lg958l Service Manual PDF

CONTENTS
SAFETY AND ENVIRONMENT………………………………………………………………1

0 INTRODUCTION……………………………………….…………………….….…………0-1
0.1 Introduction to the Loader……………………………………………….…….………0-1
0.2 Specification……………………………………………………………….…………..0-5
0.3 Tools……………………………………………………………………………..…….0-8
0.4 Signs…………………………………………………………………………………...0-9
0.5 Judgment for Maintenance and Replacement………………………………………...0-10
1 REPAIR AND MAINTENANCE…………………………….…………………………..1-1
1.1 Lubricant, Fuel and Other Liquid……………………………………………………..1-1
1.2 Repair………………………………………………………………………………….1-3
2 ENGINE SYSTEM………………………………………………………………………..2-1
2.1 Overview………………………………………………………………………………2-1
2.2 Lubrication System……………………………………………………………………2-7
2.3 Fuel System …………………………………………………………………………...2-9
2.4 Intake and Exhaust System…………………………………………………………...2-14
2.5 Cooling System………………………………………………………………………2-16
2.6 Engine Control……………………………………………………………………….2-18
2.7 Disassembly and Assembly of Engine……………………………………………….2-19
2.8 Diagnosis and Solutions for Frequently Asked Questions of Engine System……….2-52
3 ELECTRICAL AND IMFORMATION SYSTEM……………………………………..3-1
3.1 Instruction to Electrical System……………………………………………………….3-1
3.2 Diagrams…………………………………………………………………….……….3-12
3.3 Fault Diagnosis…………………………………………………………………….…3-50
3.4 Repair Instruction…………………………………………………………………….3-52
4 TRANSMISSION SYSTERM……………………………………………………………4-1
4.1 Gearbox System….........................................……………………………….................4-1
4.2 Transmission Shaft System..........................................................................................4-47
4.3 Drive Axle System........................................................................................................4-54
4.4 Diagnosis and Solutions for Frequently Asked Questions of Transmission
System..........................................................................................................................4-70
5 BRAKE SYSTEM...............................................................................................................5-1
5.1 Travel Brake ...................................................................................................................5-2
5.2 Emergency and Parking Brake System .......................................................................5-14
5.3 Diagnosis and Solutions for Frequently Asked Questions of Brake System ..............5-18
6 STEERING SYSTEM.........................................................................................................6-1
6.1 Overview.........................................................................................................................6-1
6.2 Disassembly and Assembly of Main Components.........................................................6-7
6.3 Diagnosis and Solutions for Frequently Asked Questions of Steering System...........6-25
7 FRAME, WHEEL AND WORKING DEVICE................................................................7-1
7.1 Overview of Frame and Linkage....................................................................................7-1
7.2 Disassembly and Assembly of Balance Weight.............................................................7-2
7.3 Disassembly and Assembly of Frame Junction..............................................................7-3
7.4 Disassembly and Assembly of Front and Rear Wheels.................................................7-7
7.5 Disassembly of Linkage Mechanism.............................................................................7-9
7.6 Disassembly and Assembly of Quick-change Frame ..................................................7-14
7.7 Replacement of Quick-change Bucket.........................................................................7-17
8 CAB AND COVERING PARTS SYSTEM.......................................................................8-1
8.1 Cab Description..............................................................................................................8-1
8.2 Air Conditioning System Description..........................................................................8-11
8.3 Disassembly and Assembly of Cab Assembly.............................................................8-15
8.4 Disassembly and Assembly of Engine hood ................................................................8-30
8.5 Disassemble Left and Right Platform Assembly .........................................................8-42
8.6 Disassembly and Assembly of Air Conditioning System............................................8-47
8.7 Diagnosis and Solutions for Frequently Asked Questions of Air Conditioning System
......................................................................................................................................8-66
9 WORKING HYDRAULIC SYSTEM...................................................................................9-1
9.1 Working Hydraulic System, Component Positions........................................................9-1
9.2 Principle Diagram of Working Hydraulic System, Description....................................9-2
9.3 Working Hydraulic System Components, Description..................................................9-8
9.4 Disassembly and Assembly of Main Components.......................................................9-14
9.5 Diagnosis and Solutions for Frequently Asked Questions of Working Hydraulic System
......................................................................................................................................9-76
9.6 Schematic Diagrams for Hydraulic System ................................................................9-82
Service Manual
Version:0000
Safety
Service Manual For LG958L Wheel Loader
CONTENTS
SAFETY .................................................................................................................................. 1
Preface ..................................................................................................................................... 1
EMC Guidelines ..................................................................................................................... 1
Noise Limits ............................................................................................................................ 1
Cab ROPS ............................................................................................................................... 2
Security Involved in Everyone .............................................................................................. 2
Function Checking ................................................................................................................. 3
Safety-related Electrical Systems........................................................................................ 3
Safety When Handling the Loader ....................................................................................... 4
Several Simple Safety Rules ............................................................................................... 5
Measures before Towing ..................................................................................................... 9
Measures after the Towing .................................................................................................. 9
Safety Regulations for Maintenance ..................................................................................... 9
Introduction ......................................................................................................................... 9
Maintenance Position 1 ..................................................................................................... 11
Maintenance Position 2 ..................................................................................................... 12
Working under Elevated Lifting Frame ............................................................................ 13
Fire Prevention Measures .................................................................................................... 13
Notes for Tire ........................................................................................................................ 16
Safety When Lifting and Supporting the Complete Machine .......................................... 18
Methods for Front Axle ..................................................................................................... 18
Methods for Rear Axle ...................................................................................................... 18
The Safety for Operation of the Battery ............................................................................ 19
Starting with a Booster Battery ........................................................................................... 21
Safety When Dealing with Oil and Fuel ............................................................................. 22
Safety When Dealing with Refrigerant .............................................................................. 22
Safety When Operating Accumulator ................................................................................ 25
The Safety of Hydraulic System .......................................................................................... 25
I
Checking after Experiencing a Fire or Heating................................................................. 27

Health Hazard from Paints, Plastics and Rubber ............................................................. 28
Environment ......................................................................................................................... 30
Environment Protection for the Future ............................................................................. 30
Waste Disposal .................................................................................................................. 31
Environmental Method ..................................................................................................... 31
Environmentally Hazardous Liquids ................................................................................ 33
Work in a Polluted Environment ...................................................................................... 33
Decontamination ............................................................................................................... 34
II
SAFETY
Preface
This booklet is part of Service Manual—LG958L
Wheel loader. Please carefully read this part.
Warning
Be sure to read "Safety” part in the manual before
operating
EMC Guidelines
The machine's electronic equipment may disturb other
electronic devices in some cases and may cause security
problems.
Our loaders have passed a special electromagnetic
interference test, and meet the requirements of ISO
13766. If other electronic equipment is installed on this
loader, electromagnetic interference testing should be
carried out on it.
Noise Limits
Noise level near the driver should be in accordance with
the requirements of ISO 6395: 2008. Vibration value of
the cab seat should meet the requirements of ISO7096:
2000. Vibration values are: 1.22 m/s2 for light operator;
1.25 m/s2 for heavy operator.
Change or remove the material that affects the noise
level, for example. Insulation material, sound reduction
material or sound-absorbing materials are not allowed.
In addition, it is not allowed to drill the holes in the cab
or engine room, because this will increase the noise in
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the cab.
Cab ROPS
Never carry out any unauthorized modifications on
ROPS, such as reducing the height of the roof, drilling
holes or welding on the extinguisher bracket and radio
antenna bracket or other devices. Similar unauthorized
modifications may affect the strength of ROPS structure
to invalid certificate void. ROPS has been tested and
meets the requirements of ISO 3471-1 standard. Cab
ceiling has passed the strength test and meet the
standards according to ISO 3449.
All the modification plans about the load-bearing
structure for the cab should connect with SDLG
Construction Machinery Co., Ltd., to ensure that the
modification will not affect the loader's quality and
performance. What’s important, all personnel in your
organization, including managers, should be fully aware
about these requirements of ROPS. If anyone within
your company finds that the loader is modified without
authority, you should inform the customer and
manufacturers in writing of the specific modifications.
Security Involved in Everyone

You should always comply with the instructions in
Operation and Maintenance Manual—LG958L
Wheel Loader, and this manual and Service
Manual—LG958L Wheel loader are supplementary
with each other. Operation and Maintenance
Manual—LG958L Wheel Loader must always be kept
2
in the cab so as to be easy to refer to.

SDLG is aimed at the design and manufacture of safety
and efficient machines. However, if the operators do not
carefully read the safety instructions, or do not comply
with these provisions, for example, do not replace the
guard plate, climb up and down the loader without
holding the handles, or hold the hose other than pipes,
or use wrong tools for this operation, our efforts on
design will be invalid.
To keep the functions of machine safely and effectively,
you must always use the appropriate spare parts
designed for this loader (SDLG original authentic
parts). If you use unauthorized spare parts, we will not
be responsible for the damage of the loader, and also
offer the free repair and compensation.
Staff should be with strong safety consciousness, and
keep the loader well-maintained, and we cannot only
realize safety and efficiency, but also profitable.
If the operators do not comply with safety instructions,
and do not pay attention to WARNING instructions in
this manual matters, they should ensure their methods
of operation are safe and reliable. Otherwise, there is
the risk of accidents, and even leading casualties.
Function Checking
Please check the functions after safety-related electrical
system operation are carried out, to ensure safety.
Safety-related Electrical Systems

Check the following safety-related electrical system
functions systems:
Parking brake
3
Drive Brake
Gearbox
Differential lock
Lifting function
Attachment lock
Please refer to the specific content in Part 3 of
Wheel Loader.
Safety When Handling the Loader

Shandong Lingong Construction Machinery Co., Ltd.
is responsible only for the following conditions:
Properly use and maintain the loaders based on the
instructions described in Service Manual—LG958L
Wheel loader and Operation and Maintenance
Manual—LG958L Wheel Loader.
Carry out the required examination and checking in
specified interval.
Comply with the provisions about lubrication of the
machine in the manual.
No security seal is opened by unauthorized persons.
All maintenance and repair work is carried out by the
way defined by SDLG.
Only use original authentic parts / accessories or
attachments required by SDLG.
Warning
Operation personnel must fully understand and
master the contents of Operation and Maintenance
Manual—LG958L Wheel Loader before operating the
machine.
4
It is essential that drivers should carefully read

Operation and Maintenance Manual—LG958L Wheel
Loader and follow its instructions.
Untrained personnel to drive the loader may cause
serious injury or death.
Do not operate the loader without Operation and
Maintenance Manual—LG958L Wheel Loader.
Be familiar with warning labels, symbols, and
driving instructions on the machine before using it.
Several Simple Safety Rules

Introduction
 Resolve the safety problems and faults as soon as
possible.
 Wear protective items, such as helmet made of hard
materials, safety glasses, shoes, mask or other
Figure 1 Entering or leaving the machine
things.
 When the engine is running, do not stand in front or
rear of it.
 Clean the external part of the window, and always
use a long-handled rubber window wiper or brush
to avoid climbing on the machine unnecessarily.
 For maintenance of the machine, you can use the
ladder.
 Ensure that the surface of the pedal, maintenance
sites, handrails and anti-skidding parts are clean
and without oil, diesel fuel, sludge and snow, etc.,
and ensure that if these parts are damaged or lost,
timely replace and repair them.
 Check regularly whether all anti-skidding
protection devices are secure. If not, firmly install
5
or replace them.
 Always face the machine and use pedals and
handrails when climbing on the machine. Always
use the three-point contact, namely two hands and
one foot, or two feet and one hand. Do not jump up
and down!
Before operation
 Be sure to read Operation and Maintenance
Manual—LG958L Wheel Loader before
Figure 2 Read Operation and Maintenance operating the machine. Comply with the operating
Manual—LG958L Wheel Loader before instructions, and implement the required actions
operating.
before operating.
 Here are some important rules:
 Perform all safety inspection measures in
Wheel Loader.
Warning
If you feel tired or influence of alcohol, drugs or
affected by other drugs, do not drive the machine.
 Before starting the engine, make sure there is
adequate ventilation. The machine is equipped with
diesel engine and the emission gas is harmful to
your health. Therefore, do ensure adequate
ventilation. If ventilation is insufficient, please
avoid running the engine unless it is absolutely
necessary.
 Before operation or maintenance on the machine,
please read all signs and instructions as well as the
contents in Operation and Maintenance
Manual—LG958L Wheel Loader. Each sign
6
contains information about safety, treatment and

maintenance.
 Use the seat belt during operation.
 Always sit on the operator seat when starting the
engine.
 Before the machine is used, make sure a ready for
use, all functions should be intact and effective, that
the functions are ready and effective, and all the
fault that may cause an accident should be ruled
out.
 Never use the machine without good ventilation for
a long time, or the fan is not opened in a fully
enclosed cab (avoid hypoxia).
Seat belt
Figure 3 Use safety belt in all operations  If the seat belt needs cleaning: clean it with mild
soap water, and dry it in fully opened state, and
then trap it inside. Ensure that this belt is properly
installed.
 If the seat belt is worn, or the seat belt has been
subjected to force when the machine has an
accident, this seat belt should be replaced
immediately.
 Modifications on seat belt and mounting parts are
absolutely prohibited.
 Seat belt is designed for only one adult, and it
cannot be used for a couple of people.
 When the belt is not in use, it should always bet
trapped.
When the engine is running
 Pay attention to warning lights. For red one, apply
7
immediate actions or watch it. Refer to the gauge

part in Operation and Maintenance
Manual—LG958L Wheel Loader for details.
 Before using the parking brake button, confirm
attachment/attachment brackets have been placed
on the ground.
 Be sure all the levers and handles are in the neutral
position, and gear shifting handle is in the neutral
position before leaving the machine.
Warning
Risk of serious injury
 Do not stand near hinge part between the front and
rear frame, unless it is already locked with a
locking lever frame.
 Before driving it on the road, empty the attached
devices.
 When leaving the machine and nobody watches it,
it should be parked on level ground, and put the
working device down on the ground, turn off the
engine and remove the key.
Rollover danger
This cab has a function to protect the operator, in line
with ROPS standards. Protection is provided that the
operator use of seat belts. Therefore, if the machine is
overturned, do grasp the wheel. Do not jump!
Falling objects
The structure and size of the cab reaches the
requirements of cab FOPS (i.e. FOPS standards).
Cab emergency exits
Cab has two emergency exits, namely, the door and the
8
right window.
Measures before Towing
See Operation and Maintenance Manual—LG958L
Wheel Loader.
Measures after the Towing
See Operation and Maintenance Manual—LG958L
Wheel Loader.
Safety Regulations for Maintenance

This section includes the general safety rules about
inspection and maintenance.
Other rules, information and warning are offered in
Wheel Loader
Incorrect maintenance may be very dangerous.
Before starting any maintenance work:
Make sure you have maintenance certificate, the correct
information, the right tools and equipment in good
condition to correctly perform maintenance work.
Notice
Before you master the correct knowledge about
correct repair techniques and how to carry out
maintenance on the machine, you are prohibited
doing anything on the loader.
Introduction
 If there is someone else to take over your
maintenance work, ensure the person to get more
information on the progress of work, how much has
been done, and how much needs to be done.
 When you use high pressure tap to wash the
machine, do not put the nozzle directly at the
9
anti-skipping surface or the signs attached to the

vehicle.
Warning
Step special pedals when walking up and down the
machine; refer to Operation and Maintenance
 When working on the machine, do not wear loose
cloth that may be stuck, in order to avoid personal
injury.
 Always wear protective caps, goggles, gloves,
protective boots and other safety that your work
Figure 4 Do not step the engine hood
needs.
 Always turn off the engine for maintenance unless
the marking and signs of the vehicle or this
publication have other instructions.
 Do not stand near the hinged frame, unless it is
already locked with a locking lever frame.
Figure 5 Wear protective items

 Before opening the engine cover, radiator tanks and
similar parts, turn off the engine. Make sure that no
tools or items that may cause damage left on the
machine.
 When the engine is running and the machine is in
operation, the engine cover should be kept closed.
10
Maintenance Position 1
Stop the machine on a level and hard surface, and place
it on the service position 1. (See Figure 6)
Figure 6 Maintenance Position 1

1. Put attachments on the ground.
2. Turn off the engine and take down the ignition key.
Warning
3. If the system pressure is not reduced before opening, oil will spray under high pressure,
and may cause serious personal injury accidents.
Release the pressure in pressurized pipe and oil tank to prevent accidents.
4. Press the parking brake button, so that the vehicle is in the parking brake status and wedge the
loader.
5. The steering wheel should be connected with yellow black warning flag (a red warning flag may
be used in the United States).
6. The frame lock lever has been connected.
7. Battery cut-off switch is off.
8. Let the machine cool down.
Warning
If you have to operate on the machine before it is cooled down, pay attention to hot liquid and
components, in order to avoid burns.
11
Maintenance Position 2
And the machine on a level hard surface, and place it on
the maintenance position 2. (See Figure 7)
Figure 7 Maintenance Position 2

1. Lift the bucket and tilt it forward. Fix the boom on safety support lever.
2. Turn off the engine and take down the ignition key.
Warning
3. If the system pressure is not reduced before opening, oil will spray under high pressure,
and may cause serious personal injury accidents.
Release the pressure in pressurized pipe and oil tank to prevent accidents.
4. Press the parking brake button, so that the vehicle is in the parking brake status and wedge a
good car.
5. The steering wheel should be connected with yellow black warning flag (a red warning flag may
be used in the United States).
6. The frame lock lever has been connected.
7. Battery cut-off switch is off.
8. Let the machine cool down.
Warning
If you have to operate on the machine before it is cooled down, pay attention to hot liquid and
components, in order to avoid burns.
12
Working under Elevated Lifting Frame

Before starting operation, always use the support frame.
Support frame must be mounted on a sturdy and flat
surface.
Warning
Pay attention to the exact location under the lift
arm!
Figure8 Fix the boom firmly If the support is placed too forward, it will be
overwhelming when the attached tool holder is
tipping.
Fire Prevention Measures

Introduction
 Fire danger always exists. Figure out what type of
fire extinguisher is, where it is stored and how to
use it. Fire extinguisher on the machine should be
placed in the left seat, or a storage box with lock.
 The extinguisher installed on the machine or inside
the machine must be maintained in the active state.
 The extinguisher installed on the machine used to
operate the loader must meet certain requirements.
See Operation and Maintenance
 Even if only the fire may happen, if circumstances
permit , and remember your personal safety, you
can take the following measures:
 Start the machine, leaving the fire or hazardous
sites.
 Lower the lift arm to its lowest position, so that the
attachments stay on the ground.
 Turn the ignition key to position "O" to turn off the
13
engine.
 Leave the cab.
 Disconnect the battery switch.
 Start to put out the fire, and call for the fire
department when necessary.
 When fill the machine with oil, or when the fuel is
exposed to air, the machine should not be near
Figure 9 When filling the fuel or contacting
with air, should not prevent smoking fireworks.
 Diesel fuel is flammable and cannot be used to
clean the machine. Clean the machine with
approved cleaning agent.
 Some cleaning agents may cause fire or irritate the
skin. Do avoid absorbing vapors of cleaning agent.
Cleanliness
 Cleanness is one of critical factors to keep safe and
reliable operation of the system. Therefore, we
should keep maintenance area clean. Oil and water
will make floors and escalators slippery. Electrical
systems and tools stained with oil and water are
prone to danger. Greasy clothes or clothes soaked
with grease will also be a serious fire hazard.
 Make daily inspection of machinery and equipment
to ensure no dust and oil, such as bottom
skateboard of loader body, which may reduce the
risk of fire, and easy to find defective parts or loose
parts.
If cleaning with high pressure water, must be extremely
careful, because the electronic components and cable
insulation may be damaged at a relatively moderate
pressure and water temperature. Please protect the
14
cable.
 When working the risk of fire hazard, such as in
sawmill, waste disposal sites, etc., do keep the site
clean. In this environment, install the appropriate
equipment in order to reduce the risk of
spontaneous combustion caused by accumulated
material (Such as silencer, radiator screen,
high-power air pre-cleaner, etc.).
Electrical systems
 Check whether the cable is scratched, and ensure
that the cable will not suffer such damage. This is
particularly important for the cable without fuse
and the color is red. For example , the cables are
between the following components :
- Battery
- Battery - starter motor
- Alternator - starter motor
- Warm-up coils from cable to the engine.
 If the cable without fuse is ever disconnected, do
check whether the wires are connected again, and
make sure wire connections can greatly prevent
from being scratched. The cable without fuse
cannot be close to oil or fuel hoses.
 For installing any optional equipment, be sure that
all wires are connected through a fuse and make
sure the layout of wiring and fixing of wire can
avoid being scratched.
Fuel, hydraulic and brake system
 Check fuel, hydraulic and brake hoses are not
scratched.
15
Welding and hrinding

For carrying out any welding work, fire extinguisher
must be readily available.
 Welding and grinding operations can only be
carried on clean parts of the machine, and cannot be
in a position with combustible liquids, such as fuel
tanks and hydraulic pipe. Such parts must be
soldered and polished, and be especially careful.
 You have to weld on the paint surface, and you
should first remove the painting. Welding on the
painting surface not only produces health harmful
gases, but also cause poor welding or malfunction,
resulting in accidents.
 Use personal protective equipment. If conditions
are permitted, you can use the exhaust fan to drain
the poisonous gas produced through the welding
and grinding.
Notes for Tire

Warning
When inflating the tires installed in separate rim, it
may explode, causing serious injury.
Inflation
 Do not stand near the wheel side when inflating the
tires installed in separate rim. When inflating, you
can use the automatic locking air nozzle, and use a
long enough hose so that you can stand outside the
danger zone.
Figure 10 Do not stand near tires when
inflating  When inflating the tires, verify that no person
stands in danger zone.
 Check the tire pressure only when the loader is
16
without loading.
 Spare tire should be inflated only enough to
maintain the rim parts in position.
 When the tires are inflated, use a box and a rope or
chain to fix the loose wheels. Before removing the
box, check whether the tire is correctly installed on
the rim.
 After inflation, do not adjust the side ring or lock
ring.
 If tire pressure installed on the machine is less than
80% of the normal pressure, and wheel rim or tire is
damaged, you should remove the tire.
Install tires and rims
 Only trained technicians are allowed to handle the
tires.
 Before removing the tire from the rim, you should
deflate tire firstly.
 If the tire and the rim do not match with each other,
you cannot install the tire on a rim.
 Do not install rims parts with different sizes
together, and do not use damaged and failed
components.
 If you use the repaired wheel assembly, be very
careful. Failed or incorrect welding, heating or
fusing may damage the strength of component,
resulting in failure of the future.
 Before installing the lock ring, you should confirm
the lock ring inside the rim groove with dirt and
dust.
 When installing the tire on the rim, use the
17
lubricant recommended by the tire manufacturer.

Repair tires and wheel rings
 Do not cut, weld or heat the wheel assembly in any
way.
 Be careful to use wheel side remover and hydraulic
jacks. When removing impurities from the tires,
stand outside the danger zone. It is extremely
dangerous to loosen the circular edge of the break,
which may cause serious personal injury and death.
Safety When Lifting and Supporting

the Complete Machine
Place the machine on the maintenance position, and
always use the jacks and support equipment having
sufficient bearing capacity.
Other works must be carried out in a safe manner before
providing support for front and rear axles.
Warning
When the machine is only supported by jack, it is
prohibited to entering the machine or walking under
the machine.
When replacing wheels and brake, always keep one
operation for one axle.
Methods for Front Axle

Lift the machine with lift arm, and use special tools to
support.
Methods for Rear Axle

After jacking up the machine with jack, support the
counterweight with special tooling and put wood
between the bridge and the frame to prevent the swing
18
of rear axle.
Notice
Before falling down the machine, do not forget to
remove the block.
Machine must be equipped with tooling and jacks with
sufficient support capacity (10-25 tons).
In the case that two wheels are lifted, you can more
easily rotate the hub to set the wheel nut in place.
The Safety for Operation of the Battery

Warning
Serious risk of corrosion!
Battery contains sulfuric acid, and is extremely
corrosive for loader parts and the human body. In
addition, the battery will release hydrogen when
discharging it (power supply). If hydrogen mixes with
oxygen in the air, it may form explosive mixture gas.
As to all the work involved in vehicle battery, the
mixture of explosive gases and corrosive sulfuric acid
will greatly increase the risk of accidents.
Figure11 Sulfuric acid
Therefore, when you operate the battery, you should
carefully read and follow these rules.
For operation the battery, please follow these
instructions :
Battery will release explosive gases. Do not smoke near
the battery.
Before removing the battery, firstly disconnect the
ground wire. To reduce the risk of fire hazards, when
installing the battery, connect the ground wire at last.
Do not tilt the battery in any direction. Battery
electrolyte may leak.
19
Do not put the discharged battery and fully charged

batteries in series. It will be with the risk of explosion.
Do not allow metal objects (such as tools, rings,
watches) contact with the battery terminals. It is with
risk of fire and personal injury.
When working near the battery, cover the top of the
battery with cloth or other non-conductive material.
Always install the caps of battery terminal.
Battery includes substances harmful to health and the
environment. Therefore, scraped batteries must be in
accordance with local / national regulations to deal
with. Refer to environmentally friendly approach.
Battery charging
Risk of explosion
When charging the battery, it will form an explosive
mixture hydroxide. Short circuit, open flame or sparks
near battery can cause powerful explosion. Before
disconnecting the charging clamps, always turn off the
charging current. Keep it ventilated, especially charging
in an enclosed space battery.
Warning
Corrosive sulfuric acid
Battery electrolyte includes corrosive sulfuric acid. If
electrolyte is splashed on exposed skin, you should
immediately wash it away. Clean the affected area with
soap and plenty of water. If electrolyte gets into your
eyes, or any other sensitive parts of the body,
immediately flush it with water and immediately seek
help for doctor.
20
Starting with a Booster Battery

Starting with a booster battery pack , you must comply
with the following:
Notice
Check and make sure that the voltage of battery
pack and any other step-up power supply are same.
Warning
If a fully charged battery is connected to a depleted
battery, the battery may burst open due to power
surges. Because batteries contain sulfuric acid, it
may cause personal injury accidents.
Follow these steps:
1 Open the engine hood.
2 Open the battery cover.
3 Close the battery disconnection switch.
4 Do not disconnect the machine's battery cables.
5 Remove the caps from the battery terminal.
6 Connect the positive cable from the booster battery or
other power source to positive terminal of the left
battery.
7 Connect the negative cable from the booster battery to
the engine block.
8 Open the battery disconnection switch.
9 Use the ignition switch in the cab to start the engine.
10 If the alternator charges, remove the jumper starter
cable from the negative terminal of boost battery and
the ground and the battery. Then remove the jumper
starter cable between the positive terminals.
Notice
If the alternator is not charging, use switch to turn
21
off the machine and check the reason.

11 Recover the machine.
Safety When Dealing with Oil and Fuel

Warning
Risk of scalding! Use of protective gloves.
 Replace hydraulic oil inside the engine and
transmission, remember that the oil is very hot and
may cause burns/scalds.
 Engine and gearbox oil, hydraulic oil and diesel
fuel are corrosive for the mucous membranes, such
as the eyes, throat and skin. So be especially careful
to keep these sensitive parts of the body away from
the oil.
 For evacuation or discharge oil or fuel, do take
measures to avoid unnecessary spilling. In a place
that is impossible to use the container to collect the
oil, use an absorbing pump or hose as security
measures. Casually releasing oil and fuel is not only
harmful to the environment, but also cause fire.
Waste oil should be handled by an authorized company.
See environmentally friendly approach.
 Remember that fire hazards!
Safety When Dealing with Refrigerant

Introduction
Before turning on the air-conditioning system, repair
work and further work should be carried out by the
personnel with special qualifications. Many countries
also require that the repair person should be specially
trained and officially recognized. Understand the
regulations and comply with them in the country.
22
Refrigerant R134a is used for the air conditioning unit.

Type and filling amount of refrigerant are marked on
the card.
Notice
R134a will aggravate the greenhouse effect, and
don’t expose it to the air.
Person Protective Equipment
When there is a danger of refrigerant skin, please use:
tight goggles and protective gloves, and protect other
exposed skin (frostbite hazard).
Danger
Warning
These gases are odorless and tasteless; even it can
Figure12 When contacting with refrigerant, cause serious damage to the lungs at low
wear goggles and protective gloves
concentrations.
If it is not handled correctly, R134a refrigerant can
cause serious personal injury and environmental
hazards. Therefore, be very careful when operating the
air conditioning unit! In order to avoid contact with
refrigerant personal injury, the rules given below will be
of great help.
Warning
There is a danger of frostbite! Use protective gloves.
 Liquid refrigerant can cause frostbite
 Low-concentration gaseous refrigerant has a certain
impact, especially on the nervous system.
 The high-concentration gaseous refrigerant has
anesthetic effect.
 Air conditioning units are high pressure, and the
refrigerant will inadvertently leak. Do not
23
disconnect the hose or remove oil filling plug on

the compressor.
 If you suspect the leakage of some parts, you
should contact with an authorized repair station
approved and trained personnel to troubleshoot and
repair it.
 Refrigerant gas is heavier than air and it will sink to
the ground. Therefore, ensure that any escaping gas
should be released before you start working.
In the working site during operation of refrigerant,
smoking, welding or other open flames are not
permitted. Refrigerant gas will burn and form a toxic
gas inhalation. And it is very dangerous to breathe it.
The gas formed by heating the refrigerant gas is
irrigative at high concentration.
Symptoms may appear after being exposed to the gas
after a few hours (Maybe up to 24 hours).
Actions Taken When the Accident Occurs
Inhale
If you suspect the gas escapes, please leave the area,
and try to find fresh air and move affected persons out
of the danger zone. A small amount of refrigerant
R134a vapor will have some impact, particularly on the
nervous system. When the amount of the gas is large,
the gas will have anesthetic effect. In serious cases, seek
for immediate medical attention.
Skin contact
If frostbite occurs, rinse with warm water for a long
time. If unprotected skin contacts with large amounts of
liquid refrigerant, the damage zone should be careful
24
with warm cloth or warm water. If these symptoms

persist, seek for immediate medical.
Splashing into the eyes
Rinse the damaged zone with warm water until irritation
feeling disappears. Seek for medical help immediately.
Safety When Operating Accumulator

Only qualified service personnel are allowed to operate
Warning
If the system pressure does not reduce, oil will spray
under high pressure and cause serious injury.
Before removing the accumulator from the machine, the
system should be depressurized.
Even some accumulators are removed from the
machine, they still contain pressure, that is so-called
pre-charge pressure. Therefore, be very careful in
dealing with accumulator and operating on the
accumulator.
When taking any measures on the accumulator, the
pre-charge pressure must be reduced to atmospheric
pressure.
Avoid exposing the accumulator to high temperature, do
not handle rough.
Warning
Discarded accumulator without perforation may still
contain high-pressure, be always extremely careful
to handle it.
Discarded accumulator should release the pressure
before the crushing, in order to avoid explosion.
The Safety of Hydraulic System

Loader hydraulic system runs at very high pressure,
25
about 18MPa (2610 pounds/square inch). To avoid

serious personal injury, s very important to repair
system in the right way, and all personnel that contact
with the machine should be very careful in their work,
and pay close attention to any deficiencies.
To avoid accidents, please comply with the following
requirements.
Introduction
 The pressure of pressure limiting valve must not be
adjusted to the value higher than the level
recommended by the manufacturer.
 The hydraulic hose of expansion valve (for
example, connection part) maybe rupture, replace
the hose as soon as possible! Note the leakage of
hydraulic hoses and connections. Repair the parts
before rupture!
 Discarded accumulator should be pierced before
disposal to prevent explosions.
Warning
If the system pressure does not reduce, oil will spray
under high pressure and cause serious injury.
Release the pressure (pressure relief)
After engine is shut down, there will be pressure leaving
in system. Before loosening or opening hose
connectors, plugs, etc. in hydraulic system or braking
system, you must release the pressure of system through
pressure relief.
If the engine is stopped, release the pressure of the
accumulator by moving the lift lever back and forth
several times.
26
 All pressurized tanks/containers should be opened

carefully to release any remaining pressure.
 Only after the system is fully relieved can you
check whether leakage pipes and connections are
tightening.
Warning
Leaked hydraulic hoses under high pressure may
cause serious injury. The spilled liquid is very
penetrating on the exposed skin.
 When checking leakage, check it with steel or
cardboard, and do not use hand.
Checking after Experiencing a Fire or

Heating
As precaution, the sealing ring (O-ring or an axle/shaft
seals) should always be made of the fluorine rubber, and
refer to "fluorine rubber" part.
Warning
When washing burned machine, avoid splashing!
Therefore, do not clean with high-pressure liquid.
 If you may touch with melt polymer, do not directly
touch the burnt components or parts. Wash it with
plenty of lime (a kind of solution or suspension of
calcium hydroxide, namely slaked lime).
Use thick protective rubber gloves and goggles to
protect your eyes.
 If your skin may be exposed to burnt fluorine
rubber, seek for medical help.
Symptoms may appear after a few hours after touching
fluorine rubber.
 Discard protective gloves, cloth, and other items
27
that may be exposed to fluorine burnt rubber.

 During operations, maintain good ventilation.
 If the eyes are hurt, rinse them immediately with
plenty of water for at least 15 minutes. Then seek
for medical guide.
Health Hazard from Paints, Plastics

and Rubber
Working on the paint surface
Do not weld or cut on paint surface. All paints after
heating will decompose and produce a large mount of
different substances, and it is very harmful to health if
often exposing in such an environment.
Take the following security measures:
 Clean 10cm (4 in) area around working point with
abrasive paper (use respirator mask).
If the paint cannot be sanded off, it should be removed
by other methods, such as using paint remover.
Notice
If the paint is removed with agent, use an exhaust
fan, and wear a respirator mask and protective
gloves.
The grinding machine with high-speed disc will heat the
paint and it can only be equipped with an exhaust fan.
And wear a mask or other respiratory protection
equipment at the same time.
Rubber and Plastics
Warning
Heated rubber and plastic will emit substances
harmful to health and the environment.
Must observe the following safety rules :
28
 Without insulation measures taken in advance, do

not weld or cut near polyester material (plastic or
rubber) with a flamethrower.
 Do not scrape polymeric materials when burning
them.
 After a fire or heating, the machine should be
handled carefully.
 Always use gloves, goggles and face shields, or
other respiratory protective equipment.
Fluoride rubber
Warning
Warning
Heated hydrogen fluoride rubber means that the
accumulation of hydrogen fluoride even at about
320 ° C (610°F) temperature, and it may cause
severe corrosion of the respiratory tract after
breathing this gas.
Some seals are designed to withstand high temperatures
(i.e. the seals in the engine, gearbox, axle, brake,
hydraulic motors and pumps member), which is made
of fluoride rubber, and it will generate hydrogen
fluoride and hydrogen fluoride acids when heating to
high temperature.
Hydrogen fluoride acid is strongly acidic and corrosive,
and it cannot be washed from the skin. And it would
cause very serious burning and corrosion damage, and it
takes a long time to recover. As a general principle, the
injured tissue must be surgically removed.
Hydrofluoric acid will remain parts on the machine
29
parts after the fire for long time (several years).

Notice
After contacting with hydrofluoric acid, the
symptoms will appear after a few hours.
If swelling, redness or burning happens due to
contacting with heated fluoride rubber, immediately
seek for medical advice.
If the machine or machine parts suffers a fire or other
intense heating, it can only be done by trained service
personnel.
When all fire operations are performed on the machine,
rubber gloves should be robust and effective.
Warning
Burning paint parts, plastic/rubber parts will be
harmful to health.
Decontamination
For the area subjected to heating, if you suspect it is
made of fluorine rubber, use a lot of lime (calcium
hydroxide, blended hydrated lime) to thoroughly wash it
to remove toxic substances. After the decontamination,
gloves must also be cleaned in lime, and then scrap it.
If the machine has been subjected to fire or other high
heating source, in any case, the security measures in
following checklist must be unconditionally observed:
checking after experiencing a fire or heating.
Information on asbestos
SDLG of the machine does not own asbestos, so

genuine parts of SDLG are very important.
Environment
Environment Protection for the Future
30
The whole world is facing enormous challenges of

environmental issues, and cleaning of water, climate
change and use of chemicals become the most important
issues. The machines Shandong Lingong Construction
Machinery Co., Ltd. will play the important roles facing
the challenges, contribute to the development of
ecology and rational use of natural resources.
Waste Disposal
For the treatment of waste, comply with the following
steps.
If possible, deal with the waste with the recovery
disposal methods.
Re-use is the best from an environmental point of view.
MATERIAL RECYCLING is also a good
environmental choice of means for use of new products.
ENERGY RECOVERY is a good alternative to burn it
as combustible materials.
DESTRUCTION can be used in hazardous waste.
Destruction must be operated in a special venue.
DEPOSITION is the worst way from an environmental
point of view, and should be avoided.
Figure 13 STORAGE is a temporary measure and deal with it

until a suitable recycling technology is developed.
Environmental Method
Always select a most suitable method for environmental
protection, as long as there is the possibility, for
example, use biological oil.
Always comply with national and local environmental
regulations.
All waste should be handed over to authorized waste
31
disposal company.
Liquid and oil
Do not reuse the old liquid oil, such as coolant, and
collect it in sealed container and leave it to destroy
department.
Filter
Oil and fuel filter should be drained and then placed in a
sealed container and then leave it to destroy department.
Refrigerant R134a
Refrigerant R134a contains substances affecting
greenhouse effect and should not be released into the
atmosphere. Recover it according to instructions in the
manual of Air conditioning unit.
Battery
Warning
Batteries contain environmentally harmful substances
and corrosive sulfuric acid. And should be handed over
to recycling sector.
Chemicals
Chemicals, paints, adhesives, detergents, etc. , should
be left to deal with recycling sector or destroyed.
Rubber and Plastics
Rubber and plastic parts should not be burned, and
should be handed over to recycling sector.
Tires should be based on special provisions to deal with.
Electronic component
Electrical and electronic waste parts, such as circuit
boards, bulbs, should be handed over to recycling
sector.
32
Environmentally Hazardous Liquids

Note whether fuel, oil and other fluids harmful to the
environment leak from the machine.
Take appropriate measures immediately to prevent
leakage, and eliminate the pollution of contaminated
sites as soon as possible.
Oil and fuel
When emptying or draining the oil and fuel, take
appropriate measures to prevent unnecessary spilling. If
a container cannot be used, use a pump or hose.
Air conditioning unit
Refrigerant R134a contains substances affecting
greenhouse effect and should not be released into the
atmosphere.
The personnel in charge of refrigerant maintenance
must not only understand the country's relevant
laws/regulations, but also understand the international
rules.
Recommends that all maintenance for the air
conditioning must first be trained. Many countries
require the man with a certificate of authority can
perform such operation.
Work in a Polluted Environment

The machine in a polluted/unhealthy site should be
equipped with a special device in these operating
environments.
After operating in the environment containing asbestos
or other toxic dust, used cab and engine air filter must
be placed in sealed plastic bags ( packed new filter
bag ), and leave them to the destruction department.
33
Decontamination
Clean the contamination up as soon as possible. Certain
substances will soon be scattered into the environment.
Clean-up after the leakage/spilling
Use suitable absorbent material to collect leaking oil or
fuel, such as absorbent pads.
Prevent leaked oil/fuel with the rain/flood.
Contaminated soil and materials on the ground must be
removed and collected in a suitable container.
Collect soil and absorbent material should be left to the
destruction department.
Clean-up after the accident
If possible, prevent leakage of the machine.
Use drainage barriers to isolate the leakage site.
Add the absorption material, such as sand or sawdust
water.
Prevent leakage of liquid so that leaked oil/fuel will not
discharge into sewers with the rain/floods.
Collect absorbent material and dirt floating layer in a
sealed container, and leave them to the destruction
department.
Clean up after the fire
First put out fire.
Deal with it in accordance with the post-accident
clean-up measures.
Notice
Be careful of the toxicity of certain substances after
ignited.
34
SERVICE MANUAL
Version:0020
0 GENERAL
CONTENTS
0 GENERAL ........................................................................................................................................... 0-1
01 Introduction....................................................................................................................... 0-1
02 Specification ...................................................................................................................... 0-6
03 Tools ............................................................................................................................... 0-10
04 Marks .............................................................................................................................. 0-11
05 Maintenance and Replacement Decisions ......................................................................... 0-12
051 Ocular Estimates or Hand Touching............................................................................. 0-12
052 Measure ........................................................................................................................ 0-13
Ⅰ
0 GENERAL
01 Introduction
The wheel loader with a single large bucket, hinged and

front unloading device is large construction machinery
mainly shovel loading the bulk material. It is used for
mining, infrastructure and road construction, etc., in
many Corporations, Garages, Ports and other places. It
is mainly engaged in loading or unloading the loose
soil, sand, gravel, coal, garbage and other bulk material
and for short-distance transportation, which is versatile,
high-efficiency construction machinery. It can be used
for clipping wood, grasping grass, snow removal,
forking bulk materials and other operations when its
working equipment is changed.
For details, refer to specific chapters!
Figure 0-1
1 Counterweight 2 Engine hood cover
3 Rear tires 4 Cab
5 Front tires 6 Bucket cylinder
7 Rocker arm 8 Quick-change frame
9 Quick-change bucket
0-1
Table 0-1 Overview
Items Parameters Items Parameters
Min. turning radius (external part
Bucket capacity(m3) 3.0 6039
of rear wheel)(mm)
Moving levelly radius(external
Rated operating load(kg) 5000 6775
part of bucket) (mm)
Max. dragging force
≥160 Max. breakout force(kN) ≥152
(provided by engine) (kN)
Tipping load, Bucket(kN) 100 Max. climbing angle(°) 28
Gears Ⅰ Ⅱ Ⅲ Ⅳ
Speed Forth(km/h) 0～6.8 0～12 0～24 0～36
Back(km/h) 0～7.2 0～12 0～23 ---
Table 0-2 Dimensions and Weight

Overall Length(bucket on the
8304 Bucket width(mm) 3024
ground)(mm)
Height(mm) 3545 Wheel base(mm) 2204
Width (mm) 2785 Shaft base(front/rear)(mm) 3200(1600/1600)
Max. dump Height(-45 ° dump
2945 Operation weight(kg) 17350
angle)(mm)
Max. Reach (-450 dump angle)(mm) 1300 Shaft number 2
Min. ground clearance(mm) 423
Table 0-3 Engine

Model VOLVO D7E Number of cylinder 6
Common rail, inline, water
Type Cylinder bore/stroke(mm) 108 / 130
cooling, 4 strokes
Rated power(kW) 162 Min fuel consumption (g/kWh) 215
Rated speed(r/min) 2100 Max torque(Nm) 1050
Displacement(ml) 7146 Emission standard EuroⅢ
0-2
Table 0-4 Transmission
Items Parameter/contents
Type 3-element,single-stage,single-phase
Torque coefficient 2.55
Torque converter Oil cooling type Circulation water cooling
Inlet pressure of converter(MPa) 0.85
Outlet pressure of converter(MPa) 0.5
Model Countershaft and electronic-hydraulic shifting
Shifting gears Front 4 rear 3
Forward Ⅰ 4.278
Forward Ⅱ 2.368
Forward Ⅲ 1.126
Transmission
Forward Ⅳ 0.648
Transmission box ratio
Backward Ⅰ 4.278
Backward Ⅱ 2.368
Backward Ⅲ 1.126
Variable pump model Inner set in the machine
Variable pump working
1.4～1.6
pressure(MPa)
Model Spiral bevel gear
Reduction Gear
Reduction ratio 3.7
Final reduction Model Planetary gear, single reduction
Gear Reduction ratio 6.35
Model Four-wheel-drive
Tire specification 23.5-25
Drive system
Tire pressure Front wheel 0.39±0.01
(MPa) Rear wheel 0.33±0.01
Service brakes Full hydraulic actuated, wet-brakes actuate
Brake system Brake oil pressure(MPa) 5.5MPa
Parking brake Full hydraulic drum brakes
Table 0-5 Steering system

Model Loading sensing
Priority valve VLH-240S-16
Steering pump HGP3100/1016RC
Steering cylinder-bore×diameter×stroke (mm) HSGL-90*50*480
Steering device BZZ6-1000
Steering angle(°) 38°
working pressure(MPa) 16
0-3
Table 0-6 Working device

Model Hydraulic pilot valve
Boom cylinder-bore×diameter×stroke (mm) HSGF-170×90×774
Bucket cylinder-bore×diameter×stroke (mm) HSGF-200×100×550
Working pump HGP2063/a2040BC
Multiple valve model D32A-18
Pilot valve model HC-RCL-5A-VIA
System working pressure 18MPa
Bucket lifting time(full load) ≤6.69s
Bucket lowering time(unload) ≤4.82s
Bucket unloading time(unload) ≤1.13s
Sum of three operation time ≤12.64s
Table 0-7 Service refill capacities

Fuel tank 300L Engine 21.5L
Hydraulic system 210L Transmission system 35L
Axle (front and rear) 2×34L Brake system ------
0-4
Figure 0-2
0-5
02 Specification
Standard tightening torque

Table 0-8 Tightening torque of common screws
Bolt Yield Bolt nominal diameter mm
strength strength 6 8 10 12 14
grade N/mm2 Tightening torque N·
m
4.6 240 4～5 10～12 20～25 36～45 55～70
5.6 300 5～7 12～15 25～32 45～55 70～90
6.8 480 7～9 17～23 33～45 58～78 93～124
8.8 640 9～12 22～30 45～59 78～104 124～165
10.9 900 13～16 30～36 65～78 110～130 180～210
12.9 1080 16～21 38～51 75～100 131～175 209～278
m
4.6 240 90～110 120～150 170～210 230～290 300～377
5.6 300 110～140 150～190 210～270 290～350 370～450
6.8 480 145～193 199～264 282～376 384～512 488～650
8.8 640 193～257 264～354 376～502 521～683 651～868
10.9 900 280～330 380～450 540～650 740～880 940～1120
12.9 1080 326～434 448～597 635～847 864～1152 1098～1464
m
4.6 240 450～530 540～680 670～880 900～1100 928～1237
5.6 300 550～700 680～850 825～1100 1120～1400 1160～1546
6.8 480 714～952 969～1293 1319～1759 1694～2259 1559～2079
8.8 640 952～1269 1293～1723 1759～2345 2259～3012 2923～3898
10.9 900 1400～1650 1700～2000 2473～3298 2800～3350 4111～5481
12.9 1080 1606～2142 2181～2908 2968～3958 3812～5082 4933～6577
Table 0-9 Tightening torque table when the connected piece is made of cast iron or aluminum
Bolt grade and torque 8.8

torque( N·
m)
Bolt specification Cast iron Aluminum
M8 20～25 15～20
M10 45～50 25～30
M12 70～80 50～55
M14 110～125 80～90
M16 160～180 120～140
M18 205～230 165～180
0-6
Table 0-10 Tightening torque of connector
Connector with copper washer sealing or screw sealing Connector with O ring
Connector Connector Tightening torque
Tightening torque N·
m
specification specification N·m
M14、G1/4 34±5 M12×1.5 35±3.5
M18、G3/8 73±10 M14×1.5 45±4.5
M20、G1/2 93±10 M16×1.5 55±5.5
M24 142±20 M18×1.5 70±7.0
M27、G3/4 205±30 M20×1.5 80±8.0
M33、G1 421±49 M22×1.5 110±10
M42 872±98 M27×2.0 170±17
M33×2.0 310±31
M36×2.0 310±31
Table 0-11 24°Tightening torque of cone sealing

Tightening torque of 24° cone sealing pipe nuts
Specification Tightening torque N·
m
M12×1.5 15～20
M14×1.5 25～30
M16×1.5 30～35
M18×1.5 35～45
M20×1.5 40～50
M22×1.5 45～65
M24×1.5 45～65
M26×1.5 65～85
M30×2 85～110
M36×2 120～145
M42×2 170～210
Table 0-12 Tightening torque of hinged bolt

Specification Tightening torque N·
m
M10×1 25～35
M12×1.5 60～75
M14×1.5 80～100
M16×1.5 105～115
M18×1.5 20～130
M22×1.5 140～155
M24×1.5 160～180
M27×2 190～230
M33×2 270～320
0-7
Conversion of units table
Table 0-13 Length
Unit cm m km inch foot code mile
cm 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006
m 100 1 0.001 39.37 3.2808 1.0936 0.00062
km 100000 1000 1 39370.7 3280.8 1093.6 0.62137
inch 2.54 0.0254 0.000025 1 0.08333 0.02777 0.000015
foot 30.48 0.3048 0.000304 12 1 0.3333 0.000189
code 91.44 0.9144 0.000914 36 3 1 0.000568
mile 160930 1609.3 1.6093 63360 5280 1760 1
1mm=01cm 1um=0001mm
Table 0-14 Area

unit cm2 m2 km2 acre foot2 code2 inch 2
cm2 1 0.0001 - 0.000001 0.001076 0.000012 0.155000
2
m 10000 1 0.000001 0.01 10.764 1.1958 -
2
km - 1000000 1 10000 1076400 1195800 -
acre 0.01 100 0.0001 1 1076.4 119.58 -
2
foot - 0.092903 - 0.000929 1 0.1111 144.000
2
code - 0.83613 - 0.008361 9 1 1296.00
2
inch 6.4516 0.000645 - - 0.006943 0.000771 1
2 2
1 Ha =100 Ares 1mile =259 Ares =2.59km
Table 0-15 Weight/volume

UNIT cm3 m3 dm3 inch3 foot3 code3
mL 1 0.000001 0.001 0.061024 0.000035 0.000001
kilolitre 1000000 1 1000 61024 35.315 1.30796
L 1000 0.001 1 61.024 0.035315 0.001308
3
inch 16.387 0.000016 0.01638 1 0.000578 0.000021
3
foot 28316.8 0.028317 28.317 1728 1 0.03704
3
code 764529.8 0.76453 764.53 46656 27 1
3 3
1gallon(American)=3785.41cm =231inch =083267gallon(English)
Table 0-16 Weight

unit g kg t ounce Ib.(pound)
g 1 0.001 0.000001 0.03527 0.0022
kg 1000 1 0.001 35.273 2.20459
t 1000000 1000 1 35273 2204.59
ounce 28.3495 0.02835 0.000028 1 0.0625
Ib(pound) 453.592 0.45359 0.000454 16 1
1t(metric)=1.1023t(American)=09842t(English)
0-8
Table 0-17 Pressure
unit KIPS /cm2 bar Pa=N/m2 kPa Lbf /inch2 Lbf /foot2
KIPS /cm2 1 0.98067 98066.5 98.0665 14.2233 2048.16
bar 1.01972 1 100000 0.001 0.00015 0.02086
2
Pa=N/m 0.00001 0.001 1 0.001 0.00015 0.02086
kPa 0.01020 0.01 1000 1 0.14504 20.886
2
Lbf /inch 0.07032 0.0689 6894.76 6.89476 1 144
2
Lbf /foot 0.00047 0.00047 47.88028 0.04788 0.00694 1
2
kg/cm =735.56net weight(mm Hg)=096784 atmospheric pressure
Table 0-18 Unit description

Unit Abbreviation
Newton metre N·
m
Kilopound metre kpm
Kilopascal kPa
Megapascalmpa MPa
Kilo watt kW
kiljoule kj
English thermal unit Btu
Calorie ca
0-9
03 Tools
Maintenance tool list (Table 19)

Table 0-19
Common tools Specification Number Use
Choose the specification

Pneumatic
BQ8、BQ10、BQ16、BQ30、MI-17HE 1 according to size of different
wrench
assembled bolts
sleeve 10、13、15、16、18、21、24、36、46 1 according to size of different
assembled bolts
Hit slightly when assembling
Soft hammer 1
some parts with interference.
5.5×7、8×10、10×13、11×13、12×14、
13×15、13×16、14×16、16×17、16×18、
Solid wrench 1 according to size of different
17×19、18×24、18×21、22×24、24×27、
assembled bolts
24×30、27×32、30×34、36×41、41×46
Hit slightly when assembling
Copper bar 1
some parts with interference.
Adjust the measure of gap
Feeler gauge 1
positions
Flat tip screw
1 Slotted screw
driver
Cross head
1 Cross screw
screw-driver
Pliers 1
Diagonal wrench 1
Crowbar 1
Specific tools Specification Number Use
Prepare the operation platform if it is not Install or remove working

Frame 2
offered. device and axle assembly
Wheelbarrow 1 Install or remove axle assembly
Wooden wedge 1 Fix the machine for repair
0-10
04 Marks
In order to emphasize the significance of safety and quality visually, we design the following
signs as marks.
Table 0-20
Sign Item Note
Be careful for the safety during the operation.

Safety
Be quite careful for the safety if there is pressure inside during
the operation.
Emphasize the technical requirements to ensure that the
Note operation can meet the requirements of standard during
operation.
Weight and installation means of parts or device.

Weight
Carefully select hanging tools and the operation gesture.
Tightening
Pay more attention to the tightening torque of assembly parts.
torque
Carefully note the parts need to be coated with grease or

Coating
adhesion agent.
Oil water Fill a mount of water, oil and fuel.
Be careful for the parts where water and oil need to be drained
Draining
and drainage, and judge their volumn.
0-11
05 Maintenance and Replacement Decisions
051 Ocular Estimates or Hand Touching
1. Never further use the parts which are seriously dump, having fracture and crack, or losing
function.
2. Never further use the oil seals, dust ring, O-ring and seal gasket disassembled owing to
leakage and because of low reliability and short service life in repeated use.
3. Never further use the bolts, nuts, washers, plug screws, pipe joints if they have serious
corrosion, the screw doesn’t work well in tightening operation, or the screw is damaged, worn
out or slipping.
4. Never further use locking steel wire in the connection of bolt after disassembled.
5. Never further use the bearings if they could not be turned smoothly by hand, crack exists on
their components or the ball race is seriously worn.
6. Never further use the gears and the teeth of spline with crack, sheet exfoliation, collision or
over wearing.
7. Never further use the shell with crack, bearing holes with crack, wear, elliptic or sheet
exfoliation, and screw damaged which doesn’t work well in tightening operation.
8. Never further use bearing chock, oil seal pedestal with crack, wear, elliptic, collision or sheet
exfoliation on the mating surface and spigot.
9. Never further use the pins with serious wear, collision or crack.
10 Judge the oil by visual and touching primarily, it should be replaced if hydraulic oil appears
the following situation in the process of use and inspection: present milk white in color,
accompany with acid stink, turn yellow or appear turbidity.
0-12
052 Measure
If it is hard to identify by ocular estimates or hand touching, check it by measurement.
Table 0- 21
Judgment Standard
Oversize
Parts Items Check Items Dimension
Allowable Limit Measures
(Tolerance)
ID tolerance About 0~ -0.02 +0.02

Bearing Replace
OD tolerance About 0~ -0.02 －0.04
Wear loss of teeth 12 % of the reference circle
Gear About 0～0.10 Replace
thickness thickness (usually 1.2~1.4)
OD used in common Tolerance denoted Recommend: 0.3T less than

assembly
Common by T lower limit
parts Replace
ID used in common Tolerance denoted Recommend: 0.3 T more
assembly
by T than upper limit
Fitting clearance
Multiple
between valve core >0.02 Replace
valve
and valve hole
Fitting g clearance
Steering between valve core >0.02 Replace

device
and valve hole
Stator and rotor >0.08 Replace
Fitting g clearance
Monostable
between valve core >0.02 Replace
valve
and valve hole
Fitting clearance
Priority valve between valve core >0.02 Replace
and valve hole
0-13
Service Manual of RS8160 Road Roller
SERVICE MANUAL
Version:0120
1 Repair & Maintenance

Service Manual for LG958L Wheel Loader
CONTENTS
1 Repair & Maintenance ......................................................................................... 1-1
11 Lubricant, Fuel and Other Liquids ...................................................................... 1-1
111 Lubricant ...................................................................................................... 1-1
112 Fuel .............................................................................................................. 1-1
113 Coolant......................................................................................................... 1-2
114 Selection of Oil ............................................................................................ 1-4
12 Repair................................................................................................................... 1-5
121 Notes before Repair ..................................................................................... 1-5
122 Periodic Maintenance .................................................................................. 1-8
123 Maintenance and Repair ............................................................................ 1-13
I
1 Repair &
Maintenance
Regular maintenance is necessary for high

performance of the machine. The viewpoint that the
machine doesn’t need to be checked regularly if the
machine can be used normally is absolutely wrong.
Proper examination and maintenance not only can
extend the working life of the machine, but also find
the malfunctions and deal with them in time, in this
way, the maintenance time and cost can be reduced
significantly.
11 Lubricant, Fuel and Other
Liquids
111 Lubricant
 Lubricant can help to prevent the wear of fitting

surface and noise.
 The connectors (pipe joint, connecting set) that
are not involved in this manual are only for
overhauling and not need to add lubricant. But
be sure to fill the lubricant if some parts are
difficult to operate after a long time using.
 Clean the spilled lubricant after filling.
112 Fuel
 Fuel pump is precise device, and it will not

work normally if the fuel is mixed with water
and other impurities.
1-1
 Be careful to replace or fill the fuel. Never mix

it with impurities.
 Related requirements in this manual must be
complied with when choosing fuel brand.
 Fuel will freeze at low temperature (especially
below -15oC), so choose the fuel according to
ambient temperature.
 To avoid condensed water from entering into
fuel tank, fill the fuel tank fully after work.
 If the engine fails to absorb fuel during starting
process or the filter is just replaced, drain the
air in the circuit first.
113 Coolant
 To avoid the incrustant from affecting the

performance of radiator or blocking the
radiator. Be sure to use the antifreeze specified
by SDLG all year round. Never use water as
coolant.
 If the engine is overheated, cool the engine and
then fill the coolant.
 Coolant should be filled to specified level. Too
low level will result in overheating of engine
and corrosion of cooling system.
 If ambient temperature is above 30oC in
summer, park the wheel loader in shade
because the engine may overheat.
 After operation, run the engine at idle for 5
minutes in order to prolong the service life of
engine and stop the engine until the water
temperature falls down.
 Antifreeze agent is inflammable and you
should keep it away from flame when filling.
 Antifreeze should be replaced every year.
1-2
 Never use 100% antifreeze as coolant.

 Choose different antifreeze according to
ambient temperature condition, recommended
range:
-25# is used for ambient temperature≥-15℃
ATTENTION
Never mix the different brands of oil. If
there is only one brand for selection and it is
different from the using one. Use it after
draining all the used oil out.
 Due to the severe working conditions (high
temperature and high pressure) of the
wheel loader and dusty in external service
environment, the oil is easy to be
deteriorated. If so, replace the oil at once.
 Fill the required volume of oil. Adding oil
too much or too little will cause failure.
 Clean or replace filter when filling the oil.
 Just after operating the engine, all kinds of
oil and coolant are hot. Do not open the cap
before it is cooled. After cooling, slowly
open the cab to release the internal
pressure.
1-3
114 Selection of Oil
Please use the oil specified by Shandong Lingong

Corp. and chose the oil according to the oil grades
as follows:
Table 1-1
Type Recommended types and application standards Qty. Oiling location
Ambient temperature -20oC~+40oC

CI 15W-40 diesel engine oil GB 11122
Engine oil 21.5L Engine
Ambient temperature -25oC~+30oC
CI 10W-30 diesel engine oil GB 11122
Hydraulic
transmission Diesel engine oil CH-4 15W-40 35L Transmission box
oil
Heavy duty vehicle gear oil (GL-5) 85W/90

Gear oil 2×30L Drive axle
GB13895
L-HV 46 low-temperature hydraulic oil

Hydraulic oil 240L Hydraulic oil tank
GB11118.1
Min. ambient temperature≥4oC 0# light diesel

GB252
Min. ambient temperature≥-5oC -10# light
diesel GB252
Fuel 300L Fuel tank
diesel GB252
diesel GB252
Pin in the each joint

Grease 2# or 3# lithium-base grease GB7324 2kg point of the working
device
Ethylene glycol-based engine coolant

Antifreeze 28±2L Radiator
SH0521
1-4
12 Repair
121 Notes before Repair
Park the wheel loader in maintenance position 1

 Repair should be performed on solid and flat
ground.
 Working device should on ground and bucket
should be laid flat.
 Stop the engine and pull out the key.
 All operation handles should be set in neutral
position.
 Press the parking brake button to keep the
wheel loader in the state of parking brake.
 Put the blocks under the tires.
 Lock the front and rear frame with frame lock
lever.
 Turn off the battery main switch.
Hang warning tag
Attach the warning tag near the starting switch
before maintenance to prevent someone starting the
engine during maintenance.
Spare parts preparation
Use only parts specified by Shandong Lingong
Corp.
Oil and fuel preparation
Choose oil and fuel specified in this manual
according to ambient temperature.
Use specified oil and fuel
Keep containers of oil and fuel clean and use
specified oil and fuel.
Keep the wheel loader clean
Always keep the wheel loader clean. Especially
cleanness of oil filling parts, such as grease cups, oil
1-5
filling ports, and prevent impurities from

infiltrating into those places.
Pay attention to the hot oil and coolant
It is very dangerous to drain hot oil and coolant or
remove the filters immediately after the engine just
stopped. Make sure the engine is cool. The
temperature of the oil drained is appropriately about
20oC to 40oC. If it is lower than this temperature, be
sure to warm it up to this temperature before
draining it.
Check the oil and filters
After the oil is changed or filters are replaced, check
the replaced oil and filters. If large amounts of
metallic particles or impurities are found, consult
the maintenance personnel.
Fuel coarse filter
Do not remove the fuel coarse filter while fueling.
Oil replacement
Change oil in dust-free places to keep impurities out
of the oil.
Welding guide
 Turn off the starting switch of the engine and
remove the battery cables.
 Keep the distance between the grounding cable
and welding area more than 1m.
 Avoid welding near the seal rings and
bearings.
 Never weld any pipe or tube while there is fuel
gas or oil in them.
Fire prevention
Clean the parts with uninflammable cleaner or light
oil. Keep spark or cigarette light away from them.
Seals
1-6
When replacing O-ring or sealing gaskets, clean the

sealing surfaces first, and make sure the O-ring or
sealing gaskets are in the correct assembly position.
Check the frame
After a long time of stone shoving and transporting
operation, check the frame for damage and check
whether the connecting nuts and bolts are loose and
damaged.
Notes for washing machine
 Wash machine after complete cooling of the
engine.
 Do not splash water on electric components.
Checking in raining and snowing circumstances
Clean the machine immediately after working in
rain and snow. Lubricate and coat anti-rust oil to
more parts.
Dusty circumstances
Do the following items when the machine works in
dusty circumstances:
 Inspect and clean the air filter frequently to
avoid blocking.
 Clean the radiator frequently to avoid blocking.
 Clean and replace the fuel filter frequently.
 Clean the electric components, especially the
starting motor and generator, to avoid
accumulation of dust affecting dissipation of
heat.
Refer to the bring-in Operation and Maintenance
Manual of Diesel Engine for replacing and
maintaining air filter.
1-7
122 Periodic Maintenance
See Fig. 1-1 for periodic maintenance points.
Fig. 1-1
Every 10 Hours (Daily) Maintenance
1. Check the sealing performance of working
device, steering system and brake system.
2. Check the flexibility and reliability of the
brakes.
3. Check whether the electric circuits are correct
and the electric components are normal.
4. Check the oil level in the fuel tank and the
coolant level in the water tank.
5. Add grease to the engine fan shaft, hinge joints
1-8
between front and rear frames, transmission

shafts, hinge joints of oscillating frame and
working device.
6. Check if there are other abnormalities.
7. Refer to Operation and Maintenance
Manual of Diesel Engine for maintaining the
engine.
Every 50 Hours (Weekly) Maintenance
1. Carry out the periodic maintenance of every 10
hours with this maintenance operation at the
same time.
2. Check oil level in transmission box and
hydraulic oil tank.
3. Check and tighten all connecting bolts of each
transmission shaft.
4. Check and tighten all connecting bolts of the
rim and brake caliper.
5. Check and tighten all connecting bolts of
bucket teeth.
6. Check and lubricate the accelerator controller,
parking brake and gearshift control system. In
addition, do the extra maintenance in the first
50 hours as follows:
 Check and clean the air vent of the
transmission box.
 Check and clean filter elements in speed
changer-torque converter assembly oil
line.
 Check if there is leakage in the hydraulic
system.
 Check and clean the air vent of the
hydraulic tank.
 Check and clean the oil return filter of
1-9
hydraulic tank.
 Check if there is leakage in the brake
system.
Every 100 Hours Maintenance
1. Carry out the periodic maintenance of every 10
and 50 hours with this maintenance operation
at the same time.
2. Clean the radiator components.
3. Clean fuel tank filling filter.
4. In addition, do the extra maintenance in the
first 100 hours as follows:
 Check and clean the air vent of
transmission box.
 Clean transmission oil sump and the oil
absorption filter element therein.
 Check and clean filter elements in speed
changer-torque converter assembly oil
line.
 Replace transmission oil.
 Replace the gear oil in the front and rear
axles.
Every 250 Hours (Monthly) Maintenance
1. Carry out the periodic maintenance of every 10,
50 and 100 hours with this maintenance
operation at the same time.
2. Check the storage battery. Clean surface and
terminals of the battery then coat Vaseline on
them.
3. Check whether connecting bolts of frames and
working devices are loose.
4. Check whether welding seams are cracked.
5. Check whether the connections between front
and rear axles, engine, transmission box and
1-10
frame are loose.

6. Check the tire pressure. Inflation pressure of
front tires should be (0.38~0.40)MPa, while
that of rear tires should be (0.32~0.34)MPa.
 Check if there is leakage in the brake
system.
Every 500 Hours (Seasonally) Maintenance
50, 100 and 250 hours with this maintenance
2. Check and adjust the brake clearance of
parking brake system.
3. Check the wear condition of brake disc and
friction plates. Replace them if necessary.
4. Clean the silencer of the brake electromagnetic
valve.
system.
 Check and clean the air vent of hydraulic
tank.
 Replace the oil return filter element of
hydraulic tank.
 Replace pilot filter element.
 Check the quantity and cleanness of
hydraulic oil. Filter the oil if possible. Add
them if insufficient and replace if
necessary.
Every 1000 Hours (Biannually) Maintenance
1-11
50, 250 and 500 hours with this maintenance

2. Replace the gear oil in the front and rear axles.
Replace it at least once a year.
3. Check and clean the air vent of transmission
box.
4. Clean transmission oil sump and the oil
absorption filter element therein.
5. Replace the filter elements in speed
changer-torque converter assembly oil line.
6. Replace transmission oil. Replace it at least
once a year.
7. Replace the oil return filter element of
hydraulic tank. Replace pilot filter element (if
it is installed).
system.
 Check and clean the air vent of hydraulic
tank.
 Clean the hydraulic oil tank.
 Replace the hydraulic oil.
Every 2000 Hours (Yearly) Maintenance
50, 100, 250, 500 and 1000 hours with this
maintenance operation at the same time.
2. Replace the antifreeze, replace it every 2000
working hours or once a year, whichever
comes first.
3. Check performance of the torque converter
and transmission box, differentials of front and
rear axles and the wheel side reducers.
1-12
4. Check the sealing performance of multitandem

valve and hydraulic cylinder by measuring the
natural sedimentation volume of the cylinder,
and measure the system pressure.
5. Check the welding seams of rim and other
stress areas and adjust the deformation.
6. The maintenance principles listed above are
the basic requirements. The maintenance time
should be determined by the closer one
between two the maintenance schedules. If the
working condition is very severe, please
shorten the maintenance cycle and increase the
maintenance times according to the real
conditions.
123 Maintenance and Repair
Brake check
Observe whether its appearance is normal, such as
oil leakage.
Draining of drive axle oil
If you cannot determine whether the fuel is cooled
or not, please wear protective cloth in case of
burning.
 Make sure the drain plug is at lowest position,
1
you can rotate the wheel if necessary. (See Fig.
Fig. 1-2
1 Wheel side oil drain plug (keep it at 1-2)
the lowest place while draining)
1-13
 Place the container under the main reducer and

aside the hub to drain the oil. Check and clean
the plugs and O-rings, replace them if
necessary. ( See Fig. 1-3)
1
Fig. 1-3
1 Oil drain plug on axle housing
Draining of oil in the hydraulic tank

 Wait until the engine is cooled, and wear
protective equipment.
 Connect a hose to the hydraulic oil drain valve,
put the other end of the hose into a clean
vessel (Place an empty vessel aside and the
total volume of the hydraulic oil is about 240L,
see Fig. 1-4)
1
 Open the drain valve to discharge oil.
Fig. 1-4
1 Hydraulic oil drain valve
Draining of hydraulic transmission oil in

transmission box
Do the maintenance after the machine is cooled.
Remove the drain plug and drain the oil to the
empty container. (See Fig. 1-5)
1
Fig. 1-5
1 Oil drain plug
1-14
Engine oil draining

Place the empty container under the engine and
remove the oil drain plug. (See Fig. 1-6)
1
Fig. 1-6
1 Oil drain plug
Replacement of fuel filter

 Remove the fuel filter with filter wrench (See
Fig. 1-7)
 Coat the new filter seal(s) with new engine oil.
And tighten the filter according to the
requirements described on the filter.
 Deflate fuel system after the replacement.
1
Fig. 1-7
1 Fine fuel filter
Replacement of engine oil filter

 Replace the engine oil filter.
Apply new engine oil on seals of the new filter.
(See Fig. 1-8). Tighten the filter according to
the requirements described on the filter.
1
Fig. 1-8
1 Engine oil filter
1-15
Replacement of engine air filter

 Replace the main filter at least once a year, or
replace it when the filter is blocked and alarm.
During replacing, clean the filter cover hood,
because it is used to contain the particle that is
not filtered by filter.
 Check and ensure that all the hoses and
connectors from air filter to engine manifold
1 have no leakage problem. Check and tighten
Fig. 1-9
the clamps.
1 Air filter
 Replace the safety filter at least every other
year or when the main filter is replaced 3 times.
(See Fig. 1-9)
Replacement of transmission oil filter

Overhaul the machine after it is cooled.
 Drain the oil out and then remove the filter.
(See Fig. 1-10)
 Install new filter and tighten it according to the
instructions described in the manual.
1
Fig. 1-10
1 Transmission oil filter
1-16
Clean the oil absorption filter screen of

transmission box
 Remove the cover and clean the internal parts.
Check and ensure the parts are not damaged.
 Install a new gasket between cover and
transmission box
 Reassemble the absorption screen. (See Fig.
1-11)
1
Fig. 1-11
1 Oil absorption filter screen location
Transmission belt checking

Check tension of belt and check whether the
draw-in rod is worn. (See Fig. 1-12)
1
Fig. 1-12
1 Belt
Engine oil filling

Fill the engine oil to the specified level (See Fig.
1-13).
1
Fig. 1-13
1 Engine oil filling port
1-17
Replacement of vent filter of hydraulic tank

Replace the filter. (See Fig. 1-14)
Replacement of oil return filter of hydraulic
tank
 Remove the cover and hood. (See Fig. 1-14)
 Remove the filter.
1 2  Install the new filter.
Fig. 1-14
1 Vent filter  Check the seal ring in cover hood when
2 Hydraulic oil filling port installing it.
Hydraulic oil filling
 Fill the hydraulic oil to the specified level.
 Control the oil level by using the oil level
pointer.
Transmission oil filling

Fill about 35L.
1
Fig. 1-15
1 Filling port of transmission oil
1-18
Drive axle gear oil filling

 Keep the wheel side drain plug in tire
horizontal shaft position.
 Fill specified gear oil via the oil drain ports on
the two wheel sides of drive axle and the
filling port in the middle of axle housing.
 Fill the oil until the level gets the edge of oil
level plug.
1
Fig. 1-16
1 Filling port on middle of axle housing
Replacement of cab internal circulation filter

and external circulation filter
 Open the side cover. (See Fig. 1-17)
 Rotate the fixing parts aside and then remove
external circulation filter and put it aside.
 Rotate the fixing parts aside, and then remove
the lower shell. Remove the internal
circulation filter and put it aside.
 Install new filters, shell and new prefilter and
then close the cover.
1 2
Fig. 1-17
1 Evaporator 2 Side cover
Transmission oil level checking
Transmission oil level should be in specified range
marked on the feeler lever when engine is running
idly.
1
Fig. 1-18
1 Feeler lever
1-19
Hydraulic oil level checking

Keep the boom at the lowest position. Check the
oil level via the pointer.
1
Fig. 1-19
1 Hydraulic oil level pointer
Engine oil level checking

Oil level should be between “MAX” mark and
“MIN” mark on the oil dipstick.
1
Fig. 1-20
1 Engine oil dipstick
Checking of battery, cable and connector
Touching the liquid of battery will cause severe
chemical burning.
Wear protective gloves, goggle and clothes when
maintaining the battery.
 Open the battery covers. Open one each time.
 Check and clean the connectors of cable and
1 terminals and bolts of battery, and coat the
Fig. 1-21
1 Storage battery external surface with grease as anticorrosion,
such as Vaseline. (See Fig. 1-21)
 Check the liquid level, and green color means
normal.
1-20
Cleaning of radiator
 Open the engine hood and rear window lattice.
 Clean the fins of radiator with compressed air
along the traveling direction of the machine.
(See Fig. 1-22)
 Install the grille shield.
If not being dealt properly, the fins of radiator may
be damaged.
1
Fig. 1-22
1 Radiator
1-21
Version:0220
CONTENTS
2 ENGINE SYSTEM .........................................................................................................2—1
21 Overview ..........................................................................................................................2—1
211 Functions of the Engine .............................................................................................2—1
212 Basic structure of the Engine ....................................................................................2—3
213 Overall Engine Performance Parameters ..................................................................2—6
22 Lubrication System .....................................................................................................2—7
221 Lubrication System Description ................................................................................2—7
23 Fuel System..................................................................................................................2—9
231 Overview ...................................................................................................................2—9
24 Intake and Exhaust System......................................................................................2—14
241 Intake and Exhaust System Description ..................................................................2—14
25 Cooling System ..........................................................................................................2—16
251 Cooling System Description....................................................................................2—16
252 Expansion Tank .......................................................................................................2—17
26 Engine Control ..........................................................................................................2—18
261 Reverse Control, Foot Operation ............................................................................2—18
27 Disassembly and Assembly of Engine ..........................................................................2—19
271 Disassembly of Engine ............................................................................................2—19
272 Assembly of Engine ................................................................................................2—29
273 Disassembly and Assembly of Fuel Tank................................................................2—39
274 Disassembly and Assembly of Water Tank and Oil Radiator ..................................2—44
28 Diagnosis and Solutions for Frequently Asked Questions of Engine System ..........2—52
281 Engine Fails to Start ................................................................................................2—52
282 Engine Power is not Sufficient ................................................................................2—53
283 Exhaust Exceptions (Black Smoke, White Smoke, Blue Smoke) ...........................2—53
284 Engine Oil Pressure is too High or Too Low ..........................................................2—55
285 Large Consumption of Engine Oil ..........................................................................2—56
Ⅰ
286 High Coolant Temperature...................................................................................... 2—56
Ⅰ
2 ENGINE SYSTEM
21 Overview
211 Functions of the Engine
The engine is six-in-line four-stroke
turbocharged diesel engine with direct
injector, intercooler and wet-type
replaceable cylinder liners, in line with
the EU3 emission standard. This engine
is equipped with E-ECU-controlled
common rail fuel system. All electronic
functions of the engine are controlled by
Volvo engine management system
EMS2.
Engine identification
The serial number is printed on
nameplates, which are located on engine
cylinder block and engine valve cover
respectively. You must indicate the
engine type and serial number when
ordering spare parts.
Figure 1 Engine identification
2—1
The cylinders are numbered
sequentially. Ignition sequence:
1-5-3-6-2-4. From the fly wheel end,
the rotating direction of engine is
anti-clockwise.
Engine working principle
Figure 2 Cylinder positions

The engine is four-stroke diesel engine, each
working cycle can divided into four separate
strokes—intake, compression, power, and
exhaust. For intake, fresh air is being inhaled
into the diesel, and this stroke is completed
only when the piston descends to the bottom
dead center of the cylinder. Then the piston
returns to the top dead center of the cylinder to
carry out compression stroke, fresh air is being
compressed and temperature rises. When the
piston reaches to top of the cylinder, the diesel
oil is injected into combustion chamber in the

Figure 3 The whole engine
form of spray through the injector, and then
mixed with hot gas. The compressed air–fuel
mixture is self-ignited rapidly to forces the
piston back down toward bottom dead center
to complete the power stroke. During the
exhaust stroke, the piston once again returns to
top dead center under the effect of inertia and
expels the spent fuel-air mixture.

2—2
Engine performance cures
The speed performance curves of
the engine show performance of
effect power P and torque M with
the change of engine speed n.
212 Basic structure of the

Figure 4 Engine Characteristic Cures Engine
Cylinder caps, cylinder body, cylinder
liner
The cylinder body is casted into a whole
body with cast iron, equipped with
replaceable wet-type cylinder liner.
The cylinder gasket is mounted between
the cylinder body and liner to prevent air
leakage and water leakage. On account
of the gasket works under high
temperature and high pressure, it must
have sufficient strength, high pressure

Figure 5 Cylinder body group
resistance, and combustible gas
Notes: 1 cylinder body 6 water seal ring
resistance; and it must be resistant to
2 cylinder cap 7 circular ring
corrosion of oil and water. Moreover, the
3 cylinder liner 8 water channel
gasket must have a certain flexibility and
4 cylinder gasket 9 seal ring
long life.
5 water seal ring 10 emboss
the D7E engine adopts replaceable
2—3 wet-type liners.

Crankshaft-flywheel group
The crankshaft is forged from alloy steel or
casted from nodular cast iron. Surfaces of
main journal and rod journal are hardened
and grinded. Its job is to convert the force
that comes from connecting rod into torque
and output. Meanwhile, it drives the
cylinder pistons through the connecting rod
to complete the procedures of intake,

Figure 6 Crankshaft-flywheel group
compression and exhaust, valve mechanism
Notes: 1 crank arm
and other auxiliary devices are also
2 main journal
actuated by the crankshaft.
3 thrust shoe
The flywheel is usually a castiron disc,
4 pulse wheel speed sensor
with heavy rim to gain large moment of
5 belt pulley
6 rigid ring
inertia. It is fixed on the crankshaft rear end
7 fly wheel flange with bolts. It can store a part of
8 sliding bearing energy from the crankshaft during power
9 piston stroke, which is helpful for crankshaft and

10 connecting rod connecting rod mechanism to go over the
dead point and to overcome resistance of
the other three auxiliary strokes. The fly
wheel can also help to overcome
compression resistance in the cylinder
when the engine starts; so the engine can
run smoothly at low speed and overcome
short time overload.
2—4
Valve mechanism
The valve mechanism is composed of
two sets of components, one is valve
train group that takes the valve as main
component; the other is valve
transmission group that takes camshaft
as main component.
The main requirement for valve train

Figure 6 Valve mechanism
Notes: 1 crankshaft group is tight sealing between the valve
2 timing gear and valve seat.
3 bearing block The job for valve transmission group:

4 seat ring open or close the intake/exhaust valve
5 rockerarm at proper moments or in proper order
6 phase sensor tooth and ensure a certain degree of opening.
7 pipe
8 valve
2—5
213 Overall Engine Performance Parameters
Model D7E Number of cylinders 6
Common Rail In-line

Cylinder
Type Water-cooled 108/130
diameter/stroke (mm)
Four-stroke
Minimum specific
Rated power (kw) 162 fuel consumption 215
(g/kw.h)
Maximum torque
Rated speed (r/min) 2100 1050
(N.m)
Output volume (ml) 7146 Emission standard Tier 3
Table 1 Engine parameters
2—6
22 Lubrication System
221 Lubrication System Description
Lubrication system is a forced feed oil circle system.
Oil cooler and filter are placed in the full-flow loop.
Figure 8 Lubrication system schematic diagram
Notes: 1 oil pan 10 injector lubricating oil passage
2 oil suction pipe 11 piston cooling nozzle
3 oil pump 8 water channel 12 rockerarm pulse-lubricating tappet
3.1 safety valve 13 stop rod
4 oil cooler 14 rockerarm
4.1 backflow throttling valve 15 scavenge filter
4.2 by-pass valve 16 turbocharger lubricating pipeline
2—7
4.3 drain valve 17 turbocharger
4.4 pressure controlled by-pass valve (filter) 18 air compressor outlet oil line
5 lubricating filter 19 air compressor
6 main oil pipe 20 air compressor oil line
7 crankshaft bearing 21 turbocharger outlet oil line
8 connecting rod bearing 22 main outlet oil line
9 camshaft bearing
The oil pump sucks engine oil from the tank
through the filter, engine oil is cooled in the oil
cooler and pressure-control adjusted before it
flows into the filter. The by-pass valve opened
when the viscosity of oil is high (such as
coldstart), so that the oil can flow through
bypass filter. The oil flow from the full flow
filter flows through the main oil line, then send
engine oil into camshaft, crankshaft bearings,
air compressor and valve mechanism.
The engine is also equipped with piston
cooling nozzle to spray oil to the downside of
the piston, which is helpful to keep a stable
working temperature.
2—8
23 Fuel System
231 Overview
Fuel system description
The engine is equipped with fuel common
rail system.
In common rail system, the fuel is
distributed to fuel injector from a high
pressure accumulator called “fuel rail”. The
“fuel rail” is supplied by two fuel pump with
high pressure fuel. Pressure of oil in the
“fuel rail”, and the start and end of injection
of each cylinder are all electronically
controlled.
Figure 9 Fuel system schematic diagram
2—9
Notes: 1 heating equipment 8 main filter
2 pressure sensor, feed oil 9 fuel injector
3 flow control valve 10 “fuel rail”
4 prefilter with oil-water separation function 11 high-pressure fuel pump
5 fuel pump ECU: electronic control unit
6 thermostat valve FCV: flow control valve
7 sensor, pressure of “fuel rail” PRV: pressure restrict valve
Low pressure side
The low pressure loop includes a fuel
tank, a prefilter with dewaterer, a fuel
pump, a main filter and a fuel control
valve (FCV).
Firstly, the fuel pump pumps fuel from
fuel tank to the pump inlet. Then the
pump forces fuel flows into FCV,
which is located between two
high-pressure pumps, through the main
filter.
Figure 10 Fuel control valve

Fuel control valve (FCV)
Notes: 1 magnetic valve, PWM2303
2 fuel inlet FCV is a PWM controlled magnetic

3 fuel to high-pressure pump valve, which is used to control fuel
4 backflow fuel to fuel pump flow to the high-pressure pump.
5 relief valve
FCV ensures to fill the high-pressure
pumps to a certain degree that can keep
the indicated pressure of fuel rail.
2—10
High pressure side
The high pressure loop includes two
high-pressure pumps that actuated by the
engine camshaft, a “fuel rail”, a “fuel
rail” pressure sensor and six electronic
controlled injectors. High-pressure pump
stays in working state all along and
provides required injection pressure.
This pressure is stored in the “fuel rail”
and the “fuel rail” provides pressured
fuel to injector continuously. Injector
controls injection timing and injection
quantity.
Figure 11 High pressure pumps
Notes: 1 six fuel pumping procedures brought by three cams

High-pressure pump
for each turn (each pump completes three procedures)
2 through high-pressure oil pipe to injectors There are two high-pressure pumps in
3 I/O valve (integrated) fuel system, and they are driven by
4 flow control valve
camshaft through a roller tappet. Its
function is to pressurize the fuel in “fuel
rail”. Low pressure side and high
pressure side of the pump are separated
hydraulically. For each turn of the
camshafts, the three cams complete six
strokes in total (each pump strokes three
times).
2—11
Fuel rail
The “fuel rail” works as high-pressure
accumulator. Fuel stored in the “fuel rail” is
calibrated and can stabilize pressure changes that
cause by the following reasons:
— Pump pulses from high-pressure pump
— Massive fuel output from the injector in short
time during oil injection procedure.
Figure 12 “Fuel rail” “Fuel rail” pressure sensor
Figure 12 “Fuel rail”

It provides initial variable for pressure adjustment
Notes: 1 “fuel rail”
2 pressure restrict valve (PRV)

of “fuel rail”. If a malfunction is detected, the
3 “fuel rail” pressure sensor E-ECU will force PRV to open by pressurizing
the fuel in “fuel rail”.
A sensor is used to measure the pressure of “fuel
rail” and sends data to E-ECU, and then E-ECU
compares the data with actual pressure and
reference value defined according to engine speed
and fuel injection quantity.
A valve installed on the “fuel rail” is used to limit
system pressure to avoid system damage.
2—12
Pressure restrict valve (PRV)
PRV is a mechanical safety component,
starts to work when the pressure rises to
1850-1950 bar, and to protect the system
from possible failures caused by
overpressure damage.
If the pressure opens, the “fuel rail”
pressure will maintain at 650-850 bar
(depend on engine speed and load). The
engine keeps running but performance

Figure 13 Pressure restrict valve
reduces.
PRV will not open under normal
operating conditions.
Injector
Injection timing and to-be injected
fuel quantity are decided by
E-ECU, E-ECU will send signal to

Figure 14 Injector
fuel valve located in the injector
Notes: 1 electromagnetic coil
valve body. The quantity of fuel
2 magnetic core
3 armature
injected into the cylinder is
4 reversing space dependent on length of injection
5 High-pressure channel time
6 needle return spring
2—13
24 Intake and Exhaust System
241 Intake and Exhaust System

Description
Intake system
Air is sucked in through air filter, and then
flows into turbocharger. After the air outflows
from turbocharger, it cooled in the air cooler.
Before the air enters into cylinder through the
intake manifold and intake valve, it passes
through the preheater first. When operator
turns starting key to position 1 and the
temperature of engine coolant is too low, the
fan heater starts to work. Preheating process
stops after the engine started. At this point, if

Figure 15 The intake system (schematic
the engine still needs to be heated, extra
diagram)
preheating and post preheating processes will
Notes: 1 air filter (with intake air temperature sensor and
be activated. The extra preheating and post
air filter monitor)
preheating time is controlled by the engine
2 turbocharger
control system. This approach has the virtue of
3 charger-air cooler
easier starting and less white smoke exhaust.
4 preheating coil
5 intake manifold, with charger-air temperature

When the preheating coil is in use, the
sensor and boost pressure sensor preheating sign on info panel will be lighted.
2—14
Exhaust system
Firstly, the exhaust gas flows into
exhaust manifold through the
exhaust valve; then enters into the
silencer through turbocharger,
discharge into the environment
through exhaust pipes at last.
Turbocharger
Figure 16 The exhaust system (schematic diagram)
Notes: 1 exhaust manifold

The turbocharger is driven by exhaust
2 turbocharger
gas, the exhaust gas flows through the
3 silencer
turbine casing on its way to silencer.
Exhaust airflow drives the turbine
rotor in the turbine casing. The
compressor rotor and turbine rotor
locate on the same shaft, the former
located in the housing that connected
between air filter and intake manifold.
The turbocharger is equipped with an
exhaust by-pass valve. The exhaust
by-pass valve is controlled by
Figure 17 Turbocharger pressurized air, which enables to allow
Notes: 1 turbine casing a small amount of exhaust gas bypass

2 compressor casing the turbine rotor when the engine runs
3 exhaust valve in high speed (high supercharging air
pressure).
2—15
25 Cooling System
251 Cooling System Description
The engine is used by water cooling system.
Figure 18 cooling system diagram
Notes: 1 outlet pipe of water tank 9 heat exchanger
2 thermostat 10 coolant to thermostat
3 pipeline to water pump 11 water return pipe
4 water pump 12 water compensation pipe
5 oil cooler 13 breather pipe
6 cylinders cooling 14 inlet pipe of water tank
7 cylinder caps cooling 15 expansion box
2—16
8 hot air water pipe 16 water tank compensation pipe
Coolant pump sucks coolant to the engine
through lube oil cooler, the coolant flows
around the cylinder caps and passes through
thermostat. The thermostat opens when
temperature rises to 83℃(181.4℉). It is
used to control whether the coolant should
flow out of radiator or flow back to the
engine through bypass, which is dependent
on coolant temperature. The coolant flows
back to engine cooling system after cooled
in the radiator.
Figure 19 Radiator assembly
Notes: 1 expansion box

The coolant is also transported to machine
2 water pipe components parts and cab fan heater through external
3 Intercooler pipe components pipelines and tubes. Transmission hydraulic
4 transmission pipeline components oil is cooled in the radiator and then flows
5 radiator accessories back.
6 jackstay
252 Expansion Tank
Fill glycol coolant to the expansion tank, start
the machine after filling up. Refill the tank
after the machine runs for a while until the
liquid level stays between the scales “MIN”
and “MAX”.
2—17
26 Engine Control
261 Reverse Control, Foot Operation
Figure 20 Engine control

Accelerator pedal is connected to instrument electronic
control unit (I-ECU).
When operator changes the angle of accelerator pedal, the
accelerator pedal position sensor SE2702 will record this
change and send information to I-ECU.
I-ECU send parameters about the engine speed (rpm)
changing to E-ECU, then adjust fuel injection quantity by
controlling injector open time and injection timing
Due to control units are involved in engine speed
regulation, many protective functions can be stopped to
increase engine speed (engine protection), for example,
— Engine oil pressure
— Coolant temperature
2—18
27 Disassembly and Assembly of Engine
271 Disassembly of Engine
These following steps could be referred to disassemble the engine from the machine when the
engine need to be replaced, examined or repaired.
2—19
1 Start the machine and drive it to the servicing
place. Keep the bucket flat on ground. Press the
parking brake switch on the operation box (red
and mushroom head appearance). Rotate the key
of the electrical lock one level anticlockwise to
turn off the electrical power of the whole
machine. Wedge the front and rear tires with
1 blocks.
Figure 1-1
1 block ★ Do the operation after the loader cools
down. During the processes of disassembly, all
the pipeline joints should be wrapped up to
avoid the debris entering into the pipeline.
2 Open the water drain plug of radiator. Drain the
coolant out and contain them with clean a vessel.

Coolant
1
Figure 1-2
1 water drain valve
3 Open the oil drain plug of engine sump and
drain the engine oil, contain them with clean a
vessel.
Engine oil
1 2
Figure 1-3
1 spare oil drain plug 2 oil drain plug
2—20
4 Disassemble the engine hood
Refer to 8-4 Disassembly and assembly of
Engine Hood.
Engine hood
1
Figure 1-4
1 engine hood
5 Disassemble the hydraulic oil tank

Hydraulic Oil Tank Assembly.
Hydraulic oil tank
1
Figure 1-5
1 hydraulic oil tank
6 Disconnect the connection between the engine
and wiring harness.
1) Disconnect the connection between the
generator and wiring harness.
1
Figure 1-6
1 engine wiring harness
2—21
2) Disconnect the connection between starting
motor and wiring harness.
1
Figure 1-7
1 starting motor wiring harness
3) Disconnect the the connection between air
compressor and wiring harness.
1
Figure 1-8
1 air compressor wiring harness
4) Disconnect the the connection between air
preheater and wiring harness.
1
Figure 1-9
1 air preheater wiring harness
2—22
5) Disconnect the ED
1
Figure 1-10
1 ED connector
6) Cut of the wiring harness armor tape
1
Figure 1-11
1 wiring harness armor tape
7 Cut off the connection between air conditioning
hose and the compressor.
Keep the maintenance area well
ventilated. The workers should keep away
from the machine when the refrigerant is
releasing
1 2
Figure 1-12
1 pressure cooling pipe 2 autoclaved pipe
2—23
8 Disassemble the oil inlet pipeline of fuel pump
1
Figure 1-13
1 oil inlet pipeline
9 Disconnect the connection between the water
pipe and water valve of fan heater.
1
Figure 1-14
1 water valve of heater
10 Disconnect the connection between hot-air
water inlet pipe of air condition and the engine.
1 2
Figure 1-15
1 hot-air water inlet pipe
2 hot-air water inlet valve
2—24
11 Disassemble intake hose from turbocharger
1 2
Figure 1-16
1 turbocharger 2 intake hose
12 Dismantle the hose between the turbocharger
and air cooler.
1
Figure 1-17
1 hose
13 Loosen the fastening hose clamps of water
inlet and outlet pipes separately, remove the
pipes.
1 2
Figure 1-18
1 water outlet pipe 2 water inlet pipe
2—25
14 Lift the engine with rope and open the cover
plate of torque converter. Remove the fixing nuts
between flywheel middle plate and torque
converter middle plate, and then remove the
gaskets and connecting bolts between flywheel
plate and torque converter.
1 2 3
Figure 1-19
1 fixing nut 2 gasket 3 fixing bolt
15 Remove the fixing bolt of the engine
supporting seat
1
Figure 1-20
1 fixing bolt
16 Lift down the engine.

Engine
1
Figure 1-21
1 engine
2—26
17 Disassembly of engine accessories.
1) Disassemble the bolts which connect the
silencer and exhaust pipe, the silencer and its
support. Remove the silencer.
1 2
Figure 1-22
1 connecting bolt between the silencer and
exhaust pipe
2 connecting bolt between the silencer and
its support
2) Loosen the fastening hose clamps of air inlet
and outlet hoses separately, disassemble the
bolts which connect the air filter and its
support. Remove the filter and its support.
1
Figure 1-23
1 air filter
3) Disassemble the fan heater water valve.
1
Figure 1-24
1 fan heater water valve
2—27
4) Disassemble the compressor.
1
Figure 1-25
1 compressor
2—28
272 Assembly of Engine
2—29
1 Fasten the studs
Smear some diesel on the studs and then assemble
them to the flywheel plate, fasten them.
★1 Assemble with the fine thread end.
2 Do not use a plier to do the work; two
face-to-face nuts can be used, try to tighten the
1 outer nut with a wrench.

Figure 1-26
1 stud
2 Hoist the engine to the rear frame.

Engine
3 Connect the speed changer-torque converter
assembly and the engine
1
1) Smear a layer of sealant on the end face of
Figure 1-27 engine. Remove the top cover plate of the speed
1 engine
changer-torque converter assembly. Connect the
torque converter and engine with bolts and
gaskets. Then connect the torque converter
middle plate and flywheel with nuts.
★Tighten the all connection bolts in
round-group-bolts way. Avoid debris enter into
the torque converter when connecting the
1 middle plate.
Figure 1-28
torque converter
2—30
2) After check is finished, assemble the top cover
plate of torque converter and tighten it. Coat the
609 sealant around the plate .

609 sealant
1
Figure 1-29
1 cover plate
4 Install and tighten the fixing bolts of engine
120～200Nm
1
Figure 1-30
1 fixing bolt
5 Connect the wiring harness with engine
1) Connect the starting motor electric circuits

The wiring harness of rear frame should connect
with starting motor coil and starting relay.
1
Figure 1-31
1 starting motor wiring harness
2—31
2) Connect generator electric circuits
1
Figure 1-32
1 generator wiring harness
3) Connect air condition compressor and wiring
harness
1
Figure 1-33
1 air condition compressor wiring harness
4) Connect air preheater and wiring harness
1
Figure 1-34
1 air preheater and wiring harness
2—32
5) Connection of ED connector
1
Figure 1-35
1 ED connector
6 Connect oil inlet pipe of fuel pump
1
Figure 1-36
1 oil inlet pipe
7 Connect water pipe of fan heater
Straighten out the pipe and connect it to the water
valve.
1
Figure 1-37
1 fan heater water valve
2—33
8 Connect air condition hose
1 2
Figure 1-38
1 pressure cooling pipe 2 autoclaved pipe
9 Connect the hot-air water inlet pipe of air
condition and the engine.
1
Figure 1-39
1 hot-air water inlet pipe
10 Assemble the hose between the turbocharger
and air cooler.
1
Figure 1-40
1 hose
2—34
11 Connect the intake hose to turbocharger.
1
Figure 1-41
1 intake hose
12 Connect engine water inlet and outlet pipe
1 2
Figure 1-42
1 water outlet pipe 2 water inlet pipe
13 Assemble the hydraulic oil tank
Refer to 9-43 Assembly and assembly of
Hydraulic Oil Tank Assembly.
hydraulic oil tank
1
Figure 1-43
1 hydraulic oil tank
2—35
14 Assemble the engine hood.
Engine Hood.
Engine hood
15 Add coolant and engine oil

1
Figure 1-44 1) Add coolant to radiator
1 engine hood 28±2L
★ Fill glycol coolant to the expansion box, start
the machine after filling up. Refill the box after
the machine runs for a while until the liquid
level stays between the scales “MIN” and
“MAX” stably.
1 2) Add engine oil to the engine

Figure 1-45 21.5L
1 adding port of expansion box
Keep away from open flame when adding！
★ Open the left side door of the engine hood
and add prescribed engine oil from the engine
oil adding port. Run the engine at idle status to
check whether the oil filter and oil releasing
plug are leaky. After the engine flameout for 15
minutes, let the engine oil flow back to the oil

1 2 3
Figure 1-46 pan, and check the engine oil level of the engine
1 engine oil gauge pole
again.
2 engine oil filter 3 engine oil adding port
2—36
16 Assemble engine accessories.
Coating processes of AT545 pipe thread sealant is listed as follows:
1 Wipe up the foreign material on the screw with no hair-falling tissue.
2 Coat the sealant along the outside screw for one circle. The width of it is about 3~5
circles screw. Be sure the groove is full of sealant and the beginning circle could not be
coated. Coat it just before you want to assemble it. After the assembling, there should be a
whole circle of sealant between the bolt and threaded hole edge.
3 The coated part should be tightened with hand wrench rather than pneumatic impact
wrench.
1）Assemble the fan heater water valve
Coat the valve with Neotec AT545 sealant them
assemble it to the engine.
AT545 sealant
2）Assemble the compressor

Fix the compressor bracket and the ground wire
on the engine with the built-in bolts. Fix the splint
1
on the compressor bracket. Assemble the
Figure 1-47
1 fan heater water valve supporting board to the bracket; tighten the two
transmission wheels of the engine and compressor
with vee belt and fix them with bolts.
★1 The belt grooves of compressor clutch and
engine should be in the same plane; the
elasticity of the belt should be suitable: when
98N force is loaded on it, the belt should lower
10-12mm.
1
Figure 1-48
2 The hexagon head end of the bolt should
1 compressor
toward outside.
2—37
3）Assemble the air filter
Assemble the air filter on the bracket and fix them
to the engine with bolts. Fix the turbocharger inlet
air pipe to the air filter with T shape hoop; fix the
other end to the engine.
1
Figure 1-49
1 air filter
4）Assemble the silencer

Fix the silencer on the bracket engine, and put the
sealing gasket on vent end stud. Connect the
silencer tube to the vent with jam nuts and fasten
them, connect the other end to the silencer.
45~59 Nm
1
Figure 1-50
1 silencer
2—38
273 Disassembly and Assembly of

Fuel Tank
1 Disassembly of fuel tank
1 Start the machine and park it on level capacious
ground. Lower the bucket and flat it on ground.

1
Figure 2-1 Pull up the parking brake and wedge the front and
1 block
rear tires with blocks.
★ Do the disassembly after the loader is cooled.
2 Loosen the screw plug on the bottom of tank
and drain the oil. Contain the oil with clean vessel
and covers it to avoid falling sundries.
★ Fuel oil is inflammable. In the processes of
maintaining, the fire is forbidden and the place

1
Figure 2-2 should be far away from fire. At the same time,
1 oil draining plug
prevent the generation of fire, for example:
Bumping brings spark.
3 Open the side door of engine hood and
disconnect the circuits of oil level sensor, remove
the oil level sensor.
1
Figure 2-3
1 oil level sensor
2—39
4 Remove the oil outlet pipe of the fuel tank.
1
Figure 2-4
1 oil outlet pipe
5 Remove the oil return pipe of the engine, which
is connected on the fuel tank.
1
Figure 2-5
1 oil return pipe
6 Remove the fixing bolts of fuel tank.
1
Figure 2-6
1 fixing bolt
2—40
7 Lift down the fuel tank.

Fuel tank
1
Figure 2-7
1 fuel tank
8 Remove the rubber pipe on top of the tank.
１
Figure 2-8
1 rubber pipe connecting port
2 Assembly of fuel tank
1 Lift and assemble the fuel tank.

Connect the hose to fuel tank with hoops. Lift the
fuel tank assembly to rear-bottom site of the rear
frame.
Fuel tank
１
Figure 2-9
1 fuel tank
2—41
2 Fix the fuel tank.
Fix the fuel tank on the rear frame with bolts and
gaskets.
1
Figure 2-10
1 fixing bolt
3 Fix the oil outlet pipe of engine on the fuel tank

with bolts and gaskets
1
Figure 2-11
1 oil outlet pipe
4 Fix the oil return pipe of engine on the fuel tank
with bolts and gaskets.
1
Figure 2-12
1 oil return pipe
2—42
5 Install the oil level sensor on the fuel tank, and
connect the connecting plug with the harness wire
of rear frame.
1
Figure 2-13
1 oil level sensor
6 Add fuel.
110L
1
Figure 2-14
1 fuel filling pipe
2—43

Water Tank and Oil Radiator
1 Disassembly of water and oil radiator
★1) Do the disassembly after the loader is
cooled.
2) In the processes of disassembly, the
disassembled pipeline joints should be band up
to avoid sundries entering into the pipeline.
1 Open the draining valve on the bottom of water
tank. Drain out the coolant and contain them with
clean vessel.
Coolant
1
Figure 3-1
1 water draining valve
2 Disassemble the engine rear hood.
Refer to 8-41 Disassembly of Rear Hood
1
Figure 3-2
1 engine rear hood
2—44
3 Disconnect the connection between oil inlet pipe
and transmission oil radiator. Contain the oil with
clean vessel.
1
Figure 3-3
1 transmission oil pipe
4 Disconnect the connection between oil inlet pipe
and hydraulic oil radiator.
1
Figure 3-4
1 oil inlet pipe connection port
5 Disconnect the connection between oil outlet
pipe and hydraulic oil radiator.
Hydraulic oil
★When disassemble the hydraulic connection,
do not loosen the connection bolts rashly and
completely to avoid oil bursting out. Loosen

１
Figure 3-5 them off slightly until there is oil spills out, and
1 oil outlet pipe connection port
then disconnect them completely.
2—45
6 Remove the hoses of radiator, intercooler and
expansion box.
1 2 3
Figure 3-6
1 intercooler hose
2 radiator hose
3 expansion box hose
7 Loosen the fixing clamps and remove the
bottom hoses of radiator and intercooler.
1 2
Figure 3-7
1 intercooler air inlet hose
2 radiator water return hose
2—46
8 Pull out the intercooler temperature sensor and
water temperature sensor.
1 2
Figure 3-8
1 intercooler temperature sensor
2 water temperature sensor
9 Disconnect the cable ties and pull off the plug.
1
Figure 3-9
1 cable ties
10 Remove oil pipe of fan hydraulic motor.
1 2
Figure 3-10
1 oil inlet pipe of hydraulic motor
2 oil outlet pipe of hydraulic motor
2—47
11 Hang the radiator assembly and remove the
fixing bolts of water tank.
1
Figure 3-11
1 fixing bolts
12 Lift the radiator assembly down.
1
Figure 3-12
1 radiator
2 Assembly of water tank and oil radiator
1 Place the radiator and fix it with bolts.
120±10Nm
1
Figure 3-13
1 fixing bolts
2—48
2 Connect the oil pipe of fan hydraulic motor
1 2
Figure 3-14
1 oil inlet pipe of hydraulic motor
2 oil outlet pipe of hydraulic motor
3 Connect the bottom hoses of radiator,
intercooler.
1 2
Figure 3-15
1 intercooler air inlet hose
2 radiator water return hose
4 Connect the hoses of radiator, intercooler and
expansion box.
1 2 3
Figure 3-16
1 intercooler hose
2 radiator hose 3 expansion box hose
2—49
5 Connect cable and plug
1
Figure 3-17
1 cable ties
6 Connect the intercooler temperature sensor and
water temperature sensor.
1 2
Figure 3-18
1 intercooler temperature sensor
2 water temperature sensor
7 Connect oil inlet and outlet pipes of hydraulic
oil radiator
1 2
Figure 3-19
1 oil inlet pipe 2 oil outlet pipe
2—50
8 Connect transmission oil radiator pipe.
１
Figure 3-20
1 transmission oil pipe
9 Assemble the engine rear hood.
Refer to 8-41 Assembly of Rear Hood.
1
Figure 3-21
1 engine rear hood
10 Add coolant to expansion box
Coolant
1
Figure 1-45
1 adding port of expansion box
2—51
28 Diagnosis and Solutions for Frequently Asked Questions of

Engine System
281 Engine Fails to Start
Caused by starting system
1 Power shortage of storage battery.
Solution: Check the battery carefully, recharge or replace it.

2 Damaged starting motor.
Solution: repair or replace the motor.
Caused by oil supply system
1 There is air in the oil system.
Solution: Unchoke the oil circuit (such as blow with high pressure air), tighten all joints and
discharge air.
2 Blocking of oil system.
Solution: Unchoke the oil circuit (such as blow with high pressure air), tighten all joints and
discharge air.
3 The diesel filter element is particularly dirty.
Solution: Replace the filter element.

4 Serious wear damage of plunger/delivery valve.
Solution: Repair the fuel pump professionally.

5 Damaged low pressure fuel pump.
Solution: Replace the fuel pump
Adjustment factors
1 Dislocated of fuel injection advance angle.
Solution: Adjust the fuel injection advance angle.

2 Change of valve clearance.
2—52
Solution: Check and adjust valve clearance.

3 Oil shortage when starting
Solution: Check the fuel pump professionally.
282 Engine Power is not Sufficient
1 Blockage of fuel filter or fuel pump oil inlet pipe connector filter screen.
Solution: Clean or replace it/them.

2 Low injection pressure or bad atomization.
Solution: Troubleshoot the injector or replace inject nozzle matching parts.

3 Serious wear damage of precise inject nozzle matching parts.
Solution: Regulate oil supply or troubleshoot plunger and barrel assembly.

4 Air infiltrate into the fuel system.
Solution: Discharge air of the fuel system.

5 Incorrect fuel injection advance angle.
Solution: Adjust the angle according provisions.

6 Nonuniform oil supply of each cylinder.
Solution: Adjust oil supply.

7 Blockage of air filter.
Solution: Clean or replace the filter element.
283 Exhaust Exceptions (Black Smoke, White Smoke, Blue Smoke)
The engine gives off blue smoke
1 High engine oil level of engine pan.
Solution: Drain redundant engine oil, and make sure the oil level is within specified range.
2 Diesel flows into oil pan due to oil-fuel injector needle-valve untightly closed or stucked in
open position.
Solution: Clean and adjust the injector or replace the needle valve matching parts.
2—53
3 Damaged fuel pump plunger bushing sealing ring (P pump), or bad sealing between plunger
bushing and pump body, the fuel flows into oil pan along engine oil passage.
Solution: Replace the sealing ring.

4 Damaged valve oil seal or excessive clearance between the valve and tube.
Solution: Replace all faulted valves, pipes and oil seal (the oil seal must be replaced once being
disassembled; if the clearance meets the requirements after the valve is replaced, you can spare
the tube).
5 Damaged sealing ring of turbocharger, engine oil burns after enters into the combustion
chamber along air inlet passage.
Solution: Repair or replace.
The engine gives off white smoke
1 There is moisture in the fuel system.
Solution: Clean the fuel tank and filter, and use qualified diesel oil.
2 Abrasion of cylinder valve.
Solution: Replace it.

3 Bad atomization of injected fuel, the fuel fails to burn in the combustion champ.
Solution: Adjust the injector and fuel supply advance angle.
The engine gives off black smoke
1 Exhaust back pressure is too high or exhaust pipeline is blocked.
Solution: Reduce bend positions of pipeline; dust out the silencer.

2 The injection lags
Solution: Adjust fuel injection advance angle.

3 The injector doesn’t work normal or being damaged.
Solution: Dismantle, clean and check.

4 Poor quality of diesel or wrong brand.
Solution: Replace the diesel.

5 Severe wear of cylinder liner and piston group.
2—54
Solution: Replace worn parts
284 Engine Oil Pressure is too High or Too Low
Engine oil pressure is too high
1 Malfunctioned engine oil display device.
Solution: Replace the display device.

2 High viscosity of engine oil
Solution: Choose specified brand engine oil, and take preheating action when starting the
machine in winter.
3 Too little gap in force-feed lubricating positions or blocked engine oil filter.
Solution: Adjust the gap, clean or replace the filter.

4 Misadjusted pressure restrict valve.
Solution: Readjust the spring force of the valve, so the engine oil pressure can drop to specified
value.
Engine oil pressure is too low
1 Abrasions of engine oil pump or damaged sealing gasket.
Solution: Repair the pump and replace the gasket.

2 The suction oil reduces
Solution: Check oil capacity, add engine oil and clean the suction filter.
3 Large engine oil leakage.
Solution: Check whether the lubricating pipe is broken; check and adjust the fitting clearance of
bearings in crankshaft and camshaft as required.

4 Blockage of engine oil filter or cooler.
Solution: Check and clean engine oil filter and cooler.

5 Low viscosity of engine oil
Solution: Choose specified brand engine oil.

6 Misadjusted pressure restrict valve.
2—55
Solution: Clean the valve; readjust or replace the spring.

7 Low displaced engine oil pressure.
Solution: Check and replace engine oil pressure sensor and pressure gauge.
285 Large Consumption of Engine Oil
1 Improper engine oil viscosity.
Solution: Choose proper engine oil.

2 High negative pressure in combustion chamber, result in engine oil spraying up to
combustion chamber.
Solution: Examine the reason for high negative pressure and fix it.
3 Change of rotating speed and operating mode.
Solution: Test showed that with the increase of rotating speed, engine oil consumption rises
obviously, operate the engine according to the rules.
286 High Coolant Temperature
1 Improper selection of coolant or shortage of cooling water.
Solution: Choose suitable coolant and add to specified level.

2 Blockage of water radiator.
Solution: Put the radiating fins back to their original positions with stalloy carefully, after they
return to flat shape, clean them with compressed air or water gun.
3 Wrong indication of water thermometer or warning light.
Solution: Use the water thermometer to measure the temperature of water temperature sensor
area, see whether the measured temperature is consistent with actual value.
4 Low rotating speed of fan, the blades are deformed or installed backwards.
Solution: loosened rubber belt will lead to slipping, which result in low rotating speed of fan.
Adjust the belt if necessary; if the rubber layer aged, damaged or fractured, replace it. If the
blades are deformed, replace them.

5 Malfunction of cooling-water pump.
Solution: Replace the pump.
2—56
6 Malfunction of thermostat.
Solution: Replace the thermostat.

7 Damaged cylinder head gaskets.
Solution: Replace them.

8 Overloaded operation of diesel engine.
Solution: Lower the load of engine.
2—57
Version:0320
Ⅰ
CONTENTS
3 ELECTRICAL SYSTEM ....................................................................................................... 3-1

31 Instruction to Electrical System ...................................................................................................... 3-1
311 Notes for Electrical System .......................................................................................................... 3-1
312 Electrical System Description.................................................................................................. 3-2
313 AD Generator Description ....................................................................................................... 3-3
314 Power Switch............................................................................................................................. 3-3
315 Electronic Control System Instructions.................................................................................. 3-4
316 Battery ....................................................................................................................................... 3-7
317 Gauge, Sensor, Warning and Information System .................................................................... 3-8
32 Diagrams ......................................................................................................................................... 3-12
321 Connectors .............................................................................................................................. 3-12
322 Circuit ...................................................................................................................................... 3-15
33 Troubleshooting .............................................................................................................................. 3-50
34 Repair Instructions......................................................................................................................... 3-52
341 Replace I-ECU ........................................................................................................................ 3-52
342 Replace E-ECU ....................................................................................................................... 3-53
343 Replace Transmission control unit ........................................................................................ 3-54
344 Replace Battery....................................................................................................................... 3-56

3 ELECTRICAL SYSTEM
31 Instruction to Electrical System
311 Notes for Electrical System
 It is prohibited to change any part of electrical system without our authority.

This will affect the performance of the machine, and even result in severe death and damage of
the machine.
Careless operation may cause severe death and injure, and damage the machine.
Before operating the electrical system, observe the following instructions and relative parts.
Before starting the working of electrical system, take down your watch, rings and
others metal objects.
Battery
1. For checking and repairing the faults in electrical system, please use fully-charged battery
or full-featured battery.
2. Ensure the poles of the battery are connected right when installing the battery.
3. To replace the battery, ensure the capacity is consistent with the used one. These batteries
should be with equal working life, because the charging current will vary with the
increasing of use life.
AC-generator
1. Before any test about AC-generator or regulator, you must check whether the battery and
wires are insulated well, without loosening and corrosion. Check AC-generator belt.
2. Do not disconnect the cable of generator when it is running. Otherwise this may damage the
generator and regulator.
3. You should use secure connections, to prevent sparks and transient change of voltage. If the
cable is disconnected, it will cause damage to the alternator and regulator.
4. If the socket of generator is connected to the chassis, the generator and the regulator will be
damaged.
3-1
Electrical components
Attention! Electronic equipment is sensitive to electromagnetic or susceptible to or
damaged by static electricity from the human body or the tools. Therefore, when carrying out
the operation about the electronic components, you must comply with the following
instructions:
1. When an electronic component is powered, connection leading to the unit must not be cut
off. If disconnected, it may damage the electronic components.
2. Before the maintenance of the electrical system, the tool should be in contact with a metal
mechanical part on the frame to discharge the static electricity on the tools.
3. Do not touch the plug on electronic components.
4. When maintaining electrical systems, avoid touching the circuit board. If you have to touch
it, you only grasp the edge of the circuit board.
5. Do not touch a single electronic component.
6. When replacing units, make sure the ground wire is securely connected.
Welding
1. Disconnect the terminals of battery to prevent explosion of battery.
2. After the repair is completed, be sure to install the wire connectors of the computer control
panel, otherwise the machine will not start and move.
3. For welding, sparks may fall directly on rubber hoses, wires or pressure pipe, and these pipes
may suddenly rupture, wire insulation may be damaged, so these pipes should be covered.
312 Electrical System Description
Electrical system includes battery, starter motor, AD generator, bucket automatic leveling
control system, gauges, switches, lighting, air conditioning circuits and other electrical
equipment.
Machine system voltage is DC 24V, containing two batteries 12V in series, located in the left
side of the rear frame. Negative pole is grounded, and the line applies single system. As to the
relationship and working principle between electrical equipment, please carefully read the
electrical system circuit diagram.
Battery power switch is located on the left side. When the switch turns to " " position, the
3-2
vehicle power is off; when the switch turns to " " position, the vehicle power is turned on. For
parking vehicles for a long term, turn off the power switch. Relays and fuses are mainly located
in the distribution box behind operator's seat, after the cover of distribution box is removed, you
can see the relays in distribution boxes can be interchanged.
Connectors of components were all marked with CN + digital + letter format, which is different
from other connections. A is representative of the plug, and B represents the slot. For example,
I-ECU has two connection units, CN6 and CN7, CN6-A represents plug, and CN6-B represents
the corresponding slot.
313 AD Generator Description
The current of AD generator alternator is 80A and its normal charging voltage is 28.3V, and it
contains a built-in charger.
When the engine is turned off, the battery usually provides a voltage of about 24V, depending
on the charging status. When the engine is running, the battery is usually charged by AD
generator, because the charging voltage of AD generator is higher than the normal battery
voltage.
If the battery is not charging, the charging voltage of the alternator may be not correct.
314 Power Switch
Fig. 3-1 power switch
The power switch is used to disconnect the connection between electrical system and battery
voltage on the condition that the machine is not used.
Power switch is located inside the battery box; battery cut-off switch is connected with the
battery negative pole (24V).
3-3
The figure shows that power supply is turned off.
315 Electronic Control System Instructions
The electronic device has three control units,

connected through a data bus. Each control unit
processes the values transmitted from sensors and
operation device to control the components, so as to
obtain the desired function.
The control unit of system includes gauge control
unit I-ECU, Transmission control unit and engine
control unit E-ECU.
Machine electronic equipment engine applies fault
Fig. 3-2 power switch diagnosis system that facilitates fault detection. If
1. Gauge control unit I-ECU
there is an electrical fault, the operator will get the
2. Engine control unit E-ECU
fault code on gauge panel.
Gauge control unit I-ECUis located on gauge panel, including the warning lights and the
control lights. This unit receives information from the other control units via the data bus.
Transmission control unit is located beside distribution box behind the operator seat, and is
used to control the transmission range switching while sends part of the signal to the I-ECU for
display.
Engine control unit E-ECU is located on front left of
the engine, including software used for controlling the
functions of engine. The engine control unit receives
data from engine own sensors and information from
data bus. The control unit also sends information to
other control units through data bus.
1
Fig. 3-3 power switch
1. Engine control unit E-ECU
3-4
Applying the data bus for communication

All communication between components in electronic systems should be based on the principle
via a data bus. Communication between different control groups are performed on the data bus
CAN/J1939. These buses follow SAE standards, using shielded cable, which can shield
electromagnetic interference. If a fault occurs in the system, a signal is sent from the
information bus, the operator can read fault code on the gauge penal.
CAN/J1939 control bus
System control signals are sent via the bus, and control speed of bus is very fast, which is
required to control the entire system operation and adapt quickly to changing conditions. The
main communication operations are carried out in CAN/J1939 bus.
Gauge Control Unit I-ECU instruction
Gauge control unit is integrated with the main
gauges and receives information from the data
bus. Information is processed and displayed on
the meter, control lights, warning lights.
Functions
1. Examine special warnings such as engine
Fig. 3-4 Gauge control unit with
oil pressure, and activate corresponding information display screen
warning lights.
2. Engine speed, fuel level, torque converter oil temperature, engine temperature are shown in
the measure table one gauge panel.
3. Display the working time, and display the fault code.
3-5
Transmission control unit description

Shift control unit is designed with advanced features associated with the machine, and includes
the following features. Shift control unit is located
behind the operator's seat beside distribution box, and
are connected with other control units through the
data so as to communicate with other control units.
Functions
1. Shift strategy
2. Control speed valve
3. Control shift selector Fig. 3-5 Transmission control unit
Engine control unit E-ECU description
The engine control unit is the center of injection system. The control unit continuously receives
from the information from accelerator pedal and the engine sensor, and calculates the amount of
fuel as well as the time point when the fuel injects into the cylinder. If a fault or any part of the
system occurs, the control unit will store the corresponding information. Sporadic faults are
stored in the unit, and then it can be traced back.
Functions
1. Control fuel injection
2. Temperature monitoring
3. Bond preheating device
4. Detect connected preheating devices
5. Monitoring water amount in the fuel
6. Detect the engine speed Fig. 3-6 Engine control unit
3-6
316 Battery
Battery electrolyte contains sulfuric acid, and battery can produce hydrogen and oxygen when
charging. Therefore, the wrong handling of the battery may result in serious injury or fire.
Therefore, comply with the following precautions:
1. The battery contains sulfuric acid liquid with a strong corrosive, please keep it away from
children. The user should wear protective glasses and rubber gloves when operating the
battery. Once sulfuric acid splashes on the eyes, skin or clothes, rinse immediately with
plenty of water, go to hospital for treatment if necessary.
2. Turn the engine off before doing any operation that related to the battery.
3. Connect the positive terminal of the battery and positive terminal of the engine, and then
connect the negative terminal of the battery and negative of the engine. When removing the
battery, first disconnect the negative pole (ground side). If the battery electrolyte is close to
the “low level”, fill distilled water, but be sure not exceed “high level”.
4. The battery may not be reversed and laid down, and shall not be subjected to any
mechanical shock and stress.
5. The battery will produce hydrogen and oxygen when charging. In case of fire or vent
blockage, it may cause an explosion, so the battery should stay away from open flames ,
and avoid the short circuit caused by touching metal objects ( such as tools ).
6. When cleaning the top surface of the battery, use cloth to wipe it. Do not use gasoline,
solvents and any other organic solvents or detergents. Battery case is flammable and should
stay away from open flame.
7. The battery should be stored at 5 ~ 25 ℃ in a dry, clean and well-ventilated environment,
and it should be free from direct sunlight. The battery should be at least more than 2m
away from the heat source. Too high ambient temperature will cause a great impact on the
performance of the battery. It can be stored at room temperature for six months, and it can
be used within six months without charging. The battery can still be used with charging
after being stored for more than six months. Installed battery should be removed from the
vehicle when it is not in use for the long-term (generally more than 15 days) and it should
be stored in dry and ventilated place. Charge the battery every 3 to 6 months (depending on
whether the indicator is black).
3-7
8. When replacing the battery, be sure to use the rubber pads to protect the battery and fix it
firmly with a fixed plate and, and install shield guards on it.
3-8
317 Gauge, Sensor, Warning and Information System
Fig. 3-7 Gauge control unit
Engine Water Temperature Gauge

This gauge indicates the temperature of engine cooling water.
The temperature is normal when the pointer lies in the green range
(40℃~103℃).
Notice: If the temperature pointer moves into the red range, be
sure to stop the machine for inspection.
 Torque Converter Oil Temperature Gauge
This gauge indicates the temperature of torque converter oil.
When the temperature pointer lies in the green range (60℃~120℃),
the oil temperature is normal. If the temperature pointer moves past
green into the red ranges, be sure to stop the machine for inspection.
 Fuel level Gauge (when it is installed)

This gauge shows the ratio of residual oil volume to the fuel tank
capacity.
3-8
 Engine tachometer
This gauge shows the rotation speed of the engine.
Steering indicator lamp: Turn on the steering switch, this indicator

lamp will be on and steering lamp will also be on at the same time to
warn people that the loader is steering. The left indicator lamp will on
when turn left and right indicator lamp will be on when turn right.
Preheating indicator lamp：If the machine is equipped with cold
start device, turn the starting switch to PRHEAT position and this
lamp will be on; the lamp will be off if the starting switch is not in
PRHEAT position.
Parking Brake Indicator Lamp: If the brake air pressure is normal,
the lamp will be on when the parking brake switch is pressed down;
rotate the parking brake switch gently it springs back, brake state will
be removed and this lamp will be off; the lamp will also come on if
the brake air pressure is low.
Charging indicator lamp: Turn on the starting switch and the lamp
will be on，after the engine started, it will be off automatically,
otherwise it means that there is failure in storage charging system,
inspection and repair need to be done.
High beam indicator lamp: When the headlight is lighted in high
beam form the indicator lamp will be on; the lamp will be off if the
headlight is lighted in lower beam form or the headlight is off.
Engine oil pressure alarm lamp: Turn on the starting switch and the
lamp will be on immediately; after the engine started, it will be off
automatically, otherwise it means that the lubricating oil level is too
low or there is failure in lubricating system, be sure to stop the engine
for inspection.
3-9
Low brake air pressure alarm lamp: This lamp will be on if the
brake air pressure lower than 0.4MPa.
High coolant temperature alarm lamp: If the coolant temperature

of engine ≥105℃, this lamp will be on, central warning lamp flashes
and the buzzer will ring.
If this circumstance happens, you should stop the engine and find out
the reason.
Low shifting oil pressure alarm lamp: If the transmission oil
pressure inside the gearbox is too low, this lamp will be on, central
warning lamp flashes and the buzzer will ring.
If this circumstance happens, you should stop the engine and find out
the reason.
Oil-water separator alarm lamp: Turn the key to ON, the indicator
lamp will be on if the water in water-oil separator is too much after
the switch is connected. Drain the water in the Oil-water separator
when the lamp is on.
Fuel coarse filtering indicator lamp: If the lamp is on, it means that
the fuel coarse filter blocked and it should be cleaned or replaced.
Low fuel level indicator lamp: If fuel level is too low, the lamp will
be on and buzzer will ring.
Air filter blocking alarm lamp: When the engine is running, this
lamp is on and it means that the air filter is blocked. Clean or replace
it.
3-10
Central warning lamp: Before the engine is started, the lamps of

engine oil pressure indicator and charging indicator will be on and
this lamp will stay unlighted. When other parts of the machine out of
order, the light will be on and flash.
Power cut off indicator lamp: If the light is on, it means that the
power is cut off; otherwise the power is not cut off. Stomp the left
brake pedal, the power will be cut off and this lamp will be on; stomp
the right brake pedal, the power is still on and this lamp stays
unlighted.
When the LED is just powered, it will not display anything and for
working condition is as follows：
Mode Note
Normal LED displays in two rows and the too row shows shifts
and the bottom row shows working hours.
Funnel-shaped timing figure flashes every 2.5S, hours
is not stored and only read the ECU data via CAN.
Fault LED displays in two rows, the first row is fault code
and the second row shows warning and hour timing
(WARNING)
Fault diagnosis information should meet the demands
of J1939.
3-11
32 Diagrams
321 Connectors
85
87
86
87a 30
Fig. 3-8 Relay plug
A20 A11 B12

B22
A10 A1 B11 B1
Fig. 3-9 Gauge connectors
3-12
Name Type
Radio connector
Top lamp connector
Right horn and left horn
Combination switch connector
Front right combination, front left

combination lamp
Connector between rear frame

harness and front frame harness
3-13
Name Type
harness and stopping brake harness
CN80-A

harness and rear hood harness
CN15-B
E-ECU
3-14
322 Circuit
WD1 ECU
Transmission control unit
Fig. 3-10
3-15
Component positions
Transmission control unit E-ECU
I-ECU
HMIM
M
Fig. 3-11
3-16
WD2 Preheating
Power Battery Battery

switch
Preheator
Preheating relay
Preheat relay
Fig. 3-12
Component positions
Pre-heater
Battery Power switch
E-ECU
Preheating relay
Fig. 3-13
3-17
WD3 Accelerator pedal
Accelerator pedal
Fig. 3-14
Component positions
Accelerator pedal HMIM
Fig. 3-15
3-18
WD4 Parking brake
Power cut-off relay
Parking brake
indicator switch
Power cut-off switch
Left
Lefttail
taillamp
lamp Right
Righttail
taillamp
lamp
BrakeBrake tail switch

tail lamp switch
Transmission
Gear shiftcontrol
unit control unit
Fig. 3-16
3-19
Component positions
Parking brake indicator lamp
Left tail lamp
Power cut-off indicator lamp
Brake tail switch
Fig. 3-17
3-20
WD5 Hand Brake
WD5 Parking switch
Hand brake switch
Brake releasing switch
Brake relay Brake solenoid valve
Emergency brake switch
Fig. 3-18
3-21
Component positions
Brake solenoid valve

Brake release switch
Hand brake switch

Fig. 3-19
3-22
WD6 Fuel level sensor, Converter oil temperature sensor, gearbox transmission oil
pressure sensor
Converter oil temperature

Transmission oil pressure switch
Fuel lever switch sensors
Fuel Oil
gauge temperature
gauge
Fig. 3-20
3-23
Component positions
Converter oil Gearbox oil Fuel level sensor

temperature sensor pressure switch
传感器
I-ECU
Fig. 3-21
3-24
WD7 Independent radiator
Hydraulic motor
rotation switch
Independent
radiator
controller
Rotation direction
solenoid valve
Turbo temperature sensor
Water temperature sensor
Rotation direction solenoid valve
Fig. 3-22
3-25
Component positions
Water temperature switch
Intercool temperature switch
Independent radiator controller Thermostatic

Solenoid valve
radiator valve
Hydraulic motor Rotation

液压马达正反转开关
direction switch
Fig. 3-23
3-26
WD8 Boom bucket limit switch

Boom relay Bucket relay
Bucket valve
Boom valve
Floating valve
Bucket proximity switch
Boom proximity switch
Fig. 3-24
3-27
Component positions
Bucket relay
Boom relay
Boom proximity switch Bucket proximity switch
Fig. 3-25
3-28
WD9 Quick-change device
Quick-change switch
Buzzer
Quick-change
solenoid valve
Quick-change
solenoid valve
Buzzer
Fig. 3-26
3-29
Component positions
Quick-change Electromagnet Quick-change switch
Fig. 3-27
3-30
WD10 wiper
Front wiper rocker switch

Front wiper
Rear wiper
rocker switch Rear wiper
Spraying switch
Spraying motor
Fig.3-28
3-31
Component positions
front wiper Water spraying
rocker switch switch
Rear wiper rocker switch
Spraying motor
Front wiper
Fig. 3-29
3-32
WD11 radio
Left horn
Right horn
Radio
Fig. 3-30
3-33
Component positions
Radio Horn
Fig.3-31
3-34
WD12 Working lamp
Rear working Front working
lamp rocker lamp rocker
switch switch
Relay
Left front lamp
Right front lamp

Rear light
Left rear lamp
Left rear lamp
Fig.3-32
3-35
Component positions
Front working lamp rocker switch
Rear light
Rear working lamp rocker switch
Left rear lamp
Right front lamp
I-ECU
Fig.3-33
3-36
WD13 Top warning lamp and indoor lamp
Ceiling lamp rocker switch
Ceiling lamp warning lamp
Indoor lamp
Fig. 3-34
3-37
Component positions
Top plate switch

Top warning lamp
Indoor lamp
Fig. 3-35
3-38
WD14 Combination lamp
Combination switch
Relay
A B C
Right combination lamp
Left tail lamp Right tail lamp
Left combination lamp
Fig. 3-36
A:Backing relay
B: Headlight short beam relay
C: Headlight long beam relay
3-39
Component positions
Left tail lamp
Back relay
Combination switch
Headlight Headlight
Front combination lamp
long beam short beam
relay relay
继电器
Fig. 3-37
3-40
WD15 Safety lock

Safety lock rocker valve
Safety lock solenoid valve
Fig. 3-38
Component positions
Safety lock plate switch
Fig. 3-39
3-41
WD16 Cigarette lighter
Cigarette lighter
Fig. 3-40
Component positions
Figure 3-43
Cigarette lighter
DC-DC
CONVERTER
Fig. 3-41
3-42
WD17 sensors connecting with E-ECU
Fig. 3-42
3-43
Component positions
Air filter Coolant level sensor

Inlet temperature sensor
Water in fuel sensor E-ECU
Fig. 3-43
3-44
WD18 Starter and generator
Start auto
protection
relay Start link relay
Transmission
control unit
AD
Start switch
generator
Start motor
Battery
Fig. 3-44
3-45
Component positions
HMIM Battery
I-ECU Start switch E-ECU
Fig. 3-45
3-46
Component positions
AD generator
Start motor assembly
Transmission control unit

Start link Start auto
relay protection
relay
Fig. 3-46
3-47
WD18 Horn
Horn
Horn switch
Horn assembly
Fig. 3-47
3-48
Component positions
Horn relay
Horn switch
Horn
Fig. 3-48
3-49
33 Troubleshooting
Faults Warning Indicator SPN FMI Load

Fault component Close
node type lamp color J1939 J1939 off
E01 Fuel pressure low check yellow 94 18 NO NO
E02 Water mixed in fuel warning red 97 0 NO NO
E03 Engine oil level low check yellow 98 18 NO NO
E04 Engine oil level low warning red 98 1 NO NO
E05 Engine oil level low check yellow 100 18 NO NO
E06 Engine oil level low warning red 100 1 YES YES
E07 High compression air pressure check yellow 102 16 NO NO
E08 High compressed air pressure warning red 102 0 NO NO
E09 High compressed air pressure check yellow 105 16 YES YES
E10 High compressed air pressure warning yellow 105 0 YES YES
E11 Air filter is blocked. check yellow 107 0 NO NO
E12 High coolant temperature check yellow 110 16 YES NO
E13 High coolant temperature warning red 110 0 YES NO
E14 Low coolant level check yellow 111 18 YES NO
E15 Low coolant level warning red 111 1 YES NO
E16 High crankcase pressure check yellow 153 16 YES NO
E17 High crankcase pressure warning red 153 0 YES NO
E18 High engine oil temperature check yellow 175 16 YES NO
E19 High engine oil temperature warning red 175 0 YES NO
E20 Engine speed sensor warning red 190 0 NO NO
High Air draining
E21 warning red 190 0 NO NO
compressor temperature
E22 Injector 1 check yellow 651 3&5&13 NO NO
E28 Crank shaft speed senor check yellow 637 2&3&8 NO NO
E29 Power voltage sensor 1 check yellow 3509 3&4 NO NO
E30 Power voltage sensor 2 check yellow 3510 3&4 NO NO
E31 Program memory check yellow 628 7&11 NO NO
E32 Program memory warning red 628 2&12 NO NO
Calibration memory
E33 warning red 630 2&12&14 NO NO
EEPROM
E34 Controller 1 warning red 629 8&12 NO NO
E35 ECU high temperature check yellow 1136 16 NO NO
E36 ECU high temperature warning red 1136 0 YES NO
E37 Data circuit check yellow 2023 9 NO NO
3-50
E38 Preheat relay check yellow 626 3&4&5 NO NO
E39 Fuel pressure sensor check yellow 94 3&5 NO NO
E40 Water mixed in fuel sensor check yellow 97 3&4 NO NO
E41 Oil level sensor 98 4&5 NO NO
E42 Oil pressure sensor check yellow 100 3&5 NO NO
Compressed air
E43 check yellow 102 3&5 NO NO
pressure sensor
Compressed air
temperature sensor
E45 Air filter sensor check yellow 107 3&4&5 NO NO
Environment
temperature sensor
E47 Coolant temperature sensor check yellow 110 4&5 NO NO
E48 Coolant level sensor 111 3&4&5 NO NO
E49 Crankcase level sensor check yellow 153 3&5 NO NO
E50 ECU battery level check yellow 158 3&4 NO NO
Environment
E51 171 13&14&19 NO NO
temperature sensor
E52 Oil temperature sensor check yellow 175 4&5 NO NO
E53 Engine cam sensor check yellow 636 2&3&8 NO NO
E54 Overheating of starting device 1675 0 NO NO
Output failure of
starting device
E56 Preheating sensor check yellow 729 3&4&5 NO NO
E57 ECU temperature sensor check yellow 1136 4&5 NO NO
E58 Crankcase ventilation 153 7 NO NO
CAN communication
E60 check yellow 2023 9 NO NO
connection
J1857 communication
connection
High voltage of
accelerator pedal
Low voltage of
accelerator pedal
Wrong logic of
accelerator pedal
3-51
34 Repair Instructions
341 Replace I-ECU
Note: Before replacing the I-ECU, make

sure the power is switched off.
1. Remove the screws on the gauge panel cover,

and remove the cover.
Fig. 3-49
2. Remove fixing screws of I-ECU, remove two

connectors, and then remove the I-ECU. Please
remember marked code of two connectors, and
the I-ECU on the corresponding connector
CN7-B corresponding to the right, CN6-B
Corresponding to the left.
Fig. 3-50
3. Replace with new I-ECU. Plug the connector
correctly and ensure good contact.
Fig. 3-51
3-52
4. Tightening the screws to fix I-ECU

5. Install the cover and fasten it with screws.
Fig. 3-52
342 Replace E-ECU
Note: Before replacing the E-ECU, make

sure the power is switched off.
1. Park the machine at the maintenance position.
2. Open the left side of the engine hood.
Fig. 3-53
3. Remove four fixing bolts.
Fig. 3-54
3-53
4. Push the yellow handle towards right to

disconnect the harness connector.
5. Replace new E-ECU，

Fig. 3-55
6. Connect the connectors, and pull the yellow
handle back to fix it.
7. Fix it with bolts.
343 Replace Transmission control

unit
Note: Before replacing the Transmission
control unit, make sure the power is switched
off.
1. Park the machine at the maintenance position.
2. Open the left side of the engine hood.
Fig. 3-56
3-54
3. Remove fixing bolts.
Fig. 3-57
4. Observe locking type of connector. Hold the

shift control unit with left hand, pull down iron
plates with right thumb, and remove the
connector. Do not remove it with brute force.
Fig. 3-58
5. Replace the shift control unit. Insert the top

locking device, and pull down the bottom of
iron plate. After the connector is installed, let
go the iron plate to lock the unit.
Fig. 3-59
3-55
6. Install fixing bolts.
7. Install the cover and fix it with screws.
Fig. 3-60 344 Replace Battery
Warning! Battery contains corrosive acid,

please read carefully the precautions about
removing and installing the battery in 3.1.7
before dismantling it. Make sure the power is
switched off.
Disassembly of battery
1. Place the machine in the service position, and
turn off the engine.
2. Open the cover of battery box. Remove the
battery shield board
Fig. 3-61
Fig. 3-62
3-56
3. Loose and remove the cable connector of

battery.
Note: Remove the negative one first.
Fig. 3-63
4. Loosen the clamp and remove the battery. The

battery is very heavy, please hold it firmly.
Assembly of battery
Fig. 3-64
1. Put the battery on required place and Assemble
clamps.
Fig. 3-65
2. Clean the battery cable connector and washers

with a dry cloth.
3-57
3. Install the cable connectors and use acid-free

Vaseline for lubrication.
Note: Firstly connect the positive terminal,
and then connect the negative terminal.
Fig. 3-66
4. Carefully check the fixing and connection of

battery. Install fixing plate and protective plate.
5. Reset the machine to the state of running.
6. Start the machine and make sure there is no
error info.
Fig. 3-67
3-58
Service Manual of RS8160 Road Roller
SERVICE MANUAL
Version:0420
4 Transmission System
CONTENTS
4 Transmission System ........................................................................................... 4-1
41 Transmission Box System ................................................................................... 4-1
411 General......................................................................................................... 4-1
412 Composition and Structure of Transmission ............................................... 4-2
413 Disassembly and Assembly of Transmission System ................................. 4-6
414 Troubleshooting of Transmission box System .......................................... 4-18
42 Transmission Shaft System ............................................................................... 4-22
421 Overview of Transmission Shaft ............................................................... 4-22
422 Disassembly and assembly of Transmission Shafts .................................. 4-23
43 Drive Axle System............................................................................................. 4-28
431 Overview of Drive Axle .......................................................................... 4-28
432 Maintenance of Drive Axle ..................................................................... 4-28
433 Disassembly and Assembly of Drive Axle................................................ 4-29
44 Pressure Measuring Methods and Standards of Transmission System ............. 4-37
45 Diagnosis and Solutions for Common Faults of Transmission System ............ 4-39
451 Fault Diagnosis and Solutions for Transmission box ............................... 4-39
452 Fault Diagnosis and Solutions for Drive Axle .......................................... 4-40
I
4 Transmission System
LG958L transmission system is composed of transmission box, transmission shaft, front and rear
drive axles and wheels. The principle diagram of transmission system is shown in Fig. 4-1.
Steering pump Transmission

pump
Torque converter
Working pump
Disc brake
Speed sensor
Rear axle
Front axle Parking brake
Tire
Fig. 4-1 Principle diagram of transmission system
41 Transmission Box System
411 General
4WG200 (4 forward gears, maximum transmission power 200kw) power shift transmission box is
composed of hydraulic torque converter and rear fixed axis type transmission box with a multi-disc
friction clutch. The transmission box the loader used is forward-4-reverse-3 type. Since full
four-wheel drive is adopted and large center distance between input and output shaft is provided,
4WG200 transmission box has been widely used in domestic manufacturing industries, such as wheel
loaders, bulldozers, graders, scrapers, etc.
4-1
Table 4-1
Single-stage three-element
Type
single-turbine hydraulic torque converter
Torque
converter Inlet pressure of converter (MPa) 0.85
Outlet pressure of converter
0.5
(MPa)
Type Fixed shaft electro-hydraulic shift
Transmission Shifting gears Forward-4-Reverse-3

box Transmission pump type Built-in
Shifting pressure (MPa) 1.6~1.8
Axial clearance of the three clutch
Critical 0.1~0.3
assembly (mm)
clearance
Piston stroke (mm) 1.8~2.2
412 Composition and Structure of Transmission
Fig. 4-2
1 Torque converter housing 2 Transmission control valve 3 Oil filter 4 Lifting eye
5 Main PTO 6 Auxiliary PTO 7 Speed sensor 8 Parking brake
9 Oil absorption pipe 10 Transmission box oil outlet port
11 Torque converter oil temperature measuring port
4-2
Fig. 4-3
1 Intermediate shaft assembly 2 KRK2 clutch assembly 3 K3K4 clutch assembly
4 Output shaft assembly 5 KR clutch oil pipe 6 K2 clutch oil pipe
7 K4 clutch oil pipe 8 K3 clutch oil pipe 9 KVK1 clutch assembly
10 KV clutch oil pipe 11 K1 clutch oil pipe
Fig. 4-4
1 Gear shift valve 4 2 Pressure control valve 3 Control pressure valve 4 Reversing valve
5 Second-stage pressure control valve 6 Set valve 7 Oil draining valve
8 Gear shift valve 3 9 Gear shift valve 5 10 Gear shift valve 1 11 Gear shift valve 2
4-3
The corresponding working condition of electromagnetic valves and clutches in each gear are
shown in Table 4-2.
Table 4-2
●Electromagnetic valve is electrically charged
Forward gear Reverse gear Neutral gear

Gear 1 2 3 4 1 2 3 1 2 3 4
M1 ● ● ●
M2 ● ● ●
M3 ● ● ●
M4 ● ● ● ● ● ●
M5 ●
Clutch KV KV KV K4 KR KR KR K3
Clutch K1 K2 K3 K3 K1 K2 K3
4-4
Fig.4-5 Transmission oil supply line

4-5

Transmission System
Disassembly of transmission box

Refer to following steps to remove the
transmission box off the machine:
1 Maintenance position
2 Remove the engine hood Refer to 8 Cab & Covering
3 Remove the platforms and cab Parts System
4 Remove the side plates
5 Remove the hydraulic oil tank Refer to chapter 9 Working
Hydraulic System
6 Disconnect the pump oil outlet
hose Transmission control
7 Disconnect the oil inlet and valve wiring harness
return pipes of radiator Speed sensor
8 Disconnect wiring harnesses
Transmission Pressure sensor
box 9 Disconnect the intermediate
transmission shaft Torque converter oil
temperature sensor
10 Disconnect the rear
transmission shaft
11 Drain transmission oil
12 Remove the oil filling pipe
13 Remove the brake cylinder
14 Disconnect the transmission
box from engine
15 Disconnect the transmission
box from frame
16 Straighten out the pipes, lift
up the transmission box
ATTENTION
 Wait until the transmission box is cooled to
do the disassembly.
 In the process of disassembly, the joints of
each pipeline should be bound up to avoid
the sundries entering into the pipeline.
4-6
1. Put the loader in maintenance position.

2. Remove the engine hood, hydraulic oil tank
and cab.
Fig. 4-6
3. Disconnect the hydraulic oil pipes.
ATTENTION
The pipe joints should be bound up to avoid
foreign matters entering.
Fig. 4-7
4. Disconnect the cooling oil return pipe from

transmission box.
ATTENTION
1
Fig. 4-8
1 Oil return pipe from radiator to
transmission box
4-7
5. Disconnect the radiator oil inlet pipe from

transmission box.
ATTENTION
1
Fig. 4-9
1 Oil inlet pipe of radiator (from
radiator to transmission box)
6. To avoid damaging the electrical components

like sensor, remove the sensor and plug the
sensor hole after disconnecting a circuit.
 Disconnect the wiring harness connector
from transmission control valve.
1
Fig. 4-10
1 Connecting socket
 Disconnect the output shaft speed sensor

from transmission box.
1
Fig. 4-11
1 Output shaft speed sensor
4-8
 Disconnect the transmission box pressure

sensor from rear frame wiring harness.
1
Fig. 4-12
1 Transmission box pressure sensor
 Disconnect the torque converter oil

temperature sensor from rear frame wiring
harness.
1
Fig. 4-13
1 Torque converter oil temperature
sensor
7. Disconnect the connection between

intermediate transmission shaft and
transmission box.
1 2
Fig. 4-14
1 Hexagon bolt
2 Intermediate transmission shaft
4-9
8. Disconnect the connection between rear

transmission shaft and transmission box.
1 2
Fig. 4-15
1 Rear transmission shaft
2 Hexagon bolt
9. Remove the oil drain plug and drain

transmission oil out.
ATTENTION
 Use a clean vessel to contain the oil and
cover it up to prevent sundries falling in.
 Be careful of oil splashing.
1
Fig. 4-16
1 Oil drain plug
10. Loosen the bolts and remove the oil filling

pipe.
1 2
Fig. 4-17
1 Oil filling pipe 2 Bolt
4-10
11. Remove the connecting pin. Disconnect the

connection between parking brake cylinder
and parking brake. Remove the fixing nuts of
parking brake cylinder.
1 2
Fig. 4-18
1 Parking brake cylinder
2 Connecting pin
12. Remove the torque converter upper cover plate.

Disconnect the connection between torque
converter intermediate ring and engine
flywheel.
1
Fig. 4-19
1 Nut
13. Support the engine with woodblock to prevent

it tilting.
14. Connect lifting appliance to the two lifting
eyes on transmission box.
15. Remove the connecting bolts between engine
and transmission box
1
Fig. 4-20
1 Connecting bolt
4-11
16. Remove the fixing bolts of the transmission

box.
17. Straighten out engine related pipes and lift the
transmission box up.
ATTENTION
Lift the transmission box smoothly and do
1 not tilt to prevent the torque converter
Fig. 4-21
1 Bolt slipping.
Assembly of transmission box

Refer to the following steps to recover the
transmission box:
1 Lift up the transmission box,
preparation
2 Connect to the engine
3 Connect to the frame
4 Connect the pump oil outlet
rubber hose
5 Install the oil filling pipe
Transmission control
valve wiring harness 6 Connect the brake cylinder
Speed sensor 7 Connect the transmission
Pressure sensor shafts
Torque converter oil 8 Connect the radiator oil inlet Transmission
temperature sensor and return pipes box
9 Connect wiring harnesses
and sensors
10 Install hydraulic oil tank
11 Hang and install the cab
12 Hang and install engine
hood
13 Install the side plates
14 Install the platforms
15 Fill transmission oil
16 Check the function of
transmission box
4-12
1. Connect the lifting appliance to the

transmission box.
2. Lift the transmission box to the right position.
ATTENTION
 Lift the transmission box smoothly to
prevent the torque converter slipping.
 Please be careful during operation and pay
1 special attention to the cables and hydraulic

Fig. 4-22 hoses on the machine, otherwise, they may
1 Lifting eye be damaged by clamping or extruding.
Align the torque converter intermediate
ring to the engine flywheel housing.
3. Install the two upper bolts between the engine
and the transmission box.
4. Install and tighten the connecting bolts
between the engine and the transmission box.
ATTENTION
Be careful to avoid nuts and washers falling
into the flywheel housing.
1
Fig. 4-23
1 Connecting bolt
5. Fix the transmission box on frame with bolts,

remove the lifting appliance.
120~200Nm
1
Fig. 4-24
1 Bolt
4-13
6. Install and tighten the connecting nuts between

the transmission intermediate ring and the
engine flywheel disc.
1
Fig. 4-25
1 Nut
7. Connect the hydraulic oil pipes.

Refer to 9 Working Hydraulic System and 6
Steering System.
ATTENTION
Check the O-shape ring in pipe joint before
installing.
Fig. 4-26
1 8. Install the oil filling pipe, and tighten the bolts.

Check whether the sealing gasket is intact
before installing.
9. Connect the parking brake and parking brake
cylinder.
Refer to 5 Brake System.
10. Connect the intermediate transmission shaft.
90±15Nm
1 2
Fig. 4-27
1 Parking brake
3 Oil filling pipe
4-14
11. Connect the rear transmission shaft.

90±15Nm
1 2
Fig. 4-28
2 Hexagon bolt
12. Connect the cooling oil return pipe to

transmission box.
Rubber hose: 145±15Nm
1
Fig. 4-29
1 Oil return pipe from radiator to
transmission box
13. Connect the radiator oil inlet pipe to

transmission box.
Rubber hose: 145±15Nm
1
Fig. 4-30
1 Oil inlet pipe of radiator (from
radiator to transmission box)
4-15
14. Install the sensors.

(1) When assembling the torque converter oil
temperature sensor, firstly wipe up the foreign
material in the threaded hole of the sensor with
no hair-falling tissue; then use AT755
high-efficiency detergent to spray around the
threaded hole edge, and coat the torque
converter oil temperature sensor with Aotai
AT545 pipe thread sealant. Coating processes
1
are as follows:
Fig. 4-31
1 Torque converter oil temperature ① Apply sealant around the external threads
sensor of parts for one circle with a width of 3~5
threads, fill the thread pitch shape with
sealant and do not apply sealant to the first
thread. It is required to do instant
application in the process of assembling,
and after assembling, there should be a
complete circle of sealant line at the
external threads and thread hole edge.
② After application, use a wrench rather than
a pneumatic wrench to tighten parts
manually, and fix them to the
corresponding positions as shown in the
transmission figure.
AT545 sealant
(2) Coat appropriate amount of sealant on the end
of pressure sensor connector. Then install the
connector follow the left Fig., install the
pressure switch on the joint. When coating the
sealant, starting with the second circle of the
external thread end, the width of sealant is
1
Fig. 4-32 about 3~5 threads.
1 Transmission box pressure sensor AT545 sealant
4-16
15. After assembled the cab, connect the speed

sensor wiring harness.
1
Fig. 4-33
1 Output shaft speed sensor
16. After assembled the cab, connect the

transmission control valve wiring harness.
Check all functions of the transmission box.
1 2
Fig. 4-34
1 Connecting socket
2 Transmission control valve
4-17
414 Troubleshooting of Transmission box System
Table 4-3
Problems Causes Solutions
Check whether the gear shifting handle is in
Shift neutral gear.
neutral position.
Whether the connection between EST
The wheel Press the plug, and there will be a
electronic control box and the electric plug
loader is sound of click.
is loose.
unable to start.
Whether the battery power is enough. Charge or replace the battery
Whether the starting circuit has faults; Restore the circuit back to
Whether starting fuse burnt out. normal.
Whether the transmission box is enough,
Adjust the oil level to normal.
check cold and hot machine oil level.
Check whether the electric plug of
Tighten the plug.
transmission control valve is tightened.
Whether the connection between EST
Push the plug, and there will be a
electronic control box and the electric plug
sound of click.
is loose.
Check whether the electric plug that
The wheel connected with gear shifting selector cable Insert the plug tight.
loader is able is loose.
to start, but is Whether the neutral locking switch of Turn on the neutral locking
unable to shifting selector is on. switch.
travel.
Whether the parking brake is removed. Remove the parking brake.
Check whether the gear shifting oil pressure
Check the oil pressure gauge.
on the dashboard is normal.
Check whether the ventilated valve on the Clean up the ventilated valve.
transmission box is blocked and whether Check whether the oil is too
there is oil overflow. much or too little.
Check whether the speed sensor plug is
Tighten the plug; wrap or replace
loose; check whether the speed sensor cable
the cable.
is severely worn.
The function of each component and general fault handling

 Electronic control box
Open the electric locking switch, and the gear shifting handle is in the neutral position, that is, the
electronic control box is in standby state. After the loader started, if you want to shift, turn the gear
shifting handle to select a gear, then the electronic control box can automatically determine whether
can shift to under the condition of the current speed according to the electrical signals from the
4-18
output speed sensors and the gear shifting handle. If the speed difference is too large, the computer
can command the magnetic valve to let the transmission box shift to a workable minimum speed
gear, then shift to the preselected gear by the cycle of 2.5 seconds. For example, when you shift
from gear I to gear III, after the computer receives electrical signals from the gear shifting handle，
then the computer recognizes the speed signals of the speed sensor, judges whether the speed
reaches the preselected gear, if not, automatically passes electrical signals to the magnetic valve
shifting the gear II firstly, when the loader speed reaches 14km/h, then it will shift the gear III
automatically, which can reduce the impact.
 Examples of general faults:
a) When maintaining the loader, after washing the loader with water and find that the loader
cannot shift a gear and couldn’t start. After checking, the circuit connection of electronic
control system is normal, and there is no mechanical failure. Originally when you splash water
to wash the loader, the electronic control box gets damp; after drying, the loader can travel
normally. Therefore, when washing the loader with water, pay attention to waterproof
protection of electronic control box and the handles.
b) The loader was working normally, and after parking to refuel, found that the engine can start,
but the loader couldn’t travel. After checking, the circuit connection of electronic control
system is normal, and gear shifting oil pressure is within the normal range. Later found that the
plug on bottom of electronic control box is not inserted in place. Since on the electronic control
box there is a clamp spring that used to fix the electronic control box’s plug, only when
inserting one end of the wire plug into the pin, there should be a sound of "click" after inserting
the other end, which means the clamp spring has clamped the plug in position. Otherwise when
the loader is running, vibration will cause the plug cannot be inserted tight.
1 2
Fig. 4-35
1 Plug socket 2 Electronic control box
4-19
Electronic control box of 4WG200 transmission box

a) There are faults in the loader structure parts, after welding the loader structure parts, the loader
couldn’t start. After checking, the electronic control box is burnt out.
b) After driving, turn off the electric lock, a few minutes later the timer on the dashboard suddenly
discharges smoke and the loader couldn’t start. After checking, because of violating operating
regulations, turn off the electric lock too early when the engine isn’t flameout, at this time the
generator cannot charge the battery, sometimes the generator produces a very high surge
voltage, instantaneous current may be up to tens of amps, which leads to burn out of the
electronic control box; and if the generator connects battery circuit and can do the charging
work, it can play a role in circuit of voltage stability. Therefore, you should shut electric lock
after the engine totally flameout.
 The output speed sensor
The output speed sensor is used to record the rotation frequency of the output gear; so when shifting
a gear, the computer can compare the preselected speed with the existing speed, and then decides to
shift. Resistance of the output speed sensor is1200±100, if the resistance is 0 or infinitely great, it
indicates the sensor is short circuit or broken circuit and the sensor needs to be replaced.
a) The loader can shift gear I/II, but couldn’t shift gear III/IV. Inspection method: after turn off the
electric lock, unscrew the plug of the output speed sensor, then use a multimeter to check the
output speed sensor. If the resistance is 0, it shows that the speed sensor is damaged.
b) The loader couldn’t shift any gear. After checking, the oil level is normal, later find that the
cable from the electronic control box to speed sensor is worn out by metal. Rewrap the cable,
and then the loader returns to normal.
 The gear shifting handle
There are two main micro switches inside the handle. Select directions and speed by pushing and
pulling the handle forward and backward and turning the handle cover.
A customer complained that gear IV, the loader couldn't speed up to normal range. After checking,
the transmission box oil level is normal, and found that the line 8 of the 12-hole plug, which
connecting the gear shifting handle, was loose. It was line 8 contacted poorly. When he shifted to
fourth gear, the computer could only receive the electrical signals of the gear III. Therefore, there
was no gear IV.
 Other typical faults
4-20
After changing the transmission box oil, the loader starts travelling about 20 meters and then
couldn’t run. Shut down and restart the loader, it only can travel 10~20 meters again. After checking,
the circuit of electronic control system is normal and there is no mechanical failure. Later found out
that after changing oil, the user didn’t check the oil level follow the regulations, which results in a
seriously shortage of transmission box oil. After add oil to normal level, the loader can run
normally.
4-21
42 Transmission Shaft System
421 Overview of Transmission Shaft
1. Structure and function of universal transmission device

Universal transmission device of the loader is installed between the transmission box and the drive
axle. It usually consists of a universal joint assembly and transmission shaft, etc. (Universal
transmission device is customarily called the transmission shaft assembly). Some loaders also
equipped with intermediate support in universal transmission device. Structure of front transmission
shaft is shown in Fig. 4-54.
Fig. 4-36
1 Front transmission shaft 2 Intermediate support 3 Intermediate transmission shaft
Since the axes of the loader transmission box output shaft and drive axle input shaft are difficult to
be aligned in line; moreover, during the loader operation process, due to the unfairness road and
work place, the relative position of the two axes changes frequently. So we can’t apply rigid
connection between the output shaft of the transmission box and the input shaft of the drive axle,
while we must adopt the universal transmission device, which is made of two cross universal joints
and a drive shaft.
The function of the universal transmission device is to solve the uncoaxiality between the
transmission box and the drive axle, to meet the needs of angle changing between the transmission
box and the drive axle, and pass the power of transmission box to the drive axle.
2. Structure and characteristic of transmission shaft
The transmission shaft is an important part of the universal transmission device, usually used for the
connection between the transmission box and drive axle. Generally speaking, the transmission shaft
is composed of pipe sleeve fork assembly, universal joint fork and spline shaft assembly, etc.
During the operation of the loader, the relative position of the transmission box and drive axle
changes constantly, in order to avoid the movement interference, the transmission shaft has sliding
splined connection parts, which consisting of sliding fork and spline shaft, so that, to realize the
4-22
change of the length of the transmission shaft. In order to reduce abrasion, the transmission shaft is
equipped with filling grease oil cup, oil seal and spline sheath, etc. Make sure the lubrication of the
spline shaft in the sleeve fork, and prevent water and dust entering into the sliding spline.
422 Disassembly and assembly of

Transmission Shafts
Replacement of front transmission shaft

assembly
1. Disconnect front transmission shaft assembly
from intermediate support.
ATTENTION
 Put the loader in maintenance position
before the disassembly.
 Press down the parking brake switch.
1 2
Fig. 4-37
1 Intermediate support
2 Front transmission shaft
2. Disconnect front transmission shaft assembly

from front drive axle.
1 2
Fig. 4-38
1 Front drive axle 2 Hexagon bolt
4-23
3. Replace the transmission shaft with a new one.

Connect new transmission shaft assembly to
front drive axle.
90±15Nm
1 2
Fig. 4-39
1 Hexagon bolt
4. Connect front transmission shaft assembly to
intermediate support.
90±15Nm
1 2
Fig. 4-40
Replacement of intermediate transmission shaft
assembly
1. Disconnect the intermediate transmission shaft
assembly from transmission box
1 2
Fig. 4-41
2 Hexagon bolt
4-24
2. Disconnect the intermediate transmission shaft

assembly from intermediate support
1 2 3
Fig. 4-42
2 Hexagon bolt

Connect the new intermediate transmission
shaft assembly to intermediate support
1 2 3
Fig. 4-43
2 Hexagon bolt
4. Connect the intermediate transmission shaft

assembly from transmission box
ATTENTION
Align the orientation arrows on spline shaft
and bushing when assembling.
90±15Nm
1 2
Fig. 4-44
1 Hexagon bolt
4-25
Replacement of rear transmission shaft

assembly
1. Disconnect rear transmission shaft assembly
from transmission box.
1 2
Fig. 4-45
1 Hexagon bolt
2. Disconnect rear transmission shaft assembly
from rear drive axle.
1 2
Fig. 4-46
2 Hexagon bolt
Connect the new rear transmission shaft
assembly to rear drive axle.
ATTENTION
90±15Nm
1 2
Fig. 4-47
2 Hexagon bolt
4-26
4. Connect rear transmission shaft assembly to

transmission box.
90±15Nm
1 2
Fig. 4-48
1 Hexagon bolt
4-27
43 Drive Axle System
431 Overview of Drive Axle
Drive axle locates at the end of wheel loader transmission system and it is a general term that
describes all the transmission mechanisms between transmission shaft and driving wheel. Drive
axle is mainly used to transmit the torque of transmission shaft to driving wheels, make the rotate
speed of transmission output reduce and torque increase, and it also works as a differential to realize
differential speed of left side and right side wheels. Moreover, drive axle shell also plays a role of
load-bearing and stress-passing.
432 Maintenance of Drive Axle
1. Check the oil level

——Place the loader horizontally. Wipe up all oil filling points before checking. Oil draining shall
be carried out after the loader travels for a period of time. When unscrewing the plug to drain or add
oil, be careful of hot oil splashing.
——Types of oil level: When check wheel side oil level, you should rotate wheel hub, until the plug
is in horizontal position. Fill oil until there is overflow.
Fig. 4-49
Oil lever of the drive axle: Oil level is subject to overflow of plug hole or the oil filling port.
——Check: After a few minutes, if the oil level drops, add oil, until the oil level reaches to the
regulation lever and remains unchanged.
Check oil level once a month.
2. Change oil
After the new loader running 500 hours, replace the drive axle oil for the first time, since then
change the oil every 1,000 working hours, and oil should be change at least once a year.
If any of the following case is involved, we recommend you to replace the drive axle oil every 500
hours or at least once every six months.
 Frequent operating brake or poor working conditions.
 Ambient temperature of operating conditions exceeds 40oC.
4-28

Drive Axle
Disassembly of rear drive axle

1. Start the loader and put it in maintenance
position.
2. Remove the two rear tires.
Refer to 7 Frames, Tires & Working Device.
1 2
Fig. 4-50
1 Lifting rope
2 Tire
3. Disconnect the connection between the rear

transmission shaft and the rear drive axle.
1 2
Fig. 4-51
2 Hexagon bolt
4. Remove the brake oil pipe(s) from the
T-junction.
ATTENTION
Put a vessel under the axle to contain the
hydraulic oil. Make good protection of the
joint after disassembling.
1
Fig. 4-52
1 Brake oil pipe
4-29
5. Remove the fixing clamp of the grease pipe,

and take down the pipe.
1
Fig. 4-53
1 Grease pipe
6. Hang the rear drive axle with the lifting

appliance, and the tightness of hoisting rope
should be moderate.
1 2
Fig. 4-54
1 Rear drive axle
2 Lifting rope
7. Remove the connecting bolts of the swing

frame and the rear frame.
1
Fig. 4-55
1 Connecting bolt
4-30
8. Operating the lifting appliance, keep the rear

drive axle level and put it on pre-prepared
trolley.
Fig. 4-56
Assembly rear drive axle

1. Install the swing frame, grease pipe and brake
oil pipe to the rear drive axle.
2. Put the pre-assembled rear drive axle on a
trolley and push the trolley under the frame.
ATTENTION
Since there is no axial poisoning when
1 2 installing the swing frame to rear drive axle,
Fig. 4-57
bind the swing frame and rear drive axle
1 Swing frame 2 Drive axle
with two ropes before lifting to prevent
falling off.
3. Hang the rear drive axle assembly to the

suitable position with the lifting appliance.
1 2
Fig. 4-58
1 Rear drive axle
2 Lifting rope
4-31
4. Connect the swing frame to the rear frame

with bolts.
540~650Nm
1
Fig. 4-59
1 Connecting bolt
5. Fix the grease pipe on rear frame with clamp.
1
Fig. 4-60
1 Grease pipe
6. Connect the brake oil pipe(s) to the T-junction.
1
Fig. 4-61
1 Brake oil pipe
4-32
7. Connect the rear transmission shaft assembly

to rear drive axle.
ATTENTION
90±15Nm
8. Install the rear tires and put down the machine.

1 Refer to 7 Frames, Tires & Working Device.
Fig. 4-62
1 Hexagon bolt
9. Deflate the brake system.

Refer to 5 Brake System for deflating of
brake system.
1
Fig. 4-63
1 Deflating valve
Disassembly of front drive axle

1. Remove the two front tires.
1
Fig. 4-64
1 Front tire
4-33
2. Disconnect the connection between the front

transmission shaft and the front drive axle.
1
Fig. 4-65
1 Hexagon bolt
3. Remove the brake oil pipe(s) from the

T-junction.
ATTENTION
Put a vessel under the axle to contain the
hydraulic oil. Make good protection of the
joint after disassembling.
1
Fig. 4-66
1 Brake oil pipe
4. Hang the front drive axle with the lifting

appliance, and the tightness of hoisting rope
should be moderate.
5. Remove the connecting bolts between the front
frame and the front drive axle.
6. Operating the lifting appliance, keep the front
drive axle level and put it on the pre-prepared
trolley.
1 2
Fig. 4-67
1 Bolt
2 Front drive axle
4-34
Assembly front drive axle

1. Install front axle brake oil pipe(s).
2. Hang and put the pre-assembled axle on a
trolley, and push the trolley under the frame.
1
Fig. 4-68
1 Brake oil pipe
3. Hang the front axle to the suitable position

with the lifting appliance.
1 2
Fig. 4-69
1 Lifting rope 2 Front drive axle
4. Connect front drive axle to front frame with

bolts.
1700~2000Nm
1 2
Fig. 4-70
1 Bolt
2 Front drive axle
4-35
7. Connect the brake oil pipe(s) to the T-junction.
1
Fig. 4-71
1 Brake oil pipe
8. Connect the front transmission shaft assembly

to front drive axle.
ATTENTION
90±15Nm
9. Install the front tires and put down the

1 machine.
Fig. 4-72
1 Hexagon bolt
10. Deflate the brake system.

Refer to 5 Brake System for deflating of
brake system.
1
Fig. 4-73
1 Deflating valve
4-36
44 Pressure Measuring Methods and Standards of Transmission

System
1. 6410006224 transmission 3. 6430000943 pressure gauge

2. 4030000368 Piezometer
system pressure measuring CPG063-00025
tube SMS20/M1/4-3000A
joint -01-S-B04
1. Pressure measuring method
1) Set the loader in maintenance position. Put the bucket flat on ground, pull up the parking
brake handle, and then wedge the tires with wood blocks tightly, shut down the engine.
Operate the gear control handle for 3~5 times to release residual pressure in hydraulic
circuit. ATTENTION: The electric lock should be turned ON during pressure relief.
2) Remove the pressure switch on transmission control valve as shown in the figure above,
and install the pressure measuring joint 1 to the port instead.
3) Connect one end of the piezometer tube 2 to the pressure measuring joint 1, connect the
other end to the pressure gauge.
4) Start the engine and engage the foot brake, and operate the gear control handle to
measure transmission oil pressure of each gear. Observe the pressure gauge and record
the steady pressure value, and that is the current shifting oil pressure for transmission
system.
4-37
5) After the measuring, repeat step 1 and install the pressure switch to the transmission
control valve, and wipe off the spilled transmission oil.
2. Reference pressure
Gear shifting
Items Gear I/II Gear III/IV
pressure
Pressure (MPa) 1.6~1.8 1.6~1.8 1.6~1.8
4-38
45 Diagnosis and Solutions for Common Faults of Transmission

System
451 Fault Diagnosis and Solutions for Transmission box
1. Causes of gear shifting clutch faults

In the transmission box, the clutch is a vulnerable part. Operate to engage the clutch, the hydraulic
pressure overcomes the spring force to force the piston to move and pull-in friction plate and steel
disc. And with the increase of the hydraulic pressure, the pressing force increases.
Each time you shift a gear, friction phenomenon will happen between friction plate and steel disc,
although in the design process we have considered using cooling fluid to discharge friction heat, the
cooling effect is limited. As the discs thinning, the clutch requires more hydraulic oil to generate
enough pressing force, at this time we must further accelerate the diesel engine.
When speed up the engine to high idle speed, sliding engagement time between the friction plate
and steel disc will be lengthened, and the generated friction heat will be more. If hydraulic oil is
heated to high temperature enough to change the sealing performance of the transmission box, the
transmission box will produce internal leakage. And the internal leakage results in heat increase in
two ways:
a. When high pressure oil flows through the sealing leakage area there will be friction, which
makes the oil temperature rise continuously;
b. Oil leakage will reduce the oil flow in the system, in order to fully engage the clutch, hydraulic
pump have to supply more oil to generate enough pressing force. That is, the engine needs to be
re-accelerated to make the pump output more oil. This is a vicious circle, eventually leads to
the clutch overheating or burnt, till completely ineffective.
2. Common fault diagnosis and solutions for transmission box and its oil system.
a) Couldn’t shift a gear
Fault causes: Inaccurate shifting position; leakage of clutch piston; low shifting oil pressure;
blockage of oil gallery in transmission box.
Solutions: Re-engage the gear or check the transmission control valve; overhaul and replace the
seal ring; Refer to Fault b for troubleshooting of low shifting oil pressure fault.
b) The shifting oil pressure is low
Fault analysis: Improper adjustment of the main pressure regulating valve or the spring is broken
to lose efficacy; the oil level of the transmission box is too low; the filter screen and the oil passage
is blocked; the clutch leaks; gear shifting pump loses efficacy.
4-39
Solutions: Re-adjust or change the spring; fill oil to specified level; clean or dredge; repair or
replace the seal ring.
c) Oil temperature is too high
Fault analysis: Operating time is too long; the oil is insufficient or overmuch; the clutch discs
sliding; the clutch couldn’t be disengaged.
Solutions: Stop the loader or idle running for a period of time; fill oil to overflow; check the oil
pressure and seal ring; check the clutch control oil passage or the position of operating handle.
d) Shifting oil pressure of a certain gear is low
Fault analysis: Damaged piston or seal ring of this gear; blockage or leakage of oil passage.
Solutions: Replace the seal ring; Check, clean and eliminate the problem.
e) Disordered gears
Fault analysis: Leakage of the shaft end seal ring
Solutions: Replace the seal ring.
f) System leakage
Fault analysis: Loose pipe joints; damaged seal ring.
Solutions: Tighten the joints; replace the seal ring.
g) The oil level of transmission box oil sump automatically rises
The reason for this phenomenon is that steering pump or working pump input shaft seal is damaged,
the oil of the hydraulic system flows through the torque converter gearbox to the transmission box
sump, leading to oil level rise. Replace the oil seal if necessary.
452 Fault Diagnosis and Solutions for Drive Axle
1. Drive axle produces abnormal sound

a) The phenomenon and its harm
The abnormal sound manifest in various forms: some sound continuously, some sound
intermittently; some sound when the speed changes, some sound when normal driving; some sound
when uphill, some sound when downhill; some sound dreary, some sound crisp.
The drive axle’s abnormal sound is an abnormal reflection of technical state between the drive axle
parts. If there is abnormal sound problem, the user should promptly identify the causes and
eliminate them, or it may cause bigger troubles even accidents.
b) The causes for drive axle abnormal sound and solutions
The cause of the drive axle sound is almost due to the collision or interference generated by some
parts in the rear axle (including the wheel reducer).
4-40
Since different parts in different states produce the sound with different intensity and characteristic,
you can base on the abnormal sound producing conditions and parts to estimate the sound source
and find out the sound reason.
 One reason is that the noise is produced by the loose connections and damaged parts, and this
kind of sound is much belong to the abnormal friction and collision between the parts, so the
sound is clear; The other is that the noise is produced by the abnormality of the bearing fit and
gear engagement.
 The abnormality of the gear engagement is that meshing clearance is too small or too large,
meshing position is not correct, meshing area is insufficient. At this time the gear can produce
continuous and clear sound, which increasing with the increase of rotational speed. The
abnormality of the bearing fit is that bearing clearance is too large or too small. When the
clearance is too large, the bearings can produce continuous sound, which increasing with the
increase of the speed.
 When the rear axle housing produces sound, in addition to checking whether the parts loose or
not, you should first check whether the meshing area of the main transmission bevel gear is
correct or not.
2. Drive axle is overheating
a) The phenomena and its harm
The drive axle overheating is that after the drive axle mechanically works a period of time, its
temperature exceeds the permissible normal temperature range. Generally speaking, when checking
by hand touch, you will have a hot feeling. The overheating mainly produces in the place of drive
axle housing (except the main drive and differential) and wheel reducer. The drive axle overheating
is the same as the abnormal reflection of technical state of the drive axle parts, or cooperative
relationship, or lubrication. You should promptly identify the reasons and eliminate them, in order
to avoid damaging the relevant parts.
b) The causes for drive axle overheating fault and solutions
 Causes: produce more heat; the heat can’t be dissipated in time.
 The heat source of the wheel drive axle mainly is friction heat, and that the friction heat can
only be caused by the too small fit clearance of the relative motion parts. The matching parts of
the drive axle have two categories: one is the bearing, the other is the gear. So the fundamental
cause of the overheating drive axle is too small clearance of bearing fit or of gear engagement.
 The main reason for heat dissipation problem of the drive axle is that the drive axle (and the
wheel reducer) is lack of lubricating oil or the oil is inferior oil. Lack of lubricating oil or
inferior oil not only makes the friction heat generated by the drive axle cannot be dissipated in
4-41
time, but also can make the relative movement parts are in a dry friction state, which makes the
friction heat increase greatly.
 When the drive axle is overheating, we can base on the overheating position to determine the
causes of overheating. If the bearing is overheating, we can ascertain that the fault is caused by
the bearing; when the whole drive axle housing is overheating, the reason may be caused by the
abnormal gear engagement or lubricating oil shortage; you should fill the specific lubricants
timely.
3. Oil leakage of drive axle
a) The phenomena and its harm
The oil leakage of the drive axle occurs mostly in the axle housing and wheel reducer, and mostly
leaking through the seal and the fitting surface.
b) The causes for oil leakage of drive axle and solutions
 The oil leakage of the drive axle mainly is caused by the damaged sealing elements and sealing
gaskets, for the former: such as the oil leakage caused by damaged final drive’s oil sealing; for
the latter: such as the oil leakage of the rear axle housing and wheel reducer fitting surface.
 Check the whether oil sealing is aged, cracked or damaged or not; don't widen the oil seal too
fiercely, to avoid the plastic deformation; try to warm the oil sealing with liquid that has the
same temperature as operating temperature, and then install it with special tools.
4-42
SERVICE MANUAL
Version:0520
5 Brakes
CONTENTS
5 Brakes ..................................................................................................................................................... 5-1
51 Travel Brake ............................................................................................................................................ 5-2
511 Composition of Travel Brake System and Working Principle ...................................................... 5-2
512 Power Cut off Function ................................................................................................................ 5-3
513 Component Specifications and Technical Descriptions.............................................................. 5-4
514 Disassembly and Assembly of Main Components ..................................................................... 5-8
52 Emergency and Parking Brake System ............................................................................................ 5-15
521 System Composition and Working Principle ............................................................................ 5-15
522 Component Specifications and Technical Descriptions............................................................ 5-16
53 Brakes troubleshooting guide ............................................................................................................ 5-20

5 Brakes
5-1
Pilot system
Figure 5-1 Hydraulic principle diagram

51 Travel Brake
Rear axle brake caliper
Foot brake valve Brake tail lamp switch
Oil filling
Oil tank Front axle brake cliper
valve
Accumulator
Filter Gear pump
Figure 5-2 Composition of travel brake system
511 Composition of Travel Brake
System and Working Principle
This machine adopts full hydraulic wet brake

system. During driving, the oil from pilot pump
reaches the accumulator through oil prefill
valve. When the brake pedal is depressed, high
pressure oil stored in accumulator flows
through the foot brake pedal series valve of
front and rear axles of wheel disc brake to drive
the disc brake caliper pistons, and push the
friction piece on the brake disc to slow down or
stop the machine. Loosen the brake pedal so
that the series pedal valve returns to neutral
5-2
position, hydraulic oil in the wheel side brake of

front and rear axle returns to oil tank through
series pedal valve, and the brake will be
released.
The front axle circuit is relatively independent
to the rear one, when a circuit fails, the other
brake circuit can still carry out brake, which
improves the vehicle's safety.
512 Power Cut off Function
When the shift operation lever is in forward or

backwards Ⅰ, Ⅱand power cut-off selection
switch is on (the button light id on), electronic
control box sends the signals to shifting
operation valve when carrying out travelling
brake, to set the gearbox to neutral gear and cut
1 off the power output. When the shift operation

Figure 5-3
lever is in forward or backwards Ⅰ, Ⅱand
1 power cut off switch
power cut-off selection switch is off (the button
light is off), the power will not be cut off when
carrying out travelling brake. Power cut off has
built-in lock buckle, which can avoid wrong
operation.
Power cut-off function works only the gear is in
the forward or backward Ⅰ, Ⅱ. When the
loader is in high gear, electronic control box
will not cut off the power in order to ensure
drive safely, no matter the power select switch
is on or off, this is decided by the driving
characteristics of the loader.
5-3
WARNING
When operating or driving in flat
terrain, power off function can be used
to reduce the load on the brake and
transmission. However, you can not use
power off function when operating on
slope to avoid slip, in order to ensure
traffic safety.
513 Component Specifications and
Technical Descriptions
Dual prefill valve
When the oil pressure of accumulator in brake

system reaches 179Bar, the prefill valve stops
oil supply to the brake system, and supplies oil
to the hydraulic pilot pipeline through O port.
When the oil pressure is lower than 148Bar, the
prefill valve is turned to supply oil to the brake
Fig. 5-4 Dual liquid prefill valve

system.
Figure 5-5 Connection of liquid filling valve
5-4
Filter
Nominal flow 110L/MIN

Nominal pressure 32MPa
Filtration accuracy 10um
Capsule accumulator
Capsule brake is used to store pressure oil for
Fig. 5-6 Filter
braking. Its principle is to store the pressure
liquid and capsule with pressure in a sealed
housing and it is used to brake by absorbing and
releasing the liquid due to the changing
pressure. Brake pump is working, and inject the
pressure fluid into accumulator through prefill
valve to store energy. Then, the gas is
compressed in the capsule, so that the pressure
1 2 3 of liquid is the same with that of capsule, to

Fig. 5-7
obtain energy reserves. The air in capsules is
1 rear axle travelling brake accumulator
2 parking brake accumulator nitrogen.
3 front axle travelling brake accumulator
Inflation method for accumulator
1 Firstly stop the machine, continuously
operate the travelling brake and parking
brake several times, and drain the high
pressure oil in accumulators as far as
possible. Then slowly release the exhaust
plug under accumulator and drain the
residual pressure in the accumulator.
2 Remove the protective cap of inflation
valve from top of the accumulator.
5-5
3 Connect the end with pressure gauge of

inflation tool to the inflation valve on top of
accumulator, and the other end should be
Nitrogen
connected with nitrogen cylinder.
4 Open switch of nitrogen cylinder. After the
inflation pressure of inflation tools is
stable, slowly open the switch on the
inflation tools, i.e., and fill air into the
accumulator charging.
5 Pressure may be instantly achieved, then
switch off the nitrogen cylinders, and see
whether the pressure value still reached
after the gauge of inflation tools come to
stable. If not, then refill it. If the pressure is
high, drain the air through the inflation plug
Accumulator Release through inflation tools, and reduce the

pressure to the appropriate value.
6 After air is filled to required pressure,
Fig. 5-8 working principle of accumulator
firstly switch off nitrogen cylinders, and
then close the switch on pneumatic tools.
7 Remove the air inflation tool.
8 If accumulator leaks (Wipe accumulator
head with oil, and if there is leakage,
bubbles will come out. Hit the inflation
valve inside the accumulator with a
hammer and a screwdriver. Pull it down,
and then quickly reset it until the sealing
surface can be connected.
9 Install protection caps of accumulator
inflation valve.
5-6
Wheel side brake

Since the machine applies wet axle, wheel
brake carried out braking for hydraulic clutch,
and it is closed in the bridge shell, immersed in
gear oil, and cooled by oil circulation.
Wheel side brakes do not need maintenance in
1
normal use.
Fig. 5-9
1 wheel side brake
Exhaust of brake system

After brake system is overhauled, there is still
gas remained in pipeline, which will affect
braking performance. Therefore, drain the air
after removing and replacing. There is an
exhaust nozzle on drive axle left and right
wheel brake, and drain the gas according to the
following procedures:
1
Fig. 5-10 1 Park the loader on flat road.
1 exhaust mouth 2 Place the operation lever in neutral
position, start the engine at idle status, and
pull the magnetic valve switch of parking
brake.
3 The transparent hose is covered on exhaust
mouth of left and right wheel front drive
axle, and divert the other end into oil
container pan.
4 Two people work together, one person
takes responsible for loosing and tightening
of exhaust nozzle, and observes the exhaust
situation; the other person in charge of
5-7
pressing the brake pedal. Loosen the

exhaust nozzle, and then depress the brake
pedal to the maximum stroke. Drain some
oil and then release the brake pedal, and at
the same time, tighten the exhaust nozzle.
So do this repeatedly, until no bubbles are
discharged from liquid column.
5 Drain the air in the rear axle in the same
way.
6 After the air of front and rear axles are
drained, continuously pull or press the
parking brake magnetic valve switches
about 3 to 4 times, and drain the air in the
parking brake exhaust pipe.
7 Stop the engine, pull up the parking brake
magnetic switch. Carefully and slowly
release the lower exhaust plug on the
accumulator, and then the fluid containing
bubbles will emerge. Tighten the plug after
there is no bubble comes out.
Main Components
Disassembly of series pedal valve

1 Press the brake pedal repeatedly to unload
the brake system.
2 Remove two oil pipes in front of series
1 2
pedal valve.
Fig. 5-11
★ Notice
1 P2 port connection pipe
2 P1 port connection pipe When disassemble the hydraulic connections,
5-8

them off slightly until there is oil spills out,
and then disconnect them completely.
During the processes of hydraulic pipes
disassembly, all the pipelines and ports
should be protected to avoid the debris
entering into the pipelines.
3 Remove two pipes inside the series pedal

valves connected with the front and rear
axle brake caliper.
1 2
Fig. 5-12
1 A1 port connection pipe
4 Remove two pipes connected with oil

return tank behind the series pedal valves.
1 2
Fig. 5-13
1 T1 port connection pipe
2 T2 port connection pipe
5-9
5 Remove three bolts connecting transition

plate in the cab with cab bottom plate.
6 Remove three bolts connecting foot brake
valve in the cab with transition plate.
Figure 5-14
１transition plate
7 Remove the series pedal valve in the cab.
Fig. 5-15
8 Remove straight joints of six oil ports and

take down the transition plate.
1 2
Fig. 5-16
1 transition plate
2 straight joint
5-10
Assembly of series pedal valve

1 Put the transition plate into cab from the
bottom of the foot brake, and install the
straight joints with O-ring on all oil ports.
Tightening torque: 58 ± 3 Nm
1 2
Fig. 5-17
1 transition plate
2 straight joint
2 Insert three M8×35 bolts through the series

pedal valve, and transition plate. Fix the
series pedal valve on the corresponding
positions of the cab bottom plate, and then
fix it on the bottom of the cab with washers
and nuts.
1
Figure 5-18
1 transition plate
3 Remove two pipes connected with oil

return tank behind the series pedal valves.
Tightening torque: 45 ± 5
1 2
Fig. 5-19
1 T1port connection pipe
2 T2port connection pipe
5-11
4 Remove two pipes connected with front

and rear brake system inside the series
pedal valves.
Tightening torque: 45 ± 5
1 2
Fig. 5-20
5 Remove two pipes in front of the series

pedal valves.
Tightening torque: 45 ± 5Nm
1 2
Fig. 5-21
1 P1port connection pipe
2 P2port connection pipe
Disassembly of accumulator
1 Remove the guard plate of accumulator.
2 Remove the bent plate assembly of
accumulator guard hood.
1 2
Figure 5-22
1 guard bent plate assembly
2 guard direct plate
5-12
3 Remove the pipes on the bottom of

accumulator.
★ Notice
When disassemble the hydraulic
connections, do not loosen the connection
bolts rashly and completely to avoid oil
1
bursting out. Loosen them off slightly
Fig. 5-23
1 Pipe until there is oil spills out, and then
disconnect them completely.
disassembly, all the pipelines and ports
should be protected to avoid the debris
entering into the pipelines.
4 Disassemble the fixed U-shape bolts of
accumulator, and then remove the U-shape
bolts, nuts and washers, and take the
accumulator.
5 Remove the buffer sleeve on the
accumulator, and remove straight joint head
1 2
Fig. 5-24 connecting with the bottom oil port of
1 Cushioning sleeve
accumulator.
2 U-shape bolt
5-13
Assembly of accumulator
1 Install straight joint on bottom port of

accumulator.
Travel brake accumulator straight joint
Tightening torque: 310±31Nm
Parking brake accumulator straight joint
1 2 Tightening torque: 170±17Nm

Fig. 5-25 2 Install the cushioning sleeve on the bottom
1 cushioning sleeve
2 U-shape bolt of accumulator and then put the
accumulator on the frame. Fix the
accumulator on the support frame with
U-shape bolts, nuts and washers.
3 Install the accumulator bent plate assembly

on accumulator frame.
4 Install the guard direct plate on guard plate

bent plate assembly.
1 2
Fig. 5-26
1 guard bent plate assembly
2 guard direct plate
5-14
5.1 Emergency and Parking

Brake System
Brake valve block
Brake valve cylinder
Oil tank
Oil filling valve
Accumulator
Fig. 5-27 Emergency and parking brake system
5.2.1 System Composition and
Working Principle
The system applies power-driven

hydraulic-control inner-expansion foot brake
system.
Press the parking brake switch, turn on the
power of electromagnet and open the valve
port. The high pressure oil stored in
1 2 accumulator in the parking brake circuit goes

Fig. 5-28
into brake cylinder from port A port B via the
1 Parking brake switch
2 Brake release switch magnetic valve for the brake of the loader.
5-15
Conversely, press the parking brake release

switch to release the brake, cut off the power of
magnetic valve, and hydraulic oil within the
brake cylinder returns to oil tank through the
magnetic valve port T, and the brake will be
removed.
5.2.2 Component Specifications
and Technical Descriptions

1 2 3 Brake valve blocks
There is a check valve between P and A port
used to prevent hydraulic oil in the accumulator
returns into the dual prefill valve. The
integrated magnetic valve has slide valve
structure.
Travel brake pressure alarm switch
In the operation processes, if the system fails,

which will lead to oil pressure in the
B T A P
accumulator of travel brake circuit lower than
Fig. 5-29 Brake valve block
115Bar, the travel brake low pressure alarm
1 parking brake indicator lamp switch
2 travel brake low pressure alarm switch lamp flashes and the alarm buzzer will sound.
3 emergency brake switch
At this point, you should stop the operation, and
carry out the examination for loader. To check
the loader, the loader should be parked on flat
ground, and lower the work equipment to the
ground, and pull up the parking brake magnetic
switch.
Notice
In a short time just after the loader is
5-16
started, brake pressure alarm lamp

blinks, the alarm buzzer will sound. This
is because at this time the oil pressure in
accumulator of brake circuit also below
the alarm pressure. After the pressure
rises and exceeds alarm pressure, the
warning will stop automatically. The
parking brake magnetic switch can be
pressured only after the warning is
stopped.
Parking brake indicator light switch

It is used to detect the hydraulic pressure in the
parking brake circuit.
When the brake oil pressure is normal, pull the
parking brake switch to carry out brake, and
parking brake indicator light will be on; Press
the parking brake switch to remove the brake,
and parking brake indicator light goes off.
When the air pressure of parking brake circuit is
low, the parking brake indicator light will be on
that’s may because parking brake circuit
malfunctioned, you should park the loader and
check it.
If the oil pressure in the accumulator of travel
brake circuit is less than 60Bar, this switch will
automatically cut off the power output, and set
the gearbox in neutral. Meanwhile, the power of
parking brake magnetic valve is cut off, the
hydraulic oil in the parking brake cylinder
5-17
returns to oil tank through the parking brake

magnetic valve, and the parking brake device is
used to brake the loader for emergency.
Hydraulic parking brake cylinder
Hydraulic parking brake cylinder is mounted on
the front left side of the gearbox, and its rod end
is connected with the cam of brake lever.
When the system pressure is less than that
released by the brake cylinder spring, or
parking brake magnetic switch is pulled, the
1 2 3
Fig. 5-30 spring seat and the piston are pushed upward
1 parking brake device
due to action of the spring, to pull the rod of the
2 hydraulic parking brake cylinder
3 pin shaft parking brake device, so that the parking brake
device is engaged to realize the brake of the
loader.
When the oil pressure system reaches the
working pressure and the parking brake
magnetic valve switch is pressed, the pressure
oil will enter the left chamber of brake cylinder
1 through the parking brake magnetic valve, and

Fig. 5-31 compress the spring to push the spring seat and
1 parking brake cylinder frame
piston toward right end, and push the brake
1 2 3
lever to release the brake.
WARNING
If the loader can not be operated due to
malfunctions, and it has to be towed, the
pin shaft of brake cylinder should be
removed, so that the parking brake
Fig. 5-32 Parking brake cylinder principle
diagram
device is loose before proceeding the
1 piston 2 spring seat 3 spring towing of the loader.
5-18
5-19
5.2 Brakes troubleshooting guide
Table 5-1
No. Problems Diagnosis Solutions
1 Drain the air. There are

exhaust mouths on left and
right wheel brakes of the
drive axle and outlet port
on the accumulator, and
drain the air in these areas.
2 Check brake valve, detect
1 There is air in brake
whether the maximum
pipelines
braking pressure of brake
2 Brake valve fails
device outlet is the brake
3 The pilot pump is too old to
pressure required by the
work
system. If the pressure is
Insufficient 4 There is leakage in the
not normal, adjust the
1 foot brake brake lines
brake pressure or replace
force 5 Prefill valve does not work
the brake valve.
6 Accumulator is damaged
3 Check the pressure or flow
7 Friction plates of wheel
of pump .
side brake are worn to the
4 Check whether the brake
limit.
pipelines and connectors
leak. If the connector is
loose, retighten it; If the
seal is damaged, replace it.
5 Replace prefill valve.
6 Check the accumulator.
7 Replace friction plate of
wheel side brake device.
5-20

loose, retighten it; If the
seal is damaged, replace
1 Some parts of brake pipe
the seal.
maybe leak.
2 Release the foot brake
2 Brake valve fails pedal, and detect whether
3 Pilot pump is too old to there is still pressure near
Fail to engage
2 work the brake valve outlet. If
a gear
4 Prefill valve does not work so, the brake fails, and then
5 Accumulator is damaged repair or replace brake
6 Magnetic valves or pressure valve.
switch fails. 3 Check the pressure or flow

of pump
4 4 Replace the fill valve
5 Check the accumulator
6 Check the magnetic valve
and power cut-off switch
1 Parking brake circuit leaks.
2 Parking brake cylinder
loose, retighten it; if the
leaks. seal is damaged, replace
Brake can’t be 3 Pilot pump is too old to the seal.
3 released work 2 Replace the cylinder seals
normally. 4 Prefill valve does not work 3 Check the pressure or flow
5 Accumulator is damaged of pump.
6 Magnetic valves or pressure 4 Replace the fill valve.
switch fails. 5 Check the accumulator.

6 Check the magnetic valve
and power cut-off switch.
5-21
Cycle filling
1 Pressure of accumulator 1 Check the air pressure in
rate is too fast
4 capsules is too low. the accumulator capsules.
for prefill
2 Prefill valve does not work. 2 Replace prefill valve.
valve
1 The clearance between
brake drum and brake shoe
Power of is too large. 1 Readjust it as required.
5 parking brake 2 There is oil on the brake 2 Clean brake shoe.
is not enough. shoe 3 Check the brake cylinder.
3 The spring force of the
brake cylinder is not enough
1 Check the oil level in the
1 There is no oil or oil level is
tank.
too low
Accumulator 2 Check the pump pressure or
6 2 Pump is too old to work
charging fails flow.
3 There is air in accumulator.
3 Drain the air.
4 Prefill valve does not work
4 Replace the prefill valve.
1 Pump is too old to work and
1 Check the pressure or flow
can not convey all flow or
Accumulator of pump.
pressure
7 charging time 2 Replace the prefill valve.
2 Prefill valve does not work
is too long 3 Remove, check or replace
3 Capsules are damaged and
capsules.
nitrogen leaks
Detect whether the maximum
pressure of brake valve outlet is
normal. If the maximum
No inching
8 Brake valve fails pressure of export is much
braking
greater than required system
pressure, replace the brake
valve.
5-22
Travel brake
1 System pressure is
low pressure 1 Please wait that the alarm
inadequate, in the short time
alarm lamp or will stop automatically if
of starting loader.
emergency system oil pressure is
9 2 There are system faults in
brake low sufficient.
the working process of
pressure 2 Stop the machine to check
loader and oil pressure
warning lamp it.
decreased.
are on.
1 The brake light is damaged.
2 There are system faults in 1 Check the brake lights.
The brake
10 the working process of 2 Stop the machine to check
lamp is off.
loader and oil pressure is it.
decreasing.
5-23
SERVICE MANUAL
Version:0620
6 Steering System
CONTENTS
6 STEERING SYSTEM ..................................................................................................................... 1

6.1 Overview ........................................................................................................................... 1
6.1.1 Principle Diagram of Steering System, Description ................................................... 1
6.1.2 Priority Valve, Description ......................................................................................... 5
6.1.3 Steering Gear, Description ......................................................................................... 6
6.2 Disassembly and Assembly of Main Components ............................................................ 7
6.2.1 Disassembly of Steering Gear .................................................................................... 7
6.2.2 Assembly of Steering Gear ....................................................................................... 11
6.2.3 Disassembly of Steering Cylinder ............................................................................ 13
6.2.4 Assembly of Steering Cylinder................................................................................. 16
6.2.5 Disassembly of Priority Valve .................................................................................. 18
6.2.6 Assembly of Priority Valve ...................................................................................... 21
6.3 Diagnosis and Solutions for Frequently Asked Questions of Steering System ............... 25
6 STEERING SYSTEM
6.1 Overview
The loader is equipped with flow amplifying load

sensing steering system actuated by one constant
displacement pump. This system is composed of
steering gear oil pump, priority valve, load sensing
hydraulic steering gear, steering cylinder and pipelines.
6.1.1 Principle Diagram of Steering

System, Description
1 2 3 4
Working oil line
Figure 6-1 Principle diagram of hydraulic system

1 steering pump 2 priority valve
3 steering gear 4 steering cylinder
6-1
When the steering gear is in neutral position

If the engine flameout, the pump will stop supplying;
the controlling spring of priority valve forces the spool
right to connect CF port. After the engine is started,
hydraulic oil in the tank flows into priority valve
through steering pump, the priority valve allocate oil to
steering gear through CF port, then it will result in
pressure loss when the oil flows through steering gear
neutral position throttling orifice. The two ends
pressure of steering gear neutral position throttling
orifice pass to two ends of priority valve spool, then the
resulting pressure can balance spring force and
hydrodynamic force to enable the spool stay in an
equilibrium position. Due to steering gear neutral
position throttling orifice can generate great fluid
Steering
Priority
valve
Main safety
valve
Filter
Steering pimp
Oil tank
Figure 6-2
6-2
resistance, very small flow is needed to generate

enough differential pressure to force the spool left.
When the spool is forced left further, opening degree of
EF port increases, while CF port decreases, at this point,
oil flow in CF oil line is very small and most oil flows
through EF port to working system. When the working
system is not working, hydraulic oil flows through
multi-way valve neutral position and discharges.
When steering
When relative angular displacement is produced
between the valve spool and valve bush of steering gear
and the displacement increases to a suitable quantity,
neutral position throttling orifice will be closed
completely. Hydraulic oil flows through the variable
orifice of steering gear and result in pressure loss
(smaller than neutral position throttling orifice). The
two ends pressure of steering variable orifice pass to
two ends of priority valve spool, force the spool to find
a new equilibrium position. If increase the rotating
speed of steering wheel, at the moment of change, the
flow valve in the steering gear is less than the product
of steering wheel rotating speed times steering gear
displacement; rotating speed of valve bush droved by
metering mechanism is lower than rotating speed of
spool droved by steering wheel, so angular
displacement of spool to valve bush increases and
opening degree of variable orifice increases. At this
point, larger flow is needed to produce the same
differential pressure as the one before the change
between two ends of the variable orifice to force the
priority valve spool left. So CF port opening degree of
priority valve increases with the increase the increase
6-3
of steering wheel rotating speed. Finally, the flow valve

in the steering gear will equal to the product of steering
wheel rotating speed times steering gear displacement
Steering gear
Priority
valve
Steering
Filter pimp
Oil tank
Figure 6-3
When steering load exceeds rating or the

steering cylinder rod reaches its stroke end
When steering cylinder rod reaches its stroke end and
you keep turning the steering wheel, the oil cannot flow
in to the cylinder. At this point, loading pressure
skyrockets, while differential pressure between two
ends of variable orifice C1 reduces sharply. When
steering oil line pressure exceeds the setting valve of
steering safety valve, this valve opens to work. Pressure
loss produced when pressure oil flows through variable
orifice C1, and this differential pressure pass to two
ends of priority valve spool to force the spool left,
which result in opening degree of CF valve port
6-4
decreases while EF port increases, in this way, the

pressure of steering oil line drops.
Steering when the engine flameout

Metering mechanism works as oil pump and output
pressure oil to push the piston of steering cylinder.
Discharged oil from the oil returning chamber flows
back to upper port of variable orifice C1 through the
check valve in steering gear.
6.1.2 Priority Valve, Description

The priority valve is a constant differential reducing
component. Regardless of the change in loading
pressure and oil supply, the priority valve can maintain
almost the same pressure differential between two ends
of variable orifice C1, which can ensure the flow valve
in the steering gear always equal to the product of
steering wheel rotating speed times steering gear
displacement.
Pressure oil of priority valve EF port merges into
working system to obtain a dual-pump,
flow-converging system, which can save energy.
Main technical parameters

 Nominal flow rate240L/min
 Internal control static pressure, control signal 6.9Bar
 P port and EF port are assembled with M10 bolts and
fission flange
 Thread specification of CF port M33
 Thread specification of LS port and T port M12
 Settling value of safety valve 16MPa
Figure 6-4
6-5
6.1.3 Steering Gear, Description

The load sensing hydraulic steering gear and steering
cylinder make up a position control system, and the
displacement of steering cylinder piston rod is
proportional to angular displacement of steering gear
valve element. Gerotor motor in steering gear is
metering mechanism (work as a pump when engine
flames out), it translates the assigned oil volume in
cylinder into angular displacement of steering gear
valve bush, and the angular displacement determines
Figure 6-5
opening area of oil distribution unit. The faster you turn
the steering wheel, the bigger relative angular
displacement it produces; when the wheel stops, the
relative angular displacement should be zero and the oil
distribution unit will be closed automatically, feedback
control can be realized. The return spring forces valve
bush to cross dead area and centralizes the spool.
Figure 6-6
Main technical parameters

 Static signal load sensing Nonreactive type
 Max. inlet pressure 17.2MPa
 Max. continuous backpressure 1.0MPa
 Thread specification of CF port M33
 Settling pressure of overload valve 21MPa
1 inlet check valve 2 bi-directional overload valve 3 bi-directional oil compensation valve
Figure 6-7oil lines in steering gear
6-6
Functions of combination valve in steering

gear
Inlet check valve: The check valve will be open when
oil flows into steering gear. It is used to prevent
external impact at low steering speed; it can also
prevent high pressure oil from flowing back, which will
lead to shake of steering wheel. If the oil flows
inversely, check valve closes.
Bi-directional overload valve: When the steering
cylinder is influenced by external shock, pressure of oil
in the cylinder will rise and if it gets to setting valve of
overload valve, the valve will open to load off to
protect the cylinder.
Bi-directional oil compensation valve: When
overload valve is open and in order to avoid cavitation
phenomenon, the compensation valve will open and
absorb oil from returning port of combination valve,
supplement pressure oil to cylinder left chamber or
right chamber timely.
6.2 Disassembly and Assembly of

Main Components
6.2.1 Disassembly of Steering Gear

1. Start the machine and drive it to level, spacious
and solid ground; turn the steering wheel to run
straightly, and then stop it after placing properly.
Put the bucket on the ground horizontally and shut
down the engine. Turn the steering wheel
clockwise and anticlockwise for 5~6 times. Wedge
the tires with blocks well.
Figure 6-9
6-7
2. Put clean vessel under the steering gear to contain

oil.
Figure 6-10
3. Disconnect the connection between LS port

connecting pipe and steering gear.
★ Notice
When disassemble the hydraulic connections, do not
loosen the connection bolts rashly and completely to
avoid oil bursting out. Loosen them off slightly until
there is oil spills out, and then disconnect them
completely.
1 During the processes of hydraulic pipes disassembly,
1LS port connecting pipe
Figure 6-11 all the pipe lines and ports should be protected to
avoid the debris entering into the pipeline.
4. Disconnect the connections between R port

connecting pipe, L port connecting pipe and the
steering gear.
1 2
1L port connecting pipe
2R port connecting pipe
Figure 6-12
6-8
5. Disconnect the connections between P port

connecting pipe, T port connecting pipe and the
steering gear.
1 2
1T port connecting pipe
2P port connecting pipe
Figure 6-13
6. Loosen the screws and bolts of cover plate on the

bottom of instrument platform assembly
1 2 3
1screw 2bolt 3 cover plate
Figure 6-14
7. Loosen the connecting bolts between steering gear

and steering column, and then remove the bolts and
steering gear.
★Notice:
In the processes of disassembling, someone is needed
to hold the steering gear to prevent it from falling
when all bolts are removed.
1
1connecting bolt between steering gear
and steering column
Figure 6-15
6-9
8. Loosen the straight joint in the feedback port on

the right of steering gear, remove the joint and
O-ring and keep the oil port well protected timely.
1
1straight joint
Figure 6-16
9. Loosen the straight joints of the four oil ports on

the top of steering gear, remove the joint and
O-ring and keep the oil port well protected timely.
1 2
1protective element
2straight joint
Figure 6-17
10. Pour the contained oil into dedicated hydraulic oil

recycling bin.
Figure 6-18
6-10
6.2.2 Assembly of Steering Gear
1. Remove the protective element in LS port,

assemble straight joint (with O-ring) in the port.
Tightening torque: 35±3.5 Nm
1
1straight joint
Figure 6-19
2. Remove the protective elements in P, T, R, L ports,

and then assemble straight joints (with O-ring) in
the ports.
1 2
1protective element
2straight joint
Figure 6-20
3. Assemble the steering gear to the fixed mount of

instrument platform with four bolts.
1
1connecting bolt between steering gear
and steering column
Figure 6-21
6-11
4. Assemble the screws and bolts of cover plate on

the bottom of instrument platform assembly
1 2 3
1screw 2bolt 3 cover plate
Figure 6-14
5. Remove the protective elements in oil ports,

connect T port connecting pipe and P port
connecting pipe to corresponding ports of straight
joints in steering gear separately and tighten them
★ Notice
1 2 Be sure not to distort the pipes.
1T port connecting pipe
2P port connecting pipe
Figure 6-23
6. Remove the protective elements in oil ports,

connect R port connecting pipe and L port
connecting pipe to corresponding ports of straight
joints in steering gear separately and tighten them
★ Notice
Be sure not to distort the pipes.
1 2
1L port connecting pipe
2R port connecting pipe
Figure 6-24
6-12
7. Remove the protective elements in LS oil port,

connect LS port connecting pipe (with built-up
joint) to the corresponding port of straight joint and
tighten them
Tightening torque: 65～85Nm
★ Notice
1
1LS port connecting pipe
Figure 6-25
6.2.3 Disassembly of Steering

Cylinder
and solid ground; turn the steering wheel toward
the opposite direction of to be replaced cylinder for
a certain angle, which will make the disassembling
work easier. Wedge the tires with blocks well. Put
the bucket on the ground horizontally and shut
clockwise and anticlockwise for 5~6 times to
Figure 6-26 release pressure in steering system.
2. Put clean vessel under the steering gear to contain

oil.
Figure 6-27
6-13
3. Disconnect the connection between rod-side oil

inlet pipe and the cylinder.
★ Notice
completely.
1
1rod-side oil inlet pipe During the processes of hydraulic pipes disassembly,
Figure 6-28
all the pipe lines and ports should be protected to
avoid the debris entering into the pipelines.
4. Disconnect the connection between piston-side oil

inlet pipe and the cylinder.
1
1piston-side oil inlet pipe
Figure 6-29
5. Disassemble the front holding pin bolt of the

cylinder.
Figure 6-30
6-14
6. Disassemble the fastening bolt of rear side grease

adding pipe; remove the bolt and two gaskets.
Figure 6-31
7. Disassemble the rear holding pin bolt of the

cylinder.
Figure 6-32
8. Disassemble the rear king pin by knocking it

upwards with a copper rod.
★ Notice
Do not hit the grease nipple.
Figure 6-33
6-15
9. Take down the cylinder.
Figure 6-34
6.2.4 Assembly of Steering Cylinder

1. First, pull out a part of piston rod of the steering
cylinder to make its total length generally equal to
the distance between two pin holes; then set the
piston side on the rear frame fitting seat.
★ Notice
The oil ports should face inward.
Figure 6-35
2. Put the cylinder in hinge-point location, align the

front to be hinged holes, and connect them with
front king pin to fix the cylinder on the front frame,
fix the pin with bolt and gaskets.
★ Notice
Clear the inner surface of frame pin hole and smear
some grease.
Check if there is dirt on the pin before assembling,
clean it if necessary.
Figure 6-36
6-16
3. Adjust the piston extension length to align the rear

to be hinged holes, and connect them with rear
king pin to fix the cylinder on the rear frame, fix
the pin with bolt and gaskets.
★ Notice
Clear the inner surface of frame pin hole and smear
some grease.
Check if there is dirt on the pin before assembling,
clean it if necessary.
Figure 6-37
4. Assemble the fixing bolt of cylinder piston side

grease pipe
Figure 6-38
5. Connect the piston-side oil inlet pipe to the

cylinder.
★ Notice
1
1piston-side oil inlet pipe
Figure 6-39
6-17
6. Connect the rod-side oil inlet pipe to the cylinder.

★ Notice
1
1rod-side oil inlet pipe
Figure 6-40
7. Smear grease on all pin connecting joints; make

sure there is grease squeezed out on the fitting
surface.
Figure 6-41
6.2.5 Disassembly of Priority Valve

and solid ground; turn the steering wheel to run
straightly, and then stop it after placing properly.
Put the bucket on the ground horizontally and shut
clockwise and anticlockwise for 5~6 times. Wedge
the tires with blocks well.
Figure 6-42
6-18
2. Remove the ventilation cap of hydraulic tank.
Figure 6-43
3. Put clean vessel under the priority valve to contain

oil.
Figure 6-44
4. Disconnect the connection between oil inlet pipe

and T port of priority valve, the connection
between feedback oil pipe of steering gear and LS
port of priority valve.
★ Notice
1 2 completely.
1oil inlet pipe of priority valve
2feedback oil pipe of steering gear
During the processes of hydraulic pipes disassembly,
Figure 6-45 all the pipe lines and ports should be protected to
6-19
5. Disconnect the connection between built-up joint

of steering gear inlet pipe and CF port of priority
valve.
1
1CF port connecting pipe
Figure 6-46
6. Disconnect the connection between working device

pipeline and EF port of priority valve; remove the
bolts and fission flange.
1
1EF port connecting pipe
Figure 6-47
7. Disconnect the connection between steering pump

outlet pipe and P port of priority valve; remove the
bolts and fission flange.
1
1steering pump outlet pipe
Figure 6-48
6-20
8. Disassemble the fixing bolts of priority vale, and

then remove the valve.
Figure 6-49
9. Remove the straight joints of CF, LS, and T ports.
Figure 6-50
6.2.6 Assembly of Priority Valve

1. Assemble straight joints of CF, LS, and T-ports to
their corresponding oil ports in priority valve with
an O-ring.
Tightening torque: 65±10 Nm
Figure 6-51
6-21
2. Fix the priority valve on the dead plate at the left

side of rear frame with two bolts.
Figure 6-52
3. Connect the steering pump outlet pipe to P port of

priority valve.
1
1steering pump outlet pipe
Figure 6-53
4. Connect the working device pipeline to EF port of

priority valve.
1
1EF port connecting pipe
Figure 6-54
6-22
5. Connect the steering gear inlet pipe to CF port of

priority valve.
1
1CF port connecting pipe
Figure 6-55
6. Connect the feedback oil pipe of steering gear to

LS port of priority valve.
1
1feedback oil pipe of steering gearFigure
6-56
7. Connect the oil inlet pipe and T port of priority

valve.
1
1oil inlet pipe of priority valve
Figure 6-57
6-23
8. Assemble the ventilation cap of hydraulic tank.
Figure 6-58
6-24
6.3 Diagnosis and Solutions for

Frequently Asked Questions of
Steering System
Table 6-1
NO. Problems Diagnosis Solutions
1. Add oil to prescribed level

2. Clean out the air in the
1. Low hydraulic oil level system check the low
2. There is air mixed into the pressure oil pipe joints.
steering system 3. Replace the oil inlet pipe
3. The oil inlet pipe softened 4. Replace the pump
4. Severe wear of oil pump 5. Replace the priority valve
1 Steering heavy
5. The priority valve works or the valve assembly
abnormally 6. Replace the steering gear
6. The steering gear works 7. Change the seal ring if it
abnormally is damaged, you have to
7. Bad sealing of steering cylinder replace the cylinder tube if
its inner wall is scratch or
worn.
1. Fractured spring piece, broken or
deformed pin in the steering gear
2. Wrong assembly of the steering
The loader
gear (the symmetry center line of 1. Replace the steering gear
self-steer when
rotor and stator of cycloidal gear 2. Reassemble the steering
2 no steer
motor isn’t perpendicular to the gear correctly
operation is
pin cutting groove of transmission 3. Reassemble the piston
need
shaft )
3. The piston of steering cylinder fall
off
6-25
1. Check whether the

1. Underpowered oil pump connecting bolts of
2. Short of fuel flexible connection plate
3. Severe abrasion of oil pump of torque converter are
The loader
4. Malfunctioned priority valve, the fractured
doesn’t steer
3 oil port to the steering gear is 2. Add fuel to prescribed
when operate
closed abnormally level
the wheel
5. Ablation of front/rear axle 3. Replace the oil pump
differential mechanism and 4. Replace the priority valve
doesn’t work 5. Repair the differential
mechanism
6-26
SERVICE MANUAL
Version:0720
7 Frame, Wheels and

Working Equipment
CONTENTS
7 FRAME, WHEELS AND WORKING EQUIPMENT ....................................................7-1

71 Introduction ........................................................................................................................ 7-1
711 Introduction of Frame...................................................................................................7-1

712 Introduction of Linkage ................................................................................................7-1
72 Disassembly and Assembly of Balance Weight................................................................ 7-2
721 Disassembly of Balance Weight ..................................................................................7-2

722 Assembly of Balance Weight .......................................................................................7-2
73 Disassembly and Assembly of Frame Junction ............................................................... 7-3
731 Lower Frame Junction ..................................................................................................7-4

732 Upper Frame Junction ..................................................................................................7-5
733 Frame Joint Junction ....................................................................................................7-5
734 Upper Frame Junction ..................................................................................................7-6
735 Lower Frame Junction ..................................................................................................7-6
74 Disassembly and Assembly of Front and Rear Wheels .................................................. 7-8
75 Disassembly of Linkage ................................................................................................... 7-10
751 Disassembly of Connecting rod .................................................................................7-10

752 Assembly of Connecting rod ......................................................................................7-11
753 Disassembly of Rocker Arm ......................................................................................7-12
754 Assembly of Rocker Arm ...........................................................................................7-13
755 Disassembly of Lifting arm ........................................................................................7-14
756 Assembly of Lifting arm ............................................................................................7-14
76 Disassembly and Assembly of Quick-change Frame .................................................... 7-15
761 Disassembly Quick-Change Frame ............................................................................7-15

762 Assembly of Quick-change Frame .............................................................................7-17
77 Replacement of Quick-change Bucket............................................................................ 7-18
I
7 FRAME, WHEELS AND

WORKING EQUIPMENT
71 Introduction
711 Introduction of Frame

Frame is classified as integrated frame and articulated
frame. Articulated frame consists of front frame, rear
1 2 3
Figure 7-1 frame, articulated pin and sub-frame.
1 rear frame 2 articulated pin
3 front frame
This machine adopts articulated frame. (Figure 7-1)
Front frame supports the working equipment.
Rear frame supports engine, transmission, cab and tank.
This machine replaces the sub-frame with swaying
bracket. (Figure 7-2)
The front frame and rear frame is connected by
articulated pin.
1
Figure 7-2
1 swaying bracket
712 Introduction of Linkage

Linkage adopts Z inverted six-bar linkage structure.
(Figure 7-3)
Z inverted six bar linkage consists of lift cylinder,
lifting arm, rocker arm, connecting rod, bucket cylinder
and bucket.
1 2 3
Figure 7-3
1 connecting rod 2 rocker arm
3 lifting arm
7-1

Balance Weight
721 Disassembly of Balance Weight

2
1. Connect hoisting ropes to both sides and the
middle of balance weight. (Figure 7-4)
Weight of balance weight: 1469kg
1
Figure 7-4
1 lifting eye (on both sides of the lifting
position, in the tool box and battery box)
2 Middle of the Balance Weight (middle
lifting position)
1
2. Disassemble the four balance weight bolts. (Figure
7-5)
3. Low the balance weight, and disassemble it from
the machine. Then lift and remove it.
722 Assembly of Balance Weight

1. Connect the balance weight to hoisting device, and
1 put it on the machine.
Figure 7-5
1 balance weight bolts 2. Mount the balance weight to the machine with four
bolts.
3. Remove the hoisting ropes.
7-2

Frame Junction
1. Park the machine on the solid and flat ground.

2. Put the bucket on proper spacer bush, and make
sure it can move forward.
Figure 7-6 3. Stamp the brake pedal repeatedly (about 40 times)
to release the pressure in the braking system.
4. Move back and forth the servo operating handle
repeatedly to release the pressure of hydraulic oil.
5. Turn off the power switch of battery.
6. Put blocks under front and back of rear wheels to
stop rear frame moving.
7. Disconnect the transmission shaft and remove it
from the machine.
8. Remove the lock ring and bolt from the front pin of
1
tilt cylinder, press the pin out.
Figure 7-7
1 wedge position 9. Disconnect the hose on the control valve, plug all
of the connectors. Make sure all of the other
connections are disconnect except the pin
connection between rear and front frame.
10. Put two single jacks on the rear part of the rear
frame.
11. Remove the floor mat and front floor from the cab.
12. Remove the adjusting gasket under the lower pin
and lower cover.
13. Put a car jack under the lower pin. Put braces under
1 2
Figure 7-8 the front of rear frame and front frame.
1 connecting bolt between lower cover and
frame 14. Remove connecting bolts of upper pin, and pull out
2 connecting bolt between lower cover and the pin. Cool this pin or new pin in the refrigerator
pin
or similar device.
7-3
15. Use tools to pull the pin out. Put it in the

refrigerator or similar device. (Figure 7-9)
16. Put one jack on each side of the machine, move the
front frame until it can touch the bearing position.
1
Figure 7-9
1 position for installing pin-pulling tools 731 Lower Frame Junction
17. Mark the position of bearing cover. Remove spacer
ring and upper and lower bearing covers and the
adjusting gaskets under bearings. Remove sealing
elements and clear bearing cover, and do not wash
away the marks. (Figure 7-10)
18. Install the tools and disassemble lower bearing
race.
19. Mount the lower bearing race at the junction of
Figure 7-10 lower frame. Strike it into until the bearing race
edge is 4mm (0.16inch) from junction of lower
frame. Mount two ball bearings. Use the same
method to mount bearing braces until it is 5mm
(0.2 inch) from junction of lower frame.
20. Mount lower and upper bearing races using bolts
and nuts. Put four gaskets (thickness about 3mm
(0.12 inch)) between upper cover and frame.
Tighten the bolts symmetrically until the lower
race is 4mm (0.16 inch) from lower frame junction.
1 2 3 21. Remove four gaskets. Mount pin and bear
Figure 7-11
1 gasket 2 lower pin 3 sealing ring temporarily. When rolling resistance reaches to
13-17 Nm (10-13 lb-ft), stop tightening.
22. Use clearance gauge measures the clearances
between bearing cover and frame at random points
23. Remove bearing pin.
7-4
Remove the two bearing covers and mount new

sealing rings.
According to the clearance choose proper adjusting
gaskets. Mount bearing cover and tighten bolts.
24. Mount spacer.
25. Smear hydraulic oil to the bush, press it to the
installing position of lower pin until bush aligns
with the top of the lower installing position.
732 Upper Frame Junction

26. Remove the sealing ring and lock ring of the upper
bearing. Install tools and pull the bearing out.
Figure 7-12 Upper frame Junction

Install lower lock ring.
Use grease to lubricate sliding surface of new
bearing.
Pull down the bear along the direction of lower
lock ring.
Mount the upper lock ring.
27. Install the sealing ring to the upper linkage bearing.
Use proper punch plate.
28. Put punch/gouge plate at the top of bearing and
brace at the bottom of bearing, press into the upper
sealing ring. Switch the position of these two tools,
and press into the lower sealing ring.
733 Frame Joint Junction

29. Install two chain pulleys. Make sure the car jack
and front brace can move forth and back.
Use the chain pulleys to pull back the front frame.
Align the two parts of the frame carefully. Make
sure the spacer ring inside the sealing rings doesn’t
touch the front frame, in order to protect the
sealing rings.
7-5
734 Upper Frame Junction

30. Align the upper pin. Lubricate upper bearing pin
and bearing position with hydraulic oil.
Screw the thread linkage into pin hole and guide
the pin to its position.
Press into bearing pin. Mount bolts and tighten
them.
735 Lower Frame Junction

31. Align the two parts of frame at the position of
lower pin accurately.
32. Mount the cover at the lower side of the junction if
lower frame, don’t use adjusting gaskets.
Screw the bolts in the frame loosely.
Mount the guide pin to the bearing pin.
Press the bearing pin into bearing hole using guide
device.
Press the bearing pin as low as possible.
33. Remove the jacks, braces, blocks at the wheel and
chain pulleys.
34. Fix the cover to the pin using bolts, loose the
connecting bolts between cover and frame.
Measure clearances between cover and frame using
clearance gauge. Measure clearances at least at
four points.
Remove cover, mount proper adjusting gaskets
according to the clearance between cover and
frame.
Tighten torque: 195~255Nm
35. Assemble transmission shaft.

36. Connect the hydraulic pipeline.
37. Mount front pin and nylon gaskets of tilt cylinder.
Mount lock ring and lock bolt.
7-6
38. Lubricate the positions where need lubrication (pin,

upper/lower bearing).
39. Check hydraulic oil level. Add if necessary.
40. Check whether the engine has oil leakage.
41. Rotate the machine to complete locking position in
both directions, exhaust the hydraulic system.
42. Lubricate the upper/lower bearings again.
7-7
74 Disassembly and Assembly of Front

and Rear Wheels
741 Disassembly of Rear Wheel

1. Put the machine at maintenance point 1. (Figure
7-13, for details, refer to Page 9, Safety and
Environment)
Figure 7-13 2. Put jack under balance weight. Lift the machine,
and put specialized tool under balance weight.
Remove jack.
3. Loosen wheel nuts.
4. Mount wheel forklift tool and fix the wheel.
Remove wheel nuts and wheel.
742 Assembly of Rear Wheel

1. Clear the contact surface of rim and hub. Make
sure the thread of the hub clean and no damage.
1
Figure 7-14 2. Mount the wheel.
1 specialized tool
Mount the wheel, install four evenly distributed
wheel nuts. Tighten the nuts directly.
 Notice
Tighten the nuts clockwise, screw into a little
every time to avoid the wheel tilt.
Install the rest of the wheel nuts.
Tighten torque: 480~580N·m
3. Mount the jack, lift the machine and remove the
specialized tool.
4. Low the machine and remove the jack.
5. Recover the machine, check and affirm there no
wrong information.
6. Check and make sure all functions are normal.
7-8
743 Disassembly of Front Wheel

1. Park the machine to flat, spacious and solid ground.
(Figure 7-15)
2. Shut down the engine.
3. Restrict the movement of rear wheel.
Figure 7-15
4. Lift the machine with specialized tool. Keep the
front wheel off the ground. (Figure 7-16)
5. Loosen wheel nuts
Notice
Before the shaft fixed, don’t disassemble the
wheel nuts.
6. Mount wheel forklift tool and fix the wheel
1
7. Remove wheel nuts and wheel.
Figure 7-16
1 specialized tool (similar to that of rear 744 Assembly Front Wheel
frame, there are baffles at the two support
positions to stop the frame moving) 1. Clear the contact surface of rim and hub. Make
sure the thread of the hub clean and no damage.
2. Mount the wheel.
Mount the wheel, install the four wheel nuts.
Tighten the nuts directly.
Notice
Tighten the nuts clockwise, screw into a little
every time to avoid the wheel tilt.
1
Remove the forklift.
Figure 7-17 Install the rest of the wheel nuts.
1 wheel Forklift Instrument
3. Lower the machine.
4. Recover the machine, check and affirm there is no
wrong information.
5. Check and make sure all functions are normal.
7-9
75 Disassembly of Linkage
751 Disassembly of Connecting rod

1. Start the machine and park it to flat, spacious and
solid ground. Keep the bucket flat on the ground,
keep all of the control handles in neutral position,
and press the parking brake button and shutdown
1 the engine. Fix the wheels with blocks.
Figure 7-18
2. Lift the connecting rod with travelling crane to
1 blocks
avoid hurting foot or ground when taking down the
pin. (Figure 7-19)
3. Remove the fixed bolt of pin, disassemble the
connecting pin between lower connecting rod and
quick-change frame with soft hammer.
1
Figure 7-19
1 lifting position
4. Disassemble the fixing bolt of connecting pin
between connecting rod and rocker arm. (Figure
7-20)
1
Figure 7-20
1 fixing Bolt 5. Predict the motion trail of connecting rod to avoid
hurting people or ground, remove the pin using soft
hammer and lift away the connecting rod.
Figure 7-21
7-10
752 Assembly of Connecting rod

1. Clear the hole in both sides of the connecting rod,
and fill in proper volume lubrication oil.
2. Lift the connecting rod. (Figure 7-22)
1
Figure 7-22
1 lifting rope crosses through the linkage
hole (the hole connecting quick-change and
linkage)
3. Connect the connecting rod assembly to arm

assembly with a pin and two O-shape scraper seals.
(Figure 7-23)
4. Fix the pin on arm with bolts and gaskets.
5. Put one O-shape scraper seals in both sides of the
connecting rod hole. Note that do not scratch the O
1
scraper seals.
Figure 7-23 6. Adjust the connecting rod and operate the tilt
1 O-shape scraper seal
cylinder to align the connecting rod with
quick-change frame.
7. Use a pin to connect the quick-change frame and
connecting rod assembly, use a bolt and gasket to
fix the pin.
Tighten torque: 78~104 N·m
8. Fill in proper volume grease to pin connection with
grease gun.
7-11
753 Disassembly of Rocker Arm

1. Hang the tilt cylinder with hoisting rope. Preload
the hoisting rope to prevent the tilt cylinder from
falling down when remove the pin. (Figure 7-24)
2. Remove the connecting bolt of the pin, knock
down the pin with soft hammer, and remove the
gaskets.
1
Figure 7-24
1 lifting position
3. Lift the tilt cylinder and put a block at the bottom
of tilt cylinder to support it.
1
Figure 7-25
1 reliable support
4. Lift the arm with hoisting rope. (Figure 7-26)

5. Remove the fixing bolts of pin between connecting
rod and rocker arm. Knock down the pin with soft
hammer, and remove the O-shape scraper seal.
6. Remove the fixing bolt of pin between arm and
lifting arm, knock down the pin with soft hammer
and remove the gaskets. Put the arm on clean
Figure 7-26 cushion.
7-12
754 Assembly of Rocker Arm

1. Hang the arm with hoisting rope. (Figure 7-26)
2. Align the two pin holes of the rocker arm and
lifting arm. Mount the arm to the lifting arm with
pin and gaskets. Fix the pin with bolts and adjust
the clearance of arm to 0.5~1.5mm. (Figure 7-27)
3. Hang the tilt cylinder and keep the arm stable.
Remove the blocks at the bottom of tilt cylinder.
Hang the tilt cylinder with hoisting rope. (Optimal
1 lifting position is front end of cylinder)
Figure 7-27
4. Start the engine and adjust the stroke of piston
1 alignment
connecting rod. Under the help of hoisting rope,
align the pin holes of piston connecting rod and
arm. Use a pin connecting the bucket cylinder to
arm. Put gaskets in the connecting end. Choose
proper type and installing position of gasket to
ensure the installing clearance between
0.5~1.5mm.
5. Use a bolt of M12×25 and a gasket to fix the pin to
the arm.
6. Hang the connecting rod with hoisting rope, start
engine and adjust stroke of piston connecting rod
of lifting arm. Under the help of hoisting rope,
adjust the position of connecting rod and arm.
Align the pin holes of arm and connecting rod. Use
a pin and two O scraper seals to connect the
connecting rod assembly to lifting arm assembly.
Fix the pin to lifting arm with bolts of M12×30 and
gaskets.
7. Fill in proper volume grease to pin connection
using grease gun.
7-13
755 Disassembly of Lifting arm

1. Disassembly of connection between lifting arm and
rocker arm refers to 75.3 Disassembly of Rocker
Arm.
2. Disassembly of connection between lifting arm and
quick-change refers to 76.1 Disassembly of
Quick-change Frame.
3. Start the engine, lift the lifting arm and put two
blocks with similar height under right and left
lifting arm cylinders which prepares to disassemble
pin. (Figure 7-28)
1
Figure 7-28
1 position for blocks
4. Hang lifting arm with hoisting rope. (Figure 7-29)

5. Remove fixing bolt of pin which connects lifting
arm and lifting cylinder. Knock out the pin lightly
and take away.
6. Remove fixed bolt of pin which connects front
frame and lifting arm. Remove the lifting arm
indicating plate on the lifting arm. Knock the pin
out lightly and take it away.
1
7. Take away the lifting arm and put it down.
Figure 7-29
1 lifting position
756 Assembly of Lifting arm
1. Clear the antirust oil dirt in the shaft sleeves.
Smear proper volume of lubricating grease in the
holes of the lifting arm. Use cooper stick to guide
the two sleeves into pin holes connecting lifting
arm and front frame. Mount four scraper seals in
the pin holes. The sleeves should not be tilt.
7-14
2. Clear the dirt, check whether the holes (oil passage)

in the pin are clean and unblocked. Fill proper
volume lubricating grease into the holes.
3. Hang the lifting arm with hoisting rope, approach
the front frame slowly, align the relevant holes in
the lifting arm and front frame. Knock into the pin
with soft hammer. Fix the pin with bolt and gaskets.
Adjust the gaskets to keep the clearance between
lifting arm and front frame 0.5~1.5mm.
4. Start engine, control the stroke of lifting cylinder to
adjust the position of lifting arm. Align the shaft
holes of lifting arm and lifting cylinder. Mount the
lifting arm indicating plate and fix the pin using
bolt and gasket.
Remove the hoisting rope and control the lifting
arm to lift. Then remove the blocks.

Quick-change Frame
761 Disassembly Quick-Change Frame

1. Start machine and park it on the flat, spacious and
solid ground. Keep the bucket flat on the ground,
keep all of the control levers in neutral position,
press the park braking button and shut down the
engine. Fix the wheels with blocks.
2. Remove the hydraulic parts away from the quick
attachment. (refer to chapter 9)
1
Figure 7-30
1 blocks
7-15
3. Lift quick attachment with hoisting rope, at the

same time restrict the movement of linkage to
prevent it hurting people or ground after removing
the pin. (Figure 7-31)
1
Figure 7-31
1 lift the pin position of both side of
quick-change frame
4. Remove the fixing bolt of the pin connecting

linkage and quick-change frame, knock out the pin
with soft hammer. (Figure 7-32)
1
Figure 7-32
1 pin
5. Remove the fixing bolt of pin connecting lifting

arm and quick attachment. Remove the pin
connecting linkage and quick-change frame.
(Figure 7-33)
6. Lift away the quick attachment from the machine.
Figure 7-33
7-16
762 Assembly of Quick-change Frame

1. Start the machine, lift the lifting arm off the ground
(about 30cm from the ground). Clean the sewage in
the holes. Put O-shape scraper seals on both ends
of pin hole of boom pin. (Figure 7-34)
2. Hang quick-change frame, adjust the position of
quick-change frame and align the connecting pin
holes of quick-change frame and lifting arm.
Connect the lifting arm and quick-change frame
1
Figure 7-34 with pin and gaskets. Adjust the number and
1 position of installing O scraper seal
thickness of gaskets to keep the clearance of
surface ends between lifting arm and quick-change
is 0.5~1.5mm.
3. Put the O-shape scraper seal into the clearance
between quick-change frame and lifting arm. Fix
the pin with two bolts and two gaskets.
4. Put one scraper seal on each side of shaft hole of
the pin. Note that don’t scratch the scraper seal.
Start the engine, operate the lifting cylinder, lay the
bucket to the ground. Hang the linkage, at the same
time operate the bucket cylinder, align the pin
holes of linkage and quick-change frame.
5. Connect the quick-change frame and linkage
assembly with a pin. Fix the pin with a bolt and a
gasket.
6. Fill proper volume lubricating grease into the pin
connection using grease gun. (Figure 7-35)
Figure 7-35
7-17
77 Replacement of Quick-change
Bucket
Replacement of quick-change bucket should be done

with the help of other people.
Notice
Replacement must ensure safety.
1. Put the quick-change bucket on solid ground.
(Figure 7-36)
Figure 7-36
2. Start the loader and align the connecting bases of

quick attachment and quick-change bucket. (Figure
7-38)
1 2
Figure 7-37
1 alignment
2 connecting base of quick-change bucket
3. Approach slowly and adjust the height of quick
attachment. Align the pin of quick attachment with
the set of holes in the middle of quick-change
bucket. (Figure 7-38)
1
Figure 7-38
1 hinge pin of quick-change frame
7-18
4. Lift lifting arm and hang the quick-change bucket

on the quick attachment, continue to lift lifting arm.
Move forward the loader a little. Restrict the
movement of the quick attachment and
quick-change bucket. (Figure 7-39)
1 2
Figure 7-39
1 alignment 2 stop block
5. Turn on the quick-change power switch on the

right side of maneuvering box. (Figure 7-40)
1
Figure 7-40
1 quick-change power switch
6. Operate the control handle of lifting arm and

bucket to boom-lower or bucket-backward-tilt
position. At the same time press the left side button
on the handle top. (Figure 7-41)
7. Operate the quick-change cylinder and push the pin
out, and connect with quick-change bucket.
1 2 Release the left side button of control lever. Turn
Figure 7-41
1 quick-change assembly button
the lever to neutral position. Pull down the lock
2 quick-change disassembly button button of quick-change power switch, at the same
time press the switch to locking position.
8. Turn the gear shifting handle to neutral position,
press the parking brake button, and keep the bucket
flat on the ground. Turn all control handles in
neutral position, and then shut down the engine.
7-19
9. Disassembly of quick-change bucket should be

done on the solid and flat ground. Leave back
room for the loader, and put the bucket on the
ground. (Figure 7-42)
10. Open the quick-change power switch on the right
side of the maneuvering box.
11. Operate the control handle of lifting arm and
Figure 7-42
bucket to boom-lower and bucket-backward-tilt
position.
12. At the same time press the right button on the
handle top, operate the quick-change cylinder and
push back the hinge pin of quick attachment.
Disconnect the connection of quick-change bucket.
(Figure 7-43)
13. Release the control handle button. Turn the handle
back to neutral position. Turn the quick-change
power switch to locking position.
1
14. Low the lifting arm, back the loader, withdraw the
Figure 7-43
1 the movement of right and left side of bucket and lift the lifting arm, back and leave the
quick-change cylinder doesn’t synchronize,
make sure disconnect the quick-change and quick-change bucket.
quick-change frame completely
7-20
SERVICE MANUAL
Version:0820
8 Cab and Covering Parts System

CONTENTS
8 CAB AND COVERING PARTS SYSTEM ................................................................................ 8-1
81 Cab Description ............................................................................................................................ 8-1
811 Cab Exterior Description ..................................................................................................... 8-1
812 Cab Interior Parts Description ............................................................................................ 8-2
82 Air Conditioning System Description ........................................................................................ 8-11
821 Function and Position of the Components......................................................................... 8-11
822 System Description ............................................................................................................ 8-13
83 Disassembly and Assembly of Cab Assembly ........................................................................... 8-15
831 Disassembly of Cab Assembly .......................................................................................... 8-15
832 Assembly of Cab Assembly .............................................................................................. 8-20
833 Disassembly and Assembly of Seat ................................................................................... 8-24
834 Assembly of Maneuvering Box. ........................................................................................ 8-25
835 Assembly of Maneuvering Box. ........................................................................................ 8-27
84 Disassembly and Assembly of Engine hood .............................................................................. 8-30
841 Disassembly of Rear Cover ............................................................................................... 8-30
842 Engine hood, Disassembly ................................................................................................ 8-33
843 Assembly of Engine hood ................................................................................................. 8-37
844 Assembly of Rear Cover, .................................................................................................. 8-40
85 Disassemble Left and Right Platform Assembly........................................................................ 8-42
851 Disassembly of Platform Assembly .................................................................................. 8-42
852 Assembly of Platform Assembly ....................................................................................... 8-45
86 Disassembly and Assembly of Air Conditioning System .......................................................... 8-47
861 Disassembly of Climate Unit............................................................................................. 8-47
862 Assembly of Climate Unit ................................................................................................. 8-49
863 Replacement of Evaporator Components .......................................................................... 8-51
864 Replacement of Condenser Fan ......................................................................................... 8-59
865 Replacement of Liquid Storage Tank ................................................................................ 8-60
866 Replacement of Compressor Components ........................................................................ 8-61
867 Draining and Filling of Refrigerant ................................................................................... 8-63
87 Diagnosis and Solutions for Frequently Asked Questions of Air Conditioning System ........... 8-66
871 Regular Checking Items .................................................................................................... 8-66
872 Non-refrigeration Fault Analysis ....................................................................................... 8-67
I
873 Insufficient Refrigeration Fault Analysis .......................................................................... 8-67
874 Non-Heating Fault Analysis .............................................................................................. 8-68
875 Other Fault Analysis .......................................................................................................... 8-68
II
8 CAB AND COVERING

PARTS SYSTEM
81 Cab Description
811 Cab Exterior Description

1. LG958L cab is equipped with FOPS&ROPS
(Falling-object protective structure and Roll-over
protective structure) functions, to protect the
operator in case heavy objects fall or the loader
rolls over. ROPS unit not only can stand the load
when the loader rolling over, but also can absorb
the impact energy.
1
Figure 8-1
1 cab
Figure 8-1 2. LG958L use four silicone oil dampers to connect
the cab to the frame. The dampers can reduce the
noise and vibration, and prevent them from
spreading to the cab. The cab has well-designed
frame structure, which would not be crushed when
the loader roll over.
1 2
1 2
Figure 8-2
1 silicone oil damper
2 damping bolt
8-1
3. ROPS unit (ROPS=Roll-over protective structure)

includes a heavy bolt (ROPS bolt) and permanently
installed gasket (ROPS gasket). The cab and frame
are connected by ROPS bolt. If the rolling-over
accident happened, ROSP unit can prevent the cab
breaking away from the loader. Cab Interior Parts
Description.
1
Figure 8-3
1 ROPS bolt
 Notes for using the cab:

· If cab was damaged by falling objects or roll-over accidents, its strength will be reduced and
cannot provide normal protective functions. In such cases, please connect Shandong Lingong
Construction Machinery Co., Ltd or our appointed distributors. Maintenance without
authorization is absolutely banned.
· Even though equipped with the ROPS unit, operator can not get effective protection without
fastening his seat belt. When operating the loader, seat belt must be fastened. Even though the
seat belt is not damaged, it must be replaced triennially.
· It is strictly prohibited to drill and weld in or out of the ROPS unit, which can damage or
reduce the strength of the unit.
· The cab can protect the operator. It meets “ROPS” roll-over protective structure demands
according to the test standards. So if roll-over accident occurs, operator can act according to
the following instructions: hold the steering wheel firmly, lean your body, grab the cab floor
with your feet, do not try to jump out of the cab when rolling over.
Warning
If ROPS unit was deformed or damaged for some reasons, new unit must be replaced with. For
getting new ROPS unit, please connect the nearest Shandong Lingong dealers.
812 Cab Interior Parts Description

The cab interior is commodious, operating handle is
located in the right hand side, and dashboard is located
in the front and right side of the cab. Information
8-2
display screen continuously displays information about

different functions of the loader.
1. Start switch
This switch is used for turning on or off the electric
system of the loader and start the engine.
· PRE position
This is the for the engine cold start preheating.
· OFF position
Insert or pull out the key in this position. If the key
rotates to this position, the system circuits will be shut
Figure 8-4 off.

1 start switch
· ON position
Open electric system of the loader in this position.
When engine working, please keep the key in the ON
position.
· ST position
This is the position to start the engine. When the engine
is starting up, keep the key in this position.
After the engine started, release the key immediately, it
will return back to the ON position automatically.
2. CD player/tape player control panel (optional item)
This control panel is located at the right side of the cab
roof. For its operational approaches please refer to CD
Player/Tape Player Use and Installation Manual.
3. Gears shifting handle
1
Figure 8-5 The loader adopts front-4-rear-3 gearbox.
1 player
Put shifting handle in the appropriate position and
adjust the accelerator pedal, desirable speed can be
obtained.
· Place the Handle in the “N”, the loader will
engage neutral position; push the handle forward to
1
Figure 8-6 the “F” position, and then rotate the handle to
1 gear shifting handle
position “1”to get forward gear Ⅰ , rotate to
8-3
position “2” to get forward gear Ⅱ , rotate to

position “3” to get forward gear Ⅲ,and rotate to
position “4”to get forward gearⅣ; Pull the handle
backward to “R” position, and then rotate the
handle to position “1” to get backward gearⅠ,
rotate to position “2” to get backward gearⅡand
rotate to position “3” to get backward gearⅢ.
 Notice
· Before starting, the handle should be in the “N”
position. After stopping, the handle should be in
the “P” position.
· KD function: forced downshift function. During
working, the loader starts with gearⅡ; then engage
gear Ⅲ to travel forward; shift gearⅡwhen the
bucker gets close to sand/stone pile; When
shoveling materials, press KD key (doesn’t need to
turn the gear shifting handle), the loader speed will
automatically downshift to gear Ⅰ . After the
bucket is fully loaded, pull the gear shifting handle
backward to shift reverse gears, the loader can be
automatically converted to reverse gear Ⅱ from
forward gearⅠ. Rotate the handle to remove KD
function.
4. Combination switch
· Illumination
When the start switch is in the “ON” position, rotate
the combination switch to or position, front
lamps, rear lamps, backlight will be lightened.
· High/Low beam switch
1 When the start switch is in the “ON” position, push up
Figure 8-7
1 combination switch
this switch, headlamps will be lightened in high beam,
loosen it, the switch will reset automatically; when the
8-4
combination switch is rotated to position,

headlamps will be lightened in low beam; lift and
release the switch, the headlamps can be switched
between high an low beam; press the switch,
headlamps are lightened in high beam.
· Steering lamp switch
Push forward this switch, left steering lamps will be
lightened, push backward this switch, right steering
lamps will be lightened.
 Notice
When operating this switch, the steering indicator
lamp on the dashboard will be on at the same time.
After finished the steering operation, please reset
this switch.
5. Warning light switch
Press in this switch and all steering lamps will be
lightened at the same time. This switch is used for
emergency circumstances to provide warning light, and
to attract the attention of other vehicles and pedestrians.
Press this switch again, it will spring up automatically,
and the steering lamps will be off.
1 6. Temperature control switch
Figure 8-8
1 warning light switch · Air volume switch
Switch and control the rotational speed of the
evaporator fan, including high, medium and low grade
and power switch. It is used for choosing appropriate
air volume and opening or closing the air conditioning
system.
· Fresh air switch
Control the operation of air actuator and keep the
1 2 3 internal and external air flowing circularly.
Figure 8-9
1 air volumeswitch · Refrigeration start switch
2 fresh air switch
3 refrigeration start switch
8-5
Rotating this switch clockwise can open the refrigerant

system and the control the refrigerant capacity.
· Refrigeration
Start the engine. Turn on the air volume switch, and
now the system is in the air supply status. Then rotate
the refrigeration start switch to refrigeration position,
now the refrigeration indicator shines, and system is in
the refrigerant status. Rotate the air volume switch and
choose different positions, high, medium and low grade
of air volume can be obtained. When the temperature
drops to the required temperature, rotate clockwise the
refrigeration start switch slowly until the indicator light
goes out.
· Heating
Before heating, rotate the refrigeration start switch to
the closed status. Start the engine, and then open the
hot water valve.
Open the air volume switch and choose appropriate
grade to get required air volume.
7. Top light switch
This switch is located in the middle of top light.
Push this switch to the ON position, top light will
1
be on, push it to the OFF position, it will go out.
Figure 8-10 When driving, the top light must be closed.
1 top light switch
8. Parking brake switch
Parking brake: when the loader stops working, this
switch can prevent its movement because of the
slant of the road or external force.
9. Rocker switch
· Headlamp switch
Press the low end of the switch, the headlamps on the
1 top of the cab will be on; press the upper end, they go
Figure 8-11 out.
1 parking brake switch
8-6
· Rear lamp switch

Press the low end of the switch, the rear lamps on the
top of the cab will be on; press the upper end, they go
out.
· Top warning light switch
Press the low end of the switch, the top warning light at
the top of the cab lights; press the upper end, it goes
1 2 3
out.
Figure 8-12
1 headlamp switch · Front wiper switch
2 rear lamp switch
3 top warning switch Press the low end of the switch, wiper works; press the
upper end, wiper stops working. According to the press
depth of the low end, high and low wipe velocities can
be obtained.
· Rear wiper switch
Press the low end of the switch, wiper works; press the
upper end, wiper stops working. According to the press
1 2 3 4 depth of the low end, high and low wipe velocities can
Figure 8-13
1 front wiper switch be obtained.
2 rear wiper switch
3 sprinkler switch · Sprinkler switch
4 brake release switch
Press the low end of the switch, sprinkler motor works,
water-jet nozzle sprinkles water to clean the front
window of the cab. Release the switch, it returns
automatically and the nozzle stops sprinkling. Press the
upper end of the switch, sprinkler motor works,
water-jet nozzle sprinkles water to clean the rear
window of the cab. Release the switch, it returns
automatically and the nozzle stops sprinkling.
· Brake release switch
1 2 3 4
Figure 8-14 Press this switch, parking brake released.
1 power cut-off switch
· Power cut-off switch
2 positive & negative rotation switch
3 quick-change switch Press the low end of the switch, at the same time step
4 safety lock switch
the brake pedal, power will be cut off.
8-7
Press the upper end of the switch, at the same time step
the brake pedal, power won’t cut off.
· Quick-change switch
Press the low end of the switch, at the same time
operate the quick-change button of the operating handle,
the working device can be changed quickly.
Press the upper end of the switch, at the same time
operate the quick-change button of the operating handle,
the function of quick-change is locked.
· Positive & negative rotation switch
Pressing this switch, the fan rotates reversely for
degusting. This switch is self-locking. Under normal
condition, it is locked. When using this switch, push the
lock catch on the switch to unlock it.
Warning
This switch can only be used when the engine is in
the flameout status.
· Safety lock switch
Pressing this switch, pilot operating handle will be
locked.
· Horn button
1 2
Figure 8-15
Press the button in the middle of the steering wheel, the
1 steering wheel horn sounds; release it, the horn stops sounding.
2 horn button
10. Cigarette lighter
Insert the cigarette lighter and press it until locked up,
then the electric heater band of the cigarette lighter
contacts with the socket, the heating process starts.
When the heating wire of the cigarette lighter reaches
the required temperature, the clamp spring deforms
because of the high temperature and pops the cigarette
lighter up. Then the cigarette lighter can be used for
1
Figure 8-16
lighting the cigarette. After finished, insert it back.
1 cigarette lighter 11. Working device operating handle
8-8
This handle can control the bucket and boom. There are
four gear modes in the front-rear direction, controlling
the lift, neutral position, lower and float of the boom,
respectively; there are three gear modes in the left-right
direction, controlling the forward tilt, neutral position
and backward tilt of the bucket respectively.
· Bucket
Backward tilt: retract the bucket
Neutral position: keep the bucket in a certain position
Float Forward tilt: unload
Lower Forward · Boom
tilt
Neutral position: keep the boom in a certain position
Lower: lower the boom.
Backward Lift
tilt · Float
the boom moves freely under the action of external
forces.
· Quick-change button
Left: quick-change disassemble button
1 2
Figure 8-17 Right: quick-change assemble button
1 quick-change button
12. Emergency exit
2 working device operating handle
The cab has two emergency exits: the door and the rear
window. No matter the stationary type or slide type of
the rear window is, when emergency occurs, use the
emergency hammer hanging on the left rear side of the
cab to break the window and escape from the cab
 Notice
Emergency exits can only be used in case of an
emergency.
13. Seat
1
Figure 8-18 · Weight adjustment
1 safety hammer
The weight adjustment knob is in the middle of seat
bottom. Turn the knob anticlockwise to reduce the
damping stiffness and turn it clockwise to increase the
8-9
damping stiffness. Rotate the damping stiffness

adjustment knob by hand to regulate the stiffness
steplessly from 50kg-130kg according to the operator’s
weight until feel comfortable.
· Fore-and-aft Adjustment
This handle is on the left bottom side of the seat. Pull
the fore-and-aft handle and move the seat forward or
backward to the desired position; it will lock
automatically after pushing it down. The maximum
fore-and-aft displacement is 210mm.
· Backrest Angle Adjustment
Put the backrest angle adjust handle upward to pull the
backrest until the angle is comfortable. The backrest
angle is locked when loose the handle.
· Safety Belt
If the safety belt is assembled on the seat, please tie it
1 when operating the machine. Before using safety belt,

Figure 8-19 please check the degree of wear and firm. Replace it if
1 seat
it is necessary. Adjust the length of safety belt before
using to make sure the safety belt can be used for safety
guarantee and comfort. Move the position of lock on
the safety belt to adjust the length of safety belt. The
clamp of the safety belt is at the right side of seat, and
put the lock into the opening of clamp to jam the lock.
There is a red button on the side of opening of clamp.
Press the button and the lock will jump out from the
clamp. Before using the safety belt, please check
whether the clamp of safety belt can lock and loose
normally.
8-10
82 Air Conditioning System

Description
821 Function and Position of the

Components
LG958L air conditioning system consists of
compressor, evaporator assembly, condenser assembly,
and receiver-drier and rubber hose. Compressor is
driven by the engine via the belt. Switches on the panel
control the temperature and air volume. It can supply
large air flow, good refrigerant performance and can
control the temperature of the cab automatically.
1 2 3 4 5
Figure 8-20
1 compressor
2 evaporator assembly
3 condenser assembly
4 expansion valve
5 receiver-drier
1. Refrigerant compressor is the heart of the air
conditioning system. Its role is to maintain the
circulation of the refrigerant in the system. It
absorbs the low temperature and low pressure
refrigerant vapor from evaporator and compresses
it. The pressure and temperature of the vapor rise,
and then send the compressed vapor to the to the
condenser.
1 2
Figure 8-21
1 engine
2 compressor
8-11
2. Condenser is kind of heat exchanger consisting of

pipes and cooling fins. Its role is to cool the high
temperature and high pressure refrigerant vapor
exhausted by the compressor and to congeal the
vapor into high pressure refrigerant liquid.
3. Receiver-drier is used for storing the refrigerant,
eliminating the water and filtering the
contaminants in the refrigerant and detecting its
volume.
1 2
Figure 8-22
1 receiver-drier
2 condenser
4. Expansion valve’s role is to spray the liquid

refrigerant from receiver-drier to form low
temperature, low pressure vaporific refrigerant. It
can adjust the flow of the refrigerant according to
cooling load.
5. Evaporator’s role is to absorb the hear energy and
1 2 vaporize the low temperature, low pressure and
Figure 8-23
1 evaporator vaporific refrigerant. It cools the hot air flowing
2 expansion valve
through the radiator to refrigerate the cab. Its
capacity of absorbing heat decides the refrigeration
performance of the air conditioning.
8-12
Service Manual──LG958L Wheel Loader
822 System Description

LG958L air conditioning system consists of heating system, refrigeration system, ventilating
system and pressure control system.
Refrigeration system of the loader is used for refrigerating the air in the cab or fresh air from
outside and lowering the temperature in the cab. The operating instructions are as follows:
1. Start the engine.
2. Turn on the power and air volume switches, and then turn the temperature control switch to
“COOL” position, indicator light will be on, the refrigeration process starts.
3. Turn the air volume switch; choose between low speed, intermediate speed and high speed,
to get three different air volumes.
4. When the temperature is reduced to set temperature, rotate the temperature control switch
anticlockwise until the indicator light goes out and the compressor stops working, and the
indoor temperature is the set value. When the indoor temperature is above this temperature,
indicator light will on, the compressor will start automatically and the systeem begins to
cool; When the indoor temperature is below this temperature, indicator light goes out and
the system stops working.
5. When use the air condition, please don’t turn the temperature control switch to “COOL”
position and turn the wind switch to low speed. Because this will cause evaporator frosting
and influence the refrigerant performance.
Heating system of the loader uses the heat energy of the cooling liquid. It introduces the cooling
liquid of the diesel engine to the radiator in the cab and uses the blower to blow the heated air to
the interior of the cab. At the same time, the heating system cleans the frost and fog on the front
window. Heating system instructions:
1. Turn the temperature control switch to “0” or “OFF” position (off state);
2. Start the engine and open the hot water valve;
3. Turn on the wind switch, select the mode and choose the required wind speed.
Ventilation system of the loader includes natural ventilation and forced ventilation. The natural
ventilation uses the wind pressure produced outside the cab when the loader drives to ventilate;
forced ventilation uses the blower to blow the wind outside into the cab.
Pressure system of the loader adopts the high-low pressure switch control. When the pressure of
the air conditioning system is abnormal because of the lack of refrigerant or too high pressure,
the compressor will be switched off to protect the air conditioning system.
8- 13
 Notice
When refrigerating in summer, please close the hot water valve. When heating in winter, please
close the temperature control switch.
The refrigerant of LG958L is R-134a (Freon-free environmentally friendly refrigerant). It
possesses the properties as follows: strong heat absorptivity and easily liquefied; non-flammable
and non-explosive; chemical composition stable; non-toxic; non-corrosive.
Figure 8-24 Air conditioning system schematic diagram

1 evaporator
2 expansion valve
3 the observation place
4 water filter
5 receiver-drier
6 compressor
7 condenser
A low pressure liquid
B low pressure gas state
C high pressure gas state
D high pressure liquid
8- 14
83 Disassembly and Assembly of Cab

Assembly
831 Disassembly of Cab Assembly

Instrument: 2m hoisting rope.
1. Before disassembly, lift the cab until the hoisting
rope is neither loose nor too tight.
2. Disassembly steering gear hydraulic pipeline. For
details, refer to 621 Disassembly of Steering
Gear.
3. Disassembly the brake valve hydraulic pipeline.
For details, refer to 5 BRAKE SYSTEM.
1 2
Figure 8-25
1 steering gear
2 foot brake valve
4. Disassemble pilot operating handle hydraulic
pipeline. For details, refer to 949 Disassembly
and Assembly of Triple Operating Valve Operating
handle.
1
Figure 8-26
1 pilot operating handle
5. Disassemble evaporator assembly. Refer to 86
Disassembly and Assembly of Air Conditioning
System.
1
Figure 8-27
8-15
6. Disassemble platforms referring to page 85

Disassembly and Assembly of Left and Right
Platforms.
1 2
Figure 8-28
1 platform
2 hoisting rope
7. Disassemble left hydraulic oil tank shield.
1
Figure 8-29
1 bolt
8-16
8. Disconnect the connection between upper wire

harness (as shown in Figure 8-30) and peripheral
ports of the cab.
1 2
Figure 8-30
1 cab
2 rear platform wire harness
9. Pull up the yellow plug of the rear frame wire
harness (as shown in Figure 8-31).
1
Figure 8-31
10. Disconnect the radiating valve wire harness in the
engine hood (left inside).
1
Figure 8-32
1 radiating valve wire harness
8-17
11. Disconnect the speed sensor wire harness on the

gearbox.
1
Figure 8-33
1 output shaft speed sensor
12. Disconnect the gang socket wire harness on the
gearbox.
1
Figure 8-34
1 gang socket wire harness
13. Disassemble the damper connecting nuts.
1
Figure 8-35
1 damper nut
8-18
14. Disassemble ROPS connecting bolt.
1
Figure 8-36
1 ROPS bolt
15. Hang down the cab with hoisting rope and put it on
the cab support.
 Notices:
During hoisting, don’t run the cab part into the
hydraulic tank and wire harness. When putting
down the cab, keep it stable.
1
Figure 8-37
1 cab
8-19
832 Assembly of Cab Assembly

Instrument: 2m hoisting rope.
1. As shown in Figure 8-38, lift up the cab with
hoisting rope and put it on rear frame.
 Notices
Connect the hoisting rope to the rings on the cab,
keep the cab balanced, don’t crush the hydraulic
rubber hose and wire harness. When putting the
cab down, keep it stable.
1
Figure 8-38
1 cab
2. Assemble ROPS connecting bolts
Tighten torque: 500±50Nm
1
Figure 8-39
1 ROPS bolt
3. Assemble damper connecting nuts
Tighten torque: 85±10Nm
1
Figure 8-40
1 damper nut
8-20
4. Connect the wire harness on the gearbox
1
Figure 8-41
1 gang socket wire harness
5. Connecting the speed sensor wire harness on the
gearbox
1
Figure 8-42
1 output shaft speed sensor
6. Connecting the radiating valve wire harness port in

the left side of the engine hood
1
Figure 8-43
1 radiating valve wire harness
8-21
7. Assemble the wire harness of rear frame periphery

(as shown in Figure 8-44).
1 2
Figure 8-44
1 cab 2 rear frame wire harness
8. Assemble yellow plug as shown in Figure 8-45,

press it down.
1
Figure 8-45
9. Assemble the frame, for details refer to 85
Disassembly and Assembly of Left and Right
Platforms.
1 2
Figure 8-46
1 platform 2 hoisting rope
8-22
10. Assemble evaporator, for details refer to 8.6

Disassembly and Assembly of Air Conditioning
System.
1
Figure 8-47
11. Assemble steering gear hydraulic pipeline. For
details, refer to 622 Assembly of Steering Gear.
12. Assemble brake valve hydraulic pipeline. For
details refer to corresponding section in 514
Disassembly and Assembly of Main Components
1 2
Figure 8-48
1 steering gear
2 foot brake valve
13. Assemble operating handle pilot hydraulic pipeline,
for details refer to 948 Disassembly and Assembly
of Pilot Operating Valve Assembly.
1
Figure 8-49
1 pilot operating handle
8-23
833 Disassembly and Assembly of Seat

Instrument: 2m hoisting rope
Warning
The disassembly and assembly processes involve
transporting heavy components, be focus or serious
accidents may happen.
1. Disassemble the bolts under the seat support.
1
Figure 8-50
1 bolt
2. Hang the seat out of the cab with hoisting rope.
1
Figure 8-51
1 seat
3. Replace the old seat with new one and fix it with
bolts
1
Figure 8-50
1 bolt
8-24
834 Assembly of Maneuvering Box.

1. Disassemble the bolts of the seatback panel, fold
the seat forward and twine the safety belt on the
steering column to fix the seat.
Warning
The disassembly and assembly processes involve
transporting heavy components, be focus or serious
accidents may happen.
1
Figure 8-53
1 bolt
2. Disassemble the peripheral shield. And
disassemble the bolts shown in Figure 8-54.
1
Figure 8-54
1 bolt
3. Disassemble fixed bolts on the cover of the

maneuvering box.
1
Figure 8-55
1 bolt
8-25
4. Disassemble the sponge and pipe clamp which is

used for fixing the pilot pipeline on the bottom of
the maneuvering box
1 2
Figure 8-56
1 maneuvering welding assembly
2 bolt
5. Disassemble the fixed pilot valve and fixing blots
of the small pilot valve.
1 2
Figure 8-57
1 pilot valve bolt
2 small pilot valve bolt
6. Disassemble the roof fixed on the maneuvering
welding assembly.
1 2
Figure 8-58
1 bolt
2 roof assembly
8-26
7. Disassemble the maneuvering box assembly
1 2
Figure8-59
1 bolt
2 maneuvering box welding assembly
835 Assembly of Maneuvering Box.

1. Fix the maneuvering box assembly to the cab.
1 2
Figure8-60
1 bolt
2 maneuvering box welding assembly
2. Fix the roof assembly to the maneuvering box
welding assembly with bolts.
1 2
Figure 8-61
1 bolt 2 roof assembly
8-27
3. Install fixed bolts of the pilot valve and small pilot

valve.
1 2
Figure 8-62
1 pilot valve bolt
2 small pilot valve bolt
4. Assemble the pipe clamp of the pilot pipeline and
sponge.
1 2
Figure8-63
1 maneuvering welding assembly
2 bolt
5. Fasten the cover using bolt and gasket.
1
Figure 8-64
1 bolt
8-28
6. Mount the fixed bolts on the shield of the

maneuvering box.
1
Figure 8-65
1 bolt
7. Reset the seat and mount the rear fixing bolts
1
Figure 8-66
1 seat
8-29

Engine hood
Start the engine and drive the loader to smooth and

spacious ground. Wedge the front of the front wheels
and back of the rear wheels with blocks. Keep the
bucket flat on the ground, and shut down the engine.
The disassembly of the engine hood includes two parts:
1. Disassemble the rear cover;
2. Disassemble the engine hood.
1 2
Figure 8-67
1 rear cover
2 engine hood
841 Disassembly of Rear Cover

1. Move the machine to the maintenance position.
2. Open the window lattice.
1
Figure 8-68
1 window lattice
8-30
3. Disconnect the connection between back-up buzzer

and rear lamp circuit.
1 2
Figure 8-69
1 rear lamp wire harness
2 back-up buzzer wire harness
4. Disassemble the four connecting bolts between
rear cover and rear frame.
1
Figure 8-70
1 rear cover bolt
5. Disassemble the connecting two bolts between rear
cover and engine hood.
1
Figure 8-71
1 rear cover bolt
8-31
6. Connect one end of the hoisting rope to rear cover,

the other end to the hoisting device. Lift up the rear
cover, put in on a cushion carefully.
 Notice
Keep rear cover stable when putting it down. Avoid
tilt accidents.
1 2
Figure 8-72
1 rear cover
2 hoisting rope
7. If the rear cover is not easy to lift up, disassemble
the bolts on both side of the radiator first. After
hanging the rear cover, mount the bolts.
1
Figure 8-73
1 bolt
8-32
842 Engine hood, Disassembly

1. Disassemble fixed bolts of air pre-filter and hose
clamp, remove them from the engine.
2. Disassemble fixed bolts of the tail pipe and remove
them from the engine.
1 2 3 4
Figure 8-74
1 bolt 2 prefilter
3 tail pipe 4 bolt
3. Disconnect the liquid level monitor wire harness
connecting to the expansion box.
4. Disassemble the connect rubber hose 2 which
connecting the expansion box and engine body
5. Disassemble the filling water pipe 3 connecting to
exhalent siphon of the radiator
1 2 3 4
Figure 8-75
1 expansion box
2 rubber hose
3 filling water pipe
4 monitor wire harness
8-33
6. Open the upper port on the expansion box and the

water draining valve on the bottom of the box,
drain the cooling liquid (about 28 liters) to clean
container.
1
Figure 8-76
1 water draining valve
7. Disassemble the hose clamp of the pre-filter.
1 2
Figure 8-77
1 air prefilter 2 hose clamp
8. Disassemble the connecting bolts between the right
and left panels and press plate and engine hood.
1 2 3 4
Figure 8-78
1 left panel 2 right panel
3 press plate 4 bolt
8-34
9. Disassemble fixing bolts of the engine hood.
1
Figure 8-79
1 bolt
10. Disassemble the connecting clamps between
radiator water inlet hose and engine hood and
radiator.
1 2 3 4
Figure 8-80
1 hose clamp 2 engine hood
3 radiator water inlet 4 radiator assembly
11. Disassemble the connecting V-shape hoops
between intercooler exit pipe and radiator and
engine hood.
1 2 3 4
Figure 8-81
1 radiator 2 intercooler exit pipe
3 V-shape hoop 4 engine hood
8-35
12. Connect one end of the hoisting rope to the middle

of the engine hood armrest, the other end to the
hoisting device. Then lift down the rear cover, and
put it on the cushion.
 Notice
Keep rear cover stable when putting it down. Avoid
tilt accidents.
1
Figure 8-82
1 engine hood
8-36
843 Assembly of Engine hood

hoisting device. Then lift up the rear cover, and put
it on the engine.
 Notices
Pay attention to the lifting position, avoid it falling
down. During the lift, it is forbidden to stand under
the frame. When putting down the engine hood,
1
Figure 8-83 don’t squeeze your hand.
1 engine hood
2. Assemble the V-shape hoop connection of the
intercooler exit pipe and engine hood and radiator.
1 2 3 4
Figure 8-84
1 radiator 2 intercooler exit pipe
3 V-shape hoop 4 engine hood
3. Assemble the hose clamp connection of the
radiator water inlet and engine hood and radiator.
1 2 3 4
Figure 8-85
1 hose clamp 2 engine hood
3 radiator water inlet 4 radiator assembly
8-37
4. Assemble the eight fixing bolts on both sides of the

engine hood.
1
Figure 8-86
1 bolt
5. Assemble the left and right panel and press plate to
the engine hood.
1 2 3 4
Figure 8-87
1 left panel 2 right panel
3 press plate 4 bolt
6. Assemble the air pre-filter and hose clamp.
1 2
Figure 8-88
1 air prefilter
2 hose clamp
8-38
7. Connect rubber hose 2 (connecting with engine) to

expansion box with hose clamp.
8. Connect filling water pipe 1 (connecting with
exhalent siphon of radiator) to expansion box.
9. Connect the wire harness to the liquid level sensor.
1 2 3 4
Figure 8-89
1 expansion box 2 rubber hose
3 water filling pipe 4 monitor wire harness
10. Mount the fixed bolts of air pre-filter and hose
clamp.
11. Mount the fixed bolts of the tail pipe.
12. Fill coolant, for details refer to 272 Assembly of
Engine.
1 2 3 4
Figure 8-90
1 bolt 2 prefilter
3 tail pipe 4 bolt
8-39
844 Assembly of Rear Cover,

hoisting device. Then lift up the rear cover, and put
it on the engine.
 Notice
Do not touch the handrail on the engine hood
during hoisting. Keep rear cover stable when
putting it down to avoid tilt accidents.
1 2
Figure 8-91
1 rear cover 2 hoisting rope
2. Mount the connecting bolts between rear cover and
engine hood.
1
Figure 8-92
1 rear cover bolt
3. Mount the four bolts connecting rear cover and
rear frame.
1
Figure 8-93
1 rear cover bolt
8-40
4. Connect the circuit wire harness of back-up buzzer

and rear lamp.
1 2
Figure 8-94
1 rear lamp wire harness
2 Back-up buzzer wire harness
5. Close the window lattice.
6. Recover the machine.
1
Figure 8-95
1 window lattice
8-41
85 Disassemble Left and Right

Platform Assembly

spacious ground. Fix the front of the front wheels and
back of the rear wheels with blocks. Keep the bucket
flat on the ground, and shutdown the engine.
Disassembly of Left and right platforms are similar, we
take right platform for example.
Disassembly steps are as follows:
851 Disassembly of Platform Assembly

Disassembly of platform assembly includes platform
disassembly and ladder stand disassembly.
1. Connect the platform to the hoisting rope before
disassembling. Avoid the platform falling down
after all bolts are removed.
1 2 3
Figure 8-96
1 right platform 2 ladder stand
3 hoisting rope
2. Disassemble the bolts connecting left and right
platform and hydraulic oil tank stand.
1
Figure 8-97
1 bolt
8-42
3. Disassemble the bolts connecting platform and

armrest.
1
Figure 8-98
1 bolts
4. Disassemble the bolts connecting platform and
ladder stand.
1
Figure 8-99
1 bolt
5. Lift the right platform and put it on the cushion.
 Notice
Keep the platform stable.
1 2
Figure 8-100
1 hoisting Rope
2 right platforms
8-43
6. Disassemble the bolts connecting ladder stand and

condenser support. And hang on it to the cushion.
 Notice
Don’t crush the refrigeration pipeline. Avoid
the refrigerant leaking.
1 2 3
Figure 8-101
1 ladder stand 2 condenser support
3 bolts
8-44
852 Assembly of Platform Assembly

1. Lift the ladder stand to proper position of the
machine right side and connect ladder stand and
condenser support with bolts.
 Notice
Don’t crush the refrigeration pipeline. Avoid the
refrigerant leaking.
1 2 3
Figure 8-102
1 ladder stand 2 condenser support
3 bolts
2. Lift the platform to the proper position and prepare
to mount bolts.
 Notice
Keep the platform stable.
1 2
Figure 8-103
1 hoisting Rope
2 platforms
3. Mount the connecting bolts between platform and
ladder stand.
1
Figure 8-104
1 bolt
8-45

armrest.
1
Figure 8-105
1 bolts
oil tank support. After finished, remove hoisting
rope.
1
Figure 8-106
1 bolt
8-46
86 Disassembly and Assembly of Air

Conditioning System

spacious ground. Fix the front of the front wheels and
back of the rear wheels with blocks. Keep the bucket
flat on the ground, and shut down the engine
861 Disassembly of Climate Unit

1. Drain the cooling liquid (about 28 liters) to a clear
container.
2. Open the lockpin of the air condition cover
assembly.
 Notice
Avoid directly contacting the refrigerant.
Disassemble the unit in a well-ventilated place
1
Figure 8-107
1 lockpin
3. Disassemble the filter and its cover.
4. Disconnect the wire harness connection between
temperature control panel and fresh air damper
motor.
1 2
Figure 8-108
1 filter cover
2 damper motor wire harness
8-47

temperature controller panel and evaporator
assembly. Disconnect the wire harness connection
of evaporator power source.
1 2 3
Figure 8-109
1 power source wire harness
2 temperature controller panel wire harness
3 temperature control panel
6. Disconnect the hose clamp connection between
engine heater pipe and evaporator.
7. Disassemble the bolts connecting evaporator and
cab.
1 2
Figure 8-110
1 hose clamp
2 bolts
8. Disconnect the bolts connecting the right interior
trim panel in cab and evaporator assembly.
1 2
Figure 8-111
1 interior trim panel
2 bolt hole
8-48
9. Disassemble the evaporator assembly and put it to

the proper place.
1
Figure 8-112
862 Assembly of Climate Unit

1. Assemble evaporator assembly
2. Connect the rubber hose between evaporator air
outlet and cab air inlet.
 Notice
Notice the direction of air inlet and outlet, keep
them unobstructed.
1
Figure 8-113
3. Connect the hose clamp between engine heater
pipe and evaporator.
4. Mount the bolts connecting evaporator and cab.
1 2
Figure 8-114
1 hose clamp 2 bolts
8-49
5. Connect the wire harness between temperature

controller panel and fresh air damper.
6. Connect the wire harness of evaporator power
source.
1 2 3
Figure 8-115
1 power source wire harness
2 temperature controller panel wire harness
3 temperature control panel
7. Mount the bolts connecting cab interior trim panel
and evaporator.
1 2
Figure 8-116
1 interior trim panel
2 bolt hole
8. Connect the wire harness between temperature
controller panel and fresh air damper.
9. Fix the filter cover with bolts
1 2
Figure 8-117
1 filter cover
8-50
10. Close the lockpin of the air condition assembly.

11. Fill coolant, for details refer to 272 Assembly
of Engine.
1
Figure 8-118
1 lockpin
863 Replacement of Evaporator

Components
 Notice
Evaporator for replacement must be the same
type coming from the same manufacturer.
Check whether it conforms to all technical
requirements. There is nitrogen in the air
condition components. To prevent sewage water
invading into the system, when opening the
cover, connect the pipeline immediately. When
the pipeline is opened, cover it with plug or
multilayer plastic cloth.
Replacement of heating unit
1. Disassemble the evaporator from the machine, and

put in on the platform, refer to 861 Disassembly of
Climate Unit.
2. Disassemble the fixing plate on the right of the
evaporator.
1 2
Figure 8-119
1 evaporator
2 fixing plate
8-51
3. Disassemble the clamps of the evaporator

assembly, and then remove the shell.
1
Figure 8-120
1 clamp
4. Take down the heating unit and replace it.
5. Reinstall the cover, and fix all of the clamps.
 Notice
Check whether the fan is assembled in the right
position.
6. Reinstall climate unit, refer to 862 Assembly of
Climate Unit.
1
Figure 8-121
1 heating unit
Replacement of air blower
1. Disassemble the evaporator from the machine, and
put in on the platform, refer to 861 Disassembly of
Climate Unit.
2. Disassemble the fixing plate on the right of the
evaporator.
1 2
Figure 8-122
1 evaporator
2 fixing plate
8-52

assembly, and then remove the shell.
1
Figure 8-123
1 clamp
4. Disconnect the wire harness connection, lift out the
air blower and replace with a new one.
5. Reinstall the cover, and fix all the clamps.
 Notice
Check whether the fan is assembled in the right
position.
6. Reinstall climate unit, refer to 862Assembly of
1 Climate Unit.
Figure 8-124
1 air blower
Replacement of expansion valve
Warning
Oil is harmful, avoid it contacting with
unprotected skin. Use protective gloves.
1. Drain all refrigerant in the system. Refer to 867
Draining and Filling of Refrigerant.
2. Disassemble filter cover and filter, disconnect wire
harness connection between temperature control
panel and fresh air damper motor.
1 2
Figure 8-125
1 filter cover
8-53
3. Disassemble the filter cover and right fixing plate

on the evaporator.
1 2
Figure 8-126
1 fixing plate
2 pressure sensor connector
4. Disconnect the pipeline and disassemble the
expansion valve. Plug the connector.
5. Remove the plug and mount new expansion valve.
 Notice
Keep the lumen clean and use the compressor
oil to lubricate the seal ring.
6. Connect the expansion valve pipeline.
1
Figure 8-127
1 expansion valve
7. Insert the connector of the pressure sensor.

8. Mount the fixing plate
9. Use vacuum pump to fill system with refrigerant.
Refer to 867 Draining and Filling of Refrigerant.
1 2
Figure 8-128
1 fixing plate
2 pressure sensor connector
8-54
10. Mount filter cover and damper motor wire harness.

1 2
Figure 8-129
1 filter cover
Replacement of temperature sensor

1. Disassemble evaporator from the machine and put
it on the platform. Refer to 861Disassembly of
Climate Unit.
2. Disassemble the fixing plate mounted on the right
side of the evaporator.
1 2
Figure 8-130
1 evaporator
2 fixing plate
assembly, and remove the shell.
1
Figure 8-131
1 clamp
8-55
4. Remove the temperature sensor connector, which

is in the middle of the heat filter element and
refrigeration filter element.
1 2
Figure 8-132
1 heating unit
2 refrigeration unit
5. Assemble evaporator assembly shell and right
fixing plate.
1
Figure 8-133
1 fixing plate
6. Mount filter cover and damper motor wire harness.
7. Close the air condition cover lockpin.
1 2
Figure 8-134
1 filter cover
2 damper motor Wire Harness
8-56
Replacement of evaporator
Warning
Oil is harmful, avoid it contacting with unprotected
skin. Use protective gloves.
1. Open the evaporator assembly cover.
Drain all refrigerant fluid in the system, refer to
867 Draining and Filling of Refrigerant.
2. Disassemble filter and filter cover.
damper motor and temperature control panel.
1 2
Figure 8-135
1 filter cover
2 damper motor Wire Harness
4. Disassemble the fixing plate on the right side of

evaporator.
5. Pull out the temperature sensor.
1
Figure 8-136
1 fixing plate
6. Disassemble shell clamps, take evaporator out and
move it one side.
7. Loose bolts and mount new evaporator.
 Notices:
Keep the inner chamber of evaporator clean
and use the compressor oil lubricate the seal
ring.
8. Insert temperature sensor.
1
Figure 8-137 9. Mount evaporator cover.。
1 evaporator
8-57
10. Mount right fixing plate of the evaporator.
1
Figure 8-138
1 fixing plate
11. Assemble filter cover, filter and damper motor
wire harness.
1 2
Figure 8-139
1 filter cover
12. Use vacuum pump to fill system with refrigerant.
Refer to 867 Draining and Filling of Refrigerant.
13. Recover machine.
1
Figure 8-140
1 filling hose
8-58
864 Replacement of Condenser Fan

1. Disassemble peripheral bolts on condenser cover.
2. Unplug the plug of fan motor, remove condenser
cover and fan and put them on cushion.
1
Figure 8-141
1 bolt*8
3. Loose the four connecting bolts of condenser fan.
 Notice
Pay attention to nuts inside.
4. After replacing with new fan, fasten the four
connecting bolts.
 Notice
When assemble new fan, put the fan wire
harness on the upper right position.
1 2
5. Assemble condenser cover and fan to the
Figure 8-142
1 condenser fan bolt condenser.
2 fan wire harness
6. Recover machine.
8-59
865 Replacement of Liquid Storage

Tank
1. Drain the refrigerant, for details refer to 867
Draining and Filling of Refrigerant..
2. Disassemble steam storage pipe connecting with
liquid storage tank. Protecting the steam storage
pipe connector well is required.
3. Disassemble the upper condenser connecting with
liquid storage tank. Protecting the condenser pipe
connector well is required.
1 2 3
Figure 8-143
1 steam storage pipe
2 liquid storage tank
3 condenser pipe
4. Disassemble the lower condenser connecting with
liquid storage tank. Protecting the condenser pipe
connector well is required.
5. Loose the fixed bolts connecting liquid storage
tank support and condenser. Disassemble the liquid
storage tank.
6. Replace with new liquid storage tank and connect
it with steam storage pipe and condenser pipeline.
1 2
Figure 8-144 Before connecting pipeline, it is forbidden to
1 bolt
2 condenser pipe remove the plug cap. It can only be opened in the
last stage of installation.
7. Mount fixed bolts on the liquid storage tank.
8. Fill refrigerant
8-60
866 Replacement of Compressor

Components
 Notice
Compressor for replacement must be the same
type coming from the same manufacturer.
Check whether it conforms to all technical
requirements. There is nitrogen in the air
condition components. To prevent sewage water
invading into the system, when opening the
cover, connect the pipeline immediately. When
the pipeline is opened, cover it with plug or
multilayer plastic cloth.
Replacement of compressor belt
1. Put the machine in the maintenance position.
2. Open the engine hood.
3. Loose the connecting bolts and adjusting screws,
and then remove the belt.
4. Mount new belt, adjust tensile force, tighten it
using connecting bolts and adjust to the proper
degree of tightness. When press 10kg pressure
force, it is proper if belt goes down 10~12mm, and
1 2
then fasten compressor.
Figure 8-145
1 belt 5. Recover the machine and make a test run of the air
2bolt
conditioning system.
Replacement of compressor
1. Open the engine hood.
2. Drain all refrigerant in the system, refer to 867
Draining and Filling of Refrigerant.
3. Release the tensile force in the belt, remove the
belt. Pull out the clutch wire harness plug.
4. Loosen compressor condenser pipe and vapor
1 2 compression pipe from the compressor. Protecting

Figure 8-146 the condenser connector well is required.
1 compressor condenser pipe
2 vapor compression pipe
8-61
5. Loose and disassemble the bolts which are used for

fixing the compressor, then disassemble the
compressor.
6. Drain the redundant compressor oil to a beaker
with scale, volume of which should be bigger than
250ml.
 Notice
Pay attention to the volume of compressor oil.
Deal with the leakage of compressor oil in
environmentally friendly way.
7. Replace with new compressor which prefilled
about 240ml compressor oil. Drain all the
compressor oil in the new compressor.
8. Fill the same volume oil drained from the old
compressor to the new one.
9. Assemble new compressor with connecting bolts,
but do not tighten.
10. Remove the plugs from the refrigerant pipe and
1
compressor. Mount the refrigerant pipe and O-ring
Figure 8-147
1 belt on the compressor. Lubricate O-ring using
compressor oil.
11. Insert connector, and then mount the clamp of
refrigerant pipe.
12. Reinstall belt to the compressor. Adjust the
position of compressor and keep the belt groove of
compressor clutch and that of engine coplanar.
Adjust the belt to proper degree of tightness.
13. Refill air condition system. Refer to 867 Draining
1 and Filling of Refrigerant.
Figure 8-148
1 filling hose 14. Recover the machine.
8-62
867 Draining and Filling of Refrigerant

Refrigerant, Draining
Instruments:
Refrigerant device vacuum pump
Adaptor AC leak detection
Hose platform scale
1. Put the refrigerant container on the platform scale.
Make sure the volume of the refrigerant container
is big enough to contain the refrigerant.
Weight the refrigerant, weight of refrigerant and
1
Figure 8-149 container － weight of container= weight of
1 draining hose
refrigerant.
Read the filling capacity of container from the
container.
2. Make sure there is no pressure on the recovery
device.
3. Connect the red hose in the “draining” position of
the recovery device to the low pressure connector
of compressor.
Connect blue hose in the “suction “position to low
pressure connector of the machine compressor.
Drain.
4. Open the red hose valve on the refrigerant
container.
Open the valve on the refrigerant container.
Open the “draining” valve on the recovery valve.
Rotate the central controller to recovery position.
Start the recovery device through the switch, start
draining.
Figure 8-150
1 suction 2 draining Open the blue hose valve through the lower
3 central controller pressure connector of the machine.
4 scale displayer
5 refrigerant container valve Open suction valve
6 red hose valve
7 refrigerant container
8 platform scale
8-63
5. When the weight no longer increases, check

whether the pressure is lower than the vacuum
degree displayed on the pressure gauge.
6. Stop the suction valve.
Stop the blue hose valve through the low pressure
connector of the machine.
Rotate the central controller to “auto clean”; the
blue pressure gauge falls to vacuum degree again.
Close the recovery device.
Close refrigerant container valve.
Close draining valve.
7. Disconnect the recovery device from the machine.
Refrigerant filling, including vacuum pump suction

Instruments:
Refrigerant devoice
Adaptor
· Vacuum exhaust
1. Close all of the valves on the pressure gauge box.
2. Connect the red hose to the high pressure plug on
the machine. Open the hose valve through the
machine connector.
3. Connect the blue hose to the low pressure plug on
the machine. Open the hose valve through the
machine connector.
1 2
Figure 8-151 4. Connect the yellow hose to the refrigerant
1 red hose container.
2 blue hose
Place the refrigerant container upside down on the
platform scale.
Check whether has refrigerant in the container.
weight of refrigerant and container －weight of
container= weight of refrigerant.
8-64
5. Open the two green valves on the pressure gauge

box. Start the vacuum pump.
6. Open the blue and red valves on the pressure gauge
box. Start the vacuum pump.
7. Keep the vacuum pump working at least for 50
minutes.
8. When reach the right pressure, close the two green
valves, red valve and blue one on the pressure
gauge box.
Close the vacuum pump.
2 3 4
Figure 8-152 Disconnect the hose from the machine.
1 vacuum meter
2 refrigerant container · Filling
3 platform Scale 9. Connect the adaptor to the low pressure plug on the
4 vacuum Pump
machine, and fill in the same volume of oil
consumed by system.
Remove the adaptor.
10. Connect the red hose to the high pressure
connector of the machine. Connect the blue hose to
the low pressure connector of the machine.
11. Press the TARA (reset the scale) on the scale
display unit.
Open the yellow valve on the pressure gauge box.
1
Figure 8-153 12. Open the blue valve, start filling.
1 adaptor
13. Under the condition of opening AC power, start the
engine. Run the engine at the speed of 1000rpm.
14. When the platform scale shows the right weight of
the refrigerant, close the refrigerant valve (refer to
the information on the inside of the machine
hatch).
Close the yellow valve on the pressure gauge box.
15. Coles the hose valve through the machine.
Close all of the valves on the pressure gauge box.
8-65
16. Open the red and blue valves through the machine
connector and check the pressure at the speed of
the 1800rpm.
17. Disconnect the red and blue hoses from the
machine.
1 2
Figure 8-154
1 red hose
2 blue hose
8-66
87 Diagnosis and Solutions for Frequently Asked Questions of Air

Conditioning System
When check and maintain the failures of the air condition system, you must according to the
abnormal phenomena to find out the reasons, and then take measures. The common failures of
air conditioning system are non-refrigeration, non-heating, insufficient refrigeration capacity and
so on.
871 Regular Checking Items

The air conditioning system of the loader is working in bad environment. So it may be damaged
whether it is working or not. The usual maintenance must be strengthened.
Check the pipeline connectors, compressor support, Degree of tightness of the compressor belts
regularly. Check whether the hoses of the air conditioning system have wear phenomena, check
wire harnesses and keep the surface of the condenser clean.
Table 8-1 Regular checking item list
Checking Checking time

Checking details
items daily semiannually annually
Fixed bad, with gaps ▲ ▲
Pipeline assembly
Connection loose, nuts and bolts loose ▲ ▲
Connection loose, nuts and bolts loose
Connecting bolts ▲ ▲
and fall off
Loose and bend ▲ ▲
belt Degrade, wear, scar, crack ▲ ▲
Noise, abnormal odor and heat ▲
Condenser Radiator sheets lodging ▲
assembly Foreign matter block ▲ ▲ ▲
Startup check, air volume, switch
Ari condition air ▲ ▲
control
flow switch
Switch function ▲ ▲
Refrigerant Pipe joint leakage ▲ ▲
leakage Internal leakage in the components ▲
Refrigerant
Check the volume of refrigerant ▲ ▲
volume
Compressor ▲
Noise
Condenser fan, evaporator fan ▲
Receiver-drier Exist of temperature difference means
temperature there is foreign matter blocked on the ▲
difference surface
8-66
872 Non-refrigeration Fault Analysis

Table 8-2 Non-refrigeration fault analysis list
Checking items: fan
Compressor
connector, ground
doesn’t work
Condenser fan connection, fan
doesn’t rotate Checking items:
Evaporator Compressor
temperature control switch,
fan rotates works
relay and relay connector
Condenser fan Compressor Checking item: clutch,
rotates doesn’t work connector and belt
Check whether speed-control switch is
Non-refrigerant
Condenser rotates, failure, whether fan wire is disconnected,
Evaporator compressor works whether ground connection wire of fan is
fan doesn’t good.
rotate Condenser doesn’t Check whether fuse is burned, whether
rotate, compressor relay is normal, whether connection wire is
doesn’t work loose.
If not used for long time, the R134a in the
Fans of evaporator
Compressor system might leak. Use high-low pressure
and condenser
is normal gauge to check whether there is R134a or
work normally
not.
873 Insufficient Refrigeration Fault Analysis
Table 8-3 Insufficient refrigeration Fault analysis list
Fans of Import and export of liquid storage tank are

evaporator connected reversely。
and Check whether the expansion valve is blocked by ice
condenser or contaminant, replace the liquid storage tank.
works
Compressor normally, so
Insufficient
works as the
refrigeration Replace R134a
normally evaporator
and
condenser
Fan works
Check whether there is foreign matter blocked on the
normally, so
condenser surface.
as others.
8-67
874 Non-Heating Fault Analysis

Table 8-4 Non-heating fault analysis list
Evaporator Check whether electromagnetic valve works normally, whether

works normally there are other valves of heating pipeline not opened.
Non-heating Check whether speed-control switch is failure, whether fan wire
Evaporator is disconnected, whether ground connection wire of fan is good.
doesn’t work Check whether fuse is burned, whether connecting wire is
loose.
875 Other Fault Analysis
Table 8-5Otherfaultanalysis list
Phenomena Causes Solutions
At the beginning, the
refrigeration performance is
The loader was traveled on
good. After a period of time,
the rough ground
refrigeration capacity is not Use leak detector to find the
frequently. Connectors
1 enough; observing through leaking position and tighten
become loose because of
observation hole of the leak parts carefully.
vibration and leakage
reservoir, bubbles appear;
appears.
both readings of high and
low pressure gauge are low.
System doesn’t refrigerate,
the airport blows hot air. Misused the loader,
There is no hand-feeling thermal bulb of expansion Replace expansion valve and
2
temperature difference of valve is worn and leak. The refill R134a
the import and export of the valve hole is blocked.
expansion valve.
Start refrigeration system
Air volume of outlet isn’t
intermittently, when the block
cool, compressor
There are impurities in the is not serious, this method
temperature rises. Pointer of
system, filter screen of can eliminate the
low pressure gauge decline
3 expansion valve is blocked. instantaneous blockage. Or
to near zero quickly.
Thin frost of sweat appears remove the expansion valve
Reading of high pressure
on expansion valve. and clean it with alcohol.
gauge is higher than normal
Empty the system and refill
level.
R134a.
Refrigeration capacity is not
enough, evaporator frosts; Flow restriction orifice of Empty the system, replace
4 readings of high and low expansion valve doesn’t expansion valve and refill
pressure gauges are lower work. R134a.
than normal level.
After running for a period,
Desiccant of receiver-drier
refrigeration capacity
is saturated. Flow Empty the system, replace
declines, high pressure
5 restriction orifice of liquid storage tank and refill
gauge is higher than normal
expansion valve is blocked R134a.
level and low pressure
by ice.
gauge is lower than 0.4Mpa.
8-68
Start refrigeration system, Use multi-meter to check

Temperature control switch
there is air flow but is not whether temperature control
has a bad contact or
6 cool. Readings of high and switch is damaged; replace
electromagnetic clutch coil
low pressure gauge don’t electromagnetic clutch of
of compressor is damaged.
change. compressor.
Opening degree of
Action of electromagnetic
temperature control switch
clutch of compressor is too
is too small which force Check temperature control
frequent, contact time is
7 the compressor stop switch and turn it to the
short. Cab is not cool but
automatically and cause coldest position.
readings of high and low
refrigeration capacity is not
pressure gauge is normal.
enough.
 Notes when checking refrigeration system:
1. When checking, wear protective glasses or mask as far as possible. Avoid contact with
refrigerant directly which can frostbite body. Once contacting with large number of
refrigerant, rinse the contact part with cold water.
2. Maintain the refrigeration system in well-ventilated place. As the refrigerant is colorless and
odorless, it can make people suffocate because of lack of oxygen.
3. Refrigerant will produce toxic phosgene when meeting flame. Avoid contact with fire.
4. In order to avoid the risk of explosion, do not weld or rinse with hot steam near the air
condition pipeline or components.
5. When replacing the components, keep the connector and inner chamber of system clean.
Follow the criterions as shown in Table 8-7 to replenish refrigerating engine oil.
Table 8-7 Volume of refrigerating engine oil
Component name Replenish volume/mL
evaporator 40～50
condenser 40～50
System connecting hose 30～40
Liquid storage tank 15～25
6. After replaced air condition components, connect the pipeline connectors. Tighten them in
accordance with required tightening torque as shown in Table 8-8.
Table 8-8 Tightening torque
Thread size Tightening torque
5/8-18UNF, M16×1.5 16～20Nm
3/4-16UNF, M22×1.5 20～25Nm
7/8-14UNF, M24×1.5 30～35Nm
8-69
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SERVICE MANUAL
Version:0920
9 Hydraulic System
CONTENTS
9 Working Hydraulics ............................................................................................................. 9-1

91 Working Hydraulics, Component Positions ....................................................................... 9-1
92 Principle Diagram of Hydraulic System, Description ....................................................... 9-2
921 Median Function of Multiway Valve ....................................................................... 9-2

922 Boom Floating Function .......................................................................................... 9-4
923 Hydraulic Safety Functions ...................................................................................... 9-4
924 Automatic Reset Function ........................................................................................ 9-6
925 Hydraulic System for Quick-change Device ........................................................... 9-6
926 Independent Radiating Hydr- aulic System ............................................................. 9-7
93 Hydraulic System Components, Description ...................................................................... 9-8
931 Gear Pump................................................................................................................ 9-8

932 Hydraulic Oil Tank .................................................................................................. 9-8
933 Multiway Valve........................................................................................................ 9-9
934 Pilot Operating Valve............................................................................................. 9-12
935 Pilot Operating Valve for Reserved Function ........................................................ 9-13
94 Disassembly and Assembly of Main Components ............................................................ 9-14
941 Disassembly and Assembly of Working Pump...................................................... 9-14

942 Disassembly and Assembly of Steering Pump ...................................................... 9-19
943 Disassembly and Assembly of Hydraulic Oil Tank ............................................... 9-24
944 Disassembly and Assembly of Multiway Valve .................................................... 9-33
945 Disassembly and Assembly of Boom Cylinder ..................................................... 9-42
946 Disassembly and Assembly of Bucket Cylinder .................................................... 9-52
947 Disassembly and Assembly of Quick-change Cylinder ......................................... 9-59
948 Disassembly and Assembly of Pilot Operating Valve Assembly .......................... 9-64
949 Disassembly and Assembly of Triple Operating Valve Control Handle ............... 9-69
95 Diagnosis and Solutions for Frequently Asked Questions of Hydraulic System .......... 9-76
951 Unexpected Forward Tilt of Bucket....................................................................... 9-76

952 Boom Sinking ........................................................................................................ 9-77
953 Boom Lifting Slow................................................................................................. 9-79
954 Lifting Incapacity of Boom .................................................................................... 9-81
955 Bucket Working Slow ............................................................................................ 9-82
956 Working Incapacity of Bucket ............................................................................... 9-82
96 Schematic Diagrams for Hydraulic System ...................................................................... 9-82
Ⅰ
9 Working Hydraulics
91 Working Hydraulics, Component
Positions
Figure 9-1
1 bucket cylinder 2 boom cylinders
3 multiway valve 4 pilot handle
5 steering radiating double pump 6 hydraulic oil tank
7 working pilot double pump 8 radiator
9-1
92 Principle Diagram of Hydraulic

System, Description
The working device hydraulic system is composed of

working pump, multiway valve, pilot valve, pressure
selective valve, boom cylinders, bucket cylinder,
hydraulic oil tank and pipeline accessories.
The multiway valve is a triple valve, one part for
bucket, one for boom and the third one is a reserved
slide valve for further hydraulic functions.
921 Median Function of Multiway

Valve
When set the pilot handle in neutral position, no control
oil flows into multiway valve. The multiway keeps in
neutral position under spring force. At this point, the
pumped oil flows back to hydraulic oil tank through
multiway valve directly.
Figure 9-2 oil route for neutral position
9-2
When operate the pilot handle to carry out forward tilt,

backward tilt of bucket or lift, falling of boom, the
corresponding control port of corresponding slide valve
on main control valve will receive the control oil sent
by pilot valve. The control oil pushes slide valve to all
high pressure oil from working pump flowing into the
corresponding cylinder to get the action we need.
The move of slide valve is proportional to control oil
pressure; its displacement is determined by control oil
pressure and the built-in spring.
Figure 9-3 oil route for lifting the boom

Red line working oil line Blue line oil return line
Orange line control oil line
9-3
922 Boom Floating Function

When pilot handle is in limiting position of boom
falling, on the one hand, pilot valve sends a control
pressure to boom part of the multiway valve to keep the
boom part stay in boom falling position; on the other
hand, the pilot valve make the logical valve in boom
rod side chamber connect to hydraulic tank, at this
point, the logical valve is open. The rod side chamber
of boom is connected to oil return line, and
zero-pressure idle loop is formed in the system. The
boom cylinder works in floating state under its own
gravity and the force acting by the ground.
Figure 9-4 oil route for boom floating state

Red line working oil line Blue line oil return line
Orange line control oil line Red line no pressure oil
923 Hydraulic Safety Functions

When bucket cylinder or boom cylinder is under big
external force, high oil pressure will be formed and
9-4
exert force on pipelines. This kind of pressure must be

released safely to protect hydraulic components. When
the oil pressure rises to a certain value, the main safety
valve in main control valve will open to release high
pressure oil automatically.
When the bucket tilts forward accidentally, the pressure
of oil in bucket cylinder piston side chamber will
increase, if it exceeds settling value of the
corresponding overload valve in multiway valve bucket
part, the high pressure in bucket cylinder piston side
chamber will flow back to hydraulic tank through
overload valve; meanwhile, negative pressure will be
formed in the piston side chamber, oil in piston side
chamber pipeline will flow back to offset the negative
pressure through the check valve.
When the bucket tilts backward accidentally, the
pressure of oil in bucket cylinder rod side chamber will
increase, if it exceeds settling value of the
corresponding overload valve in multiway valve bucket
part, the high pressure in bucket cylinder rod side
chamber will flow back to hydraulic tank through
overload valve; meanwhile, negative pressure will be
formed in the rod side chamber, oil in rod side chamber
pipeline will flow back to offset the negative pressure
through the check valve.
Another function of the both-way overload oil
compensation valve: When the bucket is totally
forward tilt and operate to lift the boom, the piston of
bucket cylinder will be forced to extend due to
uncoordinated movement of working device, so the
pressure of oil in bucket cylinder rod side chamber will
increase. At this point, rod side double-acting safety
valve begins to work to release pressure. When the
bucket is totally backward tilt and operate to lower the
boom, the piston of bucket cylinder will be forced to
9-5
retract, so the pressure of oil in bucket cylinder piston

side chamber will increase and negative pressure will
be formed in rod side. At this point, piston side
double-acting safety valve begins to work to release
pressure and oil in rod side chamber pipeline will flow
back to offset the negative pressure. By this way, the
working device interaction problem can be solved,
which makes the system more stable.
924 Automatic Reset Function

Automatic reset system is composed of two parts,
boom limiting control system and bucket flat control
system. When the boom is lifted to limiting position or
the bucket is turned to horizontal position, the boom or
bucket proximity switch will send electrical signal to
deenergize the coils of pilot valve, and the multiway
valve goes back to neutral position, so the boom can
stay in limiting position or the bucket can stay
horizontal.
925 Hydraulic System for

Quick-change Device
Its oil inlet port is connected to foot brake valve oil
inlet port.
Its oil return port is connected to return port of
multiway valve, and then the oil jointly flows back to
oil tank.
Figure 9-5
1 magnetic exchange valve
2 bilateral pilot-controlled valve
3 double rod hydraulic cylinder
9-6
926 Independent Radiating Hydr- aulic

System
Radiating gear pump sucks oil from oil tank, hydraulic
oil flow into temperature-control wind-cooling control
valve through the filter, this valve can control oil flow
according to signal sent by electronic control system, in
this way, rotating speed of hydraulic motor can be
controlled. Adjusted pressure oil drives the motor to
rotate the fan, and the fan is used for radiating. In the
meantime, electrical control components are used to
monitor torque converter oil temperature, transmission
oil temperature, working device hydraulic oil
temperature and engine water temperature, any of these
temperatures reaches settling value will lead to
electrical signal produced in electronic component, the
signal can control relief pressure of temperature-control
wind-cooling control valve, adjust oil flow to hydraulic
motor, to realize different rotating speed under different
temperature for hydraulic motor and fan.
The system is equipped with manual forced cooling
switch and automatic fault detection warning device at
the same time, use the switch to carry out forced
Figure 9-6
9-7
cooling if necessary. When short circuit or open circuit

of temperature sensor is detected by the controller, the
fan will rotate the fastest and the buzzer will warn.
93 Hydraulic System Components,

Description
931 Gear Pump

It is installed on gearbox, powered by engine through
the transfer gear in gearbox. The pump works as a
pressure oil source to supply the whole hydraulic
system.
Technical parameters
Rated speed 2200 r/min
Rated pressure 200 Bar
Pilot pump displacement 16 ml/r
Steering pump displacement 100 ml/r
Radiating pump displacement 40 ml/r
Figure 9-7
1 pilot pump 2 steering pump
3 radiating pump 4 working pump
932 Hydraulic Oil Tank

It is used to provide oil to the whole hydraulic system,
it also provide oil to braking system. Oil return filter is
assembled in the tank to remove impurities in the
hydraulic system, ensure the cleanness of hydraulic oil.
Figure 9-8
1 oil filling port 2 ventilation filter
3 oil return filter 4 oil level viewer 9-8
933 Multiway Valve

The multiway is mainly composed of valve body, boom
slide valve part, bucket slide valve part, reserved part,
main relief valve, bucket both-way overload valve and
check valves. Boom slide valve part and bucket slide
valve part have series structure and bucket slide valve
part has priority, if bucket slide valve part is working,
the boom slide valve part has to wait. The two oil
return structures are parallel, so they can return oil at
the same time.
Oil inlet check valve: Used to prevent backflow of oil
in boom or bucket cylinder, otherwise the cylinder may
retract unexpectedly.
Oil compensating check valve: The valve is both
designed in rod side chamber connecting port of bucket
slide valve part and boom slide part. For example,
when retracting speed of bucket cylinder rod is beyond
working pump supply ability, negative pressure will be
formed in the rod side chamber, oil in rod side chamber
pipeline will flow back to offset the negative pressure
through the check valve, in this way, cavitation can be
avoided.
Main relief valve: It is a pilot cartridge valve, and the
settling pressure is adjustable by regulating its pilot
valve spring. The settling pressure is 180Bar
Bucket both-way overload valve: This valve has a
similar function as relief valve, but has different
structure. Overload pressure for piston side chamber is
205Bar, while the rod side is 120Bar.
9-9
Reserved part Bucket slide valve part Boom slide valve part
Figure 9-9 Interior oil way of multiway valve
Figure 9-10
1 reserved part 2 bucket slide valve part 3 boom slide valve part
4 main relief valve 5 check valve 6 overload valve for bucket cylinder rod side chamber
7 overload valve for bucket cylinder piston side chamber 8 logical valve
9-10
Figure 9-11
1 control lifting of boom, a2 2 control backward tilt of bucket, a1
3 control the reserved part, a3 4 connect rod side chamber of bucket cylinder, B1
5 connect piston side chamber of bucket cylinder, A1
6 connect rod side chamber of the reserved part, B3
7 connect piston side chamber of the reserved part, A3
8 oil inlet port of multiway valve, P 9 control the reserved part, B3
10 control forward tilt of bucket, B1 11 control falling of boom, B2
12 oil outlet port of multiway valve, T 13 connect piston side chamber of boom cylinder, A2
14 connect rod side chamber of boom cylinder, B2
9-11
934 Pilot Operating Valve

Pilot operating valve is installed in the cab, right side of
the operator seat; it is a stacked double-piece valve.
The valve is composed of boom operating part and
bucket operating part. Boom slide valve part and
bucket slide valve part in multiway valve can be
controlled by operating this valve, and then the
working device can be controlled in this way.
Figure 9-12
1 operate to lower the boom
2 operate to retract the bucket
3 operate pilot valve to return oil
4 operate to lift the boom
5 operate pilot valve to supply
6 floating port
7 operate the bucket to unload
Table 9-1 Pipe connections and control relationship

Multiway
Pilot valve Multiway valve
oil port valve oil port control oil Function
port
Bucket operating 2 a1 A1 Retract bucket (backward tilt)

part
7 b1 B1 Unload (forward tilt)
4 a2 A2 lifting
Boom operating
part 1 b2 B2 falling
6 k A2, B2 floating
9-12
Figure 9-13
1 operate to lower the boom 2 operate to retract the bucket
3 operate pilot valve to return oil 4 operate to lift the boom
5 operate pilot valve to supply 6 floating port 7 operate the bucket to unload
935 Pilot Operating Valve for

Reserved Function
This valve is used to control reversing of the reserved
part in multiway valve
Figure 9-14
1 oil outlet port, T 2 oil inlet port, P
3 connect to b3 port in multiway valve
4 connect to a3 port in multiway valve
9-13

Main Components

Working Pump
Disassembly of the Working Pump
1. Draining oil.
Start the machine and drive it to the flat spacious
place. Raise the boom to the highest position. Tilt
the bucket backward to the extreme position, and
then shut down the engine.
Turn the power switch to the “ON” position. Push
the control handle of the pilot valve towards right
gently. Let the bucket tilt forward under the action
of gravity to drain the oil in bucket cylinder.
Figure 9-15 After the bucket reaches its extreme position, push
the handle forward gently. Let the boom falling
under the action of gravity to drain the oil in boom
cylinder. Keep the bucket flat on ground. Then
operate the handle left and right, back and forth for
5~6 times to drain the internal oil pressure of the
system.
Figure 9-16 2. Fix the loader tires with wedges stably.
Open the ventilation cap of hydraulic oil tank.
Figure 9-17
9-14
3. Put clean vessel under the pump to contain oil.
Figure 9-18
4. Disassemble the three fixing bolts on the back of

operator seat, and then fold the seat forward.
5. Disassemble the bolts of maintenance cover plate

in the cab, and then remove the plate.
1
Figure 9-19
1 maintenance cover plate
6. Loosen the fixing bolts between working pump oil

suction steel pipe and oil inlet port joint, remove
the bolts, fission flange and O-ring, and then
remove the pipe.
★ Notice
When disassemble the hydraulic connections,
them off slightly until there is oil spills out, and
1 then disconnect them completely.
Figure 9-20
1 working pump oil suction steel pipe During the processes of hydraulic pipes
disassembly, all the pipelines and ports should
be protected to avoid the debris entering into
the pipelines.
9-15
7. Loosen the fixing bolts between working pump oil

outlet rubber pipe and oil outlet port joint, remove
remove the pipe.
1
1 working pump oil outlet rubber pipe
Figure 9-21
8. Loosen the fixing bolts between radiating pump oil

outlet port and the flange joint; remove the bolts,
fission flange and O-ring, and then remove the
pipe.
1
Figure 9-22
1 flange joint
9. Loosen the connecting bolts between working

pump and speed changer-torque converter
assembly, remove the nuts and washers; and then
take down the working pump and sealing gasket.
Working pump
1
Figure 9-23
1 bolt
9-16

recycling bin.
Assembly of the Working Pump

Figure 9-24
1. Assemble the working pump to end face of
gearbox with four M12 nuts and washers and
sealing gasket.

Working pump
★ Notice
Tighten the stud first.

1
Figure 9-25
1 bolt
2. Put an O-ring in O-ring groove of working pump

oil outlet rubber pipe joint, and then fasten the pipe
on working pump oil outlet port end face with four
M10×30 and fission flange.
★ Notice
1
Figure 9-26 loosen the connection bolts rashly and completely to
1 working pump oil outlet rubber pipe
completely.
9-17
3. Put an O-ring in O-ring groove of radiating pump

oil outlet rubber pipe flange joint, and then fasten
the pipe on pilot pump oil outlet port end face with
four M10×30 bolts and fission flange.
★ Notice
1
Figure 9-27 all the pipelines and ports should be protected to
1 flange joint
4. Put an O-ring in O-ring groove of working pump

oil suction steel pipe joint, and then fasten the pipe
on working pump oil suction port end face with
1
Figure 9-28
1 working pump oil suction steel pipe
5. Assemble the maintenance cover plate assembly on

the platform in cab.
1
Figure 9-29
9-18
6. Reset the seat and fix it with three bolts.

Figure 9-30
Steering Pump
Disassembly of the Steering Pump
1. Draining oil.
Figure 9-31 of gravity to drain the oil in bucket cylinder.
After the bucket reaches its extreme position, push
system.
2. Fix the loader tires with wedges stably.
Figure 9-32
9-19
3. Open the ventilation cap of hydraulic oil tank.
Figure 9-33
4. Put clean vessel under the pump to contain oil.
Figure 9-34
5. Disassemble the three fixing bolts on the back of

operator seat, and then fold the seat forward.
6. Disassemble the bolts of maintenance cover plate

in the cab, and then remove the plate.
1
Figure 9-35
9-20
7. Loosen the fixing bolts between steering pump oil

suction steel pipe and oil inlet port joint, remove
the bolts and O-ring, and then remove the pipe.
★ Notice
1 completely.
Figure 9-36
1 steering pump oil suction steel pipe During the processes of hydraulic pipes disassembly,
all the pipelines and ports should be protected to
8. Loosen the fixing bolts between steering pump oil

outlet rubber pipe and oil outlet port joint, remove
remove the pipe.
1
Figure 9-37
1 steering pump oil outlet rubber pipe
9. Disconnect the connection between steering pump

and pilot pump oil outlet rubber pipe, and then
remove the fixing bolts of the joint.
1 2
Figure 9-38
1 pilot pump oil outlet rubber pipe
2 joint
9-21
10. Loosen the connecting bolts between steering

pump and speed changer-torque converter
assembly, remove the nuts and washers; and then
take down the steering pump and sealing gasket.
Steering pump
1
Figure 9-39
1 connecting bolts between steering pump
and gearbox Assembly of the Steering Pump
1. Assemble the steering pump to end face of gearbox
with four M12 nuts and washers and sealing
gasket.

Steering pump
★ Notice
Tighten the stud first.
1
Figure 9-40
1 connecting bolts between steering pump
and gearbox
2. Put an O-ring in O-ring groove of steering pump

oil outlet rubber pipe joint, and then fasten the pipe
on steering pump oil outlet port end face with four
M10×30 and fission flange.
1
Figure 9-41
1 steering pump oil outlet rubber pipe
9-22
3. Assemble the joint on steering pump with two

M8×35 and two M8×50 bolts
4. Assemble the oil outlet rubber pipe of pilot pump
1 2
Figure 9-42
1 pilot pump oil outlet rubber pipe
2 joint
5. Put an O-ring in O-ring groove of steering pump

oil suction steel pipe joint, and then fasten the pipe
on steering pump oil suction port end face with
1
Figure 9-43
1 steering pump oil suction steel pipe
6. Assemble the maintenance cover plate assembly on

the platform in cab.
1
Figure 9-44
9-23
7. Reset the seat and fix it with three bolts.

Hydraulic Oil Tank
Figure 9-45 Disassembly of Hydraulic Oil Tank
1. Draining oil.
system.
2. Connect a hosepipe to the oil draining valve on the
bottom of hydraulic tank, and put a clean vessel
under the other end. Open the draining valve of the
tank to drain the hydraulic oil out. (Open the filling
port of the tank to accelerate the draining speed)
★ Notice
Cover the drained oil to prevent contamination.
1
Figure 9-47
1 oil draining valve
9-24
3. Remove the guard on each side of hydraulic tank;

disassemble the connecting bolts between left and
right stages and the tank support.
1 2 3
Figure 9-48
1 upper right guard board
2 lower right guard board
3 right stage
4. Disassemble the engine hood.

(Refer to 8-4 Disassembly and Assembly of Engine
Hood)
Figure 9-49
5. Disconnect the connecting bolts between silencer

and bellows, and then remove the bolts, nuts and
gaskets.
1
Figure 9-50
1 connecting bolt between silencer and
bellows
9-25
6. Loosen the T-shape hold hoop that fixes the air

filter inlet rubber pipe.
1
Figure 9-51
1 T-shape hold hoop
7. Loosen the four hose clamps that connect two oil

suction rubber pipe to hydraulic oil tank outlet
ports.
1
Figure 9-52
1 hose clamps
8. Disconnect all connections between oil return

pipes and the hydraulic oil tank.
★ Notice
completely.
1 2 3
Figure 9-53 all the pipelines and ports should be protected to
1 oil return rubber pipe of series pedal valve
2 oil return pipe of priority valve avoid the debris entering into the pipelines.
3 oil return valve of prefill valve
9-26
1 2
Figure 9-54
1 oil return rubber pipe of radiator
2 oil return rubber pipe of multiway valve
1 2 3
Figure 9-55
1 oil return rubber pipe of radiator motor
2 three-port joint
3 straight joint
9. Disassemble the hose clamps back-down side of
hydraulic oil tank.
1
Figure 9-56
1 hose clamp
9-27
10. Disassemble the connecting bolts between ECU

and tank support.
1
Figure 9-57
1 ECU
11. Disassemble the connecting bolts between

oil-water separator and tank support.
1 2
Figure 9-58
1 hose clamp
2 oil-water separator
12. Disassemble the connecting bolts between tank

support and rear frame, and then hang the tank
assembly down
1
Figure 9-59
1 bolts
9-28
13. Disassemble the connecting bolts between tank and

tank support, and then take the tank down.
1
Figure 9-60
1 bolts
Assembly of Hydraulic Oil Tank
1. Assemble the tank on tank support with bolts.
1
Figure 9-61
1 bolts
2. Hang the hydraulic oil tank assembly to proper

position; fix it on the rear frame with bolts.
1
Figure 9-62
1 bolts
9-29
3. Use two M10×25 bolts to fix oil-water separator on

tank support, and then fix oil pipe on the support
with hose clamp.
1 2
Figure 9-63
1 hose clamp
2 oil-water separator
4. Assemble the connecting bolts between ECU and

tank support.
1
Figure 9-64
1 ECU
5. Fix the air filter inlet rubber pipe on the filter with
a T-shape hold hoop.
1
Figure 9-65
1 T-shape hold hoop
9-30
6. Connect the silencer and bellows with bolts.
1
Figure 9-66
1 connecting bolt between silencer and
bellows
7. Connect two oil suction rubber pipes to the tank

separately; fasten the four hose clamps to fix the
pipes.
★ Notice
Two hose clamps on one pipe should be assembled
in opposite direction.
1
Figure 9-67
1 hose clamps
8. Connect all oil return pipes.
1 2 3
Figure 9-68
1 oil return rubber pipe of series pedal valve
2 oil return pipe of priority valve
3 oil return valve of prefill valve
9-31
Oil return rubber pipe of radiator
Oil return rubber pipe of multiway valve
1 2
Figure 9-69
1 oil return rubber pipe of radiator
2 oil return rubber pipe of multiway valve
1 2 3
Figure 9-70
1 oil return rubber pipe of radiator motor
2 three-port joint
3 straight joint
9. Assemble the hose clamps back-down side of
hydraulic oil tank.
1
Figure 9-71
1 hose clamp
9-32
10. Assemble the engine hood.

(Refer to 8-4 Disassembly and Assembly of Engine
Hood)
Figure 9-72
11. Assemble the fixing bolts of oil tank left and right
guard boards; assemble the fixing bolts between
left and right stages and the tank support.

Multiway Valve
Disassembly of the Multiway Valve
1 2 3 1. Draining oil.
Figure 9-73
1 upper right guard board Start the machine and drive it to the flat spacious
2 lower right guard board
3 right stage place. Raise the boom to the highest position. Tilt
Figure 9-74 under the action of gravity to drain the oil in boom
system.
9-33
Figure 9-75
Figure 9-76
4. Put clean vessel under the valve to contain oil.
Figure 9-77
5. Remove the fixing bolts on front cover plate and

take the front cover plate down.
1
Figure 9-78 9-34
6. Disconnect the connection between multiway valve

and pilot control oil pipes of boom cylinder, bucket
cylinder, reserved part, and floating control part.
★ Notice
completely.
1 2 3 4
Figure 9-79 During the processes of hydraulic pipes disassembly,
1 pilot control oil pipe for reserved part
2 pilot control oil pipe for backward tilt of
bucket avoid the debris entering into the pipelines.
3 pilot control oil pipe for floating of the
boom
4 pilot control oil pipe for lifting of the
boom
1 2 3
Figure 9-80
1 pilot control oil pipe for falling of the
boom
2 pilot control oil pipe for forward tilt of
bucket
9-35

multiway valve and boom slide valve part rod side
and piston side steel pipes, and then disconnect the
connection between steel pipes and multiway
valve.
1 2
Figure 9-81
1 connect to boom cylinder rod side chamber
2 connect to boom cylinder piston side chamber

multiway valve and bucket slide valve part rod side
and piston side steel pipes, and remove the bolts
and fission flange.
multiway valve and the reserved part rubber pipes,
and remove the bolts and fission flange.
1 2 3 4
Figure 9-82
1 reserved part rod side rubber pipe
2 reserved part piston side rubber pipe
3 bucket slide valve part rod side steel
pipe
4 bucket slide valve part piston side steel
pipe

multiway valve and its oil inlet and outlet rubber
pipes, and remove the bolts and fission flange.
1 2
Figure 9-83
1 multiway valve oil inlet pipe
2 multiway valve oil outlet pipe
9-36
11. Loosen the U-shape fixing bolts of boom slide

valve part rod side and piston side steel pipes.
(Doesn’t need to be removed).
1
Figure 9-84
1 U-shape fixing bolts
12. Loosen the U-shape fixing bolts of bucket slide
(Doesn’t need to be removed).
1
Figure 9-85
1 U-shape fixing bolt
1
Figure 9-86
9-37
13. Disassemble the fixing bolts between multiway

valve and front frame, lift down the valve, and then
disassemble the straight joints in all oil ports.
1
Figure 9-87
1 bolt Assembly of the Multiway Valve
1. Assemble straight joints in relevant oil port of
multiway valve, and then lift the valve on front
frame, insert two M12×165 and two M12×145
bolts from top to down, use gaskets and nuts to
fasten them.
1 Multiway valve
Figure 9-88
1 bolt
2. Put an O-ring in the pipe joint between the

transition body and multiway valve oil outlet
rubber pipe. Fix it on end face of multiway valve
oil outlet port with four M12×65 bolts and fission
flange.
★ Notice
1 2
Figure 9-89 The O-ring side of transition body assembly should
1 multiway valve oil inlet pipe
2 multiway valve oil outlet pipe face down.
9-38
3. Put an O-ring in the pipe joint of multiway valve

oil inlet rubber pipe. Fix it on end face of multiway
valve oil inlet port with four M10×30 bolts and
fission flange.
★ Notice
Adjust the direction of rubber pipe, keep it
1 2 3 4
Figure 9-90 horizontal.
1 reserved part rod side rubber pipe
2 reserved part piston side rubber pipe
3 bucket slide valve part rod side steel
pipe
4 bucket slide valve part piston side steel
pipe
4. Put O-ring in O-ring grooves of bucket slide valve

part piston side and rod side joints and the reserved
part rubber pipe joints; fix them on multiway valve
with four M10×30 bolts and fission flange.
1 2
Figure 9-91
1 connect to boom cylinder rod side chamber
2 connect to boom cylinder piston side chamber
9-39
5. Assemble the fixing bolts of boom cylinder rod

side and piston side steel pipes.
1 2 3 4
Figure 9-92
2 pilot control oil pipe for backward tilt of
bucket
3 pilot control oil pipe for floating of the
boom
4 pilot control oil pipe for lifting of the
boom
6. Assemble pilot control oil pipes of boom cylinder,

bucket cylinder, reserved part, and floating control
part.
1 2 3
Figure 9-93
1 pilot control oil pipe for falling of the
boom
2 pilot control oil pipe for forward tilt of
bucket
9-40
7. Tighten the U-shape fixing bolts of boom slide

1
Figure 9-94
8. Tighten the U-shape fixing bolts of bucket slide

1
Figure 9-95
1 U-shape fixing bolt
1
Figure 9-96
9-41
9. Put the front cover plate back to the frame.
1
Figure 9-97
10. Assemble the ventilation cap of hydraulic oil tank.

Check hydraulic oil level, fill oil if necessary.
Figure 9-98
945 Disassembly and Assembly of Boom

Cylinder
Disassembly of the Boom Cylinder
1. Start the machine and drive it to the front of
bearing frame (the frame should be put on flat
spacious ground), find a proper position and stop
the machine, and then fix the loader tires with
wedges stably.
Figure 9-99
9-42
2. Raise the boom to the highest position and tilt the

bucket backward to the extreme position, and then
shut down the engine.
Figure 9-100
3. Push the pilot operating handle to boom falling

position, to let the boom falling on the bearing
frame gently. Then push the handle between lifting
and falling positions back and forth for 5~6 times.
Figure 9-101
4. Put clean vessel under the to-be replaced cylinder

to contain oil.
Figure 9-102
9-43
5. Loosen the connecting bolts between steel pipes

and rubber pipes of boom cylinder rod side and
piston side, and then remove the bolts, fission
flanges and O-rings, take down the rubber pipes
★ Notice
1 2
Figure 9-103 completely.
1 boom cylinder rod side rubber pipe
2 boom cylinder piston side rubber pipe
6. Bind the cylinder body with lifting rope and lift it

up a bit.
Figure 9-104
7. Loosen boom cylinder front pin fixing bolts,

remove the bolts and gaskets.
1
Figure 9-105
1 boom cylinder front pin
9-44
8. Disassemble boom cylinder front pin, remove the

adjusting shim, and avoid scratching the pin during
the operation.
Figure 9-106
9. Loosen the rear two fixing bolts of front fender;

rotate the fender clockwise for a certain angle to
make the disassembly of rear pin more easily
1
Figure 9-107
1 front fender
10. Loosen boom cylinder rear pin fixing bolts,

remove the bolts and gaskets.
1
Figure 9-108
1 boom cylinder rear pin
9-45
11. Dismount boom cylinder rear pin, and hang the

cylinder body off the machine.
Figure 9-109
12. Loosen the U-shape fixing bolts of boom cylinder

steel pipes. (Doesn’t need to be removed).
1
Figure 9-110
13. Loosen the connecting bolts between boom

cylinder and its steel pipe fixing plate, remove the
bolts and gaskets.
1
Figure 9-111
1 fixing plate
9-46

cylinder and its rod side steel pipe.
1
Figure 9-112
1 boom cylinder rod side steel pipe

cylinder and its piston side steel pipe.
1
Figure 9-113
1 boom cylinder piston side steel pipe

recycling bin.
Figure 9-114
9-47
Assembly of the Boom Cylinder

1. Put O-ring in O-ring groove of boom cylinder
piston side steel pipe, and fix the pipe on piston
side oil port with two M10×50 and two M10×55
bolts separately.
1
Figure 9-115
1 boom cylinder piston side steel pipe
2. Put O-ring in O-ring groove of boom cylinder rod

side steel pipe, and fix the pipe on rod side oil port
with two M10×50 and two M10×55 bolts
separately.
1
Figure 9-116
1 boom cylinder rod side steel pipe
3. Use two M10×25 bolts and gaskets to fasten the

fixing plate on the boom.
1
Figure 9-117
1 fixing plate
9-48
4. Tighten the U-shape fixing bolts of boom cylinder

steel pipes.
1
Figure 9-118

to assembling position.
★ Notice
Be careful when assembling the boom cylinder, the
piston side steel pipe should be on the outside, do
not mistake the left and right cylinders.
Boom cylinder
Figure 9-119
6. Smear some grease on boom cylinder rear pin, and

then use it to connect cylinder to the front frame.
1
Figure 9-120
1 pin
9-49
7. Assemble boom cylinder rear pin fixing bolts.
1
Figure 9-121
1 boom cylinder rear pin
8. Put O-ring in O-ring groove of two boom cylinder

rubber pipes, and connect the pipes to
corresponding ports with four M10×30 bolts and
fissions.
1 2
Figure 9-122
1 boom cylinder rod side rubber pipe
2 boom cylinder piston side rubber pipe
9. Smear some grease on boom cylinder front pin,
add a gasket, and then start the engine. Operate
pilot handle to adjust stroke of boom cylinder
piston rod, keep its connecting hole aligned with
the pin joint hole on boom, and connect them with
pin.
★ Notice
Be careful when assembling the boom cylinder,
1 the screw base on piston rod head should be on
Figure 9-123
1 pin outside; use proper numbers of gaskets to
ensure the clearance between piston rod head
end face and boom is within 0.5～1.5mm.
9-50
10. Assemble boom cylinder front pin fixing bolts.
1
Figure 9-124
1 boom cylinder front pin
11. Reset the front fender and fix it with bolts.
1
Figure 9-125
1 front fender
12. Add grease to boom cylinder front pin until there is

grease squeezed out of the fitting surface.
Figure 9-126
9-51
13. Add grease to boom cylinder rear pin until there is

grease squeezed out of the fitting surface.
946 Disassembly and Assembly of Bucket

Cylinder
Figure 9-127 Disassembly of the Bucket Cylinder
1. Draining oil.

system.
Figure 9-129
9-52
Figure 9-130
4. Put clean vessel under the to-be replaced cylinder

to contain oil.
Figure 9-131
5. Disassemble the connecting bolts between flat

fender and bucket cylinder piston rod head; remove
the bolts, gaskets and flat fender.
1
Figure 9-132
1 flat fender
9-53
6. Disassemble the connecting bolts between limiting

lay-flat holder and bucket cylinder.
1
Figure 9-133
1 limiting lay-flat holder
7. Disconnect the connecting bolts between bucket

cylinder and bucket cylinder piston side rubber
pipe, and then remove the bolts and fission flange.
★ Notice
1
Figure 9-134 then disconnect them completely.
1 bucket cylinder piston side rubber pipe
the pipelines.
8. Disconnect the connecting bolts between bucket
cylinder and bucket cylinder rod side rubber pipe,
and then remove the bolts and fission flange.
1
Figure 9-135
1 bucket cylinder rod side rubber pipe
9-54

up a bit. Disassemble the fixing bolts between the
cylinder and rocker arm connecting pin.
1
Figure 9-136
1 pin
10. Dismount the connecting pin between bucket

cylinder and rocker arm.
Figure 9-137
11. Lift up the cylinder, and make the cylinder body

tend to upright. Disassemble the pin fixing bolt
between cylinder and front frame.
1
Figure 9-138
1 pin
9-55
12. Hang bucket cylinder down and remove piston side

oil inlet steel pipe.
1
Figure 9-139
1 bucket cylinder piston side oil inlet steel pipe
Assembly of the Bucket Cylinder
1. Put O-ring in O-ring groove of bucket cylinder
piston side steel pipe, and fix the pipe on piston
side oil port with two M10×50 and two M10×55
bolts and gaskets separately.
1
Figure 9-140
1 bucket cylinder piston side oil inlet steel pipe
2. Smear some grease on pin, add a gasket, and then

lift the cylinder up to proper position with lifting
rope, use the pin to connect the cylinder to front
frame.
★ Notice
Be careful when assembling the boom cylinder,
the screw base on piston rod head should be on
outside; use proper numbers of gaskets to
1 ensure the clearance between piston rod head

Figure 9-141
1 pin
end face and boom is within 0.5～1.5mm.
9-56
3. Assemble pin fixing bolt.
Figure 9-142
4. Put O-ring in O-ring grooves of bucket cylinder

rod side and piston side rubber pipes, and then
connect them to rod side oil port and piston side
steel pipe with M10×30 bolts and fission flanges
separately.
1 2
Figure 9-143
1 bucket cylinder rod side rubber pipe
2 bucket cylinder piston side rubber pipe
5. Start the engine and operate pilot handle to adjust

stroke of bucket cylinder piston rod, keep its
connecting hole aligned with the pin joint hole on
bucket, and connect them with pin. Use proper
numbers of gaskets to ensure the clearance
between piston rod head end face and rocker arm is
within 0.5～1.5mm.
6. Assemble pin fixing bolt.
1
Figure 9-144
1 pin
9-57
7. Fix flat fender on bucket cylinder piston rod head

with two M10×25 bolts and gaskets.
1
Figure 9-145
1 flat fender
8. Assemble the connecting bolts between limiting
lay-flat holder and bucket cylinder.
1
Figure 9-146
1 limiting lay-flat holder
9. Tighten the ventilation cap of hydraulic oil tank.
Figure 9-147
9-58
10. Add grease to all hinge points until there is grease

squeezed out of the fitting surface.
Figure 9-148
Quick-change Cylinder
Disassembly of Quick-change Cylinder
1. Operate pilot handle to separate quick-change
device from bucket. Stop the machine and load off
brake system by stepping brake pedal again and
again.
2. Put clean vessel under the cylinder to contain oil.
Figure 9-149
3. Disassemble fixing bolts of cylinder cover plate
1
Figure 9-150
1 cover plate
9-59
4. Disconnect rubber pipe 1 and 2.
★ Notice
completely.
1 2 all the pipelines and ports should be protected to
Figure 9-151
1 rubber pipe avoid the debris entering into the pipelines.
2 rubber pipe
5. Use nipper pliers to disassemble the ring between

quick cylinder piston rod and slip shaft, remove the
connecting pin.
1
Figure 9-152
1 slip shaft
6. Disassemble four fixing bolts between the cylinder

and cylinder support.
1 2
Figure 9-153
1 bolts
2 support
9-60
7. Rotate the cylinder, use nipper pliers to

disassemble the ring between quick-change
cylinder left piston rod and slip shaft, remove the
connecting pin, and then take down the cylinder.
1
Figure 9-154
1 slip shaft
8. Loosen quick-change cylinder rod side and piston

side oil pipes.
Figure 9-155

recycling bin.
Figure 9-156
9-61
Assembly of Quick-change Cylinder

1. Assemble quick-change cylinder rod side and
piston side oil pipes.
Figure 9-157
2. Put the cylinder in the support, the end with rubber
pipe connector should towards right. Connect the
cylinder left to slip shaft with a pin, and then
assemble the ring.
1
Figure 9-158
1 slip shaft
3. Assemble the fixing bolts between the cylinder and

cylinder support.
1 2
Figure 9-159
1 bolts
2 support
9-62
4. Connect the cylinder and slip shaft with a pin, and

then assemble the ring.
1
Figure 9-160
1 slip shaft
5. Assemble rubber pipe 1 and 2.
1 2
Figure 9-161
1 rubber pipe
2 rubber pipe
6. Assemble fixing bolts of cover plate
1
Figure 9-162
1 cover plate
9-63
7. Start the machine and connect the cylinder to

bucket.
948 Disassembly and Assembly of Pilot

Operating Valve Assembly
Figure 9-163 Disassembly of the Pilot Operating Valve
Assembly
1. Draining oil.
system.
Figure 9-165
9-64
Figure 9-166
4. Disassemble fixing bolts of operation box shell

plate, take down the plate.
1
Figure 9-167
1 shell plate
5. Disassemble fixing bolts of operation box upper

cover, take down the cover.
1
Figure 9-168
1 upper cover
9-65
6. Disconnect the seven oil pipes on pilot operating

valve assembly.
★ Notice
Figure 9-169 During the processes of hydraulic pipes
the pipelines.
7. Disconnect the two wire harness connectors of the

valve assembly.
Figure 9-170
8. Disassemble fixing bolts of pilot handle, and then

take down the handle.
1
Figure 9-171
1 bolt
9-66
9. Disconnect the seven straight joints of the valve

assembly, remove the joints and gaskets.
Figure 9-172 Assembly of the Pilot Operating Valve

Assembly
1. Assembly the seven straight joints back to their
corresponding oil ports.
Figure 9-173
2. Use four M10×16 bolts to fix pilot operating valve

assembly on operation box.
1
Figure 9-174
1 bolt
9-67
3. Connect the seven rubber pipes to their

corresponding oil ports on pilot operating valve
assembly.
★ Notice
Straighten out the pipes, avoid interference and
do not distort them.
Figure 9-175
4. Connect the two wire harness connectors to valve

assembly.
Figure 9-176
5. Assemble fixing bolts of operation box upper

cover.
1
Figure 9-177
1 upper cover
9-68
6. Assemble fixing bolts of operation box shell plate.
1
Figure 9-178
1 shell plate
7. Tighten the ventilation cap of hydraulic oil tank.
949 Disassembly and Assembly of Triple

Operating Valve Control Handle
Disassembly of Triple Operating Valve
Control Handle
Figure 9-179 1. Draining oil.
Figure 9-180 under the action of gravity to drain the oil in boom
system.
9-69
Figure 9-181
4. Disassemble fixing bolts of operation box shell

plate, take down the plate.
1
Figure 9-183
1 shell plate
5. Disassemble fixing bolts of operation box upper

cover, take down the cover.
1
Figure 9-184
1 upper cover
9-70
6. Disassemble fixing bolts of pilot valve, and then

take down the pilot operating valve assembly.
1
Figure 9-185
1 bolt
7. Disconnect the two lateral oil pipes of triple
operating valve control handle assembly, and then
take down the pipes, bolts and gaskets.
★ Notice
1 2
Figure 9-186 During the processes of hydraulic pipes
1 oil return pipe of triple operating valve disassembly, all the pipelines and ports should
2 oil inlet pipe of triple operating valve
the pipelines.
8. Disconnect the two oil pipes from the bottom of

triple operating valve.
1 2
Figure 9-187
1 connect to multiway valve control oil port
9-71
9. Disassemble fixing bolts of triple operating valve

and take down the valve.
1
Figure 9-188
1 bolt
10. Disassemble the two straight joints of triple pilot

valve assembly, remove the joints and gaskets.
1
Figure 9-189
1 straight joint
Assembly of Triple Operating Valve Control

Handle
1. Assembly the two straight joints back to their
corresponding oil ports on triple operating valve
assembly.
1
Figure 9-190
1 straight joint
9-72
2. Use two M8×16 bolts to fix the valve assembly on

operation box.
1
Figure 9-191
1 bolt
3. Connect the two oil pipes back to the bottom of

triple operating valve.
1 2
Figure 9-192
4. Assemble the two lateral oil pipes of triple

operating valve control handle assembly.
Tightening torque: 70 ~ 85 Nm
1 2
Figure 9-193
1 oil return pipe of triple operating valve
2 oil inlet pipe of triple operating valve
9-73
5. Use four M6×16 bolts to fix pilot valve assembly

on operation box.
1
Figure 9-194
1 bolt
6. Assemble fixing bolts of operation box upper
cover.
1
Figure 9-195
1 upper cover
7. Assemble fixing bolts of operation box shell plate.
1
Figure 9-196
1 shell plate
9-74
95 Diagnosis and Solutions for Frequently Asked Questions of

Hydraulic System
951 Unexpected Forward Tilt of Bucket

Fault phenomena: When operation handle of pilot valve is in neutral position, the bucket tilt
forward unexpectedly.
Fault analysis: Due to link mechanisms are used in working device, when the bucket is under
retract state and operation handle of pilot valve is in neutral position, the bucket cylinder piston side
chamber will suffer extra force caused by self-weight. At this point, if there is leakage in piston side
chamber, it will result in unexpected forward tilt of bucket.
Six situations can cause the leakage in piston side chamber of bucket cylinder:
1. Obvious external leakage exists in pipelines, joints and fitting surfaces from the piston side
chamber to multiway valve.
2. Multiway valve bucket slide vale part fails to go back to neutral position (due to valve rod gets
stuck, valve element of pilot valve cannot reset or there are faults exist in the valve body, such
as sand holes and grooves that connect to piston side chamber).
3. While inner leakage exists in bucket cylinder, leakage also exists from rod side chamber to oil
outlet port.
4. Low overload pressure for bucket cylinder piston side overload valve (may caused by damaged
pressure adjusting spring, valve element stuck in open position, dirt exists in the conical fitting
surface between valve element and valve body, or there are defects exist in the valve body,
such as sand holes and grooves that connect to piston side chamber).
5. Leakage exists in bucket cylinder piston side oil compensation valve (may caused by damaged
reset spring, valve element stuck in open position, dirt exists in the conical fitting surface
between valve element and valve body, or there are defects exist in the valve body, such as
sand holes and grooves that connect to piston side chamber)
6. Excessive wear of selector valve body or element, which result in fit clearance between valve
body and valve element is far more than design value.
Diagnosis and solutions:
1. Six situations that cause leakage are listed above and the simplest and easiest to diagnose is the
first one: Start the machine and lift the boom to a certain height, retract the bucket to its
extreme position, and then observe the pipelines, joints and fitting surfaces from the piston side
9-76
chamber to multiway valve to find out whether there are obvious external leakage phenomena
exist.
2. If the first situation is being excluded, consider the second situation: Start the machine and
operate pilot valve handle to lift the boom to highest position, and retract the bucket to its
extreme position, and then shut down the engine, disassemble the two pilot pipes that
connected to two ends of multiway valve bucket slide vale part. At this point, if the unexpected
forward tilt phenomenon disappeared, then we can come to a conclusion that the fault is caused
by pilot valve, which causes multiway valve bucket slide vale part fails to go back to neutral
position. Disassemble and clean the pilot valve or replace it. Otherwise, check the third
situation.
3. For the third situation, we can do some simple check: Start the machine and operate pilot valve
handle to lower the boom to lowest position, and retract the bucket to its extreme position, and
then shut down the engine, disconnect bucket cylinder piston side rubber pipe and diver it to
hydraulic oil tank. Start the machine again, operate the pilot valve handle to backward tilt the
bucket, observe whether there is oil comes out from piston side oil port continually. If there is,
which means server inner leakage exists in bucket cylinder, the cylinder needs to be repaired or
replaced. Otherwise, check the fourth and fifth situations.
4. For the fourth and fifth situations, method of pressure detection can be used: Connect a
0-250Bar pressure gauge to gauge port of bucket cylinder piston side chamber. Start the
machine and operate pilot valve handle to extend the bucket to its extreme position; step on the
gas and operate pilot valve handle to lift the boom, at the same time, check whether the reading
on the gauge reach the design value when the boom is lifting. If not, either situation
mentioned in the first place is possible, the overload valve or oil compensation valve for bucket
cylinder piston side chamber need to be checked and cleaned.
5. If situation 1 to situation 5 have been excluded and the fault still exists, then stop the machine,
low boom and bucker to lowest positions and disassemble multiway valve bucket slide valve
part, look through the valve rod, valve opening and their fitting situation.
952 Boom Sinking

Fault phenomena: When operation handle of pilot valve is in neutral position, the boom sinks
automatically and exceeds allowed range.
9-77
Fault analysis: When the boom is lifted and stays in a certain height, the boom cylinder piston side
chamber will suffer extra force caused by self-weight. At this point, if there is leakage in piston side
chamber, the boom will fall automatically.
Six situations can cause the leakage in piston side chamber of boom cylinder:
1. Obvious external leakage exists in pipelines, joints and fitting surfaces from the piston side
chamber to multiway valve.
2. Multiway valve boom slide vale part fails to go back to neutral position (due to valve rod gets
stuck, valve element of pilot valve cannot reset or there are defects exist in the valve body, such
as sand holes and grooves), which cause boom cylinder rod side chamber connect to pump, or
piston side chamber connect to oil return port.
3. While inner leakage exists in boom cylinder, leakage also exists from rod side chamber to oil
outlet port.
4. Malfunctioned selector valve of control oil combination valve, (may caused by machining
defects, jammed valve element, inner leakage of pilot valve or defects exist in the valve body,
such as sand holes and grooves), which make selector valve element fail to cut off the channel
between boom cylinder piston side chamber and combination valve and pilot valve, result in
leakage in piston side chamber of boom cylinder.
1. Six situations that cause leakage are listed above and the simplest and easiest to diagnose is the
first one: Start the machine and lift the boom to a certain height, and then observe the pipelines,
joints and fitting surfaces from the piston side chamber to multiway valve to find out whether
there are obvious external leakage phenomena exist.
2. If the first situation is being excluded, consider the second situation: Start the machine and
operate pilot valve handle to lift the boom to highest position, and retract the bucket to its
extreme position, and then shut down the engine, disassemble the two pilot pipes that
connected to two ends of multiway valve bucket slide vale part. At this point, if the boom
sinking phenomenon disappeared, then we can come to a conclusion that the fault is caused by
pilot valve, which causes multiway valve boom slide vale part fails to go back to neutral
position. Disassemble and clean the pilot valve or replace it. Otherwise, check the third
situation.
handle to lift the boom to highest position, and retract the bucket to its extreme position, and
9-78
then shut down the engine, disconnect boom cylinder piston side rubber pipe and divert it to
hydraulic oil tank. Start the machine again, operate the pilot valve handle to lower the boom,
observe whether there is oil comes out from piston side oil port continually. If there is, which
means server inner leakage exists in boom cylinder, the cylinder needs to be repaired or
replaced. Otherwise, check the fourth situation.
handle to lift the boom to highest position, and then shut down the engine. Open pilot valve oil
return port, observe whether there is oil comes out. If there is, which means inner leakage of
pilot valve causes the fault, the pilot valve needs to be repaired or replaced. Otherwise; If there
is not, then open combination valve oil return port and check whether there is oil comes out, if
there is, which means inner leakage of combination valve causes the fault, the combination
valve needs to be repaired or replaced.
5. If situation 1 to situation 4 have been excluded and the fault still exists, then stop the machine,
low boom and bucker to lowest positions and disassemble multiway valve boom slide valve
part, look through the valve rod, valve opening and their fitting situation.
953 Boom Lifting Slow

Fault phenomena: When the diesel engine is running under rated speed, operate pilot valve handle
to lift the boom from lowest to highest position, the time it needed exceeds full load lifting time.
Fault analysis: Consider the characteristics of Hydraulic power units, the reason for boom lifting
slow: insufficient flow from hydraulic pump to cylinder.
Ten situations are listed below that may cause insufficient flow from hydraulic pump to
cylinder:
1. Severe external leakage exists in joints, pipelines, valves and fitting surfaces from pump to
boom cylinder piston side chamber.
2. The hydraulic oil contain a lot of bubble or turns black, or goes bad, and its viscosity has been
changed.
3. Blocked oil suction filter or oil suction pipe, which make the working pump hard to suck oil.
4. Severe inner leakage exists in working pump.
5. Severe inner leakage exists in boom cylinder (caused by cylinder scoring or damaged sealing
element ).
6. Severe inner leakage exists between boom cylinder piston side chamber and combination
valve oil return port through selector valve.
9-79
7. Low adjusting pressure of multiway valve main safety valve (may caused by damaged pressure
adjusting spring, valve element stuck in open position, or there are defects exist in the valve
body, such as sand holes and grooves that connect to oil return chamber).
8. Severe inner leakage exists between oil inlet channel an oil return channel of multiway valve
body (caused by sand hole or breakage of valve body).
9. Excessive wear of selector valve rod or valve opening of multiway valve boom slide valve part,
which result in fit clearance between valve body and valve element is far more than design
value.
10. Insufficient opening of multiway valve (due to selector valve rod gets stuck, valve element of
boom cylinder piston side pilot valve cannot reset or there are sand holes and grooves exist in
the valve body, or low setting pressure of combination valve that result in insufficient pilot
pressure).
1. For all situations mentioned above, firstly, we should start the machine and lift the boom, check
out whether there is obvious external leakage exists in pipelines, joints and fitting surfaces from
working pump to boom cylinder piston side chamber.
2. If there is no severe external leakage, then basic inspection should be done: Whether the
hydraulic oil level is above “LOW” level, whether there is too much bubble in hydraulic oil or
the oil turns black. Add hydraulic oil if necessary; if the oil turns bad, clean the tank and the
whole hydraulic system, and then replace the oil.
3. If the hydraulic oil is good, then start the machine and operate pilot handle to retract the bucket,
at the same time, listen carefully and check whether there is screaming in working pump. If
there is, which means the pump have severe oil suction problem, check and clean oil suction
filter and rubber pipes.
4. If there is no screaming phenomenon, check the forth situation: Start the machine, operate the
pilot valve to load the pump for 1-2 minutes, then shut down the engine; carefully touch the
shell of working pump, if it feels too hot, then we can come to a conclusion that severe inner
leakage exist in working pump, which causes the oil shortage problem.
5. For the fifth to ninth situations, we need to do some simple tests first: Connect a 0-25Bar
pressure gauge to gauge port of multiway valve P port. Start the machine and operate pilot
valve handle to pressurize the hydraulic system, at the same time, check whether the reading on
the gauge reach the design value. If not, check situation 5 to 9 one by one.
6. For the fifth situation, start the machine and operate pilot valve handle to lower the boom to
lowest position, and retract the bucket to its extreme position, and then shut down the engine,
9-80
disconnect boom cylinder piston side rubber pipe and divert it to hydraulic oil tank. Start the
machine again, operate the pilot valve handle to lower the boom, observe whether there is oil
comes out from piston side oil port continually. If there is, which means server inner leakage
exists in boom cylinder, the cylinder needs to be repaired or replaced.
7. For situation 6: Shut down the engine and operate pilot valve handle to lower the boom to
lowest position, then reverse the check valve between boom cylinder piston side chamber and
combination valve.
8. For situation 7: Check and clean main safety valve, if there is irreparable damage for valve
element or valve body, please replace the safety valve.
9. If situation 5 to 7 are being excluded and the system pressure still fails to reach design value,
then focus on situation 8 and 9. Disassemble multiway valve boom slide valve part, look
through the valve rod, valve opening and their fitting situation.
10. If the hydraulic system pressure reaches design value but the boom still lifting slow, check the
tenth situation:
a) Operate pilot valve handle to lower the boom and bucket to their lowest positions, and then
open the spring-free end cover(the one with short axial dimension) of multiway valve
boom slide valve part, force the valve rod to do axial movement, check whether the rod can
get to the right positions, whether it can return to neutral position smoothly.
b) Exchange control oil pilot pipes of bucket slide valve part and boom slide valve part, then
start the machine and operate pilot valve, check whether the boom can be lifted normally.
If it turns normal, check and clean pilot valve of multiway valve boom slide valve part.
954 Lifting Incapacity of Boom

Fault phenomena: When the diesel engine is running under rated speed, operate pilot valve handle
to lift the boom under full load, the boom fails to be lifted.
Fault analysis: The most direct reason for lifting incapacity of boom is low pressure of boom
cylinder piston chamber.
Primary reasons for low pressure in boom cylinder piston chamber:
1. Low overload pressure for main safety valve of multiway valve (may caused by damaged
pressure adjusting spring, valve element stuck in open position, or there are defects exist in the
valve body, such as sand holes and grooves that connect to oil return chamber).
2. Severe inner leakage of working pump, due to that the system cannot build up pressure or the
system pressure cannot reach design value.
9-81
3. Severe inner leakage exists in boom cylinder (caused by cylinder scoring or damaged sealing
element ).
4. Severe inner leakage exists between oil inlet channel an oil return channel of multiway valve
body (caused by sand hole or breakage of valve body), due to that the system cannot build up
pressure or the system pressure cannot reach design value.
Focus on the four reasons mentioned above and refer to 9.5.3 Boom Lifting Slow for
troubleshooting.
955 Bucket Working Slow

Refer to 9.5.3 Boom Lifting Slow for troubleshooting.
956 Working Incapacity of Bucket

Refer to 9.5.5 Bucket Working Slow for troubleshooting.
96 Schematic Diagrams for Hydraulic System
Symbols Explanations
Pipelines
Pipeline joints
Inserted joints
Quick connections (such as pressure checking

connection)
Restraint unit
9-82
Restraint unit, low viscosity control
Adjustable restraint unit
Open type oil tank
Accumulator
Filter, filter screen
Magnetic core filter
Heat exchanger
Radiator, no coolant indicating line
Control equipment
Manual control (with button)
9-83
Manual control (with lever)
Manual control (with pedal)
Mechanical control (with reset spring)
Electromagnetic control (with one coil)
Hydraulic control
Hydraulic control (with two pressure ratings)
Reduced hydraulic pressure control
Pneumatic control
Reduced pneumatic pressure control
Power source
Internal combustion engine
Electric motor
9-84
Pump
Hydraulic pump, constant displacement and

single-flow direction
Hydraulic pump, variant displacement and single-flow

direction
Hydraulic pump, variant displacement and

double-flow direction
Hydraulic pump, variant displacement and pressure

control
Hydraulic pump, variant displacement and pressure

control, with pressure compensation control
9-85
Motor
Hydraulic motor, constant displacement and

single-flow direction
Hydraulic motor, constant displacement and

double-flow direction
Hydraulic cylinder
Single-acting cylinder, reset by spring force
Double-acting single rod cylinder
Valve
Check valve (with low opening pressure)
Check valve (with a certain opening pressure)
Shuttle valve
Pressure restriction valve
9-86
Pressure restriction valve (with adjustable opening

pressure)
Pressure reducing valve
Pressure reducing valve (with adjustable closing

pressure)
Pressure reducing valve (pressure control)
Three-way valve (with manual lever and centering

springs)
The lines that parallel with the rectangle represent that

the valve can be in any position within its two ends
(variable displacement).
Cut-off valve/air breather
9-87
Maintenance Manual──LG958L Wheel Loader
Application
The symbols above show line connection, flow channel
and the components’ function, but they don’t indicate the
component structure.
In hydraulic symbols, the valve always pictured in neutral
Valve symbol
position.
Valve symbol
Square is the basic element for valve symbol. A square
represents a position that valve moveable part (sliding part
Valve symbol, unfixed or something like that) can get.
valve body
If the valve body is not fixed, we use parallel lines

represent it in the symbol.
Closed valve
Inner flow path and flow direction are expressed in the

square. When other components connect to a square
(position), the path to the valve will be showed in it.
Opened valve
Interpretation for valve symbol

In three-way valve, the moveable part of the valve has
three positions, each square represents a position. The
square represents ideal position is connected with lines.
Neutral position
The moveable part of the valve is centered in neutral
position by spring force, the inlet ports are connected to
outlet ports through the moveable part.
1 oil inlet port of the valve
2 oil outlet port of the valve
Figure 9-197 Neutral position
9-88
Maintenance Manual──LG958L Wheel Loader
Piston rod extension position

Operate the control lever to move the moveable part of the
valve, let the piston side chamber of the cylinder connect
to oil supply port, the other chamber connect to oil tank.

Figure 9-198 Piston rod extension position
Piston rod retraction position

Operate the control lever to move the moveable part of the
valve, let the rod side chamber of the cylinder connect to
oil supply port, the other chamber connect to oil tank.

Figure 9-199 Piston rod retraction position
9-89

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CONTENTS

SAFETY AND ENVIRONMENT………………………………………………………………1

Checking after Experiencing a Fire or Heating................................................................. 27

the requirements of ISO 6395: 2008. Vibration value of

the cab seat should meet the requirements of ISO7096:

2000. Vibration values are: 1.22 m/s2 for light operator;

1.25 m/s2 for heavy operator.

Change or remove the material that affects the noise

level, for example. Insulation material, sound reduction

material or sound-absorbing materials are not allowed.

In addition, it is not allowed to drill the holes in the cab

or engine room, because this will increase the noise in

ROPS, such as reducing the height of the roof, drilling

holes or welding on the extinguisher bracket and radio

antenna bracket or other devices. Similar unauthorized

modifications may affect the strength of ROPS structure

to invalid certificate void. ROPS has been tested and

meets the requirements of ISO 3471-1 standard. Cab

ceiling has passed the strength test and meet the

standards according to ISO 3449.

All the modification plans about the load-bearing

structure for the cab should connect with SDLG

Construction Machinery Co., Ltd., to ensure that the

modification will not affect the loader's quality and

performance. What’s important, all personnel in your

organization, including managers, should be fully aware

about these requirements of ROPS. If anyone within

your company finds that the loader is modified without

authority, you should inform the customer and

manufacturers in writing of the specific modifications.

Security Involved in Everyone

in the cab so as to be easy to refer to.

Safety-related Electrical Systems

Safety When Handling the Loader

It is essential that drivers should carefully read

Several Simple Safety Rules

contains information about safety, treatment and

immediate actions or watch it. Refer to the gauge

Safety Regulations for Maintenance

anti-skipping surface or the signs attached to the

Figure 5 Wear protective items

Figure 6 Maintenance Position 1

Figure 7 Maintenance Position 2

Working under Elevated Lifting Frame

Fire Prevention Measures

Welding and hrinding

Notes for Tire

lubricant recommended by the tire manufacturer.

Safety When Lifting and Supporting

Methods for Front Axle

Methods for Rear Axle

The Safety for Operation of the Battery

Do not put the discharged battery and fully charged

Starting with a Booster Battery

off the machine and check the reason.

Safety When Dealing with Oil and Fuel

Safety When Dealing with Refrigerant

Refrigerant R134a is used for the air conditioning unit.

disconnect the hose or remove oil filling plug on

with warm cloth or warm water. If these symptoms

Safety When Operating Accumulator

The Safety of Hydraulic System

about 18MPa (2610 pounds/square inch). To avoid