lower tank of the engine coolant radiator. For the heat exchanger, please refer to chapter "1.9 COOLING SYSTEM".

9

1

4 6

8

3 5 7

Fig. 2-41

1. 2. 3. 4. 5.

10

Transmission oil circuit

HEAT EXCHANGER TORQUE CONVERTER OIL DISTRIBUTION COVER (FORW./REV. SHAFT) OIL DISTRIBUTION COVER (1st / 2nd SPEED SHAFT) FEEDING DOUBLE PUMP

6. 7. 8. 9. 10.

TRANSMISSION CONTROL VALVE STRAINER DELIVERY FILTER OIL DISTRIBUTION COVER (3rd / 4th SPEED SHAFT) TRANSMISSION HOUSING

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

TRANSMISSION

2 - 45

Delivery filter The delivery filter is located in the transmission clutch engagement control oil delivery circuit. The oil flows through the filtering element from the outside to the inside and filtered oil is sent to the transmission control valve.

When the filtering element is clogged, the pressure at the filter inlet port increases so that the by-pass valve opens, letting the oil flow directly to the outlet port of the filter.

Operating pressure of the by-pass valve: 1.75 bar (24.9 psi) Filtering capacity: 25 µ

A

A

3 1

2

Section A-A

Fig. 2-42 1. 2. 3.

Delivery filter

FILTER SUPPORT FILTER BODY FILTER SAFETY VALVE (BY-PASS)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 46

TRANSMISSION

2.9 DISASSEMBLY TRANSMISSION Nota: • Use a working bench, hoist, bearing puller and hangers for easy and safe disassembly. • Put the disassembled parts to insure speedy parts in order, and efficient reassembly of them. • Unit weight: 804 kg (1770 lbs).

a)

Torque converter disassembly Draining oil and removing charging pump

1.

Lift the drive unit in an upright position or put on the working bench to drain the oil from the drain outlet. Quantity oil: 40 l (10.6 U.S. gal)

Fig. 2-43

2.

Remove the tube from the charging pump.

Fig. 2-44

3.

Remove the 2 bolts securing the charging pump. Tapping with a copper hammer or using a bar remove the charging pump along with the drive sleeve for the shaft.

Fig. 2-45

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270

TRANSMISSION

4.

Put the drive unit with the torque converter side pointed upward.

5.

Remove the tube of the transmission case and detach the suction strainer and "O"-ring from the transmission case. It the strainer is hard to detach, rake it out by inner diameter using a screwdriver.

Fig. 2-46

b)

Removing distributor cap and hose

1.

Loosen the two hose clips and remove the hose connecting to the distributor cap.

Fig. 2-47

2.

Loosen the five bolts securing the 3rd/4th speed distributor cap and remove the distributor cap. If it is too hard to remove, use a copper hammer or bar.

Fig. 2-48

3.

Then, remove the spacer.

Fig. 2-49

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 47

2 - 48 4.

W270

TRANSMISSION

Remove the snap ring from the groove at the outer diameter of the bearing.

Fig. 2-50

c)

Removing distributor cap and hose

1.

Remove the cap assembly (on the 1st and 2nd speed shaft) in the same manner as the distributor cap.

Fig. 2-51

2.

Remove the plug (1) (with an "O"-ring) from the cap. Remove the adapter (2), spring (3) and check ball (4) in that order.

4 3

2 1 Fig. 2-52

3.

Remove the hex. plug (1) (with an "O"-ring). Remove the spool (2) and spring (3) in that order. 1 2

3

Fig. 2-53

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

TRANSMISSION

d)

Removing converter housing

1.

Temporarily lift the converter housing and the 30 bolts attaching the transmission case.

Fig. 2-54

2.

Suspending the mating surface with 2 punched bolts and checking the housing is removed smoothly, lift the converter housing little by little with a hoist.

Fig. 2-55

e)

Removing converter wheel

1.

Turn the converter housing upside down with converter wheel downward and remove the 9 bolts securing the stator support.

Fig. 2-56

2.

Turn the converter housing upside down again with converter wheel upward.

3.

Attach a hanger to the input guide and lift it gently to remove. It it is too hard to remove, use a copper hammer.

Fig. 2-57

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 49

2 - 50

TRANSMISSION

f)

Removing converter wheel

1.

With the converter wheel lifted, remove the twenty-four bolts securing the impeller wheel and cover wheel.

Fig. 2-58

2.

Disconnect the cover wheel with a copper hammer.

Fig. 2-59

3.

Loosen the 6 bolts securing the input guide and remove the input guide from the cover wheel. Remove the bearing from the covr wheel.

Fig. 2-60

4.

Remove the snap ring and spacer from the shaft and remove the turbine wheel.

Fig. 2-61

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270 5.

TRANSMISSION

Remove the snap ring in the stator support and detach the stator wheel.

Fig. 2-62

6.

Pull up the impeller wheel assembly and remove it.

Fig. 2-63

7.

Remove the seal ring from the turbine shaft left behind. And remove the snap ring and pull out the spacer and bearing.

Fig. 2-64

8.

Disconnect the stator support from the impeller wheel assembly using a soft hammer.

Fig. 2-65

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 51

2 - 52 9.

TRANSMISSION

Remove the seal ring from the stator support.

Fig. 2-66

10. Loosen the 16 bolts securing pump drive gear and remove the pump drive gear from the impeller wheel. Remove the bearing from inside the pump drive gear.

11. Remove the remaining impeller hub at the center of the impeller wheel.

Fig. 2-67

g)

Removing pump drive gear

1.

Loosen the bolt securing the pump drive gear and remove the gear, bearing and bearing support as one unit.

Fig. 2-68

2.

Remove the snap ring from inside the gear. Removed the bearing and bearing support as one unit.

Fig. 2-69

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270

TRANSMISSION

3.

Remove the bearing from the bearing support.

4.

Remove the other 2 pump drive gears in the same manner.

Fig. 2-70

h)

Removing safety valve

1.

Loosen the plug of the safety valve.

Fig. 2-71

2.

Remove the plug, spring and plunger.

Note - The plunger mounting seat is strongly fitted into the case. Do not remove it as long as it is normal.

Fig. 2-72

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 53

2 - 54 1.

TRANSMISSION

Put the transmission case upright. Loosen the 6 bolts securing the distributor cap of the forward/ reverse shaft and remove the distributor cap.

Fig. 2-73

2.

Remove the snap ring from the groove at the outer diameter of the bearing.

Fig. 2-74

3.

Put the transmission case with its opening upward. Remove the snap ring from the idler shaft and detach the bearing using a puller.

Fig. 2-75

4.

Remove the idler gear from the spline.

Fig. 2-76

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270 5.

TRANSMISSION

Attach a hanger to the forward/reverse shaft and remove it from the case using a hoist. Clutch shaft: Approx. 45 kg (100 lbs)

Fig. 2-77

6.

Using the same procedure, remove the 1st/2nd speed shaft and 3rd/4th speed shaft. Clutch shaft: Approx. 50 kg (110 lbs)

Fig. 2-78

7.

The flange at the converter side is inserted into the spline. Remove it in this state.

Fig. 2-79

l)

Removing and disassembling parking brake

1.

Turn the transmission case upside down with its opening downward. Remove the 6 socket bolts securing the brake assembly.

Fig. 2-80

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 55

2 - 56 2.

TRANSMISSION

With a copper hammer, rise the contact surface and remove the brake assembly.

Fig. 2-81

3.

Remove the "O-ring" from the contact surface.

Fig. 2-82

4.

Remove the snap ring from the shaft.

Fig. 2-83

5.

Remove the disk hub, end plate, 6 palates and 5 disks in that order.

Fig. 2-84

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270 6.

TRANSMISSION

Remove the 2 bolts securing the brake housing to the transmission case.

Fig. 2-85

7.

With a bar or others, rise the contact surface and remove the brake housing from the transmission case. Remove it along with the "O"-ring from the mating surface of the housing.

Fig. 2-86

8.

Put the brake assembly on a working bench. Loosen the 2 hex. bolts alternately little by little and remove the cap from piston housing. WARNING

Use caution when loosening the bolts since strong springs are incorporated inside the cover. Loosen the bolts in turns little by little until you come to feel no spring force.

Fig. 2-87

9.

Remove the 22 springs.

Note - In this state, pay attention to the marks on the piston and piston housing near the oil pressure piping port.

Fig. 2-88

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 57

2 - 58

TRANSMISSION

10. Remove the "O"-ring from the piston housing groove.

Fig. 2-89

11. Remove the piston from the piston housing using a soft hammer. 12. Remove the (large and small) "D"-rings from the outer diameter of the piston.

Fig. 2-90

m) Removing and disassembling rear case 1. Remove the snap ring from the case groove next to the brake shaft (1st/2nd speed shaft) bearing.

Fig. 2-91

2.

Loosen the 4 bolts securing the cover plate of the 3rd/4th speed shaft and remove the plate and "O"-ring.

Fig. 2-92

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270 3.

TRANSMISSION

Remove the snap ring from the case groove next to the 3rd/4th speed shaft bearing.

Fig. 2-93

4.

Remove the 4 bolts securing the flange and detach the flange, retainer plate and "O"-ring.

Fig. 2-94

5.

Remove the 2 bolts securing the seal retainer and detach the seal retainer. If it is too hard to remove, rise it using a bar.

6.

Remove the "O"-ring and oil seal from the seal retainer.

Fig. 2-95

7.

Remove the spacer from the output shaft.

Fig. 2-96

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 59

2 - 60 8.

TRANSMISSION

Remove the speed sensor.

Fig. 2-97

9.

Attach a hanger to the rear case and temporarily lift it with a hoist. Loosen the 33 bolts securing the case. If the case is floated, rise it gently using a punched bolt or soft hammer.

Fig. 2-98

10. Press the outer diameter of the roller bearing to remove them of the 1st/2nd speed, 3rd/4th speed and output shafts which remain in the rear case. Note - Use caution to prevent losing the lock ball between the 1st/2nd speed shaft bearing and case.

Fig. 2-99

n)

Removing and disassembling gear and shafts

1.

Remove the 2 bolts securing the oil baffle and detach the oil baffle.

Fig. 2-100

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270 2.

2 - 61

TRANSMISSION

Pull out the roller bearing inner race which remains in the output shaft using a bearing puller.

Fig. 2-101

3.

Remove the snap ring. Remove the output shaft gears (1) and (2) from the spline shaft.

1 2

Fig. 2-102

4.

Remove the high gear on the transmission case. Remove the bearing from the high gear using a puller.

Fig. 2-103

5.

Remove the low gear on the transmission case. Remove the bearing from the low gear using a puller.

Fig. 2-104

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 62 6.

TRANSMISSION

Put the transmission case upright. Remove the snap ring from the groove at the outer diameter of the idler shaft bearing.

Fig. 2-105

7.

Remove the idler shaft together with the gear and bearing by tapping the shaft with a copper hammer toward the opposite side.

Fig. 2-106

8.

Remove the snap ring from the idler shaft and detach the bearing and gear using a puller.

Fig. 2-107

9.

Remove the 2 bolts securing the seal retainer from the front side of the transmission case. Remove the seal retainer. Remove the oil seal and "O"-ring from the seal retainer.

Fig. 2-108

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270

TRANSMISSION

10. Remove the output shaft and bearing as one unit from the opposite side with a copper hammer.

Fig. 2-109

11. Remove the snap ring from the output shaft. Remove the bearing using a puller.

Fig. 2-110

12. Remove the snap ring from the 1st/2nd speed shaft hole in the transmission case. Press the outer diameter of the roller bearing outer race little by little to remove. Using the same manner, remove the bearing outer race from the 3rd/4th speed shaft hole. Note - Use caution to prevent losing the lock ball between the 1st/2nd speed shaft bearing and case.

Fig. 2-111

13. Remove the snap ring from the back gear shaft.

Fig. 2-112

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 63

2 - 64

TRANSMISSION

14. Remove the shaft by attaching the drawing stud to the tap hole (M10) on the back gear shaft. Use caution to prevent losing the lock ball.

Fig. 2-113

15. Remove the back gear and spacer.

Fig. 2-114

16. Remove the 2 bearings and snap ring from inside the back gear.

Fig. 2-115

o)

Removing control valve

1.

Attach a hanger (M10) to the valve (upper section) and lift it with a hoist temporarily.

2.

Remove the 11 bolts securing the valve (upper section). Remove the valve (upper section) tapping it with a soft hammer.

Note - Record the position of the one short bolt.

Fig. 2-116

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270 3.

TRANSMISSION

Using the same manner, remove the valve (lower section). The number of bolts is 3. Lower valve: Approx. 26 kg (57 lbs).

Fig. 2-117

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 65

2 - 66

TRANSMISSION

p)

Disassembling forward/reverse clutch shafft

1.

Put the shaft upright with the forward clutch pack (spline shaft side) upward, and secure it.

2.

Remove the snap ring from the groove in the shaft.

Fig. 2-118

3.

Using a chisel, move the gear outward a little so that the puller's claw catches the gear.

Fig. 2-119

4.

Using a puller, remove the hub gear.

Fig. 2-120

5.

Remove the 2 snap rings from inside the hub gear and pull out the bearing using a jig.

Fig. 2-121

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270 6.

TRANSMISSION

Press the belleville spring using a press and remove the snap ring from the groove in the clutch drum.

WARNING

Return springs are installed inside the clutch. Be sure to press the belleville spring using a press.

Fig. 2-122

7.

Loosen the press and remove the belleville spring, end plate, plate, return spring and disk in that order.

Fig. 2-123

8.

Using a puller, remove the bearing from the shaft.

Fig. 2-124

9.

Turn the clutch shaft upside down. Feed air through the forward clutch oil pressure hole to down the piston and remove it from the clutch drum.

Fig. 2-125

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 67

2 - 68

TRANSMISSION

10. Remove the seal ring from the piston. Remove the seal ring from the shaft groove next to the piston. Note - Do not remove the check ball of the piston as long as it is normal.

Fig. 2-126

11. Remove the snap ring from the bottom of the clutch drum and detach the spacer. Remove the "O"-ring from the spacer.

Fig. 2-127

12. Remove the 3 seal rings from the shaft end of the reverse clutch pack. 13. Remove the snap ring from the shaft. Using a puller, remove the bearing. Remove the remaining snap ring.

Fig. 2-128

14. Disassemble the clutch shaft in the same manner as for the forward clutch pack.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270

TRANSMISSION

q)

Disassembling 3rd/4th speed clutch shaft

1.

Put the shaft with the 3rd speed clutch (spline shaft side) upward and secure it.

2.

Remove the snap ring securing the roller bearing inner race. Using a puller, remove the inner race and the spacer.

Fig. 2-129

3.

For the disassembly procedure, refer to the step (4) to (10) of "(1) Disassembling forward/reverse clutch shaft".

4.

Disassemble the 4th speed clutch shaft on the other end in the same manner as for the 3rd speed clutch shaft.

r)

Disassembling 1st/2nd speed clutch shaft For the disassembly procedure, refer to "(2) Disassembling 3rd/4th speed clutch shaft".

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 69

2 - 70

W270

TRANSMISSION

s)

Disassembling control valve (upper section)

1.

Remove the 6 bolts securing the 6-bolt cover. Remove the cover. If the cover is hard to remove, tap it with a copper hammer. WARNING

Pay your utmost attention when loosening the screws, since springs are incorporated in the cover. Loosen the screws alternatively, a little bit at a time, until the pressure of the springs is no further felt. Remember that the two central springs are longer than the other ones. Fig. 2-130

2.

Remove the rod (1), inner spring (2), outer spring (3) and center spring (4) and load piston (5) from the outer spool bore. Remove the flow sensing spool (6) and spring (7) from the center spool bore. Remove the plug (8) and regulator spring (9).

7

6

9 8 5 4 2

3

1 Fig. 2-131

3.

Remove the 7 bolts securing the cover at the opposite side. Remove the cover. If the cover is hard to remove, tap it with a copper hammer.

WARNING

Use caution when loosening the bolts since strong springs are incorporated inside the cover. Loosen the bolts in turns little by little until you come to feel no spring force. Fig. 2-132

4.

Remove the rod (1), inner spring (2), outer spring (3), center spring (4) and load piston (5) from the outer spool bore. Remove the spring (6), inner spring (11), and modulation spool (7) from the center spool bore. Remove the regulator spool (8) and piston (10) from the remaining spool bore.

1

2

4

3

5

6 7

11

8 10

Fig. 2-133

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

TRANSMISSION

t)

Disassembling control valve (lower section)

1.

Remove the manual spool lock plate and lock bolt from the upper surface of the valve. Draw out the spool.

Fig. 2-134

2.

Remove the 5 socket bolts securing the solenoid valve adapters. Remove the adpters from the valve body, together with the solenoid valves. If the adapters are hard to remove, tap them with a soft hammer.

Fig. 2-135

3.

Remove the 4 solenoid valves with a special spanner.

Note - Special spanner size Width across flat: 34 mm (1.34 in) Thickness: 3 mm (0.12 in)

Fig. 2-136

4.

Remove the 8 bolts securing the cover. Remove the cover. If the cover is hard to remove, tap it with a soft hammer.

Fig. 2-137

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 71

2 - 72 5.

W270

TRANSMISSION

Remove the F/R select spool (1), adapter (2) and spring (3) from the spool bore. Remove the spool A (4) and select spring (5) from the center spool bore. Remove the spool B (6) and select spring (5) from the remaining spool bore.

4 6 5 3 2 1 2 3 Fig. 2-138

6.

There 8 throttle plugs: 4 in the adapter and 4 on the valve body surface which mates with the upper valve body. They can be removed using a plug wrench.

Note - The throttle plugs are select fit. If more than 2 throttle plugs are to be removed, put matchmarks to ensure correct reinstallation. Incorrectly installed throttle plugs might cause poor performance of the loader.

Fig. 2-139

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

TRANSMISSION

2.10 REASSEMBLY TRANSMISSION Cautions to be taken when reassembling • Clean all the disassembled parts in cleaning solvent, then dry with compressed air. In particular, remove LOCTITE and gaskets thoroughly from the mating surfaces of the case and others using a scraper. • Make sure the cleaned parts are free from dirt or foreign matter. Handle them carefully so as not to cause dent, score or scratches. • Replace all the seals with new ones.

a)

Reinstalling safety valve

1.

Insert the plunger and spring into the safety valve fitting hole.

Fig.2- 140

2.

Attach a new "O"-ring to the plug and screw plug into the case.

Fig. 2-141

b)

Reinstalling pump drive gear

1.

Fit the bearing support into the bearing.

Fig. 2-142

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 73

2 - 74

TRANSMISSION

2.

Fit the bearing (with bearing support) into the gear, and attach the snap ring to secure it.

3.

Using the same manner, install the other 2 pump drive gears.

Fig. 2-143

4.

Insert the 3 assembled gears into the support holes in the housing. Tighten mounting bolts.

Note - Gear fitting position Center : 83T gear Left and right: 80T gear

Fig. 2-144

c)

Reassembling converter wheel

1.

Press the bearing into the pump drive gear with the ball grove pointed inside.

Fig. 2-145

2.

Install the impeller hub into the impeller wheel with a soft hammer.

Fig. 2-146

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270 3.

TRANSMISSION

Install the impeller wheel, impeller wheel plate and pump drive gear with 8 bolts.

Fig. 2-147

4.

Apply converter oil on the seal ring, and install it on the sartor support.

Fig. 2-148

5.

Press the assembled impeller wheel into the stator support using a press.

Fig. 2-149

6.

Fit the bearing into the turbine shaft and install the spacer and snap ring. Apply converter oil on seal ring and install it.

Fig. 2-150

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 75

2 - 76 7.

TRANSMISSION

Put the turbine shaft upright. Install the impeller wheel assembly into the turbine shaft.

Fig. 2-151

8.

Install the stator wheel into the spline and secure it with a snap ring.

Fig. 2-152

9.

Install the turbine wheel into the spline and spacer. Fit the snap ring to the tubine shaft groove.

Fig. 2-153

10. Press the bearing into the cover wheel and install the input guide to it with 6 bolts.

Fig. 2-154

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270

TRANSMISSION

11. Lift the cover wheel with a hoist and put it onto the wheel assembly to align bolt holes.

Fig. 2-155

12. Secure the impeller wheel and cover wheel with 24 bolts.

Fig. 2-156

d)

Reionstalling converter wheel

1.

Lift the input control with a hoist and press the stator support bearing into the converter housing mounting hole using a soft mallet.

Fig. 2-157

2.

Tighten 9 bolts from the opposite side of the converter housing.

Fig. 2-158

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 77

2 - 78

W270

TRANSMISSION

e)

Reassembling forward/reverse clutch shaft

1.

Install a greased "O"-ring on the piston spacer outer groove.

Fig. 2-159

2.

Install a greased outer seal ring on the clutch piston. Note - As shown in the sketch on the right, make sure the seal ring's lip pointed upward.

Fig. 2-160

3. 4. 5.

Put the shaft upright with its forward clutch (spline shaft side) pointed upward and secure it. Press the spacer onto the bottom of the clutch drum and secure it with a snap ring. Install a greased piston inner seal ring onto the clutch shaft. Insert the clutch piston into the drum.

Fig. 2-161

6.

Install the neccesary number of plates, return springs, and disks into the drum in that order. At this step, it is advisable to use rod jigs (A) for aligning theplate splines.

A A

Fig. 2-162

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

TRANSMISSION

7.

Finally put the end plate and belleville spring, and press it to compress the return spring until the snap ring groove inside the drum comes into view. Note - Put the belleville spring with its concave side pointed upward.

Fig. 2-163

8.

Remove all the rod jigs and attach the snap ring into the groove in the drum.

Fig. 2-164

9.

Fit the hub gear ball bearing (inner) onto the clutch shaft. Note - Remember that the inner bearing does not have a shield.

Fig. 2-165

10. Make sure the 2 snap rings are installed inside the hub gear. 11. Install the hub gear inside the clutch drum, turning it to the right and left by hand to align the gear teeth with the disk splines. Fit the hub gear onto the shaft with a soft hammer until it comes in contact with the bearing on the shaft.

Fig. 2-166

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 79

2 - 80

TRANSMISSION

12. Install the shield bearing into the hub gear with th the shield side pointed outside. Install the snap ring into the shaft groove.

Fig. 2-167

13. Reassemble the reverse clutch shaft, using the same procedure for the forward clutch shaft. (Refer to step 1 to 12.) 14. Install the snap ring onto the clutch shaft. Install the bearing onto the shaft with its snap ring groove on its outer diameter pointing upward. Install the snap ring onto the shaft.

Fig. 2-168

15. Install the 3 seal rings onto the clutch shaft.

Fig. 2-169

f) 1.

Reassembling 3rd/4th speed clutch shaft Using the same procedure for the forward clutch pack reassemble the 3rd speed clutch pack (spline shaft side) till the hub gear shield bearing. Refer to (1) Reassembling forward/reverse clutch shaft, step (2) to (12). Remember that a spacer is not used between the drum and piston. A belleville spring is not used either.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270 2. 3.

TRANSMISSION

Install the spacer onto the shaft's hub gear shield bearing. Install the spacer onto the shaft's hub gear shield bearing.

Fig. 2-170

4.

5.

g)

Turn the clutch shaft upside down. Reassemble the 4th speed clutch pack, using the same procedure. Finally install the 3 seal rings onto the clutch shaft.

Reassembling 1st/2nd speed clutch shaft For the reassembly of the 1st/2nd speed clutch shaft, refer to (2) Reassembling 3rd/4th speed clutch shaft.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 81

2 - 82 g)

W270

TRANSMISSION

Reassembling control valve (lower section)

Caution to be taken when reassemblig • Clean all the disassembled perts in cleaning solvent and dry with compressed air. Do not use a shop rag or paper for cleaning purposes; otherwise dirt or might enter the hydraulic circuit, thus causing the malfunction of the system. • Check the oil passage and orifice of each spool for clogging. If any spool is found to be clogged in its oil passage or orifice, remove the clog an clean the spool. • When reinstalling plugs without "O"-ring, apply LOCTITE#572 on their threaded area. • Do not use sealing tape because it might cause clogging.

1.

Apply LOCTITE#572 on the threaded area of each of the 8 throttle plugs: 4 on the side surface and 4 on the top surface. Install the throttle plugs into the valve body. Use caution not to have the wrong positions.

Fig. 2-171

2.

Install the spring (3), adapter (2) and F/R select spool (1) into the 8-bolt hole side. Install the select spring (5) and spool A (4) into central spool bore. Install the select spring (5) and spool B (6) into remaining spool bore.

4 6 5 3 2 1 2 3 Fig. 2-172

3.

Bond a gasket to the cover and install the cover to the valve body using 8 bolts. Tighten the 8 bolts in turns little by little, to compress the springs inside the cover properly.

Fig. 2-173

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270 4.

2 - 83

TRANSMISSION

Using the same spanner which was used during disassembly, install the 4 solenoid valves onto the adapter.

Fig. 2-174

5.

Bond gasket to the adapter. Install the adapter to the valve body with 5 socket bolts.

Fig. 2-175

6.

Insert the manual spool into the adapter and secure it with the lock plate and lock bolt.

Fig. 2-176

i)

Reassembling valve (upper section)

1.

Install the load piston (5), center spring (4), inner spring (2), outer spring (3) and rod (1) into the 7bolt hole side. Install the spring (6), inner spring (11) and modulate spool (7) into the central spool bore. Install the regulator spool (8) and piston (10) into the remaining spool bore.

1

2

4

3

5

6 7

11

8 10

Fig. 2-177

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 84 2.

W270

TRANSMISSION

Bond a gasket to the cover and install the cover to thevalve body with 7 bolts. Tighten the 7 bolts in turns little by little, to compress the spring inside the cover properly.

Fig. 2-178

3.

Install the load piston (5), center spring (4), inner spring (2) outer spring (3) and rod (1) into the 6bolt hole side. Install the flow sensing spool (6) and spring (7) into central spool bore. Install the regulator spring (9) into the plug hole and tighten the plug (8).

7

6

9 8 5 3 4 2 1 Fig. 2-179

4.

Bond a gasket to the cover and install the cover to the valve body with 6 bolts. Tighte the 6 bolts in turns little by little, to compress the spring inside the cover properly. Note that the two center bolts are longer than the others.

Fig. 2-180

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

TRANSMISSION

l)

Reinstalling clutch shaft

1.

Put the transmission case with its converter mounting surface pointed upward. Install the snap rings onto the 1st/2nd and 3rd/4th speed shaft mounting holes. Install the roller bearing outer race against the snap ring.

2.

Fig. 2-181

3.

Install the snap ring into the back gear fit the ball bearings from both sides.

Fig. 2-182

4.

Set greased lock ball into the hole in the largerdiameter end of the back gear shaft. Use caution not to drop the ball.

Fig. 2-183

5.

Attach the spacer in the transmission case in the area on which the back gear shaft front end rests.

Fig. 2-184

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 85

2 - 86 6.

TRANSMISSION

Put the back gear position in the case. Fit the shaft aligning with the lock ball position. After installing the shaft, attach the snap ring in the groove in the case to secure the shaft.

Fig. 2-185

7.

Lift the forward/reverse shaft with a hoist. Install the shaft bearing into the hole in the case, engaging reverse hub gear with the back gear.

Fig. 2-186

8.

Install the 3rd/4th and 1st/2nd speed shafts onto the roller bearing outer race attached into the hole in the case.

Fig. 2-187

m) Reinstalling gear and shafts 1.

Install the snap ring, 38D gear and another snap ring into the 3 snap ring grooves in the idler shaft. Install the roller bearing to the step of the shaft and secure it with a snap ring.

Fig. 2-188

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270 2.

TRANSMISSION

Install the snap ring and 61T gear onto the opposite end of the shaft. Press the roller bearing and secure it with a snap ring.

Fig. 2-189

3.

Put the reassembles idler shaft with the 38T gear pointed downward. Install it onto the transmission case engaging with the hub gear on the 1st/ 3rd speed shaft and back gear.

Fig. 2-190

4.

Press the shaft barring into the hole in the case, engaging the 51T gear with the hub gear on the 2nd/ath speed shaft and forward hub gear.

Fig. 2-191

5.

Press the ball bearing into the output shaft and secure it with a snap ring.

Fig. 2-192

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 87

2 - 88 6.

TRANSMISSION

Press the output shaft into the snap ring installed in the transmission case with a copper hammer.

Fig. 2-193

7.

Press the oil seal into the seal retainer and install the "O"-ring into it.

Note - Apply LOCTITE#262 on the outer diameter of the oil seal . Apply grease on the oil seal lips.

Fig. 2-194

8.

Install the seal retainer onto the transmission case and secure with 2 bolts.

Fig. 2-195

9.

Put the transmission case upright. Install the snap ring into the groove at the outer diameter of the forward/reverse shaft bearing.

Fig. 2-196

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270

TRANSMISSION

10. Install the snap ring into the groove at the outer diameter of the bearing on the idler shaft.

Fig. 2-197

11. Install the locks onto the 1st/2nd a 3rd/4th speed shaft not to drop them.

Fig. 2-198

12. Put the transmission case with its converter side pointed downward. 13. Install the snap ring onto the output shaft. Install the 34T gear into the spline.

Fig. 2-199

14. Press the roller bearing into the high gear and secure it with a snap ring. 15. Install the assembled high gear into the spline on the 3rd/4th speed shaft, engaging it with the output gear.

Fig. 2-200

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 89

2 - 90

TRANSMISSION

16. Install the 66T gear into the output shaft. Install the snap ring.

Fig. 2-201

17. Press the roller bearing inner race onto the low gear. Install it into the 1st/2nd speed shaft engaging with the output gear.

Fig. 2-202

18. Install the oil baffle and two two tubes on the transmission case and tighten the two mounting bolts.

Fig. 2-203

n)

Reinstalling rear case

1.

Apply LOCTITE FMD-127 linearly on the transmission case in its torque converter mounting surface without a break. Avoid the bolt holes.

Fig. 2-204

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270 2.

TRANSMISSION

Lift the rear case with a hoist and mount it on the transmission case using a soft hammer with the 33 bolts aligning the bearing holes and bolt mounting holes.

Fig. 2-205

3.

Install the roller bearing onto the output shaft using a driving jig.

Fig. 2-206

4.

Apply LOCTITE#572 on the threaded area of the speed sensor. Threaded it into the rear case. Apply the front end of the sensor to the output gear. Back off one and a half of a turn secure with the nut.

Fig. 2-207

5.

Install the spacer into the output shaft.

Fig. 2-208

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 91

2 - 92 6.

TRANSMISSION

Press the oil seal into the seal reatiner and install the "O"-ring.

Note - Apply LOCTITE#262 on the outer diameter of the oil seal . Apply grease on the lips.

Fig. 2-209

7.

Install the seal retainer onto the output shaft and tighten 2 mounting bolts.

Fig. 2-210

8.

Install the flange into the output shaft. Put the "O"-ring in the groove. Put the retainer plate on it and apply LOCTITE#262 on four mounting bolts to tighten them.

Fig. 2-211

9.

Install the snap ring into the groove of the case at the outer diameter of the 3rd/4th speed shaft high gear bearing.

Fig. 2-212

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270

TRANSMISSION

10. Install the "O"-ring onto the cover plate. Install them into the case and tighten the four mounting bolts.

Fig. 2-213

11. Press the roller bearing outer race into the 1st/2nd speed shaft low gear. At this step, install the spacer for the bearing shaft into it. Note - Remember the lock ball between the outer race and case.

Fig. 2-214

12. Install the snap ring into the groove of the case at the outer diameter of the bearing.

Fig. 2-215

o)

Reassembling and reinstalling parking brake

1.

Install the 2 "O"-rings into the groove at the (large and small) outer diameter of brake piston. Install the piston into the piston housing aligning marks. Install the "O"-ring into the groove in the piston housing.

2.

Fig. 2-216

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 93

2 - 94 3.

TRANSMISSION

Put 22 springs into the drill holes in the brake piston.

Fig. 2-217

4. 5.

Put the cap so as to properly house the springs in the holes on the cap side. Tighten 2 hex. bolts alternately to properly compress the spring inside.

Fig. 2-218

6.

Install the brake disk hub onto the low gear splines of the 1st/2nd speed shaft and secure with the snap ring.

Fig. 2-219

7.

Install the 2 "O"-rings in the brake housing. Install it to the case with 2 soket bolts.

Fig. 2-220

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270 8.

TRANSMISSION

Install the plates and disks alternately onto the brake housing, and finally install end plate.

Fig. 2-221

9.

Install the brake assembly (reassembled at the step 5) and tighten 6 socket bolts.

Fig. 2-222

10. Put the transmission upright. Apply converter oil on the seal rings on the fwd/rev shaft.

Fig. 2-223

11. Put the distribuidor cap for the forward/reverse clutch shaft using a gasket and yighten the 6 mounting bolts.

Fig. 2-224

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 95

2 - 96

TRANSMISSION

p)

Reinstalling torque converter

1.

Put the transmission with its torque converter mounting surface pointed upward. Put the oil stainer and install the "O"-ring into the groove at the outer diameter.

2.

Fig. 2-225

3.

Install the flange on the converter side into the spline of the output shaft.

Fig. 2-226

4. 5.

Remove the locks from the 1st/2nd and 3rd/4th speed shafts. Apply LOCTITE FMD-127 linearly on the transmission case in its torque converter mounting surface without a break. Avoid the bolt holes.

Fig. 2-227

6.

lift the converter housing with a hoist and mount it on the transmission case aligning the bearing holes, shafts, knock pins and bolt holes. Tighten the 30 mounting bolts after aligning the mounting surface.

Note - Check the mating surface of the converter housing and transmission case for foreign matter and "O"-ring for damage.

Fig. 2-228

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270

2 - 97

TRANSMISSION

q)

Reassembling cap assembly

1.

Install the spring (3) and spool (2) from the top of the cap (the 1st/2nd distributor cap) and tighten the hex. plug (with a "O"-ring) (1).

1

2 3

Fig. 2-229

2.

Install the check ball (4), spring (3) and adapter (2) from the side and tighten with the plug(with a "O"-ring)(1).

4 3

2 1 Fig. 2-230

r)

Reassembling and reinstalling distributor cap

1.

Install the snap ring into the groove at the outer diameter of both the 1st/2nd and 3rd/4th speed shaft bearings.

Fig. 2-231

2. 3.

Install the spacer onto both the 1st/2nd and 3rd/4th speed shafts. Apply converter oil on the seal ring of the 1st/2nd and 3rd/4th speed shafts.

Fig. 2-232

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 98 4.

TRANSMISSION

Install the "O"-ring onto the 3rd/4th speed distributor cap. Make sure the 2 "O"-rings on the oil port of the seating surface and install the cap onto the converter housing. Tighten 5 Mounting bolts.

Fig. 2-233

5.

Install the cap assembly (the 1st/2nd speed distributor cap) in the same manner.

Fig. 2-234

6.

Install a hose between the 3rd/4th speed distributer cap and 1st/2nd speed distributer cap and secure them with a clip.

Fig. 2-235

s)

Reinstalling charging pump

1.

Install the suction tube flange using a gasket. Tighten the 4 mounting bolts.

Fig. 2-236

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270 2. 3.

TRANSMISSION

Put the tranmission assembly upright. Install the drive sleeve into the pump drive gear and install the charging pump onto the converter housing. Tighten the 2 bolts securing the pump.

Fig. 2-237

4.

Install the cap assembly (the 1st/2nd speed distributor cap) in the same manner.

Fig. 2-238

t)

Reinstalling control valve

1.

With a new gasket, install the control valve (lower section) onto the transmission case with 3 bolts.

Fig. 2-239

2.

With a new gasket, install the control valve (upper section) onto the control valve (lower section) with 11 bolts.

Fig. 2-240

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 99

2 - 100

TRANSMISSION

W270

2.11 TROUBLESHOOTING GUIDE 2.11.1 Torque converter Problem

Cause

Inspection

Corrective Action

Low oil level

Check oil level with oil level gauge

Add oil to the specified level

Improper oil used

Check oil type

Change for the specified oil

Malfunction of cooler line

Check cooling water for dirt

Clean

Measure oil pressure at inlet port of torque converter

Disassemble and replace parts

Check breather for oil flash

Disassemble and replace parts

Measure oil pressure at inlet port of torque converter

Disassemble and replace parts

Observe foreign material in transmission drain

Disassemble and replace parts

Check line filter and oil

Disassemble and replace parts

Check transmission strainer for clogging

Clean

Measure oil pressure at inlet port of torque converter

Replace pump

Measure oil pressure of transmission clutch

Replace pump

Check operating conditions and operation

Use properly

Defective oil seal ring

Malfunction of safety valve Overheat or lower horsepower Broken bearing

Low discharge from charging pump

Excessive use Transmission failure

Oil leak (from flywheel)

Defective oil baffle oil seal

Check for oil leak to flywheel

Replace parts

Defective O-ring of oil baffle

Check for oil leak to flywheel

Replace parts

Observe foreign material in transmission drain

Disassemble and replace

Check line filter and oil

Disassemble and replace parts

Broken gear or improper backlash

Check with sound checker

Disassemble and replace parts

Broken pump or drive unit

Check with sound checker

Replace pump

Check oil for air mixed

Retighten piping or replace parts

Check oil type

Change for the specified oil

Broken bearing

Unusual noises

Refer to "2.10.2 TRANSMISSION"

Air in oil Improper oil used

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

TRANSMISSION

2 - 101

2.11.2 TRANSMISSION Problem

Cause Torque converter overheat

Inspection

Corrective Action

Refer "TORQUE CONVERTER"

Low oil level

Check oil level with oil level gauge

Add oil to the specified level

Improper oil used

Check oil type

Change for the specified oil

Slipping or seizing of clutch

Measure oil pressure of transmission clutch

Disassemble replace parts

Low clutch lubrificant

Measure oil pressure at outlet port of torque converter

Clean oil cooler

Overheat or lower horsepower

Broken bearing

Observe foreign material in transmission drain Check line filter and oil

Low engine output and speed

Check stolen speed

Disassemble replace parts

and

and

Adjust engine

Check with sound checker Broken bearing or improper assembling

Observe foreign material in transmission drain

Disassemble replace parts

and

Disassemble replace parts

and

Measure oil pressure of transmission clutch

Disassemble replace parts

and

Check oil level with oil level gauge

Add oil to the specified level

Measure oil pressure of transmission clutch (lowered in all ranges)

Replace charging pump

Regulator valve stayed open

Measure oil pressure of transmission clutch (lowered in all ranges)

Disassemble replace parts

Broken bolts securing torque converter input plate

Check the operation of load handling system

Replace parts

Check line filter and oil Check with sound checker

Unusual noises Broken gear or excessive backlash

Observe foreign material in transmission drain Check line filter and oil

Seizing clutch Low oil level Machine won't travel forward/ reverse

Machine won't travel forward/ reverse

Malfunction of changing pump

Parking brake won't release (stuck or dragged)

Refer to "2.11.3 PARKING BRAKE"

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

and

2 - 102

TRANSMISSION

Problem

Machine won't travel forward (can travel reverse)

Machine won't travel reverse (can travel forward)

W270

Cause

Inspection

Corrective Action

Manual spool (emergency travel spool) is pressed in the position for reverse travel

Check manual spool position at the control valve

Raise the spool to locate it in the normal condition

Slipping forward clutch (F solenoid valve is not operated

Measure oil pressure of forward clutch

Disassemble replace parts

and

Seizing reverse clutch

Check if machine travels reverse with clutch in neutral

Disassemble replace parts

and

Manual spool (emergency travel spool) is pulled in the position for forward travel)

Check manual spool position at the control valve

Lower the spool to locate it in the normal condition

Slipping reverse clutch (R solenoid valve is not operated)

Measure manual spool position at the control valve

Disassemble replace parts

and

Check if machine travels forward with clutch in neutral

Disassemble replace parts

and

Seizing forward clutch

Machine won't travel in 2nd gear

Slipping 2nd clutch (A and B solenoid valves are not operated)

Measure oil pressure of 2nd clutch

Disassemble replace part

and

Machine won't travel in 1st gear

Slipping 1st clutch (A solenoid valve is not operated)

Measure oil pressure of 1st clucth

Disassemble replace parts

and

Machine won't travel in 4th gear

Slipping 4th clutch (B solenoid valve is not operated)

Measure oil pressure of 4th clutch

Disassemble replace parts

and

2.11.3 Parking brake Problem

Parking brake won't release (stuck or dragged)

Parking brake won't activate

Cause

Inspection

Corrective Action

Oil leak from parking brake piston (defective D-ring)

Measure braking oil pressure (Check for oil leakage)

Malfunction of disk brake (Piston has foreign matter caught or stuck, or brake disk is seized)

Overhaul

Wash and replace parts

Slackened or broken brake spring of disk brake

Overhaul

Wash and replace parts

Malfunction of disk brake (Piston has foreign matter caught or stuck, or brake disk is worn)

Overhaul

Wash and replace parts

Disassemble replace parts

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

and

W270

TRANSMISSION

2 - 103

2.12 STANDARD VALUES FOR MAINTENANCE 2.12.1 Torque converter Item Pump drive gear backlash Turbine shaft seal ring

Width (axial) Thickness (radial)

Width o seal ing groove in turbine shaft I.D. of stator holder in turbine shaft seal ring sliding area Stator holder seal ring

Width (axial) Thickness (radial)

Width of seal ring roove in stator holder I.D. of Pump drive gear in stator holder seal ring sliding area

Standard value

Useful limit

0.13 - 0.23 (0.0051 - 0.0091)

-

3.0 - 3.1 (0.118 - 0.122)

2.6 (0.102)

2.9 (0.114)

2.76 (0.109)

3.2 - 3.3 (0.126 - 0.130)

3.5 (0.138)

50 (1.969)

50.05 (1.970)

2.99 - 3.09 (0.118 - 0.122)

2.6 (0.102)

3.3 (0.130)

3.14 (0.124)

3.2 - 3.3 (0.126 - 0.130)

3.5 (0.138)

84 (3.307)

84.05 (3.309)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Unit: mm (in) Remarks

2 - 104

TRANSMISSION

W270

2.12.2 Control valve

Unit: mm (in) Item

Regulator spring

Modulation spring

Flow sensing spring

Load piston L spring

Load piston H spring

F/R select spool spring

Spool a spring Spool B spring

Throttle diameter

Standard value

Free heiht 97.9 (3.85) Setting load kg (lbs) 31.62 (69.71) Setting height 82.4 (3.24) Free height 53.1 (2.09) Inner Setting load kg (lbs) 3.61 (7.96) Setting height 34.5 (1.36) Free height 53.1 (2.09) Outer Setting load kg (lbs) 7.27 (16.0) Setting height 34.5 (1.36) Free heigh 65.4 (2.57) Setting load kg (lbs) 0.90 (2.0) Setting height 57.5 (2.26) Free height 116 (4.57) Inner Setting load kg (lbs) 10.58 (23.32) Setting height 90 (3.54) Free height 116 (4.57) Center Setting load kg (lbs) 27.38 (60.36) Setting height 90 (3.54) Free height 91 (3.58) Outer Setting load kg (lbs) 32.76 (72.22) Setting height 65 (2.56) Free height 109.9 (4.327) Inner Setting load kg (lbs) 15.69 (34.59) Setting height 85 (3.35) Free height 109.9 (4.327) Center Setting load kg (lbs) 23.23 (51.21) Setting height 85 (3.35) Free height 84.9 (3.34) Outer Setting load kg (lbs) 28.16 (62.08) Setting height 60 (2.36) Free height 39 (1.54) Setting load kg (lbs) 8.47 (18.7) Setting height 26.5 (1.04) Free height 43 (1.69) Setting load kg (lbs) 6.84 (15.1) Setting height 32.5 (1.28) main (W) 6.0 (0.236) 0.9 (0.035) 1st/2nd speed (X) 2nd speed (Y) 0.9 (0.035) 3rd/4th sped (Z) 1.5 (0.059) solenoid valve

0.8 (0.031)

Useful limit 94.0 (3.70) 28.5 (62.83) 50.1 (1.97) 3.3 (7.28) 51.0 (2.01) 6.5 (14.3) 62.8 (2.47) 0.8 (1.8) 111.4 (4.386) 9.5 (20.9) 111.4 (4.386) 24.6 (54.2) 87.4 (3.44) 29.5 (65.0) 105.5 (4.154) 14.1 (31.1) 105.5 (4.154) 20.9 (46.1) 81.5 (3.21) 25.3 (55.8) 37.4 (1.47) 7.6 (16.8) 41.3 (1.63) 6.2 (13.7) -

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Remarks

W270

TRANSMISSION

2 - 105

2.12.3 Transmission

Unit: mm (in) Item

Standard value

Useful limit

I.D. of distributor cap in clutch shaft seal ring sliding area (fwd/rev, 1st/2nd, 3rd/4th)

55.00 - 55.02 (2.165 - 2.166)

55.07 (2.168)

Width (axial)

1.95 - 2.05 (0.0768 - 0.0807)

1.7 (0.067)

Thickness (radial)

1.95 - 2.05 (0.0768 - 0.0807)

1.9 (0.075)

Width of seal ring groove in clutch shaft

2.10 - 2.15 (0.0827 - 0.0846)

2.3 (0.091)

Clutch plate thickness

1.65 - 1.75 (0.0650 - 0.0689)

1.5 (0.059)

Clutch disk thickness

2.12 - 2.28 (0.0835 - 0.0898)

1.9 (0.075)

4.105 - 4.355 (0.1616 - 0.1715)

3.94 (0.155)

Clutch shaft seal ring

Return spring

Free height

Compression load 92.2 - 112.8 when height is (203.3 - 248.7) 2.20 mm (0.0866 in) kg (lbs)

83.0 (183.0)

89.9 - 90.0 (3.539 - 3.543)

89.863 (3.5379)

O.D. of companion flange in oil seal sliding area

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Remarks

2 - 106

TRANSMISSION

W270

2.12.4 Accumulator

Unit: mm (in) Item

Standard value 24.967 - 24.980 (0.9830 - 0.9835)

O.D. of accumulator spool I.D. of distributor cap in accumulator spool sliding area Accumulator spring

Free hight Setting load kg (lbs) Setting height

Orifice diameter

25.000 - 25.021 (0.9843 - 0.9851)

Useful limit

Remarks

Clearance 0.064 (0.0025)

56.3 (2.22)

54.0 (2.13)

2.142 (4.722)

-

55.3 (2.18)

-

1.0 (0.039)

-

Note: The accumulator is incorporated in the distributor cap of the 1st/2nd speed shaft.

2.12.5 Parking brake

Unit: mm (in) Item

Standard value

Useful limit

Brake plate thickness

1.65 - 1.75 (0.0650 - 0.0689)

1.53 (0.0602)

Brake disk thickness

2.12 - 2.28 (0.0835 - 0.0898)

1.98 (0.0780)

Free hight

77 (3.03)

75.6 (2.98)

Setting load kg (lbs)

53.5 (118)

48.2 (106)

Setting height

62.9 (2.48)

-

Brake spring

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Remarks

W270

TRANSMISSION

2 - 107

2.13 Tightening torques of main fixture 2.13.1 Torque converter Item

Tightening torque kg-m (ft-lbs)

Pump drive gear fiting bolt

20.9 (151)

Stator holder fitting bolt

10.6 (76.7)

Bolt securing impeller wheel to cover wheel

4.01 - 4.58 (29.0 - 33.1)

Bolt securing pump drive gear to impeller hub

5.21 - 5.95 (37.7 - 43.0)

Input guide fitting bolt

4.01 - 4.58 (29.0 - 33.1)

Charging pump fitting bolt

Remarks Apply LOCTITE#262

3.49 (25.2)

2.13.2 Transmission Item

Tightening torque kg-m (ft-lbs)

Distributor cap fitting bolt

3.49 (25.2)

Output shaft bearing cap fitting bolt

23.7 (171)

Output shaft companion flange retainer plate fitting bolt

9.0 (65)

Brake housing fitting socket bolt

5.31 (38.4)

Parking brake assembly hex. Bolt

9.30 (67.3)

Parking brake fiting socket bolt

9.30 (67.3)

Converter housing fitting bolt

3.49 (25.2)

Control valve fitting bolt

5.31 (38.4)

Remarks

Apply LOCTITE#262

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

TRANSMISSION

2 - 108

W270

2.14 PROP SHAFTS The prop-shafts transfer the power of the transmission to the front and rear axles. The prop-shaft connected to the front axle is equipped with an intermediate support, secured to the front frame, as a stopping element, since the loader is articulated. The prop-shafts have the purpose of compensating the changes of the distance and angle between the transmission output shafts and input shafts of each axle, thus ensuring a smooth transfer of power from the transmission to the axles.

Type ...................................................... universal Length (between pins): Front .....................................................796 mm Intermediate ..........................................784 mm Rear ................................................... 226,6 mm

5

4

2

Fig. 2-241

Nota -

1

7

1

2

2

2

6

Prop-shafts group

14.6 daNm (106 ft-lbs)

2

FRONT PROP SHAFT INTERMEDIATE PROP SHAFT REAR PROP SHAFT FRONT AXLE

8.8 ÷ 10.2 daNm

Threaded part: LOCTITE 262

Threaded part: LOCTITE 262

1. 2. 3. 4.

3

1

5. 6. 7.

TRANSMISSION REAR AXLE RIGID SUPPORT

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

TRANSMISSION

4

3

2 - 109

1

1

2

3

7

5

8

4

2

2

2 1. 2. 3. 4. 5. 6. 7. 8.

SHAFT BEARING SUPPORT BEARING SPIDER FLANGE GREASE FITTING WASHER NUT

Fig. 2-242

6

Front prop-shaft

4 3

3

5

6

3

1 5

1. 2. 3. 4. 5. 6.

SPIDER SPIDER SHAFT SCREW 3/8" - 24 SPIDER GREASE FITTING SHAFT GREASE FITTING

Fig. 2-243

1

Intermediate prop-shaft

1 2

2

2 4

3 4 1. 2. 3. 4.

SHAFT SCREW 1/22 - 20UNF SPIDER GREASE FITTING

Fig. 2-244 Note -

2

Rear prop-shaft

1

15.5 ÷ 18.5 daNm

3

Lubricate the spider with litium base EP grease NIG L 2

2

15 ÷ 16 daNm

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

TRANSMISSION

2 - 110

W270

2.15 FRONT AND REAR AXLES Drive:

4 wheel

Front axle:

Fixed to the frame Semi floating type

Rear axle:

Pivot pin Semi floating type

Reduction unit and differential Model: Type:

TCM 678-30 Current, 2 stage reduction

Differential housing:

Single piece

Differential limiting device:

Torque proportioning differential

Final reduction: Model: Type:

TCM 678-30 Planetary

Weight: Front: Rear:

1216 Kg (2680 lbs) 1184 Kg (2609 lbs)

2.15.1 AXLE

Axle mounting

The axle is composed of a differential, final reduction units, oil-bath disc brakes and axle shafts connected to the wheels. The power output from the transmission is driven by the prop shafts to the front and rear axles. Thus, the power is driven to the differential that splits it to the axle right and left shafts driving the final drives, reaching the wheels. The oil bath disc brake is mounted in front of the final drive and operates as service brake. As for the operation of the service brakes, please refer to section "3 - BRAKES SYSTEM".

The front axle is mounted directly on the front axle by screws. The rear axle is mounted with a pivot pin, using supports on both sides of the axle, secured by screws to the rear frame. Consequently, the rear axle can pivot around the axle of the differential with an amplitude depending upon the ground conditions travelled by the loader. The drive axle mounted with a pivoting pin improves the driving conditions of the loader when travelling on rough terrain, since the loader jumps at a lesser extent than a loader with axle supported by a traditional oscillating cradle system.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

TRANSMISSION

2 - 111

2

1

1

2

3

4

5

6

Fig. 2-245

Note -

1. 2. 3.

1

Mounting of axles

1

78.8 daNm

2

161 daNm

FRONT PIVOTING SUPPORT REAR PIVOTING SUPPORT TYRE

4. 5. 6.

RIM FRONT AXLE REAR AXLE

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

TRANSMISSION

2 - 112

1

8

Fig. 2-246

Note -

1

4

1

3

3

5

3

4

6

9

2

10

Assembly of rear axle and pivoting supports

Threaded parts: LOCTITE 262

22.7 daNm (164 ft-lbs) Install with the groove toward plate (6)

3

Install with lip outwards

5

4

5

2

4

1. 2. 3. 4. 5.

2

3

W270

Grease the inner surface of the bushes. Install the bevel towards the axle. Align the greasing holes with the grooves. Grease until it flows out the opposite side.

DUST SEAL FRONT PIVOTING SUPPORT REAR AXLE DUST SEAL REAR PIVOTING SUPPORT

6. 7. 8. 9. 10.

THRUST PLATE COVER BUSHING BUSHING SPACER DISCS

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

7

1

W270

TRANSMISSION

4

1

2

3

4

6

2 - 113

5

8

7 1

9

A

3

3

11

Note -

12

3

13

5

A

5

Brake piping connection ports, 2 points

Fig. 2-247

1. 2. 3. 4. 5.

10

3

14

2

Front axle

1

23 daNm (170 ft-lbs)

Threaded part: LOCTITE 262

2

23 daNm (170 ft-lbs)

Threaded part: LOCTITE 262

3

Threaded part: LOCTITE 572

4

Lip: Grease

5

Mating surfaces: LOCTITE FMD-127

OIL SEAL AXLE SHAFT FINAL DRIVE DIFFERENTIAL HOUSING DIFFERENTIAL

6. 7. 8. 9. 10.

CROWN GEAR HUB PIN DOWEL AXLE SHAFT HOUSING DIPSTICK

11. 12. 13. 14.

BLEEDING SCREW BLEEDING SCREW COVER DRAINING PLUG

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

TRANSMISSION

2 - 114

4

1

2

3

4

6

Fig. 2-248

Note:

1. 2. 3. 4. 5.

5

8

1

7

9

3

A Brakes piping connection parts, 2 points

W270

3

10

11

13

3

3

12

14

5

A

3

15

5 2

Rear axle

1

23 daNm (170 ft-lbs)

Threaded part: LOCTITE 262

2

23 daNm (170 ft-lbs)

Threaded part: LOCTITE 262

3

Threaded part: LOCTITE 572

4

Lip: Grease

5

Mating surfaces: LOCTITE FMD-127

OIL SEAL AXLE SHAFT FINAL DRIVE HOUSING DIFFERENTIAL

6. 7. 8. 9. 10.

PIN CROWN WHEEL DOWEL AXLE HOUSING BLEEDING SCREW

11. 12. 13. 14. 15.

BLEEDING SCREW COVER PLUG (LEVEL CHECK) DRAINING PLUG DIPSTICK

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

TRANSMISSION

2 - 115

2.15.2 DIFFERENTIAL

Operation of the differential

The differential forms a single body with the reduction unit. The power is driven from the prop shafts to the differential gear housing through the pinion/bevel gear group. Thus, it is driven through the right and left gears, to the final drives. The reduction of r.p.m. is obtained by the pinion/bevel gear ratio.

When the loader is moving straight, the bevel ring gear, the differential gear cage and the differential side gears rotating together; the idle pinions inside the gear cage do not rotate. Thus the right and left side gears drive the power to the wheels. When the loader turns, the right and left wheels turn at different speeds, the idle pinions in the gear cage rotate around their pin, proportionally with the speed difference between the right and left side gears.

While travelling straight

While making turns

1 2 3

High speed

4

5 6

Fig. 2-249 1. 2. 3. 4.

Low speed

7

Operation of differential

IDLE GEAR SIDE GEAR AXLE SHAFT DIFFERENTIAL GEAR CAGE

5. 6. 7.

IDLE PINION SPIDER BEVEL DRIVE PINION BEVEL DRIVE RING GEAR

Proportional torque differential Wheel loaders often operate under severe terrain conditions, such as sandy or muddy grounds. Under such unfavourable terrain conditions, a loader equipped with a standard differential could experience a spinning of the wheels, thus making difficult to exploit fully its potential performance. Also, the tyres could wear quickly. To avoid this, some models are equipped with a proportional torque type differential, limiting its function.

A proportional torque differential design is almost identical to a normal differential, with the exception of the idle pinions, having an odd number of teeth with a special profile. When the tyres start spinning on soft ground, the idle pinions continue to drive both side gears, without turning on their pins, until the difference of the adhesive force of the right and left tyres on the ground reach a certain value. In this manner, the spinning of the tyres is prevented.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

TRANSMISSION

2 - 116

1

2

2

3

4

5

W270

3

1

6

6

7

12

8

13

9

14

10

15

11 Fig. 2-250

5

20

19

18

4

17

7

16

Differential

Note 1

9 daNm (65 ft-lbs)

Threaded part: LOCTITE 262

2

15 daNm (110 ft-lbs)

Threaded part: LOCTITE 262

3

23 daNm (170 ft-lbs)

Threaded part: LOCTITE 262

4

67 daNm (480 ft-lbs)

Threaded part: LOCTITE 262

5

Outer diameter: LOCTITE 262

6

Backlash between bevel pinion/crown gear: 0.25 ÷ 0.36 mm (0.000 ÷ 0.014 in)

7

1. 2. 3. 4. 5. 6. 7.

Lip: Grease

After reassembling the differential, set the spacer so that the rolling torque is 0.01 ÷ 0.04 daNm, without seal.

ADJUSTING NUT BEARING RETAINER HALF-HOUSING (B) BEVEL CROWN GEAR HALF-HOUSING (A) LOCKING PLATE THRUST WASHER

8. 9. 10. 11. 12. 13. 14.

THRUST WASHER SPIDER DRIVE PINION BEARING HOLDER HOUSING IDLE GEAR PIN PLANET GEAR

15. 16. 17. 18. 19. 20.

SHIM SPACER SPACER (for W190) NUT FLANGE OIL SEAL

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

TRANSMISSION

2 - 117

2.15.3 FINAL DRIVES The final drive units are of a planetary type and create the final rpm reduction in the power train.

shaft rotates the three planet gears inside the toothed drum, thus driving the axle shaft through the planet gear carrier.

The power driven by the differential to the sun gear

8

7

6

5

4

3

2

A

A

1

4 6

3

5 Section A-A (Operation of planet gears)

Fig. 2-251 1. 2. 3. 4.

Power transmission

Drive of power

PINION DIFFERENTIAL SUN GEAR SHAFT PLANET GEAR PIN

5. 6. 7. 8.

PLANET GEAR TOOTHED DRUM PLANET CARRIER AXLE SHAFT

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

TRANSMISSION

2 - 118

1

13

Fig. 2-253

Note -

1 2

2

14

2

3

4

15 16

5

6 7

17 18

8

9

W270

10

11

12

1

19 20

Final drive

5 daNm (36 ft-lbs)

Threaded part: LOCTITE 262

Procedure for the setting of shims 1) Tighten screw (1) to a torque of 5 daNm (36 ft-lbs) and set inward the taper bearing, by rotating the axle shaft. 2) Loosen screw (1) without turning the shaft 3) Measure the gap between thrust ring (3) and axle shaft. Value measured = Y. 4) Select the adjusting shims to form a stack no thicker than 0.03 to 0.10 mm than value Y. 5) Install the shim pack, the retaining ring and the screw.

111 daNm (803 ft-lbs)

Threaded part: LOCTITE 262

The rolling torque of the bearing must be included between 2 and 4 daNm (4.4 ÷ 8.8 ft-lbs).

1. 2. 3. 4. 5. 6. 7.

SCREW SPACER RETAINING PLATE THRUST RING LOCK PIN BRAKE DISC (OUTER TOOTHED) BRAKE DISC (INNER TOOTHED)

8. 9. 10. 11. 12. 13. 14.

ADAPTER O-RING SPRING O-RING PISTON PLANET CARRIER PIN

15. 16. 17. 18. 19. 20.

BALL THRUST RING NEEDLE BEARING PLANET GEAR DISC HUB SUN GEAR

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

TRANSMISSION

2 - 119

2.16 AXLE DISASSEMBLY Cautions to be used when disassembling • The illustrations for disassembly and reassembly in this manual show the front axle of the model W190. The construction of the inner components of the motor axle is the same for models from W190 through W270. • When disassembling and reassembling the drive axle, it is good practice to place it on a unit table and use disassembly and reassembly jigs. • Unit weight:

front: 1216 kg (2680 lbs)

1)

Removing axle tube

1.

Remove the drain plug and drain gear oil. Front 38l (8.4 U.S. gal) Rear 38l (8.4 U.S. gal)

rear: 1184 kg (2610 lbs)

Fig. 2-253

2.

Remove the axle tube mounting bolts. Number of bolts: 20

Fig. 2-254

3.

Lift the axle tube with a crane temporarily, holding the axle tube at the opposite side to prevent it from lowering.

Fig. 2-255

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 120 4.

TRANSMISSION

Remove the axle tube from the differential body. If they are joined, separate one from the other using a screwdriver and soft mallet.

Fig. 2-156

5.

Remove the sun gear and shaft from the differential.

Fig. 2-157

6. 7.

Remove the snap ring and disk hub from the splines. Then, remove the snap ring. Remove the axle tube and shaft at the opposite side, using the same procedure as above.

Fig. 2-158

2)

Disassembling axle tube

1.

Put the axle tube with the differential mounting side upward. Using a nut runner (special tool), loosen the retainer plate mounting bolt and remove it from the axle shaft.

Fig. 2-159

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270 2.

TRANSMISSION

Using a prying tool, separate the final reduction gear assembly (planet carrier) from the shaft splines, and remove it with a crane. Remove any shim, if attached to the axle shaft.

Fig. 2-260

3.

Lay the axle tube on the bench. Using a screwdriver, remove the oil seal from the axle tube.

Fig. 2-261

4.

Remove the bearing cone from the differential side of the axle tube.

Fig. 2-262

5.

Using a crane, lift the axle tube with its differential side upward to let the axle shaft drop from opposite side.

Fig. 2-263

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 121

2 - 122 6.

W270

TRANSMISSION

Using a gas burner, heat up the bearing cone attached to the shaft, and remove the bearing come from the shaft.

Note - Make sure to replace the bearings with a new one. 7.

Remove the oil seal from the axle shaft.

Fig. 2-264

8.

Remove the bearing cups from the differential and wheel sides of the axle tube by tapping their outer diameter evenly.

Fig. 2-265

9.

Using a portal jig, remove the ring gear from the axle tube.

Thrust bolt Portal jig

Plate

Ring gear

Fig. 2-266

3)

Disassembling final reduction gear assembly

1.

Remove the snap ring from the planet gear shaft.

Fig. 2-267

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270 2.

TRANSMISSION

Drive the shaft from the gear. Use caution not to lose the lock ball that the shaft has.

Fig. 2-268

3.

Remove the planet gear and the (2) thrust washers.

Note - Use caution not to lose the needle roller because they may come off with the planet gear.

Fig. 2-269

4.

Remove the needle rollers and the spacer from inside the gear. Number of needle rollers: 66

5.

Remove the (2) other planet gear shafts, using the same procedure as above.

Fig. 2-270

6.

Remove the retainer plate from inside the planet carrier. Keep any shim, if attached.

Fig. 2-271

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 123

2 - 124

W270

TRANSMISSION

4)

Removing brake unit

1.

Remove the end plate, brake ring, brake disk, brake ring, brake disk and brake ring in this order from the differential body. Then, remove the 8 pins.

Fig. 2-272

2.

Remove the bolt (3), adapter (2) and spring (1) from the brake piston. Remove the bolts, adapters and springs from other five positions in the same way. 3

2

1

Fig. 2-273

3.

4.

Install a stopper (1) on the differential body tube mounting surface, to prevent the piston from popping out. Supply compressed air through the oil pressure port to remove the piston from the differential body.

Fig. 2-274

5.

6.

Remove the D-rings respectively from the larger diameter and smaller diameter of the brake piston. Remove the brake unit at the opposite side, using the same procedure.

Fig. 2-275

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

TRANSMISSION

5)

Removing drive pinion (bearing cage)

1.

Remove the bolts securing the cover from the differential body, and remove the cover. Number of bolts: 28

Fig. 2-276

2.

3.

Check the ring gear for tooth surface contact pattern and backlash. Refer to steps (5) and (6) in "2. Reassembly". Remove the bolts securing the bearing cage. Number of bolts: 8 for front axle 10 for rear axle

Fig. 2-277

4.

5.

Install two of the bolts removed at step (3), into the puller screw holes in the bearing cage. Tighten both evenly to separate the seating surface. Holding the bolts, remove the bearing cage and the drive pinion as a unit. Remove the half shim from between the differential body and bearing cage.

Fig. 2-278

6)

Disassembling drive pinion

1.

Put the drive pinion with the flange side upward. Using a nut runner (special tool), loosen the flange lock nut.

Fig. 2-279

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 125

2 - 126 2. 3.

TRANSMISSION

Remove the nut and detach the washer ring and O-ring. Remove the flange from the drive pinion.

Fig. 2-280

4.

Using a press, push down the drive pinion and remove it from the bearing cage.

Fig. 2-281

5. 6.

Remove the two spacers from the pinion shaft. Using a separator, remove the bearing cone from the pinion shaft.

Fig. 2-282

7.

Break the oil seal on the bearing cage with a screwdriver and remove it.

Fig. 2-283

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270 8.

TRANSMISSION

Remove the other bearing cone.

Fig. 2-284

9.

Remove the two bearing cups from inside the bearing cage, tapping their outer diameter evenly. 10. Remove the O-ring from the outer diameter of the bearing cage.

Fig. 2-285

7)

Removing differential case

1. 2.

Lift the differential case with a crane temporarily. Remove the bolts securing the bearing retainer, along with the lock plate. Number of bolts: 10

Fig. 2-286

3.

Install two of the bolts removed at step (2), into the puller screw holes in the bearing retainer and tighten both evenly. Remove the bearing retainer, holding the bolts.

Fig. 2-287

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 127

2 - 128 4.

5.

TRANSMISSION

Remove the adjusting nut from the retainer. Then turn the retainer upside down and remove the bearing cup. Remove the bearing retainer at the opposite side, using the same procedure as above.

Fig. 2-288

6.

Remove the ring gear and differential case assembly from the differential body.

Fig. 2-289

8)

Disassembling differential case

1.

Loosen the bolts securing the ring gear and remove the ring gear. Number of bolts: 20

Fig. 2-290

2.

Turn the differential case upside down and remove the 12 bolts securing the case from the plane half case side.

Fig. 2-291

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270 3.

TRANSMISSION

Tap the center of the spider with a rod to separate the case into two halves.

Fig. 2-292

4.

Remove the 2 side gears, spider, 4 pinion gears and 6 thrust washers from inside the differential case.

Fig. 2-293

5.

Using the bearing puller, remove the bearing cone from the plane half case and flange half case.

Fig. 2-294

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 129

2 - 130

TRANSMISSION

W270

2.17 AXLE REASSEMBLY Precautions to be implemented during the re-assembly • Wash disassembled parts with a clean washing oil and dry by blowing air. • Handle the washed parts, with care not to damage or contaminate them. • Check the disassembled parts for wear or damage and replace any worn or damaged part with a new one. Refer to "4. STANDARD VALUES FOR MAINTENANCE". • Replace all the seals with new ones.

1)

Reassembling differential case

1.

Place the flanged half case (differential case A) on a work bench, and press the bearing cone using a press or soft mallet.

Fig. 2-295

2.

Make sure the (2) dowel pins in the differential case. Align the (2) holes in the thrust washer with the dowel pins and install the thrust washer into the case.

Fig. 2-296

3.

Install the side gear.

Fig. 2-297

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

4.

TRANSMISSION

Install the (4) pinion gears and (4) thrust washers onto the spider, and install them as a unit on the side gear, engaging the gears.

Fig. 2-298

5.

Using a soft mallet, lock-up the spider to the mounting holes in the case.

Fig. 2-299

6.

Put the plane half case (differential case B) on the work bench and press the bearing cone into it using a press or soft mallet.

Fig. 2-300

7.

Turn the plane half case upside down and align the thrust washer with the pins and paste it with grease.

Fig. 2-301

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 131

2 - 132

8.

TRANSMISSION

Engage the other side gear with the pinion gears and install the plane half case, matching the marks. Tap the case with a soft mallet to make sure that the two case halves are closely fitted to each other.

Fig. 2-302

9.

Apply LOCTITE 262 to the threaded area of each of 12 case bolts. Install the bolts and tighten them in a diagonal order.

Fig. 2-303

10. Install the ring gear from upward. Using a soft mallet, bring it into close contact with the flange surface of the case. Tighten the mounting bolts from downward temporarily.

Fig. 2-304

11. Turn the differential case upside down. Apply LOCTITE 262 to the threaded area of each of the ring gear mounting bolts and tighten them. Number of bolts: 20

Fig. 2-305

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270

TRANSMISSION

2)

Reassembling drive pinion (bearing cage)

1.

Press the smaller-diameter bearing cup into the bearing cage. Turn the bearing cage upside down and using a press the larger-diameter bearing cup.

Fig. 2-306

2.

Apply grease to the O-ring and install into the groove at the outer diameter of the bearing cage.

Fig. 2-307

3.

Press the bearing cone into the drive pinion.

Fig. 2-308

4.

Install the longer spacer into the bearing cone with the chamfered area at the inner periphery pointed downward, and install the shorter spacer.

Fig. 2-309

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 133

2 - 134 5.

W270

TRANSMISSION

Put the bearing cage on the drive pinion. Then put the bearing cone on it.

Fig. 2-310

6.

Press the bearing cone into the drive pinion.

Fig. 2-311

7.

After pressing, give a load to the bearing cone using a hydraulic press. Measure the rotational resistance torque with a spring balancer. The capacity of the press should be high enough to give a load of about 9500 kg (21000 lbs).

Reference - Instead of giving a load using a press, the rotational torque may be measured after installing the companion flange temporarily; putting the washer on it and tightening the flange nut to the specified torque value. Fig. 2-312

8.

If the rotational resistance torque is lower than the standard value, remove the drive pinion and grind the shorter spacer properly. The standard value of the drive pinion's rotational resistance torque (value by a spring balancer) 1.3 to 2.3 kg (2.9 to 5.1 lbs)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270 9.

TRANSMISSION

Apply a thin coat of LOCTITE on the outer diameter of the oil seal.

Fig. 2-313

10. Using a jig, press the oil seal into the cage.

Fig. 2-314

11. Apply grease to the oil seal lip.

Fig. 2-315

12. Install the companion flange onto the drive pinion splines. Slide the flange several times to eliminate strain on the seal lip.

Fig. 2-316

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 135

2 - 136

TRANSMISSION

13. Then put the O-ring into the groove between the flange and pinion, and put the washer on it.

Fig. 2-321

14. Apply LOCTITE 262 to the threaded area of the lock nut and tight the lock nut using a nut runner. Make sure that the drive pinion turns smoothly without binding.

Fig. 2-322

3)

Installing differential case

1.

Install the bearing cup to the (2) bearing retainers.

Fig. 2-323

2.

Screw in the adjust nut until it comes in contact with the cup.

Fig. 2-324

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270 3.

TRANSMISSION

Lift the reassembled differential case with a crane and put the case in the differential body, aligning the ring gear with the notch in the differential body.

Fig. 2-321

4.

Install the bearing retainers at the right and left sides of the differential body to hold the differential case. Tighten the mounting bolts. Number of bolts (at one side): 10

Fig. 2-322

4)

Installing drive pinion (bearing cage)

1.

Putting shims between the bearing cage and the differential body, install the drive pinion (bearing cage) to the differential body.

Fig. 2-323

2.

Tighten the bearing cage with the mounting bolts. Number of bolts: 8 for front axle 10 for rear axle

Fig. 2-324

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 137

2 - 138 3.

W270

TRANSMISSION

Using a jig (1), tighten the right and left adjusting nuts to 10 to 12 kg-m (72 to 87 ft-lbs). Use a torque wrench to check the tightening torque.

1

Fig. 2-325

4.

Carry out steps "(5) Adjusting backlash of ring gear" and "(6) Adjusting the tooth surface contact pattern of ring gear". After that, install the lock plate and lock the adjusting nut.

Fig. 2-326

5)

Adjusting backlash of ring gear

1.

Set a dial gauge on the tooth profile outer edge of the ring gear. Fix the drive pinion, and turn the ring gear back and forth to measure the backlash.

2.

Fig. 2-327

3.

If the backlash is too large, loosen the adjusting nut on the plane half case, tighten the adjusting nut on the flange half case and bring the ring gear closer to the drive pinion. If the backlash is too small, adjust it in the opposite procedure as above.

Ring gear backlash Standard value: 0.25 - 0.36 mm (0.0098 - 0.0142 in)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

2 - 139

TRANSMISSION

6)

Adjusting the tooth surface contact pattern of ring gear

1.

Apply a thin coat of red lead to several ring gear teeth and turn the ring gear back and forth with a hand to check the tooth surface contact pattern.

Fig. 2-328

2. 3.

Adjust the tooth surface contact pattern, referring to the following steps a. to e. After acquiring the normal tooth surface contact pattern, check the backlash again.

Toe (small end) Heel (big end) Face Frank

Fig. 2-329

a.

Normal contact pattern (Fig. 330) The normal contact pattern of the tooth surface is from the toe to the heel and its length is approx. 80% of the total tooth length.

Note - The following adjustment items (b. to e.) show the procedures for checking the convex surface side of the tooth. Remember that the concave surface side has opposite contact conditions.

Ring gear

Fig. 2-330

b.

Adjusting contact condition at toe (Fig. 331) Loosen the adjusting nuts on the flange half case, tighten the adjusting nuts on the plane half case and shift the ring gear away from the drive pinion. Then, reduce the shim thickness of the bearing cage and bring the drive pinion closer to the ring gear.

Ring gear Drive pinion

Fig. 2-331

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 140 c.

W270

TRANSMISSION

Adjusting contact condition at heel (Fig. 332) Loosen the adjusting nuts on the plane half case side, tighten the adjusting nuts on the flange half case, bring the ring gear closer to the drive pinion. Then, increase the shim thickness of the bearing cage and shift the drive pinion away from the drive gear.

Ring gear Drive pinion

Fig. 2-332

d.

Adjusting contact condition at face (Fig. 333) Reduce the shim thickness of the bearing cage and bring the drive pinion closer to the ring gear. Then, loosen the adjusting nuts on the flange half case, tighten the adjusting nuts on the plane half case and shift the ring gear away from the drive pinion.

Ring gear Drive pinion

Fig. 2-333

e.

Adjusting contact condition at frank (Fig. 334) Increase the shim thickness of the bearing cage and shift the drive pinion away from the ring gear. Then, loosen the adjusting nuts on the plane half case, tighten the adjusting nuts on the flange half case and bring the ring gear closer to the drive pinion.

Ring gear Drive pinion

Fig. 2-334

7)

Installing brake unit

1.

Install D-rings at the (2) grooves at the outer diameter of the brake piston. After that, apply grease.

Fig. 2-335

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270 2.

2 - 141

TRANSMISSION

Press the piston into the differential body using an installing jig (refer to the illustration on the right).

Trust bolt Plate Block

Brake piston Fig. 2-336

3.

Install the spring (1), adapter (2) and bolt (3) of the piston return mechanism onto the differential body passing through each of the (6) piston holes. 3

2

1

Fig. 2-337

4.

Install the snap ring, disk hub and snap ring onto the sun gear and shaft.

Note - Direct the stepped area of the disk hub upward.

Fig. 2-338

5.

6.

Install the sun gear and shaft which has the disk hub, onto the side gear splines installed in the differential case. Install the (2) lock pins into the lower part of the differential body. Install the brake ring aligning them.

Fig. 2-339

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 142 7.

TRANSMISSION

Install the brake disk onto the disk hub splines, and then install the brake ring.

Fig. 2-340

8. 9.

Install the second brake disk, aligning with the first disk. Then, install the brake ring and end plate in this order.

Fig. 2-341

10. Install the other (6) lock pins using a soft mallet. 11. Install the brake unit at the opposite side, using the same procedure as above.

Fig. 2-342

8)

Reassembling axle tube

1.

If the ring gear was replaced with a new one, press the ring gear onto the axle tube using a press or soft mallet and secure with (4) pins.

Fig. 2-343

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270 2.

TRANSMISSION

2 - 143

Turn the tube upside down, press the bearing cup from the wheel side and install the bearing cone.

Fig. 2-344

3.

Then press the oil seal and apply grease to the lip.

Note - Install the inner sleeve to the oil seal.

Fig. 2-345

4.

Turn the tube upside down and lift it by the differential side with a crane. Lower it onto the standing axle shaft.

1

Fig. 2-346

5.

Put the tube jig (item (1) in Fig. 560) onto the axle shaft and press the oil seal and bearing of the wheel onto the shaft.

Fig. 2-347

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 144 6.

TRANSMISSION

Install the bearing (cup and cone) onto the axle tube.

Fig. 2-348

7.

Using a jig, press the bearing between the shaft and tube.

Fig. 2-349

9)

Adjusting the preload of axle shaft bearing (shim adjustment)

1.

Install the planet carrier without gear on the axle shaft splines.

Fig. 2-350

2.

Put the retainer plate in the planet carrier. Turning the axle tube, tighten the retainer plate mounting bolt to the torque of 5 kg-m (36 ft-lbs).

Fig. 2-351

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270 3.

2 - 145

TRANSMISSION

Loosen the retainer plate mounting bolt and remove the retainer plate. Measure the difference in height (Y in Fig. 352) between the axle shaft end surface and the planet carrier.

Fig. 2-352

4.

Select a shim which is 0.03 to 0.10 mm (0.0012 to 0.0039 in) thicker than the height difference (Y). (Y)

Note - The measurement position of the height difference (Y) is shown in Fig. 353.

Fig. 2-353

5.

Install the selected shim on the axle shaft and the retainer plate in this order. Tighten the bolt.

Fig. 2-354

6.

7.

Hook a spring balancer on the knock pin of the axle tube, and measure the bearing's rotational resistance torque by pulling it along the fitting pitch circle. If the measurement is not within the range (2) to (4) kg (4.4 to 8.8 lbs), readjust the shim. If the value is smaller, reduce the shim thickness, and if it is larger, increase the shim thickness.

Fig. 2-355

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 146 8.

TRANSMISSION

After the shim thickness is determined, loosen the bolt securing the retainer plate and remove the planet carrier which was temporarily installed.

Fig. 2-356

10) Reassembling and installing final reduction gear assembly 1.

Install the needle bearing on the planet gear. Needle rollers are arranged in two rows with (1) spacer at the center. Apply grease properly to prevent the rollers from dropping off. Number of needle rollers: 66

Fig. 2-357

2.

Install the (2) thrust washers in the planet carrier.

Note - Set the washer's torque in the groove of the carrier.

Fig. 2-358

3.

Insert the planet gear between the thrust washers.

Fig. 2-359

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270 4.

TRANSMISSION

Install the lock ball on the planet shaft and press the planet shaft into the planet carrier.

Fig. 2-360

5.

Install the snap ring in the groove of the carrier to lock the shaft.

Fig. 2-361

6. 7.

Put the retainer plate into the planet carrier. Reassemble the other (2) planet gears and install them in the planet carrier, using the same procedure as above.

Fig. 2-362

8.

Put the selected shim on the axle shaft and install the reassembled planet carrier on the shaft.

Fig. 2-363

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 147

2 - 148

TRANSMISSION

9.

Apply LOCTITE 262 to the threaded area of the retainer plate mounting bolt and tighten the bolt to the specified torque to secure the planet carrier. Fig. 364 shows the planet carrier being installed with the nut runner. 10. Reassemble the other axle tube, using the same procedure as above. Refer to the (8) to (9).

Fig. 2-364

11) Installing axle tube 1.

Apply LOCTITE FMD-127 to the differential body surface which will mate with the axle tube. Make sure that the beads of LOCTITE are applied, without a break, on the differential body surface inside row of the bolt holes. The bead width is 2 to 3 mm (0.08 to 0.12 in) each.

Fig. 2-365

2.

Lift axle tube horizontally and install it onto the differential body, aligning with the sun gear and mounting bolt holes. Apply LOCTITE 262 to the threaded area of mounting bolts and tighten them. Number of bolts: 20

3.

Install the axle tube at the opposite side, using the same procedure as above.

Fig. 2-366

4.

Apply LOCTITE FMD-127 to the cover mounting area of the differential body. Make sure that the beads of LOCTITE are applied, without a break, on the body surface inside row of the bolt holes.

Fig. 2-367

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270 5.

TRANSMISSION

Fill the differential with gear oil before mounting the cover. Oil capacity Unit: l (U.S. gal.) Axle (front) 38

Axle (rear) 38

Fig. 2-368

6.

Install the cover on the differential body and tighten the mounting bolts. Number of bolts 28

Fig. 2-369

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 149

2 - 150

W270

TRANSMISSION

2.18 Troubleshooting Trouble

Problem Cause

Noisy differential.

Noisy axle tube.

Gear worn, damaged or broken.

Replace.

Excessive backlash of each gear.

Adjust or replace.

Bearing worn, damaged or broken.

Replace bearing.

Loose engagement of side gear and shaft splines.

Replace.

Loose bolts.

Retighten.

Low gear oil.

Add oil to specified level.

Gear (final reduction gear) worn, damaged or broken.

Replace.

Excessive backlash of each gear.

Replace.

Bearing worn, damaged or broken.

Replace bearing.

Loose planet carrier holding bolt (retainer plate mounting bolt).

Oil leakage from differential

Oil leakage from axle shaft.

Remedy

Retighten (Adjust shims).

Improper preload of axle shaft bearing.

Adjust shims.

Low gear oil.

Add oil to specified level.

Broken liquid packing of differential cover.

Apply liquid packing.

Broken liquid packing of axle tube.

Apply liquid packing.

Worn or damaged O-ring of bearing cage.

Replace O-ring.

Oil seal worn or damaged.

Replace oil seal.

Loose bolt.

Retighten.

Oil seal worn or damaged.

Replace oil seal.

Oil seal installed improperly.

Repair or replace.

Brake piston seal (D-ring) deteriorated or damaged. Brake disk or brake ring worn or damaged. Poor braking.

Brake piston rusted.

Overhaul and replace.

Foreign matter caught on brake disk. Loose or damaged bleeder screw of disk brake. Erratic braking.

Brake disk or brake ring run-out or worn unevenly.

Retighten or replace. Overhaul and replace.

Wornparallel pin of disk brake. Dragging brake.

Rusted brake piston.

Overhaul and replace.

Brake disk and brake ring seized.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

2 - 151

TRANSMISSION

2.19 STANDARD VALUES FOR MAINTENANCE Item Thickness of bearing cage shim

Standard Size

Useful limit

0.1, 0.2, 0.25 (0.004, 0.008, 0.010)

-

Inner diameter of differential pinion gear

35.05 to 35.13 (1.380 to 1.383)

Diameter of differential spider pin

34.90 to 34.93 (1.374 to 1.375)

Thickness of differential pinion gear thrust washer Thickness of differential side gear thrust washer

Backlash between drive pinion and ring gear

Clearance 0.2 (0.0079)

1.575 to 1.625 (0.06201 to 0.06398)

1.44 (0.0567)

2.31 to 2.36

2.24

(0.0909 to 0.0929)

(0.0882)

0.25 to 0.36

-

(0.0098 to 0.0142) Rotational resistance torque of drive pinion (no oil seal)

kg-m (ft-lbs)

Outer diameter of the companion flange in the oil seal sliding area Rotational resistance torque of axle shaft bearing (tube fitting bolt pitch circle) kg (lbs) Shim thickness of axle shaft

0.15 to 0.26

Remarks

Adjustment by adjusting nut

-

(1.08 to 1.88)

Adjustment by machining spacer

89.913 to 90.000

89.863

(3.540 to 3.543)

(3.538)

2.0 to 4.0 (4.4 to 8.8)

-

0.1, 0.2, 0.25, 0.5 (0.004, 0.008, 0.010, 0.020)

-

Shim adjustment

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 152

W270

TRANSMISSION

Item

Standard Size

Useful limit

5.9 to 6.5 (0.232 to 0.256)

5.58 (0.220)

4.9 to 5.1

4.5

9.9 to 10.1

9.5

(0.193 to 0.201)

(0.177)

Free height

33 (1.30)

31.7 (1.25)

Settings load kg (lbs)

20.8 (45.9)

Setting height

20.0 (0.787)

Brake disk thickness

Brake ring thickness

Remarks

18.8 (41.4)

2.20 TIGHTENING TORQUE VALUES FOR MAIN BOLTS Item Ring gear mounting bolt Differential case mounting bolt

Flange nut

Brake piston return spring mounting bolt Planet carrier holding bolt

Remarks

23 (166)

Apply LOCTITE 262.

W170

9 (65)

W190

15 (108)

Differential bearing retainer mounting bolt Bearing cage mounting bolt

Tightening torque

9 (65) W170

9 (65)

W190

23 (166)

W170

55 (398)

W190

67 (485)

Apply LOCTITE 262.

Apply LOCTITE 262. Apply LOCTITE 262.

Apply LOCTITE 262.

5 (36)

Apply LOCTITE 262.

111 (803)

Apply LOCTITE 262.

23 (166)

Apply LOCTITE 262.

(Retainer plate mounting bolt) Axle tube mounting bolt Differential cover mounting bolt

5 (36)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

2 - 153

TRANSMISSION

2.21 WHEELS

2.21.1 Tyres

The wheel is composed of rim and disc. The wheel disc is bolted to the axle shaft. The tyre is mounted on the rim forming a single body with it. Consequently, it is of the utmost importance that the correct rim is used, based upon the type of tyre to be mounted. The use os a inappropriate rim could shorten the life of the tyre and, in the worst cases, cause serious accidents. Also, the dimensions of the rim is provided in inches. The first number indicates the width of the rim and the second indicates the diameter.

In a standard configuration, the loader is equipped with radial type tyres with tread type L3, having high traction characteristics. It is recommended that the most appropriate tyres are selected, since a large variety of types is available, based upon the type of operation and working requirements. Example: 23.5 R 25 XHA TL

= = = = =

23.5 R 25 XHA TL Width of the tyre (~ 600 mm) Radial Diameter of rim (~ 635 mm) Type of tread Tubeless

F

A

Fig. 2-370

Rim Q.ty 5 pieces

Fig. 2-371 Thread of XHA tyre

Coppia di serraggio viti fissaggio ruote 78,8 da Nm

MODEL

RIM (F x A)

WORK

TRAVEL

FRONT REAR FRONT REAR 26.5R25 GP-2B

G.Y.

22.00x25

4.00

2.50

2.75

2.75

26.5R25 XHA

Mich.

22.00x25

4.25

2.75

2.00

2.00

26.5R25 XLD D2

Mich.

22.00x25

4.25

2.75

2.00

2.00

26.5R25 XLD D1

Mich.

22.00x25

4.25

2.75

2.00

2.00

26.5R25 XMINE D2

Mich.

22.00x25

4.25

2.75

2.00

2.00

26,5R25 RL-5K

G.Y.

22.00x25

4.00

2.50

2.75

2.75

(*) The pressure can be increased 0.5 bar when the working conditions do not require particular floating capabilities

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

SECTION 3

BRAKES SYSTEM TABLE OF CONTENTS

PARAGRAPH

SUBJECT

3.1

GENERAL DESCRIPTION .................................................................................... 1

3.2 3.2.1

OPERATION .......................................................................................................... 3 Operation conditions .............................................................................................. 3

3.3

DISC BRAKE ......................................................................................................... 6

3.4 3.4.1

BRAKE PEDAL VALVE ........................................................................................... 7 Operation of circuit separation valve in the brake group ......................................... 9

3.5

BRAKES/POWER SYSTEM PUMP ....................................................................... 10

3.6

PARKING BRAKE CONTROL VALVE .................................................................... 11

3.7 3.7.1 3.7.2 3.7.3

PARKING BRAKE .................................................................................................. Procedure for manual disengagement .................................................................... Operation of discs parking brake ............................................................................ Disengagement of brake ........................................................................................

3.8 3.8.1 3.8.2

OTHER COMPONENTS ........................................................................................ 14 Service brakes accumulator ................................................................................... 14 Check valve ............................................................................................................ 14

3.9

HYDRAULIC CONNECTIONS OF BRAKE PEDAL VALVE ................................... 15

3.10 3.10.1 3.10.2 3.10.3 3.10.4 3.10.5 3.10.6 3.10.7

TROUBLE SHOOTING - TESTS ........................................................................... Test of brakes actuation pressure .......................................................................... Setting of minimum and maximum accumulators recharge pressure ..................... Inspection of parking brake engagement................................................................ Inspection of accumulator pre-charge .................................................................... Instructions for the pre-charging of the service brakes accumulator ...................... Air bleeding of brakes system ................................................................................ Check of brake discs wear .....................................................................................

PAGE

12 12 13 13

16 18 19 20 21 22 23 24

BRAKES SYSTEM

W270

3-1

3.1 GENERAL DESCRIPTION The brake system consists of (refer to Fig. 3-1): - a recharge pump, gear type; - a two sections feed pump of the gear type (11) i flanged to the torque converter cover; - a filter (10) on pump outlet; - a brake pedal valve (5) controlling simultaneously front and rear brakes (1 and 2, respectively), which are located inside the drive axles; - two accumulators (8 and 9) which during normal operation stabilise system pressure and, in case of emergency, with the engine stopped, allow to positively apply the brakes for several times; - the oil used in the brakes system is the same of the equipment hydraulic system and it is taken from hydraulic reservoir (S) through a filter.

- a three-way diverter valve (14) which controls engagement and disengagement of the parking brake (16); - a hydraulic ram (16) composed of springs and a hydraulic cylinder to counter-act them. Spring force is used to lock the parking brake discs when pressure oil in the cylinder is dumped by means of the diverter/control valve. When fed with pressure oil (by means of the diverter/control valve), the cylinder overcomes spring action and consequently the brake is released; - an accumulator (not illustrated) mounted on the pressure relief valve, that during normal operation stabilises the pressure inside the circuit, and, with engine inoperative, allows the disengagement of the parking brake, for a certain number of times.

The parking brake consists in:

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

3-2

W270

BRAKES SYSTEM

1

1

6 7 9 5 4 8 12 3

V

M

10

13

T

11 S

14 15

16

2

2

Fig. 3-1 Brakes system S. Reservoir - M. To pressure regulating valve - V. To pressure regulating valve - T. Discharging (hydraulic reservoir) - 1. Front brakes-2. Rear brakes - 3. and 4. Quick release pressure pick-up points - 5. Brake pedal valve - 6. Stop light pressure switch 7. Transmission cut-off pressure switch - 8. and 9. Brakes system accumulators - 10. Oil delivery filter - 11. Brakes oil pump 12. Check valve - 13. Parking brake control three way diverter - 14. Parking brake pressure switch - 15. Hydraulic cylinder (included in the parking brake) - 16. Parking brake.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

BRAKES SYSTEM

W270

3-3

3.2 OPERATION GENERALITIES (Fig. 3-2)

3.2.1 OPERATING CONDITIONS (Fig. 3-2)

Braking system

With:

The brake system is fed by the pump (10) which draws oil from the attachment oil reservoir and sends it to the flow regulator valve (24). This valve is pilot controlled by the accumulator recharge valve (16). Two hydraulic accumulators (7 and 8) and two check valves (17 and 18) allow to store an amount of pressure oil sufficient to positively apply the brakes a limited number of times, also with the engine stopped, and therefore without pump (10) delivery.

Parking brake The parking brake is composed of a disc brake (15) acting on the output shaft of the transmission. The system receives pressurised oil from the power system pressure relief valve (25). The braking force is applied by springs (23); the release of the brake is actuated by sending oil under pressure into the cylinder, through diverter (12). In this manner, the springs are pressed and the brake is released. Pressure switch (13) closes the electric circuit “parking brake engaged” when the pressure drops below the value of 15 bar, with the consequential engagement of the parking brake.

Service brakes The brakes are disc type, in oil bath, and are located within the axle side reduction gears (1 and 2). When the brake pedal is pressed, the valve (5) supplies control oil to the braking circuit at a pressure (and consequently with braking action) proportional to the travel of the brake pedal (Pf max = 45 bar). When the pedal is released, the valve (5) dumps brake circuit oil and nullifies the braking action on the discs (1 and 2). During braking, the sensor (4) activates the stop lights electrical circuit. The sensor (3) controls the transmission disengagement system (22).

-

engine running brakes released parking brake applied accumulators being recharged

The flow from the pump (10) reaches the flow regulating valve (24). The oil flow opens and goes through the primary check valve (19), then opens and goes through the check valves (17 and 18) thereby charging the brake accumulators (7 and 8). The brake pedal (P) being released, the distributing spools (20 and 21) stop oil flowing from the pump and keep dumping oil from the brake pistons (1 and 2). The brakes are disengaged. The parking brake diverter/control valve (12) is positioned as to dump oil from the parking brake chamber. Therefore the parking brake (15) is kept applied by the spring force. Accumulator recharge ends when the maximum recharge pressure has been attained, the plunger of the valve (16) moves to the right.

With: -

engine running brakes released parking brake applied accumulators charged

Under the conditions represented in the diagram the plunger of valve (16) when it opens, allows the oil in the spring side cavity of valve (24) to discharge, thus the valve moves rightward, deviating the oil of the pump toward (M). At the same time, the primary check valve (19) closes and traps pressure oil inside the brake hydraulic circuit. When, following braking or leakage in the brake valves, pressure after the valve (19) drops below the minimum preset value, the spool of the valve (16) moves to the left closing the valve (24) and the accumulators start being recharged.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

3-4

BRAKES SYSTEM

With: -

engine running brakes applied parking brake released accumulators charged.

This condition occurs when the machine is braked while working. The parking brake is released as the diverter valve (12) sends pressure oil to the brake piston which overcomes the action of the control springs (23). When the brake pedal (P) is pressed, it compresses the springs which act on the distributing valves (20 and 21) and cause the inlet ports (1 and 2) to the brakes to open.

W270

The braking pressure acting on the bottom side of the distributing valve (21) packs the brake discs (1 and 2). In the way, as pressure on the brake discs increases, the distributing valves (20 and 21) are pushed upwards and close the inlet ports. As a result, the pressure applied to the brake discs (1 and 2), and consequently the braking action, are proportional to the pressure applied to the pedal (P). The presence of two accumulators (7 and 8) and two distributing valves (20 and 21) allow separate control circuits for the front and rear brakes. Should one circuit fail, this will not affect proper operation of the other circuit.

Fig. 3-2 Brake system hydraulic diagram P. Brake pedal - S. Reservoir - M. To equipment pilot system - 1. Rear brakes - 2. Front brakes - 3. Transmission disengagement pressure switch - 4. Brake lights pressure switch - 5. Brake pedal valve - 6. Accumulator control pressure switch - 7 and 8. Brake system accumulators - 9. Pressure oil filter - 10. Brakes oil pump - 11. Check valve - 12. Three ways diverter valve for parking brake actuation - 13. Parking brake pressure switch - 14. Hydraulic ram - 15. Parking brake - 16. Accumulators recharge valve -17 and 18. Check valves - 19. Primary check valve - 20. Front axle brake control valve - 21. Rear axle brake control valve - 22. Trasmission disengagement device - 23. Hydraulic ram springs - 24. Flow regulating valve - 25. Pilot system pressure regulation valve - 26. Heat exchanger - 27. Pilot controls safety valve - 28. Equipment pilot valve.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Fig. 3-2

3-5

HYDRAULIC BRAKING CIRCUIT SCHEMATIC P

22

1

1

2

2

5

13

17

7

12

3

21

18

20 8 14 4

23 15

6

19

28

9 16

STEERING POMPA STERZO PUMP M

26 24 27

25 10

Hydraulic circuit shown with engine running, accumulators being recharged, brakes disengaged, parking brake applied.

S P

11

3-6

W270

BRAKES SYSTEM

3.3 DISC BRAKE The disc brake is composed of two oil-bath, discs and it is mounted inside the axle housing. On this loader, four brake groups are mounted in axle, one on each axle shaft. The structure of the disc brake is described in the “TRANSMISSION” section.

The inner circumference of the discs is splined and it is keyed to the axle shaft. The outer circumferences of the pressure plate and reaction plate are secured to the axle housing by dowels, so that, the locking of the brake discs causes the stopping of the axle, thus braking.

OPERATION

2) Releasing the brakes When oil pressure is relieved from the brake piston, this moves slightly rearwards to release the brake disc and the the braking action stops.

1) Actuation of the brake The pressure of the brake oil acts on the rear face of the brake piston and locks the brake discs between the disc pressure plate and the reaction plate.

4

5

6

7

8

11

9

10

Brake pressure oil

Drive line

1

2

3 12 13 14

Fig. 3-3 Operation of disc brake 1. Axle shaft - 2. Planetary carrier - 3. Solar shaft - 4. Disc hub - 5. Reaction plate - 6. Pin - 7. Disc brake - 8. Disc pressure plate - 9. Piston - 10 and 11. Sealing ring - 12. Spring - 13. Piston guide - 14. Screw.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

BRAKES SYSTEM

W270

3-7

3.4 BRAKE PEDAL VALVE

To dump To other users or dump

T1 Rear brake feed port (45 bar)

Accumulator pressure adjustment (80 - 110 bar)

T2 Front brake feed port (45 bar)

Fig. 3-4 Brake pedal valve Flow regulating valve

Accumulator maximum recharge pressure adjust screw Plug

Primary check valve Accumulator minimum recharge pressure adjust screw

Accumulator recharge pressure regulating valve

Fig. 3-5 Accumulator recharge pressure and flow regulating valve section view

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

3-8

W270

BRAKES SYSTEM

Angle adjustment with pedal released 40° to 60°

3°

Min. angle from released position to start sending pressure oil to the brakes Max working angle 16°

Pedal angle adjust screw

Backlash take-up screw

Brake oil delivery spools

Brake feed ports

Brake pressure adjustment stop screw = Pf Max.

Fig. 3-6 Section view of oil delivery spools to users

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

BRAKES SYSTEM

W270

3-9

From the recharge valve

To accumulator no. 1

1 6 4

2

3 To accumulator no. 2

5 Fig. 3-7 Section view of circuit separation valve and accumulator recharge one-way valves 1. ONE-WAY VALVE 2. ONE-WAY VALVE

3. CIRCUIT SEPARATION VALVE 4. TAPERED PISTON

5. SPRING 6. PISTON SEAL SEAT

3.4.1 CIRCUIT SEPARATION VALVE OPERATION INSIDE THE BRAKING SYSTEM This valve allows, once a determined pressure value is exceeded, to connect the reference accumulator and the sensing element to the charging pressure and, below it, the distinct separation of the valve and the accumulator.

Operation description The charge valve starts operating by sending oil to the accumulators through the one-way valves (see figure). The pressure created acts also on the tapered piston (4) which after reaching a certain pressure, overcomes the spring (5) action and moves away from the sealing seat (6). At charge end, the one-way valves close, and the charge valve senses only pressure in accumulator no. 1 through the piston (4) and its seat (6). The spring (5) pin depends upon accumulator pressure and it is usually kept at -10/-15 bars maximum below the accumulator recharge pressure. This adjustment is obtained by means of shims. To test the separation valve operation and setting, cause a minor oil leak in the accumulator feed line and read the pressure at the reference accumulator no. 1. Pressure decreases, the spring (5) overcomes the pressure on the piston (4) which closes the valve/ accumulator communication port. Residual pressure into accumulator no. 1 corresponds to the valve regulation pressure.

Note - If the leak from the accumulator charge valve is considerable due to pressure drop, the piston (4) pin closes the valve/accumulator communication port before the reference accumulator attains minimum pressure. This feature is to the advantage of normal operation, but it alters pressure reading. Therefore, it is important that the oil leak purposely created be small. Possible failures 1. Failure in the accumulator no. 2 side, not used as a reference for the charge valve. In this case, pressure in accumulator no. 1 decreases to the setting value given by the spring (5). Note - If the oil leak is considerable, the accumulator pressure remains at the value as it is. 2. Failure accumulator no. 1 side. In this case, accumulator no. 2 remains in the condition as it is. 3. Accumulator charge valve failure. If the leak is small, accumulator no. 2 remains at the pressure as it is, while reference accumulator no. 1 drops to the cut-out pressure given by the spring. If the leak is considerable, accumulator pressures remain as they are as the piston (4) immediately closes the accumulator/valve port.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

3 - 10

W270

BRAKES SYSTEM

3.5 BRAKES/POWER SYSTEM PUMP

The brakes circuit is powered by the hydraulic oil delivered by the pump keyed on the transmission housing, together with the steering pump. The same pump powers the power system.

BRAKES PUMP (AND POWER SYSTEM) Designation: ............................................................................................................ Kayaba KP1013CBG Type: ................................................................................................................................................. gear Drive: .............................................................................................................. mounted on steering pump Delivery: ..................................................................................................................................... 13.2 gpm Maximum pressure: ...................................................................................................................... 170 bar Engine/pump speed ratio: ........................................................................................................... 1 : 0.982 5

4

10

3

9

2

8

1

7

6

Item "C"

Section A-A

Section B-B

13

12

11

Fig. 3-8 Brakes/power steering pump sections 1. Driven gear 2. Mounting flange 3. Gear plate 4. Centering dowel 5. Closing plate

6. Oil seal 7. Driving gear 8. Side plate 9. Side plate 10. O-Ring

11. Sealing device 12. Gasket B 13. Gasket A

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

BRAKES SYSTEM

W270

3 - 11

3.6 PARKING BRAKE CONTROL VALVE The parking brake valve controls the delivery of pressurised oil to the disc brake. The movement of the parking brake valve is controlled by the appropriate knob actuating the discs brake.

The parking brake is equipped with detent devices to hold the spool, in each position.

B

A T

11

12 A T

2 T

A 7

8

6

5 4 3

9

10

1

B

B

Fig. 3-9 Parking brake valve 1. Rod - 2. Valve body - 3. Gland ring - 4. Ring - 5. O-Ring seal - 6. Cover - 7. Spool - 8. Detent spring - 9. Sleeve - 10. Detent ball - 11. Dust ring - 12. Oil seal.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

3 - 12

W270

BRAKES SYSTEM

3.7 PARKING BRAKE Parking brake manual disengagement (in case of emergency)

WARNING

If it is not possible to release the parking brake by means of the control knob following pump failure or for any other reason, disengage it manually through the parking brake release screw.

WARNING

Disengage the parking brake manually only if it is absolutely necessary. Namely, this should be done only when towing a failed loader to traffic-free areas. If the loader is on an incline, check that the wheels are securely blocked with wedges or stones prior to releasing the parking brake.

3.7.1 MANUAL RELEASE PROCEDURE 1. Remove the manual release bolt and nut (1) from the parking brake cover on the transmission housing. 2. Remove the plug (2) from the middle of the cover.

into the threaded hole at the centre of the brake piston (3), as shown in Fig. 3-11. 4. Screw the release bolt fully in to retract the brake piston (3) and release the brake disc.

3. Insert the bolt (1) into the plug hole and screw it

3

2

1 1

Fig. 3-10

Fig. 3-11

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

BRAKES SYSTEM

W270

3 - 13

packs the brake discs (rotating) against the fixed plates.

The parking brake is of an oil-bath, multiple disc type and it is mounted on the intermediate shaft of the transmission. The brake is actuated by a series of inner springs and it is disengaged by the oil pressure controlled by the parking brake valve. Its structure is described in the section “2. TORQUE CONVERTER - TRANSMISSION”.

2. The inner toothing of the rotating brake discs is keyed to the transmission shaft by the brake discs hub. The outer toothing of the fixed brake discs is keyed to the brake seat. As the rotating brake discs are locked with the fixed brake discs, they stop rotating. This causes the stopping of the rotation of the transmission shaft, by the disc carrier hub, thus braking the loader.

3.7.2 DISC PARKING BRAKE OPERATION 1. When pressure oil acting on the piston brake is dumped, this is pushed by the spring force and

Brake pressure oil dump

8

6

1

2

7

5

4

3

Fig. 3-12 Parking brake 1. Brake piston - 2. Spring - 3. Support plate - 4. Brake housing - 5. Brake discs - 6. Disc hub - 7. Bearing - 8. Transmission shaft.

3.7.3 BRAKE DISENGAGEMENT 1. When pressure oil is sent to the rear surface of the brake piston, this overcomes the spring action and moves.

2. A clearance is established between each brake disc and fixed plate, the brake discs are released and the brake is disengaged.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

3 - 14

W270

BRAKES SYSTEM

3.8 OTHER COMPONENTS 3.8.1 SERVICE BRAKES ACCUMULATOR The membrane accumulator is used to store pressure oil to release the parking brake.

Oil from the charge pump is diverted by the check valve to the accumulator which maintains the pressure at a certain value.

1

2

CAPACITY ..................................................................................... 1.4 lt. MAX. WORKING PRESSURE PER ACCUMULATOR ............ 210 bar

3

GAS TO BE USED ............................................................ NITROGEN GAS PRE-CHARGE PRESSURE .............................................. 45 bar WEIGHT ............................................................................... 5.4 kg abt

Fig. 3-13

Accumulator

1. Gas filling plug - 2. Accumulator body - 3. Oil inlet connection.

3.8.2

CHECK VALVE (Parking brake)

The check valve is used to prevent oil back-feeding from the accumulator.

A

A

Fig. 3-14

.

.

.

.

.

.

.

.

.

.

B

B

Check valve

A. From the accumulator - B. To parking brake control valve.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

BRAKES SYSTEM

W270

3 - 15

3.9 BRAKE PEDAL VALVE HYDRAULIC CONNECTIONS

N

M T1

F

R1

R2

T2

T2 TI2

P T1

P

M R1 N

F

R2

TI1

Fig. 3-15

Brake pedal valve hydraulic connections

F. Accumulator control pressure switch - M. Other users or to dump - N. Dump - P. Inlet - R1-2. Accumulator - T1-2. To the brakes -TI1-2. Brake control pressure switch.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

3 - 16

W270

BRAKES SYSTEM

N

10

T

Fig. 3-16

To pilot valve locking

17

16

18

15

13

To hydraulic oil reservoir

11

PV

20

P

19

14

M

12

8

P

3

9

To steering valve

From equipment reservoisar

4

T2

T1

7

5

6

1

2

3.10 DIAGNOSTICS AND TESTING

Braking system schematic

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

BRAKES SYSTEM

W270

3 - 17

Brake system schematic 13. Check valve T1.

Front brakes delivery port. (P Max 45 bar)

T2.

Rear brakes delivery port. (P Max 45 bar)

1.

Rear axle brakes

2.

Front axle brakes

3.

Quick release pressure pick-up

4.

Quick release pressure pick-up

5.

Transmission cut-off pressure switch (setting = 15 bar)

14. Pressure relief valve (setting 30 bar) 15. Three way diverter, parking brake engagement/ disengagement control 16. Parking brake pressure switch (setting of pressure switch: OFF = 15 bar; ON = 10 bar) 17. Parking brake caliper cylinder 18. Brake disc

6.

Stop lights pressure switch (setting = 1.8 bar)

7.

Brake pedal valve (operating pressure = 45 bar)

8.

Accumulator control pressure switch (60 ± 5 bar)

9.

Brake accumulator (capacity = 1.4 litres - precharge = 45 bar)

10. Brake accumulator (capacity = 1.4 litres - precharge = 45 bar) 11. Powering pump (for brake system) 12. Delivery oil filter

19. Heat exchanger 20. Accumulator (capacity 0.7 litres - pre-charge 19 bar)

WARNING - DANGER

Always disconnect and connect all fittings with the engine stopped and braking system disabled. Accumulators keep some branches of the circuit under pressure even if the engine is stopped. Pressure oil escaping from loose fittings may cause personal injury and damages to things. Wear safety glasses with side shields.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

3 - 18

W270

BRAKES SYSTEM

3.10.1 BRAKE CONTROL PRESSURE TESTING

Connect two pressure gauges (end of scale 100 bar) to the pressure ports shown in Fig. 3-17. Apply the parking brake. Start machine engine and wait until it settles to maximum torque speed. With the engine idling, press the brake pedal and check that pressure reading on the gauges is

approximately 45 bar. Release the lock-nut (E, Fig. 3-17) and turn the screw in or out if pressure values are not within the rated range. Such a pressure must be measured after a pedal stroke of about 70 mm (2.79 in). Seal the screw after adjustment.

Rear axle pressure port Front axle pressure port

E

Fig. 3-17

Braking pressure adjustment

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

BRAKES SYSTEM

W270

3 - 19

3.10.2 MINIMUM AND MAXIMUM ACCUMULATOR RECHARGE PRESSURE ADJUSTMENT Connect two pressure gauges (end of scale 200 bar) to the quick coupling pressure ports (7 and 8, Fig. 3-18) on the accumulators. Start machine engine and bring oil temperature to approximately 40 to 50°C by means of the attachment control lever. Cycle the brake pedal several times to make oil temperature even.

lock-nut (5) and turn the screw (4) with micrometric variations until obtaining correct value. Check pressure again before tightening the lock-nut (5). Maximum recharge value With the engine idling and the parking brake applied, observe maximum recharge pressure on pressure gauges M1 and M2. Pressure should be 110 ± 5 bar. If maximum recharge pressure is different from the rated value, remove the plug (1), release the lock-nut (3) and turn the screw (2) out to increase the accumulator maximum recharge pressure.

Minimum recharge value With the engine idling and machine at a standstill, brake slowly 4 or 5 times. Observe minimum pressure values on pressure gauges M1 and M2 before recharge starts. The pressure gauges should momentarily read 80 ± 5 bar. If minimum recharge pressure is different from the rated value, remove the plug (1), release the

M1 M2

7 8

5

1

2

Fig. 3-18

3 4

6

Minimum and maximum accumulator recharge pressure adjustment

M1 & M2. Pressure gauges - 1. Plug - 2. Maximum pressure adjust screw - 3. Lock-nut - 4. Minimum pressure adjust screw - 5. Lock-nut - 6. Accumulators - 7 & 8. Pressure ports.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

3 - 20

W270

BRAKES SYSTEM

3.10.3 PARKING BRAKE ENGAGEMENT TEST Start the engine and let it run for about thirty seconds to charge the accumulator.

Operate the control lever two or three times always checking that the brake linkage moves completely.

Move the parking brake control lever to the “released” position.

The machine, set on 30° slope, shall be stopped.

With the help of an assistant, observe the operation of the parking brake control linkage.

2

1

4

7

P

M

TO BRAKE VALVE

5

PV

6

TO PILOT VALVE BLOCKING

T

3

T TO HYDRAULIC OIL RESERVOIR

Fig. 3-19

Parking brake diagram

T. Discharge to oil reservoir - 1. Parking brake locking/release - 2. Three way valve - 3. Heat exchanger - 4. Check valve 5. Ram - 6. Parking brake - 7. Pressure relief valve.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

BRAKES SYSTEM

W270

3 - 21

3.10.4 ACCUMULATORS PRE-CHARGE TEST Accumulators fitted to the braking system are membrane type, pre-charged using nitrogen.

- disconnect tool (D) from the accumulator; - tighten the screw (2) to a torque of 1.1 daNm;

Normal minimum membrane porosity and continued use reduce pre-charge pressure in time and limit accumulator efficiency.

- test accumulator sealing using soapy water; - screw on protective cover (1).

It is advised to check the nitrogen pre-charge every six months and restore it, if necessary.

Recharge the accumulator if the pressure is lower than rated value.

Pre-charge pressure should never drop below approximately 90% of the rated value. Check is to be carried out with the accumulators drained of hydraulic oil. This condition is obtained as follows: - as regards accumulators (7 and 8, Fig. 3-2) by pressing the brake pedal slowly several times; - as regards the parking brake release accumulator (13, Fig. 3-2) by operating repeatedly the diverter valve (14) with the engine stopped.

D1

D

Check the pre-charge as follows: - remove protection cover (1, Fig. 3-20); - loosen the screw (2) by half turn using an hexagonal Allen wrench;

M M

D1

- screw in tool (D) on the accumulator connection; - ensure that tap (D2) is closed; - turn the handwheel (D1) to loosen the screw (2); D

- when the pointer of the pressure gauge (M) starts moving, turn out the handwheel (D1) by one more turn.

D2

1 Now the pressure gauge shows the accumulator precharge pressure, which should be 45 bar.

2

If pressure is within the specified range of values, proceed as follows: - close handwheel (D1); - open tap (D2) to discharge nitrogen pressure from within the tool (D);

Fig. 3-20 Accumulators pre-charge test D. Accumulators pre-charge test tool - D1. Plug control handwheel (2) - D2. Discharge tap - M. Pressure gauge 1. Protective cover - 2. Threaded plug.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

3 - 22

W270

BRAKES SYSTEM

3.10.5 INSTRUCTIONS FOR THE RESTORATION OF THE SERVICE BRAKES ACCUMULATORS PRE-CHARGE Using tool (D, Fig. 3-21) screwed to the accumulator connection (see 3.10.4 before) proceed as follows. Loosen the plug and screw in the hose from a nitrogen bottle complete with safety valve (V).

Close the nitrogen bottle tap. Wait five minutes. Check on the pressure gauge (M) that inflating pressure is 45 bar. Repeat the operation if lower. If pressure is higher, proceed as follows: - slowly turn the handwheel (D2) to let the nitrogen out and close;

WARNING - DANGER

Use only nitrogen to recharge accumulators. Never use oxygen or other gases for any reason whatever as explosion hazard may result. Slowly open the nitrogen bottle tap and check refilling pressure as it increases on the pressure gauge (M). IMPORTANT - Refilling pressure should be 10% at least higher than rated pressure considering that pressure inside the accumulator decreases when the compressed gas cools down.

- check on the pressure gauge (M) that pressure is as required. If not, repeat the operation; - turn the handwheel (D1) to screw in the accumulator screw (2); - remove tool (D); - tighten the screw (2) to a torque of 1.1 daNm; - check accumulator sealing using soapy water; - screw on protection cover (1).

D1 D M

D1

V M

D 1

D2 2

Fig. 3-21

A

Accumulators recharge device

D. Accumulators pre-charge test tool - D1. Plug control handwheel (2) - D2. Discharge tap - A. Nitrogen bottle - M. Pressure gauge - V. Safety valve - 1. Protection cover - 2. Threaded plug.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

BRAKES SYSTEM

W270

3 - 23

3.10.6 BLEEDING THE BRAKE SYSTEM It is necessary to bleed the brake system when anyone of the conditions here below occurs:

- position the machine on a level surface and start the engine;

- after replacing hydraulic oil in the attachment oil reservoir;

- with the engine idling, one operator should release the bleed screw (two on each axle) while the other is pressing the brake valve pedal. Tighten the bleed screw before releasing the brake pedal;

- when air has entered the system because of poor sealing of hoses or charge pump; - after disconnecting or replacing any of the system parts. Bleed the system as detailed below (this is a twoman operation):

- repeat this operation until bleeding all air from the system (fluid should come out of the bleed screw free of bubbles); - repeat for the other axle.

S

Fig. 3-22

S

Brake oil bleed screw (S) locations on the axle (1 per brake)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

3 - 24

W270

BRAKES SYSTEM

3.10.7 BRAKE DISC WEAR CHECK

A

Fig. 3-23

B

Brake disc wear check hole locations

Threads: LOCTITE 572

The control of the wear on the 4 brake discs (for each axle) is carried out after draining the oil from the group. Remove inspection plugs (A) and (B); The brake discs are to be replaced if a thickness gauge blade of the 5,3 mm can be made to pass through the steel discs. Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

SECTION 4

STEERING SYSTEM TABLE OF CONTENTS

PARAGRAPH

SUBJECT

PAGE

4.1

GENERAL DESCRIPTION .................................................................................... 1

4.2

STEERING GROUP ............................................................................................... 5

4.3

STEERING VALVE ................................................................................................. 7

4.4

STEERING SYSTEM PUMP ...............................................................................

9

4.5 4.5.1 4.5.2

STEERING VALVE CONTROL LINKAGE ............................................................. Linkage installation procedure ............................................................................... Operation...............................................................................................................

12 13 14

4.6 4.6.1 4.6.2 4.6.3

STEERING CYLINDERS ..................................................................................... Removal ............................................................................................................... Disassembly and reassembly ............................................................................... Installation ............................................................................................................

18 18 19 19

4.7 4.7.1

EMERGENCY STEERING CIRCUIT ................................................................... Components of the emergency steering ..............................................................

20 21

W270

4-1

STEERING SYSTEM

4.1 GENERAL DESCRIPTION Type: ..................................................................................................................................................... follower Mechanism: ................................................................................................................................... linkage chain Articulation angle of frames: ...................................................................................... 40° rightward and leftward Number of turns of steering wheel: ................................................................................................................ 4.2 Steering reduction unit: ............................................................................................................... worm and balls Pressure setting: .................................................................................................................... 206 bar (2980 psi) Flow setting: ..................................................................................................................... 100 lt/min (26.4 gpm) Steering pump: .......................................................................................................................... See “4.4 PUMP” Steering cylinder: Type: ........................................................................................................................ double acting piston Q.ty: ...................................................................................................................................................... 2 Cylinder stroke: ........................................................................................................................ 542 mm (21.3 in) Weight (per piece): ........................................................................................................................ 34 kg (75 lbs) The loader is of the articulated frames type. The steering system uses two hydraulic cylinders controlled by a control valve, to which the steering wheel is connected through a set of rods, links and levers. The steering force is applied between the front and rear modules by a couple of cylinders powered by the steering valve. The complete system includes: - two gear pumps, one of which is used in case of

emergency; - a steering valve with priority valve; - two hydraulic cylinders; - connecting pipes; - steering box/steering column; - steering wheel. Also, the emergency steering circuit, besides the pump, includes a multiple check valve and a diverter valve.

Cylinder

Steering valve

Steering box

To main circuit Linkage

Pump

Hydraulic reservoir Fig. 4-1 Chained leverage steering system Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

4-2

STEERING SYSTEM

NOTES:

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

Fig. 4.2 STEERING HYDRAULIC CIRCUIT EMERGENCY STEERING

The oil taken from the reservoir by the steering pump is delivered to the steering valve. The steering valve regulates the pressure and the flow of the oil. Also, it is equipped with a priority valve sending the excess oil from the steering circuit to the equipment circuit, when the steering does not require all the oil. When the steering wheel is actuated, the steering valve is activated, intercepting the oil coming from the pump, sending it to the steering cylinders. The oil discharged returns through the steering wheel to the oil reservoir.

STEERING CYLINDERS

IN 1,5 bar

A

B

STEERING VALVE

245 245 bar bar T

206 bar

EMERGENCY STEERING PUMP

DISCHARGE (IN COMMON WITH EQUIPMENT CONTROL VALVE)

P

TO EQUIPMENT CONTROL VALVE DELIVERY

PB

TO BRAKE VALVE

PILOT VALVE/BRAKE AND STEERING PUMP

HYDRAULIC OIL RESERVOIR

4-4

STEERING SYSTEM

BIANCA

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270

4-5

STEERING SYSTEM

4.2 STEERING GROUP The steering group is composed of steering wheel, steering column, steering box of the adjustable angle type. The steering box is of the recirculating-ball type and is characterised by a smooth operation.

Operation When the steering wheel is turned, a rotation of the steering shaft and the worm corresponds. The latter one drags, axially, the ball block, on the front part of which, the rack is located. The rack, with its axial movement, rotates the sector gear and its shaft keyed to the pitman arm that, through the linkages, actuates the steering control valve.

Note: the sketch does not illustrates the connection pipes and the circuit of the “Emergency steering”

Steering wheel Upper shaft Shaft support

Universal joint

Lower shaft

Spring cylinder

Steering column support

Steering wheel Power link

Steering valve

Steering cylinder

Fig. 4-3 Steering system Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

4-6

W270

STEERING SYSTEM

3 4

2

2

9 10

4

1 11

3

5

5

4 12

6

5

7

5

13

5

14 15

16

8 9

2

1

SECTION A-A

Fig. 4-4 Steering box

Notes -

1. 2. 3. 4. 5. 6.

1

2-3 daNm (14-22 ft-lbs)

2

3.5-5.4 daNm (25-39 ft-lbs)

3

20-24 daNm (140-170 ft-lbs)

5

Sliding area: grease

4

Lip area: grease

DUST COVER DUST SEAL REAR COVER SHIM STEERING BOX BALL BLOCK

7. SHAFT 8. BEARING 9. PITMAN ARM 10. DUST SEAL 11. BUSH 12. GEAR SECTOR

13. BUSH 14. SETTING SCREW 15. SHIM 16. SIDE COVER

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

5

W270

4-7

STEERING SYSTEM

4.3 STEERING VALVE Designation: ..................................................................................................................................... KVMT-200L Type: ................................................................................................. Valve with pressure compensation device Maximum regulated flow: .............................................................................................. 100 lt/min (19.8 US gal) Main pressure setting: ............................................................................................................ 206 bar (2980 psi) Safety and anticavitation valve setting: .................................................................................. 245 bar (3550 psi) Weight: ...................................................................................................................................... 22 kg (48.5 lbs) The steering valve is a control valve with a pressure compensation valve providing a delivery proportional to the movement of the steering valve spool, independently from the variation of the load pressure (steering cylinder pressure). The steering valve is equipped with a priority valve that, when no oil is required by the steering system, commutes automatically toward the equipment system. Thus, all the oil coming from the steering pump flows to the equipment control valve. As soon as the steering wheel is actuated, the priority valve feels the pressure drop at one of its ends. The action of the spring, plus the action of the pressure, acting from the opposite side, is capable of moving the valve plunger, directing the oil toward the steering

cylinders. The steering valve consists of a valve body, spool, priority plunger, main pressure relief valve and two anticavitation safety valves. The main pressure relief valve limits the pressure in the steering cylinders to 206 bar. As soon as such value is exceeded, the valve opens, connecting the steering system to the discharge. The excess oil, then, is directed to the hydraulic reservoir and the pressure returns within the maximum value. The safety/anticavitation valves, set at 245 bar, protect the two circuits of the steering cylinders from overloads, when the control valve is in neutral.

2

1 2 Stroke

Fig. 4-5 Steering valve 1. 2. A. B.

MAIN PRESSURE RELIEF VALVE SAFETY AND ANTICAVITATION VALVE CYLINDER PORT CYLINDER PORT

P. PUMP PORT PB. OUTLET PORT (to main hydraulic circuit) T. DISCHARGE PORT

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

4-8

W270

STEERING SYSTEM

1

4

P

2 5 8

6 T

SECTION A-A

3

SECTION B-B P

7

A

B

SECTION C-C

7

T

Fig. 4-6 Configuration of steering valve sections 1. 2. 3. 4.

PLUNGER MAIN PRESSURE RELIEF VALVE SPOOL SPRING

5. 6. 7. 8.

SPRING SAFETY AND ANTICAVITATION VALVE SAFETY AND ANTICAVITATION VALVE SPOOL SPRING COVER

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

4-9

STEERING SYSTEM

4.4 STEERING SYSTEM PUMP The steering cylinders control circuit is powered by a two section hydraulic pump. One section of the pump powers, through a priority valve, the steering system.. The other section powers the brakes system and the power system pilot valve. The pump sucks oil from the hydraulic reservoir, with

the steering system at rest, sending it to the equipment control valve. The oil flow in the delivery circuit is proportional to the performance required. A main pressure relief valve, set at 206 bar, regulates the maximum pressure of the system, discharging the pressure in excess.

1

2

Fig. 4-7 Installation of the steering pump on the transmission-torque converter group Notes: 1

Pay attention to the installation position of the elastic ring

1. STEERING PUMP 2. BRAKES/POWER SYSTEM PUMP

2

Mating surface LOCTITE 509

3. COUPLING SLEEVE 4. TORQUE CONVERTER

Steering section

Designation: ................................................................................................................ Kayaba KFP5190 Type: ............................................................................................................................................... gear Drive: .............................................................................................................................................. gear Delivery at rated speed: ................................................................................ 193 lit/min (50.9 U.S. gpm) Maximum pressure: ................................................................................................... 210 bar, 2200 rpm Engine/pump speed ratio: .......................................................................................................... 0.982 : 1

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

4 - 10

W270

STEERING SYSTEM

Delivery side

Suction side

Suction

Delivery

Rotation direction

1. STEERING PUMP (CENTRAL)

2. BRAKES AND POWER SYSTEM PUMP (REAR)

Fig. 4-8 Steering/brakes and power system pump

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

4 - 11

STEERING SYSTEM

Section B-B

Section A-A

Fig. 4-9 Steering pump sections

1. 2. 3. 4. 5.

MOUNTING FLANGE DRIVEN GEAR INTERMEDIATE PLATE CENTERING DOWEL COVERING PLATE

6. 7. 8. 9. 10.

ADAPTER BRAKES/POWER SYSTEM PUMP (see fig. 4.11) SEALS WASHER PLATE

11. 12. 13. 14. 15.

DRIVING GEAR COUPLING SLEEVE PLATE BACK-UP RING SEAL

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

4 - 12

W270

STEERING SYSTEM

4.5 STEERING VALVE CONTROL LINKAGE

10

1

9 2

10 2

3

2 11 4

5

10

1 View from A

6

1

7

8

Fig. 4-10 Control linkage Notes: 1

1. 2. 3. 4.

Threaded area: LOCTITE 262

STEERING VALVE STROKE END SCREW STEERING BOX ROD

5. 6. 7. 8.

BALL JOINT SUPPORT PLATE RUBBER PAD ROD

2

Align with central articulation pin centre line

9. BEARING 10. LEVER 11. PIN

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

4 - 13

STEERING SYSTEM

The steering control linkage transfers the movement of the steering wheel to the spool of the steering valve, through the steering box located under the steering column (cab). The pivot centre line between the steering valve control

rod and lever 10 (fig. 4.11) passes exactly through the centre line of the pivot of the two frames of the machine. In this manner, a perfect operation of valve 1 is ensured, independently from the steering angle of the loader.

Unit: mm (in) [ ]: Reference dimension

A

10

1

(L)

M

1

Fig. 4-11 Installation of linkage Notes: 1 2

Length of rod mm (in) Tighten the screw at the top of the threaded area

L (ref) 494 (19.4)

M 697 (27.4)

4.5.1 Installation procedure for the linkage - Set the rod length at the value indicated in the sketch, prior to assembling the linkage. - Set the length of stop (A) connected to the driver compartment at 28 mm.

- Rotate the loader on the place and set the length of stop screw (A) so that the gap between the front and rear frame becomes 15 mm.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

4 - 14

W270

STEERING SYSTEM

4.5.2 Operation 1. Steering valve in neutral If the steering wheel is not turned, the steering valve remains in neutral. The cylinder ports of the steering

valve are closed and there is no flow of oil into the steering cylinders. Thus the loader moves straight.

LEVER

STEERING WHEEL (STATIONARY)

STEERING VALVE IN NEUTRAL

STEERING BOX

POWER LINK

PIN

Fig. 4-12 Steering valve in neutral

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

4 - 15

STEERING SYSTEM

2. Turning the steering wheel in a clockwise direction Operation of the linkage - When turning the steering wheel in a clockwise direction, the gear sector shaft of the steering box turns to move the pitman arm in the direction of the rear side of the loader. - The movement of the arm, moves the lever through the rod, pushing the spool of the steering valve. - When the steering valve is open, pressurised oil from the steering pump is delivered to the steering cylinders, that move the front frame rightward,

steering the loader in a clockwise direction. - The movement of the steering valve spool, thus the entire linkage, is proportional to the turns made by the steering wheel. Thus, the steering radius of the loader changes with the rotation of the steering wheel. - The speed of operation of the linkage is determined by the rotation speed of the steering wheel and changes with the opening of the oil passage to the cylinders.

ROD

ROTATION OF LEVER

SUPPORT POINT

LEVER

ROTATION OF RELAY LEVER

ROTATION OF STEERING WHEEL CLOCKWISE

SPOOL PUSHED LEFTWARD

POWER LINK

Fig. 4-13 Rotation of steering wheel in clockwise direction

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

4 - 16

W270

STEERING SYSTEM

3. Operation of the linkage under reaction - After rotating the steering wheel clockwise, stop it and hold it in position. The steering linkage stops. - Under the effect of the consequential rotation of the front frame, the linkage returns the rod connected to the spool of the steering valve into neutral position

ROTATION OF THE FRAME RIGHTWARD

as well as the spool. - At his point, the front frame stops rotating, maintaining the steering angle arranged by the rotation of the steering wheel.

SPOOL DRAGGED INTO NEUTRAL POSITION

ROD SUPPORT POINT

ROD

LEVER ROTATION

Fig. 4-14 Operation of the linkage under reaction

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

4 - 17

STEERING SYSTEM

4. Rotation of the steering wheel in anticlockwise direction When the steering wheel is rotated leftward, the spool is pulled toward the rear side of the loader, allowing pressurised oil to flow toward the cylinders in a direction opposite to the situation of the clockwise steering.

Also the operation of the linkage under reaction is opposite, although the spool is returned, in any case, into neutral, as a consequence of the stopping of the steering wheel (see page 4-18).

LEVER ROTATION

SUPPORT POINT

ROTATION OF STEERING WHEEL ANTICLOCKWISE RELAY LEVER ROTATION

SPOOL PULLED RIGHTWARD

Fig. 4-15 Rotation of the steering wheel in anticlockwise direction

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

4 - 18 4.6

W270

STEERING SYSTEM STEERING CYLINDERS

4.6.1. Removal

The two, double acting, steering cylinders, with rod and cylinder sleeve mounted, respectively, to the front and rear module of the frame. The loader is steered by extracting or retracting the rod. Specifications: Cylinder bore ................................................ 80 mm Rod diameter................................................ 45 mm Piston stroke........................................ 542 ± 2 mm Weight ................................................. 34 kg 70 lbs

1

1

2

3

4

8

Proceed as follows: - drain the oil from the equipment reservoir; - disconnect the oil pipes; - from the rod side, loosen the retaining plate securing screw and extract the pin; - disconnect the greasing pipe of the pivot pin from the left cylinder; - from the bottom side, loosen the retaining plate

9

10

11

12

2

13

5

6

7

17

Section

3

14

4

15

16

Fig. 4-16 Steering cylinder components Notes -

1

46 daNm (330 ft-lbs)

2

105 daNm (759 ft-lbs)

3

1.65 daNm (11.9 ft-lbs)

4

Pressure pick-up (PT 1/8) Threaded area: LOCTITE 767

1. Cylinder head - 2. O-Ring - 3. Back-up ring - 4. O-Ring - 5. Mud scraper - 6. Bushing - 7. Seal - 8. Cylinder rod - 9. Cylinder sleeve - 10. Piston seal -11. O-Ring - 12. Piston - 13. Stop screw - 14. Steel ball - 15. Ball bushing - 16. Snap ring - 17. Pressure pick-up plug.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

STEERING SYSTEM

securing screw and extract the pin;

4 - 19

4.6.3 Installation

- remove the cylinder assembly.

Reinstall the cylinder on the machine, reversing the removal sequence.

4.6.2 Disassembly and reassembly

After starting the engine, check, with repeated movements of the steering, that the cylinder rod does not show signs of leakages.

Loosen cylinder head (1) and extract rod (8) complete with piston (12). Loosen the piston securing screw (13), then loosen it from the cylinder rod (8).

Handle all components with great care. Do not place hands and fingers between parts. Wear glasses, gloves and safety shoes.

In the event the ball bushing has an excessive play, replace it as follows: - remove retaining snap rings (16); - using a punch or a press, extract bushing (15) from its seat, taking care to push on the outer side of the bushing only. Check that the rod is free from signs of denting, burring or wear. Check, using a ruler or placing it on a flat surface, that the rod is not bent. Inspect the inside of the cylinder; in the case of scratches or wear, it must be replaced. Replace all damaged components. Reassemble the cylinders, reversing the disassembly phases considering the following: - lubricate all parts appropriately; - install new seals, ensuring the correct position and direction; - tighten the piston to torque 2 ; - tighten screw (13) to torque 3 and stake; - tighten front head (1) to torque . 1

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

4 - 20 4.7

W270

STEERING SYSTEM STEERING EMERGENCY CIRCUIT

General description the flow of oil to the emergency circuit is ensured. The oil sucked by the emergency pump flows, through a multiple check valve, to the diverter valve that, in case of failure of the steering pump, acts in a manner allowing the flow of oil toward the steering control valve and the cylinders.

The emergency steering circuit has the purpose of allowing the steering of the machine, in the event of accidental cutting-off of the engine or in case of failure of the main steering pump. Its intervention is signalled by the activation of an indicator light located on the right of the dashboard. The configuration of the device includes a gear pump keyed directly to the 3rd - 4th speed shaft, so that, when the machine is moving forward or backward,

STEERING VALVE

1.0

E/G EQUIPMENTSTEERING-BRAKES PUMP

IN

1,5 bar

A

T STEERING T/M EMERGENCY PUMP

CAB DASHBOARD C

H

1\10 h

EMERGENCY STEERING INDICATOR

HOURMETER

Fig. 4-17 Emergency steering diagram

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

4 - 21

STEERING SYSTEM

4.7.1 COMPONENTS OF EMERGENCY STEERING

Emergency Steering Pump

From Steering Pump

Multiple Check Valve

Diverter Valve

Check Valve

Check Valve

Fig. 4-18 Components of the emergency steering circuit 1. PUMP Designation: ................................................................................................................................ R20 150M Type: .................................................................................................................................................... gear Drive: ................................................................................................................................................... gear Delivery: ................................................................................................................................. 55 cu cm/turn Max. pressure: ................................................................................................................................. 175 bar Max. speed: ......................................................................................................................... 600 - 2500 rpm

Fig. 4-19 Emergency steering pump

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

4 - 22

W270

STEERING SYSTEM

2. DIVERTER VALVE From emergency steering pump

A

To hydraulic reservoir To steering valve Sensor seat

AT

P1

Piloting (from steering pump)

P Plunger

Fig. 4-20 3. MULTIPLE CHECK VALVE From Steering Emergency Pump

P

P

To diverter valve

A

B

T Discharge

P A

B T

Fig. 4-21

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

SECTION 5

BUCKET BOOMS AND FRAME TABLE OF CONTENTS

PARAGRAPH

SUBJECT

PAGE

5.1 5.1.1 5.1.2 5.1.3

GENERAL DESCRIPTION ...................................................................................... Bucket .................................................................................................................... Bucket positioner device ......................................................................................... Boom kick-out setting .............................................................................................

1 5 6 7

5.2 5.2.1

FRAME ................................................................................................................... 8 Frame centre pivoting .............................................................................................. 9

5.3

BUCKET ABUTTING .............................................................................................. 11

W270

BUCKET BOOMS AND FRAME

5-1

5.1 GENERAL DESCRIPTION The load handling system is composed of: - booms - strut - link - bucket - bucket cylinder - boom cylinders - pins

The bucket positioner device and the boom kick-out ensure an optimised efficiency of the equipment. All pivot pins of the handling system have dust seals to prevent the entry of debris. The three bucket pivot pins and the lower strut hinging pin are equipped with O-rings. All pivot pins are mounted with securing screws. For the part relative to bucket and boom cylinders, please refer to Section 6 (Hydraulic system).

Linkage ........................................................................................................................................ Zed Bucket shape ................................................................................................... DEB, general purpose Bucket capacity: Heaped ................................................................................................................ 4 cu m (3.92 cu yd) Struck ............................................................................................................... 3.4 cu m (3.77 cu yd) Bucket positioner ........................................................................................ Mounted (proximity type) Boom kick-out ............................................................................................. Mounted (proximity type) Weight: Booms .................................................................................................................. 1490 kg (3284 lbs) Strut .......................................................................................................................... 390 kg (860 lbs) Link ............................................................................................................................. 72 kg (258 lbs) DEB bucket (without cutting edge) ........................................................................ 1675 kg (3690 lbs)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

5-2

W270

BUCKET BOOMS AND FRAME

3

4

2 1

6 5

11 7

8 12

8

9

7

12

9

11

10

10

Detail of typical pin

Bucket pins

Fig. 5-1 Booms, strut and bucket

Note: Apply grease to the inner surfaces of the bushings and dust seals, prior to inserting the pins. Apply rust preventing oil to the inner surfaces of the bosses. 1. 2. 3. 4. 5. 6.

BUCKET STRUT BOOM BUCKET CYLINDER LINK BOOM CYLINDER

7. 8. 9. 10. 11. 12.

LOCKING SCREW DUST SEAL BUSHING PIN GREASE FITTING O-RING

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

5-3

BUCKET BOOMS AND FRAME

1

1

Section A-A

Section B-B

Section C-C

1

1 1

Section D-D

Section E-E

Section F-F

Section H-H

Section I-I

1

Section G-G

Fig. 5-2 Booms, Strut and Bucket

Note -

1

Set a maximum play at 1. 5 mm (0.059 in) or less.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

5-4

W270

BUCKET BOOMS AND FRAME

The 5 mm. diam. hole of the bush must be aligned with the centre line of the link and cylinder ringes.

D

D

Section D-D

Duter lube groove

Bush installation diagram

8 mm

Immer lube groove

Fig. 5-3 Installation of equipment central hinging bushes. Note: On the central hinging of the link (section D-D) the bushes must be oriented with the outer grooves directed inword.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

5-5

BUCKET BOOMS AND FRAME

5.1.1 BUCKET A standard bucket, with a screw-on reversible cutting edge, is supplied as a standard. Upon request, a welded cutting edge and a bolted teeth version is

available. The choice of the type of bucket, as a function of the material and the work conditions, is essential, to ensure an efficient performance.

(Multiple purpose bucket with reversible cutting edge, DEB) Note -

107 daNm (788 ft-lbs)

1

1

(Multiple purpose bucket with bolted teeth) Notes - 1

194 daNm (1430 ft-lbs) 107 daNm (788 ft-lbs)

2

2 1

Fig. 5-4 Bucket

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

5-6

W270

BUCKET BOOMS AND FRAME

5.1.2 BUCKET POSITIONER DEVICE WARNING

Setting of automatic bucket positioner The purpose of the bucket positioner is to stop the bucket at a predetermined digging angle. (It is set at the Plant so that the bucket is parallel with the ground surface) As an example, when the equipment control lever is moved into the roll-back position, after dumping a load, the lever is kept in this position until the bucket reaches the pre-defined angle. Then the lever is automatically returned to neutral.

Setting procedure

Notice - Do not apply an excessive force on the bucket cutting edge during the roll-back. Cracks and damages could be caused to the bucket and other accessories that could have been mounted. The setting of the bucket automatic positioner can be performed, by setting the position of the proximity switch. The bucket automatic positioner is set so that the bucket is parallel with the ground surface. In the event it is necessary to change the setting, operate as follows:

1. Position the bucket with the desired angle. Stop the engine: The bucket can be tilted forward up to 6°. 2. Loosen the nuts securing the proximity switch and slide the rear end of the positioner bar to full stroke, until it is positioned in the middle of the sensing surface (orange). Tighten the securing nuts. 3. If a bucket angle exceeding 6° is required, loosen the two nuts securing the U clamps and move the bracket into the appropriate position and retighten them. 4. After the setting, start the engine and check that the bucket stops at the desired angle.

Prior to setting the bucket automatic positioner, apply the parking brake. Do not allow anyone to stand near the loader equipment.

Fig. 5-5 Installation of the bucket positioner 1. 2. 3.

POSITIONING BAR PROXIMITY SWITCH BRACKET

4. 5.

WIRING BUCKET CYLINDER

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

5-7

BUCKET BOOMS AND FRAME

5.1.3 SETTING OF BOOMS KICK-OUT When the loading work is almost continuously the same, it is good practice to set the raise kick-out in a predetermined position, appropriate for the job to be performed. To set the position, it is necessary to act upon the two screws securing bracket 2, so that proximity sensor 1 is moved with respect to plate 5 fixed to the booms. In this manner, it is possible to obtain an anticipated or retarded intervention, with respect to the value arranged on new machines.

The kick-out device stops the loader booms at a predetermined heights, during the raise phase. (It is set at the Plant at a height just below full stroke). When the booms raise lever is pulled backward, beyond the stroke end, it is kept automatically in detent by a solenoid inside the pilot valve. This type of detent makes the loader booms to raise automatically until a pre-determined height is reached, to which corresponds the release of the control lever, that returns to neutral position.

1

2

3

4

5

Wiring diagram Proximity switch Booms kick-out

Fuse

Float Proximity switch Bucket positioner

Fig. 5-6 Installation of booms kick-out 1. 2. 3.

PROXIMITY SWITCH BRACKET BOOMS

4. 5.

FRONT FRAME PLATE

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

5-8

W270

BUCKET BOOMS AND FRAME

5.2 FRAME WARNING The frame is of a welded steel plate type and is divided into two parts: front and rear frames. The cab is mounted on the rear frame.

Do not attempt any modification on the ROPS (Roll over protection structure), if installed, without prior authorisation by the Manufacturer. In the event the ROPS is damaged or deformed, as a consequence of a roll over or a collision, it is recommended that it is replaced by a new one, since a damaged or deformed ROPS has a low structural resistance.

COWLING ROPS CAB

BALANCE WEIGHT

OPERATOR COMPARTMENT

REAR AXLE

FRONT AXLE FRONT FRAME

REAR FRAME

Fig. 5-7 Frame

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

5-9

BUCKET BOOMS AND FRAME

1

2

1

Fig. 5-8 Rear ballast installation Note 1. 2.

1

151 daNm (1110 ft-lbs)

PIN REAR BALLAST - (2550 kg - 56100 lbs)

5.2.1. FRAME CENTRAL PIVOT The loader is of an articulated frames type: the front frame is connected to the rear frame by two hinging pins around which the loader is pivoting, when steering.

WARNING

The steering action could crush the body between the two modules (front and rear) of the frame. Block the articulation with the safety bar, prior to transporting the machine or performing repair interventions. On the other hand, relocate the safety bar in its original position, prior to starting operating the machine.

(With loader under repairs) Fig. 5-9 Safety bar

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

5 - 10

W270

BUCKET BOOMS AND FRAME

(Upper hinging)

4

1

3

5

6 7

1 2

4

3

8

9

13

(Lower hinging)

3

14

1

15 6 16 10

17

11

18

4

12 2

1

Fig. 5-10 Central hinging Notes - 1 2

1. 2. 3. 4. 5. 6.

COVER DUST SEAL BUSHING COVER SHIM GREASE FITTING

9 daNm (65 ft-lbs)

3

Threaded area: LOCTITE 262

22.3 daNm (165 ft-lbs)

4

Ring outer area: LOCTITE 262

7. 8. 9. 10. 11. 12.

BEARING PIN BUSHING COVER SHIM WASHER

13. 14. 15. 16. 17. 18.

PIN COVER SHIM BEARING DUST SEAL BUSHING

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

BUCKET BOOMS AND FRAME

5 - 11

5.3 BUCKET ABUTTING END PLUGS

640

A

30

MAX LENGHTH -5 mm

Fig. 5-11

Set lower bucket hinging pin axis at 640 mm from ground. Extend bucket cylinder to its max. position and then retract it by 5 mm. Weld the two upper abutting end plugs "A" to the bucket. Plug thickness shall be equal to the span between boom and bucket.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

5 - 12

W270

BUCKET BOOMS AND FRAME

20

C B

Fig. 5-12

Set booms to max. height. Weld the two lower abutting end plugs "B" to the bucket so that with completely tilted bucket, "C" span is equal to 2 mm max.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

SECTION 6

EQUIPMENT HYDRAULIC SYSTEM TABLE OF CONTENTS

PARAGRAPH

SUBJECT

PAGE

6.1

GENERAL DESCRIPTION .................................................................................... 1

6.2 6.2.1 6.2.2

HYDRAULIC SYSTEM PUMP ............................................................................... 5 By-pass valve ......................................................................................................... 7 Inspection and repair of equipment pump .............................................................. 8

6.3 6.3.1 6.3.2 6.3.3

EQUIPMENT CONTROL VALVE ............................................................................ General description ................................................................................................ Main pressure relief valve ....................................................................................... Safety and anti-cavitation valves ............................................................................

6.4 6.4.1 6.4.2

CONTROL VALVE CONTROLS ............................................................................. 15 Control valve hydraulic control ................................................................................ 16 Supplementary hydraulic function (variant) ............................................................. 20

6.5

HYDRAULIC OIL RESERVOIR............................................................................... 26

6.6 6.6.1 6.6.2

CYLINDERS ........................................................................................................... 27 Boom cylinders ....................................................................................................... 27 Bucket tilt cylinder .................................................................................................. 27

6.7 6.7.1 6.7.2 6.7.3 6.7.4 6.7.5 6.7.6

LOAD TRAVEL STABILISER L.T.S. (variant) ......................................................... Description ............................................................................................................. Discharging the accumulators ................................................................................ L.T.S. hydraulic diagram ......................................................................................... Functional tests of L.T.S. system ............................................................................ Check of L.T.S. accumulator pre-charge ................................................................ Instructions for the resetting of the accumulator pre-charge ..................................

10 10 12 13

30 30 30 32 33 34 35

W270

EQUIPMENT HYDRAULIC SYSTEM

6-1

6.1 GENERAL DESCRIPTION The configuration of the hydraulic system is as follows: An hydraulic oil reservoir with a capacity of 124 l (32.7 U.S. Gal), capacity of the system about 220 l (58 U.S. Gal) mounted centrally on the right side of the loader, complete with filter protected by a by-pass valve set at 1 bar, located on the return oil circuit from the actuators. An hydraulic pump with a by-pass valve mounted on the transmission housing and driven by a gear secured to the converter pump wheel. A two-section, monobloc type control valve receives the oil from the pump, setting the system pressure through a main pressure relief valve set at 206 bar. The control valve, as already stated is a two section series type feeding two circuits: bucket roll back/dump and boom raising and lowering. Each one of these two circuits is equipped with safety and anti-cavitation valves, preventing dangerous pressure peaks that could occur in the pipes and cylinders. Each section is equipped with a spool, hydraulically piloted by a power assisted pilot valve; the control valve control circuit operates at a pressure of about 30 bar and it is connected with the brakes circuit. The pilot valve can be hydraulically cut-off by a three-way diverter valve (stop valve), so that the accidental actuation of the levers, causing possible undesired reactions by the equipment, is prevented. The equipment control valve is connected with the steering circuit. The excess oil arriving from the steering pump is sent, with steering in neutral, to the equipment circuit through a priority valve. The circuit includes also, as an optional, a stress reducing device when the machine is travelling on rough terrain with a full bucket, the device is called L.T.S. (Load Travel Stabiliser). It is known, in fact, that during the travel of the machine on rough terrain, the load of materials causes a troublesome pitching of the unit, reflecting on the stability of the machine itself, of the load and on the operator’s comfort. In this case, a big hydraulic accumulator, pre-loaded with nitrogen and capable of absorbing the dynamic loads, is connected through a block of valves with the boom cylinders.

Once the speed of 7 km/h (3.1 m/h) is exceeded, a solenoid valve automatically activates the system, connecting the cylinder chambers with the accumulator and allowing the actuation of the damping effect. A sequence valve set at 120 bar, has the function of protecting the accumulator from pressure peaks.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

6-2

EQUIPMENT HYDRAULIC SYSTEM

W270

Control valve lever

Control lines Control valve

Oil reservoir

Pump

Bucket tilt cylinder

Control valve

Main hydraulic circuit

Boom left cylinder

Fig. 6-1 Equipment hydraulic system

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Fig. 6-2

Equipment hydraulic system A

T

NEUTRAL BOOM CYLINDERS

STEERING VALVE

B

STOP VALVE

P B2

3

1

EQUIPMENT PILOT VALVE

274 bar

A2

X

Pb2

A1

Pa2

B1

B1 230 bar

186 bar

2

A1 Pb1

BUCKET CYLINDER

A2

Pa1

B2 206 bar

T

T1 P1

ACCUMULATOR

P2

T2 TO PARKING BRAKE

Y

PRESSURE RELIEF VALVE

TO DISCHARGE FROM STEERING VALVE X2

0,7 l 0.7 l

FROM STEERING VALVE (PRIORITY VALVE)

B

19 bar (5 l/min)

P

M

FROM BRAKE VALVE (FEEDING)

X1

MX

MA

A

Y

30 bar

T

PV

LTS VALVE (OPTIONAL)

T

HEAT EXCHANGER

172 bar

x

EQUIPMENT PUMP WITH QUICK DISCHARGE VALVE

RETURN FILTER

EQUIPMENT PUMP

1 bar

OIL RESERVOIR

6-4

EQUIPMENT HYDRAULIC SYSTEM

BIANCA

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270

EQUIPMENT HYDRAULIC SYSTEM

6-5

6.2 HYDRAULIC SYSTEM PUMP This valve, set at 206 bar, regulates the maximum pressure of the system, discharging pressure in excess.

The circuit controlling the hydraulic cylinders is powered by an hydraulic pump sucking oil from the hydraulic reservoir and sending it to the equipment control valve. The pressure established in the delivery circuit is proportional to the performance required and it is, in any case, limited by the pressure relief valve.

3 Note:

1

Pay attention to the mounting position of the circlip

4 A

2

1

1

5 B Fig. 6-3 Installation of pump on transmission/torque converter group A. B. 1. 2.

from HYDRAULIC OIL RESERVOIR (suction) to EQUIPMENT CONTROL VALVE (delivery) EQUIPMENT PUMP PUMP DRIVE SLEEVE

3. 4. 5.

TORQUE CONVERTER TRANSMISSION PUMP BY-PASS VALVE

Designation: .................................................................................................................. Kayaba KFP5190 Type: ................................................................................................................................................. gear Drive: ................................................................................................................................................ gear Flow rate at nominal speed: ..................................................................................... 193 ltr/min a 170 bar Max. pressure: .............................................................................................................................. 206 bar Engine/pump speed ratio: ........................................................................................................... 0.982 : 1 Pump speed: ................................................................................................................... 600 ÷ 2500 rpm Weight: ......................................................................................................................... 22.3 kg (49.2 lbs)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

6-6

EQUIPMENT HYDRAULIC SYSTEM

5

10

1

6

9

8

W270

3

11

B

A

B

A

2

7

6

14

7

Section B - B

4

8

Section A - A

Fig. 6-4 Sectional views of equipment pump

1. 2. 3. 4. 5. 6. 7.

INTERMEDIATE PLATE DRIVE GEAR DRIVEN GEAR MOUNTING FLANGE LOCK PLATE PLATE SEAL

8. 9. 10. 11. 12. 13. 14.

BACK UP RING PLATE DOWEL O-RING SEAL SNAP RING WASHER

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

12

13

9

W270

EQUIPMENT HYDRAULIC SYSTEM

6-7

6.2.1 BY-PASS VALVE the equipment circuit. The setting value is 172 bar.

The by-pass valve, mounted on the equipment pump outlet, allows the by-passing of the oil delivered by the pump itself, in the event of excessive pressure in

15

Section B - B

7

6

5

3

4

2

View from A

14

13

12

11 10

9

8

Sezione C - C

Fig. 6-5 By-pass valve section 1. 2. 3. 4. 5.

PLUG SPRING BODY PLUNGER PLUG

6. 7. 8. 9. 10.

RETAINING VALVE PLUG PLUG TAPER VALVE SPRING

11. 12. 13. 14. 15.

SPRING GUIDE SETTING VALVE LOCKNUT NUT ADAPTER

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1

6-8

EQUIPMENT HYDRAULIC SYSTEM

6.2.2 INSPECTION AND REPAIR OF EQUIPMENT PUMP

Suction chamber

When disassembling, mark all components so that they can be re-installed in the correct position. After cleaning each individual item, inspect all the parts of the pump. 1) Gear plate One of the methods to obtain a better volumetric efficiency of a gear pump is the design allowing the end of the teeth to stay in contact with the inner wall of the chamber containing the gear itself. Consequently, once the pump starts running, marks left by the gear teeth are shown around the suction port (fig. 6-6). The contact mark is normal as long as it is less than 1/2 the inner circumference of the gear cavity. Dimension a of the mark depth (fig. 6-7) is normal if it as about 0.05 mm (0.00196 in). When dimension a exceeds 0.15 mm (0.00589 in) also the shaft and bearings can wear out. Thus, these items as well, must be thoroughly checked. If a is ≥ 0.15 mm (0.00589 in), replace the pump with a new one.

W270

a

Contact mark

Fig. 6-7 Dimension of mark depth

2) Driving and driven gear In case the shaft or the gear surface shows roughness felt by running a finger nail, or in case the surface of the teeth shows excessive wear zones, it is necessary to replace the item.

Ø

d

Suction chamber

Contact mark

Fig. 6-6 Gears intermediate plate

Fig. 6-8

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

EQUIPMENT HYDRAULIC SYSTEM

3) Pressure plate (9, fig. 6-4) As shown in fig. 6-9, the pressure plate, under normal conditions, shows smoothed irregularities on the copper alloy side of the surface touching the gear. If during the disassembly operation, the following situation is found, replace the part with a new one:

6-9

Sliding bearing

– In case the level of roughness found shows several scratches that can be felt by a finger nail. Suction side

Irregularities

Fig. 6-10

Discharge side

Irregularities on the bearings

Suction side

Irregularities

Fig. 6-9 Irregularities on the plates 4) Mounting flange (4) and covering plate (5) (fig. 6-4) Regarding the mounting flange and the cover plate, check to find out it there is an eventual wear in the bearing zone (fig. 6-13). If the teflon film is worn-out and the red surface of the copper base metal is showing for an arc larger than 150° along the inner circumference of the bearings, change the part.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

6 - 10

EQUIPMENT HYDRAULIC SYSTEM

W270

6.3 EQUIPMENT CONTROL VALVE

EQUIPMENT CONTROL VALVE 2 - SPOOL (PILOT CONTROLLED)

Model: ...................................................................................................................... Kayaba KVML-270-2 Type: ................................................................................................... In series - 2 spools pilot controlled Spool sequence: .............................................................................. P ––> BUCKET ––> BOOMS ––> T Setting of main valve: ........................................................................................................... 206 ± 10 bar Setting of safety and anticavitation valve (A1): ...................................................................... 230 ± 10 bar Setting of safety and anticavitation valve (B1): ...................................................................... 186 ± 10 bar Setting of safety and anticavitation valve (A2): .............................................................................. 274 bar Delivery: .................................................................................................................................... 270 l/min Weight: ........................................................................................................................................... 54 Kg

6.3.1 GENERAL DESCRIPTION The equipment control valve is a 2 spools monobloc type. The internal oil passages are of the series type so that the bucket function has the priority on the boom function. The pressure oil therefore reaches the boom outlet port only when the bucket spool is in neutral position. The control valve is hydraulically actuated by means of a pilot valve located in the cab; it is equipped with a main pressure relief valve and three safety and anticavitation valves. When the pressure in the system exceeds the value of 206 bar, the main pressure relief valve discharges oil to protect cylinders and pipes. The safety and anti-cavitation valves protect the relevant circuits from sudden pressure peaks due to mechanical loads on the equipment capable of causing a pressure increase beyond the pre-set value, and they are mounted on the single spools of the control valve.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

EQUIPMENT HYDRAULIC SYSTEM

1

2

View from C

3

Fig. 6-11 1. 2. 3. 4. A1 B1

4

Equipment 2 spool control valve

SAFETY AND ANTICAVITATION VALVE (186 bar ± 10) MAIN PRESSURE RELIEF VALVE (206 bar ± 10) SAFETY AND ANTICAVITATION VALVE (274 bar ± 10) SAFETY AND ANTICAVITATION VALVE (230 bar ± 10) BUCKET SPOOL SECTION BUCKET SPOOL SECTION

A2 B2 P1. P2. T1. T2.

BOOMS SPOOL SECTION BOOMS SPOOL SECTION OIL INLET (FROM PUMP) OIL INLET (FROM STEERING VALVE) DISCHARGE DISCHARGE (FROM STEERING VALVE)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

6 - 11

6 - 12

EQUIPMENT HYDRAULIC SYSTEM

6.3.2 MAIN PRESSURE RELIEF VALVE The main pressure relief valve is located in the inlet section, between the neutral duct and the low pressure duct (discharge duct).

Operation

W270

b) Operation (A) When the pressure in neutral duct (HP) increases and exceeds the pressure setting of the main relief valve piloted valve (5) opens. Pressurised oil, discharged by the pilot valve, enters low pressure duct (LP), flowing through sleeve (4) and valve seat (6).

a) At rest Oil at the delivery pressure in neutral duct (HP) flows through orifice (2) of main valve (1) filling inner cavity (3). Because of the surface difference on which the pressure actuates, main valve (1) stays closed in its seat in sleeve (4).

4 6 LP

HP

LP 4

5

LP Fig. 6-13

Operation (A)

HP

LP

2

1

Fig. 6-12

3

At rest

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

EQUIPMENT HYDRAULIC SYSTEM

c) Operation (B)

6 - 13

Operation

When pilot valve (5) opens, the pressure in inner cavity (3) decreases, moving main valve (1), so that pressurized oil in neutral duct (HP) can discharge directly into low pressure duct (LP).

a) At rest Pressurized oil, in the port connected to cylinder (HP), flows through the orifice in piston valve (1) and acts on the opposite surfaces of make-up valve (2) and safety valve (3). Due to the surface difference on which the pressure works, the two valves are kept closed, one against the other.

LP 2

LP HP HP LP 1

3

5

1

Fig. 6-15

Fig. 6-14

LP

3

At rest

Operation (B)

b) Operation (A) 6.3.3

SAFETY AND ANTI-CAVITATION VALVES

The safety and anti-cavitation valves are mounted in the bucket and booms sections. In the bucket section, a valve is located between port (A1) connected with the cylinder (bottom side) and the discharge duct, and a valve between port (B 1) connected with the cylinder (rod side) and the discharge duct. The booms section is equipped with a single safety valve, located between port (A2) connected with the cylinders (bottom side) and the discharge duct. The eventual auxiliary section is also equipped with two valves configurated, respectively, between the ports connected with the cylinder chambers and the discharge.

When the pressure in the port connected to cylinder (HP) increases and exceeds the setting of the safety pressure, pilot valve (4) opens. Pressurized oil, discharged by the pilot valve, enters low pressure duct (LP) flowing through make-up valve (2) and valve seat (5).

5 LP

2

HP

LP

Fig. 6-16

Operation (A)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

4

6 - 14

EQUIPMENT HYDRAULIC SYSTEM

c) Operation (B)

W270

e) Operation in make-up

When pilot valve (4) opens, the pressure on the raer side of piston valve (1) decreases, moving piston valve (1). Consequently, the orifice of piston valve (1) closes so that the pressure on the rear side of safety valve (3) decreases further.

If the pressure at port (HP) connected to the cylinder is lower than the value in low pressure duct (LP), being a condition for potential cavitation, make-up valve (2) moves proportionally to the surface difference on which a negative pressure intervenes. Consequently, to avoid cavitations, oil can flow from low pressure duct (LP) to port (HP) connected to the cylinder.

LP LP

2

HP HP 1

3

LP

4 LP

Fig. 6-17

Operation (B) Fig. 6-19

Operation in make-up

d) Operation (C) The pressure acting on the opposite surfaces of safety valve (3) are unbalanced. Due to this pressure difference, the safety valve opens so that pressurized oil can be discharged directly from port (HP) connected to the cylinder, to low pressure duct (LP).

LP

HP

3

LP

Fig. 6-18

Operation (C)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

EQUIPMENT HYDRAULIC SYSTEM

6 - 15

6.4 CONTROL VALVE CONTROLS The control system of the control valve is of a power assisted type with different levers for the functions: booms lowering/raising and bucket roll-back/dumping. The control valve spools are actuated by hydraulic connections. The circuit pressure (30 bar) is ensured by a pressure relief valve equipped with an hydraulic accumulator. It is possible to install, upon request, a third lever controlling a third spool of the control valve, in case it becomes necessary to mount a special type of equipment requiring a third hydraulic function. For this

Fig. 6-20

purpose, the support in the cab is arranged for receiving a third control spool.

WARNING

The piloting system of the control valve is equipped with a safety device allowing its cutting-off. Actuate the cut-off device to lock the control levers in neutral position when the equipment is not in use.

Spool valve hydraulic controls assembly

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

6 - 16

EQUIPMENT HYDRAULIC SYSTEM

W270

6.4.1 CONTROL VALVE HYDRAULIC CONTROL Pilot valve The pilot valve is of a modular type and is composed of two valve assemblies connected by two screws. If the booms or the bucket lever is actuated, the plunger of the pilot valve moves to direct pressurised oil to the port of the equipment control valve selected, moving the corresponding spool. The plungers of the booms valve body and the bucket roll-in plunger are

equipped with solenoid type detents that hold them respectively in booms max. raise, float and bucket roll-in positions. The detent occurs when the relevant control levers are forced full stroke. The levers can be, in any case, disengaged at any moment.

20.5° 20.5°

Valve body assembly (for booms)

Valve body assembly (for bucket)

Connecting screw

(Code) 1: Port A1 - coil side (booms raise) 2: Port A2 - coil side (bucket rollin) 3: Port B1 - coil side (float) [3] A2

A1

B2

B1

T

P [1]

P

[3] Booms

[1]

A1 B1

[2]

[2] A2 B2

Bucket

Booms

T

Fig. 6-21Pilot valve

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Bucket

W270

EQUIPMENT HYDRAULIC SYSTEM

6 - 17

16 1 17 2 3 4 12

13 14

5

15 6 7 8 9 18

19

10 11

A

T B2

A2

View from A

Fig. 6-22 1. 2. 3. 4. 5. 6. 7.

Bucket control valve body

NUT ROCKER ARM ADJUSTING SCREW SUPPORT FLANGE PISTON SPRING CUP

8. 9. 10. 11. 12. 13. 14.

SPLIT PIN SPRING PLUNGER VALVE BODY SOLENOID PLATE PISTON

15. GUIDE 16. SCREW CONNECTING UPPER AND LOWER BODIES 17. DUST BOOT 18. O-RING 19. ELECTRICAL CONNECTION

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

6 - 18

EQUIPMENT HYDRAULIC SYSTEM

1

W270

18 19

2 3

4

14

5

15 16

6 7 8 9 10

17

20

11

21

12 13 A

B1

A1 P

View from A

Fig. 6-23 1. 2. 3. 4. 5. 6. 7. 8.

Bucket control valve body

NUT ROCKER ARM ADJUSTING SCREW SUPPORT FLANGE PISTON SPRING GUIDE SPRING CUP

9. 10. 11. 12. 13. 14. 15. 16.

SPRING SUPPORT RING SPLIT PIN SPRING PLUNGER VALVE BODY SOLENOID CAP PISTON

17. GUIDE 18. SCREW CONNECTING UPPER AND LOWER BODIES 19. DUST BOOT 20. O-RING 21. ELECTRICAL CONNECTIONS

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

EQUIPMENT HYDRAULIC SYSTEM

6 - 19

3 functions hydraulic pilot valve Three way pilot valve cut-off Radiator Piloting/brakes pump From brake valve

Steering pump

To brake valve

Pilot system pressure regulating valve accumulator

Brakes/pilot valve high pressure filter Implement control valve

Heat exchanger

Third hydraulic function lever

To reservoir To control valve

Fig. 6-24

To control valve

Feeding (port PV)

Equipment control valve assembly

Note - The lay-out represent the variation regarding the 3 functions hydraulic pilot valve.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

6 - 20

EQUIPMENT HYDRAULIC SYSTEM

W270

6.4.2 SUPPLEMENTARY HYDRAULIC FUNCTION (Variant) The variant allows the use of a multi-purpose bucket (4 in 1) or other attachements requiring a third hydraulic function.

A three spool equipment control valve is arranged, a third control lever in the cab besides the hydraulic piping.

Lever of supplementary hydraulic function

Fig. 6-25

Configuration of supplementary hydraulic function

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

EQUIPMENT HYDRAULIC SYSTEM

B1

Safety and pressure relief valve set at 230 ± 10 bar

Auxiliary section

A1 Safety and pressure relief valve set at 230 ± 10 bar

Configuration of 3 section control valve for 3rd hydraulic function

Fig. 6-26

A3

A2

(3)

A1

B3

B2

(1)

B1

P

T (2)

BUCKET

Fig. 6-27

BOOMS

AUX.

“AUX.” valve section

Three levers pilot control valve

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

6 - 21

6 - 22 6.4.3

EQUIPMENT HYDRAULIC SYSTEM

W270

Equipment single lever control (variant)

15˚

24˚

Maximum torque on levers: 8 DaN.m Tightening torque on ports: 3 DaN.m

Output pressure (bar)

17˚

Prefeeling on ports 1,3,4

Push rod stroke (mm) Lever angle (dg)

3

P

4

2

1

T

1

View F 3

4

5

6

7

8

9

F

4

2

View F 1

2

3

4

5

6

2

1

F

3 REPERE CONNECT. 1 4 2 5 3 6

REPERE CONNECT. El. detent port 1 El. detent port 3 El. detent port 4

1 2 3 4 5 6 7 8 9

COLOR WIRE Gray Black Red Blue Yellow Green White Brown None

Fig. 6-28 Single lever pilot control

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

EQUIPMENT HYDRAULIC SYSTEM

6 - 23

DECRIPTION OF OPERATION Piloting device with stroke-end detent. The pilot valve operates as a direct control pressure reduction valve. It includes, essentially, control lever (1), four pressure reduction valves, body (6) and stops. Each pressure reduction valve is composed of control spool (2) actuating spring (3) reaction spring (4) plunger (5). In rest condition, control lever (1) is held in neutral position by reaction springs (4). Ports (1, 2, 3, 4) are connected to tank port T through duct (8). When control lever (1) is pulled, pusher group (5) is moved against reaction spring (4) and actuating spring (3). Actuating spring (3), at first, moves control spool (2) downward and closes the connection between the relevant port and tank port T. At the same time, the relevant port is connected to port P through duct (8). The control phase begins as soon as spool (2) balancing between the force of actuating spring (3) and the force resulting from the hydraulic pressure in the relevant ports 1, 2, 3, 4. Due to the interaction between actuating Electro-magnetic spool (2) and actuating spring (3) the pressure in the lock relevant ports is proportional to the stroke of pusher group (5) thus to the position of control lever (1). This controls allows the proportional hydraulic actuation of the equipment control valve. Rubber boot (9) protects the mechanical components from contamination, thus these piloting units are suitable also under the most unfavourable operating conditions.

Stroke-end detent Only the ports requiring a stroke-end detent of the control lever are equipped with this device.

Solenoid block An additional spring (7) under plate (12)warns by increasing the force required to press this spring, that the stroke of pusher group (5) and control lever (1) is nearing its limit. Once this limit is reached, ring (10) is touching solenoid armature (11). If the solenoid is energised, control lever (1) is held in this position by the magnetic force. The block is released automatically, once the solenoid is de-energised.

Hydraulic system

Port 4

Fig. 6-29

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Port 2

6 - 24

EQUIPMENT HYDRAULIC SYSTEM

W270

4

1

2 3

Torque: 30 Nm

5

7

Torque: 10 Nm

9 Port 2

Port 1-3-4 8

Torque: 10 Nm 9

Torque: 10 Nm 6

Torque: 48 Nm

10 13 Port 2

11

14 Port 2 18

Port 1-3-4 12

16

Torque: 5 Nm

19 17

Fig. 6-30

2

HANDGRIP ASS.LY LEVER GROUP GROMMET BUTTON KIT NUT SHIM SET JOINT HOLDER PLATE U-JOINT GROUP PUSHER GROUP CENTRAL U-JOINT FLANGE SOLENOID 24 VOLT INTERMED. PISTON PISTON GUIDE PROT. BUSH GROUP PLUGS 6-WAY BLOCK VALVE BODY

Single lever pilot valve components

CONTROL PORT DESCRIPTION PORT 1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

FUNCTION BOOM LOWERING/ FLOAT BUCKET DUMP

HIDRAULIC SPCIFICATIONS DETENT TYPE ELECTRICAL WITHOUT DETENT

3 BOOM RAISE ELECTRICAL 4 BUCKET ROLL-BACK ELECTRICAL SOLENOID POWER SUPPLY: (20V – 27V) POWER CONSUMPTION FOR EACH SOLENOID: 8W

BACKPRESSURE AT PORT T FLUID FLOW ON PILOT LINES (PTO 1, 2, 3, 4) HYDRAULIC FLUID

≤ 3 bar

16 L/min. Max Mineral oil (HI-TECH 46) WORKING TEMPERATURE RANGE -20 ~ +80 °C FLUID VISCOSITY RANGE 10 ~ 380 mm2/sec FLUID MAX DEGREE OF CONTAMINATION NAS 1638 class 9 FLUID RECOMMENDD FILTRATION

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

ß10 ≥ 75

6.4.4

EQUIPMENT HYDRAULIC SYSTEM 3rd function control for single lever pilot valve

1

1

2

25˚

25˚

6 - 25

Output pressure (bar)

W270

2

Pushing stroke

T

T P

1

P

Lever angle

T P 2

4 1

5

HYDRAULIC CONNECTIONS DATA: Ports P, T, 1, 2: G1/4 Pipe thread ISO228-1; ISO 1179 matching port type 1 2 3 4

HANDGRIP GROMMET LEVER LEVER SECURING GROUP (tightening torque of screws: 1.2 Nm) 5 LEVER FULCRUM 6 COVER GROUP (tightening torque of screws: 8 Nm) 7 PLATE 8 PISTON GROUP 9 SPRINGS 10 VALVE BODY

2

6 3

7

Technical data, mechanical

8

9

10

Inlet pressure Back presure at port T Control fluid flow (P to 1-2) Hysterisis Pressure fluid 1) suitable for NBR seals 2) suitable for FPM seals Pressure fluid temperature range Viscosity range Degree of fluid contamination

Max. permissible lever actuating moment Weight (dependent on the actuating element)

Fig. 6-31

bar bar L/min bar

°C mm2/s

Nm Nm kg

up to 50 up o 3 up to 16 up to 1 Mineral oils (HL, HLP) to DIN 51524 Phosphate aster (HFD-R) 2)

1)

-20 to ÷ 80 10 to 380 maximum permissible degree of contamination of the pressure fluid is to NAS 1638 class 9. We, therefore, recommnd a filter with a mini-mum retention rate of ß10 ≥ 75 10 in operation 80 for an exceptional, one time loading 1.6 to 2

3 rd hydraulic function pilot valve for single lever equipment control

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

6 - 26

EQUIPMENT HYDRAULIC SYSTEM

W270

6.5 HYDRAULIC OIL RESERVOIR Type ................................................................................................................................................. Pressurised Capacity of reservoir ......................................................................................................... 124 l (32.74 U.S. Gal) Setting of by-pass valve on oil filter ........................................................................................................... 1 bar Filter on return ................................................................................................................... filtering capacity 15µ The reservoir contains the hydraulic oil for the main hydraulic system, the steering system and the brakes system. Inside the reservoir a filter is mounted, on the oil return

line, equipped with a by-pass valve that, in case of clogging of the filtering element, discharges the oil directly into the reservoir.

1 2 3 4 6

5

7

8

9

C A

10 D

B

E F

11 Fig. 6-32 1. 2. 3. 4. 5. 6. 7.

12

13

Hydraulic oil reservoir

OIL FILTER COVER O-RING SPRING FILTER HOLDER OIL RETURN FILTER PLUG INTRODUCTION FILTER

8. 9. 10. 11. 12. 13. A.

BREATHER PIPE RESERVOIR OIL LEVEL INDICATOR COVER O-RING INSPECTION PASSAGE from HEAT EXCHANGER

B. C. D. E. F.

from EQUIPMENT CONTROL VALVE to STEERING PUMP to EQUIPMENT PUMP to DIVERTER VALVE (EM.ST.) to EMER. ST. PUMP

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

EQUIPMENT HYDRAULIC SYSTEM

6 - 27

6.6 CYLINDERS

Booms cylinders: Type: ......................................................................................................................... Kayaba double acting Q.ty: ........................................................................................................................................................ 2 Inside diameter of cylinder: ................................................................................................... 170 mm (6.7") Diameter of rod ....................................................................................................................... 95 mm (3.7") Cylinder rod stroke .............................................................................................................. 920 mm (36.2") Weight (unit) ....................................................................................................................... 200 Kg (441 lbs) Bucket cylinder: Type: ......................................................................................................................... Kayaba double acting Q.ty: ........................................................................................................................................................ 1 Inside diameter of cylinder: ................................................................................................... 210 mm (8.3") Diameter of rod: .................................................................................................................... 110 mm (4.3") Cylinder rod stroke .............................................................................................................. 570 mm (22.4") Weight (unit) ...................................................................................................................... 245 Kg (540 lbs)

6.6.1 BOOMS CYLINDER The two boom cylinders are double acting. The cylinders are extended or retracted, respectively to raise or lower the booms. The booms cylinder is composed of: cylinder sleeve, head, rod, piston and seal pack.

6.6.2 BUCKET TILT CYLINDER The bucket tilt cylinder is double acting. Depending upon the extension or retraction of the cylinder, the bucket is rolled-in or tilted by the linkage composed of the strut and rod.The bucket cylinder is composed of: cylinder sleeve, head, rod, piston and seal pack.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

6 - 28

EQUIPMENT HYDRAULIC SYSTEM

5

1

6

3

8

7

W270

9

10

11

12

2

13

1

2

(Inner Section)

4

15

14

17 16 4

Fig. 6-33

Boom cylinder

Notes - 1

1. 2. 3. 4. 5. 6.

116 daNm (839 ft-lbs)

2

571 daNm (4128 ft-lbs)

3

5.7 daNm (41 ft-lbs) after tightening cold head in 2 places

4

5.1 daNm (36 ft-lbs)

MUD SCRAPER SLIDING RING O-RING SEAL FRONT HEAD O-RING RETAINER

7. 8. 9. 10. 11. 12.

CYLINDER SLEEVE ROD SLIDE RING SEAL RING/O-RING PISTON LOCK NUT

13. 14. 15. 16. 17. 18.

3

LOCK SCREW STEEL BALL SHIM STEEL PIPE BUSHING MUD SCRAPER

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

18

W270

EQUIPMENT HYDRAULIC SYSTEM

12

1

2

3

5

7

4

6 - 29

9

8

6

2

10

(Inner Section)

1

7

6

13

11

14

15

16 4

Fig. 6-34

Bucket cylinder

Notes - 1

1. 2. 3. 4. 5. 6.

116 daNm (839 ft-lbs)

2

1723 daNm (12460 ft-lbs)

3

5.8 daNm (42 ft-lbs) (fter tightening cold-head in two places)

4

9.42 daNm (68.1 ft-lbs)

MUD SCRAPER RING O-RING HOLDER O-RING CYLINDER SLEEVE ROD SEAL

7. 8. 9. 10. 11.

O-RING PISTON SEAL/O-RING HOLDING SCREW STEEL BALL

12. 13. 14. 15. 16.

FRONT SLEEVE SHIM BUSH MUD SCRAPER STEEL PIPE

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

3

6 - 30

EQUIPMENT HYDRAULIC SYSTEM

6.7 L.T.S. ANTI-PITCHING SYSTEM

W270

Position 0 (L.T.S. OFF)

(Variant) 6.7.1 DESCRIPTION The L.T.S. (Load Travel Stabilizer) system, supplied as an optional, ensures a better driving comfort and a reduction of dynamic loads on the components of the machine (frame, axles etc.) when the unit travels with or without load. Without the L.T.S. system, the machine is subject, as a result of irregular terrains, to unwanted pitching, increasing with the travel speed. With the L.T.S. system ON, the terrain irregularities are absorbed by the equipment. In this manner, it is possible to exploit completely the potential of the machine, especially on uneven terrains, without stressing mechanical components and providing max. comfort for the operator. The system includes, essentially: - A switch (incorporating the indicator) located on the dashboard, to activate or disactivate the system; - A piston type accumulator (oil capacity = 5.5 Liters; gas capacity = 6 Liters) preloaded with nitrogen and connected to the boom raise/lowering cylinders; - A valve block controlled by a solenoid valve.

Position 1 (L.T.S. ON) Automatic gearbox The transmission control unit automatically engages the L.T.S. system whenever the speed of the machine exceeds 7 km/h (3.1 mph) and disengages it when the speed drops, thus allowing the loading and dumping of the bucket without unwanted movements of the boom. The indicator comes on when the system is ON and stays out when the system is OFF. This position is recommended for normal use of the system. Manual gearshifting The L.T.S. is OFF when the gearshift lever is in first speed. Position 2 (L.T.S. constantly ON) The indicator stays constantly ON. This position is useful only to allow the discharge of the accumulator in view of maintenance or repair interventions (for this purpose, it is necessary to place the equipment control valve in float position). This position can be used for occasional operation only, to obtain the cushion effect at speeds below 5 km/h (3.1 mph). IMPORTANT - For an efficient performance of the L.T.S. system, the boom must be free to move. Do not use the L.T.S. system when travelling on open roads requires the locking of the boom.

L.T.S. system ON The system is activated by a switch (incorporating an indicator) located on the dashboard.

WARNING - DANGER The L.T.S. switch has three positions:

Prior to any maintenance intervention on the equipment and the L.T.S. system it is required that the accumulator is discharged to avoid the exit of pressurised fluid.

6.7.2 DISCHARGE OF THE ACCUMULATORS

0

Fig. 6-35

1

L.T.S. three position switch

2

To discharge the accumulator, proceed as follows: - start the engine at idle speed; - place the L.T.S. switch on position 2 (the indicator must come ON); - position the bucket flat on the ground; - lock the equipment control lever in "Float" position; - waiting a few seconds in this position the accumulator is discharged.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

EQUIPMENT HYDRAULIC SYSTEM

6 - 31

Transmission selector

Automatic transmission logic box

L.T.S. control switch

To electronic unit

A.T.C.

Steering valve

Hydraulic Accumulator

Fig. 6-36

L.T.S. valve

Components of L.T.S. system

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

6 - 32

EQUIPMENT HYDRAULIC SYSTEM

W270

6.7.3 L.T.S. HYDRAULIC DIAGRAM

1 2

6

Y

X2

B 7

X1

5

4

MX MA A

Y

DISTRIBUTORE COMANDO ATTREZZO T

3

A

T

X2

VALVOLA LTS TIPO MHRSM25 B2X/EG26C4M

B

Y X1 MA MX

Fig. 6-37 1. 2. 3. 4.

L.T.S. hydraulic system diagram

ACCUMULATOR SOLENOID VALVE "1" DISCHARGE CYLINDER BOTTOM SIDE VALVE

5. 6. 7. 8.

CYLINDER ROD SIDE VALVE SEQUENCE VALVE EQUIPMENT CONTROL VALVE BOOM CYLINDERS

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

EQUIPMENT HYDRAULIC SYSTEM

6 - 33

6.7.4 FUNCTIONAL TESTS OF L.T.S. SYSTEM Testing of electrical system Start the engine. Place the L.T.S. switch on position 2; the indicator must come ON. Bring the engine to medium/high speed and raise the boom to max. height. Lower quickly the boom and stop it suddenly at midlevel.

position (valve activation) for about five seconds. Lower the bucket to the ground. Engage the L.T.S. system placing the L.T.S. switch into position 2 (the indicator must come ON). The bucket should raise about 200 mm (7.87 in).

Test of hydraulic circuit between boom cylinders, bottom side, and accumulator

The boom must oscillate before stopping and no waving movements must be felt in the cab.

Start the engine and run it at idle speed.

Bring the engine speed back to idle and move the L.T.S. switch to position 1.

With flat bucket, raise it about 30 cm (11.81 in) from the ground.

The indicator must remain OFF.

Lift the machine from the ground by tilting the bucket.

Engage second speed and start the machine.

Move the equipment pilot valve to "Float" position so that the machine drops to the ground.

When the speed of the machine reaches 5 km/h (3.1 mph), the indicator in the switch must come ON. Slow down the machine and stop it; the indicator must go OFF.

Engage the system positioning the L.T.S. switch on position 2 (the indicator comes ON) so as to discharge the accumulator. Move the pilot valve back to neutral. Roll-back the bucket: the boom should drop until touching the ground.

Valve opening test The scope of the test is to check the opening of valves (4 and 5, fig. 6-37). Start the engine and run it at idle speed. Move the L.T.S. switch to position 2; the indicator must come ON. With bucket flat on the ground, move the equipment pilot valve to "Float" position to discharge accumulator (1). Move the pilot valve to neutral. Switch OFF the L.T.S. system moving the switch to position 0. Raise the boom to max. height and insist in this

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

6 - 34

EQUIPMENT HYDRAULIC SYSTEM

W270

6.7.5 TEST OF L.T.S. ACCUMULATOR PRECHARGE The accumulator installed on the L.T.S. anti-pitching system is of a piston type preloaded with nitrogen. The nominal precharge pressure is 18 bar at 15°C (59°F) with a 6 Ltr capacity. D1 Important - A precharge of the accumulator lower than the nominal value, can cause a defective operation of the L.T.S. anti-pitching system.

D

If could be useful to check yearly and when required the nitrogen precharge. The checking operation must be performed with the accumulator emptied of hydraulic oil. M D1

M WARNING

Prior to any maintenance intervention on the equipment and the L.T.S. systems it is required that the accumulator is discharged to avoid pressurised fluid from escaping. D

For the accumulator discharge procedure, please refer to point 6.7.2.

1

Check the pre-load, proceeding as follows: - remove protection cover (1, fig. 6-38); - loosen 1/2 turn screw (2) with an Allen wrench; - install tool (D) on the accumulator connection; - ensure that valve (D2) is closed; - rotate handle (D1) so as to loosen screw (2); - when the pointer of pressure gauge (M) starts moving, unscrew handle (D1) a turn further. At this point, the pressure gauge indicates the precharge pressure of the accumulator, that must result 18 bar. If the pressure is below the nominal value, recharge the accumulator. After re-closing screw (2) using handle (1) discharge the nitrogen accumulated in block (D) opening cock (D2).

D2

Accumulator

2

Fig. 6-38 D. Tool - D1. Handle - D2. Discharge cock - M. Pressure gauge - 1. Protection cap - 2. Threaded plug.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

EQUIPMENT HYDRAULIC SYSTEM

6 - 35

6.7.6 INSTRUCTIONS FOR THE RESETTING OF ACCUMULATOR PRECHARGE With tool applied to the accumulator connection proceed as explained below:

- Close the valve of the nitrogen bottle. Wait for about five minutes.

- Remove the cap and install the hose of the nitrogen bottle equipped with pressure reduction valve (V).

- Check on pressure gauge (M) that the filling pressure is 18 bar. If it is lower, repeat the operation. If the pressure is higher, proceed as follows: - Rotate slowly handle (D2) so as to make the nitrogen flow and re-close it.

WARNING - DANGER

- Check on pressure gauge (M) that the pressure is at the desired value, otherwise repeat the operation.

To recharge accumulators use nitrogen only. Never and for no reasons use oxygen or other gases, since there is a great risk of explosions.

- Move handle (D1) so as to tighten screw (2) on the accumulator. - Remove the filling rig.

- With valve (D2) closed, open slowly the valve of the nitrogen bottle and check the filling pressure increment on the pressure gauge (M).

- Tighten screw (2) to a torque of 1.1 daNm. - Check that the accumulator is not leaking, using soapy water.

Important - The filling pressure must be at least 10% higher than the nominal value, considering that the pressure in the accumulator decreases when the compressed gas cools.

M

- Retighten the protective cap of the accumulator.

D1

A V

D

D2

Fig. 6-39 A. Nitrogen bottle - D. Tool - D1. Handle - D2. Discharge valve- M. Pressure gauge.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

SECTION 7

ELECTRICAL SYSTEM CONTENTS

PARAGRAPH

SUBJECT

PAGE

SAFETY RULES ............................................................................................................ 7-1 7.1

GENERAL LAY-OUT OF ELECTRICAL SYSTEM ......................................................... 7-2

7.2 7.2.1 7.2.2

LOGIC BOARD AND CAB CONNECTIONS ................................................................. 7-3 Connections - Relays - Timers ....................................................................................... 7-3 Fuses table .................................................................................................................... 7-4

7.3 7.3.1

CAB INSTRUMENTS CLUSTER ................................................................................... 7-5 Indicators on instrument cluster ..................................................................................... 7-7

7.4

SWITCH PANEL ............................................................................................................ 7-7

7.5

TRANSMISSION CONTROL SELECTOR .................................................................... 7-8

7.6

ATC ELECTRONIC UNIT .............................................................................................. 7-9

7.7

CONNECTORS ........................................................................................................... 7-11

7.8

COLD START AND LINK FUSES ................................................................................ 7-13

7.9

STARTER SWITCH ..................................................................................................... 7-14

7.10

MAIN SWITCH ............................................................................................................ 7-14

7.11

SOLENOID SWITCHES .............................................................................................. 7-16

7.12

PRESSURE SWITCHES-SENSOR-SWITCHES ........................................................ 7-17

7.13

ACOUSTIC TRANSDUCERS ...................................................................................... 7-26

7-14

ALTERNATOR ............................................................................................................. 7-27 MACHINE GROUPS ELECTRIC DIAGRAMS ............................................................. 7-29

W270

7-1

ELECTRICAL SYSTEM

SAFETY RULES

WARNING: When working on the electrical system, always wear safety glasses and remove rings, wrist watches or any other metal jewellery.

DISCONNECT WARNING: Prior to any maintenance or repair of electrical components, disconnect the GROUNDING CABLE “A” from the negative post “B” of the battery. DISCONNECT CABLE “C” FROM POSITIVE POST “D”.

A B

C

BATTERY 12V x 2

GROUND

WARNING: NEVER PLACE METAL OBJECTS on the battery to avoid short-circuits.

WARNING: BATTERY GASES ARE FLAMMABLE. Never get near batteries with open flames or sparks. During recharging, the generation of gases is higher. WARNING: BATTERY GASES ARE DANGEROUS if contacting the skin or other materials.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

7-2

W270

ELECTRICAL SYSTEM

7.1 GENERAL LAY-OUT OF ELECTRICAL SYSTEM The electric wirings are divided into three main groups: 1. Cab wiring group, identified by different colours connected to all the electrical components in the cab. 2. Front frame wiring group identified by numbers, connected to all the electrical components involving the front frame.

3. Rear frame wiring group, identified by numbers, connected to all the electrical components involving the rear frame.

The three groups of main wirings are connected among themselves by four connectors (A-B-C-D) located in the area under the cab floor. All wires are connected to the logic board (S) located inside the rear panel behind the operator’s seat.

A

B

C

D

1

3

2

A-B-C-D. Connectors - S. Logic board - 1. Cab wiring - 2. Front frame wiring - 3. Rear frame wiring.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

7-3

ELECTRICAL SYSTEM

7.2 LOGIC BOARD AND CAB CONNECTIONS The logic board is located inside the rear panel behind the operator seat. To reach it, loosen the four retaining knobs. All the components of the machine are connected to the board by the “CN” connections.

Here are also located the fuses, the solenoid switches (“R” relays), the timers “Z” and two switches “SW1” and “SW2” to divert the gearshift control from automatic to manual and viceversa

7.2.1 CONNECTIONS - RELAYS - TIMERS - BUZZER CONNECTIONS CN LINE CONNECTED cab switches

COLOUR violet black

TERMINALS 17 21

C D E F

engine switches transmission box dashboard and lights

white brown white red

17 17 17 17

G H J K

dashboard engine switches engine

yellow black green violet

17 19 11 21

L M N O

optional instruments engine transmission gearshift

light blue white white white

13 21 11 7

P Q R S

engine voltage reduction thermo starter service relay, buzzer

yellow white white black

13 5 13 5

white

11

N-N

bridges manual gearshift

RELAY R R=relay

FUNCTION

2 3 4 5 6

horn light switching starter and anti repetition neutral starter safety clock

7 8 9 10

back-up lights and alarm air cond. condenser fan transmission cut-off L.T.S.

11 12

kick-down kick-down

Z1 Z2 Z3 C1

steering low pressure switch check timer emergency flasher capacitor

B

A

R2

SW1

R3

1 INPUT Km/h 2 INPUT Km/h 3 MODE SELECT 4 MODE SELECT

F

G

H

1 2 3 4

R5

Z2

Z1

E

SW2

R4

D

C

J

SYSTEM ATC

CN A B

Z3

FUSES

K

L

M

R9

N

O

P

N-N

Q

R

R6

R7

R8

R10

R11

R12

TIMERS AND OTHERS

C2 SW1 SW2 JP1

capacitor micro switch micro switch bridge

JP2 R1

bridge resistor

4 5

S 6

7 3

P 2 1

P. Engine warm-up control unit - S. Logic board - 1. Wiper timer - 2. Steering column wire - 3. Front dashboard wire - 4. Cab roof wire - 5. Heater wire - 6. Side dashboard wire - 7. Cab wire

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

7-4

W270

ELECTRICAL SYSTEM 7.2.2 FUSES TABLE

F1

F2

F3

F4

F5

F6

F7

F8

F9

F10

F11

A

SPARE

B

SPARE

C

SPARE

A

RH SIDE LIGHTS FUSE

B

LH SIDE LIGHTS FUSE

C

OPTIONAL FUSE

A

FRONT WORK LIGHT FUSE

B

LIGHTS CONTROL SWITCH FUSE

C

SIDE LIGHTS SWITCH POWER FUSE

A

FUSE FOR COIL OF STARTING IN NEUTRAL RELAY

B

ELECTRIC STOP - CONTATS FOR STARTING IN NEUTRAL RELAY (R5) - COIL FOR STARTING AND REPEATED ACTUATION PREVENTION RELAY (R4)

C

HAZARD LIGHTS FUSE

A

REAR WORK LIGHS FUSE

B

OPTIONAL FUSE

C

FRONT WINDSCREEN WIPER FUSE HIGH BEAM LAMPS (UNSTABLE)

A

POWER VOLTAGE DIVIDER FUSE

B

MAIN BEAM FUSE

C

BUCKET SOL/V, MAX. HEIGHT SOL/V, FLOAT SOL/V, SENSORS FUSE

A

REVERSE LIGHTS / REVERSE HORN FUSE

B

OPTIONAL FUSE

C

FANS CONDITIONER FUSE

A

REAR WINDSCREEN WIPER FUSE TURN LIGHT FUSE

B

DIP BEAM FUSE

C

FAN CAB FUSE

A

BEACON AND 4TH FUNCTION SWITCH FUSE

B

TIMERS Z1, Z2, BUZZER, SERVICE RELAY FUSE

C

ROOF LIGHT, HORN, CLOCK FUSE

A

STOP LIGHTS FUSE

B

CIGAR LIGHTER FUSE

C

RADIO AND 12 V SOCKET FUSE

A

ATC CONTR.UNIT, MONITOR, LTS - TRANSMISSION SOLENOIDS FUSE

B

OPTIONAL FUSE

C

(NOT USED)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

7-5

ELECTRICAL SYSTEM

7.3 CAB INSTRUMENTS CLUSTER The operating status monitor system monitors the loader operating status by means of the sensors and switches installed on the loader and siplays the information on the cluster guage unit in the operator's compartment to inform the operator of the current operating status of the loader.

13

22

12 25

2

3

10

4-68-15

The cluster guage unit consists of meters including the speedometer, monitor lamps (warning lamps) which indicates whether or not each system is operating properly, and indicator lamps.

5 7 16

21

26

17

27-28

CN1

CN3

1

23

11 18-19

CN2

CONNECTION CN1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Indicat. accumul. oil low pressure Indicat. engine coolant high temperature Indicat. coolant temperature Light, instrument cluster Light, left turning Light, instrument cluster High beams Light, instrument cluster Ground Fuel level Indicator, parking brake Indicator, battery charge Indicator, fuel reserve Not connected Light, instrument cluster Light, right turning Speedometer

CONNECTION CN2

CONNECTION CN3

18 19 20 21 22 23 24 25 26 27 28

Buzzer General indicator Instrument cluster lights Indicat. transmission oil temperature Indicat. air cleaner clogging Indicat. emergency steering Batteries Indicat. engine oil low pressure Indicat. transm. oil high temperature Hourmeter (ground) Hourmeter (battery)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

7-6

W270

ELECTRICAL SYSTEM Positions on connections CNI-4 CNI-6 CNI-8 CNI-15

DC24V

LI L2 L3 L4

CN2-24 CN2-22

L5

CN2-25

L6

CN2-26

L7 3W

CNI-13

L8

CN2-23

L9

CNI-2

L10

CNI-11

L11

CNI-1

L12

Connection CN1 Connection CN1 1

2

3

4

5

6

7

Connection CN2

8

9 10 11 12 13 14 15 16 17 BUZZER

3W

CN2-18

L13

CN2-19 CNI-7

Connection CN2 18 19

CNI-16

20 21

22 23 24 25 26

CNI-5

G

CNI-12

L14 L15 L16 L17

CNI-10

Connection CN3

RI

CNI-3

R2

28 CN2-21

27

Connection CN3

R3

CN3-28 CN3-27 CNI-17

R4

ZDI CN2-20

L18 L19 L20 L21 L22

CNI-9

Instrument panel wiring diagram

FM WTM OTM EHM SM L1-L13 L14 - L18

: : : : : : :

FUEL METER ENGINE WATER TEMPERATURE GAUGE TRANSMISSION OIL TEMPERATURE GAUGE ENGINE HOUR METER SPEEDOMETER MONITOR LAMPS INSTRUMENT LAMPS

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

7-7

ELECTRICAL SYSTEM 7.3.1 INDICATORS ON INSTRUMENT CLUSTER Engine water temperature gauge

Transmission oil temperature gauge 150°C

135°C

67°C 102°C

50°C ▲

C

▲

H

▲

50°C ▲

▲

▲

▲

C

E

120°C

F

E

▲

Scale

Fuel meter

H

F ▲

Meter

↑ 67°C00

↑ 102°C00

↑ 50°C00

↑ 120°C00

E00

↑ F00

Standard value

Ω 49.8Ω

Ω 16.8Ω

Ω 91.7Ω

Ω 10.4Ω

Ω 80Ω

Ω 10Ω

↑

Measurement point

7.4 SWITCH PANEL 2

3 17 4

5

12

1

13 11

6

10

7 14 8

16

15

9

18

1. Front washer button - 2. Rear wiper switch - 3. Rotary beacons switch - 4. Automatic transmission switch - 5. Pre-heating indicator - 6. Emergency lights switch - 7. Rear work light switch - 8. Front work lights switch - 9. Head lights and low beams switch - 10. L.T.S. engagement switch - 11. Transmission cut-off switch - 12. Fan switch - 13. Warm-cold switch - 14. Air recirculation switch - 15. Air conditioner switch - 16. Cigarette lighter - 17. Boom kick-out function switch - 18. Direction reverser auxiliary switch control button.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

7-8

W270

ELECTRICAL SYSTEM

7.5 TRANSMISSION CONTROL SELECTOR (S41, TAB. 2) CONNECT.

X1

X3 X2

WIRE

TERMINAL

1

VP

COLOUR RED

2

E

YELLOW

3 4

F G

PINK GREY

1

C

BROWN

2

D

GREEN

3 4

A H

BLUE VIOLET

1

B

WHITE

3 4

ND ND

X1

4 3 2 1

1

X2

1 2 3 4

X3

SPEED SELECTION 1 = 1st speed 2 = 2nd speed 3 = 3rd speed 4 = 4th speed

SPEED SELECTION F = FORWARD R = REVERSE N = NEUTRAL

A CD 1

2 3

B F (R)

E (F)

G (N)

4

R

H

N F

VP

Diagram of electric gearshift selector

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

7-9

ELECTRICAL SYSTEM

7.6 ATC ELECTRONIC UNIT (K8, TAB. 2)

13 12 11 X 10 9 8

17 16 15 14 X 13 12 11 10 9

7 6 5 4 3 2 1

8 7 6 5 4 3 2 1

CN2

CN1

WARNING: To prevent ATC control unit damages, the electrical system must not be powered (battery switch and starting switch to OFF) during ATC connection and disconnection operations.

Position 1 2

CN2 Connection Speed sensor Ground nd

CN1 Wire 537 535

3 4

2 indicator 1st indicator

531 530

5 6

LTS solenoid Switch “B”

865 937

7 8

Switch “A” Reverse selector

849 022

9 10

Forward selector Tachometer nd

033 515

11 12

2 speed sensor Ground

534 000

13 14

Batteries Solenoid “B”

960 002

15 16

Solenoid “A” Solenoid “Reverse”

001 004

17

Solenoid “Forward”

003

Position 1

Connection -

Wire -

2

Switch, parking brake engaged

665

3 4

Selection “2” Selection “1”

541 540

5 6

Selection AUTOM./MANUAL -

539 -

7 8

4th indicator

533 -

9 10

Accelerator pedal sensor -

538 -

11 12

Shift down switch -

815 -

13

3rd indicator

532

-

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

7 - 10

W270

ELECTRICAL SYSTEM

CONFIGURATION OF AUTOMATIC TRANSMISSION

POSITION OF MICROSWITCH "SW1"-"SW2" ON LOGIC BOARD SW2-1 SW2-2 SW2-3 SW2-4 CODE

SW1-4 CODE

W170

OFF

ON

OFF

OFF

12

W170

12

W190

OFF

ON

OFF

ON

13

W190

13

W230

OFF

ON

ON

OFF

14

W230

14

15

W270

W270

OFF

ON

ON

ON

ON

OFF

ON

ON

SW1 JP1

▲

15

▲

FUSES

SW1-1 SW1-2 SW1-3

AUTOMATIC TRANSMISSION JP1 BRIDGE 1-2

MECHANICAL TRANSMISSION JP1 BRIDGE 2-3

SW2

BUTTON AUTOMATIC TRANSMISSION ENGAGEMENT

R11 R12

▲

JP2

▲ ▲

▲

LOGIC BOARD

▲

▲

▲

AUTOMATIC TRANSMISSION "ATC" ELECTRONIC CONTROLLER

▲

"ATC" CONTROLLER CONNECTING WIRE

▲

▲

▲

TRANSMISSION SENSOR SPEED

THROTTLE PEDAL SENSOR

TEST SOL. FOR TR. FOR SOL. REV

Indicator speed engaged

TR. REV SOL. A TR. A SOL. B TR. B

OTHER TEST

TR = TRANSISTOR Interruzione cavo Rottura Interruzione cavo Rottura Interruzione cavo Rottura Interruzione cavo Rottura

{

SOL = SOLENOIDE

Flashing 1st light 0.5 Hz Flashing 1st light 1 Hz Flashing 2 nd light 0,5 Hz Flashing 2nd light 1 Hz Flashing 3rd light 0,5 Hz Flashing 3 rd light 1 Hz Flashing 4th light 0,5 Hz Flashing 4th light 1 H z

INPUT SIGNAL OUTPUT SIGNAL MEMORY

Self troubleshooting on automatic transmission Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

7 - 11

ELECTRICAL SYSTEM

7.7 CONNECTORS The connectors (A-B-C-D) are located in the lower part of the cab, connecting the main wiring to the logic board (S). The coloured wires arrive from the upper side, the numbered wires from the lower side.

On connectors A-B-C (see connectors figure) there are 24 connecting points while connector D has 18 connecting points. The description and the function of each wire on the connector has a corresponding number/colour, as it can be found in the description of each connector.

CONNECTOR A Reference on connector 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) 24)

Description - Function – – POWER BOOM KICKOUT PROXIMITY SIGNAL BOOM KICKOUT POWER BUCKET POSIT. PROX. SIGNAL BUCKET POSITIONER RIGHT TURNING LIGHT LEFT TURNING LIGHT LEFT HEAD LIGHT RIGHT HEAD LIGHT LEFT LOW BEAM RIGHT LOW BEAM RIGHT HIGH BEAM LEFT HIGH BEAM EVENTUAL 4TH FUNCTION * HORN POWER GND EVENTUAL LTS GND EVENTUAL LTS * * EMERGENCY STEERING PRESS. *

Colour

Wire

– –

980 981

S–N S–G V–B V–N A L G G–N H H–N V V–R A–G – C–N N Z–N B–N – –

995 980 994 981 103 109 339 330 231 223 221 219 997 – 138 000 956 954 – – 844 –

–

1

2

3

4

5

6

995

980 994 981

7

103 109 339

330 231 223

12

13

221 219 997

138 000

18

956 954

844

19 20 21

22 23 24

* NOT CONNECTED

Symbol of wires

A

B

C

A = Light blue M = Brown B = White

N = Black

C = Orange

R = Red

G = Yellow

S = Pink

H = Grey

V = Green

L = Blue

Z = Purple

A-B-C-D. Connectors

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D

7 - 12

W270

ELECTRICAL SYSTEM CONNECTOR B

Reference on connector 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) 24)

Description - Function RIGHT REAR WORK LIGHT LEFT REAR WORK LIGHT RIGHT STOP LIGHT LEFT STOP LIGHT LEFT HEAD LIGHT RIGHT HEAD LIGHT RIGHT TURNING LIGHT LEFT TURNING LIGHT LICENCE PLATE LIGHT BACKUP ALARM RIGHT BACKUP LEFT BACKUP LIGHT FRONT WINDSHIELD WASHER EMERG. STEERING PRESSURE OUTPUT REAR WINDSHIELD WASHER TRANSM. CUTOFF PRESSURE GND CLOCK * * AIR CONDITIONING SWITCH COMPRESSOR * * ELECTROSTOP

Colour

Wire

G C G-V B-G G G-N A L L-G C-N A-G R-V

225 226 172 177 332 331 125 120 337 163 302 301 885

A-B – V-B G-R V-N R-N

835 886 974 044 809 824 903

1

2

3

4

5

6

225 226 172 A A B

177 332 331 B B B

7

125 120 337 B A B

163 302 301 B B B

12

13

885 835 886 B A B

974 044 A A

18

809 824 B A

903 B

19 20 21

22 23 24

* NOT CONNECTED

CONNECTOR C Reference on connector 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) 24)

Description - Function ALTERNATOR I ALTERNATOR R STARTER RELAY SWITCH POWER FOR EVENT. B * ENGINE OIL LOW PRESSURE BRAKE ACCUMULATOR LOW PRESSURE TRANSM. OIL TEMPERATURE AIR CLEANER SWITCH COOLANT HIGH TEMPRAT. GND COOLANT TEMP. GAUGE FUEL LEVEL RESERVE INDICAT. - OPTION TRANSM. OIL TEMP. GAUGE EV. A EV. B POWER FOR EV. A EV. F EV. R POWER FOR EV. F * COLD STARTING RELAY POWER FOR EV. R

Colour

Wire

G G-N G-V – – B

637 522 802 987 – 503

A B-V C-B V-N N R-V Z Z-B A-G A-R A-B A-N L-G Z-N S – – –

613 559 663 528 000 552 557 555 550 1 2 960 3 4 979 – 860 986

1

2

3

4

5

6

637 522 802 B B B

987 B

503 B

7

613 559 663 A A A

528 000 552 B A B

13

557 555 550 B B B

1 B

2 B

960 B

979 B

860 986 B A

19 20 21

22 23 24

3 B

4 B

12 18

* NOT CONNECTED

CONNECTOR D Reference on connector 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18)

Description - Function

CONNECTION BOX * * * HORN (PEDAL BUTTON SIGNAL) * * * GROUND 1st SPEED SENSOR SPEED SENSOR 1 SPEED SENSOR 2 STOP LIGHT SWITCH INPUT STOP LIGHT SWITCH OUTPUT ACC. PEDAL SENSOR SIGNAL INLET ACC. PEDAL SENSOR SIGNAL INPUT PARKING BRAKE PRESS.SWITCH SIGNAL GROUND, 2nd SPEED SENSOR EMERGENCY STEERING PUMP OPERATION

Colour

Wire

R

772

– – -

– 116 -

N L G-R R R-N B-N B – –

535 534 537 117 175 538 981 978 536

–

844

7

6

8

18 844 A

17

16

536 B 978 A

1 5 116 A

15

2

772 A

3 538 B

14

9

534 A

4 981 B

535 B

175 B

537 A

117 A

13

* NOT CONNECTED

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

12

10

11

W270

ELECTRICAL SYSTEM

7 - 13

7.8 COLD START AND “LINK” FUSES MACHINE SERVICES “LINK” FUSE (50A) WIRES 777: to + of batteries 772: to derivation box 777

772

ALTERNATOR “LINK” FUSE (80A) WIRES 777: to + of batteries 773: to alternator 777

773

COLD START FUSE (150A) WIRES 777: to + of batteries 780: to thermostarter relay

777

LINK FUSES COLD START FUSE

Fuses location: inside left battery compartment.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

780

7 - 14

W270

ELECTRICAL SYSTEM

7.9 STARTER SWITCH LOCATION - Right cab console

OFF

AC C

H

B

L

BG

ON

R

STAR T B

G1

G2 ACC

M

LOCATION

ST

H OFF ACC

B

ST

G2

G1

M

ON

ACC

START

WIRES RED: BROWN: WHITE/YELLOW: BLUE: WHITE:

TECHNICAL DATA DC: 24 V B-G1, G2: 8 A B-ACC: 10 A B-M: 5A B-ST: 3A

location “B” location “G1” location “ACC” location “M” location “ST”

7.10 MAIN SWITCH LOCATION - Inside rear cover of machine.

Battery –

To Ground

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

M

W270

7 - 15

ELECTRICAL SYSTEM

SINGLE LEVER SOLENOID VALVE RELAYS LOCATION: under the equipment pilot valve, inside box "APV12" 86 87 87

85 30

2

RELAY 1

M

B 87a

85

87

R

30

4

86

N

1

R

87

RELAY 2

85 86

N

87a

3

30

5 H

WIRE 1 Locat. N Locat. R Locat. 2 Locat. B Locat. M Locat. 4 Locat.

86 to cab wire connector 86 to location 86 on relay 2 seat 87 to location 87 on relay 2 seat 85 to cab wire connector 30 to location 30 on diode seat 87 to cab wire connector 30 to equipment pilot valve connector

WIRE N Locat. R Locat. 3 Locat. 5 Locat.

86 to location 87a on diode seat 87 to location 87 on relay 1 seat 85 to cab wire connector 30 to equipment pilot valve connector

N

SINGLE LEVER PILOT VALVE DIODE BOX LOCATION: Under the equipment pilot valve, inside APY12 box WIRE B Location 30 to location 30 on relay 1 seat N Location 87a to location 86 on relay 2 seat and to location 87c N Location 87c to position 87a on diode seat H Location 87d to location 30 on relay seat

30

87c

87a 87b 87c

N N

87a

87b

87c

B N

30 87d

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

H

7 - 16

W270

ELECTRICAL SYSTEM

7.11 SOLENOID SWITCHES

WIRES 870: 780: 782: 000:

000

COLD START SOLENOID SWITCH (204, TAB.4)

to starter key through fuse (205) to fuse 150 A (226) to thermostarter resistor (203) to ground

STARTER SOLENOID SWITCH (4, TAB.4) WIRES 700: 802: 888: 000:

802

location G to starter switch connection box location g to starter neutralizer solenoid switch location B to starter motor location e to ground

TECHNICAL DATA Rated voltage: ≤ 24 V Coil rated current: ≤ 2 A Rated load: 100 A

e

700

888

G

B

000

g

FUSE 4 A

STARTER SOLENOID

COLD START SOLENOID SWITCH

Solenoid location: inside engine compartment (right side)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

782

780

870

TECHNICAL DATA Rated voltage: 24 V

W270

7 - 17

ELECTRICAL SYSTEM

7.12 PRESSURE SWITCHES - SENSORS-SWITCHES

3

2

1

1 - STOP LIGHTS CONTROL SWITCH (69, TAB.7b) WIRES 117: to fuse F10A on logic board 175: to stop lights TECHNICAL DATA Thread: M10 x 1 Setting: 1.8 ± 0.5 bar

3 - BRAKES ACCUMULATOR OIL LOW PRESSURE SENSOR (117,TAB.3a) WIRES 613: to instrument and switch cluster 000: to ground on front frame TECHNICAL DATA Thread: R 1/8 tapered Setting: 60 ± 5 bar

2 - TRANSMISSION CUT-OFF SWITCH (75,TAB.2) WIRES 974: to transmission cut-off switch on right cab panel 000: to ground TECHNICAL DATA Thread: M10 x 1 Setting: 15 ± 1 bar Tightening torque: 2 daNm

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

7 - 18

ELECTRICAL SYSTEM MAIN STEERING CIRCUIT OIL LOW PRESSURE SENSOR (92, TAB.3a)

WIRES 835: to low pressure steering timer “Z1” on logic board 000: to ground

TECHNICAL DATA Thread: M14 x 1.5 Setting: (Push-OFF)

EMERGENCY STEERING CIRCUIT OIL LOW PRESSURE SENSOR (91,TAB.3a) WIRES 844: to indicator on instrument cluster 000: to ground

TECHNICAL DATA Thread: M10 x 1 tapered Setting: 1 ± 0.2 bar

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270

7 - 19

ELECTRICAL SYSTEM AIR CLEANER CLOGGING SENSOR (118,TAB.3a)

LOCATION - On air cleaner inside engine compartment WIRES 663: to indicator on instrument cluster 000: to ground

TECHNICAL SPECIFICATIONS Setting (closing of contact): 57 to 67 mbar Tightening: tighten manually, without using tools

663

000

ENGINE OIL LOW PRESSURE SENSOR (114,TAB.3a) WIRE 503:

to instrument and switch cluster

TECHNICAL SPECIFICATIONS Thread: R 1/8 tapered Setting: 0.5 ± 0.1 bar 503

LOCATION - On crankcase

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

7 - 20

W270

ELECTRICAL SYSTEM PARKING BRAKE ENGAGED PRESSURE SWITCH (88, TAB. 3a)

LOCATION - On transmission parking brake clutch pack

000

978

WIRES 978: to indicator on instrument cluster 000: to ground

TECHNICAL SPECIFICATIONS Thread: R 1/8 tapered Setting: 10 ± 1 bar COOLANT MAX.TEMPERATURE SWITCH (60A, TAB. 3a) WIRES 528: to indicator on instrument cluster 000: to ground

528

000

TECHNICAL SPECIFICATIONS Thread: M16x1.5 Setting: 101 ± 2°C

TRANSMISSION OIL MAX. TEMPERATURE SWITCH (120, TAB. 3a) WIRES 559: to indicator on instrument cluster 000: to ground

559

000

TECHNICAL SPECIFICATIONS Thread: M16x1.5 Setting: 122 ± 3°C Tightening torque: 2 daNm

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

7 - 21

ELECTRICAL SYSTEM 1st TRANSMISSION SPEED SENSOR (181, TAB. 2)

WIRES 537: to ATC control unit 536: to ground

537

536

2nd TRANSMISSION SPEED SENSOR (208, TAB. 2) WIRES 535: to ground 534: to ATC control unit

535

534

D

1st speed sensor

2nd speed sensor

D = distance between sensor and transmission gear (refer to setting) Note for the installation of the sensors: Apply LOCTITE 572 to 1st and 2nd sensor. Setting: In order to obtain a correct installation of the sensors, tighten them to contact the transmission gear, then loosen the sensor one and 1/2 turn.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

7 - 22

W270

ELECTRICAL SYSTEM BUCKET POSITIONER PROXIMITY SENSOR (136, TAB. 5)

WIRES 981: to bucket solenoid valve "EV11" 994: to F6C fuse on logic board 000: to ground TECHNICAL SPECIFICATIONS Thread: M18x1 Tightening torque: 2.5 daNm Proximity sensor

000 994

981 LOCATION -

On end of bucket control right cylinder rod

BOOM KICK-OUT PROXIMITY SENSOR (132, TAB. 5) WIRES 980: to bucket positioner exclusion/limitation switch 995: to F6C fuse on logic board 000: to ground on frame TECHNICAL SPECIFICATIONS Thread: M18x1 Tightening torque: 2.5 daNm

000 995

980 LOCATION -

On front frame, at the upper end of left boom

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

7 - 23

ELECTRICAL SYSTEM PROXIMITY SENSOR (180, TAB. 2) (Accelerator pedal)

WIRES 538: 981: 000:

to ATC electronic unit to F10A fuse on logic board to ground

TECHNICAL SPECIFICATIONS Thread: M18x1 Tightening torque: 2 daNm

981 000

538

ACCELERATOR PEDAL CAB FLOOR

1.5 - 3 mm

SENSOR

LOCATION - Under accelerator pedal

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

7 - 24

W270

ELECTRICAL SYSTEM

FUEL LEVEL SENSOR WIRES 555 To fuel level indicator light (dashboard) 557 To fuel level meter (dashboard) FUEL METER

LOCATION - Inside reservoir 24V3W A

24V

3/4

V

409

262

272

25

(55˚) 1/2

320

409

227

R500 110˚

1/4

(55˚)

557 555

WARNING POINT FIAT FULL 3/4 1/2 1/4 EMPTY

(Ω) 10 19 32 49.5 80

Floater

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

7 - 25

ELECTRICAL SYSTEM COOLANT TEMPERATURE SENSOR (60B,TAB.3b)

WIRES 552: to coolant temperature indicator on cluster

TECHNICAL DATA Thread: M16 x 1.5

552

TRANSMISSION OIL TEMPERATURE SENSOR (121,TAB.3b) WIRES 550: to transmission oil temperature indicator on cluster

TECHNICAL DATA Thread: M16 x 1.5 550

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

7 - 26

W270

ELECTRICAL SYSTEM

7.13 ACOUSTIC TRANSDUCERS HORN (95,TAB.7b) LOCATION - Inside front frame WIRES 138: to horn relay “R2” 000: to ground

TECHNICAL DATA Rated voltage: 24 V Current draw: ≤ 5A (0.2 Ω) Acoustic level: 117 db at 1.2 m Fundamental frequency: 405 ± 25 Hz Predominant acoustic level: 710 ÷ 2800 Hz

000

138

BACK-UP ALARM (82, TAB.2) LOCATION - Radiator compartment

163

WIRES 163: to back-up Alarm relay “R7” 000: to ground:

000

+

-

TECHNICAL DATA Rated voltage: 24 V Acoustic level: adjustable (97-107-112 db)

DETAIL OF BRIDGE TO SELECT ACOUSTIC LEVEL MIN.

MED.

MAX

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

7 - 27

ELECTRICAL SYSTEM

7.14

ALTERNATOR TYPICAL WIRING DIAGRAM

OPTIONAL CONNECTIONS TO 1 TERMINAL - USE ONE DIODE 15 AMPI

637 I

773

I

I

522

BAT R

WHEN THE INDICATOR LIGHT COMES ON WARNING: DO NOT EXCEED 1 Amp output

000

SEE OPTIONS

I BAT+ II

10 OHM. 30 WATT TO 50 OHM. 10 WATT 110 OHM. RECOMMENDED 3 CP BULB IGN SWITCH B+

SHUNT AMMETER (IF USED) A

CHARGING LINE CABLE Ø 6 CABLE OR LARGER LOAD

TACHOMETER CHARGE INDICATOR

BAT V

RECOMMENDED CHARGING SYSTEM INDICATOR MOTOR SOLENOID TERMINAL OR A POINT NEAR THE BATTERY CONNECTED BY A LARGE DIAMETER CABLE

WIRES 773 To fuse LINK (80 Amp) 637 On connector "C" (cab connections) 522 On connector "C" (cab connections) 000 To ground LOCATION - Left side of engine compartment TECHNICAL DATA NOMINAL VOLTAGE OF ELECTRICAL SYSTEM: NOMINAL CURRENT OUTPUT:

24 Volt 70 Amp

7.15 EQUIPMENT CONTROL SINGLE LEVER PILOT VALVE KICK-DOWN SINGLE E-CONTACT

YU FORW/REV. DOUBLE E-CONTACT

1

17˚

2

4

24˚

NEUTRAL SINGLE E-CONTACT

YU

3 Identification Wire in the colour plug

Identification in the plug

Wire colour

1

grey

5

yellow

2

black

6

green

3

red

7

white

4

blue

Grip YU

8

yellow

black grey

white

green

red blue

brown

Neutral

brown

Kick-down Forward/Reverse

F 1

2

3

4

5

6

7

8

9

LOCATION: Right side of operator's seat TECHNICAL DATA

View F

View F

A 1

2

3

4

5

6

SWITCHES POWER SUPPLY F

CONTACT RESISTANCE: MAX. CURRENT LOAD PEAK:

24V - DC / 1.25 AMP ( ) < 20 MΩ ≤100 100 Amp / 30 ms

B

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

7 - 28

ELECTRICAL SYSTEM

NOTE:

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270

ELECTRICAL SYSTEM

MACHINE GROUPS ELECTRIC DIAGRAMS

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

7 - 29

7 - 30

W270

ELECTRICAL SYSTEM

TABLE 1 LTS ELECTRIC DIAGRAM Description of main components

Item

Description

Position on machine

Key switch 1st position ACC

Seat right side

Connectors B - D - E - K - N

Relays holder slide

Connector A

Cab floor

Solenoid valve EV1

Front frame

D12-D15-D22

Diode

Relays holder slide

F1C-F11A

Fuse

Relays holder slide

K8

ATC Electronic Unit

Near relays holder slide

S38

LTS Switch

Swithes panel R. H. of seat

“ACC”

169

Numbered wires are located outside the cab. Colored wires are located inside the cab. Colours of wires. A

LIGHT BLUE

H

GREY

R

RED

B

WHITE

L

BLUE

S

PINK

C

ORANGE

M

BROWN

V

GREEN

G

YELLOW

N

BLACK

Z

PURPLE

Operation The current is supplied to the solenoid valve through switch S38. In position 1 the ground is managed by the transmission control unit. When the speed exceeds 7 km/h the LTS is engaged and disengages when speed drops below 5 km/h. With switch S38 in position 2 the LTS is always engaged.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

ELECTRICAL SYSTEM

7 - 31

TABLE 1 LTS ELECTRIC DIAGRAM

W270

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

7 - 32

ELECTRICAL SYSTEM

TABLE 2 AUTOMATIC TRANSMISSION WIRING DIAGRAM Description of main components

Item “ACC”

1-2-3-4 F7A-F9B-F11A 75 82 88 180 181 191 192 208 A B F R JPI K8 MV3 R7 R9 SERV. RELAY S29 S37 S41 SW1-3/4 SW2-3/4 DSS D1,D3, D7, D10 D11, D27, D28, D29 D30, D31, D32, D33 D38, D42, D43 300 301 +30 VC2 234

Description

Location

Key switch 1st click "ACC"

Right side of seat

Connectors B-G-M-D-E-P-C-N-S-O

Relay board

Connectors B-C-D

Cab floor

Gearshift wire connections

Steering column

Speed indicator lights

Dashboard

Fuses Cut-off pressure switch Back-up alarm Parking brake pressure switch Proximity switch Rpm sensor Rh back-up light Lh back-up light Rpm sensor Solenoid A Solenoid B Forward speed solenoid Reverse speed solenoid Bridge (ground of sensors) ATC transm. Controller Transitory suppresser Back-up alarm relay Transm. Solen. Control relay Accessory relays

Relay board Brake pedal valve Radiator compartment Parking brake (transm.) Transmission Transmission Rear of machine Rear of machine Transmission Transm. Control valve Transm. Control valve Transm. Control valve Transm. Control valve Relay board Near relay board Relay board Relay board Relay board Under relay board

Transm. Cut-off switch Gearshift Gearshift Dip-switch 1 Dip-switch 2 Kick-down switch

Switch pan. Rh side of seat Steering column Steering column Relay board Relay board Equipment control lever

Diodes

Relay board

Capacitor = µ F 100V Resistor = 10w Relay board power From cont. Closing serv. Relay Fuse ATC

Relay board Relay board Relay board Under relay board Near relay board

I Numbered wires are located outside the cab. Colour coded wires are located inside the cab. Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

W270

ELECTRICAL SYSTEM

7-33

RELAIS SERVICES

TABLE 2 AUTOMATIC TRANSMISSION ELECTRIC DIAGRAM Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

7 - 34

W270

ELECTRICAL SYSTEM

A

LIGHT BLUE

H

GREY

R

RED

B

WHITE

L

BLUE

S

PINK

C

ORANGE

M

BROWN

V

GREEN

G

YELLOW

N

BLACK

Z

PURPLE

Switches SW1 and SW2 are represented as they must be in the in the automatic transmission version.

Operation All the functions are controlled by control unit K8. All the components are connected to control unit and the inlet main signal is supplied by switch S29. In the OFF position the engaged speeds will be and will correspond to those of the selector. in the ON position all the shifts are managed by the control unit according to its operating logic. The only engagement that is not directly controlled by the control unit concerns the parking brake. In fact it is the only one that does not interfere with the signals of solenoids open circuit and as a conseguence of the indications of the lamps on the panel. The bridge JP1 is installed on ground of rev sensor 181 and 208. In the case of the automatic transmission it must be connected as illustrated in the diagram, in a way to have also this function controlled by the control unit.

Cutt-off operation The cut-off operates both in forward or reverse and is obtained by the opening of relay R9 contacts. In the normal position the contacts are as shown in the diagram, closing the circuit of solenoids F and R. The cut-off can be obtained in two ways: with the parking brake engaged or with the operation of service brakes. With the parking brake engaged the coil of relay R9 is grounded by pressure switch 88 fitted to the brake itself. When using the parking brakes it is instead grounded when the contacts of switch S37 and those of pressure switch 75, fitted on brake pedal valve, are closed.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

7 - 35

ELECTRICAL SYSTEM

TABLE 3a & 3b INSTRUMENTAL PANEL Description of main components Item “ACC”

1-2-3-4 F9B-F11A D8, D9, D11, D14 60A 88 91 92 110 114 117 118 120 BZ1 G h K8 Z1 Z2

Item

60B 110 121 181 208 F6B K8 R3 SW1/2 JP1 JP2

Description

Location

“ACC” key switch contact (1st pos.)

Cab R. S. of the operator seat

Connettori C-E-F-G-H-M-S

Scheda relè

C-E-F-G-H-M-S Connectors

Main board

Instrument panel connectors

Behind the instrument panel

Instr. panel and m. board connect.

Steering column

Gear indicator lamp

Instrument panel

Fuses Diodes Coolant temperature switch Hand brake pressure switch Emerg. steer. low pressure switch Main steer. low pressure switch Fuel level sensor Eng. oil low pressure switch Brake accumulator low press. sw. Air filter clogging switch Transmiss. oil high temp switch Warning buzzer Alternator Hourmeter A.T.C. Steering alarm timer Check timer

Main board Main board Engine Transmission Side of the hydraulic oil tank Near the main priority valve Fuel tank Engine Brake pedal valve Air filter housing Out port of torque converter Main board Side of engine Instrument panel Near the main board Main board Main board

Description

Location

C-E-F-G-H-K Connectors

Main board

A-B-C-D Connectors

Underneath the cab

Connettori del cruscotto

Dietro cruscotto

Instrument panel connectors

Behind the instrument panel

Coolant temperature sensor Fuel lever sensor Transmiss. oil temp. sensor Speed sensor Main speed sensor Fuse A.T.C. Lights relay DIP-Switch 1/2 Jump Jump

Engine Fuel tank Out port of torque converter Transmission Transmission Main board Near main board Main board Main board Main board Main board

Numbered cables outside the cab. Coloured cables inside the cab. A B C G

LIGHT BLUE WHITE ORANGE YELLOW

H L M N

GREY BLUE BROWN BLACK

R S V Z

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

RED PINK GREEN PURPLE

7 - 36

W270

ELECTRICAL SYSTEM

PER BUZZER SUPPLEMENTARE FOR ADDITIONAL BUZZER

TAV. 3a INSTRUMENT PANEL 1ST PART

TAV. 3b INSTRUMENT PANEL 2ND PART

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

ELECTRICAL SYSTEM

7 - 37

Operation The components connected to other groups such as lights, turn lights are going to be explained with those groups. In table 3a are represented all the warning indicators, those of the transmission speeds, the hourmeter, the timers Z1 for main steering circuit low pressure and Z2 for initial check and buzzer functions. When the key switch is turned to the first position “ACC” all the indicator lamps light on, and both Z1 than Z2 are supplied, in this condition the timers are connected to fuse F9B. The battery charging indicator is connected to terminal +I of alternator that is considered as negative when the alternator is not rotating. In the same manner are also connected the terminals 4 of the check timer Z2 and the hourmeter. This Z2 connection prevents the buzzer intervention during the initial check. Remember that the initial check is carried out for a 5 seconds interval as soon as the key is turned in 1st position “ACC”. In effect as the engine starts driving the alternator the terminal +I of the alternator becomes positive and the buzzer ground is managed by Z2 and goes on each time there is a defect. The hourmeter, as shown in the diagram with the alternator at rest, is connected to a totally negative circuit through terminal +I while during alternator rotation the circuit becomes positive and normally operating. In diagram 3b are represented the components concerning the instruments and indicator lamps for turning lights and high beam lights. The complete lights circuit is represented in diagrams 7a and 7b. For what concerns the speedometer are represented the rev sensor for automatic transmission, the dip-switches and the bridge JP1 that can be positioned differently according to machine model. Connection CN2-24 on dashboard is positively connected to relays holder slide connection G1, the fuse F11A is under current when the key is turned in 1st position ACC.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

7 - 38

W270

ELECTRICAL SYSTEM

TABLE 4 THERMOSTARTER STARTING AND SAFETY DEVICES ELECTRIC DIAGRAM Description of main components

Item

Description

Position on machine

Key switch 1st position at left “H”

Seat right side

M

Key switch 2nd position “M”

Seat right side

“ST”

Key switch 3rd position “ST”

Seat right side

Connectors B-H-O-R-A-M-P-D

Relays holding slide

Connector C-B

Cab floor

Connector on transmission selector cable Connection from batteries Batteries Ground master switch Starting relay Diodes Fuses Fuse link Fuse link Stop solenoid (170-190-230) F.V. 270 Resistor Thermostarter relay Fuse 4A Electrostop control relay Indicator pump Alternator Cold starting unit Starter motor Transient suppressor Relay for transmission solenoids Starting inhibitor relay Neutral starting safety relay Transmission selector Front wiper timer Fuse 4A Diodes box

Cab floor Relays holding slide Machine rear side Radiator compartment Engine compartment, injection pump side Relays holding slide Relays holding slide Battery compartment L.H. (170-230) R.H. 270 Battery compartment L.H. (170-230) R.H. 270 On injection pump Engine inlet manifold Engine compartment R.H. side Engine compartment R.H. side Engine compartment Switch panel on R.H. of seat Engine compartment Under relays holding slide Engine compartment inject. pump side Relays holding slide Relays holding slide Relays holding slide Relays holding slide Steering column Engine compartmet Engine compartmet Engine compartmet

“G1”

+30 1 2 4 D20,D36,D12,D7 F4A-F4B 50A link 80A link 229 203 204 205 233 L18 G K6 M MV1 R10 R4 R5 S41 241 242 243

Numbered wires are located outside the cab. Colored wires are located inside the cab. Colours of wires. A B C G

LIGHT BLUE WHITE ORANGE YELLOW

H L M N

GREY BLUE BROWN BLACK

R S V Z

RED PINK GREEN PURPLE

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

7-39

ELECTRICAL SYSTEM

Thermostarter operation (170-190)

TABLE 4 THERMOSTARTER STARTING AND SAFETY DEVICES

W270

The thermostarter turn-on is not automatic, but is obtained by turning the starter key to the first position and keeping it in this position for all the necessary time. In any case no more than 30 seconds. After this rotate the key in the normal starting position. With the key in position “H”, described above, the relay 204 is energized closing the contacts and connecting directly the battery with resistor 203.

Operation of starting and safety rules There are two 80 Amp LINK fuses in the connection between batteries and alternator and another one 50 Amp in the batteries starter motor connection. The main switch installed on the negative pole of the batteries cuts-off all functions, except switch and cab ceiling light. When the key of the starter switch is moved into "M", the coil of electric cut-off 229 is powered. The electric cut-off of models W170-190 consists of two coils, one holder and one puller. When the key is in "M", the first coil is energised, which is unable to move the magnet. With the key in "M" position, the first coil (holder) is energised by the electric cut-off and, at the same time, the second coil of the electric cut-off (puller) is energised for a fraction of a second, which, moving the injection pump link, positions the governor rod in operation condition. The starter motor is engaged when relay R4 is energised and this occurs only when relay R5 is energised, as well, condition obtained when the key is moved into position START (third click) and selector S41 is in neutral. Please note that the negative of coil R4 is connected to terminal +I of the alternator, which is negative only when the alternator is not turning. Once the engine is started, this terminal becomes positive and relay R4 cannot be energised. Consequently, a safety is implemented to avoid further starting operations while the engine is turning. This wiring diagram shows that the alternator has an R terminal connected to the relay board to final connector L4. An electronic rpm counter can be connected to this point.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

7 - 40

W270

ELECTRICAL SYSTEM

TABLE 5 EMERGENCY STEERING AND BUCKET-BOOM POSITIONERS ELECTRIC DIAGRAM Description of main components

Item “ACC”

VC2 +I 132 136 91 92 BZ1 EV10 EV11 EV9 F6C-F9B-F11A D16,D13,D19 D9,D8 138 137 K5 Z1 Z2

Description

Position on machine

Key switch 1st position ACC

Seat right side

Connectors F-G-J-H-K-M-S-D

Relays holder slide

Connectors A-B-C

Cab floor

From contacts closing of services relay Terminal I of alternator Max. boom height proximity switch Bucket position proximity switch Emergency steering low pressure switch Steering low pressure switch Buzzer Bucket detent. magnet Boom max. height detent magnet Boom float detent magnet Fuses Diodes

Under relays holding slide Engine compartment Boom rear end Near the bucket cylinder Near hydraulic oil tank On diverter valve Under relays holding slide Pilot valve / bucket spool Pilot valve / boom spool Pilot valve / boom spool Relays holder slide Relays holder slide

Boom positioner limitation/exclusion switch Indicator lamp Instrument panel Steering low pressure alarm timer Check timer

Switch panel R.H. of seat Switch panel R.H. of seat Steering column Relays holder slide Relays holder slide

Numbered wires are located outside the cab. Colored wires are located inside the cab. Colours of wires. A B C G

LIGHT BLUE WHITE ORANGE YELLOW

H L M N

GREY BLUE BROWN BLACK

R S V Z

RED PINK GREEN PURPLE

Steering operation When in the main circuit there is a consistent lowering of pressure, the switch 92 closes and if the pressure lowering lasts more than 5 seconds, controlled by timer Z1 the dashboard indicator lights up and also the buzzer goes on. The buzzer is controlled by timer Z2 that is used also by all the other indicators. When the pressure in the steering emergency circuit is too low the switch 91 closes and the same lamp in the dashboard immediately lights up. Bucket and boom positioner The circuit is activated with the contacts closing of services relay that is energized when the key is rotated in ACC (1st position). The magnets EV10 and EV11 are controlled by proximity switch 132 and 136. The magnet EV10 is controlled by switch 138 that has 3 position: a) OFF position - the magnet is never energized b) position 1st click - the magnet is always energized c) position 2nd click - the activation of magnet is controlled by sensor 132 The magnet EV9 for boom float position is always energized. This means that everytime the boom control lever is shifted in float position the lever is held in position and its return must be actuated manually.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

ELECTRICAL SYSTEM

7 - 41

TABLE 5 EMERGENCY STEERING

W270

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

7 - 42

W270

ELECTRICAL SYSTEM

TABLE 6 AIR CONDITIONING AND VENTILATION ELECTRIC DIAGRAM Description of main components Item “ACC”

VC2 F8C 145 227 302 K3 M7 M8 M9 S21 S22 S23 S24 S25 S26

Description

Position on machine

Key switch 1st position “ACC”

Seat right side

Connectors J-M

Relays holder slide

Connectors B

Floor cab

From contacts closing of services relay Fuses Triple pressure switch Compressor clutch Condenser Electronic control unit Recirculation control motor Hot/cold valve motor Cab fan Recirculation control switch Temperature control potentiometer Hot/cold valve knob Cab fan switch Air conditioning switch Conditioner thermostat

Under relays holder slide Relays holder slide Engine compartment Engine compartment Relays holder slide Inner side of switches panel Near switches panel Near switches panel Inside cab on R.H. side Near switches panel Near switches panel Near switches panel Near switches panel Near switches panel Inside cab near evaporator

Numbered wires are located outside the cab. Colored wires are located inside the cab. Colours of wires. A B C G

LIGHT BLUE WHITE ORANGE YELLOW

H L M N

GREY BLUE BROWN BLACK

R S V Z

RED PINK GREEN PURPLE

Operation Air conditioning is optional equipment. Standard equipment is the heater. Rotating the key in ACC, 1st position the current flows in all the system. With fan off it is possible to open or close the heating and re-circulation. Whit fan off it is impossible to turn on the air conditioning. The triple pressure switch 145 feels the gas pressure in the circuit and has two functions: 1) to engage the compressor clutch 2) system safety: in case of excessive or low pressure in the circuit to stop the compressor. The thermostat S26 is a safety device of the system. Should the temperature in the evaporator decrease under the thermostat setting of about 2°C, it will stop the air conditioning. The cab temperature regulation is obtained by acting exclusively on the cab fan speed and by the opening of the cold/warm tap. The potentiometer S22 mounted on small motor opening the hot water tap is used to transmit to the control unit the rotation value manually obtained through potentiometer S23 this to assure correspondence of values. The opening position is a function of the S23 setting. The re-circulation motor, actuated by switch S21, has only two possible positions: open and closed. Both the re-circulation and the cold/warm tap are controlled by the electronic control unit K3.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

ELECTRICAL SYSTEM

7 - 43

TABLE 6 AIR CONDITIONING AND VENTILATION

W270

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

7 - 44

W270

ELECTRICAL SYSTEM

TABLE 7a LIGHTING ELECTRIC DIAGRAM Description of main components Item

F3B-F5C-F5AF3A-F2B-F2AF6B-F8B-F3C +30 VC2 19 21 22 23 (optional) 24 (optional) 26 28 31 33 34 36 65 66 L10 (optional) L11 (optional) L12 L13 R3 S32 S33 S34 S42

Description

Position on machine

Connectors A-M-K-F-B

Relays holder slide

Connector A-B

Cab floor

Fuses

Relays holder slide

Connection from batteries From contacts closing of services relay Rear right parking light Front left parking light Front right parking light Left side light T.U.V. Right side light T.U.V. Rear left parking light License plate light Front left low beam head lamp Front right low beam head lamp Front left high beam head lamp Front right high beam head lamp Right rear work light Left rear work light Parking left road traffic Italy light Parking left road traffic Italy light Front work light Front work light Lamps relay switch Lights switch Rear work lights switch Front work lights switch Lighting change-over and turn signal switch

Relays holder slide Under relays holder slide Rear ballast Front frame Front frame Bucket tooth guard Bucket tooth guard Rear ballast Rear of machine Front frame Front frame Front frame Front frame Rear of machine Rear of machine Side left cab Side right cab Cab front Cab front Relays holding slide Switches panel Switches panel Switches panel Steering colunm

Numbered wires are located outside the cab. Colored wires are located inside the cab. Colours of wires. A LIGHT BLUE H B WHITE L C ORANGE M G YELLOW N

GREY BLUE BROWN BLACK

R S V Z

RED PINK GREEN PURPLE

Operation All the system is power supplied when the key switch is turned in ACC, 1st position, through the contacts of services relay. The switches S32, S33, S34 incorporate a lamp that lights up when they are closed. The fuse F3B feeds the high beam and dim lights circuits, but each one of them has its own fuse F8B and F6B. The passage from high to low beam lights and viceversa is obtained through relay R3 controlled by lever switch S42 located to the right of steering column. With the first click of switch S32, the parking lights are actuated, while with the second click also the high and low beam lights come on according to position S42. The switch S42 has three positions. With contact on 56B the low beam lights are activated. With contacts on 30 (unstable position, the lever is spring loaded) the high beam lights are switched on. With contact on 56 the high beam lights stay on. Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

ELECTRICAL SYSTEM

7 - 45

TABLE 7a LIGHTING ELECTRIC DIAGRAM

W270

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

7 - 46

W270

ELECTRICAL SYSTEM

TABLE 7b TURN SIGNAL LIGHTS AND HORN ELECTRIC DIAGRAM Description of main components

Item “ACC”

F8A-F4CF10A-F9C +30 VC2 25 (optional) 27 (optional) 39 41 45 47 69 71 72 95 82 191 192 MV3 107 MV2 R7 R1 S28 S41 S42 Z3

Description

Position on machine

Key switch 1st position “ACC”

Seat right side

Connectors D-K-M-F-C-O

Relays holder slide

Connectors A-B-D Fuses

Cab floor Relays holder slide

Connection from batteries From contacts closing of services relay Front left turn signal light (T.U.V.) Front right turn signal light (T.U.V.) Front left turn signal light Rear left turn signal light Front right turn signal light Rear right turn signal light Pressure switch Left stop light Right stop light Horn Back-up alarm Right reversing light Left reversing light Transient suppressor Horn button Transient suppressor Relay Horn relay Emergency lights switch Speeds selector and horn control Lighting change-over and turn signal switch Turn signal intermittence

Relays holder slide Under relays holder slide Bucket tooths guard Bucket tooths guard Front frame Rear of machine Front frame Rear of machine Brake valve under cab Rear of machine Rear of machine Front frame Radiator compartment Rear of machine Rear of machine Relays holder slide Cab floor Relays holder slide Relays holder slide Relays holder slide Switches panel L.H. side of steering colunm R.H. side of steering colunm Relays holder slide

Numbered wires are located outside the cab. Colored wires are located inside the cab. Colours of wires. A B C G

LIGHT BLUE WHITE ORANGE YELLOW

H L M N

GREY BLUE BROWN BLACK

R S V Z

RED PINK GREEN PURPLE

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

7-47

ELECTRICAL SYSTEM Operation TABLE 7b TURN SIGNAL LIGHTS AND HORN

W270

Emergency lights When switch S28 is closed the intermittence unit Z3 flashes all the four directional lights. The normal direction signal is obtained by placing the contacts of switch S42 to the right or to the left. The fuse F8A is for turning lights, while the F4C is for emergency lights. The stop lights are controlled through pressure switch 69 located in brake pedal valve. The horn is directly connected to batteries through connection +30. Pressing push button 107 or pushing in the selector lever S41 the relay R2 closes the contacts and the horn goes on. Note the transient suppressor MB2 that operates as a filter controlling the voltage peaks generated during horn operation. The voltage peaks are discharged to ground. The back-up alarm 82 and the lamps 191, 192 that indicate the reverse gear engagement are controlled by the closing of contacts of relay R7 in turn grounded through gearshift selector S41.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

7 - 48

W270

ELECTRICAL SYSTEM

TABLE 8

CAB COMPONENTS ELECTRIC DIAGRAM

Description of main components

Item

F7B-F6A-F8AF5C-F9A-F9C-F11B F2B-F10C-F10B D45-D46 +30 VC2 53 57 K4 K7 L14 L15 L16 M10 M6 N1 N2 12V 24V S27 S30 S31 S32 S35 S43 R6

Description

Position on machine

Connectors B-A-Q-D-F-J-K-M

Relays holder slide

Connectors B

Cab floor

Fuses

Relays holder slide

Transient suppressor Connection from batteries From contact closing of services relay Front washer pump Rear washer pump Front wiper timer Tension reducer Ceiling lamp Rotary beacon Rotary beacon Front wiper motor Rear wiper motor Radio Clock Power socket Connector for electric seat Cigarette lighter Rear washer button Rear wiper switch Lights switch (See table 7a) Rotary beacons switch Front wiper and washer switch Time relay

Relays holder slide Relays holder slide Under relays holder slide Engine compartment Engine compartment Relays holders slide Under relays holder slide Cab ceiling Cab roof Cab roof Front of cab Rear of cab Inside cab Cab ceiling Seat left side Under relays holder slide Seat left side Switches panel Switches panel Switches panel Switches panel Steering column Relays box

Numbered wires are located outside the cab. Colored wires are located inside the cab. Colours of wires. A B C G

LIGHT BLUE WHITE ORANGE YELLOW

H L M N

GREY BLUE BROWN BLACK

R S V Z

RED PINK GREEN PURPLE

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

7-49

ELECTRICAL SYSTEM

TABLE 8 CAB COMPONENTS

W270

Operation The clock together with the ceiling light are operating independently from the main switch. In fact they are directly connected to the batteries ground. The clock light goes on when the lights are switched on. The wipers can be operated when the key is rotated to first position ACC with contacts of services relay closed. The Rear wiper S31 has three positions: in 0 through contacts 7 and 5 the current flows to the motor so to have the wiper return in rest position. In position 1 the intermittence unit will operate through contacts 3/5 and 4/6 of switch S31. In position 2 the wiper will remain connected in one frequency speed. The interested contacts are 3/5/1 and 4/2/6. Each time that the switch is moved in 1 or 2 the inner lamp will light. The Front wiper has two speeds. As the rear one it is equipped for intermittent operation. The switch position is represented in this way: Zero = off J = intermittence I = first speed II = second speed Wash = washing The rotary beacons are controlled by switch S21 also housing an inner lamp that lights when closed. They are connected to machine by means of two sockets mounted outside the cab.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

7 - 50

W270

ELECTRICAL SYSTEM

TAV. 9 ELECTRICAL DIAGRAM SINGLE LEVER PILOT CONTROL Description of main components

ITEM

VC2 F6C D13, D16, D19 132 136 137 138 EV. 9 EV. 10 EV. 11 230 231 232

DESCRIPTION

LOCATION

Connectors J-K-D

Main board

Connector A

Underneath the cab

From contact of tractor relay Fuse Diodes Indictive proximity sw. for boom Indictive proximity sw. for bucket Indicator light Limitation/off switch Boom floating detention solenoid Bucket detention solenoid Boom max. lift detention solenoid Relay Relay Diode box

Underneath the board Main board Main board Near to priority valve Near to priority valve Sw. panel (R. side operator seat) Sw. panel (R. side operator seat) Hydr. manipulator Hydr. manipulator Hydr. manipulator Manipulator support Manipulator support Manipulator support

Numbered wires are located outside the cab. Colored wires are located inside the cab. Colours of wires. A B C G

LIGHT BLUE WHITE ORANGE YELLOW

H L M N

GREY BLUE BROWN BLACK

R S V Z

RED PINK GREEN PURPLE

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

ELECTRICAL SYSTEM

7 - 51

TAV.9 SINGLE LEVER PILOT CONTROL

W270

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

7 - 52

W270

ELECTRICAL SYSTEM

TAV. 10 AUXILIARY INVERTER WIRING DIAGRAM Description of main components

ITEM “ACC”

DESCRIPTION

LOCATION

“ST” key switch contact

Cab r. s. of the operator seat

O-N Connector

Main board

B-G Connectors

Near the main board

Selector control transmission

Steering colum

F4A-F4B-F5A-F7A Fuses D7, D27, D33 K8 MVI R4 R5 R7 235 236 237 238 S41

Main board

Diodes A.T.C. Transient suppresser One-off starting relay Starting safety relay Starting safety relay Aux. F-N-R enabling push-butt. sw. Direct. control aux. switch F-N-R Micro controller Single lever F-N-R arrangement Transmission control switch

Main board Near the main board Main board Main board Main board Main board Switches panel Near hidr. manipulators Near main board Underneath the hidr. manipolator Steering column

Numbered wires are located outside the cab. Colored wires are located inside the cab. Colours of wires. A B C G

LIGHT BLUE WHITE ORANGE YELLOW

H L M N

GREY BLUE BROWN BLACK

R S V Z

RED PINK GREEN PURPLE

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W270

7 - 53

CN1-4 CN1-3 CN2-13 CN2-12 CN2-1

CN1-9

ATC

CN2-2

"ST" CN1-2

CN2-11

B1

CN2-17 CN2-10

TAV.10 AUXILIARY INVERTER

ELECTRICAL SYSTEM

M

CN2-16

K8

F4A

CN2-15

F4B

CN2-14

CN2-4

R5 CN2-3

07 CN1-13 CN1-7 CN1-5 CN1-11 CN2-7 CN2-8 CN2-9 CN2-6 937

033

R4

022

N1 N2

N3

N6

033

D37 SW2-3

H13

SW2-4

H5 06

07

C1

03

04

05

02

F7A

01

A-R

S-G

C-B

A-V

C-V

C-H

R-N

R7 C3

D27

M14

B11

L-B

B2

R-G A-V R-V C-N R-N

B3 B4 B5 B7 B6

L-B B-R G-R A-B R-V C-N R-N

3

1

2

3

2

3

2

N 4

1

2

F

R

541

ACC

D10

R

G/V

A-V

A-V

H-L

B

G/R

N

G1

235

3 5 8 10 9 12 13 2 6

1 0

9

1

1

R

7 11 1 4

R-G

L-B

C-B

S-G

A-B

F11A

3

G1 G3 G5 G2 G4 G6

236 238

237

5

10

R

D

R

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

SECTION 8

CAB CONTENTS

PARAGRAPH SUBJECT

PAGE

8.1

GENERAL DESCRIPTION ..................................................................................

1

8.2

WINDSCREEN WIPERS AND WASHERS ..........................................................

2

8.3

HEATER ...............................................................................................................

4

8.4 8.4.1 8.4.2

GLASSES ............................................................................................................ Characteristics ...................................................................................................... Disassembly and assembly ..................................................................................

5 5 5

8.5 8.5.1

REPAIR ................................................................................................................ Cab (removal/installation) .....................................................................................

6 7

8.6 8.6.1 8.6.2 8.6.3 8.6.4 8.6.5 8.6.6 8.6.7

AIR CONDITIONING UNIT .................................................................................. Operating istructions ............................................................................................ Technical data ...................................................................................................... Service precautions ............................................................................................. Tool connections .................................................................................................. Discharging .......................................................................................................... Refrigerant charging ............................................................................................ Leak inspection ....................................................................................................

11 11 12 13 15 16 16 17

8.7

TROUBLESHOOTING .........................................................................................

19

CAB

W270

8-1

8.1 GENERAL DESCRIPTION

Fig. 8-1

The cab is a tested protection structure against rollover hazard (ROPS). The cab is complete with the driver’s seat, steering column, controls and instruments to drive and operate the machine. Other standard features are the heating system, demister, front and rear windscreen washer-wipers, ceiling light, clock/thermometer, loud-speakers, safety glasses, rear-view mirrors, sun visor, and emergency exit. Access inside the cab is through the left-hand door. The right-hand door is used to gain access to the heater/air conditioning system compartment. Doors can be locked wide open and are fitted with a key lock. The main components such as the hydraulic reservoir, hydraulic pump and control valve, steering control valves and cylinders, and drive shafts can be removed or repaired without disassembling the cab.

Fig. 8-2 The cab serial number is etched on a plate located on the inner side of the cab left-hand post.

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

W270

CAB

8-2

8.2 REPAIR 8.2.1 CAB (REMOVAL/INSTALLATION) Removal Park the machine on level ground and block wheels securely to prevent motion. Disconnect the battery isolator switch.

Loosen the four safety screws and the four screws securing the cab to the frame. Provide a suitable hoist above the cab and hook it to the lifting eyebolts(q.ty 4) . These should have been screwed in at the cab top beforehand (cab weight: 700 kg approx.). Take out any slack in the lifting chains.

WARNING

Always disconnect the battery isolator switch before cleaning, repairing, overhauling or parking the machine.

WARNING

Always use hoists or similar devices of suitable capacity to lift or move heavy components. Ensure that the sling is perfectly made. Use the lifting eyes.

Fig. 8-3

Remove rear fenders (1) and steps (2). Remove protection panels (3) at the cab bottom, on both sides. Disconnect the cab to frame ground braid.

3

2

1

Fig. 8-5 Lifting cab

Fig. 8-4

Slightly raise the cab taking care not to tension any electrical cables or hoses. Lifting height should be such to allow detachment of all lines and cables from machine assemblies.

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

CAB

W270

Disconnect the four connections A-B-C-D from the bottom of the cab, on the left side, loosening the Allen screws retaining the connection. Disconnect the throttle pedal linkage, ball joint (5), link (6) from steering column (10). Loosen the screws securing the brake pedal valve and remove the pedal assembly, without disconnecting the pipes. From the right side of the cab, open the panel and label the hoses of the equipment control levers (3) and three way valve (4). Disconnect the piping of the windshield washer from the reservoir, and disconnect the piping of the parking brake valve from

8-3

the right side of the cab. Close the heater feeding valves. Disconnect the two heater hoses located in the rear right side of the cab. Make sure that all connections on the machine are disconnected, then lift the cab, moving it sideways.

Reinstallation The installation is the reversal of the removal. Tighten the cab screws to the frame to the specified torque.

9

4 10

3 5

6

11

1

7

2

A B C D

11

8

1

1

Fig. 8-6 Note -

1. 2. 3. 4. 5. 6.

1

Screw M16 - Tightening torque 23 daNm

SAFETY SCREW M30 SAFETY SCREW M24 EQUIPMENT CONTROL LEVER PIPES THREE-WAY VALVE PIPES THROTTLE BALL JOINT STEERING LEVER BALL JOINT

CAB AND FRAME FRONT SECURING NUT M16 8. CAB AND FRAME REAR SECURING NUT M16 9. THROTTLE PEDAL 10. STEERING COLUMN 11. ELASTIC PADS 7.

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

W270

CAB

8-4

8.3 WINDSCREEN WIPERS AND WASHERS The front windscreen wiper motor (1) is located at the front of the steering column. The front windscreen wiper has two intermittent working speeds: 35 strokes per min (slow) and 55 strokes per min (fast). A dog-leg mechanism transforms the motor shaft rotary motion into 45° strokes of the wiping arm.

The rear windscreen wiper motor (2) is located under the cab trim behind the driver’s seat, on the righthand side. The rear windscreen motor has but one speed (approx. 54 strokes per min). Internal gears provide an 80° oscillation of the wiping arm.

Note 1 - Before setting the wiper blades in motion, operate the windscreen washer to minimise the risk of scratching the glass. Note 2 - Use the cleaning fluid DP1 diluted with water dependent upon working temperature. A 50% detergent/water solution does not freeze down to -10°C. Below this temperature, use cleaning fluid only.

Pump hoses are connected to the nozzles located at the sides of the wiping arms.

1

2

3 5 4 Fig. 8-7 The windscreen washer fluid bottle (3) is located inside the engine compartment, on the left-hand side. The bottle is fitted with two pumps (4) and (5) for the front and rear windscreens, respectively.

Specifications Bottle capacity ............................................... 2.5 lt. Rated voltage ................................................... 24V Absorbed current ............................................. ≤ 2A Max. flow ................................................ ≥ 3 lt./min

Fig. 8-8 In case of motor or arm assembly replacement, it will be necessary to reassemble the arm assembly to the drive part correctly to centre the wiping action over the glass width. To this aim, select the most suitable position for the arm on the knurled drive part shown by the arrow in the figure.

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

CAB

W270

8-5

8.4 HEATER 8.4.1 GENERALITIES 6 The cab heater is placed in a special compartment, on the cab right-hand side. The associated switches are located on the control console and are used to:

3 1

2

9 - adjust air temperature; - control air flow intensity; - admit air from the outside or recirculate the air inside the cab. In case of air intake from the outside, air is drawn in through the filter A. If air is being recirculated, internal cab air is driven through the filtering panel B. Both filter A and filtering panel B should be replaced periodically.

4

7

A

5

8

Fig. 8-10 MAIN COMPONENTS AND SPECIFICATIONS B

Fig. 8-9

The heater main components are: 1. 2. 3. 4. 5. 6. 7. 8. 9.

Electrical fan Outside air filter Filtering panel Heat exchanger Shroud Housing Water lines Air ducting Feed valve

Specifications Heat value ........................................ 10,000 Kcal/h Air flow .......................................... 575 ± 10% m3/h Absorbed power .......................................... 400 W Working temperature range ................. –15 + 50°C

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

W270

CAB

8-6

8.5 CAB GLAZING All cab glasses are differential hardening type. Glasses should be ordered from FIAT-HITACHI. They should be kept clean at all times to guarantee good visibility. When cleaning the glasses, pre-wash them with a water and detergent solution or other proprietary product using a squeegee to reduce abrasion and make cleaning easier.

4 6 2

NOTICE - Never use hot water over cold glasses.

All glasses fitted to the cab have been subjected to differential hardening and have a 5 ± 0.2 mm thickness. They are firmly bonded to their seats by means of a polyurethane sealant.

5

1 7 5 ± 0.2 mm 3

Fig. 8-11 Fig. 8-12 1. 2. 3. 4. 5. 6. 7.

Front windscreen Rear windscreen Door glass RH side glass (emergency exit) LH rear glass RH rear glass Bonding kit

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

CAB

W270

8-7

8.5.1 DISASSEMBLY AND ASSEMBLY Disassembly

Preparing the replacement glass

1. Push a pointed object through the adhesive from inside the cab and insert the wire.

1. Place the glass momentarily in position and mark with adhesive tape to position it correctly during final bonding.

2. Using the wire, cut the adhesive all around the glass. Lift out the glass using two suction cups. 3. Using a knife, cut off the adhesive left on the body to leave a smooth bevel of approximately 1 or 2 mm, which should be kept clean as it will be the bonding base for the polyurethane adhesive. Should the paint be partially damaged, apply some glass primer as a protection against corrosion.

Note - Work only in well ventilated premises. The polyurethane adhesive does not contain low molecular weight (monomolecular) volatile isocyanates. Therefore, there is no danger of irritation for the respiratory tract. However, all precautions required when using chemicals should be observed. Avoid contact with the eyes and skin. Fig. 8-14

2. Thoroughly clean the glass edge using the special cloth moistened in the degreaser supplied.

Important - After degreasing, wipe the degreased part using a clean dry cloth.

Fig. 8-13

WARNING

Always wear gloves and use special suction cups with handles when replacing the glasses. Do not strike the glasses to remove. Fig. 8-15

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

W270

CAB

8-8 3. Shake well the glass activator bottle before use (at least 1 minute after ball separation from the sediment). Apply an even continuous bead of activator along the black stencil using the applicator supplied.

5. Punch the membrane in the threaded connection.

Important - Once applied, allow the activator to dry for at least 10 minutes keeping the surface clean.

Fig. 8-18

6. Cut off the nozzle and apply a smooth continuous bead of BETASEAL sealant-adhesive along the edge of the body or windscreen keeping the gun vertical. Fig. 8-16

4. Remove the sealant cartridge bottom cover and salts therein.

Fig. 8-19

Fig. 8-17

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

CAB

W270

8-9

Glass assembly WARNING 1. Position the glass in its seat slightly pressing it.

Any variation to instructions specified, such as use of materials after expire date or improper work procedures, may negatively affect the results of the operation. The manufacturer does not assume any responsibility for damages which may derive to persons and/or things.

Fig. 8-20

Note - The glass must be fitted to the machine within maximum 15 minutes after applying the BETASEAL sealant-adhesive.

Note - Work only in well ventilated premises. The polyurethane adhesive does not contain low molecular weight (monomolecular) volatile isocyanates. Therefore, there is no danger of irritation for the respiratory tract. However, all precautions required when using chemicals should be observed. Avoid contact with the eyes and skin.

Note - The BETASEAL sealant-adhesive hardens with air moisture. Hardening depends upon ambient humidity and relative penetration degree. Therefore, machine downtime ranges from 2 to 3 hours at a temperature of 23°C. During this period the machine should not be submitted to any stress whatever.

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

8 - 10

CAB

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

W270

W270

CAB

8 - 11

8.6 AIR CONDITIONING UNIT

8.6.1 OPERATING INSTRUCTIONS The principle of operation can be summarised as follows: the refrigerant, Freon R134a, in its gaseous state, is sucked by the compressor at a pressure of 1-5 bar and taken to a final compression at a pressure of 10-20 bar. The gas, heated by the compression to 89-100 °C, flows, still in a gaseous state, into the condenser where, under the effect of the cooling provided by the air flowing through it by the action created by the fan, reaches the condensation point, passing into a liquid state at high pressure. Subsequently, the refrigerant, at liquid state, reaches a dehydration filter, which has the function of capturing impurities, absorb moisture trapped into the system and operate as a reserve reservoir for the refrigerant itself. Then, the Freon reaches the expansion thermostatic valve, which has the purpose of regulating the refrigerant flow into the evaporator at a pressure of 1~5 bar, causing its passage from liquid to gaseous state. At the same time, the air flowing through the evaporator, under the action of the fan, having a temperature which is higher than the refrigerator contained by the evaporator itself, causing its boiling and full evaporation, releasing heat. The air, being cooled, deposits on the fins of the evaporator parts of its moisture content, under the form of little drops, which drop into the tanks and are discharged outside the cab. Air cooled and dehumidified, is sent into the cab. The refrigerant, at the outlet of evaporator, is sucked again by the compressor, beginning a new cycle. Expansion valve

Fan unit

Evaporator

Compressor

Condenser

High pressure

Intake

Low pressure Pressure switch

Filter

Fig. 8-21

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

W270

CAB

8 - 12

8.6.2 TECHNICAL DATA Fan Voltage Electrical input Air flow Speed Heater Power Rate of flow Air flow Input air temperature Evaporator Power Rate of flow Air flow Input air temperature Relative humidity Vaporisation temperature Condensation temperature Condenser Mass dimension Input air temperature Relative humidity Vaporisation temperature Condensation temperature Expansion valve Type Gas Superheat Compressor Type Displacement Pulley Lubricant oil q.ty Filter Type Dimension Capacity Dehydrating Pipe fitting Pressure switch Type Interruption:

24 V 17 A 1190 m3/h 3 11,7 KW 500 l/h 575 m3/h -15°C 8,17 KW 500 l/h 575 m3/h 43°C 30% 5°C 60°C 375 x 520 x 28 mm 43°C 30% 5°C 60°C TGK TEV 216 PO-2 FREON R134A 4°C SANDEN SD7H15 md 7948 for 134A 154.9 cc ø 135,6 mm 200 cc SKG CC164 141 x ø76 mm 415 cc 140 gr 5/8'' - 18 UNF 3L-F LMH-971-641 Low pressure High pressure (Fan)

Thermostat Type Setting

RANKO K50-L9421 Cold

OFF ON OFF ON OFF ON

2,45 2,6 28 25 12 17

OUT 0 IN 5

bar bar bar bar bar bar

°C °C

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

W270

CAB

8 - 13

Conditioning Performance IN ACCORDING WITH ISO 10263

8.6.3 SERVICE PRECAUTIONS

Piping precautions

It is known that CFC refrigerants (including R 12) are among those substancens that destroy the ozone layer producing an increase of ultra violet radiation resulting from the destruction of the ozone layer. They stay in the atmosphere for over 00 years, with a potential increment of cataract and skin cancer. As a result of the global evaluation of the environmental impact, a new refrigerant R134a has been used. This refrigerant has a potential destruction of the ozone (ODP) equal to 0 and a low global warming potential (GWP).

- Position the O-ring against the bulge in the pipe when connecting hoses and pipes. - Coat the piping connections and the O-rings with PAG oil. - Fit the nuts and unions tightly against the base of the companion pieces then hand tighten the nut as much as possible. Then, tighten to the specific torque. Note Always use oil specified for R134a systems to coat the O-rings.

WARNING Direct contact with refrigerant can cause frostbite or blindness. Always wear safety glasses and protective gloves. Do not work with refrigerant colse to the face.

CAUTION PAG oil , in the R134a systems, absorbs moisture quickly when exposed to the atmosphere

Handle the air conditioner componenets carefully. Do not knock or drop them.

Fig. 8-22

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

W270

CAB

8 - 14

Do not mistakes refrigerants Before charging an air conditioning system be sure that refrigerant is correct. Confirm before charging that the type of air conditioner system is in fact an R134a system.

R 12

CAUTION Cap the oil container after use and the air conditioner system parts, when servicing. Never mix compressor oil with other types of oil

R134a

Fig. 8-23

Do not release refrigerant into the air Although R134a is not subject to CFC regulations, it can have an effect on global warming, and so should not be released into the air.

Cap all containers and components Fig. 8-25

The oil must be replaced or replenished in the following cases: WARNING When removing refrigerant from the air conditioner system, always use a refrigerant recovery unit made especially for R134a

- when refrigerant or oil leaks from the system - when refrigerant is suddenly discharged from the system - when system components are replaced. Note The oil plug O-ring must be replaced with a new one. Refrigerant charge inspection As shown in the left hand figure, R134a compressor oil will not blend with refrigerant (R134a) at certain temperatures. At these temperatures, the refrigerant may appear 'cloudy' when checked using the sightglass, and the charge may be mistakenly judged as insufficient.

R134a

Fig. 8-24

Compressor oil Use compressor oil made specifically for use with R134a. R134a system compressor oil has an extremely high moisture absorption capacity.

Fig. 8-26

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

W270

CAB

8 - 15

8.6.4 TOOL CONNECTIONS WARNING Do not connect hoses to the air conditioner system when the manifold gauge valves are open.

1. Fully close both manifold gauge valves. 2. Connect the three hoses securely to the manifold gauge. 3. Connect the utility hose to the vacuum pump or refrigerant source

CAUTION If there is any refrigerant in the air conditioner system, connect the hoses only after the service hoses and the manifold gauge have been evacuated.

4. Connect the couplers to the high and low pressure hoses. Turn the knob on the fitting to depress the core if so equipped. Before disconnecting hoses, close both manifold gauge valves.

Fig. 8-27

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

W270

CAB

8 - 16

8.6.5 DISCHARGING WARNING

CAUTION If the needle moves towards 0, the system is not alright. Check the system for leaks and repair.

Do not release the refrigerant into the air. Discharge refrigerant only into the refrigerant recovery unit.

CAUTION Never use a refrigerant recovery unit for CFC12 on an HFC134a system.

The recovered refrigerant must be recycled trough a refrigerant recovery unit to ensure that it is clean and free of moisture. Refer to the user's instruction manual for refrigerant recovery unit handling and operations.

Fig. 8-28

Evacuation 8.6.6 REFRIGERANT CHARGING There are various methods of charging refrigerant into the air conditioner system. these include using refrigerant recovery units and direct charging using a scale.

1. Operate the vacuum pump. 2. Open both manifold gauge valves 3. Evacuate the system for at least 20 minutes. 4. Close both manifold gauge valves.

Initial charge 1. Put the refrigerant container on the scale.

Note: Change refrigerant in the system of wheel loader W170/170PL-W190 every 2 years.

Initial evacuation 1. Close both manifold gauge valves. 2. Connect the high and low pressure hoses to the system. 3. Connect the utility hose to the vacuum pump. 4. Open the manifold gauge's high and low pressure valves. 5. Operate the vacuum pump. 6. Evacuate the system for at least 5 minutes to stabilize the vacuum inside the system. 7. Close both valves and stop the vacuum pump.

Checking air tightness 1. Leave the system as it is for 5 to 10 minutes. Ensure the low pressure gauge needle does not move towards the atmospheric pressure side (gauge pressure 0).

Fig. 8-29

2. Disconnect the utility hose from the vacuum pump and connect it to the refrigerant container. 3. Purge air from the utility hose. 4. Record the refrigerant weight. 5. Open the refrigerant container valve. 6. Slowly open the manifold gauge's low pressure side valve to charge refrigerant from the low pressure side valve to charge refrigerant from the low pressure side.

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

W270

CAB

8 - 17

7. Charge with refrigerant until the low pressure gauge reaches 0.2 MPa (2 bar, 28psig). The optimal refrigerant's weight is approximally 1100 gr. 8. Close the manifold gauge's low pressure valve.

CAUTION Do not overcharge the system.

Initial Leak check Using the leak detector, check the system connection for leaks.

Fig. 8-31

Note As the system pressure is not yet high, only large leaks can be detected at this time.

Inspection procedure Evacuation

Refrigerant charging

Operate compressor for at last 5 min Fig. 8-30

Check for refrigerant leaks from high pressure side parts

8.6.7 LEAK INSPECTION

Operation test

To facilitate refrigerant leak detection, operate the air conditioner at the full cooling setting with the fan running at maximum speed for at least 5 minutes. Stop the engine and, using a leak detector, check for refrigerant leaks on the high pressure side. This must be done immediately because when the refrigerant stops circulating, the high pressure decreases gradually, as shown in the graph, while the low pressure side pressure increases gradually.

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

Repair

W270

CAB

8 - 18

Inspection sequence

High pressure side Compressor discharge port

Condenser inlet and outlet

Cooling unit inlet

Receiver drier inlet and outlet

Low pressure side Compressor suction port

Cooling unit outlet

CAUTION Clean all inspection points. Check all connections carefully. To prevent incorrect diagnoses, ensure there is no refrigerant or cigarette smoke in the vicinity of the vehicle.

Inspection points

Fig. 8-32 Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

W270

CAB

8 - 19

8.7 TROUBLESHOOTING

14

22

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

W270

CAB

8 - 20

Troubleshooting chart (a) Fan motor does not operate Inspection

Possible cause

Remedy

1. Blown fuse

Inspect the air conditioner fuse.

Replace.

2. Broken wiring or bad connection

Check the fan motor earth and connectors.

Repair the wiring or connect correctly.

3. Fan motor malfunction

Check the two lead wires from the motor with a circuit tester. If there is no conductance, the motor is malfunctioning.

Replace.

4. Broken resistor wiring

Check resistor conductance using a circuit tester. If there is no conductance, the wiring is broken.

Replace.

5. fan motor switch failure

Operate the fan switches in sequence and check whether the fan operates.

Replace.

(b) Fan motor operates normally, but air flow is insufficient Inspection

Possible cause

Remedy

1. Evaporator iniet obstruction

Check the iniet.

Remove the obstruction and clean.

2. Air leak

Check the cooling unit case fittings.

Repair of adjust.

3. Defective thermo switch

Check whether the evaporator is frozen. Check the switch using a circuit tester.

Replace.

(c)

Insufficient cooling although air flow and compressor operation are normal

Inspection

Remedy

1. Insufficient refrigerant.

There will be little temperature difference between the lowand high-pressure sides. Air bubbles or a "cloudy" flow will be visible in the sightglass.

Repair any leaks and recharge the refrigerant to the correct level.

2. Excessive refrigerant

The high-pressure side pressure will be high and even if the condenser is cooled using water, air bubbles will not appear in the sightglass.

Drain small quantity of refrigerant until air bubbles appear periodically through the window.

Possible cause

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

W270

CAB

8 - 21

(d) The compressor does not operate at all, or operates improperly Possible cause

Inspection

Remedy

1. Loose V-belt

The belt oscillates considerably.

Adjust the tension.

2. Internal compressor malfunction

The V-belt slips.

Repair or replace.

• Low battery voltage

Clutch slips.

Recharge the battery.

• Faulty coil

Same as above.

Replace the magnetic clutch.

• Oil on the clutch surface

The magnetic clutch face is dirty, causing it to slip.

Replace, or clean the clutch surface.

3. Magnetic clutch related

• Excessive clearance between the clutch plate and clutch disk. The clutch plate clings when pushed.

Adjust the clearance, or replace.

• Open coil

Clutch does not engage and there is no reading when a circuit tester is connected between the coil terminals.

Replace.

• Broken wiring or poor earth

Clutch will not engage at all. Inspect the earth and connections.

Repair.

• Wiring harness components

Test the conductance of the pressure switch, thermoswitch, relay, etc.

Check operation, referring to the wiring diagram, and replace defective parts.

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

W270

CAB

8 - 22

Normal compressor suction and discharge pressures at an atmospheric temperature of 30 ~ 35° C (86 ~ 95°F) and engine speed of approx. 1500 rpm are: High pressure side pressure : 1.47 ~ 1.67 MPa (15 ~ 17 kg/cm2, 213 ~ 242 psi) Low pressure side pressure: 0.13 ~ 0.2 MPa (1.3 ~ 2.0 kg/cm2, 18 ~ 28 psi) Possible cause

Inspection

Low -pressure side pressure too high.

The pressure in the low-pressure side becomes, normally, too high when the pressure on the high-pressure side is excessive. As explained here below, the check that follows is performed only when the pressure on the low-pressure side is too high.

1. Defective thermoswitch.

The magnetic clutch switch turns off before the outlet air temperature is sufficiently low.

Adjust or replace.

2. Defective compressor gasket or valve.

The high- and low-pressure side gauge pressures equalize when the magnetic clutch is turned off.

Repair or replace the compressor.

3. Poor expansion valve temperature sensor contact.

Frost has adhered to the compressor connector so that the temperature is lower than that of the evaporator outlet side piping.

Install the temperature sensor against the low-pressure pipe.

4. The expansion valve opens too far.

Same as above, or there is little pressure fluctuation when the temperature sensor is places against the pipe and then removed.

Replace.

5. Clogged compressor suction filter.

The compressor connector is cool but the low-pressure hose is not.

Remove and clean the filter.

1. Insufficient refrigerant.

Refer to "Insufficient refrigerant" on previous page.

Same as at left.

2. Clogged receiver drier.

Considerable temperature difference between the inlet and outlet sides, or the tank is frosted.

Replace the receiver drier.

3. Clogged expansion valve.

The expansion valve's inlet side is frosted.

Clean the filter or replace the expansion valve.

4. Expansion valve temperature sensor gas leak (damaged capillary tube, etc.)

The expansion valve's outlet side is chilled, and low pressure gauge indicates a vacuum.

Clean or replace the piping.

5.Clogged or blocked piping.

When the piping is clogged or blocked, the low-pressure gauge reading will decrease, or a negative reading may be shown.

Clean or replace piping.

6. Defective thermoswitch.

The evaporator is frozen.

Adjust or replace.

1. Poor condenser cooling.

Dirty or clogged condenser. Cooling fan does not operate correctly. Blown fuse, broken wiring or poor contact. Fan motor malfunction.

Clean, and repair the fan. Repair the wiring or replace the fuses.

2. Excessive refrigerant.

Refer to "Excessive refrigerant" on previous page.

Remedy

Low-pressure side pressure too low.

High-pressure side pressure too high.

Evacuate and recharge with refrigerant.

3. Air in the system.

High-pressure side pressure too low 1. Insufficient refrigerant.

Refer to "Insufficient refrigerant" on previous page.

Same as at left.

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

W270

CAB

8 - 23

• Problems in the system can be diagnosed using a

Gauge pressure diagnosis

manifold gauge by reading the system's low and high pressures. High pressure side

Low pressure side

1.47 - 1.67 MPa {15 - 17 kg/cm2, 213 - 242 psig}

0.13 - 0.2 MPa {1.3 - 2.0 kg/cm 2, 18 - 28 psig} 5 4

6

7

8

5

3

1.5

9 10

10

11 12

2 0

1

15

0

1.0

2.0 2.5

20 25

5

0.5

3.0

30 0

13

15

15 10

Normal pressures Low-pressure side: 0.13 ~ 0.2 MPa {1.3 ~ 2.0 kgf/ cm2, 18 ~ 28 psig} High-pressure side: 1.47 ~ 1.67 MPa {15 ~ 17 kgf/ cm2, 213 ~ 242 psig}

35

0

3.5

14

Conditions Atmospheric temperature: Engine speed: Blower speed: Temperature switch:

30 ~ 35°C (86 ~ 95°F) 1,500 r/min HI (high-speed) Full cooling

Insufficient refrigerant Indications: Fig. 8-33

• Low pressures on both the low pressure and highpressure sides. • Discharge temperature will not decrease. Cause: Refrigerant leakage. Remedy: Inspect using a gas leak detector, repair the leak, and replenish the refrigerant. Low pressure side

High pressure side

98 MPa {1.0 kg/cm2, 18 psig}

0.78 - 0.98 MPa {8 - 10 kg/cm 2, 114 - 142 psig}

5 4

6

7

8

5

3

1.5

9

10

10 11 12

2 0

1 0

15 15

13 14

1.0

15 10 5

0.5

2.5 25 3.0

30 0

0

2.0 20

35 3.5

Fig. 8-34

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

W270

CAB

8 - 24

Low pressure side

High pressure side 2.26 MPa {23 kg/cm2, 327 psig}

0.25 - 0.29 MPa {2.5 - 3.0 kg/cm2, 36 - 43 psig} 5 4

6

7

8

5

10

10

3

1.5

9 11 12

2 0

1

15

0

1.0

25 3.0

30 0

Indication: both the low and high pressures are too high.

2.5

20

10 5

0.5

13

15

15

2.0

Excessive refrigerant (poor condenser radiation)

35

0

3.5

14

Causes: • Pressure increment due to excessive refrigerant. • Insufficient condenser cooling. Remedy: • Clean the condenser. • Inspect and adjust the fan belt and condenser motor. • Check the refrigerant level.

Air in cooling system (insufficient suction)

Fig. 8-35

Low pressure side

High pressure side

0.25 - 0.34 MPa {2.5 - 3.5 kg/cm2, 36 - 50 psig}

1.96 - 2.45 MPa {20 - 25 kg/cm2, 284 - 356 psig}

5 4

6

7

8

5

10

3

1.5

9 10 11 12

2 0

1 0

15 15

13 14

1.0

15 10 5

0.5

2.5

20 25

3.0

30 0

0

2.0

35 3.5

Indications: • Both the low and high pressures are too high. • The low-pressure side piping is not cold. Cause: Air entered the cooling system. When the suction is not applied, the reading of the instruments are indicated in the illustration on the left. Remedy: • Evacuate the system, replenish the refrigerant and check the gauge readings. • After prolonged operation with air in the system, the receiver drier must be replaced.

Fig. 8-36

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

W270

CAB

Low pressure side High pressure side 2.16 - 2.26 MPa {22 - 23 kg/cm2, 313 - 327 psig}

0.25 MPa {2.5 kg/cm2, 36 psig} 5 4

6

7

8

5

3

1.5

9 10

10

11 12

2 0

1

15

0

1.0

2.0 2.5

20 25

5

0.5

Defective expansion valve Indication: Both the low and high pressures are too high. Causes:

3.0

30 0

13

15

15 10

8 - 25

35

0

3.5

14

Improper refrigerant charge. Defective expansion valve. Improper temperature sensor installation.

Remedy: • Check temperature sensor installation, and insulation. • If normal, replace the expansion valve.

Insufficient compressor compression Indications:

Fig. 8-37

Low pressure side

High pressure side

• High pressure on the low-pressure side, pressure too low on the high pressure side.

0.39 - 0.59 MPa {4 - 6 kg/cm 2, 18 psig}

0.69 - 1.08 MPa {7 - 11 kg/cm2, 99 - 156 psig}

• The high and low pressures are already equal when operation is stopped.

5 4

6

7

8

5

3

1.5

9

10

10 11 12

2 0

1 0

15 15

13 14

1.0

15

0

2.5 25

0

35

5

0.5

Causes:

2.0 20

10

3.0

30

Insufficient compression due to a defective compressor gasket or damaged suction valve.

3.5

Remedy: Disassemble and repair the compressor.

Fig. 8-38

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

W270

CAB

8 - 26

Low pressure side

High pressure side 0.59 - 1.77 MPa {6 - 18 kg/cm2, 85 - 256 psig}

Vide - 0.13 MPa {Vide - 1.3 kg/cm2, Vide - 18 psig} 7

6

5 4

8

5

1.5

9

3

1.0

10

10

11 12

2 0

1

15

0

13

2.0

15 10

2.5

20 25

5

0.5

0

35

0

3.5

14

15

3.0

30

Infiltration of moisture Indication: The low-pressure side pressure alternates between a vacuum and normal pressure. Causes: Moisture has frozen in the air conditioner system, clogging the expansion valve, which then blocks the air conditioner system. When the ice melts, normal operation resumes. Remedy: • Replace the receiver drier. • Evacuate the system. • Recharge with refrigerant to the proper level.

Refrigerant does not circulate Fig. 8-39

Indications: High pressure side

Low pressure side

0.49 - 0.59 MPa {5 - 6 kg/cm 2, 71 - 85 psig}

- 101.3 MPa {- 760 mm Hg, - 29.92 in Hg} 6

5 4

7

8

5

10

3

10 11 12

2 0

1 0

Fig. 8-40

1.5

9

15 15

13 14

1.0

15

0

2.5

10

25

0

35

5

0.5

2.0 20

3.0

30

3.5

• The low pressure side pressure becomes a vacuum and the high pressure side pressure reads 0.49 ~ 0.59 MPa {5 ~ 6 kgf/cm2, 71 ~ 85 psig}. • Ice or condensation are forming on the piping connections of the drier receiver or the expansion valve. Causes: • The air conditioner system is blocked by ice or dirt. • The air conditioner system is shut off by a defective expansion valve temperature sensor. Remedy: Stop operation and check for ice or contamination. • If the problem is moisture, evacuate the system. • Replace the expansion valve temperature sensor if defective. • Replace the receiver drier. • Recharge with refrigerant to the proper level.

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

COPYRIGHT BY FIAT-HITACHI EXCAVATORS S.p.A.

Reproduction of text or illustration, in whole or in part, is strictly prohibited.

FIAT-HITACHI EXCAVATORS S.p.A. Technical Publications Dept. - Lecce (Italy) Print No. 604.02.247 - 2000 - GRAFICA DESSÌ S.N.C. •

RIVA PR. CHIERI (TO)

Issued by the Technical Publications Dept. Print No. 604.02.247 - English Printed in Italy