Table of contents

Table of contents
Chapter 1 Safety Precautions .................................................................................................... [1]
Chapter 2 Diagrams and Parameters of Loader ..................................................................... [4]
Chapter 3 Maintenance Points of Loader ............................................................................... [8]
Chapter 4 Standard Data Sheet ....................................................................................... [14]
Chapter 5 Malfunction removal ................................................................................................ [23]
5-1 Torque converter and gearbox system ............................................................................... [23]
5-2 Drive axle system ............................................................................................................... [35]
5-3 Working hydraulic system................................................................................................... [38]
5-4 Pilot control system ............................................................................................................ [43]
5-5 Steering hydraulic system .................................................................................................. [49]
5-6 Foot brake system .............................................................................................................. [53]
5-7 Electric system ................................................................................................................... [60]
Chapter 6 Main Parts ................................................................................................................ [66]
Section 1 Drive axle ................................................................................................................ [67]
6-1-1 Structure and Functions .................................................................................................. [67]
6-1-2 Dismounting and Installation ........................................................................................... [69]
6-1-3 Disassembly and Repair ................................................................................................. [70]
Section 2 Priority valve ............................................................................................................ [107]
6-2-1 Structure and Functions ................................................................................................ [107]
6-2-2 Dismounting and Installation ......................................................................................... [107]
6-2-3 Disassembly and Repair ............................................................................................... [109]
Section 3 Bucket cylinder .......................................................................................................... [114]
6-3-1 Structure and Functions ................................................................................................ [114]
6-3-2 Dismounting and Installation ......................................................................................... [114]
6-3-3 Disassembly and Repair ............................................................................................... [115]
Section 4 Steering cylinder ...................................................................................................... [121]
6-4-1 Structure and Functions ................................................................................................ [121]
6-4-2 Dismounting and Installation ......................................................................................... [121]
6-4-3 Disassembly and Repair ............................................................................................... [123]
Section 5 Brake valve and energy accumulator ....................................................................... [124]
6-5-1 Structure and Functions ................................................................................................ [124]
6-5-2 Dismounting and Installation ......................................................................................... [125]
Table of contents

6-5-3 Disassembly and Repair .............................................................................................. [125]

6-5-4 Disassembly and Repair of Accumulator ..................................................................... [129]
Section 6 Charging valve ........................................................................................................ [130]
6-6-1 Structure and Functions ................................................................................................ [130]
6-6-2 Dismounting and Installation ......................................................................................... [131]
6-6-3 Disassembly and Repair .............................................................................................. [132]
Section 7 Lift arm cylinder ....................................................................................................... [136]
6-7-1 Structure and Functions ................................................................................................ [136]
6-7-2 Dismounting and Installation ......................................................................................... [136]
6-7-3 Disassembly and Repair .............................................................................................. [139]
Section 8 Steering gear ........................................................................................................... [144]
6-8-1 Structure and Functions ................................................................................................ [144]
6-8-2 Dismounting and Installation ......................................................................................... [144]
6-8-3 Disassembly and Repair ............................................................................................... [146]
Section 9 Working hydraulic oil cooler ..................................................................................... [163]
6-9-1 Structure and Functions ................................................................................................ [163]
6-9-2 Testing and adjustment ................................................................................................. [163]
6-9-3 Dismounting and Installation ......................................................................................... [164]
Section 10 Air conditioning system .......................................................................................... [166]
6-10-1 Structure and Functions .............................................................................................. [166]
6-10-2 Testing and adjustment ............................................................................................... [167]
6-10-3 Dismounting and Installation ....................................................................................... [170]
Section 11 Torque converter ................................................................................................. [174]
6-11-1 Structure and Functions .............................................................................................. [174]
6-11-2 Testing and adjustment ............................................................................................... [175]
6-11-3 Dismounting and Installation ....................................................................................... [175]
6-11-4 Disassembly and Repair ............................................................................................. [175]
Section 12 Gearbox ................................................................................................................ [182]
6-12-1 Structure and Functions .............................................................................................. [182]
6-12-2 Testing and adjustment ............................................................................................... [186]
6-12-3 Dismounting and Installation ....................................................................................... [187]
6-12-4 Disassembly and Repair ............................................................................................. [194]
Section 13 Steering pump ....................................................................................................... [282]
6-13-1 Structure and Functions .............................................................................................. [282]
6-13-2 Dismounting and Installation ....................................................................................... [282]
Section 14 Double gear pump ................................................................................................. [286]
Table of contents

6-14-1 Structure and Functions .............................................................................................. [286]

6-14-2 Dismounting and Installation ....................................................................................... [286]
Chapter 7 Schematic diagram of hydraulic system ............................................................ [289]
Chapter 8 Electrical Diagram ................................................................................................ [291]
Preface

Preface

In order to enable distributors and repair service centers to know more about Lonking CDM858.00I
wheel loaders, we have compiled this Maintenance Manual for CDM858.00I Wheel Loaders and provide
it to Lonking’soverseas agents and repair service centers.

This Manual emphasizes the introduction of structure and functions, test and adjustment, installation and
disassembly, dismantling and repair, troubleshooting, etc., and aims to provide the basic knowledge
about repair service.

The factors like difference of product sales regions, different environmental conditions, working
conditions and operating skills and timeliness of daily maintenance will affect the operating status of
loader. This Manual is based on the information available at the time of compilation, so it may not cover
all the possible situations. We hope that during the use of this Manual, distributors and repair service
centers may feedback their opinions and suggestions on a timely basis so that we will be able to make
improvement in the next edition.

Prior to repairing a loader, please carefully read and understand the safety precautions and make repairs
in full accordance with safety instructions. Incorrect disassembly, installation and repairing are
dangerous and may lead to injury or death.

The pressures of some hydraulic components requiring parameters setting have been set at the time
when the loader is shipped out of Lonking’s factory. If such components need repairing, in principle, the
entire assembly shall be replaced (whether this Manual has introduced the dismantling and
commissioning process or not). If an assembly is not available, only after the written consentof Lonking
and component manufacturers has been obtained can these components be dismantled and repaired,
and repairing entities shall be responsible for the quality and safety of these components after
disassembly, installation and adjustment.

We are making continuous efforts to improve our products. We reserve the right to change the
parameters and configurations of the loader. In addition, the contents of this Manual are subject to
change without notice. The technical parameters mentioned in this Manual shall not be used as the
basis for delivery and acceptance.

This Manual is its first edition.

Lonking Holdings Limited

December 30, 2013

4
Chapter 1 Safety Precautions

Chapter 1 Safety Precautions

I. Safety precautions before repair/maintenance

1. Flat and solid ground or special site shall be selected as the repair/maintenance site, which shall be
far away from operating machines and personnel;
2. Unauthorized personnel are not allowed to stay close to machines;
3. When the gear is at neutral position, the bucket shall be placed on the ground horizontally. The pilot
joystick shall be returned to its original position, and the hand brake shall be pulled up;
4. The electric lock on the direction pillar shall be turned to the “OFF” position and the startup key shall
be removed.
5. The master power switch shall be cut off. In order to prevent short circuit, the storage battery shall
be removed if necessary;
6. A plate of “do not operate” shall be placed next to the master power switch to inform others that the
machine is under maintenance;
7. The parking brake shall be pushed down and a wedge block shall be placed before the front wheel
or the rear wheel;
8. The brake pedal shall be stepped down repeatedly to release all the pressure in the braking system;
9. The pilot joystick shall be moved in full range to release all the pressure in the hydraulic system. The
lift arm control lever and bucket control lever shall be placed at the “HOLD” position.
10. The steering wheel shall be turned left and right for several times to release the pressure in the
steering system.
11. The wheel rims of four tires shall be fixed tightly in the grooves and the tire pressure shall be within
the specified scope;
12. The water or antifreeze fluid in the water tank shall be released if necessary, and it shall be done
carefully not to burn hand, face or skin of other parts;
13. In case any oil storage container or relevant oil-way is to be disassembled, the hydraulic oil or fuel
shall be released first and contained in proper containers;
14. All the fluid shall be disposed according to local laws and regulations;
15. The front and rear chassis fixing rods shall be assembled properly to avoid injury or death caused
by sway of machine.
16. Upon the completion of repair/maintenance, the front and rear chassis fixing rods shall be released
before the startup of machine. The rods shall be fixed at their storage places, otherwise the steering
of machine will be affected.

II. Safety precautions during repair/maintenance

1. During the complete-machine repair/maintenance, a maintenance sign shall be set to prevent
irrelevant personnel from staying close to the repair/maintenance site;
2. The oil temperature shall be confirmed to be cool before any components or pipes are to be
disassembled. Only after the engine is shut down and the oil filing cover is cooled to be touchable

1
Chapter 1 Safety Precautions

can the oil filling cover be removed.

3. Failure around the engine shall be repaired after water and gas pipes, silencers, exhaust pipes,
engine body, etc. cool down to prevent the hand or skin from being burnt；

4. Special tools shall be used during disassembly of screws or fastening of components. Utilization of
self-made tools is prohibited. The repairer shall start to conduct repair after steadying his body to
prevent slipping.
5. Large scope repair shall be conducted according to the following disassembly sequence: pipe, line
– hood – cab – hydraulic component and pipe – bucket – lift arm – water tank – transmission shaft–
gearbox-torque converter assembly of engine – chassis assembly – drive axle – tire;
6. Slings for lifting loads and lifting equipment with safety parameter higher than 1.5 shall be selected
according to the component weight reference table
7. During lifting, the hang-point shall be chosen first, and then the assembly hole on the component
shall be chosen. The lifting shall be conducted on the front-rear and left-right symmetric basis. The
lifting hook shall have separation prevention device. Standing under lifted goods is prohibited. The
disassembled components shall be placed steadily.
8. During the repair of tire assembly or replacement of inner tube, the internal pressure inside the tire
shall be released first and protection frame shall be prepared.
9. Protection frame or protection net shall be used when retainer is being disassembled to prevent
injury due to release of retainer elasticity.
10. Protection frame shall be used during tire inflation to prevent the ejection of retainer and check ring
or tire burst, etc. due to excess air pressure.
11. After tire inflation, barometer shall be used to check the tire pressure and excess pressure shall be
released.
12. When operation is conducted under lift arm, the lift arm shall be placed on the protection bracket or
installed with special cylinder protection bracket;
13. When pneumatic or electric tools are used, operation shall be conducted strictly according to
stipulations.
14. When engine and gearbox-torque converter assembly are being disassembled, the core
components of converter may drop and cause injury, so protection measures shall be adopted.
15. When transmission shaft is disassembled, the spline shaft in the middle may disengage and cause
injury, so protection measures shall be adopted.
16. When components with residual oil are gripped by hand, they may slip and cause injury, so
protection measures shall be adopted.
17. When oil is sprinkled on the ground, people may slip and get injured, so protection measures shall
be adopted.
18. When welding is conducted directly on the machine, proper grounding near the welding point shall
be ensured, otherwise the electric line throughout the machine, tire or other non-metal components
may be burnt or fire hazard may occur.
19. High-pressure fluid leakage, even leakage as small as a pinhole, may penetrate human tissue and
cause serious injury or even death. If fluid permeates skin, the injury must be treated immediately by
a doctor who is familiar with such kind of injury.
20. During check of leakage, a wood board or thick board shall be used as shield.

2
Chapter 1 Safety Precautions

III. Safety precautions for commissioning

1. Prior to the start of the complete-loader, the gear shall be at the neutral position, the hand brake
shall be released, various oil, lubrication grease, water or antifreeze fluid shall be filled, irrelevant
personnel are not allowed to be around the machine, and horn shall be blown for warning;
2. Various control cable shall be commissioned to be accurate and reliable, and the service brake and
parking brake system shall be the first priority to be commissioned;
3. The over-pressure protection switch of air reservior shall be checked to operate properly;
4. Various instrument display and back-up alarm devices shall be checked to operate properly;
5. The turn light and work light shall be checked to operate properly;
6. The back-up mirror shall be adjusted to the right angle;
7. The original safety signs on the loader shall be checked; any missing sign shall be supplemented;
8. The loader shall be kept at idle speed before running till the braking pressure reaches standard.

3
Chapter 2 Picture and Parameters of Loader

Chapter 2 Picture and Parameters of Loader

Figure 2-1

Overall Dimensions
Code Description Dimension
A Overall length 8150 mm
B Wheel base 3230 mm
C Minimum ground clearance 380 mm
D Maximum total height of main unit 3530 mm
E Pin height at maximum lifting 4160 mm
F Dumping height 3103 mm
Distance between bucket tooth and
G 2860 mm
ground at dumping
H Dumping reach 1210 mm
Distance between rear shaft and
I 1615 mm
hinge joint
J Length of rear suspension 1988 mm
K Height of delivery location 400 mm
L Overall height at maximum lift 5300 mm
a2 Dumping angle 45°

4
Chapter 2 Picture and Parameters of Loader

Standard specifications
Item Specs
Bucket capacity 3.0 m3
Rated load 5000kg
Lift arm lifting time ≤6.0s
Total time ≤ 11s
Forward gear I 6.8 km/h
Reverse gear I 6.8 km/h
Forward gear II 13 km/h
Maximum speeds at
Reverse gear II 13 km/h
various gears
Forward gear III 23 km/h
Reverse gear III 23 km/h
Forward gear IV 36 km/h
Traction force 155±3kN
Maximum breakout force (rotating bucket) 170±3kN
Performance Maximum grade ability 28゜
Outside of bucket 7200mm
Minimum turning radius
Tire center 6500mm
Length of loader (while the bucket is put on the
8150±100mm
ground horizontally)
Width of loader (outside of wheel) 2835±50mm
Bucket width 3000±30mm
Height of loader (top of the cab) 3530±30mm
Geometric dimensions
Wheel base 3230±30mm
Wheel tread 2240±10mm
Minimum ground clearance (at the hinge joint) 400±20mm
Dumping height 3103±50mm
Dumping distance at maximum lifting 1210±50mm
Weight of loader 18020±300kg

5
Chapter 2 Picture and Parameters of Loader

Item Specification
Type CUMMINSQSB6.7 diesel engine
Rated rotating speed 2200r/min
Maximum torque 949N·m /1500r/min
Ratedfuel consumption ≤164g/kW·h
Engine
Consumption rate (bench test)
Fuel (customers may choose the type of fuel according 0# light diesel oil
to the local ambient temperature)
Diameter of fan (backward air exhaust) Φ811mm
Type Single stage, three components
(single turbine)
Torque coefficient 2.5
Cooling method Water-cooling pressure circulating
Hydraulic torque converter Type of gear shift Planetary hydraulic gear shift
Shifts of gearbox Four forward gears
Three reverse gears
Transmission oil pump Gear pump
Operating pressure 1.6~1.8MPa
Transmission system Main drive type One-stage, bevel gear reduction
Type of Wheel hub Straight-toothed cylinder gear
Main drive and hub reduction Planetary transmision
reducers Reduction ratio 23.215
Main drive reduction ratio 4.111
Hub reduction ratio 5.645
Type Four wheel drive
Tire 23.5-25L-3 16PR
Drive axle and wheels
Air pressure of tire Front wheel 0.30±0.01MPa
Rear wheel 0.28±0.01MPa
Braking type Fully hydraulic wet type braking
Diameter of brake disc 500mm
Drive Diameter of brake Φ75mm (32 PCS)
Braking cylinder
2
Braking system Effective area of friction 175cm (16 PCS)
plate
Braking type Hydraulic caliper disc brake
Parking and emergency
Opening pressure of 0.4-0.28Mpa
braking
brake caliper

6
Chapter 2 Picture and Parameters of Loader

Item Specification
Type Fully hydraulic steering
Number of steering cylinders – inside 2-φ100×324mm
Steering system diameter × stroke
Steering pump Quantitative gear pump
System working pressure 15MPa
Steering angle 35°to the left or right
Number of lift arm cylinders -- inside 2-φ180×721mm
diameter × stroke
Number of bucket cylinders -- inside 1-φ200×563mm
diameter × stroke
Distribution valve Hydraulic pilot dual valve
Working hydraulic system Model DF32
Working pump displacement 100ml/r
Flow/rotating speed 220L/2200r/min
System working pressure 16MPa
Form of control Hydraulic pilot control
System voltage 24V
Capacity of storage battery 2-N120
Electric system
Voltage of bulb 24V
Start of diesel engine 24V electric start
Customers shall fill the oil to the upper oil mark
Fuel tank: total volume is 285L of 235L (the actual oil filling volume is subject
to the scale of oil level gauge)
Customers shall fill the oil to the upper oil mark
Hydraulic oil tank: the total volume is 285L of 270L (the actual oil filling volume is subject
to the scale of oil level gauge)
18.9L (the actual oil filling volume is subject to
Name of oil (Oil filling) Crank case: engine oil
the scale of oil level gauge)
Gearbox system: Hydraulic transmission 45L (the actual oil filling volume is subject to
oil the scale of oil level gauge)
28L (the actual oil filling volume is subject to
Axle (main drive Front axle gear oil
the scale of oil level gauge)
reducer and hub
28L (the actual oil filling volume is subject to
reducer) Rear axle gear oil
the scale of oil level gauge)
Working medium Diesel engine coolant
Warm air
Heating capacity 5000 (an error within 10%)
Air conditioning system Working medium R134a
Cool air
Cooling capacity 4200 (an error within 10%)
System voltage 24V

7
Chapter 3 Maintenance Points of Loader

Chapter 3 Maintenance Points of Loader

I.Diagram of lubrication points

Points of grease injection are at various sliding bearings or rolling bearings, including:
1. Bearing at the joint spider of transmission shaft.
2. Pin bushes at both sides of all oil cylinders.
3. Pin bushes that connect front and rear car frames; swing pin pushes of subframe
4. Various pin bushes of operating devices.
Grease shall be injected to the aforesaid positions according to the requirements in the diagram. The
injection shall be conducted in time according to operating conditions.

II.Maintenance cycle table

Instruction for using maintenance cycle table:
Before any operation or maintenance, make sure the instruction manual of the machine concerning
safety, warning and descriptive information has been read and understood completely.
The user is responsible for proper maintenance of the machine, including adjusting mechanism, adding
lubricants and other operating fluids, replacing filters and replacing parts due to normal wear or aging.
Failing to maintain the entire machine according to correct cycles and specified procedures may lead to
a drop in performance to the machine as well as accelerated wear on its parts and components.

Note:
1. Before any continuous maintenance cycle, it is necessary to complete all previous maintenance
work firstly.
2. A maintenance cycle shall be determined according to working time. If a maintenance plan
is carried out more conveniently according to calendar time, and the numerical readings are
close to the working time, then the calendar time cycle (every day, every year, etc.) may replace
8
Chapter 3 Maintenance Points of Loader

the working time cycle. No matter the maintenance is calculated according to working time or
calendar time, the closer maintenance cycle willhave priority, and the maintenance shall be
conducted according to the closer cycle;
3. Under extreme, dusty and humid working conditions, the specified time in the maintenance cycle
table must be shortened, and the complete-machine maintenance must be conducted more
frequently;
4. During maintenance, the maintenance items of shorter cycles shall be conducted simultaneously.
For example, while the maintenance for every 500 working hours or every three months is conducted,
the maintenance items to be performed once every 250 working hours or every month, for every 100
working hours or every half month, and for every 10 working hours or every day shall be conducted
simultaneously.

I. Routine maintenance items to be performed once every 10 hours or once a day

1. The coolant of engine shall be checked to ensure that it has been filled up;
2. The engine oil level of the engine shall be checked to ensure that the height of oil is within the normal
working scope;
3. The fixing bolts and nuts of the engine, gear box, drive axle and wheel rim shall be checked to
ensure that they are not loose;
4. The air pressure of front and rear tires shall be checked to ensure that the pressure is normal; at
the same time, the tires shall be ensured to have no abnormal wearing;
5. As for an air-pressure braking loader, all the air reservoirs shall be tested with water discharge
operation; as for a hydraulic braking loader, such test is not necessary;
6. The oil level of hydraulic oil tank and gear box shall be checked;
7. Water shall be discharged from the coarse strainer(oil water separator) of the fuel system of the
engine;
8. According to the requirements of Lubrication Points Indication, grease shall be injected into various
hinge joints and shaft sleeves;
9. The oil, water and gas in various systems shall be checked to ensure that there is no leakage;
engine fan and drive belt shall be visually inspected to ensure that they are not loose or damaged;
the bucket teeth and main cutting-board of the bucket shall be checked and replaced if necessary;
10. The following components shall be checked to ensure that they operate properly: instruments of
complete-loader, working lamps of complete-loader, safety belt of chair, reverse warning system,
braking system of complete-loader, and steering system of complete-loader;
11. The starting performance, color of exhaust, and operating sound shall be checked to ensure that
they are normal;
12. Various switches, fast connectors, control rods, pedals, joysticks, buttons shall be ensured to work
properly;
13. The operation of the complete-machine shall be closely observed for 10 minutes to see whether
there is abnormal sound or alarm due to local overheating, etc.

II. Maintenance items to be performed once every 50 hours or every week

1. The fixing bolt and nets of all the transmission shafts shall be fastened to ensure there are no loose
bolts and nuts.
2. The braking fluid of the complete-load shall be checked and supplemented; (note: the supplemented

9
Chapter 3 Maintenance Points of Loader

braking fluid must be the same type as the original fluid, otherwise the original fluid must be
completely discharged at the position of the wheel braking clamp before new braking fluid is added)
3. The gap between the brake shoe and the brake disc of the parking brake shall be checked and
adjusted in case the gap is not appropriate.
4. After one or two operating cycle of the complete-loader, the oil level of hydraulic oil tank and gearbox
shall be checked after the engine is shut down; The oil shall be supplemented if necessary (note: the
supplemented oil shall be same type as the original oil, otherwise the service life the oil will be
affected.)
5. If it is the maintenance of the complete-loader after the first 50-hour operation, the following
operation shall be conducted, otherwise the following shall be neglected; the engine oil and engine
oil filter shall be replaced.
6. The oil level of the wheel gears at both sides of the drive axle and the oil level of the main drive gear
at the middle of the axle housing shall be checked; the oil shall be supplemented if necessary; (note:
the supplemented oil shall be the same type as the original oil, otherwise the service life of oil will be
affected.)

III. Maintenance items to be performed once every 100 hours or every half month
1. All the sundries on the wind radiator shall be cleaned to ensure that the radiator system of the
complete-loader is able to radiate heat properly;
2. The oil filling filter screen and clean breather of the air filter on the fuel tank and hydraulic oil tank
shall be cleaned;
3. If it is the maintenance of the complete-loader after the first 100-hour operation, the following
operation shall be conducted, otherwise the following shall be neglected:
(1) The transmission oil of gearbox, and the oil filter and oil strainer of the gearbox-torque converter
assembly (the filter is an optional component, not every loader has such component) shall be
replaced; the gearbox sump shall be opened and reinstalled after the filter screen and magnet
have been conscientiously cleaned.

IV. Maintenance items to be performed once every 250 hours or every month
1. The air intake system of the engine shall be checked. The service indicator of air filter shall be
visually inspected. If the yellow piston of the indicator rises to the red area, the filter element of the
air filter shall be cleaned or replaced.
2. The tightening torque of the fixing bolts of the wheel rims shall be checked.
3. The stressed weld joints and fixing bolts of the working devices and front and rear frames shall be
checked to ensure that there are no cracks and looseness.
4. The tension and damage of drive pulley of engine, belt of compressor of air conditioner, belt of
generator shall be checked;
5. The gap between the brake shoe and the brake disc of the parking brake shall be checked and
adjusted in case the gap is not appropriate;
6. All the fixing bolts of the storage battery shall be tightened and the top of storage battery shall be
cleaned.
7. The engine oil and the engine oil filter shall be replaced; and water shall be removed from the
oil-water separator connected to the engine (the filter is an optional component, not every loader has
such component);
8. If it is the maintenance of the complete-loader

10
Chapter 3 Maintenance Points of Loader

after the first 250-hour operation, the following operation shall be conducted, otherwise the following
shall be neglected: operating hydraulic oil shall be collected and filtered, oil suction filter element of
hydraulic oil tank shall be replaced, return oil filter element shall be replaced, the interior of hydraulic oil
tank shall be cleaned, the filtered hydraulic oil shall be refilled into the hydraulic oil tank and the oil shall
be supplemented and kept at an appropriate level. (Note: when the filter element of hydraulic oil is
replaced, the original hydraulic oil must be filtered or replaced).

V. Maintenance items to be performed once every 500 hours or every three months
1. The bolts that connect the front and rear axles and the frame shall be fastened;
2. The engine oil, the engine oil filter, the fuel filter and the filter element of the oil-water separator shall
be replaced (the filter is an optional component, not every loader has such component);
3. The hinge bearing plate bolts of the front and rear frames shall be checked to ensure that they are
not loose.
4. The brake pads and brake discs shall be checked, and the thinner-than-14mm brake pads and
damaged brake discs shall be replaced.
5. The operating hydraulic oil shall be collected and filtered, the oil suction filter element of hydraulic oil
tank shall be replaced, the hydraulic oil tank shall be cleaned, the filtered hydraulic oil shall be refilled
into the hydraulic oil tank and the oil shall be supplemented and kept at an appropriate level. (Note:
when the filter element of hydraulic oil is replaced, the original hydraulic oil must be filtered or
replaced).
6. The transmission oil of gearbox and the bivariatereturn oil filter shall be replaced; the gearbox sump
shall be opened and reinstalled after the filter screen and magnet have been conscientiously
cleaned.
7. The oil level of the wheel gears at both sides of the drive axle and the oil level of the main drive gear
at the middle of the axle housing shall be checked; if the operating time has not exceeded 500 hours,
the gear oil of the drive axle shall be replaced at least once a year.

Note:
As a part of the maintenance plan, the maintenance of diesel engine (e.g. replacement of engine oil,
maintenance of air filter, etc.) shall be conducted in compliance with the attached document: Instruction
for Usage and Maintenance of Diesel Engine. In case there are discrepancies between the aforesaid
and the Instruction, the attached Instruction for Usage and Maintenance of Diesel Engine shall prevail.

The following Registration Form of Stage Examination and Maintenance of Loader shall be filled in by
local agents after the sales of a complete-loader is completed; if the product malfunctions later, the Form
shall be provided while the customer claims compensation from Lonking.

VI. Maintenance items to be performed once every 1000 hours or every half a year
1. Replace the hydraulic oil, the return oil filter element of hydraulic oil, and the oil suction filter element
of hydraulic oil, and clean the hydraulic oil tank;
2. The brake system shall be checked, the booster pump shall be cleaned and brake oil shall be
replaced;
3. The diesel oil tank and diesel oil filter shall be cleaned;
4. The diesel oil filter of the engine shall be replaced;
5. The roll over protection structure shall be checked; (this mode uses a built-in roll over protection

11
Chapter 3 Maintenance Points of Loader

support)
6. Replace the dryer of the brake system; (it is optional, replace it based on the model)

VII. 2,000 hours or one year

1. Check the foot brake and parking brake for their condition, and if necessary, remove and check the
brake pads for wear;
2. Replace the engine coolant;

Note:
1. The steering bearings of the front and rear frames shall be checked after 5000 hours of use, and shall
be replaced if there is abnormal sound;
2. The seat belt shall be replaced within three years from the date of purchase or five years from the date
of manufacture.

12
Chapter 3 Maintenance Points of Loader

Registration Form of Stage Examination and Maintenance of Loader

Maintenance Brief
Date of
item 50h 100h 250h 500h 1000h 2000h Examiner description
examination
Operating time of defect
50h ●
100h ● ●
150h ●
200h ● ●
250h ● ●
300h ● ●
350h ●
400h ● ●
450h ●
500h ● ● ● ●
550h ●
600 h ● ●
650h ●
700h ● ●
750h ● ●
800h ● ●
850h ●
900h ● ●
950h ●
1000h ● ● ● ● ●
1050h ●
1100h ● ●
1150h ●
1200h ● ●
1250h ● ●
1300h ● ●
1350h ●
1400h ● ●
1450h ●
1500h ● ● ● ●
1550h ●

13
Chapter 4 Standard Data Sheet

Chapter 4 Standard Data Sheet

1. Standard tightening torque of bolts and nuts
(1) Standard tightening torque

a.Table of tightening torque of ordinary bolts

Strength Yield Nominal diameter of bolt (mm)

grade of strength(N/mm) 6 8 10 12 14 16 18 20
bolt Tightening torque (N.m)
4.6 240 4~5 10~12 20~25 36~45 55~70 90~110 120~150 170~210
5.6 300 5~7 12~15 25~32 45~55 70~90 110~140 150~190 210~270
6.8 480 7~9 17~23 33~45 58~78 93~124 145~193 199~264 282~376
8.8 640 9~12 22~30 45~59 78~104 124~165 193~257 264~354 376~502
10.9 900 13~16 30~36 65~78 110~130 180~210 280~330 380~450 540~650
12.9 1080 16~21 38~51 75~100 131~175 209~278 326~434 448~597 635~847

Strengt Yield Nominal diameter of bolt (mm)

h grade strength 22 24 27 30 33 36 39
of bolt (N/mm) Tightening torque (N.m)
4.6 240 230~290 300~377 450~530 540~680 670~880 900~1100 928~1273
5.6 300 290~350 370~450 550~700 680~850 825~1100 1120~1400 1160~1546
6.8 480 384~512 488~650 714~952 969~1932 1319~1759 1694~2259 1559~2079
8.8 640 512~683 651~868 952~1269 1293~1723 1759~2345 2259~3012 2932~3898
10.9 900 740~880 940~1120 1400~1650 1700~2000 2743~3298 2800~3350 4111~5481
12.9 1080 864~115 1089~146 1606~2142 2181~2908 2968~3958 3812~5084 4933~6577
2 4

b. Table of tightening torque of ordinary rubber pipe (specification of open-end spanner and Table of
Recommended Thread Torque)

1. Metric Thread Specification of spanner opening

Thread N.M NUT TORQUE mm
M12X1.5 10-20 17
M14X1.5 20-35 19
M16X1.5 25-40 22
M18X1.5 30-45 22 or 24
M20X1.5 35-50 27
M22X1.5 40-70 27
M24X1.5 40-70
M26X1.5 60-100 32
M27X1.5 32
M30X2 80-120 36
M36X2 100-150 41
M42X2 150-220 50
M45X2 180-250 55
M52X2 200-300 60

2. Thread adhesive

14
Chapter 4 Standard Data Sheet

No. Name and specification Usage Remark

(Aotai series)
1 AT598 Thread sealing for drive axle plug, Or Debang
2577
2 AT515 Plane sealing for articulated interface between diesel and Or Debang
torque converter 2515
3 AT577 Thread sealing for joint of fan heater, joint of unloading Or Debang
valve and air reservoir joint 2577
4 AT262 Thread sealing for pin bolt of oscillating axle Or Debang
2243
5 AT243 Thread sealing for steering shaft. Thread sealing for oil Or Debang
drain plug of hydraulic oil tank and fuel tank. 2243

3. Code of electric wire

Circuit
Code Color Diameter of wire
Function
1 Red 1.5-6.0
1C Red 6.0
Battery charging
3 Grey 1.5
3a Grey 1.0
1a Red 1.5
Start 4 Brown 1.5
2c White 1.5
0 Black 1.1-4.0
Grounding 0A Black 1.5
0B Black 2.5
42 White 2.5
Flameout
42a Yellow 1.5-2.5
27 Red 1.0-1.5
Fan heater
58 Yellow 2.5
2 Purple 1.5-2.5
Power supply of main circuit 2a Red 2.5
2b Red 2.5-6.0
33 Red 1.0
59 Green 1.0
Wiper 62 Yellow 1.0
78 Purple 0.85
79 Purple 0.85

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Chapter 4 Standard Data Sheet

Circuit
Code Color Diameter of wire
Function
6 Orange 1.0-2.5
7 Brown 2.5
11 Orange 2.5
16 Pink 1.5
24 Green 1.0
Load power supply 32 Purple 1.5
40 Brown 1.5
66 Yellow 1.5
69 Blue 1.5
83 Grey 1.5
97 Blue 2.5
8 Pink 1.5
9 White 1.5
14 Orange 1.5
Illumination
15 Red 1.5
29 Brown 1.5
56 Purple 1.5
34 Pink 1.0
Instrument 51 Purple 1.0
53 Brown 1.0
Warning 75 Red 1.0

Circuit Code Color Diameter of wire

Function
Signal 12 White 1.0
17 Purple 1.0
22 Green 1.0
23 Blue 1.0
93 Yellow 1.0
25 Grey 1.0
26 Red 1.0
61 Red 1.0
Others 19 Brown 1.0
21 Purple 1.5
35 Green 1.0
40 Brown 1.5

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Chapter 4 Standard Data Sheet

4. The grade, specified volume and additive volume (adopt international label and measurement unit) of
engine oil, gearbox oil, hydraulic oil, drive axle oil, hinge pin grease, diesel oil and antifreeze recommended
for various temperature ranges between -30 to +50℃.

Type of oil Ambient temperature Capacity

Filling quantity

and above
Engine oil
20L

50L
Hydraulic
transmission oil

270L

Hydraulic oil

30L

Drive axle gear oil

Lubrication grease

Diesel oil

27L

Anti-freezing fluid

17
Chapter 4 Standard Data Sheet

5. Conversion table
Conversion from millimeter to inch ·····················1mm=0.03973 inch

Conversion from kilogram to pound ·····················1kg=2.2046Ib

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Chapter 4 Standard Data Sheet

5. Conversion table
Conversion from kilogram to US gallon ·····················1liter = 0.2642 US gallon

Conversion from liter to UK gallon ·····················1liter = 0.21997 UK gallon

19
Chapter 4 Standard Data Sheet

5. Conversion table
Conversion from kilogram·meter to foot·pound·····················1kgm=7.232ft·Ib

20
Chapter 4 Standard Data Sheet

5. Conversion table

Conversion from kilogram/centimeter2 to pound/inch2 ·····················1kg/cm2=14.2233Ib/in2

Temperature

Conversion between Fahrenheit and Celsius

A simple way to convert Fahrenheit readings to

Celsius readings (or vise versa) is to refer to the
numbers in the middle or boldface column of the
attached table. These numbers represent Fahrenheit
or Celsius readings

If you want to convert Fahrenheit readings to Celsius

readings, you shall consider the middle column as
the column of Fahrenheit readings, and the column at
the left side of the middle column is the column of
Celsius readings

If you want to convert Celsius readings to Fahrenheit

readings, you shall consider the middle column as
the column of Celsius readings, and the column at
the right side of the middle column is the column of
Fahrenheit readings

21
Chapter 4 Standard Data Sheet

Table of conversion between Celsius and Fahrenheit ················1℃=33.8℉

22
Chapter 5 Troubleshooting
Contents

Chapter 5 Troubleshooting

Contents
5-1 Torque converter and gearbox system ....................................................................................... [23]
5-2 Drive axle system ............................................................................................................... [35]
5-3 Working hydraulic system ................................................................................................. [38]
5-4 Pilot control system............................................................................................................ [43]
5-5 Steering hydraulic system ................................................................................................. [49]
5-6 Foot brake system .............................................................................................................. [53]
5-7 Electric system ................................................................................................................... [60]

Precautions for the installation, maintenance and repair of torque converter and gearbox are as follows:
Pressure control:
The oil inlet pressure of torque converter shall be controlled at 0.45-0.65MPa,
The outlet pressure of torque converter shall be controlled at 0.25-0.35MPa,
The pressure of lubrication oil shall be 0.1-0.2MPa,
The speed-changing working pressure shall be 1.5-1.7 MPa.

5-1 Malfunction cases of torque converter and gearbox:

5-1-01 Excessively rapid rise of oil temperature and water temperature of gearbox ................... [24]
5-1-02 After gear shift, the pressure cannot reach the normal value ............................................. [25]
5-1-03 Insufficient pressure of various gears, and insufficient driving and operating power .... [26]
5-1-04 The pressure is normal at any gear, but the loader cannot run .......................................... [27]
5-1-05 When the loader is under normal operation, the oil temperature of the gearbox will exceed
120℃ in short time .............................................................................................................................. [28]
5-1-06 Oil level of the gearbox decreases quickly ............................................................................ [28]
5-1-07 A loader does not run at cold start, but after the engine is heated for a while, the loader
starts to run ......................................................................................................................................... [29]
5-1-08 No matter which gear is shifted, there is no pressure and the loader cannot run. Meanwhile,
the steering and lifting of lift arm do not work ................................................................................. [29]
5-1-09 The loader runs at cold start, but when the engine temperature rises, the loader stops
running (runs for a while and stops for a while)............................................................................... [30]
5-1-10 During the operation, the loader may suddenly stop, which is similar to automatic
emergent braking ................................................................................................................................. [30]
5-1-11 Oil level of gearbox rises quickly............................................................................................ [32]
5-1-12 The pressure of various gears is normal, but the cut of the bucket is powerless and there
is a “rat-tat” sound form the gearbox ................................................................................................ [32]
5-1-13 Gearbox gives abnormal sound .............................................................................................. [33]
5-1-14 Torque converter malfunctions and troubleshooting ......................................................... [34]

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Chapter 5 Troubleshooting
Torque convertor and gearbox system

Malfunction case 5-1-01:

Excessively rapid rise of oil temperature and water temperature of gearbox

Description of malfunction:
Under the normal operation of loader, the oil temperature of gearbox rises above 120℃ in very short
time. The water temperature of engine rises above 95℃. After the engine is shut down and cooled down,
it may continue to operate again.

Possible reasons:
This is a rare phenomenon. Generally speaking, the main factors include: working condition, usage
method, altitude, heat dissipation effect, malfunction of the loader itself, etc.

The engine:
1. Special working condition
2. Improper usage
3. Damage of instruments and electric devices
4. Coolant is not enough and the return water pipe is blocked.
5. Thermostat is damaged or the working efficiency of water pump decreases.
6. The throttle control cable or flameout cable of the engine get stuck and are not in the right position.
7. The air filter element is too dirty.
8. The dissipation effect of the engine oil radiator is not good or the cylinder cover leaks gas or water.
9. The pressure of oil injector is adjusted too high.

Gearbox-torque converter assembly:

1. Damage of sensor and instrument.
2. Improper oil use or deterioration of oil or blocking of filter screen.
3. The dissipation effect of cooler of gearbox-torque converter assembly is not good or the pressure of
return oil is too high.
4. The variable speed pump leaks internally.

Inspection steps or actions

Precondition 1: The working condition shall be confirmed. Special working environment such as paper
mill.
Precondition 2: The operating method shall be confirmed. The loader shall not be operated under heavy
load for a long time or climb long slope continuously and the slope gradient shall not be higher than 30
degree. During operation, the loader shall be operated at gear I, and the throttle control shall be adjusted
reasonably according to the work load.
Precondition 3: The area where the heat comes from shall be identified, is it the engine or the gearbox?,
if the heat of engine makes the temperature of gearbox higher, the steps for checking high water
temperature of engine shall be followed; if the heat of gearbox makes the temperature of engine higher,
the steps for checking high oil temperature of gearbox shall be followed.
Steps for checking high water temperature of the engine:
1. The water temperature sensor and instrument shall be checked to see if they are damaged.
2. The coolant shall be checked to see if it is sufficient, and the return water pipe of the water tank shall
be checked to see if it is blocked.The water tank cover shall be checked to see if it is damaged. For
ordinary regions, the opening pressure of water tank cover shall be set at 0.05MPa; for plateau regions,
the pressure shall be set at 0.07MPa.
3. The thermostat of the engine shall be checked to see if it has been turned on.
4. The water pump shall be checked to see if it works properly. At the same time, the water suction

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Chapter 5 Troubleshooting
Torque convertor and gearbox system
pipe of the pump shall be checked to see if its inner layer falls off or it becomes flat or the caliber
becomes smaller.
5. The throttle control cable or flameout cable of the engine shall be checked to see if they are stuck
6. The tightness of fan belt shall be checked and the water tank shall be cleaned.
7. The distance between the fan and the wind scooper shall be checked.
8. The air filter element shall be checked.
9. The engine cooler shall be checked to see if it is blocked.
10. The cylinder cover shall be checked to see if there is leakage of water or gas.
11. The opening pressure of oil injector shall be checked to see if the pressure is too high.

Steps for checking the gearbox:

1. The oil temperature meter and oil temperature sensor shall be checked to see if they are accurate.
2. The oil (additive amount and oil quality) used by the speed changer - torque converter assembly
shall be checked to see if the oil complies with the requirements.
3. The oil bottom filter screen and oil filter of the gearbox shall be checked. (See Figure 5-01)

Filter screen

Figure 5-01
4. The gearbox oil radiator shall be checked.
5. The return oil pressure of torque converter shall be checked to see if the pressure is too high, which
may cause the fluidic resistor of the return oil system to be high and the oil temperature to rise rapidly.
6. The internal leakage volume of the variable speed pump shall be checked to see if it is within the
normal scope.
7. The gearbox-torque converter assembly shall be checked to see if there is internal malfunction.

Malfunction case 5-1-02:

After gear shift, the pressure cannot reach the normal value

Malfunction description:
After the loader is started, the pressure of various gears of the gearbox cannot reach the normal value
(1.6-1.8MPa). Though the pressure of various gears is abnormal, the driving and operation are normal.

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Chapter 5 Troubleshooting
Torque convertor and gearbox system

Possible reasons:
The pressure of various gears of the gearbox cannot reach normal value, but the driving and operation is
normal. According to such characteristic, it can initially diagnosed that the torque converter and gearbox
does not malfunction internally, but the malfunction exists between the speed-changing controller and
the pressure meter, so the malfunction can be rapidly removed according to the following steps.

Check steps and disposal measures:

1. The pressure meter shall be checked to see if it operates properly. If it is damaged, it shall be
replaced by new meter. If the pressure meter is normal, please refer to the step 2.
2. The connecting pipes and joints of the pressure meter shall be checked to see if they are blocked. If
they are blocked, diesel oil or gasoline can be used to clean the blocked position.
3. The pressure regulating spring of the speed-changing control value shall be checked to see if it is
deformed (shortened, bent or broken).

Malfunction case 5-1-03:

Insufficient pressure of various gears, and insufficient driving and operating power.

Malfunction description: after the loader is started, the pressure of various gears of the gearbox cannot
reach 1.6-1.8MPa. Meanwhile, the driving and operation are not normal.

Possible reasons:
According to the initial analysis of the malfunction, insufficient oil supply of the oil supply system causes
insufficient pressure of various gears and the abnormal driving and operation.
1. Insufficient oil usage or improper oil usage.
2. The pressure regulating spring of the speed-changing control valve is broken.
3. The speed-changing control valve leaks internally.

Inspection steps or actions:

1. The gearbox oil shall be checked to see if it is sufficient. If the oil is not sufficient, please add the
hydraulic transmission oil of the same brand and same model. If the oil quantity is normal, please check
the next step.
2. The pressure regulating spring of the speed-change control valve shall be checked to see if it is
broken. If it is broken, please replace the pressure regulating spring. If the pressure regulating spring is
normal, please check the next step.
3. The paper gasket at the main oil-way of the speed-changing control valve shall be checked to see if
it is broken. When it is broken, the oil inside the speed-changing control valve will flow through the
lubrication oil outlet back to the oil pool. Therefore, the malfunction will be removed if the paper gasket is
replaced. If the paper gasket is normal, please check the next step.
4. The oil bottom filter screen shall be checked to see if it is blocked. If it is blocked, please replace the

26
Chapter 5 Troubleshooting
Torque convertor and gearbox system
filter screen, fine filter element and gearbox oil. If the oil and filter screen is clean, please check the next
step.
5. The speed-changing pump shall be checked to see if it leaks internally or it is burnt. If there is
internal leakage or burn, the oil supply of the speed changer - torque converter assembly will be
insufficient, and the speed-changing pump shall be replaced. If the oil supply of the speed-changing
pump is normal, please check the next step.
6. The joint surface between the gearbox housing and the speed-changing control valve shall be
checked to see if there are sand holes or cracks. If there are cracks, the large amount of pressure oil
from the speed-changing pump will directly flow back to the oil pool, which will cause insufficient
pressure of the system.

Malfunction case 5-1-04:

The pressure is normal at any gear, but the loader cannot run.

Description of malfunction: though the loader cannot run, the oil temperature will rise rapidly and the
steering and lifting of lift arm are normal.

Possible reasons:
1. Inappropriate oil is used or maintenance is not conducted properly.
2. The valve rod of the speed-changing control valve is blocked.
3. The torque converter leaks internally or there are sand holes on wheel cover and pump wheel or the
spring of the inlet overflow valve is broken.
4. The components of worm wheel are damaged.
5. The output shaft (fourth shaft) is twisted off.

Inspection steps or actions:

1. The added volume of the gearbox oil and the oil specification shall be checked to see if they comply
with the requirements (LGX6 hydraulic transmission oil or Mobil Delvac 1300).
2. The speed-changing control valve shall be disassembled to see if the pressure-relief valve rod is
blocked. After the pressure oil discharged by a blocked speed-changing pump meets the oil
consumption requirements of the gearbox, a great amount of the remaining pressure oil cannot enter the
torque converter, so the power is the torque converter is not sufficient.
3. The sump shall be disassembled to see if there is abnormal aluminum powder in the oil. Usually
there is a great amount of aluminum powder in the oil after the torque converter is damaged.
4. The front output flange of the gearbox shall be disassembled to see if the fourth shaft is twist off.
5. The housing of the torque converter shall be disassembled to check if the valve core and spring of
the overflow valve and back pressure valve are stuck or damaged.

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Chapter 5 Troubleshooting
Torque convertor and gearbox system
Malfunction case 5-1-05:

When the loader is under normal operation, the oil temperature of the gearbox will exceed 120℃
in short time.

Description of malfunction: the oil temperature rises rapidly, but the pressure, driving and operation of
the gearbox are normal, and the water temperature of the engine is also normal.

Possible reasons:
The reasons for causing the rise of oil temperature mainly include: influence of working condition,
improper use such as long time overload operation, insufficient oil supply of the oil supply system,
improper heat dissipation, etc.
1. Special working condition or application method (such as paper mill, upslope operation, etc.).
2. Damage of instruments or electric devices.
3. Improper use of oil.
4. The throttle or flameout cable of the engine is stuck.
5. The oil outlet pressure of the torque converter is too high.

Inspection steps or actions:

1. The working condition and application methods shall be checked (long time heavy-load push
operation or continuous upslope operation shall be avoided, and gradient shall not be higher than 30
degrees). The operation methods shall be checked to see if it is correct. During operation, the loader
shall work at gear I and the throttle control shall match the work load.
2. The oil temperature sensor and the oil temperature meter shall be check to see if they are damaged.
3. The oil consumption of the speed changer - torque converter assembly shall be checked to see if it
complies with the requirement. The filter element of the gearbox shall be replaced and the oil radiator of
the gearbox shall be cleaned.
4. The throttle control cable or flameout cable of the engine shall be checked to see if they are stuck
5. The oil outlet pressure of the torque converter shall be checked to see if pressure is high (normal
value 0.3-0.65MPa), which will cause excessively high fluidic resistance and then lead to rapid rise of oil
temperature.
Malfunction Case 5-1-06:
Oil level of the gearbox decreases quickly
Description of malfunction: hydraulic drive oil enters the water tank.
Possible reasons:
When the oil return pressure of the gearbox is set to be higher, oil will enter the water tank if the core
tube of heat radiator is broken or soldering is removed.
Inspection steps or actions:
Replace heat radiator and reset the oil return pressure of the gearbox (0.18-0.3MPa).

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Chapter 5 Troubleshooting
Torque convertor and gearbox system

Malfunction case 5-1-07:

A loader does not run at cold start, but after the engine is heated for a while, the loader starts to
run (after the loader is started and the gear is shifted, the loader does not run. However, after the
engine is heated for a while, the loader starts to run).

Description of malfunction:
After cold-start, no matter which gear is shifted, the loader does not run. However, when the oil
temperature of the gearbox exceeds 50℃, the loader starts to run normally under any gear.

Possible reasons:
1. The pipe joint is loose.
2. Improper use of oil.
3. The air does not circulate.
4. The oil inlet valve of torque conveter is damaged or adjustment pressure is too high.
5. The speed-changing pump leaks internally.
6. The gap between the valve cartridge and the valve body of the speed-changing control valve is too
wide, and the tightening torque of the fixing bolts of the control valve is not even.

Inspection steps or actions:

1. All the pipe joints of the oil supply system of the gearbox shall be checked to see if they are loose. If
pipe joints become loose, a great amount of air will enter the system (butter or soapy water may be used
to conduct check).
2. The oil shall be checked to see if it is too thick. If the oil is too thick, the speed-changing pump will
have difficulty in oil suction during cold start.
3. The air holes of the gearbox shall be checked to see if they are blocked.
4. Check, replace or adjust spring’s pressure.
5. The speed-changing pump shall be removed to check if the pump leaks internally. Meanwhile, the
wearing of the spline of the speed-changing pump shall also be checked.

Malfunction case 5-1-08:

No matter which gear is shifted, there is no pressure and the loader cannot run. Meanwhile, the
steering and lifting of lift arm do not work.

Description of malfunction: after the malfunction occurs, the engine operates properly, but the running of
the complete-loader, steering and hydraulic system stop operating immediately.
Possible reasons:
1. The spring plate, wheel cover or pump wheel breaks completely.

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Chapter 5 Troubleshooting
Torque convertor and gearbox system
Inspection steps or actions:
This malfunction is typical, but the reason is specific. The torque converter shall be disassembled, the
broken components (in most cases, the elastic bolts or wheel cover is broken) shall be replaced, and
then the loader will operate properly.

Malfunction case 5-1-09:

The loader runs at cold start, but when the engine temperature rises, the loader stops running
(runs for a while and stops for a while)

Description of malfunction:
After the loader is started, it is able to run normally at any gear. After the engine is heated, the running
ability declines with the rise of the oil temperature, and the pressure of various gears goes down
accordingly. In case of serious situations, the pressure goes down to zero and the loader stops running.
However, after the engine is shut down for a while and restarted, the loader starts to run again, and such
situation will go on repeatedly. What is noteworthy is that the pressure goes down as well at neutral
position.

Possible reasons:
The malfunction symptoms and characteristics indicate that the running ability declines with the drop of
pressure following the rise of oil temperature. There are a lot of reasons that may cause the rise of oil
temperature, but the main reason for pressure drop lies in the oil supply system. In addition, when the oil
supply system malfunctions, the oil temperature will inevitably rise. Therefore, the main reason still lies in
the oil supply system.
1. Improper maintenance
2. The oil suction pipe of the speed-changing pump is blocked.

Inspection steps or actions:

1. The cleanness of the oil of the speed-changing box shall be checked. If there are too many
contaminants in the oil, the contaminants will concentrate at the oil outlet of the oil pan and block the oil
outlet during oil suction, so the oil suction of the speed-changing pump is affected, and the pressure
goes down and causes the declining of the running ability. However, after the loader is shut down for a
while, the contaminants will scatter into the oil, the loader will be able to run again after starting, and
such phenomenon will repeat.
2. It shall be checked whether the coarse filter and fine filter of the oil suction pipe of speed changing
pump are blocked.

Malfunction case 5-1-10:

During the operation, the loader may suddenly stop, which is similar to automatic emergent
braking

Description of malfunction:

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Chapter 5 Troubleshooting
Torque convertor and gearbox system
No matter the engine is hot or cold, the loader stops randomly and the gear positions are not clearly
identifiable during shifting. However, the oil temperature and pressure are normal.

Possible reasons:
1. The bolts of cab are loose or the speed-changing joystick is loose or dislocated.
2. The wiring of speed changing control system has poor contact.

Inspection steps or actions:

1. The fastening bolts of the cab shall be checked to see if they become loose. The loosened cab will
move forward, backward, up and down under gravity and inertia, which will cause the
speed-changing rod to move accordingly with cab, so the gears will not stabilize in the desired gears,
but gear skipping or gear disorder will occur.(See Figure 5-04)

Figure 5-04 Position of the fastening bolts of the cab

2. Check electro-hydraulic speed changing control system. (See Figure 5-05)

Figure 5-05 Diagram of electro-hydraulic speed changing control

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Chapter 5 Troubleshooting
Torque convertor and gearbox system
Malfunction Case 5-1-11:
Oil level of gearbox rises quickly

Description of malfunction: cooling water enters the gearbox oil.

Possible reasons:
When the oil return pressure of the gearbox is set to be lower and the water pressure inside water tank is
higher, cooling water will enter the gearbox oil if the core tube of heat radiator is broken or soldering is
removed.

Inspection steps or actions:

Replace heat radiator (refer to Figure 5-06).

Heat
Radiator

Figure 5-06 Heat Radiator

Malfunction case 5-1-12:

The pressure of various gears is normal, but the cut of the bucket is powerless and there is a
“rat-tat” sound form the gearbox.
Malfunction characteristics:
The pressure and response of various gears are normal (which indicates that there is no shift delay).
Possible reasons:
1. The components of the worm wheel are damaged.
2. The clutch skids.
Inspection steps or actions:
1. The sump shall be disassembled and the impurities in the oil shall be checked to determine the
malfunction position.

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Chapter 5 Troubleshooting
Torque convertor and gearbox system
2. If there is aluminum power in the oil, then the torque converter assembly shall be replaced.

Malfunction 5-1-13:
Gearbox gives abnormal sound
Malfunction description:
The noise is small during cold engine operation, but during hot engine operation, the noise becomes
large. However, the pressure and operation of various gears are normal.

Possible reasons:
1. Too little or too much oil consumption
2. The oil suction pipe or strainer of the speed-changing pump is blocked.
3. Bearings are damaged or the meshing clearance between gears is too large.
4. The meshing of gears is not regular.
5. Noise from the transmission shaft of drive axle

Inspection steps or actions:

The first test run: when the gear is at neutral position, the engine shall be started to check if there is
abnormal noise at neutral position. If there is no abnormal noise at neutral position, it can be ensured
that there is no speed-changing malfunction. Then the oil supply system and the torque converter shall
be extensively checked.
Check steps are as follows:
The oil bottom filter screen shall be disassembled to check the oil consumption situation, including
added oil volume, oil specification and quality and oil cleanness. The oil shall be carefully checked to see
if there are any impurities in the oil. Meanwhile, the tightness of the joints of the oil suction pipe of the
speed-changing pump and other pipes shall be checked and the oil shall be replaced.
The second test run: the front and rear transmission shaft shall be disassembled, and then the test run
shall be started at gear I, gear II and gear III. There are two kinds of test run results:
1. If the abnormal noise disappears, the noise comes from the transmission shaft. The transmission
shaft shall be replaced.
2. The abnormal noise exists at gear I, gear II and gear III. Therefore, the gearbox shall be opened to
check the speed-changing bearings.

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Chapter 5 Troubleshooting
Torque convertor and gearbox system

Malfunction case 5-1-14

Torque converter malfunctions and troubleshooting

Malfunction S/N Cause Solutions

1 Low output speed of motor Check and adjust the engine
See the lower item of oil supply
Low output
2 Low oil supply pressure of torque converter pressure
torque
3 High oil temperature See the high item of oil temperature
4 Use of improper oil Replace with specified oil
1 Insufficient oiling amount Add to a specified value
2 Slightly high oil level Discharge oil to a proper level
3 Oil filter blocked Check and clean the oil filter
Radiator and pipe blocked Check and clean the radiator, check
4 and fasten the pipe
High oil
5 Problem with the cooling system Check the cooling system
temperature
6 Loose connection of oil suction pipe Adjust the operation cycle and abate
the operation load
7 Long time of low-speed operation at high throttle The inlet valve is damaged or the
adjusting pressure is slightly low
1 Insufficient oil amount Replenish to specified amount
2 Oil supply of speed-changing pump insufficient or Check the oil pump for wear
the speed-changing pump damaged
Low oil
3 Excessive internal leakage Check the sealing ring for wear and
supply
replace the sealing ring
pressure
4 The inlet valve damaged or adjusting pressure Check, replace or adjust the spring
slightly low
5 Suction pipe not smooth or pipe not airtight Check the pipe system
1 Oil seals, paper pads and O rings damaged Check and replace
Oil leakage
2 Loose connecting threads Check and fasten
Excessive 1 Bearing failing Check and replace
sound 2 Gears and splines worn out Check and replace

34
Chapter 5 Troubleshooting
Drive axle system
5-2 Malfunction cases of drive axle:

5-2-01 Insufficient driving force ............................................................................................ [35]

5-2-02 Wheel edges make a large noise during running ...................................................... [35]
5-2-03 Main drive device makes an abnormal noise ............................................................... [36]
5-2-04 Loader makes abnormal noise during turning .......................................................... [36]

Malfunction case 5-2-01: Insufficient driving force

Malfunction characteristics: the pressure and response of various gears of the loader is normal. The
loader may lose power suddenly during operation, but road running is normal.

Possible reasons:
The semi-axle of the front axle or the rear axle is twisted off, which causes the insufficient driving force.

Check measures and disposal methods:

1. First the rear transmission shaft shall be disassembled, and then the engine shall be started and
shifted to gear I. If the loader cannot run, then the semi-axle of front axle has already been twisted off.
2. If the loader can still run after the rear transmission axle is disassembled, then the rear transmission
axle shall be installed and the front transmission axle shall be disassembled. If the loader cannot run,
then the semi-axle of the real axle has already been twisted off.
3. As an alternative and direct way, the wheel edge covers of the front and rear axles can be
disassembled to check if the semi-axles have been twisted off.

Remark: if semi-axles are twisted off, the interior of the drive axles shall be cleaned before the
semi-axles are replaced.

Malfunction case 5-2-02:

Wheel edges make a large noise during running

Malfunction characteristics: during running, the wheels swing noticeably left and right. Under serious
circumstances, loader shakes or even is not able to run.

Possible reasons:
1. The gap between wheel edge bearings is too large or the bearings are burnt.
2. Wheel edge gears are broken.
3. Round nuts at the wheel edge are loose.

35
Chapter 5 Troubleshooting
Drive axle system
Inspection steps or actions:
The wheel edge shall be dismantled for examination and repairing.

Malfunction case 5-2-03: Main drive device makes an abnormal noise

Malfunction characteristics: the noise is more noticeable when the loader slows down during high speed
straight line running.

Possible reasons:
Bearings are loose;
The gap between driving gears and driven gears is too large or the meshing is not regular.

Inspection steps or actions:

1. After the transmission shaft is disassembled, the input flange of the main drive device shall be held
by both hands and pushed upward and pulled downward or pushed inward and pulled outward to see if it
swings noticeably. At such time, if there is no obvious travel, we are able to confirm which main drive
device (the front or the rear main drive device) malfunctions.
2. The main drive device shall be disassembled to check to the gap between the bearings of the
driving spin chute gears and the gap between the supporting bearings of the left and right housing shaft
journals.
3. The meshing surface and gap between the driving spin chute gears and driven spin chute gears.
4. The difference velocity device shall be disassembled to check the gap between bevel gears.

Note: the installation shall be conducted strictly in compliance with the requirements for driving axle
corresponding to various loader models.

Malfunction case: 5-2-04

Loader makes abnormal noise during turning

Malfunction characteristics: the noise is more noticeable during turning, and the steering wheel feels
heavy.
Possible reason: the difference velocity device is damaged.

Inspection steps or actions:

The main drive device shall be dismantled to be repaired.

36
Chapter 5 Troubleshooting
Drive axle system

Forward stress surface Larger end Backward stress surface

The contract surface is The contact surface is near

near the middle (slightly the gear top of the larger
deviating to the flank at end, but the stress is not
the larger end) concentrated on the gear top

Correct meshing of the driven spin chute gear

Figure 5-06

The installation and adjustment methods of the main drive device are shown in the following table:

Position of contact mark on Adjustment method Gear movement

driven gear face direction
Drive forward Drive back

Make driven gear move close to driving gear. If gear

clearance thus becomes too small, move the driving
gear outward.

Make driven gear move away from driving gear. If gear

clearance thus becomes too big, move the driving gear
inward.

Make driving gear move close to driven gear. If gear

clearance thus becomes too small, move the driven
gear outward.

Make driving gear move away from driven gear. If gear

clearance thus becomes too big, move the driven gear
inward.

37
Chapter 5 Troubleshooting
Working Hydraulic system
5-3 Malfunction cases of working hydraulic system:

5-3-01 During the loading operation, suddenly the lift arm and the bucket are not able to work
................................................................................................................................................... [38]
5-3-02 During loading, the bucket automatically turns upward ............................................. [39]
5-3-03 During loading, the bucket is able to operate normally. However, after the bucket is
taken back, it automatically turns downward ......................................................................... [39]
5-3-04 During loading, the bucket automatically turns upward when it hits a hard object, and
after the bucket is taken back, it automatically turns downward .......................................... [40]
5-3-05 The bucket automatically turns downward when it is taken back, and the lift arm also
automatically lowers after it is lifted........................................................................................ [40]
5-3-06 The lift arm automatically lowers after it is lifted ........................................................ [41]
5-3-07 Lifting of bucket and lift arm is powerless ................................................................... [42]

Malfunction case 5-3-01:

During the loading operation, suddenly the lift arm and the bucket are not able to work

Malfunction characteristics: when the malfunction occurs, the control rod, lift arm and bucket do not
respond, but the steering is normal.

Possible reasons:
1. The oil suction rubber pipe of the triple gear pump is blocked.
2. The shaft of the triple gear pump is twisted off.
3. The safety valve of the distribution valve is damaged.
4. The oil supply valve is damaged.
5. The pilot valve is damaged.

Inspection steps or actions:

1. The suction pipe of the triple gear pump shall be checked to see if the fall-off of inner layer causes the
difficulty of oil suction. (See Figure 5-11)

Figure 5-11: Installation position of triple gear pump

38
Chapter 5 Troubleshooting
Working Hydraulic system

2. The oil outlet pipe of the gear pump shall be disassembled, and the motor shall be clicked at idle
speed (the engine shall not be completely started, otherwise oil liquidation will waste too much oil). At
such time, if no oil emerges from the oil outlet of the triple gear pump, then the shaft of gear pump has
already been twisted off or seriously worn out.
3. According to the second step test, if oil emerges from the oil outlet, a pressure meter shall be
installed to measure the pressure of the system. Then the safety valve spring or O-ring of the distribution
valve shall be checked to see if they are broken.
4. Pressure meter shall be installed to measure the oil outlet pressure of the oil supply valve.
5. Pressure meter shall be installed to measure the outlet pressure of the pilot valve. If the pressure of
the oil supply valve is normal but the pressure of the pilot valve is abnormal, then the pilot valve is
damaged.

Malfunction case 5-3-02:

During loading, the bucket automatically turns upward

Malfunction characteristics: when the bucket hits a hard object, it will automatically turn upward at a
certain angle, but will not turn downward.
Possible reasons:
According to the malfunction characteristics, the bucket turns upward automatically but does not turn
downward, which indicates that the cylinder sealing members of bucket are not damaged. If the cylinder
sealing members of bucket are damaged, the bucket will turn upward and downward automatically, so
the internal leakage of the cylinder can be eliminated at the first step.
1. The pressure of the small chamber overload valve is too low.
2. The sealing members of the small chamber overload valve are damaged.
Inspection steps or actions:
1. A pressure meter shall be installed to measure if the small chamber overload pressure of the bucket
cylinder is too low. Usually the small chamber overload pressure shall be set at 12MPa.
2. The small chamber overload valve shall be disassembled to check if the sealing members are
damaged.

Malfunction case 5-3-03:

During loading, the bucket is able to operate normally. However, after the bucket is taken back, it
automatically turns downward.
Malfunction characteristics: during loading, the bucket does not automatically turn upward. However,
after the bucket is taken back, it automatically turns downward.
Possible reasons:
According to the malfunction characteristics, the bucket does not automatically turn upward, but after the
bucket is taken back, it automatically turns downward, which indicates that the sealing members of the
bucket cylinder are not damaged. If the sealing members of the cylinder are damaged, usually the
bucket will turn upward and downward automatically, so the internal leakage of the cylinder can be

39
Chapter 5 Troubleshooting
Working Hydraulic system
eliminated at the first step
1. The pressure of the large chamber overload valve is too low.
2. Sealing members of the large chamber overload valve are damaged.
Inspection steps or actions:
1. A pressure meter shall be installed to measure if the large chamber overload pressure of the bucket
cylinder is too low. Usually the large chamber overload pressure shall be set at 18MPa.
2. The large chamber overload valve shall be disassembled to check if the sealing members are
damaged.

Malfunction case 5-3-04:

During loading, the bucket automatically turns upward when it hits a hard object, and after the
bucket is taken back, it automatically turns downward.
Malfunction characteristics:, the bucket not only automatically turns upward during loading, but also
automatically turns downward after the bucket is taken back.
Possible reasons:
According the malfunction characteristics, the bucket automatically turns upward during loading and
automatically turns downward when the bucket is taken back. Such phenomenon indicates that the
sealing members of the bucket cylinder may be damaged, which causes the pressure oil to circulate
between the large and small chambers.
1. The overload pressure of the large and small chambers is adjusted too low.
2. The sealing members of the overload valves of the large and small chambers are damaged.
3. The sealing members and piston of the bucket cylinder are loose.
Inspection steps or actions:
1. A pressure meter shall be installed to measure if the overload pressure of the large and small
chambers of the bucket cylinder is adjusted too low. The requirements for the overload pressure of large
and small chambers are: 18Mpa for large chamber and 12Mpa for small chamber.
2. The overload valves of the large and small chambers of the distribution valve shall be disassembled
to check if the sealing members are damaged.
3. The sealing members and piston of the bucket cylinder shall be checked to see if they are loose.

Malfunction case 5-3-05:

The bucket automatically turns downward when it is taken back, and the lift arm also
automatically lowers after it is lifted
Malfunction characteristics: both the bucket cylinder and lift arm cylinder have internal leakage.
Possible reasons:
Usually the bucket cylinder and lift arm cylinder do not have damaged sealing members simultaneously.
However, there is possibility that damaged components may lead to damage of multiple cylinders, but in
most cases, the malfunction is caused by improper use of oil or internal leakage.
1. Improper use of oil

40
Chapter 5 Troubleshooting
Working Hydraulic system
2. Oil inlet pipes of working pump and steering pump are loose.
3. Distribution valve has internal leakage.
4. Sealing members of the hydraulic cylinder are damaged.
Inspection steps or actions:
1. The hydraulic oil usage shall be checked, including usage time, oil specification, etc.
2. The hydraulic system shall be checked to see if a great amount of air enters the system.
3. The fit clearance between the slide valve bore and the slide valve rod of the distribution valve shall
be checked to see if it is too large.
4. The bucket cylinder and lift arm cylinder shall be checked to see if the sealing members are
damaged and if the piston is loose.

Malfunction case 5-3-06: the lift arm automatically lowers after it is lifted
Malfunction characteristics: the lift arm automatically lowers at a high speed after it is lifted, but the
bucket cylinder is normal.
Possible reasons:
The bucket cylinder and lift arm cylinder share the same oil. The bucket cylinder never leaks internally,
so probably the malfunction does not stem from oil, but other reasons of the distribution valve and lift
arm cylinder shall be extensively checked.
1. The sealing members of the distribution valve leaks internally after being damaged.
2. The fit tolerance between the slide valve bore and the slide valve rod of the distribution valve is too
large. (Usually new valves may leak internally)
3. The sealing members of the lift arm cylinder are damaged or the piston is loose.
Inspection steps or actions:
1. The sealing members of the slide valve link of the distribution valve shall be checked to see if they
are damaged.(See Figure 5-12)

Distribution
valve

Figure 5-12: distribution valve and its installation position

2. The fit clearance between the slide valve bore and slide valve rod of the distribution valve shall be
checked to see if it is too large.
3. The lift arm cylinder shall be checked to see if the sealing members are damaged or the piston and
the piston rod are damaged by pulling.

41
Chapter 5 Troubleshooting
Working Hydraulic system

Malfunction case 5-3-07:

Lifting of bucket and lift arm is powerless

Malfunction characteristics: no matter how much the oil temperature is, the lifting of bucket and lift arm is
power and the lifting speed is low.
Possible reasons:
1. The oil deteriorates or the added oil does not comply with the specified requirements or oil of
different specifications is mixed together. (If the oil does not comply with requirements, usually it will lead
to high temperature of the hydraulic oil)
2. The air filter element is blocked.
3. The oil-suction filter screen is blocked or the oil-suction rubber pipe becomes flat, which affects the
oil suction during operation.
4. The distribution valve leaks internally.
5. The pressure of working pump or distribution valve is too low.
6. The sealing members of the bucket cylinder or lift arm cylinder are worn out or damaged.

Inspection steps or actions:

1. The cleanness of oil shall be checked to see if it deteriorates or complies with the requirements.
Usually No.46 hydraulic oil shall be used. However, at cold regions, No.40 low-freezing hydraulic oil shall
be used.
2. The air filter element (hydraulic oil tank cover) shall be checked to see if it is blocked.
3. The oil suction and oil return filter screen of the hydraulic oil tank shall be checked to see if they are
blocked, and at the same time, the oil suction rubber pipe of working pump shall be checked to see if it
becomes flat.
4. The valve core of distribution valve shall be disassembled to check if the valve core and valve body
have sand holes, etc., which may cause internal leakage.
5. The bucket cylinder and lift arm cylinder shall be checked to see if they have internal leakage. If
there is internal leakage, the bucket cylinder, lift arm cylinder shall be dismantled to check if the sealing
members, piston and piston rod are damaged.
6. A pressure meter shall be installed to check if the pressure of distribution valve is adjusted
improperly or the safety valve is damaged so as to confirm if the working pump leaks internally.

42
Chapter 5 Troubleshooting
Pilot control system
5-4 Malfunction cases of the pilot control system:
5-4-01 Lifting of lift arm is powerless (I) .................................................................................. [43]
5-4-02 Lifting of lift arm is powerless (II) ............................................................................... [44]
5-4-03 Lifting of lift arm is powerless (IIII) ............................................................................... [44]
5-4-04 Lifting of lift arm is powerless (IV)................................................................................ [44]
5-4-05 Lifting of lift arm is powerless (V)................................................................................. [44]
5-4-06 Lifting of lift arm is powerless (VI)................................................................................ [45]
5-4-07 Lifting of lift arm is powerless (VII)............................................................................... [45]
5-4-08 Lift arm cylinder automatically moves downward rapidly .......................................... [46]
5-4-09 Bucket cylinder automatically lowers too rapidly (I) ................................................... [46]
5-4-10 Bucket sometimes automatically turns upward ........................................................ [47]
5-4-11 Bucket cylinder automatically lowers too rapidly (II) .................................................. [47]
5-4-12 Unable to realize floating function................................................................................ [48]
5-4-13 Control joystick of the pilot valve cannot be gripped properly at the extreme position
................................................................................................................................................... [48]

Malfunction case 5-4-01: Lifting of lift arm is powerless (I)

Malfunction characteristics: the working pump releases big noise and there are a great amount of
bubbles in the oil.
Possible reasons:
The oil inlet pipe of the working/braking double pump is loose, so air enters into the system.
Inspection steps or actions:
The oil inlet rubber pipe of the working/braking double pump shall be checked to see if it is loose.
(See Figure 5-13: working pump and its installation position)
Working/braking double
pump

Figure 5-13

Malfunction case 5-4-02: lifting of lift arm is powerless (II)

43
Chapter 5 Troubleshooting
Pilot control system
Malfunction characteristics: the oil temperature rises rapidly; while the throttle becomes bigger, the lift
arm is elevated more slowly.

Possible reasons:
The oil-inlet rubber pipe or the oil-suction filter element of the working/braking double pump is blocked,
which causes unsmooth oil supply.

Inspection steps or actions:

The filter screen of the hydraulic oil tank and the oil suction rubber pipe of the working pump shall be
replaced or cleaned.

Malfunction case 5-4-03: lifting of lift arm is powerless (III)

Malfunction characteristics: the hydraulic oil temperature rises rapidly. Under serious circumstances, the
oil turns black.
Possible reasons:
1. Oil is used improperly, oil is too thick or air filter element is blocked, which causes oil suction
difficulty.
2. The safety valve of distribution valve is stuck.
3. The engine does not provide sufficient power, the air filter element of the engine is blocked or the
fuel has quality problems.
Inspection steps or actions:
1. The air filter element shall be cleaned, or the oil shall be replaced with oil that complies with
requirements. (At ordinary regions, No.46 hydraulic oil shall be used. At cold regions, No.46 low-freezing
hydraulic oil shall be used.)
2. The safety valve of distribution valve shall be cleaned or replaced.

Malfunction case 5-4-04: lifting of lift arm is powerless (IV)

Malfunction characteristic: the system pressure is not sufficient, and the working pump releases big
noise.
Possible reasons:
1. The working/braking double pump leaks internally and is not able to provide the pressure oil needed
for normal operation.
2. The sealing members of the main safety valve of the distribution valve are damaged, which causes
insufficient system pressure.
3. The hydraulic oil quantity is not sufficient or the oil suction rubber pipe becomes flat, which causes
the large noise, or the distribution valve rod is adjusted to an incorrect position.
Inspection steps or actions:
1. The system pressure shall be re-adjusted or the main safety valve shall be replaced.
2. The working/braking double pump shall be replaced.
3. The system shall be re-adjusted.

Malfunction case 5-4-05: lifting of lift arm is powerless (V)

44
Chapter 5 Troubleshooting
Pilot control system
Malfunction characteristics: with the rise of oil temperature, the lifting capacity continues to decline, and
the automatic downward movement of lift arm cylinder and bucket cylinder is obvious.
Possible reasons:
1. Oil is used improperly, or oil is used for too long, so the oil deteriorates and causes the oil to be too
thin.
2. The distribution valve leaks internally or the cylinder leak internally.
3. The sealing members of the bucket cylinder are damaged, which causes the pressure oil to circulate
between the large and small chambers.
Inspection steps or actions:
1. The oil usage shall be checked and the oil shall be replaced if necessary. (Under normal
circumstances, the hydraulic oil shall not be used over 1,200 hours)
2. The sealing members of the distribution valve shall be replaced.
3. The sealing members of the hydraulic oil cylinder shall be replaced.

Malfunction case 5-4-06: lifting of lift arm is powerless (VI)

Malfunction characteristics: the pressure of the hydraulic system is normal, but the steering feels heavy.
Possible reasons:
1. The steering pump leaks internally or the valve core of the priority valve is stuck, which causes the
oil interflowing to the hydraulic system to decline significantly.
2. The oil supply valve malfunctions.
Inspection steps or actions:
1. The priority valve shall be cleaned or the steering pump shall be replaced.
2. A pressure meter shall be installed to measure the oil outlet pressure of the oil supply valve when
the lift arm moves. An excess low pressure indicates that the oil supply valve malfunctions.

Malfunction case 5-4-07: lifting of lift arm is powerless (VII)

Malfunction characteristics: system pressure is normal but lifting is powerless

Possible reasons:
1. Oil is not used properly, oil is too thick, or oil tank filter screen is blocked.
2. The valve core of pilot valve is stuck by contaminants or the internal discharge is too large, which
causes that the pilot valve is unable to provide normal pressure oil to push the slide valve rod of the
distribution valve.
3. The slide valve rod of the distribution valve is stuck, so the normal corresponding opening cannot be
opened according to requirements.
4. The lift arm cylinder leaks internally.
5. The efficiency of the working/braking double pump declines.
Inspection steps or actions:

45
Chapter 5 Troubleshooting
Pilot control system
1. The filter element of the hydraulic oil tank shall be cleaned and the hydraulic oil shall be replaced.
2. The pilot valve shall be cleaned and the relevant damaged components such as sealing members,
etc. shall be replaced.
3. The slide valve rod of the hydraulic-control multi-way valve shall be checked to see if it is stuck by
contaminants.
4. The lift arm cylinder shall be checked to see if the piston and cylinder barrel are damaged by pulling
or the sealing members are damaged.
5. The working/braking double pump shall be replaced.

Malfunction case 5-4-08: the lift arm cylinder automatically moves downward rapidly
Malfunction characteristics: the bucket cylinder does not have obvious automatic downward movement
Possible reasons:
1. The valve core of the lowering valve that links the pilot valve and the lift arm is stuck.
2. The slide vale rod that links the distribution valve and the lift arm is stuck.
3. The lift arm cylinder leaks internally.
Inspection steps or actions:
1. The control rod that links pilot valve and lift arm shall be checked to see if it is stuck and cannot
return to the middle position. The stuck will cause the large chamber that links hydraulic-control
multi-way valve and lift arm to be slightly opened, so the oil of the large chamber of the lift arm cylinder
leaks back to the oil tank.
2. The control rod that links pilot valve and lift arm is able to return to the middle position, but the slide
valve rod that links hydraulic-control multi-way valve and lift arm is stuck by contaminants and cannot be
closed completely, so the oil of the large chamber of the lift arm cylinder leaks through the oil inlet of the
multi-way valve back to the oil tank
3. The sealing members of the lift arm cylinder are damaged, so the internal leakage is too large. The
sealing members shall be replaced.

Malfunction case 5-4-09:

The bucket cylinder automatically lowers too rapidly (I)
Malfunction characteristics: during operation, when the bucket contacts hard objects, it will not
automatically turns upward, and the lift arm cylinder will not automatically move downward obviously.
Possible reasons:
1. The valve core that links pilot valve and bucket is stuck.
2. The large chamber overload valve that links the multi-way valve and bucket is stuck or the pressure
is set too low. (See Figure 5-14: multi-way valve and its installation position)

46
Chapter 5 Troubleshooting
Pilot control system

Multi-way valve

Figure 5-14
3. The slide valve rod that links multi-way valve and bucket is stuck.

Inspection steps or actions:

1. The pilot valve is cleaned.
2. The pressure of the large chamber overload valve of the multi-way valve shall be re-adjusted, or the
sealing members shall be replaced.
3. The multi-way valve shall be cleaned.

Malfunction case 5-4-10: the bucket sometimes automatically turns upward

Malfunction characteristics:
During operation, the bucket automatically turns upward when it contacts hard objects, but the bucket
does not automatically turns downward after it is taken back, and the lift arm cylinder does not
automatically lowers obviously.
Possible reasons:
1. The valve core that links pilot valve and bucket is stuck.
2. The small chamber overload valve that links the multi-way valve and bucket is stuck or the pressure
is set too low.
3. The slide valve rod that links multi-way valve and bucket is stuck.
Inspection steps or actions:
1. The pilot valve shall be cleaned.
2. The pressure of the large chamber overload valve of the multi-way valve shall be re-adjusted, or the
sealing members shall be replaced.
3. The multi-way valve shall be cleaned.

Malfunction case 5-4-11:

The bucket cylinder automatically lowers rapidly (II)
Malfunction characteristics:
During operation, the bucket automatically turns upward when it contacts hard objects, but the bucket
does not automatically turns downward after it is taken back, and the lift arm cylinder does not
automatically lowers obviously.
Possible reasons:

47
Chapter 5 Troubleshooting
Pilot control system
1. The large chamber and small chamber overload valves that link the multi-way valve and bucket are
stuck or the pressure is set too low.
2. The clearance between the slide valve rod (that links multi-way valve and bucket) and the valve
body is too large, which causes internal leakage.
3. The oil seal of the bucket cylinder is worn out or damaged, which causes the pressure oil to circulate
between the large chamber and small chamber.
Inspection steps or actions:
1. The multi-way valve and overload valve shall be cleaned and the pressure shall be re-adjusted.
(18MPa for large chamber and 12MPa for small chamber)
2. The multi-way valve shall be replaced.
3. The sealing members of the bucket cylinder shall be replaced.

Malfunction case 5-4-12: unable to realize floating function

Malfunction characteristics: when the control joystick is used to place floating devices, the devices
cannot realize the floating function, but other functions are not affected.
Possible reasons:
1. After the K-opening cone valve at the bottom of the small chamber that links multi-way valve and lift
arm is blocked, the small chamber oil of the lift arm cylinder cannot flow through the pilot valve to the oil
tank.
2. The sequence valve inside the pilot valve is stuck, so the small chamber oil of the lift arm cylinder
cannot flow to the oil return chamber after entering the pilot valve (sequence valve).
Inspection steps or actions:
1. The K-opening cone valve at the bottom of the small chamber that links multi-way valve and lift arm
shall be cleaned.
2. The sequence valve (inside 2C opening) inside the pilot valve shall be cleaned.

Malfunction case 5-4-13:

The control joystick of the pilot valve cannot be gripped properly at the extreme
position.
Malfunction characteristics: When the control joystick is at its maximum angle during the lifting and
lowering of lift arm and the upward turning of bucket, it cannot be gripped by the electromagnet, but will
rebound back to the middle position automatically.
Possible reasons:
1. The power is not turned on or has poor contact.
2. The components of the electromagnet coil of the pilot valve are damaged.
Inspection steps or actions:
1. The contact of the electric system shall be checked.
2. The components of electromagnet coil shall be replaced.

48
Chapter 5 Troubleshooting
Steering hydraulic system

5-5. Malfunction cases of steering hydraulic system:

5-5-01 Steering seeming sluggish (I) ....................................................................................... [49]

5-5-02 Steering seeming sluggish (II) .................................................................................... [49]
5-5-03 Steering seeming heavy .............................................................................................. [50]
5-5-04 Steering failure or no steering ...................................................................................... [50]
5-5-05 Idle stroke in steering, and a free swing at an angle in the direction......................... [51]
5-5-06 Steering wheel kickback. .............................................................................................. [51]
5-5-07 Steering wheel swinging ............................................................................................... [51]
5-5-08 Steering wheel shaking. ................................................................................................ [52]
5-5-09 Steering endless and idling .......................................................................................... [52]

Malfunction case 5-5-01: Steering seeming sluggish (I)

Malfunction characteristics: Steering sometimes sluggish and sometimes not sluggish, without regularity.

Possible reasons:
1. The single-channel stable shunt valve is stuck, leading to inadequate fluid to the steering gear,
causing instant heaviness and sluggishness of steering.
2. Oil pollution, causing the steering spool and sleeve or the stator and rotor to be sluggish.
Inspection steps or actions:
1. Clean
2. Replace the fluid and clean the hydraulic system.

Malfunction case 5-5-02: Steering seeming sluggish (II)

Malfunction characteristics: Steering sometimes sluggish, but regular, and sluggish each time rotating to
the same angle.
Possible reasons:
1. The steering shaft deformed.
2. The steering shaft bearing damaged.
3. Friction between the steering shaft and the steering gear front cover.
4. Friction between the steering spool and sleeve or the stator and rotor has friction.
Inspection steps or actions:
1. Replace the steering shaft.
2. Replace the bearing.
3. Re-install.
4. Replace the steering gear.

49
Chapter 5 Troubleshooting
Steering hydraulic system

Malfunction case 5-5-03: Steering seeming heavy

Malfunction characteristics: When the engine has a higher speed, steering will be lighter, and when the
engine rotates at low speed, steering will be heavier.
Possible reasons:
1. The engine idle speed is too low.
2. The drive axle differential damage results in the decrease of differential function of the left and right
wheels during steering.
3. The oil is dirty.
4. Steering pressure adjusted too low.
5. Internal leakage from the steering gear is excessive.
6. Steering pump leaking or spline damage causes decline of steering pump efficiency. (The factors are
usually affects lift arm lifting speed will decrease.)
7. Internal leakage of the steering cylinder.
Inspection steps or actions:
1. Adjust the engine idle speed.
2. Check the drive axle differential damage.
3. Replace the oil and clean or replace the filter.
4. Re-adjust the steering pressure. When the pressure cannot be increased, the reason can be judged
preliminary to lie in the steering pump or relief valve. According to the actual situation, replace the
steering pump or relief valve.
5. Check the clearance between the steering gear spool and the valve body, and If necessary, replace
the steering gear.
6. Replace the steering cylinder seals, and check the piston for looseness.

Malfunction case 5-5-04: Steering failure or no steering

Malfunction characteristics: Sudden steering failure or no steering, but the work hydraulic system
working properly.
Possible reasons:
1. The spring in the steering gear is broken.
2. Serious leakage from the stator and rotor in the steering gear.
3. The steering cylinder piston seals severely damaged or the piston fallen off.

Inspection steps or actions:

1. Dismantle the steering gear and check the spring leaf, stator and rotor for meshing.
2. Check the steering cylinder.

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Chapter 5 Troubleshooting
Steering hydraulic system

Malfunction case 5-5-05:

Idle stroke in steering, and a free swing at an angle in the direction
Malfunction characteristics: During steering, some idle stroke may occur suddenly, or when the road is
uneven, it will automatically deflect towards the direction of gravity.
Possible reasons:
1. There is a lot of oil in the air.
2. The steering gear check valve (small ball) has not been completely closed.
3. More serious internal leakage in steering gear stator and rotor.
4. The steering cylinder piston seals are damaged or loose.
5. Steering gear overload valve pressure is below the pressure of the relief valve, or the seals and
springs of the overload valve are damaged.
6. The return oil back pressure of the steering system is slightly low.
Inspection steps or actions:
1. Put the direction to the maximum angle (with the hands pulling the steering wheel), increase the
engine throttle up to about 800 rpm for 5 seconds, repeat the operation two or three times at the
maximum left and right angle so that oil bubbles and air in oil discharges the air into the oil tank through
high pressure unloading.
2. Clean the steering gear.
3. Replace the steering gear.
4. Replace the steering cylinder piston seals and check the piston for tightness.
5. Re-adjust the steering system operating pressure and overload valve pressure.
6. Improve the oil return back pressure of the steering system.

Malfunction case 5-5-06: Steering wheel kickback.

Malfunction characteristics: Steering wheel kickback during steering.
Possible reasons:
1. The steering gear and the steering shaft installed and adjusted improperly.
2. The steering system oil flowing back.

Inspection steps or actions:

1. Reinstall the steering gear.
2. Replace or re-tighten the inlet check valve at the steering gear oil inlet.

Malfunction case 5-5-07: Steering wheel swinging.

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Chapter 5 Troubleshooting
Steering hydraulic system

Malfunction characteristics: The steering wheel swinging during steering.

Possible reasons:
1. The steering cylinder seal damaged;
2. Steering gear spool sluggish;
3. The steering gear damaged;
Inspection steps or actions:
1. Check the steering cylinder seal for damage, and replace any damaged one.
2. Check the steering gear for damage or the steering spool for sluggishness. In the event of damage or
sluggishness, replace the steering gear.

Malfunction case 5-5-08: Steering wheel shaking.

Malfunction characteristics: The steering wheel shaking during steering.
Possible reasons:
1. Steering gear damage causing uneven oil circulation.
Inspection steps or actions:
1. Check the steering gear and if damaged, replace it.

Malfunction case 5-5-09: Steering endless and idling.

Malfunction characteristics: Steering wheel idling and endless during steering
Possible reasons:
1. Steering gear damaged.
Inspection steps or actions:
1. Check the steering gear and replace it if damaged.

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Chapter 5 Troubleshooting
Foot brake system
5-6 Some malfunctions of foot brake system :
5-6-01 Dual-line pedal valve ...................................................................................................... 53
5-6-01-01 Brake operation very slow ......................................................................................... 53
5-6-01-02 The brake not sufficient ............................................................................................. 54
5-6-01-03 Braking too sensitive ................................................................................................. 54
5-6-01-04 Brake release incomplete........................................................................................... 55
5-6-01-05 No braking................................................................................................................... 55
5-6-01-06 The pedal rebounding when the brake pedal acting ................................................ 56
5-6-02 Dual-way charging valve and accumulator .................................................................... 56
5-6-02-01 When the accumulator fails to discharge properly during operation, the charging
valve will frequently start for charging .................................................................................... 56
5-6-02-02 The accumulator starts charging but can not reach the upper pressure limit ..... 56
5-6-02-03 Too long charging time of accumulator .................................................................... 57
5-6-02-04 Charging failure of accumulator ................................................................................ 57
5-6-02-05 Too fast cyclic charging frequency of charging valve ............................................. 57
5-6-02-06 No enough oil to pass the charging valve ................................................................ 58
5-6-03 Fan motor ......................................................................................................................... 58
5-6-03-01 Motor speed low, and torque small ........................................................................... 58
5-6-03-02 Abnormal or excessive vibration and noise ............................................................. 58

Malfunction case 5-6-01-01: Brake operation very slow

Malfunction characteristics: Brake operation very slow.
Possible reasons:
1. No or too little air in the accumulator.
2. The brake can not be adjusted correctly.
3. The brake does not work.
4. Hydraulic tubing or fittings leaking.
5. Automatic regulator does not work.
6. Hydraulic brake pipe is damaged.

Inspection steps or actions:

1. Check the accumulator for inflation condition.
2. Adjust the brakes.
3. Check the brakes.
4. Check for leaks and make repair.
5. Check the operation of the regulator.

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Chapter 5 Troubleshooting
Foot brake system
6. Check the hydraulic pipes for any defect.

Malfunctioncase 5-6-01-02: The brake not sufficient

Malfunction characteristics: The brake not sufficient.
Possible reasons:
1. No oil in the tank or oil level too low.
2. The brake can not be adjusted correctly.
3. The surface of the brake lining bears oil or grease.
4. The brake pipe damaged.
5. The automatic regulator not working.
6. No or less inflation pressure in the accumulator.
7. The brake not working.
8. The brake valve not working.
9. The system relief valve not working.
10. The pump too old.
Inspection steps or oractions:
1. Check the oil level in the tank.
2. Check the brake regulator.
3. Remove the oil dirt or replace with a new lining.
4. Check the piping or make replacement.
5. Check the operation of the regulator.
6. Check the accumulator for inflation.
7. Check the brakes.
8. Check the brake valve.
9. Check the hydraulic line of the relief valve for pressure.
10. Check the pressure from the pump to the valve pipe.

Malfunction case 5-6-01-03: Braking too sensitive

Malfunction characteristics: Braking too sensitive.
Possible reasons:
1. The brake not working.
2. The brake valve not working.
Inspection steps or actions:
1. Adjust the brake.
2. Replace the brake.

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Chapter 5 Troubleshooting
Foot brake system

Malfunction case 5-6-01-04: Brake release incomplete

Malfunction characteristics: Brake release incomplete.
Possible reasons:
1. The brake can not be adjusted correctly.
3. The brake does not work.
3. The angle of pedal is not within adjustable range.
4. The cylinder on the wheel does not work.
5. The automatic regulator does not work.
6. Air exists in the brake (for the use of a regulator on a large torque brake only).
7. The oil return pressure in the oil return pipe is too high.
8. The brake valve does not work.
Inspection steps or actions:
1. Adjust the brake.
3. Check the brake.
3. Adjust the angle of pedal.
4. Change the cylinder on the wheel.
5. Adjust the automatic regulator.
6. Release the brake.
7. Reduce the pressure.
8. Replace the brake valve.

Malfunction case 5-6-01-05: No braking

Malfunction characteristics: No braking.
Possible reasons:
1. No hydraulic oil in the system.
2. The brake line broken or damaged.
3. The brake cannot be adjusted properly.
4. The inlet overflow valve of the system does not work.
5. The inlet overflow valve of the system does not work.
6. The brake does not work or is too old.
7. The brake valve does not work.
Inspection steps or actions:
1. Check the level of oil in the tank.
2. Check the line for breakage or damage.

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Chapter 5 Troubleshooting
Foot brake system
3. Adjust the brake.
4. Check the hydraulic pipe of the overflow valve for pressure.
5. Check the brake line for pressure.
6. Check the brake.
7. The brake valve does not work.

Malfunction 5-6-01-06: The pedal rebounding when the brake pedal acting
Malfunction characteristics: The pedal rebounding when the brake pedal acting.
Possible reasons:
1. There is air in brake.
Inspection steps or actions:
1. Release the brake.

Malfunction case 5-6-02-01: When the accumulator fails to discharge properly during
operation, the charging valve will frequently start for charging
Malfunction characteristics: When the accumulator fails to discharge properly during operation, the
charging valve will frequently start for charging.
Possible reasons:
1. The oil pipe or joint of the accumulator leaks.
2. Wrong setting of inflation pressure of the accumulator.
3. The oil pipe of the accumulator is blocked.
4. The charging valve does not work.
Inspection steps or actions:
1. Check and replace the leaking oil pipe or joint.
2. Check the inflation pressure of the accumulator.
3. Check the oil pipe of the accumulator.
4. Replace the charging valve.

Malfunction case 5-6-02-02: The accumulator starts charging but can not reach the
upper pressure limit
Malfunction characteristics: The accumulator starts charging but can not reach the upper pressure limit.
Possible reasons:
1. No oil in the tank, or too low oil level.
2. The pump is too old to work, and cannot deliver all flow or pressure.
3. The overflow valve of the system does not work (the valve leaks or the overflow valve is set too low so
that the system cannot reach the all flow or pressure).

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Chapter 5 Troubleshooting
Foot brake system
4. The charging valve does not work.
Inspection steps or actions:
1. Check the level of oil in the tank.
3. Check the pump.
3. Check the overflow valve.
4. Replace the charging valve.

Malfunction case 5-6-02-03: Too long charging time of accumulator

Malfunction characteristics: Too long charging time of accumulator.
Possible reasons:
1. The pressure setting of the overflow valve is too low.
2. The pump is too old or does not work, and cannot deliver all flow or pressure.
3. The charging valve does not work.
Inspection steps or actions:
1. Check the pressure setting of the overflow valve.
2. Check the pump.
3. Replace the charging valve.

Malfunction case 5-6-02-04: Charging failure of accumulator

Malfunction characteristics: Charging failure of accumulator.
Possible reasons:
1. No oil inthe tank or oil level too low.
2. The pump is too old to work.
3. The overflow valve does not work.
4. Air exists in the oil pipe of accumulator.
5. The charging valve does not work.

Inspection steps or actions:

1. Check the oil tank for oil level.
2. Check the pump for pressure or flow.
3. Check the overflow valve for setting.
4. Release the air in the oil pipe.
5. Replace the charging valve.

Malfunction case 5-6-02-05: Too fast cyclic charging frequency of charging valve

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Chapter 5 Troubleshooting
Foot brake system
Malfunction characteristics: Too fast cyclic charging frequency of charging valve.
Possible reasons:
1. Wrong setting of air pressure of the accumulator.
2. The charging valve does not work.
Inspection steps or actions:
1. Check the air pressure of the accumulator.
2. Replace the charging valve.

Malfunction case 5-6-02-06: No enough oil to pass the charging valve

Malfunction characteristics: No enough oil to pass the charging valve.
Possible reasons:
1. The pump does not work.
2. The overflow valve does not work.
3. The pipe is blocked.
4. The charging valve does not work.
Inspection steps or actions:
1. Check the pump for flow and pressure.
2. Check the overflow valve for setting.
3. Change the oil pipe.
4. Replace the charging valve.

Malfunction case 5-6-03-01: Motor speed low, and torque small

Malfunction characteristics: Motor speed low, and torque small.
Possible reasons:
1. External leaking occurs.
2. Oil return pressure is high.
3. Oil pressure is low or oil supply amount is insufficient.
4. Low oil viscosity.
Inspection steps or actions:
1. Check the pump and motor for loose condition of the connectors and connecting flanges and for
damage of hoses and sealing rings.
2. Check the oil return line or oil return filter for blockage.
3. Check the pump for pressure and flow and charging valve for setting.
4. Check the hydraulic oil for viscosity.

Malfunction case 5-6-03-02: Abnormal or excessive vibration and noise

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Chapter 5 Troubleshooting
Foot brake system
Malfunction characteristics: Motor speed is low and torque is small.
Possible reasons:
1. The speed is too high.
2. Fan or motor mounting bolts are loose.
Inspection steps or actions:
1. Check the inlet oil of motor for working pressure.
2. Check the fan or motor mounting bolts for loose condition, which may cause the disalignment of a fan.

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Chapter 5 Troubleshooting
Electrical system
5-7. Malfunction cases of the electrical system:

5-7-01 Machine failing to start (I) ............................................................................................. [60]

5-7-02 Machine failing to start (II) ............................................................................................ [60]
5-7-03 Starting immediately after power-on .......................................................................... [61]
5-7-04 Not charging .................................................................................................................. [61]
5-7-05 Excessive charging ....................................................................................................... [61]
5-7-06 Insufficient charge or over-discharge .......................................................................... [62]
5-7-07 Thermometer not functioning ....................................................................................... [62]
5-7-08 Thermometer pointer rising to the maximum .............................................................. [62]
5-7-09 The horn not ringing ...................................................................................................... [63]
5-7-10 Wiper not working ......................................................................................................... [63]
5-7-11 Poor air-conditioning cooling effect ............................................................................. [63]
5-7-12 Table of electric wires of loaders and routing ............................................................. [65]

Malfunction case 5-7-01: Machine failing to start (I)

Fault Feature: Starter not responding
Possible reasons:
1. The fuse is blown.
2. Poor contacts of buttons, harnesses and connectors.
3. Insufficiency of battery voltage.
4. The motor magnetic switch coil burned out, or the start circuit faulted.
Inspection and troubleshooting:
1. Replace the fuse.
2. Check switches, harnesses and connectors for condition (4 # line).
3. Replace the battery (when the battery voltage is lower than 12V, recharging shall be considered; when
the battery voltage is lower than 10V, replace the battery, and recharge the removed battery with a
special charger.)
4. Check the starting circuit or motor, and replace the magnetic switch.

Malfunction case 5-7-02: Machine failing to start (II)

Malfunction characteristics: After the start button is pressed, a “click” sound can be heard from the motor,
the engine will not run or can only turn one or two circles.
Possible reasons:
1. The battery voltage insufficient.
2. The motor coil burned out.
3. The motor or engine flywheel ring gear damaged.
Inspection and troubleshooting:
1. With a special discharge tester, measure the voltage of each battery, and remove and recharge the

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Chapter 5 Troubleshooting
Electrical system
battery whose voltage is lower than 12V.
2. Short the motor terminal with the magnetic switch terminal, and If failing to start, replace the starter
motor.
3. Replace the motor or engine flywheel ring gear.

Malfunction case 5-7-03: Starting immediately after power-on

Malfunction characteristics: The engine will start when the start electric lock is not yet placed on “start”
position.
Possible reasons:
1. The ignition switch contacts stuck.
2. The motor magnetic switch contacts stuck.
3. Short circuit.
Inspection and troubleshooting:
1. Replace the ignition switch.
2. Replace magnetic switch.
3. Check whether 4#, 8# and 82a# wires are short circuited with other power line.。
3. Check whether # 4, 8#, 82a# lines are shorted with other power cord.
Note: If the circuit and the motor operate normally, and the diesel engine fan can also turn, check the
engine oil and the mechanical system for failure.

Malfunction case 5-7-04: Not charging.

Malfunction characteristics: Insufficiency of battery voltage.
Possible reasons:
1. Poor contact of lines and connectors.
2. The generator belt slack.
3. The generator damaged.
4. The battery damaged.
Inspection and troubleshooting:
1. Check whether the charge indicator is off after completion of startup, and if it is bright, check whether
the connecting circuit from the generator to the battery is in good condition.
2. Check the generator belt for looseness and adjust the belt.
3. Replace the generator.
4. Replace the battery.

Malfunction case 5-7-05: Excessive charging.

Malfunction characteristics: Voltmeter pointer up to the highest point.
Possible reasons:
1. The generator voltage too high.
2. The voltage regulator damaged.

Inspection and troubleshooting:

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Chapter 5 Troubleshooting
Electrical system
1. Replace the generator voltage regulator.

Malfunction case 5-7-06: Insufficient charge or over-discharge.

Malfunction characteristics: Battery voltage is low, and the electric appliance cannot work properly.
Possible reasons:
1. The engine belt too loose;
2. The generator exciting coil and its mechanism fail;
3. Starting frequently and the engine working for a short time;
4. The night working too long or the vehicle electrical load too large;
5. At shutdown, the power switch not turned off.
Inspection and troubleshooting:
1. Adjust the belt tension;
2. Replace generator or its exciting coil or resistance;
3. Minimize the number of starts;
4. At night work, minimize the number of starting the electrical equipment;
5. Be sure to turn off the main power switch when you shut down.

Malfunction case 5-7-07: Thermometer not functioning

Malfunction characteristics: After power-on, the thermometer does not respond, regardless of cold or hot
machines.
Possible reasons:
1. The circuit broken.
2. The thermometer damaged.
3. The sensor thermistor damaged.
Inspection and troubleshooting:
1. Check the 51 # line (for oil temperature) and 53 # line (for water temperature) for connection. Check 0
# line (for grounding) and 83 # line (for power supply).
2. Replace the thermometer.
3. Replace the sensor.

Malfunction case 5-7-08: Thermometer pointer rising to the maximum.

Malfunction characteristics: After power-on, the thermometer pointer will directly rise to the maximum.
Possible reasons:
1. Short circuit.
2. The sensor thermistor damaged.
3. Thermometer grounding wire broken.
Inspection and troubleshooting:
1. Check 51 # line (for oil temperature) and 53 # line (for water temperature) for shorting or grounding
with 0 # line (for ground wire).
2. Replace the sensor.
3. Check the thermometer ground wire for disconnection.

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Chapter 5 Troubleshooting
Electrical system

Malfunction case 5-7-09: The horn not ringing.

Malfunction characteristics: The horn not ringing after the electric key turned on and the horn pressed.
Analysis:
1. The fuse blown.
2. The horn relay bad or the coil burned out.
3. Poor contact of buttons, harnesses, connectors and ground wires.
4. Horn contacts bad or coils burned out.
Inspection and troubleshooting:
1. Replace the fuse.
2. Replace the horn relay.
3. Check buttons, harnesses, connectors and ground wires for connection (power 16 # line, button 19 #
line).
4. Replace the horn assembly.

Malfunction case 5-7-10: Wiper not working.

Malfunction characteristics: After the wiper switch is turned on, the wiper does not work.
Possible reasons:
1. The fuse blown.
2. Poor contact of switches, harnesses and connectors.
3. Wiper motor coils burned out.
4. The wiper lever not locked firmly.
5. Spindle of rain wiper is twisted off or rain wiper rod is distorted.
Inspection and troubleshooting:
1. Replace the fuse.
2. Check the switches, harnesses, connectors and ground wire for connection.
3. Replace the wiper motor assembly.
4. Lock the wiper lever nut.
5. Regulate spindle motor or replace rain wiper motor. Adjust rain wiper rod and driving mechanism.

Malfunction case 5-7-11: Poor air-conditioning cooling effect.

Malfunction characteristics: Air conditioning not working or not cooling.
Possible reasons:
1. The fuse blown.
2. Poor contact of harnesses and connectors.
3. The air conditioning compressor not working
(1) The belt too loose
(2) The pressure switch wire on the drying bottle not connected properly or damaged
(3) System pressure too low (high). For the normal pressure parameters, please see table below
(4) The pipe damaged

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Chapter 5 Troubleshooting
Electrical system
(5) The compressor damaged.
(6) Refrigerant charged inadequately.
4. Failure of drying bottle.
Inspection and troubleshooting:
1. Replace the fuse.
2. Check the wiring harness and connector for contact. (Total power 58 #, compressor power 38 #)
3.
(1) Tension the belt
(2) Check the wire on the pressure switch for connection or replace the drying bottle
(3) Fill (appropriately discharged) refrigerant
(4) Detect the leakage location and replace the leaking part
(5) Replace the compressor.
4. Replace the drying bottle and empty the system, and re-fill refrigerant (refrigerant type: R134a, filling
amount: 950-1000g).

Normal pressure of air-conditioning system

Ambient temperature
Value of low pressure gauge
Value of high pressure gauge
25℃
0.2MPa±0.02MPa
1.4MPa±0.2MPa
30℃
0.21MPa±0.02MPa
1.6MPa±0.2MPa
35℃
0.23MPa±0.02MPa
1.8MPa±0.2MPa
40℃
0.27MPa±0.02MPa
2.2MPa±0.2MPa
Conditions: compressor speed of 2000rpm; maximum air volume; humidity of 60%

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Chapter 5 Troubleshooting
Electrical system

5-7-12. Table of electric wires of loaders and routing

When repairing the failure of electrical system, refer to the following table to find a relevant line number:
Table:

Electric device Relevant line Circuit routing

name number
Combination 7#、14#、15# Fuse box 7 # → Six-hole jack → Combination switch (low beam
headlight 14 #, high beam 15 #) → Six-hole jack → Eight-hole socket (to
wiring harness of the front frame) → Combination headlight
Work light 6#、9#、56# Fuse box 6 # → Rocker switch (low beam 9 #, high beam 56 #)
→ Four-hole jack → Cab work light
Rear headlight 11#、8#、29# Fuse box 11 # → Rocker switch (low beam 8 #, high beam 29 #)
→ Eight-hole jack → (Connected to harness of rear frame) → Rear
headlight
Turn light 21#、22#、23# (Fuse box 66 # → Flasher 21 # → Nine-hole jack → Turn signal
switch (left 22 #, right 23 #) → Nine-hole jack
Eight-hole jack (Connected to harness of rear frame) →Front turn
light
Eight-hole jack (Connected to harness of rear frame) → Rear turn
light
Small light, 7#、12#、34# Fuse box 7 # → Six-hole jack → Combination switch → Six-hole
instrument light jack → Twelve-hole jack → Instrument light (34 #)
Rocker switch indicator (34 #) → Eight-hole jack (Connected to
harness of front and rear frames 12 #) → Small light
Brake light 16#、17# Fuse 16 # → Eight-hole jack → Brake light switch (17 #) → Brake
light
Horn 16#、19# Fuse box 16 # → Eight-hole jack → Horn relay → Horn → 19 #
Eight-hole jack → Twelve-hole Jack → Combination
switch → Horn button → Grounding
Wiper 32#、59#、62# Return circuit: 32 # → Wiper return device 62 #
(Return line) Fuse box 32 # → Twelve-hole jack → Wiper switch (59 #)
→ Twelve-hole jack → Four-hole wiper jack → Wiper
motor twelve-hole jack
Heater (air 11#、58# Fuse box 11 # → Rocker switch 58 # → Eight-hole jack (Connected
conditioning) to harness of rear frame) → Heater jack → Heater (air conditioning)
Cooler 11#、27# Crisper 11 # → Rocker switch 27 # → Fan jack → Fan

65
Chapter 6 Main parts

Chapter 6 Main Parts

Section 1 Drive axle ................................................................................................................ [67]

Section 2 Priority valve........................................................................................................... [107]
Section 3 Bucket cylinder ...................................................................................................... [114]
Section 4 Steering cylinder .................................................................................................... [121]
Section 5 Brake valve and energy accumulator .................................................................. [124]
Section 6 Charging valve ...................................................................................................... [130]
Section 7 Lift arm cylinder ..................................................................................................... [136]
Section 8 Steering gear .......................................................................................................... [144]
Section 9 Working hydraulic oil cooler ................................................................................. [163]
Section 10 Air conditioning system ....................................................................................... [166]
Section 11 Torque converter .................................................................................................. [174]
Section 12 Gearbox ................................................................................................................ [182]
Section 13 Steering pump ...................................................................................................... [282]
Section 14 Double gear pump ................................................................................................ [286]

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Chapter 6 Main parts
Section 1 Drive Axle

Section 1 Drive Axle

Table of Contents
1. Structure and Functions ..................................................................................................................[67]
2. Dismounting and Installation ...........................................................................................................[69]
3. Disassembly and Repair..................................................................................................................[70]

1. Structure and Functions

Axle housing 3 Differential 5 Semi-axle 2 Wheel hub
reducer 1

Main drive 4 Brake 6

Figure 6-1-1
(I) Functions of Drive Axle:
1. Transmission of power: After the power inputted via transmission shaft of the gearbox goes through
speed reduction and torque multiplication, the driving direction is changed (via driving and driven gear).
Through semiaxle driving the rotation of left and right tires, the vehicle moves forward or backward and
left and right driving wheels are able to rotate at different speeds.
2. Supporting vehicle weight: Front and rear axles support the weight of the whole vehicle via frame.
3. Turning: It performs the turning of the whole vehicle (except whole-axle integral turning)
4. Differential speed: It offers such functions as vehicle swerving.

(II) Structure of Drive Axle:

Drive axles of wheel loader include front axle and rear axle. Their difference lies in different rotation
directions and installation forms of the spiral bevel gear pair in main drive. The driving spiral bevel gear
of the front axle is right hand and that of rear axle is left hand. The drive axle primarily comprises axle
housing, main drive (including differentials), semiaxle, wheel hub reducer and brake. Through drive
components, the power from the engine is inputted into main drive for single stage reduction, and then is
transmitted via semiaxle to wheel hub reducer for speed reduction before power output via hubs and
tires.
(III) Structure and Principle of Wheel Hub Reducer:

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Chapter 6 Main parts
Section 1 Drive Axle

Flat shaft

Hub

Figure 6-1-2
The wheel hub reducer mainly comprises sun wheel, planetary wheel, planetary carrier and gear ring.
The planetary transmission principle of wheel hub reducer is illustrated as the figure. The semiaxle
drives the sun wheel integrated with spline to rotate at the speed of nsun in a certain direction, while the
planetary wheel engaged with the sun wheel rotates in the reverse direction. Due to stationary gear ring,
the planetary carrier rotates at the speed of n carrier in the direction contrary to the rotation direction of the
sun wheel. Since n carrier is below nsun, speed reduction is thus achieved.

(IV) Structure and Principle of Differential:

Figure 6-1-3
A differential generally comprises 4 cone planetary gears, criss-cross shaft, 2 axle shaft gears and left &
right differential housings. Operating principle of the differential is as follows: When the driving wheel is
running on the ground, the resisting moment of the contact between left/right wheel and the ground
acting on semiaxle line is not equal. If the difference between resisting moment of the two wheels
exceeds the moment required for the rotation of planetary gear to overcome internal resistance, the
planetary gear will rotate around its own axis, thus causing the left semiaxle gear and the right semiaxle
gear to rotate in contrary directions. As long as the difference between resisting moment of left and right
wheels exceeds the moment enough to overcome the friction against internal rotation of the differential,
the left and right semiaxles rotate at their different speeds, thus realizing speed reduction.

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Chapter 6 Main parts
Section 1 Drive Axle

2. Dismounting and Installation

Tools needed:
1. Two 10t travelling cranes 6. 46 anti-reverse wrench
2. Special lifting tools 7. 46 sleeve
3. Special carrier for front and rear axles 8. 1”, 2” adjustable wrench
4. Special lengthened sleeve 9. 16-8 open end wrench
5. K50 air blasting machine 10. 19-22 open end wrench
11. 27-30 open end wrench
12. 700N·m, 1200N·m torque wrench

(1) Schematic diagram for location of drive axle in the product

(See Figure 6-1-4)

Front drive axle

Middle/rear Front assembly
transmission shaft Rear axle front bushing
assembly swing frame
Tire Hub
assembly

Rear drive axle Front transmission Intermediate support

assembly Rear Support shaft Rear axle rear
shaft assembly assembly swing frame
transmission
shaft assembly

Figure 6-1-4

①As shown in Figure 6-1-4, drive axle consists of front and rear axles, with front axle directly fixed on
front frame and rear axle connected to rear frame via swing frame; front and rear axles are installed with
4 tires; flange face of front axle is linked to front transmission shaft; front axle is provided with protection
plate and steel oil pipe; flange face of rear axle is linked to rear transmission shaft; rear axle is equipped
with steel oil pipe.

②Mounting bolts M24×1.5×160 (8 pcs) and lock nuts M24×1.5 (8 pcs) are used for connecting front axle
to front frame; bolts M30×2×155 (8 pcs) and lock nuts M30×2 (8 pcs) are used for connecting rear axle
to rear frame; bolts M12×1.5×45 (8 pcs) and lock nuts M12×1.5 (16 pcs) are used for front axle to
transmission shaft and rear axle to rear transmission shaft; bolts M14×1.5×45 (8 pcs) and lock nuts
M16×1.5 (16 pcs) are used for connecting intermediate transmission shaft .

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Chapter 6 Main parts
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(1) Dismounting steps

①Remove connecting bolts between front/rear axle and front/rear transmission shaft to separate
front/rear axle from front/rear transmission shaft;

②Remove steel pipe assembly and tee joint connecting front and rear axles;

③Remove connecting bolts M24×1.5×160 (8 pcs) and lock nuts M24×1.5 (8 pcs) between front axle and
front frame; remove connecting bolts M30×2×155 (8 pcs) and lock nuts M30×2 (8 pcs) between rear axle
and rear frame; use two 10t travelling cranes to lift the frame system and push out front & rear axles;

④Hoist front and rear axles onto the fixed support and remove connecting bolts M20×2 (12 pcs)
between front/rear axle and front/rear tire. Loosen nuts at the position of symmetry via 2-3 operations, lift
down the tires with a special lifting device and properly mark them before placing them on tire rack;

(3) Debugging requirement

If necessary, debugging shall be performed by designated personnel.
(4) Installation

①Installation sequence: install front and rear axles on the frame system; connect tee joints to steel pipe
assembly on front and rear axles; connect flange face of front/rear axle to front/rear transmission shaft;
finally install front and rear tires on front and rear axles respectively;

②Ensure cleanliness during assembly; pay attention to flange direction of front and rear axles in the
course of lifting front and rear axles;

③Take mounting torque according to the requirement of torque meter.

3. Disassembly and Repair

(1) Disassembly process
1. Remove the drain plug assembly of bridge package, O-ring 21×2, bridge package filler plug,
O-ring 38×2.5; (see Figure 6-1-5)

Figure 6-1-5 (rear axle)

2. Remove the drain plug assembly of bridge package, O-ring 21×2, bridge package filler plug and
O-ring 38×2.5; (see Figure 6-1-6)

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Chapter 6 Main parts
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Figure 6-1-6 (front axle)

3. Remove the vent valve assembly and O-ring 21×2; (see Figure 6-1-7)

Figure 6-1-7

4. At the deflation opening of the wheel support shaft in the traveling direction and the vertical direction,
remove the O-ring 13.5×2, and the vent valve assembly;
(See Figure 6-1-8)

Figure 6-1-8

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Chapter 6 Main parts
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5. Remove the wheel drain plug assembly, O-ring 38×2.5, wheel filler plug and O-ring
13.5×2; (see Figure 6-1-9)

Figure 6-1-9

6. From corresponding bolt holes, remove 32 bolts M14×1.5×45. (front axle) (see Figure 6-1-10)

Figure 6-1-10

7. At corresponding bolt holes, remove the 24 bolts M14×40 (rear axle) (see Figure 6-1-11)

Figure 6-1-11

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Chapter 6 Main parts
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8. Remove the wheel cover assembly, O-ring 310×2.5, sun gear spacers and sun gear. (See Figure
6-1-12)

Figure 6-1-12

9. Remove it and mount the piston press plate and hole spring circlip 284. (See Figure 6-1-13)

Figure 6-1-13

10. From the rear axle, remove dual-discs and friction plates in sequence, a total of 4 dual-discs and
3 friction plates; in the front axle, mount the dual-discs and friction plates in sequence, a total of 5
dual-discs and 4 friction plates. (See Figure 6-1-14)

Figure 6-1-14

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Chapter 6 Main parts
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11. Remove the outer ring gear assembly and the positioning plate. (See Figure 6-1-15)

Figure 6-1-15

12. Remove the right axle. (See Figure 6-1-16)

Figure 6-1-16 (right wheel)

13. Penetrate the left axle; (see Figure 6-1-17)

Figure 6-1-17 (on the left wheel)

14. Unscrew the nut to remove the thrust wear plates and hubs. (See Figure 6-1-18)

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Chapter 6 Main parts
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Figure 6-1-18

15. Remove the cylinder / ring gear assembly, O-ring 100×3. (Figure 6-1 - 19)

Figure 6-1-19

16. Remove the adjusting pads, bearing spacers and O-ring 92×3 in turns (rear axle);

17. Remove the adjusting pads, bearing spacers, O-ring 112×3 and O-ring 110×3; (see Figure 6-1-20)

Figure 6-1-20

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Chapter 6 Main parts
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18. Take the hub assembly out of the support shaft and remove the bearing 32021 (rear axle) and
bearing 32028 (front axle). (See Figure 6-1-21)

Figure 6-1-21

19. Remove the wheel support shaft, bolt M18×60 (rear axle), bolt M24×80-10.9 and washer 24 (front
axle). (See Figure 6-1-22)

Figure 6-1-22 (rear axle)

Figure 6-1-23 (rear axle)

20. Remove the 18 toothed bolts M14×1.5×40, 3 flexible cylindrical pins 16×35, flexible cylindrical pins
10×35 and take out the main reducer assembly. (See Figure 6-1-24)

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Chapter 6 Main parts
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Figure 6-1-24 (rear axle)

21. Remove the 16 toothed bolts M14×1.5×45 and take out the main reducer assembly. (See Figure
6-1-25)

Figure 6-1-25 (front axle)

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Chapter 6 Main parts
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3. Disassembly and Repair

(1) Repair of drive axle

Note: Before assembly, all parts should be cleaned; any worn or damaged parts should be replaced with
new ones.

(I) Repair of hub components

A-1. Under the action of the hydraulic machine, with the tooling, press the hub bolts, put on the spherical
spring washers, and screw in the hub nuts (see Figure 6-1-26);

Figure 6-1-26

A-2. Flip the hub, and with the tooling, knock the outer rings of 32026 bearing (rear axle) and 32030
bearing (front axle) to place (see Figure 6-1-17).
Figure 6-2-17

Figure 6-1-27

A-3. Flip the hub component, with special tooling, knock in the outer rings of the bearings 32021 (rear
axle) and 32028 (front axle), and put in the bearing inner ring; (See Figure 6-1-28).

Figure 6-1-28

A-4. With the tooling, lightly knock the combined oil seals 136. 8 × 165 × 13.5 (rear axle) and skeleton oil

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Chapter 6 Main parts
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seal 190×230×17 (front axle) to place, with direct knocking at the oil seal not allowed.

(II) Repair of piston components

B-1. As shown, from left to right, the spare parts are as follows: guide ring 2, retainer ring 2, seal ring 2,
piston, seal ring 1, retainer ring 1, and guide ring 1 (see Figure 6-1-29 and 6-1-30).

Figure 6-1-29

Figure 6-1-30

B-2. In the order as shown, mount the parts, and during the assembly, coat the piston with a small
amount of lithium grease for easy assembly. Note: the thickness of front axle piston is 50 and that of rear
axle piston is 47.5.

(III) Repair of cylinder /inner ring gear components

C-1. First clean the cylinder oil passages to ensure that the oil passages are smooth and parts are free
of sand holes and other defects.
C-2. With a hex wrench, screw in 2 pipe plugs (coat the threads with thread locking agent) (see Figure
6-1-31).

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Chapter 6 Main parts
Section 1 Drive Axle

Figure 6-1-31

C-3. Flip the cylinder, and mount the piston component by aligning the machined hole in the cylinder with
a casting hole of the piston component (during assembly, the assembled position can be coated with
lubricating oil) (see Figure 6-1-32).

Figure 6-1-32

C-4. Flip the cylinder, mount the tension spring fixing ring 1 by aligning the hole on the cylinder (see
Figure 6-1-33).

Figure 6-1-33

C-5. Flip the cylinder again, and mount the tension spring fixing ring 2.
C-6. Keep held the tension spring fixing ring 1 manually and mount 8 reset extension springs to ensure
that the tension spring is assembled in place.

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Chapter 6 Main parts
Section 1 Drive Axle

Figure 6-1-34

C-7. Flip the cylinder assembly, heat the inner rings of bearing 32026 (rear axle) and bearing 32030
(front axle) to 90 - 100℃, and after wearing protective gloves, put on the bearing on a heat basis (if the
bearing is not in place, the special tooling can be used to knock at the inner ring, and it is prohibited to
knock at the roller body and the holder) (see Figure 6-1-35).

Figure 6-1-35

C-8. Fit the cylinder component into the inner tooth rings (the lengths of tooth rings of front and rear
axles are different), and get it stuck in the snap ring (See Figure 6-1-36 and Figure 6-1-37).

Figure 6-1-36

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Chapter 6 Main parts
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Figure 6-1-37

(IV) Wheel hub support shaft components

D-1. First check whether the oil passage hole of the support shaft is smooth, and whether there are burrs
and flanging at the oil port. Corresponding to each hole, screw in 4 pipe plugs, and coat thread-locking
agent on the threads. Electrically welded dust cover is needed for front axle.

Figure 6-1-38 (front axle)

Figure 6-1-39 (rear axle)

(V) Repair of wheel hub end cover components

E -1. Mount the 12X15 roller onto the bearing’s inner ring surface (see Figure 6-1-40);

Figure 6-1-40

E-2. With a special tooling, press in the roller, bearing inner ring and retainer ring by means of an oil
press (see Figure 6-1-41);

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Chapter 6 Main parts
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Figure 6-1-41

E-3. With an oil press, press the pressed planet gear components into 4 wheel hub end cover columns;
E-4. With circlip pliers, snap in 4 retainer rings 50 (rear axle) and retainer rings 54 (front axle);
E-5. Rotate the planet gear, and confirm rotation flexibility; if jamming occurs, tap the appropriate wheel
hub end cover column. (See Figure 6-1-42 and Figure 6-1-43)

Figure 6-1-42

Note: assembly methods of the hub end covers of front and rear axles are consistent and differenes exist
for different parts.

Figure 6-1-43

(VI) Repair of differential assembly

F-1. Prior to assembly, it is required to ensure that the differential housing is free of iron chips, burrs, and
flashings;
F-2. Mount the washers, thrust washers, and wire retainer rings in the order. (See Figure 6-1-44)

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Chapter 6 Main parts
Section 1 Drive Axle

Figure 6-1-44

F-3. Corresponding to the pin holes on the differential casing, mount into six 12×58 cylindrical pins to
ensure that pins will not fall out (see Figure 6-1-45).

Figure 6-1-45

F-4. Corresponding to the pins, mount into dual-discs, friction plates, dual-discs, and friction plates, two
groups, and align the teeth-missing location of splines in the friction plate (see Figure 6-1-46).

Figure 6-1-46

F-5. Corresponding to the cylindrical pin, load a thrust plate, and load a differential gear; during
assembling, apply lubricating oil to ensure that the thrust plate can be loaded satisfactorily (see Figure
6-1-47);

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Chapter 6 Main parts
Section 1 Drive Axle

Figure 6-1-47

F-6. Take two cross shafts, mount a bevel gear, and in the corresponding groove, mount the cross shaft
component (see Figure 6-1-48).

Figure 6-1-48

F-7. Mount the other differential gear, and mount the other thrust plate (thrust plate is ensured to
correspond to the cross axis) (see Figure 6-1-49).

Figure 6-1-49

F-8. Corresponding to the splines of the differential gear, mount the friction plate, dual-disc, friction plate
and dual-disc (the missing teeth of two friction plates should be aligned) (see Figure 6-1-50).

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Chapter 6 Main parts
Section 1 Drive Axle

Figure 6-1-50

F-9.By aligning the pin holes of the two dual-discs with the pin holes of the differential casing, and then
mount six 12×28 cylindrical pins;
Note: The backlash between friction plates should be guaranteed 0.3 ~ 0.7mm, and can be adjusted by
dual-discs of different thicknesses (Fig. 6-1-51);

Figure 6-1-51

F-10. When the backlash between friction plates is ensured, mount the differential housing cover (mount
the washers and thrust washers in the order) (see Figure 6-1-52).

Figure 6-1-52

F-11. After aligning two threaded holes, mount two socket head cap screws M10×16 (see Figure 6-1-53).

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Chapter 6 Main parts
Section 1 Drive Axle

Figure 6-1-53

F-12. Heat the bearing JM714249/JM714210 heated to 90 ~ 100°C, and after wearing protective gloves,
with special tooling, assemble the bearing in place (see Figure6-1-54).

Figure6-1-54

F-13. Flip the differential component as shown, heat the bearing 33281/33472-N to 90 ~ 100°C, and
after wearing protective gloves, with special tooling, assemble the bearing in place (see Figure 6-1-55).

Figure 6-1-55

(VII) Front axle differential assembly

G-1. Prior to assembly, ensure that the differential housing is free of scrap iron, burrs, fins etc.;
G-2. Mount the spacer and the thrust washer in turns. (See Figure 6-1-56)

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Chapter 6 Main parts
Section 1 Drive Axle

Figure 6-1-56

G-3. Mount the dual-discs and the friction plates (two groups totally) in turns, and mount the thrust
plate into the differential housing groove; (Figure 6-1-57)

Figure 6-1-57

G-4. Mount the side gear and spline its friction plate.

G-5. Take two cross shafts, mount a bevel gear, and in the corresponding groove, mount a cross
shaft component; (see Figure 6-1-58)

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Chapter 6 Main parts
Section 1 Drive Axle

Figure 6-1-58

G-6. Mount the other side gear, and mount the other thrust plate into a corresponding differential
housing groove; (see Figure 6-1-59)

Figure 6-1-59

G-7. Mount the friction plate and the dual-disc in turns, a total of two groups. (See Figure 6-1-60)

Figure 6-1-60

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Chapter 6 Main parts
Section 1 Drive Axle

G-8. In grooves of corresponding differential housing covers, mount the washer and thrust washer,
and mount them into the corresponding holes in the differential housing cover; (see Figure 6-1-61)

Figure 6-1-61

G-9. In corresponding threaded holes, mount two screws M10 × 16, and lock them; (see Figure
6-1-62)

Figure 6-1-62

G-10. Heat the bearing 47686/47620 to 90 ~ 100 ℃, and by wearing protective gloves, with special
tooling, assemble the bearing in place; (see Figure 6-1-63)

Figure 6-1-63

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Chapter 6 Main parts
Section 1 Drive Axle

G-11. Heat the bearing 27695/27620 to 90 ~ 100 ℃, and by wearing protective gloves, with special
tooling, assemble the bearing in place; (see Figure 6-1-64)

Figure 6-1-64

(VIII) Front driving gear component

H-1. With special tooling, by means of an oil press, press into the bearing T7FC070 to ensure that the
bearing is in place.
H-2. Mount the bearing spacers, and adjusting washers. (See Figure 6-1-65)

Bearing clearance
adjusting washer

Bearing T7FC070

Figure 6-1-65

(IX) Rear driving gear component

I-1. With special tooling, by means of an oil press, press into the bearing 31313 to ensure that the
bearing is in place.
I-2. Mount the bearing spacers, and adjusting washers. (See Figure 6-1-66)

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Chapter 6 Main parts
Section 1 Drive Axle
Bearing clearance
adjusting washer

Bearing 31313

Figure 6-1-66

(X) Input flange component

J-1. Put in 8 bolts (Lonking anti-rotation type) and screw in the nut M12.
J-2. After assembling the dust cover, using the three-point spot welding, weld the dust cover securely
(see Figure 6-1-67 and Figure 6-1-68).

Figure 6-1-67

Figure 6-1-68

(XI) Front main drive asembly

K-1. Check the front bracket to ensure the assembly position is free of bumps, sand holes, burrs, etc.; to

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Chapter 6 Main parts
Section 1 Drive Axle
ensure the threads to be free of bumps and mess teeth;
K-2. Mount plate toothing meshing print adjusting washers, and then mount the front driving gear
components, and bearings T7FC060. (See Figure 6-1-69)

Bearing T7FC060

Print adjusting spacer

Figure 6-1-69

K-3. Check the oil seal for notch, deformation and other defects;
K-4. With special tooling, mount two oil seals FB85×140×13 to ensure assembly to be in place, and coat
the oil seal lip with grease. (See Figure 6-1-70)

Figure 6-1-70

K-6. Mount the input flange component, nut washer, and nut;
K-7. Shake the input flange, and if too tight, increase bearing clearance washers; if too loose, reduce
such washers. (See Figure 6-1-71)

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Chapter 6 Main parts
Section 1 Drive Axle

Figure 6-1-71

K-8. Turn the bracket, mount the driven spiral bevel gear on the differential gear component
corresponding to the driving gear, and with 12 bolts M16x1.5x50, lock it (coat the threads with
thread-locking agent), with tightening torque of 310 ~ 330Nm. (See Figure 6-1-72)

Figure 6-1-72

K-9. Mount two adjusting nuts, and preliminarily adjust the backlash between the driving and driven
gears; according to prints, select the appropriate print adjusting washers. (See Figure 6-1-73)

Figure 6-1-73

K-10. Mount two bracket bearing pedestals, and with 4 bolt M16×120 gaskets 16, lock the bearing
pedestals;
K-11. Adjust the blacklash between the driving and driven gears, smear the big spiral bevel gear with red
lead powder, turn the large gear, check prints (Note: the edge tooth height of the contact area is not less

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Chapter 6 Main parts
Section 1 Drive Axle
than 40%, and edge tooth length is not less than 50%), and lock them securely, with tightening torque of
310 ~ 330Nm. (See Figure 6-1-74)

Figure 6-1-74

K-12. Corresponding to the bracket bearing pin holes, mount two spring pins 6×40, and ensure that the
other end of the pin is located between the bosses of adjusting nuts. (See Figure 6-1-75)

Figure 6-1-75

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Chapter 6 Main parts
Section 1 Drive Axle

Figure 6-1-55

Position of contact trace on driven gear

surface

Adjusting method Gear movement direction

Forward Reverse
Move the driven gear towards
the driving gear, and if this
causes the backlash to be too
small, move the driving gear
outwards.

Move the driven gear away

from the driving gear, and if
this causes the backlash to
be too large, move the driving
gear inwards.
Move the driving gear
towards the driven gear, and
if this causes the backlash to
be too small, move the driven
gear outwards.

Move the driving gear away

from the driven gear, and if
this causes the backlash to
be too large, move the driven
gear inwards.

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Chapter 6 Main parts
Section 1 Drive Axle
(XII) Repair of rear main driving assembly
L-1. Check the front bracket to ensure the assembly position is free of bumps, sand holes, burrs, etc.; to
ensure the threads to be free of bumps and mess teeth;
L-2. Mount plate toothing meshing print adjusting washers, and then mount the front driving gear
components, and bearings K72487/K72200C. (See Figure 6-1-76)

Bearings K72487/K72200C

Print adjusting
spacer

Figure 6-1-76

L-3. Check the oil seal for notch, deformation and other defects;
L-4. With special tooling, mount two oil seals FB75x125x13 to ensure assembly to be in place, and coat
the oil seal lip with grease.
L-5. Mount the input flange component;
L-6. Shake the input flange, and if too tight, counter-remove the spacers in the order of assembly, and
increase bearing clearance washers; if too loose, reduce such washers. (See Figure 6-1-77)

Figure 6-1-77

L-7. Mount the nut gaskets and nuts in the order, and lock them; (See Figure 6-1-78)

Figure 6-1-78

L-8. Turn the bracket, mount the driven spiral bevel gear on the differential gear component

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Chapter 6 Main parts
Section 1 Drive Axle
corresponding to the driving gear, and with 12 bolts M16x1.5 x45, lock it (coat the threads with
thread-locking agent); (See Figure 6-1-79)

Figure 6-1-79

L-9. Mount two adjusting nuts, and preliminarily adjust the backlash between the driving and driven
gears; according to prints, select the appropriate print adjusting washers; (See Figure 6-1-80)

Figure 6-1-80

L-10. Mount two bracket bearing pedestals, and with 4 bolt M16×120 gaskets 16，lock the bearing
pedestals;
L-11. Adjust the blacklash between the driving and driven gears, and lock them; (See Figure 6-1-801

Figure 6-1-81

L-12. Corresponding to the bracket bearing pin holes, mount two spring pins 6×40, and ensure that the
other end of the pin is located between the bosses of adjusting nuts. (See Figure 6-1-82)

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Chapter 6 Main parts
Section 1 Drive Axle

Figure 6-1-82

Figure 6-1-83

Position of contact trace on driven gear

surface

Adjusting method Gear movement direction

Forward Reverse
Move the driven gear towards
the driving gear, and if this
causes the backlash to be too
small, move the driving gear
outwards.

Move the driven gear away

from the driving gear, and if
this causes the backlash to be
too large, move the driving
gear inwards.
Move the driving gear towards
the driven gear, and if this
causes the backlash to be too
small, move the driven gear
outwards.

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Chapter 6 Main parts
Section 1 Drive Axle
Move the driving gear away
from the driven gear, and if
this causes the backlash to be
too large, move the driven
gear inwards.

(XIII) Repair of drive axle assembly

M-1. Mount the main reducer assembly; when assembling, it is required to smear the joint surface with
gasket sealant adhesive continuously to ensure tightness;
M-2. Corresponding to the axle housing threaded holes, mount 16 toothed bolts M14×1.5×45, with bolt
tightening torque of 180 ~ 230Nm; (See Figure 6-1-84)

Figure 6-1-84 (front axle)

M-3. Mount the main reducer assembly; when assembling, it is required to smear the joint surface with
gasket sealant adhesive continuously to ensure tightness;
M-4. Knock in 3 elastic cylindrical pins 16×35, and elastic cylindrical pins 10×35;
M-5. Corresponding to the axle housing threaded holes, mount 18 toothed bolts M14×1.5×40, with bolt
tightening torque of 180 ~ 230Nm; (See Figure 6-1-85)

Figure 6-1-85 (rear axle)

K-6 By aligning its axle housing groove, at the combined back-up between the wheel hub support shaft
and the axle housing, apply the gasket sealant adhesive, mount the wheel hub support shaft, put
through the bolt M18×60 (rear axle), bolts M24×80-10.9 and washers 24 (front axle), and lock them, with
tightening torque of 380-440Nm; (See Figure 6-1-86 and Figure 6-1-87)

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Chapter 6 Main parts
Section 1 Drive Axle

Figure 6-1-86

Figure 6-1-87

K-7. Put the support shaft in the assembled hub component, and with special tooling, tap the bearing
32021 (rear axle) and bearing 32028 (front axle) in place (to protect the oil seal lip). (See Figure 6-1-88)

Figure 6-1-88

K-8. As shown in the figure, mount the adjusting washer, bearing spacer, and O-rings in the order 92×3
(rear axle) (O-rings coated with grease for easy assembly).
K-9. Mount adjusting washer, bearing spacer, O ring 112×3 and O ring 110×3; (See Figure 6-1-89)

Figure 6-1-89

K-10. Pre-load the O-ring 100×3 into the O-ring groove in a cylinder and grease it (limited to rear axle);
K-11. Align the support shaft hole and the cylinder hole (which can be marked by lines), and mount the
cylinder / gear ring component; (See Figure 6-1-90)

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Chapter 6 Main parts
Section 1 Drive Axle

Figure 6-1-90
K-12. Screw in the locking nut, and while tightening process, mount the wheel hub to prevent the
bearing from being distorted;
K-13. By aligning the grooves of the locking nut and the support shaft, mount the thrust wear plate;
(See Figure 6-1-91)

Figure 6-1-91

K-14. Penetrate the left differential shaft; (See Figure 6-1-92)

Figure 6-1-92 (left wheel hub)

M-15. Penetrate the right differential shaft; (See Figure 6-1-93)

Figure 6-1-93 (right wheel hub)

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Chapter 6 Main parts
Section 1 Drive Axle
M-16. Pre-load a positioning plate into outer gear ring to ensure the positioning plate to be assembled in
place;
M-17. By aligning the outer gear ring component with its differential shaft axle splines, mount the outer
gear ring component; (See Figure 6-1-94)

Figure 6-1-94

M-18. For rear axle, mount the dual-discs (4pcs) and friction plates (3pcs) (the dual-disc grooves shall
be flush and perpendicular to the downward running direction of the vehicle; friction plates shall be
soaked in gear oil for 24 hours before use);
M-19. For front axle, mount the dual-discs (5pcs) and friction plates (4pcs) (the dual-disc grooves shall
be flush and perpendicular to the downward running direction of the vehicle; friction plates shall be
soaked in gear oil for 24 hours before use); (See Figure 6-1-95)

Figure 6-1-95

M-20. Mount the piston plate and the hole circlip 284 (it is needed to ensure that the circlip is assembled
in place). (See Figure 6-1-96)

Figure 6-1-96

M-21. By aligning outer gear ring splines, mount the sun gea, and measure the size from the wheel hub
end cover joint surface to the sun gear end surface;
M-22. Measure the size from the wheel hub end cover joint surface to the sun gear washer; (indirect
measurement may be performed);
M-23. Based on two measurements, select sun gear washer of an appropriate thickness, to ensure the

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Chapter 6 Main parts
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backlash of sun gear to be 1.2 ~ 1.7mm;
M-24. Fit the O-ring 310×2.5 into the O-ring groove of wheel hub end cover , and according to the
selected washers, put it into the groove;
M-25. Mount the wheel hub end cover component, and align its end cover with the threaded hole of the
hub; (See Figure 6-1-97)

Figure 6-1-97

M-26. In corresponding bolt holes, mount 24 bolts M14×40, and smear the reads with thread-locking
fastening agent, with bolt tightening torque of 180 ~ 210Nm; (See Figure 6-1-98)

Figure 6-1-98

M-26. In corresponding bolt holes, mount 32 bolts M14×1.5×45, and smear the reads with thread-locking
fastening agent, with bolt tightening torque of 180 ~ 210Nm; (See Figure 6-1-99)

Figure 6-1-99
M-27. Mount the wheel hub drain plug assembly, and O-ring 38×2.5, and mount the wheel hub oil filler
plug and O-ring 13.5×2; (See Figure 6-1-100)

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Chapter 6 Main parts
Section 1 Drive Axle

Figure 6-1-100
M-28. In the vehicle traveling direction, at the wheel hub support shaft air-bleed hole in the
perpendicular direction, mount the O-ring 13.5×2 and the release valve assembly; (See Figure 6-1-101)

Figure 6-1-101

M-29. Mount the ventilation valve assembly and O-rings 21×2; (See Figure 6-1-102)

Figure 6-1-102

M-30. Mount the axle package drain plug assembly, and O-ring 21×2, and mount the axle package oiling
plug, and O-ring 38×2.5; (See Figure 6-1-103)

Figure 6-1-103 (front axle)

M-31. Mount the axle package drain plug assembly, and O-ring 21×2, and mount the axle package oiling

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Chapter 6 Main parts
Section 1 Drive Axle
plug, and O-ring 38×2.5; (See Figure 6-1-104)

Figure 6-1-104 (rear axle)

(End of repair)

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Chapter 6 Main parts
Section 2 Priority Valve

Section 2 Priority Valve

Table of Contents
1. Structure and Functions ................................................................................................................... [107]
2. Dismounting and Installation ............................................................................................................ [107]
3. Disassembly and Repair .................................................................................................................. [109]

1. Structure and Functions

(I) Functions
The priority valve is intended to ensure adequate oil supply for steering system and cause surplus oil to
flow together to the hydraulic system.
(II) Working principle
When the flow amplifying and steering unit is at the neutral position, oil released from the priority valve is
transmitted to LS opening via throttle hole inside the flow amplifying and steering unit and acts on one
side of priority valve core. Meanwhile, its oil release also acts on another side (i.e., CF opening) via
control opening inside the priority valve core. The pressure at CF opening of priority valve is greater than
the pressure at LS opening and spring force. Under the pressure at CF opening, small amount of oil left
in the priority valve flows via CF opening to the flow amplifying and steering unit, and the remaining oil
supply for steering pump flows via EF opening to the hydraulic system of the work device. When the flow
amplifying and steering unit deviates from the neutral position, the pressure at LS opening rises and the
priority valve core moves toward PP opening under the influence of spring force.
As a result, oil released from EF opening decreases and oil released from CF opening increases, thus
meeting the steering requirement.

EF interface

P interface

LS interface

CF interface

2. Dismounting and Installation

Tools required:

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 Chapter 6 Main parts
Section 2 Priority Valve
①.16-18 open end wrench;

②.350N·m torque wrench;

③.1”, 2” monkey wrench.

(1) Location of priority valve on the product

Figure 6-02-1

Figure 6-02-2

①Priority valve is fitted on the left side of hinged panel on the rear frame (see Figure 6-02-1);

② It is fitted with two bolts M10×100 bolts and corresponding flat and elastic washers;

(2) Dismounting steps

①Before dismounting, flame out the engine without oil drain;

②Dismounting method 1 is dismounting the cab entirely according to cab dismounting requirement.
Method 2 is removing the left chassis from the cab inside the cab without dismounting the cab; taking
down connecting pipes of 5 joints as shown in Figure 6-02-2 and then dismounting the priority valve;

③Fluid oil will leak in the dismounting process and total oil leak does not exceed 1L; oil pans are readied
for use; protect oil ports and make reassembly marks;

④Remove two bolts M10×100 and flat & elastic washers;

(3) Inspection notes

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Chapter 6 Main parts
Section 2 Priority Valve
①Check if there is any foreign matter in the internal chamber of each oil port;

②Screw plugs and pressure regulating & fastening ends on valve body may not be loosened without
authorization; any adjustment shall be done by professionals only;
(4) Installation

①Pay attention to mounting directions. Oil returns port points to the inside of vehicle body; confluence
port points upward;

②Mount two bolts M10×100 and flat & elastic washers;

③Install the priority valve in place;

④Install connecting pipes of 5 joints as shown in Figure 6-3-2;

⑤Install the cab (method 1) or the left chassis in the cab (method 2) according to method 1 or method 2
adopted in the dismounting process.
NOTE:
(1) Check sealing elements in the pipeline during assembly. Replace any damaged sealing element with
new one and ensure cleanliness; pay attention to reassembly marks to avoid wrong connection;
(2) Locking torque shall meet the requirement of torque meter;

3. Disassembly and Repair

I. Disassembly
(1) Put the priority valve horizontally on the disassembly stand (see Figure 6-02-3);

Figure 6-02-3
(2) Screw off the transition joint (see Figure 6-02-4)

Figure 6-02-4
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Chapter 6 Main parts
Section 2 Priority Valve
(3) Screw off the pressure valve core (see Figure 6-02-5);

Figure 6-02-5
(4) Screw off the pressure valve core seat (see Figure 6-02-6);

Figure 6-02-6
(5) Take out the spring (see Figure 6-02-7);

Figure 6-02-7
(6) Turn the valve body by 180 degrees and take off pipe plug on the other end (see Figure 6-02-8);

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Chapter 6 Main parts
Section 2 Priority Valve

Figure 6-02-8
(7) Take out valve core (see Figure 6-02-9). After disassembly, parts are shown in Figure 6-02-10.

Figure 6-02-9

Figure 6-02-10
II. Repair
(1) Clean all parts with special cleaning fluid before putting them on the clean assembling stand in the
dust-free room; replace any worn or damaged part;
(2) Put valve core in the hole of valve body (see Figure 6-02-11);

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Chapter 6 Main parts
Section 2 Priority Valve

Figure 6-02-11
(3) Mount and tighten pipe plug (see Figure 6-02-12);

Figure 6-02-12
(4) Put in the spring from the hole on the other end (see Figure 6-02-13);

Figure 6-02-13

(5) Put the valve body vertically and screw in the pressure valve core seat (Figure 6-02-14);

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Chapter 6 Main parts
Section 2 Priority Valve

Figure 6-02-14
(6) Screw in the pressure valve core (see Figure 6-02-15);

Figure 6-02-15
(7) Mount the transition joint (see Figure 6-02-16)

Figure 6-02-16

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Chapter 6 Main parts
Section 3 Bucket Cylinder

Section 3 Bucket Cylinder

Table of Contents
1. Structure and Functions ................................................................................................................ [114]
2. Dismounting and Installation ......................................................................................................... [114]
3. Disassembly and Repair................................................................................................................ [115]

1. Structure and Functions

(I) Functions
As an actuating element of hydraulic system, bucket cylinder lifts and lowers the bucket by controlling oil
feed into small and big chambers of the cylinder.
(II) Working principle
The cylinder generally comprises cylinder barrel and piston rod, and the cylinder barrel has two oil inlets
with one connected to big chamber of the cylinder (i.e., non-rod chamber) and the other connected to
small chamber of the cylinder (i.e., rod end chamber). When oil is fed into big chamber of the cylinder,
the piston rod is pushed out; when oil is fed into small chamber of the cylinder, the piston rod is taken
back. Through the said actions, the action of the mechanical device is controlled.

2. Dismounting and Installation

Tools required:

①32 open end torque wrench (for assembling and disassembling rubber hoses);

②27 torque wrench (for assembling and disassembling hinge pin bolts);

③Lifting device with minimum load bearing of 1T.

The dismounting and installation of bucket cylinder are detailed below:

(1) Before dismounting the bucket cylinder, place the bucket on the ground and then drain off hydraulic
oil in the cylinder.
(2) Dismounting steps

①Remove two fixing bolts M20×40 and elastic washers for the hinge pins as shown in Figure 6-03-1
and Figure 6-03-2;

②Remove the joint between rubber hose and steel pipe of bucket cylinder, and oil drip pans are readied
to collect leaking oil during removal; protect oil ports with clean plastic bags and make reassembly
marks;

③Suspend the bucket cylinder using a lifting device with minimum load bearing of 1T, use a tool to force
out two hinge pins, and remove the bucket cylinder from the vehicle and transport it to the maintenance
site;

(3) Inspection notes

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Chapter 6 Main parts
Section 3 Bucket Cylinder
①Check if oil seal and cylinder rod are severely worn. If necessary, replace the oil seal or further
disassemble the cylinder for repair;
(4) Installation

①Hoist the cylinder above the lift arm and adjust its position. Mount the hinge pin linking the cylinder to
the moving arm before mounting the hinge pin linking the cylinder to the rocking arm;

②Install hinge pin fixing bolts M20×40 together with elastic washers;

③Join rubber hose of bucket cylinder to steel pipe and check the integrity of O ring (replacement of O
ring is recommended);

④Check sealing surfaces and sealing elements of the pipeline and ensure their cleanliness in the
mounting process;

⑤Mounting torque meets the requirement of torque meter.

Bucket cylinder

Figure 6-03-1

Bucket cylinder

Figure 6-03-2

3. Disassembly and Repair

I. Disassembly process
(1) Place the bucket cyclinder on the working table (see Figure 6-03-3).

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Chapter 6 Main parts
Section 3 Bucket Cylinder

Figure 6-03-3

(2) Take down 8 bolts of guide sleeve (see Figure 6-03-4).

Figure 6-03-4

(3) Draw out the guide sleeve (see Figure 6-03-5).

Figure 6-03-5

(4) Pull out the guide sleeve & piston rod assembly (see Figure 6-03-6).

Figure 6-03-6

(5) Remove the seal assembly on the piston (see Figure 6-03-7).

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Chapter 6 Main parts
Section 3 Bucket Cylinder

Figure 6-03-7

(6) Remove two fixing bolts and steel balls from the piston (see Figure 6-03-8).

Figure 6-03-8

(7) Remove the piston (see Figure 6-03-9).

Figure 6-03-9

(8) Remove the guide sleeve (see Figure 6-03-10).

Figure 6-03-10

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Chapter 6 Main parts
Section 3 Bucket Cylinder
(9) Remove the seal ring assembly from the guide sleeve (see Figure 6-03-11).

Figure 6-03-11

II. Repair process

(1) Clean all parts and check and replace damaged parts with new ones. For rubber sealing elements,
whether damaged or not, they shall be replaced with new ones after disassembly.
(2) Assemble the seal ring component on the guide sleeve (see Figure 6-03-12).

Figure 6-03-12

(3) Fit the guide sleeve on the piston rod (see Figure 6-03-13).

Figure 6-03-13

(4) Mount the piston (see Figure 6-03-14).

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Chapter 6 Main parts
Section 3 Bucket Cylinder

Figure 6-03-14

(5) Fit steel balls and two fixing bolts on the piston (see Figure 6-03-15).

Figure 6-03-15

(6) Fit the seal assembly on the piston (see Figure 6-03-16).

Figure 6-03-16

(7) Install the guide sleeve & piston rod assembly into the cylinder body (see Figure 6-03-17).

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Chapter 6 Main parts
Section 3 Bucket Cylinder

Figure 6-03-17

(8) Align the site of screw hole in the guide sleeve with the hole site in the cylinder body (see Figure
6-03-18).

Figure 6-03-18

(9) Fit 8 bolts on the guide sleeve (see Figure 6-03-19).

Figure 6-03-19

(10) Assembly completed (see Figure 6-03-20)

Figure 6-03-20

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Chapter 6 Main parts
Section 4 Steering Cylinder

Section 4 Steering Cylinder

Table of Contents
1. Structure and Functions ................................................................................................................ [121]
2. Dismounting and Installation ......................................................................................................... [121]
3. Disassembly and Repair................................................................................................................ [123]

1. Structure and Functions

(I) Functions
As a control element for hydraulic system, the steering cylinder realizes left and right turn of the vehicle
by controlling oil supply to big and small chambers of the cylinder.
(II) Working principle
The cylinder generally comprises cylinder barrel and piston rod, and the cylinder barrel has two oil inlets
with one connected to big chamber of the cylinder (i.e., non-rod chamber) and the other connected to
small chamber of the cylinder (i.e., rod end chamber). When oil is fed into big chamber of the cylinder,
the piston rod is pushed out; when oil is fed into small chamber of the cylinder, the piston rod is taken
back. Through the said actions, the action of the mechanical device is controlled.

2. Dismounting and Installation

Tools required:

①16-18 open end wrench;

②1”, 2” monkey wrench;

③27-30 open end wrench;

④350N·m torque wrench;

⑤1T crane and hoisting sling.

The dismounting and installation of steering cylinder is detailed below:

(1) Location of steering cylinder on the product

Steering cylinder
Figure 6-04-1
①This model has two symmetrical and non-interchangeable steering cylinders mounted on the left and

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Chapter 6 Main parts
Section 4 Steering Cylinder
right side of the linkage point respectively, which both connect the front and rear frames (see Figure
6-04-1);

②Each steering cylinder is fitted on the front and rear frames using two hinge pins.

(2) Dismounting steps

①Before dismounting, flame out the engine without oil drain;

②Dismantle the lines of left and right steering cylinders.

③Fluid oil will leak from the pipeline during dismounting, and oil drip pan is readied for use for oil leak
from the pipeline of each cylinder does not exceed 0.5L; protect oil ports and make reassembly marks;

④Remove hollow bolts M10×1.5×30 fixing the lubricating pipe for steering hinge pin of the front frame,
and each link bolt has 2 spacers;

⑤Use a special steel bar (DN: <40mm) to point at the lower end face of the hinge pin and the hole and
strike with a hand hammer to force the hinge pin out;

⑥Carry down the cylinder by two persons or remove the cylinder using 1T crane with hoisting sling;

(3)Inspection notes

①Check if there is any foreign matter in the internal chamber of each oil port;

②If necessary, commissioning, pressure measurement or disassembly of steering cylinder shall be

performed by designated personnel;

(4) Installation

①Pay attention to the mounting direction of left and right steering cylinders during installation, and pay
attention to the mounting direction of steel oil inlet & outlet pipes; pay attention to different methods of
oiling of 4 groups of hinge pin for steering cylinders;

②Confirm the integrity of shaft sleeves, knuckle bearings, sealing sockets and sealing elements inside
the cylinders and replace any damaged parts;

③Hoist the cylinders to the place between front and rear frames and align mounting holes according to
the requirement of symmetrical parts;

④After confirming that the hinge pin linking the front frame takes the form of hollow bolt and the hinge
pin linking the rear frame takes the form of oil cup and slightly lubricating hinge pin surface, mount the
hinge pins into shaft holes and drive them in through gentle strike; meanwhile align the pins;

⑤Install hollow bolts M10×1.5×30 fixing the lubricating pipe for steering hinge pin of the front frame, and
each link bolt has 2 spaces;
NOTE:

①Check sealing surfaces and elements in the pipeline during assembly, and ensure cleanliness;

②Mounting torque meets the requirement of torque meter.

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Chapter 6 Main parts
Section 4 Steering Cylinder

3. Disassembly and Repair

Due to high structural similarity between the steering cylinder and the lift arm cylinder, their
disassembling and repair processes are also similar. Please refer to the disassembling and repair
process of the lift arm cylinder. (See P91)

123
Chapter 6 Main parts
Section 5 Brake Valve and Energy Accumulator

Section 5 Brake Valve and Energy Accumulator

Table of Contents
1. Structure and Functions ................................................................................................................ [124]
2. Dismounting and Installation ......................................................................................................... [125]
3. Disassembly and Repair................................................................................................................ [125]
4. Disassembly and Repair of Accumulator....................................................................................... [129]

1. Structure and Functions

Figure 6-05-1

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Chapter 6 Main parts
Section 5 Brake Valve and Energy Accumulator
(I) Functionality
It serves as the control element of service brake which enables the whole vehicle to decelerate and stop.

(II) Working principle

When the brake pedal is stepped on, certain pressure is exerted on balancing spring via post rod and the
piston is forced to move down. As a result, the passage between air outlet and the air is closed, and the
air inlet valve is pushed open. Compressed air inflates the braking element via air outlet, thus effecting
the braking. When the brake pedal is released, the balancing spring pushes all valves back to original
position. Air inlet is closed, and the air outlet is connected to the exhaust opening. Compressed air is
discharged into the air through exhaust opening, thus releasing the braking.

2. Dismounting and Installation

Tools:
1. 22-24 open end wrench;
2. 5044 air blasting machine;
3. M8 sleeve.

I. Location of brake valve assembly on the product

The brake valve is fitted in the cab by fixing it on cab chassis with three M10×25 bolts. Foot pedal is on
cab chassis; other parts are below cab chassis;

II. Dismounting steps

①Before dismounting, step on the foot pedal several times to make sure all pressure is released. Check
and make sure the loader’s power switch is disconnected;

②Unscrew the connecting nuts of 6 flexible hoses and 2 electric wires connected to the air brake valve,
and separate 6 flexible hoses and 2 electric wires from the brake valve;

③Loosen the M8×25 bolts linking the air brake valve to cab chassis with the wrench, and take out the air
brake valve;

III. Installation

① Fix the air brake valve on cab chassis; join the dismounted 6 flexible hoses and 2 electric wires to
corresponding joints of the foot brake valve;

② Check sealing surface and sealing elements of pipes and ensure their cleanliness during the fitting
process.

3. Disassembly and Repair

Tools: a) Pincers;
b) Open end wrench;

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Chapter 6 Main parts
Section 5 Brake Valve and Energy Accumulator
c) Double offset ring spanner;
d) Socket wrench;
e) Circlip pliers.

Figure 6-05-2

Figure 6-05-3

(I) Dismantling process (see Figure 6-05-4)

1. Remove the safety cover (22) from the piston (21) and the valve body (13), not all models using the
safety cover (22);

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Chapter 6 Main parts
Section 5 Brake Valve and Energy Accumulator
2. Take out the piston (21), springs (18), (19) and (20), washer (17) and clip ring (16) from the valve body,
not all models using the spring (18);
Note: be sure to define the number of washers removed from the valve body.
3. Carefully take out CUP (15) and the seal (14) from the valve body (13).
Note: Do not scratch the interior of the valve;
4. Take out the end pipe plug (1) and the spring (3) from the valve body (8), and remove the O-ring (2)
from the pipe plug (1);
5. From the valve body (8), take out the pipe plug (6), and from the plugs (6), remove the O-ring (2), not
all models using plugs and O-rings;
6. Remove the end cover bolts (4) and washers (5), and separate the valve body (8) from the valve body
(13). From the valve bodies (8) and (13), take out the O-rings (10) and (11) respectively;
7. Carefully remove the spools (9) and (12) from the valve bodies (8) and (13) respectively;
Note:
1. Do not damage the spool and the valve body.
2. Do not confuse the spool with the valve body, and similar to the spool 12 and the valve body 13, the
spool 9 and valve body 8 are used for support.
3. The piston (21) must be retained mechanically. If the power source is connected to the tank port
wrongly, you can prevent it from being ejected at high speed. Ensure that the oil port is connected
properly, or it may cause injury or death.
4. The valve bodies (8 and 13) are used for support of the spools (9 and 12), and may not be exchanged
with other models.
(II). Repair process (see Figure 6-05-4)
With clean system oil, lubricate each of the rubber elements in the maintenance kit.
1. Thoroughly clean each element before installation;
2. Mount the O-rings (10) and (11) into the O-ring grooves of the valve bodies (8) and (13) respectively;
3. With clean system oil, lubricate the spool (12) and carefully slide it into the bottom of the valve body
(13) inside, paying attention to the guide of the spool (12);
Note: Be sure to have the spool to slide into the valve body freely, and if either one is damaged, it is
required to replace with a new spool or valve body;

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Chapter 6 Main parts
Section 5 Brake Valve and Energy Accumulator

Figure 6-05-4

4. With the end cover bolt (4) and washer (5), connect the valve bodies (8) and (13), put the thread
rubber 242 on the nut, and with 27.1-33.9Nm (22-25Ibs-ft) torque, tighten it.
Note: During installation, ensure that the two valve bodies are properly aligned and the o-ring is always
located in the O-ring groove;
5. On the pipe plug (6), install the new O-ring (7) and place it into the valve body (8), fixing it carefully.
Not all models use the pipe plug (6) and O-ring (7);
6. With clean system oil, lubricate the spool (9) and carefully slide it into the valve body (8). Note the
guide of the spool (9).
Note: Be sure to have the spool to slide into the valve body freely, and if either one is damaged, it is
required to replace with a new spool or valve body;
7. At the end pipe plug (1), install a new O-ring (2);
8. Mount the spring (3) and end pipe plug (1) into the valve body (8), and with a torque of 54.2-67.8Nm
(40-50Ibs-ft), tighten the pipe plug;
9. Carefully, mount CUP15 and a new seal ring (14) into the valve body (13), and note the guide of the
cup seals and seal rings;
Note: Great care shall be given to avoid scratching the valve body.
10. Mount the springs (18, 19 and 20), washer (17) and circilp (16) into the piston (21) in turn. Some
models do not use the spring (18);
11. Carefully mount the assembled piston (21) into the valve body (13);
12. Mount the new safety cover (22) onto the valve body (13) and the piston (21), and not all models use
the new safety cover;
13. With new hex head end cover screws (23), mount the pedal onto the valve body, its thread being
Class 8 of 5/16-18 accuracy. The torque is 24.4-29.8Nm (18-22Ibs-ft).

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Chapter 6 Main parts
Section 5 Brake Valve and Energy Accumulator

4. Disassembly and Repair of Accumulator

1. Pin; 2. Nut; 3. Washer; 4. Screw plug; 5. Washer; 6. Piston; 7. Nut; 8. Compression ring
9. O-ring; 10. Retainer ring; 11. Retainer ring; 12. Support ring; 13. Rubber ring; 14. Valve body
15. Spring; 16. Valve; 17. Casing; 18. Capsule; 19. O-ring; 20. Nut; 21. Nameplate; 22. Inflation valve;
23.Gasket; 24. Gasket; 25. Cap

(I) Disassembly process

1. Exhaust the oil and gas in the accumulator;
2. Unscrew the cap and nut on the accumulator inflation ends, remove the sign and the inflation valve;
3. Unscrew oil discharge screw plug on the valve body;
4 Unscrew the nut on the valve body;
5. Push the valve body into the accumulator casing;
6. Remove the compression ring, and take out the O-ring, iron retainer ring, and PTFE retainer ring;
7. Rotate and take out the support ring;
8. Remove the rubber ring and the valve body;
9. Pull out the capsule.

(II) Repair process

1. Clean the accumulator casing and parts thoroughly, and put the small O-ring into the seal groove of
the capsule;
2. Mount the capsule into the casing, and push the valve body into the casing;
3. Put the rubber ring and supporting ring in the valve body, and align the notches to pull out the valve
body;
4. Put in the iron ring, O-ring, and PTFE ring;
5. Mount the compression ring and the nut, then put a copper washer on the drain hole in the valve body,
and tighten the oil drain screw plug;
6. Mount the copper washer and inflation valve, tighten and inflate;
7. Mount the sign, nut, and cap at the inflation valve end.

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Chapter 6 Main parts
Section 6 Charging Valve

Section 6 Charging Valve

Table of Contents
1. Structure and Functions ................................................................................................................ [130]
2. Dismounting and Installation ......................................................................................................... [131]
3. Disassembly and Repair................................................................................................................ [132]

1. Structure and Functions

Figure 6-06-1

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Chapter 6 Main parts
Section 6 Charging Valve

(I) Functions
Service brake key elements are mainly designed to fill the accumulator with the high pressure oil
generated by the brake pump according to the pressure requirements of the system to ensure that the
brake system has enough oil pressure and diverts excess oil to other systems.

(II) Working principle

The oil from the pump enters the accumulator through the charging valve; when the pressure of any one
accumulator is lower than 11.3Mpa, the dual-way charging valve opens and charges the system; when
the pressure of the accumulator is higher than 13.8Mpa, the dual-way charging valve closes and stops
charging the system, the oil from the pump returning to the hydraulic system for cooling.

Figure 6-06-2
2. Dismounting and Installation
Tools:
1. 22-24 spanner;
2. 16-18 spanner;
3. 2-inch adjustable wrench.
I. Introduction to the position of the dual-way charging valve assembly on the product
The dual-way charging valve is assembled on the rear frame and with two bolts, fixed to the accumulator
support.
II. Dismounting steps

① Prior to dismounting, depress the brake pedal several times and make sure all the pressure has been
released;

② Release the 5 hoses connected to the dual-way charging valve;

③ With the wrench, loosen the two bolts fixing the dual-way charging valve to the accumulator support
to take out the dual-way charging valve.
III. Installation

① First, fix the dual-way charging valve to the accumulator support, screw on the bolts, and then
connect 5 hoses to corresponding connectors of the charging valve;

③ During assembly, note to check the pipe sealing surfaces and sealing elements to maintain clean.

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Chapter 6 Main parts
Section 6 Charging Valve

3. Disassembly and Repair

Tools:
a) Pliers; b) open-end wrench;
c) Box spanner; d) hex wrench;
e) Snap ring pliers.

(I) Dismounting process (see Figure 6-06-3)

1. From the charging valve body (14), remove the plug (8) and, from the plug, remove the O-ring (7);
Note: the plug has the spring to be in compressed state.
2. Take out the spring (5) and the mandrel (6) from the valve body;
3. Remove the plug (1) from the valve body and remove the O-ring (2) from the plug;
4. Take out the plug (3) from the plug (8) on the valve body, and can only take it out from here;
5. Loosen the nut (38), remove the pipe plug assembly (37) from the valve body and remove the O-ring
(36) from the pipe plug;
6. Remove the spring (35), poppet (34), valve core seat (33), O-ring (32), gasket (31), filter (30) and
gasket (29) from the valve body in turn;
7. Before removing the pipe plug (24), measure the depth from the pipe plug to the bottom of the body,
maintain the record for reference in the installation, and then remove the pipe plug from the valve body
(24);
8. Remove the spring (26), ball retainer (27) and ball (28) in turn, and note to separate the ball (28) from
the ball (19) to prevent confusion when installing again;
9. With a pin puller, pull out the pin (25) from the pipe plug (24);
10. Remove the pipe plug (23) from the valve body), and remove the O-ring (22) from the pipe plug;

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Chapter 6 Main parts
Section 6 Charging Valve

Figure 6-06-3

11. Remove the spring (21), mandrel (20) and ball (19) from the valve body in turn;
12. Put the valve body on the work bench with the oil port (23) downward, and at the moment the spool
may fall down;
13. With a wood stick or plastic stick in a diameter of 6.35~7.87mm or 0.25 "~ 0.31", pull out the bushing
(17) and spool (18) from the valve body, and the bushing (17) will fall from the port (23) at the lower end
of the valve body; be careful not to scratch the cushion on the bushing (17) ;
14. From the bushing (17), remove the spool (18) and then from the bushing, remove the O-rings (15)
and (16);
15. Remove the pipe plug (47) from the valve body, and remove the O-ring (46) from the pipe plug;
16. From the valve body, remove the spring (45), spool 44, sleeve 42, spool 40 and spring 39 in turn.
NOTE: Do not scratch the holes on the valve body and the sleeve;
17. Remove O-rings 41 and 43 from the sleeve 42.

(II) Repair process

Prior to installation, with clean solvent, clean and air each part of the system, and with clean system
hydraulic oil, lubricate each spare part in the maintenance kit to ensure that all parts are not
contaminated during installation.

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Chapter 6 Main parts
Section 6 Charging Valve
1. On the pipe plug (1), install a new O-ring (2) and mount a valve body oil port onto the pipe plug (1).
The torque is 54.2-67.8Nm (40-50Ibs);
2. On the spool, install a new seal 4, to ensure that the seal is not distorted in the groove;
3. Lubricate the SPOOL , and mount it in a correct position in the valve body;
4. Mount the spring 5 and spool 6 in the valve body;
5. On the pipe plug 8, replace with a new O-ring 7, and mount it in the valve body. The torque is
54.2-67.8Nm (40-50Ibs);
6. Mount the new O-rings 15 and 16 to the bushing 17 and mount the bushing in the valve body. Note the
installation direction. Insert a wood stick in diameter of 12.7mm (0.50 ") into the bushing cushion and
install it;
7. Mount the SPOOL into the bushing 17 and mount it in the valve body; pay attention to SPOOL
orientation, with the end of the long step against the end of the pipe plug 23;
8. Mount the ball 19 into bushing 17 and mount it into the valve body; put the stopper pin 20 on the
outside of ball 19, and put the spring 21 on the outside of the stopper pin 20;
9. On the pipe plug 23, replace with a new O-ring 22. Mount the pipe plug into the valve body carefully,
and place it in the center of the spring 21, with a torque of 54.2-67.8Nm (40-50Ibs);
10. Flip the valve body, and place it vertically with the oil port 1 upward.Mount a ball 28 in a diameter of
6.35mm (0.25 ") to ensure that it is in the center of the hole in the valve body. Put the ball retainer 27 and
the spring 26 into the valve body;
11. Mount the new pin 25 into the pipe plug 24. Make sure the pins are mounted into the pipe plug
properly without damaging the threads on the pipe plug;
12. According to the record depth prior to dismounting, re-tighten the pipe plug 24 to the valve body;
13. On the pipe plug assembly 37, install a new O-ring 36;
14. Mount the gasket 29, new filter 30, gasket 31, new O-ring 32, valve core seat 33, new spool 34,
spring 35 and pipe plug assembly 37 into the valve body. The torque of pipe plug assembly is
24.4-29.8Nm（18-22Ibs-ft）;

15. Tighten the nut 38 to the pipe plug assembly 37, with its torque of 34.4-51.5Nm (32-38Ibs-ft);
16. Replace with new O-rings 41 and 43 on the sleeve 42.
17. Mount the spring 39, new spool 40, bushing 42, new spool 44 and spring 45 into the valve body;
18. On the pipe plug 47, install a new O-ring 46, and tighten it to the valve body with torque of
54.2-67.8Nm (40-50bs).

(II) Valve adjustment

1. Re-install the valve correctly, and on the pipe of each accumulator, mount a precise pressure gauge.
2. Start the pump, in which case the charging valve is allowed to work after about a minute, (oil pressure
gauge shows the pre-inflation pressure of the accumulator).If the valve does not work, tighten the pipe
plug 24; when the pressure shown on the pressure gauge continues to rise, stop oil supply. View the
information about the upper limit of on the charging valve and then adjust the pipe plug 24 to have the
upper limit to be the viewed value. Only through adjustment of the screw 24 each time can the pressure
be set to an accurate position. When the accumulator pressure drops below the lower limit of the
charging valve, the charging valve will automatically charge the accumulator to its upper limit of

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Chapter 6 Main parts
Section 6 Charging Valve
pressure.

Note: After every adjustment, connect the oil tube of the accumulator properly to prevent leakage from
the oil port.

135
Chapter 6 Main parts
Section 7 Lift Arm Cylinder

Section 7 Lift Arm Cylinder

Table of Contents
1. Structure and Functions ................................................................................................................ [136]
2. Dismounting and Installation ......................................................................................................... [136]
3. Disassembly and Repair................................................................................................................ [138]

1. Structure and Functions

(I) Functions
As an actuating element of hydraulic system, lift arm cylinder lifts and lowers the lift arm by controlling oil
feed into small and big chambers of the cylinder.

(II) Working principle

The cylinder generally comprises cylinder barrel and piston rod, and the cylinder barrel has two oil inlets
with one connected to big chamber of the cylinder (i.e., non-rod chamber) and the other connected to
small chamber of the cylinder (i.e., rod end chamber). When oil is fed into big chamber of the cylinder,
the piston rod is pushed out; when oil is fed into small chamber of the cylinder, the piston rod is taken
back. Through the said actions, the action of the mechanical device is controlled.

2. Dismounting and Installation

(1) Location of lift arm cylinder on the product

Lift arm cylinder

Figure 6-07-1

①This vehicle has two lift arm cylinders (including left and right cylinders) fitted between the lift arm and
the front frame (shown in Figure 6-07-1); steel oil inlet & outlet pipes for external connection are
non-interchangeable symmetrical parts;

②Each lift arm cylinder is mounted between front frame and the lift arm using two hinge pins; each hinge
pin is provided with one fixing bolt M20×40 and elastic washer and flat washer;

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Chapter 6 Main parts
Section 7 Lift Arm Cylinder

(2) Dismounting steps

①Lift and put the lift arm on a special lift arm holder horizontally or at an appropriate angle, and then
release the oil pressure of the pipeline by operating the hydraulic control handle; consequently, fluid oil in
the cylinder and oil pipe flows back to the oil tank; alternatively, the lift arm may be hoisted using a ≥5T
crane. Shut down the vehicle.

②In case of oil leak during pipeline dismounting, oil drip pans and oil drums are ready for use; oil ports
are protected with reassembly mark;

③Remove the connection between steel oil inlet & outlet pipes and rubber oil inlet & outlet hoses for the
left lift arm cylinder before taking off two fixing bolts M20×40 and elastic and flat washers for hinge pins
of the cylinder linking the lift arm to the front frame.

④It is advisable to dismount the cylinder wholly before removing the steel oil inlet & outlet pipes on the
cylinder (if necessary);

⑤Avoid any bruise to oil nipple; in case of interference, remove the oil nipple before taking down the
hinge pin;

⑥Tie up the cylinder in the center using a hoisting sling with ≥200kg load bearing and suspend the
cylinder on the crane hook. Use a special steel bar (DN: <50mm) to point at the end face inside the hinge
pin and the hole and strike the steel bar from inside to outside with a hand hammer to force the hinge
pins out; and steady the cylinder and then hoist and remove the left cylinder; meanwhile arrange the
pipelines.

⑦Remove the right lift arm cylinder in the same manner.

(3) Inspection notes

①Check if there is any foreign matter in the internal chamber of each oil port;

②Whenever necessary, commissioning, pressure measurement or disassembly of cylinder components

shall be performed by designated personnel;

(4) Installation

①Pay attention to the mounting direction (front, back, left, right) direction of oil cylinder during installation,
and pay attention to the mounting direction of steel oil inlet & outlet pipes of the left and right cylinders;

②Confirm the integrity of shaft sleeves, knuckle bearings, sealing sockets and sealing elements inside
the cylinders and replace any damaged parts;

③Mount the lift arm cylinder in the sequence contrary to the dismoutning sequence and point at the pilot
hole of hinge pin by hoisting and moving the lift arm up and down with the use of a crane (≥5T) or
presetting the displacement of piston rod;

④After confirming the integrity of hinge pins and applying some lubricating oil to their surface, fit the
hinge pins into corresponding pilot holes;

⑤Install the oil nipple if it is removed in the dismounting process;

⑥Mount two fixing bolts M20×40 and elastic & flat washers of the hinge pin linking the cylinder to the lift
arm and front frame before joining steel oil inlet & outlet pipes (if previously removed) and rubber oil inlet

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Chapter 6 Main parts
Section 7 Lift Arm Cylinder
& outlet hoses for the left lift arm cylinder. Install the right lift arm cylinder in the same manner.

⑦Check sealing surfaces and elements in the pipeline during assembly, and ensure cleanliness;

⑧Mounting torque meets the requirement of torque meter;

(5) Dismounting tools

①Circlip pliers, flathead screwdriver and hex wrench;

②350N·m torque wrench;

(6)Keep dismounting record.

3. Disassembly and Repair

I. Disassembling process
(1) Place the lift arm cylinder on the workbench (see Figure 6-07-2).

Figure 6-07-2

(2) Dismantle front circlips with circlip pliers and take out circlips and retaining ring(see Figure 6-07-3).

Figure 6-07-3

(3) Draw out the guide sleeve (see Figure 6-07-4).

Figure 6-07-4

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Chapter 6 Main parts
Section 7 Lift Arm Cylinder
(4) Pull out the guide sleeve & piston rod assembly (see Figure 6-07-5).

Figure 6-07-5

(5) Remove the seal assembly on the piston (see Figure 6-07-6).

Figure 6-07-6

(6) Remove two fixing bolts and steel balls from the piston (see Figure 6-07-7).

Figure 6-07-7

(7) Remove the piston (see Figure 6-07-8).

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Chapter 6 Main parts
Section 7 Lift Arm Cylinder

Figure 6-07-8

(8) Remove the guide sleeve (see Figure 6-07-9).

Figure 6-07-9

(9) Remove the seal ring assembly from the guide sleeve (see Figure 6-07-10).

Figure 6-07-10

II. Repair process

(1) Clean all parts and check and replace damaged parts with new ones. For rubber sealing elements,
whether damaged or not, they shall be replaced with new ones after disassembly.
(2) Fit the seal ring assembly on the guide sleeve (see Figure 6-07-11).

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Chapter 6 Main parts
Section 7 Lift Arm Cylinder

Figure 6-07-11

(3) Fit the guide sleeve on the piston rod (see Figure 6-07-12).

Figure 6-07-12

(4) Mount the piston (see Figure 6-07-13).

Figure 6-07-13

(5) Fit steel balls and two fixing bolts on the piston (see Figure 6-07-14).

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Chapter 6 Main parts
Section 7 Lift Arm Cylinder
Figure 6-07-14

(4) Fit the seal assembly on the piston (see Figure 6-07-15).

Figure 6-07-15

(5) Install the guide sleeve & piston rod assembly into the cylinder body (see Figure 6-07-16).

Figure 6-07-16

(8) Mount guide sleeve kit into the cylinder (see Figure 6-07-17).

Figure 6-07-17

(9) Mount retaining ring and circlipscompnents into the cylinder (see Figure 6-07-18).

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Chapter 6 Main parts
Section 7 Lift Arm Cylinder

Figure 6-07-18

(10) Mount circlips with circlip pliers (see Figure 6-07-19).

Figure 6-07-19

(10) Assembly is completed (see Figure 6-07-20).

Figure 6-07-20

143
Chapter 6 Main parts
Section 8 Steering Gear

Section 8 Steering Gear

Table of Contents
1. Structure and Functions ................................................................................................................ [144]
2. Dismounting and Installation ......................................................................................................... [144]
3. Disassembly and Repair................................................................................................................ [146]

1. Structure and Functions

(I) Functions
As the control element for the vehicle’s steering system, the steering gear realizes the vehicle’s steering
function through the steering wheel.
(II) Working principle
The control/amplifying valve rotator, which comprises valve core, valve bush and valve body, plays the
double role of controlling oil flow direction and amplifying the flow quantity; the cycloidal pin wheel gear
pair, which comprises rotator and stator, plays the role of measuring motor and ensures that oil quantity
of the outlet is directly proportion to the turning angle of the steering wheel; release pin and the rotor of
connected shaft linking the control/amplifying valve rotator to the cycloidal pin wheel gear pair
constitutes the mechanical feedback link; retracting spring enables the valve core and valve bush of the
control/amplifying valve rotator to override the dead band and realize precise centering.

When the steering gear is at the neutral position, oil from the priority valve returns directly from the oil
return port to the oil tank. When the steering gear deviates from the neutral position with the turning of
the steering wheel, oil from the priority valve is divided into two routes: some oil (in small quantities)
flows to the cycloidal pin wheel gear pair via the control/amplifying valve rotator, thus pushing the rotator
to turn with the steering wheel. The rate of oil flow through the cycloidal pin wheel gear pair is
proportional to the speed of the steering wheel. The faster the steering wheel turns, the higher the rate of
oil flow through the cycloidal pin wheel gear pair is, and vice versa. Other oil directly flows to the steering
cylinder via the control/amplifying valve rotator, thus pushing the vehicle frame to steer. Flow rate is
controlled by the mechanical feedback link, which comprises release pin and the rotor of connected shaft
linking the control/amplifying valve rotator to the cycloidal pin wheel gear pair. In other words, the flow
rate is proportional to the speed of the steering wheel. The faster the steering wheel turns, the higher the
flow rate is and the quicker the steering is, and vice versa.

2. Dismounting and Installation

(1) Location of steering gear on the product

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Chapter 6 Main parts
Section 8 Steering Gear
Oil inlet, oil return,
Steering gear working oil pipe

Figure 6-08-1
Steering column

Fixing bolts for

steering gear

Figure 6-08-2

Oil inlet, oil return,

working oil pipe joint

Mounting hole

Spider shaft
sleeve

Figure 6-08-3
①Steering gear is mounted below cab chassis and joined to steering column inside the cab through pipe
saddle fitted on cab chassis (see Figure 6-08-1);

②Mount four bolts M10×85 and corresponding elastic washers;

(2) Dismounting steps

①Release the pressure before dismounting. Dismount the connecting pipelines of the 5 joints as shown
in Figure 6-08-1, and the pipeline with the smallest diameter is the feedback pipeline on the flank of the
steering gear;

②Oil leak is possible during dismounting and oil pans are readied for use; protect oil ports and make
reassembly marks;

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Chapter 6 Main parts
Section 8 Steering Gear
③The following operations are done inside the cab: remove the housing of the steering column before
taking down four M10×85 fasteners as shown in Figure 6-08-2; meanwhile, personnel outside the cab
are required to hold the steering gear to prevent the steering gear from being overturned or placed
upside down and stop the spider shaft sleeve from falling off (see Figure 6-08-3);
(3)Inspection notes

①Check if there is any foreign matter in internal chamber of each oil port;

②Screw plugs and pressure regulating & fastening ends of the steering gear may not be loosened
without authorization; any adjustment shall be performed by designated personnel only
(4) Installation

①Pay attention to the mounting direction of the steering gear during installation with 4 groups of oil ports
pointing to the rear side of vehicle body;

②Check if connecting paper gaskets are intact and make replacement if necessary;

③Check if the spider shaft sleeve is installed, and make sure that it is mounted in correspondence with
the flat side below the steering shaft;

④Mount four M10×85 bolts (with elastic washers) as shown in Figure 6-08-2;

⑤Mount the housing of steering column;

⑥The following operations are done outside the cab: install the connecting pipelines of the 5 joints as
shown in Figure 6-08-1, and the pipeline with the smallest diameter is the feedback pipeline on the flank
of the steering gear.
NOTE:

①In the mounting process, check the sealing surfaces and sealing elements of the pipeline and ensure
cleanliness;

② Mounting torque meets the requirement of torque meter.

Tools required:

①16-18 open end wrench;

②16-18 open end torque wrench;

③1”, 2” monkey wrench;

④27-30 open end wrench;

⑤350N·m torque wrench.

3. Disassembly and Repair

I. Disassembling process
(1) Put the steering gear on the workbench (see Figure 6-08-4);

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Chapter 6 Main parts
Section 8 Steering Gear

Figure 6-08-4
(2) Take off two bolts from joint seat (see Figure 6-08-5);

Figure 6-08-5
(3) Remove the joint seat (see Figure 6-08-6)

Figure 6-08-6
(4) Remove four seal rings from the joint seat (see Figure 6-08-7);

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Chapter 6 Main parts
Section 8 Steering Gear

Figure 6-08-7
(5) Remove external end plug, copper backing and internal end plug (see Figure 6-08-8);

Figure 6-08-8

(6) Remove end plug and copper backing on the other side (see Figure 6-08-9)

Figure 6-08-9
(7) Remove four bolts on the upper end cover (see Figure 6-08-10)

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Chapter 6 Main parts
Section 8 Steering Gear

Figure 6-08-10
(8) Remove the upper end cover (see Figure 6-08-11)

Figure 6-08-11
(9) Remove the joint inside the end cover linked to the steering rod (see Figure 6-08-12);

Figure 6-08-12
(10) Remove two seal rings on the upper end cover (see Figure 6-08-13)

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Chapter 6 Main parts
Section 8 Steering Gear

Figure 6-08-13
(11) Remove 7 bolts on the lower end cover (see Figure 6-08-14)

Figure 6-08-14

(12) Remove the lower end cover, seal ring and gear washer (see Figure 6-08-15)

Figure 6-08-15
(13)Remove gear ring and seal ring (see Figure 6-08-16);

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Chapter 6 Main parts
Section 8 Steering Gear

Figure 6-08-16
(14) Remove the gear wheel and push pipe inside the gear wheel (see Figure 6-08-17)

Figure 6-08-17
(15) Remove the seal ring assembly from the gear wheel (see Figure 6-08-18);

Figure 6-08-18
(16) Remove universal joint shaft, oil distribution disc and steel balls on the oil distribution disc (see
Figure 6-08-19);

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Chapter 6 Main parts
Section 8 Steering Gear

Figure 6-08-19
(17) Remove the seal ring (see Figure 6-08-20)

Figure 6-08-20

(18) Take small tubes out of the valve body (see Figure 6-08-21)

Figure 6-08-21
(19) Take the valve core assembly out of the valve body (see Figure 6-08-22)

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Chapter 6 Main parts
Section 8 Steering Gear

Figure 6-08-22
(20) Take down the seal ring assembly, axial bearing and its two spacers from valve core (see Figure
6-08-23);

Figure 6-08-23
(21) Remove the neutral-position spring assembly (6 pieces) (see Figure 6-08-24);

Figure 6-08-24
(22) Remove the cross bolt from valve core (see Figure 6-08-25)

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Chapter 6 Main parts
Section 8 Steering Gear

Figure 6-08-25
(23) Separate valve core from valve bush (see Figure 6-08-26)

Figure 6-08-26

II. Repair process

Clean all parts and check and replace damaged parts with new ones. For rubber sealing elements,
whether damaged or not, they shall be replaced with new ones after disassembly.
(1) Mount the valve core and valve bush (see Figure 6-08-27)

Figure 6-08-27
(2) Align the hole site of valve bush with the hole site of cross bolt on valve core, and insert the cross bolt
(see Figure 6-08-28);

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Chapter 6 Main parts
Section 8 Steering Gear

Figure 6-08-28
(3) Install the neutral-position spring assembly (see Figure 6-08-29)

Figure 6-08-29
(4) Install the seal ring assembly, axial bearing and its two spacers on valve core (see Figure 6-08-30)

Figure 6-08-30
(5) Install the valve core assembly into the valve body (see Figure 6-08-31)

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Chapter 6 Main parts
Section 8 Steering Gear

Figure 6-08-31
(6) Install small tubes into the valve body (see Figure 6-08-32)

Figure 6-08-32

(7) Mount the seal ring (see Figure 6-08-33)

Figure 6-08-33
(8) Install universal joint shaft, oil distribution disc and steel balls on the oil distribution disc (see Figure
6-08-34);

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Chapter 6 Main parts
Section 8 Steering Gear

Figure 6-08-34
(9) Install the seal ring assembly on the gear wheel (see Figure 6-08-35)

Figure 6-08-35
(10) Install the gear wheel and push pipe in the gear wheel (see Figure 6-08-36)

Figure 6-08-36
(11) Install the gear ring and seal ring (see Figure 6-08-37)

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Chapter 6 Main parts
Section 8 Steering Gear

Figure 6-08-37
(12) Install the lower end cover, seal ring and gear washer (see Figure 6-08-38)

Figure 6-08-38

(13) Install 7 bolts on the lower end cover (see Figure 6-08-39)

Figure 6-08-39
(14) Install 2 seal rings on the upper end cover (see Figure 6-08-40)

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Chapter 6 Main parts
Section 8 Steering Gear

Figure 6-08-40
(15) Install the joint linked to the steering rod (see Figure 6-08-41)

Figure 6-08-41

(16) Install the upper end cover (see Figure 6-08-42)

Figure 6-08-42
(17) Install 4 bolts on the upper end cover (see Figure 6-08-43)

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Chapter 6 Main parts
Section 8 Steering Gear

Figure 6-08-43
(18) Install end plug and copper backing on one side of joint seat (see Figure 6-08-44);

Figure 6-08-44

(19) Install external end plug, copper backing and internal end plug on the other side of joint seat (see
Figure 6-08-45)

Figure 6-08-45
(20) Install 4 seal rings on the joint seat (see Figure 6-08-46);

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Chapter 6 Main parts
Section 8 Steering Gear

Figure 6-08-46
(21) Install the joint seat (see Figure 6-08-47);

Figure 6-08-47

(22) Install 2 bolts on the joint seat (see Figure 6-08-48)

Figure 6-08-48

161
Chapter 6 Main parts
Section 8 Steering Gear

(23) The assembly is completed (see Figure 6-08-49).

Figure 6-08-49

162
Chapter 6 Main parts
Section 9 Working Hydraulic Oil Cooler

Section 9 Working Hydraulic Oil Cooler

Table of Contents
1. Structure and Functions ................................................................................................................ [163]
2. Testing and Adjustment ................................................................................................................. [163]
3. Dismounting and Installation ......................................................................................................... [164]

1. Structure and Functions

The working hydraulic cooler is mainly composed of the inlet and return pipes and the radiator
cores. The working hydraulic cooler is arranged in parallel with an intercooler and a water tank, and
through the heat convection of engine fan, cools the hydraulic oil. High temperature hydraulic oil flows in
the pipe, transfers heat to the cooling fins of a hydraulic oil cooler, and the heat is taken away via the air
flow, thus lowering the temperature of the hydraulic oil.

2. Testing and Adjustment

(I) Location of water tank and fan on the product

Water tank

Fan

Figure 6-09-1

(II) Layout plan of water tank and fan

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Chapter 6 Main parts
Section 9 Working Hydraulic Oil Cooler

Protective Water tank

hood

Fan
Figure 6-09-2

(III) If necessary, make the following adjustments to water tank and fan with reference to Figure 6-09-2:

①Hoist the engine to the rear frame and complete the assembly according to the section “Dismounting
and Installation”;

②Hoist the water tank to the rear frame according to the section “Dismounting and Installation” and
make sure that the bolt hole in water tank support plate is aligned with the bolt hole in water tank
supporting plate on vehicle frame;

③Adjust the position of water tank by moving it back and forth and make sure that approximately 1/3 of
each blade of fan is inside wind scooper;

④Tighten bolts on water tank support plate;

⑤Assemble fan protective hood with wind scooperwind scooper via protective hood bolts, and pay
attention to the spacing between protective hood and motor pulley.

(IV) Inspection notes

①About 1/3 of each fan blade is inside wind scooper;

②Protective hood and motor pulley do not interfere with each other.

(V) Dismounting tools

①Monkey wrench

3. Dismounting and Installation

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Chapter 6 Main parts
Section 9 Working Hydraulic Oil Cooler

Hydraulic oil cooler

(I) Dismounting

① Get ready oil drip pans. Loosen link bolts joined to torque converter’s hose and bleed off some of
hydraulic oil. (do well in oil collection and hose protection for fear of pollution);

②Dismount the fixing bolts of the heat radiator on the frame and their connecting accessories and take
down the heat radiator;

③Remove the bolts between the support and core body of heat radiator.

(II) Inspection notes

If oil taking rubber hose leaks, check whether threads and sealing gasket are damaged.

(III) Installation

①Install the bolts between the support and core body of heat radiator;

②Place heat radiator on the frame and install the fixing bolts of heat radiator on the frame;

④ Install the hinge bolts of rubber hose;

⑤ Determine the parts to be disassembled based on actual needs. During dismounting, pay attention
to the rearrangement of components and keep them clean;

(IV) Dismounting tools

①32 open end torque wrench;

②Slotted screwdriver.

165
Chapter 6 Main parts
Section 10 Air Conditioning System

Section 10 Air Conditioning System

Table of Contents
1. Structure and Functions ..................................................................................................................... [166]
2. Testing and Adjustment ..................................................................................................................... [167]
3. Dismounting and Installation .............................................................................................................. [170]

1. Structure and Functions

(I) Structure of air conditioning system assembly
(1) Compressor

Figure 6-10-1

(2) Condenser

Wind direction

Wind direction

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Chapter 6 Main parts
Section 10 Air Conditioning System
Figure 6-10-2

(3) Evaporator

Figure 6-10-3
(II) Working principle
(1) Refrigeration
Low temperature and low pressure refrigerator gas is inhaled and compressed by the compressor into
high temperature high pressure gas, which then enters into the condenser via pipeline and is condensed
into high temperature high pressure liquid. After drying and filtration within the receiver dryer and
throttling and pressure reduction through throttling element (expansion valve), the said liquid becomes
low temperature low pressure liquid before flowing into the evaporator. After absorbing heat from the air
in the cab, the foregoing liquid evaporates into gas, which is sucked in by the compressor to enter the
next working cycle. With the repetition of such operations, the evaporator continuously absorbs heat
from air in the cab, thus achieving the refrigeration and cooling effect.
(2) Heating
The high and low pressure end of circulating cooling water of the engine are joined to inlet and outlet
hose of the radiator respectively. Whenever heating is required, open the hot water valve and turn on the
air rate switch of the air conditioning system. Circulating water from the engine is continuously circulated
via the radiator to heat the air flowing through the radiator. The fan continually offers hot air to heat the
cab.

2. Testing and Adjustment

(1) Locations of air conditioning components on the product

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Chapter 6 Main parts
Section 10 Air Conditioning System

Figure 6-10-4

Figure 6-10-5
(2) Schematic diagram of air conditioning system

Condenser
assembly
Receiver dryer

Compressor
Complete machine Engine

Figure 6-10-6
(3) Look at Figure 6-10-6 to learn about the location of each part of air conditioning system on complete
machine
a. The air conditioning system comprises compressor, evaporator assembly, condenser assembly,
receiver dryer, throttling element, refrigeration hose, etc. The compressor is driven by vehicle engine via
belt. It is powered by the vehicle’s power supply system. Panel switch controls the temperature and air

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Chapter 6 Main parts
Section 10 Air Conditioning System
rate of the air conditioning system. First of all, install the air conditioning system according to the
installation process described in the section “Dismounting and Installation of air conditioning system” of
this Manual;
b. Examine the air tightness of all air conditioning pipes and the reliability of power connection;
vacuumize the air conditioning system in the following steps;

①Connect low and high pressure joints between vacuum machine and the compressor;

②Connect the vacuum pump to power receptacle;

③Turn on the switch of vacuum pump to draw off the air from the air conditioning system (working time:
approx. 5 minutes);

④After vacuumization, remove the pipe joining the vacuum pump to the compressor and then turn off
the vacuum pump;
c. Put the control handle at neutral position, apply the hand brake, and turn off the switch of water pipe
from the engine to the air conditioning system;
d. Add refrigerant to the air conditioning system:

① Turn on complete machine, turn on the air conditioning system, and turn the switch to the maximum
position (turn the refrigeration knob also to the maximum position);

②Join the mouth of refrigerant bottle to the Freon filling machine;

③Connect the high pressure pipe of the Freon filling machine to the high pressure joint on the
compressor, and exhaust the air from the filling machine through air vents below the high-pressure and
low-pressure gauges on the Freon filling machine; then turn on the switch of high pressure joint to add
refrigerant to the air conditioning system and remove the high pressure pipe joint until flowing refrigerant
is not found through the sight hole of the filling machine;

④Connect the low pressure pipe of the Freon filling machine to the low pressure joint on the compressor,
and exhaust the air from the filling machine through air vents below the high-pressure and low-pressure
gauges on the Freon filling machine; then turn on the switch of low pressure joint to add refrigerant to the
air conditioning system and remove the high pressure pipe joint until flowing refrigerant is not found
through the sight hole of the filling machine; then start the engine to continue adding refrigerant to the air
conditioning system, and the amount of such addition is generally 950--1200ml(the amount of refrigerant
now used by our company is 300ml/bottle, so the amount of addition is approx. 3~4 bottle). The amount
of actual addition depends on the specification of air conditioner manufacturer.

⑤After the foregoing addition, check and verify the operation of all subsystems of the air conditioner
before flameout.
(4) Working principle of air conditioning system
Low temperature and low pressure refrigerator gas is inhaled and compressed by the compressor into
high temperature high pressure gas, which then enters into the condenser via pipeline and is condensed
into high temperature high pressure liquid. After drying and filtration within the receiver dryer and
throttling and pressure reduction through throttling element (expansion valve), the said liquid becomes
low temperature low pressure liquid before flowing into the evaporator. After absorbing heat from the air
in the cab, the foregoing liquid evaporates into gas, which is sucked in by the compressor to enter the
next working cycle.
(5) Maintenance requirement
a. Before adding refrigerant, it is necessary to vacuumize and check the quantity of refrigerating oil in the

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Section 10 Air Conditioning System
compressor; check the tightness of belt; check the fastening of fixing bolts;
b. After adding refrigerant, observe through sight glass of liquid receiver and make sure there is no air
bubble; check the air tightness of all pipes in the air conditioning system;
c. Check the fastening of all electrical connectors and the operation of air conditioning system;
(6) Dismounting tools
a. Slotted screwdriver
b. Binding tape
c. Diagonal pliers
d. 13-15 box wrench
e. 16-18 open end wrench
f. 19-22 open end wrench
g. 22-24 open end wrench
h. 27-30 open end wrench

Caution

Adding refrigerant through high pressure joint after vehicle operation is strictly prohibited (for fear of
personal injury resulting from potential explosion of refrigerant bottle)!

3. Dismounting and Installation

Dismounting tools required:

① 13 open end wrench (for assembling/disassembling seat, machine cover plate and condenser);

② 16, 18 open end wrench (for assembling/disassembling compressor and compressor bracket).
Dismounting and installation steps of air conditioning system:

Figure 6-10-7

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Chapter 6 Main parts
Section 10 Air Conditioning System

Figure 6-10-8

Figure 6-10-9

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Chapter 6 Main parts
Section 10 Air Conditioning System

Figure 6-10-10

Figure 6-10-11

Figure 6-10-12
(1) Dismounting

①Remove 4 groups of rubber nails, bolts M8×25 and nuts M8 under the seat with reference to Figure
6-10-7 and Figure 6-10-8;

②Remove air conditioning assembly (see Figure 6-10-9), take out connecting pipe (see Figure 6-10-10)

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Chapter 6 Main parts
Section 10 Air Conditioning System
and then remove the condenser (see Figure 6-10-11);

③As shown in Figure 6-10-12, loosen nuts on tension device, remove the belt before taking off wire
harnesses and pipes on air compressor (remember to make reassembly marks). Take off fixing bolts and
nuts from compressor and compressor bracket and then remove the compressor;
(2) Installation

①Compressor installation: do the pretension of fixing bolts and nuts on compressor and compressor
bracket, and then mount the belt and adjust the tension device properly before tightening bolts and nuts.
Finally connect wire harnesses and pipes;

②Condenser installation: fix the condenser in original position, connect wires and pipes and finally
mount the machine cover plate and tighten bolts;

③Evaporator installation: fix the evaporator on cab chassis, connect the pipes and restore the seat to
the position before dismounting and mount rubber nails;

④Determine the parts to be disassembled based on actual needs. During dismounting, pay attention to
the rearrangement of components and keep them clean;
(3) Inspection notes
①Check the integrity of exhaust units of the evaporator and condenser, regularly add refrigerant and
check if compressor runs properly.

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Section 11 Torque Converter

Section 11 Torque Converter

Table of Contents
1. Structure and Functions ..................................................................................................................... [174]
2. Testing and Adjustment ..................................................................................................................... [175]
3. Dismounting and Installation .............................................................................................................. [175]
4. Disassembly and Repair .................................................................................................................... [175]

1. Structure and Functions

A torque converter, connected to a diesel engine, can automatically adjust the output torque and rotating
speed so that the loader can, according to the road conditions and the resistance, automatically change
the speed and traction to adapt to changing conditions. After a gear is shifted, it can achieve stepless
speed change from start-up to the maximum speed, and start smoothly, with good acceleration
performance. In case of a slope or sudden obstacles on the road, without gear shifting, it can
automatically slow down, increase traction, run at arbitrarily small speed and get across the
obstacles. After external resistance becomes less, it can quickly and automatically increase its speed to
improve operational efficiency. When skimming materials, it is able to cut in a pile of materials at a
greater speed, decelerate automatically as the resistance increases, and improve wheel traction to
ensure cutting-in.

Torque converter

Figure 6-11-01
The torque converter consists of four working impellers: pump impeller, first-stage turbine, second-stage

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turbine and stator, with its working chamber filled with working oil. The pump impeller is designed to
convert mechanical energy from the engine to kinetic energy of liquid. Driven by the engine, it rotates at
the same speed and forces the oil in the cavity to impact the turbines at a great speed and pressure. The
two turbines absorb the kinetic energy of liquid and restore it to mechanical energy, and by means of
n1 and n2 rotations, transmit the momentum to a large overrunning clutch via a gear; the stator is fixed,
and when impacting a stator blade, liquid flow gives it the torque. Because of not moving, the stator is
made to generate a countertorque of the equal size in the opposite direction and to reflect it to the
turbine via liquid in order to change the torque value from the turbine. The blades of the four working
wheels have a certain shape and inlet and outlet angle so that the liquid goes in and out of each low out
of each impeller according to specified channel and direction.
However, because the rotating speed of the pump impeller becomes high or low due to the throttle
control, the rotating speed of the turbine increases or decreases or even fails to rotate (e.g. working
condition of starting or braking, the wheel does not move) depending on the speed imposed on the
output shaft by the external load (through the bridge and gearbox feedback) so that the speed and
pressure of liquid flowing into each wheel and angle of attack are changing constantly, and the moment
from the pump impeller and the moment of stator also change. The turbine output torque becomes large
when the pump impeller moment obtained by the turbine through liquid is in forward direction and
becomes small when it is in reverse direction.
The torque converter pump impeller and the cover wheel are integrated with a diesel engine flywheel
through a flexible disc, and rotate at the same speed as the diesel engine. The power of the diesel
engine is transmitted to the pump impeller, and then passed to a first-stage turbine and a second-stage
turbine through oil. The power of torque converter second-stage turbine is transmitted to the output shaft
via an input second-stage gear, the power of torque converter first-stage turbine is transmitted to the
input first-stage gear and then to an outer ring gear of a large overrunning clutch. When the external load
is small, the large overrunning clutch roller is relaxed because the gearbox middle input shaft has a
higher speed than the outer ring gear of large overrunning clutch, the outer ring gear of large
overrunning clutch idles and at the moment, the second-stage turbine works alone. When the outer load
increases, the gearbox middle input shaft is forced to reduce gradually; when the speed of the gearbox
middle input shaft is less than that of outer ring gear of a large overrunning clutch, the roller is clamped,
the power from the first-stage turbine is transmitted to the large overrunning cam, and the cam is bolted
to the middle input shaft, the first-stage turbine and second-stage turbine work simultaneously.

2 Testing and Adjustment

The torque converter and the gearbox are mounted to the machine as a whole, and thus, the details of
“Testing and adjustment” of mounted torque converter will be jointly discussed in the “Testing and
adjustment” of gearbox.
Please refer to the page of “Testing and adjustment of gearbox”.

3 Dismounting and Installation

When installed to and dismounted from the machine, the torque converter and the gearbox are an
integral body, and thus, the content of “Dismounting and Installation” of torque converter has been
consolidated to the descriptive page of gearbox.
Please refer to the page of “Dismounting and Installation of Gearbox”.

4 Disassembly and Repair

The following is the list of required tools, supplies and equipment:

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Chapter 6 Main parts
Section 11 Torque Converter
(1) Hex wrench;
(2) Socket wrench;
(3) Pneumatic wrench;
(4) Inside and outside snap ring pliers;
(5) Puller;
(6) Pry bar
(7) Hammer;
(8) Iron rod (diameter of 8 mm, length of 150 mm);
(9) Container, brush and cleaning fluid for cleaning parts;
(10) Copper rod (diameter of 10 mm, length of 400 mm);
(11) Grease.

Repair of torque converter

In the following operations, use of cotton gloves is prohibited.

A. Repair of torque converter movement assembly
1. Check the parts for any fins, burrs, scratches, pumps, rust marks and appearance defects.
2. Mount a plug into O-rings φ 25×3 (see Figure 6-11-02 a and Figure 6-11-02b)

Figure 6-11-02 a

Figure 6-11-02 b

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Chapter 6 Main parts
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3. Apply grease to the plug component and mount it into the torque converter movement; during
mounting, the retainer ring groove position shall be exposed. (See Figure 6-11-03)

Figure 6-11-03

4. Mount the retainer ring 30. (See Figure 6-11-04)

Figure 6-11-04

5. By aligning with the bolt holes, mount 2 elastic plates. (See Figure 6-11-05)

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Chapter 6 Main parts
Section 11 Torque Converter

Figure 6-11-05

6. By aligning with the bolt hole, mount the washer. (See Figure 6-11-06)

Figure 6-11-06

7. Mount 12-M12×30-10.9, coat the first 2-3 threads of bolt M12×30 with 262 thread tightening glue, and
screw the bolt into 2-3 threads manually. With a jackhammer, in the order as shown in the attached
drawing, lock by 80%, and then with a forcing wrench, apply the force completely in the order as shown
in (Figure 6-11-07). The bolt is M12-10.9, and tightening torque is 126 N.m. After tightening a bolt, mark
it with a paint pen. (See Figure 6-11-07)

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Chapter 6 Main parts
Section 11 Torque Converter

Figure 6-11-06

Figure 6-11-07

8. Mount 12-M12×18-10.9, coat the first 2-3 threads of bolt M12×18 with 262 thread tightening glue, and
screw the bolt into 2-3 threads manually. With a jackhammer, in the diagonal order, lock by 80%, and
then with a forcing wrench, apply the force completely in the diagonal order. The bolt is M12-10.9, and
tightening torque is 126 N.m. After tightening a bolt, mark it with a paint pen. (See Figure 6-11-08)

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Chapter 6 Main parts
Section 11 Torque Converter

Figure 6-11-08

9. Mount the sealing ring YH×70. (See Figure 6-11-09)

Figure 6-11-09

B. Repair of torque converter movement assembly

1. Check the parts for any fins, burrs, scratches, pumps, rust marks and appearance defects.
2. Mount the access plate, during such mounting align with the bolt hole position, insert the bolt
4-M10×20 together with a washer into the bolt hole, and screw the bolt into 2-3 threads manually. With a
jackhammer, in the diagonal order, lock by 80%, and then with a forcing wrench, apply the force
completely in the diagonal order. The bolt is M10-8.8, and tightening torque is 55N.m. After tightening a
bolt, mark it with a paint pen. (See Figure 6-17-10)

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Chapter 6 Main parts
Section 11 Torque Converter

Figure 6-17-10

3. Mount the cover plate, during such mounting align with the bolt hole position, insert the bolt 4-M10×20
together with a washer into the bolt hole, and screw the bolt into 2-3 threads manually. With a
jackhammer, in the diagonal order, lock by 80%, and then with a forcing wrench, apply the force
completely in the diagonal order. The bolt is M10-8.8, and tightening torque is 55N.m. After tightening a
bolt, mark it with a paint pen. (See Figure 6-17-11)

Figure 6-17-11

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Section 12 Gearbox

Section 12 Gearbox

Table of Contents
1. Structure and Functions ..................................................................................................................... [182]
2. Testing and Adjustment ..................................................................................................................... [186]
3. Dismounting and Installation .............................................................................................................. [187]
4. Disassembly and Repair .................................................................................................................... [194]

1. Structure and Functions

The gearbox is composed of box, overrunning clutch, planet shift gear, friction plate clutch, cylinder
piston, variable speed pump, variable speed control valve, oil filter, shaft and gear and other
components.

Figure 6-12-01a

Figure 6-12-01b

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Chapter 6 Main parts
Section 12 Gearbox

Forward gear I

Figure 6-12-01c

Forward gear II

Figure 6-12-01d

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Chapter 6 Main parts
Section 12 Gearbox

Forward gear III

Figure 6-12-01e

Forward gear IV

Figure 6-12-01f

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Chapter 6 Main parts
Section 12 Gearbox
Reverse gear I

Figure 6-12-01g

Reverse gear II

Figure 6-12-01h

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Chapter 6 Main parts
Section 12 Gearbox
Reverse gear III

Figure 6-12-01i

2. Testing and Adjustment

Because the torque converter and gearbox are mounted to the machine as a whole, the content of
gearbox “Testing and adjustment” described in this chapter has contained the content of the torque
converter.

①During operation, check the connection of each oil line for closeness every day, and if oil leakage is
found, repair it in time.

②The arrow shown above is a sight glass for torque converter. During shutdown, you can open the sight
glass cover to check inside condition or looseness of the fasteners, without allowing the ingress of any
foreign matter into the machine. The machine cannot be started until the sight glass cover and gaskets
are replaced and there is no abnormal condition.

③ Before starting the engine, adjust the working oil level of the torque converter and the gearbox.
Check the two drain plugs on the right of the gearbox, with the upper plug representing the maximum oil
level and the lower plug representing the minimum oil level. Under normal conditions, oil should be
between the upper and lower oil levels. If oil is too much, some oil shall be released from the oil pan of
the gearbox, if too little, some oil shall be added from the oil filler of gearbox.
④ Monitoring and adjustment of the working oil pressure of the torque converter and gearbox The
pressure at the inlet and outlet of monitoring and adjusting torque converter has been adjusted in the
manufacturer; for the working oil pressure of the gearbox, after operation of the engine, the pressure
meter shall point the range of 1.2~1.5MPa, and in case of abnormal condition, inspection shall be
conducted.

⑤ Adjustment of working oil temperature of torque converter and gearbox The maximum oil
temperature for general tasks and driving must not exceed 120℃, and if this figure is exceeded, the
machine shall be stopped for cooling and inspection. After the gearbox passes the breaking-in period, oil
replacement shall be made generally after 600 hours; however, if oil is deteriorated or mixed with
impurity, it shall be cleaned, checked and replaced with new oil of required grade.

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Chapter 6 Main parts
Section 12 Gearbox

Sight glass

Cooler to torque
convertor rubber
pipe

Torque convertor
to cooler rubber
pipe

Figure 6-12-02

3. Dismounting and Installation

Because the torque converter and gearbox are mounted to the machine as a whole, the content of
dismounting and installation of gearbox described in this chapter has contained the torque converter.
The details for dismounting and installation of the gearbox (including a torque converter) are stated as
follows:
1) Introduction to the position of the gearbox-torque converter assembly

Gearbox-torque
converter assembly

Figure 6-12-03

As shown in Figure 6-12-03, the gearbox-torque converter assembly is connected to the front and rear
drive axles through the front and rear transmission shafttransmission shafts; by means of internal and
external hinges, the torque converter is connected to the diesel engine.
2) Dismounting steps
(1) Dismount the cab in the following steps:

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-04

Figure 6-12-05 (Seel the form in P.122 for details)

Figure 6-12-06
a) With a traveling crane and slings, hang on the cab, pull straight the rope but not forcefully (See
Figure 6-12-04);
b) Dismount the nylon self-locking nut, pin and washer (serial numbers 5, 6 and 7 in
Figure 6-12-05);
c) Lift the cab, and put it in a safe place;
d) Dismount the shock pad component (see Figure 6-12-06);

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Chapter 6 Main parts
Section 12 Gearbox

Caution
Tips for lifting safety:

①When lifting the cab, the sling must be suspended on a reasonable position to avoid overturn;

②Lift it evenly and notice whether any person around is within the safety range.

(2) Dismantle the gearbox-torque converter assembly in the following steps:

Figure 6-12-07
a. As shown in Figure 6-12-07, with a wrench, dismount the Φ8 enlarged flat washers and spring
washers connecting the oil filler assembly support to the frame.

Figure 6-12-08
b. As shown in 6-12-08, with a wrench, dismount the rubber tube and oil tank steel pipe connecting the
working pump to the steering pump (Note: Before dismounting, please open the drain plug at the bottom
of the gearbox, exhaust the transmission oil, then loosen the steel pipe and rubber tube joints to be
dismounted, put cotton cloth around the joint to be dismounted, tap steel pipe and rubber tube joints to
be dismounted, release the pressure completely, and then take down the steel pipe or rubber tube).

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Chapter 6 Main parts
Section 12 Gearbox

Oil filter

Figure 6-12-09
c. As shown in 6-12-09, with a wrench, dismount the rubber tubes on the torque converter connecting to
the oil filter and diesel engine water tank.

Bolt M16×140

Figure 6-12-10

d. With jackhammers and supporting sleeves, dismount two M18×140 bolts, nuts and washers (Φ18
enlarged flat washers and arc-shaped washers) connecting the gearbox to the gearbox supporting seat
on the rear frame.

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 Chapter 6 Main parts
Section 12 Gearbox
Gearbox

Middle transmission shaft

Rear transmission shaft

Bolt M12 × 1.5 × 45
Spring washer 12 Bolt M14 × 1.5 × 45, M14×1.5
self-locking nut

Figure 6-12-11
e. As shown in 6-12-11, with jackhammers and supporting sleeves, dismount eight M12×1.5×55 bolts and
Φ12 spring washers connecting the gearbox to the middle transmission shaft; with jackhammers and
supporting sleeves, dismount eight M14×1.5×55bolts and M14×1.5 self-locking nuts connecting the
gearbox to the rear transmission shaft;

Internal hinge M10 studs, M10 External hinge M12 x 45 bolts,

x 1 nuts, spring washers and spring washers

Figure 6-12-12

f. With a wrench, dismount the twelve M10 × 1 nuts for the internal hinges of the torque converter and
the engine; with a wrench, dismount M12 × 45 bolts, nuts and spring washers for the external hinges of
the torque converter and the engine. (See Figure 6-12-12)
g. With special slings, lift the gearbox-torque converter assembly to a designated bracket.
Requirements for commissioning
Any commissioning required shall be treated by designated personnel;

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Chapter 6 Main parts
Section 12 Gearbox
Installation
(1) Install the gearbox-torque converter assembly in the following sequence:
a. First, with special slings, lift the gearbox onto the frame;
b. Connect properly the internal and external hinges of the gearbox-torque converter assembly;
c. Assemble the bolts and nuts for connecting the front and rear transmission shafts to the gearbox;
d. With bolts, fix the gearbox-torque converter assembly to the gearbox support.
Note: During assembly, keep clean;
(2) Install the cab in the following order:
a. Before lifting, check the interior parts of the cab assembly for completeness;
b. Pre-install the base plate and shock pad. Assemble the shock pad component (upper component) to
the cab supporting seat, and align the hole positions, as shown in Figure 6-12-13;

Figure 6-12-13

c. As shown in Figure 6-12-14, with special slings and a traveling crane, at a uniform speed, lift the cab
to the top of the frame, slowly adjust the height in relation to the frame, put the washers (SN. 4, 8 pcs)
and the lower component of the rubber pad on the position as shown in Figure 6-12-15, finally lower the
cab to the cab supporting seat, align the holes, and connect them with a pin (SN. 7).

Figure 6-12-14

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-15
d. Spare parts used for installation of the cab

S/N. Name of material Material code Quantity of material Remark

1 Cab system 1
30812900004

2 Base plate 30812101013 4

3 Rubber pad 30812000118 4

4 Washer 30812101413 8

5 Washer 30812101012 4

6 Nylon self-locking nut 4

51342000819
M18×1.5

7 Pin 30890100864 4

Used equipment and tools

① 10-ton traveling crane, 1;

② Special lifting tools;

③ Bracket;

④ 5044 jackhammer;

⑤ 12 sleeve;

⑥ 1”, 2” adjustable wrenches;

⑦ 16” open-end wrench, 18” open-end wrench.

Caution

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Chapter 6 Main parts
Section 12 Gearbox
Safety prompt for lifting:
(1) During lifting, the sling must be hung on a reasonable position to avoid overturn;
(2) Lift it evenly and notice whether any person around is within the safety range.

4. Disassembly and Repair

The list of tools, supplies and equipment:
(1) Wrench
(2) Impact wrench
(3) Hammer
(4)Copper rod
(5)Pliers
(6) Socket wrench
(7)Puller
(8)Snap ring pliers
(9)Jackscrew
(10) Slings
(11)Special gripper
(12)Ring spanner
(13)Screwdriver
(14) Lifting bolts and iron wire
(15) Hex socket
(16) Special tool
(17) Gauge block
(18) Front and rear output shaft jackets
(19) Mounting bracket for gearbox assembly
(20) Lifting screw
(21)Dial indicator
(22) Scraper

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Chapter 6 Main parts
Section 12 Gearbox

I. Gearbox repair
In the following operations, use of cotton gloves is prohibited.
A. Repair of working pump assembly
A-1. Check the housing, working pump gear and spline shaft for any fins, burrs, scratches, pumps, rust
marks and appearance defects. All parts must be clean (except bearings and retainer rings).
A-2. Mount the retainer ring into the lower retainer ring groove of the housing. (See Figure 6-12-16)

Figure 6-12-16

A-3.With a special tool, tap the needle bearing HK4516 until the upper retainer ring groove is
exposed. (See Figure 6-12-17)

Figure 6-12-17

A-4. Mount the inner retainer ring into the retainer ring groove on the housing. (See Figure 6-12-18)

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-18

A-5. Mount the working pump gear, and have the lower step of inner spline of gear toward the bearing
HK4516. (See Figure 6-12-19)

Figure 6-12-19

A-6. Mount the spline shaft into the working pump gear. (See Figure 6-12-20)

Figure 6-12-20

A-7.As shown in the figure, put the outer retainer ring over the spline shaft. (See Figure 6-12-21)

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-20

A-8. With a special tool, mount the outer retainer ring into the spline shaft retainer ring groove. (See
Figure 6-12-21)

Figure 6-12-21

A-9. Mount two snap rings 85/91.6 (one of which is supplied with the bearing) into the housing retainer
ring groove, and ensure that both of the snap ring openings are in the housing notch. (See Figure
6-12-22)

Figure 6-12-22

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Chapter 6 Main parts
Section 12 Gearbox
A-10.With special tooling, assemble the bearing 6209N (inlet) in place, and during assembling, with snap
ring pliers, open the two snap rings simultaneously. (See Figure 6-12-23)

Figure 6-12-23

A-12.With snap ring pliers, mount the retainer ring 45. (See Figure 6-12-24)

Figure 6-12-24

B. Repair of variable speed pump assembly

B-1. Check the variable speed pump, shafts, etc., for any fins, burrs, scratches, pumps, rust marks and
appearance defects. All parts must be clean (except bearings and retainer rings).
B-2. As shown, mount the retainer ring 30 into the retainer ring groove of the shaft. (See Figure 6-12-25)

Figure 6-12-25

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Chapter 6 Main parts
Section 12 Gearbox
B-3. With special tooling, tap the bearing 6206-2RS1 to the retainer ring position. (See Figure 6-12-26)

Figure 6-12-26

B-4. With a soft iron bar, tap the keys 6×4×28 into the shaft keyways. (See Figure 6-12-27)

Figure 6-12-27

B-5. Mount the shaft component into the variable speed pump, and note to align with the keyways. (See
Figure 6-12-28)

Figure 6-12-28
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Chapter 6 Main parts
Section 12 Gearbox

B-6.With a special tooling, install the shaft component into the position of bearing 6206-2RS. (See
Figure 6-12-29)

Figure 6-12-29

B-7.With a special tooling, mount the bearing 6206-2RS into the bearing position. Remarks: prior to
mounting, conduct gap adjustment, with the distance between outsides of two snap ring grooves of the
shaft - (measuring the distance of two bearing positions of the variable speed pump + 32 + 2×snap ring
width) = 0.2-0.4. (See Figure 6-12-30)

Figure 6-12-30

B-8. Mount the retainer ring 30 into the shaft retainer ring groove. (See Figure 6-12-31)

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-31

B-9. Mount the seal ring YH×30. (See Figure 6-12-32)

Figure 6-12-32

C. Repair of bearing component.

C-1. Check the bearing seat for any fins, burrs, scratches, pumps, rust marks and appearance
defects. The bearing seat must be clean; inspect the bearings and seal rings for damage. (See Figure
6-12-33)

Figure 6-12-33

C-2. With special tooling, tap the HK7518 bearing completely. (See Fig 6-12-34 a 6-12-34b)

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-34 a

Figure 6-12-34 b

C-3.With special tooling, tap the seal ring FW75×100×10 completely. (Figures 6-12-35 a, 6-12-35b and
6-12-35c)

Figure 6-12-35 a

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-35 b

Figure 6-12-35 c

D. Repair of stator base assembly

D-1. Check the stator base, input shaft, input gear, etc., for any fins, burrs, scratches, pumps, rust marks
and appearance defects. All parts must be clean (except for standard parts and paper pads). (See
Figure 6-12-36)

Figure 6-12-36

D-2.With a special tooling, tap bearing NJ209E into the bearing position. (See Figure 6-12-37)

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-37

D-3. Mount the input gear, with the higher part of the step on the spline facing up (with the lower part
facing the bearing NJ209E). (See Figure 6-12-38)

Figure 6-12-38

D-4. Mount the seal ring YH×45 into the input shaft. (See Figure 6-12-39)

Figure 6-12-39
D-5.Smear the grease on the seal ring, and try to ensure that the seal ring is coaxial with the input
shaft. (See Figure 6-12-40)

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-40

D-6. Mount the input shaft component. (See Fig 6-12-41 a 6-12-41b)

Figure 6-12-41 a

Figure 6-12-41 b

D-7.With a special tooling, tap 6308 (inlet) bearing completely (until the input shaft snap ring groove is
exposed). (See Figure 6-12-42)

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Chapter 6 Main parts
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Figure 6-12-42

D-8.With snap ring pliers, mount the retainer ring 40. (See Figure 6-12-43)

Figure 6-12-43

D-9. Mount the bearing component, during such mounting align with the oil hole position, insert the bolt
8-M8×25 together with a washer into the bolt hole, and screw the bolt into 2-3 threads manually. With a
jackhammer, in the order as shown in (Figure 6-12-44), lock by 80%, and then with a boosting wrench,
apply the force completely in the order as shown in (Figure 6-12-44). The bolt is M8-8.8, and tightening
torque is 30N.m. After tightening a bolt, mark it with a paint pen. (See Figure 6-12-45)

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-16-44

Figure 6-16-45

E. variable speed pump - repair stator assembly seat

E-1. Check the parts for any fins, burrs, scratches, pumps, rust marks and appearance defects.
E-2. Measure the depth H1 of variable speed pump bearing position step and maintain the record. (See
Figure 6-12-46)

Figure 6-12-46

E-3.Meausre the distance H2 from the bearing to the stator base end surface and record it. (See Figure
6-12-47)

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Chapter 6 Main parts
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Figure 6-12-47

E-4.Adjust the gasket end surface, smear it with grease and mount it, with gasket thickness H =
H1-H2-(0.2 ~ 0.4). (See Figure 6-12-48)

Figure 6-12-48

E-5. Mount the steel ball 20. (See Fig 6-12-49 a 6-12-49b)

Figure 6-12-49 a

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Chapter 6 Main parts
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Figure 6-12-49 b

E-6. Mount the spring. (See Figure 6-12-50)

Figure 6-16-50

E-7. Mount the variable speed pump gasket, smear grease at the bottom and prevent misalignment of
the bolt hole position of the paper pad during assembly. (See Figure 6-12-51)

Figure 6-16-51

E-8. Mount the variable speed pump component. During such mounting align with the bolt hole position,
insert the bolts 4-M8×85 and 4-M8×115 together with washers into the bolt holes, and screw the bolt into
2-3 threads manually. With a jackhammer, in the order as shown in (Figure 6-12-52), lock by 80%, and
then with a boosting wrench, apply the force completely in the order as shown in (Figure 6-12-52). The

209
Chapter 6 Main parts
Section 12 Gearbox
bolt is M8-8.8, and tightening torque is 30N.m. After tightening a bolt, mark it with a paint pen. (See
Figure 6-12-53)

Figure 6-12-52

Figure 6-12-53

G. Assembling of a filter
G-1. Check the first shaft for any fins, burrs, scratches, pumps, rust marks and appearance defects. Also
check whether the distance from the first shaft to the hole is smooth, and whether perforation occurs
G-2. Mount three seal rings and smear with grease, and try to ensure the concentricity of the seal ring
with the shaft. (See Figure 6-12-54)

Figure 6-16-54

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Chapter 6 Main parts
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G-3. Mount the O-ring 48×3.55 and smear the grease out of the O-ring. (See Figure 6-16-55)

Figure 6-16-55

H. Assembly of components of planet carrier of front gear and fourth gear

H-1. Check the piston for any fins, burrs, scratches, pumps, rust marks and appearance defects. Also
check the seal ring lip for any fins, notches and other defects.
H-2. Mount the inner seal ring, and during such process, smear the seal ring groove of piston with
lithium-based lubricant and ensure the lip upward (oil inlet direction). (See Figure 6-12-56)

Figure 6-12-56

H-3. The lip of the seal ring is oblique, and the diameter upward after assembly is smaller than the
diameter downward. (See Figure 6-12-57)

Figure 6-12-57

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Chapter 6 Main parts
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H-4. Mount the outer seal ring, and during such process, smear the seal ring groove of piston with
lithium-based lubricant and ensure the lip to face the left (oil inlet direction). Note: The lip of the seal ring
is oblique, and the diameter on the left after assembly is larger than the diameter on the right. (See
Figure 6-12-58)

Figure 6-12 - 58

I. Repair of first shaft first gear component

I-1. Check the first shaft first gear for any fins, burrs, scratches, pumps, rust marks and appearance
defects. Parts must be clean (except for standard parts). (See Figure 6-12-59)

Figure 6-12-59

I-2. Mount the hole retainer ring, with the retainer ring without steps facing up. (See Figure 6-12-60)

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Chapter 6 Main parts
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Figure 6-12-60

I-3. Mount the roller bearing 45×75×28. (See Figure 6-12-61)

Figure 6-16-61

I-4. Mount the hole retainer ring, with the surface of the retainer ring with a step facing up. (See Figures
6-12-62 a and 6-12-62b)

Figure 6-12-62a

Figure 6-12 - 62b

I-5. Mount the retainer ring 75. (See Figure 6-12-63)

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-16-63

I-6. With special tooling, tap the bearing 6009 in place. (See Figure 6-12-64)

Figure 6-12-64

I-7. Measure the bearing clearance. (See Figure 6-12-65)

Figure 6-12-65

I-8. Mount the bearing clearance adjustment gasket to ensure the clearance of 0-0.05. (See Figure
6-12-66)

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-66

I-9. Mount the retainer ring 75. (See Figure 6-12-67)

Figure 6-16-67

J. First shaft assembly

J-1. Check the parts for any fins, burrs, scratches, pumps, rust marks and appearance defects.
J-2. Check the hub assembly oil duct for smoothness. (See Figure 6-12-68)

Figure 6-12-68

J-3. With special tooling, tap HK4026 in place. (See Figure 6-12-69)

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-69

J-4. Mount the retainer ring in the retainer ring groove. (See Figure 6-12-70)

Figure 6-12-70

I-5. Coat the piston position with lithium-based lubricant. (See Figure 6-12-71)

Figure 6-16-71

I-6. Mount the piston component. (See Figure 6-12-72)

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-72

I-7. Mount successively the 8 driving plates and 7 driven plates, and adjust the clearance of the friction
plate through a driven plate of different thickness to ensure the friction plate clearance of 2.5-3mm. (See
Figure 6-12-73)

Figure 6-12-73

I-8. Mount the pressure plate and inner retainer ring successively. (See Figure 6-12-74)

Figure 6-12-74

I-9. Sequentially, mount the spring seat, spring and spring seat. (See Figures 6-12-75a and 6-12-75b)

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-16-75 a

Figure 6-16-75 b

I-10. In turns, put the guide ring and the outer retainer ring above the spring base, with special tooling
press the spring seat to the snap ring position, and then with snap ring pliers, stick the outer retainer ring
into the retainer ring groove. (See Figure 6-12-75a, Figure 6-12-75b and Figure 6-12-75c)

Figure 6-12 -76a

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-76b

Figure 6-12-76c
J-11. Sequentially, mount the bearing HK3526and inner retainer ring. (See Figure 6-12-77)

Figure 6-12-77

J-12. According to the assembly methods and precautions of the other side, mount the piston
component, driving and driven friction plates, pressure plate, inner retainer ring, and spring component.
The remaining are the same except the number of friction plates is different. (12 driving plates and 11
driven plates) (See Figure 6-12-78)

219
Chapter 6 Main parts
Section 12 Gearbox
Figure 6-12-78

J-13. Mount the thrust gasket (with a notch) to the clutch cylinder axle head (K1 clutch). (See Figures
6-12-79a and 6-12-79b)

Figure 6-12-79a

Figure 6-12-79b

J-14. Mount the thrust gasket to first shaft gear, and during assembly, apply grease for fixing. (See
Figure 6-12-80)

Figure 6-12-80

J-15. Mount the first shaft first gear component to the clutch hub (K1 clutch). (See Figure 6-12-81)

220
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-16-81

J-16. Mount the thrust washer into the cylinder axle head. (See Figure 6-12-82)

Figure 6-12-82

J-17. Mount the thrust gasket to the first shaft gear. (See Figure 6-12-83)

Figure 6-12-83
J-18. Mount the thrust gasket (during assembly, smear the lower end surface with grease). (See Figure
6-12-84)

221
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-84

J-19. Mount the first shaft gear component into the clutch. (See Figure 6-12-85)

Figure 6-12-85

J-20. At the installation position of roller, smear grease and then mount 14 rollersφ10×20. (See Figure
6-12-86)

Figure 6-12-86

J-21. Mount the pad. (See Figure 6-12-87)

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-87

J-22. Mount the 14 rollersφ10×17. (See Figure 6-12-88)

Figure 6-12-88

J-23. Mount the thrust gasket. (See Figure 6-12-89)

Figure 6-12-89

K. Assembling the second shaft component

K-1. Check the second shaft for any fins, burrs, scratches, pumps, rust marks and appearance
defects. Also check whether the distance from the first shaft to the hole is smooth, and whether
perforation occurs
K-2. Mount 3 seal rings and smear with grease, and try to ensure the concentricity of the seal ring with
the shaft. (See Figure 6-16-90)

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-90

K-3. Mount the O-ring 48×3.55 and smear the grease out of the O-ring. (See Figure 6-12-91)

Figure 6-12-91

L. Assembling of second shaft second gear component

L-1. Check the second shaft for any fins, burrs, scratches, pumps, rust marks and appearance
defects. Also check whether the distance from the first shaft to the hole is smooth, and whether
perforation occurs
L-2. Mount the hole retainer ring into a snap ring groove in the red zone, with the end face with a step
downward. (See Figure 6-12-92)

Figure 6-12 - 92

L-3. Sequentially mount the roller bearing 45×75×32 and hole retainer ring. (See Figure 6-12-93)

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-93

L-4. Mount the hole retainer ring into a snap ring groove, with the end face with a step downward. (See
Figure 6-12-94)

Figure 6-12-94

L-5. Mount the roller bearing 45×75×24. (See Figure 6-12-95)

Figure 6-12-95

M. Assembling of second shaft second gear component

M-1. Check the parts for any fins, burrs, scratches, pumps, rust marks and appearance defects.
M-2. Check the hub assembly oil duct for smoothness. (See Figure 6-12-96)

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-96

M-3. With special tooling, tap HK4026 in place. (See Figure 6-12-97)

Figure 6-12-97
M-4. Mount the retainer ring in the retainer ring groove. (See Figure 6-12-98)

Figure 6-12-98

M-5. Coat the piston position with lithium-based lubricant. (See Figure 6-12-99)

226
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-99

M-6. Mount the piston component. (See Figure 6-12-100)

Figure 6-12-100

M-7. Mount successively the 8 driving plates and 7 driven plates to clutch K2 (K2 clutch corresponding to
L1, and KR clutch corresponding to L2, L1 <L2), and adjust the clearance of the friction plate through a
driven plate of different thickness to ensure the friction plate clearance of 2.5-3mm. (See Figure
6-12-101)

Figure 6-12-101

M-8. Mount the pressure plate and inner retainer ring successively. (See Figure 6-12-102)

227
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-103

M-9. Sequentially, mount the spring seat, spring and spring seat. (See Fig 6-12-104 a 6-12-104a)

Figure 6-12-104 a

Figure 6-12-104 b

M-10. In turns, put the guide ring and the outer retainer ring above the spring base, with special tooling
press the spring seat to the snap ring position, and then with snap ring pliers, stick the outer retainer ring
into the retainer ring groove. (See Figure 6-12-105a, Figure 6-12-105b, and FIG. 6-12-105c)

228
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-105a

Figure 6 - 12-105 b

Figure 6-12-105 c

M-11. Sequentially, mount the bearing HK3526and inner retainer ring. (See Figure 6-12-106)

Figure 6-12-106

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Chapter 6 Main parts
Section 12 Gearbox
M-12. According to the assembly methods and precautions of the other side, mount the piston
component, driving and driven friction plates, pressure plate, inner retainer ring, and spring component.
The remaining are the same except the number of friction plates is different. (12 driving plates and 11
driven plates) (See Figure 6-12-107)

Figure 6-12-107

M-13. Mount the thrust gasket (with a notch) to the clutch cylinder axle head (K1 clutch). (See Fig
6-12-108 a 6-12-108b)

Figure 6-12-108 a

Figure 6-12-108 b

M-14. Mount the thrust gasket to second shaft second gear component, and during assembly, apply
grease for fixing. (See Figure 6-12-109)

230
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-109

M-15. Mount the second shaft second gear component to the clutch hub (K2 clutch). (See Figure
6-12-110)

Figure 6-12-110

M-16. Mount the thrust washer into the cylinder axle head. (See Figure 6-12-111)

Figure 6-12-111

M-17. Mount the thrust gasket to the first shaft gear. (See Figure 6-12-112)

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-112

M-18. Mount the thrust gasket (during assembly, smear the lower end surface with grease). (See Figure
6-12-112)

Figure 6-12-112

M-19. Mount the first shaft gear component into the clutch. (See Figure 6-12-113)

Figure 6-12-113

M-20. At the installation position of roller, smear grease and then mount 14 rollers φ10×20. (See Figure
6-12-114).

232
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-114

M-21. Mount the pad. (See Figure 6-12-115).

Figure 6-12-115

M-22. Mount the 14 rollersφ10×17. (See Figure 6-12-116)

Figure 6-12-116

M-23. Mount the thrust gasket. (See Figure 6-12-117)

233
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-117

N. Assembling the third shaft component

N-1. Check the third shaft for any fins, burrs, scratches, pumps, rust marks and appearance
defects. Also check whether the distance from the first shaft to the hole is smooth, and whether
perforation occurs
N-2. Mount 3 seal rings and smear with grease, and try to ensure the concentricity of the seal ring with
the shaft. (See Figure 6-12-118)

Figure 6-12-118

N-3. Sequentially mount the O-ring48×3.55 and smear grease outside the O-ring. (See Figure 6-12-119)

Figure 6-12-119

O. Assembly of piston component

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Chapter 6 Main parts
Section 12 Gearbox
O-1. Check the piston for any fins, burrs, scratches, pumps, rust marks and appearance defects. Also
check whether the seal ring lip for any fins, notches and other defects.
0-2. Mount the inner seal ring, and during such process, smear the seal ring groove of piston with
lithium-based lubricant and ensure the lip upward (oil inlet direction). (See Figure 6-12-120)

Figure 6-12-120

O-3. The lip of the seal ring is oblique, and the diameter upward after assembly is smaller than the
diameter downward. (See Figures 6-12-121a and 6-12-121b)

Figure 6-12-121 a

Figure 6-12-121 b
O-4. Mount the outer seal ring, and during such process, smear the seal ring groove of piston with
lithium-based lubricant and ensure the lip to face the left (oil inlet direction). Note: The lip of the seal ring
is oblique, and the diameter on the left after assembly is larger than the diameter on the right. (see
Figure 6-12-122)

235
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-16-122

P. Assembling of third shaft assembly

P-1. Check the parts for any fins, burrs, scratches, pumps, rust marks and appearance defects.
P-2. Check the hub assembly oil duct for smoothness. (See Figure 6-12-123)

Figure 6-12-123

P-3. With special tooling, tap HK4026 in place (inner diameter of the bearing is φ47) and mount the
retainer ring into the retainer ring groove. (See Figure 6-12-124)

Figure 6-12-124

P-4. Coat the piston position with lithium-based lubricant. (See Figure 6-12-125)

236
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-125

P-5. Mount the piston component. (See Figure 6-12-126)

Figure 6-12-126

P-6. Mount successively the 10 driving plates and 9 driven plates to K3 clutch, and adjust the clearance
of the friction plate through a driven plate of different thickness to ensure the friction plate clearance of
2.5-3mm. (See Figure 6-12-127)

Figure 6-12-127

P-7. Mount the pressure plate and inner retainer ring successively. (See Figure 6-12-128)

237
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-128

P-8. Sequentially, mount the spring seat, spring and spring seat. (See Figures 6-12-129a and
6-12-129b)

Figure 6-12-129a

Figure 6-12-129b

P-9. In turns, put the guide ring and the outer retainer ring above the spring base, with special tooling
press the spring seat to the snap ring position, and then with snap ring pliers, stick the outer retainer ring
into the retainer ring groove. (See Figure 6-12 -130 a, Figure 6-12-130b, Figure 6-12-130c and Figure
6-12-130d)

238
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-130 a

Figure 6-12-130 b

Figure 6-12-130 c

Figure 6-12-130 d

P-10. Sequentially, mount into the bearing HK3520 and inner ring. (See Figure 6-12-131)

239
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-131

P-11. According to the assembly methods and precautions of the other side, mount the piston
component, driving and driven friction plates, pressure plate, inner retainer ring, and spring component.
The remaining are the same except the number of friction plates is different. (9 driving plates and 8
driven plates) (see Figure 6-12-132)

Figure 6-12-132

P-12. Mount the thrust gasket (with a notch) to the clutch cylinder axle head (K3 clutch). (See Figures
6-12-133a and 6-12-133b)

Figure 6-12-133 a

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-133 b

P-13. Mount the thrust gasket to Gear III gear, and during assembly, apply grease for fixing. (See
Figure 6-12-134)

Figure 6-12-134

P-14. Mount the washer to third gear, and grease assembly for fixing. (See Figure 6-12-135)

Figure 6-12-135

P-15. Mount the third shaft gear component to the clutch hub (K3 clutch). (See Figure 6-12-136)

241
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-136

P-16. Mount the needle roller bearings K45×53×28 to the third gear bearing position. (See Figure
6-12-137)

Figure 6-12-137

P-17. Mount 12 rollers φ15.6×31 to the three gear bearing position. (See Figure 6-12-138)

Figure 6-12-138

P-18. Mount the thrust gasket to the cylinder axle head. (See Figure 6-12-139)

242
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-139

P-19. Mount the thrust gasket to the fourth gear. (See Figure 6-12-140)

Figure 6-12-140

P-20. Mount the fourth gear in the clutch. (See Figure 6-12-141)

Figure 6-12-141

P-21. Mount the needle roller bearings K35×50.6×30.4 into fourth gear. (See Figure 6-12-142)

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-142

P-22. Mount the thrust gasket. (See Figure 6-12-143)

Figure 6-12-143

P-23. Mount the lock plate. (See Figure 6-12-144)

Figure 6-12-144

P-24. Mount the adjusting gasket (gasket thickness is selected according to the measured actual
assembly clearance, and ultimately the axial clearance is ensured to be 0.2-0.3mm). (See Figure
6-12-145)

244
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-145

Q. Assembling of front output flange assembly

Q-1. Check the front output flange for any fins, burrs, scratches, pumps, rust marks and appearance
defects. Also check the bolts M14×1.5×45-10.9 for bad threads.
Q-2. Mount eight bolts M14×1.5×45 and the fixed baffle and arrange four welding points in the position
as shown. (See Figure 6-12-146)

Figure 6-12-146
Q-3. Mount eight bolts M10×25 and flat gaskets, and insert the bolts M10×25 together with a washer into
the bolt hole, and screw the bolt into 2-3 threads manually. With a jackhammer, in the order as shown in
(Figure 6-12-147), lock by 80%, and then with a boosting wrench, apply the force completely in the order
as shown in (Figure 6-12-147). The bolt is M10-10.9, and tightening torque is 72N.m. After tightening a
bolt, mark it with a paint pen. (See Figure 6-12-148)

Figure 6-12-147

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-148

R. Assembling of the steering pump flange component

R-1. Check the steering pump flange for any fins, burrs, scratches, pumps, rust marks and appearance
defects. Also check the needle bearing HK4516 for any damage.
R-2. Mount the needle bearing HK4516. (See Figure 6-12-149)

Figure 6-12-149

R-3. Mount the inner retainer ring to the retainer ring groove. (See Figures 6-12-150a and 6-12-150b)

Figure 6-12-150 a

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-150 b

S. Assembling of idler shaft components

S-1. Check the parts for any fins, burrs, scratches, pumps, rust marks and appearance defects.
S-2. Smear grease on the roller installation position. (See Figure 6-12-151)

Figure 6-12-151

S-3. Mount 14 rollersφ10×17 into the idler. (See Figure 6-12-152)

Figure 6-12-152

S-4. Turn to the other side, and mount 14 roller φ 10×17 into the idler. (See Figure 6-12-153)

247
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-153

S-5. Mount the O-ring 56.7×3 into the idler shaft. (See Figure 6-12-154)

Figure 6-12-154

S-6. Mount the idler shaft into the idler. (See Figure 6-12-155)

Figure 6-12-155

S-7. Mount the thrust gasket into the idler shaft for use in general assembly. (See Figure 6-12-156)

248
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-156

T. General assembly
T-1. Check the parts for any fins, burrs, scratches, pumps, rust marks and appearance defects. Check
the oil ducts of all parts for smoothness.
T-2. At the top of the case, install two M20 eye bolts. (See Figure 6-12-157)

Figure 6-16-157

T-3. After penetrating bolts M8×50 and spring washers into the upper joint of suction pipe and the paper
pad, mount them into the case, and screw the bolt into 2-3 threads manually. After screwing the bolt of
lower joint by 2-3 threads, with a jackhammer, lock by 80%, and then with a boosting wrench, apply the
force completely. The bolt is M8-8.8, and tightening torque is 30N.m. After tightening a bolt, mark it with a
paint pen. (See Figure 6-12-158)

Figure 6-12-158

T-4. After penetrating bolts M8×50 and spring washers into the lower joint of suction pipe and the paper
pad, mount them into the case, and screw the bolt into 2-3 threads manually. With an Allen wrench,
pre-tighten them, and then with a boosting wrench, apply the force completely. The bolt is M8-8.8, and
tightening torque is 30N.m. After tightening a bolt, mark it with a paint pen. (See Figure 6-12-159)

249
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-159

T-5. With a special sling, mount the third shaft assembly into the gearbox (the thrust gasket, lock plate
and adjusting gasket to be assembled in next step). (See Figures 6-12-160a and 6-12-160b)

Figure 6-12-160a

Figure 6-12-160b

T-6. After that, mount the thrust gasket, lock plate (the bending part of the lock plate must stick into the
anti-rotation slot in the case) and adjusting gasket respectively, and after calibration, turn the case to the
other side. (See Figure 6-12-161)

250
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-161

T-7. Pull out the analog shaft and check whether the third shaft assembly has deviated from the
position. (See Figure 6-12-162)

Figure 6-12-162

T-8. Mount the third shaft components (The third shaft is mounted in cold condition, with temperature of
-30 °). (See Figure 6-12-163)

Figure 6-12-163

T-9. Mount the studs M8×20 and nuts M8, two respectively. (See Figure 6-12-163)

251
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-163

T-10. With a feeler gauge, check the axial clearance for compliance with the requirements (clearance
requirements: 0.2-0.3mm). (See Figure 6-12-164)

Figure 6-12-164

T-11. Mount the idler component, and align with the mounting position, with the small end (red end)
downward. (See Fig 6-12-165a 6-12-165b)

Figure 6-12-165a

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-165 b

T-12. Mount the screw M12×100. (See Figure 6-12-166)

Figure 6-12-166

T-13. In the same method as the first shaft, mount the second shaft into the case. (See Figure 6-12-167)

Figure 6-12-167

T-14. After aligning the second shaft assembly with the hole position, in turns mount the thrust gasket
(anti-rotation), thrust washer (wear pad) and adjusting gasket. (See Figure 6-12-168)

253
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-168

T-15. Check the second shaft components and after aligning with the mounting position, mount the
second shaft components (The second shaft is mounted in cold condition, with temperature of
-30 °). (See Figure 6-12-169)

Figure 6-12-169

T-16. Mount the stud M8×20 and nut M8. (See Figure 6-12-170)

Figure 6-12-170

T-17. With a feeler gauge, check the axial clearance for compliance with requirements (clearance
requirements: 0.2-0.3mm). (See Figure 6-12-171)

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Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-171

T-18. As same as above, mount the first shaft hub components, the thrust gasket (anti-rotation), thrust
washer (wear pad) and adjusting gasket. (See Figure 6-12-172)

Figure 6-12-172

T-19. As above, mount the first shaft component, stud M8×20 and nut M8. (See Figure 6-12-173)

Figure 6-12-173

T-20. Mount the washers. (See Figures 6-12-174a and 6-12-174b)

255
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-174 a

Figure 6-12-174 b

T-21. Mount the spring, piston and valve sleeve. (See Fig 6-12-175a 6-12-175b)

Figure 6-12-175a

Figure 6-12-175 b

T-22. Mount the O-ring 27×2.5 into the plug. (See Figure 6-12-176)

256
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-176

T-24. With bolts M8×20, mount the oil baffle plate into the case. (See Figures 6-12-177a and 6-12-177b)

Figure 6-12-177 a

Figure 6-12-177 b

T-25. Mount two snap rings 85/91.6 into the retainer ring groove of the case (one of which is for
assembly of 6209N bearing). (See Figures 6-12-178a and 6-12-178b)

257
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-178 a

Figure 6-12-178 b

T-26. Mount 6209N bearing into the special tooling. (See Figure 6-12-179)

Figure 6-12-179

T-27. With special tooling, mount 6209N bearing into the case (until upper snap ring enters into the
bearing retainer ring groove). (See Figure 6-12-180)

258
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-180

T-28. Mount the steering pump gear, with the red zone (with a lower step) upward. (See Figure
6-12-181)

Figure 6-12-181

T-29. Mount the outer retainer ring into the spline shaft. (See Figure 6-12-182)

Figure 6-12-182

T-30. Mount the spline shaft equipped with an outer retainer ring into the steering pump gear. (See
Figure 6-12-183)

259
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-183

T-31. Align the steering pump drive shaft assembly gasket with the steering pump flange bolt hole
(smear some grease for fixing). (See Figure 6-12-184)

Figure 6-12-184

T-32. Put the steering pump flange components equipped with a paper pad into the case; during such
mounting, align with the bolt hole position, insert the bolts 8-M8×20 together with washers into the bolt
holes, and screw the bolt into 2-3 threads manually. With a jackhammer, in the order as shown in (Figure
6-12-185), lock by 80%, and then with a boosting wrench, apply the force completely in the order as
shown in (Figure 6-12-185). The bolt is M8-8.8, and tightening torque is 30N.m. After tightening a bolt,
mark it with a paint pen. (See Figure 6-12-186a and Figure 6-12-186b)

Figure 6-12-185

260
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-186a

Figure 6-12-186b

T-33. With special tooling, mount the seal cover 2 into the case (before mounting, apply 262 sealant on
the fitting location between the seal cover 2 and the case circumference). (See Figure 6-12-187)

Figure 6-12-187

T-34. Mount the retainer ring 45 into the spline shaft of steering pump assembly. (See Figure 6-12-188)

261
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-188

T-35. With special tooling, mount the seal cover 1 into the case (before mounting, apply 262 sealant on
the fitting location between the seal cover 2 and the case circumference). (See Figure 6-12-189a,
Figure 6-12-189b and Figure 6-12-189c)

Figure 6-12-189a

Figure 6-12-189b

262
Chapter 6 Main parts
Section 12 Gearbox
Figure 6-12-189 c

T-36. With special tooling, mount the roller bearing NJ213EC inner retainer ring into the output shaft
gear. (See Figure 6-12-190)

Figure 6-12-190

T-37. Mount the outer retainer ring of roller bearing NJ213EC into the case, and with special tooling, tap
the bearing outer retainer ring until the retainer ring groove is exposed. (See Figure 6-12-191)

Figure 6-12-191

T-38. Mount the oil receiving plate 1. (See Figure 6-12-192)

Figure 6-12-192

T-39. Mount the output gear components into the case. (See Figure 6-12-193)

263
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-193

T-40. Mount by aligning the bolt hole with the oil receiving plate 2. (See Figure 6-12-194)

Figure 6-12-194

T-41. Penetrate two bolts M8×20 through the spring washer and then mount them (one of which in the
figure requires sealing with raw material tape). (See Figure 6-12-195)

Figure 6-12-195

T-42. By using special tooling, mount the bearing 6311 into the output shaft. (See Figure 6-12-196)

264
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-196

T-43. Mount the spacer. (See Figure 6-12-197)

Figure 6-12-197

T-44. Mount the retainer ring 120. (See Figure 6-12-198)

Figure 6-12-198

T-45. Mount the output shaft component. (See Figure 6-12-199)

265
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-199

T-46. Mount the adjusting gasket (the thickness of adjusting gasket is determined after measurement to
ensure the axial clearance of 0.2-0.4). (See Figure 6-12-200)

Figure 6-12-200

T-47. Mount the retainer ring 120. (See Figure 6-12-201)

Figure 6-12-201

T-48. Mount the framework oil seal FW90×120×12. (See Figures 6-12-202a and 6-12-202b)

266
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-202a

Figure 6-12-202b

T-49. Break into the brake assembly. (See Figure 6-12-203)

Figure 6-12-203

T-50. Smear lithium-based lubricant on two hole positions of case. (See Figure 6-12-204)

267
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-16-204

T-51. On the two holes of the case, mount pin 1 and pin 2. (See Figure 6-12-205)

Pin 1 Pin 2

Figure 6-12-205

T-52. Mount the brake cam assembly into pin 1. (See Figure 6-12-206)

Figure 6-12-206

T-53. Mount the brake shoe assembly and spring. (See Figure 6-12-207)

268
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-207

T-54. Mount the gasket and retainer ring 22. (See Figure 6-12-208)

Figure 6-12-208

T-55. In the inner end face of pin 2, mount the gaskets and bolts M10×40 (262 thread fastening glue
coated on the bolt). (See Figure 6-12-209)

Figure 6-12-209

T-56. In the inner end face of pin 1, mount the gaskets and bolts M10×22 (262 thread fastening glue
coated on the bolt). (See Figure 6-12-210)

269
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-210

T-57. Mount the front output flange component. (See Figure 6-12-211)

Figure 6-12-211

T-58. Mount the O-rings 48×4. (See Figure 6-12-212)

Figure 6-12-212

T-59. In turns, mount the end shaft baffle, lock plate, and two bolts M10×30; after locking, turn the lock
plate to the hex side of bolt. (See Figure 6-12-213)

270
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-213

T-60. Sequentially, mount the adjusting gaskets (through measurement, ensure the axial clearance of
0.2-0.4mm) and the retainer ring 120. (See Figures 6-12-214a and 6-12-214b)

Figure 6-12-214 a

Figure 6-12-214 b
T-61. Mount the framework oil seal FW90×120×12. (See Figure 6-12-215)

Figure 6-12-215

271
Chapter 6 Main parts
Section 12 Gearbox

T-62. After mounting the output flange, insert the 8 bolts M12×1.5×35 into the flange and fix with a
rubber band. (See Figure 6-12-216)

Figure 6-12-216

T-63. Mount the O-ring 48×4. (See Figure 6-12-217)

Figure 6-12-217

T-64. In turns, mount the end shaft baffle, lock plate, and two bolts M10×30; after locking, turn the lock
plate to the hex side of bolt. (See Figures 6-12-218a and 6-12-218b)

Figure 6-12-218a

272
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-218b

T-65. Mount the O-ring 27×2.5 into the plug 1 and mount the component into the case. (See Figures
6-12-219a and 6-12-219b)

Figure 6-12-219a

Figure 6-12-219b

T-66. Mount the vent cap. (See Figure 6-12-220)

Figure 6-12-220

273
Chapter 6 Main parts
Section 12 Gearbox
T-67. Mount the plug (at the same time, mount the O-ring 11×2). (See Figure 6-12-221a and Figure
6-12-221b)

Figure 6-12-221a

Figure 6-12-221b

T-68. Mount the oil drain plug (at the same time, mount the O-ring 35×2.5). (See Figures 6-12-222a and
6-12-222b)

Figure 6-12-222a

274
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-222b

T-69. Mount the injector tube assembly. (See Figure 6-12-223)

Figure 6-12-223

T-70. Mount the twoφ10×30 pins and the stator base paper pad. (See Figure 6-12-224)

Figure 6-12-224

. T-71. Mount the variable speed pump - stator base assembly. (See Figure 6-12-226)

275
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-226

T-72. Assemble the torque converter housing; during such assembling, align with the bolt hole position,
insert the bolts 14-M10×50 together with washers into the bolt holes, and screw the bolt into 2-3 threads
manually. With a jackhammer, in the order as shown in (Figure 6-12-227), lock by 80%, and then with a
boosting wrench, apply the force completely in the order as shown in (Figure 6-12-227). The bolt is
M10-8.8, and tightening torque is 55N.m. After tightening a bolt, mark it with a paint pen. (See Figure
6-12-228a and Figure 6-12-228b)

Figure 6-12-227

Figure 6-12-228 a

276
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-228 b

T-73. Align the working pump paper pad with the bolt hole and put it on the housing for assembly. (See
Figure 6-12-229)

Figure 6-12-229

T-74. Assemble the working pump assembly; during such assembling, align with the bolt hole position,
insert the bolts 8-M8×20 together with washers into the bolt holes, and screw the bolt into 2-3 threads
manually. With a jackhammer, in the order as shown in (Figure 6-12-230), lock by 80%, and then with a
boosting wrench, apply the force completely in the order as shown in (Figure 6-12-230). The bolt is
M8-8.8, and tightening torque is 30N.m. After tightening a bolt, mark it with a paint pen. (See Figure
6-12-231)

Figure 6-12-230

277
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-231

T-75. Sequentially, mount the control valve assembly (the speed control valve bolt M8-10.9 class
tightening torque is 23Nm). (See Figure 6-12-232a to Figure 6-12-232h)

Figure 6-12-232a

Figure 6-12-232b

Figure 6-12-232c

278
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-232d

Figure 6-12-232e

Figure 6-12-232f

Figure 6-12-232g

279
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-232h

T-76. Mount the components of two transition joints (including O-ring 13.3×2.4 and metal retainer
ring). (See Figure 6-12-233)

Figure 6-12-233

T-77. Mount the components of two transition joints into the second shaft (including O-ring 13.3×2.4 and
metal retainer ring). (See Figure 6-12-234)

Figure 6-12-234

T-78. Mount the oil pipe at each gear. (See Figure 6-12-235)

280
Chapter 6 Main parts
Section 12 Gearbox

Figure 6-12-235

T-79. Mount the fine filter (coat the seal ring with a thin layer of grease, press the filter until it contacts
with the sealing surface on the case, and then tighten about 1/3 to 1/2 circle manually). (See Figure
6-12-236)

Figure 6-12-236

T-80. Mount the speed sensor (through measurement, ensure the clearance from the sensor to the gear
to be 0.8-1.2mm). (See Figure 6-12-237)

Figure 6-12-237

281
Chapter 6 Main parts
Section 13 Steering Pump

Section 13 Steering Pump

Table of Contents
1. Structure and Functions ................................................................................................................... [282]
2. Dismounting and Installation ............................................................................................................ [282]

1. Structure and Functions

(I) Functions
As the source of power for the hydraulic system, steering pump powers the hydraulic system by
converting mechanical energy into hydraulic energy.
(II) Working principle
Steering pump is fastened on the body of the gearbox. It is driven by the engine via gear pair. This pump
is an external gear pump, which comprises an engaged pair of driving and driving gear, pump body, side
plate, bearings and sealing elements. The rotation of driving gear also causes the rotation of driven gear.
The place where gear teeth begin to exit from the engagement is suction chamber, while the place
where gear teeth enter the engagement is pumping chamber. Suction chamber and pumping chamber
are separated by the line of engagement of driven gear and by radial clearance and end clearance. With
the rotation of the two gears, fluid oil is brought by main belt of suction chamber to pumping chamber,
thus realizing oil suction and pumping of gear pump.

2. Dismounting and Installation

(1) Location of steering pump on the product

Steering pump

Figure 6-13-1

①Steering pump and working pump are directly fitted at power take-off of torque converter (see Figure
6-13-1);

②Steering pump is mounted on 4 double end bolts of the power take-off through 4 M12 nuts and elastic
washers. Pump body is taken out only after the nuts and elastic washers are removed; Since operating
space is quite limited to due to the pump located below the cab and large oil inlet and outlet pipes, the

282
Chapter 6 Main parts
Section 13 Steering Pump
steering pump is generally dismounted only after removing the entire cab from the vehicle;

(2) Dismounting steps

①The cab is dismounted according to relevant requirement (see the content of the section “gearbox
Dismounting and Installation” on cab dismounting). Interconnected lines and pipelines shall not be
yanked and work safety shall be ensured during hoisting operation;

②In case of oil leak during pipeline dismounting, oil drip pans and oil drums are ready for use; protect oil
ports and make reassembly marks;

③Remove the steel oil inlet pipe of steering pump, four M10×35 bolts and elastic washers, protect
sealing elements of oil port and recycle fluid oil;

④Remove flange gland for steel oil inlet pipe of steering pump, four fixing bolts M10×42 and elastic
washers, protect sealing elements of oil port and recycle fluid oil;

⑤Take the steering pump out of power take-off with a special tool (e.g., crowbar). Guard against
personal injury resulting from the slippage of pump from oil-stained hands;

(3) Inspection notes

①Check if there is any foreign matter in inner chamber of each oil port; if splines and sealing gaskets are
intact;

② Fastening parts on pump body (e.g., bolts) may not be loosened without authorization; any
commissioning is performed by professionals only;

(4) Installation

①Pay attention to direction during installation and the direction of oil inlet is on the inside;

②Check and clean the mounting surface. If sealing gaskets on pump body or at the power take-off end
are damaged, replace them with sealing gaskets of the same model number or apply 515 plane sealant;

③Perform other operations in the sequence contrary to the dismounting sequence;

④Install the steering pump in the power take-off with a special tool (e.g., crowbar).

⑤Install flange gland for steel oil inlet pipe of steering pump, four fixing bolts M10×42 and elastic
washers;

⑥Install oil inlet seal and steel oil inlet pipe of steering pump, four bolts M10×35 and elastic washers;

⑦Check sealing elements in the pipeline during assembly. Replace any damaged sealing element with
new one and ensure cleanliness; pay attention to reassembly marks to avoid wrong connection;

⑧Locking torque meets the requirement of torque meter;

(5) Dismounting tools

283
Chapter 6 Main parts
Section 13 Steering Pump
①16-18 open end wrench, 16, 18 sleeve and plate stem;

②200N•m torque wrench; crowbar.

(6) Keep dismounting record.

284
Chapter 6 Main parts
Section 13 Steering Pump

Figure 6-13-2
1. Hole circlip 2. Outer roller 3.O-ring 4. Oil seal skeleton 5. Skeleton oil seal
bearing
6. Front cover 7. Secondary seal 8. Needle roller 9. Oil choking 10. Cylindrical pin
ring bearing screw
11. Side plate 12. Primary driving 13. Primary driven 14. Rectangular 15. Primary pump
gear gear ring body
16. Intermediate 17. Stud 18. Washer 19. Hex nut 20. Connecting
shaft
21. Sliding bearing 22. Cylindrical pin 23. E-shaped 24. E-shaped seal 25. Side plate
retainer ring ring
26. Secondary 27. Secondary 28. Rear pump 29. Rectangular 30. Rear cover
driving gear driven gear body seal ring
31. Washer 32. Safety valve 33. Hex head bolt

285
Chapter 6 Main parts
Section 14 Double gear pump

Section 14 Double Gear Pump

1. Structure and Functions ...................................................................................................... [286]

2. Dismounting and Installation ............................................................................................... [286]

1. Structure and Functions

(I) Functions
As the power source for the working system and steering system, the double gear pump converts
mechanical energy into hydraulic energy to power the hydraulic system and the steering system.

(II) Working principle

The double gear pump is joined to a torque converter. It is driven by the engine via gear pair. The pump
is an external gear pump, which comprises an engaged pair of driving and driven gears, pump body, side
plate, bearings and sealing elements. The rotation of driving gear also causes the rotation of driven gear.
The place where gear teeth begin to exit from the engagement is a suction chamber, while the place
where gear teeth enter the engagement is a pumping chamber. Suction chamber and pumping chamber
are separated by the line of engagement of driven gear and by radial clearance and end clearance. With
the rotation of the two gears, fluid oil is brought from suction chamber to pumping chamber, thus
realizing oil suction and pumping of gear pump.

2. Dismantling and Installation

(1) Position of double gear pump on the product

Double gear pump

Figure 6-14-01

①The double gear pump is fitted at power take-off of torque converter (see Figure 6-14-01);

②The double gear pump is mounted on 4 double end bolts of the power take-off through 4 M12 nuts and
elastic washers. The pump body is taken out only after the nuts and elastic washers are removed; since
operating space is quite limited to due to the pump located below the cab and large oil inlet and outlet
pipes, the double gear pump is generally dismounted only after removing the entire cab from the vehicle;
Figure 6-14-01
286
Chapter 6 Main parts
Section 14 Double gear pump

(2) Dismounting steps

① The cab is dismounted according to relevant requirement (see the content of the section gearbox
“dismounting and installation” on cab dismounting). Interconnected lines and pipelines shall not be
yanked and work safety shall be ensured during hoisting operation;

② In case of oil leak during pipeline dismounting, oil receiver and oil drums are ready for use; oil ports
are protected with reassembly mark;

③ Remove the oil inlet steel pipe of double gear pump, four M12×40 bolts and elastic washers, protect
sealing elements of oil port and recycle fluid oil;

④ Remove flange gland for steel oil inlet pipe of double gear pump, four fixing bolts M10×35 and elastic
washers, protect sealing elements of oil port and recycle fluid oil;

⑤ Take the working pump out of power take-off with a special tool (e.g., crowbar). Guard against
personal injury resulting from the slippage of pump from oil-stained hands;

(3) Inspection notes

① Check if there is any foreign matter in inner chamber of each oil port; if splines and sealing gaskets
are intact;

② Fastening end on pump body (e.g., bolts) cannot be loosened without authorization; any
commissioning is performed by professionals only;

(4) Installation

① Pay attention to direction during installation and the direction of oil inlet is on the inside;

② Check and clean the mounting surface. If sealing gaskets on pump body or at the power take-off end
are damaged, replace them with sealing gaskets of the same model number or apply 515 plane sealant;

③ Perform other operations in the sequence contrary to the dismounting sequence:

④ Install the double gear pump in the power take-off with a special tool (e.g., crowbar).

⑤ Install flange gland for steel oil inlet pipe of double gear pump, four fixing bolts M10×35 and elastic
washers;

⑥ Install steel oil inlet pipe of double gear pump, four bolts M12×40 and elastic washers;

⑦ Check sealing elements in the pipeline during assembly. Replace any damaged sealing element with
new one and ensure cleanliness; pay attention to reassembly marks to avoid wrong connection;

⑧ Locking torque meets the requirement of torque meter;

(5) Dismounting tools

① 16-18 open end wrench, 16, 18 sleeve and plate stem;

② 200N•m torque wrench; crowbar.

(6) Keep a dismounting record.

287
Chapter 6 Main parts
Section 14 Double gear pump

Figure 6-14-02

1. Elastic retainer ring 2. Extenral ball bearing 3. O seal ring 4. Oil seal skeleton 5. Skeleton oil seal
for holes

6. Front cover 7. Secondary seal ring 8. Oil blocking screw 9. Round pin 10. Needle bearing

11. Side plate 12, Primary driving gear 13. Primary driven gear 14. Square seal ring 15. Primary pump body

16. Intermdiate body 17. Double end bolt 18. Wahser 19. Hex nut 20. Connecting shaft

21. Sliding bearing 22. Round pin 23. E shaped retainer 24. E shaped seal ring 25. Side plate
ring

26. Secondary driving 27. Secondary driven 28. Rear pump body 29. Square seal ring 30. Back cover
gear gear

31. Washer 32. Hexagon head bolt

288
Chapter 7 Hydraulic Schematic Diagram

Refer to Appendix I for schematic diagram of hydraulic system

(I) Working principle of steering system:

Pressure oil from steering oil pump first flows to the priority valve for distribution of fluid oil: while ensuring
enough steering oil, the priority valve supplies surplus oil to the hydraulic system, thus eliminating power
loss due to excessive oil supply to steering pump and increasing the efficiency of hydraulic system.

(II) Working principle of hydraulic system

The handle of pilot valve has three control positions “Down Turn”, “Neutral”, “Up Turn” over the bucket to
control the action of bucket.

When the engine works, the control handle of the pilot valve pushes rightwards. At this time, pilot oil flows
into the rear control chamber b1 of the first linkage (i.e., bucket linkage) of the hydraulic selector valve (6)
through 1A opening of pilot valve, thus pushing the bucket valve stem to move forward. Pressure oil from
main oil pipeline enters the small chamber of bucket cylinder through the opening of the first linkage of
selector valve, thus realizing the downward turn of bucket (i.e., bucket unloading) by retraction of piston
rod of oil cylinder. When the control handle of pilot valve pushes leftward, pilot oil enters the front control
chamber a1 of the first linkage of selector valve through 1B opening of pilot valve, thus pushing the bucket
valve stem to move backward. Pressure oil from main oil pipeline enters the big chamber of bucket
cylinder through A1 opening of the first linkage of selector valve, thus realizing upward turn of bucket (i.e.,
bucket retraction). When the handle of pilot valve is at the neutral position, pilot oil in the two (left and right)
control chambers of the first linkage of selector valve is directly connected to the oil tank, and bucket
valve stem is kept at the neutral position under the influence of retracting spring. At this time, bucket oil
chamber is under the locked state.

The handle of pilot valve has four control positions “Lift”, “Neutral”, “Lower” and “Float” over the lift arm to
control the action of lift arm. When the control handle of pilot valve pushes forward, pilot oil flows into the
rear control chamber b2 of the second linkage (i.e., lift arm linkage) of selector valve through 2A opening
of pilot valve, thus pushing lift arm valve stem to move forward. Pressure oil from main oil pipeline enters
the small chamber of lift arm cylinder through B2 opening of the second linkage of selector valve, thus
pushing piston rod of the cylinder to retract and realizing the lowering of lift arm. At this time, oil in big
chamber of lift arm cylinder returns to oil tank via hydraulic selector valve. When the control handle of pilot
valve pushes backward, pilot oil enters the front control chamber a2 of the second linkage of selector
valve through 2B opening of pilot valve, thus pushing lift arm valve stem to move backward. Pressure oil
from main oil pipeline enters the big chamber of lift arm cylinder through A2 opening of the second linkage
of selector valve, thus pushing piston rod of oil cylinder to move forward and realizing the lifting of lift arm.
At this time, oil in the small chamber of lift arm cylinder returns to oil tank through hydraulic selector valve.

When the control handle of pilot valve continues to push forward after reaching the “Lower” position, it will
arrive at the “Float” position. At this time, the hydraulic selector valve realizes the interconnection of
working pump, oil tank and both big and small chambers of lift arm cylinder, and the piston of lift arm
cylinder is under the floating state. Therefore, the cutting edge of the bucket is able to float up and down

289
Chapter 7 Hydraulic Schematic Diagram

with different landform; when the control handle b of pilot valve is at the neutral position, pilot oil from the
two (left and right) control chambers of the second linkage of selector valve returns to oil tank. At that time,
the lift arm valve stem is kept at the neutral position under the influence of retracting spring, thus keeping
both big and small chambers of lift arm cylinder locked and stopping the action of the lift arm.

Under the mode of engine flameout, “lower” operation of lift arm and “down turn” operation of bucket: If
flameout occurs when the lift arm is being lifted, it is required to lower the lift arm slowly to the ground. At
that time, pressure oil stored in the accumulator inside oil supply valve (4)is supplied to the pilot valve (6).
When the control handle of pilot valve pushes forward to “lower” or “float” position, pilot oil enters the rear
control chamber b2 of the second linkage of selector valve, thus pushing lift arm valve stem to move
forward and connecting the oil port of big chamber of lift arm cylinder to oil tank; meanwhile, the oil
recharging valve for B2 oil port of the second linkage of selector valve is opened to conduct oil recharging
by connecting the oil port of small chamber of lift arm cylinder to oil tank. Under the influence of the gravity
of work device, the bucket lowers to the ground.

In order to perform “down turn” of the bucket, push the handle of pilot valve rightward to the “down turn”
position. Pressure oil stored in the accumulator inside the oil supply valve (4) enters the rear control
chamber b1 of the first linkage of the hydraulic selector valve according to the abovementioned route,
thus pushing the bucket valve stem to move forward and causing the oil in big chamber of bucket cylinder
to return to oil tank. Meanwhile, the oil recharging valve of B1 oil port of the first linkage of selector valve
is opened to connect oil port of the small chamber of bucket cylinder to oil tank. The bucket realizes the
“down turn” operation under the gravity of work device.

290
Chapter 8 Electrical Schematic Diagram

Refer to Appendix Ⅱ for electrical diagram of CDM858.00I loader

291
Appendix I Schematic Diagram of Hydraulic System

1. Oil suction filter element 8. Oil supply valve assembly

2. Fan steering pump 9. Bucket cylinder assembly
3. Priority valve assembly 10. Lift arm cylinder assembly
4. Steering gear assembly 11. Hydraulic heat radiator
5. Steering cylinder assembly 12. Oil return filter element
6. Hydraulic multi-way valve assembly 13. Fan motor
7. Pilot valve assembly 14. Working pump

292
 Chapter 6 Main parts
Section 17 Air Conditioning System

Appendix II Electrical Schematic Diagram

293