3.

Maintenance

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 Table of contents

3. Maintenance..................................................................................................................................................1
3.1 Recommended Lubricant And Oil ..............................................................................................4
3.1.1. Recommended Lubricant And Oil...........................................................................................4
3.1.2. Special recommendation “XUG specialized oil” .....................................................................5
3.1.3 Applicable air temperature for different oil product grades .....................................................4
3.1. Parts to be lubricated and lubricating schedule ...................................................................................5
3.2. Periodic Maintenance and Service Cycles ..........................................................................................6
3.2.1. Periodic Maintenance and Service Instructions .......................................................................6
3.2.2. Maintenance and service every 10h/day ..................................................................................6
3.2.3. Maintenance and service every 50h/week ...............................................................................6
3.2.4. Maintenance and service every 100h/2 weeks .........................................................................7
3.2.5. Maintenance and service every 250h/month............................................................................7
3.2.6. Maintenance and service every 500h/2 months .......................................................................7
3.2.8. Maintenance and service every 1000h/6 months .....................................................................8
3.2.9. Maintenance and service every 2000h/year .............................................................................8
3.3. Inspection and adding of oil ...............................................................................................................8
3.3.1. Notes about the oils ................................................................................................................8
3.3.2. Fuel oil...................................................................................................................................9
3.3.3. Hydraulic oil ........................................................................................................................ 10
3.3.4. Brake fluid ........................................................................................................................... 11
3.3.5. Gearbox oil .......................................................................................................................... 12
3.3.6. Drive axle oil ....................................................................................................................... 13
3.3.7. Engine oil............................................................................................................................. 14
3.3.8. Engine cooling liquid ........................................................................................................... 15
3.4. Checking and Maintaining Components ........................................................................................... 16
3.4.1. Electrical system .................................................................................................................. 16
3.4.2. Maintenance for battery ........................................................................................................ 17
3.4.3. Recharging ........................................................................................................................... 17
3.4.4. Drive Unit ............................................................................................................................ 18
3.4.5. Maintenance for Tyres .......................................................................................................... 18
3.4.6. Working device .................................................................................................................... 19
3.4.7. Braking system..................................................................................................................... 19
3.4.8. Air reservior ......................................................................................................................... 20
3.4.9. Air-conditioner (optional)..................................................................................................... 20
3.4.10. Others .................................................................................................................................. 21
3.5. Trouble and shootings ...................................................................................................................... 22
3.5.1. Power System ...................................................................................................................... 22
3.5.2. Steering System ................................................................................................................... 23
3.5.3. Electrical System.................................................................................................................. 24
3.5.4. Braking System .................................................................................................................... 25
3.5.5. Working hydraulic system .................................................................................................... 26
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3.6 Weichai Engine ECU Malfunction Troubleshooting ......................................................................... 28
3.7 Replacement of the key parts ........................................................................................................... 27

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 3.1 Recommended Lubricant And Oil
3.1.1. Recommended Lubricant And Oil
Table 3- 1
Fuel
Categories Names and designations Fuelling parts Notes
quantity
0# light diesel oil Summer
Fuel -10# light diesel oil 300L Fuel tank Winter
-35# light diesel oil Extremely cold areas
Weichai engine and
CH-4 15W/40 diesel engine oil
Shangchai engine
Engine oil 20L Engine oil sump
Winter and extremely cold
CH-4 5W/40 diesel engine oil
areas
Including oil for
Transmission Transmission
CF l5W-40 diesel engine oil 28 L transmission, oil radiator,
oil Torque converter
and pipeline

L-HML46 hydraulic oil Fixed volume

Fixed volume in cold
L-HS32 hydraulic oil
regions
Hydraulic oil 200L Hydraulic oil tank
Mobil 10W engineering
hydraulic oil (API CD SFSAE Full-hydraulic wet brake
10W)
Dry axle Main drive of the
GL-5 85W/90 Summer and winter
2×27L drive axle and
Gear oil
Wet axle wheel-sided Oil used for extremely
GL-5 75W/90
2×60L reducer cold areas
Pin rolls of working devices, pin rolls on front
Lubricating 2# extreme pressure lithium- and rear frames, universal joint pin and spline of
2.5kg
grease based lubricating grease all transmission shafts, the fan and pump
joints of the engine, and etc.
DOT4/HZY4 motor vehicle
Brake fluid 3kg Brake oil cup Dry-type drive axle
brake fluid
Radiator
Antifreeze - No. 45 antifreeze About45L Cooling system
expansion tank
Bleed the air from the axle brakes after the replacement with new axle or after the repair works related to the axle
brake pipeline.
* The above is for reference only, please select specific oil products according to the usage and maintenance manual
of the engine, gearbox and drive axles and in principle, lower-grade oil can be replaced with higher-grade oil.
* Under special circumstances, select the oil products according to local air temperature environment or consult to
the factory.
3.1.3 Applicable air temperature for different oil product grades
Table 3- 2

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 Applicable Air Notes
Type Oil Grades
Temperature (℃)
Fuel 10# light diesel oil ≥12 GB 252
5#light diesel oil ≥8
0# light diesel oil ≥4
-10# light diesel oil ≥-5
-20# light diesel oil ≥-14
-35# light diesel oil ≥-29
-50# light diesel oil ≥-44
Engine Oil Viscosity Grade 15W/40 heavy diesel -20~+40 GB 11122
Viscosity Grade 10W/40 heavy diesel -25~+40
Viscosity Grade 5W/40 heavy diesel -30~+40
Viscosity Grade 10W/30 heavy diesel -25~+30
Viscosity Grade 5W/30 heavy diesel -30~+30

3.1. Parts to be lubricated and lubricating schedule

图 3- 1

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3.2. Periodic Maintenance and Service Cycles

3.2.1. Periodic Maintenance and Service Instructions

● Be sure to read and understand all safety information, warnings and instructions before carrying out
operation or maintenance measures.
● The user shall be responsible for the maintenance. During the maintenance, properly use or adjust all
the lubricating oil, oil and fluid, and oil filter and replace the normally worn or aging parts.
● Failure to comply with the proper periodic maintenance and service cycles and steps may lead to
degradation of performance and/or acceleration of parts wear.
● The maintenance and service cycles listed in this Manual is determined by general working time,
operating conditions and operating time totalizer or calendar (day, week or month), whichever occurs
first. Poor working conditions like dusty or damp environment will need more frequent lubrication and
maintenance than the required intervals.
● Periodic maintenance and service cycles is classified into 10, 50, 100, 250, 500, 1000, 2000 hours.
● During maintenance and service, all the maintenance items listed in the original requirements shall be carried
out repeatedly. For example, while performing the maintenance and service every 250h (month), the user shall
also carry out all the items listed in every 100h (2 weeks), 50h (week) and 10h (day) maintenance at the same
time.
● If the machine is used less frequently and is still far from the corresponding hours of using in the same calendar
period, at least the following provisions shall be complied with:
 Items listed in working period between 10h to 100h shall be conducted every 3 months.
 Items listed in working period between 250h to 500h shall be conducted every 6 months.
 Items listed in working period between 1000h to 2000h shall be conducted every year.

3.2.2. Maintenance and service every 10h/day

● Check the coolant level of radiator panel, and fill it up if necessary.
● Check the fuel and engine oil level, and fill it up if necessary.
● Check the brake fluid level in oil cup, and fill it up if necessary.
● Check the hydraulic fluid level, and fill it up if necessary.
● Check the operational performance of parking brake and service brake for normal condition.
● Check the movement of steering cylinder and steering wheel.
● Check the accelerator control and transmission control for reliability and flexibility.
● Open the discharge valve of the air reservoir to empty its water (Available for dry axle pneumatic brake).
● Check the electrical system wiring and electrical components for normal operation.
● Apply grease to all lubrication points at working device and sway bracket pin according to instructions
identified on lubrication diagram.
● Check the hydraulic and brake system pipelines for leakage.
● Visually inspect all systems for abnormities and leakage.

3.2.3. Maintenance and service every 50h/week

● Conduct the maintenance and service every 10h at the same time
● Release the drain plug at the bottom of fuel tank to drain deposit and water.
● Check and fasten the attachment bolts of front and rear drive shaft.
● Check the transmission fluid level, and fill it up if necessary.

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● Apply grease to all lubrication points at drive shaft, frame hinge pin, front and rear steering pins, center pin,
cab and steering pin etc., according to instructions identified on lubrication diagram.
● Clean the filter element of breather at fuel tank, transmission and driving cylinder.
● If air conditioner is used, clean its strainer.
In addition, the followings shall be conducted for the first 50h:
● Replace engine oil (except for Shangchai engine)

3.2.4. Maintenance and service every 100h/2 weeks

● Conduct the maintenance and service every 10h and 50h at the same time
● Check the oil level of front and rear axle, and fill it up if necessary.
● Clean the air filter element.
● Clean the fueling filter of the fuel tank.
● Check and fasten the fixing bolts of rim and brake disc.
● Check the tire pressure (tire pressure under cold condition: front tire 0.38~0.40MPa, and rear tire
0.32~0.34MPa), inflate the tire if necessary.
In addition, the followings shall be conducted for the first 100h:
● Replace transmission fluid and transmission filter.
● Replace engine oil and oil filter element (Applicable Shangchai engine)

3.2.5. Maintenance and service every 250h/month

● Conduct the maintenance and service every 10h, 50h and 100h at the same time
● Adjust the fan belt tensity: depress one point between the generator pulley and fan belt with fingers (about 10
kg force), the tensioning deflection of normal belts shall be about 10-12 mm. Tighten the screw bolt and nut
firmly after adjustment.
● Replace engine oil.
● Replace engine oil element.
● Replace fuel filter element.
● Replace fuel preliminary filter element.
● Replace fuel fine filter element.
● Fasten the attachment bolts for front and rear axle, engine, transmission and frame.
● If air conditioner is used, clean its strainer.
In addition, the followings shall be conducted for the first 250h:
● Replace gear oil of front and rear axle.

3.2.6. Maintenance and service every 500h/2 months

● Conduct the maintenance and service every 10h, 50h, 100h and 250h at the same time
● Replace suction filter cotton of air conditioner.
● Replace breather filter element of hydraulic fluid tank.
● Check the wear conditions of the disc brake friction plates, replace if necessary.
● Check the fastening condition of the disc brake.
● Check the wear conditions of parking brake.
● Check the fastening condition of parking brake.
● Check and adjust the hand brake clearance.
● Check and fasten the attachment bolts for front and rear axle, engine, transmission and frame.
In addition, the followings shall be conducted for the first 500h:
● Replace the hydraulic return oil filter.
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 3.2.7. Maintenance and service every 1000h/6 months
● Conduct the maintenance and service every 10h, 50h, 100h, 250h and 500h at the same time
● Replace the countershaft transmission oil and transmission oil filter element and clean the oil sump.
● Replace the oil filling strainer of the fuel tank.
● Replace the oil suction element of the fuel tank.
● Replace the gear oil of front and rear axle.
● Clean the fuel tank.
● Replace the brake booster oil.
● Check the clearance and wear conditions between every hinged joint and the cover.
● Replace hydraulic oil return filter.

3.2.8. Maintenance and service every 2000h/year

● Conduct the maintenance and service every 10h, 50h, 100h, 250h, 500h and 1000h at the same time
● Replace the hydraulic oil, and clean the fuel tank and return oil filter.
● Replace the coolant liquid of radiator panel.
● Check the functional performance of the engine, transmission, front and rear axles.
● Carry out inspection of steering engine and steering valve under disassembled condition and calibrate the
steering angle.
● Check the leakproofness of the multi-way valve and operating fuel tank and measure the system working
pressure by testing the natural declining quantity of the operating fuel tank. If the declining quantity exceeds
up to double the specified value, carry out inspection of the fuel tank and distribution valve under disassembled
condition.
● Check the welding seams of the working devices and different frame parts for cracks and also check the
fastening condition of bolts and nuts.
● Check the weld seam and all forced parts of the rim and calibrate the deformation if any.
When the contents of this manual do not conform to the specialized operation
Caution instructions of parts and components which come with the machine, the specialized
operation instructions shall prevail.

3.3. Inspection and adding of oil

3.3.1. Notes about the oils

● Pay attention to fire because the fuel oil, the lubricant, the hydraulic oil and the antifreezing solution can be
fired by the open flame.
● Smoking and fire shall be prohibited in the area having oil.
● The places for adding or storing the fuel oil, the lubricant, the hydraulic oil and the antifreezing solution shall
be ventilated well.
● The covers of the containers for packing all fuel oil, lubricant, hydraulic oil and antifreezing solution shall be
screwed up tightly.
● The fuel oil, the oil of the torque converter, the hydraulic oil and all kinds of lubricants must be pure and in
line with the quality requirements specified.
● The tools for filling the oil, the containers and the filling holes shall be wiped up in order to prevent the water
contaminants from entering into the oil.

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● The engine shall be stopped when filling the fuel oil or the lubricant.
● The overflowing fuel oil, the lubricant, the hydraulic oil and the antifreezing solution shall be wiped up
immediately.
● The oils of different viscosities shall be taken in different ambient temperature; please use the oils in strict
accordance with the oil trademark mentioned.
● The liquid shall be packaged by the appropriate containers when replacing the parts, such as the cooling liquid,
the engine oil, the gearbox oil and the filter.
● The treatment of the wastewater shall be in line with the local laws and regulations for environment protection.
● Inspect whether oil leakage appears after refueling and replacement of the oil.
● If not otherwise specified, the machine shall be stopped on the flat floor when inspecting the oil level and
replacing the oil; and the bucket shall be placed on the floor flatwise, and the engine shall be stopped.
● The oil may be at high temperature; therefore the operators shall wear the protective equipments when
discharging the sundries and replacing the oil and operate carefully in order to protect the operators from
injuries.

3.3.2. Fuel oil

3.3.2.1. Inspect the oil level
● Method 1: open the power key switch if the LCD display Fuel gauge
screen of the instrument panel is equipped with the fuel
gauge, wherein the pointer of the fuel gauge should be
remained at the scale of 1/8
Figure 3- 2 Fuel gauge (optional) on instrumental
panel
● Method 2: the fuel oil shall be filled if the oil level indicator
is installed at the right corner of the fuel oil tank and the
level of the fuel oil is reduced to the minimum oil level of
the lower oil level indicator.(Error! Reference source not
found.)

Figure 3-3 oil level indicator of the fuel oil tank

3.3.2.2. Discharge the sundries
● Discharge the water and the sundries accumulated in the oil
tank from the oil drainage flange at the bottom. (Error!
Reference source not found.)

Figure 3-4 Oil drainage flange of the fuel oil tank

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● Unscrew the filling cover of the diesel tank and take out
and wash the filter element. (Error! Reference source not
found.)

Figure 3-5 Filling strainer of the fuel oil tank

3.3.3. Hydraulic oil

3.3.3.1. Requirements to oil quality
Pollution grade of particles in hydraulic oil:—/20/17
The replacement interval of the hydraulic oil is 2,000h or 1 year.
(Whichever comes first.)

3.3.3.2. Complement oils Oil return filter

element cover plate

● Inspect the oil level indicator of the working oil tank,

Oil return filter
wherein the oil level shall be remained at the place near the element
Ventilator filter
middle scale of the oil level indicator; please complement element

the oil if the oil level is lower than the bottom level of the
oil level indicator, and the hydraulic oil shall be
complemented by means of the oil complementing hole on
the cover plate of the return oil filter. (Figure 3-6)

Oil drainage plug

Figure 3-6 Filling hole and the oil level indicator of

the hydraulic oil tank

3.3.3.3. Replace the oil

● Clean the sundries in the bucket.
● Elevate the swing arm to the maximum height and incline the bucket maximally; and shut down the engine.
● Unscrew the oil drainage plug at the bottom of the oil tank when the oil is warm and discharge the sump oil.
● Operate the bucket control lever and overturn the bucket downward to the maximum position gradually by virtue
of the gravity; then operate the control lever of the swing arm to make the swing arm fall gradually and discharge
the oil in the cylinder completely.
● Dismantle the cover plate of the return oil filter and fill the hydraulic oil. (Figure 3-6)
● Fill the new oil from the return oil filter to the position specified in the middle of the oil level indicator; and the oil
10
 cannot be filled into the oil tank directly after removing the oil hole filter.
● Start the engine and run it at idle speed; operate the swing arm gradually to elevate, wherein the receiving/unloading
of the bucket shall be implemented for 2-3 times respectively; then discharge the air in the system by keeping the
engine run at idle speed for 5min.
● Place the bucket on the floor flatwise and shut down the engine; and inspect the level of the hydraulic oil and
complement the oil to the position specified again.
Operations to the machine shall be implemented in accordance with relevant
safety specifications when replacing the oil; and pay attention to safety.
Warning Moreover, the hydraulic oil cannot be filled by dismantling the breathing
apparatus.
3.3.3.4. Discharge the sundries
● Inspect and discharge the water and settlements accumulated at the lower part of the oil tank every 1000h; and the
water and settlements accumulated can be discharged from the oil drainage plug at the bottom when the whole
machine is stopped for 2h.(Figure 3-6)
The nut on the top end of the breathing apparatus shall be unscrewed when dismantling
the hydraulic pipeline or connector connecting with the oil tank; and the compressed
Notice air in the oil tank shall be discharged completely by pressing the exhaust valve; then the
hydraulic pipeline or connector can be dismantled.

3.3.4. Brake fluid (Dry type axle)

● The brake fluid is contained in two brake fluid cups
(located in right stand, as shown in Figure 3-7).

3.3.4.1. Inspect the oil level

● Visually observe the brake fluid level. The height from the
Figure 3- 3 Brake fluid cup
level to the oil port shall be 15~25mm. Timely add if
insufficient.
It’s prohibited to mix the brake fluids of different trademarks or use a mineral oil as brake
Notice fluid.
3.3.4.2. Replacement with new brake fluid (Dry
type axle) Vent valve
● Shift the gearshift joystick to neutral gear and apply the
parking brake.
● Remove the deposited dirt from the brake pipeline, fluid
reservoir, filler port, and bleeder valve of booster, and
bleeder valve of wheel caliper disc brake.
● Prepare an appropriate container, disassemble the
connecting nut between brake oil pipeline and brake
caliper, and drain the used brake fluid into the container. Figure 3- 8
● Clean the brake fluid cups and brake pipelines and then
reinstall securely.
● Top up the brake fluid into the brake fluid cups.
● Start the engine, run the engine till the reading of brake
pressure gauge reaches 0.6-0.8MPa, and then stop the

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 engine.
● Attach one end of a transparent air bleeding pipe to the air
bleeder valve and place the other end into the oil container.
(Figure 3-8)
● Loosen completely bleeder valve to bleed the air, depress
the brake pedal repeatedly for several times, and then
depress and hold the brake pedal, till no air bubble
overflows from the bleeder valve.
● Tighten the bleeder valve and release the brake pedal.
● While bleeding the air, observe the level in the brake fluid
cups and timely add the brake fluid to prevent the re-ingress
of air into the pipeline system.
● Add brake fluid to the fluid cups to the specified level.

3.3.5. Gearbox oil

The torque converter and the gearbox shall share the hydraulic pressure transmission oil to implement circulation, and
the oil mass shall be inspected strictly and replaced regularly.
3.3.5.1. Inspect the oil level
●Park the vehicle on a level place.
●Shift the gearshift lever of transmission to neutral gear “N”.
●Idle the engine (Approximately 1,000r/min)
●Unscrew counter-clockwise the oil dipstick, wipe it dry,
screw it in place, and then unscrew it again. Repeat the above
procedure at least twice. The oil level shall be between the
Error! Reference source not found.
middle of lower notch and the upper notch of the oil dipstick.
(Error! Reference source not found.)
At 40ºC, the oil level shall be between the middle marking
and lower marking "Cold”.
At 80ºC, the oil level shall be between the middle marking
and upper marking "Hot”.

3.3.5.2. Replace the oil

● Place the machine on the level ground, put the stop dogs at
the front and rear tires, put the gear shift lever in the neutral
position and pull up the parking brake;
● Start engine, make it in idle running for several minutes and
then shut down it.
● Open the drain plug on the bottom of the side of gearbox, Figure 3- 4
and use a vessel to hold it.(Figure 3- 10)

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● Change the filter element of gearbox;
● After the oil is exhausted, clean up the greasy dirt around
the oil outlet of gearbox, clean out the sundries attached on
the drain plug, and re-twine the appropriate raw material on
the plug screw according to the screwing direction of thread
and then install it in the original place.(Error! Reference
source not found.)
Figure 3- 11
● Open the oil filler of gearbox on the side of rear frame,
inject the transmission oil according to the stipulated code
and volume, and then screw on the filler cap;
● Start the engine, make it in idle running for 5 minutes and
then re-examine the oil level of gearbox.(Error! Reference
source not found.)
Figure 3- 12

3.3.6. Drive axle oil

3.3.6.1. Inspect the oil level
● Unscrew the main driving (examination) oil filler plug on
the axle housing. If the oil level is lower than the plug
outlet, it is appropriate; if it is not, the oil needs to be
supplied.(Error! Reference source not found.)
Figure 3- 13
3.3.6.2. Replace the oil
● Drive the machine on the level ground slowly, and make
the drain plug on the end face of wheel side of the front
drive axle in the lowest position.(Figure 3- 5)
● Shut down the engine, put the gear shift lever in the neutral
position and press the parking brake;
● Unscrew the drain plugs on the center bottom of axle
housing of the front drive axle and on the end faces of sides
of the two wheels to discharge the oil, and use a vessel to
hold it.
● After the oil is exhausted, screw on the drain plug on the
center bottom of axle housing of the front drive axle.
● Start the engine, pull up the parking brake, drive the
machine slowly, and make the arrow of the end face of the
wheel side of the front drive axle to point to the direction
of right below, and then shut down the engine, put the gear
shift lever in the neutral position, and last press the parking
brake; Figure 3- 5
● Unscrew the main driving (examination) oil filler plug on
the axle housing of the front drive axle and the plug of view
hole on the end of arrow of wheel side of both end faces.
● Inject the new oil from the place of oil filler plug of wheel
side (examination) and oil filler plug of main drive
13
 (examination) until the moment that the oil overflows from
the oil filler of main drive in the axle housing and the oil
overflows from the view hole wheel side.
● Screw the five spout plugs mentioned above.
● Change the gear oil of rear drive axle according to the
above process.
3.3.7. Engine oil

3.3.7.1. Inspect the oil level

● Drive the machine on the level ground, shut down the
engine, put the gear shift lever in the neutral position and
press the parking brake.
● Pull out the dipstick on the side of engine body, infix its
head and then infix its whole body, and last pull out it for
examination.(Figure 3- 6)

Figure 3- 6
● The engine oil level shall be within the markings of “L” and
“H” on the stationary side of the oil dipstick. if the oil level
is too low, more oil shall be added.(Figure 3- 7)
● Inspect whether the oil is polluted and whether there are
some sundries in the oil. If the oil is polluted excessively,
the oil shall be changed.

Figure 3- 7
The time to check the oil level must be before operation or after 15 minutes when the
Notice engine is shut down.
3.3.7.2. Replace the oil
● Place the machine on the level ground, put the stop dogs at
the front and rear tires, put the gear shift lever in the neutral
position and pull up the parking brake. If the engine is not
heated, start the engine and make it in idle running, and
when the oil temperature reaches to 20℃ to 40℃, shut
down the engine.
● Open the drain plug of engine oil at the right front of fuel
tank of the engine, discharge the oil and use a vessel to hold
it.(Figure 3- 8)
● Change the oil filter.
● After the oil is exhausted, screw the drain plug.
● Inject the new stipulated oil from the oil filler on the left
posterior of engine. Figure 3- 8 Drain outlet of engine oil
● Start the engine keep it ticking over, and check whether the
oil filter and drain plug leak.
14
● After about 15 minutes when shutting down the engine,
make the oil to flow circularly and sufficiently, and re-
check the oil level of engine.
3.3.8. Engine cooling liquid
3.3.8.1. Inspect oil level
● When the water temperature of engine is too high, firstly
check the cooling liquid level. If it is not enough, more
cooling liquid shall be added. At the same time, check
whether the radiator core is blocked and whether the tube
is damaged.
● Place the machine on the level ground, put the gear shift
lever in the neutral position, press the parking brake and
Figure 3- 9
shut down the engine. If the water temperature of engine is
high, wait the water temperature to drop to below 50℃.
● Observe the liquid level of expansion tank, which shall be
near the midline. If it is not enough, more water shall be
added.
● Open the radiator cap from the view hole at the rear top of
the engine cover, and the cooling liquid level shall reach to
the bottom of filling neck of water tank of the radiator; and Figure 3- 10
complement the cooling liquid if it is not enough. (Figure
3- 9,Figure 3- 10)
● After checking, fasten down the radiator cap to prevent the
cooling liquid from evaporating.

The radiator cap shall not be opened when the engine stops just for a moment or it is running,
if not, the hyper-thermal cooling liquid will spewing out and it is very dangerous.
Warning When opening the radiator cap, it shall be covered with a piece of cloth and shall be opened
slowly.

3.3.8.2. Change of antifreezing solution and

Fuel tank
internal clean of radiator
● Operate the engine for 1 to 1.5 hours under normal water
temperature (at least 85°C).
● Place the machine on the level ground, put the gear shift
lever in the neutral position, pull on the parking brake, shut
down the engine, and wait the water temperature to drop to
below 50℃.
● Firstly open the radiator cap, then switch on the water drain
valve on the bottom, and last switch off the water drain
valve after all antifreezing solution is discharged.(Figure 3- Figure 3- 11
11)

15
● Fill the clean water into the cooling system to be the normal
water level.
● Start the engine, speed up the engine gradually, and
continue to make the engine in idle running for 5 minutes
under the condition that the water temperature is over 85°C.
● Shut down the engine, and discharge the cooling water after
the water temperature is below 50°C. If the discharged
water is still dirty, it shall be continued to wash until the
clean water is discharged. Switch off the water drain valve Figure 3- 12
after all water is discharged.(Figure 3- 12)
● Fill antifreezing solution until the cooling liquid level
reaches to the bottom of filling neck of water tank (or
expansion tank) of the radiator.
● Start the engine, make the liquid level drops slightly, and
then shut down the engine and re-supply the antifreezing
solution.

Don’t use the detergent with corrosivity for the cooling system, or the aluminium units
will be damaged.
Warning The cooling liquid is poisonous, so it shall be avoided from touching children and pets.
If the cooling liquid is not continued to be used any more, is shall be treated according
to the local environmental protection regulations.

3.3.8.3. Notes
● The antifreezing solution is required to be the cooling liquid for the machine. When the machine leaves from the
factory, the antifreezing solution has been filled into the radiator. When the machine is operated under normal
conditions, the antifreezing solution is required. Don’t use rainwater, tap water or river water to replace it, or the
diesel engine or radiator will be damaged prematurely.
● When the temperature is under 0℃, the antifreezing solution may not be discharged. If under the urgent situation,
the antifreezing solution must be replaced with the ordinary water temporarily, all water drain valves must be
switched on to discharge all cooling water and to prevent the machine from being frosted cracking.
● When the temperature is over 30℃, the engine shall be placed in the shady and cool place because it is easy to
overheat.
● After operation, in order to prolong the service life of engine, the engine must be operated at low speed for 5
minutes and shall be stopped after the water temperature drops.

3.4. Checking and Maintaining Components

3.4.1. Electrical system
● Only the qualified technician can service the electrical system.
● When adjusting the external power supply, please attach the
ground cable at last in order not to produce sparks around the
battery and cause an explosion. Please note that the ground
cable is from the regulator end to the starter end.
● Adjust the key of starter before service the electrical system.

16
● Before repairing the electrical system, remove the negative (-) Figure 3- 13
electrode of the battery to prevent the flowing of
current.(Figure 3- 13)
● Electric circuits and fuses
 Check the circuit connectors for presence of looseness, check wire rubber insulations for presence of
damage, and check the fuses for secure and tight assembling. In event of dysfunction of any circuit, firstly
check the fuse of the circuit for burnout. During replacement of fuse, ensure to find out the burnout cause of
the fuse and further check for bulb burnout and circuit damage.
 The fuses are located within the cab. During replacement, please notice the capacities (amperes) on the fuse
tubes and clamps.
● Lamps and instruments
 Check the switches of all lamps for normal functioning. Thoroughly remove the dirt from the lamps.
 Press the horn button to check for normal sounding of horn.
 The pointers of the instruments shall be within green zone under normal status.
3.4.2. Maintenance for battery

● This battery is free of maintenance.

● Before operating about the battery, remember to stop the
engine.
● Never get the lighted cigarette or flame close to the
battery.(Figure 3- 14)
● Open the battery compartment and check the battery surface.
Ensure that no electrolyte leaks out and there is no signs of
crack, strike and pollution. Figure 3- 14
● Check the working status of the battery ( there is an indicator
light on the battery):
-GREEN: meaning that the battery energy sufficient, and it can be
used normally.
-BLACK: meaning that the battery needs to be charged.
-WHITE: meaning that the battery has to be discarded as junk and
be replaced.
● Clean the battery compartment and the battery surface.
● Clean the electrodes of battery.
● Check the fastening for the battery.
● Avoid the touching of metal staffs (e.g: tools), which could cause short circuit to positive pole ( +) and
negative pole (−) of the battery.
● When installing the battery, fix the positive pole (+) first; when dismounting the battery, disconnect the
negative pole (−) first.
● When cleaning the top surface of the battery, use a piece of cloth to wipe it. Never use petroleum oil and
other organic solvent and cleaning solvent.
● Tighten the top cover of the battery.
3.4.3. Recharging

● When recharging the battery, if handle the battery incorrectly, then there is the risk of battery explosion. So
the procedure for recharging the battery should be in line with required process and instruction, and also
obey the following points.
17
● Recharging for the battery should be done in a place with good ventilation. Take out its top cover, by doing
so hydrogen scattering and explosion can be prevented.
● Set the recharging voltage according to the voltage requirement for the battery to be recharged. If the
recharging voltage is wrongly set, then it will cause the recharger getting too hot or fire and also possibly
explosion.
● Connect the positive (+) clamping-terminal of the recharger with positive pole (+), and negative terminal
(−) with negative pole (−). And fasten their connection.
● If the recharging ratio is less than 1/10, then you have to make rapid-recharging and set it within the battery’s
rated capacity. If the recharging current is too much, then it may cause electrolyte leakage or evaporation,
which will possibly cause fire or explosion.
3.4.4. Drive Unit
● Break down the torque converter, transmission, drive axle main drive, and wheel reducer for checking after
2,000 working hours of the machine. During cleaning, check the drive system for presence of abnormal
“splash” or "creak" sound.
● During the replacement of this filter element, drain the internal impurities and oil dirt, disassemble the filter,
take out the filter element, replace with new filter element, and assemble the upper cover.
● Drive shaft
 Check the mounting bolts of connectors for looseness, check the vibration status of the shaft end, and check
spline part for looseness.
 During the disassembling and assembling of the drive shaft, notice the relative position of the universal
joints on two ends and ensure the aligned arrows during assembling.
● Wheels
 Check the tire inflation pressure as well as the tires surface for wear status.Look for any metal partials
embedded in tires. Check the mounting nuts on the wheel rims. Checking should be done while the machine
is cold. Normally the tire inflation pressure should be a little bit lower when machine operating in a sandy
area than when machine operating on hard-ground.
 After 2000 hours, check the welding seams on wheel rims and also check the parts which are loaded. Correct
any deformation that may occur to the case.
3.4.5. Maintenance for Tyres

● If the tyres explode, the explosion itself will throw the wheel hub, tyres, driving axle and other components
500m or more far away from the machine. And explosion and its partials will cause server damage and
healthy injury, so the tyres pressure must be maintained at normal pressure range. Never inflate the tyres
beyond its rated pressure range.
● During traveling, the heat produced due to high-speed machine traveling will cause the tyres pressure arising
to some extent, which is the normal case, please don’t attempt to reduce the tyres pressure. What you should
do is to reduce the machine traveling speed or just stop the machine to have the tyres cooling down. However,
if the machine keeps moving at very high speed continuously, which will cause the tyres being overheated,
then tyres explosion will be led, so attention should be given.

CAUTION Check if the locking ring is disengaged or not.

18
● When adjusting tyre pressure, keep away from the tyre
as far as possible. And you should always stand at the
back of the tyre.
● It it prohibited to inflate the tyres with combustible gas.
It is recommended to use dry Nitrogen. If the tyres have
already been filled with air, you can also use Nitrogen
for pressure adjustment purpose, and Nitrogen can be
well mixed with air. Inflating tyres with Nitrogen can Figure 3- 15
possibly reduce the risk of tyres explosion, since
Nitrogen doesn’t help combust but can prevent the
rubber oxidation and deterioration and avoid rust for
wheel hubs.
● In order to avoid tyres being over inflated, it is
necessary to have proper tools to be used for inflating
tyres with Nitrogen and relative training on how to use
these kind of tools.
● Check tyres and wheel hub. Don’t operate the loader
when the tyre pressure is very low. And also check if
there are any cracks or deformation on the tyres.
● Check the mounting screws and bolts on the wheels to
see if they are securely fastened as required by the
manufacturer.
● During checking the wheels, don’t make any access to
the steering wheels, both in the front and in the back.
Such checking should be done from the wheel sides.
When you need to remove one of the wheel, other
wheels should be blocked with wedges.(Figure 3- 15)。
3.4.6. Working device

● After 2000 hours, the natural subsidence of the working mechanism should be checked.
 Raise the main booms up to their utmost limit while the machine bucket is empty. Then stop the engine, be
sure descending length of the lift-cylinders should not be beyond 65mm within 15 minutes. If the descending
volume is too much (over 65mm), check the sealing performance for distribution value and lift cylinders
and measure the system working pressure.
3.4.7. Braking system

● Disc brake: Check the wear status for the brake friction plate and carry out air-bleeding for the system
periodically.
● Brake friction plates: Screw off the screw pin and remove the plate cover. The friction plate can then be
taken out. There are 3 ditches on the plate, which shows how much the plates are worn. If the ditches become
disappeared, the plate has to be replaced.
● Brake pedal:
 The performance for braking pedal can only be checked while the machine is traveling. And also figure out
if the braking performance is only acting on one side.
 Check the pedal clearance after the pedal has been trampled down, movement to its front end must be of the
clearance of 13 to 23mm.
19
● Booster pump: After working for 2000 hours , the booster pump should be dismantled and thoroughly
serviced.
● Parking brake：Engage the hand brake and check if the loader is under braking condition. If the braking
performance is not good or abnormal phenomena appears, please find out the reason and eliminate it. The
frictional lining and braking drum must be checked.
● Breather of afterburner cylinder: Turn on the cover of afterburner cylinder breather every week (should be
every day in dusty environment of long time operation). Take the filter element out for cleaning to avoid
danger of brake failure.
3.4.8. Air reservior

● Discharge the water from air reservoir every day, especially in winter. Ensure that the water draining valve
is closed before starting the machine.
If the brake pad is worn to the maximum limit, the ineffective braking will be really
Notice dangerous. When the wear of the brake pad is closing to the limit, check the brake
pad more frequently.
3.4.9. Air-conditioner (optional)

● Only the professional technician can repair the air-conditioner.

● In case of needing to check and repair any part on the machine, you need to park the machine onto a flat
ground, and keep the transmission lever at Neutral position, have the braking system engaged, and keep
unconcerned people away from the repair site or working area.
● Contacting with freezer can cause injury, so please wear eyes protector and other safety guards to protect
the eyes and skin from being hurt by exposed cooling liquid. Take special care when touching any
machine parts, especially the parts with high temperature or any moving parts.
● No matter if or not the engine is running, the air conditioner system is always with pressure, so never try to
heat the cooling-agent system. In case of needing to empty the air conditioner system, it is a must to wear
eye-protector, even if the pressure gauge reads at zero. It is kindly required to dismount the air conditioner
parts with much care, even with protective measures being taken.
● Smoking, flame and fire are extremely not allowed at the repair site for air conditioner, as the cooling-agent
inside the air conditioner will produce a kind of poisonous air when it is getting near the heating source, so
sucking in such poisonous air will cause severe human casualty or even death.
● The air conditioner can be started only after the machine engine being started. After the engine totally stops,
switch off the air conditioner power, so as to save the machine power.
● For soundly operating the air conditioner system, it is highly recommended to use “High”-gear for cooling
performance.
● In case of none use of air-conditioner for a long period of time in spring, autumn or in winter, it is a must to
have the air conditioner run for 5 minutes every two week at least, so as to prevent the air conditioner parts
from getting rusty due to long-term none-running.
● In case of needing to replenish cooling agent to the air conditioner, please select and use the proper cooling
agent as stated in the Air Conditioner Manual. Never try to mix two different kinds of cooling agent together
on the air conditioner.
● During using the air conditioner, you should keep the cab doors and windows closed.
● During using the air conditioner, try not to always keep the temperature regulator at the maximum cooling
application while with fan blowing at low speed, otherwise, it will cause the evaporator to be frosted.
● Park the machine on a shadowy place in summer for avoiding the direct sunlight.
● Before running the air conditioner for heating performance, you should firstly let the engine run for a while.
20
 Only after the engine water rises to 80℃ can you switch on the hot water valve and switch on the air
conditioner blower. If the ambient temperature is below 0℃, drain off the water inside the hose and radiator
to prevent water freezing, but water with anti-freezing agent inside the water tank is exceptional.
Maintenance
● Sufficient and scheduled maintenance to the air conditioner is critically important for maintaining sound and
reliable, prolonged service-life of the air conditioner. So scheduled maintenance to air conditioner is very
necessary and needed. ( for details, please see table 3-4)
Table 3- 3
Maintenance Interval
Maintenance Items Checking Methods Every Every Every Every Every
Day Week Month Quarter Year
Cooling agent Check the flowing condition
△
status through the watching hole.
Check the hoses for any
△
Cooling signs of cracks or damages. .
system Check that if each joint
Pipes △
leaks or not.
Check that if each clamp is
△
loose or damage or not.
Replace the cooling oil
(please use the oil with
Cooling oil △
correct brand as stated in the
manual.).
Compressor
Check the tension and wear
Belt △
of belt.
Compressor Check the bracket is reliable
△
bracket or not.
Condenser Check to see if it is clean
△
core and good or not.
Face side of Check if there is any foreign
Condenser △
condenser debris on the front side.
Condenser Check to see if the bracket
△
bracket get loose or not.
Evaporator Check that it is damaged or
△
bracket not.
Inlet of Check that if the ventilation
Evaporator △
cycling wind is good or not.
Check to see if the motor
Blow motor △
can work properly.
Check the coupler is ok or
Coupler △
not.
Electrical Electromagne- Check that if it can work
△
system tic clutch properly.
Check that if it can work
Control switch △
properly.
3.4.10. Others
21
 ● After 2000 hours operation, the whole loader must be visually checked. Pay attention to damages,
deformations, cracking, welding peelings and other shortcomings which can hinder normal operation,
especially the working apparatus and wheels.
● After 2000 hours, check the fastening of each screw and nut on the loader. Fasten it if necessary. Special
attentions should be paid to the rim nuts and screws on the suspending parts.
● Check the sealing of each hose connection, engine, radiator and transmission system for oil or water leakage.
If leakage is hard to be found, stop the engine and clean the part that is to be checked, then restart the engine.

3.5. Trouble and shootings

3.5.1. Power System

Table 3- 4
Trouble Symptom Causes Remedies

1. Gear has not been engaged.

1. Engage the gear.
2. The oil amount in transmission system
2. Replenish oil to regulated amount.
Engine is running but is not enough.
3. Replace or repair the oil pump.
machine can’t drive . 3. Transmitting oil pump is damaged and
4. Check if the torque converter has
the pressure gauge has no indication.
leakage or is damaged.
4. Trouble occurs in torque converter.
1. Valve pressure is adjusted improperly 1. Adjust it to regulated value
2. Clutch has serious oil leakage 2. Replce the oil seal and its bracket .
3. Gear-shifting valve restores to its 3. Check the valve return spring and
Oil pressure for gear-
original position if there is any debris in the cavity
shifting is too low
4. Leakage from oil circuit 4. Fasten the tubes.
5. Oil pump fails to work. 5. Replace the oil pump.
6. Oil filter is blocked. 6. Clean the oil filter.
1. Oil pressure for gear-shifting is low 1. See Trouble No. 2.
Gear-shifting could
2. Transmission pipeline is clogged . 2. Dismantle and dredge it .
not be engaged.
3. Clutch has serious oil leakage. 3. See Trouble No. 2.
1. Oil in the transmission system is
1. Replenish the oil.
insufficient .
2. See Trouble No. 2.
2. Oil pressure for gear-shifting is too low .
3. Check and adjust it .
3. Braking system is adjusted improperly,
4. When the oil temperature is over
The driving force is the brake clamp couldn’t be disengaged.
100℃, please stop the machine and
insufficient. 4. The temperature in torque converter is
check it .
too high.
5. Dismantle , clean and replace the
5. The driving and driven clutch plates do
plate.
not engage correctly .
6.Check and adjust the rotating speed.
6. The rotating speed of the engine is slow.
1. Replenish oil.
The gearbox and 1. Oil is insufficient .
2. Check and repair the clutch and
torque converter get 2. Clutch slips
adjust its pressure.
overheated. 3. Working time is too long.
3.Stop working to cool the machine.
Gear shifting is 1. Arrangement of gear is wrong. 1. Readjust and repair it .
22
 disordered
3.5.2. Steering System
Table 3- 5
Trouble Symptom
1. It is quite hard to make steering.
2.The steering wheel can still rotate
after the machine steers to its max.
limitation.
3.Steering being unstable.
4.Steering to left and right is quite
slow.
5.Steering to one side is quite quick
and to other side is low.
6.When steering resistant force is
low, steering is all right, but when
resistant force getting large, steering
gets slow( to both left and right
sides).
7.When steering resistance force is
low, steering is all right, but when
steering resistance gets large, it is
quick to make steering to one side
and slow to other side.
8.When turning the machine, the
machine doesn’t make steering.
Causes
1.Oil temperature being too low.
2.Wrong connection for oil
pipelines of pilot-control oil
circuit.
3.Oil pipelines of pilot-control
oil circuit being blocked.
4.Pilot-control oil pressure
being too low.
5.The mounting bolts on fully-
hydraulic steering mechanism
being fastened too tight.
There is something wrong with
steering limitation mechanism.
The function of oil flow-control
valve being unstable.
1.Improper adjustment for the
spring of oil flow-control valve.
2.Insufficient oil flow for
steering pump.
3.The valve bar of flow
amplifying valve does not move
to the end.
The pads pieces, on both ends of
the valve bar for oil flow
amplifying valve, are not
correct.
1.Very serious oil leakage from
the valve seat of overflow valve
for main oil circuit.
2.Very serious oil leakage from
shuttle valve.
3.Too low pressure for steering
system.
Different leakage between two
ends of spherical judgment valve
1.Oil flow-control valve doesn’t
work.
23
Remedies
1.Try to operate it again after oil
temperature warming up.
2.Re-connect the oil pipelines correctly as
required.
3.Clean the oil pipelines of pilot-control
oil circuit.
4.Adjust the overflow valve pressure, as
required.
5.Turn the bolts to make them get loose a
little bit.
Check and make repairing for steering
limitation mechanism.
Check, repair or replace the flow-control
valve.
1.Adjust the spring pad correctly.
2.Check, repair or replace the steering
pump.
3.Adjust the pilot-control pressure or
change the spring.
Adjust the pads pieces correctly as
required.
1.Check, repair or replace the sealing ring.
2.Check, repair or replace the valve and
sealing ring.
3.Adjust the steering system pressure.
Check and repair or replace spherical
judgment valve and replace seal ring.
1.Check, repair or replace the oil flow-
control valve.

9.The machine makes steering by
itself even without being operated
by the operator.
10.The steering-wheel turns by itself
even without being operated by the
operator.
11.The steering gets very quick
when the machine is traveling at
high speed.
12.Loud sound from steering pump,
and steering cylinder piston moving
slowly.
3.5.3. Electrical System
Table 3- 6
Trouble Symptom
2.Something wrong with 2.Check and repair the overflow valve of
overflow valve of pilot-control pilot-control oil circuit.
oil circuit. 3.Check and repair the overflow valve of
3.Something wrong with main oil circuit.
overflow valve of main oil
circuit.
1.The valve bar of flow 1.Check, repair the valve bar and restore
amplifying valve could not the spring to its original position.
restore to its neutral position.
2.The mounting bolts for flow 2.Get the bolts a little bit loose.
amplifying valve are fastened
too tight. 3.Get the bolts a little bit loose.
3.The bolts on the cover of flow
amplifying valve are fastened 4.Check, repair and replace the valve bar.
too tight.
4.Improper configuration for the
valve bar and its socket.
1.The valves set of hydraulic 1.Clean away the foreign bodies.
steering system is blocked. 2.Replace the spring discs.
2.The spring discs of the steering
system being broken.
1.The oil flow-control valve 1.Adjust the valve pads as requested.
being improperly adjusted.
2.The valve bar of oil flow 2.Check, repair or replace the valve bar.
amplifying valve can’t move
freely. 3.Clean or replace the valve bar.
3.The sockets for both ends of
valve bar of oil flow amplifying
valve being blocked or being
wrong position.
1.There is air inside the steering 1.Improve the sealing status of steering
oil circuit. pump.
2.The steering pump gets worn 2.Check, repair or replace the steering
down, with insufficient oil flow. pump.
3.Oil viscosity being thin. 3.Change the hydraulic oil, as required.
4.Insufficient hydraulic oil level. 4.Replenish with new oil, as instructed.
5.Pressure for overflow valve of 5.Re-adjust the pressure value for
main oil circuit is adjusted too overflow valve.
low. 6.Check and repair the hydraulic cylinder
6.Serious oil leakage from or replace the sealing ring.
steering cylinder.
Causes Remedies
24

It is hard to start the engine or
the engine can’t be started at
all.
Starting motor is always burnt
down frequently.
Wrong display of gauges
Warning buzzer keeps
sounding.
The bulbs don’t light.
The generator doesn’t work,
or its current is too little or
too much.
3.5.4. Braking System
3.5.4.1. Air-assisted hydraulic brake
Table 3- 7
Trouble Symptom
Foot-braking 1.
1.The battery is damaged or not be
charged fully.
2. Switch is damaged.
3. Starting motor is damaged.
4. Poor wires connection.
5. Fuel oil way or the air way has
breakdown.
6. The shift lever is not in neutral
gear.
7. The fuse is broken.
1. The starting key can’t restore to
its original position.
2. The electrical contactor for
starting motor could not be well
disengaged due to somehow
adhension.
3. Starting circuit has shortcut.
1. The wire connection gets
loose or disconnected.
2. The sensor being broken.
3. Gauges being broken.
1. The warning buzzer for
monitoring gauge keeps
sounding.
2. Low braking Pressure.
3. The air pressure sensor being
broken.
4. The wire connection for the
warning buzzer being short-
circuit.
1. The fuse is broken.
2. The bulb is broken.
3. The wire connection gets
disconnected.
1. The wire connection for the
engine gets loose.
2. The pulley belt gets too loose.
3. The regulator or the generator
being broken.
Causes
There is oil leakage from braking plates.
25
1.Replace the battery or charge it fully.
2. Repair or replace the switch.
3. Repair or replace the starting motor.
4. Check and repair the starting wires.
5. Check the fuel oil way or air way.
6. Put the lever at neutral gear.
7. Replace the fuse.
1. Repair or replace the starting key.
2.Repair or clean the contactor.
3. Check and repair the starting circuit.
1. Fasten the wire connection.
2. Replace the sensor.
3. Replace the gauges.
1. Please see the instruction manual of
the monitoring gauge.
2. Check the braking loop.
3. Replace the air pressure sensor.
4. keep the pilot wire insulated.
1. Replace the fuse.
2. Change the bulb.
3. Fasten the wire connection.
1. Retighten the wire connection.
2. Adjust the tension of the pulley belt.
3. Replace the generator.
Remedies
1. Replace the seal ring.
 pressure is 2. There is air in braking hydraulic circuit. 2. Bleed air out.
insufficient. 3. Low braking air pressure. 3. Chek air-compressor, oil-water
4. Pressure booster gets worn. separator, safety valve and sealing
5. Oil leaks onto braking plates from hub. performance.
6. Braking plates wear out totally. 4. Replace the pressure booster
5. Check or replace the hub sealing
ring.
6. Replace the braking plates.
1. Braking valve is wrongly positioned .And the
piston rod is blocked and the spring fails to
The braking 1. Check or replace the braking valve.
work or just is broken.
system could not 2. Check or replace pressure booster.
2. Pressure-booster works defectively.
be disengaged. 3. Check or replace the sealing ring.
3. Pump piston could not restore to its original
position.
Braking oil
1. Poor sealing for pneumatic system. 1. Check and repair the pneumatic
pressure gauge
2. Air compressor can’t work well. system.
shows the pressure
3. Oil-drainage plug of the oil-water separator is 2. Ccheck the air compressor.
reading increases
not firmly tightened. 3. Re-tighten the plug.
slowly.
There is not 1. The gap between the braking drum and braking
1. Make re-adjustment
enough power for plate is too large
2. Clean the braking plate
hand brake. 2. There is some oil on the braking plate.
3.5.4.2. Full hydraulic brake
Table 3- 8
Trouble Symptom Causes Remedies
1. There is still air inside the braking 1. Discharge the air
hydraulic pipelines. 2. Adjust it to 17.5MPa.
2. The adjusted pressure is too low
Foot-braking pressure is 3. The nitrogen pressure of accumulator 3. Fill the nitrogen until the pressure
insufficient. is too low. reach to 5MPa
4. The lead pump is damaged. 4. Repair or replace the pump.
5. The braking discs have been worn out 5. Replace the braking disc or oil seal.
or braking oil chamber leaks oil.
1. The position of braking valve rod is 1. Repair or replace the bake valve.
wrong, the piston rod is jammed or the
The braking device can’t
returning spring breaks down. 2. Replace the returning spring.
be disengaged soundly.
2. The returning spring of rim brake fail
to work.
1. Too much clearance between the 1. Make re-adjustment.
There is not enough
braking drum and braking discs. 2. Clean the braking discs.
power for hand brake.
2. There is oil on the braking discs.
3.5.5. Working hydraulic system

Table 3- 9
Trouble Symptom Causes Remedies

26
 Insufficient power for 1. Oil sealing ring for cylinders wears out or gets
raising the main boom, or broken.
insufficient power for 2. The distribution valve wears too much, and
tilting bucket. the valve clearance is out of its acceptable limit.
3. There is oil leakage from hydraulic oil circuit.
4. Severe inner oil leakage in the oil pump.
5. Wrong adjustment for the safety valve, which
causes the problem of low system pressure.
6. The oil suction pipe and oil filter get blocked.
When the engine rotates 1. Please see details in No. (1) of this section.
at high speed, the bucket 2. The safety valve gets blocked deadly.
or main boom raises
quite slow.
Hydraulic oil gets mixed Hydraulic oil and transmission oil come
with transmission oil. together due to over-wearing and aging of the
sealing ring for oil pump.
1. Replace the oil sealing ring.
2. Dismount the valve, and check
and repair it, so as to have its
clearance be up to desired value,
or just replace the distribution
valve with a new one.
3. Figure out where oil leaks, and
eliminate the oil leakage problem.
4. Replace the oil pump.
5. Reset the system pressure to
desired value.
6. Clean the oil filter and change
oil.
1. Please see details in No. (1)
of this section.
2. Dismount and check the
safety valve.
Replace the oil sealing ring, clean
the oil filter, and check to see if
the oil-suction pipe-lines get
deformed or cracked.

3.6. Replacement of the key parts

● Customers must service the loader periodically to ensure the safety. Those parts which are listed in the
following list are important to your safety and should be replaced according to schedule
● Those parts will get aged and wore out along with working time increasing, it is hard to judge the condition of
those parts, so replace those key parts periodically without regarding if they are normal or not.
● Repair or replace the damaged part right away without regarding to the schedule.
● When replacing a hose, please replace the O-ring and seal cushion at the same time.
● For replacing those key parts correctly, it is better to consult with XCMG or its agent, table 3- 11。

Table 3- 10 Key Parts Replacement List

Brake System
No. Key parts that need to be replaced periodically Quantity Replacement period
1 Hose(Oil-water separator combination valve - air 1
cylinder)
2 Hose(air cylinder - foot brake) 1
3 Hose(foot brake - booster pump) 1
4 Hose(Booster pump - Front axle) 1 Every two years or
5 Hose(Booster pump - Rear axle) 1 4000 hours (whichever
6 Hose(foot brake - Handbrake) 2 is earlier)
7 Hose (Handbrake- Handbrake booster cylinder) 2
8 Hose (Handbrake - Power cutoff cylinder) (If 2
equipped with planetary transmission)
9 Hose (Rear axle brake pipe) 2
10 Air cylinder 1 Every three years

27
Note: Refer to Parts Catalog for the detailed list of materials.

Steering system
No. Key parts that need to be replaced periodically Quantity Replacement period
1 Hose (Steering gear L/R - Left/right limit valve) 2
2 Hose(Left limit valve――Flow amplifying valve) 1
3 Hose(Right limit valve――Flow amplifying valve) 1
4 Hose(Pilot pump――Steering gear P) 1
5 Hose(Steering gear T――Limit valve T) 1
6 Hose(Flow amplifying valve――Left steering cylinder) 1 Every two years or 4000
7 Hose(Flow amplifying valve――Right steering 1 hours (whichever is earlier)
cylinder)
8 Hose(Left steering cylinder ――Right steering cylinder) 2
9 Hose(Left limit valve T――Right limit valve T) 1
10 Hose(Left limit valve T――Hydraulic oil tank) 1
11 Hose(Steering pump――Flow amplifying valve) 1
Note: Refer to Parts Catalog for the detailed list of materials.

3.6 Cummins Engine ECU Malfunction Troubleshooting

Table 3-11

28
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52