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Teknisk Træning Manual W230-W270 GB
Teknisk Træning Manual W230-W270 GB
4 - ENGINE (W270)
7 - TRANSMISSION
8 - BRAKE SYSTEM
9 - STEERING SYSTEM
10 - HYDRAULIC SYSTEM
GENERAL
INFORMATIONS
W230 W270
CUMMINS 6CTAA8.3 CUMMINS QSM11 with
ENGINE (is not C.R.) electronic Injection (is not C.R.)
P = 179 Kw @ 2200 Rpm P = 199 Kw 2100 Rpm
STEERING
With control valve (No Orbitrol)
SYSTEM
BRAKE Brake are supplied by a gear pump mounted in tandem with steering pump.
SYSTEM Same pump after brake will supply the manipulator
WALK
AROUND
W230
W270
ACCESSIBILITY
Access to the engine compartment is provided by two
side doors with a “seagull wing” opening. The panelling
of the doors is made of a plastic material (Telene)
secured to a metal net type structure having also the
purpose of supporting hinges, lock, gas cylinders and a
mechanical stop device in open position.
The rear mudguards are of a wrapping type in the
standard version. They are made with the same material
of the hood in two pieces: one fixed (toward the cab
access platform) and one mobile (rear side). The mobile
part of the rear mudguard is solid with the access door to
the engine compartment.
4
3
ACCESS TO ENGINE FILTERS:
2
1. Air cleaner;
2. Coolant filter;
3. Fuel filter;
4. Fuel pre-filter;
5. Engine oil filter;
5
OTHER FILTERS:
Left Side
TANK CAPACITIES
PRESSURE PORT
1 3 5 7 9 11
2 4 6 8 10 12
ON-THE-ROAD LIGHTS
Note: the front work lights are integrated with the cab roof.
5
3
7
6
Indice Esci
1
X18
2
6 X21
MAIN CONNECTIONS
X23
X22
4
X20
Lato dx Indice Esci
1
2
TRANSMISSION
TRANSMISSION CONTROL
CONTROL VALVE
VALVE
Manual engagment
HYDRAULIC PUMP
2
4
3 1
5
BRAKE SYSTEM
3 2
Legend
BRAKE SYSTEM
CONTROLS AND
INSTRUMENTS
1
2
1. Cigarette lighter
2. Transmission cut-off selector switch
3. Automatic/manual transmission selection switch
4. Equipment proximity sensors actuation switch
5. Maintenance indicator and “wait-to-start”indicator
6. Fan rotation activation button
7. Load Travel Stabiliser actuation switch
8.Auxiliary reverse button selection switch
(present with joystick and multilever version)
9. Starter switch
Multiple instrument
2 16 4
11 01. Tachometer
02. Coolant temperature
6
7 03. Fuel level indicator
04. Transmission oil temperature
12 05. Hourmeter
8
06. Coolant temperature indicator light
9 13 07. Engine oil low pressure indicator light
08. Battery charge indicator light
09. Air cleaner clogging indicator light
10 14 10. Fuel reserve indicator light
11. Transm. oil temperature indicator light
12. Brake oil low pressure indicator light
13. Emergency steering indicator light
14. Parking brake engaged indicator light
3 1 5 15 15.General warning indicator light (+
buzzer)
16. Gear engaged indicator lights
STEERING COLUMN
TILTABLE
HEIGHT ADJUSTABLE
STEERING WHEEL
1. Transmission control lever lock
2. Emergency switch
4 3
PEDAL CONTROLS
2
1. Horn
2. Accelerator pedal
4. Footrest
W230 - W270.
1 The parking brake control is made of
mechanical lever (1) connected by a
flexible cable to a 3-way 2-position
hydraulic valve. It is located on the
left side inside the cab.
W230 - 270
W190
The parking brake control is made of
electric switch (2) located on the left
side of the steering column,
immediately below the gearshift pilot
valve. This switch controls a 3-way 2-
position solenoid valve integrated
2
W190 with the brake pedal valve..
ENGINE
(Cummins QSM11)
6
5 11
9 1 Turbocharger
8
2. Engine oil heat exchanger
3. Coolant pump
4
7 4. Alternator
5. Exhaust manifold
6. Air intake (fom aftercooler)
7. Air intake (from filter)
1 8. Exhaust
9. Air inlet pipe to aftercooler
10. Coolant inlet
11. Coolant outlet
3
10
2
7 6 6 9
COMPONENTS
1. Fuel pump
2. “Shut-off” valve
3. Engine oil dipstick
2 4. Oil filler pipe
5. Starter motor
1
6. Fuel filters (*)
7. Coolant filter (**)
8. ECM570 electronic controller
3 4 5 8
9. Breather
Note: (*) The illustration shows the Cummins standard arrangement that prescribes the use of
Fleetguard FS1000 filters. In this application the right filter is replaced by the Fleetguard FS1003
arranged for the installation of the “water in fuel” sensor.
Note: (**) Is a special filter that release a protective gel (anticorrosive) when is crossed by
coolant liquid. This gel will mix to coolant liquid to protect the external cylinders surface.
COMPONENTS
6 1. Damper wheel (visco-static type)
3. Alternator pulley
6. Coolant delivery
4
3 1 2
Filters
COMPONENTS
1. Coolant filter
1 2 3 4 5
PTO Detail
The oil filter is located in a remote position with respect to its original place (immediately under the heat
exchanger) in order to facilitate the replacement operations. In this manner the filter is grouped together
the fuel and coolant filters.
1 2 3
WARNING!
Identify the correct numbering of ECM 570 CONTROLLER
the pins based upon the
4 pin DEUTZ connect.
orientation of the key for Service Tooling
16
Maintenance lamp
5
48
47
49
3
13
10
9
6
16
ENGINE
TROUBLESHOOTING
(QSM11 Cummins)
Notes on troubleshooting
Notes on troubleshooting
Mode trouble
warning Engine
indicator diagnostic
“warning” switch
Notes on troubleshooting
Notes on troubleshooting
ENGINE SELF-PROTECTION
(Fuel shut-off):
Cutting-off of engine within 30 sec. pfor:
(*) In the Cummins QSM11 engines the temperature and pressure of the engine oil
is monitored by a single sensor (combined sensor)
Notes on troubleshooting
122 Yellow High voltage detected at the intake manifold pressure sensor circuit. Derate in power output of the engine.
123 Yellow Low voltage detected on the intake manifold pressure sensor circuit. Derate in power output of the engine.
131 Red High voltage detected at accelerator position sensor. Severe derate (power and speed). Limp home power only.
132 Red Low voltage detected at the accelerator position sensor circuit. Severe derate (power and speed). Limp home power only.
135 Yellow High voltage detected at the oil pressure circuit. No engine protection for oil pressure.
141 Yellow Low voltage detected at the oil pressure circuit. No engine protection for oil pressure.
Progressive power and speed derate with increasing time after alert. If
Oil pressure signal indicates oil pressure is below the low oil
143 Yellow Engine Protection Shutdown feature is enabled, engine will shutdown
pressure engine protection limit.
30 seconds after the red lamp starts flashing.
Low voltage detected on the ECM voltage supply line to some Engine will run derated. No engine protection for oil pressure or coolant
187 Yellow
sensors (VSEN 2 supply). level.
212 Yellow High voltage detected at the oil temperature circuit. No engine protection for oil temperature.
213 Yellow Low voltage detected at the oil temperature circuit. No engine protection for oil temperature.
221 Yellow High voltage detected at the ambient air pressure sensor circuit. Derate in power output of engine.
222 Yellow Low voltage detected at the ambient air pressure circuit. Derate in power output of engine.
High voltage detected on the electronic control module (ECM) Engine will run derated. No engine protection for oil pressure and
227 Yellow
voltage supply line to some sensors. (VSEN 2) coolant level.
Engine speed signal indicates engine speed is greater than 2650 Fuel shutoff valve is closed until the engine speed drops. The fuel
234 Red
rpm. shutoff valve will open when engine speed falls below 2000 rpm.
343 Yellow Internal ECM error. Possibly none on performance, or severe derate.
Mainten
418 Water has been detected in the fuel filter. Possible white smoke, loss of power, or hard starting.
ance
428 Yellow High voltage detected at water-in-fuel (WIF) sensor circuit. None on performance.
429 Yellow Low voltage detected at water-in-fuel (WIF) sensor circuit. None on performance.
Supply voltage to the electronic control module (ECM) fell below (+)
Possible no noticeable performance effects or engine dying or hard
6.2 VDC for a fraction of a second or the ECM was not allowed to
434 Yellow starting. Fault information, trip information, and maintenance monitor
power down correctly (retain battery voltage for 30 seconds after
data can be inaccurate.
keyswitch is turned off).
441 Yellow Battery voltage below normal operating level. Possible no noticeable performance effects or possible rough idle.
442 Yellow Battery voltage above normal operating level. None on performance.
581 Yellow High voltage detected on fuel inlet restriction sensor signal pin. Fuel inlet restriction monitor deactivated.
582 Yellow Low voltage detected at the fuel inlet restriction sensor signal pin. Fuel inlet restriction monitor deactivated.
583 Yellow Restriction has been detected by the fuel inlet restriction sensor. Fuel inlet restriction monitor warning is set.
596 Yellow High battery voltage detected by the battery voltage monitor feature. Yellow lamp will be lit until high battery voltage condition is corrected.
Red lamp lit until very low battery voltage condition is corrected. The
Very low battery voltage detected by the battery voltage monitor electronic control module (ECM) can increase idle speed and
598 Red
feature. deactivate idle decrement switch if idle speedup is enabled. The
engine will run continuously if ICON™ is active (automotive only).
Mainten
775 A slow leak has been detected in the air system. None on performance.
ance
776 Yellow A fast leak has been detected in the air system. None on performance.
951 None A power imbalance between cylinders was detected by the ECM. Engine may have rough idle or misfire.
Notes on troubleshooting
MANUALS
Notes on troubleshooting
Indice Esci
Error code;
Status of trouble (active or inactive);
Number of times the system
aamonitored the same trouble;
Number of hours at which the active
xxtrouble has been monitored .
Error code;
Status of trouble (active or
inactive);
Colour of diagnostic
indicator ON;
Number of times the
system monitored the same
trouble;
Number of hours at which
the active trouble has been
monitored .
Visible effects on machine.
Detailed information
display
(Fault overview).
It is entered after selecting
the button “more fault info” by
clicking with the mouse.
It shows:
Code of active error and
date of system;
Cause of trouble;
Menu for the identification
of the components that
generated the trouble;
Menu data of reference;
Menu of guided
troubleshooting procedures;
Visible effects on machine.
Guided troubleshooting
procedures display
(troubleshooting steps)
It is entered after clicking the
menu “TROUBLESHOOTING
STEPS” with the mouse.
It shows::
Messages related to safety
of operations and tooling to
be used;
“step - by - step”
procedures for the
troubleshooting and its
solution..
Graphic display of
component (diagram)
It is entered after clicking the
menu “DIAGRAM” with the
mouse.
It shows the diagram of the
component suspected of
generating the operational
trouble..
HYDRAULIC SYSTEM
ENGINE COOLING
(Fan Drive System)
General description
The hydraulic engine cooling system (well konwn as Fan Drive System) is
composed by 2 circuit:
• circuit to control the hydraulic motor on cooling radiator;
• circuit to control the hydraulic motor on aftercooler radiator.
Both circuit are supplied by a gear pump (1) mounted on engine PTO (below
injection pump). Hydraulic oil is sent to circuit through a filter (7), an then will be sent
to hydraulic block FDS (2), which works as follow:
1
• Separate circuit (cooling circuit from aftercooler circuit;
• Control the maximum pressure (200 bar for cooling circuit and 50 bar for
aftercooler circuit);
• To invert the fan rotation , through a solenoid valve located in same hydraulic
block.
Inside rear frame (right side) Fan rotation is used to clean only the cooling radiator.
An accumulator (8) is mounted on delivery line in order to absorb the pressure
peack during change rotation.
7
8
General description
Hydraulic oil in outlet from FDS block (A port for normal rotation or
B port when change rotation) supply the bi-directional hydraulic
motor (3) for the cooling system, hydraulic oil, transmission and
supplementary transmission oil radiators.
5
To hyd. Radiator
(coming from
aftercooler motor)
To tank
Al serbatoio
General description
Hydraulic oil coming from aftercooler motor (4) is sent to hydraulic tank passing before to hydraulic oil radiator (5).
A by-pass valve (6) setted to 4 bar protect radiator crash in case of oil with high density due to low external temperature.
Through this valve, the oil is sent directly to tank.
1. FDS pump
Dispacement: 19 cc./rev.
3
2. Hydraulic block (FDS)
5. Hydraulic radiator
5
11 6. By-pass valve
10 6
8 50 bar
7. Filter
9 8. Accumulator
2 9. Main circuit pressure relief valve (200 bar);
Engine
stop
12
System Adjustment
Start engine;
12
To reverse the fan rotation is necessary to press the push button in figure.
Once activated a solenoid valve 12 located in the hydraulic block FDS, the hydraulic oil change direction so is possible to
clean the radiator. The inverted rotation remain until operator keep depressed this push button. Releasing the push button, the
solenoid will be disenergized and the oil will restore the original rotation.
Even if the system is protected by accumulator, is it opportune before to carry out the fan inversion to wait until engine is at low
speed.
TRANSMISSION
TCM
TCM Transmission
Transmission
TCM
TCM Transmission
Transmission
Drive direction
TCM
TCM Transmission
Transmission
2
4
3 1
5
TCM
TCM Transmission
Transmission –– Left
Left side
side
Implement pump
with
unloading valve
TCM
TCM Transmission
Transmission –– Right
Right side
side
4
5
2
3
TCM
TCM Transmission
Transmission –– front
front view
view
Parking brake
pressure switch
Emergency
steering pump
Transmission
control valve
Parking brake
clutch Speed sensors
(one for ATC and
one for speedmeter)
SPEED
SPEED SENSORS
SENSORS
TCM
TCM Transmission
Transmission –– rear
rear view
view
Lap valve
TORQUE
TORQUE CONVERTER
CONVERTER // SAFETY
SAFETY VALVE
VALVE
TRANSMISSION
TRANSMISSION CONTROL
CONTROL VALVE
VALVE
Manual engagment
F4
F3
F2
F1
N
R1
R2
R3
R4
III
IIIFORWARD
FORWARD
Lap
valve
IIFORWARD
FORWARD
Lap
valve
IIIIFORWARD
FORWARD
Lap
valve
IV
IVFORWARD
FORWARD
Lap
valve
orificies
CONTROL
CONTROL VALVE
VALVE -- DISASSEMBLY
DISASSEMBLY
CONTROL
CONTROL VALVE
VALVE -- DISASSEMBLY
DISASSEMBLY
2
3
1 - Accumulators
2 – Modulating valve
3 – Modulating valve (flow sensibile)
4 – Pressure regulating valve 21 ÷ 24 bar
CONTROL
CONTROL VALVE
VALVE -- DISASSEMBLY
DISASSEMBLY
1 - “F/R” spool
2 - “B” spool
3 - “A” spool
CONTROL
CONTROL VALVE
VALVE -- DISASSEMBLY
DISASSEMBLY
Manual engagment
spool
1
R
2
F
3
A
1 - “F/R” Spool
2 - “A” Spool
B
3 - “B” Spool
LAP
LAP VALVE
VALVE
FUNZIONAMENTO
FUNZIONAMENTO LAP
LAP VALVE
VALVE
LAP
LAP VALVE
VALVE
LAP
LAP VALVE
VALVE
LAP
LAP VALVE
VALVE
Check
Accumulator valve
orifice
CONTROL
CONTROL VALVE
VALVE -- DISASSEMBLY
DISASSEMBLY
Forward / Reverse
clutch
Brake oil
1 – Brake piston
2 – Springs
Parking brake
Parking brake
Transmission selector
Wiper Timer
Transmission
control
connections
W270 Evolution
Proximity switch
(Hold function)
W230 Evolution
Proximity switch
(Hold function)
A.T.C. - Codes
1. Key ignition in ON
click
Models Code :
On display will appear the model code W230: 36
W270: 39
ATC - codes
2nd Number:
• Automatic/manual switch:
• 0 - manual;
Floating point in • 2 - automatic.
this position inform
that we are entered
in the 2nd display
3rd Number:
• Gear selector position (forward/reverse):
• 0 - neutral
Access to this functions, is • 1 - forward
given by pressing one time, • 2 - reverse
after swiching on the starter
key, the first push button on 4th Number:
the left on display. • Gear selector position (speed selected)
• 1 - 1st speed
• 2 - 2nd speed
• 3 - 3rd speed
• 4 - 4th speed
ATC - codes
Floating point in
this position inform
that we are entered
in the 3rd display.
ATC - codes
5. Error codes
0: Normal Functioning;
1: Transistor solenoid F’ fault. Replace ATC.
2: Transistor solenoid R fault. Replace ATC.
3: Transistor solenoid A fault. Replace ATC.
4: Transistor solenoid B fault. Replace ATC.
5: Transistor control lamps or LTS. Replace ATC
6: Not used.
Two floating points in 7: Not used.
this position inform 8: A Solenoid short circuit or disconnected Check the circuit.
that we are entered
in the 6th display. 9: B Solenoid short circuit or disconnected Check the circuit.
10: Speed sensor circuit. Check the circuit
Pressure
Pressure measurement
measurement
Pressure
Pressure measurement
measurement
Brake
System
General description
The brake valve also includes the control system to keep the brake
accumulators charges whenever the engine is running. Once the
brake circuit oil requirements are satisfied, the oil then flows to
servocontrol (manipulator).
Descrizione generale.
The pump (1) take oil directly from the tank and send it in the brake
circuit through a filter in line (3) .
2 This filter is located near to oil transmission filter (4)
1 The oil coming from the brake valve goes in feeding to the
servocontrols circuit.
3
2
Legend
Accumulator
low pressure switch
(60 bar)
3
Declutch pressure switch
(15 bar)
2 4
1 - Priority valve (before charge the accumulator and then supply servocontrols)
2 - Accumulator charging valve with differential surface
To servocontrol
system
To steering valve
To
servocontrol
system
To Hydraulic tank
PARKING
PARKING BRAKE
BRAKE CONTROL
CONTROL VALVE
VALVE
PARKING
PARKING BRAKE
BRAKE CONTROL
CONTROL VALVE
VALVE -- LOCATION
LOCATION
Brake oil
1 - Brake piston
2 - Springs
Brake
Brake pedal
pedal valve
valve
Backlash compensating
Front and rear brakes
screw
output control spools
Output pressure
setting screw
Brake System
2 2
PRESSURE PORT
1 - Front Brake
2 - Rear brake
Brake System
Connect 2 pressure gauges (end scale 350 bar) to the quick disconnect pressure check ports (A & B,) located near
the accumulators right side.
Start the engine and warm-up the hydraulic oil up to 40° - 50°C by using the front implement.
Push several times on the brake pedal to equalize the oil temperature between the brakes and the implement circuit.
Steering
System
General description
Main pump
The main circuit is supplied by a gear pump (1), flanged on
1 transmission PTO. In tandem on steering pump is mounted another
gear pump (2) for brake / servocontrols system.
2
Steering pump supply a steering valve fixed on front frame.
Through this steering valve, are supplied the steering cylinders.
Emergency Pump
Emergency circuit is supplied by a bi-directional gear pump (3),
located near the parking brake clutch.
Emergency pump is driven by wheel sprocket on transmission
through a gear fixed to transmission outlet shaft. Therefore, the
emergency pump is controlled by the movement of the wheels.
STEERING
STEERING PUMP
PUMP
EMERGENCY
EMERGENCY STEERING
STEERING PUMP
PUMP
Normal
Normal funtioning
funtioning
Implement
Implement control
control valve
valve
In
In case
case of
of emergency
emergency steering
steering .. .. ..
DIVERTER
DIVERTER VALVE
VALVE
HYDRAULIC
HYDRAULIC OIL
OIL TANK
TANK
Frizione
retromarcia
STEERING
STEERING VALVE
VALVE
STEERING
STEERING VALVE
VALVE
STEERING
STEERING
VALVE
VALVE
SECTION
SECTION
STEERING
STEERING VALVE
VALVE
Overload and
anti/cavitation valve
set to 245 bar
ELECTRIC
SYSTEM
21
21 MAIN CONNECTORS
1
Left side
2
1. Connector X18 (Engine harness)
2. Connector X21 (Transmission harness)
3. CAN connector
3
LEFT SIDE
3
Right side
5 5
3. Connector X23
3 4. Connector X20
5. Connector X22
6. Ground.
6 4
4
RIGHT SIDE
MAIN CONNECTOR
(Only W270 - On W230 thre isn’t connector)
MAIN CONNECTOR
(W270 - W230)
MAIN CONNECTOR
(W270 - W230)
MAIN CONNECTOR
(W270 - W230)
MAIN CONNECTOR
(W270 - W230)
6 2 16 4 11 01. Speedmeter
02. Coolant temperature gauge
03. Fuel level gauge
7 04. Transmission oil temperature gauge
12 05. Hourmeter
8 06. Coolant temparature warning light
07. Low engine oil pressure warning light
9 13 08. Battery charge warning light
09. Clogged air cleaner warning light
10. Fuel level warning light
11. Transmission oil temperature warning light
10 14 12. Brake oil low pressure warning light
13. Emergency steering warning light
14. Parking brake indicator light
15. General warning light (+ buzzer)
16. Engaged gear indicator lights
3 1 5 15
CONNECTOR CN1 CONNECTOR CN2
1 Brake oil low pressure warning light 21 Transmission oil temperature gauge
2 Coolant temperature warning light 22 Clogged air cleaner warning light
3 Coolant temparature gauge 23 Emergency steering warning light
4 Dashboard backlight 24 Batterie
5 Left turning light 25 Low engine oil pressure warning light
6 Dashboard backlight 26 Coolant temperature warning light
7 Hi - beam indicator light
8 Dashboard backlight
9 Ground CONNECTOR CN3
10 Fuel level gauge
11 Parking brake indicator light 27 Hourmeter (ground)
12 Battery charge warning light 28 Hourmeter (power)
13 Fuel level warning light
14 Not connected
15 Dashboard backlight
16 Right turning light
17 Speedmeter
18 Buzzer
19 General warning light
20 Dashboard backlight
Digital monitor
2 3 4 5
Switches board
6 7 8
06. Rotating beacon switch (optional)
07. Rear washer switch
08. Rear wiper switch
9 10 11
09. Rear working light switch
10. Front working light switch
11. General lighting switch
P.S.
P.S.
On
On W230
W230 ee W270
W270 models
models ,, display
display works
works only
only as
as digital
digital clock
clock
1 2 3 4
1. Cigarette lighter
2. Transmission cut-off selector switch
3. Automatic/manual transmission selection switch
4. Equipment proximity sensors actuation switch
5. Maintenance indicator and “wait-to-start”indicator
6. Fan rotation activation button
7. Load Travel Stabiliser actuation switch
8. Auxiliary reverse button selection switch
9. Starter switch
TRANSMISSION
TRANSMISSION
Parking brake
pressure switch
Speed sensors
Transmission
Transmission Control
Control Valve
Valve
Controls
In case of FNR (Forward / Reverse) CPU replacement, is necessary to carry out the “initializzation” procedure
before start to work.
n
dow
AUXILIARY
AUXILIARY FNR
FNR CONTROL
Kick
CONTROL
(Hydraulic
(Hydraulic manipulator joystick version)
manipulator joystick version)
2/3
2/3LEVER
LEVERON
ONHYDRAULIC
HYDRAULICMANIPULATOR
MANIPULATOR
ELECTRIC COMPONENTS
A
A
1 2
A
Legend:
4
6
3 2 1
5
Legend:
2 1
3
Legend:
W270
W270
Potenziometer
(throttle function)
Proximity switch
(HOLD function)
W230
W230
Proximity switch
(HOLD function)
3
2
Legend
DIVERTER
DIVERTER VALVE
VALVE
(Steering
(Steering System)
System)
HYDRAULIC
HYDRAULIC OIL
OIL TANK
TANK
Timer
(Wiper)
Transmission
control lever
connectors
ELECTRIC COMPONENTS
2 4
5
7 6
8
1. A.T.C. (Automatic Transmission Control)
2. Auxiliary FNR Controller
3. Voltage converter (from 24V to 12V)
4. Diagnostic lamps
5. 90 A Relay
6. Flasher
7. 7.5 A relays group
8. “F” fuses group
F1 F2
A B C A B C
X1
F3 F4
A B C A B C
F5 F6
X2
A B C A B C
F7 F8
A B C A B C
X3
F9 F10
A B C A B C
F11 F12
X4
A B C A B C
X5 ACC +B
Description relays
SERV
K3
K1 K2
ASERV B C
XC K4 K5 K6 K7 K8
ATC Connectors
X19
++ 24V
24V
1 2 3
3
1 2
1 - Relay
2 - Reay
3 - Diod box