SD 200

Shop Manual
950106-00444
Serial Number 1001 and Up (Tier II)
July 2011

DISD reserves the right to improve our products in a continuing process to provide the best
possible product to the market place. These improvements can be implemented at any time
with no obligation to change materials on previously sold products. It is recommended that
consumers periodically contact their distributors for recent documentation on purchased
equipment.
This documentation may include attachments and optional equipment that is not available
in your machine’s package. Please call your distributor for additional items that you may
require.
Illustrations used throughout this manual are used only as a representation of the actual
piece of equipment, and may vary from the actual item.

950106-00444 Shop Manual

 TABLE OF CONTENTS
Safety
Wheel Loader Safety .................................................................................... S0103010K

Specifications
Specifications for SD 200................................................................................ SP002380

General Maintenance
General Maintenance Procedures................................................................... S0302000
Standard Torques............................................................................................ S0309000

Upper Structure
Counterweight................................................................................................. SP002360
Hydraulic Oil Tank ...........................................................................................SP002361

Lower Structure and Chassis

Center Joint (Articulation Joint)....................................................................... SP002362

Engine and Drive Train

Engine .......................................................................................................... SP002530
Front Axle ....................................................................................................... SP002363
Rear Axle ....................................................................................................... SP002364
Air Conditioner................................................................................................ SP002345
Transmission and Torque Converter …………............................................... SP002365

Hydraulics
Cylinders......................................................................................................... SP002366
Main Pump...................................................................................................... SP002367
Main Control Valve.......................................................................................... SP002368
Pilot Control Valve.......................................................................................... SP002369
Priority Valve.................................................................................................. SP002370
Steering Unit................................................................................................... SP002371
Hydraulic Schematic (SD 200)........................................................................ SP002372

Table of Contents
Page 1
Brake
Brake System ................................................................................................. SP002359
Parking System ............................................................................................ SP002373

Electrical System
Electrical System ............................................................................................ SP002374
Electrical Schematic (SD 200)........................................................................ SP002375

Attachments

Table of Contents
Page 2
1SAFETY
 S0103010K

2WHEEL LOADER
SAFETY
WHEEL LOADER SAFETYS0103010K

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual or
those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

MODEL SERIAL NUMBER RANGE

SD200 1001 and Up
SD300 1001 and Up

Copyright 2011 DISD

November 2011

Wheel Loader Safety S0103010K

Page 1
TABLE OF CONTENTS
To the Operator of a DISD Wheel Loader ..................................................................... 3
General Safety Essentials ............................................................................................. 6
Location of Safety Labels ........................................................................................... 6
Unauthorized Modifications............................................................................................ 6
General Hazard Information .......................................................................................... 7
Before Starting Engine ................................................................................................ 14
Machine Operation ...................................................................................................... 17
Maintenance................................................................................................................ 24
Battery.......................................................................................................................... 32
Towing ........................................................................................................................ 34
Shipping and Transportation ....................................................................................... 35

S0103010K Wheel Loader Safety

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TO THE OPERATOR OF A DISD WHEEL LOADER

DANGER!
Unsafe use of the wheel loader could lead to serious injury or death. Operating procedures,
maintenance and equipment practices or traveling or shipping methods that do not follow the
safety guidelines on the following pages could cause serious, potentially fatal injuries or extensive
damage to the machine or nearby property.

Please respect the importance of taking responsibility for your own safety, and that other people who may be
affected by your actions.

Safety information on the following pages is organized into the following topics.
1. ―General Safety Essentials‖ on page 6.
2. ―Location of Safety Labels‖ on page 6.
3. ―Unauthorized Modifications‖ on page 6.
4. ―General Hazard Information‖ on page 7.
5. ―Before Starting Engine‖ on page 15.
6. ―Machine Operation‖ on page 18.
7. ―Maintenance‖ on page 25.
8. ―Battery‖ on page 33.
9. ―Towing‖ on page 35.
10. ―Shipping and Transportation‖ on page 36.

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 WARNING!
Improper operation and maintenance of this machine can be hazardous and could result in serious
injury or death.

Operator and maintenance personnel should read this manual thoroughly before beginning
operation or maintenance.

Keep this manual in the storage compartment to the rear of the operator’s seat, and have all
personnel involved in working on the machine periodically read the manual.

Some actions involved in operation and maintenance of the machine can cause a serious accident,
if they are not done in a manner described in this manual.

The procedures and precautions given in this manual apply only to intended uses of the machine.

If you use your machine for any unintended uses that are not specifically prohibited, you must be
sure that it is safe for any others. In no event should you or others engage in prohibited uses or
actions as described in this manual.

DISD delivers machines that comply with all applicable regulations and standards of the country to
which it has been shipped. If this machine has been purchased in another country or purchased
from someone in another country, it may lack certain safety devices and specifications that are
necessary for use in your country. If there is any question about whether your product complies
with the applicable standards and regulations of your country, consult DISD or your DISD
distributor before operating the machine.

S0103010K Wheel Loader Safety

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 SAFETY ALERT SYMBOL
Be Prepared - Get to Know All Operating and Safety Instructions
This is the Safety Alert Symbol. Wherever it appears - in this manual or on safety signs on the
machine - you should be alert to potential for personal injury or accidents. Always observe safety
precautions and follow recommended procedures.

LEARN SIGNAL WORDS USED WITH SAFETY ALERT SYMBOL

Words "CAUTION," "WARNING," and "DANGER" used throughout this manual and on labels on machine
indicate hazards or unsafe practices. All three statements indicate that safety is involved. Observe
precautions indicated whenever you see the Safety Alert "Triangle," no matter which signal word appears next
to the "Exclamation Point" symbol.

CAUTION!
This word is used on safety messages and safety labels and indicates potential of a hazardous
situation that, if not avoided, could result in minor or moderate injury. It may also be used to alert
against a generally unsafe practice.

WARNING!
This word is used on safety messages and safety labels and indicates potential of a hazardous
situation that, if not avoided, could result in serious injury or death. It may also be used to alert
against a highly unsafe practice.

DANGER!
This word is used on safety messages and safety labels and indicates imminent hazard of a
situation that, if not avoided, is very likely to cause death or extremely serious injury. It may also be
used to alert against equipment that may explode or detonate if handled or treated carelessly.

Safety precautions are described in SAFETY from page 6 on.

DISD cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore the safety messages in this manual and on the machine may not include all possible safety
precautions. If any procedures or actions not specifically recommended or allowed in this manual are used,
you must be sure that you and others can do such procedures and actions safely and without damaging the
machine. If your unsure about the safety of some procedures, contact a DISD distributor.

Wheel Loader Safety S0103010K

Page 5
GENERAL SAFETY ESSENTIALS
ACCESSORY APPLICATIONS
This wheel loader has been designed primarily for moving earth with a bucket. For use as a grapple or for
other object handling, contact Daewoo. Lifting-work applications are permitted in approved lift configuration,
to rated capacity only, with no side-loading (unless prohibited by local regulation). Do not use machine for
activities for which it was not intended. Do not use bucket for lifting work, unless lift slings are used in
approved configuration.

LOCATION OF SAFETY LABELS

Location of safety labels (decals) can vary from unit to unit. Refer to appropriate Operation and Maintenance
Manual, and Parts Manual for your unit.
There are several specific warning signs on this machine. The exact location of hazards and the description of
the hazards are reviewed in the appropriate Operation and Maintenance Manual.
Please become familiarized with all warning signs.
Make sure that all of the warning signs are legible. Clean the warning signs or replace the warning signs if you
cannot read the words. Replace the illustrations if the illustrations are not visible. When you clean the warning
signs, use a cloth, water and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety
signs. Solvents, gasoline, or other harsh chemicals could loosen the adhesive that secures the warning sign.
Loose adhesive will allow the warning sign to fall off.
Replace any safety sign that is damaged, or missing. If a safety sign is attached to a part that is replaced,
install a safety sign on the replacement part.

UNAUTHORIZED MODIFICATIONS
Any modification made without authorization or written approval from Daewoo can create a safety hazard, for
which the machine owner must be held responsible.
For safety’s sake, replace all OEM parts with the correct authorized or genuine Daewoo part. For example,
not taking the time to replace fasteners, bolts or nuts with the correct replacement parts could lead to a
condition in which the safety of critical assemblies is dangerously compromised.

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GENERAL HAZARD INFORMATION
SAFETY RULES
Only trained and authorized personnel can operate and maintain the machine.
Follow all safety rules, precautions and instructions when operating or performing maintenance on the
machine.
Do not operate the machine if you are not feeling well, if you are taking medication that makes you feel sleepy,
if you have been drinking, or if you are suffering from emotional problems. These problems will interfere with
your sense of judgement in emergencies and may cause accidents.
When working with another operator or with a person on work site traffic duty, be sure that all personnel know
the nature of the work and understand all hand signals that are to be used.
Always observe strictly any other rules related to safety.

SAFETY FEATURES
Be sure that all guards and covers are installed in their proper position. Have guards and covers repaired
immediately if damaged.
Be sure that you understand the method of use of safety features such as transmission lever neutral lock and
the seat belt, and use them properly.
Never remove any safety features. Always keep them in good operating condition.
Failure to use safety features according to the instructions in the Operation and Maintenance Manual could
result in serious bodily injury.

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INSIDE OPERATOR'S COMPARTMENT
When entering the operator's compartment, always remove all mud and oil from the soles of your shoes. If
you operate the accelerator and brake pedals with mud or oil stuck to your shoes, your foot may slip and this
may cause a serious accident.
Clean grease and dirt from pedals and controls. This contributes to safe operation. Cleaning also provides an
opportunity to inspect equipment. Minor damage can be repaired or corrected before major problems result.
Keep cab floor and consoles free of tools and personal items.
After using the ashtray, make sure that any matches or cigarettes are properly extinguished, and be sure to
close the ashtray. If the ashtray is left open, there is danger of fire.
Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
Do not leave lighters laying around the operator's compartment. If the temperature inside the operator's
compartment becomes high, there is danger that the lighter may explode.
Do not use cellular telephones inside the operator's compartment when driving or operating the machine.
There is danger that this may lead to an unexpected accident.
Never bring any dangerous objects such as flammable or explosive items into the operator's cab. To ensure
safety, do not use the radio or music headphones when operating the machine. There is danger that this may
lead to a serious accident.
When operating the machine, do not put your hands or head out of the window.
When standing up from the operator's seat, always place transmission neutral lock lever in the "LOCK"
position and set pilot cutoff switch to "O" (OFF) position. If you accidentally touch the work equipment levers
when they are not locked, the machine may suddenly move and cause serous injury or damage.
When leaving the machine, lower the work equipment completely to the ground, set transmission neutral lock
lever in the "LOCK" position, set pilot cutoff switch to "O" (OFF) position, "APPLY" parking brake, and shut
down engine. Use the key to lock all the equipment. Always remove the key and take it with you.

CLOTHING AND PERSONAL PROTECTIVE ITEMS

Contain long hair, and avoid loose clothing and
jewelry. They can catch on controls or in protruding
parts and cause serious injury or death.

Do not wear oily clothes. They are highly flammable.

Full eye protection, a hard hat, safety shoes and

gloves may be required at the work site. While
working on the machine, never use inadequate
tools.
They could break or slip, causing injury, or they may not adequately perform intended functions.

S0103010K Wheel Loader Safety

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BREATHING MASKS, EAR PROTECTION MAY BE REQUIRED
Do not forget that some risks to your health may not be immediately apparent. Exhaust gases and noise
pollution may not be visible, but these hazards can cause disabling or permanent injuries.

ASBESTOS DUST HAZARD PREVENTION

Asbestos dust can be HAZARDOUS to your health if
it is inhaled. Materials containing asbestos fiber can
be present on work site. Breathing air that contains
asbestos fiber can ultimately cause serious or fatal
lung damage. To prevent lung damage from
asbestos fiber, observe following precautions;
• Use a respirator that is approved for use in an
asbestos-laden atmosphere.
• Never use compressed air for cleaning.
• Use water for cleaning to keep down the dust.
• Work on the machine or component with the wind
at your back whenever possible.
• Always observe any rules and regulations related to the work site and working environment

MOUNTING AND DISMOUNTING

Before getting on or off the machine, if there is any
oil, grease, or mud on the handrails, steps, or track
shoes, wipe it off immediately. Always keep these
parts clean. Repair any damage and tighten any
loose bolts.
Never get on or off a moving machine. In particular,
never get on or off a moving machine. These actions
may lead to serious injury.
When getting on or off the machine, always face the
machine, and maintain a three-point contact (both
feet and one hand or one foot and both hands) with
the handholds and steps to ensure that you support
yourself securely.
Never hold any control levers when getting on or off
the machine.
Never get up from operator’s seat or leave operator’s station and dismount machine if engine is running.

Wheel Loader Safety S0103010K

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FUEL, OIL AND HYDRAULIC FLUID FIRE HAZARDS
Fuel, oil and antifreeze will catch fire if it is brought
close to a flame. Fuel is particularly flammable and
can be hazardous.
Always strictly observe the following.
Add fuel, oil, antifreeze and hydraulic fluid to the
machine only in a well-ventilated area. The machine
must be parked with controls, lights and switches
turned "OFF." The engine must be "OFF" and any
flames, glowing embers, auxiliary heating units or
spark-causing equipment must be doused, turned off
and/or kept well clear of the machine.
Static electricity can produce dangerous sparks at the fuel filling nozzle. In very cold, dry weather or other
conditions that could produce a static discharge, keep the tip of the fuel nozzle in constant contact with the
neck of the fuel filling nozzle, to provide a ground.
Keep fuel and other fluid reservoir caps tight and do not start the engine until caps have been secured.

PRECAUTIONS WHEN HANDLING FLUIDS AT HIGH TEMPERATURE

Immediately after operations are stopped, the
coolant, engine oil, and hydraulic oil are at high
temperature and the radiator and hydraulic tank are
still under pressure. Attempting to remove the cap,
drain the oil or coolant, or replace the filters may
lead to serious burns. Always wait for the
temperature to go down, and follow the specified
procedures when carrying out these operations.

To prevent hot coolant from spurting out, shut down

engine, wait for the coolant to cool, then loosen the
cap slowly to relieve the pressure. To prevent hot oil
from spurting out, shut down engine, wait for the oil
to cool, then loosen the cap slowly to relieve the
pressure

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INJURY FROM WORK EQUIPMENT
Do not enter or put your hand, arm or any other part
of your body between movable parts, such as
between the work equipment and cylinders, or
between the machine and work equipment.
If the control levers are operated, the clearance
between the machine and the work equipment will
change and this may lead to serious damage or
personal injury.
If going between movable parts is necessary, always
position and secure the work equipment so that it
cannot move.

FIRE EXTINGUISHER AND FIRST AID KIT

As a precaution if any injury or fire should occur,
always do the following.
• Be sure that fire extinguishers have been
provided and read the labels to ensure that you
know now to use them. It is recommended that
an appropriately sized (2.27 kg [5 lb] or larger)
multipurpose "A/B/C" fire extinguisher be
mounted in the cab. Check and service the fire
extinguisher at regular intervals and make sure
that all work site crew members are adequately
trained in its use.
• Provide a first aid kit in the storage compartment and keep another at the work site. Check the kit
periodically and make any additions if necessary.
• Know what to do in case of injury from fire.
• Keep emergency numbers for doctor, ambulance service, hospital and fire department you’re your
telephone.
If the machine catches fire, it may lead to serious personal injury or death. If a fire occurs during operation,
escape from the machine as follows;
• Turn the starter switch "OFF" and shut down engine.
• If there is time, use the fire extinguisher to extinguish as much of the fire as possible.
• Use the handrails and steps to escape from the machine.
The above is the basic method for escaping from the machine, but changing the method may be necessary
according to the conditions, so carry out practice drills at the work site.

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PROTECTION FROM FALLING OR FLYING OBJECTS
On work sites where there is danger that falling
objects or flying objects may hit the operator's cab
select a guard to match the operating conditions to
protect the operator.
Work in mines, tunnels, deep pits or on loose or wet
surfaces could produce danger of falling rock, roll
over or hazardous flying objects. Additional
protection for operator’s cab could be required in
form of a FOPS/Falling Object Protective Structure
and/or ROPS/Roll Over Protective Structure
reinforcement system (Option).
Any reinforcement system that is installed on
machine must pass safety and certification
standards and carry appropriate labeling and rating
information. For example, most often added type of
reinforcement system, FOPS, must meet or exceed
Society of Automotive Engineers standard SAE
J1356, "Performance Criteria for Falling Object
Guards for Wheel loaders. (Option)"
Never attempt to alter or modify any type of protective structure reinforcement system, by drilling holes,
welding or remounting or relocating fasteners. Any serious impact or damage to system requires a complete
integrity reevaluation. Reinstallation, recertification and/ or replacement of system may be necessary.

INSTALL ADDITIONAL SAFETY EQUIPMENT IF CONDITIONS REQUIRE

Laminate glass protection for the front, side or rear windows may also be recommended depending upon
particular site conditions.
Contact your DISD distributor for available safety guards and/or recommendations if there is any danger of
getting hit by objects that could strike the operator’s cab. Make sure that all other work site crew members are
kept well away from wheel loader and safe from potential hazards.

MAINTAIN STANDARD SAFETY EQUIPMENT IN GOOD CONDITION

Machinery guards and body panel covers must be in place at all times. Keep well clear of rotating parts. Pinch
point hazards such as cooling fan and alternator drive belts could catch hair, jewelry or oversize or very loose
clothing.
Safety labels must be replaced if they are damaged or become unreadable. Information on labels gives work
crew members an important safety reminder. Part numbers for each decal and required mounting locations
are shown on pages 1-2 through 1-4 of this section.
S0103010K Wheel Loader Safety
Page 12
ATTACHMENT PRECAUTIONS
Options kits are available through your dealer. Contact DISD for information on available one-way
(single-acting) and two-way (double-acting) piping / valving / auxiliary control kits. Because DISD cannot
anticipate, identify or test all attachments that owners may wish to install on their machines, please contact
DISD for authorization and approval of attachments and their compatibility with options kits.

ACCUMULATOR
The pilot control system is equipped with an accumulator. For a brief period of time after the engine has been
shut down, the accumulator will store a pressure charge that may enable hydraulic controls to be activated.
Activation of any controls may enable the selected function to operate under force of gravity.
When performing maintenance on the pilot control system, the hydraulic pressure in the system must be
released as describe in Operation and Maintenance Manual.
The accumulator is charged with high-pressure nitrogen gas, so it is extremely dangerous if it is handled in
the wrong way. Always observe the following precautions;
• Do not drill or make any holes in the accumulator or expose it any flame, fire or heat source.
• Do not weld on the accumulator, or try attaching anything to it.
• When carrying out disassembly or maintenance of the accumulator, or when disposing of the accumulator,
the charged gas must be properly released. Contact your DISD distributor.
• Wear safety goggles and protective gloves when working on an accumulator. Hydraulic oil under pressure
can penetrate the skin and cause serious injuries.

ENGINE VENTILATION
Engine exhaust gases can cause loss of judgment,
loss of alertness, and loss of motor control. These
gases can also cause unconsciousness, serious
injury and fatal accidents.
Make sure of adequate ventilation before starting
engine in any enclosed area.
You should also be aware of open windows, doors
or ductwork into which exhaust may be carried, or
blown

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BEFORE STARTING ENGINE
WORK SITE PRECAUTIONS
Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
Check the terrain and condition of the ground at the work site, and determine the best and safest method of
operation.
Make the ground surface as hard and horizontal as possible before carrying out operations. If there is a lot of
dust and sand on the work site, spray water before starting operations.
If you need to operate on a street, protect
pedestrians and cars by designating a person for
work site traffic duty or by erecting fences and
posting "No Entry" signs around the work site.
Erect fences, post "No Entry" signs, and take other
steps to prevent people from coming close to or
entering the work site. If people come close to a
moving machine, they may be hit or caught by the
Figure 12
machine, and this may lead to serious personal
injury or death.
Water lines, gas lines, phone lines and high-voltage electrical lines may be buried under the work site.
Contact each utility and identify their locations. Be careful not to damage or cut any of these lines.
NEVER be in water that is in excess of the permissible water depth. Refer to "Operation Manual."
Any type of object in the vicinity of the boom could represent a potential hazard, or cause the operator to react
suddenly and cause an accident. Use a spotter or signal person working near bridges, phone lines, work site
scaffolds, or other obstructions.
Minimum levels of insurance coverage, work permits or certification, physical barriers around the work site or
restricted hours of operation may be mandated by governing authorities. There may also be regulations,
guidelines, standards or restrictions on equipment that may have to be followed for local requirements.
There may also be regulations related to performing certain kinds of work. If there is any question about
whether your machine and work site complies with the applicable standards and regulations contact your local
authorities and agencies.
Avoid entering soft ground. It will be difficult for the machine to escape.
Avoid operating your machine to close to the edge of cliffs, overhangs, and deep ditches. The ground may be
weak in such areas. If the ground should collapse, the machine could fall or tip over and this could result in
serious injury or death.
Remember that the soil after heavy rain, blasting or after earthquakes, is weakened in these areas.
Earth laid on the ground and the soil near ditches is loose. It can collapse under the weight of vibration of your
machine and cause your machine to tip over Install the head guard (FOPS) if working in areas where there is
danger of falling rocks.
S0103010K Wheel Loader Safety
Page 14
CHECKS BEFORE STARTING ENGINE
Every day before starting the engine for the first time, carry out the following checks. If these checks are not
carried out properly, there is danger of serious injury.
• Completely remove all wood chips, leaves, grass, paper and other flammable materials accumulated in
the engine compartment and around the battery. They could cause a fire.
Remove any dirt from the window glass, mirrors, handrails, and steps.
• Do not leave tools or spare parts laying around in the operator's compartment. The vibration of the
machine when traveling or during operations may cause them to fall and damage or break the control
levers or switches. They may also get caught in the gap of the control levers and cause the work
equipment to malfunction or move dangerously. This may lead to unexpected accidents.
• Check the coolant level, fuel level, and hydraulic tank oil level, and check for clogged air cleaner and
damage to the electrical wiring.
• Adjust the operator's seat to a position where it is easy to operate the machine, and check the seat belt
and mounts for damage and wear.
• Check the operation of the gauges and the angle of the mirrors, and check that the safety lever is in
"LOCKED" position.
• If any abnormalities are found in the above checks, carry out repairs immediately.

ENGINE STARTING
• Walk around your machine before getting in operator’s cab. Look for evidence of leaking fluid, loose
fasteners, misaligned assemblies or any other indications of possible equipment hazard.
• All equipment covers and machinery safety guards must be in place, to protect against injury while
machine is being operated.
• Look around work site area for potential hazards, or people or property that could be at risk while
operation is in progress.
• NEVER start engine if there is any indication that maintenance or service work is in progress, or if a
warning tag is attached to controls in cab.
• A machine that has not been used recently, or is being operated in extremely cold temperatures, could
require a warm-up or maintenance service before start up.
• Check gauges and monitor displays for normal operation before starting engine. Listen for unusual noises
and remain alert for other potentially hazardous conditions at start of work cycle.
• Check tire inflation and check tires for damage or uneven wear. Perform maintenance before operation.
• Do not short circuit the starting motor to start the engine. This is not only dangerous, but may also damage
the machine.
• When starting the engine, sound the horn as an alert.
• Start and operate the machine only while seated.

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BEFORE OPERATING MACHINE
If checks are not carried out properly after starting the engine, it may result in a delay in discovering
abnormalities in the machine, and this may lead to personal injury or damage to the machine.
Carry out the checks in an open area where there are no obstructions. Do not let anyone near the machine
when carrying out the checks.
• Check the operating condition of the equipment, and the actuation of the bucket, boom, and travel
systems.
• Check the machine for any abnormal noise, vibration, heat, smell, or abnormality with the gauges. Check
also for leakage of air, oil, and fuel.
• If any abnormality is found, repair the problem immediately. If the machine is used without repairing the
problems, it may lead to unexpected injury or failure.
• Clear all personnel from directly around machine and from the area.
• Clear all obstacles from the machine's path. Beware of hazards.
• Be sure that all windows are clean. Secure the doors and the windows in the open position or in the shut
position.
• Adjust the rear view mirrors for best visibility close to the machine. Make sure that the horn, the travel
alarm (if equipped), and all other warning devices are working properly.
• Fasten the seat belt securely.
• Warm up the engine and hydraulic oil before operating machine.
• Before moving the machine, check the position of undercarriage. The normal travel position is with idler
wheels to the front under the cab and the drive sprockets to the rear. When the undercarriage is in the
reversed position, the travel controls must be operated in opposite directions

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MACHINE OPERATION

IMPORTANT
If you need more information or have any questions or concerns about safe operating procedures
or working the wheel loader correctly in a particular application or in the specific conditions of your
individual operating environment, please consult your local DISD representative.

OPERATE WHILE SEATED AT OPERATOR’S

STATION ONLY
Never reach in through a window to work a control.
Do not try to operate wheel loader unless you’re in
command position - seated at controls. You should
stay alert and focused on your work at all times. Do
not twist out of seat if job activity behind you (or to
the side) requires your attention.
Figure 13
Use a spotter or signal person if you cannot see
clearly and something is happening behind you.
Replace damaged safety labels and lost or damaged
operator’s manuals.
Do not let anyone operate machine unless they’ve
been fully and completely trained, in safety and in
operation of the machine.

SEAT BELTS SHOULD BE USED AT ALL TIMES

Whenever engine is running, operator should be
seated at the control station with seat belt properly
engaged.

Figure 14

MOVEMENT ALARMS
If wheel loader is equipped with an audible travel movement alarm, test alarm on a daily basis. Audible alarm
should sound as soon as travel system is engaged.

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TRAVEL PRECAUTIONS
When traveling, wheel loader always keeps lights on; make sure that you are in compliance with all state and
local regulations concerning warning flags and signs.
Never turn the starter switch to the "O" (OFF) position when traveling. It is dangerous if the engine stops when
the machine is traveling. It will be impossible to operate the steering unless the unit is equipped with an
emergency steering system.
Pilot control valve lever (joystick) should not be operated while traveling.
Lower work equipment so that it is 400 mm (16 in) above ground.
Never travel over obstacles or slopes that will cause machine to tilt severely. Travel around any slope or
obstacle that causes 10°tilt, or more.
Do not operate the steering suddenly. The work equipment may hit the ground and cause the machine to lose
its balance, and this may damage the machine or structures in the area.
When traveling on rough ground, travel at low speed, and avoid sudden changes in direction.
Always keep to the permissible water depth.
When traveling over bridges or structures on private land, check first that the bridge or structure can withstand
the weight of the machine. When traveling on public roads, check with the local authorities and follow their
instructions.

SLOPING TERRAIN REQUIRES CAUTION

Dig evenly around work site whenever possible,
trying to gradually level any existing slope. If it’s not
possible to level area or avoid working on a slope,
reducing size and cycling rate workload is
recommended.
On sloping surfaces, use caution when positioning
wheel loader before starting a work cycle. Stay alert
for unstable situations to avoid getting into them. For Figure 15

example, you should always avoid working bucket

over downhill side of machine when parked
perpendicular to slope. Avoid full extensions of
bucket in a downhill direction. Lifting bucket too high,
too close to machine, while wheel loader is turned
uphill can also be hazardous.

S0103010K Wheel Loader Safety

Page 18
AVOID HIGH-VOLTAGE CABLES
Serious injury or death can result from contact or
proximity to high-voltage electric lines. The bucket
does not have to make physical contact with power
lines for current to be transmitted.
Use a spotter and hand signals to stay away from
power lines not clearly visible to operator.
MINIMUM SAFE
VOLTAGE Figure 16
DISTANCE
6.6 kV 3 m (9’ 10")

33.0 kV 4 m (13’ 1")

66.0 kV 5 m (16’ 5")

154.0 kV 8 m (26’ 3")

275.0 kV 10 m (32’ 10")

Use these minimum distances as a guideline only. Depending upon voltage in line and atmospheric
conditions, strong current shocks can occur with boom or bucket as far away as 4 - 6 m (13 - 20 ft) from power
line. Very high voltage and rainy weather could further decrease that safety margin.
NOTE: Before starting any type of operation near power lines (either above ground or buried cable-type) you
should always contact power utility directly and work out a safety plan with them.

BEFORE STARTING TO DIG, CONTACT AUTHORITIES

Below ground hazards also include natural gas lines, water mains, tunnels and buried foundations. Know
what’s underneath work site before starting to dig.

BE AWARE OF HEIGHT OBSTACLES

Any type of object in vicinity of boom could represent a potential hazard, or cause operator to react suddenly
and cause an accident. Use a spotter or signal person working near bridges, phone lines, work site scaffolds,
or other obstructions.

USE CARE ON LOOSE SUPPORT

Working heavy loads over loose, soft ground or uneven, broken terrain can cause dangerous side load
conditions and possible tip over and injury. Travel without a load or balanced load may also be hazardous.
If temperatures are changing, be cautious of dark and wet patches when working or traveling over frozen
ground. Stay away from ditches, overhangs and all other weak support surfaces. Halt work and install support
mats or blocking if work is required in an area of poor support.

Wheel Loader Safety S0103010K

Page 19
USE SOLID SUPPORT BLOCKING
Never rely on lift jacks or other inadequate supports
when work is being done. Block wheels fore and aft
to prevent any movement.

DIGGING BENEATH OVERHANGS

Digging beneath an overhang is dangerous.
Overhand could collapse on top of operator and
cause serious injury or death. Go on to another
Figure 17
digging area before steep overhangs are formed.
Know height and reach limits of wheel loader and
plan ahead while working. Park wheel loader away
from overhangs before work shut down.

DIGGING BENEATH WHEEL LOADER

Digging beneath wheel loader is dangerous. Earth beneath could collapse. This could cause wheel loader to
tip, which could cause serious injury or death to operator. Working around deep pits, trenching or along high
walls may require support blocks, especially after heavy rainfalls or during spring thaws.

STAY ALERT FOR PEOPLE MOVING THROUGH WORK AREA

When loading a truck you should always know
where the driver is.
Avoid loading over the cab of a truck even if the
driver is in a safe spot. Someone else could have
gone inside, for any number of reasons. Avoid
working where unseen passersby might be.
Slow down work cycle and use slower travel speeds
in congested or populated areas. Use a commonly
understood signal so that other members of work Figure 18

crew can warn operator to slow or halt work in an

impending hazardous situation.

BE AWARE OF AND CONFORM TO LOCAL REGULATIONS

Minimum levels of insurance coverage, work permits or certification, physical barriers around work-site or
restricted hours of operation may be mandated by governing authorities. There may also be guidelines,
standards or restrictions on equipment that may be used to perform certain kinds of work. Check and follow all
local requirements, which may also be related to below ground hazards and power lines.

S0103010K Wheel Loader Safety

Page 20
NEVER USE ETHER STARTING AIDS
An electric-grid type manifold heater is used for cold
starting. Glowing heater element can cause ether or
other starting fluid to detonate, causing injury.

Figure 19

OBSERVE GENERAL SAFETY RULES

Only trained and authorized personnel, with a good knowledge and awareness of safe procedures, may be
allowed to operate or perform maintenance or service on wheel loader.
All personnel at work site should be aware of assigned individual responsibilities and tasks.
Communication and hand signals used should be understood by everyone.
Terrain and soil conditions at work site, approaching traffic, weather-related hazards and any above or below
ground obstacles or hazards should be observed and monitored by all work crew members.

TAKE TIME TO PROVIDE GOOD VISIBILITY

Be careful not to go close to the edge of a cliff by mistake.
Use the machine only for its main purpose. Using it for other purposes will cause failures.
To ensure an ample view, do as follows:
• When working in dark areas, attach working lights and front lights to the machine. If necessary, set up
lighting at the work site.
• Stop operations when the visibility is poor, such as in fog, mist, snow, and rain. Wait for the visibility to
improve to a level which causes no problems for the operation.
• Keep dirt and dust off of windows and off lens surfaces of work lights. Stop working if lights, windows or
mirrors need cleaning or adjustment.
To avoid hitting the work equipment, always do the following;
• When working in tunnels, on bridges, under electric wires, or when parking the machine or carrying out
other operations in places with limited height, be extremely careful not to hit the bucket or other parts.
• To prevent collisions, operate the machine at a safe speed when working in confined spaces, indoors, or
in crowded areas.
• Do not pass the bucket over the heads of workers or over the operator's compartment of dump truck.

Wheel Loader Safety S0103010K

Page 21
KEEP "PINCH POINT" AREAS CLEAR – USE
CAUTION IN REVERSE
Use a signal person in high traffic areas and
whenever operator’s view is not clear, such as when
traveling in reverse.
Anyone standing near wheels, or working
assemblies of the attachment, is at risk of being
caught between moving parts of machine.
Never allow anyone to ride on any part of machine or Figure 20

attachment, including any part of operator’s cab.

OPERATE CAREFULLY ON SNOW AND ICE AND IN VERY COLD TEMPERATURES

In icy cold weather avoid sudden travel movements and stay away from even very slight slopes. Machine
could skid off to one side very easily.
Snow accumulation could hide or obscure potential hazards. Use care while operating or while using machine
to clear snow.
Warming up engine for a short period may be necessary, to avoid operating with sluggish or reduced working
capacity. Jolting shocks and impact loads caused by bumping or bottoming boom or attachment are more
likely to cause severe stress in very cold temperatures. Reducing work cycle rate and work load may be
necessary.
When the temperature rises, frozen road surfaces become soft, so the machine travel becomes unstable.
In cold weather, do not touch metal surfaces with your bare hands. If you touch a metal surface in extremely
cold weather, your skin may freeze to the metal surface.

PARKING MACHINE
Avoid making sudden stops, or parking machine wherever it happens to be at the end of the work day. Plan
ahead so that the wheel loader will be on firm, level ground away from traffic and away from high walls, cliff
edges and any area of potential water accumulation or runoff. If parking on inclines is unavoidable, block
wheels to prevent movement. Lower bucket or other working attachment completely to ground, or to an
overnight support saddle. There should be no possibility of unintended or accidental movement.
When parking on public roads, provide fences, signs, flags, or lights, and put up any other necessary signs to
ensure that passing traffic can see the machine clearly, and park the machine so that the machine, flags, and
fences do not obstruct traffic.

S0103010K Wheel Loader Safety

Page 22
SHUTDOWN CONTROL FUNCTIONS
After bucket has been lowered to overnight storage position, move all switches and controls to "OFF" position.
Pull parking brake knob to "APPLIED" position. This will apply parking brake. Move pilot cutoff switch to
"LOCK" position. This will disable pilot control valve lever (joystick). Move key in starter switch to "OFF"
position, and remove key from switch.
Engage all lock-down security equipment that may have been installed on machine.

IMPORTANT
When hydraulic system maintenance or service work must be performed, be aware that
accumulators in system store fluid under pressure after system has been shut down. To release
hydraulic pressure in accumulators, operate control with engine "OFF" until accumulator pressure
is completely dissipated.

NEVER LET ANYONE RIDE ON ATTACHMENT

Never let anyone ride on any work attachment, such
as the bucket, crusher, grapple, or clamshell (grab
bucket). There is a danger of the person falling and
suffering serious injury.

Figure 21

Wheel Loader Safety S0103010K

Page 23
MAINTENANCE
USE WARNING TAG DURING SERVICE
Alert others that service or maintenance is being
performed and tag operator’s cab controls - and
other machine areas if required - with a warning
notice.
Warning tags for controls are available from DISD
distributors; see Figure 22.

Figure 22
CLEAN BEFORE INSPECTION ORMAINTENANCE
Clean the machine before carrying out inspection
and maintenance. This prevents dirt from getting into
the machine and also ensures safety during
maintenance.
If inspection and maintenance are carried out when the machine is dirty, it will become more difficult to locate
the problems, and also there is danger that you may get dirt or mud in your eyes or that you may slip and
injure yourself.
When washing the machine, do the following;
• Wear shoes with nonslip soles to prevent yourself from slipping and falling on wet places.
• Wear safety glasses and protective clothing when washing the machine with high-pressure steam.
• Take action to prevent touching high-pressure water and cutting your skin or having mud fly into your
eyes.
• Do not spray water directly on electrical components (sensors, connector) (1, Figure 23). If water gets into
the electrical system, there is danger that it will cause defective operation and malfunction.

Figure 23
Pick up any tools or hammers that are laying in the work place, wipe up any grease or oil or any other slippery
substances, and clean the area to make it possible to carry out the operation in safety. If the work place is left
untidy, you may trip or slip and suffer injury.
S0103010K Wheel Loader Safety
Page 24
PROPER TOOLS
Use only tools suited to the task. Using damaged,
low qualify, faulty, or makeshift tools could cause
personal injury. There is danger that pieces from,
chisels with crushed heads, or hammers, may get
into your eyes and cause blindness.

Figure 24

USE OF LIGHTING
When checking fuel, oil, battery electrolyte, or
window washing fluid, always use lighting with
anti-explosion specifications. If such lighting
equipment is not used, there is danger of explosion.
If work is carried out in dark places without using
lighting, it may lead to injury, so always use proper
lighting.
Even if the place is dark, never use a lighter or flame
Figure 25
instead of lighting. There is danger of fire.
There is also danger that the battery gas may catch
fire and cause and explosion.

FIRE PREVENTION AND EXPLOSION PREVENTION

All fuels, most lubricants and some coolant mixtures are flammable. Leaking fuel or fuel that is spilled onto hot
surfaces or onto electrical components can cause a fire.
Store all fuels and all lubricants in properly marked containers and away from all unauthorized persons.
Store oily rags and other flammable material in a protective container.
Do not smoke while you refuel the machine or while you are in a refueling area.
Do not smoke in battery charging areas or in areas the contain flammable material.
Clean all electrical connections and tighten all electrical connections. Check the electrical wires daily for wires
that are loose of frayed. Tighten all lose electrical wires before you operate the machine. Repair all frayed
electrical wires before you operate the machine.
Remove all flammable materials before they accumulate on the machine.
Do not weld on pipes or on tubes that contain flammable fluids. Do not flame cut on pipes or on tubes that
contain flammable fluids. Before you weld on pipes or on tubes or before you flame cut on pipes or on tubes,
clean the pipes or tubes thoroughly with a nonflammable solvent.

Wheel Loader Safety S0103010K

Page 25
BURN PREVENTION
When checking the radiator coolant level, shut down engine, let the engine and radiator cool down, then
check the coolant recovery tank. If the coolant level in the coolant recovery tank is near the upper limit, there
is enough coolant in the radiator.
Loosen the radiator cap gradually to release the internal pressure before removing the radiator cap.

Figure 26

If the coolant level in the coolant recovery tank is below the lower limit, add coolant.
Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact the
skin, the eyes, or the mouth.
Allow cooling system components to cool before you drain the cooling system.
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the
skin.
Remove the hydraulic tank filter plug only after the engine has been stopped. Make sure that the hydraulic
tank filter plug is cool before you remove it with your bare hand. Remove the hydraulic tank filter plug slowly to
relieve pressure.
Relieve all pressure in the hydraulic oil system, in the fuel system, or in the cooling system before you
disconnect any lines, fittings, or related items.
Batteries give off flammable fumes that can explode.
Do not smoke while you are checking the battery electrolyte levels.
Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or the
eyes.
Always wear protective glasses when you work on batteries.

S0103010K Wheel Loader Safety

Page 26
WELDING REPAIRS
When carrying out welding repairs, carry out the welding in a properly equipped place. The welding should be
performed by a qualified worker. During welding operations, there is the danger of, generation of gas, fire, or
electric shock, so never let an unqualified worker do welding.

The qualified welder must do the following;

• To prevent explosion of the battery, disconnect the battery terminals and remove batteries.
• To prevent generation of gas, remove the paint from the location of the weld.
• If hydraulic equipment, piping or places close to them are heated, a flammable gas or mist will be
generated and there is danger of it catching fire. To avoid this, never subject these places to heat.
• Do not weld on pipes or on tubes that contain flammable fluids. Do not flame cut on pipes or on tubes that
contain flammable fluids. Before you weld on pipes or on tubes or before you flame cut on pipes or on
tubes, clean the pipes or tubes thoroughly with a nonflammable solvent.
• If heat is applied directly to rubber hoses or piping under pressure, they may suddenly break so cover
them with a fireproof covering.
• Wear protective clothing.
• Make sure there is good ventilation.
• Remove all flammable objects and provide a fire extinguisher.

PRECAUTIONS FOR REMOVAL, INSTALLATION,

AND STORAGE OFATTACHMENTS
Before starting removal and installation of
attachments, decide the team leader.
Do not allow anyone except the authorized workers
close to the machine or attachment.
Place attachments that have been removed from the
machine in a safe place so that they do not fall. Put
up a fence around the attachments and take other Figure 27

measures to prevent unauthorized persons from

entering.

Wheel Loader Safety S0103010K

Page 27
PRECAUTIONS WHEN WORKING ON MACHINE
When carrying out maintenance operations on the
machine, keep the area around your feet clean and
tidy to prevent you from falling.
Always do the following;
• Do not spill oil or grease.
• Do not leave tools laying about.
• Watch your step when walking.
Figure 28

Never jump down from the machine. When getting on or off the machine, use the steps and handrails, and
maintain a three-point contact (both feet and one hand or both hands and one foot) to support yourself
securely.
If the job requires it, wear protective clothing.
To prevent injury from slipping or falling, when working on the hood or covers, never use any part except the
inspection passage fitted with nonslip pads.

LOCK INSPECTION COVERS

When carrying out maintenance with the inspection cover open, lock the cover securely in position with the
lock bar.
If maintenance work is carried out with the inspection cover open but not locked, there is danger that it may
suddenly close and cause injury if there is a gust of wind.

CRUSHING PREVENTION AND CUTTING PREVENTION

You should always have at least two people working together if the engine must be run during service. One
person needs to remain in the operator’s seat, ready to work the controls or stop the machine and shut off the
engine.
Unless you are instructed otherwise, never attempt adjustments while the machine is moving or while the
engine is running.
Stay clear of all rotating parts and moving parts.
Keep objects away from moving fan blades. The fan blades will throw objects and the fan blades can cut
objects.
Do not use a wire rope cable that is kinked or flayed. Wear gloves when you handle a wire rope cable.
When you strike a retainer pin, the retainer pin might fly out. The loose retainer pin can injure personnel.
Make sure that the area is clear of people when you strike a retainer pin. To avoid injury to your eyes, wear
protective glasses when you strike a retainer pin.

S0103010K Wheel Loader Safety

Page 28
DO NOT RUN ENGINE IF REPAIRS OR WORK ARE BEING PERFORMED ALONE
You should always have at least two people working together if engine must be run during service. One
person needs to remain in operator’s seat, ready to work controls or stop machine and shut "OFF" engine.

ALWAYS USE ADEQUATE EQUIPMENT SUPPORTS AND BLOCKING

Do not allow weight or equipment loads to remain suspended. Lower everything to ground before leaving
operator’s seat. Do not use hollow, cracked or unsteady, wobbling weight supports. Do not work under any
equipment supported solely by a lift jack.

DO NOT WORK ON HOT ENGINES OR HOT COOLING OR HYDRAULIC SYSTEMS

Wait for engine to cool off after normal operation. Park wheel loader on firm, level ground and lower all
equipment before shutting down and switching "OFF" controls. When engine lube oil, gearbox lubricant or
other fluids require change, wait for fluid temperatures to decrease to a moderate level before removing drain
plugs.
NOTE: Oil will drain more quickly and completely if it is warm. Do not drain fluids at temperatures exceeding
95°C (203°F), however do not allow full cool down.

HYDRAULIC CYLINDER SEALS REQUIRE PERIODIC REPLACEMENT

Check cylinder drift rate at regular intervals. Overhaul seal kits are available through DISD.

HIGH PRESSURE HYDRAULIC LINES CAN STORE A GREAT DEAL OF ENERGY

Exposed hydraulic hoses on arm or boom could react with explosive force if struck by a falling rock, overhead
obstacle or other work site hazard. Extra safety guards may be required. NEVER allow hoses to be hit, bent or
interfered with during operation.

Wheel Loader Safety S0103010K

Page 29
PRECAUTIONS WITH HIGH PRESSURE LINE, TUBES AND HOSES
When inspecting or replacing high-pressure piping or hoses, check that the pressure has been released from
the circuit. Failure to release the pressure may lead to serious injury. Always do the following;
• Wear protective glasses and leather gloves.
• Fluid leaks from hydraulic hoses or pressurized components can be difficult to see but pressurized oil has
enough force to pierce the skin and cause serious injury. Always use a piece of wood or cardboard to
check for suspected hydraulic leaks. Never use your hands or expose your fingers.
• Do not bend high pressure lines. Do not strike high pressure lines. Do not install lines, tubes or hoses that
are bent or damaged.
• Make sure that all clamps, guards and heat shields are installed correctly to prevent vibration, rubbing
against other parts, and excessive heat during operation.
– If any of the following conditions are found, replace the part.
– Damage or leakage from hose end.
– Wear, damage, cutting of covering, or exposure of strengthening wire layer.
– Cover portion is swollen in places.
– There is twisting or crushing at movable parts of hose.
– Foreign material is embedded in the covering.
– Hose end is deformed.

Figure 29

OBTAIN IMMEDIATE MEDICAL ATTENTION IF PRESSURIZED OIL PIERCES SKIN.

WARNING!
Failure to obtain prompt medical assistance could result in gangrene or other serious damage to
tissue.

S0103010K Wheel Loader Safety

Page 30
USE CORRECT REPLACEMENT FASTENERS TIGHTENED TO PROPER TORQUE
Refer to "General Maintenance" section of Shop Manual for information on tightening torques and
recommended assembly compounds and always use correct part.
Poor or incorrect fastener connections can dangerously weaken assemblies.

SAFETY-CRITICAL PARTS MUST BE REPLACED PERIODICALLY

Replace following fire-related components as soon as they begin to show any sign of wear, or at regular
periodic intervals, whether or not deterioration is visible:
• Fuel system flexible hoses, the tank overflow drain hose and the fuel filler cap.
• Hydraulic system hoses, especially the pump outlet lines and front and rear pump branch hoses.
• Keep mounting brackets and hose and cable routing straps tight. Hose routing should have gradual bends.

DISPOSE OF ALL PETROLEUM-BASED OILS

AND FLUIDS PROPERLY
Physical contact with used motor oil may pose a
health risk. Wipe oil from your hands promptly and
wash off any remaining residue.
Used motor oil is an environmental contaminant and
may only be disposed of at approved collection
facilities. To prevent pollution of the environment,
always do the following; Figure 30
• Never dump waste oil in a sewer system, rivers,
etc.
• Always put oil drained from your machine in
containers. Never drain oil directly onto the
ground.
• Obey appropriate laws and regulations when
disposing of harmful materials such as oil, fuel,
solvent, filters, and batteries.

CHECK TIRE PRESSURE AND CONDITION

Maintain tire pressure but do not over inflate. Inspect tires and wheels daily. When inflating tires, follow
procedures in Maintenance Section, which include using an extension to allow you to avoid standing in front
of or over a tire. Do not change a tire unless you have both experience and proper equipment.

Wheel Loader Safety S0103010K

Page 31
BATTERY HAZARD PREVENTION
Battery electrolyte contains diluted sulfuric acid and batteries generate hydrogen gas. Hydrogen gas is highly
explosive, and mistakes in handling them can cause serious injury or fire. To prevent problems, always do the
following;
• Do not smoke or bring any flame near the battery.
• When working with batteries, ALWAYS wear safety glasses and rubber gloves.
• If you spill battery electrolyte on yourself or your clothes, immediately flush the area with water.
• If battery electrolyte gets into your eyes, flush them immediately with large quantities of water and see a
doctor at once.
• If you accidentally drink battery electrolyte, drink a large quantity of water or milk, raw egg or vegetable oil.
Call a doctor or poison prevention center immediately.
• When cleaning the top surface of the battery, wipe it with a clean, damp cloth. Never use gasoline, thinner,
or any other organic solvent or detergent.
• Tighten the battery caps securely.
• Explosive battery gas can be set off by sparks from incidental contact or static discharge. Turn "OFF" all
switches and engine when working on batteries. Keep battery terminals tight. Contact between a loose
terminal and post can create an explosive spark.
• If the battery electrolyte is frozen, do not charge the battery or start the engine with power from another
source. There is danger that the battery may catch fire.
• When charging the battery or starting with power from another source, let the battery electrolyte melt and
check that there is no leakage of battery electrolyte before starting the operation.
• Always remove the battery from the machine before charging.

Figure 31

DISCONNECT BATTERIES BEFORE ELECTRICAL SERVICE OR ELECTRICAL WELDING

Remove cable to negative terminal first when disconnecting cable. Connect positive terminal cables first when
installing a battery.

S0103010K Wheel Loader Safety

Page 32
USE LOW HEAT PORTABLE LIGHTING
Hot surfaces on trouble lights or portable work lights can set off fuel or battery explosive gases.

BOOST STARTING OR CHARGING ENGINE

BATTERIES
If any mistake is made in the method of connecting
the booster cables, it may cause an explosion or fire.
Always do the following;
• Turn off all electrical equipment before
connecting leads to the battery. This includes
electrical switches on the battery charger or
boost starting equipment. Figure 32
• When boost-starting from another machine or
vehicle do not allow the two machines to touch.
Wear safety glasses or goggles while required
battery connections are made.
• 24 volt battery units consisting of two series-connected twelve volt batteries have a cable connecting one
positive terminal on one of the 12 volt batteries to a negative terminal on the other battery. Booster or
charger cable connections must be made between the nonseries-connected positive terminals and
between the negative terminal of the booster battery and the metal frame of the machine being boosted or
charged. Refer to the procedure and illustration in Operation and Maintenance Manual.
• Connect positive cable first when installing cables and disconnect the negative cable first when removing
them. The final cable connection, at the metal frame of the machine being charged or boost-started,
should be as far away from the batteries as possible.

Wheel Loader Safety S0103010K

Page 33
TOWING
PRECAUTIONS WHEN TOWING
If any mistake is made in the method of selecting or inspecting the towing wire or in the method of towing, it
may lead to serious personal injury. Always do the following;
• Always use the method of towing given in this Operation and Maintenance Manual. Do not use any other
method.
• Use leather gloves when handling the wire rope.
• When carrying out the preparation work for towing with two or more workers, determine the signals to use
and follow these signals correctly.
• If the engine on the problem machine will not start or there is a failure in the brake system, always contact
your DISD distributor.
• Never go between the towing machine and the towed machine during the towing operation.
• It is dangerous to carry out towing on slopes, so select a place where the slope is gradual. If there is no
place where the slope is gradual, carry out operations to reduce the angle of the slope before starting the
towing operation.
• When towing a problem machine, always use a wire rope with a sufficient towing capacity.
• Do not use a frayed, kinked rope or a rope with any loss of diameter.

S0103010K Wheel Loader Safety

Page 34
SHIPPING AND TRANSPORTATION
OBEY STATE AND LOCAL OVER-THE-ROAD REGULATIONS
Check state and local restrictions regarding weight, width and length of a load before making any other
preparation for transport.
Hauling vehicle, trailer and load must all be in compliance with local regulations governing intended shipping
route.
Partial disassembly or tear-down of wheel loader may be necessary to meet travel restrictions or particular
conditions at work site.
Refer to the section "Transportation" section of operation manual.

SUMMARY OF SAFETY PRECAUTIONS FOR

LIFTING

WARNING!
Improper lifting can allow load to shift and
cause personal injury or damage to the
machine

To make safe lifts, the following items must be Figure 33

evaluated by operator and work site crew.
• Condition of ground support.
• Wheel loader configuration and attachments.
• Weight, lifting height and lifting radius.
• Safe rigging of load.
• Proper handling of suspended load.

Taglines on opposite sides of load can be very helpful in keeping a suspended load secure, if they are
anchored safely to control points on ground.

Wheel Loader Safety S0103010K

Page 35
S0103010K Wheel Loader Safety
Page 36
1SPECIFICATIONS
 SP002380

1SPECIFICATIONS FOR
SD 200

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual or
those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

MODEL SERIAL NUMBER RANGE

SD200 1001 and Up

Copyright 2011 DISD

July 2011

Specifications for SD 200 SP002380

Page 1
TABLE OF CONTENTS
Component Locations ...................................................................................................4
General Specifications ..................................................................................................6
Engine Performance Curves .........................................................................................8
Working Range and Dimensions...................................................................................9
Working Capacities .....................................................................................................10
Bucket Capacity ....................................................................................................10
Tipping Load .........................................................................................................10
Material Weight ...........................................................................................................10
Approximate Weight of Workload Materials ..........................................................10

SP002380 Specifications for SD 200

Page 2
Specifications for SD 200 SP002380
Page 3
COMPONENT LOCATIONS
Figure 1 identifies the location of major machine components.

Figure 1

SP002380 Specifications for SD 200

Page 4
 Reference Reference
Description Description
Number Number
1 Frame 15 Handrail

2 E/G and T/M Ass`y 16 Engine Cover

3 Fuel Tank 17 Damper

4 Oil Tank 18 Cabin Interior

5 Axel and Driving shaft 19 Radiator Grille

6 Axel and Driving shaft 20 Counterweight

7 Tire 21 Working Device

8 Axle Hub 22 Bucket

9 Cooling Pipe line 23 Tooth

10 Main Pipe line 24 Cutting Edge

11 Steering Pipe line 25 Cabin

12 Brake Pipe line 26 Seat

13 Brake System 27 Lamp-Rear

14 Main Control valve 28 Lamp-Front

Specifications for SD 200 SP002380

Page 5
GENERAL SPECIFICATIONS
Item SD 200
Serial Number 1001 thru UP
3 3
Standard Bucket Capacity 1.70 m (2.22 yd )
Vehicle Weight 10,300 kg (22,708 lb)
Engine
Type Weichai
Rated power (SAE J 1995 gross) 125 ps @ 2,200 rpm (123 hp @ 2,200 rpm)
Max. Torque (SAE J 1995 gross) 51 kg•m / 1,500 rpm (368 ft lb @ 1,500 rpm)
Transmission
Mechanical gear shift Mechanical gear shift
Speeds 2 Forward, 1 Reverse
Brake Systems
Service Brakes 4 Wheel, Dry Disks, Single Pedal
Parking Brake Dry Disc on Transmission
Performance
Travel Speed (1 / 2) 8 (4.97) / 15 (9.3) km/h (mph)
Steering Angle + 40°
Min. Tire Turning Radius (Tire Center) 4,241 mm
Max Tractive Effort 9,693 kg (21,772 lb)
Max. Breakout Force 9,184kg (20,247 lb)
Bucket Rise Time 5.5 Seconds
Bucket Dump Time 1.0 Seconds
Bucket Descent Time 3.2 Seconds
Working Range
Dump Height at 45°(w/o teeth) 2,910 mm (9’ - 6")
Dump Reach at 45°(w/o teeth) 950 mm (3’ - 1")
Max Dump Angle at Fully Raised 45°
Max Tilt Angle at Carry 50°
Travel Dimension
Overall Length 6,900 mm (22’ - 8")
Overall Width 2,515 mm (8’ - 3")
Overall Height 3,280 mm (10’ - 9")
Tread 1,850 mm (6’ - 1")
Axle Base 2,830mm (9’ - 3")
Ground Clearance 340 mm (1’ - 1")

SP002380 Specifications for SD 200

Page 6
Specifications for SD 200 SP002380
Page 7
ENGINE PERFORMANCE CURVES

Figure 2

Serial Number 1001 and Up

Engine Type WP6G125E22
Rated Power (209 hp @ 2,200 rpm) 125 ps @ 2,200 rpm (123 hp @ 2,200 rpm)
Maximum Torque (666 ft lb @ 1,300 rpm) 51 kg•m @ 1,500 rpm (368 ft lb @ 1,500 rpm)
Fuel Consumption 158 g / ps.h
Performance Standard SAE J 1995 gross
NOTE: Barometric Pressure: 760 mm (30") Mercury
Temperature: 20°C (68°F)
W/O Cooling Fan: Driven by engine
Alternator: 24 V, 50 amp
Exhaust System: Complete, attached
Air Cleaner; Installed
SP002380 Specifications for SD 200
Page 8
WORKING RANGE AND DIMENSIONS
Figure 3, illustrates exterior machine dimensions and working range of machine when it is equipped with a
standard bucket.

Figure 3

Category Dimension Category Dimension

Overall Length (A) 6,900 mm (22’ - 8") Dump Height, to tooth (H) 2,900 mm (9’ - 6")

Overall Width (B) 2,515 mm (8’ - 3") Dump Distance, to Bucket Edge (I) 950 mm (3’ - 1")

Overall Height (C) 3,280 mm (10’ - 9") Dump Height to Bucket Pivot (K) 3,727 mm (12’3")

Axle Base (E) 2,830mm (9’ - 3") Max. Dump Angle at Fully Raised (a) 45°

Tread (F) 1,850 mm (6’ - 1") Max. Tilt Angle at Carry (b) 50°

Ground Clearance (G) 340 mm (1’ - 1") Tire Size 17.5-25

Specifications for SD 200 SP002380

Page 9
WORKING CAPACITIES
BUCKET CAPACITY
Standard toothed bucket has a capacity of 1.7 m3. An optional bucket equipped with big bucket has a capacity
of 2.2 m3.

TIPPING LOAD
Static Tipping Load with bucket at max reach position is 6,530 kg (14,396 lb).

MATERIAL WEIGHT
The data below describes weight of a cubic meter (cubic yard) of many types of workload materials.

APPROXIMATE WEIGHT OF WORKLOAD MATERIALS

LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR
3 3 3
DENSITY 1,100 KG/M DENSITY 1,600 KG/M DENSITY 2,000 KG/M
MATERIAL 3 3 3
(1,850 LB/YD ), (2,700 LB/YD ), (3,370 LB/YD ),
OR LESS OR LESS OR LESS
3
401 kg/m
Charcoal 3
--------------------- ---------------------
(695 lb/yd )
3
Coke, blast furnace 433 kg/m
3
--------------------- ---------------------
size (729 lb/yd )
3
449 kg/m
Coke, foundry size 3
--------------------- ---------------------
(756 lb/yd )
3
Coal, bituminous slack, 801 kg/m
3
--------------------- ---------------------
piled (1,350 lb/yd )
3
Coal, bituminous r. of 881 kg/m
3
--------------------- ---------------------
m., piled (1,485 lb/yd )
3
897 kg/m
Coal, anthracite --------------------- ---------------------
(1,512 lb/yd3)
3
Clay, DRY, in broken 1,009 kg/m
3
--------------------- ---------------------
lumps (1,701 lb/yd )
3
Clay, DAMP, natural 1,746 kg/m
--------------------- 3
---------------------
bed (2,943 lb/yd )

SP002380 Specifications for SD 200

Page 10
 LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR
3 3 3
DENSITY 1,100 KG/M DENSITY 1,600 KG/M DENSITY 2,000 KG/M
MATERIAL 3 3 3
(1,850 LB/YD ), (2,700 LB/YD ), (3,370 LB/YD ),
OR LESS OR LESS OR LESS
3
Cement, Portland, DRY 1,506 kg/m
--------------------- 3
---------------------
granular (2,583 lb/yd )
3
Cement, Portland, DRY 1,362 kg/m
--------------------- 3
---------------------
clinkers (2,295 lb/yd )
3
1,522 kg/m
Dolomite, crushed --------------------- 3
---------------------
(2,565 lb/yd )
3
Earth, loamy, DRY, 1,202 kg/m
--------------------- 3
---------------------
loose (2,025 lb/yd )
3
1,522 kg/m
Earth, DRY, packed --------------------- 3
---------------------
(2,565 lb/y d )
3
1,762 kg/m
Earth, WET, muddy --------------------- ---------------------
(2,970lb/yd3)
3
Gypsum, calcined, 961kg/m
3
--------------------- ---------------------
(heated, powder) (1,620 lb/yd )
3
Gypsum, crushed to 3 1,522 kg/m
--------------------- 3
---------------------
inch size (2,565 lb/y d )
3
Gravel, DRY, packed 1,810 kg/m
--------------------- --------------------- 3
fragments (3,051 lb/y d )
3
Gravel, WET, packed 1,522 kg/m
--------------------- --------------------- 3
fragments (3,240 lb/y d )
3
Limestone, graded 1,282 kg/m
--------------------- 3
---------------------
above 2 (2,160 lb/y d )
3
Limestone, graded 1,362 kg/m
--------------------- 3
---------------------
1-1/2 or 2 (2,295 lb/y d )
3
1,522 kg/m
Limestone, crushed --------------------- 3
(2,565 lb/y d )
3
1,602 kg/m
Limestone, fine --------------------- --------------------- 3
(2,705 lb/y d )
3
1,282 kg/m
Phosphate, rock --------------------- 3
---------------------
(2,160 lb/y d )

Specifications for SD 200 SP002380

Page 11
 LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR
3 3 3
DENSITY 1,100 KG/M DENSITY 1,600 KG/M DENSITY 2,000 KG/M
MATERIAL 3 3 3
(1,850 LB/YD ), (2,700 LB/YD ), (3,370 LB/YD ),
OR LESS OR LESS OR LESS
3
929 kg/m
Salt 3
--------------------- ---------------------
(1,566 lb/yd )
3
529 kg/m
Snow, light density 3
--------------------- ---------------------
(891 lb/yd )
3
1,522 kg/m
Sand, DRY, loose --------------------- 3
---------------------
(2,565 lb/yd )
3
1,922 kg/m
Sand, WET, packed --------------------- --------------------- 3
(3,240 lb/yd )
3
1,362 kg/m
Shale, broken --------------------- 3
---------------------
(2,295 lb/y d )
3
529 kg/m
Sulphur, broken 3
--------------------- ---------------------
(891 lb/yd )

IMPORTANT
Weights are approximations of estimated average volume and mass. Exposure to rain, snow or
ground water; settling or compaction due to overhead weight and chemical or industrial processing
or changes due to thermal or chemical transformations could all increase value of weights listed in
table..

SP002380 Specifications for SD 200

Page 12
11GENERAL MAINTENANCE
 S0302000

GENERAL MAINTENANCE
PROCEDURES

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual or
those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

MODEL SERIAL NUMBER RANGE

ALL MODELS ALL RANGES

Copyright 2011 DISD

July 2011

General Maintenance Procedures S0302000

Page 1
TABLE OF CONTENTS
Welding Precautions and Guidelines ............................................................................. 3
Hydraulic System - General Precautions ....................................................................... 4
Maintenance Service and Repair Procedure ................................................................. 5
General Precautions ................................................................................................ 5
Hydraulic System Cleanliness and Oil Leaks................................................................. 6
Maintenance Precautions for Hydraulic System Service ......................................... 6
Oil Leakage Precautions.......................................................................................... 6
Cleaning and Inspection................................................................................................. 7
General Guidelines .................................................................................................. 7
Bearing inspection ................................................................................................... 8

S0302000 General Maintenance Procedures

Page 2
WELDING PRECAUTIONS AND GUIDELINES

IMPORTANT
To avoid accidents, personal injury and the possibility of causing damage to the machine or to
components, welding must only be performed by properly trained and qualified personnel, who
possess the correct certification (when required) for the specific welding fabrication or specialized
repair being performed.

WARNING!
Structural elements of the machine may be built from a variety of steels. These could contain
unique alloys or may have been heat treated to obtain particular strength characteristics. It is
extremely important that welding repairs on these types of steel are performed with the proper
procedures and equipment. If repairs are performed incorrectly, structural weakening or other
damage to the machine (that is not always readily visible) could be caused. Always consult DISD
After Sales Service before welding on integral components (loader arm, frames, car body, track
frames, turntable, attachment, etc.) of the machine. It is possible that some types of structurally
critical repairs may require Magnetic Particle or Liquid Penetrant testing, to make sure there are no
hidden cracks or damage, before the machine can be returned to service.

CAUTION!
Always perform welding procedures with the proper safety equipment on hand. Adequate
ventilation and a dry work area are absolutely essential. Keep a fire extinguisher nearby and always
wear protective clothing and the recommended type of eye protection.

General Maintenance Procedures S0302000

Page 3
 CAUTION!
Observe the following safety precautions:
1. Use extra caution and adequate safety shielding when welding near fuel and oil tanks, batteries,
hydraulic piping lines or other fire hazards.
2. Never weld when the engine is running. Battery cables must be disconnected before the welding
procedure is started.
3. Never weld on a wet or damp surface. The presence of moisture causes hydrogen embrittlement
and structural weakening of the weld.
4. If welding procedures are being performed near cylinder rods, operator’s cab window areas or
any other assemblies that could be damaged by weld spatters, use adequate shielding protection
in front of the assembly.
5. During equipment setup, always attach ground cables directly to the area or component being
welded to prevent arcing through bearings, bushings, or spacers.
6. Always use correct welding rods for the type of weld being performed and observe recommended
precautions and time constraints. AWS Class E7018 welding rods for low alloy to medium carbon
steel must be used within two hours after removal from a freshly opened container. Class
E11018G welding rods for T-1 and other higher strength steel must be used within 1/2 hour.

HYDRAULIC SYSTEM - GENERAL PRECAUTIONS

Always maintain oil level in the system at recommended levels. Assemblies that operate under heavy loads,
at high speed, with extremely precise dimensional tolerances between moving parts - pistons and cylinders,
or shoes and swash plates, for example - can be severely damaged if oil supply runs dry.
Assemblies can be run dry and damaged severely in a very short time when piping or hoses are disconnected
to repair leaks and/or replace damaged components. Hoses that are inadvertently switched during
disassembly (inlet for outlet and vice versa), air introduced into the system or assemblies that are low on oil
due to neglect or careless maintenance, could all produce sufficient fluid loss to cause damage.
When starting the engine (particularly after long layoff or storage intervals), make sure that all hydraulic
controls and operating circuits are in neutral, or "OFF." That will prevent pumps or other components that may
be temporarily oil-starved from being run under a load.
Replacement of any hydraulic system component could require thorough cleaning, flushing, and some
amount of pre-filling with fresh, clean oil if the protective seal on replacement parts has obviously been broken
or if seal integrity may have been compromised. When protective seals are removed before installation and
reassembly, inspect all replacement parts carefully, before they are installed. If the replacement part is bone
dry (with no trace of factory pre-lube) or has been contaminated by dirt or by questionable oils, flushing and
pre-filling with clean hydraulic fluid is recommended.
Vibration, irregular or difficult movement or unusual noise from any part of the hydraulic system could be an
indication of air in the system (and many other types of problems). As a general precaution (and to help
minimize the risk of potential long-term damage), allow the engine to run at no-load idle speed immediately
after initial start-up. Hydraulic fluid will circulate, releasing any air that may have been trapped in the system
before load demands are imposed.
A daily walk-around pre-start equipment safety inspection, including a quick visual scan for any exterior
evidence of leaking hydraulic fluid, can help extend the service life of system components.
S0302000 General Maintenance Procedures
Page 4
 IMPORTANT
Hydraulic system operating conditions (repetitive cycling, heavy work loads, fluid circulating under
high pressure) make it extremely critical that dust, grit or any other type of contamination be kept
out of the system. Observe fluid and filter change maintenance interval recommendations and
always pre-clean any exterior surface of the system before it is exposed to air. For example, the
reservoir filler cap and neck area, hoses that have to be disassembled, and the covers and external
surfaces of filter canisters should all be cleaned before disassembly.

MAINTENANCE SERVICE AND REPAIR PROCEDURE

GENERAL PRECAUTIONS
Fluid level and condition should always be checked whenever any other type of maintenance service or repair
is being performed.
NOTE: If the unit is being used in an extreme temperature environment (in sub-freezing climates or in
high temperature, high humidity tropical conditions), frequent purging of moisture condensation
from the hydraulic reservoir drain tap should be a regular and frequent part of the operating
routine. In more moderate, temperate climates, draining reservoir sediment and moisture may not
be required more than once or twice every few months.
Inspect drained oil and used filters for signs of abnormal coloring or visible fluid contamination at every oil
change. Abrasive grit or dust particles will cause discoloration and darkening of the fluid. Visible
accumulations of dirt or grit could be an indication that filter elements are overloaded (and will require more
frequent replacement) or that disintegrating bearings or other component failures in the hydraulic circuit may
be imminent or have already occurred. Open the drain plugs on the main pump casings and check and
compare drain oil in the pumps. Look for evidence of grit or metallic particles.
Vibration or unusual noise during operation could be an indication of air leaking into the circuit (Refer to the
appropriate Troubleshooting section for component or unit for procedures.), or it may be evidence of a
defective pump. The gear-type pilot pump could be defective, causing low pilot pressure, or a main pump
broken shoe or piston could be responsible.
NOTE: If equipped, indicated operating pressure, as shown on the multidisplay digital gauge on the
Instrument Panel ("F-Pump" and "R-Pump") will be reduced as a result of a mechanical problem
inside the pump. However, pressure loss could also be due to cavitation or air leakage, or other
faults in the hydraulic system.
Check the exterior case drain oil in the main pumps. If no metallic particles are found, make sure there is no
air in the system. Unbolt and remove the tank return drain line from the top part of the swing motor, both travel
motors and each main pump. If there is air in any one of the drain lines, carefully pre-fill the assembly before
bolting together the drain line piping connections. Run the system at low rpm.

General Maintenance Procedures S0302000

Page 5
HYDRAULIC SYSTEM CLEANLINESS AND OIL LEAKS
MAINTENANCE PRECAUTIONS FOR HYDRAULIC SYSTEM SERVICE
Whenever maintenance, repairs or any other type of troubleshooting or service is being performed, it’s
important to remember that the hydraulic system - including both the interior and exterior surfaces of
assemblies, and every drop of operating fluid - must be protected from contamination.
Dust and other foreign contaminants are major contributors to premature wear in hydraulic circuits. The
narrow tolerances, rapidly moving parts and high operating pressures of the system require that fluid be kept
as clean as possible. The performance and dependability of the machine (and the service lift of individual
components) can be noticeably reduced if proper precautions are not observed:
• Use a safe, noncombustible, evaporative-type, low-residue solvent and thoroughly clean exterior surfaces
of assemblies before any part of the circuit is opened up or disassembled.
NOTE: It’s just as important to clean the cap and reservoir top before routine fluid changes or quick
checks as it is before major repairs. (Accumulated dirt attracts moisture, oil and other fluids - and
more dirt.)
• Keep dismantled parts covered during disassembly. Use clean caps, plugs or tape to protect the
disconnected openings of flanges, manifolds and piping.
• Do not allow cleaning solvents or other fluids to mix with the oil in the system. Use clean oil to flush any
traces of solvent or other residue before reassembly.
• If metal or rubber fragments are found in the system, flush and replace all fluid in the system and
troubleshoot the circuit to identify the source of contamination.

IMPORTANT
Make sure that cleaning solvents will be compatible with rubber materials used in the hydraulic
system. Many petroleum based compounds can cause swelling, softening, or other deterioration of
system sealing elements, such as O-rings, caps and other seals.

OIL LEAKAGE PRECAUTIONS

Oil that is visibly seeping from joints or seals should always serve as a "red flag" alarm.
Leaks must alert the machine operator and maintenance crew that air, water and dirt have an open, free
passageway through which to enter the circuit. Harsh, corrosive salt air, freezing and thawing condensation
cycles and working environments that are full of fine dust are especially hazardous. Clogging of valve spools
or external piping (especially pilot circuit piping) can gradually diminish or very suddenly put a complete stop
to normal hydraulic function. You can prevent having to make these types of repairs by following
recommended assembly procedures:
1. Use new O-rings and oil seals whenever hydraulic assemblies are rebuilt.
2. Prepare joint surfaces before assembly by checking alignment and flatness. Clean and repair corrosion
or any other damage.
3. Follow bolt torque recommendations and all other assembly requirements
S0302000 General Maintenance Procedures
Page 6
 NOTE: Grease lip seals before assembly.

CLEANING AND INSPECTION

GENERAL GUIDELINES
All parts must be clean to permit an effective inspection. During assembly, it is very important that no dirt or
foreign material enters unit being assembled. Even minute particles can cause malfunction of close fitting
parts such as thrust bearing, matched parts, etc.

WARNING!
Care should be exercised to avoid inhalation of vapors, exposure to skin and creating fire hazards
when using solvent type cleaners.
1. Clean all metal parts thoroughly using a suitable cleaning fluid. It is recommended that parts be
immersed in cleaning fluid and moved up and down slowly until all oils, lubricants, and/or foreign
materials are dissolved and parts are thoroughly clean.
2. For bearings that can be removed, soak them in a suitable cleaning fluid for a minute or two, then
remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified
particles of lubricant. Immerse again in cleaning fluid to flush out particles. Repeat above operation until
bearings are thoroughly clean. To dry bearings, use moisture-free compressed air. Be careful to direct
air stream across bearing to avoid spinning bearings that are not lubricated. DO NOT SPIN BEARINGS
WHEN DRYING; bearings may be rotated slowly by hand to facilitate drying process.
3. Carefully inspect all bearing rollers, cages and cups for wear, chipping or nicks to determine condition.
Do not replace a bearing cone or cup individually without replacing mating cup or cone at the same time.
After inspection, dip bearings in light weight oil and wrap in clean lintless cloth or paper to protect them
until installation.
For those bearings that are to be inspected in place; inspect bearings for roughness of rotation, scoring,
pitting, cracked or chipped races. If any of these defects are found, replace bearings. Also inspect
defective bearing housing and/or shaft for grooved, galled or burred conditions that indicate bearing has
been turning in its housing or on its shaft.
4. It is more economical to replace oil seals, O-rings, sealing rings, gaskets and snap rings when unit is
disassembled than waiting for premature failures; refer to latest Micro Fiche and/or Parts Book for
replacement items. Be extremely careful when installing sealing members, to avoid cutting or

General Maintenance Procedures S0302000

Page 7
 scratching. Curling under of any seal lip will seriously impair its efficiency. Apply a thin coat of Loctite
#120 to outer diameter, of metal casing, on oil seals to assure an oil tight fit into retainer. Use extreme
care not to get Loctite on lips of oil seals. If this happens, that portion of the seal will become brittle and
allow leakage.
When replacing lip type seals, make sure spring loaded side is towards oil to be sealed.
5. If available, use magna-flux or similar process for checking for cracks that are not visible to the eye.
Examine teeth on all gears carefully for wear, pitting, chipping, nicks, cracks or scores. Replace all
gears showing cracks or spots where case hardening has worn through. Small nicks may be removed
with suitable hone. Inspect shafts and quills to make certain they have not been sprung, bent, or splines
twisted and that shafts are true.
NOTE: Spline wear is not considered detrimental except where it affects tightness of splined parts.
Inspect thrust washers for distortion, scores, burs, and wear. Replace thrust washer if defective or
worn.
6. Inspect bores and bearing surfaces of cast parts and machined surfaces for scratches, wear, grooves
and dirt. Remove any scratches and burrs with crocus cloth. Remove foreign material. Replace any
parts that are deeply grooved or scratched which would affect their operation.

BEARING INSPECTION
The conditions of the bearing are vital to the smooth and efficient operation of the machinery. When any
component containing bearings is disassembled, always carefully examine the condition of the bearings and
all of its components for wear and damage.
Once the bearing is removed, clean all parts thoroughly using a suitable cleaning solution. If the bearing is
excessively dirty soak the bearing assembly in a light solution and move the bearing around until all lubricants
and or foreign materials are dissolved and the parts are thoroughly clean.
When drying bearings, moisture free compressed air can be used. Be careful not to direct the air in a direction
which will force the bearing to dry spin while not being properly lubricated.
After the bearings have been cleaned and dried, carefully inspect all bearing rollers, cages and cups for wear,
chipping or nicks. If the bearing cannot be removed and is to be inspected in place, check foe roughness of
rotation, scoring, pitting, cracked or chipped races. If any of these defects are found replace the whole bearing
assembly. NEVER replace the bearing alone without replacing the mating cup or the cone at the same time.
After inspection lightly coat the bearing and related parts with oil and wrap in a clean lintless cloth or paper
and protect them from moisture and other foreign materials until installation.
It is also important to inspect the bearing housing and/or shaft for grooved, galled or burred conditions that
indicate that the bearing has been turning in its housing or on its shaft.
If available, use magna-flux or similar process for checking for cracks that are not visible to the naked eye.
The following illustrations will aid in identifying and diagnosing some of the bearing related problems.
NOTE: The illustrations will only show tapered roller bearings, but the principles of identifying, diagnosing
and remedying the defects are common to all styles and types of bearings.

S0302000 General Maintenance Procedures

Page 8
Normal Bearing
Smooth even surfaces with no discoloration or
marks.

Bent Cage
Cage damage due to improper handling or tool
usage.
Replace bearing.

Galling
Metal smears on roller ends due to over heat,
lubricant failure or overload.
Replace bearing - check seals and check for proper
lubrication.

General Maintenance Procedures S0302000

Page 9
Abrasive Step Wear
Pattern on roller ends caused by fine abrasives.
Clean all parts and housings, check all parts and
housings, check seals and bearings and replace if
leaking, rough or noisy.

Etching
Bearing surfaces appear gray or grayish black in
color with related etching away of material usually at
roller spacing.
Replace bearings - check seals and check for proper
lubrication.

Misalignment
Outer race misalignment due to foreign object.
Clean related parts and replace bearing. Make sure
races are properly seated.

Indentations
Surface depressions on race and rollers caused by
hard particles of foreign materials.
Clean all parts and housings, check seals and
replace bearings if rough or noisy.

S0302000 General Maintenance Procedures

Page 10
Fatigue Spalling
Flaking of surface metal resulting from fatigue.
Replace bearing - clean all related parts.

Brinelling
Surface indentations in raceway caused by rollers
either under impact loading or vibration while the
bearing is not rotating.
Replace bearing if rough or noisy.

Cage Wear
Wear around outside diameter of cage and roller
pockets caused by abrasive material and inefficient
lubrication.
Replace bearings - check seals.

Abrasive Roller Wear

Pattern on races and rollers caused by fine
abrasives.
Clean all parts and housings, check seals and
bearings and replace if leaking, rough or noisy.

General Maintenance Procedures S0302000

Page 11
Cracked Inner Race
Race cracked due to improper fit, cocking or poor
bearing seat.
Replace all parts and housings, check seals and
bearings and replace if leaking.

Smears
Smearing of metal due to slippage caused by poor
fitting, lubrication, overheating, overloads or
handling damage.
Replace bearings, clean related parts and check for
proper fit and lubrication.
Replace shaft if damaged.

Frottage
Corrosion set up by small relative movement of parts
with no lubrication.
Replace bearing. Clean all related parts. Check
seals and check for proper lubrication.

S0302000 General Maintenance Procedures

Page 12
Heat Discoloration
Heat discoloration can range from faint yellow to
dark blue resulting from overload or incorrect
lubrication.
Excessive heat can cause softening of races or
rollers.
To check for loss of temper on races or rollers, a
simple file test may be made. A file drawn over a
tempered part will grab and cut metal, whereas a file
drawn over a hard part will glide readily with no
metal cutting.
Replace bearing if over heating damage is indicated.
Check seals and other related parts for damage.

Stain Discoloration
Discoloration can range from light brown to black
caused by incorrect lubrication or moisture.
if the stain can be removed by light polishing or if no
evidence of overheating is visible, the bearing can
be reused.
Check seals and other related parts for damage.

General Maintenance Procedures S0302000

Page 13
S0302000 General Maintenance Procedures
Page 14
 S0309000

1STANDARD TORQUES

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual or
those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

MODEL SERIAL NUMBER RANGE

ALL MODELS ALL RANGES

Copyright 2011 DISD

July 2011

Standard Torque S0309000

Page 1
TABLE OF CONTENTS
Torque Values for Standard Metric Fasteners .............................................................. 3
Torque Values for Standard U.S. Fasteners ................................................................. 4
Type 8 Phosphate Coated Hardware ............................................................................ 6
Torque Values for Hose Clamps.................................................................................... 7
Torque Values for Split Flanges..................................................................................... 8
Torque Wrench Extension Tools.................................................................................... 9
Torque Multiplication ............................................................................................... 9
Other Uses for Torque Wrench Extension Tools .................................................. 10
Tightening Torque Specifications (Metric) ............................................................ 10

S0309000 Standard Torque

Page 2
TORQUE VALUES FOR STANDARD METRIC
FASTENERS

NOTE: The units for the torque values are kg•m (ft lb).
Dia. x Grade
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
Pitch (mm)
(4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)

0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.50 0.75 0.90
M5 x Std.
(1.08) (1.15) (1.80) (1.59) (2.24) (2.02) (3.11) (3.47) (3.61) (5.42) (6.50)

0.28 0.30 0.55 0.40 0.55 0.47 0.77 0.85 0.90 1.25 1.50
M6 x Std.
(2.02) (2.16) (3.25) (2.89) (3.97) (3.39) (5.56) (6.14) (6.50) (9.04) (10.84)

0.43 0.46 0.70 0.63 0.83 0.78 1.20 1.30 1.40 1.95 2.35
M7 x Std.
(3.11) (3.32) (5.06) (4.55) (6.00) (5.64) (8.67) (9.40) (10.12) (14.10) (1.99)

0.70 0.75 1.10 1.00 1.40 1.25 1.90 2.10 2.20 3.10 3.80
M8 x Std.
(5.06) (5.42) (7.95) (7.23) (10.12) (9.04) (13.74) (15.18) (15.91) (22.42) (27.48)

0.73 0.80 1.20 1.00 1.50 1.35 2.10 2.30 2.40 3.35 4.10
M8 x 1
(5.28) (5.78) (8.67) (7.23) (10.84) (9.76) (15.18) (16.63) (17.35) (24.23) (29.65)

1.35 1.40 2.20 1.90 2.70 2.35 3.70 4.20 4.40 6.20 7.20
M10 x Std.
(9.76) (10.12) (15.91) (13.74) (19.52) (19.99) (26.76) (30.37) (31.18) (44.84) (52.07)

1.50 1.60 2.50 2.10 3.10 2.80 4.30 4.90 5.00 7.00 8.40
M10 x 1
(10.84) (11.57) (18.08) (15.18) (22.42) (20.25) (31.10) (35.44) (36.16) (50.63) (60.75)

2.40 2.50 3.70 3.30 4.70 4.20 6.30 7.20 7.50 10.50 12.50
M12 x Std.
(17.35) (18.08) (26.76) (23.86) (33.99) (30.37) (45.56) (52.07) (54.24) (75.94) (90.41)

2.55 2.70 4.00 3.50 5.00 4.50 6.80 7.70 8.00 11.20 13.40
M12 x 1.5
(18.44) (19.52) (28.93) (25.31) (36.16) (32.54) (49.18) (55.69) (57.86) (81.00) (96.92)

3.70 3.90 6.00 5.20 7.50 7.00 10.00 11.50 12.00 17.00 20.00
M14 x Std.
(26.76) (28.20) (13.23) (37.61) (54.24) (50.63) (72.33) (83.17) (86.79) (122.96) (144.66)

4.10 4.30 6.60 5.70 8.30 7.50 11.10 12.50 13.00 18.50 22.00
M14 x 1.5
(29.65) (31.10) (47.73) (41.22) (60.03) (54.24) (80.28) (90.41) (94.02) (11.26) (158.12)

5.60 6.00 9.00 8.00 11.50 10.50 15.50 17.90 18.50 26.00 31.00
M16 x Std.
(40.50) (43.39) (65.09) (57.86) (83.17) (75.94) (112.11) (129.47) (133.81) (188.05) (224.22)

6.20 6.50 9.70 8.60 12.50 11.30 17.00 19.50 20.00 28.00 35.50
M16 x 1.5
(44.84) (47.01) (70.16) (62.20) (90.41) (81.73) (122.96) (141.04) (144.66) (202.52) (256.77)

7.80 8.30 12.50 11.00 16.00 14.50 21.00 27.50 28.50 41.00 43.00
M18 x Std.
(56.41) (60.03) (90.41) (79.56) (115.72) (104.87) (151.89) (198.90) (206.14) (296.55) (311.01)

9.10 9.50 14.40 12.50 18.50 16.70 24.50 27.50 28.50 41.00 49.00
M18 x 1.5
(65.82) (68.71) (104.15) (90.41) (133.81) (120.79) (177.20) (198.90) (206.14) (296.55) (354.41)

11.50 12.00 20.50 18.00 25.00 22.50 35.00 39.50 41.00 58.00 68.00
M20 x Std.
(83.17) (86.79) (148.27) (130.19) (180.82) (162.74) (253.15) (285.70) (296.55) (419.51) (491.84)

12.80 13.50 20.50 18.00 25.00 22.50 35.00 39.50 41.00 58.00 68.00
M20 x 1.5
(92.58) (97.64) (148.27) (130.19) (180.82) (162.74) (253.15) (285.70) (296.55) (419.51) (491.84)

M22 x Std. 15.50 16.00 24.50 21.00 30.00 26.00 42.00 46.00 49.00 67.00 75.00
(112.11) (115.72) (177.20) (151.89) (216.99) (188.05) (303.78) (332.71) (354.41) (484.61) (542.47)

17.00 18.50 28.00 24.00 34.00 29.00 47.00 52.00 56.00 75.00 85.00
M22 x 1.5
(122.96) (133.81) (202.52) (173.59) (245.92) (209.75) (339.95) (44.76) (405.04) (542.47) (614.80)

20.50 21.50 33.00 27.00 40.00 34.00 55.00 58.00 63.00 82.00 92.00
M24 x Std.
(148.27) (155.50) (238.68) (195.29) (289.32) (245.92) (397.81) (419.51) (455.67) (593.10) (655.43)

23.00 35.00 37.00 31.00 45.00 38.00 61.00 67.00 74.00 93.00 103.00
M24 x 1.5
(166.35) (253.15) (267.62) (224.22) (325.48) (202.52) (441.21) (484.61) (535.24) (672.66) (744.99)

Standard Torque S0309000

Page 3
TORQUE VALUES FOR STANDARD U.S. FASTENERS
S.A.E. BOLT HEAD
TYPE DESCRIPTION
GRADE MARKING

WILL HAVE NO MARKINGS IN THE CENTER OF THE HEAD.

1 1 OR 2
Low or Medium Carbon Steel Not Heat Treated.

WILL HAVE THREE RADIAL LINES.

5 5
Quenched and Tempered Medium Carbon Steel.

WILL HAVE 6 RADIAL LINES.

8 8
Quenched and Tempered Special Carbon or Alloy Steel.

Recommended torque, in foot pounds, for all Standard Application Nuts and Bolts, provided:
1. All thread surfaces are clean and lubricated with SAE-30 engine oil. (See Note.)
2. Joints are rigid, that is, no gaskets or compressible materials are used.
3. When reusing nuts or bolts, use minimum torque values.
NOTE: Multiply the standard torque by:
0.65 when finished jam nuts are used.
0.70 when Molykote, white lead or similar mixtures are used as lubricants.
0.75 when parkerized bolts or nuts are used.
0.85 when cadmium plated bolts or nuts and zinc bolts w/waxed zinc nuts are used.
0.90 when hardened surfaces are used under the nut or bolt head.
NOTE: When reusing bolts and nuts in service, use minimum torque values.

S0309000 Standard Torque

Page 4
The following General Torque Values must be used in all cases where SPECIAL TORQUE VALUES are not
given
NOTE: TORQUE VALUES LISTED THROUGHOUT THIS MANUAL ARE LUBRICATED (WET)
THREADS; VALUES SHOULD BE INCREASED 1/3 FOR NONLUBRICATED (DRY)
THREADS.
HEAT TREATED MATERIAL GRADE 5 AND GRADE 8
GRADE 5 GRADE 8
THREAD SIZE (3 RADIAL DASHES ON HEAD) (6 RADIAL DASHES ON HEAD)
FOOT POUNDS NEWTON FOOT POUNDS NEWTON
(ft lb) METER (N•m) (ft lb) METER (N•m)
1/4" - 20 6 8 9 12
1/4" - 28 7 9 11 15
5/16" - 18 13 18 18 24
5/16" - 24 15 20 21 28
3/8" - 16 24 33 34 46
3/8" - 24 27 37 38 52
7/16" - 14 38 52 54 73
7/16" - 20 42 57 60 81
1/2" - 13 58 79 82 111
1/2" - 20 65 88 90 122
9/16" - 12 84 114 120 163
9/16" - 18 93 126 132 179
5/8" - 11 115 156 165 224
5/8" - 18 130 176 185 251
3/4" - 10 205 278 290 393
3/4" - 16 240 312 320 434
7/8" - 9 305 414 455 617
7/8" - 14 334 454 515 698
1" - 8 455 617 695 942
1" - 14 510 691 785 1064
1 1/8" - 7 610 827 990 1342
1 1/8" - 12 685 929 1110 1505
1 1/4" - 7 860 1166 1400 1898
1 1/4" - 12 955 1295 1550 2102
1 3/8" - 6 1130 1532 1830 2481
1 3/8" - 12 1290 1749 2085 2827
1 1/2" - 6 1400 2034 2430 3295
1 1/2" - 12 1690 2291 2730 3701
1 3/4" - 5 2370 3213 3810 5166
2" - 4 1/2 3550 4813 5760 7810
NOTE: If any bolts and nuts are found loose or at values less than what the chart states, it is
recommended that the loose bolt and/or nut be replaced with a new one.
Standard Torque S0309000
Page 5
TYPE 8 PHOSPHATE COATED HARDWARE
This chart provides tightening torque for general purpose applications using original equipment standard
hardware as listed in the Parts Manual for the machine involved. DO NOT SUBSTITUTE. In most cases,
original equipment standard hardware is defined as Type 8, coarse thread bolts and nuts and thru hardened
flat washers (Rockwell "C" 38 - 45), all phosphate coated and assembled without supplemental lubrication (as
received) condition.

The torques shown below also apply to the following:

1. Phosphate coated bolts used in tapped holes in steel or gray iron.
2. Phosphate coated bolts used with phosphate coated prevailing torque nuts (nuts with distorted threads or
plastic inserts).
3. Phosphate coated bolts used with copper plated weld nuts.

Markings on bolt heads or nuts indicate material grade ONLY and are NOT to be used to determine required
torque.
STANDARD TORQUE ±10%
NOMINAL THREAD
KILOGRAM METER FOOT POUNDS
DIAMETER
(kg•m) (ft lb)
1/4" 1.1 8
5/16" 2.2 16
3/8" 3.9 28
7/16" 6.2 45
1/2" 9.7 70
9/16" 13.8 100
5/8" 19.4 140
3/4" 33.2 240
7/8" 53.9 390
1" 80.2 580
1 - 1/8" 113.4 820
1 - 1/4" 160.4 1160
1 - 3/8" 210.2 1520
1 - 1/2" 279.4 2020
1 - 3/4" 347.1 2510
2 522.8 3780

S0309000 Standard Torque

Page 6
TORQUE VALUES FOR HOSE CLAMPS
The following chart provides the tightening torques for hose clamps used in all rubber applications (radiator,
air cleaner, operating lever boots, hydraulic system, etc.).

TORQUE
RADIATOR, AIR CLEANER,
HYDRAULIC SYSTEM
BOOTS, ETC.
CLAMP TYPE AND SIZE
KILOGRAM KILOGRAM
INCH POUNDS INCH POUNDS
METER METER
(in lb) (in lb)
(kg•m) (kg•m)
"T" Bolt (Any Diameter) 0.68 - 0.72 59 - 63 ------- ------

Worm Drive - Under 0.2 - 0.3 20 - 30 0.5 - 0.6 40 - 50

44 mm (1-3/4 in) Open
Diameter

Worm Drive - Over 44 mm 0.5 - 0.6 40 - 50 ------- ------

(1-3/4 in) Open Diameter

Worm Drive - All "Ultra- 0.6 - 0.7 50 - 60 0.5 - 0.6 40 - 50

Tite"

Standard Torque S0309000

Page 7
TORQUE VALUES FOR SPLIT FLANGES
The following chart provides the tightening torques for split flange connections used in hydraulic systems.
Split flanges and fitting shoulders should fit squarely. Install all bolts, finger tight and then torque evenly.

NOTE: Over torquing bolts will damage the flanges and/or bolts, which may cause leakage.

BOLT TORQUE
FLANGE BOLT
KILOGRAM METER INCH POUNDS
SIZE (*) SIZE
(kg•m) (in lb)
1/2" 5/16" 2.1 - 2.5 15 - 18
3/4" 3/8" 3.0 - 3.7 22 - 27
1" 3/8" 3.7 - 4.8 27 - 35
1 - 1/4" 7/16" 4.8 - 6.2 35 - 45
1 - 1/2" 1/2" 6.4 - 8.0 46 - 58
2" 1/2" 7.6 - 9.0 55 - 65
2 - 1/2" 1/2" 10.9 - 12.6 79 - 91
3" 5/8" 19.1 - 20.7 138 - 150
3 - 1/2" 5/8" 16.2 - 18.4 117 - 133

(*) - Inside diameter of flange on end of hydraulic tube or hose fitting.

NOTE: Values stated in chart are for Standard Pressure Series (Code 61) Split Flanges.

S0309000 Standard Torque

Page 8
TORQUE WRENCH EXTENSION TOOLS
Very large diameter, high grade fasteners (nuts, bolts, cap screws, etc.) require a great deal of turning force to
achieve recommended tightening torque values.
Common problems that could occur as a result are:
• Recommended torque exceeds the measuring capacity of the torque wrench.
• Specialized sockets do not fit the adapter on the front end (nose) of the torque wrench.
• Generating adequate force on the back end (handle) of the wrench is difficult or impossible.
• Restricted access or an obstruction may make use of the torque wrench impossible.
• A unique application requires fabrication of an adapter or other special extension.
Most standard torque wrenches can be adapted to suit any one of the proceeding needs or situations, if the
right extension tool is used or fabricated.

TORQUE MULTIPLICATION
A wrench extension tool can be used to increase the
tightening force on a high capacity nut or bolt.
For example, doubling the distance between the bolt
and the back (handle) end of the torque wrench
doubles the tightening force on the bolt.
It also halves the indicated reading on the scale or
dial of the torque wrench. To accurately adjust or
convert indicated scale or dial readings, use the
following formula:
I = A x T / A + B where:
I = Indicated force shown on the torque wrench scale or dial.
T = Tightening force applied to the nut or bolt (actual Torque).
A = Length of the torque wrench (between the center of the nut or bolt and the center of the handle).
B = Length of the extension.
As an example, if a 12" extension is added to a 12" torque wrench, and the indicated torque on the dial reads
"150 ft lb," the real force applied to the bolt is 300 ft lb:

NOTE: The formula assumes that there is no added deflection or "give" in the joint between the extension
and torque wrench. Readings may also be inaccurate:
• If the extension itself absorbs some of the tightening force and starts to bend or bow out.
• If an extension has to be fabricated that is not perfectly straight (for example, an extension made to go
around an obstruction, to allow access to a difficult to tighten fastener), the materials and methods used
must be solid enough to transmit full tightening torque.
Standard Torque S0309000
Page 9
OTHER USES FOR TORQUE WRENCH EXTENSION TOOLS
Torque wrench extensions are sometimes made up for reasons other than increasing leverage on a fastener.
For example, a torque wrench and extension can be used to measure adjustment "tightness" of a linkage or
assembly. Specially fabricated extensions can be used to make very precise checks of the force required to
engage or disengage a clutch mechanism, release a spring-applied brake assembly, or "take up" free play in
most any movable linkage.
Once the value of the adjustment force is established, repeated checks at regular intervals can help to
monitor and maintain peak operating efficiency. These types of adjustment checks are especially useful if
physical measurements of linkage travel are difficult to make or will not provide the needed degree of
precision and accuracy.
To allow the assembly or mechanism to accept a torque wrench, welding a nut or other adapter on the end of
a linkage shaft or other leverage point will allow turning the shaft or assembly manually.

TIGHTENING TORQUE SPECIFICATIONS (METRIC)

(For coated threads, prelubricated assemblies.)

CAUTION!
Disassembly, overhaul and replacement of components on the machine, installation of new or
replacement parts and/or other service-related maintenance may require the use of thread or flange
sealing assembly compound.
Use the information on this page as a general guide in selecting specific formulas that will meet the
particular requirements of individual assembly installations. DISD does not specifically endorse a
specific manufacturer or brand name but the following table of "Loctite" applications is included for
which cross-references to other makers’ products should also be widely available.

IMPORTANT
Use primer "T" or "N" for all cold weather assembly of fastener adhesives, with Thread locker
sealers 222, 242/243, 262, 271, 272, or 277.

S0309000 Standard Torque

Page 10
I. "Loctite" Fastener Adhesives
Break-away
Cure Strength
Product Application Color Removal
(in lb) of Sealer
Alone
Low strength for 6 mm (1/4") or smaller
222 Purple Hand tools 45
fasteners.
242 or Medium strength for 6 mm (1/4") and
Blue Hand tools 80
243 larger fasteners.
Heat/260°C (500°F)
High strength for high grade fasteners
262 Red Remove HOT 160
subject to shock, stress and vibration.
(NO solvent)
Extra high strength for fine thread Heat/260°C (500°F)
271 Red 160
fasteners up to 25 mm (1") diameter. Remove HOT
High temperature/high strength for Heat/316°C (600°F)
272 Red 180
hostile environments to 232°C (450°F). Remove HOT
Extra high strength for coarse thread
Heat/260°C (500°F)
277 fasteners 25 mm (1") diameter and Red 210
Remove HOT
larger.

II. "Loctite" Pipe Thread Sealant

Product Application Color Removal Required Setup
"No-filler/non-clog" formula for high-pressure 4 Hours (or 1/2 hour
Hand
545 hydraulic systems. Over-application will not Purple with Locquic "T"
tools
restrict or foul system components. Primer)
Solvent-resistant, higher viscosity tapered 4 Hours (or 1/2 hour
Hand
656 thread sealer. White with Locquic "T"
tools
Primer)

III. "Loctite" gasket/flange sealer

Product Application Color Notes
Gasket eliminator specifically made for Use Locquic "N" primer for fast (1/2
518 aluminum flanges/surfaces. For hydraulic Red - 4 hours) setup. Unprimed setup 4 -
systems to 34,475 kPa (5,000 psi). 24 hours.
Low pressure/wide-gap gasket eliminator Use Locquic "N" primer for faster
504 compound. Fills gaps to 0.0012 mm (0.030"), Orange (1/2 - 4 hours) setup. Unprimed
cures to rigid seal. setup 4 - 24 hours.
General purpose, fast setup, flexible-cure Use Locquic "N" primer for faster
515 gasket eliminator. For nonrigid assemblies Purple (1/4 - 2 hours) setup.
subject to shock, vibration or deflection. Unprimed setup 1 - 12 hours.

Standard Torque S0309000

Page 11
IV. "Loctite" retaining compounds
Product Application Color Notes
For bushings, sleeves, press-fit bearings, Use Locquic "N" primer for increased
609 splines and collars. For gaps to 0.0002 mm Green bond strength and all cold
(0.005"), temperatures to 121°C (250°F). temperature applications.
620 For high temperatures to 232°C (450°F). Green Same as 609, above.
For high strength bonds and tight clearance Same as 609, above.
680 Green
gaps, to 0.00008 mm (0.002").

V. "Loctite" Adhesives
Product Application Color Notes
Black Max instant adhesive for shock and May take 120 hours to reach full cure
380 Black
vibration-resistant bonds. strength.
454 Adhesive for porous surfaces. Clear Full strength in 24 hours.
Increased strength (+50%), shock and Full strength in 24 hours.
480 Black
vibration-resistant.

S0309000 Standard Torque

Page 12
1UPPER STRUCTURE
 SP002360

1COUNTERWEIGHT
SD 200

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual or
those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

MODEL SERIAL NUMBER RANGE

SD200 1001 and Up
SD300 1001 and Up

Copyright 2011 DISD

July 2011

Counterweight SP002360
Page 1
TABLE OF CONTENTS
Specifications ......................................................................................................... 3
Counterweight ........................................................................................................ 3

SP002360 Counterweight
Page 2
Specifications
NOTE: weight

Model Weight Serial Number Range

SD200 800 kg (1,764 lb) 1001 and Up

SD300 1568 kg (3,457 lb) 1001 and Up
SD300(Long Boom) 1848 kg (4,074 lb) 1001 and Up

Counterweight
1. Parts list

4 1 6

3
2

Figure 1

Reference Reference
Description Description
Number Number
1 COUNTERWEIGHT 5 COVER(R,H)
2 BOLT 6 COVER(L,H)
3 WASHER;HARDEN 7 LOCK
4 PIN

Counterweight SP002360
Page 3
 2. TORQUE

BOLT

Fig.2

NOTE: 1) Tighten bolt to torque value list in the following table.

SD200 100kg·m (726 ft lb)

SD300 100kg·m (726 ft lb)

SP002360 Counterweight
Page 4
 SP002361

HYDRAULIC OIL TANK

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual or
those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

MODEL SERIAL NUMBER RANGE

SD200 1001 and Up

Copyright 2011 DISD

July 2011

Hydraulic Oil Tank SP002361

Page 1
TABLE OF CONTENTS
General Description....................................................................................................... 3
Parts List................................................................................................................. 3
Specifications................................................................................................................. 4

SP002361 Hydraulic Oil Tank

Page 2
GENERAL DESCRIPTION
Parts list

Figure 1

Reference Number Description Reference Number Description

01 Oil Tank 08 Cover

02 Adapter 09 Air Breather

03 Return Pipe 10 Spring

04 Return Filter 11 Air Breather

05 Rubber 12 Level Gauge

06 O Ring 13 Adapter

07 Spring

Hydraulic Oil Tank SP002361

Page 3
Specifications
SD200

TYPE Pressure seal

Capacity (system0 128 L

Air breather

Starting pressure 0.035 MPa

Return filter

Filter accuracy 12μ

Pressure descending 0.045 MPa @800L/min

SP002361 Hydraulic Oil Tank

Page 4
1LOWER STRUCTURE AND CHASSIS
 SP002362

1CENTER JOINT
(ARTICULATION JOINT)
SD 200

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual or
those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

MODEL SERIAL NUMBER RANGE

SD200 1001 and Up

Copyright 2011 DISD

July 2011

Center Joint (Articulation Joint) SP002362

Page 1
TABLE OF CONTENTS
General Description ..................................................................................................... 3
Maintenance Standard ........................................................................................... 4

SP002362 Center Joint (Articulation Joint)

Page 2
General Description
The loader frame is an articulated type: the front frame is joined to the rear frame with two hinge pins around
which the loader pivots for steering.

CAUTION!
When the loader is steered, the area near center
hinge pins becomes so narrow that you may get
caught between front and rear frames. Before
trying to service the loader, make sure to set
frame lock plate.
Prior to moving (traveling) the loader, make sure
Figure 1
the frame lock plate is set to original position.

Center Joint (Articulation Joint) SP002362

Page 3
Maintenance Standard

(UPPER HINGE BEARING) (LOWER HINGE BEARING)

Figure 2

SP002362 Center Joint (Articulation Joint)

Page 4
UNIT :mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between upper size Clearance limit
1
hinge pin and front frame 0 +0.046
60 0-0.065 -
-0.019 0
Clearance between upper 0 0 -0.015-0.01
2 60 -
hinge pin and bearing -0.019 -0.015 9
Clearance between 0 0 -0.035-0.01
3 90 -
bearing and rear frame -0.015 -0.035 5
Clearance between lower 0 +0.046
4 66 0-0.12 -
hinge pin and front frame -0.074 0
Clearance between lower 0 +0.414
5 60 0.34-0.433 -
hinge pin and spacer -0.019 +0.34 Replace

Clearance between lower 0 0 -0.015-0.01

6 60 -
hinge pin and bearing -0.019 -0.015 9
Clearance between lower 0 0 -0.035-0.01
7 hinge bearing and rear 90 -
-0.015 -0.035 5
frame
Shim thickness for lower
8 hinge and cap 0.5~1.0 - - - -
(rear frame)
Shim thickness for upper
9 hinge and cap 0.5~1.0 - - - -
(rear frame)
Tightening torque of lower
10 hinge cap mounting bolt Final value: 9±1.0 kg·m
(M12)
Tightening torque of lower
11 hinge cap mounting bolt Final value: 9±1.0 kg·m
(M16) Retighten

Tightening torque of lower When adjusting with shim: 6~7 kg·m

12
hinge pin mounting bolt Final value: 9±1.0 kg·m

Tightening torque of upper

13 Final value: 9±1.0 kg·m
hinge cap mounting bolt

Center Joint (Articulation Joint) SP002362

Page 5
SP002362 Center Joint (Articulation Joint)
Page 6
1ENGINE AND DRIVING TRAIN
 SP002530

3ton Diesel Engine

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual or
those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

MODEL SERIAL NUMBER RANGE

SD200 1001 and Up

Copyright 2011 DISD

July 2011

3ton Diesel Engine SP002530

Page 1
TABLE OF CONTENTS
Description of the Illustration Marks…………………………………………………3
Usage Instruction………………………………………………………………….4
Guide for Maintenance of Diesel Engine………………………………7
Maintenance Contents of Diesel Engine……………………………………………11
The Main System Flow Chart of Engine…………………………………………19
Tightening torque and tightening method of High Strength bolts…………25
Fuel, Oil, Coolant and Auxiliary Materials……………………………………….31
Electric System…………………………………………………………………….33
Adjustment and Replacement of Main Components………………………35
Typical Troubles and Remedy of Diesel Engine…………………………………..57

SP002530 3ton Diesel Engine

Page 2
DESCRIPTION OF THE ILLUSTRATION MARKS
Dismounting
Oil coating
(assembly parts)

Special tools, such as

Fitting
K --- ---, KUKKO, --- ---,
(assembly parts)
TS --- ---W
Marking
Pay attention to assembly
(do before disassemble, adjust
direction
when assemble)

Filling- full charge (such as

Deflating
lubricating oil, cooling water etc.)

Unloosing
Draining off (lubricating oil or
(such as: unloose clamping
cooling water)
equipment)
Clamping
(loose-proof-fixed) Coat fluid
(such as: reinforcing clamp
sealant
equipment)
Inspecting-adjusting (such
Accident preventing (marks for as: tightening torque,
dangerous occasion) dimension pressure and
clearance)
Replacement
Inspecting
when reassembly

3ton Diesel Engine SP002530

Page 3
USAGE INSTRUCTION
OPERATING NOTICE FOR NEW DIESEL ENGINE
During the first 60th, the speed of diesel engine for construction machinery and tactor is limited to work an
partial load (fuel throttle is at 3/4 position).
During the first 2000km (about 60h), the speed of diesel engine for vehicle is limited to not exceed 80% of
the rated speed.
After a running-in period in the first use, the oil in new diesel engine should be replaced, If not, the parts of
diesel engine could be worn out or damaged, The correct maintenance will make diesel engine better in
performance, more economic running and longer in service life.
Oil-pressure gauge, temperature gauge, warning indicating lights and other instruments shall be checked
every day for their normal function.
Daily inspection and maintenance should be done according to this instruction.

UNSEALING DIESEL ENGINE

After you have unpacked your diesel, firstly you should check diesel engine and the accessories with it and
inspect if diesel engine is damaged, and then you begin to do the followings:
Clean the antirust coat and anti-corrosive agent on parts close to the air.
Drain off the oil in oil seals inside fuel filter and parts in fuel system (Start-up is also permitted without
draining off the oil-seal’s oil in fuel system, but diesel engine may not run under full load until the oil-seal’s oil
is used up and normally replenished by diesel engine).
Turn the wheel and spray in the air inlet valve with solvent until the oil-seal’s oil id driven out.
Spray in the exhaust port of turbocharger with solvent until the oil-seal’s oil is driven out.
According to the agreement between the manufacturer and the user, fill oil in the empty oil sump as per
specifications.
According to the agreement between the manufacturer and the user, check the performance of coolant that
has been filled up, if needed. The usable coolant must be under the conditions of temperature -30°or-
50°，Ph value7-8(neutral), general hardness value 5-15° d[9-27°f(hardness)]. If the coolant cannot meet the
above-mentioned requirements, drain off it and new coolant with antifreezing agent.

MOUNTING AND POSITIONING OF DIESEL ENGINE

Hoisting, mounting and positioning of diesel engine shall be done in accordance with diesel engine operation
manual.

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Page 4
PREPARATION BEFORE START-UP
Add coolant.
Add oil.
Add fuel.

START-UP OF DIESEL ENGINE

Put the power switch and key in the starting position.
Place the gear shift lever in the neutral position.
Step on the clutch pedal and accelerator pedal, then pull the handle of excessive fuel device (if available),
and operate the starter. After start-up of diesel engine, return the handle of excessive fuel device to its
original position, If diesel engine cannot be started, wait for about one minute and repeat the above
operation. The pressure value is shown value is shown at once on the oil manometer after start-up of the
engine, In heat starting of the engine, it is unnecessary to use the excessive fuel device.
Start-up in low-temperature.
Flame-preheat starting device with electronic control.
When the water temperature of the engine is below -23°C，open the key switch and the preheating
indicating light on lighting, the electro-heat plug is heated through electricity, and for 50 seconds, the preheat
indicating light twinkles automatically. After the electro-heat plug has been heated to 850°C -950°C, Press
the starting button and switch on the starter, So the fuel way automatically opened by the electromagnetic
valve, through which the electro-heat plug can be supplied with fuel so as so start the engine at -25°
smoothly with the flame preheat starting device.

RUNNING OF DIESEL ENGINE

When the engine running at the speed lower than the speed of the biggest torque, it is not allowed to
continue running on full load over 1 min.
After running on full load, the engine should run in idling speed for 3-5minutes before stopped.
Often watch and check the oil pressure gauge and coolant temperature meter, Stop the engine if the
pressure and temperature cannot meet the standard requirement.
NOTE: Diesel engine can not continue to run when the coolant temperature is lower than 60°C or higher
than 100°C, because this would damage the engine.

Engine’s running stop

The oil pressure gauge and the coolant thermometer shall often be watched. If the pressure and temperature
do not conform to the specified values, diesel engine should be stopped.
NOTE: The Engine should run in idling speed for 1-2 minutes before stopped.

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Page 5
SP002530 3ton Diesel Engine
Page 6
GUIDE FOR MAINTENANCE OF DIESEL ENGINE
DAILY MAINTENANCE
Inspection
1. Check the oil level;
2. Check the coolant level;
3. Check whether the fan id damaged;
4. Check whether the V-belt is cracked or scratched;
5. Check whether the accessories are fixed well;
6. Check whether the water or oil is leaking;
7. Check whether the charging indicator light is in order.

PERIODIC MAINTENANCE
Regular maintenance can be conduct on as per the following table. If the operating condition is heavy dust
content or engine running on started-stopped frequently, the regular maintenance period should be
shortened accordingly.

Maintenance Period:
Period Running hours(h) Running Kilometer
The first inspection 30-50 1500-2000
Periodical inspection Every 250 10,000
Maintenance I(WD1) Every 500 20,000
Maintenance2(WD2) Every 1000 40,000
Maintenance 3(WD3) Every 2000 80,000
Maintenance4(WD4) Every 4000 160,000

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Page 7
Maintenance Items:

Items Replacement Adjustment Inspection

Oil Tighten pipe clamps.
First checking Valve clearance
Oil filter Tighten V-belts.

Oil
Routine checking Tighten V-belts.
Oil filter

Air filter.
Oil
Air intake system.
Oil filter
Level 1 maintenance Valve clearance
Tighten pipe clamps.
Fuel filter
Tighten V-belts.

Air filter.
Oil
Air intake system.
Oil filter
Level 2 maintenance Valve clearance
Tighten pipe clamps.
Fuel filter
Tighten v-belts.

Air filter.
Oil
Air intake system.
Oil filter
Tighten pipe clamps.
Fuel filter
Level 3 maintenance Valve clearance
Tighten V-belts.
Coolant
Inspect and adjust the injection fuel
Air filter
pump on test bench.

Air intake system.

Tighten pipe clamps.
Oil
Oil filter Tighten V-belt.

Fuel filter Check the bearing clearance of

Level 4 maintenance Valve clearance
Coolant turbocharger.

Air filter Inspect and adjust the Injection fuel

pump on test bench.

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Page 8
MAINTENANCE RECORD
Engine number Model
User Equipment

Running Kilometers/
Date Actual Kilometers Maintenance contents Operator Remark
hours or interval hours

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Page 9
SP002530 3ton Diesel Engine
Page 10
MAINTENANCE CONTENTS OF DIESEL ENGINE
DAILY MAINTENANCE
Preventive maintenance should be done everyday in order
to understand the engine’s condition.
Before starting the engine should check the oil level and
coolant level.
Inspect：
y Leakage
y Fast wearing parts
y Any unconventionality

Inspect the oil level height

When the oil level is lower than the lower limit or higher
than the upper limit, it is not allowed to start the engine.
After the engine stopped, inspect the oil level at least 5
minutes later in order to ensure the oil can flow back to the
oil sump.
The oil-volume values from the low scale mark to the high
scale mark are respectively 3.25 liter (3-cylinder engine), 5
liter (4-cylinder engine) and 6liter (6-cylinder engine).

Inspect the coolant level

Inspect the coolant level through the vitreous view hole，if
the coolant is not sufficient，open the inlet cover and fill
into the coolant.
NOTE: When opening the inlet cover，must press down
the exhaust button firstly to prevent hot coolant
from injuring people.

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Inspect the fan
Check whether the plastic fan is distorted. For steel
fan，check whether the rivet loosened and the vane is
curved to ensure reliable running.

Inspect the V-belts

Inspect the V-belts with your eyes to find if there is any
crack or scratch on the V-belts．Replace them if
necessary.

MAINTENANCE CONTENTS AT INTERVALS OF

250H (OR RUNNING MILEAGE 10,000KM)
The following contents will be added except daily
maintenance items:

Replace the oil and oil filter.

The oil will be polluted after using，the pollution contents
is of accordance with the consumption of fuel and oil．
NOTE: The replacement period of oil under proper
using condition cannot beyond 250h
(10,000Kilometers).

Replace the oil and oil filter to clean the impurities

containing in oil.
NOTE: The oil should be drained off when it is hot．

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Page 12
Dismantle draining plug screw; prepare to collect the oil of
7.25L, 9.25L and 13L respectively to 3-cylinder, 4 cylinder
and 6cylinder engines.

Note: Hot oil can injure people.

Tool: The special wrench forfilter.

Clean the end surrounding of the filter, and remove
it.

Install the new oil filter.

NOTE: Adjust the seal ring and smear some lubricating oil
on it while fitting the oil filter.

Check and clean the screw thread and seal ring，and then
install the whorl plug.
TOOL: 19mm open-ended wrench.

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Page 13
Fill the cleaned oil into diesel engine and let it reach the
upper scale mark of dipstick, The capacity of oil sump is
7.25L, 9.25L or 13L respectively to 3-cylinder, 4cylinder or
6 cylinder engine.
Note: For 3ton diesel engine CD 15W/40 grade oil must be
used.

Run the engine at idling speed and check the filter to find
whether it leaks or not．
Stop the engine and make the oil run into the sump from
the upper parts 5 minutes later，then check the oil
level，fill oil up to the upper limit if necessary．

Check and adjust the valve clearance.

Disassemble 6 cylinder head covers.
TOOL: 13mm sleeve wrench

Turn diesel engine slowly, make the upper scale mark on

flywheel housing align the OT scale mark on flywheel, and
at this time, let the piston of the first cylinder be located in
the top dead center in the compression stroke (intake and
exhaust valves of Cylinder 1 closed)

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Page 14
The clearance of intake valve is 0.20mm
The clearance of exhaust valve is 0.30 mm
Note: When check the clearance of valve, the engine
should be at the Cool condition-its temperature is
less than 60D°C. When the clearance guage glides
between the top of valve rod and rocker arm and
can be felt retarded and sticky, the measuring result
is proper.
TOOL: Clearance gauge.

The piston of 1st cylinder is at TDC of the compression

stroke.
At this time, adjust the 1st, 2nd, 3rd, 6th, 7th and 10th of 6-
cylinder engine (from crankshaft pulley end).Adjust the
clearance by using the feeler and tighten the lock nuts of
the rock arm. Recheck the valve clearance till it is qualified.

Check and adjust the valve clearance as step A (I-air

intake Valve E-air exhaust valve)
Adjust the clearance by guage and tighten the fixing nut of
rocker arm, re-check the clearance till it meets the
requirement.
TOOL ： 6# screwdriver and 14mm double offset ring
wrench．

Next, turn the crankshaft to 360°C; or mark on the shock

absorber, and then turn it to 360°C. At this time, adjust the
4th, 5th, 7th and 8th valve clearances of the 4-cylinder
engine and 4 the, 5th, 8th, 9th, 11th and 12th of the 6-
cylinder engine (counted from the crankshaft pulley end).
Loosen the lock pinch nut of the rock arm, adjust it by
using the feeler and tighten it well.

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Page 15
Adjust the valve clearance as step B.
Loosen the fixing nut of rocker arm, adjust the clearance
by guage then tighten the nut again.

Install the gasket and cylinder head cover.

The tightening torque of bolt is 10-15N·m.

Check the tension of V-belts.

Measure the flexibility in the max. span of poly V-belt.
Generally, under the pressure of 4-5kgf, the belt flexibility
is less than 20mm.

8mm inner-hexagon spanner and 16mm open-ended

wrench.
If the flexibility is over 20mm, the poly V-belt is shown
loose, Unscrew the tensioning bolt and the lock nut,
retension the V-belt, and then tighten the tensioning bolt
and the lock nut.

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Page 16
Check the rubber hose in the cooling pipeline for its aged
and cracked situation, and check the hose clamps for its
loosing. Fasten or change the related parts, if necessary,
to ensure the seal Performance.

ADD THE FOLLOWING MAINTENANCE

CONTENTS EVERY 500H(20,000 KILOMETERS)
Replace the fuel filter.
Special spanner for filter.
Clean the fuel filter around the head and take down it.

Mount a new fuel filter.

Release the air out of the low-pressure fuel passage and

the fuel filter.
Unscrew the fuel-draining screw fixed in the fuel inlet of
injection pump.
Press on the plunger of fuel transfer pump until no air
exists in diesel fuel that flows out of the fuel-draining
screw; and then tighten up the fuel-draining screw.

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Page 17
Check the air filter element
In diesel engine, the allowable max inlet resistance is
5KPa and it must be inspected when the engine works at
rated speed and full load. If this resistance reaches the
maximum permissible limited value, the filter element shall
be cleaned or replaced according to the requirements of
manufacturer.
Caution: Never operate the engine in any case of no air 1. Paper filtering element
filter otherwise the dust and impurities will come 2. Blanketry safety filtering element
into diesel engine and result

Take down the filter element from the air filter, clap it at
end lightly and make dust on it fall down. Alternatively,
blow it inversely with compressed air (from inner to out).
Note: Don’t blow off the air filtering paper.
Don’t clean the air filtering paper by water and oil.
Don’t beat the core forcibly.

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Page 18
THE MAIN SYSTEM FLOW CHART OF ENGINE
● Lubricating system;
● Cooling system:
● Intake and exhaust system;
● Fuel supplying system;
To understand the main system flow chart of the engine will give help to you for operating and maintaining
the engine．

Lubricating System
1. Strainer
2. Oil pump
3. Oil filter
4. Filter seat
5. Relief valve
6. Safety valve of oil pump
7. Main oil passage
8. Pressure limiting valve

Lubricating for main moving parts

1. The oil flowing from the oil cooler
2. Main oil passage
3. Oil to the main crankshaft journal

4. Connecting rod journal

5. The main journal of crankshaft
6. Oil to connecting rod beating

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Page 19
7. The branch oil passage passing to main Dearing
8. Sub-passage of oil
9. Oil injection nozzle to Cool piston
10. Camshaft beating

11. Lubricating air compressor with oil from main oil

passage.

12. Lubricating fuel injection pump with oil from secondary

oil passage.

13. Lubricating two-stage balancing mechanism with oil

from main oil passage.

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Page 20
Lubricating for rocker arm system
1. Oil flowing from the oil branch passage
2. Tappet oil hole
3. Push rod oil hole
4. Oil hole of rocker arm bolt
5. Oil hole of rocker arm

Lubricating turbocharger
1. Oil from the main oil passage
2. Oil inlet of turbocharger
3. The oil outlet of turbocharger

Cooling System
1. Water pump inlet
2. Water pump
3. Water jacket of cylinder block
4. Oil cooler

1. Water jacket of cylinder block

2. Cooling water flowing from water jacket of cylinder block
3. Cylinder head gasket
4. Cooling water passing through the water passage of
cylinder head
5. Cooling water outlet

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Page 21
1. Coolant flowing from cylinder block
2. Thermostat
3. Bypass valve
4. Coolant flowing into water pump
5. Bypass valve closed
6. Coolant flowing into the radiator

Intake and Exhaust System

1. Air cleaned through air filter into supercharger (no
supercharger unless supercharged engine)
2. Pressurized air through inter-cooler (no inter-cooler for
supercharged and noninter cooled engine)
3. Inter-cooler
4. Intake manifold
5. Intake valve

1. Exhaust Valve
2. Exhaust manifold
3. Exhausting gas flowing into the turbo of turbocharger
4. Exhaust outlet of turbocharger

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Page 22
Fuel Supplying System
1. Fuel from the fuel tank
2. Fuel delivery pump
3. Fuel filter
4. Fuel delivery pipe
5. Air-limiting pipe of fume limiter( Only existing in
supercharger)
6. Fuel injection pump
7. High pressure fuel pipe
8. Injector
9. Fuel returning pipe of injector
10. Fuel pipe back to the fuel tank

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Page 23
SP002530 3ton Diesel Engine
Page 24
TIGHTENING TORQUE AND TIGHTENING METHOD O

F HIGH STRENGTH BOLTS

MAIN-BEARING BOLT
8 pieces M14 (10 pcs for 4-cylinder engine and 14 pcs for 6-cylinder engine), sleeve wrench 22mm.

For a 6-cylinder engine, tightening is done in two times (in sequence as shown in the above figure).
Firstly, in 70 N·m;
Secondly, the bolt is turned 90°±4°. For 3-cylinder and/or 4-cylinder engines, in reference to the same figure,
the bolt is screwed down in two steps, namely even in the middle and extended at two ends.

CYLINDER HEAD BOLT

12 pieces M14 (16 pcs for 4-cylinder engine and 24 pcs for 6-cylinder engine), 17mm sleeve wrench.
Following such tightening sequence：
Step 1: Cylinder head must be aligned after amounted, i.e. the sides of both air inlet and exhaust outlet
should be on the same plane;
Step 2: The cylinder head bolts on each cylinder shall be screwed down in the order of the under figure;

3ton Diesel Engine SP002530

Page 25
1. Pre-tighten in 30 N·m torque;
2. Turning angle is 120°± 4°
3. Re-turning angle is 120°± 4°
Step 3: The tightening sequence of the cylinder head bolts in the whole engine is as follows:
3-cylinder engine: 2-1-3
4-cylinder engine: 2-3-4-1
6-cylinder engine: 3-4-5-2-1-6
And as per Step 2, the course of screw-down shall be carried out in three times.
Caution: In every tightening, the bolt itself has an extension of 0.2-0.6 mm in length. In spite of its repeated
use, its length cannot be over 160.5 mm, if so, it must be replaced with a new one.

CONNECTING ROD BOLT

2 pcs M12x1.5 for each connecting rod, 19 mm sleeve
wrench.
Step 1 ： Tighten tightly ， then tighten these bolts
symmetrically with a torque of 30N·m.
Step 2：Turn these bolts 60°±5°
Caution: The connecting-rod bolt is only of one-time use
and may not be used again.

FLYWHEEL BOLT
6 pieces M16, 24mm sleeve wrench
Step1: Firstly screw on symmetrically.
Step 2: Screw down symmetrically in 285-295N·m torque.
The bolt under the expected torque must be changed.
Note：The flywheel bolt is only allowed to be reused for 2
times.

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Page 26
BOLT FOR FLYWHEEL HOUSING
12pieces M10, 6pieces M12, 16mm and 18mm sleeve
wrenches.
Step 1: Screw on the bolts.
Step 2: Screw down the bolts in such tightening torque, for
M10 80-85N·m and M12, 140-145N·m;

Replace the bolt under the required torque.

The flywheel housing bolt can only be used twice.
Caution: All the above-mentioned strengthening bolts
should be coated with lubricating oil on the thread and
bearing surfaces before their screwing in.

INTERMEDIATE GEAR SHAFT BOLT (EURO II ENGINE)

4 pieces M10, 15mm sleeve wrench.
Step 1: Tighten the bolts with torque 60N·m symmetrically.
Step 2: Turn the bolts 90°, let the torque value come to
100-125N·m, Replace torque value come to 100-125N·m,
Replace the bolt under the required torque value.
Before screwing-in, the thread should be coated with the
LOCTITE 242 Sealant (a Chinese Brand).

OIL PUMP BOLT

2 pcs M8, M8 nut (1 piece), 13mm sleeve wrench
The bolt M8 is once tightened to 30-40N·m and the lock
nut to 20-25N·m.
Before screwing-in, the thread should be coated with the
LOCTITE 242 sealant.

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Page 27
ROCKER-ARM SEAT BOLT
Bolt M10, 16mm sleeve wrench
The bolt is once tightened to 40-45N·m

FASTENING BOLT FOR TWO-STAGE BALANCING

MECHANISM
4 pcs bolts M10, 16mm sleeve wrench
The bolt is once tightened to 35-40N·m

FASTENING BOLT FOR INJECTION-PUMP GEAR

4 pcs bolts M8 (M10), 13mm (16mm) sleeve wrench.
The bolt is once tightened to 30-35N·m (60-65 N·m)
Before screwing-in, the thread should be coated with the
LOCTITE 242 sealant.

NUT FOR INJECTION-PUMP SHAFT

M18x1.5, 27mm sleeve wrench.
The nut is once tightened to 100-110N·m.
Before screwing-in, the thread should be coated with the
LOCTITE 242 sealant.

SP002530 3ton Diesel Engine

Page 28
FASTENING BOLT FOR CAMSHAFT GEAR
4 pcs M10x1.25, 16mm sleeve wrench. The bolt is
symmetrically tightened to 85-90N·m.
Before screwing-in, the thread should be coated with the
LOCTITE 242 sealant.

FASTENING BOLT FOR DRIVING GEAR OF

CAMSHAFT-AIR COMPRESSOR
4 pcs M8, 13mm sleeve wrench.
The bolt is symmetrically tightened to 55-60N·m.
Before screwing-in, the thread should be coated with the
LOCTITE sealant.

FASTENING BOLT FOR BELT PULLEY AND HUB

6 pcs M10, inner- hexagon spanner 8mm.
The bolt is symmetrically tightened to 65-75N·m.

FASTENING NUT FOR INTAKE AND EXHAUST

MANIFOLDS
M10, 16mm sleeve wrench.
Symmetrically tightened to 45-50N·m.

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Page 29
SP002530 3ton Diesel Engine
Page 30
FUEL, LUBRICANT, COOLANT AND AUXILIARY

MATERIALS
FUEL
In Summer No.0 iesel Fuel GB 252-87 In Winter No.-10 Diesel fuel GB252-87
In winter, when the temperature is -20°C, you should use NO.-20 Diesel Fuel. If the temperature is below -
30°C，you should use No.-35 Diesel Fuel.

LUBRICANT
Turbocharged Engine: GB11123 CD oil.
It is allowed to replace low-grade oil with high-grade oil.
Please reference the following chart to choose viscosity of lubricant.

When the oil level is located in the upper limit position of the oil dipstick, the oil capacity is about 7.25L (9.5L
for 4-cylinder engine and 13L for 6-cylinder). According to the agreement with users, by the date or
delivering the machine, whether or not the oil has been charged in the oil sump is no matter. The oil that has
already been filled contains a special kind of running-in (anti-corrosive) agent. Users may drain off the oil
and refresh it after the working period of 2000Km or 50 hours. It is recommended to make use of the oil
product, by name as Changcheng Diesel Engine Oil CD-grade 15W/40, produced by China Petrochemistry
Changcheng High-Grade Lubricant Company.

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Page 31
COOLANT
The antifreeze that can be against rusting and freezing is added in the cooling system. Its compounding pro
portion is stated in the instruction of antifreeze.

AUXILIARY MATERIALS
In the course of installation and maintenance of this diesel engine, the sealant and adhesive, such as LOCTI
TE 510,242, 271,277 and 262, can be applied.
Fine molybdenum powder
Where all kinds of auxiliary materials can be used is listed in the following table.
Various auxiliary materials for 3ton Diesel Engine
Serial
Name Color Function and Application
No．
Fine
Apply to smooth surface of metal to prevent biting．
1 Molybdenum Black
eg: Apply to exterior surface of cylinder liner．
Powder
Molybdenum To prevent adhesion of parts under higher temperature．
2 Dark Grey
disulfide Lube eg，Apply to the bolts of exhaust outlet of turbocharger．
Loctite 242 Apply to thread to seal．
3 Blue
glue eg，Apply to bolts and thread．
Loctite 262 Apply to thread to lock and seal．
4 Red
glue eg，Apply to auxiliary bolts of cylinder head．
Apply to surface of metal to seal．
Loctite5910
5 eg，Apply to bond surface of cylinder block and
glue Red
crankcase．
Loctite 271 Apply to surface of metal to seal．
6 Red
glue eg，Apply to oil channel plug．
Loctite 277 Sealing of plug and hole．
7 Red
glue eg，Apply to the water reservoir plug of cylinder block．

Caution in this Chapter: TO ensure that the diesel engine you have bought functions normally, you must h
ave have a correct option relating to the brand and type of fuel and oil according to this instruction.

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Page 32
ELECTRICAL APPLIANCE
This section consists of generator, starter, starter, sensor of water temperature indicator, induction plug of oil
pressure, etc.

GENERATOR
The generator is three-phase alternator, after silicon rectification the current change into direct current.
Output voltage:14V, Current: 80A; output voltage 28V; According to user requirement, the etectric current
provided are: 27V、35A、55A、70A Rotary direction: Right.
Max. allowable revolution speed :12000r/min
Revolution speed at rated load: 7333 r/min
Circuit Diagram:

CONNECTION POLE
D+connect to Charging (electri6cation) Indicating Lamp, the screw specification: M4
W connect to Speed Measuring Motor, the screw specification: M5
B+ connect to the positive electrode of battery, generator shell is grounded, the screw specification: M6

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Page 33
STARTER
DC starter voltage: 12V,Power: 4KW; Dcstarte voltage: 24V; Power: 6KW( 4KW) right rotation( face to diesel
engine output end),10 teeth.
Circuit Diagram:

EXTEMAL CONNECTION POLE

30 connect to the positive electrode of battery, the screw specification: M10
50 connect to the electromagnetic switch the screw specification:M5
Starter casing earthing.

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Page 34
ADJUSTMENT AND REPLACEMENT OF MAIN

COMPONENTS
COOLING SYSTEM
Replace poly V-belt
Tool: Inner-hexagon spanner 8mm, open-ended spanner
16mm.

Replace water pump

Unscrew the fastening bolt and nut of tensioning bolt, and
take down the belt of generator.
Tool: Inner-hexagon spanner 8mm, open-ended spanner
16mm.

Loosen the fastening bolt of fan and dismantle the fan,

intermediate flange and the belt pulley of water pump.
Tool: Open-ended spanner 13mm.

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Page 35
Loosen the clamp ring on rubber hose for small cycle.
Tool: 6# screw-driver.

Loosen the hose clamp ring in the water inlet of water

pump.
Tool: 6#screw-driver.

Take apart the fastening bolt on water pump and take

away the away the water pump.
Tool: Sleeve wrench 13mm.

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Page 36
Clean the sealed surface of water pump.
Change the seal gasket of water pump.
Put on a new water pump and screw down the 4 bolts to fix
it.
Tool: Sleeve wrench 13mm.

Tighten the hose clamp ring in the water inlet of water

pump.
Tool: 6# screw-driver.

Tighten the clamp ring on rubber hose for small cycle.

Tool: 6# screw-driver.

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Page 37
Reassemble the belt pulley, inter-flange and fan in the
proper order, and tighten the 4 bolts.
Tool: Open-ended spanner 13mm.

Put on the V-belt and tension it properly, and then re-

tighten the fastening bolt and nut of tensioning bolt.
Tool: Inner-hexagon spanner 8mm, open ended spanner
16mm.

LUBRICATING SYSTEM
Replace oil cooler
Dismantle the oil filter
Tool: Special wrench for oil filter

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Page 38
Loosen the water inlet/out hose clamp ring of oil cooler.
Tool: 6# screw-driver.

Unscrew the fastening bolt of oil cooler.

Tool: 6mm Open-ended spanner.

Unscrew the nipple and take down the oil cooler.

Tool: 27mm Sleeve wrench.

Dismantle the water-draining valve.

Tool: Open-ended spanner 17mm.

3ton Diesel Engine SP002530

Page 39
Mount the drain valve on the new oil cooler.
Tool: Open-ended spanner 17mm.

Clean the oil cooler and the connecting surface of filter

seat, change the seal gasket and substitute the oil cooler
with a new one, and then tighten the nipple.
Tool: 27mm Sleeve wrench.

Screw down the fastening bolt for the oil cooler.

Tool: 16mm Open-ended spanner.

Tighten the water inlet/out hose clamp ring on the oil cooler.
Tool: 6#screw-driver.

SP002530 3ton Diesel Engine

Page 40
Put on the oil filter.
Tool: Special spanner for oil filter.

Unscrew the bolt connecting the oil sump with the flywheel
housing, loosen the fastening bolt of oil sump and take
down the oil sump.
Tool: 18mm Sleeve wrench, 6mm Inner-hexagon spanner.

Loosen the mounting screw and the thread joint on

lubricating oil inlet pipe, then take down the oil inlet pipe.
Tool: 13mm and 19mm Sleeve wrenches.

Unscrew the fastening bolt and nut of tensioning bolt of

generator, and then pull down the poly V-belt.
Tool: 8mm, Inner-hexagon sleeve wrench, 16mm open-
ended spanner.

3ton Diesel Engine SP002530

Page 41
Unscrew the fastening bolt for generator and take down
the generator.
Tool: 4mm Inner-hexagon sleeve wrench.

Loosen the hose clamp ring in the water inlet connecting

pipe, and then dismantle the water inlet connecting pipe.
Tool: 6# screw-driver, 13mm sleeve wrenches.

Unscrew the mounting bolt for belt pulley of crankshaft and

dismantle the belt pulley the shock absorber.
Tool: Inner-hexagon 8mm sleeve wrench.

Dismantle the hub after loosening the hub bolt.

Tool: Inner-hexagon 14mm sleeve wrench.

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Page 42
Unscrew the fastening bolt on front wall cover and
dismantle the front wall cover.
Tool: Inner-hexagon 4mm sleeve wrench, 13mm sleeve
wrenches.

Unscrew the fastening bolt and nut, dismantle the oil pump.
Tool: 13mm Sleeve wrench.

Clean the connecting surface of oil pump with cylinder

block, mount a new oil pump, adjust the side clearance of
gear（ side clearance 0.2 mm）,and then tighten the bolt
and nut.
Tool: 13mm Sleeve wrench.

Clean up the connecting surface of the front wall cover with

the cylinder body, coat the sealant on it, and then re-mount
the front wall cover and tighten the bolt on it.
Tool: 4mm Inner-hexagon sleeve wrench, 13mm sleeve
wrench.

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Page 43
Re-mount the hub and screw the bolt on it.
Caution: To avoid damage to the front-seal lip of
crankshaft, put in the hub lightly.
Tool: Inner-hexagon 14mm sleeve.

Put on the shock absorber and the belt pulley of crankshaft

in turn, and then screw down the bolt on the belt pulley of
crankshaft.
Tool: Inner-hexagon 8mm sleeve wrench.

Put on the water inlet connecting pipe, tighten the water

inlet hose clamp ring and the bolt on it.
Tool: 6# screw-driver, 13mm sleeve wrench.

Mount the generator and tighten the bolt on it.

Tool: Inner-hexagon 4mm sleeve wrench.

SP002530 3ton Diesel Engine

Page 44
Put on the poly V-belt and adjust it properly, and then
screw down the fastening bolt and nut for generator.
Tool: Inner-hexagon 8mm Sleeve wrench, 16mm open-
ended spanner.

Replace the O-seal ring, fit on the lubricating oil inlet pipe,
and instalt the oil inlet pipg and fasten with bolt on the
angle plate.
Tool: 13mm and 19mm Sleeve wrench.

Fit on the oil sump, tighten the bolt connecting oil sump
with flywheel housing and the fastening bolt for the oil
sump.
Tool: 18mm Sleeve wrench, 6mm Inner-hexagon spanner.

Loosen the connecting bolt between oil sump and flywheel

housing, unscrew the fastening bolt on oil sump and take
down the oil sump.
Tool: 18mm Sleeve wrench, 6mm Inner-hexagon spanner.

3ton Diesel Engine SP002530

Page 45
Loosen the joint of lubricating oil pipe.
Tool: 17mm Open-ended spanner.

Unscrew the fastening bolt and take down the two-stage

balancing mechanism.
Tool: 16mm Sleeve wrench.

Re-mount the two-stage balancing mechanism; adjust the

side clearance of gear to 0.3-0.4mm and the tightening
torque to 34-40N·m.
Tool: 16mm Sleeve wrench.

Screw down the joint of lubricating oil pipe.

Tool: 17mm Open-ended spanner.

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Page 46
Fit on the oil sump, tighten the bolt connecting oil sump
with flywheel housing and the fastening bolt on the oil
sump.
Tool: 18mm Sleeve wrench, 6mm Inner-hexagon spanner.

FUEL SUPPLYING SYSTEM

Replace fuel injection pump
Dismantle the joint connecting high-pressure fuel pipe and
fuel injection pump.
Tool: 18mm Open-ended spanner.

Dismantle the fuel injection pump and the oil in/out pipes of
fuel filter.
Tool: 19mm Open-ended spanner.

Dismantle the lubricating-oil pipe of the fuel injection pump.

Tool: 16mm Open-ended spanner.

3ton Diesel Engine SP002530

Page 47
Dismantle the oil inlet joint.
Tool: 18mm Open-ended spanner.

Take down the stopping electromagnet.

Tool: 10mm Sleeve wrench.

Unscrew the bolt and dismantle the cover of inspection

hole on fuel injection pump. Make a slow barring of engine
and let the scale mark on the flywheel housing align the
“OT” mark on the flywheel, so as to determine that the
piston of the first cylinder is exactly in the top dead center.
Tool: 13mm Sleeve wrench.

Unscrew the bolt and take down the fuel injection pump
gear.
Tool: 13mm Sleeve wrench.

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Page 48
Unscrew the bolt and take down the fuel injection pump.
Tool: 16mm Sleeve wrench.
Caution: Do not damage the O-ring.

Unscrew the nut and dismantle the fuel injection pump hub.
Tool: 27mm Sleeve wrench.

Put the hub on a new fuel injection pump and screw down
the lock nut to the required torque value.
Tool: 27mm Sleeve wrench.

Mount the new pump and tighten the bolt to fix it.
Tool: 16mm Sleeve wrench.

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Page 49
Turn the camshaft of fuel injection pump until the fuel level
in the first cylinder’s fuel outlet moves slightly.
Tool: 27mm Sleeve wrench.

Put on the gear of fuel injection pump and tighten the bolt
on it.
Tool: 13mm Sleeve wrench.

Put on the inspection hole cover of fuel injection pump and

tighten the bolt on it.
Tool: 13mm Sleeve wrench.

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Fix the lubricating-oil inlet pipe and tighten the hollow bolt.
Tool: 16mm Open-ended spanner.

Mount the inlet and outlet pipes of fuel injection pump and
fuel filter, and then tighten the hollow bolt.
Tool: 19mm Open-ended spanner.

Mount the high-pressure fuel pipe and tighten the joint.

Tool: 18mm Open-ended spanner.

Clean the fuel injector all round and dismantle the joint
connecting the high-pressure fuel pipe with the fuel injector.
Tool: 18mm Open-ended spanner.

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Dismantle the fuel return pipe of fuel injector.
Tool: 10mm Open-ended spanner.

Unscrew the fastening nut on support and take down the

support.
Dismantle the fuel injector.
Tool: 13mm Open-ended spanner.

Clean the fuel-injector seat hole.

Replace the seal gasket
Mount a new fuel injector, and then put on new shaft
checking-ring flat gasket and 0-seal ring.
Mount a new fuel injector in the fuel injector’s seat hole.

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Mount the support and screw down the nut to10-15N·m.
Tool: 13mm Open-ended spanner.

Mount the fuel return pipe of injector.

Tool: 10mm Open-ended spanner.

Screw down the joint connecting the fuel injector with the
high-pressure fuel pipe.
Tool: 18mm Open-ended spanner.

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INTAKE AND EXHAUST SYSTEM
Replace the waste gas supercharger
Loosen the hose clamp ring of supercharger oil return pipe.
Tool: 6mm Screw-driver.

Dismantle the inner-hexagon bolt on the inlet pipe of

supercharger and lift the flange of inlet pipe.
Tool: 6mm Inner-hexagon spanner.

Loosen the self-lock nut on the flange connecting

exhausting pipe with supercharger, and then take down the
supercharger.
Tool: 13mm Open-ended spanner.

Replace the supercharger.

Caution: If the waste gas supercharger is not replaced
immediately, so all the air inlet and outlet ports should be
properly covered to prevent any substances from coming
into the cylinder.

SP002530 3ton Diesel Engine

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Mount new inlet pipe gasket and tighten the bolt on the
inlet pipe.
Tool: 6mm Inner-hexagon spanner.
Caution: When the oil inlet pipe is mounted, it is
necessary to align the oil holes of the gasket and the
supercharger flange, to add the clean oil and turn the blade
wheel of turbine for the entrance of oil into the bearing area.

3ton Diesel Engine SP002530

Page 55
SP002530 3ton Diesel Engine
Page 56
TYPICAL TROUBLES AND REMEDY OF DIESEL ENGINE
There are various symptoms of diesel troubles. The failure causes vary from one diesel engine to another
because of the differential structures and using environments of different diesels. A trouble might be caused
by many factors; different troubles should be studied according to their peculiar symptoms.

NO START OR HARD STARTING

No Cause Remedy

1 Fuel system failure

1. Fuel tank switch is off or there is no fuel in

Switch on it or refuel sufficiently.
fuel tank.
Check whether the joints of pipelines are loose
2. Air in fuel system.
and exhaust the air in fuel line.
Check the feed pump and change the
3. Feed pump failure
unqualified.

4. Bad fuel atomization Check and adjust the fuel injectors.

5. Incorrect fuel supply advance angle Check and adjust the fuel supply advance angle

6. Fuel pipes or fuel filter jammed Check and clean them

2 Low compression pressure of cylinders

1. Excessively-worn piston rings or cylinder Check and change the piston rings. If necessary,
liners change the cylinder liners and pistons
Check the valve clearance and valve sealing.
2. Valve leakage
Grind the valves.
Check whether the cylinder gaskets leak and
3. Cylinder gasket Leakage
remedy them.

3ton Diesel Engine SP002530

Page 57
 3 Starting system faults

Low battery voltage Check and recharge the battery

Poor contact of the electrical circuit Check and repair the electrical circuit.

Starter stall or low power output Check and repair the starting motor.

Turn the flywheel ring gear for a certain angle. If

Starter gear is unable to engage correctly with
it still cannot engage correctly, then check and
the flywheel ring gear.
repair the starter.

INSTABLE RUNNING

No Cause Remedy

Check whether the joints of pipelines are loose

1 Air in fuel system
and exhaust the air in fuel line.

2 Fuel system jammed Clean or change the fuel filter.

Check the fuel injection pump and adjust the

3 Uneven fuel delivery for each cylinder pump on the test-rig to uniform the fuel delivery
for each cylinder.
Pick out the poor injectors. Clean or change
4 Some injectors work poorly.
them.

5 Governor works unsteadily. Check and repair the governor.

6 Poor fuel quality or water in fuel Check the fuel. Change it if necessary.

SP002530 3ton Diesel Engine

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INSUFFICIENT POWER

No Cause Remedy

1 Fuel system failure

1. Fuel system jammed or air in the system Clean or change the fuel filter. Exhaust the air.

2. Bad atomization of injectors, low injection Check the fuel injectors. Change them if
pressure necessary.
3. Injection pump failure, insufficient fuel
Check or change it.
supply or uneven delivery

4. Incorrect fuel supply advance angle Check and adjust the fuel supply advance angle

5. Poor fuel quality or water in fuel Check the fuel. Change it if necessary.

Low compression pressure

2
of cylinders
Excessively-worn piston rings or cylinder Check and change the piston rings. If necessary,
liners change the cylinder liners and pistons.
Check the valve clearance and valve sealing.
Valve leakage
Grind the valves.
Check whether the cylinder gaskets leak and
Cylinder gasket Leakage
remedy them.

3 Air filter jammed Clean or change the filter element

Check and clean the exhaust passage and

4 Exhaust passage and muffler jammed
muffler.

5 Exhaust pipe jammed Find out the cause and solve the problem.

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ABNORMAL ENGINE OIL PRESSURE

No Cause Remedy

1 Low oil level in the sump Add oil to specified level

2 Oil pressure gauge failure Check, repair or replace

3 Primary oil filter or filter jammed Clean or change the fuel filter element.

Excessively-worn crankshaft main bearing

4 Check or change them.
and connecting rod bearings
Incorrect engine oil grade or water in engine Check the oil grade and cause. Change the
5
oil engine oil.

6 Engine oil driving, driven gears wear Change engine oil pump

7 Pressure limiting valve failure Check and change it.

8 Engine oil line jammed or oil leakage Check and solve the problem correspondingly

SP002530 3ton Diesel Engine

Page 60
OVERHEATING

No Cause Remedy

1 Long time overloaded running Reduce the load

Check the fuel injection and fuel supply

2 Poor combustion
advance angle.

3 Overheated engine oil

Check the oil dipstick. Increase or reduce the

1. Insufficient or excessive engine oil
engine oil according to requirement.

2. Oil cooler jammed Clean or change the oil cooler.

4 Overheated coolant

1. Insufficient coolant Change engine oil pump

Check the impeller clearance. Change it, if

2. Low delivery capacity of the water pump
necessary.

3. Low fan speed Adjust the tension of fan belt.

4. Excessive scale in cooling system Clean the scale

Clean the dirt on the cooling fins and improve

5. Low radiating capability of the radiator
the ventilation of the radiator.

6.Thermostat failure Change it after finding out the cause

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ABNORMAL SMOKE

No Cause Remedy

1 Excessive white smoke

1. Bad atomization of fuel injectors and fuel

Check the fuel injection pressure and spray.
dribbling
Clean the fuel tank and filter. And change the
2. Water in diesel fuel
diesel fuel.
Check reason for leakage of the valves, cylinder
3. Low compression pressure of cylinders
gaskets and piston rings. Solve the problems.

2 Excessive blue smoke

1. Excessively-high oil level in sump Drain the redundant engine oil.

2. Piston ring wear or low flexibility, oil blow-

Check and change the piston rings.
by
Check the valve sealing and change the seal
3. Valve sealing failure
sleeve of valve stem.

3 Excessive black smoke

1. Diesel over-loaded Reduce the load to the given level.

Check or change the delivery valves of the fuel

2. Bad fuel injection and bad atomization
pump and injectors.
3. Delayed fuel supply and excess post-
Adjust the fuel supply advance angle
combustion
4. Incorrect valve clearance or bad valve
Check the valve clearance and valve sealing.
sealing

5. Air filter jammed Clean the air filter element.

6. Poor fuel quality Use high quality fuel.

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Page 62
SUDDEN STOP

No Cause Remedy

Crankshaft is unable to rotate after diesel

1
engine stopped.
1. Crankshaft and bearing shell locked
Check and change parts.
together
Check and change the pistons, piston rings and
2. Pistons and cylinder liners locked together
cylinder liners.
Crankshaft is able to rotate easily after diesel
2
stopped.

1. Air in fuel system Exhaust the air and check the sealing of lines.

2. Fuel system jammed Clean or change the fuel filter element.

3. Racks or plungers of injection pump

Check and repair the injection pump.
jammed.

4. Inlet air pipe or air filter jammed Check and clear the air filter.

5. Lack of fuel Add fuel.

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Page 63
UNUSUAL SOUNDS

No Cause Remedy

Premature fuel injection and rhythmic tinkling

1 Check and adjust the fuel injecting time.
knock in cylinders
Delayed fuel supply and hollow rapping sound
2 Check and adjust the fuel injecting time.
in cylinders
Excess clearance between valves and valve
3 arms and metallic beating sound in valve Check and adjust the valve clearance
structures
Excess clearance between pistons and Check the cylinder liners fit clearance. Change
4
cylinders the pistons and cylinders.
Excess clearance between the piston pin and
small rod connecting bearing, pealing with a Change the connecting rod bushing to satisfy the
5
metallic beating sound, especially at high or clearance requirement.
low speed
Big clearance between connecting rods and
6 Change the bearings.
muffled raucous beating sound
Excess clearance of main bearing, the sound
7 Change the main bearings.
resembling the connecting rod beating sound
Piston bumps the valve, tinkling near the
8 Check the valve timing.
cylinder head at low speed
Excess gear clearance and bumping sound at Check and adjust the gear clearance. Change
9
sudden deceleration the gears if necessary.

SP002530 3ton Diesel Engine

Page 64
 SP002363

FRONT AXLE

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual or
those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

MODEL SERIAL NUMBER RANGE

SD200 1001 and Up

Copyright 2011 DISD

July 2011

Front Axle SP002363

Page 1
TABLE OF CONTENTS
Generation Description………………………………….…………………………………….3
Structure Chart………………………...….……………………..………………………..3
Basic Parameters of Drive Axle ……………...…………………….…………………...3
Internal Structure of Drive Axle …………….….….………...…………………………..3
Parts List …………………………………..……….………….……………………………..4
Disassembling of Front and Rear Axle …………………………………………………4
Assemble of Hub Drive Axle ……….…….….………………..…………………………5
Brake Assembly ……………………………..…………………………………………..7
Main Drive Assembly ……….………………...…...…………………………………..8
Scheduled Maintenance……...………………….………………..………………………..10
Every Month Maintenance ………………….…...……………………………………..10
Every Half Year Maintenance ……………..…………………………………………..10
Every Year Maintenance………………….….………….……………………………..10
General Disassembly and Reassembly Instructions.……………………...……………..11
Axle Disassembly …………………………….….……………………………………….....12
Disassembly of Drive axle ……………...….………………….…………………….....12
Assembly Dismantling ……………………….………………………………………....16
Axle Reassembly …………………………….….………………………………………......24
Axle Assembly …………………….……….……..………………………...………......24
Assembly Parts Assembling ………….……...…………………………...……….......29

SP002363 Front Axle

Page 2
GENERAL DESCRIPTION
Structure chart

Figure 1
1. EDGE REDUCER ASS’Y 2. BRAKE CLAMP ASS’Y 3. SHELL 4. MAIN REDUCER ASS’Y
5. HUB ASS’Y

Basic parameters of drive axle:

Type Spiral bevel gear grade one reduction
Main drive
Reduction ratio 4.222
Type Grade one planet reduction
Hub reduction gear
Reduction ratio 4.8

Axle oil GB13895-1992 gear oil 10Kg

Internal structure of drive axle

Drive axle assembly is one of the most important spare parts of transmission system, its main function is
reduce rotation speed from gear box and increase torque, and make wheels at both sides having speed
difference. Besides, it also plays the role of bearing and transmitting. Drive axle assembly of loader is mainly
composed of shell, main drive (including differential mechanism), semi axis, hub reduction gear, brake caliper
assembly and other parts. Of which, the parts having reduction and differential function is main driver and hub
reduction gear; power transmission between main drive and hub reduction gear is realized through semi axis,
multiple spine at both sides of semi axis and axle shaft gear of differential mechanism and sun gear of hub
reduction gear mesh with each other to realize power connection between main drive and hub reduction gear.

Front Axle SP002363

Page 3
PARTS LIST
Disassembling of front and rear axle

Figure 2

Reference Reference
Description Description
Number Number
1 WHEEL REDUCER ASS’Y 10 MAIN REDUCER ASS’Y
2 AXLE ASSY;SHELL 11 STUD BOLT
3 GROUP WASHER φ24 12 SPACER 12
4 PLUG,SCREW 13 NUT M12
5 DEFLATION VALVE Z1/8 14 BOLT M12X35-10.9
6 O-RING 15 SPACER 12
7 PLUG,SCREW 16 BOLT
8 PLUG,SCREW 17 PIN
9 O-RING 18 BRAKE ASSY

SP002363 Front Ax le
Page 4
Assemble of Hub drive axle

Figure 3

Front Axle SP002363

Page 5
 Reference Reference
Description Description
Number Number
1 PLUG,SCREW 19 PLANET WHEEL
2 O-RING 20 PLANET WHEEL WASHER
3 BOLT M12X1.5-25 21 HALF SHAFT
4 SPACER 12 22 SUN WHEEL
5 COVER 23 SCREW M8X15
6 BLOCK 24 HOLDING NUT
7 RETAINER RING 48 25 INSIDE GEAR
8 PLUG,SCREW 26 BEARING 7521E
9 O-RING 27 HUB
10 HUB NUT 28 SPRING WASHER
11 HUB BOLT 29 NUT M18
12 SHELF,PLANET 30 BEARING 2007122E
13 O-RING SEAL 31 O-RING SEAL
14 STEEL BALL φ6 32 BRAKE DISC
15 PLANET WHEEL WASHER 33 WASHER 16
16 NEEDLE ROLLER 4×23.8 34 BOLT M16X45
17 SAPCER SLEEVE 35 SEAL ASSY,OIL
18 PLANET WHEEL SHAFT

SP002363 Front Axle

Page 6
 Brake assembly

Figure 4

Reference Reference
Description Description
Number Number
1-1 BRAKE,EXTERIOR 9 WASHER
1-8 BRAKE,INNER 10 CONNECTING
2 PISTON 11 DEFLATING VALVE
3 RECTANGULAR SEAL 12 SPACER 12
4 CASE,DUST 13 BOLT
5 BLOCK RING 14 WASHER SPRING 10
6 BRAKE DISK 15 PIN;BOLT
7 O-RING 20X2.4

Front Axle SP002363

Page 7
Main drive assembly

Figure 5

SP002363 Front Axle

Page 8
 Reference Reference
Description Description
Number Number
1 PIN 5X45 24 HOLDING PLATE
2 NUT M27×1.5-7H 25 DIFFERENTIAL SHELL –LEFT
3 WASHER 26 GEAR,BEVEL;DRIVE(REAR)
4 O-RING BAFFLE 28 DIFFERENTIAL BEARING COVER
5 O-RING SEAL 40X5.3 29 HOLDING PLATE
6 INPUT FLANGE GROUP 30 BOLT M18×90
7 OIL SEAL B62×93×6 31 HOLDING PLATE
8 OIL SEAL FB62×93×13 32 HOLDING PLATE
9 STOPPER WASHER 33 BOLT M8X12
10 BOLT M12×45-10.9 34 REGULATE NUT
11 SPACER 12 35 BEARING 7516E
12 OIL SEAL SEAT 36 BOLT M14X1.5
13 BEARING 27311E 37 DIFFERENTIAL SHELL – RIGHT
14 REGULATE WASHER 38 HALF SHAFT GEAR WASHER
15 SPACER SLEEVE 39 HALF SHAFT GEAR
16 BEARING SEAT 40 SUPPORT WASHER
17 BEARING 27311E 41 CROSS SHAFT
18 REGULATE WASHER 42 PLANET GEAR
19 REGULATE NUT 43 MAIN REDUCER SHELL
20 BEARING 7516E 44 RETAINER RING 30
21 NUT M14X1.5 45 BEARING 92606E
22 HOLDING PLATE 46 DRIVE GEAR;RIGHT
23 HOLDING PLATE

Front Axle SP002363

Page 9
SCHEDULED MAINTENANCE
Oil of new drive axle must be replaced after working for 15 days (about 100 working hours), oil shall be
replaced once after working for every six months (about 1200 working hours) in following days.

Every month maintenance

1. Check abrasion condition of brake disc, if there is disruptive abrasion; please handle in time if there is
any.
2. Check abrasion condition of brake block to guarantee separation and reunion of brake caliper is flexible;
it shall be replaced in time when brake block is wearing close to abrasion line (at the bottom of groove).
3. Check if oil level of shell complies with requirements, please add new oil if the oil level descends.
4. Keep axle clean, keep vent pipe smooth, and avoid silt going into axle. Check loosening condition of all
fasteners, especially rim nuts, if it is loosed, please refasten again.

Every half year maintenance：

Lubrication oil in axle shall be replaced every half a year, different brands of lubrication oil shall be adopted for
different areas and seasons. Please refer to 4.2 for oil replacing method.

Every year maintenance：

Overhaul checking every working year:
1. Check the gap, mesh and abrasion condition of spiral bevel gear of main reducer.
2. Check abrasion condition of differential mechanism gear.
3. Check abrasion condition of hub gear.
4. Check abrasion condition of needle bearing of hub planetary gear.
5. Requirements of installation and debugging items after overhaul checking:
1) After assembling, axle shaft gear and bevel gear shall move flexibly with hand touching rather than
locking. The Min. gear backlash of gear is 0.18-0.23mm. Tooth length and tooth height of contacting
area of two gears cannot be less than 50%.
2) In order to guarantee enough bearing rigidity of active spiral gear, before assembling oil seal and
sealing cover, adopt gradually reducing spacer shim between tapered roller bearing to give
1.0-1.5N.m preloaded torque to roller bearing.
3) Gear backlash between the driving and driven spiral bevel gear is 0.25-0.45mm, the changing amount
cannot be more than 0.15mm, gear backlash can be realized through adjusting nuts of both sides of
differential mechanism and spacer shim of bearing sleeve. Tooth surface contacting area shall
guarantee direction of tooth length and tooth height is not less than 50%, contacting position shall be
at the middle side of tooth surface and closer to the smaller side.
4) Adjusting of bearing clearance of shell at both sides of drive axle: Fasten adjusting nuts, give 28 ~
38N.m preload to shell roller bearing, and then lock two round nuts with screw fastening
SP002363 Front Axle
Page 10
GENERAL DISASSEMBLY AND REASSEMBLY

INSTRUCTIONS

WARNING!
Never use gasoline, solvents, or other flammable fluids to clean components. Only use approved
commercial solvents that are nonflammable and nontoxic.

IMPORTANT
Use only GENUINE DOOSAN SPARE PARTS to warrant proper operations and prevent
interchangeability problems.

GENERAL INSTRUCTIONS
1. Thoroughly clean and dry axle before disassembly.
2. All components should be thoroughly cleaned and dried before reassembly. Dirt, chips, and foreign
material may cause failures.
3. All ducts and castings should be thoroughly cleaned and dried to remove dirt, chips, and foreign material
to prevent damage after reassembly.
4. Reassembly should be done in a clean shop, and should be as dust free as possible.
5. Make sure tools and equipment are at hand.
6. When reassembling Daewoo strongly recommends to replace the following parts with new.
• Seal Rings.
• O-rings.
• Gaskets.
• Threaded rings with notched collar.
• Any component damaged during disassembly.
7. When mounting heat fitted components, make sure of their proper position and direction of assembly,
after they have cooled.
8. To heat bearings, use proper heating plates, piping, or suitable ovens.
NOTE: Never heat parts by using a torch. Oil bath, heated by a torch, maybe used to warm components.
9. Lubricate all sections concerned when reassembling shafts, bearings, etc.
10. Lubricate O-rings before installing them in relevant seats to prevent kinking during assembly, such a
position would impair proper sealing.
11. Replace gears only in matched sets to make sure of proper tooth mating.

Front Axle SP002363

Page 11
AXLE DISASSEMBLY
1 Disassembly of drive axle
1. Put drive axle on supporting and make sure main
driver assembly is upward.

Figure 6

2. Loosen the connection bolts between brake

caliper and brake caliper support, dismantle brake
caliper assemble.

Figure 7

3. Release gear oil from planet carrier

Loosen hub oil releasing drain plug and shell oil
releasing drain plug, turn on slowly with hands to
avoid oil spilling.

Note：Store gear oil with clean container.

Figure 8

SP002363 Front Axle

Page 12
4. Release gear oil from shell
Turn on oil releasing bolts axle end cap to release
gear oil.

Note： Store gear oil with clean container.

Figure 9

5. Dismantle end cap

ure 9
Loosen connection bolts between planet carrier
and end cap, then get end cap from hub reducer
assembly with jackscrew, dismantle end cap.

Figure 10

6. Dismantle locating block

Take down locating block with hands.

Note：If it is tight when taking down, please use

assistant tools to pry out.

Figure 11

7. Dismantle stop collar

Dismantle stop collar from semi axis with stop
collar pincers.

Note：Before dismantling stop collar, pull out a

section of semi axis from shell.
Note：It must clamp firmly when using stop collar
pincers to avoid safety hazard when it is
Figure 12
popup.

Front Axle SP002363

Page 13
8. Dismantle sun gear
Dismantle semi axis from sun gear.。

Figure 13

9. Dismantle locating block

Dismantle locating block from semi axle with
hands.

Figure 14

10. Dismantle semi axis

Take semi axis from shell slightly.

Figure 15

11. Hub reducer

First loosen rim bolts with relative tools, then
loosen rim from planet carrier with jackscrew and
dismantle planet carrier assembly.

Note：Please slowly loosen planet carrier to

avoid safety hazard resulted from
dropping of planet carrier assembly. Figure 16

SP002363 Front Axle

Page 14
12. Dismantle round bolts
Dismantle round bolts.

Figure 17

13. Dismantle round nuts

Dismantle round nuts.

Figure 18

14. Dismantle internal gear

Take internal gear out by slightly rocking.

Figure 19

15. Dismantle rolling bearing

Take out rolling bearing with special dismantling
tool.

Figure 20
Front Axle SP002363
Page 15
16. Dismantle wheel hub assembly
Take wheel hub assembly from supporting axle.
Note: During hanging and dismantling process,
please keep axis of wheel hub assembly
is in line with axis of hub reduction
supporting axle to avoid scratching oil
surface and internal spare parts during
dismantling process.
Figure 21
Remark: dismantle all parts at the other side of
drive axle with the same methods.

17. Dismantle main drive assembly

Dismantle connection bolts between main drive
and shell assembly, take out main drive with
jackscrew, and suspend main drive assembly.
Note: When suspending main drive assembly,
guarantee suspending and dismantling
tools are at the above of main drive
assembly to avoid spare parts inside are
knocked again during suspending and Figure 22

dismantling process.

2 Assembly dismantling
2.1 Dismantle planet carrier assembly
1. O ring
Take out O ring.

Figure 23

2. Put planet carrier on working platform horizontally.

Figure 24
SP002363 Front Axle
Page 16
3. Take out planet axle with tools.

Figure 25

4. Take out steel balls.

Figure 26

5. Take out planet wheel.

Figure 27

6. Take out baffle ring and quill roller from inside of

planet wheel.

Figure 28

Front Axle SP002363

Page 17
2.2 Dismantle hub assembly
1. Put hub assembly on working platform; loosen
connection bolts between brake disc and hub.

Figure 29

2. Take out brake disc.

Figure 30

3. Take out bearing.

Figure 31

4. Take out oil seal.

Figure 32

SP002363 Front Axle

Page 18
2.3 Dismantle main drive assembly
1. Put main drive assembly (input flange upward)
horizontally and fixed on supporting.

Figure 33

2. Dismantle locknut gasket, O ring and baffle ring.

Figure 34

3. Take out input flange.

Figure 35

4. Dismantle connection bolts between sealing cover

and bearing sleeve, take out sealing cover.

Figure 36

Front Axle SP002363

Page 19
5. Turn main drive for 180°, dismantle bolts fastening
locking plate, take out locking plate.

Note：Some of the machine structure may be

different from this figure, please adjust
working content according to actual
structure.

Figure 37

6. Dismantle connection bolts of bearing seat and

take out bearing seat.

Figure 38

7. Dismantle adjusting nuts.

Figure 39

8. Dismantle bearing outer ring.

Figure 40

Front Axle SP002363

Page 20
9. Hang out differential mechanism assembly.

Note：Keep balance when hanging out to avoid

safety hazard.

Figure 41

10. Separate active spiral bevel gear assembly and

bracket with jackscrew.

Figure 42

2.4 Dismantle differential assembly

1. Put differential assembly vertically on working
platform, and guarantee it is stable.

Figure 43

2. Dismantle bearing on left and right shell of

differential mechanism.

Figure 44

Front Axle SP002363

Page 21
3. Loosen connection nuts between driven spiral
bevel gear and right shell of differential
mechanism, dismantle driven spiral bevel gear.

Note：Before taking out driven spiral bevel gear,

please check or mark assembling sign
first so that it can be placed back to the
original position.
Figure 45

4. Loosen connection nuts of left and right shell,

separate left and right shell of differential
mechanism.

Note：Before separating left and right shell of

differential mechanism, please check or
mark assembling sigh first so that it can
be placed back to the original position. Figure 46

5. Take out semi axis gear gasket and semi axis gear.

Figure 47

6. Take out joint cross and differential gear together,

take out differential gear gasket and gear from
joint cross.

Figure 48

SP002363 Front Axle

Page 22
7. Take out semi axis gear gasket and gear.

Figure 49

2.5 Dismantle active spiral bevel gear assembly

1. Put active spiral bevel gear assembly on working
platform, support flange of bearing sleeve, clamp
down on thread end of active spiral bevel gear
assembly with down device.

Note：Do not clamp too much to avoid damaging

flange, pull out bearing sleeve from active
Figure 50
spiral bevel gear assembly.

2. Reverse bevel gear assembly and take out

bearing.

Figure 51

3. Take out bearing sleeve.

Figure 52

Front Axle SP002363

Page 23
4. Take out adjusting gasket.

Figure 53

5. Take out spacer bush.

Figure 54

AXLE REASSEMBLY
1. Axle assembly
1. Shell
Clean shell and suspend with special supporting.
Fasten gummed plug screw at oil inlet and oil filler.

Note：Plug screw fastening torque：280～330Nm

Note：Loctite 262 taper thread sealant.

Figure 55

SP002363 Front Axle

Page 24
2. Wheel hub assembly
Coat lubrication grease on hub supporting axle of
shell assembly; assemble wheel hub assembly on
both sides of supporting axle of shell assembly.

Note：Use lubrication oil.

Figure 56

3. Rolling bearing
Assemble rolling bearing on hub supporting axle.

Figure 57

4. Internal gear
Assemble internal gear of drive axle at multiple
spline at the end of supporting bearing.

Figure 58

5. Round nuts
Assemble round nuts and fasten. Knock internal
gear slightly with copper stick to make internal
gear in place.

Figure 59

Front Axle SP002363

Page 25
6. Assemble round bolts
1) Grapple the hole on wheel hub with push and
pull ergometer, pull ergometer along with
tangential direction, indication on ergometer is
160±10N, if the indication is not within the
range of 160±10N, adjust tightness degree of
round bolts according to the indication until it is
within the range of 160±10N. In the end, coat
Loctite 262 thread fastening sealant for 5~6 Figure 60

from the second thread hole of internal gear

(form a liquid level at 1/3 circle of thread), then
fasten bolts, and fix round nuts.
2) Before dynamometry, rotate hub wheel for more
than 5 times.
Note：Loctite 262 thread fastening sealant

Figure 61

7. Assemble O sealing ring

Assemble O sealing ring on hub assemble.

Figure 62

8. Planet carrier assembly

Assemble planet carrier assembly on wheel hub
with rim bolts, gaskets and nuts.

Note：Fastening torque：540～650Nm

Figure 63

SP002363 Front Axle

Page 26
9. Assemble semiaxis
Assemble semiaxis in wheel hub.

Figure 64

10. Assemble sun gear

Assemble sun gear at one side of semiaxis with
baffle ring groove (pay attention to semiaxis
multiple spline and gear assembly).

Figure 65

11. Assemble baffle ring

Assemble baffle ring with baffle ring used for
axle.

Note：It must be clamped firmly when using

baffle ring pincer to avoid safety hazard
when it is popping out during assembling
process.
Figure 66

12. Assemble locating block

Stake steel ball on locating block, it can rotate
flexibly after staking steel ball.

Figure 67

Front Axle SP002363

Page 27
13. Assemble end cap
Coat Loctite 262 thread fastening sealant on
screws, location of sealant is 15mm on top of
thread end. Fasten cap with bolts and gaskets.

Note: Fasten all screws according to

symmetrical and crossing principle.
Note：Fastening torque：110～130Nm
Figure 68
Note：Loctite 262 thread fastening sealant

14. Assemble brake caliper assembly

Assemble disc brake on brake caliper supporting,
fix with bolts and gaskets.

Note：Fastening torque：540～650Nm
Note：Coat Loctite 262 thread fastening sealant
at 20mm length at thread end during
assembling.
Figure 69

15. Assemble main drive assembly

Coat Loctite 598 silicon rubber surface sealant at
the joint surface between shell and bracket,
coatφ3 ～ φ6 glue saluting ring with sealing
surrounding inside of thread hole at the large
end of shell. The coated sealant cannot be in the
air for more than ten minutes.

Figure 70
Note：Loctite 598 silicon rubber surface sealant

16. Assemble main drive

Hand up main drive assembly with overhead
crane, put main drive at main drive shell of the
axle, assemble locating pin.

Figure 71

SP002363 Front Axle

Page 28
17. Assemble bolts
Coat proper Loctite 262 threat fastening sealant
on bolts, the coating position is 15mm length at
thread end. Fasten main drive assembly and
shell assembly with bolts and gaskets.
Note：Fastening torque：110～130Nm
Note：Loctite 262 threat fastening sealant
Note：Fasten all screws according to
Figure 72
symmetrical and crossing principle.

18. Add oil

Add 10L 85W/90 GL-5 gear oil (GB13895-1992)
in axle bag of shell and fasten plug screws.

Note：Use 85W/90 GL-5 gear oil

Note：Anaerobic type pipe threat sealant
Note：Fastening torque：280～330Nm
Figure 73

19. Inject 4.5L (subject to overflowing from planet

carrier) 85W/90 GL-5 gear oil (GB13895-1992)
into two hub reducers and fasten plug screws.

Note：Use 85W/90 GL-5 gear oil

Note：Anaerobic type pipe threat sealant

Figure 74

2. Assembly parts assembling

2.1 Install hub assembly
1. Keep the large end of hub upward, assemble
bearing outer ring and turn over to keep the small
end of hub upward and assemble bearing inner
ring.

Figure 75

Front Axle SP002363

Page 29
2. Coat lubrication oil at oil seal end, check
completeness of oil seal, coat lubrication oil in
groove of oil seal evenly, and assemble oil seal
in side of oil seal end.

Figure 76

3．Assemble brake disc on hub and fasten with bolts

and gaskets.

Note：Fastening torque：280～330Nm
Note：Fasten all screws according to
symmetrical and crossing principle.

Figure 77

2.2 Assemble planet carrier assembly

1．Stick lubrication grease quill roller (27 units each)
on walls of inner holes of planet gears, assemble
baffle ring in the middle of quill roller, assemble
gaskets at both sides of planet gear, then
assemble to the seat hole of planet carrier.

Figure 78

2. Assemble steel balls in holes of planet gear

shaft, steel ball shall aim at semi circle of planet
carrier, go through the inner hole of planet gear
and gasket and assemble on planet carrier. After
assembly, planet gear shall rotate flexibly there is
no blocking.

Figure 79

SP002363 Front Axle

Page 30
2.3 Install of main drive assembly
1. Assemble rolling bearing on bear neck of the
terminal with pressure machine, rotate to the left
on active spiral bevel gear front axle, and rotate
to the right side.

Figure 80

2．Press inner ring into rolling bearing with pressure

machine at the other side

Figure 81

3. Turn over gear and assemble outer ring of gear

Figure 82

4．Install spacer bush

Figure 83

Front Axle SP002363

Page 31
5．Install gaskets

Figure 84

6．Install bearing sleeve

Figure 85

7．Press inner ring of antifriction bearing in the end.

Note: when assembling main reducer, taper
rolling bearing shall have certain
tightness, that is on the basis of
eliminating bearing clearance, and give
certain preload. The purpose is to reduce
axial force caused during transmission
process which will result in axial
displacement, improve supporting rigidity,
and guarantee normal mesh of bevel Figure 86
gear pair. But if it is too tight, it will
accelerate abrasion of taper rolling
bearing. Press with P= 5420 kg pressure
at the top side of inner ring of rolling
bearing, grapple Φ14.5 hole with pull and
push ergometer, pull ergometer along
with tangential direction, indication of
ergometer when pushing shall be
17.34-30.06N, if the indication is not
within the range of 17.34-30.06N,
increase or reduce thickness of spacer Figure 87
shim, repeat the above process until the
indication is within 17.34-30.06N.

SP002363 Front Axle

Page 32
2.4 Assemble of differential assembly
1. Assemble rolling bearing at the bearing position of
right shell terminal of differential mechanism.

Figure 88

2. Assemble rolling bearing at the bearing position of

left shell terminal of differential mechanism.

Figure 89

3. Assemble semiaxis gear

Assemble semiaxis gear gasket in left shell of
differential mechanism.

Note：The side of gasket with groove shall toward

to the direction of joint cross

Figure 90

4. Install semiaxis gear

Figure 91

Front Axle SP002363

Page 33
5. Assemble joint cross assembly
Assemble bevel gear (internal of small terminal)
and bevel gear gasket on four axles of joint cross.

Note：Lubricate with grease when assembling

bevel gear and bevel gear gasket
Note：Lubricate lubrication oil

Figure 92

6. Differential mechanism shell

Assemble joint cross in right shell of differential
mechanism to make bevel gear and semiaxis gear
mesh, turn over left shell assembly of differential
mechanism to assemble right shell assembly of
differential mechanism, join right shell and left
shells of differential mechanism with bolts and
fasten with gaskets and nuts. Figure 93

Note：Nuts fastening torque180～210Nm

Note：1) Guarantee assembling mark of right shell
and left shell of differential mechanism
align.
2) Coat proper Loctite 262 thread fastening
sealant at the thread bottom within 12mm
length.
3) After assembling, semiaxis gear and
taper gear can be rotated manually without
blocking. Figure 94

SP002363 Front Axle

Page 34
7. Install driven spiral bevel gear
Aim at assembling mark, fasten driven spiral bevel
gear (rotate to the left for rear axle, rotate to the
right for front axle) with bolts, gaskets and nuts,
and fasten screws.

Note：Nuts fastening torque 180～210Nm。

Note：1) Coat proper Loctite 262 thread fastening
sealant at the thread bottom within 12mm
length. Figure 95
2) Judging method of left and right spiral:
face to positive side of gear, right rotation
refers to the spiral gear rotates to large
terminal clockwise; on the contrary, left
rotation refers to the spiral gear rotates to
large terminal anticlockwise.

2.5 Install main reducer

1. Install the assembled active sprial bevel gear
assembly in bracket, coat sealant line with
diameter 2-4mm at the small end, refer to the
picture for sealant line; sealant line and diameter
of bearing sleeve (the other side of gasket) shall
be done according to the above requirements.

Figure 96

2. Assemble sealing cover

Press oil seal in sealing cover.

Note：Coat a layer of proper lubrication oil when

assembling oil seal.

Figure 97

Front Axle SP002363

Page 35
3. Install input flange
Put gasket on the end face of bracket, install
sealing cover assembly (coat lubrication grease
on oil seal according to common requirements of
drive axle), and connect with bracket with bolts
and gaskets.

Note：Screw fastening torque 110～130Nm。

Figure 98

4. Install input flange.

Figure 99

5. Install baffle ring, O ring, coat sealant on one end

face of gasket, the surface with sealant is
downward, install gasket.

Note：Coat Loctite 598 sealant

Figure 100

6. Install gasket

Figure 101

SP002363 Front Axle

Page 36
7. Install round screws and fasten.
Note：Screw fastening torque: 320～400Nm 。
Note：Before installing flange, install flange on
multiple spline on main spiral bevel gear,
measure radial play eccentricity of flange,
guarantee it cannot be more than 0.08,
and mark matching and assembling signs.
If it is out of tolerance, rotate flange to
certain angle and measure unitl it complies
Figure102
with requirements, otherwise, replace
flange.

8. Gasket shall be close to φ2～φ3 glue line.

9. Install differential assembly
Turnover carrier, install differential assembly in
bracket.

Figure103

10. Install bearing seat with gaskets and bolts (bolts

shall be a little bit tight).

Figure104

11. Install adjusting nuts.

Note：Two bearing seats cannot be exchanged.

12. Coat proper thread sealant on the length of 15～

25mm on thread end surface of bolts.

Note：Coat Loctite 262 thread fastening sealant.

Figure105

Front Axle SP002363

Page 37
13. Adjust spiral bevel gear
Adjustment of spiral bevel gear mesh condition
refers to adjustment of mesh zone and back lash,
when adjusting back lash of spiral bevel gear
pair, dial gauge can be used to touch the gear
surface of large side edge of driven spiral bevel
gear, then rotate driven spiral bevel gear to
measure back lash directly, the clearance shall
be 0.2 ～ 0.35mm. Adjusting method of back
mesh is to twist adjusting nuts to change position Figure 106
of driven spiral bevel gear (when it is necessary,
move active spiral bevel gear assembly to
adjust).
If the clearance is larger than the regulated value, approach active spiral bevel gear from driven spiral
bevel gear; otherwise be away from it. In order to keep the adjusted preload of taper rolling bearing of
differential mechanism, twisting numbers of adjusting nuts at one side shall be equal to twisting numbers
of adjusting nuts at the other side.
When adjusting contact zone of spiral bevel gear pair, coat red color (red lead powder) on driven spiral
bevel gear teeth (coat three teeth usually), rotate driven spiral bevel gear with hands repeatedly, check
contacting moulage. Adjust the correct position of spiral bevel gear mesh moulage: it shall not be less
than 50% along with teeth height direction and teeth length direction, mesh moulage of driven bevel gear
shall be close to the center, and in the middle of teeth height, smaller than the small end on teeth length
direction. Increasing preload of differential bearing: after adjusting back lash of spiral bevel gear well, it
shall guarantee the clearance between taper rolling bearings at both sides of differential mechanism is 0.
Following is the adjusting methods.
Adjustment of contact zone and back lash when installing spiral bevel gear
Contact zone of driven spiral
Adjusting method Gear moving direction
bevel gear

Move driven gear to the direction of active gear,

if the clearance is too small, move active gear
outside

Move driven gear away from active gear, if the

clearance is too large, move active gear inside

Move active gear to the direction of driven gear,

if the clearance is too small, move driven gear
inside and outside

Move active gear away from driven gear, if

clearance is too large, move driven gear inside

SP002363 Front Axle

Page 38
Method of adjusting mesh zone is usually increasing and decreasing adjusting gaskets and rotating adjusting
nuts. Adjusting of contact zone will affect performance and service life greatly, it shall be carried out carefully.

Note：After adjusting, clean off red lead powder.

14. Install locking plate

Fasten the fixed bolts on bearing seat, fastening
torque is 380～450Nm. Put locking plate at the
right position, fix it on bearing seat with bolts and
gaskets, and fasten fixing bolts of locking plate.

Note：Fastening torque 30～36Nm

Note：Coat proper Loctite 262 thread fastening
sealant on 5-10mm length at the end Figure 107
surface of fixing bolt.
Note：Coat Loctite 262 thread fastening sealant

Front Axle SP002363

Page 39
SP002363 Front Axle
Page 40
 SP002364

REAR AXLE

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual or
those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

MODEL SERIAL NUMBER RANGE

SD200 1001 and Up

Copyright 2011 DISD

July 2011

Rear Axle SP002364

Page 1
TABLE OF CONTENTS
General Description………………………………………………………………………….3
Structure Chart………..………………………………………………………………….3
Basic Parameters of Drive Axle……………………………………………………….3
Internal Structure of Drive Axle………………………………………………………..3
Parts List………………………………………...………..……………………………………4
Disassembly of Rear Axle………………………………………………………...……4
Assembly of Hub Drive Axle…………..…………………………………...…………5
Brake Assembly………………………………..…………………………………………7
Main Drive Assembly………………………………..………………………………….…8
Scheduled Maintenance……………………... ..……………………………………….…10
Every Month Maintenance……………..………………………………………….…10
Every Half Year Maintenance………..…………………………………………….…10
Every Year Maintenance………………..………………………………………….…10
General Disassembly and Reassembly Instructions…………………………….…11
Axle Disassembly…………………………………..………………………………….…..12
Disassembly of Drive Axle…………. ……….………………………………….…..12
Assembly Dismantling…………………..………………………………………….…..16
Axle Reassembly…………………………………..………………………………….……24
Axle Assembly………………………………..…………………………………….……24
Assembly Parts Assembling……….. ………………………………………….……29

SP002364 Rear Axle

Page 2
GENERAL DESCRIPTION

Structure chart

Figure 1
1. EDGE REDUCER ASS’Y 2. BRAKE CALMPS ASS’Y 3. SHELL 4. MAIN REDUCER ASS’Y
5. HUB ASS’Y

Basic parameters of drive axle:

Type Spiral bevel gear grade one reduction

Main drive
Reduction ratio 4.222
Type Grade one planet reduction
Hub reduction gear
Reduction ratio 4.8

Axle oil GB13895-1992 gear oil 10Kg

Internal structure of drive axle

Drive axle assembly is one of the most important spare parts of transmission system, its main function is
reduce rotation speed from gear box and increase torque, and make wheels at both sides having speed
difference. Besides, it also plays the role of bearing and transmitting. Drive axle assembly of loader is mainly
composed of shell, main drive (including differential mechanism), semiaxis, hub reduction gear, brake caliper
assembly and other parts. Of which, the parts having reduction and differential function is main driver and hub
reduction gear; power transmission between main drive and hub reduction gear is realized through semiaxis,
multiple spline at both sides of semiaxis and axle shaft gear of differential mechanism and sun gear of hub
reduction gear mesh with each other to realize power connection between main drive and hub reduction gear.

Rear Axle SP002364

Page 3
PARTS LIST
Disassembly of rear axle

Figure 2

Reference Reference
Description Description
Number Number
1 WHEEL REDUCER ASS’Y 10 MAIN REDUCER ASS’Y
2 AXLE ASSY;SHELL 11 STUD BOLT
3 GROUP WASHER φ24 12 SPACER 12
4 PLUG,SCREW 13 NUT M12
5 DEFLATION VALVE Z1/8 14 BOLT M12X35-10.9
6 O-RING 15 SPACER 12
7 PLUG,SCREW 16 BOLT
8 PLUG,SCREW 17 PIN
9 O-RING 18 BRAKE ASSY
SP002364 Rear Axle
Page 4
Assembly of hub drive axle

Figure 3

Rear Axle SP002364

Page 5
 Reference Reference
Description Description
Number Number
1 PLUG,SCREW 19 PLANET WHEEL
2 O-RING 20 PLANET WHEEL WASHER
3 BOLT M12X1.5-25 21 HALF SHAFT
4 SPACER 12 22 SUN WHEEL
5 COVER 23 SCREW M8X15
6 BLOCK 24 HOLDING NUT
7 RETAINER RING 48 25 INSIDE GEAR
8 PLUG,SCREW 26 BEARING 7521E
9 O-RING 27 HUB
10 HUB NUT 28 SPRING WASHER
11 HUB BOLT 29 NUT M18
12 SHELF,PLANET 30 BEARING 2007122E
13 O-RING SEAL 31 O-RING SEAL
14 STEEL BALL φ6 32 BRAKE DISC
15 PLANET WHEEL WASHER 33 WASHER 16
16 NEEDLE ROLLER 4×23.8 34 BOLT M16X45
17 SAPCER SLEEVE 35 SEAL ASSY,OIL
18 PLANET WHEEL SHAFT

SP002364 Rear Axle

Page 6
Brake assembly

Figure 4

Reference Reference
Description Description
Number Number
1-1 BRAKE,EXTERIOR 9 WASHER
1-8 BRAKE,INNER 10 CONNECTING
2 PISTON 11 DEFLATING VALVE
3 RECTANGULAR SEAL 12 SPACER 12
4 CASE,DUST 13 BOLT
5 BLOCK RING 14 WASHER SPRING 10
6 BRAKE DISK 15 PIN;BOLT
7 O-RING 20X2.4
Rear Axle SP002364
Page 7
Main drive assembly

Figure 5

SP002364 Rear Axle

Page 8
 Reference Reference
Description Description
Number Number
1 PIN 5X45 24 HOLDING PLATE
2 NUT M27×1.5-7H 25 DIFFERENTIAL SHELL –LEFT
3 WASHER 26 GEAR,BEVEL;DRIVE(REAR)
4 O-RING BAFFLE 28 DIFFERENTIAL BEARING COVER
5 O-RING SEAL 40X5.3 29 HOLDING PLATE
6 INPUT FLANGE GROUP 30 BOLT M18×90
7 OIL SEAL B62×93×6 31 HOLDING PLATE
8 OIL SEAL FB62×93×13 32 HOLDING PLATE
9 STOPPER WASHER 33 BOLT M8X12
10 BOLT M12×45-10.9 34 REGULATE NUT
11 SPACER 12 35 BEARING 7516E
12 OIL SEAL SEAT 36 BOLT M14X1.5
13 BEARING 27311E 37 DIFFERENTIAL SHELL – RIGHT
14 REGULATE WASHER 38 HALF SHAFT GEAR WASHER
15 SPACER SLEEVE 39 HALF SHAFT GEAR
16 BEARING SEAT 40 SUPPORT WASHER
17 BEARING 27311E 41 CROSS SHAFT
18 REGULATE WASHER 42 PLANET GEAR
19 REGULATE NUT 43 MAIN REDUCER SHELL
20 BEARING 7516E 44 RETAINER RING 30
21 NUT M14X1.5 45 BEARING 92606E
22 HOLDING PLATE 46 DRIVE GEAR;RIGHT
23 HOLDING PLATE

Rear Axle SP002364

Page 9
SCHEDULED MAINTENANCE
Oil of new drive axle must be replaced after working for 15 days (about 100 working hours), oil shall be
replaced once after working for every six months (about 1200 working hours) in following days.

Every month maintenance

1. Check abrasion condition of brake disc, if there is disruptive abrasion; please handle in time if there is
any.
2. Check abrasion condition of brake block to guarantee separation and reunion of brake caliper is flexible;
it shall be replaced in time when brake block is wearing close to abrasion line (at the bottom of groove).
3. Check if oil level of shell complies with requirements, please add new oil if the oil level descends.
4. Keep axle clean, keep vent pipe smooth, and avoid silt going into axle. Check loosening condition of all
fasteners, especially rim nuts, if it is loosed, please refasten again.

Every half year maintenance

Lubrication oil in axle shall be replaced every half a year, different brands of lubrication oil shall be adopted for
different areas and seasons. Please refer to 4.2 for oil replacing method.

Every year maintenance

Overhaul checking every working year:
1. Check the gap, mesh and abrasion condition of spiral bevel gear of main reducer.
2. Check abrasion condition of differential mechanism gear.
3. Check abrasion condition of hub gear.
4. Check abrasion condition of needle bearing of hub planetary gear.
5. Requirements of installation and debugging items after overhaul checking:
1）After assembling, axle shaft gear and bevel gear shall move flexibly with hand touching rather than
locking. The Min. gear backlash of gear is 0.18-0.23mm. Tooth length and tooth height of contacting
area of two gears cannot be less than 50%.
2）In order to guarantee enough bearing rigidity of active spiral gear, before assembling oil seal and
sealing cover, adopt gradually reducing spacer shim between tapered roller bearing to give
1.0-1.5N.m preloaded torque to roller bearing.
3）Gear backlash between the driving and driven spiral bevel gear is 0.25-0.45mm, the changing amount
cannot be more than 0.15mm, gear backlash can be realized through adjusting nuts of both sides of
differential mechanism and spacer shim of bearing sleeve. Tooth surface contacting area shall
guarantee direction of tooth length and tooth height is not less than 50%, contacting position shall be
at the middle side of tooth surface and closer to the smaller side.
4）Adjusting of bearing clearance of shell at both sides of drive axle: Fasten adjusting nuts, give
28-38N.m preload to shell roller bearing, and then lock two round nuts with screw fastening.

SP002364 Rear Axle

Page 10
GENERAL DISASSEMBLY AND REASSEMBLY

INSTRUCTIONS

WARNING!
Never use gasoline, solvents, or other flammable fluids to clean components. Only use approved
commercial solvents that are nonflammable and nontoxic.

IMPORTANT
Use only GENUINE DOOSAN SPARE PARTS to warrant proper operations and prevent
interchangeability problems.

GENERAL INSTRUCTIONS
1. Thoroughly clean and dry axle before disassembly.
2. All components should be thoroughly cleaned and dried before reassembly. Dirt, chips, and foreign
material may cause failures.
3. All ducts and castings should be thoroughly cleaned and dried to remove dirt, chips, and foreign material
to prevent damage after reassembly.
4. Reassembly should be done in a clean shop, and should be as dust free as possible.
5. Make sure tools and equipment are at hand.
6. When reassembling Daewoo strongly recommends to replace the following parts with new.
• Seal Rings.
• O-rings.
• Gaskets.
• Threaded rings with notched collar.
• Any component damaged during disassembly.
7. When mounting heat fitted components, make sure of their proper position and direction of assembly,
after they have cooled.
8. To heat bearings, use proper heating plates, piping, or suitable ovens.
NOTE: Never heat parts by using a torch. Oil bath, heated by a torch, maybe used to warm components.
9. Lubricate all sections concerned when reassembling shafts, bearings, etc.
10. Lubricate O-rings before installing them in relevant seats to prevent kinking during assembly, such a
position would impair proper sealing.
11. Replace gears only in matched sets to make sure of proper tooth mating.

Rear Axle SP002364

Page 11
AXLE DISASSEMBLY
1 Drive axle disassembly
1. Put drive axle on supporting and make sure
main driver assembly is upward.

Figure 6

2. Dismantle brake caliper assembly

Loosen the connection bolts between brake
caliper and brake caliper support, dismantle brake
caliper assemble.

Figure 7

3. Release gear oil from planet carrier

Loosen hub oil releasing drain plug and shell oil
releasing drain plug, turn on slowly with hands to
avoid oil spilling.

Note：Store gear oil with clean container.

Figure 8

SP002364 Rear Axle

Page 12
4. Release gear oil from shell
Turn on oil releasing bolts axle end cap to release
gear oil.

Note：Store gear oil with clean container.

Figure 9

5. Open end cap

Loosen connection bolts between planet carrier
and end cap, then get end cap from hub reducer
assembly with jackscrew, dismantle end cap.

Figure 10

6. Dismantle locating block

Take down locating block with hands.

Note：If it is tight when taking down, please use

assistant tools to pry out.

Figure 11

7. Dismantle stop collar

Dismantle stop collar from semiaxis with stop
collar pincers.

Note：Before dismantling stop collar, pull out a

section of semiaxis from shell.
Note：It must clamp firmly when using stop collar
pincers to avoid safety hazard when it is
Figure 12
popup.

Rear Axle SP002364

Page 13
8. Dismantle sun gear
Dismantle semiaxis from sun gear.。

Figure 13

9. Dismantle locating block

Dismantle locating block from semi axle with
hands.

Figure 14

10. Dismantle semiaxis

Take semiaxis from shell slightly.

Figure 15

11. Hub reducer

First loosen rim bolts with relative tools, then
loosen rim from planet carrier with jackscrew and
dismantle planet carrier assembly.

Note：Please slowly loosen planet carrier to avoid

safety hazard resulted from dropping of
planet carrier assembly.

Figure 16
SP002364 Rear Axle
Page 14
12. Dismantle round bolts
Dismantle round bolts.

Figure 17

13. Dismantle round nuts

Dismantle round nuts.

Figure 18

14. Dismantle internal gear

Take internal gear out by slightly rocking.

Figure 19

15. Dismantle rolling bearing

Take out rolling bearing with special dismantling
tool.

Figure 20

Rear Axle SP002364

Page 15
16. Dismantle wheel hub assembly
Take wheel hub assembly from supporting axle.
Note：During hanging and dismantling process,
please keep axis of wheel hub assembly
is in line with axis of hub reduction
supporting axle to avoid scratching oil
surface and internal spare parts during
dismantling process.
Figure 21
Remark: dismantle all parts at the other side of
drive axle with the same methods.

17. Dismantle of main drive assembly

Dismantle connection bolts between main drive
and shell assembly, take out main drive with
jackscrew, and suspend main drive assembly.
Note：When suspending main drive assembly,
guarantee suspending and dismantling
tools are at the above of main drive
assembly to avoid spare parts inside are
Figure 22
knocked again during suspending and
dismantling process.

2. Assembly dismantling
2.1 Dismantle planet carrier assembly
1. O ring
Take out O ring.

Figure 23

2. Put planet carrier on working platform horizontally.

SP002364 Figure 24 Rear Axle

Page 16
3. Take out planet axle with tools.

Figure 25

4. Take out steel balls.

Figure 26

5. Take out planet wheel.

Figure 27

6. Take out baffle ring and quill roller from inside of

planet wheel.

Figure 28

Rear Axle SP002364

Page 17
2.2 Dismantle hub assembly
1. Put hub assembly on working platform, loosen
connection bolts between brake disc and hub.

Figure 29

2. Take out brake disc.

Figure 30

3. Take out bearing.

Figure 31

4. Take out oil seal.

Figure 32

SP002364 Rear Axle

Page 18
2.3 Dismantle main drive assembly
1. Put main drive assembly (input flange upward)
horizontally and fixed on supporting.

Figure 33

2. Dismantle locknut gasket, O ring and baffle ring.

Figure 34

3. Take out input flange.

Figure 35

4. Dismantle connection bolts between sealing cover

and bearing sleeve, take out sealing cover.

Figure 36

Rear Axle SP002364

Page 19
5. Turn main drive for 180°, dismantle bolts fastening
locking plate, take out locking plate.

Note：Some of the machine structure may be

different from this figure, please adjust
working content according to actual
structure.

Figure 37

6. Dismantle connection bolts of bearing seat and

take out bearing seat.

Figure 38

7. Dismantle adjusting nuts.

Figure 39

8. Dismantle bearing outer ring.

Figure 40

Rear Axle SP002364

Page 20
9. Hang out differential mechanism assembly.
Note：Keep balance when hanging out to avoid
safety hazard.

Figure 41

10. Separate active spiral bevel gear assembly and

bracket with jackscrew.

Figure 42

2.4 Dismantle differential assembly

1. Put differential assembly vertically on working
platform, and guarantee it is stable.

Figure 43

2. Dismantle bearing on left and right shell of

differential mechanism.

Figure 44

Rear Axle SP002364

Page 21
3. Loosen connection nuts between driven spiral
bevel gear and right shell of differential
mechanism, dismantle driven spiral bevel gear.
Note：Before taking out driven spiral bevel gear,
please check or mark assembling sign
first so that it can be placed back to the
original position.

Figure 45

4. Loosen connection nuts of left and right shell,

separate left and right shell of differential
mechanism.
Note：Before separating left and right shell of
differential mechanism, please check or
mark assembling sigh first so that it can
be placed back to the original position.

Figure 46

5. Take out semiaxis gear gasket and semiaxis gear.

Figure 47

6. Take out joint cross and differential gear together,

take out differential gear gasket and gear from
joint cross.

Figure 48

SP002364 Rear Axle

Page 22
7. Take out semiaxis gear gasket and gear.

Figure 49

2.5 Dismantle active spiral bevel gear assembly

1. Put active spiral bevel gear assembly on working
platform, support flange of bearing sleeve, clamp
down on thread end of active spiral bevel gear
assembly with down device.
Note：Do not clamp too much to avoid damaging
flange, pull out bearing sleeve from active
spiral bevel gear assembly.

Figure 50

2. Reverse bevel gear assembly and take out

bearing.

Figure 51

3. Take out bearing sleeve.

Figure 52

Rear Axle SP002364

Page 23
4. Take out adjusting gasket.

Figure 53

5. Take out spacer bush.

Figure 54

AXLE REASSEMBLY
1. Axle assembly
1. Shell
Clean shell and suspend with special supporting.
Fasten gummed plug screw at oil inlet and oil filler.

Note：Plug screw fastening torque：280～330Nm

Note：Loctite 262 taper thread sealant.

Figure 55

SP002364 Rear Axle

Page 24
2. Wheel hub assembly
Coat lubrication grease on hub supporting axle of
shell assembly; assemble wheel hub assembly on
both sides of supporting axle of shell assembly.

Note：Use lubrication oil.

Figure 56

3. Rolling bearing
Assemble rolling bearing on hub supporting axle.

Figure57

4. Internal gear
Assemble internal gear of drive axle at multiple
splines at the end of supporting bearing.

Figure 58

5. Round nuts
Assemble round nuts and fasten. Knock internal
gear slightly with copper stick to make internal
gear in place.

Figure 59

Rear Axle SP002364

Page 25
6. Assemble round bolts
1) Grapple the hole on wheel hub with push and
pull ergometer, pull ergometer along with
tangential direction, indication on ergometer is
160±10N, if the indication is not within the
range of 160±10N, adjust tightness degree of
round bolts according to the indication until it is
within the range of 160±10N. In the end, coat
Figure 60
Loctite 262 thread fastening sealant for 5~6
from the second thread hole of internal gear
(form a liquid level at 1/3 circle of thread), then
fasten bolts, and fix round nuts.
2) Before dynamometry, rotate hub wheel for
more than 5 times.

Note：Loctite 262 thread fastening sealant

Figure 61

7. Assemble O sealing ring

Assemble O sealing ring on hub assemble.

Figure 62

8. Planet carrier assembly

Assemble planet carrier assembly on wheel hub
with rim bolts, gaskets and nuts.

Note：Fastening torque：540～650Nm

Figure 63
SP002364 Rear Axle
Page 26
9. Assemble semiaxis
Assemble semiaxis in wheel hub.

Figure 64

10. Assemble sun gear

Assemble sun gear at one side of semiaxis with
baffle ring groove (pay Note to semiaxis multiple
spline and gear assembly).

Figure 65

11. Assemble baffle ring

Assemble baffle ring with baffle ring used for
axle.
Note：It must be clamped firmly when using
baffle ring pincer to avoid safety hazard
when it is popping out during assembling
process.

Figure 66

12. Assemble locating block

Stake steel ball on locating block, it can rotate
flexibly after staking steel ball.

Figure 67

Rear Axle SP002364

Page 27
13. Assemble end cap
Coat Loctite 262 thread fastening sealant on
screws, location of sealant is 15mm on top of
thread end. Fasten cap with bolts and gaskets.

Note：Fasten all screws according to symmetrical

and crossing principle.
Note：Fastening torque：110～130Nm
Note：Loctite 262 thread fastening sealant Figure 68

14. Assemble brake caliper assembly

Assemble disc brake on brake caliper supporting,
fix with bolts and gaskets.

Note：Fastening torque：540～650Nm
Note：Coat Loctite 262 thread fastening sealant at
20mm length at thread end during
assembling.
Figure 69

15. Assemble main drive assembly

Coat Loctite 598 silicon rubber surface sealant at
the joint surface between shell and bracket,
coatφ3 ～ φ6 glue saluting ring with sealing
surrounding inside of thread hole at the large
end of shell. The coated sealant cannot be in the
air for more than ten minutes.
Note：Loctite 598 silicon rubber surface sealant
Figure 70

16. Assemble main drive

Hand up main drive assembly with overhead
crane, put main drive at main drive shell of the
axle, assemble locating pin.

Figure 71

SP002364 Rear Axle

Page 28
17. Assemble bolts
Coat proper Loctite 262 threat fastening sealant
on bolts, the coating position is 15mm length at
thread end. Fasten main drive assembly and
shell assembly with bolts and gaskets.
Note：Fastening torque：110～130Nm
Note：Loctite 262 threat fastening sealant
Note：Fasten all screws according to symmetrical
Figure 72
and crossing principle.

18. Add oil

Add 10L 85W/90 GL-5 gear oil (GB13895-1992)
in axle bag of shell and fasten plug screws.
Note：Use 85W/90 GL-5 gear oil
Note：Anaerobic type pipe threat sealant
Note：Fastening torque：280～330Nm

Figure 73

Figure 74

2 Assembly parts assembling

2.1 Install hub assembly
1. Keep the large end of hub upward, assemble
bearing outer ring and turn over to keep the small
end of hub upward and assemble bearing inner
ring.

Figure 75

Rear Axle SP002364

Page 29
2 ． Coat lubrication oil at oil seal end, check
completeness of oil seal, coat lubrication oil in
groove of oil seal evenly, and assemble oil seal in
side of oil seal end.

Figure 76

3．Assemble brake disc on hub and fasten with bolts

and gaskets.

Note: Fastening torque：280～330Nm

Note：Fasten all screws according to symmetrical
and crossing principle.

Figure 77

2.2 Install planet carrier assembly

1．Stick lubrication grease quill roller (27 units each)
on walls of inner holes of planet gears, assemble
baffle ring in the middle of quill roller, assemble
gaskets at both sides of planet gear, then
assemble to the seat hole of planet carrier.

Figure 78

2. Assemble steel balls in holes of planet gear shaft,

steel ball shall aim at semi circle of planet carrier,
go through the inner hole of planet gear and
gasket and assemble on planet carrier. After
assembly, planet gear shall rotate flexibly there is
no blocking.

Figure 79

SP002364 Rear Axle

Page 30
2.3 Assemble of main drive assembly
1. Assemble rolling bearing on bear neck of the
terminal with pressure machine, rotate to the left
on active spiral bevel gear front axle, and rotate
to the right side.

Figure 80

2．Press inner ring into rolling bearing with pressure

machine at the other side

Figure 81

3. Turn over gear and assemble outer ring of gear,

Figure 82

4．Install spacer bush

Figure 83

Rear Axle SP002364

Page 31
5．Assemble gasket

Figure 84

6．Assemble bearing sleeve

Figure 85

7．Press inner ring of antifriction bearing in the end.

Note: when assembling main reducer, taper
rolling bearing shall have certain tightness,
that is on the basis of eliminating bearing
clearance, and give certain preload. The
purpose is to reduce axial force caused
during transmission process which will
result in axial displacement, improve
supporting rigidity, and guarantee normal
Figure 86
mesh of bevel gear pair. But if it is too tight,
it will accelerate abrasion of taper rolling
bearing. Press with P= 5420 kg pressure
at the top side of inner ring of rolling
bearing, grapple Φ14.5 hole with pull and
push ergometer, pull ergometer along with
tangential direction, indication of
ergometer when pushing shall be
17.34-30.06N, if the indication is not within
the range of 17.34-30.06N, increase or
reduce thickness of spacer shim, repeat
Figure 87
the above process until the indication is
within 17.34-30.06 N.

SP002364 Rear Axle

Page 32
2.4 Assemble of differential assembly
1. Assemble rolling bearing at the bearing position of
right shell terminal of differential mechanism.

Figure 88

2. Assemble rolling bearing at the bearing position of

left shell terminal of differential mechanism.

Figure 89

3. Assemble semiaxis gear

Assemble semiaxis gear gasket in left shell of
differential mechanism

Note：The side of gasket with groove shall toward

to the direction of joint cross

Figure 90

4. Assemble semiaxis gear

Figure 91

Rear Axle SP002364

Page 33
4. Assemble joint cross assembly
Assemble bevel gear (internal of small terminal)
and bevel gear gasket on four axles of joint cross.

Note：Lubricate with grease when assembling

bevel gear and bevel gear gasket
Note：Lubricate lubrication oil

Figure 92

6. Differential mechanism shell

Assemble joint cross in right shell of differential
mechanism to make bevel gear and semiaxis gear
mesh, turn over left shell assembly of differential
mechanism to assemble right shell assembly of
differential mechanism, join right shell and left
shells of differential mechanism with bolts and
fasten with gaskets and nuts.
Figure 93

Note：Nuts tightening torque180～210Nm

Note：1) Guarantee assembling mark of right shell
and left shell of differential mechanism
align.
2) Coat proper Loctite 262 thread fastening
sealant at the thread bottom within
12mm length.
3) After assembling, semiaxis gear and
Figure 94
taper gear can be rotated manually
without blocking.

SP002364 Rear Axle

Page 34
7. Assemble driven spiral bevel gear
Aim at assembling mark, fasten driven spiral bevel
gear (rotate to the left for rear axle, rotate to the
right for front axle) with bolts, gaskets and nuts,
and fasten screws.

Note：Nuts fastening torque 180～210Nm。

Note：1) Coat proper Loctite 262 thread fastening Figure 95
sealant at the thread bottom within
12mm length.
2) Judging method of left and right spiral:
Face to positive side of gear, right
rotation refers to the spiral gear rotates
to large terminal clockwise; on the
contrary, left rotation refers to the spiral
gear rotates to large terminal
anticlockwise.

2.5 Assemble main reducer

1. Install the assembled active spiral bevel gear
assembly in bracket, coat sealant line with
diameter 2-4mm at the small end, refer to the
picture for sealant line; sealant line and diameter
of bearing sleeve (the other side of gasket) shall
be done according to the above requirements.

Figure 96

2. Assemble sealing cover

Press oil seal in sealing cover.

Note：Coat a layer of proper lubrication oil when

assembling oil seal.

Figure 97

Rear Axle SP002364

Page 35
3. Install input flange
Put gasket on the end face of bracket, install
sealing cover assembly (coat lubrication grease
on oil seal according to common requirements of
drive axle), and connect with bracket with bolts
and gaskets.

Note：Screw fastening torque 110～130Nm.

Figure 98

4. Install input flange.

Figure 99

5. Install baffle ring, O ring, coat sealant on one end

face of gasket, the surface with sealant is
downward, install gasket.

Note：Coat Loctite 598 sealant

Figure 100

6. Install gasket

Figure 101

SP002364 Rear
AxlePage 36
7. Install round screws and fasten.
Note：Screw fastening torque: 320～400Nm 。
Note：Before installing flange, install flange on
multiple spline on main spiral bevel gear,
measure radial play eccentricity of flange,
guarantee it cannot be more than 0.08,
and mark matching and assembling signs.
If it is out of tolerance, rotate flange to
certain angle and measure until it complies
Figure 102
with requirements, otherwise, replace
flange.

8. Gasket shall be close to φ2～φ3 glue line.

9. Install differential assembly

Turnover carrier, install differential assembly in
bracket.

Figure 103

10. Install bearing seat with gaskets and bolts (bolts

shall be a little bit tight).

Figure 104

11. Install adjusting nuts.

Note：Two bearing seats cannot be exchanged.

12. Coat proper thread sealant on the length of 15～

25mm on thread end surface of bolts.

Note：Coat Loctite 262 thread fastening sealant.

Figure 105

Rear Axle SP002364

Page 37
13. Adjust spiral bevel gear
Adjustment of spiral bevel gear mesh condition
refers to adjustment of mesh zone and back lash,
when adjusting back lash of spiral bevel gear
pair, dial gauge can be used to touch the gear
surface of large side edge of driven spiral bevel
gear, then rotate driven spiral bevel gear to
measure back lash directly, the clearance shall
be 0.2 ～ 0.35mm. Adjusting method of back
mesh is to twist adjusting nuts to change position Figure106
of driven spiral bevel gear (when it is necessary,
move active spiral bevel gear assembly to
adjust). If the clearance is larger than the
regulated value, approach active spiral bevel
gear from driven spiral bevel gear; otherwise be
away from it. In order to keep the adjusted
preload of taper rolling bearing of differential
mechanism, twisting numbers of adjusting nuts
at one side shall be equal to twisting numbers of
adjusting nuts at the other side.
When adjusting contact zone of spiral bevel gear pair, coat red color (red lead powder) on driven spiral
bevel gear teeth (coat three teeth usually), rotate driven spiral bevel gear with hands repeatedly, check
contacting moulage. Adjust the correct position of spiral bevel gear mesh moulage: it shall not be less than
50% along with teeth height direction and teeth length direction, mesh moulage of driven bevel gear shall
be close to the center, and in the middle of teeth height, smaller than the small end on teeth length
direction. Increasing preload of differential bearing: after adjusting back lash of spiral bevel gear well, it
shall guarantee the clearance between taper rolling bearings at both sides of differential mechanism is 0.
Following is the adjusting methods.

Adjustment of contact zone and back lash when installing spiral bevel gear
Contact zone of driven spiral
Adjusting method Gear moving direction
bevel gear

Move driven gear to the direction of active

gear, if the clearance is too small, move
active gear outside

Move driven gear away from active gear, if

the clearance is too large, move active gear
inside
Move active gear to the direction of driven
gear, if the clearance is too small, move
driven gear inside and outside
Move active gear away from driven gear, if
clearance is too large, move driven gear
inside
SP002364 Rear Axle
Page 38
Method of adjusting mesh zone is usually increasing and decreasing adjusting gaskets and rotating adjusting
nuts. Adjusting of contact zone will affect performance and service life greatly, it shall be carried out carefully.

Note： After adjusting, clean off red lead powder.

14. Install locking plate

Fasten the fixed bolts on bearing seat, fastening
torque is 380～450Nm. Put locking plate at the
right position, fix it on bearing seat with bolts and
gaskets, and fasten fixing bolts of locking plate.

Note：Fastening torque 30～36Nm

Note: Coat proper Loctite 262 thread fastening
Figure 107
sealant on 5-10mm length at the end
surface of fixing bolt.
Note：Coat Loctite 262 thread fastening sealant

Rear Axle SP002364

Page 39
SP002364 Rear Axle
Page 40
 SP002345

2AIR CONDITIONER

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual or
those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

MODEL SERIAL NUMBER RANGE

SD200 1001 and Up
SD300 1001 and Up

Copyright 2011 DISD

July 2011

Air Conditioner SP002345

Page 1
TABLE OF CONTENTS
General Description....................................................................................................3
Circulation of Refrigeration Agent……………………………..…………..…………........4
Control Panel…………..………..…………………………………………........................6
AC System Circuit Diagram ……………………………………..….……...................7
Maintenance…………….…........................................................................................8
Trouble Shooting…….…………..……………..………..……......................................10

SP002345 Air Conditioner

Page 2
GENERAL DESCRIPTION
Heater and AC evaporator share one air blower, and it is located at the front side of driving cab. When it is
necessary, the driver can install it in control panel room at the right of control platform to control indoor
temperature.
AC of the machine has three functions of refrigeration, heating and natural wind.

Figure 1 AC system schematic diagram

Reference Number Description Reference Number Description

1 Compressor 4 Evaporator

2 Condenser 5 Control Panel

3 Receiver/Drier

Air Conditioner SP002345

Page 3
Circulation of refrigeration agent

Figure 2 Refrigeration agent circulation schematic diagram

SP002345 Air Conditioner

Page4
 • Refrigeration agent (R134a) is compressed to 15kg/cm2（213psi）within sight view.

• Compressed refrigeration agent flows into condenser under high temperature (about 80℃（176°F）).

• Refrigeration agent of condenser is cooled down by condensation fan to about 60℃. At the same time,
refrigeration agent is changed from gas state to liquid state, even if the temperature is reduced from
80°— 60℃（176°— 140°F）to 20℃（68°F）.

• Refrigeration agent is sprayed to evaporator in gas state through expansion valve. And pressure is
reduced for 2 kg/cm2（28psi）, and temperature is reduced, too. The result is refrigeration agent absorbs
heat from surrounding air to create refrigeration effect, refrigeration agent is changed from gas state to
liquid state.

• Refrigeration agent flows into compressor in gas state again and repeat the above process.

CAUTION!
Refrigeration agent is compressed and sealed in AC system. Special protective measures are
needed when injecting or releasing refrigeration agent correctly. It is strictly controlled by laws to
release refrigeration agent into air. Before maintaining or repair AC, please obey the orders of all
federation, states and districts, refrigeration agent used in the system must reach or exceed R134a
specifications or environmental standards issued later.

Air Conditioner SP002345

Page 5
 Control panel

Figure 3 AC control panel diagram

Control specifications
Control item Control switch Control specifications

―CLOSE‖ switch
Rotation speed ―LOW SPEED‖ switch
control of air blower ―INTERMEDIATE SPEED‖ switch
―HIGH SPEED‖ switch

Compressor control Temperature sensor

SP002345 Air Conditioner

Page 6
AC system circuit diagram

Figure 4 AC system circuit diagram

Reference Number Description Reference Number Description

1 Fuse Box 6 LED

2 Blower Switch 7 Press. Cut Off Switch

3 Blower 8 Compressor

4 Thermistor 9 Condenser

5 Temperature Sensor

Air Conditioner SP002345

Page 7
Maintenance
 AC outdoors radiator-―condenser‖ must be
cleaned regularly; refer to figure 5.
Treatment method: dismantle condensing fan,
condenser is completely exposes, wash with
water, but do not use high water pressure to
avoid lodging of condenser fan and affect
radiation effect.
Maintenance standard: wash once a month in
summer, if working environment is too bad,
increase washing times properly. Figure 5

 Check if fixed bolts of compressor are loosed

regularly, if belt of compressor is loosed; refer to
figure 6.
Checking method: visually check if AC bolts are
loosed, checking method of belt tightness
degree: put about 10kg force on middle of belt,
force is downward, descending amplitude of belt
is about 10-15mm, it cannot be too high or too
low; maintenance standard: check once a week
Figure 6
in summer.

 Check if there is refrigeration agent in the

system
Checking method: check Freon injection mouth
of compressor head (refer to the picture), screw
off plastic plug, poke with keys or other sharp
things (its structure is like the air tap of tyre),
check if there is large amount of air jets out, if
there is no air or air current is very small, it
proves that Freon is leaked (wear gloves and
protect eyes during operation, do not burn skin Figure 7
and eyes with refrigeration agent).

SP002345 Air Conditioner

Page 8
 Power on checking of the entire machine. Open
AC control panel, turn III gear switch to H gear
and check if there is wind coming from
evaporator and if wind is big enough. Turn on
temperature control switch on AC control panel
and turns to the maximum position, check if
indication light is on, at the same time, listen if
AC compressor is absorbing (turn on and turn
off temperature control switch repeatedly, there Figure 8
should be clear and melodious absorbing
―Pitter-patter‖ at compressor).

 Confirmation of charging amount of refrigeration.

Agent charging amount of refrigeration agent
R134a of the AC system is 1000±50g, the
process is vacuumizing, charging and retrieving.

Figure 9

Comparison table between liquid sight glass state of reservoir and trouble analysis

Liquid sight glass state Trouble analysis

Liquid sight glass is locate, bubbles can be seen at the

moment of turning on and turning off AC, and bubbles Freon charging quantity is proper
become transparent suddenly.
Few bubbles flowing, compressor head is hot,
Freon charging quantity is not enough or the
refrigeration output is not enough, high and low pressure
system is leaking
of the system are both very low.
Turn on and turn off AC, it is hard to see bubbles flowing,
compressor head is cold, high and low pressure of the Freon is over charged
system are both high.
Freon charging is proper, AC does not refrigerate, it is Expansion valve is dirty and blocked or frozen
hard to see bubbles flowing in reservoir, low pressure is and blocked, it shall be solved by professional
negative. personnel

Air Conditioner SP002345

Page 9
Trouble shooting
Following is the common troubles and reasons
1. The entire AC system is power off
• Reason analysis
- Fuse of AC is burnout.
- Wiring harness of AC power is not connected.
2. Evaporation fan is running, after turning on temperature control switch, indication light is not on,
condensation fan and compressor do not work.
• Reason analysis
- Indoor temperature of driving cab is lower than 4º
- Temperature sensing detector is open circuit or not connected.
- AC temperature control switch relay is broken.

3. Evaporation fan rotates, condensation fan rotates, compressor does not absorb
- Coil of compressor clutch is broken
- High/low pressure switch is broken.
- Freon is leaked
- Circuit from high/low pressure switch to compressor is open.

4. Evaporation fan does not run, condensation fan runs, compressor absorbs
- Earth wire of evaporation fan drops, or earth wire contact is not good.
- III gear switch is broken
- Evaporation fan is broken

SP002345 Air Conditioner

Page 10
 SP002365

Transmission and Torque Converter

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual or
those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

MODEL SERIAL NUMBER RANGE

SD200 1001 and Up

Copyright 2011 DISD

July 2011

Transmission and Torque Converter SP002365

Page 1
TABLE OF CONTENTS
Brief Introduction...........................................................................................................3
Structure of Transmission Gear............................................................................3
Basic Parameters of Transmission........................................................................4
Transmission Principle……………………...............................................................5
Working Principle of Torque Converter.................................................................6
Disassembly of Transmission.......................................................................................7
Disassembly of Transmission Assembly...............................................................7
Assembly Parts Dismantling..................................................................................15
Assembling of Transmission.......................................................................................20
Assembling of Transmission Assembly................................................................20
Assembly Parts Assembling.................................................................................30

SP002365 Transmission and Torque Converter

Page 2
Brief Introduction
Structure of transmission

Figure 1

Reference Reference
Description Description
Number Number
1 Transmission housing 7 Rear output Flange

2 Cover 8 Release Sliding sleeve

3 Rear shaft ass′y 9 Gear ring

4 Input shaft flange 10 Oil sump

5 Input shaft ass′y 11 Front output flange

6 Mid shaft ass′y 12 Parking break

Transmission and Torque Converter SP002365

Page 3
Basic parameters of transmission

Model of bivariant assembly ZL30 T/M

Applicable model SD200 Wheel Loader

Hydraulic torque converter type Single Stage, Four Part, Two turbo T/M

Max. input rotate speed 2500 r/min

Max. input torque 650 Nm

Max. input power 74 kW

Torque ratio 3.0~3.6

Type of oil cooling Cooling Water Circulating

Working pressure 1.1~1.5MPa

Gearbox type Dead Axle, Constant Mesh Gear, Shifting fork

Gears Four Front Gears and Two Rear Gears

I gear ratio 3.82

II gear ratio 2.08

III gear ratio 1.09

IV gear ratio 0.59

I reverse gear ratio 3.05

II reverse gear ratio 0.87

Gear box oil 6#Fluid Drive Oil

Allowable oil temperature at the bottom of oil pan 100℃

Manipulate pressure of brake safety valve >0.55MPa

SP002365 Transmission and Torque Converter

Page 4
Transmission principle

Figure 2

Transmission and Torque Converter SP002365

Page 5
Working principle of torque converter

Figure 3

Reference Reference
Description Description
Number Number

1 Spring plate 6 Turbine shaft

2 Turbine cover 7 Output initiative gear

3 turbine 8 Output driven gear

4 Pump pulley 9 Output shaft

5 guide pulley 10 Output flange

SP002365 Transmission and Torque Converter

Page 6
Disassembly of transmission
Disassembly of transmission assembly
1．Put transmission horizontally on working platform
with oil pan upward.

Figure 4

2．Dismantle oil pan

Use relative tools (such as sleeve, open spanner,
same with following conditions, and will not state
again). Loosen fixed bolts on oil pan, and
dismantle oil pan.

Figure 5

3．Dismantle fixing block of oil pan

Knock out with tools and take out fixing block.

Figure 6

4．Dismantle shifting fork

Twist fixed blots and take out shifting fork.

Figure 7

Transmission and Torque Converter SP002365

Page 7
5. Dismantle supporting seat of tie bar of shifting fork
twist fixed bolts, take out supporting seat.

Figure 8

6. Turn over transmission, make the side with brake

caliper upward, dismantle end cap and twist fixed
bolts, take out end cap.

Figure 9

7．Dismantle speed change valve

Twist fixed bolts and get out speed change valve.

Figure 10

8．Take out clutch end cap of the first and the third
gear twist fixed bolts and take out end cap.

Figure 11

SP002365 Transmission and Torque Converter

Page 8
9．Take out brake caliper assembly
Twist fixed bolts and take out brake caliper
assembly.

Figure 12

10．Take out fixed plate, sealing ring and cover plate

of front output flange, then take out front output
flange.

Figure 13

11．Overturn transmission; take out screw fixing

plate, sealing ring and cover plate of front output
flange, then take out output flange.

Figure 14

12．Take out output flange end cap

Twist fixed bolts and take out end cap.

Figure 15

Transmission and Torque Converter SP002365

Page 9
13．Take down bearing
Take down bearing with special tool.

Figure 16

14．Take down spacer bush.

Figure 17

15．Take down high speed gear.

Figure 18

16．Take down sliding tooth set

Figure 19

SP002365 Transmission and Torque Converter

Page 10
17．Take out output axle
Knock out output axle with tools and take out.

Figure 20

18．Take out low speed gear

Figure 21

19．Take out bearing

Knock out bearing with tools and take out.

Figure 22

20．Take out adjusting screws of the II gear, the IV

gear and reverse gear.

Figure 23

Transmission and Torque Converter SP002365

Page 11
21．Take out nuts, gaskets and flange of input axle

Figure 24

22．Take out end cap.

Figure 25

23．Overturn transmission; twist fixed bolts of the

cover

Figure 26

24．Take out clutch end cap of the second gear, the

fourth gear and reverse gear.
Twist fixed bolts and take out end cap.

Figure 27

SP002365 Transmission and Torque Converter

Page 12
25．Take out sealing ring of each clutch

Figure 28

26．Take out end cap of transmission.

Twist fixed bolts and take out end cap.

Figure 29

27．Take out clutch of the first and the third gear, the
second and the fourth gear and reverse gear.

Figure 30

28．Take out fixed set of brake caliper

Twist fixed bolts and take out fixed seat.

Figure 31

Transmission and Torque Converter SP002365

Page 13
29．Take out end cap of output axle
Twist fixed bolts and take out end cap.

Figure 32

30．Take out bearing of output axle.

Figure 33

31．Take out sleeve of clutch.

Figure 34

32．Overturn transmission; take out clutch end cap of

the second and the fourth gear and reverse
gear.

Figure 35

SP002365 Transmission and Torque Converter

Page 14
Assembly parts dismantling
Disassembling of torque converter assembly
1. Put torque converter on work platform
horizontally.

Figure 36

2． Dismantle fixed plate of spring plate.

Twist fixed bolts, take out fixed plate.

Figure 37

3．Dismantle elastic plate.

Figure 38

4．Dismantle cover wheel

Twist fixed bolts and take out cover wheel.

Figure 39

Transmission and Torque Converter SP00236

Page 15
5．Dismantle baffle ring

Note：It must be clamped reliably when using

baffle ring pincer to avoid safety hazard.

Figure 40

6．Dismantle turbine shell

Figure 41

7．Take out sealing ring

Figure 42

8．Take out baffle ring

Note：It must be clamped reliably when using

baffle ring pincer to avoid safety hazard.

Figure 43

SP002365 Transmission and Torque Converter

Page 16
9．Take out guide wheel

Figure 44

10．Take out pump pulley

Figure 45

11．Take out gear baffle ring

Note：It must be clamped reliably when using

baffle ring pincer to avoid safety hazard.

Figure 46

12．Take out gear

Figure 47

Transmission and Torque Converter SP002365

Page 17
13．Take out guide wheel seat

Figure 48

14．Take out bearing

Figure 49

15．Overturn torque converter and take out flange.

Twist bolts and take out flange.

Figure 50

16．Take out all output axles.

Figure 51

SP002365 Transmission and Torque Converter

Page 18
17．Take out baffle ring and shaft sleeve.

Figure 52

18．Take out bearings

Figure 53

19．Take out output flange

Twist fixed bolts and take out flange.

Figure 54

20．Take out sealing end cap.

Figure 55

Transmission and Torque Converter SP002365

Page 19
Assembling of transmission
Assembling of transmission assembly
1. Put transmission shell on work platform
horizontally.

Figure 56

2. Install clutch end cap of reverse gear and the II

and the IV gear

Figure 57

3. Overturn shell and put on work platform

horizontally.

Figure 58

4. Install end cap spacer bush of reverse gear and

the second and fourth gear.

Figure 59
SP002365 Transmission and Torque Converter
Page 20
5．Install output axle bearing.

Figure 60

6．Install output flange.

Note：45～59Nm

Figure 61

7．Install fixed supporting seat of hand brake disc.

Note：Bolts fastening torque 45～59Nm

Figure 62

5. Install bearing sleeve of the second and fourth

gear.

Figure 63

Transmission and Torque Converter SP002365

Page 21
9．Install clutch of the II and IV gear.

Figure 64

10. Install reverse gear bearing sleeve and reverse

gear clutch.

Figure 65

11. Install bearing sleeve of the first and third gear

and clutch of the first and third gear.

Figure 66

12．Install sealing ring of transmission end cap.

Figure67

SP002365 Transmission and Torque Converter

Page 22
13．Install end cap.
Note：Bolts fastening torque is 45～59Nm
Note：Use Loctite 262 thread fastening sealant
Note：Use Loctite 598 surface sealant

Figure 68

14．Install shaft sleeve of all clutches.

Figure 69

15．Install sealing rings of all clutches.

Figure 70

16. Install end cap of the first and third gear and
reverse gear.

Note：Bolts fastening torque is 45～59Nm

Note：Use Loctite 262 thread fastening sealant
Note：Use Loctite 598 surface sealant

Figure 71

Transmission and Torque Converter SP002365

Page 23
17. Overturn transmission, and put on work
platform horizontally.

Figure 72

18．Install end cap of the first and third gear.

Note：Bolts fastening torque is 45～59Nm
Note：Use Loctite 262 thread fastening sealant

Figure 73

19．Install input flange.

Figure 74

20. Install adjusting nuts of the second and fourth

gear and reverse gear
Align teeth of the second and fourth gear and
reverse gear; the horizontal height difference
shall be controlled at 20-30.

Figure 75

SP002365 Transmission and Torque Converter

Page 24
21．Install output axle bearing.

Figure 76

22．Install output low speed gear.

Figure 77

23．Install output axle.

Figure 78

24．Install sliding teeth set.

Figure 79

Transmission and Torque Converter SP002365

Page 25
25．Install output axle high speed gear.

Figure 80

26．Install space ring.

Figure 81

27．Install bearing.

Figure 82

28．Install rear output axle end cap.

Note：Bolts fastening torque is 45～59Nm
Note：Use Loctite 598 surface sealant
Note：Use Loctite 262 thread fastening sealant

Figure 83

SP002365 Transmission and Torque Converter

Page 26
29．Install output flange

Figure 84

30. Install sealing ring, pressing plate and bolt

stator of output flange.

Note：Screw fastening torque is 45～59Nm

Figure 85

31. Turnover transmission, install flange of front

output axle.

Figure 86

32. Install sealing ring, pressing plate and bolts

stator respectively for front output flange.

Note：Screw fastening torque is 45～59Nm

Figure 87

Transmission and Torque Converter SP002365

Page 27
33．Install hand brake assembly

Note：Screw fastening torque is 124～165Nm

Figure 88

34．Install reverse gear bearing sleeve

Figure 89

35．Install reverse gear clutch end cap

Note：Use Loctite 598 surface sealant

Note：Screw fastening torque is45～59Nm
Note：Use Loctite 262 thread sealant

Figure 90

36．Install speed change control valve.

Note：Use Loctite 262 thread sealant

Note：Screw fastening torque is45～59Nm

Figure 91

SP002365 Transmission and Torque Converter

Page 28
37．Install end cap

Figure 92

38．Install supporting seat of shifting fork

Note：Screw fastening torque is45～59Nm

Figure 93

39． Install shifting fork

Note：Screw fastening torque is45～59Nm

Figure 94

40. Bind shifting fork with iron wire to avoid

dropping of bolts.

Figure 95

Transmission and Torque Converter SP002365

Page 29
41．Install fixed seat of oil pan

Figure 96

42．Install sealing gasket of oil pan.

Figure 97

43．Install oil pan

Note: Screw fastening torque is45～59Nm

Note: Use Loctite 598 surface sealant

Figure 98

Assembly parts assembling

Installation of II & IV gear clutch
1．Install low speed gear on gear ring

Figure 99

SP002365 Transmission and Torque Converter

Page 30
2．Install stator and screw down bolts.

Note：Screw fastening torque is22～30Nm

Note：Use Loctite 262 thread sealant

Figure 100

3．Tilt the surrounding edge of stator with tool

Figure 101

4． Put clutch gear ring on platform horizontally

Figure 102

5．Install piston sealing ring

Figure 103

Transmission and Torque Converter SP002365

Page 31
6．Install piston

Figure 104

7．Install bearing sleeve

Figure 105

8．Install return spring

Figure 106

9．Install spring fixing seat

Figure 107

SP002365 Transmission and Torque Converter

Page 32
10．Install baffle ring
Note：It must be clamped firmly when using
baffle ring pincer to avoid safety hazard.

Figure 108

11．Install driven and driving friction plate

Figure 109

12．Install fixed block

Figure 110

13．Install spring lamination

Figure 111

Transmission and Torque Converter SP002365

Page 33
14．Install axle

Figure 112

15．Install baffle ring of driven gear

Note：It must be clamped firmly when using

baffle ring pincer to avoid safety hazard.

Figure 113

16．Install driven gear

Figure 114

17．Install bearing

Figure 115

SP002365 Transmission and Torque Converter

Page 34
18．Install baffle ring

Note：It must be clamped firmly when using

baffle ring pincer to avoid safety hazard.

Figure 116

19．Install high speed gear

Figure 117

20．Install bearing

Figure 118

21．Install located block

Figure 119

Transmission and Torque Converter SP002365

Page 35
22．Install bearing

Figure 120

23．Install cover plate

Figure 121

24．Install location

Figure 122

25. Screw down bolts and tilt the edge of stator with
tool.

Note：Screw fastening torque is22～30Nm

Note：Use Loctite 262 thread sealant

Figure 123

SP002365 Transmission and Torque Converter

Page 36
26. Reverse assembly, put it on work platform and
install bearing.

Figure 124
Installation of reverse gear clutch
1．Install low speed gear on gear ring

Figure 125

2．Install stator and screw down bolts

Note：Screw fastening torque is22～30Nm

Note：Use Loctite 262 thread sealant

Figure 126

3．Tilt edge of stator with tools

Figure 127

Transmission and Torque Converter SP002365

Page 37
4．Turnover gear ring and put it on work platform

Figure 128

5．Install piston sealing ring

Note：Use lubrication oil

Figure 129

6．Install piston

Note：Use lubrication oil

Figure 130

7．Install bearing sleeve

Figure 131

SP002365 Transmission and Torque Converter

Page 38
8．Install return spring

Figure 132

9．Install spring fixed seat

Figure 133

10．Install baffle ring

Note：It must be clamped firmly when using

baffle ring pincer to avoid safety hazard.

Figure 134

11．Install driven and driving friction plate.

Figure 135

Transmission and Torque Converter SP002365

Page 39
12．Install located block

Figure 136

13．Install spring plate

Figure 137

14．Install bearing

Figure 138

15．Install baffle ring on driven gear

Note：It must be clamped firmly when using

baffle ring pincer to avoid safety hazard.

Figure 139

SP002365 Transmission and Torque Converter

Page 40
16．Install driven gear

Figure 140

17．Install 2 bearings with press machine

Figure 141

18．Install baffle ring

Note：It must be clamped firmly when using

baffle ring pincer to avoid safety hazard.

Figure 142

19．Install spacer bush

Figure143

Transmission and Torque Converter SP002365

Page 41
20．Install bearing

Figure 144

21．Install location block

Figure 145

22．Install shaft sleeve

Figure 146

23．Install cover plate

Figure 147

SP002365 Transmission and Torque Converter

Page 42
24．Install location plate

Figure 148

25. Screw down bolts and tilt edge of stator with

tools

Note：Bolts fastening torque is 22～30Nm

Figure 149

26. Reverse assembly and put it on work platform

and install bearing

Clutch structure of I & III gear and reverse gear

clutch are the same, but just size of gear is
different, so installation process will not be
repeated here.

Figure 150

Installation of torque converter assembly

1. Put torque converter shell on installation
platform horizontally.

Figure 151

Transmission and Torque Converter SP002365

Page 43
2．Install end cap

Note：Screw fastening torque is22～30Nm

Note：Use Loctite 262 thread sealant

Figure 152

3．Screw on plug

Note：Bolt fastening torque is 193～257Nm

Figure 153

4．Install output flange

Note：Screw fastening torque is110～130Nm

Note：Use Loctite 262 thread sealant

Figure 154

5．Install working pump and steering pump bearing

Figure 155

SP002365 Transmission and Torque Converter

Page 44
6．Install space ring on top of bearing

Figure 156

7．Install baffle ring

Note：It must be clamped firmly when using

baffle ring pincer to avoid safety hazard.

Figure 157

8．Install output axle

Figure 158

9．Install output flange

Note：Screw fastening torque is110～130Nm
Note：Use Loctite 262 thread sealant

Figure 159

Transmission and Torque Converter SP002365

Page 45
10. Overturn torque converter and put it on work
platform horizontally

Figure 160

11. Install spacer bush and bearing of working

pump and steering pump

Figure 161

12．Install guide wheel seat

Note：Use lubrication oil

Figure 162

13．Install gear

Figure 163

SP002365 Transmission and Torque Converter

Page 46
14．Install baffle ring

Note：It must be clamped firmly when using

baffle ring pincer to avoid safety hazard.

Figure 164

15．Install sealing gasket

Figure 165

16．Hang transmission shell on pump pulley shell.

Note：Bolt fastening torque is 22～30Nm

Note：Use Loctite 598 surface sealant
Note：Guarantee suspending tool is on top of
main drive assembly to avoid knocking
spare parts inside during suspending
process.
Figure 166

17．Install bearing

Figure 167

Transmission and Torque Converter SP002365

Page 47
18．Install guide wheel

Figure 168

19．Install guide wheel baffle ring

Note：It must be clamped firmly when using

baffle ring pincer to avoid safety hazard.

Figure 169

20．Install O ring

Figure 170

21．Install turbine

Note：Bolt fastening torque is 22～30Nm

Figure 171

SP002365 Transmission and Torque Converter

Page 48
22．Install turbine baffle ring

Note：It must be clamped firmly when using

baffle ring pincer to avoid safety hazard.

Figure 172

23．Install turbine spacer bush

Figure 173

24．Install spacer bush baffle ring

Note：It must be clamped firmly when using

baffle ring pincer to avoid safety hazard.

Figure 174

25．Install pump pulley shell

Note：Bolt fastening torque is 45～59Nm

Figure 175

Transmission and Torque Converter SP002365

Page 49
26．Install elasticity plate

Figure 176

27．Install gasket

Note：Bolt fastening torque is 45～59Nm

Figure 177

28．Install sealing gasket on pressure regulating

valve

Figure 178

29．Install pressure regulating valve

Note：Bolt fastening torque is 45～59Nm

Note：Loctite 598 surface sealant

Figure 179

SP002365 Transmission and Torque Converter

Page 50
Installation of guide wheel seat assembly
Put guide wheel on installation platform
horizontally

Figure 180

2．Install shaft sleeve

Figure 181

3．Install shaft

Figure 182

4．Install bearing

Figure 183

Transmission and Torque Converter SP002365

Page 51
5．Install baffle ring

Note：It must be clamped firmly when using

baffle ring pincer to avoid safety hazard.

Figure184

6．Install gear

Figure 185

7．Install gear baffle ring

Note：It must be clamped firmly when using

baffle ring pincer to avoid safety hazard.

Figure 186

Installation of output flange

 Put flange on work platform horizontally, install
bearing

Figure 187

SP002365 Transmission and Torque Converter

Page 52
2．Install bearing baffle ring

Note：It must be clamped firmly when using

baffle ring pincer to avoid safety hazard.

Figure 188

3．Install shaft

Figure 189

4．Install gear

Figure 190

5．Install bearing

Figure 191

Transmission and Torque Converter SP002365

Page 53
6．Install bearing baffle ring

Note：It must be clamped firmly when using

baffle ring pincer to avoid safety hazard.

Figure 192

7．Reverse output flange and put it on work platform

Figure 193

8．Install flange

Figure 194

9. Install shock insulator, sealing ring, shock

insulator and hold-down but, and fix bolts with
cotter pin.

Figure 195

SP002365 Transmission and Torque Converter

Page 54
1HYDRAULICS
 SP002366

CYLINDERS

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual or
those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

MODEL SERIAL NUMBER RANGE

SD200 1001 and Up
SD300 1001 and Up

Copyright 2011 DISD

July 2011

Cylinder SP002366
Page 1
TABLE OF CONTENTS
General Description................................................................................................ 3
Working Principle..................................................................................................... 3
Detailed List of Spare Parts...................................................................................... 4
Disassembling and Assembling Steps........................................................................... 5

SP002366 Cylinders
Page 2
General Description
Working principle
It is usually composed of cylinder body, piston rod and sealing parts, internal of cylinder body is divided
into two parts and connect with a oil hold respectively. Since compression of liquid is very small, when
oil coming into one oil hole, piston will be propelled to make oil going out from another oil hole, piston
drives piston rod stretching (compressing), on the contrary as before.
Cylinder is the implementing part of the straight line movement of output force and piston effective area and
the pressure difference at both sides. It is used to change hydraulic energy into mechanic energy. The input of
cylinder is flow rate and pressure of fluid, the output is speed and force of straight line movement. Piston of
cylinder can finish straight line alternating motion, the output straight line displacement is limited. Cylinder is
the energy converting device from hydraulic energy to mechanic energy for alternating straight line movement.
Cylinder is basically composed of cylinder barrel, cylinder cover, piston, piston rod, sealing device and
cushioning device.

Figure 1

Cylinders SP002366
Page 3
Detailed list of spare parts

Figure 2

Reference Number Description Reference Number Description

1 Cylinder rod 12 Support ring

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

SP002366 Cylinders
Page 4
Disassembling and assembling steps
Disassembling steps
Note：Prepare a container which can store all hydraulic oil of the maintained cylinder, hydraulic oil
will flow out from cylinder.
1. Put the cylinder on special supporting vertically,
screw down bolts of cylinder cover with
pneumatic wrench or torque wrench.

Figure 3

2. Hang piston rod assembly out from cylinder and

put it on special protective support.

Figure 4

3. Twist piston lock screw with special tools.

Figure 5

Cylinders SP002366
Page 5
4. Dismantle piston with special piston tightening
tool and jackhammer.

Figure 6

5. Dismantle piston and cylinder cover assembly.

Figure 7

6. Dismantle sealing parts with special tools.

Figure 8

SP002366 Cylinders
Page 6
Assembling steps
1. Install sealing parts of cylinder.

Figure 9

2. Install cylinder cover assembly.

Figure 10

3. Install piston with special tools.

Figure 11

Cylinders SP002366
Page 7
4. Screw down piston bolts with special tools.

Figure 12

5. Put piston rod in cylinder barrel.

Figure 13

6. Screw down bolts of cylinder cover and cylinder

barrel.

Figure 14

SP002366 Cylinders
Page 8
 SP002367

Main Pump

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual or
those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

MODEL SERIAL NUMBER RANGE

SD200 1001 and Up
SD300 1001 and Up

Copyright 2011 DISD

July 2011

Main Pump SP002367

Page 1
TABLE OF CONTENTS
General Description…………………………………..……………………………………….3
Work principle...........................................................................................................3
Detailed List of Spare Parts..................................................................................... 4
Parts Replacement principle................................................................................... 5
Preparation before Disassembling..................................................................................5
Disassembly and Assembly Steps..................................................................................6

SP002367 Main Pump

Page 2
General description
Work principle
Function of main pump is to convert mechanic energy of diesel into pressure energy of working liquid. Main
pump is a kind of hydraulic pump with simple structure and wide application, it has small size, light weight,
reliable work, low cost and not too sensitive to hydraulic oil, convenient for maintenance and repair, and
therefore it is widely applied in hydraulic system of loaders.
Main pump has many types, according to different pressure grade, it can be divided into four types which are:
low pressure (P＜2.5MPa), medium pressure (P＞2.5—8MPa), mesohigh pressure (P＞8—16MPa) and high
pressure (P＞16—31.5MPa). At present, mesohigh pressure main pumps are used often for loaders.
According to difference of gear mesh form, it can be divided into main pump with external mesh and main
pump with internal mesh. Of which main pumps with external mesh are more popular.

Figure 1
1. Driving gear 2. Extrusion chamber 3. Driven gear 4. End cap 5. Transmission shaft
6. Pump body 7. Suction chamber

Main Pump SP002367

Page 3
Detailed list of spare parts

Figure 2

Reference Number Description Reference Number Description

1 BOLT 12 Side Plate
2 WASHER 13 Pump Block
3 BOLT 14 Seal Ring
4 WASHER 15 Block
5 BOLT 16 Needle Roller
6 WASHER 17 Rear Cover
7 Drive Gear 18 Driven Gear
8 Snap Ring 19 Seal Ring
9 Oil Seal 20 Label
10 Front Cover 21 Screw
11 Fixing Cover

SP002367 Main Pump

Page 4
Parts replacement principle
If main pump needs to be repaired to reach the original performance index, parts replacement principle must
be followed to replace parts, following is the detailed replacing rules:
1．Side plate: replace side plate when it is scratched, there is pit, spray and finishing layer sheds, burnt,
deformed and cavitations corrosion.
2．Gear: replace gear when one of the following conditions happens: shaft diameter of gear shaft is scratched
or worn in sealing zone; teeth surface of gear is worn, scratched, broken or deformed; addendum circle is
damaged seriously; multiple spline or flat key and spindle nose are worn, deformed and broken.
3．Castings (front cover, pump body, and rear cover):
3.1 If there is flaw on castings, and sealing zone has chip, rust, deformed pin hole, then replace castings.
3.2 Replace pump body when one of the following conditions happens: oil mouth is broken, pump body is
broken and rusty; when bore depth of pump body ＞0.08mm.
4．Round pin: round pin must be replaced when the matching does not comply with requirements, pin is broke
and deformed, replace the front cover, pump body and rear cover matched with round pin when it is
necessary.
5．Rolling bearing: new parts must be replaced when quill roller drops, retainer is damages, quill roller has
surface pitting, roller path has surface pitting, over sintering.
6．Second sealing ring: replace with new parts when there is inner diameter abrasion, end face abrasion,
thickness is milled, deformed, surface is coarse.
7．Non-metal sealing parts: all non-metal sealing parts must be replaced.
8．Outboard bearing: replace with new parts when parts are worn and rusty.
9．Fastener: replace it when it is drawn out, deformed and damaged.

Preparation before disassembling

1．Clean the surface of pump, and check if the surface has chip and rust.
2．Check model and factory releasing number on nameplate, if there is no nameplate on pump, check factory
releasing number at seam allowance of front cover.
3．Fill in relative information on main pump returned for maintenance card before disassembling, such as
manufacturer, applicable machine model, applicable working condition, pump model, factory releasing
number, factory releasing date, head and marks of fabricator, working parameters (pressure, rotation,
impact and the constant running time at the highest pressure) on main machine, total working time of main
pump and reason for returning for maintenance, etc.
4．Make sure the production is released from the factory as a whole and it is not disassembled after releasing,
otherwise it is not maintained.
5、If there is external leaking, do gas tightness checking to the entire pump and find out leaking position.
6．Check tightening torque of bolts (screw down bolts again with torque wrench, record the Max. tightening
torque), learn if tightening torque of all bolts have reached the required specification.
Main Pump SP002367
Page 5
Disassembly and assembly steps
Disassembly steps

1. Dismantle front end cap.

Figure 3

2. Dismantle jump ring with jump ring pincer.

Figure 4

3. Take out framework oil seal.

Figure 5

SP002367 Main Pump

Page 6
4. Take out support wire.

Figure 6

5. Dismantle sealing ring.

Figure 7

6. Dismantle bearing.

Figure 8
7. Dismantle front ear type sealing ring

Figure 9
Main Pump SP002367
Page 7
8. Dismantle ear type sealing ring.

Figure 10

9. Dismantle side plate.

Figure 11

10. Dismantle driven gear.

Figure 12

11. Dismantle active gear.

Figure 13
SP002367 Main Pump
Page 8
12. Dismantle rear cover bolts.

Figure 14

13. Dismantle rear cover.

Figure 15

14. Dismantle wire of lower limitation.

Figure 16

15. Dismantle sealing ring.

Figure 17
Main Pump SP002367
Page 9
16. Dismantle bearing.

Figure 18

Installation steps
1. Install bearing.

Figure 19

2. Install sealing ring.

Figure 20

SP002367 Main Pump

Page 10
3. Install limitation wire.

Figure 21

4. Install rear cover.

Figure 22

5. Install rear cover bolts.

Figure 23

6. Install active gear.

Figure 24
SP002367 Main Pump
Page 11
7. Install driven gear.

Figure 25

8. Install side plate.

Figure 26

9. Install ear type sealing ring.

Figure 27

10. Install front ear type sealing ring.

Figure 28
Main Pump SP002367
Page 12
11. Install bearing.

Figure 29

12. Install sealing ring.

Figure 30

13. Install support wire.

Figure 31

14. Install framework oil seal.

Figure 32
SP002367 Main Pump
Page 13
15. Install jump ring with jump ring pincer.

Figure 33

16. Install front end cover.

Figure 34

Note:
1. Clean parts with cleaning agent, do not use rag to avoid remaining any clothing fiber.
2. Slide touching parts and bearing, coating with hydraulic oil and assemble after cleaning.
3. Replace O ring and sealing parts with new ones:
Disassembling order: front cover →framework oil seal→ O ring →bearing →sealing ring →side plate
→driven gear →active gear →rear cover →O ring →bearing.

Assembling order: bearing →O ring →rear cover→ active gear→ driven gear→ side plate →sealing
ring→ bearing→ O ring→ framework →oil seal→ front cover.

Main Pump SP002367

Page 14
 SP002368

Main Control Valve

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual or
those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

MODEL SERIAL NUMBER RANGE

SD200 1001 and Up

Copyright 2011 DISD

July 2011
Main Control Valve SP002368
Page 1
TABLE OF CONTENTS
General Description........................................................................................................3
Schematic Diagram............................................................................................... 3
Detailed List of Spare Parts....................................................................................... 4
Disassembly and Assembly Steps................................................................................. 5
Basic Faults and Overcoming ……….......................................................................... 7

SP002368 Main Control Valve

Page 2
General description
1. Source: the hydraulic multi-way directional valve is domestic assorting parts for 950B, 966D and 980S
wheel loaders introduced in from abroad.
2. Purpose: the valve is combined with DJS pilot valve, mainly used for ZL40, ZL50, ZL60 and other medium
and large size loaders, it can also be used for hydraulic system of bulldozers and other medium and large
size engineering machines.
3. Characteristics:
a. Adopt decompression type pilot valve to control which reduce reversing operating force greatly.
b. Improve jogging feature of multi-way valve greatly.
c. Relief valve, overload valve, oil compensating valve and check valve adopt plug-in mounting which has
good generality and easy for maintenance.
d. Four floating is easily realized on the basis of three main valves, which make four main valve structure
simple.
e. It is convenient for pipe lay out, and reduces pressure loss of the system.
4. Schematic diagram

Figure 1
Main Control Valve SP002368
Page 3
Detailed list of spare parts

Figure 2

SP002368 Main Control Valve

Page 4
 Reference Number Description Reference Number Description

1 Cover 18 Check valve

2 Boom Valve spool 19 Cover

3 Valve body 20 Name Plate

4 Check valve 21 Spool joint

5 Cover ① O-Ring 50x3.1

6 Spring seat ② O-Ring 20x2.4

7 Spring ③ O-Ring 60x3.1

8 Spring ④ Gasket2

9 Spring gasket ⑤ Bolt M12x20

10 Cover board ⑥ Bolt M10x100

11 Bucket valve spool ⑦ Gasket10

12 Cover ⑧ Gasket12

13 Spring ⑨ Bolt M12x30

14 Make-up valve ⑩ O-Ring 45x3.1

15 Overload valve ⑾ Bolt M10x45

16 Relief valve ⑿ O-Ring 44x3.5

17 Spring ⒀ Rivet 2x4

Disassembly and assembly steps

When repairing the entire valve, put multi-way valve at a flat and clean place, clean all parts after disassembly
and then assemble.

1. Dismantle and assemble overload valve and

relief valve, do not loosen locknut when
dismantling, put wrench at cartridge valve, mark
signs on high and low pressure overload valve.
Check sealing ring of cartridge valve; assemble
again when it is confirmed well.

Figure 3

Main Control Valve SP002368

Page 5
2. Dismantle end cap at both sides with inner
hexagon screw, check if sealing ring is good. Pull
out valve rod from long end cap; check if the
valve rod and valve surface is impacted; install
valve rod to valve when it is moving smoothly and
there is no blockage, put O ring in oil seal groove
of end cap, keep end cap connection oil mouth
upward when installing end cap, fastening torque
Figure 4
of end cap bolts is 35～40N.m.

3. If valve rod end spring needs to be replaced, fix

valve rod with special fixture, screw out end cap
bolts with wrench. Check if the spring is broken or
deformed, when installing spring and valve rod,
the clearance between return spring and spring
seat when spring is at free state is around
2.5mm.

Figure 5

4. Dismantle and assemble check valve. Dismantle

three end caps of check valve with inner hexagon
screw, mark on each end cap with chalk, check if
the check valve is leaking by checking if the
spring is deformed and surface normal line of
check valve is good. Guarantee check valve and
valve seat can move flexibly during installation;
while check if 1.0 hole on top of the hydraulic
control check valve is blocked before installation.
Check if all screw plugs are complete, check if Figure 6

screw plug is screw down and sealing ring is

complete when oil is leaking.

SP002368 Main Control Valve

Page 6
Basic faults and overcoming
S/N Faults Reasons Overcoming methods
Pressure of relief valve is regulated too
Adjust pressure of relief valve
low

Slide valve of relief valve is blocked Dismantle, clean and assemble again
Working pressure is
1 Pressure regulation spring is broken Replace with new one
not enough
Replace pipeline or regulate pressure of

System pipe pressure is lost too much relief valve within the allowable

pressure range

Oil supply of the system is not enough Check oil source, check oil pump

Leakage in valve is large

a. Oil temperature is too high, viscosity a. Take measures to reduce oil

Working flow is not decreases temperature

2
enough b. Selection of oil is improper b. Replace oil

c. Clearance between slide valve and c. Replace slide valve according to

valve is too large reasonable clearance

Fault of relief valve Repair relief valve

Resetting spring is damaged or

Replace new ones
Resetting does not deformed
3
work There is pollutant between valve rod
Clean parts
and valve

Sealing ring is damaged Replace new ones

4 External leakage
Fasteners are loosed Screw down fasteners

Slippage of swing Clearance between multi-way valve and

5 Replace valve rod
arm is large valve rod increases

Overload valve or oil compensating

6 Rotating bucket falls Dismantle, clean and reassemble
valve is blocked by pollutant

Main Control Valve SP002368

Page 7
SP002368 Main Control Valve
Pag 8
 SP002369

Pilot Control Valve

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual or
those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

MODEL SERIAL NUMBER RANGE

SD200 1001 and Up
SD300 1001 and Up

Copyright 2011 DISD

July 2011

Pilot Control Valve SP002369

Page 1
TABLE OF CONTENTS
General Description............................................................................................ 3
Schematic Diagram......................................................................................... 3
Detailed List of Parts for DXS Mono Lever Pilot Control Valve ............................4
Detailed List of Parts for DJS Double Handle Pilot Control Valve ……………..... 6
Disassembly & Assembly Steps of DXS Mono Lever Pilot Control Valve……………....7
Disassembly & Assembly Steps of DJS Double Handle Pilot Control Valve…………. 11
Basic Faults and Overcoming....................................................................................... 14

SP002369 Pilot Control Valve

Page 2
General description
Schematic diagram

Figure 1

Pilot Control Valve SP002369

Page 3
Detailed list of parts for DXS monolever pilot control valve

Pilot Control Valve SP002351

Page 3
零件明细表

Figure 2

SP002369 Pilot Control Valve

Page 4
 Reference Reference
Description Description
Number Number

1 Nut 18 Gasket

2 Rubber cover 19 Electromagnet

3 Mound layer 20 Pin roll

4 Pressure pin group 21 Cotter pin

5 Glue set seat 22 Nut

6 Fixed plate 23 Support

7 Shaft sleeve 24 Valve rod assembly

8 Pressing plate 25 Screw plug

9 Sleeve 26 Spring

10 Spring 27 Guide sleeve

11 Gasket 28 Measuring assembly II

12 Inner hexagonal sunk screw 29 Sequence valve group

13 Compression bar assembly 30 Nameplate

14 Spring 31 Rivet

15 Cone screw plug 32 Bolt

16 Measuring assembly I 33 O ring

17 Rotating bucket valve 34 Poppet valve

Pilot Control Valve SP002369

Page 5
Detailed list of parts for DJS double handle pilot control valve

Figure 3

SP002369 Pilot Control Valve

Page 6
 Reference Number Description Reference Number Description
1 Handle assembly 17 Compression bar I
2 Elastic round pin 18 Shaft sleeve

3 Handle joint 19 Sequence valve

4 Nut 20 Guide sleeve

5 Nut 21 Spring
6 Small gasket 22 O ring
7 Nut 23 Screw plug
8 Pressing plate assembly 24 Compression bar II
9 Fixing plate 25 Electromagnet
10 Pressure pin group 26 Cone screw plug
11 Shield plate 27 Measuring assembly II
12 Mounting plate assembly 28 Bolt
13 Valve 29 Rubber plug
14 Rubber cover 30 Name plate
15 Measuring assembly I 31 Rivet
16 Spring

DISASSEMBLY AND ASSEMBLY STEPS OF DXS MO

NOLEVER PILOT CONTROL VALVE

Disassembly steps of DXS mono lever pilot control valve

1. Loosen two screws on head with wrench

Figure 4

Pilot Control Valve SP002369

Page 7
2. Dismantle handle assembly and pressing plate
assembly.

Figure 5

3. Screw off four cock screws with wrench and take

out cover plate and installation plate assembly.

Figure 6

4. Take out pressing plate assembly with vice clamp,

take out spool assembly.
Note：Compression bar of swing arm leaguer is
different from that of rotating bucket
league; mark well to avoid wrong
assembling.

Figure 7

Enclose: When spool is only need to be taken out,

it can be dismantle at the bottom,
loosen bottom valve seat with wrench.
Check if O ring is good, take out spool
assembly.

Figure 8

SP002369 Pilot Control Valve

Page 8
Assembly steps of DXS monolever pilot control valve
1. Clean all parts before assembling, blow with
compressed air, and guarantee there is no oil,
dirt and other sundries.
When only the bottom seats is dismantled, clean
spool and replace spring and assemble directly,
and lock valve seat.

Figure 9

2. Install spool assembly and pressing plate

assembly from upward to downward in order,
keep the hole on the sleeve outside as is shown
in the picture, assemble well and press down.

Figure 10
3. Install electromagnet, pressing plate assembly
and cover plate, fix with bolts, keep
electromagnet clean. Pay attention to color of
electromagnet wire.

Figure 11

4. Install pressing plate assembly and press pin

assembly, adjust with small inner hexagonal
wrench, keep the clearance between pressing
plate and press pin assembly between 0.2-0.5.

Figure 12

Pilot Control Valve SP002369

Page 9
5．Pull handle, adjust nuts to make four pressing
plates can coincide with electromagnet, lock nuts,
install handle assembly and lock.

Figure 13

SP002369 Pilot Control Valve

Page 10
DISASSEMBLY AND ASSEMBLY STEPS OF DJS DOUBLE HANDLE PILOT CONTROL
VALVE
Disassembly steps of DJS double handle pilot control valve
1. Loosen locknuts on top with wrench.

Figure 14

2. Take out pressing plate and contact terminal.

Figure 15

3. Loosen four locknuts with wrench, take out

mounting plate.

Figure 16

Pilot Control Valve SP002369

Page 11
4. Take out electromagnet, sleeve, pressing plate,
paper washer, gaskets, etc, pay attention to the
position of sleeve and order of paper washer and
gaskets.

Figure 17

5. Take out press bar assembly with vice clamp and

take out spool assembly.

Note：Compression bar of swing arm leaguer is

different from that of rotating bucket league;
mark well to avoid wrong assembling.

Figure 18

Enclose: When spool is only need to be taken out,

it can be dismantle at the bottom, loosen
bottom valve seat with wrench. Check if
O ring is good, take out spool assembly.

Figure 19

SP002369 Pilot Control Valve

Page 12
Assembly steps of DJS double handle pilot control valve
1. Clean all parts before assembling, blow with
compressed air, and guarantee there is no oil, dirt
and other sundries.

Note：When only the bottom seats is dismantled,

clean spool and replaces spring and
assemble directly, and lock valve seat.

Figure 20

2. Install press bar assembly, paper washer, gasket

and spring from upward to downward in order.

Figure 21
3. Install electromagnet, mounting plate and other
assembly, and lock the mounting plate, install
pressing plate, adjust nuts to guarantee the
swinging clearance between pressing bar and
pressing pin is 0.25-1.27mm, and lock it.

Figure 22
Pilot Control Valve SP002369
Page 13
Basic faults and overcoming
Faults Reasons Overcoming methods
Resetting spring of pilot control
Replace with new products
valve deforms
1 Resetting does not work There are pollutants between
pressing bar and matching Clean parts
hole
Suction of electromagnet is not
Replace with new ones
enough
Electric current and voltage of
electric circuit does not comply Overhaul
with requirements
There are pollutants between
２ Location is not reliable
electromagnet and pressing Get rid of pollutants
plate
Clearance between pressing
bar and pressing lever is not
Adjust according to requirements
adjusted according to
requirements
Measuring spool is blocked or Check if oil is clean, clean spool

Control of pilot valve is not moving is not flexible and valve port
３ Measuring spring deforms Replace spring
flexible
Control flow rate or pressure is Check if oil supplying system of
not enough pilot is normal

SP002369 Pilot Control Valve

Page 14
 SP002370

Priority Valve

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual or
those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

MODEL SERIAL NUMBER RANGE

SD200 1001 and Up

Priority Valve SP002370

Page 1
TABLE OF CONTENTS
General Description…………………………………..……………………………………….3
Work principle.............................................................................................................3
Detailed List of Spare Parts........................................................................................4
Disassembly Steps of Priority Valve.............................................................................. 5
Matters Need Attention for Disassembling Priority Valve.............................................. 7
Assembling Steps of Priority Valve.................................................................................8
Matters Need Attention for Assembling Priority Valve.................................................. 10
Tools for Disassembly and Assembly........................................................................... 10

SP002370 Priority Valve

Page 2
General description
Work principle
When steering unit is in the middle, if the engine misses, oil pump does not supply oil, control spring of priority
valve will push spool to the right side to connect with CF oil way. When diesel engine is started, priority valve
will distribute pressure oil to CF oil way, pressure will be reduced after going through meso-position throttle
mouth of steering unit, pressure at both sides of throttle mouth will be transferred to both sides of priority spool,
the caused hydraulic force will balance with spring force of control spring and liquid power which will make
spool balance. Since fluid resistance at throttle mouth is big, very few flow will create enough differential
pressure to push priority valve spool moving to the left side and will push spool move to the left, EF valve is
opened larger and CF valve is smaller, then flow rate of CF oil way is small.
When turning steering wheel, meso-position throttle mouth of steering unit closes, fluid flowing through
steering unit creates pressure drop. Pressure from both sides of throttle changing mouth is transferred to both
sides of priority valve spool and forces spool to find a new balanced position. If rotation of steering wheel is
improved, throttle changing mouth is larger at the moment of changing, at this time, only more flow rate can
create pressure drop before rotation speed is different at throttle mouth so that priority valve spool can be
pushed to move to the left side. Therefore, open of valve mouth of CF oilway connecting with priority valve
will increase with improving of steering wheel rotation. In the end, oil supplying quantity of priority valve
steering unit is equal to rotation of steering wheel plus displacement of steering unit.
When steering cylinder reaches the travelling terminal, if steering wheel is continued to be turned, pressure oil
cannot flow to cylinder, then overload pressure will rise quickly, pressure difference between both sides of
throttle changing mouth will reduce quickly, when pressure of steering cylinder exceeds regulated value of
safety valve, the valve is turned on to discharge load. Pressure drop is created when pressure oil flowing
through throttle mouth, the pressure drop is transferred to both sides of priority valve spool and push spool to
move to the left side which will force valve mouth connecting with CF oilway get smaller, and valve mouth
connecting with EF oilway get bigger, and pressure of steering oilway decreases.
When turning flames out, steering unit can play the role of manual oil pump. Input pressure oil pushes
steering cylinder piston, oil from cylinder turns to upstream of throttle mouth of check valve, that is turning
when flaming out has nothing to do with priority valve.

Figure1
Priority Valve SP002370
Page 3
 Detailed list of spare parts

Figure2

Reference Number Description Reference Number Description

1 Valve body 9 Adjustable Bolt

2 Valve spool 10 Locking Ring

3 O-Ring35X3.1 11 Relief Valve body

4 Plug 12 O-Ring 22X2.4

5 O-Ring38X3.1 13 Relief Valve seat 2

6 Relief Valve seat 1 14 Spring

7 Relief Valve spool 15 Gasket

8 Relief Valve Spring

SP002370 Priority Valve

Page 4
Disassembly steps of priority valve
1. Turn on relief valve on the left side.

Tools: pneumatic wrench, M24 sleeve

Figure 3

2. Turn on valve seat 2 of relief valve on the left to

take out spring.

Tools: pneumatic wrench, self made sleeve (41#

wrench)

Figure 4

3. Turn on screw plug on the right to take out spool

and gasket.

Figure 5

Priority Valve SP002370

Page 5
4. Screw out lock ring and adjustable bolt of relief
valve to take out spring and relief spool, then take
our valve seat 1 of relief valve.

Tools: 4mm inner hexagonal wrench, special

screwdriver (plain screwdriver), 14 #wrenches

Figure 6

5. Screw out bolts of pressure mouth

Tool: 8mm inner hexagonal wrench

Figure 7

SP002370 Priority Valve

Page 6
Matters need attention for disassembling priority valve
1. All parts shall be taken slightly during disassembling process, spool shall be pulled out slightly to avoid
knock and scratch parts.
2. Step two and step three cannot be reversed (avoid screw out the screw plug on the right and spring pop out
spool and cause danger).
3. Dismantle bolts of pressure mouth according to requirements.
4. Check if O ring is deformed, trimmed and aged after disassembling, usually O ring cannot be used again
after disassembling.
5. After disassembling, valve body and spool shall be cleaned with 32# hydraulic oil, check if spool surface
has obvious scratch; do not use spool and valve body if there is scratch.

Priority Valve SP002370

Page 7
Assembling steps of priority valve
1. Screw on bolts of pressure mouth.

Tool: 8mm inner hexagonal wrench

Figure 8

2. Screw on valve seat 1 of relief valve, install spool

and spring, then install adjustable bolts and lock
ring.

Tools: 4mm inner hexagonal wrench, special

screwdriver (plain screwdriver), 14# wrench

Figure 9

3. Install spool and gasket.

Figure 10

SP002370 Priority Valve

Page 8
4. Install spring, screw on valve seat 2 of relief valve
and screw plug.

Tools: pneumatic wrench, self made sleeve (41#

wrench)

Figure 11

5. Screw on valve seat 1 of relief valve.

Tools: pneumatic wrench, M24 sleeve

Figure 12

Priority Valve SP002370

Page 9
Matters need attention for assembling priority valve
1. Keep all parts clean before assembling.
2. During installation, all spools shall be installed slowly and guarantee they can slide flexibly, if there is
blockage, grind spool surface and sharp corner slightly with find abrasive paper, clean the valve again.
3. Avoid to damage trim of O ring when screwing on screw plug, it is better to coat grease on the surface
before installation.

Tools for disassembly and

assembly
Main tools for disassembly and assembly are:
Torque wrench (Electric wrench)
M27 sleeve
M22 sleeve
M16 sleeve
M6 inner hexagonal spearhead

Figure 9

SP002370 Priority Valve

Page 10
 SP002371

Steering Unit

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual or
those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

MODEL SERIAL NUMBER RANGE

SD200 1001 and Up
SD300 1001 and Up

Steering Unit SP002371

Page 1
TABLE OF CONTENTS
General Description........................................................................................................3
Work Principle……...................................................................................................3
Detailed List of Spare Parts......................................................................................4
Disassembly Steps of Steering Unit............................................................................... 5
Assembling Steps of Steering Unit.............................................................................. 11
Matters Need Attention for Disassembling Steering Unit............................................. 14

SP002371 Steering Unit

Page 2
General description
Work principle
When steering unit is in the middle, spool and valve bush is at meso-position with the effect of spring
lamination, oil from oil pump will enter spool from two rows of holes of valve bush and spool, then returns to oil
tank through T oil mouth.
When steering wheel turns right (or left), spool is driven to turn to the right (or left), since the Max. rotation
quantity between spool and valve bush is 10.5°, so spool rotates against valve bush, at this moment, oil
groove is connected with oil inlet way of valve bush, oil goes through valve bush and oil groove of spool,
returns to rotor and stator from valve bush, drives rotor rotating against stator. At the same time, oil from rotor
and stator enters one of the chamber of cylinder through oil mouth A (or B) to make cylinder piston stretch out
(compress inside), and push steering wheel turns right (or left), oil from the other chamber of cylinder enters
valve bush through oil mouth B (or A), returns oil groove through spool, and goes back to oil tank through T oil
mouth from valve bush. The relative rotation angle of spool and valve bush is 1.5°, oil way is connected, and
rotation of rotor makes oil connects with cylinder, oil supplying quantity and rotation angle of steering wheel
become direct ratio.
When steering wheel turns right (or left) for an angle and keeps the state, since the above mentioned oilway is
open and oil from oil pump will push rotor to turn right (left), when rotation angle of rotor is the same with
rotation angle of steering wheel, since valve bush and rotor is connected through linkage axle, so rotor will
drive valve bush to turn right (or left) to keep the same angle with steering wheel. At this moment, valve bush
and spool form the position without rotation angle, oilway going to rotor and oil cylinder is closed, oil from oil
pump will go into spool through two rows of holes through valve bush and spool, oil goes back to oil tank
through T oil way from valve bush. At this time, tyre stops moving, this is hydraulic feedback servo action.

Figure 1

Steering Unit SP002371

Page 3
Detailed list of spare parts

Figure 2

Reference Number Description Reference Number Description

1 Link block 12 Stator

2 Front cover 13 O-Ring

3 Valve body 14 Plate

4 Spring lamination 15 Steel ball

5 Pin 16 Big Baffle ring

6 Valve bush 17 Baffle ring

7 Valve spool 18 Baffle ring

8 Shaft 19 O-Ring

9 Rotor 20 X-Ring

10 Limited post 21 O-Ring

11 Rear cover

SP002371 Steering Unit

Page 4
Disassembly steps of steering unit
1. Take out link block.

Figure 3
2. Take out front cover.

Figure 4
3. Take out multi-roll bearing

Figure 5

Steering Unit SP002371

Page 5
4. Take out bolts of rear cover.

Figure 6
5. Take out rear cover.

Figure 7
6. Dismantle stator

Figure 8

7. O-RING Dismantle O-RING

Figure 9
SP002371 Steering Unit
Page 6
8. Dismantle rotor.

Figure 10

9. Take out limitation block

Figure 11

10. Take out link axle

Figure 12
11. Take out clapboard

Figure 13

Steering Unit SP002371

Page 7
12. Take out valve bush and spool assembly

Figure 14
13. Take out dial pin

Figure 15
14. Take out spring lamination

Figure 16
15. Take out valve spool 5

Figure 17

SP002371 Steering Unit

Page 8
16. Dismantle valve block

Figure 18

17. Take out check valve

Figure 19

18. Take out oil return throttle valve

Figure 20

19. Take out oil inlet throttle valve

Figure 21

Steering Unit SP002371

Page 9
20. Take out oil compensating valve (4EA)

Figure 22

SP002371 Steering Unit

Page 10
Assembly steps of steering unit
1. Keep four bolt holes of valve body upward.

Figure 23

2. Install valve spool, valve bush, spring lamination

and dial pin.

Figure 24

3. Install well assembled valve spool and valve bush

into valve body

Figure 25

Steering Unit SP002371

Page 11
4. Install big baffle ring, needle roller thrust bearing
and small baffle ring

Figure 26
5. Install front cover with well assembled sealing ring

Figure 27
6. Keep fourteen holes of steering unit upward

Figure 28
7. Install sealing ring

Figure 29

SP002371 Steering Unit

Page 12
8. Put Φ8mm steel balls into the thread holes as
shown in the picture

Figure 30

9. Install spacer plate and align the holes.

Figure 31
10. Install couple axle, stop dial pin with linkage
shaft

Figure 32
11. Install turn stator vice (note: mark on linkage
shaft shall align with groove on rotor)

Figure 33

Steering Unit SP002371

Page 13
12. Install upper limitation column and sealing ring

Figure 34

13. Install rear cover, combined gasket, bolts, the

position shown in the picture by arrow is cotter
bolt.

Figure 35

Matters need attention during assembling

1. Clean all parts (except rubber ring) with gasoline or kerosene before assembling. If there is paint on
combination surface, clean with acetone, it is forbidden to clean parts with cotton yarn or cloth, soft
banister brush or silk shall be used to clean parts, it is better to blow with compressed air, after steering
unit is installed well, add 50-100ml hydraulic oil before install in machines, turn around spool, install in
machine for test if everything is normal
2. Combination surface of valve body, spacer plate, stator and rear cover must be highly clean, do not knock
or scratch.
3. There are spot mark on end surface of rotor and linkage shaft, that is teeth of linkage shaft groove shall
align with multiple spline groove inside rotor teeth bottom, pay attention to the relative position during
installation.
4. Bolts of rear cover shall adopt qualified combined gaskets.
5. when fastening seven bolts of rear cover, screw on every two bolts in order, screw on gradually, the
fastening torque is 40～50 N.m.
6. (Note) ―P‖, ‖T‖, ‖A‖, ―B‖ oil mouth of valve body and valve block shall align with each other one by one
during installation.

SP002371 Steering Unit

Page 14
 SP002372

Hydraulic Schematic (SD 200)

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual or
those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

MODEL SERIAL NUMBER RANGE

SD200 1001 and Up

Copyright 2011 DISD

July 2011

Hydraulic Schematic (SD200) SP002372

Page 1
TABLE OF CONTENTS
General Description.................................................................................................. 3
Schematic Diagram................................................................................................ 3

SP002372 Hydraulic Schematic (SD200)

Page 2
General description
Schematic diagram

Hydraulic Schematic (SD200) SP002372

Page 3
、

SP002372 Hydraulic Schematic (SD200)

Page 4
Hydraulic Schematic (SD200) SP002372
Page 5
SP002372 Hydraulic Schematic (SD200)
Page 6
1BRAKE
 SP002359

BRAKE SYSTEM

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual or
those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

MODEL SERIAL NUMBER RANGE

SD200 1001 and Up

Copyright 2011 DISD

July 2011

Brake System SP002359

Page 1
TABLE OF CONTENTS
General Description……………………..…………………………………………………….3
Structure of Travelling Brake …………………………….…………………………….3
Working Principle of Travelling Brake ………….………..……………..…………….3
Parts List………………..……………………………………………………………………...4
Structure Chart of Brake System………………………………………………….....4
Oil-water Separator …….……………………...………………………………………...6
Pneumatic Brake Valve ……………………..……………………………………….....7
Booster pump ……..……………………………………………………………………...8
Special Tools and Materials……………………..………………………………………….8
System Maintenance and Failures Analysis……………………………………………9

SP002359 Brake System

Page 2
General Description

Structure of travelling brake

It usually includes air compressor, oil-water separation combination valve (oil-water separator, pressure
control valve), air tank, pneumatic brake valve, air booster pump and caliper disc brake. If it is equipped with
emergency braking function, it usually also includes emergency and stopping brake control valve, brake air
chamber, quick release valve. In air circuit of brake system, there are some other accessories, such as switch
of brake light, switch of power off, etc.

Working Principle of Travelling Brake

Compressed air is output from air compressor driven by engine, and enters into air tank through oil-water
separation combination valve (oil-water separator, pressure control valve). When air pressure in air tank
reaches the highest braking pressure (usually around 0.784MPa) of brake system, pressure control valve will
close the exit going to air tank, open load discharging mouth and discharge the compressed air from air
compressor to the air directly. When compressed air in air tank reaches the lowest pressure (usually around
0.71MPa) of brake system, pressure control valve will open the exit going to air tank, and close load
discharging mouth to let compressed air from air compressor into air tank for supplementation until the
compressed air in air tank reaches the highest working pressure of brake system.
Following is the fundamental diagram

Figure 1
Reference Number Description Reference Number Description
1 REAR AXLE 9 HOSE
2 HOSE 10 HOSE
3 PUMP 11 PEDAL
4 HOSE 12 HOSE
5 SWITCH;PRESSURE 13 ACCUMULATOR
6 FRONT AXLE 14 HOSE
7 HOSE 15 VALVE
8 PUMP 16 HOSE
Brake System SP002359
Page 3
PARTS LIST

Structure Chart of Brake System

Figure 2

SP002359 Brake System

Page 4
 Reference Number Description Reference Number Description

1 PUMP 35 HOSE,AIR

2 VALVE 36 HOSE,AIR

3 ACCUMULATOR 38 CLIP

5 VALVE 40 CLIP

7 SWITCH;PRESSURE 41 BOLT

8 HOSE,AIR 42 CLIP

9 HOSE,AIR 43 BOLT

10 HOSE 44 BOLT

11 HOSE,FLUID 45 SEALRING

12 TUBE 46 WASHER;PLAIN M10

13 PIPE,AIR 47 WASHER

14 ADAPTER 49 TUBE

15 PLATE 50 BOLT

16 BRACKET 52 ADAPTER

17 BOLT 53 WASHER

18 BOLT 101 VALVE,BRAKE PEDAL

20 BOLT M12X1.75X30 102 SWITCH;SHUT OFF

21 NUT 103 BOLT

22 WASHER;PLAIN 104 BOLT (M5X0.8)

23 SEAL RING 105 WASHER;PLAIN M5

24 WASHER,SEAL 106 WASHER

25 TUBE 107 ADAPTER

26 TUBE 108 WASHER,SEAL

29 WASHER 109 ADAPTER

30 BOLT 110 HOSE; ;

31 SEALRING 111 HOSE

32 BOLT 112 SWITCH,LAMP

33 CLAMP 113 SEAL RING

34 TEE

Brake System SP002359

Page 5
Oil-water separator

Figure 3

Reference Reference
Description Description
Number Number
1 SHELL ASS’Y 9 RELIEF VALVE ASS’Y

2 REGULATING VALVE 10 ORIFICE PLUG

3 EAR DRUM 11 ONE-WAY VALVE

4 STEM 12 FILTER ASS’Y

5 REGULATING SPRING 13 OIL COLLECTOR

6 UPPER COVER 14 AIR BLEEDING PISTON

7 REGULATING SCREW 15 LOWER SHELL

8 CONTROLING PISTON ASS’Y 16 AEROFIOL NUT

SP002359 Brake System

Page 6
Pneumatic brake valve

Figure 4

Reference Reference
Description Description
Number Number

1 MANDRIL 7 VALVE BODY

2 PEDAL ASS’Y 8 INTAKE VALVE ASS’Y

3 ANTIDUST COVER 9 VALVE ASS’Y

4 BALANCING SPRING 10 OUTLET VALVE ASS’Y

5 PISTON ASS’Y 11 SEALING FIN

6 PISTON FOUR SPRING 12 SPRING SEAT

Brake System SP002359

Page 7
Booster pump

Figure 5

Reference Number Description Reference Number Description

1 STRENGTH CYLINDER 8 PISTON

2 Y-SEAL RING 9 BREAKING PUMP

3 PISTON 10 AIR OUTLET SCREW

4 RELEASING SPRING 11 PUSHING BORER

5 ENDPLATE 12 MAIN PUMP FUR BOWL

6 STORAGE CUP 13 X-SEAL RING

7 PUTTING SEAT

SPECIAL TOOLS AND MATERIALS

LUBRICANTS、 SEALANTS AND OIL

SP002359 Brake System

Page 8
System Maintenance and Failures Analysis

Brake caliper is locking

The so called ―locking‖ failure refers to brake caliper does not return to the original position, that is one of the
common failures of brake system. There are many reasons causing such kind failures, such as brake caliper
is blocked, booster pump is blocked or brake caliper valve is blocked. If the brake caliper of front and rear
bridge is locking, it is may caused by blocking of pneumatic brake caliper. When the failures are solved,
loosen pipeline between booster pump and brake caliper, manually check if the brake caliper can return, if it
does not work, it may be caused by blocking of brake caliper, if it can be returned manually, but booster pump
may be blocked.

No brake or brake distance is too long

1. Pressure adjustment is improper, which causes pressure of compressed air is too low, brake moment is
too small. Adjust pressure gauge to the regulated range.
2. It may be caused because air compressor is air leaking or air inlet and outlet valve are blocked because
wearing of cylinder barrel and piston ring is too much, driving belt is too loosened. The worn parts shall
be replaced in time.
3. Foot brake valve is adjusted improperly, when brake pedal is stepped to the end, air inlet valve of brake
valve is not totally opened, air throttle is caused, air pressure becomes weak when going through foot
brake valve, and it cannot reach rated working pressure. Adjust the adjusting screw of brake pedal.
4. Failure of booster pump: sealing ring of booster pump is worn, compressed air goes into low pressure
chamber, and movement of brake pump piston is slow, or even there is no moving distance, which cause
braking power is not enough; compensation hole of brake pump is blocked by dirt, brake fluid cannot go
into ante chamber of piston and oil in brake oil way is not enough.

Brake lags behind

1. Air in brake system is not evacuated, air is compressed when braking, air resets when releasing brake,
which affects returning of friction plate.
2. Brake air pressure is not enough;
3. Piston of brake caliper is blocked;
4. Foot brake air bleeder or filter screen is blocked, return spring of valve core is broken, piston cannot
return and blocks outlet of air hole, which makes brake air discharging is not smooth, brake pressure and
oil pressure cannot reduce quickly, brake moment cannot be released, thus it is lagged behind.
5. The hole of non-pressure chamber of booster pump connecting with air is blocked or return spring is
broken, which affects sensitivity of chamber piston return and cause lag.

Brake System SP002359

Page 9
Braking deviation
The direct reason of braking deviation is the brake moments of the left side and right side wheels are different,
the common phenomenon are:
1. Brake caliper of one side of the wheel is locking, it is hard to trip off during travelling, and usually the
rectangle sealing ring of brake caliper is broken.
2. When stepping foot pedal, one side brake caliper is braking, while the other side is inside leaking and oil
way is blocked, brake fluid cannot go into brake caliper, which makes different brake moments and
causes deviation. Under such kind of condition, please check if the sealing rings of gas cap and brake
caliper are turned up or the pipelines are blocked.

There is bridle during braking, and brake is hot

1. Connection screws between brake caliper and drive axle are loosed, they rub, impact or abrade each
other.
2. There are hard things between brake lining and brake disc.

Storage and usage of brake fluid

1. Brake fluid belongs to inflammable goods; please pay Note to avoid evaporation and fire during usage
and storage.
2. Brake fluid shall be stored in warehouse or other assigned place, but it cannot be stored in open air and
close to hot source to avoid deteriorating and become invalid.
3. The using department shall set up independent room for storage and there must be obvious marks.
4. It is forbidden to mix and use brake fluid of different brands to avoid layering and lose braking effect.
5. There must be special containers to store brake fluid to avoid mixing of other oil and cause reaction and
invalidity.
6. Containers storing brake fluid must be clean and covered to avoid mechanical sundries and water. If the
surface of brake fluid has dust and sundries, they must be removed before using, do not mix them, clean
and special tool shall be used to add brake fluid.

Replacement of brake fluid and Notes:

Technicians shall guide clients to use and replace brake fluid strictly, when following conditions appear, all
brake fluid must be replaced immediately.
1. When brake fluid is mixed with mineral substance, such as gas oil and diesel.
2. When vehicle is travelling normally, brake is light and heavy.
3. When brake fluid in the system is less or when the vehicle having liquid level is warning.
4. When oil color of brake fluid is muddy or there are sundries and sediment.

SP002359 Brake System

Page 10
Notes during replacement:
1. When replacing brake fluid, clean the residual liquid in brake system, and check new brake liquid.
2. When replacing brake fluid, try to reduce the contacting time between brake fluid and air to avoid
reducing performance of brake fluid.

3. Before replacing brake fluid, it is better to clean brake system with alcohol, release air in the oil way after
replacement.

Treatment of air source

1. Clean air filter core in time.
2. Release water from air tank in time.

Brake System SP002359

Page 11
SP002359 Brake System
Page 12
 SP002373

PARKING SYSTEM

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual or
those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

MODEL SERIAL NUMBER RANGE

SD200 1001 and Up

Copyright 2011 DISD

July 2011

Parking System SP002 373

Page 1
TABLE OF CONTENTS
General Description………………………………………………………………………….3
Structure of Parking Brake…………………………………………………………….3
Working Principle of Parking Brake………………………………………………….3
Parts List………………………………………………………………………………….4

SP002373 Parking System

Page 2
General Description
Structure of parking brake
Brake is located at the front end of output axle of gearbox. Driven method is pneumatic control. Pneumatic
control usually has emergency brake function. When brake pressure is lower than safe pressure, the system
can stop loader automatically.

Working principle of parking brake:

When the loader is driven normally, emergency and parking brake control valve are normally open.
Compressed air from air tank goes through emergency and parking brake control valve, quick release valve,
one part goes into brake chamber to push piston, compressed spring in brake chamber and store energy. The
other part goes into the small chamber of stop valve of variable speed control valve, and connects with shift
gear oilway. When emergency and parking brake are needed, emergency and parking brake valve is
controlled to stop compressed air, brake chamber, compressed air in stop valve chamber will be discharged
into air through quick release valve, shift gear oilway is stopped, gear box is on empty gear automatically, at
the same time spring in brake chamber is released to push piston driven shoe brake in brake chamber to
realize parking brake or emergency brake. When pressure of brake system is lower than safe pressure
(0.3MPa usually), emergency and parking brake control valve will act automatically to realize emergency
brake.

Parking System SP002373

Page 3
PARTS LIST

Assembly structure chart

Figure 1

Reference number Description Reference number Description

1 ACCUMULATOR 8 WASHER
2 HOSE 9 ADAPTER
3 BRACKET 10 SEAL RING
4 BOLT,HEX 11 VALVE,CONTROL
5 SEAL RING 12 WASHER
6 ADAPTER 13 ADAPTER
7 ADAPTER

SP002373 Parking System

Page 4
1ELECTRICAL SYSTEM
 SP002374

2ELECTRICAL SYSTEM
(SD200)

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual or
those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

MODEL SERIAL NUMBER RANGE

SD200 1001 and Up

Copyright 2011 DISD

July 2011

Electrical System SP002374

Page 1
TABLE OF CONTENTS
Overview..................................................................................................................3
Electric Wire Color………….……………………………………...............................3
Electric Supply System................................................................................................5
Engine Starting Circuit.................................................................................................7
Operation during Start Process….…………………………………….………………7
Operation after Start Process …………………………….……………………..……7
Engine Preheating System………................................................................................9
Principle of Operation …………………...………………………….….………………9
Engine Stop System...........................................................................................11
Operation in Engine Running Mode………………..……………………..……...….11
Operation in Engine Stop Mode ………..………....………………….…………..…11
Charging System.......................................................................................................13
Monitoring System.....................................................................................................15
Gauge Panel…………………………….……………………..……………………....16
Windshield Wiper……................................................................................................21
Lighting System……..................................................................................................22
Electric Detent System..................................................................................24
Electric Circuit …………………………….…………………..……………………….24
Boom Kick-Out……………………………………………..…………..………………25
Return to Dig………………………………..…………….……………………………25
Proximity Switch………………………………………….……………….…..…….....25

SP002374 Electrical System

Page 2
OVERVIEW
Voltage of electrical system of the machine is DC 24V, the rated voltage of all electrical parts is 24V. Electrical
cable wire adopts single wire system, and negative earth is adopted. Electrical system includes two serial 12V
storage batteries and three phase DC generator with entire rectifier. Wire harness of the system can be
distinguished by different insulation color. Each color symbol used for electrical system is listed below.

Electric Wire Color

Symbol Color Symbol Color

W White R Red
G Green Gr Gray
Or Orange P Pink
B Black Y Yellow
L Blue Br Brown
Lg Light Green V Violet

NOTE: RW: Red wire with White stripe.

R - Base Color, W - Stripe Color.
NOTE: 0.85G: Nominal sectional area of wire core less insulator = 0.85 mm2 (0.03 in2).

Electrical System SP002374

Page 3
SP002374 Electrical System
Page 4
ELECTRIC SUPPLY SYSTEM
Power circuit supplies electric current to each electrical part. It is composed of storage battery, generator,
fusible line and fuse box. Negative electrode of storage battery is earth connected and connects with balance
weight.

Even if keys switch is at ―OFF‖ position, when the general power is switched off, storage battery still supplies
electric current to following parts, and returns back to fuse box through fusible link.
1. Input terminal of storage battery relay power supply.
2. Key switch terminal ―B‖.
3. Cabin light power supply terminal.
4. General stop electromagnet power input terminal.
5. Generator terminal ―B‖.
6. Preheat relay power input terminal.

When switch of keys is at ―ON‖ and ―START‖ position, electric current flows to fusible wire from storage
battery, reaches key switch terminal ―B‖/‖BR‖ through fuse box, and reaches storage battery relay control
terminal ―+‖ through guide line, activate storage battery relay coil and make the system power on.

When all contact terminals of storage battery are connected well, electrical device can be operated.

When generator does not work, all electrical equipments power source is supplied by storage battery. Once
diesel engine is started, power will be supplied by generator.

Electrical System SP002374

Page 5
Figure 1 Power supply circuit diagram

Reference Number Description Reference Number Description

1 Disconnect Switch 6 Battery Relay

2 Battery 7 Diode

3 Starter 8 Fuse

4 Starter Relay 9 Alternator

5 Starter Switch

SP002374 Electrical System

Page 6
ENGINE STARTING CIRCUIT

Running condition during starting process

Turn key switch (6) to ―ON‖ position, connect terminal ―B‖ and ―BR‖, output electric current starts power relay

(8), then fuse box is power on.

After key switch (6) is turned to ―ON‖ position, terminal ―R2‖ and ―B‖ are connected, starter relay (4) is started,

then other contact terminals ―B‖ and ―PP‖ are connected, active gear of starter (3) is propelled to contact ring

gear of flywheel and connect with contact terminal of starter.

Electric current comes out from storage battery (2), goes through terminal ―B‖ and ―PP‖ of starter relay (4) and

arrives at starter (3) terminal ―50‖.

Running condition after starting

Once generator is started, the belt will drive AC generator (9) to create electric current. Electric current goes

through generator (9) terminal ―B‖, safety plate (7), power relay (8) terminal ―B‖ and supply power to fuse box.

Electrical System SP002374

Page 7
Figure 2 Starter circuit

Reference Number Description Reference Number Description

1 Disconnect Switch 6 Starter Switch

2 Battery 7 Fuse

3 Starter 8 Battery Relay

4 Starter Relay 9 Alternator

5 Diode

SP002374 Electrical System

Page 8
Engine Preheating System
Engine preheating system is flame preheating system, its main functions are: heat air inlet temperature
through burning diesel to solve the problem that engine is difficult to be started in winter resulted from low
temperature. Main parts include: preheating switch (6), temperature sensor (11), preheating controller (7),
preheating indicator (12), preheating relay (8), flame preheating solenoid valve (10) and preheating plug (9).

Working principle:
1. Preheating switch (6) is turned on;
2. When water temperature of engine is higher than 0℃ (water temperature Rt resistivity is smaller than
2700±300Ω), controller (7) is not at preheating state, preheating indicator light (12) is on for 2S and
then off;
3. When water temperature of engine is lower than 0℃ (water temperature Rt resistivity is smaller than
2700±300Ω), controller (7) is at preheating state; preheating time is related with voltage;
Relationship between preheating time and voltage

Voltage（V） 18 20 22 24

Time （S） 55±5 41±4 30±3 26±2

4. When preheating time is up, preheating indicator light (12) is off (if ignition switch is off during
preheating time, controller stops working), it enters into 30S period waiting for starting;
① Turn off starting gear (ON) of ignition switch (4) during this period (preheating plug is power on
during this period), oil supplying solenoid valve is connected, preheating indicator light (12) is on
again, flame preheating plug (9) is power on;
② Turn off starting gear (ON) of ignition switch (4) during this period, 24V voltage is not input into 50
terminals, engine is not starter, controller stops working;
5. After starting switch (40 is reset from starting position, if generator (3) does not send out D+ signal to
controller (7) (that is starting is unsuccessful), controller stops working after 6S; if generator sends out
D+ signal to controller (that is starting is successful), after entering into preheating period, working
time RT resistivity and water temperature sensor (11) is functional relation, the longest is 120S, the
shortest is 60S;
6. When Rt circuit of water temperature sensor (11) is broken, the system enters into preheating state,
after all starting procedures are finished, preheating indicator light (12) blinks for 15S for warning, the
heating time is the longest of the system after then;
7. When working voltage is lower than 15V, the system does not at preheating state, preheating
indicator light (12) blinks for 15S for warning.
8. When controller (7) stops working under any working state, preheating switch (6) must be turned off to
enter into preheating state again, that is cancel 15 terminal voltage, connects with preheating switch
(6) again.
Electrical System SP002374
Page 9
Figure 3 Control circuit of preheating system

Reference Number Description Reference Number Description

1 Disconnect Switch 7 Preheat Controller

2 Battery 8 Preheat Relay

3 Alternator 9 Pre-heater

4 Starter Switch 10 Solenoid Fuel Valve

5 Fuse 11 Water Temp. Sensor

6 Preheat Switch 12 Preheat Indicator

SP002374 Electrical System

Page 10
ENGINE STOP SYSTEM
Engine stopping system is composed of key switch (4), flameout electromagnet (6) and flameout relay (5).

There are two kinds of work process: before engine is started and engine flameout.

Operation in engine running mode

When key switch (4) is turned to ―ON‖ gear, its terminal ―ACC‖ and ―B‖ are connected. Electric current goes

through security of electrical box (3) through positive pole of storage battery (2) and ―B‖ and ―ACC‖ terminals

of key switch, goes through holding coil of flameout electromagnet and earth connected and forms circuit.

Turns key switch to ―START‖ gear, terminals ―ACC‖, ―C‖ and ―B‖ are connected. Electric current goes through

insurance of electrical box (3) from positive pole of storage battery (2) and terminals ―B‖ and ―C‖ of key switch,

flameout relay (5) coil is power on and works, terminal 15A and 269 are connected, flameout electromagnet (6)

terminal 85 is power on, pulls in coil and works, fuel injection pump is opened and lever is closed.

Then key switch will be back to ―ON‖ gear automatically, pulling in coil is broken, while coil is kept to be power

on, keep the state of lever closing.

Operation in engine stop mode

Turns key switch (4) to ―OFF‖ gear, its terminals ―ACC‖ and ―C‖ are power off. Electric current going through

flameout electromagnet (6) holding circuit and flameout replay (5) coil is cut off. Closing lever of fuel injection

pump is reset, fuel supplying is stopped, engine flames out.

Electrical System SP002374

Page 11
Figure 4 Engine starting system

Reference Number Description Reference Number Description

1 Disconnect Switch 4 Starter Switch

2 Battery 5 Engine Stop Relay

3 Fuse 6 Engine Stop Motor

SP002374 Electrical System

Page 12
Charging System
Turn key switch (5) to ―ON‖ position, its terminals ―BR‖ and ―B‖ are connected, power relay (6) acts, terminals
―02A‖ and ―02‖ are connected, electric current coming from storage battery (2) goes through fuse box (4),
power relay (6), charging indication light (8) and excitation resistance (9) and reaches ―D+‖ terminal of
generator (5), earth connected and forms a circuit, charging indication light (8) is on to warn and supplies
excitation electric current for generator (5). After engine is started, generator (5) starts charging. Electric
current comes from terminal ―B+‖ of generator (5), goes through fuse box (4) and reaches storage battery (2).
Charging indication light (8) is off.

Generator (5) also supplies power to other electrical parts through fuse box (4) and power relay (6).

Electrical System SP002374

Page 13
Figure 5 Charging system circuit diagram

Reference Number Description Reference Number Description

1 Disconnect Switch 6 Battery Relay

2 Battery 7 Diode

3 Starter Switch 8 Charge Indicator

4 Fuse Box 9 Resistor

5 Alternator

SP002374 Electrical System

Page 14
Monitoring System
Monitoring system of the equipment includes all kinds of oil pressure gauges, oil pressure sensor plug, water
temperature gauge, water temperature sensor plug, voltmeter, barometer and low pressure warning device,
etc. Four instruments on instrument panel are sensing type, three instruments are directly operated type.

9
3

4
8

7
5
6

Figure 6 Monitoring system

Reference Number Description Reference Number Description

1 Gauge Panel 6 Fuel Sensor

2 Battery 7 Oil Temperature Sensor

3 Alternator 8 Water Temperature Sensor

4 Rocker Switch 9 Back Buzzer Switch

5 Switchgroup

Monitoring system will process information collected from all sensors, the instrument panel will indicate all
data and warning signals.

Electrical System SP002374

Page 15
 Gauge panel

Figure 7 Gauge panel

Reference Reference
Description Description
Number Number

1 T/M Oil Pressure Meter 8 Turn and Hazard Warning Light

2 Fuel Gauge 9 Charging Warning Light

3 Air Pressure Meter 10 Turn and Hazard Warning Light

4 Torque Converter Oil Temperature Meter 11 High Beam Indicator

5 Voltmeter 12 Preheat Indicator

6 Engine Coolant Temperature Gauge 13 Parking Brake Indicator

7 Engine Oil Pressure Gauge 14 Hour Meter

SP002374 Electrical System

Page 16
 Instruments
Sensor Specification
Function Display
Input Terminal Input Specification

40℃ — More than 180Ω

Oil temperature 80℃ — 40Ω ~ 60Ω
gauge of torque CN-05 100℃— 20Ω ~ 40Ω
converter 120℃— less than 20Ω
140℃— more than 10Ω

40℃— More than 180Ω

Water 60℃— 80Ω ~ 100Ω
temperature CN-03 80℃— 40Ω ~ 60Ω
gauge of engine 100℃— 20Ω ~ 40Ω
120℃— less than 20Ω

Brake barometer Directly operated type Directly operated type

Empty — more than 80Ω

1/4 — around 46Ω
Fuel gauge CN-04 1/2 — around 32Ω
3/4 — around 22Ω
Full — around 8Ω

Electrical System SP002374

Page 17
 Sensor Specification
Function Display
Input Terminal Input Specification

Oil pressure
gauge of Directly operated type
gearbox

Voltmeter CN-08

Fuel pressure
Directly operated type
gauge of engine

Hour meter CN-01

SP002374 Electrical System

Page 18
Indication light
Function Indication Input terminal Operation Remark
The light is on when
Turn right and turning right signal or
dangerous CN-18 dangerous warning light
indication light is turned on (the Max.
terminal input is 24V)
Under normal
The light is on when not
condition, light is on
CN-08 charging (Generator D +
Charging when starting, light is
CN-09 terminal output voltage
off when engine starts
reduces to 24V)
working
The light is on when
Headlights on headlight on full beam is
CN-20
full beam turned on (The Max.
terminal input is 24V)

The light is on when

Preheat CN-105 preheating system is
working

The light is on when

brake switch is turned on When braking, the
(pressure switch is off light is on before
Parking brake CN-10
when pressure is more engine is started under
than 0.3Mpa, the Max. any conditions.
input terminal is 24V)
The light is on when
Turn left and turning left signal or
dangerous CN-19 dangerous warning light
indication light is turned on (the Max.
input terminal is 24V)

Electrical System SP002374

Page 19
Schematic diagram of monitoring system

Figure 8 Schematic diagram of monitoring system

Reference Reference
Description Description
Number Number

1 Disconnect Switch 11 Transmission Temp. Sensor

2 Battery 12 T/M Oil Pressure Switch

3 Starter Switch 13 Break Pressure Switch

4 Fuse Box 14 Eng. Oil Pressure Switch

5 Alternator 15 Air Pressure Alarm Switch

6 Starter Relay 16 Preheat Controller

7 Diode 17 Combination Switch

8 Gauge Panel 18 Position Lamp Switch

9 Water Temperature Sensor 19 Hazard Switch

10 Fuel Sensor 20 Blinker Unit

SP002374 Electrical System

Page 20
Windshield Wiper
Windshield wiper can be operated by combination switch (2).

1. Low speed wiper (I gear)

When wiper is running with low speed, electric current comes from fuse box (1), goes through wire
inlet terminal and terminal ―L‖ of wiper motor (3), reaches terminal ―6‖ and ―4‖ of combination switch
(2) and connects with earth.
2. When wiper is running with high speed, electric current comes from fuse box (1), goes through wire
inlet terminal and terminal ―H‖ of wiper motor (3), reaches terminal ―1‖ and ―4‖ of combination switch
(2) and connects with earth.

Figure 9 Circuit diagram of front windshield wiper

Reference Number Description Reference Number Description

1 Fuse Box 3 Wiper

2 Combination Switch 4 Washer

Electrical System SP002374

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Lighting System
Lamping system includes big lamp, position lamp, turning signal lamp, dangerous lamp, parking lamp,
working light and switches of all lamps.

1. When indoor lamp (4) is turned on, electric current goes to indoor lamp from fuse box (1), indoor lamp is
on.

2. Press front lamp switch (18), combination switch (2) is turned to passing lamp, terminal ―8‖ and ―9‖ are
connected, electric current from fuse box (1) is sent to coil terminal ―86‖ of passing lamp relay (6), passing
lamp relay (6) works, its terminal ―30‖ and ―87‖ are connected, passing lamp of front lamp(12) and (13)
gets power and works.

3. Press front lamp switch (18), combination switch (2) is turned to distance lamp, terminal ―8‖ and ―10‖ are
connected, electric current from fuse box (1) is sent to coil terminal ―86‖ of distance lamp relay (5),
distance lamp relay (5) works, its terminal ―30‖ and ―87‖ are connected, distance lamp of front lamp (12)
and (13) gets power and works.

4. Combination switch (2) is turned to left handed rotation, its terminal ―13‖ and ―14‖ are connected, electric
current from fuse box (1) goes through flasher (7), combination switch (2) and reaches left turning lamp of
front combination lamp (12) and rear combination lamp (14).

5. Combination switch (2) is turned to right handed rotation, its terminal ―13‖ and ―12‖ are connected, electric
current from fuse box (1) goes through flasher (7), combination switch (2) and reaches right turning lamp
of front combination lamp (13) and rear combination lamp (15).

6. When brake switch (3) works, electric current from fuse box (1), reaches brake lamp of rear combination
lamp (14) and rear combination lamp (15), brake lamp works.

7. When pressing switch of position lamp (17), its terminal ―5‖ and ―1‖ are connected. Electric current from
fuse box (1) reaches small lamps of (10), (11, (16), (17), and (18), and front combination lamp (120 and
(13), position lamp of rear combination lamp (14) and (15).

8. When pressing switch of working lamp (10), its terminal ―5‖ and ―1‖ are connected. Electric current from
fuse box (1) reaches working lamp (9), working lamp is on.

9. When pressing rear lamp switch (11), its terminal ―5‖ and ―1‖ are connected. Electric current from fuse
box (1) reaches working lamp (8), rear working lamp is on.

10. When pressing dangerous lamp (16), terminal ―5‖ and ―1‖, ―2‖ and ―37‖ are connected. Electric current
from fuse box (1) is sent to turning lamp of front combination lamp (12) and (13), and rear combination
lamp (14) and (15).

SP002374 Electrical System

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Figure 10 Lighting system circuit diagram

Reference Number Description Reference Number Description

1 Fuse Box 10 Working Lamp Switch

2 Combination Switch 11 Rear Lamp Switch

3 Stop Lamp Switch 12 Front Combination Lamp(L)

4 Room Lamp 13 Front Combination Lamp(R)

5 High Lamp Relay 14 Rear Combination Lamp(L)

6 Low Lamp Relay 15 Rear Combination Lamp(R)

7 Blinker Unit 16 Hazard Switch

8 Rear Lamp 17 Position Lamp Switch

9 Working Lamp 18 Front Lamp Switch

Electrical System SP002374
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Electric Detent System
Electric detent system includes swing arm lifting limitation system and cylinder automatic laid flat system.

Electric circuit

Figure 11 Electric detent system circuit

Reference Number Description Reference Number Description

1 Fuse Box 5 Float Magnet

2 Raise Relay 6 Return to Dig Magnet

3 Return to Dig Relay 7 Proximity Switch 1

4 Raise Magnet 8 Proximity Switch 2

SP002374 Electrical System

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Boom Kick-Out
1. Swing arm lifting limitation
When swing arm operation handle is pulled to the rear limitation position, swing arm operation handle will be
gripped by swing arm lifting electromagnet (4) (swing arm operation handle will not return to middle-position
after loosening hands), swing arm will keep lifting; when swing arm reaches the limitation, proximity switch (7)
works, its terminal ―0‖ and ―-‖ are connected, coil of lifting relay (2) is power on and works, its terminal ―30‖
and ―87a‖ disconnect. Lifting limitation electromagnet (4) and float electromagnet (5) are power off and lose
suction ability, swing arm operation handle will return middle-position automatically with the effect of resetting
spring, lifting hydraulic circuit of cylinder is cut off, and swing arm does not lift again.

2. Swing arm floating device

When swing arm operation handle is pushed to the limitation, swing arm operation handle will be gripped by
swing arm floating electromagnet (5) (swing arm operation handle will not return to middle-position after
loosening hands), at this moment, swing arm is at floating state, the swing arm operation handle will return
meso position when releasing swing arm floating state. When swing arm descends, it can be pushed to flat
position, swing arm will descend with effect of dead weight. At this moment, the driver can operate other
items (such as flat bucket) with the right hand, thus working efficiency is improved. Push swing arm operation
handle to floating position during slicking, bucket will rise along with rising of ground, and will not damage the
road.

RETURN TO DIG
When bucket is at material discharging state, pull bucket operation handle to rear limitation, since proximity
switch (8) is at suction state, its terminal ―0‖ and ―-‖ are connected, automatic laid flat relay (3) coil is power on
and pulls in, bucket operation handle is gripped by bucket collecting holding electromagnet (6) and keep at
the rear limitation position (bucket operation handle will not return to middle-position after loosening hand),
bucket will keep rotating backward until reaching limitation, proximity switch (8) acts, its terminal ―0‖ and ―-‖
are disconnected, automatic laid flat replay (3) is power off and disconnect, bucket collecting holding
electromagnet loses power and gripping ability, bucket operation handle returns to middle-position with effect
of resetting spring, bucket stops rotating, swing arm descends, when bucket reaches to the ground, bucket
bottom is flat with the ground.

PROXIMITY SWITCH
Operating distance：10mm ± 1mm
Operation indication light：Indication light is on when
proximity switch is
acting.

Figure 12 Proximity switch

Electrical System SP002374

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SP002374 Electrical System
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 SP002375

2SCHEMATIC
(SD200)

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual or
those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

Copyright 2011 DISD

November 2011

Electrical Schematic (SD200) SP002375

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TABLE OF CONTENTS
GENERAL DESCRIPTION........................................................................................3
SD200………………………..........................................................................................4

SP002375 Electrical Schematic (SD200)

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General Description
The overlapped edge has been considered for convenient copy, a complete schematic diagram can be
formed when they are put together.

Figure 1

Electrical Schematic (SD200) SP002375

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SD200

SP002375 Electrical Schematic (SD200)

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Electrical Schematic (SD200) SP002375
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SP002375 Electrical Schematic (SD200)
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1ATTACHMENTS