16x2(8)

FRONT

REAR

12x1,5(6)

12x1,5(6)

16x2

(8)

16x2

(8)

16x2

(8)

25x2,5(12)

POSI--STOPBRAKES

8x1(4)

8x1(4)

14,4cm

8x1(4)

16x2

(8)

14,4cm

8x1(4)

16x2

(8)

16x2

(8)

12x1,5(6)

BREAKOUT

A203

STEERING

16x2

(8)

16x2

(8)

16x2

(8)

16x2(8)

16x2(8)

16x2

(8)

16x2(8)

16x2(8)

16x2(8)

16x2(8)

25x2,5(12)

25x2,5(12)

30x4

(16)

30x4

(16)

100/50x450

200/110x410

A301

A301

LIFT

140/90x665

100/50x360

A202

A212

A202

A212

125bar

250bar

190bar

250bar

220bar

210bar

V302

V313

OPTIONAL

20=75

p=0,4bar

92l/m

in36

l/min

P308

Z307

V336

A309

Steering

S348

1,0

25x2,5(12)

10=75

p=1,6bar

Z308

35bar

V309

P3102650

RPM

Stand--by25

bar

Enginecooler

25x2,5(12)

8x1(6)

8x1(6)

AIRCONDITIONUNIT

PC

11cm3

M5AF

18cm3

2500RPM

25x2,5(12)

3

25x2,5(12)

12x1,5(6)

16x2

(8)

20x2(10)

Z209

20x2(10)

12x1,5(6)

12x1,5(6)

12x1,5(6)

25x2,5(12)

8x1(4)

38x3(20)

12x1,5(6)

20x2(10)

25x2,5(12)

12x1,5(6)

25x2,5(12)

8x1(4)

A4

A3

A2

A1

LIFT

TILT

UP

UP

LIFT

TILT

DOWN

DOWN

PT

Y324

Y325

Y328

Y327

V303

8x1(4)

8x1(4)

8x1(4)

8x1(4)

3

TRANSMISSION

HYDRAULICS

38x3

(20)

38x3

(20)

V323

V325

M318

BRAKE

RELE

ASE

V306

pI

pI

pI

M5

V334

20x2(10)

12x1,5(6)

25x2,5(12)

25x2,5(12)

25x2,5(12)

12x1,5(6)

38x3

(20)

12x1,5(6)

20x2(10)

12x1,5(6)

(withcabinonly)

Engine

16x2

(8)

48,3x2,6

V310

12x1,5(6)

M318

Y367

Y289

S377

S376

S378

B357B356

B334

Y301

Y348

Y319

Y352

100bar

210bar

350bar

V221Y203

20bar

RIGHT

LEFT

Y322

Y332

Y323

Y331

12x1,5(6)

8x1(4)

41cc

16cc

Coolers

92l/m

in41cc

Bucket

16cc

Brake

36l/m

in

P309

(OPTION)

BOOMSUSPENSION

0,4bar

28cc,55l/m

in,180bar

EJECTORBUCKET

Y237

Y236

Y259

25x2.5(12)

PP

b2

b2

B2

B2

B1

B1

a2A2

A2

A1

A1

T1

T2

Emergency

steering

(option)

T

b1a1

M

p

0

=90bar

p

1

=150bar

p

2

=190bar

6,0l

Z306

140

bar

p=5bar

=75

10

152--190

bar

300bar

0,6

2,5

P

AC1

0,8

12

P2

P1

T

PV

LB

S

V105

TPA

2,0bar T2

T1

M4

PEDALIN

PEDALOUT

J1J2

M2

A306

M

210bar

V324

A307

V307

M1

Right

Left

lubrication

Central

(option)

CP

P1

P3

P4

PM

AB

CP2

0,8

4,6

2

31

p0=90

bar

p1=180bar

p=230bar

V212

Z204

121bar

TP

PS

1 2

200bar

GENERAL HYDRAULICS LH307

316 (733)

10.2. Hydraulic diagram

TKU-D01060-5EN3007

1. FOR THE READER OF THIS MANUAL2. GENERAL SAFETY INSTRUCTIONS2.1. Warning signs2.2. General safety precautions during operations

3. GENERAL REPAIR INSTRUCTIONS3.1. Location of the main switch3.2. Hydraulics maintenance3.3. Electric system maintenance3.4. Battery maintenance3.5. Welding3.6. Blocking the machine for repair procedures3.7. Lifting

4. FRAME STRUCTURES4.1. Locking devices4.1.1. Frame locking pin4.1.2. Boom locking pins

4.2. Middle hinge joint4.2.1. Design features of upper hinge4.2.2. Lower hinge pin4.2.3. Disassembly of middle hinge joints4.2.4. Assembly of the middle hinge joint4.2.5. Adjusting of the middle hinge joint

4.3. Oscillating axle4.3.1. Disassembly of oscillating axle4.3.2. Assembly

4.4. Pins4.4.1. Design features4.4.2. Pin removal4.4.3. Pin removal with a puller4.4.4. Pin removal without special tools4.4.5. Pin installation

4.5. Lift arm4.5.1. Design features4.5.2. Bushing replacement

4.6. Bucket stopper adjustment4.7. Removing the bucket4.8. Installing the bucket4.9. Removing the swing lever4.10. Installing the swing lever4.11. Removing the dogbone4.12. Installing the dogbone4.13. Welding4.13.1. Precautions before welding4.13.2. Basic quality requirements4.13.3. Frame welding4.13.4. Bucket welding4.13.5. Edge preparation4.13.6. Working temperature and pre--heating4.13.7. Heat--input -- number of welding passes4.13.8. Welding to other steels4.13.9. Gas cutting

5. LUBRICATION SYSTEM5.1. System description5.1.1. Safety interlocks5.1.2. Inputs5.1.3. Outputs

5.2. Functional description of the components5.2.1. Removing the lubrication unit5.2.2. Installing the lubrication unit

5.3. Checking and adjusting5.3.1. Forced functions (requires service password)5.3.2. Diagnostics5.3.3. Filling the lubricant barrel5.3.4. Bleeding the pump5.3.5. Main piping5.3.6. Doser adjustment

5.4. General troubleshooting5.5. Control system troubleshooting

6. FIRE SUPPRESSION SYSTEM6.1. Ansul6.1.1. Main components6.1.2. System description6.1.3. Inputs6.1.4. Outputs6.1.5. Specifications6.1.6. System components6.1.7. Ansul system operation

6.2. SDS6.2.2. System description6.2.3. Inputs6.2.4. Outputs6.2.5. Specifications6.2.6. System components6.2.7. SDS system operation

6.3. Checking and adjusting6.3.1. Forced functions (requires service password)6.3.2. Diagnostics

6.4. Control system troubleshooting

7. CABIN7.1. Functional description of components7.1.1. Steering joystick S1497.1.2. Boom and bucket joystick S1487.1.3. Throttle pedal7.1.4. Door switch S1477.1.5. Brake pedal

7.2. Heating and air conditioning system (option)7.2.1. System description7.2.2. Component descriptions

7.3. Window washer and wiper (Machines with cabin)7.3.1. Inputs7.3.2. Outputs7.3.3. Removing the wiper motor assembly (Machines with cabin)7.3.4. Installing the wiper motor assembly (Machines with cabin)

7.4. Removing the cabin7.5. Installing the cabin7.6. Removing the cabin seat7.7. Installing the cabin seat7.8. Removing the window (Machines with cabin)7.9. Installing the window (Machines with cabin)7.10. Removing cabin door7.11. Installing the door to the cabin7.12. Checking and adjusting7.12.1. Testing the door switch7.12.2. Forced functions (requires service password)7.12.3. Throttle pedal calibration (requires service password)7.12.4. Diagnostics

7.13. Control system troubleshooting

8. POWERPACK8.1. Engine8.1.1. Technical data8.1.2. System description8.1.3. Explanation of concepts8.1.4. Starting and stopping the engine8.1.5. Overdrive protection8.1.6. Jump--starting8.1.7. Restarting an Out of Fuel Engine8.1.8. Changing engine oil and filter8.1.9. Engine mounts inspection8.1.10. Removing the engine8.1.11. Installing the engine

8.2. Fuel system8.2.1. System description8.2.2. Fuel filters8.2.3. Fuel lines8.2.4. Fuel gauge

8.3. Air cleaner system8.3.1. System description8.3.2. Air filter8.3.3. Electrical restriction indicator

8.4. Exhaust system8.4.1. System description8.4.2. Exhaust8.4.3. Catalytic converter8.4.4. Servicing the Catalytic converter8.4.5. Removing the catalytic converter8.4.6. Installing the catalytic converter

8.5. Turbocharger8.5.1. Servicing the turbocharger8.5.2. Removing the turbocharger8.5.3. Installing the turbocharger

8.6. Pumps8.7. Cooler system8.7.1. Main components of the engine cooler8.7.2. System description8.7.3. Functional description of the components8.7.4. Cleaning the engine cooler cores8.7.5. Engine cooler tube and sealing removal8.7.6. Removing the blower pump8.7.7. Installing the blower pump8.7.8. Removing the engine cooler8.7.9. Installing the engine cooler8.7.10. Removing and installing the water pump

8.8. Checking and adjusting8.8.1. Adjusting the engine cooling pump8.8.2. Forced functions (requires service password)8.8.3. Diagnostics

8.9. General troubleshooting8.10. Control system troubleshooting

9. POWER TRAIN9.1. System description9.2. Transmission hydraulics9.3. Transmission9.3.1. Gear box9.3.2. Transmission filter unit9.3.3. Gear selection9.3.4. Controlling manual transmission9.3.5. Controlling automatic transmission9.3.6. Filling instructions9.3.7. Removing the transmission9.3.8. Installing the transmission9.3.9. General troubleshooting

9.4. Transmission cooling9.4.1. System description9.4.2. Removing and installing the transmission oil cooler

9.5. Torque converter9.5.1. System description9.5.2. Functional description of components9.5.3. Torque converter change

9.6. DeClutch9.7. Wheels9.7.1. Removal of the tires9.7.2. Installing the tires9.7.3. Rim9.7.4. Structures and functions of the off--road tyre components9.7.5. Tire Mounting and demounting

9.8. Axles9.8.1. Technical data9.8.2. Planetary hub and differential oil change9.8.3. Tightening torques of power train flanges and bolts9.8.4. Removal of the rear axle9.8.5. Installing the rear axle9.8.6. Removal of the front axle9.8.7. Installing the front axle9.8.8. Disassembling wheel ends

9.9. Cardan shafts9.9.1. General Maintenance and Inspection9.9.2. Cardan shaft speed sensors9.9.3. Removing the cardan shaft9.9.4. Installing the cardan shaft

9.10. Checking and adjusting9.10.1. Measuring speed and travelled distance, and sensor diagnostics9.10.2. Measuring the transmission pressure9.10.3. Forced functions (requires service password)9.10.4. Diagnostics

9.11. Control system troubleshooting

10. GENERAL HYDRAULICS10.1. Hydraulic oil10.2. Hydraulic diagram10.3. General hydraulic maintenance10.3.1. General troubleshooting10.3.2. Basic causes of hydraulic system failures10.3.3. Checking hydraulic system for leaks10.3.4. Low temperature starting10.3.5. Prevent of cavitation formation10.3.6. Oil filters10.3.7. Servicing filters and strainers10.3.8. Level of oil in tank10.3.9. Oil storage and handling

10.4. Hydraulic oil tank10.4.1. Design features10.4.2. Filter diagnostics10.4.3. Inputs (In three--module systems)10.4.4. Inputs (In five--module systems)10.4.5. Outputs10.4.6. Functional description of components10.4.7. Level sensors for the oil tanks10.4.8. To change filter element Z30810.4.9. Changing oil in hydraulic system10.4.10. Repairing the tank10.4.11. Hydraulic tank cover resealing

10.5. Suction lines10.5.1. Design features

10.6. Pilot pressure control unit10.6.1. Pilot control pressure unit V309

10.7. Pressure measuring points10.8. Hoses and tubing10.8.1. Marking of the hydraulic hoses

10.9. Hydraulic oil cooler and return lines10.9.1. System description10.9.2. Functional description of components10.9.3. Cleaning the hydraulic cooler cores10.9.4. Removing the hydraulic oil cooler10.9.5. Installing the hydraulic oil cooler10.9.6. Removing the hydraulic cooler fan motor10.9.7. Installing the hydraulic cooler fan motor

10.10. Pumps10.10.1. Gear--type double pump P30810.10.2. Gear--type double pump P30910.10.3. Variable displacement type blower pump P31010.10.4. Starting new pumps10.10.5. Removing the double pump P30810.10.6. Removing the double pump P30910.10.7. Installing the double pump

10.11. Checking and adjusting10.11.1. Pilot pressure test10.11.2. Measuring the temperatures of the hydraulic oils10.11.3. Forced functions (requires service password)

10.12. Control system troubleshooting10.13. Hydraulic component symbols

11. STEERING11.1. Main components11.2. Hydraulic diagram11.3. System description11.3.1. Safety interlocks11.3.2. Inputs11.3.3. Outputs

11.4. Functional description of components11.4.1. Steering main valve V302

11.5. Emergency steering (option)11.5.1. System description11.5.2. Components11.5.3. Safety interlocks11.5.4. Inputs11.5.5. Outputs

11.6. Steering cylinder11.6.1. Removing the steering cylinder11.6.2. Installing the steering cylinder11.6.3. Cylinder disassembly11.6.4. Inspection and repair11.6.5. Reassembly and installation

11.7. Removing the steering main valve11.8. Installing the steering main valve11.9. Checking and adjusting11.9.1. Steering cylinder bypass test11.9.2. Steering valve pressure test11.9.3. Forced functions (requires service password)11.9.4. Diagnostics

11.10. Control system troubleshooting

12. BOOM / BUCKET HYDRAULICS12.1. Main components12.2. Hydraulic diagram12.3. System description12.3.1. Safety interlocks12.3.2. Inputs (Controlling the boom)12.3.3. Outputs (Controlling the boom)12.3.4. Inputs (Controlling the bucket)12.3.5. Outputs (Controlling the bucket)

12.4. Functional description12.4.1. Pilot control valve V30312.4.2. Bucket main valve V313

12.5. Ejector bucket (option)12.5.1. System description12.5.2. Components

12.6. Bucket counter and weighing (option)12.6.1. Inputs12.6.2. Outputs

12.7. Ride control (option)12.7.1. Components12.7.2. Safety interlocks12.7.3. Inputs12.7.4. Outputs

12.8. Boom float (option)12.8.1. Components12.8.2. Safety interlocks12.8.3. Inputs12.8.4. Outputs

12.9. Bucket shaking12.9.1. Lockings12.9.2. Inputs12.9.3. Outputs

12.10. Lift and tilt cylinders12.10.1. Removing the tilt cylinder hoses12.10.2. Installing the tilt cylinder hoses12.10.3. Removing the tilt cylinder12.10.4. Installing the tilt cylinder12.10.5. Tilt cylinder disassembly12.10.6. Removing the lift cylinder hoses12.10.7. Installing the lift cylinder hoses12.10.8. Removing lift cylinders12.10.9. Installing lift cylinders12.10.10. Lift cylinder disassembly12.10.11. Inspection and repair12.10.12. Reassembly and installation

12.11. Checking and adjusting12.11.1. Boom / bucket hydraulic system pressure12.11.2. Checking of the boom / bucket shock--load valves opening pressure12.11.3. Ejector bucket hydraulic pressure test12.11.4. Lift cylinder leakage test12.11.5. Tilt cylinder leakage test12.11.6. Switching the control directions of the control joystick12.11.7. Forced functions (requires service password)12.11.8. Diagnostics12.11.9. Testing the buttons12.11.10. Testing the movement of the control joystick12.11.11. Control joystick calibration (requires service password)12.11.12. The measurement data of the modules (requires service password)

12.12. Control system troubleshooting

13. BRAKE SYSTEM13.1. Main components13.2. Hydraulic diagram13.3. System description13.3.1. Service-- and parking brake inputs13.3.2. Service-- and parking brake outputs

13.4. Functional description of components13.4.1. Brake charging valve V30713.4.2. Sequence valve V30613.4.3. Brake pedal valve V10513.4.4. Filter unit Z30613.4.5. Brake release pump unit A30713.4.6. Pressure accumulator Z309

13.5. Pressure accumulators13.5.1. Recharging piston accumulators13.5.2. Disassembly and assembly of the piston accumulator13.5.3. Recharging diaphragm accumulator

13.6. Brake flushing13.6.1. Hydraulic diagram13.6.2. System description13.6.3. Functional description of components

13.7. Automatic Brake Activation13.8. Neutral brake (option)13.8.1. Inputs13.8.2. Outputs

13.9. Disassembly of brakes13.10. Assembly of brakes13.11. Brake friction disc lining wear check procedure13.12. Checking and adjusting13.12.1. Brake flushing pressure check13.12.2. Brake charging valve pressure check13.12.3. Brake pressure check13.12.4. Testing the brake accumulator13.12.5. Measuring the brake accumulator pre--charge pressure P013.12.6. Test service and parking brake function13.12.7. Automatic brake activation test (requires service password)13.12.8. Measuring brake pressures13.12.9. Forced functions (requires service password)13.12.10. Diagnostics

13.13. Control system troubleshooting

14. GENERAL ELECTRICAL SYSTEM14.1. System description14.2. Lights14.2.1. Driving lights14.2.2. Parking lights14.2.3. Brake lights and blinkers14.2.4. Cabins corner lights14.2.5. Loading lights14.2.6. Warning light (beacon)14.2.7. Direction indicator lights (optional)

14.3. Horn signal and reversing warning14.3.1. Horn signal14.3.2. Alarm signal and light for reversing

14.4. Emergency stop14.4.1. Inputs14.4.2. Outputs

14.5. Warning and alarm condition14.5.1. Outputs

14.6. Batteries14.6.1. Battery technical data14.6.2. Removing the batteries14.6.3. Installing the batteries:

14.7. Alternator14.7.1. Removing the alternator14.7.2. Installing the alternator

14.8. Circuit breakers14.8.1. Location of circuit breaker boxes14.8.2. Circuit breaker descriptions and values

14.9. Control system user interface14.9.1. Using the display module14.9.2. Symbols on the display windows14.9.3. Main window14.9.4. Gauge windows14.9.5. Alarm log14.9.6. Service windows for the operator14.9.7. Service windows for service personnel (requires service password)

14.10. Service password14.11. Control system self test on start--up14.11.1. Conditions for starting the system (the enable)

14.12. Checking and adjusting14.12.1. Display settings14.12.2. Status data of the CAN bus (requires service password)14.12.3. Forced functions (requires service password)14.12.4. Diagnostics14.12.5. Checking emergency stop and shutdown system

14.13. Control system troubleshooting14.14. Module I/O list and signal levels14.14.1. I/O list14.14.2. Signal level and scaling of the sensors

14.15. Changing the control modules14.15.1. Location of the control modules14.15.2. Changing a single I/O module14.15.3. Changing several I/O modules14.15.4. Changing the display module14.15.5. Programming a new module (requires service password)14.15.6. Updating manually the programs of system modules (requires service14.15.7. System implementation

14.16. Downloading new installation package into machine14.16.1. How to check installation package version14.16.2. Loading new installation package into machine

14.17. Controlling optional functions (options)14.17.1. Controlling the optional functions on the service window

14.18. Parameter control14.18.1. Restoring parameters14.18.2. Saving parameters

14.19. How to read electric diagrams14.19.1. Marking14.19.3. Parts location14.19.4. The consecutive number14.19.5. Marking of cables14.19.6. Drawing sheets14.19.7. Control system module connections

15. CONTROL SYSTEM ERROR CODES15.1. Alarm log15.2. How to upload alarm log with update display15.3. How to upload alarm log with Hyper terminal program15.4. Error codes

16. APPENDICES1. The tightening torques for screws and nuts2. Gear pumps service instructions3. Piston accumulator operation and service --instructions4. Dana transmission Maintenance / Service manual5. Dana converter Maintenance / Service manual6. Dana axle manual7. Radiator service manual8. Hydraulic oil cooler installation and servicing manual9. Exide battery10. Dana cardan shafts11. Donaldson air filter manual12. Wiggins refueling system technical manual (option)13. Wiggins installation and operators manual (option)14. SDS Ausminco fire suppression system manuals (option)15. ANSUL fire suppression system installation, recharge, inspection and16. Function of lubrication system (option)17. Doser groups18. Toro Automatic Central Lubrication19. Emergency radio operation instructions (option)20. ADM2 Manual21. Minidiag 222. Diaphragm accumulators23. Rexroth piston pump repair instructions24. Shark Installation and Maintenance procedure25. Weighing system General Workshop Maintenance instructions (option)

Oikea_palkki:

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