Professional Documents
Culture Documents
Table of contents
Chapter 1 Safety precautions..................................................................................................................[1]
Chapter 2 Diagrams and parameters of complete-loader............................................................... [3]
Chapter 3 Maintenance points of complete-loader........................................................................... [7]
Chapter 4 Standard Data Sheet............................................................................................................ [12]
Chapter 5 Troubleshooting....................................................................................................................[21]
5-1 Torque converter and gearbox system.........................................................................................[22]
5-2 Drive axle system.............................................................................................................................[39]
5-3 Working hydraulic system...............................................................................................................[42]
5-4 Pilot control system................................................................................................................................... [48]
5-5 Steering hydraulic system.............................................................................................................. [54]
5-6 Foot brake system........................................................................................................................... [58]
5-7 Electric system................................................................................................................................. [61]
Chapter 6 Main Parts..................................................................................................................................[67]
Section 1 Hydraulic torque converter................................................................................................ [68]
6-1-1 Structure and Functions.................................................................................................... [68]
6-1-2 Testing and Adjustment.....................................................................................................[71]
6-1-3 Dismounting and Installation............................................................................................ [72]
6-1-4 Disassembly and Repair................................................................................................... [73]
Section 2 Gearbox .............................................................................................................................. [86]
6-2-1 Structure and Functions.................................................................................................... [86]
6-2-2 Testing and Adjustment.....................................................................................................[87]
6-2-3 Dismounting and Installation............................................................................................ [88]
6-2-4 Disassembly and Repair................................................................................................... [94]
Section 3 Drive axle........................................................................................................................... [120]
6-3-1 Structure and Functions..................................................................................................[120]
6-3-2 Dismounting and Installation.......................................................................................... [121]
6-3-3 Disassembly and Repair................................................................................................. [123]
Section 4 Air brake valve assembly.................................................................................................[144]
6-4-1 Structure and Functions..................................................................................................[144]
6-4-2 Dismounting and Installation.......................................................................................... [145]
6-4-3 Disassembly and Repair................................................................................................. [146]
Section 5 Combination valve of oil-water separator (SH380D) .................................................[155]
6-5-1 Structure and Functions..................................................................................................[155]
6-5-2 Dismounting and Installation.......................................................................................... [156]
1
Table of contents
2
Table of contents
3
Table of contents
4
Preface
Preface
In order to enable distributors and repair service centers to know more about Lonking CDM835E I.00I
loader, we have compiled this Repair Manual for CDM835E I.00I Wheel Loader and provide it to Lonking’s
overseas agents and repair service centers.
This Manual emphasizes the introduction of structure and functions, test and adjustment, installation and
disassembly, dismounting 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 feed back 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 dismounting and
commissioning process or not) If an assembly is not available, only after the written consent of Lonking
and component manufacturers has been obtained can these components be dismounted 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 effort 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.
5
6
Chapter 1 Safety precautions
1
Chapter I Safety precautions
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 retainer 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 2 Picture and parameters of complete-loader
Figure 2-1
Overall Dimensions
Code Description Dimension
A Overall length 7390 mm
B Wheel base 2850 mm
C Minimum ground clearance 347 mm
D Maximum total height of main unit 3180 mm
E Pin height at maximum lifting 3710 mm
F Dumping height 2890 mm
Distance between bucket tooth and
G 2747 mm
ground at dumping
H Dumping reach 1083 mm
Distance between rear shaft and
I 1425 mm
hinge joint
J Length of rear suspension 2045 mm
K Height of delivery location 400 mm
L Overall height at maximum lift 4720 mm
a2 Dumping angle 450
3
Chapter 2 Picture and parameters of complete-loader
Standard specifications
Item Specs
Bucket capacity 1.7 m3
Rated load 3500kg
Lift arm lifting time ≤5.5s
Total time ≤10.5s
Forward gear I 6.5km/h
4
Chapter 2 Picture and parameters of complete-loader
Item Specification
Engine Type Weichai WP6G140E22
Rated rotating speed 2200r/min
Maximum torque 560N·m /1400-1600r/min
Rated fuel consumption ≤225g/kW·h
Consumption rate (bench test)
Fuel oil (customers may choose the type of fuel oil Light diesel oil No.0
according to the local ambient temperature)
Diameter of fan (backward air exhaust) Φ600mm
Hydraulic Type Single-stage three-elements (single
torque turbine)
converter Torque coefficient 3.45±5%
Cooling method Water-cooling pressure circulating
Transmission Gearbox Type Fixed shaft power gear shift
system Shifts of gearbox Three forward gears
Three reverse gears
Transmission oil pump Gear pump
Working pressure 1.1~1.5MPa
Main drive and Main drive type Helical bevel gear
hub reduction One-stage reduction
Wheel hub reducer type Straight-toothed cylinder gear
Planetary gear reducer
Reduction ratio 20.521
Main drive reduction ratio 5.286
Hub reduction ratio 3.882
Drive axle and Type One-stage bevel gear reduction
wheel Tire 17.5-25 tire E-3/L-3PR
Air pressure of tire Front wheel 0.32±0.01MPa
Rear wheel 0.28±0.01MPa
Braking Drive Braking type Single-line dry type brake
system Braking Diameter of brake disc 450mm
Diameter of brake cylinder Φ75mm (8pcs X 2)
Effective area of friction plate 176.3 mm2 (4pcs X2)
Parking & Braking type Soft shaft control clamp plate type brake
emergency Opening pressure of brake 04Mpa
braking caliper
5
Chapter 2 Picture and parameters of complete-loader
6
Chapter 3 Maintenance point of complete-loader
Chapter 3 Maintenance points of complete-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.
7
Chapter 3 Maintenance point of complete-loader
8
Chapter 3 Maintenance point of complete-loader
III. Maintenance items for 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 oil 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.
9
Chapter 3 Maintenance point of complete-loader
6. The transmission oil of gearbox, and the return oil filter of the gearbox-torque converter assembly 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.
VI. Maintenance items for every 1000 hours or every half year
1. Hydraulic oil, return oil filter element and oil suction filter element shall be replaced, and the hydraulic
oil tank shall be cleaned.
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; (equipped with an roll over protection bracket)
6. The dryer of the braking system shall be replaced. (This is an optional component and shall be
replaced according to loader models)
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.
10
Chapter 3 Maintenance point of complete-loader
Maintenance
Date of Brief description of
item 50h 100h 250h 500h 1000h Examiner
examination defect
Operating time
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 ●
11
Chapter 4 Standard Data Sheet
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
b. Table of tightening torque of ordinary rubber pipe (specification of open-end spanner and Table of
Recommended Thread Torque)
12
Chapter 4 Standard Data Sheet
2. Thread adhesive
No. Name and Dosage for Usage Remark
specification (Aotai 100 units
series)
1 AT598 2 canisters Thread sealing for drive axle plug, Or Debang
(300ml) 2577
2 AT515 5 canisters Plane sealing for articulated interface between Or Debang
(300ml) diesel and torque converter 2515
3 AT577 5 barrels Thread sealing for joint of fan heater, joint of Or Debang
(300ml) unloading valve and air reservoir joint 2577
4 AT262 3 bottles Thread sealing for pin bolt of oscillating axle Or Debang
(250ml) 2243
5 AT243 Thread sealing for steering shaft. Thread sealing Or Debang
8 bottles for oil drain plug of hydraulic oil tank and fuel oil 2243
(250ml) tank.
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
2a Red 2.5
circuit
2b Red 2.5-5.0
33 Red 1.0
59 Green 1.0
62 Yellow 1.0
Wiper
75 Red 1.0
78 Purple 0.85
79 Purple 0.85
13
Chapter 4 Standard Data Sheet
14
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℃.
36L
Hydraulic transmission
oil
173L
Hydraulic oil
18.5L
Lubrication grease
Diesel oil
25L
Anti-freezing fluid
15
Chapter 4 Standard Data Sheet
5. Conversion table
Conversion from millimeter to inch · ···················· 1mm=0.03973 inch
16
Chapter 4 Standard Data Sheet
5. Conversion table
Conversion from kilogram to US gallon ·····················1liter = 0.2642 US gallon
17
Chapter 4 Standard Data Sheet
5. Conversion table
Conversion from kilogram·meter to foot·pound ·····················1kgm=7.232ft·Ib
18
Chapter 4 Standard Data Sheet
5. Conversion table
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
19
Chapter 4 Standard Data Sheet
20
Chapter 5 Troubleshooting
Table of Contents
Chapter 5 Troubleshooting
Table of Contents
5-1 Torque converter and gearbox system.........................................................................................[22]
5-2 Drive axle system.............................................................................................................................[39]
5-3 Working hydraulic system...............................................................................................................[42]
5-4 Pilot control system................................................................................................................................... [48]
5-5 Steering hydraulic system.............................................................................................................. [54]
5-6 Foot brake system........................................................................................................................... [58]
5-7 Electric system................................................................................................................................. [61]
21
Chapter 5 Troubleshooting
Table of Contents
22
Chapter 5 Troubleshooting
Torque Converter and Gearbox System
Precautions for the installation, maintenance and repair of torque converter and gearbox are
as follows:
1. 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 be1.5-1.7MPa.
5-1-01. Excessively rapid rise of oil temperature of gearbox and water temperature of engine .....[23]
5-1-02. When the loader is shifted to gear I or III, the loader cannot run until a few minutes later.r[25]
5-1-03. After Gear II is shifted, the loader will not run until several minutes later .............................[26]
5-1-04. After gear shift, the pressure cannot reach the normal value .................................................[27]
5-1-05. Insufficient pressure of various gears, and insufficient driving and operating power ..........[28]
5-1-06. When the loader is under normal operation,the oil temperature of the gearbox will exceed
120℃ in short time ......................................................................................................................................[29]
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)..............................................................................[29]
5-1-08. 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]
5-1-09. During the operation, the loader may suddenly stop, which is similar to automatic emergent
braking ........................................................................................................................................................... [31]
5-1-10. The pressure is normal at any gear, but the loader cannot run ..............................................[33]
5-1-11. 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 ..........................................................................................[33]
5-1-12. The oil level of the gearbox rises rapidly ....................................................................................[34]
5-1-13. The oil level of the gearbox declines rapidly ..............................................................................[35]
5-1-14. The pressure of various gears is normal, but the cut of the bucket is powerless and there is a
“drumming” sound form the gearbox ........................................................................................................ [35]
5-1-15. the pressure of gear I is not sufficient
[35]
5-1-16. Gearbox releases abnormal sound .............................................................................................[36]
5-1-17. Common Malfunctions and Troubleshooting Methods of Troque Converter ........................[38]
23
Chapter 5 Troubleshooting
Torque Converter and Gearbox System
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 fan belt is too loose, the water tank is too dirty or the installation distance of the wind scooper does
not comply with requirements.
8. The air filter element is too dirty.
9. The dissipation effect of the engine oil radiator is not good or the cylinder cover leaks gas or water.
10. The pressure of oil injector is adjusted too high.
24
Chapter 5 Troubleshooting
Torque Converter and Gearbox System
Filter screen
Figure 5-01
25
Chapter 5 Troubleshooting
Torque Converter and Gearbox System
Description of malfunction. After gear shift, the pressure of gearbox rises slowly, the oil temperature rises
rapidly, and the pressure goes down after the engine is heated. However, gear II operates properly.
Possible reasons:
1. Different gears of the gearbox use the same oil. The proper operation of gear II indicates that the oil
itself is not the main reason that causes the shift delay of gears I and III.
2. Gear I and gear III are used more frequently, so the main reason is the gear I’s clutch.
3. The speed-changing control valve leaks internally or valve core or spring gets stuck.
4. Bolts of end cover are loose or sealing members of the clutch of gear I are damaged.
5. Fixing locking plates of the separating frame is bent or deformed or the piston travel of gear I is too
long.
6. There are cracks on the oil pipe of gear I or the gap of end cover is not adjusted properly.
4. The speed-changing control valve shall be disassembled to see if the inclined holes on the pressure
reducing valve rod is blocked. (See Figure 5-02)
26
Chapter 5 Troubleshooting
Torque Converter and Gearbox System
5. After the clutch is removed, the bolts of the end cover shall be checked to see if they are loose. Then
the gear II clutch shall be dismounted to check if the piston is able to return. If the return is not complete, it
will lead to serious shift delay of gear I and gear III.
6. The middle cover of gearbox shall be disassembled to check if the O-shaped ring between the oil inlet
of gear I cylinder and the gearbox housing is misplaced or damaged. The misplacement or damage of this
O-ring will cause the leakage of the oil that enters the gear I cylinder, which will lead to the delay of gear I
engagement.
7.The piston travel shall be checked. The travel shall be controlled between 3.63mm and 5.5mm. If the
wearing of friction plate is serous, the piston travel will become longer, which will lead to longer piston
engagement time, and then cause shift delay. The piston travel control is usually calculated via the
thickness of friction plate. The requirements for the thickness of the friction plates are: the cumulative
thickness of 6 driving discs and 6 driven discs shall be controlled between 25.5mm and 26.1mm, and the
maximum thickness shall not exceed 26.3mm.
8. The bearings, bolts, etc. shall be checked to see if they are damaged or loose.
9. The oil channels on the gear I and gear III housings shall be carefully checked to see if there are
cracks.
Description of malfunction:
After every gear shift, the pressure of gearbox increases slowly. After the engine is heated, the pressure
will go down to an extent, but gear I and gear III operate properly.
Possible reasons:
The oil is shared by various gears of clutches. The proper operation of gear I and gear III indicates that oil
27
Chapter 5 Troubleshooting
Torque Converter and Gearbox System
is not the main reason that causes the shift delay of gear II.
Malfunction description:
After the loader is started, the pressure of various gears of the gearbox cannot reach the normal value
(1.2MPa) Though the pressure of various gears is abnormal, the driving and operation are normal.
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.
28
Chapter 5 Troubleshooting
Torque Converter and Gearbox System
Malfunction description: after the loader is started, the pressure of various gears of the gearbox cannot
reach 1.2MPa. 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 speed-changing control rod is loose or dislocated.
3. The pressure regulating spring of the speed-changing control valve is broken or the decompression
lever is stuck.
4. The return of the stop valve rod of the speed-changing control valve is not in the right position.
5. The speed-changing control valve leaks internally.
6. The oil suction pipe of the variable-speed pump is blocked or the operating efficiency of the
variable-speed pump declines.
3. 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.
4. The pressure regulating valve rod of the speed-changing control valve shall be checked to see if they
are stuck. If they are stuck and unable to return, diesel oil or gasoline can be used to clean them. If they
are normal, please check the next step.
5. The stop valve rod of the speed-changing control valve shall be checked to see if it is stuck. If it is stuck,
some pressure oil will directly flow back to the oil pool, which will cause insufficient pressure of various
gears and insufficient driving and operating power. If the stop valve rod is not stuck, please check the next
step.
6. 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.
7. The oil bottom filter screen shall be checked to see if it is blocked. If it is blocked, please replace the
filter screen, filter element and gearbox oil. If the oil and filter screen is clean, please check the next step.
8. The oil sanction rubber pipe of the variable-speed pump shall be checked to see if the inner layer falls
off or the pipe is blocked. When the inner layer falls off or the pipe is blocked, the oil suction will become
difficult. The malfunction can be removed if the oil suction rubber pipe is replaced. If the rubber pipe is
29
Chapter 5 Troubleshooting
Torque Converter and Gearbox System
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 return oil pressure of the torque converter is too high.
30
Chapter 5 Troubleshooting
Torque Converter and Gearbox System
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. Oil inlet valve of torque converter is damaged or adjustment pressure is too high.
5. The stop valve of the speed-changing control valve does not return to the right position.
6. The speed-changing pump leaks internally.
7. 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.
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
31
Chapter 5 Troubleshooting
Torque Converter and Gearbox System
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 sucked flat or blocked.
32
Chapter 5 Troubleshooting
Torque Converter and Gearbox System
33
Chapter 5 Troubleshooting
Torque Converter and Gearbox System
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 impeller breaks completely.
Inspection steps or actions:
34
Chapter 5 Troubleshooting
Torque Converter and Gearbox System
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.
Radiator
35
Chapter 5 Troubleshooting
Torque Converter and Gearbox System
36
Chapter 5 Troubleshooting
Torque Converter and Gearbox System
Malfunction 5-1-16:
Gearbox releases 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:
2. The oil suction pipe of the speed-changing pump is blocked or filter screen is blocked.
3. Bearings are damaged or the meshing clearance between gears is too large.
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.
1. The oil bottom filter screen shall be disassembled to check the oil consumption situation, including
37
Chapter 5 Troubleshooting
Torque Converter and Gearbox System
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 rubber pipe of
the speed-changing pump and other pipes shall be checked and the oil shall be replaced.
2. After the oil is replaced, the second test run shall be started: if the abnormal noise at the neutral
position still exists, the speed-changing pump shall be disassembled and the engine shall be started
again (the engine running time shall be short) If the abnormal noise disappears, then the malfunction is
caused by the speed-changing pump or a flat rubber pipe. If the abnormal noise still exists, then the
malfunction is caused the torque converter. There are three reasons: 1. the bearings of the torque
converter are damaged; 2. The friction between the pump impeller and the worm wheel or the fall-off of
elastic pin; 3. The meshing between the transfer gear and the driving gear of the working pump or the
driving gearing of the speed-changing pump is not regular. Among them, the check shall be focused on if
the flat key between the pump driving gear and the driving shaft is worn out.
The third test run: the front and rear driving 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. The abnormal noise disappears, so the noise comes from the driving shaft. The driving 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.
38
Chapter 5 Troubleshooting
Torque Converter and Gearbox System
Malfunction S/
Cause Troubleshooting method
No. N
1 Low output speed of engine Check and adjust the engine
Low output Low oil supply pressure of torque
2 See the item on low oil supply pressure
torque converter
3 High oil temperature See the item on high oil temperature
4 Use of unsuitable oil Replace it with the required oil
1 Insufficient oil charge Replenish it to the required value
2 Excessively high oil level Drain the oil to an appropriate level
3 Clogged oil filter Check and clean the oil filter
Check and clean the radiator and check and
High oil 4 Clogged radiator and pipeline
fasten the pipeline
temperature 5 Problem with cooling system Check the cooling system
Loose connection of oil suction Adjust the operating cycle, reduce the
6
line operating load
High throttle, long-time slow Damaged inlet valve or excessively low
7
operation pressure setting
Low oil supply
1 Insufficient oil Replenish it to the required value
pressure
Insufficient oil supply or damage
2 Check the wear and tear of oil pump
to variable speed pump
Check the wear and tear of matching parts of
3 Excessively big internal leakage
seal ring, replace the seal ring
Damaged inlet valve or
4 Check, replace or adjust the spring
excessively low pressure setting
Obstructed or unsealed oil suction
5 Check the piping system
line
Damaged oil seal, paper gasket,
1 Check, replace
Oil leak O-ring
2 Loosened thread connection Check, fasten
1 Bearing failure Check, replace
Wear and tear of gear wheel and
High noise 2 Check, replace
spline
level
Broken retaining ring on
3 Check, replace
turboshaft or guide impeller seat
39
Chapter 5 Troubleshooting
Drive Axle System
40
Chapter 5 Troubleshooting
Drive Axle System
Note: The installation shall be conducted strictly in compliance with the requirements for driving axle
corresponding to various loader models.
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 dismounted to be repaired.
The contract surface is near the middle (slightly The contact surface is near the gear top
deviating to the flank at the larger end) of the larger end, but the stress is not
concentrated on the gear top
41
Chapter 5 Troubleshooting
Drive Axle System
42
Chapter 5 Troubleshooting
Working hydraulic system
5-3-01.During the loading operation, suddenly the boom and the bucket are not able to work....... [42]
5-3-02.During loading, the bucket automatically turns upward.............................................................. [43]
5-3-03.During loading, the bucket is able to operate normally. However, after the bucket is taken
back, it automatically turns downward........................................................................................................[44]
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............................................................................[44]
5-3-05.The bucket automatically turns downward when it is taken back, and the boom also
automatically lowers after it is lifted............................................................................................................ [44]
5-3-06.he boom automatically lowers after it is lifted...............................................................................[45]
5-3-07.Lifting of bucket and boom is powerless....................................................................................... [46]
43
Chapter 5 Troubleshooting
Working hydraulic system
Working
pump
2. The oil outlet pipe of the working 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 working pump, then the shaft of working 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.
44
Chapter 5 Troubleshooting
Working hydraulic system
45
Chapter 5 Troubleshooting
Working hydraulic system
46
Chapter 5 Troubleshooting
Working hydraulic system
Distribution
valve
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 boom cylinder shall be checked to see if the sealing members are damaged or the piston and the
piston rod are damaged by pulling.
47
Chapter 5 Troubleshooting
Working hydraulic system
internal leakage, the bucket cylinder, boom cylinder shall be dismounted 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.
48
Chapter 5 Troubleshooting
Pilot control system
Working pump
Figure 5-13
49
Chapter 5 Troubleshooting
Pilot control system
The oil-inlet rubber pipe or the oil-suction filter element of the working 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.
50
Chapter 5 Troubleshooting
Pilot control system
Malfunction case 5-4-08: the boom cylinder automatically moves downward rapidly
Malfunction characteristics: the bucket cylinder does not have obvious automatic downward movement
51
Chapter 5 Troubleshooting
Pilot control system
Possible reasons:
1. The valve core of the lowering valve that links the pilot valve and the boom is stuck.
2. The slide vale rod that links the distribution valve and the boom is stuck.
3. The boom cylinder leaks internally.
Inspection steps or actions:
1. The control rod that links pilot valve and boom 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 multiple unit valve
and boom to be slightly opened, so the oil of the large chamber of the boom cylinder leaks back to the oil
tank.
2. The control rod that links pilot valve and boom is able to return to the middle position, but the slide valve
rod that links hydraulic-control multiple unit valve and boom is stuck by contaminants and cannot be
closed completely, so the oil of the large chamber of the boom cylinder leaks through the oil inlet of the
multiple unit valve back to the oil tank
3. The sealing members of the boom cylinder are damaged, so the internal leakage is too large. The
sealing members shall be replaced.
Figure 5-14
3. The slide valve rod that links multiple unit valve and bucket is stuck.
Inspection steps or actions:
52
Chapter 5 Troubleshooting
Pilot control system
53
Chapter 5 Troubleshooting
Pilot control system
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 multiple unit valve and
boom is blocked, the small chamber oil of the boom 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 boom 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 multiple unit valve and boom
shall be cleaned.
2. The sequence valve (inside 2C opening) inside the pilot valve shall be cleaned.
54
Chapter 5 Troubleshooting
Steering hydraulic system
55
Chapter 5 Troubleshooting
Steering hydraulic system
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 treatment methods:
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 characteristics: During steering, some idle stroke may occur suddenly, or when the road is
uneven, it will automatically deflect towards the direction of gravity.
56
Chapter 5 Troubleshooting
Steering hydraulic system
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.
57
Chapter 5 Troubleshooting
Steering hydraulic system
58
Chapter V Troubleshooting
Foot Brake System
59
Chapter V Troubleshooting
Foot Brake System
Booster pump
Figure 5-08
2. Replace the brake fluid, which shall be plant synthetic brake fluid, with Longking special 719 synthetic
brake fluid required. (Brake fluids of different grades and specifications can not be mixed)
3. Confirm whether the brake pads comply with brake requirements, and replace them if not.
4. Clean the brake system, and as required, empty the air in the system.
5. Check the brake caliper piston for return flexibility. If necessary, dismount the corresponding brake
calipers to ensure their flexible return.
6. Carry out a comprehensive inspection of brake lines.
7. Check whether the brake disc hardness is too hard. If yes, replace brake discs meeting the
requirements.
60
Chapter V Troubleshooting
Foot Brake System
Figure 5-09
2. Disassemble the booster pump, and clean and replace the seals.
3. Disassemble the brake caliper, clean the brake the system, replace the piston seal and replace
damaged pistons and brake fluid.
4. Discharge air from the brake caliper bolts.
61
Chapter 5 Troubleshooting
Electrical system
62
Chapter 5 Troubleshooting
Electrical system
63
Chapter 5 Troubleshooting
Electrical system
64
Chapter 5 Troubleshooting
Electrical system
65
Chapter 5 Troubleshooting
Electrical 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%
66
Chapter 5 Troubleshooting
Electrical system
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
67
Chapter 6 Main Parts
68
Chapter 6 Main parts
Section 1 Hydraulic torque converter
Table of Contents
1 Structure and Functions.......................................................................................................... [68]
2 Testing and Adjustment...........................................................................................................[71]
3 Dismounting and Installation.................................................................................................. [72]
4 Disassembly and Repair......................................................................................................... [73]
Figure 6-1-01
The torque converter chiefly comprises three working wheels, namely pump impeller, turbine wheel and
guide impeller, and its working chamber is filled with working oil. Pump impeller is designed to convert the
mechanical energy of the engine into the kinetic energy of the liquid. Powered by the engine, the pump
impeller rotates at the same speed, forcing the oil in the chamber to impact the turbine wheel at a huge
speed and pressure. The turbine wheel absorbs and reverts the kinetic energy of liquid flow into
mechanical energy, thus transmitting the dynamic force to output flange; the guide impeller is fixed and
does not rotate. While impacting guide impeller blades, the liquid flow gives a torque to the guide impeller.
69
Chapter 6 Main parts
Section 1 Hydraulic torque converter
Since the guide impeller is fixed, it generates a counter torque that has an equal force in the opposite
direction and transfers it to the turbine wheel via liquid flow, thus changing the output torque of the guide
impeller. The blades of the three working wheels have given shapes and inlet/outlet angles so that the
liquid can pass through different blade wheels according to the required flow passages and directions.
Items
Type of hydraulic torque converter Single-stage single-phase centrifugal turbine
Direction of rotation (seen at the input end) Clockwise
Maximum input speed 2400r/min
Input power 38~105kW
Working fluid 6# or 8# hydraulic transmission oil
Outlet oil Normal 80~100℃
pressure Short time 120℃
Inlet oil pressure 0.45~0.65Mpa
Outlet oil pressure 0.25~0.5Mpa
Performance parameters
Effective diameter D 315mm
Maximum efficiency ηmax ≥0.82
Zero-speed torque ratio K0 3.45±5%
Nominal torque MBgη 69.16±5% N.m
Inside the hydraulic torque converter, the flow channels of pump impeller 14, turbine 5 and guide wheel
11 make up the space for liquid circulation, and the aforesaid three components and pump impeller cover
6 form a closed container together.
The power of engine is transmitted to pump impeller 14 via spring disc 3 and pump impeller cover. Under
the effect of centrifugal force, the pump impeller transforms the mechanical energy of engine to the kinetic
energy and pressure energy of working fluid to drive the turbine to rotate. Then the turbine transforms the
liquid energy to mechanical energy again.
Via the fixed guide wheel, the fluid that flows out of the turbine transforms part of the pressure energy to
kinetic energy, increases the rotation degree of fluid and flows back to the entrance of the pump impeller.
Such circulation forms the normal operation of hydraulic torque converter.
The guide wheel increases the velocity circulation of the fluid at the entrance of the pump impeller, and
consequently increases the output torque of the hydraulic torque converter and completes the “torque
conversion”. The increasing degree of output torque depends on the condition at the exit of turbine, i.e.
such change automatically adapts to the change of load. When the load increases, the output rotating
speed automatically decreases, and the velocity circulation of fluid at the exit of turbine decreases, the
velocity circulation of fluid at the entry of pump impeller increases, and the torque outputted by turbine
increases simultaneously. On the contrary, when the load decreases, the output rotating speed
automatically increases, and consequently the output torque decreases. This feature is the
auto-adaptation of rotating speed and torque to external load.
The guide wheel is fixed with guide wheel base 47 on shell 45. Pump impeller is fixed with pump impeller
hub 49. On the pump impeller hub, there is a pump-driving gear 28 that meshes two pump-driven gears
26. The driven gears drive working pump and variable speed pump via two pump-driving shafts 20 and 23.
The variable speed pump provides oil to shift valve and hydraulic torque converter of gearbox.
The oil that enters hydraulic torque converter flows through the oil inlet chamber of the guide wheel base
and the gap between bearing balls and enters the circulating circle of hydraulic torque converter from the
exit of pump impeller, and then flows through the gap between the exit of turbine and the exit of guide
wheel as well as the gap between turbine shaft 39 and guide wheel base, finally flows out of the shell
through the oil outlet chamber of guide wheel base.
70
Chapter 6 Main parts
Section 1 Hydraulic torque converter
Figure 6-1-02
List of parts
No. No. of diagram Name
1 YJ31502GA-01 Cover
2 YJ31502GA-03 Transition disc
3 YJ31505X-01 Spring disc
4 YJ31505X.02 Spring disc assembly
5 YJ31502A.02 Turbine assembly
6 YJ31502GA-02 Pump impeller cover
9 YJ31505X-06 Pressure plate of spring disc
11 YJ31502A-04 Guide wheel
12 YJ31502GA-04 Cover plate
14 YJ31502F-06 Pump impeller
17 YJ31502D-08 Upper cover plate
18 YJ31502D-09 Paper gasket
19 Vent plug 15276
20 YJ31502D.01 Pump-driving shaft assembly (I)
22 YJ31502A-14 Spigot ring
23 YJ31502F.01 Pump-driving shaft assembly (II)
24 YJ31502D-11 Secondary separating plate
25 YJ31502D-12 Primary separating plate
List of parts
No. No. of diagram Name
26 YJ31502D-13 Pump-driven gear
28 YJ31502D-14 Pump-driving gear
35 YJ31502C-09 Shaft sleeve
37 YJ31502C-07 Retainer ring
38 YJ31502D-15 Output flange
39 YJ31502C-05 Turbine shaft
41 YJ31505C.04 Back-pressure valve
42 YJ31502B-04 Paper gasket
44 YJ31502C-10 End cover
45 YJ31502G-02 Shell
46 YJ31502A-13 Sealing ring
47 YJ31502D-16 Guide wheel base
48 YJ31502A-09 Sealing ring
71
Chapter 6 Main parts
Section 1 Hydraulic torque converter
72
Chapter 6 Main parts
Section 1 Hydraulic torque converter
73
Chapter 6 Main parts
Section 1 Hydraulic torque converter
k. Check the wear and tear of contact area between guide impeller seat 47 and seal ring 46. Replace the
guide impeller seat or bushing if groove wear is more than 0.15mm deep.
l. The dimension of wear limit for contact area of seal lip is nominal dimension 100 plus 0.2mm.
4. Disassembly and repair
During disassembly and assembly, spare parts must be kept clean and the operation shall be performed
on work benches at the worksite free of dust and sand soil.
Spring disc
Figure 6-1-03
A-2 Dismount the bolts that connect cover and shell, and use the jackscrew hole on the cover to dismount
the cover. (See Figure 6-1-04)
Shell
Cover
Figure 6-1-04
A-3 Dismount the bolts that connect pump impeller cover and pump impeller, and use the jackscrew hole
to dismount pump impeller cover. (See Figure 6-1-05)
74
Chapter 6 Main parts
Section 1 Hydraulic torque converter
Pump
Pump impeller cover impeller
Figure 6-1-05
A-4 (see Figure 6-1-06)
a. Dismount the bearing snap ring on the left side of turbine shaft, and dismount the support bearing of
pump impeller cover.
b. Dismount the bolts that fix the retainer ring on the left side of turbine shaft, and dismount the retainer
ring.
c. Dismount the turbine assembly from the turbine shaft.
Turbine
shaft
Turbine
assembly
Retainer
ring
Figure 6-1-06
A-5 Dismount retainer ring and guide wheel. (See Figure 6-1-07)
75
Chapter 6 Main parts
Section 1 Hydraulic torque converter
Guide
wheel
Retainer
ring
Figure 6-1-07
A-6 Dismount the bolts that connect the pump impeller and pump impeller hub, dismount baffle plate, and
then dismount pump impeller. (See Figure 6-1-08)
Pump
impeller
Baffle plate
Pump impeller
hub
Figure 6-1-08
A-7 (see Figure 6-1-09)
a. Dismount the bolts that connect primary separating plate and shell, and use the jackscrew to separate
the primary separating plate and shell.
b. Dismount the components such as primary separating plate, secondary separating plate, pump
impeller hub, bearing, oil seal, pump-driving gear, etc. from the shell.
c. Dismount the aforesaid components.
76
Chapter 6 Main parts
Section 1 Hydraulic torque converter
Primary Shell
separating plate Secondary
separating
plate
Oil seal
Pump impeller hub
Figure 6-1-09
A-8 Dismount nut, and then dismount retainer ring, output flange and shaft sleeve.
(See Figure 6-1-10)
Output flange
Shaft sleeve
Figure 6-1-10
A-9 Dismount the bolts that connect upper end cover and shell, and then dismount end cover together
with oil seal 43 from the shell. (See Figure 6-1-11)
77
Chapter 6 Main parts
Section 1 Hydraulic torque converter
Shell
End cover
Figure 6-1-11
A-10 Dismount retainer ring and O-shaped ring. Use a copper bar to knock the turbine shaft from the left
side, and then dismount the turbine shaft together with bearing from the guide wheel base hole. (See
Figure 6-1-12)
Turbine shaft
Figure 6-1-12
78
Chapter 6 Main parts
Section 1 Hydraulic torque converter
Figure 6-1-13
Shell
Bearing
Pump-driving
shaft
Figure 6-1-14
A-12 Dismount the pump-driven gear together with bearing from the shell.
(See Figure 6-1-15)
79
Chapter 6 Main parts
Section 1 Hydraulic torque converter
Shell
Pump-driven gear
Figure 6-1-15
(Disassembly is completed)
Shell Bearing
Spigot ring
Bearing
Figure 6-1-16
80
Chapter 6 Main parts
Section 1 Hydraulic torque converter
B-2 After installing the bearing and sealing ring (see Figure 6-1-02) onto the turbine shaft, install the
turbine shaft onto the guide wheel base, and then install retainer ring, O-shaped ring and sealing ring (see
Figure 6-1-02). Install the aforesaid components onto the shell, and then install O-shaped ring. (See
Figure 6-1-17)
Turbine shaft
Figure 6-1-17
Figure 6-1-18
81
Chapter 6 Main parts
Section 1 Hydraulic torque converter
bearing, and then connect pump impeller and pump impeller hub.
c. Fix the components of Step (b) and Step (a) together, install the pump-driving gear onto the pump
impeller hub, and then install the retainer ring.
Secondary
separating
plplate
Primary
separating
Bearing plate
Retainer
ring
Figure 6-1-19
Guide
Guide wheel
wheel base
Retainer ring
Shell
Figure 6-1-20
B-6. Install the support bearing of pump impeller cover onto the turbine assembly, install the fixing retainer
ring, install the turbine assembly onto the turbine shaft, and then install the retainer ring and fixing bolt.
82
Chapter 6 Main parts
Section 1 Hydraulic torque converter
Turbine
assembly
Support bearing
Fixing bolt
Retainer
ring
Fixing
retainer
ring
Figure 6-1-21
B-7 Install the O-shaped ring onto the pump impeller, and fix the pump impeller cover and pump impeller
together. (See Figure 6-1-22)
Pump impeller
Pump impeller cover Pump
impeller
Figure 6-1-22
B-8 Install the cover onto the shell. (See Figure 6-1-23)
83
Chapter 6 Main parts
Section 1 Hydraulic torque converter
Cover
Cover
Shell
Figure 6-1-23
Spring disc
Shell
Figure 6-1-24
B-10. Install paper gasket 18 (see Figure 6-1-02) and upper cover plate, and then install vent plug and
lifting ring. (See Figure 6-1-24)
84
Chapter 6 Main parts
Section 1 Hydraulic torque converter
Lifting
ring
Upper
cover
plate
Figure 6-1-25
B-11. Install paper gasket 42 (see Figure 6-1-02), back-pressure valve and pipe close. (See Figure
6-1-26)
Back-pressure
valve
Figure 6-1-26
85
Chapter 6 Main parts
Section 1 Hydraulic torque converter
86
Chapter 6 Main parts
Section 2 Gearbox
Section 2 Gearbox
Table of Contents
1 Structure and Functions.......................................................................................................... [86]
2 Testing and Adjustment...........................................................................................................[87]
3 Dismounting and Installation.................................................................................................. [88]
4 Disassembly and Repair......................................................................................................... [94]
Figure 6-2-01
87
Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-02
88
Chapter 6 Main parts
Section 2 Gearbox
④The torque converter oil pressure and oil temperature are monitored through instruments. If abnormal
condition is discovered, first check the oil filter 2, replace the filter screen or assembly. If failure remains,
check other locations.
⑤Before 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.
⑥ 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 1.5~1.7MPa, and in case of abnormal condition, inspection shall be
conducted.
⑦ 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.
Sight window
Pipeline from
Pipeline from control oil filter to Oil filter
valve to torque converter control valve
Return oil pipe Pipeline from Pipeline from Oil outlet pipe of
variable torque converter cooler
Oil suction pipe speed pump to cooler
of variable to oil filter
speed pump
Figure 6-2-03
89
Chapter 6 Main parts
Section 2 Gearbox
Gearbox Torque
converter
Figure 6-2-04
As shown in Figure 6-2-04, torque converter assembly is connected to gearbox assembly through upper
transmission shaft; front and rear output flanges of the gearbox are connected to front and rear drive
axles through transmission shaft; torque converter is connected to the diesel engine through internal and
external reaming.
(II) Disassembly steps
(1) Disassemble the cab in the following steps:
Figure 6-2-05
90
Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-06
Figure 6-2-07
a. Hoist up the cab with a traveling crane and hoisting device. Ropes shall be straightened up but not
tightly stretched;
b. Dismount nylon lock nut, pin and gasket;
c. Hoist the cab and put it at a safe place;
d. Remove the shock pad assembly;
91
Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-08
a. Use the wrench to dismount bolts and gaskets connecting the bracket of oil filling pipe assembly to the
frame.
b. Use the wrench to dismount hoses and steel pipes connected to the variable speed pump (Note:
Before dismounting, open the oil drain plug at the bottom of gearbox to drain off transmission oil. Then
loosen the joints of steel pipe and hose to be dismounted. Put cotton cloth at the dismounting joint and
strike lightly the joint of steel pipe or hose to be dismounted. After releasing all pressure, remove the steel
pipe or hose).
Bolt M16×110
Figure 6-2-09
c. As shown in Figure 6-02-09, use pneumatic wrench and supporting sleeve to dismount four (4)
M16×110 bolts, nuts and washers (M16 flat washer and self-locking nut) connecting the gearbox to
the mounting base of the gearbox on the rear frame.
92
Chapter 6 Main parts
Section 2 Gearbox
Bolt M12×1.5×35,
M12×1.5 self-locking nut
Gearbox Middle transmission shaft
Intermediate support
Figure 6-2-10
e. As shown in Figure 6-2-10, use pneumatic wrench and supporting sleeve to dismount four (4)
M14×1.5×60 bolts and self-locking nuts connecting the gearbox to the central transmission shaft; to
dismount four (4) M14×1.5×42 bolts and self-locking nuts connecting the gearbox to the rear transmission
shaft.
f. Use pneumatic wrench and supporting sleeve to dismount M12×1.5×35 bolts and self-locking nuts
connecting the gearbox to the upper transmission shaft.
g. Use the specialized hoisting device to lift the gearbox assembly to the given bracket.
(III) Commissioning requirement
Commissioning, if needed, shall be conducted by designated personnel;
(IV) Installation
(1) Install the gearbox in the following steps:
a. Use the specialized lifting device to hoist the gearbox to the frame;
b. Mount bolts and nut connecting upper transmission shaft, front and rear transmission shafts to the
gearbox;
c. Use bolts to fix the gearbox on the gearbox mounting base.
Note: Keep clean during installation.
(2) Install the cab in the following steps:
a. Before hoisting, check if all interior trims of cab assembly are intact;
b. Preassemble back plate and shock pad. Mount the shock pad assembly (upper components) on the
pedestal of the cab, with hole sites aligned, as shown in Figure 6-2-11;
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Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-11
Figure 6-2-12
c. As shown in Figure 6-2-12, use a special lifting device and traveling crane to lift the cab at a uniform
velocity to the top of the frame and slowly adjust the height of the frame. Put the gasket and rubber pad
assembly on the position as shown in Figure 6-2-13 and let the cab steadily fall on the cab mounting base.
Align holes and join them with pins.
94
Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-13
1 Cab system 1
30812900102
2 Rubber pad 4
30812000118
3 Pin 51512091801 4
4 Nylon self-locking nut 4
51331001120
M18×1.2
5 Washer 51420170121 4
6 Base plate 4
30812100843
95
Chapter 6 Main parts
Section 2 Gearbox
(1) Wrench (for dismounting the oil level check valve, etc.)
(2) Impact wrench (for dismounting oil pan bolts, variable speed distribution valve mounting bolts,
transmission oil pump bolts, rear end cover screws, etc.)
(3) Hammer
(4)Copper rod
(5)Pliers (for dismounting cotter pins)
(6) Socket wrench
(7)Puller
(8)Snap ring pliers
(9)Jackscrew (for pushing out the rear end cover)
(10) Slings (for lifting the second gear assembly, reverse planet carrier assembly, rear output shaft,
gearbox assembly, etc.)
(11)Special gripper (for dismounting the bearings on the the second gear assembly)
(12)Ring spanner (for dismounting the second gear friction plate screws, reverse planet pinion shaft
screws, etc.)
(13)Screwdriver (for dismounting the second gear rotating bearings, dismounting framework oil seals and
bearings on the intermediate output shaft)
(14) Lifting bolts and iron wire (for lifting reverse gear planet carrier assembly)
(15) Hex socket (for dismounting the rear output flange fastening nuts)
(16) Special tool (for mounting the second gear piston jacket)
(17) Gauge block (for checking the second gear piston bearing holes)
(18) Front and rear output shaft jackets (not required if a new gearbox has no separate front and rear
output shafts)
(19) Mounting bracket for gearbox assembly
(20) Lifting screw (used for lifting reverse pistons)
(21)Dial indicator (for checking the perpendicularity of box end surface to the output shaft of variable
speed pump)
(22) Scraper (for trimming the variable speed pump mounting surface on the box)
I. Disassembly of gearbox
(1)Disassembling of gearbox assembly
A-1. Put the gearbox assembly flat on the mounting jig. Use the wrench to take down 6 fastening bolts of
control valve. (See Figure 6-2-14)
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Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-14
A-2. Disassemble oil pipes of all gears and lubricating pipes of all shafts with the wrench and pay
attention to worn thread of bolts. (See Figure 6-2-15)
Figure 6-2-15)
A-3. Dismount the oil filling pipe assembly with the wrench and check if O-ring is in good condition. (See
Figure 6-2-16)
97
Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-16
A-4. Unscrew 4 bolts with the wrench and take down the brake. (See Figure 6-2-17)
Figure 6-2-17
A-5. Use pneumatic wrench to dismount nylon nut M33×1.5 of the front output flange, and remove clamp
plate, O-ring, washer and front output flange assembly in order. (See Figure 6-2-18)
Figure 6-2-18
A-6. Use the wrench to unscrew bolt M10. Use four (4) M10 bolts and screw them into screwed holes in
box cover to take down the box cover assembly. (See Figure 6-2-19)
98
Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-19
A-7. Remove bearing 6312 with a pulling tool and then take out adjusting washer, output driven gear and
shaft sleeve. (See Figure 6-2-20)
Figure 6-2-20
A-8. Use pneumatic wrench to take out nut M24×1.5 and then take out gasket, rubber pad and input
flange (See Figure 6-2-21)
Figure 6-2-21
A-9. Use pneumatic wrench to take out nut M33×1.5 and then take out clamp plate and rear output flange.
(See Figure 6-2-22)
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Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-22
A-10. Take down the gear III clutch assembly before dismounting the gear I clutch assembly and the gear
II clutch assembly; (Alternatively, take down two-shaft NF308 bearing and conduct step-by-step
dismounting) (See Figure 6-2-23)
Figure 6-2-23
A-11. Take down output shaft by striking it with copper bar and try to protect output shaft from damage
due to falling off. (See Figure 6-2-24)
Figure 6-2-24
A-12. Use the wrench to unscrew all clamp plates, end covers and flange bolts. (See Figure 6-2-25)
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Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-25
A-13. Take out filter screen assembly, front bearing cover assembly, end cover, oil seal cover assembly,
etc. (See Figure 6-2-26)
Figure 6-2-26
A-14. Turn on return oil control valve with the jig. (See Figure 6-2-27)
Figure 6-2-27
(2) Disassembling of gear I clutch assembly
B-1. Remove two seal rings and check if they are worn or damaged. (See Figure 6-2-28)
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Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-28
B-2. Use the pulling tool to take out bearing NF308, and take down adjusting washer and shaft sleeve
separately. (See Figure 6-2-29)
Figure 6-2-29
B-3. Use the puller to take down the reverse gear I assembly, and then use jig to remove 2 bearings 6209,
and use circlip pliers to take out 2 retaining rings 85 and one shaft sleeve. (See Figure 6-2-30 and Figure
6-2-31)
Figure 6-2-30
102
Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-31
B-4. Use circlip pliers to take out retaining ring150 and take down clutch piston clamp plate, driving clutch
disc and driven clutch disc separately. (See Figure 6-2-32)
Figure 6-2-32
B-5. Use circlip pliers to take out retaining ring 52, take out clamp plate, spring and piston assembly, and
check if seal ring has such damage as 切边, wear and tear. (See Figure 6-2-33)
Figure 6-2-33
B-6. Disassemble the other side in the steps stated in A-5. (See Figure 6-2-34)
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Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-34
(3) Disassembling of gear II clutch assembly
The disassembling steps are similar to those of gear I clutch assembly.
Figure 6-2-35
C-2. Check and make sure external seal ring (new) and internal seal ring are in good condition and have
no quality defects as cut edge, wear and tear. During fitting, pay attention to the facing direction of the lip
of internal seal ring. (See Figure 6-2-36)
Figure 6-2-36
C-3. Mount piston assembly, spring and clamp plate in order, and then use circlip pliers to mount retaining
ring52. (See Figure 6-2-37)
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Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-37
C-4. Mount 6 driven clutch discs and 6 driving clutch disc and clutch piston clamp plate in order, and then
use circlip pliers to mount retaining ring150.
(Note: Depending on actual condition of friction disc, determine if new friction discs are used) (See Figure
6-2-38)
Figure 6-2-38
C-5. Use the jig to knock in bearing 6209, mount 2 retaining rings 85 into circlip groove of reverse gear I,
and then mount shaft sleeve and bearing 6209 separately. (See Figure 6-2-39)
Figure 6-2-39
C-6. Mount shaft sleeve and bearing NF308 (Thermal assembling at a temperature of100℃ is
recommended for bearing). (See Figure 6-2-40)
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Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-40
C-8. Mount the following components in order according to fitting method as stated in A-6: piston
assembly, spring, clamp plate, retaining ring 52, driven clutch disc (6 pcs), driving clutch disc (6 pcs),
clutch piston clamp plate, retaining ring 150, bearing 6209 (2 pcs), retaining ring85 (2 pcs), shaft sleeve,
forward gear I and bearing NF308. (See Figure 6-2-41)
Figure 6-2-41
(2) Repair of gear II clutch assembly
D-1. Mount piston assembly and prevent cut edge of internal and external seal rings. Mount spring and
use circlip pliers to put retaining ring 52 in place. (See Figure 6-2-42)
Figure 6-2-42
D-2. Mount 6 driven clutch discs and 6 driving clutch discs, clamp plate and retaining ring150 in order.
(Note: Depending on actual condition of friction disc, determine if new friction discs are used) (See Figure
6-2-43)
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Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-43
D-3. Use the jig to mount bearing 6209. (See Figure 6-2-44)
Figure 6-2-44
D-4. Then mount shaft sleeve, retaining ring 85 (2 pcs); drive home No.2 axle shaft gear assembly slowly
with copper bar. (See Figure 6-2-45)
Figure 6-2-45
D-5. Drive home bearing 6209 slowly with the jig. (See Figure 6-2-46)
107
Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-46
D-6. Mount shaft sleeve and No.2 axle forward gear. (See Figure 6-2-47)
Figure 6-2-47
D-7. Mount gasket and bearing NF308 (bearing adopts thermal assembling at temperatures 90~100℃).
(See Figure 6-2-48)
Figure 6-2-48
D-8. Fit the other side by repeating the methods as stated in D-1 ~ D-3;
D-9. Use the jig to mount bearing 6209 and shaft sleeve, fit retaining ring 85 onto No.2 axle first gear, and
then drive home No.2 axle first gear assembly slowly with copper bars. (See Figure 6-2-49)
108
Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-49
D-10. Drive home bearing 6209 with the jig. (See Figure 6-2-50)
Figure 6-2-50
D-11 Mount shaft sleeve and No.3 axle reverse gear. (See Figure 6-2-51)
Figure 6-2-51
D-12. Mount gasket and bearing NF308 (bearing adopts thermal assembling at temperatures 90~100℃).
(See Figure 6-2-52)
109
Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-52
(3) Repair of No.3 axle clutch assembly
E-1. Mount the piston assembly and prevent cut edge of internal and external seal rings. Mount the spring
and use circlip pliers to put retaining ring 52 in place. (See Figure 6-2-53)
Figure 6-2-53
E-2. Mount 6 driven clutch discs and 6 driving clutch discs, clamp plate and retaining ring150 in order.
(See Figure 6-2-54)
Figure 6-2-54
E-3. Use the jig to mount bearing 6209 and shaft sleeve, fit retaining ring 85 onto No.3 axle second gear,
and then drive home the No.3 axle second gear assembly slowly with copper bar. (See Figure 6-2-55)
110
Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-55
E-4. Drive home bearing 6209 with the jig. (See Figure 6-2-56)
Figure 6-2-56
E-5. Mount shaft sleeve, No.3 axle third gear, shaft sleeve and bearing NF308 (bearing adopts thermal
assembling at temperatures 90~100℃). (See Figure 6-2-57)
Figure 6-2-57
E-6. Fit the other side and mount shaft sleeve, No.3 axle output gear and bearing NF309 in order (bearing
adopts thermal assembling at temperatures 90~100℃). (See Figure 6-2-58)
111
Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-58
(4) Repair of gearbox assembly
F-1. Fit together the control valve assembly and make sure fitting surface must be free of particles,
foreign matters or scar. Apply force (100Nm twisting force) on bolt M12×110 with torque wrench. (See
Figure 6-2-59)
Figure 6-2-59
F-2. Fit together oil seal cover assembly, end cover, rear output flange assembly (Note: Adjust the gap
behind oil seal cover and end cover before fitting paper gasket and adjusting washer). Afterwards, install
the rear bearing end cover and tighten bolt M12×35 using torque wrench with a 100Nm torque. (See
Figure 6-2-60)
Figure 6-2-60
F-3. Use jig to mount the output shaft assembly. (See Figure 6-2-61)
112
Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-61
F-4. Remount the repaired No.1 axle clutch assembly into No.2 axle clutch assembly, and then fit the
No.3 axle assembly. Afterwards, rotate all shafts to see that they engage well. (See Figure 6-2-62)
Figure 6-2-62
F-5. Mount shaft sleeve, output driven gear, shaft sleeve and bearing 6312. (See Figure 6-2-63)
Figure 6-2-63
F-6. d and kept clean, and fit together box cover assembly (including new paper gasket for box cover),
spring pad 10 and bolts 10×30 (after tightening, apply a 55Nm torque on bolts with torque wrench)
(Before fitting, check if outer race of bearing for check box cover assembly NF308/NF309 has any scar.
Make bearing replacement if there is scar on outer race). (See Figure 6-2-64)
113
Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-64
F-7. Check and make sure seal ring is in good condition and has no quality defects as cut edge,
expiration, wear and tear. Fit seal ring of each shaft. (See Figure 6-2-65)
Figure 6-2-65
F-8. Mount sealing gasket, end cover assembly of each shaft and bolts M12×35 (after tightening, apply a
100Nm torque using torque wrench). (See Figure 6-2-66)
Figure 6-2-66
F-9. Mount adjusting washer, sealing gasket (new), front bearing end cover assembly (including seal ring,
check if seal ring is in good condition) in order, and tighten the bolts (after tightening, apply a 100Nm
torque using torque wrench). (See Figure 6-2-67)
Figure 6-2-67
114
Chapter 6 Main parts
Section 2 Gearbox
F-10. Fit joints on first gear, second gear, third gear, R gear, F gear and oil inlet end covers in order; apply
567 sealant on screw thread before fitting. (See Figure 6-2-68)
Figure 6-2-68
F-11. Fit the joints. Apply 567 sealant at 2~3 threads of the joints before fitting. (See Figure 6-2-69)
Figure 6-2-69
F-12. Mount joints A8 and A10 and then use a special jig to tighten the joints. (See Figure 6-2-70)
Figure 6-2-70
F-13. Mount lubrication joint of reverse shaft. (See Figure 6-2-71)
115
Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-71
F-14. Use the wrench to mount first gear oil pipe, second gear oil pipe (with O-ring 11×1.9 mounted inside
the joint), third gear oil pipe, reverse oil pipe, forward oil pipe, reverse lubricating oil pipe, No.1 axle
lubricating oil pipe, No.3 axle lubricating oil pipe in order. Conduct reliable thread connection of each oil
pipe and rule out oil leakage. (See Figure 6-2-72)
Figure 6-2-72
F-15. Install the upright pedestal of the brake and 4 bolts M12×35. (See Figure 6-2-73)
Figure 6-2-73
F-16. Mount front output flange assembly, brake, washer, O-ring and clamp plate in order, and tighten
nuts with pneumatic wrench. (See Figure 6-2-74)
116
Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-74
F-17. Mount 4 bolts M12×35, pull up the handle on brake caliper assembly by hand to press two friction
discs close to brake disc. Then tighten the 4 bolts with pneumatic wrench. (See Figure 6-2-75)
Figure 6-2-75
F-18. Mount rear output flange and gasket in order and install nylon self-locking nuts M33×1.5. Tighten
the nuts with pneumatic wrench. (See Figure 6-2-76)
Figure 6-2-76
F-19. After repair of filter assembly, check if sealing gasket is in good condition. After removal of
impurities including oil sludge, mount sealing gasket, filter screen assembly, sealing gasket, flange
assembly and bolts in order. (See Figure 6-2-77)
117
Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-77
F-20. After repair of clearance adjustment, fit adjusting washer onto corresponding shafts and do not mix
them up. (See Figure 6-2-78)
Figure 6-2-78
F-21. Mount sealing gasket, end cover and oil seal cover. (See Figure 6-2-79)
Figure 6-2-79
F-22. Tighten bolts M10×30 (after tightening, apply a 100Nm torque using the torque wrench). (See
Figure 6-2-80)
118
Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-80
F-23. Mount input flange, mount rubber pad and gasket, and tighten nuts M24×1.5 with pneumatic wrench.
(See Figure 6-2-81)
Figure 6-2-81
F-24. Install valve body assembly, mount spring, valve body and valve cap, and then fit copper backing
27 and pipe joint. (See Figure 6-2-82)
Figure 6-2-82
F-25. Install the oil filling pipe assembly, check if screws for oil filling pipe are in good condition and if
screw threads are damaged, and tighten screws with pneumatic wrench.
(See Figure 6-2-83)
119
Chapter 6 Main parts
Section 2 Gearbox
Figure 6-2-83
(Repair is complete)
120
Chapter 6 Main parts
Section 2 Gearbox
121
Chapter 6 Main parts
Section 3 Drive Axle
Main drive 4
Brake 6 Differential 5 Wheel hub reducer 1
Figure 6-3-1
122
Chapter 6 Main parts
Section 3 Drive Axle
Flat shaft
Rim
Figure 6-3-2
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 6-3-3
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.
2. Dismounting and Installation
Tools needed:
1. Two 10t travelling cranes
2. Special lifting tools
3. Special carrier for front and rear axles
4. Special lengthened sleeve
5. K50 air blasting machine
6. 46 anti-reverse wrench
7. 46 sleeve
8. 1”, 2” adjustable wrench
9. 16-18 open end wrench
123
Chapter 6 Main parts
Section 3 Drive Axle
Front
transmi Rear drive axle
Front ssion Intermediate Middle/rear
drive support transmission shaft assembly
shaft
axle assembl assembly assembly
y
Tire
Rim assembly
Figure 6-3-4
①As shown in Figure 6-3-4, 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 driving shaft; rear axle is equipped with
steel oil pipe.
②Mounting bolts M24×280 (8 pcs) and lock nuts M24 (8 pcs) are used for connecting front axle to front
frame; bolts M24×240 (8 pcs) and lock nuts M24 (8 pcs) are used for connecting rear axle to rear frame;
bolts M14×1.5×42 (4 pcs) and lock nuts M14×1.5 (4 pcs) are used for the connection between front axle
and front transmission shaft and the connection between rear axle and rear transmission shaft; lock nuts
M20 (48 pcs) are used for connecting front/rear axle to front/rear rims.
(2) Dismounting steps
①Remove connecting bolts between front/rear axle and front/rear driving shaft to separate front/rear axle
from front/rear driving shaft;
②Remove steel pipe assembly and tee joint connecting front and rear axles;
③ Remove connecting bolts M24×280 (8 pcs) and lock nuts M24 (8 pcs) between front axle and front
frame; remove connecting bolts M24×240 (8 pcs) and lock nuts M24 (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 nuts between front/rear axle
and front/rear tire (12 M20 nuts per 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
124
Chapter 6 Main parts
Section 3 Drive Axle
Figure 6-3-5
3. Strike the end of the semiaxle with copper bar to eject the semiaxle (see Figure 6-3-6);
Figure 6-3-6
3. Remove semiaxle circlip and the sun wheel (see Figure 6-3-7);
125
Chapter 6 Main parts
Section 3 Drive Axle
Figure 6-3-7
Figure 6-3-8
6. Take down the cushion from outer end face of planetary carrier and check if the cushion is damaged
(see Figure 6-3-9);
Figure 6-3-9
7. Screw out bolts on the perimeter of planetary carrier; (NOTE: bolts screwed out shall be properly kept
by fitting them with corresponding nuts, washers and elastic cushions) (see Figure 6-3-10);
126
Chapter 6 Main parts
Section 3 Drive Axle
Figure 6-3-10
8. Let an iron bar go through bolt holes at both ends of the junction surface of planetary carrier, pry the
planetary carrier gently to separate the junction plane (see Figure 6-3-11) Then turn the bolt holes with the
iron bar inside to face downward, hook on the two bolt holes in planetary carrier with two hooks of the
lifting device, pull out the iron rod, and remove and dismount the planetary carrier;
Figure 6-3-11
9. Use a slotted screwdriver to pry up the thrust washer (see Figure 6-3-12), strike gently in the loosening
direction of circular nut with a hammer and chisel (or thin iron bar) to loosen the nut (see Figure 6-3-13),
and then screw off the circular nut by hand;
Figure 6-3-12
127
Chapter 6 Main parts
Section 3 Drive Axle
Figure 6-3-13
Figure 6-3-14
11. Twist off fixing bolts of brake caliper with a wrench and then remove the brake caliper (see Figure
6-3-15);
Figure 6-3-15
128
Chapter 6 Main parts
Section 3 Drive Axle
Figure 6-3-16
13. Hook on the bolthole of hub assembly with the lifting device to cause the assembly to move outward a
little. Then fix the hub with iron chain and dismount the hub assembly (see Figure 6-3-17);
Figure 6-3-17
14. Take down oil baffle plate, oil seal seat, wheelside oil seal and dust guard from the support shaft (see
Figure 6-3-18);
Figure 6-3-18
(II) Disassembly of Main drive
15. Take down main drive bolts with the wrench and lift out the main drive with the lifting device (see
Figure 6-3-19);
129
Chapter 6 Main parts
Section 3 Drive Axle
Figure 6-3-19
Figure 6-3-20
A-2. Press oil baffle and 2 seal rings (FB150×180×15) in order (or knock into with a jig) into the rim. After
pressing oil seal in, apply certain grease to avoid dry friction (see Figure 6-3-21)
Figure 6-3-21
A-3. Mount brake disc on the rim using sixteen (16) M18×2 bolts for brake disc. Elastic gasket must be
provided (see Figure 6-3-22).
130
Chapter 6 Main parts
Section 3 Drive Axle
Figure 6-3-22
(II) Repair of planetary carrier assembly
B-1. Divide 42 roller pins into two groups, which are separated by spacers. During the mounting of
planetary wheel, lubricate roller pins with grease. (See Figure 6-3-23)
Figure 6-3-23
B-2. Put three fitted planetary wheel assemblies inside the planetary carrier, and align axle holes of
planetary wheels; (See Figure 6-3-30)
Figure 6-3-30
B-3. Divide 6 planetary wheel washers into three groups, with one such washer laid on and under each
planetary wheel assembly. (See Figure 6-3-31)
131
Chapter 6 Main parts
Section 3 Drive Axle
Figure 6-3-31
B-4. Strike 3 planetary wheel axles lightly into planetary wheel axle hole with iron bar until axle end step is
level with the surface of planetary carrier; (See Figure 6-3-32)
Figure 6-3-32
(III) Repair of planetary wheel and planetary carrier assembly
C-1. Use oil press to fit the single row cylindrical roller bearing on driving spiral bevel gear, and make sure
that the bearing is pressed close to the end face of driving spiral bevel gear. (See Figure 6-3-33)
132
Chapter 6 Main parts
Section 3 Drive Axle
Figure 6-3-33
C-2. Use the jig to fit outer race of 30310 bearing and outer race of 30311bearing via oil press into bearing
seat. (See Figure 6-3-34)
Bearing 30310
Bearing 30311
Bearing 30310
Bearing 30311
Figure 6-3-34
C-3. Use the jig and oil press to fit bearing seat on driving spiral bevel gear. (See Figure 6-3-35)
Figure 6-3-35
C-4. Use oil press to press two FB65×90×10 oil seals into gland bonnet. Flatten oil seal and then apply
grease to avoid dry friction of oil seal at an early stage; (See Figure 6-3-36)
Figure 6-3-36
C-5. Fit together sealing paper gasket, gland bonnet (with oil seal flattened) and mount them on bearing
seat. Make sure bearing oil sump is aligned with oil sump of sealing paper gasket; (See Figure 6-3-37)
133
Chapter 6 Main parts
Section 3 Drive Axle
Figure 6-3-37
C-6. Fit the already welded flange assembly via spline engagement on driving spiral bevel gear; (See
Figure 6-3-38)
Figure 6-3-39
(IV) Repair of differential gear assembly
D-1. Purge the right shell of differential gear and put in semi-axle gear washer, semi-axle gear. Manually
rotate semi-axle gear and check if there is any jamming during the fitting between semi-axle gear and
right shell. (See Figure 6-3-40)
134
Chapter 6 Main parts
Section 3 Drive Axle
Figure 6-3-40
D-2. Purge the left shell of differential gear and put in semi-axle gear washer, semi-axle gear. Manually
rotate semi-axle gear and check if there is any jamming during the fitting between semi-axle gear and left
shell. (See Figure 6-3-41)
Figure 6-3-41
D-3. Check and put the cleaned crisscross shaft on semi-axle gear, and mount bevel gear and bevel gear
washer in order on the vertical shaft. After overturn, mount bevel gear and bevel gear washer in order on
other 3 shafts. (See Figure 6-3-42)
Figure 6-3-42
D-4. Put the crisscross shaft assembly on crisscross hole of the right shell of differential gear, and strike
lightly the center of crisscross shaft with soft iron bar to make sure crisscross shaft integrates closely into
crisscross hole of the right shell of differential gear. (See Figure 6-3-43)
135
Chapter 6 Main parts
Section 3 Drive Axle
Figure 6-3-43
D-5. Integrate the left and right shells of differential gear through alignment. Strike the ribbed plate of left
shell lightly with soft iron bar to ensure close integration of left and right shells. (See Figure 6-3-44)
Figure 6-3-44
D-6. Use eight (8) M14×139×1.5 flange bolts to connect left and right shells, and use eight (8)
M14×1.5-10 nuts for tightening. Twisting torque of bolts is 200~230N.m. (See Figure 6-3-45)
Figure 6-3-45
D-7. After force application, use eight (8) 3.2×26 cotter pins for loosening prevention. Two heated
bearings 30215 (heating temperature: 90°C~100°C) are mounted at bearing position of the left and right
shell of differential gear. Do remember not to strike the bearings directly with iron bar. Instead, use the jig
to jack up the inner race of bearing and strike lightly for fitting. (See Figure 6-3-46)
136
Chapter 6 Main parts
Section 3 Drive Axle
Figure 6-3-46
D-8. Install the driven spiral bevel gear and make sure the fitting surface is clean. After mounting
12-M14×1.5×52 bolts, put the gear on the jig. Screw in 12-M14×1.5 slotted nuts and pretighten them with
80% torque before applying a 200~230N.m torque with torque wrench (see Figure 6-3-47). Finally use
twelve (12) 3×25 cotter pins to prevent loosening. (See Figure 6-3-48)
Figure 6-3-47
Figure 6-3-48
137
Chapter 6 Main parts
Section 3 Drive Axle
Figure 6-3-49
E-2. Turn over the carrier and put the differential gear assembly on the carrier as shown in the diagram.
Screw in 2 adjusting nuts, cover them with two bearing caps, screw in four (4) M22 ×2.5×105 bolts and
pretighten them with 80% torque using pneumatic wrench. The torque of M22×2.5 ×105 is 500~600N.m
(See Figure 6-3-50);
Figure 6-3-50
E-3. For the purpose of backlash adjustment between driving and driven spiral bevel gears, first use red
lead on tooth face of driven spiral bevel gear and observe mesh mark. Mesh mark shall be ≥40% in the
tooth depth direction and ≥50% in the tooth length direction (See Figure 6-3-51).
138
Chapter 6 Main parts
Section 3 Drive Axle
E-4. Tighten M10 bolts tighten, fasten adjusting nuts, and wind up M10 bolts with intertwined iron wires for
loosening prevention (See Figure 6-3-52).
Figure 6-3-52
E-5. Install thrust bolts, apply 598 surface sealant to thrust bolts with copper bush, lock washer and nuts
already mounted, and screw those bolts into the carrier. Use the pneumatic tool to drive them to required
positions (Screw in thrust bolt to contact the driven spiral bevel gear before loosening about 1/4), fasten
them with nuts and tighten them with lock washers (See Figure 6-3-53).
139
Chapter 6 Main parts
Section 3 Drive Axle
Figure 6-3-53
(VI) Repair of drive axle assembly
F-1. Mount oil baffle and oil seal seat on wheel-side support shaft through thermal assembling, and
ensure uniform contact between end face of oil seal seat and dust shield; dust shield shall have uniform
contact with end face of end axle φ130, and spacer shall be installed at the end of wheel-side support
shaft. Such spacer shall be flattened through light strike (See Figure 6-3-54).
Spacer installation and maintenance
Figure 6-3-54
F-2. Fit the already installed rim assembly onto wheel-side support shaft. While fitting the bearing, apply
grease evenly along inner race of the bearing; while fitting the rim, use the special jig on wheel-side
support shaft to protect oil seal (See Figure 6-3-55).
Figure 6-3-55
F-3. Mount inner ring before putting it into taper sleeve. Flatten taper sleeve with the jig. (See Figure
6-3-56)
140
Chapter 6 Main parts
Section 3 Drive Axle
Figure 6-3-56
F-4. Mount round nut, gasket 85and round nut in order. It is noted that gasket 85 should have two claws
planted on round nuts, with one claw grasping the gap of inner round net and with the other claw grasping
the gap of outer round nut (See Figure 6-3-57).
Figure 6-3-57
F-5. Fit the planetary carrier assembly. Check if the interior of planetary carrier is clean and free of foreign
matters. Align rim bolt holes using an iron bar to go through rim bolt holes of planetary carrier and the rim
(See Figure 6-3-58).
Figure 6-3-58
F-6. Mount 12 rim bolts, and mount twelve (12) 20 spring pads and 12-M20×1.5 nuts. Turn the wheel
carrier and check if it has such problem as jamming. Screw in 12-M20 nuts by 3-4 threads and pretigthen
M20nut diagonally with a 80% pretightening force using a pneumatic tool. The required torque is
370~450N.m, and make sure rim nuts are mounted on the outside. (See Figure 6-3-59)
Rim
Nut
141
Chapter 6 Main parts
Section 3 Drive Axle
Rim,
nut
Figure 6-3-59
F-7. Fitting of brake caliper: put two brake discs into brake caliper with friction surface facing inward, and
brake discs are supported by copper column of brake caliper (See Figure 6-3-66).
Figure 6-3-66
F-8. Tighten the fitted brake caliper using six (6) M20×65 bolts and six (6) M20 elastic gaskets, and
tightening torque of bolt is 370~450N.m. Pre-tighten the bolt with 80% force using a pneumatic wrench,
and then apply the required torque with a torque wrench. (See Figure 6-3-67)
Figure 6-3-67
F-9. Check if internal chamber of axle housing has any foreign matter. Use a caulking gun to apply 598
surface sealant evenly on the big flange surface of axle housing to form a closed loop without any gap.
Use 2-M12×50 bolts, 9-M12×40 and 3 M12 stud bolts to fasten the fitted main reducing gear assembly on
axle housing, and the torque of M12 bolt is 100N.m. After application of force on bolts, check if elastic
gasket is damaged. (See Figure 6-3-68)
142
Chapter 6 Main parts
Section 3 Drive Axle
Figure 6-3-68
F-10. Install semi axle with its side with circlip groove facing outward. Put in sun wheel and turn the
planetary carrier to see if there is any jam during engagement between planetary wheel and sun wheel.
(See Figure 6-3-69)
Figure 6-3-69
F-11. Mount elastic retaining ring 50 and plug. (See Figure 6-3-70)
Figure 6-3-70
F-12. Knock stop block into wheel-side end cover. (See Figure 6-3-71)
143
Chapter 6 Main parts
Section 3 Drive Axle
Figure 6-3-71
F-13. Mount sealing gasket and wheel-side end cover and fasten them with six (6) M12×1.25×30 bolts
and six (6) gaskets 12. Tightening torque of bolt is 80~100N.m (See Figure 6-3-72)
Figure 6-3-72
F-14. After installation, conduct air pressure test on axle housing with test pressure of 0.2~0.3Mpa; after
charging of gear oil, conduct test run in accordance with running test program. (See Figure 6-3-73)
Figure 6-3-73
144
Chapter 6 Main parts
Section 3 Drive Axle
Appendix: Tools, devices and appliances used for disassembly and repair of drive axle
1. Carrier for drive axle assembly;
2. Pneumatic wrench;
3. Iron bar (its diameter is slightly smaller than that of screw hole in the planetary carrier and its length is
about 300mm);
4. Crane, hooks and iron chain;
5. Hex wrench (used for disassembling and assembling circular nuts and fixing bolts);
6. Hammer and chisel;
7. Socket wrench (used for disassembling and assembling fixing bolts of brake caliper);
8. Jig fixed on the workbench and matched with inner diameter of 32224 bearing outer race;
9. Press machine;
10. Flat and round iron bar capable of pressing 32024 bearing outer race below end face;
11. Copper bar (its diameter is some 50mm and its length is some 300mm)
12. 0# crocus cloth;
13. Weight for installation of 32215 bearing inner race;
14. Weight for installation of 31310 bearing outer race;
15. Weight for installation of NUR2306E bearing inner race;
16. Circlip pliers;
17. Weight for installation of 31311 bearing inner race;
18. Fixing jig for driving spiral bevel gear;
19. Dial gauge;
20. Red lead;
21. Mounting jig for input flange;
22. Sealant;
23. Iron wire;
24. Socket wrench.
145
Chapter 6 Main parts
Section 4 Air Brake Valve Assembly
Figure 6-4-1
146
Chapter 6 Main parts
Section 4 Air Brake Valve Assembly
(I) Functions
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 air brake valve assembly on the product
The air brake valve is fitted in the cab by fixing it on cab chassis with four M8×25 bolts. Foot pedal is on
cab chassis, see Figure 6-4-2; other parts are below cab chassis, see Figure 6-4-3;
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 4 flexible hoses and 2 electric wires connected to the air brake valve,
and separate 4 flexible hoses and 2 electric wires from the air 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
①Fix the air brake valve on cab chassis; join the dismounted 4 flexible hoses and 2 electric wires to
corresponding joints of the foot brake valve;
②Check sealing surface and sealing elements of pipes and ensure their cleanliness during the fitting
process.
147
Chapter 6 Main parts
Section 4 Air Brake Valve Assembly
Figure 6-4-2
Figure 6-4-3
148
Chapter 6 Main parts
Section 4 Air Brake Valve Assembly
Cotter pin
Figure 6-4-4
Pedal pin
Figure 6-4-5
2.Screw off 3 bolts on cab connecting plate (see Figure 6-4-6), and take down dust hood and cab
connecting plate (see Figure 6-4-7);
Figure 6-4-6
149
Chapter 6 Main parts
Section 4 Air Brake Valve Assembly
Figure 6-4-7
3. Press the piston down by hand, take out the circlip fixing the piston with circlip pliers (see Figure 6-4-8),
and remove the piston and spring (see Figure 6-4-9);
Figure 6-4-8
Figure 6-4-9
150
Chapter 6 Main parts
Section 4 Air Brake Valve Assembly
NOTE: If piston ring and the bottom of piston rod are worn or damaged, they shall be replaced.
4. Screw out pressure switch (see Figure 6-4-10) and take out closing ring and diaphragm (see Figure
6-4-11);
Figure 6-4-10
Figure 6-4-11
5. Keep the piston hole of valve body downward (see Figure 6-4-12) One person holds down the outer
cover of air return port, and the other person takes out the retainer ring out of the port using the circlip
pliers. After relaxing the hands slowly, remove the outer cover and take out inner cover, spring and
copper bush (see Figure 6-4-13); by this time, the disassembly of the air brake valve is completed.
Figure 6-4-12
151
Chapter 6 Main parts
Section 4 Air Brake Valve Assembly
Figure 6-4-13
Figure 6-4-14
(2)Keep the big role of valve body (i.e., piston hole) downward, put copper bush in air return hole (see
Figure 6-4-15), and then put in the spring (see Figure 6-4-16), inner cover and outer cover (see Figure
6-4-17) Press against the outer cover with an iron rod or socket and install the circlip (see Figure 6-4-18);
152
Chapter 6 Main parts
Section 4 Air Brake Valve Assembly
Figure 6-4-15
Figure 6-4-16
Outer cover
Inner cover
Figure 6-4-17
153
Chapter 6 Main parts
Section 4 Air Brake Valve Assembly
Figure 6-4-18
(3)Turn the valve body by 180 degrees, keep piston hole upward, put in the spring and piston, and then
install the circlip; (see Figure 6-4-19 ~ Figure 6-4-21)
Figure 6-4-19
Figure 6-4-20
154
Chapter 6 Main parts
Section 4 Air Brake Valve Assembly
Figure 6-4-21
(4) Put the diaphragm and circlip in the hole of pressure switch (see Figure 6-4-22), and then screw on
the pressure switch (see Figure 6-4-23);
Figure 6-4-22
Figure 6-4-23
5. Install the cab connecting plate and 3 bolts (see Figure 6-4-24), and tighten up with the wrench;
155
Chapter 6 Main parts
Section 4 Air Brake Valve Assembly
Figure 6-4-24
Figure 6-4-25
7. Put the pedal in place and install the pedal pin (see Figure 6-4-26) Then push cotter pins through the
hole at the end of pedal pin and use the pincers to split cotter pins at the ends (see Figure 6-4-27) to
prevent pedal pin from slipping out; by this time, the repair of the air brake valve is complete.
Figure 6-4-26
156
Chapter 6 Main parts
Section 4 Air Brake Valve Assembly
Figure 6-4-27
157
Chapter 6 Main parts
Section 4 Air Brake Valve Assembly
158
Chapter 6 Main parts
Section 5 Combination valve of oil-water separator (Model SH380D)
Automatically adjust the working pressure of the pneumatic brake system, and automatically discharge
the filtered-out oil, water and dust via load-removal.
1. Structure and function
(I) Functions
1. Separate the oil and water inside the compressed air and automatically discharge the separated oil and
water.
2. Control the pressure of the air circuit system within the scope of rated pressure.
3. Safety protection of system pressure. Automatically release pressure when the system pressure
exceeds the pressure limit.
(II) Structure
1. Adjusting screw
2. Pressure adjusting spring
3. Upper regulating valve
4. Control piston
5. Lower regulating valve
6. Oil and water release valve
7. Oil collector
159
Chapter 6 Main parts
Section 5 Combination valve of oil-water separator (Model SH380D)
160
Chapter 6 Main parts
Section 6 Booster Pump (Braking System)
Table of Contents
1 Structure and Functions ..................................................................................................................................[157]
2 Testing and Adjustment .................................................................................................................................. [157]
3 Dismounting and Installation ..........................................................................................................................[158]
4 Disassembly and Repair .................................................................................................................................[159]
161
Chapter 6 Main parts
Section 6 Booster Pump (Braking System)
162
Chapter 6 Main parts
Section 6 Booster Pump (Braking System)
(3) Installation
①In the course of installation, pay attention to the mounting direction of booster pump;
②Check if red light paper spacer linking hollow bolts is damaged; make replacement in case of damage;
③Conduct other operations in the sequence contrary to the dismounting sequence;
④Install the front booster pump inside the front frame (Before operation, it is necessary to lift the movable
arm so that the operator is able to enter the front of the front frame (NOTE: Before entry, the movable arm
must be reliably supported to prevent any fall) Afterwards, open the closing plate of the front frame)
Mount two M10×30 fixing bolts before mounting air pipes and hollow bolts.
⑤Install the rear booster pump in the engine cover (it is required to open the door of engine cover before
dismounting) Mount two M10×30 fixing bolts before mounting air pipes and hollow bolts;
⑥Install air pipes, brake oil pipe (hollow bolts) and fixing bolts separately;
⑦Check sealing surface and sealing elements of pipes and ensure their cleanliness during the fitting
process;
⑧Take mounting torque according to the requirement of torque meter;
(4) Dismounting tools
①16-18 open end wrench, 16-18 open end torque wrench;
②1”, 2” monkey wrench; 27-30 open end wrench, 350N·m torque wrench;
(5) Keep dismounting record.
4. Disassembly and Repair
I. Disassembling process
(1)Grasp the flat position of the oil return port of booster pump with a bench clamp, use a wrench to clamp
and turn the fixed plate in the loosening direction to loosen the oil outlet (see Figure 6-6-01);
Figure 6-6-01
(2)Then place the booster pump on the disassembly stand and screw off the oil outlet (see Figure 6-6-02);
163
Chapter 6 Main parts
Section 6 Booster Pump (Braking System)
Figure 6-6-02
(3)Screw off 6 fixing bolts of air chamber of booster pump and strike the air chamber gently with a
hammer to loosen the chamber (see Figure 6-6-03) Then remove the air chamber of the booster pump
(see Figure 6-6-04 and Figure 6-6-05);
Figure 6-6-03
Figure 6-6-04
164
Chapter 6 Main parts
Section 6 Booster Pump (Braking System)
Figure 6-6-05
(4)Take the piston out of the air chamber of booster pump, and check the integrity of the seal ring of the
piston and make replacement in case of any damage (see Figure 6-6-06);
Figure 6-6-06
(5)Keep the spring clamp downward, press the cover plate down with both hands, screw off the fixing
bolts of the spring and take out spring clamp and the spring (see Figure 6-6-07);
Figure 6-6-07
(6)Screw off the lid of oil cup and take out the filter screen out of the oil cup (see Figure 6-6-08);
Figure 6-6-08
(7)Take out 3 seal rings and 2 support rings from the cylinder body (see Figure 6-6-09 and Figure 6-6-10);
165
Chapter 6 Main parts
Section 6 Booster Pump (Braking System)
Figure 6-6-09
Figure 6-6-10
(8)Hold the cylinder body with a bench clamp, loosen the circular nut on the lid of booster pump by
striking the nut with a chisel and hammer, and then screw off the nut (see Figure 6-6-11);
Figure 6-6-11
(9) Strike the cover plate gently with a hammer and remove it (see Figure 6-6-13);
166
Chapter 6 Main parts
Section 6 Booster Pump (Braking System)
Figure 6-6-13
(10)Hold the cylinder body with the bench clamp and loosen the fixing bolt of the oil cup with a socket
wrench (see Figure 6-6-13) Screw off the nut and remove the oil cup (see Figure 6-6-13);
Figure 6-6-13
Figure 6-6-13
(11)Screw off the transition joint on cylinder body (see Figure 6-6-15);
167
Chapter 6 Main parts
Section 6 Booster Pump (Braking System)
Figure 6-6-15
(12)Screw off the fixing bolt of the respirator and remove the dust hood (see Figure 6-6-16);
Figure 6-6-16
Figure 6-6-15
(14)Screw off the fixing bolt of the supporting rack of cover plate (see Figure 6-6-18);
168
Chapter 6 Main parts
Section 6 Booster Pump (Braking System)
Figure 6-6-18
Figure 6-6-19
(2) Install 3 seal rings and 2 support rings in the cylinder body (see Figure 6-6-20);
Figure 6-6-20
(3) Mount the cover plate and ensure the alignment of locating key (see Figure 6-6-21);
169
Chapter 6 Main parts
Section 6 Booster Pump (Braking System)
Figure 6-6-21
Figure 6-6-22
(5) Mount the spring and spring clamp (see Figure 6-6-23), and then turn it by 180 degrees and keep
spring clamp downward. Press the cover plate down with both hands and another person puts in fixing
bolt of the spring and tighten the bolt (see Figure 6-6-24);
Figure 6-6-23
170
Chapter 6 Main parts
Section 6 Booster Pump (Braking System)
Figure 6-6-24
(6) Mount the piston at the bottom of air chamber of booster pump (see Figure 6-6-25);
Figure 6-6-25
(7) Join the air chamber of booster pump to the cover plate, mount 6 bolts on the perimeter of the air
chamber of booster pump and tighten such bolts (see Figure 6-6-26);
Figure 6-6-26
(8) Install the respirator on the cover plate (see Figure 6-6-27) and mount the dust cover and screws (see
Figure 6-6-28)
171
Chapter 6 Main parts
Section 6 Booster Pump (Braking System)
Figure 6-6-27
Figure 6-6-28
(9) Mount the fixed seat on the cover plate and tighten the bolts (see Figure 6-6-29);
Figure 6-6-29
(10) Screw on the oil outlet and the oil inlet joint (see Figure 6-6-30 and Figure 6-6-31);
172
Chapter 6 Main parts
Section 6 Booster Pump (Braking System)
Figure 6-6-30
Figure 6-6-31
(12) Mount the oil cup and fasten it with nuts (see Figure 6-6-32);
Figure 6-6-32
(13) Mount the filter screen (see Figure 6-6-33) and screw on the lid of oil cup (see Figure 6-6-34);
Figure 6-6-33
173
Chapter 6 Main parts
Section 6 Booster Pump (Braking System)
Figure 6-6-34
Attachment: List of tools and devices required for disassembly and repair of booster pump
1. Bench clamp;
2. Monkey wrench;
3. Chisel;
4. Hex wrench;
5. Hammer;
6. Screwdriver.
174
Chapter 6 Main parts
Section 7 Brake Caliper
Brake caliper
175
Chapter 6 Main parts
Section 7 Brake Caliper
I. Disassembling process
(1) Take down brake pads from brake caliper (see Figure 6-7-01);
Figure 6-7-01
(2) Screw out 2 deflating valves and deflating seats at both ends of internal caliper (see Figure 6-7-02)
Figure 6-7-02
(3)Remove bolts and take down end cover (see Figure 6-7-03).
Figure 6-7-03
(4) Take out piston on brake caliper and dust hood circlip and dust hood on the piston in order. (See
176
Chapter 6 Main parts
Section 7 Brake Caliper
Figure 6-7-04
Figure 6-7-05
(6) Take out seal ring in piston hole of caliper body (see Figure 6-7-06);
Figure 6-7-06
(7) Take out fixing pins (see Figure 6-7-07).
177
Chapter 6 Main parts
Section 7 Brake Caliper
Figure 6-7-07
Figure 6-7-08
(2)Mount fixing pins (see Figure 6-7-09)
Figure 6-7-09
(3) Install the end cover and fasten it with bolts (see Figure 6-7-10)
178
Chapter 6 Main parts
Section 7 Brake Caliper
Figure 6-7-10
(4) Wipe piston surface and piston hole on caliper body, and mount O-ring (see Figure 6-7-11)
Figure 6-7-11
(5) Press the piston into piston hole (see Figure 6-7-12)
Figure 6-7-12
(6) Mount the dust hood on piston (see Figure 6-7-13)
179
Chapter 6 Main parts
Section 7 Brake Caliper
Figure 6-7-13
(7) Mount circlips of dust hood and install other seal rings, pistons, dust hood and circlips by repeating the
foregoing steps (see Figure 6-7-14)
Figure 6-7-14
(8) Mount 2 deflating valves and deflating seats at both ends of internal caliper (see Figure 6-7-15)
Figure 6-7-15
(9) Mount brake pads on brake caliper (see Figure 6-7-16)
180
Chapter 6 Main parts
Section 7 Brake Caliper
Figure 6-7-16
(10) The assembly is complete (see Figure 6-7-17)
Figure 6-7-17
181
Chapter 6 Main parts
Section 8 Working Pump
Table of Contents
1 Structure and Functions ..................................................................................................................................[178]
2 Dismounting and installation .......................................................................................................................... [178]
3 Dismounting and repair ...................................................................................................................................[179]
Working pump
Figure 6-8-01
①Working pump and steering pump are directly fitted at power take-off of torque converter (see Figure
6-8-01);
182
Chapter 6 Main parts
Section 8 Working Pump
②Working 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
working pump is generally dismounted only after removing the entire cab from the vehicle;
183
Chapter 6 Main parts
Section 8 Working Pump
Figure 6-8-02
Figure 6-8-03
(2) Take down the front cover (see Figure 6-8-04) and take out oil seal and retainer ring;
Figure 6-8-04
(3) Take out the seal ring, 2 bearings and shaft sleeves (see Figure 6-8-05) and one 8-shaped side plate
(see Figure 6-8-06);
184
Chapter 6 Main parts
Section 8 Working Pump
Figure 6-8-05
Figure 6-8-06
(4) Take out main gear shaft and pinion (see Figure 6-8-07);
Figure 6-8-07
(5) Take up the pump body to detach the bottom end cover from the body (see Figure 6-8-08). Take off the
seal ring;
185
Chapter 6 Main parts
Section 8 Working Pump
Figure 6-8-08
(6) Take out two bearings and shaft sleeves (see Figure 6-8-09);
Figure 6-8-09
(7) Check wear and tear of bearings, 8-shaped side plate and gear face (see Figure 6-8-010 and Figure
6-8-11). Generally speaking, debris from bearing wear often leads to the wear and tear of side plate and
gear face, thus causing internal leakage; make replacement in case of wear or damage.
Figure 6-8-10
186
Chapter 6 Main parts
Section 8 Working Pump
Figure 6-8-11
Figure 6-8-12
(2) Put in an 8-shaped sealing side from the bottom of pump body (i.e., end face with 6 screw holes)
(Figure 6-8-13);
187
Chapter 6 Main parts
Section 8 Working Pump
Figure 6-8-13
(3) Put bearings on the shaft sleeves and then, press them into the side plate (see Figure 6-8-14) to keep
their perimeters slightly below the end face of pump body;
Figure 6-8-14
(4) Put the seal ring in the end face of pump body (see Figure 6-8-15);
Figure 6-8-15
(5) Mount the bottom end cover on the end face of pump body, fit and tighten secondary bolts (see Figure
6-8-16) (tightening torque: 50N·m);
188
Chapter 6 Main parts
Section 8 Working Pump
Figure 6-8-16
(6) Turn the pump body by 180 degrees (see Figure 6-8-17);
Figure 6-8-17
(7) Put in the main gear shaft (see Figure 6-8-18);
189
Chapter 6 Main parts
Section 8 Working Pump
Figure 6-8-19
Figure 6-8-19
(9) Hold the main gear shaft with hand to see if it rotates freely (see Figure 6-8-20);
190
Chapter 6 Main parts
Section 8 Working Pump
Figure 6-8-20
(10) Mount another 8-shaped side plate (see Figure 6-8-21);
Figure 6-8-21
191
Chapter 6 Main parts
Section 8 Working Pump
(11) Install two bearings into shaft sleeves and then, press them into the side plate holes (see Figure
6-8-22);
Figure 6-8-22
(12) Install the seal ring (see Figure 6-8-23);
Figure 6-8-23
192
Chapter 6 Main parts
Section 8 Working Pump
Figure 6-8-24
(13) Install retainer ring and oil seal. (See Figure 6-8-25);
Figure 6-8-25
(14) Clean the mounting surface of pump body and install the upper cover plate (see Figure 6-8-26);
193
Chapter 6 Main parts
Section 8 Working Pump
Figure 6-8-26
(15) Mount four king bolts and tighten them in the diagonal sequence (see Figure 6-8-27);
Figure 6-8-27
194
Chapter 6 Main parts
Section 8 Working Pump
(16) Turn the gear shaft by hand to see if it rotates freely (see Figure 6-8-28); If necessary, adjust the
tightening torque of king bolts and secondary bolts.
Figure 6-8-28
195
Chapter 6 Main parts
Section 9 Distribution Valve
Table of Contents
1 Structure and Functions ..................................................................................................................................[192]
2 Testing and adjustment ...................................................................................................................................[193]
3 Dismounting and installation .......................................................................................................................... [195]
4 Dismounting and repair ...................................................................................................................................[196]
Figure 6-9-1
196
Chapter 6 Main parts
Section 9 Distribution Valve
Figure 6-9-2
Distribution valve
Overload valve
Overload valve
Figure 6-9-3
(III) Exploded view of distribution valve
197
Chapter 6 Main parts
Section 9 Distribution Valve
Figure 6-9-4
198
Chapter 6 Main parts
Section 9 Distribution Valve
③ If the adjustable bolt proves ineffective in pressure regulation, it is necessary to screw off the valve
body and replace the entire overload valve.
(V) Inspection notes
①Check if there is any foreign matter in any inner chamber of each oil port;
②Adjusting the pressure regulating bolt is not recommended. It is advisable to replace the entire overload
valve.
3. Dismounting and Installation
(1) Location of distribution valve on the product
Figure 6-9-5
①Distribution valve is fitted in the center of the interior of front frame, as shown in the figure;
② Three bolts M12×180 together with flat washers and elastic washers are fitted on valve body and
front frame;
(2) Preparations before dismounting
① Dismounting method: Select a dedicated maintenance site where maintenance personnel can work
underneath the vehicle conveniently;
② Shut down the vehicle, set level the bucket and remove pipe joints connected to the selector valve;
make reassembly marks for similar pipes;
③ Given oil leak during dismounting, oil drip pan and oil drum are ready for use; exposed oil ports are
protected.
(3) Dismounting steps
①Remove pilot control group-5 pipeline and make reassembly marks;
②Remove in turn 4 fixing bolts M12×35 and elastic washers for steel oil return pipe clamp of the valve, 4
fixing bolts M12×45 and elastic washers for steel oil inlet pipe clamp of the valve, 8 fixing bolts M12×42
and elastic washers for steel oil inlet & outlet pipe clamp of tilt cylinder, and 8 fixing bolts M12×42 and
elastic washers for steel oil inlet & outlet pipe clamp of boom cylinder; make reassembly marks;
③After arranging all pipelines, remove 3 mounting bolts M12×180 and flat washers & elastic washers for
valve body.
④ Lift the valve body out of the front frame using >100kg lifting rope and crane. If the valve body is
manually carried, guard against any personal injury resulting from the slippage of the valve body from
oil-stained hands.
(4) Inspection notes
①Check if there is any foreign matter in inner chamber of each oil port;
199
Chapter 6 Main parts
Section 9 Distribution Valve
②Screw plugs and the pressure regulating and tightening end of valve body may not be loosened without
authorization; any commissioning shall be performed by professionals;
(5) Installation
①Pay attention to directions during installation;
②Conduct other operations in the sequence contrary to the dismounting sequence;
③Lift the valve body to the mounting position on the front frame using >100kg lifting rope and crane;
④Install 3 mounting bolts M12×180 and flat washers & elastic washers on valve body.
⑤After arranging all pipelines, install in turn 8 fixing bolts M12×42 and elastic washers for steel oil inlet &
outlet pipe clamp of boom cylinder, 8 fixing bolts M12×42 and elastic washers for steel oil inlet & outlet
pipe clamp of tilt cylinder, 4 fixing bolts M12×45 and elastic washers for steel oil inlet pipe clamp of the
valve, and 4 fixing bolts M12×35 and elastic washers for steel oil return pipe clamp of the valve;
⑥Install pilot control group-5 pipeline;
⑦During assembly, check sealing elements in the pipelines, make replacement in case of damage and
ensure cleanliness; conduct assembly according to reassembly marks and avoid wrong pipeline
connection;
⑧Locking torque meets the requirement of torque meter;
(6) Dismounting tools
①16-18, open end trench, 19, 21 socket and crowbar;
②200N·m torque wrench;
(7) Keep dismounting record.
Figure 6-9-6
(2) Remove the sequence valve by loosening it with the wrench (see Figure 6-9-7);
200
Chapter 6 Main parts
Section 9 Distribution Valve
Figure 6-9-7
(3) Screw off the bolts on end cover of bucket valve core (see Figure 6-9-8) and remove the end cover
(see Figure 6-9-9);
Figure 6-9-8
Figure 6-9-9
(4) Draw out bucket valve core, screw off fixing bolts on front cover of bucket valve core hole in the valve
body, and remove spring seat, washer, spring, screw rod and valve rod (see Figure 6-9-10);
Figure 6-9-10
(5) Screw off fixing bolts on end cover of boom valve core (see Figure 6-9-11) and take out the end cover
201
Chapter 6 Main parts
Section 9 Distribution Valve
Figure 6-9-11
Figure 6-9-12
(6) Draw the boom valve core out of the valve body (see Figure 6-9-13);
NOTE: Because the boom valve core controls more gears, its rear end has one more spring and two more
steel balls than the bucket valve core. Draw out the boom valve core with a little more force.
Figure 6-9-13
(7) Screw off fixing bolts on front cover of boom valve core hole and remove spring seat, washer, spring,
screw rod and valve rod (see Figure 6-9-14);
202
Chapter 6 Main parts
Section 9 Distribution Valve
Figure 6-9-14
(8) Take off the main safety valve (see Figure 6-9-15);
Figure 6-9-15
(9) Take off two overload and oil recharging valves (see Figure 6-9-16);
Figure 6-9-16
(10) Take off four screws on rear cover (see Figure 6-9-17) and remove the rear cover and seal ring (see
Figure 6-9-18);
203
Chapter 6 Main parts
Section 9 Distribution Valve
Figure 6-9-17
Figure 6-9-18
(11) Screw off three pressure measuring end caps (see Figure 6-9-19);
Figure 6-9-19
(12) Take off three one-way valve assemblies (see Figure 6-9-20); break down each one-way valve (see
Figure 6-9-21). The disassembly is completed (see Figure 6-9-22).
204
Chapter 6 Main parts
Section 9 Distribution Valve
Figure 6-9-20
Figure 6-9-21
Figure 6-9-22
205
Chapter 6 Main parts
Section 9 Distribution Valve
Figure 6-9-23
(2) Assemble one-way valves (see Figure 6-9-24) and install them on the valve body (see Figure 6-9-25);
Figure 6-9-24
Figure 6-9-25
(3) Mount three pressure measuring end caps (see Figure 6-9-26);
Figure 6-9-26
(4) Install the rear cover and fit the screws (see Figure 6-9-27);
206
Chapter 6 Main parts
Section 9 Distribution Valve
Figure 6-9-27
(5) Install two overload and oil recharging valves (see Figure 6-9-28);
Figure 6-9-28
Figure 6-9-29
(7) Assemble the boom valve core and insert it into the valve body (see Figure 6-9-30); mount the front
end cover of the boom valve core and tighten the fixing bolts (see Figure 6-9-31);
207
Chapter 6 Main parts
Section 9 Distribution Valve
Figure 6-9-30
Figure 6-9-31
(8) Assemble the bucket valve core and insert it into the valve body (see Figure 6-9-32); mount the rear
end cover of the bucket valve core and tighten the fixing bolts (see Figure 6-9-33);
Figure 6-9-32
Figure 6-9-33
(9) Install the sequence valve (see Figure 6-9-34); the repair is completed (see Figure 6-9-35).
208
Chapter 6 Main parts
Section 9 Distribution Valve
Figure 6-9-34
Figure 6-9-35
209
Chapter 6 Main parts
Section 10 Lift arm Cylinder
①This vehicle has two lift arm cylinders (including left and right cylinders) fitted between the lift arm and
the front frame (shown in Figure 6-10-1); 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;
(2) Dismounting steps
① Lift 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
210
Chapter 6 Main parts
Section 10 Lift arm Cylinder
211
Chapter 6 Main parts
Section 10 Lift arm Cylinder
Figure 6-10-2
(2) Take down the front circlip with circlip plier and take out ring and spring collar (see Figure 6-10-3)
Figure 6-10-3
(3) Draw out the guide sleeve (see Figure 6-10-4)
Figure 6-10-4
(4) Pull out the guide sleeve & piston rod assembly (see Figure 6-10-5)
212
Chapter 6 Main parts
Section 10 Lift arm Cylinder
Figure 6-10-5
(5) Remove the seal assembly on the piston (see Figure 6-10-6)
Figure 6-10-6
(6) Remove two fixing bolts and steel balls from the piston (see Figure 6-10-7)
Figure 6-10-7
(7) Remove the piston (see Figure 6-10-8)
Figure 6-10-8
(8) Remove the guide sleeve (see Figure 6-10-9)
213
Chapter 6 Main parts
Section 10 Lift arm Cylinder
Figure 6-10-9
(9) Remove the seal ring assembly from the guide sleeve (see Figure 6-10-10)
Figure 6-10-10
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 6-10-11)
Figure 6-10-11
(3) Fit the guide sleeve on the piston rod (see Figure 6-10-12)
214
Chapter 6 Main parts
Section 10 Lift arm Cylinder
Figure 6-10-12
(4) Mount the piston (see Figure 6-10-13)
Figure 6-10-13
(5) Fit steel balls and two fixing bolts on the piston (see Figure 6-10-14)
Figure 6-10-14
(6) Fit the seal assembly on the piston (see Figure 6-10-15)
215
Chapter 6 Main parts
Section 10 Lift arm Cylinder
Figure 6-10-15
(7) Install the guide sleeve & piston rod assembly into the cylinder body (see Figure 6-10-16)
Figure 6-10-16
(8) Mount the guide sleeve assembly into the cylinder (see Figure 6-10-17)
Figure 6-10-17
(9) Mount the flexible retainer ring and ring assembly into the cylinder (see Figure 6-10-18)
Figure 6-10-18
216
Chapter 6 Main parts
Section 10 Lift arm Cylinder
Figure 6-10-19)
(11) The assembly is completed. (see Figure 6-10-20)
Figure 6-10-20
217
Chapter 6 Main parts
Section 10 Lift arm Cylinder
218
Chapter 6 Main parts
Section 11 Bucket Cylinder
219
Chapter 6 Main parts
Section 11 Bucket Cylinder
mounting process;
2 Mounting torque meets the requirement of torque meter.
Figure 6-11-1
Figure 6-11-2
Figure 6-11-3
(2) Dismount the 8 bolts on the guide sleeve (see Figure 6-11-4)
220
Chapter 6 Main parts
Section 11 Bucket Cylinder
Figure 6-11-4
(3) Pull out the guide sleeve (see Figure 6-11-5)
Figure 6-11-5
(4) Pull out the guide sleeve and piston rod assembly (see Figure 6-11-6).
Figure 6-11-6
(5) Remove the sealing assembly on the piston (see Figure 6-11-7)
221
Chapter 6 Main parts
Section 11 Bucket Cylinder
Figure 6-11-7
(6) Remove two fixing bolts and steel balls on the piston (see Figure 6-11-8)
Figure 6-11-8
(7) Remove the piston (see Figure 6-11-9).
Figure 6-11-9
222
Chapter 6 Main parts
Section 11 Bucket Cylinder
Figure 6-11-10
(9) Remove the sealing ring assembly on the guide sleeve (see Figure 6-11-11).
Figure 6-11-11
Figure 6-11-12
223
Chapter 6 Main parts
Section 11 Bucket Cylinder
(3) Install guide sleeve onto the piston rod (see Figure 6-11-13).
Figure 6-11-13
(4) Install piston (see Figure 6-11-14).
Figure 6-11-14
(5) Install steel balls and two fixing bolts onto the piston (see Figure 6-11-15)
Figure 6-11-15
(6) Install sealing assembly onto the piston (see Figure 6-11-16).
224
Chapter 6 Main parts
Section 11 Bucket Cylinder
Figure 6-11-16
(7) Install the guide sleeve and piston rod assembly into the cylinder (see Figure 6-11-17).
Figure 6-11-17
(8) Align the thread hole position on the guide sleeve with the hole position on the cylinder (see Figure
6-11-18).
225
Chapter 6 Main parts
Section 11 Bucket Cylinder
Figure 6-11-18
(9) Install 8 bolts on the guide sleeve (see Figure 6-11-19).
Figure 6-11-19
(10) Finish the assembly (see Figure 6-11-20).
Figure 6-11-20
226
Chapter 6 Main parts
Section 12 Priority Valve
Table of Contents
1 Structure and Functions ..................................................................................................................................[222]
2 Dismounting and installation .......................................................................................................................... [222]
3 Dismounting and repair ...................................................................................................................................[224]
P opening
LS opening
CF opening
Figuer 6-12-1
227
Chapter 6 Main parts
Section 12 Priority Valve
Figure 6-12-2
①Priority valve is fitted on the left side of hinged panel on the rear frame (see Figure 6-12-2);
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;
② Dismounting 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 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;
228
Chapter 6 Main parts
Section 12 Priority Valve
new one and ensure cleanliness; pay attention to reassembly marks to avoid wrong connection;
(2) Locking torque shall meet the requirement of torque meter;
Figure 6-12-3
(2) Screw off the transition joint (see Figure 6-12-4)
Figure 6-12-4
(3) Screw off the pressure valve core (see Figure 6-12-5);
Figure 6-12-5
(4) Screw off the pressure valve core seat (see Figure 6-12-6);
229
Chapter 6 Main parts
Section 12 Priority Valve
Figure 6-12-6
(5) Take out the spring (see Figure 6-12-7);
Figure 6-12-7
(6) Turn the valve body by 180 degrees and take off pipe plug on the other end (see Figure 6-12-8);
Figure 6-12-8
(7) Take out valve core (see Figure 6-12-9). After disassembly, parts are shown in Figure 6-12-10.
Figure 6-12-9
230
Chapter 6 Main parts
Section 12 Priority Valve
Figure 6-12-10
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 6-12-11);
Figure 6-12-11
(3) Mount and tighten pipe plug (see Figure 6-12-12);
Figure 6-12-12
(4) Put in the spring from the hole on the other end (see Figure 6-12-13);
231
Chapter 6 Main parts
Section 12 Priority Valve
Figure 6-12-13
(5) Put the valve body vertically and screw in the pressure valve core seat (Figure 6-12-14);
Figure 6-12-14
(6) Screw in the pressure valve core (see Figure 6-12-15);
Figure 6-12-15
(7) Mount the transition joint (see Figure 6-12-16)
232
Chapter 6 Main parts
Section 12 Priority Valve
Figure 6-12-16
233
Chapter 6 Main parts
Section 12 Priority Valve
234
Chapter 6 Main parts
Section 13 Steering Gear
Figure 6-13-1
235
Chapter 6 Main parts
Section 13 Steering Gear
Steering column
Figure 6-13-2
Mounting hole
Spider bushing
Figure 6-13-3
①Steering gear is mounted below cab chassis and joined to steering column inside the cab through pipe
saddle fitted on cab chassis (see Figure 6-13-1);
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 6-13-1, and the pipeline with the smallest diameter is the feedback pipeline on the flank of the
steering gear;
② Oil leak is possible during dismounting and oil pans are readied for use; protect oil ports and make
reassembly marks;
③ The 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 6-13-2; 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 bushing from falling off (see Figure 6-13-3);
(3) Inspection notes
①Check if there is any foreign matter in internal chamber of each oil port;
236
Chapter 6 Main parts
Section 13 Steering Gear
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 bushing 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 6-13-2;
⑤Mount the housing of steering column;
⑥ The following operations are done outside the cab: install the connecting pipelines of the 5 joints as
shown in Figure 6-13-1, 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;
②Mounting torque meets the requirement of torque meter.
Tools required:
①.16-18 open end wrench;
②.16-18 open end torque wrench;
③.1”, 2” monkey wrench;
④.27-30 open end wrench;
⑤.350N·m torque wrench.
3. Disassembly and Repair
I. Disassembling process
(1) Put the steering gear on the workbench (see Figure 6-13-4);
Figure 6-13-4
(2)Take off two bolts from joint seat (see Figure 6-13-5);
237
Chapter 6 Main parts
Section 13 Steering Gear
Figure 6-13-5
3) Remove the joint seat (see Figure 6-13-6)
Figure 6-13-6
(4) Remove four seal rings from the joint seat (see Figure 6-13-7);
Figure 6-13-7
(5) Remove external end plug, copper backing and internal end plug (see Figure 6-13-8);
238
Chapter 6 Main parts
Section 13 Steering Gear
Figure 6-13-8
(6) Remove end plug and copper backing on the other side (see Figure 6-13-9)
Figure 6-13-9
(7) Remove four bolts on the upper end cover (see Figure 6-13-10)
Figure 6-13-10
(8) Remove the upper end cover (see Figure 6-13-11)
Figure 6-13-11
(9) Remove the joint inside the end cover linked to the steering rod (see Figure 6-13-12);
239
Chapter 6 Main parts
Section 13 Steering Gear
Figure 6-13-12
(10) Remove two seal rings on the upper end cover (see Figure 6-13-13)
Figure 6-13-13
(11) Remove 7 bolts on the lower end cover (see Figure 6-13-14)
Figure 6-13-14
(12) Remove the lower end cover, seal ring and gear washer (see Figure 6-13-15)
240
Chapter 6 Main parts
Section 13 Steering Gear
Figure 6-13-15
(13) Remove gear ring and seal ring (see Figure 6-13-16);
Figure 6-13-16
(14) Remove the gear wheel and push pipe inside the gear wheel (see Figure 6-13-17)
Figure 6-13-17
(15) Remove the seal ring assembly from the gear wheel (see Figure 6-13-18);
241
Chapter 6 Main parts
Section 13 Steering Gear
Figure 6-13-18
(16) Remove universal joint shaft, oil distribution disc and steel balls on the oil distribution disc (see Figure
6-13-19);
Figure 6-13-19
(17) Remove the seal ring (see Figure 6-13-20)
Figure 6-13-20
(18) Take small tubes out of the valve body (see Figure 6-13-21)
242
Chapter 6 Main parts
Section 13 Steering Gear
Figure 6-13-21
(19) Take the valve core assembly out of the valve body (see Figure 6-13-22)
Figure 6-13-22
(20) Take down the seal ring assembly, axial bearing and its two spacers from valve core (see Figure
6-13-23);
Figure 6-13-23
(21) Remove the neutral-position spring assembly (6 pieces) (see Figure 6-13-24);
243
Chapter 6 Main parts
Section 13 Steering Gear
Figure 6-13-24
(22) Remove the cross bolt from valve core (see Figure 6-13-25)
Figure 6-13-25
(23) Separate valve core from valve bush (see Figure 6-13-26)
Figure 6-13-26
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 6-13-27)
244
Chapter 6 Main parts
Section 13 Steering Gear
Figure 6-13-27
(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 6-13-28);
Figure 6-13-28
(3) Install the neutral-position spring assembly (see Figure 6-13-29)
Figure 6-13-29
(4) Install the seal ring assembly, axial bearing and its two spacers on valve core (see Figure 6-13-30)
245
Chapter 6 Main parts
Section 13 Steering Gear
Figure 6-13-30
(5) Install the valve core assembly into the valve body (see Figure 6-13-31)
Figure 6-13-31
(6) Install small tubes into the valve body (see Figure 6-13-32)
Figure 6-13-32
(7) Mount the seal ring (see Figure 6-13-33)
246
Chapter 6 Main parts
Section 13 Steering Gear
Figure 6-13-33
(8) Install universal joint shaft, oil distribution disc and steel balls on the oil distribution disc (see Figure
6-13-34);
Figure 6-13-34
(9) Install the seal ring assembly on the gear wheel (see Figure 6-13-35)
Figure 6-13-35
(10) Install the gear wheel and push pipe in the gear wheel (see Figure 6-13-36)
247
Chapter 6 Main parts
Section 13 Steering Gear
Figure 6-13-36
(11) Install the gear ring and seal ring (see Figure 6-13-37)
Figure 6-13-37
(12) Install the lower end cover, seal ring and gear washer (see Figure 6-13-38)
Figure 6-13-38
(13) Install 7 bolts on the lower end cover (see Figure 6-13-39)
248
Chapter 6 Main parts
Section 13 Steering Gear
Figure 6-13-39
(14) Install 2 seal rings on the upper end cover (see Figure 6-13-40)
Figure 6-13-40
(15) Install the joint linked to the steering rod (see Figure 6-13-41)
Figure 6-13-41
(16) Install the upper end cover (see Figure 6-13-42)
249
Chapter 6 Main parts
Section 13 Steering Gear
Figure 6-13-42
(17) Install 4 bolts on the upper end cover (see Figure 6-13-43)
Figure 6-13-43
(18) Install end plug and copper backing on one side of joint seat (see Figure 6-13-44);
Figure 6-13-44
(19) Install external end plug, copper backing and internal end plug on the other side of joint seat (see
Figure 6-13-45).
250
Chapter 6 Main parts
Section 13 Steering Gear
Figure 6-13-45
(20) Install 4 seal rings on the joint seat (see Figure 6-13-46);
Figure 6-13-46
(21) Install the joint seat (see Figure 6-13-47);
Figure 6-13-47
(22) Install 2 bolts on the joint seat (see Figure 6-13-48)
251
Chapter 6 Main parts
Section 13 Steering Gear
Figure 6-13-48
(23) The assembly is completed (see Figure 6-13-49).
Figure 6-13-49
252
Chapter 6 Main parts
Section 14 Steering cylinder
Figure 6-14-1
①This model has two symmetrical and non-interchangeable steering cylinders mounted on the left and
right side of the linkage point respectively, which both connect the front and rear frames (see Figure
6-15-1);
253
Chapter 6 Main parts
Section 14 Steering cylinder
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;
②Remove the pipes of the left and right steering cylinders;
③ Fluid 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;
④ Remove 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;
② If necessary, commissioning, pressure measurement or disassembly of steering cylinder shall be
performed by designated personnel;
(4) Installation
① Pay 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;
② Confirm 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 (as shown in Figure 16-5-1) 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 pin’s position;
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.
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 P123)
254
Chapter 6 Main parts
Section 15 Hydraulic oil cooler
Table of Contents
1 Structure and Functions ..................................................................................................................................[249]
2 Testing and adjustment ...................................................................................................................................[249]
3 Dismounting and installation .......................................................................................................................... [251]
Fan
Water tank
Figure 6-15-1
255
Chapter 6 Main parts
Section 15 Hydraulic oil cooler
Figure 6-15-2
1. Protective hood 2. Bolt for protective hood 3. Wind scooper
4. Fan 5. Water tank 6. Bolt 7. Water tank support plate
256
Chapter 6 Main parts
Section 15 Hydraulic oil cooler
(III) If necessary, make the following adjustments to water tank and fan with reference to Figure 6-15-2:
①Hoist the engine to the rear frame and complete the assembly according to the section “Dismounting
and Installation”;
② Hoist the water tank 5 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 7 on vehicle frame;
③Join the water tank to the engine via water tank pull bar and at this time there is no need to tighten the
bolt on the pull bar of water tank;
④Adjust the position of water tank 5 by moving it back and forth and make sure that approximately 1/3 of
each blade of fan 4 is inside wind scooper 3;
⑤Tighten bolts on water tank pull bar and bolts 6 on water tank support plate separately;
⑥Assemble fan protective hood 1 with wind scooper wind scooper 3 via protective hood bolts 2, 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 15 Hydraulic oil cooler
(I) Dismounting
① Prepare an oil pan and loose the bolt that tightens the rubber pipe of torque converter to release part
of the hydraulic oil, (prepare to contain the oil in the oil pan and protect the rubber pipe to prevent
pollution);
② Dismount the fixing bolt on the frame that tightens the radiator, and then dismount the radiator;
③ Dismount the bolt between the holder and core of the radiator.
(II) Instruction for examination
If oil leaks from the oil pipe, examine the thread and sealing gasket to see if they are damaged.
(III) Installation
① Install the bolt between the holder and core of the radiator;
② Lift the radiator onto the frame and then install the fixing bolt on the frame that tightens the radiator;
③ Install the bolt that tightens the rubber pipe;
④ You can choose to disassemble certain parts according to your own needs, and be sure to put the
components appropriately and keep them clean during the dismounting and installation process;
(IV) Dismounting and installation tools
① 32 open-end torque wrench;
② Straight screwdriver.
258
Chapter 6 Main parts
Section 16 Air Conditioning System
Table of Contents
1 Structure and Functions....................................................................................................................................[253]
2 Testing and Adjustment.................................................................................................................................... [254]
3 Dismounting and Installation............................................................................................................................ [258]
Figure 6-15-1
(2) Condenser
Figure 6-15-2
(3) Evaporator
259
Chapter 6 Main parts
Section 16 Air Conditioning System
Figure 6-15-3
(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.
260
Chapter 6 Main parts
Section 16 Air Conditioning System
Figure 6-15-4
Figure 6-15-5
(2) Schematic diagram of air conditioning system
261
Chapter 6 Main parts
Section 16 Air Conditioning System
5. receiver
4. condenser dryer
assembly 6. air 7. compressor
conditioning
pipeline assembly
3. evaporator
1. complete machine assembly
2. engine
Figure 6-15-6
(3) Look at Figure 6-15-6 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
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;
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;
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Chapter 6 Main parts
Section 16 Air Conditioning System
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;
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);
③ Connect 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.
⑤ After the foregoing addition, check and verify the operation of all subsystems of the air conditioner
before flameout.
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.
a. Before adding refrigerant, it is necessary to vacuumize and check the quantity of refrigerating oil in the
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
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Chapter 6 Main parts
Section 16 Air Conditioning System
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;
a. Slotted screwdriver
b. Binding tape
c. Diagonal pliers
Adding refrigerant through high pressure joint after vehicle operation is strictly prohibited (for fear of
personal injury resulting from potential explosion of refrigerant bottle)!
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)
① Remove 4 groups of rubber nails, bolts M8×25 and nuts M8 under the seat with reference to Figure
6-15-7 and Figure 6-15-8;
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Chapter 6 Main parts
Section 16 Air Conditioning System
Figure 6-15-7
Figure 6-15-8
3 Remove the condenser (see Figure 6-15-9);
Figure 6-15-9
③ As shown in Figure 6-15-11, 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.
265
Chapter 6 Main parts
Section 16 Air Conditioning System
Figure 6-15-10
(2) Installation
① Compressor 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;
① Check the integrity of exhaust units of the evaporator and condenser, regularly add refrigerant and
check if compressor runs properly.
266
Chapter 7 Hydraulic Schematic Diagram
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 boom to
control the action of boom. When the control handle of pilot valve pushes forward, pilot oil flows into the
rear control chamber b2 of the second linkage (i.e., boom linkage) of selector valve through 2A opening of
pilot valve, thus pushing boom valve stem to move forward. Pressure oil from main oil pipeline enters the
small chamber of boom 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 boom. At this time, oil in big chamber of
boom 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 boom valve stem to move backward. Pressure oil from
main oil pipeline enters the big chamber of boom 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 boom. At
this time, oil in the small chamber of boom cylinder returns to oil tank through hydraulic selector valve.
267
Chapter 7 Hydraulic Schematic Diagram
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 boom cylinder, and the piston of boom
cylinder is under the floating state. Therefore, the cutting edge of the bucket is able to float up and down
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 boom valve stem is kept at the neutral position under the influence of retracting spring, thus keeping
both big and small chambers of boom cylinder locked and stopping the action of the boom.
Under the mode of engine flameout, “lower” operation of boom and “down turn” operation of bucket: If
flameout occurs when the boom is being lifted, it is required to lower the boom 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 boom valve stem to move
forward and connecting the oil port of big chamber of boom 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 boom 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.
268
Chapter 8 Electric Schematic Diagram
269
Appendix I Schematic Diagram of Hydraulic System
1. Oil suction filter core; 2. Gear pump; 3. Priority valve assembly; 4. Steering gear assembly
5. Steering cylinder assembly; 6. Hydraulic multi-way valve assembly. 7. Pilot valve assembly. 8. Oil supply
valve assembly. 9. Bucket cylinder assembly. 10. Lift arm cylinder assembly. 11. Hydraulic radiator. 12.
Return oil filter core.
270
Appendix II Electrical Diagram
271
272