LW900KN Wheel Loader

Operator’s Manual

XCMG Construction Machinery Co., Ltd.

 Foreword
Welcome to purchasing and using LW900KN wheel loader manufactured by XCMG Construction

Machinery Co., Ltd.

This manual is an important part of the machine, which shows you the useful information regarding:

machine components and its operation, safety, service, maintenance, troubleshooting and technical

specifications. This manual can help you operate machines smoothly, safely and efficiently.

Please read carefully and understand completely this manual content before using, maintaining and repairing

the machine, especially those information about safety precautions. Please operate this machine according to

this manual strictly. The operator of the machine must keep this manual within his reach, and the service

people of this machine also must be familiar with and understand this manual content. If this manual gets lost

or become dirty, please get a new one from XCMG Construction Machinery Co., Ltd. or its authorized agent.

If you re-sell the machine to others, please hand over this manual to the new machine user.

The contents of this Operation and Maintenance Manual includes the operation and safety precautions,

lubrication, maintenances, transport, storage and preservation, and technical specification. Due to continuous

improvement of machine design and the specific configuration needs of the users, the contents, specifications,

diagrams, and main technical performances of this Operation and Maintenance Manual are probably subject

to changes at any time, which will probably result in the differences between this manual and your purchased

machine and influence the maintenances of the machine. Obtain the complete latest data before starting

operations. For the relevant latest information of the machine or for any question on this Operation and

Maintenance Manual, please contact XCMG Construction Machinery Co., Ltd. or its designated dealer.

The operations, maintenances, and precautions related to the safety operation practices defined in this

manual are applicable for the designated applications of this machine. For the applications beyond the

specified scope of this manual, XCMG Construction Machinery Co., Ltd. will not be liable for any

safety consequences thereof, which will be solely borne by the user. In all cases, do not perform any

operation prohibited by this manual.

I
 Warning Signs for Safety Precautions

Warning sign for safety Explanation

Caution denotes the potentially dangerous locations, for which the

CAUTION negligence will probably result in minor or moderate harms.
Caution denotes the potentially dangerous locations, for which the
WARNING negligence will probably result in death or serious harms.
Danger denotes extremely dangerous locations, for which the negligence
DANGER will result in death or serious injury.

Warning This safety warning sign show you the very important information about the
safety! When you see the sign in this manual, please read the item beside the sign and obey with the

item strictly, and inform it to other people.

● User’s modifications without the consent of the XCMG Construction Machinery Co., Ltd. will probably

result in danger. If the modification is required, please consult with XCMG Construction Machinery Co.,

Ltd. or its designated dealer and ask for the consent from XCMG Construction Machinery Co., Ltd.

before modification. Otherwise, XCMG Construction Machinery Co., Ltd. will not be liable for any

adverse consequence arising from the unauthorized modifications.

● The incorrect operations, repairs, and maintenances are probably dangerous and will probably result in
personal injuries.

● Before the operations or repairs, the operation personnel and repair personnel shall carefully and

completely understand the contents of this manual and carefully read the relevant information of the

parts equipped on this machine, including engine and A/C.

● Due to continuous improvement of equipment design and the diversified user demands and

configurations, the contents, specifications, diagrams, and other contents in this manual may be subject

to alternations at any time and such alteration will probably influence the repairs and maintenances of

the equipment. Obtain the complete latest data before starting operations. For the latest information of

this machine or the questions about this manual, please contact XCMG Construction Machinery Co.,

Ltd. or its designated dealers to obtain the latest information.

● The safety precautions and warning signs are provided in this manual and on this product. The
II
 negligence of these precautions or warnings will result in personal injuries or even casualty accident to

you or others.

● Abide by local laws and regulations during the operations of this loader.

III
 Contents
Foreword ......................................................................................................................................................................................I
Warning Signs for Safety Precautions ................................................................................................................................... II
Contents .....................................................................................................................................................................................IV
1. Product Overview.......................................................................................................................................................... 1

1.1 Purpose........................................................................................................................................................................ 1

1.2 Component Names And Decals ................................................................................................................................ 2

1.3 Technical Specification .............................................................................................................................................. 5

1.3.1 Overall Dimensions ......................................................................................................................................... 5

1.3.2 Technical Specification .................................................................................................................................... 6

1.4 Safety decals and the sticking position...................................................................................................................... 9

2. Operation and sayfty................................................................................................................................................... 12

2.1 The Use Of The New Loader .................................................................................................................................. 12

2.1.1 Notices ............................................................................................................................................................ 12

2.1.2 Study the safety items ..................................................................................................................................... 12

2.1.3 Learn the checking method ........................................................................................................................... 12

2.1.4 Be Familiar With Your Machine ................................................................................................................... 13

2.1.5 Running-In Of The Machine ......................................................................................................................... 14

2.2 Instruments And Controls ........................................................................................................................................ 16

2.3 Operation and safety................................................................................................................................................. 44

2.3.1 Safety Rules .................................................................................................................................................... 44

2.3.2 Checking before Start of Engine ................................................................................................................... 48

2.3.3 Driving Safety................................................................................................................................................. 51

2.4 Working Method ...................................................................................................................................................... 55

2.4.1 Excavating Performance ............................................................................................................................... 55

2.4.2 Loading operation (Handling engineering methods) .................................................................................. 57

2.4.3 Dump operation ............................................................................................................................................. 58

2.4.4 Ground preparation ....................................................................................................................................... 59

2.4.5 Soil Pushing.................................................................................................................................................... 59

2.4.6 Snow Sweeping .............................................................................................................................................. 60

IV
 2.4.7 Towing Performance...................................................................................................................................... 60

3. Lubrication , Maintenance and Repair ................................................................................................................... 63

3.1.General Principle of Maintenance ................................................................................................................................. 63

(1) Fault Notification ................................................................................................................................................ 63

(2) Warning Mark ..................................................................................................................................................... 63

(3) Common knowledge............................................................................................................................................ 63

(4) Servicing the machine while the engine is running........................................................................................... 67

(5) Checking cooling system..................................................................................................................................... 67

(6) Inspection and service for hydraulic system...................................................................................................... 68

(7) Maintenance for battery...................................................................................................................................... 69

(8) Maintenance for tyres ......................................................................................................................................... 70

(9) Electrical system.................................................................................................................................................. 72

(10) Engine hood ................................................................................................................................................... 73

(11) Replacement Of The Key Parts ..................................................................................................................... 73

(12) Rejected staffs ................................................................................................................................................. 73

3.2 Lubricating The Machine......................................................................................................................................... 39

3.2.1 List of Daily Maintenance Parts ................................................................................................................... 39

3.2.2 Lubricating points and periods of machine.................................................................................................. 40

3.2.3 Maintenance oils/fluids, trademarks, and working temperatures............................................................... 39

3.2.4 Lubrication precautions................................................................................................................................. 40

3.3 Maintaining to the Machine..................................................................................................................................... 54

3.3.1 Checking before working............................................................................................................................... 54

3.3.2 Checking and maintaining after the working............................................................................................... 54

3.3.3 Periodical Checking and Repairing ............................................................................................................. 55

3.4 System Principles ..................................................................................................................................................... 63

3.4.1 Engine ............................................................................................................................................................. 63

3.4.2 Transmission .................................................................................................................................................. 63

3.4.3 Hydraulic system............................................................................................................................................ 72

3.4.4 Brake system................................................................................................................................................... 84

3.4.5 Electrical system ............................................................................................................................................ 86

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 3.4.6 Air-conditioner system................................................................................................................................. 128

3.4.7 Automatic fire-extinguishing system ........................................................................................................... 135

3.5 Trouble and shootings ............................................................................................................................................ 139

3.5.1 Power System ............................................................................................................................................... 139

3.5.2 Steering System ............................................................................................................................................ 141

3.5.3 Hydraulic System ......................................................................................................................................... 141

3.5.4 Electrical System.......................................................................................................................................... 142

3.5.5 Braking System............................................................................................................................................. 142

4. Transportation, Storage And Protection................................................................................................................ 143

4.1 Safe Transportation................................................................................................................................................. 143

4.1.1 Load Or Unload The Machine.................................................................................................................... 143

4.1.2 Hoist or put down the machine ................................................................................................................... 144

4.1.3 Transporting The Loader On A Public Road ............................................................................................. 144

4.1.4 Long-Distance Transfer Operation............................................................................................................. 145

4.2 Storage And Protection .......................................................................................................................................... 145

4.2.1 Daily Parking ............................................................................................................................................... 145

4.2.2 Long Time Storage ....................................................................................................................................... 146

4.2.3 After A Long Time Storage .......................................................................................................................... 146

VI
1. Product Overview

1.1 Purpose

This loader is of a construction machinery with a single bucket, front dumping, articulated frame and wheel

type. It can be widely used in construction worksites, port wharfs, stations and storage areas for loading or

short-distance transporting loose materials such as mud, sand, coal and dust. Also it can be applied in towing,

ground leveling, stacking and piling. All of these application make it become a high-efficient and

multi-function construction machinery.

The machine is featured in the following characteristics:

① Applied with articulated frame, with the articulating center being placed in the middle of the two

wheelbases, and small steering radius, so the loader is very maneuverable and suitable for narrow places.

② Applied with hydraulic mechanical transmission, so the power of the engine can be fully used, and the

torque can be increased, so as to obtain a bigger drawing force. Meanwhile, the loader adopt variable

infinitively speed, which can effectively protect the transmission system and the engine.

③ With the full hydraulic steering and power shift and hydraulic operating system, it is flexible, steady and

reliable to operate the machine.

④ Having the low-pressure & wide-base tyres and the swing rear axle, the loader has a good off-road

performance, so it can travel and work freely on rough terrains..

Requirements For The Working Environment:

Elevation : Cummins QSM11 engine is suitable for the applications of up to 3,600m altitude.

Ambient temperature : -12℃~45℃ (with low temperature starting:-20℃～＋45℃)

This machine is a common purpose construction machinery, so it is not can be used in easy burning, easy

explosive, high dusty or poisonous environment.

Forbidden Operation:

Overloading.

Only one side of the loader bears the load.

Digging the hard material.

Hanging a cable on bucket teethes to lift heavy object.

Excavating at the over-head position of the loader.

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1.2 Component Names And Decals

Figure 1-1 Overall figure and component name

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① Power transmission devices and the components

Figure 1-2 Power transmission devices and the components

② Decals And Number

The vehicle nameplate is fixed on the right side of front frame (At the articulated joint between front and rear

frames). Indicate the vehicle type, product model, manufacture year, vehicle identification number, and

manufacturer. (Figure 1-3, and the contents of the nameplate vary depending on the specific configuration of

the machine ordered by the user or dealer. )

Figure 1-3 Vehicle nameplate

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The engine plate is fixed on the engine body.

The product types, manufacturing number and manufacturer information etc.are all plated or coined on the

main parts of the vehicle.

The XCMG combination logo is located on the rear of engine hood.

Figure 1-4 XCMG Combination Logo

4
1.3 Technical Specification

1.3.1 Overall Dimensions

Figure 1-5 Machine overall dimension

5
1.3.2 Technical Specification

Model LW900KN
3
Type of working device 5m standard bucket
Weight
Operating weight (kg) 30500

Bucket capacity (full-load) (m3) 5

Rated load (kg) 9000
Traveling speed
1st forward gear (km/h) 6.8
2nd forward gear (km/h) 11.6
rd
3 forward gear (km/h) 24.5
4th forward gear (km/h) 35
st
1 reverse gear (km/h) 6.8
2nd reverse gear (km/h) 11.6
rd
3 reverse gear (km/h) 24.5
Characteristics
Maximum gradeability (°) >25
Max traction force kN 260
Lifting time of boom s ≤6.8
Total cycling time s ≤12
Rear axle swing angle (°) ±12
Bucket auto leveling performance Yes
Center of wheel (mm)
6200
Minimum Outer side of bucket at transport
turning radius 7460
position (mm)
Overall length (mm) 9300
Overall width (chassis) (mm) 3210
Bucket width (mm) 3600
Overall height (top of cab) (mm) 3850
(fully lifted bucket) (mm) 6415

Dimensions Wheelbase (mm) 3600

Boom hinge pin height (with bucket fully lifted) (mm) 4595
Dumping height (bucket tooth edge) (mm) 3400
Dumping distance (bucket tooth edge) (mm) 1470
Dumping angle at highest position (°) 45
Digging depth (at 10ºinclination angle) (mm) 75

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 Model LW900KN
Model: X12
Type: 4-stroke, water cooling, turbine charged .
Number of cylinders 6
Piston displacement (L): 10.8
Flywheel horsepower (kW) 277
Top torque/speed (N.m/rpm) 1898/1400
Engine
Rated fuel consumption (g/kW.h) 227
High idling speed (rpm) 2200
Low idling speed (rpm) 800
Starter motor: (kW) 24V 7.5
Alternator: (A) 24V 80
Battery: (Ah) 12V 120
Torque converter: Single-stage two-phase four-element
Transmission: Fixed shaft type electro-hydraulic gearshift
Power
system Type of main reducer: Spiral bevel gear single-stage reduction
Type of wheel reducer: Single-stage planetary reducer
Drive mode: Four-wheel drive
Front axle: Fixed with body
Rear axle: Central swing type
Drive
Tires: Michelin 29.5R25
axle
and
wheels
Inflation pressure:
Front wheel (MPa) 0.4-0.45
Rear wheel (MPa) 0.35-0.4
Independent control of front and rear wheels,
Foot brake: full-hydraulic wet brake, multi-plate wet brake, and
two-pedal brake system

Brake
Parking brake: Electric control, caliper type, and spring application,
controlled by brake button on the rear portion of
Braking oil pressure (bar) operating panel.
≤80

Type: Articulated full-hydraulic flow amplified steering

Steering
system Maximum steering angle (°) ±40

7
 Model LW900KN
Type of hydraulic pump: Gear pump
Working pump: 110
Flow (ml/r)
Steering pump: 110
Maximum pressure of working device (MPa) 24
Hydraulic
Control valve Maximum pressure of steering system (MPa) 19.5
system
Boom cylinder Reciprocated piston
Hydraulic cylinder Bucket cylinder Reciprocated piston
Steering cylinder Reciprocated piston

Working Type of arm: Single arm

device Bucket: Bucket tooth
Working medium of heater: Diesel engine coolant
Refrigerating output: (W) 5400
A/C Working medium of air conditioner: Coolant (R-134a)
system
Refrigerating output: (W) 8100
Working voltage: (V) DC 24
Optional
Stabilizer module, timber clamp, rock bucket, light material bucket, and high dumping device
equipment

8
1.4 Safety decals and the sticking position

Some positions of the machine are stuck with safety marks, so please carefully read and follow the

descriptions for all safety marks on the machine. The section introduces the positions where such safety

marks are stuck and descriptions for figures of the safety marks.

Take good care of safety marks. If they are lost or damaged, or the words and figures on them are not clear,

please repair them or add new ones. If a part stuck with safety marks is to be replaced, make sure that a

newly replaced part is stuck with corresponding safety marks. Cloth and soapy water may be used to scrub

safety marks. Do not use cleaning agent and gasoline, etc.

Figure1-6 Safety decals and the sticking position

Affixing precautions:

1. The affixing surfaces shall be dry and level without dusts and no secondary affixing is allowed.

2. All self-adhesive labels shall be affixed securely and levelly, without any air bubble or falloff.

3. The parts 4, 5, 6, and 7 shall be affixed on the inner side of cab glasses.

9
1 Don’t walk under the raised working device
(Located on boom - Two sides of bucket end)

2 Use the safety bracket when maintaining the boom.

(Located on boom - Two sides of frame end)

3. Keep away from the machine and the articulated area

(Located at the articulated joint of between front and rear
frames - Two sides of front frame)

4. Emergency exit
(Located on the right door of cab)

5. Keep away from high-voltage cables to prevent electric

shock
(Located on the right door of cab)

6. Read operation and maintenance instructions

(Located on the left door of cab)

7. Stop engine and withdraw key before maintenance and

repair.
(Located on the left door of cab)

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8. Keep away from fan while the engine is running.
(Located on two sides of rear engine hood)

9. Do not disassemble high pressure vessel without

permission.
(Located on accumulator)

10. Keep away from machine.

(Located on rear ballast)

Figure 1-7 Hoisting diagram

11
2. Operation and sayfty

2.1 The Use Of The New Loader

2.1.1 Notices

New machine has passed stringent checking and test run before delivery. However, ensure to fulfill 8~10h

run-in from the beginning. Start from no-load running, gradually increase the load, and drive and operate the

motions of all working devices under no-load condition to run in all friction portions of machine. Within the

initial 50h, control the workload within 70%, in order to maintain smooth working status of vehicle and

prolong the life of machine.

During the operations of vehicle, please abide by the following precautions:

 Regardless of the season, after the start of engine and before the start of working, ensure to warm up

sufficiently.

 Avoid the high-speed running of engine under no-load condition, especially when the engine is not

warmed up.

 Avoid of emergent driving, sudden turnaround and unnecessary emergent braking.

 Check and repair the machine according to regulations.

2.1.2 Study the safety items

Study all relevant data attached in the machine equipment. Study its structure, operations, working natures,

and maintenances.

Understand the positions and functions of all operation and control systems, indicating instruments, and

warning devices.

Study to identify the warning and safety signals on the machine, which will alert you of the low pressure and

high temperature statuses, in order to prevent the harms arising from the further operations under such

condition.

Carefully read and abide by the descriptions of all safety signs on the machine, properly protect them, and

timely repair any missing or damaged safety sign.

2.1.3 Learn the checking method

Understand the safety protection devices installed on your machine and observe and ensure that every device

is under safe and operational condition, including seat belt, lamps, horn, cab doors and guard railings, ladder,

12
standby alarm, and rearview mirrors.

Check if tyres are wore out or damaged or not. Check if all tyre air pressures are normal or not. Don’t operate

the loader if some tyre air pressure are insufficient.

If the lock bar of steering pin is installed, please keep it in ready condition. The locked machine can’t be

turned.

2.1.4 Be Familiar With Your Machine

Get familiar with the positions and functions of pedals, control units, and instruments. Thoroughly removing

the oil and grease from steering joystick, pedals, hand joystick, and ball handle can guarantee your easy

operations without slip.

Remove unnecessary tools and other objects from the inside of cab and always keep clean the ground, in

order to avoid your distraction during operations.

Only the authorized technician can operate and maintain the loader.

When operating or maintaining the machine, please obey with all safety regulations and notices.
Read the Operator’s Manual of the loader, study the structure,
maintenance and operation of the loader, and be familiar with all
buttons, handles and meters.

Please understand all regulations about operation, get known all

the signals which are used in working process. If there are some
grease on the operating area, please wipe it out immediately
because it can result slippery.

Before and after machine operation, please check every system.

Check if all safety protecting methods are in safe condition or not.
Check if all tyres are wore out or not, and theirs air pressures are
normal or not. Breakdowns and accidents should occur if you
neglect oil leakages, water leakages, deformations, looseness and
abnormal noise. So please check the loader frequently.

13
2.1.5 Running-In Of The Machine

Although the loader has been checked and adjusted, but if it is used in a bad operating environment at the

beginning, the service life of it should be shortened. Please apply running-in operation for 50 hours at initial

stage.

Please obey with the following regulations during the run-in period:

 After starting the loader, idle the machine for 5 minutes to get it warmed up.

 It is forbidden to accelerate the engine suddenly during warming up process.

 Avoid of sudden startup, sudden accelerating and steering and sudden braking, except in emergency

case.

 During running in period, every gear should be engaged equally in time.

 During run-in period, it is better to load the bucket with loose materials and avoid of rude operation. The

loading capacity should not exceed 70% of its rated capacity and the driving speed should not exceed

70% of the rated maximum speed.

 Pay attention to the lubricating state of the machine, and replace or inject the lubricant according to

prescribed schedule.

 Pay attention to the temperature of transmission, torque converter, front and rear axle, wheel hub and

brake drum. If overheating occurs, please find out the reason and resolve the problem.

 Check the tightness of every bolt and nut.

After 10 hours of running in period, the following operations should be carried out:

 Check the tightness of every bolt and nut overall, especially, the cylinder head bolt of diesel engine,

fixing bolts on engine, transmission and front & rear axle, hub nuts, and the connecting bolts of the

transmission shaft etc. All the above mentioned bolts should be checked.

 Clean the rough engine oil filter, fine engine oil filter and fuel filter.

 Check the tightness of fan belt, generator belts and belts on air-conditioner compressor.

 Check the status of the battery electrolyte and tighten the joints of the battery.

 Check the oil level in the transmission system.

 Check the airproof status of the hydraulic system and braking system.

 Check if every control lever and accelerator lever are well connected and tightened.

 Check the temperature and connection of every component in the electric system, and check the

14
generator performance, illumination lamps and steering lamps.

15
2.2 Instruments And Controls

Figure 1-8 Cab Instruments and Controls

1. Front working lamp
2. Rotating warning lamp
3. Rearview mirror
4. Gearshift joystick
5. Brake pedal
6. Horn button
7. Front wiper
8. Combination instrument
9. Lighting combination switch
10. Reversing camera
11. Accelerator pedal
12. Pilot joystick
13. Weighing system (Optional)
14. Rocker switch
15. Power socket
16. Emergency stop switch
17. Natural gas level indicator (For natural gas
powered vehicles)
18. Rear working lamp
19. Rear wiper
20. Fire extinguisher
21 Air conditioning system

16
1. Front working lamp

2. Rotating warning lamp

3. Rearview mirror

4. Gearshift joystick
The kick-down (KD) function is adopted. The
method is to push down the joystick along its
axial direction.

5. Brake pedal
Left: Power cutoff brake
Right: Power non-cutoff brake

39
6. Horn button

7. Front wiper

8. Combination instrument (layout and

function)
G1—Tachometer G2—Engine oil pressure
gauge
G3—Water temperature gauge
G4—Battery Voltage Gauge
G5—Transmission Oil Temp Gauge
List of warning lamps
No. Name Symbol Color
Left turn
1 Green
signal
Right turn
2 Green
signal
Charging
3 Red
indicator
Low brake air
4 pressure Red
warning
Low engine
5 Red
oil pressure
6 Parking brake Red Button

Axle oil
7 Red
temperature

40
8 Preheating Red

Engine
coolant
9 Red
temperature
warning
Low fuel level
10 Red
warning
Low
transmission
11 Red
oil pressure
warning
Transmission
oil
12 Red
temperature
warning
Air filter
13 Red
blockage
14 Buzzer mute Red
Reserved
fuel-water
15 TBD TBD
separator
warning
Hydraulic oil
16 filter blockage Red
warning
Axle filter
17 blockage Red
warning
Engine
18 Red
maintenance
Inter-wheel
19 differential Green
lock
Waiting for
20 Red
start
Hydraulic oil
21 Red
temperature

41
 22 Power cutoff Yellow

Engine stop
23 Red
indicator
Engine
24 Yellow
diagnosis
9. Lighting combination switch (from left to
right)
Diethyl ether switch, pilot lock switch, front
auxiliary lamp switch, cab front working lamp
switch, cab rear working lamp switch, and
engine hood rear working lamp switch
10. Reversing camera

11. Accelerator pedal

12. Pilot joystick

42
14. Rocker switch (from left to right)
Stabilizer module switch, front wiper switch,
rear wiper switch, front washer switch, rear
washer switch, power cutoff switch,
manual/automatic switch, indicator lamp, and
blind cover
15. Power socket

16. Emergency stop switch

18. Rear working lamp

19. Rear wiper

43
 Engine key starter switch

Two-way cushioned seat: It’s cushioned in

vertical and longitudinal directions to improve
comfort.

2.3 Operation and safety

2.3.1 Safety Rules
Safety guard
Don’t operate the loader if you feel uncomfortable or take
medicines or drink alcohol. Operating the loader with bad health
may injure others or yourself.

When you work together with other people, please make

them understand the gesture language.

When operating or maintaining the loader, please take safety

guards.
When operating or maintaining the loader, please wear safety hat
which is made up of hard material, safety glasses, safety shoes,
glistening coat, veil, earplugs and gloves. When scattering metal
scrapes or cleaning the debris from air filter by hammer or

44
compressed air, please wear safety glasses, hard hat and thick
gloves.
Don’t wear loose clothing as loose clothing can be easily enwinded
in control levers or moving parts to cause casualty.
Don’t wear greasy clothing which can incur burning.
Check if the safety guards are normal or not before putting them
into use.

Unauthorized restructuring
Any unauthorized restructuring to this loader can result danger or
casualty. Before restructuring the loader, please consult with
manufacturer or authorized agent. Manufacturer should not be
responsible for the damages caused by unauthorized restructuring.
When you leave the seat
Before leaving the seat, the operstor must press down the rocket
switch on panel and place the 22E-10 solenoid valve at power-cut
status (if no solenoid valve, leave the pilot oil cutting-off ball valve
at OFF status, the ball valve is on the right side of the working
device control handle) as well as cut off pilot oil connecting to pilot
valve. Avoid any touches on the control lever which may lead to
accident due to working device movement.
On the other side, press down the parking brake switch (red button)
to leave the whole machine at brake status.
Before leaving the machine, lower the working device completely
on the ground. Press down the 22E-10 solenoid valve rocket switch
(or place pilot oil cutting-off ball valve at OFF status) to leave the
control lever at invalid status. Then shut down the engine.
Lock up all devices with the key and carry it personally.
Get on and off the loader
Inspect the ladder and handrail before and after getting on and off
the loader. Wipe away oil, lubricant and sludge that are on the

45
ladder or handrail.
Don’t jump on or off from the loader. Never getting on or off the
loader when the loader is moving.
When getting on or off the loader, please face to the loader, grip the
handrail and step on the ladder and ensure your body is stable.
Don’t grip any control levers when you getting on or off the loader.
Don’t get on and off the loader from the rear ladder or tyres.
Don’t climb up and down the loader carrying with tools or other
materials, please use ropes to hoist the tools or other materials.
Fire-prevention
Fuel and lubricant used by loader are combustible materials, so it is
dangerous when fire approaching the loader. Therefore, ensure to
pay attention to following items:
 Keep fuel and lubricant far away from fire.
 Stop the engine when injecting fuel. Smoking and fire are
forbidden during oil injecting process.
 Screw up all caps of oil tanks.
 Use marked vessels to hold combustible liquid, and put them
on a fixed place. Unconcerned people is disallowed to use it.
 Move combustible material away from the loader surface,
ensure that no greasy cloth or combustible material exists on
the loader surface.
 Don’t weld or incise the pipes containing combustible liquid.
Before welding or incising pipes, please use non-combustible
liquid to clean the pipes.
 When the loader is working, keep the exhauster of muffler far
away from combustible materials, such as withered grass or
waste paper and so on.
 Choose the parking place carefully and keep hot parts of the
loader far away from combustible materials.
 Prevent pipes and hoses from leaking. Replace the damaged

46
 pipes and hoses. Use the pipes and hoses which have been
repaired or cleaned.
 Battery can produce out explosive gas, so don’t let smoking
and fire approach the battery. Maintain the batteries according
to Operator’s Manual strictly.
Toolbox
 When checking the dark area, don’t use fire to lighten the area.

Road driving
Front-located working apparatus may obstruct the visual field of operator. When the bucket is filled
with load, weight is concentrated on two front wheels of the loader, so take stability into consideration
when driving on a road.
Fog, flappy soot and sand can obstruct the visual field of operator.
Investigate the working place in advance, watch the road condition, keep vigilance against to obstacles,
sludge, snow and cave.
Before driving on speedway and public road, please refer to Operator’s Manual in advance and obey
with local traffic rules. Don’t incur traffic jam and be quickly when getting through a crossing.
Understand all operating regulations and signals, operator must know the meaning of every signal and
sign at the first glance.
Fire extinguisher and first-aid kit
Take steps according to following items if injure or fire accident has
occurred.
 You must prepare a fire extinguisher and know how to use it.
 First-aid kit must be prepared on the working place. Refresh
the first-aid kit with new medicines.
 You must know how to save yourself when fire accident
occurring or you have been injured.
 Some useful telephone numbers must be pasted on a obvious
place, such as telephone number of doctors or hospitals, ensure

47
 all people know these telephone numbers and know the
communicating method.
 Guard against crushing or incising injuring
 Any part of your body should never get into working area of
moving parts of the loader. Along with the movement of
working equipment, the space of linkage devices will increase
or decrease, approaching to this area can result injuring. If it is
necessary to enter into the space that between moving parts,
please stop the engine and lock the working equipment.
 Support the loader reliably and firmly when you have to work
under the machine. Don’t rely on the cylinder to support the
loader. Accessory may fall down if controlling device moves or
pipes leak oil.
 Don’t adjust anything when the loader or the engine is running.
 Evade away from all rotating parts and working parts.
 Ensure that no sundries exist in laminas of fan. Rotating
laminas of fan can eject out or break the sundries which exist in
the fan.
 It is dangerous to check the engine when the engine is running,
avoid of doing that.
Notices about accessories
 When installing and using a accessory, please read the manual which is about to the accessory.
 Don’t use the accessories that are unauthorized by XCMG Construction Machinery Co., Ltd. or its
agent. The unauthorized accessories can cause dangers and tamper with the normal operation.
 XCMG Construction Machinery Co., Ltd. is not be responsible for the damages and accidents
caused by using the unauthorized accessories.

2.3.2 Checking before Start of Engine

a) Walk-around checking
Before entering the cab for operations each day, the driver must walk around to check the machine
and machine underbody and carefully check the following items:

48
 Check the bolts and nuts for presence of looseness (especially drive shaft, wheel rim, and
drive axle).
 Check the lubricating oil, fuel, and coolant for leakage.
 Check the working state of working device and hydraulic system.
 Check the circuits for looseness.
 Check surroundings of high temperature parts (such as engine muffler and turbocharger) for
accumulation of inflammables.
b) Check the loader before starting it
Check the loader before every daily work, perform daily maintenance insistently. Treat abnormal
condition seriously, repair breakdown immediately and report to managing personnel.
 Take notice to oil leakage, water leakage, looseness of bolts, abnormal sound and lost of parts.
 Ensure that the lock bar has been disengaged.
 Check the oil level of cooling liquid and fuel and oil in engine sump, check that air filters are
blocked or not.
 Ensure that all illuminating devices and lamps are normal, repair the abnormal one
 Ensure that all meters and gauges are normal, put operating levers at theirs right positions.
 Clean the cab windows and clean all lamps to get a good visual field.
 For get a good visual field, turn rear-view mirrors to a proper angle. Replace the damaged
glass of rear-view mirror.
 Don’t leave tools or parts around the operator’s seat. Vibrations can make these tools or parts
fall down to damage operating levers or switches.
 Adjust the angle of seat until operator feel comfortable, and ensure safety belt and its fixing
are reliable. Replace the safety belt which has been used for 3 years.
 Ensure the fire extinguisher is normal.
 Clear grease and sludge away from handrail, ladder and shoes to avoid of sliding.
c) Start of engine
Notice the following items before start of engine:

49
 Sound the horn at the start of engine and ensure there is
Beep! Beep!
no person or obstacle around the machine, especially in
the case of cooperation with others.
 At the time of start each time, do not run the motor
continuously for more than 30s and keep an interval of
2min before next start.
 If the engine fails to start by one time, wait for at least
2min before retry, in order to prevent burning the starter
motor.
 The engine can’t be started if the gearshift lever is not in
the neutral position.
Start procedure:
(1) Lightly depress the accelerator pedal to help the start.
(2) Rotate the starter switch to position START to start the
motor and drive the running of engine.
(3) After the start of engine, loosen the starter key. The
starter switch will automatically return to position ON.
d) Checking after the loader has been started
Inspect the loader according to following items after the
loader has been started and before working.
 Run the engine at medium idling speed for
approximately 5min to warm up and wait for the
machine to reach best working state, which will
effectively prolong the service life of machine,
especially the engine.
 Ensure that the engine oil pressure indicator lamp,
accumulator low pressure warning lamp, and battery
charging indicator lamp are off.
 Check the exhaust gas color, sound, and vibration of
engine for abnormality. If abnormal, repair timely.
 Preheat the hydraulic oil as per the following method

50
 only in cold regions. Overflow the bucket for the
hydraulic oil to reach working pressure, which will
accelerate the preheating of hydraulic oil. Notice: Do
not overflow the bucket at dumping position for more
than 10s.
After the start of engine, pay special attention to the
following items:
① Do not accelerate engine suddenly during the preheating
stage.
② Notice: Do not idle the engine at low speed for a long
time. The long-term idling at low speed for more than 10min
will damage the engine. Cause: Low temperature of
combustion chamber, incomplete combustion, carbon
deposit, and blockage of valves.
At stop of machine: Stop the machine and idle the engine at
low speed for 5min to cool the engine and prevent the coking
problem of oil due to over-high temperature of turbocharger
housing.
2.3.3 Driving Safety
a) Start of loader
To start the loader, check the surrounding safety. Before
driving the loader, sound the horn and keep irrelevant Beep! Beep!

personnel away from machine. Start up the machine as per

the following procedure:
(1) Unlock the safety lock of working device.
(2) Operate the boom joystick to place the working dev
ice to driving state (Bucket pin is in height of 400
~600mm).
(3) Depress brake pedal, release the parking brake, and
keep the brake pedal depressed.
(4) Shift the speed joystick to the desired position.

51
(5) Shift the direction joystick to desired position.
(6) Release brake pedal and depress slowly accelerator to
start up machine.
b) Gearshift (speed change)
To reduce the impact on internal structure of transmission, apply the brake for deceleration before
speed change and avoid sudden speed change during high-speed driving.
For speed change, release the accelerator and shift the speed joystick to desired gear, with
out any necessity of stopping the machine.
c) Direction change
While choosing a forward or reverse gear, notice the safety of new driving direction. As there is a
blind zone behind the vehicle, pay special attention during reversing.
To change the direction of vehicle, operate the steering wheel, without any necessity of stopping
the machine. If the traveling speed is higher than 12km/h before the direction change, apply the
brake to decelerate before speed change and do not change direction during high-speed driving.
d) Steering
As the front and rear frames of the vehicle are connected by central articulated pin, the front and
rear frames can rotate mutually at this articulated joint so that the front and rear wheels have same
trajectory during steering.
To turn the vehicle right, rotate the steering wheel clockwise. To turn the vehicle left, rotate the
steering wheel counter-clockwise. The turning radius depends on the rotation degree of the
steering wheel.
Notice: It’s really dangerous to steer suddenly during high-speed driving of the vehicle or
make steering on a steep slope. No steering can be made after the stop of engine, even
when the vehicle is still traveling, which shall be specially noticed.
e) Parking of vehicle
To park the vehicle, decelerate by applying the brake pedal and do not brake by using the parking
brake switch. The parking brake will be applied automatically after the stop of the engine.
The parking procedure is as below:
(1) Release the accelerator pedal and depress the brake pedal to apply the brake.
(2) Shift the direction joystick to neutral position.
(3) After stop of vehicle, engage the parking brake switch and release brake pedal.

52
Notice: Do not park vehicle on a slope. If it’s necessary to park the vehicle on a slope, face the
vehicle head towards downslope direction, plug the bucket into ground, and block the wheels by
cushion block to prevent movement.
f) Keep a good operating habit.
When operating the loader, operator must sit on the seat and
take the safety belt. The loader should always be in controllable
condition.
Operate the working device joystick correctly. Operate the
joysticks in completely correct manner to avoid maloperations.
Repair the breakdown at once if the breakdown occur, and
listen the abnormal sound to distinguish the reasons of
breakdown. Don’t repair the part that is in working.
Do not overload. Performance that is beyond the capability of
the loader is extremely dangerous. It is very dangerous to
disobey the instructions when operating. Please investigate the
load weight in advance to avoid of overload. XCMG should not
be responsible for the damages and injures caused by overload.

Dashing with high speed is equal to suicide. Dashing not only can damage the loader but also can
injure the operator. Never try doing it.
The loader should be aligned vertically to the heap to be loaded. If handling the heap from an oblique
direction, the loader may be unbalanced.
Investigate the surrounding condition in advance before starting operation.
Check the ground condition before passing through a tunnel or over a bridge.
When working in heavy windy weather, operate the loader favourably with the wind.
Be careful when the load must be lifted to the highest position. Lifting the load to high position is
dangerous because it make the loader unbalanced, so move the loader slowly and take notices when
tilting the bucket forward.

53
When a truck cooperating with the loader, avoid of the bucket
colliding with the truck. No one can stand under the bucket and
don’t hang the bucket over the cab of the truck.

Before traversing the loader, please observe the behind are

a carefully.
Stop working when the visibility is weakened by smoking,
heavy fog and flay dust. Please prepare illuminating devi
ces if the working place is dark.
When working at night, please notice the following items.
 Ensure that sufficient illuminating devices have been
prepared.
 Ensure that all working lamps of the loader can work
normally.
 You will easily have a wrong impression to the distance
and height of objects at night.
 When working at night, please stop the loader to insp
ect its condition frequently and check the surrounding
condition.

54
2.4 Working Method
The machine is equipped with KD mandatory gear-shifting function. The machine can travel to
material piles at speed gear II. When the machine reaches material piles, press “KD” button
(refer to Fig.1-8), the machine will change into gear I automatically. After the bucket is full with
material, move the gear-shifting control handle backwards to Reverse position, then the machine
will change into Reverse gear II from Forward gear I. So during working with carrying materials,
it is not necessary to turn the gear-shifting control handle for selecting speed gear. You can follow
the following steps:

Press KD button Move backward

Forward gear II Forward gear I Reverse gear II

Figure 1-8

2.4.1 Excavating Performance

The digging operation denotes the loading and digging operation that inserts the bucket into
material piles (Such as sand and rock) under the stopped or forward driving condition of machine.
The digging operation is divided into shoveling operation and digging operation.

During the digging operation, ensure the uniform load application on two sides
of the bucket and do not apply load onto one side of the bucket. Face the loader
straight forward and do not form any angle between front and rear frames.

a) Shoving Operation
Keep the bucket parallel with the ground while driving the loader, insert the bucket into heap fully,
raise the lifting arms and reverse the loader. Operate the bucket 2-3 times to make it tilt backward.
In addition, if it’s difficult to shovel the bucket into the material pile, operate the bucket end in
proportion of forward tilting 1 → backward tilting 2 while ensuring that the wheels are free of slip.
Keep the bucket parallel with ground.

55
Shift to a low gear and start up the vehicle (or press KD
button to downshift to 1st gear when in 2nd gear) to directly
approach the material to be loaded. Depress the accelerator
pedal to shovel the bucket into the material to be loaded.
Keep the bucket tilting backwards to its maximum limit, and
raise it 400-500mm above the ground (Transport status).

Raise the lifting arms and operate the bucket control lever to
make it tilt back for 2-3 times to fully load material to be
loaded.

CAUTION During the digging operation, ensure the uniform load application
on two sides of the bucket and do not apply load onto one side of the bucket. Face the
loader straight forward and do not form any angle between front and rear frames.

b) Digging operation
The proper inclining angle of the bucket is 0~10º. Drive the loader with a low speed, raise the
lifting arm after the bucket inserting into 10~30cm, at the same time tilt the bucket backward. The
less the bucket digs, the easier the loader does.
Keep the bucket tilt forwards a little.

Drive the loader to fill the material into bucket (cutting depth
can be adjusted by controlling the handles of lifting arm and
bucket).

56
Raise the lifting arm and keep the bucket tilting backwards.

Keep the bucket tilting backward to its maximum limit, and

keep it away from the ground 400~500mm.

2.4.2 Loading operation (Handling engineering methods)

Choose efficient methods to pour sand, soil, rocks and mineral into truck, lorry and container.
Transfer methods are chosen according to site condition: one is transferred by loading machine
and carrier vehicles, the other is wheeled loader.
Wheel loaders can be used under the following conditions:
● Too soft or unlevelled sites, when the carrier vehicle can’t pass.
● Transportation distance within 500M which it’s a time waste for carrier vehicles.The
transportation speed should be decided by transportation distance and road surface conditions.
In order to keep safety and good visionability, rotate the bucket up to its limits position (the
bucket touching boom spacing block) as well as keep the lower hinged point on the boom at
transportation position (400~500mm).

CAUTION Clear the gravels and stones away from the ground by bucket,
which can prevent wheels from damaging and the road surface frequently.

CAUTION Pay attention on the road surface when transporting, choose a

speed that will not make loaded material splash out and lower the bucket
when driving.

 Dig and load on a flat ground

Keep the bucket slightly tilted forward with respect to the horizontal ground and drive forward the
machine while operating the boom and bucket joysticks to adjust the digging depth. (Pay special
attention on varying road surfaces) Afterwards, operate as per the essentials of “Shoveling

57
operations”.
 Supporting engineering modes of loader and transport vehicle
These modes are shown in the diagram and there are 4 working methods. However, depending on
the situation of working site, select a working method of short cycle time (Time required for one
loading cycle) - Loading and handling engineering mode.

V-type cycling operation I-type cycling operation

L-type cycling operation T-type cycling operation

The above mode is to shovel, handle, and dump continuously by a wheel loader.It’s commonly
applicable for 30~100m handling distances.

2.4.3 Dump operation

 When discharging material into the heavy truck or goods yard, the boom should be raise up to
where the bucket can’t reach the carriage and material piles (inclined forward to the max.
inclined angle). Pull forward the bucket control lever to inclined forward discharge loads, the
loads can partially or completely discharged by controlling bucket control lever. Discharge
motion should be soft to reduce material shocks to the heavy truck.
 If the materials stick onto bucket, may pull the bucket tilt control lever back and forth to
remove material.
 The bucket auto leveling function can be used after discharging. Firstly pull the bucket tilt
control lever to the draw-backposition, when the bucket tilt control lever holding solenoid
valve inside of the pilot valve, release bucket tilt control lever until reaches bucket leveling

58
 location, the bucket tilt control will auto rebound to neutral position.
2.4.4 Ground preparation
By the angle formed by bucket cutting edge and the ground, the loader can perform soil scattering,
ground levelling and foundation laying.

CAUTION When performing the ground preparing, the machine must be driven backward.
If it is a must to prepare the ground while the loader is forward moving, please keep the
forward tilting angle within 0º~10º.

Soil scattering
Load sand or soil into bucket, then tilt the bucket forward to 10º~15º and scatter the sand or soil
evenly while the loader is moving backwards.

2.4.5 Soil Pushing

The bucket can be used as a scraping plate to level up the ground. At this time, fill the bucket with
sand or soil and keep it parallel with ground, then perform levelling up.

 Coarse levelling
Tilt the bucket forward completely, keep the bucket teeth contacting with ground and reverse the
loader at a low speed to make the ground levelling.
 Fine levelling

59
Fill the bucket with sand or soil and keep it contacting with ground horizontally. Put the handle of
the lifting arms at “float” position, then reverse the loader slowly. When working on a hard ground,
put the handle of the lifting arms at “float” position, make the bucket stick to ground and scrape
the ground clearly.

During operations, the engine coolant temperature shall not exceed 100ºC
(including 100ºC), the torque converter oil temperature shall not exceed 110ºC,
and the braking air pressure shall not be lower than 10.2MPa. Otherwise, stop
the operations immediately and figure out the problem reason.

2.4.6 Snow Sweeping

Please pay special attentions on following items.
Using this machine for snow removal is same with general loading operations. However, as the
snow accumulated road differs from general condition, it will result in slip of wheels and difficult
operations of steering wheel.

Avoid of hurry driving, emergent braking, rapid turning , and operate the loader with
care.
Notices of snow sweeping
● Ensure the safety when fog weakening your visual field.
● Take notices to those objects buried under the snow.
● Know the positions of ditches and curb.
● Anti-skid chains must be installed on 4 wheels
2.4.7 Towing Performance
Raise up the towing pin which is located at the counterweight and thread towing cable through it,
then put the towing pin down.

The towing cable should be threaded firmly.

The braking device of the vehicle which is to be towed can function normally,
otherwise don’t attempt to tow it.

Notices to towing performance

a) When towing a break-down loader in short distance, please obey with the following
instructions. The speed should not exceed 2km/h, move the break-down loader to a safe place

60
 to repair it. This method can only be used in emergent case. Please use a truck to move the
break-down loader for the long-distance transportation.
b) Necessary security protection should be made for the towing vehicle, and try to prevent any
injury happening on operators caused due to the failure of towing cable and towing link.
c) It is forbidden to operate the vehicle unless the operator can control the steering and braking
of the vehicle to be towed.
d) Before towing a loader, please check the condition of towing cable and towing link, ensuring
that they have enough intensity. The strength of the towing cable must be 1.5 times to the
weight of the loader. Towing cable can also be used to draw the loader that is trapped in
sludge or on a slope.
e) Chains can not be used as towing cable because it may break and cause casualty. Assign a
observer on a safe place who can stop the towing performance if the towing cable breaks or
gets loose. Terminate the towing performance when the towed vehicle can move by itself.
f) The minimum towing angle must be ensured, which should not be over 30º.
g) Hurry towing can break the towing cable, so it is suggested to apply slow and smooth towing.
h) Under the normal condition, the size of the towing vehicle should be same with that of the
loader to be towed, and the towing vehicle should also be of proper braking performance,
sufficient power and weight to meet the demands in terms of towing slope and towing
distance.
j) When towing a break-down loader downhill a slope, a larger vehicle should be needed and
follow after the loader, so as to prevent the break-down loader from rolling.
k) Towing force should vary according to different terrain condition. If the terrain condition is
level and smooth, the needed towing force is small. If the terrain condition is bad, the towing
force is large.
l) If the machine engine is still running, the break-down loader only can be moved for a short
distance just under special case, while the machine’s power system and steering system also
can be operated. Bear in mind that the machine can only be towed for a short distance, e.g.,
tow the machine out of mud trap or tow it onto a road edge.
m) Before towing, keep the direction of the loader in line with the towing direction. A improper
towing method or bad steel cable can result casualty or damage, so obey with following items.
 Operate as per the related towing descriptions in this manual. Other incorrect towing methods

61
 will probably cause dangers.
 The towing vehicle and towed machine must be installed with ROPS&FOPS.
 Choose the high quality steel cable, and please wear gloves when dealing with steel cable.
 Before cooperating with other workers, discuss with them and determine the signals that will
be used.
 If the engine and braking systems of the break-down loader gets troubles, please consult with
their manufacturer for repairing them.
 Towing a machine on a slope is dangerous. Select a place with the gradient as smooth as
possible.
 The steel cable to be used for towing should be strong enough to tow the break-down machine.
No one should stay between the towing machine and the towed machine.
 Keep the hook of the towed machine be in alignment with the towing machine.
 Don’t stand astride on towing cables by two feet.
 When the machine is being towed with engine stopped, the emergency steering system can be
used. The emergency steering control switch is located on the right switch group of the
instrument panel.

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3. Lubrication , Maintenance and Repair

3.1.General Principle of Maintenance

(1) Fault Notification
If the maintenance carried out is not described in the "User's Manual", it may cause unexpected
faults. Please contact with XCMG Construction Machinery Co., Ltd. or its designated distributor
for repair.
(2) Warning Mark
● When the operator is maintaining or refueling the machine, starting engine or operating the
joystick by other persons may cause severe injury or death to the operator.
● Post a warning label on the joystick in the cab to show that service and maintenance are being
done to the machine. If necessary, post the warning labels around the machine.
(3) Common knowledge
● The operator and the service people should be trained and get relative professional
certification. The persons who have nothing with the inspection and maintenances are not allowed
to enter in the working areas. You can appoint the special person to guard the areas.
● You should repair the loader according to the this manual. If you do not know how to repair
the loader, you should ask help from manufacturer.
● Repairing procedures should be programmed in advance. When the loader is to be repaired or
its parts to be dismantled, assign a service foreman who is in charge of the service work on site,
and do the service work in the order as programmed..
● The operator should wear a safety hat, protection suit with the wristbands and trouser-legs
tightened. Sometimes according to the maintenance work scope, safety glasses, gloves and mask
should also be worn.
● Please use the proper tools and do not use the broken and inferior tools.
● To avoid the accident, you should always lower down all the
working apparatus. Stop the engine, engage the hand brake and
place the chock under the wheels when you repairing the loader.

63
● Pay attention the decals. The most important points are
decaled on the loader and they must be followed strictly. If
the decals are peeled off or polluted, new ones must be
attached or clean them.
● Before repairing the loader, you should post a warning
tab—“Operation is forbidden” or other similar sign in the cab
to alarm others not to touch any handle in cab. If you do not
do this, it is very dangerous for the service man and himself.
● Appoint a director for assembly or disassembly the
accessories.
● Fuel and oil is dangerous. Fuel, oil, grease and linoleum are
not allowed to be exposed to any fire and flame.
● No smoking when adding oil and doing inspection work.
● Put the accessories taken down from the loader in a safe
place, and make sure these accessories will not disappear.
Make rails beside the working areas and hang a sign to forbid
irrespective people get close.
● Forbid any irrespective people to enter into the working areas.

● Keep the working area clean and orderly. Do not get oil and
grease scattering to all over the working areas. Avoid firing
and slipping.
● When checking or maintaining the machine, the frames
should be locked by a locking bar.
● When the bucket is being raised, dismantle down the safety
bracket and lock it to the piston rod of lifting arm cylinder
which can prevent the lifting arm cylinder from withdrawing.
● Put the operating lever at neutral position and lock it with
locking system.

64
Cleaning
● Clean the machine before doing any service and maintenance, so as to prevent dirt getting into
the machine.
● If the machine is dirty when doing service and maintenance, it is not easy to find problems
and may cause dirt spatter into eyes or may have the danger of sliding or hurting due to greasy
dirt on the machine.
● While cleaning the machine, use the cleaning-addition which is not flammable.
● When cleaning the inside part of machine, should lock the control handles by locking-device
to prevent the working mechanism moving. And get the braking system be engaged.
● When cleaning the machine, wear anti-slip shoes to avoid slipping on wet ground. When using
the high pressure water to wash the machine, please wear the protection clothes.
● Don't splash out water directly on the electric component ( e.g: sensor, and sockets and plugs ).
If water gets into the electric system, it can cause breakdown.
● When cleaning the filter elements with compressed air, wear the protection clothes and safe
glasses.
Illumination
● When checking the fuel, lubricant, electrolyte of the storage battery or cleanser of window
glass, it is required to use the illuminator which is of exploding-proof. Otherwise, there is a
danger of explosion.
● If the operator works at a dark place without lighting, there is a danger of injury. So lighting
should be equipped.
● Even if in the dark, it is not allowed to use lighter or fire to light. There is a danger of fire.
Explosion may occur when gas emitted from the storage battery meets with the fire.
● When taking the machine as a lighting power source, please follow the instructions in this
manual.

65
Fire prevention
● When refilling fuel, it is a must to stop the engine. And during refilling fuel, it is prohibited to
smoke or expose to fire or flame.
● The storage for fuel, grease and other combustible staffs should be kept far away fire.
● Clean away all the combustible staffs, such as: fuel, lubricating oil and other foreign articles
built-up on the machine. And make sure there is no any oily cloth or other combustible
material existing.
● There will be some explosive gas producing near the battery, so never get it near to fire or
flame. Strictly follow the relative instructions to maintain and use the battery.
● When parking the machine, care should be taken to select the suitable parking location and its
surrounding environment. And special attention should be paid to ensure that there is no
withered grass, used paper and other combustible material near the muffler of the machine.
● Check if there is any leakage of fuel, engine oil and hydraulic oil. If it is in case, replace the
broken hoses. And only after cleaning and fixing the problems, you can make another attempt
to drive the machine again.
● Check if the electrical wires get broken or failed. If finding any damage, replace it with a new
one.
● When cleaning the components, use the non-combustible cleaning solvent. Don’t use the
petroleum oil or other combustible liquid for cleaning.
● Don’t make any welding or fire-cutting on the pipelines or tanks which contain combustible
liquid. Before you make any welding or cutting, clean the pipeline first with non-combustible
cleaning solvent, then make welding and cutting.
● The ether is a kind of combustible material, so avoid it exposing to fire or flame. When using
it, strictly follow relative instructions.
● Prior to making any service and repairing, check if the fire-extinguisher is proper or not.
Know the storage location of the fire-extinguisher and first-aid kit.
● When it is needed to check the dark area on the machine, don’t use flame or fire to lighten this
area.
Rules to be followed for filling of fuel or oils
The fuel, lubricating oil, hydraulic oil, and antifreeze can be ignited by open fire. Abide by the
following rules:

66
 Stop the engine before filling fuel or oils.
 The smoking is absolutely prohibited.
 Any overflown fuel, oil, hydraulic oil, and antifreeze must be wiped clean immediately.
 The caps of all containers for fuel, lubricating oil, hydraulic oil, and antifreeze shall be
securely tightened.
 Keep the place for filling or storage of fuel, lubricating oil, hydraulic oil, and antifreeze well
ventilated.
(4) Servicing the machine while the engine is running
In order to avoid injury and accident, don’t carry out maintenance work for the running engine. If
maintenance has to be carried out while the engine is running, follow the following instructions:
● Appoint a man sitting on driver’s seat and get ready to stop the engine at any time.
● Don't touch exhausting pipe or high temperature parts, such as end tube, muffler, etc. so as to
avoid scalding.
● When working close to a rotating part, there is the risk to be rolled inside by rotating parts, so
special care should be given.
● Don’t touch any control handle. If it is necessary to operate a control handle, firstly make a
alarming to other people and ask them to leave.
● Never touch the rotating leafs of the fan or the fan belt as it is very dangerous.
● Don't adjust the part that you do not understand.
(5) Checking cooling system
● When just finishing work, the hydraulic oil temperature, the oil and water temperature in
engine and radiator are very high and still have pressure. At this moment, any attempt to open
oil tank, radiator, drain oil or water, or change the filter may be severely burnt. Wait till the
temperature fall down and observe the required program when doing the above operation.
● To prevent splashing hot oil, turn off the engine, cool the hot water and open slowly to release
the pressure. When checking the temperature, put your hand close to the front of water
radiator, check the air temperature. But pay attention not to touch the radiator.
● For preventing hot oils from splashing out , stop the engine and let oil get cooled. And slowly
open the cover of hot oil tank cover to release its pressure. When checking if the oil
temperature has been cold or not, get your hand near the front of radiator for hydraulic oil and
torque converter oil. And check air temperature. Don’t touch the radiator.

67
● Don’t touch the engine body or muffler, exhaust tail tube and relay when the machine is still
hot, and avoid being scalded.
● Don’t remove the engine oil temperature sensor, water temperature sensor, torque converter
sensor and air-conditioner tubes so as not to get scaled.
● Cooling system contain alkaline material, so pay attention to not to have the cooling system
touch your skin and eyes.
● When replacing coolant liquid, engine oil, transmission oil and oil filters, etc, use the proper
container to hold these oil liquid. The disposing to waste liquid should be conformed with the
local rules and regulations.
● When you need to remove the air-conditioner tubes, remember not to expose the tubes to fire
and flame. Otherwise it will cause injury due to poisonous gas.
(6) Inspection and service for hydraulic system
● Before making any inspection and service for hydraulic system, securely lock the hydraulic
cylinders and other hydraulic devices. Have the hydraulic oil get cool, then release all the
pressure from the hydraulic system.
● Don’t bend or hit the high-pressure pipelines. And never mount the tubes and hoses that are
bent abnormally or already broken on the machine.
● If some tubes or hoses which are used for fuel circuit, lubricating oil circuit and hydraulic
system circuit become loose or broken, get them fixed. Leakage may also cause fire, please
repair it or make replacement.
● Please check carefully all the tubes and hoses, and tighten all the connection fittings with
torque as required. When making inspection for any oil leakage, use a clean piece of plate or
paper board to make such inspection rather than by means of hand, since the liquid pressure
from leaking point will cause severe health injury, even if the leaking point is very small, like
a needle eye, the leakage pressure can strike through your skin. If oil liquid splashes onto your
skin, seek help from the competent surgeon to treat the case within several hours. And
replacement should be made if following cases are found:
△ Connecting fittings be broken or leakages appear.

68
△ The external coating of hoses are worn out or cracked and their reinforcing wires are exposed.
△ Hoses get bulged at some particular locations.
△ Hoses get obviously twisted or deformed due to pressing.
△ The hose reinforcing wires get extending out.
△ End is connected wrongly.
● Make sure that all pipelines clamping, protection and insulating plates are correctly mounted,
so as to prevent shocking and conflicting with other parts.
● When replacing coolant liquid, engine oil, transmission oil and oil filters, etc, use the proper
container to hold these oil liquid. The disposing to waste liquid should be conformed with the
local rules and regulations concerning environmental protection.
(7) Maintenance for battery
The battery electrolyte contains sulphuric acid and can produces hydrogen, so incorrect handling
for the battery will cause serious injury and fire risk, therefore, the following points must be
obeyed:
 Never get the lighted cigarette or flame close to the battery.
 When you have to touch the battery during working, you ought to wear safety glasses and
rubber gloves.
 If the electrolyte is splashed onto your clothes or skin, rinse it off with plenty of fresh water
immediately.
 If the battery electrolyte is splashed into eyes, it will cause blindness. In this case, rinse the
eyes with plenty of fresh water and go to hospital right away.
 If you drink the electrolyte carelessly, then you must drink a lot of water, milk, fresh egg or
vegetable oil, and get help from doctors or go to hospital immediately.
 Before operating about the battery, remember to stop the engine.
 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 disassembling or installing the battery, firstly check which pole is positive pole and
which is negative pole, then tighten it with screws. If the electrolyte level reaches near
“ lower”, then refill stilled water till it reaches “ upper” level.

69
 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.
 If the electrolyte has been frozen, don’t recharge the battery and start the engine with other
power source either, otherwise it is very dangerous and will cause battery gets fire. When
charging the battery or starting the engine with
other power source, melt the battery electrolyte
first before attempting to start the engine, and you
also need to check if there is any leakage.
 Remove the battery from the machine before
recharging the battery.
 Before any repair operation of electric system or any electric welding on machine, place the
battery negative switch to “OFF” to prevent the flow of current.
Dispose the waste battery
When the battery can’t be used further due to aged electrode plates or other causes, the damaged or
discarded battery, battery residues, accessories, and battery spillages shall be contained in the
designated acid-resistant containers and disposed as per local relevant waste disposal standard or
regulation.
(8) Maintenance for tyres
a) Notes
● 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. (Air pressure: 0.55~0.60Mpa for
front wheels and 0.50~0.55Mpa for rear wheels).
● During traveling, the heat produced due to
high-speed machine traveling will cause the tyres

70
 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.
● When adjusting tyre pressure, keep away from the
tyre as far as possible.
● 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
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.
● 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.
● When performing welding near a wheels, special care should be given because the tyre wheel may

71
 cause explosion.
● When replacing a tyre, make sure the tyre to be used is correct. All tyres should be same in terms of
specification data and texture.
b) Obey with following instructions when storing the tyres.
● Being as a general principle, the tyres must be stored in warehouse. Anybody without prior
approval should not enter into the warehouse. If tyres have to be stored outdoors, please settle
a protecting fence surrounding the storing area. Notes which show “No Entrance” should be
settled.
● Tyres should be stored in dry and clean area, otherwise moisture will speed up the oxidation
of the tyres and oil or polluted dirt will make tyres corroded more quickly. When storing tyres,
you should consider, as much as possible, sheltering and heat-insulation, and avoid air
ventilation. The tyres under storing should be covered with canvas, plastic or other covering
staffs. Incorrect storage for tyres will seriously affect their quality and service life.
● Put tyres on the flat ground vertically, and fix them by means of wedges, so as to prevent them
falling down if it touched by somebody disapproved. If a tyre is placed on the ground by its
side, then it may be pressed flat, which ,being as a result, will worsen its quality. The tyres
under storage should be turned once every month. ( turn 90).

● If wheel tyre is to fall down, get away from it, since the tyres of construction machinery are
very heavy, and any attempt to hold it by hand will incur serious injury.
(9) Electrical system
● Only the qualified technician can service the electrical system.
● While adjusting the external power supply, to prevent the generated spark around the battery
from causing explosion, please close the negative switch in the final step. The negative switch
is located in the right battery compartment.
● Before any repair operation of electric system, ensure to turn off the starter switch key.

72
(10) Engine hood
Don’t service the non-mental engine hood willingly. The dust produced by polishing the hood can
cause exploding, and the dust is injurious to your health.
(11) 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.

(12) Rejected staffs

To prevent pollution, especially in the places with living people or animals, ensure to abide by the
following procedure:
● Don’t pour the rejected oil liquid into rivers and sewer network.
● The drained oil must be placed in a container rather than pouring it directly onto the ground.
● Please respect the local relative laws and regulations when disposing the harmful and
poisonous materials, for instance: lubricant, fuel, cooling liquid, battery and so on.

73
3.2 Lubricating The Machine
3.2.1 List of Daily Maintenance Parts
Maintenance parts for LW900KN Loader
Quantity
Material Replacement period
Material name (Piece / Note
number of filter element
unit)
250h
860156940 LF14000NN Engine oil filter element (QSM11-TIER3) (50-100h for first 1
maintenance）
FS36215 Fuel-water separator filter element (spare
860127333 250h 1
parts)(Engine QSM11-C335)
FS1000 fuel filter element (Engine QSM11-C335)(spare Engine
860118168 250h 2
parts)

860118169 WF2075 coolant filter element (Engine QSM11-C335) 500h 1

860119746 AA2960/AF26433 air filter element 250h 1

900KN Transmission
daily 250h
and torque
maintenance 860119555 0501333764 transmission filter element (50-100h for first 2
converter
maintenance）
system
Transmission
and torque
251702785 XG-1102002 ventilator assembly 1000h 3
converter/driv
e axle
0950R010BN4HC/-B6-S0441 hydraulic oil return filter
803407295 1000h 1
element Hydraulic
system
803407291 XGKL11-10×0.2 Preloaded air filter for hydraulic oil tank 1000h 1

860153789 T0132010 Evaporator filter screen 2000h (as required) 1 A/C system

Note ★ Please shorten the maintenance and replacement intervals under severe working conditions!

39
3.2.2 Lubricating points and periods of machine

Figure 3-1 Lubrrication Illustration

40
3.2.3 Maintenance oils/fluids, trademarks, and working temperatures
Names and designations Oil Oil
Categorie Applicable (Fluid) (Fluid) Replacement
Model
s Trademark temperature filling filling period
(℃) capacity location
Light diesel oil 0#, 10# ≥0
-10# 0～-15 Fuel
Fuel 420L —
-35# -15～-30 tank

-50# ≤-50
CH-4 15W/40
SAE 15W/40 diesel ≥0
engine oil 500h
Engine
oil Engine (50-100h for
CH-4 10W/40 0～-15
33L oil first
Engine Shell Rimula sump maintenance
oil R6LE10W-40 (Extremely )
cold regions) ≤-15
CH-4 5W/40
Cooling Fleetguard CC8996 -45# Water
— 65L 5000h
system antifreeze tank
CH-4 15W/40 diesel
≥0
engine oil
900KN Transmis CH-4 10W/40 diesel
0～-15 Transm
loader sion oil engine oil 64L 2000h
ission
Gear oil Shell Spirax S3 ATF MD3
(Extremely cold regions) ≤-15
CH-4 5W/40
TITAN UTTO ZF Front: 2000h
20W-40 Special gear oil ＞-15 54L (1,000h
Transmis for ZF drive axle Rear: Drive under
sion oil 54L axle frequent
Shell Spirax S3 ATF MD3 Total:
≤-15 braking
(Extremely cold regions) 108L condition)
API CD/SF SAE10W
(Mobil 10W engineering ＞-15 Hydrau
Hydraulic
hydraulic oil) 180L lic oil 2000h
oil
tank
Shell Tellus S4VX32 ≤-15
0# lithium-base
≥0 Automa
lubricating grease tic
Lubricant 0# anti-freezing 4kg lubricat —
lithium-base lubricating 0～-20 ion
grease pump

39
 00# anti-freezing tank
lithium-base lubricating ≤-20
grease
★ To replace with oil (fluid) of different brand or trademark, fully drain the oil (fluid) reservoir,
parts, and pipelines before replacement, in order to ensure the cleanliness and purity of the oil
(fluid).
Notice
★ Timely fill the oil (fluid) to the specified level depending on the actual situation.
★ Please shorten the oil (fluid) replacement intervals under severe working conditions!

The above fuel charge is a reference value. The actual fueling operation shall be carried out according to the
scale of the oil leveler.

3.2.4 Lubrication precautions

Because the drive shaft is a rotating component, its lubricating grease is filled every 50 hours by
hand, and other lubrication is completed automatically by the central lubrication system. If the
central lubrication system is abnormal, please refer to Figure 3-1 to fill grease to the lubrication
points.
1) Precautions
 The fuel, torque converter oil, hydraulic oil, and all types of lubricating oils must be pure and
must be precipitated for a period to meet the specified quality requirements.
 Oil injector and oil-filling area must be clean. Prevent contaminated water entering into oil.
 When checking oil quantity, the machine must be kept in a level state.
 Under different ambient temperature, please use oil with different viscosity and trademark.
Please strictly adhere to the relative instruction in this manual.
 After filling oil or changing oil, please check if there are any oil leakage.

40
2) Inject oil to the hydraulic tank
Checking of hydraulic oil tank level
① When the car stop at a plat road, the movable arm lift
to its highest position, turn off the engine, take use of
weight loss and lower the movable arm and turn the
bucket, so that the oil tank to be completely discharged.
(Control the time from the lowering of boom to the
touchdown of bucket onto the ground within 10~15s.)
② After the bucket is lowered onto the ground, wait for
at least 5min for the oil level to stop rising and then
check the oil level. the oil should be above the middle of
the scale, add if insufficient.
CAUTION When checking oil level, the bucket
should be positioned on the ground in level state, and
the engine stops running.
Replacement of the hydraulic oil
③ Slowly unscrew the fuel inlet cover. Filling
maouth

④ After opening the drain plug then discharge the

waste oil, after oil discharged, and tighten.

41
⑤ Remove the stand cover plate bolts, remove the
cover, directly into the new oil from the fuel inlet to a
predetermined position. Filters at the oil
mouth
Note: Not allowed to take off the filter when refueling

Replacement of the return filter element

⑥ Remove the side cover bolts and remove the cover.

Insallation location of oil

return filter element

⑦ Check the filter housing for presence of internal impurities and then clean.
⑧ Replace with new filter element, install the spring and oil filter cap in turn, and tighten the
bolts of filter cap uniformly.
⑨ Add a predetermined amount of hydraulic oil from the oil inlet, then cover.
⑩ Check the hydraulic oil level if in the central scale or above.
⑪ After adding the oil must be vented:
a．Start the engine at a low speed, make the steering bucket and lift cylinder repeat for 4-5 back
and forth, make the cylinder not reach at the end of the cylinder.
b．Then operating the steering system, bucket and lift cylinder respectively to the end of cylinder
for 3-4 times until no gas evolution.
⑫Check hydraulic oil level and fuel to a predetermined level.
⑬Check each part of the hydraulic tank if leakage.

42
 Discharging contaminated remains
The contaminated remains and water inside the oil tank could be discharged from the drainage
plug.
3) Inject fuel to fuel tank
Replacement of the fuel and fuel filter
① Check the fuel volume, turn on the power key switch,
and observe the fuel indicator on the monitor. If red,
add fuel.
② Loosen the drainage flange on the bottom of fuel tank
to drain the dirty fuel and impurities and clean the
fuel filler port and suction filter (replace if damaged) Alarm at low fuel level:
Red indicator

③ Fill the fuel from the quick fill port,Until filling to

the fuel gun to automatic jump gun so far.

Fuel suction filter

Fuel drainage flange

Disassembling of filter
④ Clean the surrounding area of fuel filter and fuel
filter seat.
⑤ Disassemble the fuel filter with a filter wrench.

Fuel filter

43
⑥ Disassemble the threaded seal ring (1). Wipe clean
the surface of fuel filter seat gasket by a clean
lint-free towel.

Installation of filter
Engine oil Fuel

⑦ Clean the surrounding area of fuel filter and fuel

filter seat.
⑧ Lubricate the fuel filter sealing gasket by clean
engine oil.
⑨ Add clean diesel to the fuel filter.
⑩ Install threaded seal ring (1) attached in new filter.

Notice:
 If the metallic can of the filter is damaged, do not
continue the use. An indentation or scratch can lead
to breakage of filter or early malfunction.
 Tightening mechanically the filter excessively will
distort and deform the thread or damage the fuel filter
seal.
⑪ Install the filter on the filter seat.
⑫ Rotate the filter, till the gasket comes into contact
with surface of filter seat.
⑬ After the sealing gasket comes into contact with the

44
 surface of fuel filter base, tighten the filter by ½ ~¾
turn by hand.

Discharging contaminated remains

Drain off water and contaminated remains inside the tank from the drainage flange at the bottom
of the tank. And then clean the fuel filling plug and fuel filter. Replace the filter if it gets worn.
Deposited sediments at oil cup, oil drainage port, and air vent valve.

4) Inject new oil to the torque converter and transmission system

Upon detection of transmission abnormality or water content in oil, check the oil level or replace
oil.
Inspection oil level

① Stops the vehicles in the smooth place, the transmission shifts gears the handle in the neutral
position “N”
② Transmission in operating temperature scope, engine idling regime, approximately 1000
revolutions/Minute
③ The counter clockwise twists the loose oil
dipstick, takes out and polishes

Oil
dipstick

④ In the oil dipstick insertion oil level tube and

tightens, after the arriving takes out at least
(2 times again)

45
⑤ Under low temperature state (approximately
Oil temperature at 40ºC
40ºC), the oil level shall be between lower
marking “COLD” and middle marking.
Under high temperature state
(approximately 80ºC), the oil level shall be
between upper marking “HOT” and middle
Hot Middle Cold
marking.

Oil temperature at 80ºC

Hot Middle Cold

Notice:
a. To check the oil level, the engine must be under idling state.
b. Checking the oil level under cold state is to ensure sufficient recirculation flow for
transmission and torque converter and the decisive criterion for oil level is to meet the oil
level requirement under hot state.
Replacement of drive oil and filter
⑥ Slowly loosen drainage plug to drain oil.

Drainage of torque
converter oil

⑦ After the full drainage of oil, tighten the

Fuel tank
drainage plug. Fully drain oil from torque
converter radiator.

46
⑧ Disassemble the filter by a filter wrench.
Clean the filter bracket.

Shaft Filter

⑨ Apply some lubricating oil to the sealing surface of new filter and tighten fastening bolts on
filter.
⑩ Disassemble the transmission oil sump and check and clean the filter screen on oil sump.
⑪ Open filler cap, add an appropriate amount of oil of specified trademark, and tighten filler cap.
Start the engine and idle, place the gearshift joystick of transmission at neutral gear, place the
parking brake at safe position, and shift to every gear for one time and then check the oil level. If
necessary, add oil once again.
Notice: a. Ensure to replace the oil for the first time after the first 100 hours of vehicle.
Afterwards, replace the oil at least once every 1,000 working hours or once a year.
b. Ensure to replace filter during the replacement of oil each time. It’s prohibited to use a damaged
filter.
c. Make sure to use clean transmission oil and filter and ensure to meet the marking on oil dipstick
in all cases.
5) Fill oil to front and rear driving axle
Oil level checking
Screw off the oil-filling plug and check the oil level, if the oil level is near the plug, it is ok,
otherwise, replenish with new oil.
Oil replacing
① Park the loader on a level and solid road.
② Rotate the wheel reducer drainage port to the lowest position and disassemble the drainage
plug of axle wheel reducer and the bottom oil plug of axle main reducer by an Allen wrench to
fully drain the axle oil (under hot state). Tighten the oil plugs. Check and clean the dusts from the
drive axle ventilator.

47
 Axle wheel reducer Axle main reducer oil
drainage port plugt

③ Disassemble the axle filler plug by an Allen wrench, add the gear oil of specified volume, till
the main reducer oil overflows from the filler port and the wheel reducer oil overflows from the
observation port, and then tighten the plugs.

48
 6) Fill oil to engine oil
Checking of coolant level
Notice: It’s prohibited to run the engine when the engine
oil level is less than marking L (lower limit) or higher
than marking H (upper limit). Otherwise it will lead to
deteriorated engine performance or damage the engine.
Ensure to place the engine horizontally while checking
the engine oil level, in order to ensure the accurate
measurement.
Oil dipstick
The correct reading can be measured only after the stop
of engine.
Wait for the engine to stop for 15min before checking the
engine oil level. This period is intended for the engine oil
to return to the oil sump.

Replacement with new oil

Drainage

The used engine oil contains carcinogenic effect and can yield to reproductive disease.
Avoid the inhalation of engine oil vapor and the accidental swallowing or long-term contact
of used engine oil. The engine oil that can’t be used further shall be disposed as per the local
environment protection regulations. To reduce the possibility of personal injuries, avoid the
direct contact of your skin with hot engine oil.

49
Replace the engine oil and filter at the time of
designated replacement interval or in event of
insufficient engine oil.
Park the loader on a horizontal ground, withdraw the
oil dipstick, wipe it clean, and reinsert it into dipstick
tube (ensure to insert in proper position) and withdraw
it for reading. The oil level shall be within marking L
and marking H. If less than marking L, add the engine.
Note: Check the oil level before operations or after the
stop of engine for approximately 15min. Check the oil
for contamination degree and mixture of impurities. In
event of excessive contamination, replace with new
oil.
Run the engine, till the water temperature reaches
60ºC. Stop the engine. Disassemble the drainage plug
from the central water drainage point.

Fuel tank

Drainage of engine oil

Adding of oil
Notice: a. The insufficient lubrication arising from the
empty engine oil filter is harmful to the engine.
b. Tightening mechanically the filter excessively will
distort and deform the thread or damage the filter seal.
Disassemble the filter by a filter wrench.
Clean the filter bracket, add new engine oil through
filter screen side hole of new filter, and apply engine
oil to sealing opening and threads for installation.
Install the filter on the filter seat.
Tighten the filter to the technical specification

50
specified for the filter.
Clean and check the threads and sealing surface of
drainage plug.
Install the drainage plug.
Note: Check the torques for the side and bottom
drainage plugs to ensure both plugs are tightened.
If the remote drainage hose is provided and the oil
replacement pump is used, disconnect the hose from
the pump, install the cover to the end of hose, and use
the clamp provided to fix the hose to the engine oil
part number side.
Use a high quality multi-grade viscosity engine oil and
choose a correct engine oil suitable for specific
working weather condition.

Add clean engine oil into the engine, till the engine oil
reaches marking “H” (upper limit) of oil dipstick.

Note: Within 15 seconds after starting, the oil pressure

must be indicated on the instrument. If the oil pressure
is not indicated within 15 seconds, stop the engine
immediately to prevent it from being damaged. Make
sure that the oil level in the oil sump is correct.
Idle the engine and check the engine oil filter and
drainage plug for leakage.

51
Stop the engine. Wait for approximately 10min for the
engine oil to return from upper engine parts to oil
sump. 10 minutes

Check engine oil level once again. If necessary, add

engine oil, till the engine oil level reaches the marking
“H” (upper limit) of oil dipstick.

7) Fill the cooling water

Checking of coolant level

Do not open the pressure cap when the engine is hot.

Wait for the coolant temperature to drop to <50ºC[120ºF]
before opening the pressure cap. Otherwise, the high
temperature coolant or steam will spray out, which may cause
personal injuries.
Notice: Do not use sealing additive to solve the leakage problem
of cooling system. It will lead to blockage of cooling system and
obstructed flow of coolant to cause engine overheating.
Make sure to daily check the coolant level.
Notice: Do not add cold coolant into the hot engine. Otherwise
it will damage the engine castings. Add the coolant only after the
coolant temperature drops to <50°C[120°F].
The coolant to be added into the engine must be mixed with
antifreeze, coolant additives, and water in correct proportion, in
order to prevent damaging the engine.
Adding coolant to the cooling system
①The replacement of coolant must be conducted under cold
status of radiator. Open the filler cap.

②Unscrew the radiator cap and open the water drainage valve to
fully drain the coolant.

52
③Add the coolant.
④After the replacement of coolant, start the engine to slightly
Fuel tank
lower the coolant level and then stop the engine and add coolant
to the specified level. (Maintain the level in the expansion tank Drainage of
water tank
observation window at the right top side of the radiator tank.)

With liquid level indication on the

back

● Notes
 The cooling water with good quality should be chosen.
 In summer, when the ambient temperature exceeds 30℃, the engine is easy to get overheated.
So it is better to park your machine in a shadowed place.
 In order to prolong the service life of the engine, at the end of daily work firstly keep the
engine run at a low speed for about 5 minutes till the water gets cool, and then stop the engine.
 The freezing point of anti-freezer should lower than the local lowest temperature 10℃.
 Replace the anti-freezer every year.

53
3.3 Maintaining to the Machine
3.3.1 Checking before working
● Water level of the radiator.
● Oil levels inside the sump of the engine.
● Oil levels inside the fuel tank, hydraulic reservoir and transmission.
● Seal of each oil hose, water hose, water hose, air hose and their connectors.
● Connections of the batteries.
● Reliability of service brake and park brake.
● Flexibility of each control lever and shift them into their neutrals.
● Inflation of each type.
● Check wheel rim bolts, axle mounting bolts, drive shaft connecting bolts, and other bolts for
looseness.
Note:
When implementing maintenance, please support the machine with appropriate support, and do
not rely on hydraulic cylinders to support the operation devices. If the operating handle is moved
or hydraulic pipe burst, the devices are likely to fall.

After removal of drive shaft, the loader will lose the power output and the parking
brake function, which is followed by rolling and will cause casualties. To prevent the
movement of vehicles, you should add the fixed block with safety and reliability.
3.3.2 Checking and maintaining after the working
● Check the fuel level.
● Oil level and cleanness of the oil sump. If the oil is found over-leveled and diluted, cause
should be found out and cleared.
● Leakage from each hose and their connectors.
● Fastening, sealing and overheating of transmission, torque converter, hydraulic pump, steering
devices, axles and brake clippers.
● Fastening of all the pins and bolts on wheel rims and transmitting shafts.
● Empty the radiator when the environmental temperature is below 0℃(except with antifreeze).
● Lubricate each grease point as required in the time schedule.
● Reasonable inspections and maintenance are necessary to your loader. Be careful not to cause

54
 any accident or hurt yourself. If something abnormal is found during your inspection, mark it
first and fix it after all the checking items.
● When inspection is carried out with the bucket highly raised, make sure that it cannot fall
down.
● Fire is strictly forbidden when checking or maintaining. No smoking is permitted and fire
extinguisher must be at hand.
3.3.3 Periodical Checking and Repairing
1) Time schedule for periodical maintenance
This schedule is designed according to normal working time and conditions. If the working
condition is too bad, adjust it as soon as possible. The time intervals listed in the following forms
is decided with the time accumulator of the loader.
Mark explanation : ●Check ★Replenish ◇Replace △Clean

55
 Engine
Check time
every 10 hours every 50 hours every 100 hours every 250 hours every 500 hours every 1000 hours
Check Items
Engine oil quantity ● ◇
Engine inlet pipe sealing ●
Radiator water quantity
● (core)，△ ◇
(antifreeze fluid)
Fuel tank (fuel quantity) ●
when necessary, cleaning the filter element, replace it after use of
Filter element of air filter ●
up to one year
Discharge debris in the fuel
filter, clean the filter △ ◇when necessary
element
Engine oil filter ◇See engine user’s manual
Fan belt tension ●
Cylinder head bolt fastening ●See engine user’s manual
Valve clearance
Oil injection time
Spraying state of the nozzle
Turbocharger rotor gap and
rotating condition
Fastening bolts on all parts ●
Exhaust state ●
Action status of the
●
accelerator pedal

56
Circuit device
Check time
every 500
every 10 hours every 50 hours every 100 hours every 250 hours every 1000 hours
hours
Items
Charging effect ●
Electrical wiring connections relaxation ●
Action of instruments, lights lighting condition,
●
sound of speaker

Wear and fouling of the starter motor and engine ●

Steering device

Check time every 10

hours every 50 hours every 100 hours every 250 hours every 500 hours every 1000 hours
Items

Action status of steering cylinder ●

Power steering devices hose every 4 years◇

Loose and gap of the steering wheel ●

Frame hinge center pin Grease★

57
Gearing
Check time
every 10 hours every 50 hours every 100 hours every 250 hours every 500 hours every 1000 hours
Items
Torque converter, transmission Only the first
● ◇
case oil quantity time◇
Drive shaft grease ★
Relaxation of the drive shaft bolt ●
Vent hole of drive axle and
△
transmission case
Differential oil replacement every 2000 hours◇
Final gear oil replacement every 2000 hours◇
Only the first
Transmission case coarse filter ◇
time◇
Damage and pressure of the tire
●
air
Shift handle gear engaging
●
condition

58
Operation devices
Check time
every 10 hours every 50 hours every 100 hours every 250 hours every 500 hours every 1000 hours
Items
The gap and action status of operation
● ●
device joystick
Movable arm and bucket damage ●
Wear state of bucket teeth and cutting
●
edges, etc.
Dirt, damage of hydraulic cylinder ●
Debris ◇The first 500
Oil quantity of operation oil tank ◇every 2000 hours
discharge● hours
Filter of operation oil tank ◇
Grease supply ★

Brake
Check time
every 10 hours every 50 hours every 100 hours every 250 hours every 500 hours every 1000 hours
Items
Brake piping damage and oil leakage ●
Braking action status ●
Effect and gap of the brake pedal ●
●every 2000
Wear of brake linings
hours
Nitrogen pressure in the accumulator ●
Hand brake effect and positioning condition ●
Loose conditions of parking brake fastening ●
59
bolts

Wear condition of parking brake disc ●

Others
Check time
every 10 hours every 50 hours every 100 hours every 250 hours every 500 hours every 1000
hours
Items

Cleaning vehicles ●

Fastening of main fastening bolts ●The first time ●

Oil leakage at all positions ●

Pipeline damage ●

Abnormal sound of pumps and valves ●

Abnormity in previous day ●

60
2) Periodical maintenance
The proper lubricating and maintain can ensure the normal operation and prolong the machine
service life, so the time and cost of repair can be reduced.
The periodical inspection and maintenance time and contents shall be adjusted properly
according to the environmental conditions of the machine, including high temperature, high
humidity, dusty and high altitude. Please consult XCMG Construction Machinery Co., Ltd.
or the appointed distributor.

The periodical maintenance is divided into six time modes: 50hrs, 100hrs, 250hrs, 500hrs, 1000hrs,
2000hrs.
Maintenance every 50 hours
 Fasten the connecting bolts of front and rear transmitting shaft .
 Check the accelerator control hand brake and gear-shifting performance.
 Inject grease to various lubricating points of working device, articulated joints between front
and rear frames, drive shaft, and rear axle support.
 For draining sediments and mixed water from fuel , loosen the drainage plug that is at the
bottom of fuel tank.

Maintenance every 100 hours, at the some time, the 50 hours maintenance should be made.
 Replace the transmission oil and the transmission filter.
 Check the fastening status of wheel rim fastening bolts.
 Clean the air filter element. (Under sever working environment, the cleaning interval shall be
shortened.)
 Measure the inflation pressure of tyres.

Only after the first 250 working hours has been finished, the following maintenance can be
done. At the same time, the 50 and 100 hours maintenance should be done.
Replace the filter core of the fuel filter.
 Check the oil level of front and rear axle (Once every 300h, check timely in event of leakage.).
 Clean the filters of oil filter and fuel filter and transmission filter.
 Fill the battery liquid and clean its surface , apply some Vaseline on its connector.
 Check if the working mechanism, frame, weld and fixing bolts get loose or cracked. And fasten
the nuts on wheel rims.
 Check the wear status of the parking brake drum
 Adjust the tension of fan belt.
61
 Press the central point between engine pulley and fan pulley with about 6kg force. The normal
tension flexibility of the belt is about 10mm. After adjusting, mounting bolts should be tightly
fastened.

Maintenance every 500 hours (at the same time, maintenance every 50,100,250hours should
also be made).
 Fasten the bolts that connect the axles and frame.
 Replace the diesel oil.

Maintenance every 1000 hours (at the same time, maintenance every 50,100,250,500hours
should also be made).
 Jack up the frame and turn the wheel to check the brake is sensitive or not.
 Replace the coolant of the engine.
 Replace the transmission oil and torque converter oil.
 Replace hydraulic oil return filter element and the hydraulic oil tank air filter.

Maintenance every 2000 hours (at the same time, maintenance every 50,100,250,500, 1000
hours should also be made).
 Check and repair the engine.
 Replace the gear oil of front and rear axle.
 Maintenances of transmission and torque converter
 Replace the working oil of hydraulic system and clean the oil tank.
 Dismantle and check the axle, axle differential and rim reducer .
 Dismantle and check the steering device and steering valve and adjust the steering angles.
 Check the sealing status and system pressure of the multi-way valve cylinder and working
cylinder by visibly checking how much the working cylinder has dropped down. If the cylinder
has dropped down one time beyond the designed value, then you need to dismount the cylinder
and valves to figure out cause.
 Check if the cracks occur on working apparatus and welded parts. And check if the nuts and
bolts are securely fastened.
 Check the welding position on rim and correct any deformation.

62
3.4 System Principles

The machine consists of engine, transmission system, steering system, brake system, chassis, operation

devices, hydraulic control system, cab, electrical equipments.

3.4.1 Engine

The machine of 900KN adopts the United States QSM11-C335 engine. Diesel engine use and maintenance

is according to the relevant regulations in diesel engine technical information.

3.4.2 Transmission

Transmission system consists of the hydraulic torque converter, transmission case, drive shaft, front and rear

drive axle and wheels.

a) Drive principle of transmission and torque converter

It is the 4WG-310 power shift transmission case produced by Germany-based ZF Company, which consists

of hydraulic torque converter and fixed shaft power shift transmission case. The torque converter and

transmission case are the integrated structure. The torque converter is directly connected with the engine, and

that is using the spring steel plate to connect with the flywheel.

Torque converter

The torque converter is a three-component structure, consisting of the pump wheel, turbine and guide wheel.

Pump wheel, turbine wheel and guide wheel constitute a loop round system, and the liquid flows through the

loop round in the order of above components. The oil pump for transmission case continuously supply oil to

the torque converter, so that the converter can work and play a role, that is, increase the engine output torque,

while goes through the oil discharged from the converter to take away the heat generated by torque

converter.

Liquid flows into the turbine through the pump wheel, fluid flow changes direction in the process. The

torque received by turbines and output shaft depends on the load. The role of guide wheel is to guide the oil

from the turbine to flow to the pump wheel via the oil duct after changing direction, so the guide wheel has a

reaction torque. The ratio between the turbine wheel torque and pump torque is called torque converter ratio.

The torque converter usually increases as the speed ratio between the turbine and the pump wheel deceases.

So the biggest torque converter ratio is that when the turbine does not rotate. Torque converter ratio decreases

as output speed increases.

Through the torque converter, the output speed can realize stepless change. The drive torque can
63
automatically adapt to the required load torque.

When the turbine speed reaches 80% of the speed of the pump wheel, torque converter ratio closes to 1, the

turbine torque is equal to the pump wheel torque, then the torque converter acts as a coupling.

64
Power gear shifting transmission case

The transmission case is a fixed axis structure, with 4 forward gears and 3 backward gears gear, the gear ratio

and gear combinations are shown as follows:

Solenoid valve
Gear Gear ratio Clutch
M1 M2 M3 M4 M5
Gear 1 3.731 ● ● ● KV+K1
Gear 2 2.207 ● ● KV+K2
Forward
Gear 3 0.970 ● K4+K2
Gear 4 0.608 ● K4+K3
Gear 1 3.731 ● ● ● KR+K1
Backward Gear 2 2.207 ● ● KR+K2
Gear 3 0.970 ● KR+K3

Gear drive is shown in Figure 3-2:

Figure 3-2 4WG-310 Gear Drive Chart

The cooling and lubrication of gears, bearings and clutch are all carried out by the transmission oil.

There are six multi-plate wet transmission friction clutches, and in gear shifting the corresponding clutch

friction plate is pressed by the piston driven by axially acted oil pressure. The release of clutch friction plate

is realized by pushing the piston back by the force of the coil spring.

Control System

4WG-310 transmission case adopts electro-hydraulic control.

 ZF gear pump supplying oil for torque converter and the control valve is installed inside the
65
 transmission case, driven directly by the engine through the power drawing shaft.

 The flow rate is Q = 115 L/2000r/min, the pump absorbs oil through the coarse filter, and pump the

pressure oil directly into the fine filter at the top of the tank.

 Oil filtering accuracy of the coarse filter is 450um, and the filter area is 1000cm2.

 The fine filter is equipped with a pressure bypass valve (playing the security protection role), the set

pressure difference of the bypass valve is 5.7 +1.5

-0.5bar. Fine filter filtration area should not be less than

12200cm2 (2×6100 cm2).

 The main pressure regulating valve restricts the working oil pressure from the filter to be (16 +2
0bar),

then the pressure oil directly flows into the clutch through the control valve.

 The pressure control valve limits the maximum working oil pressure, while delivering the oil into the

torque converter and lubricating oil way.

 The inlet port of the torque converter is equipped with a safety valve (with opening pressure of 8.5bar),

to prevent damage to the components due to over high pressure in the torque converter.

 According to the working principle of hydraulic transmission, oil is the energy transfer medium in the

torque converter. To prevent cavitation phenomenon of the torque converter blade wheel oil, the torque

converter should always be filled with pressure oil, which is ensured by the back pressure valve

(opening pressure 5bar) at the outlet port of the torque converter.

 The oil from the torque converter directly flows into the oil cooler. The oil cooler is located at the back

of loader water tank. The cooling oil from the oil cooler flows into the transmission case, and after

cooling the transmission clutch and gear flows back to the transmission oil pan.

Principles of electro-hydraulic control

4WG-310 transmission adopts electro-hydraulic control, and its schematic is shown in Figure 3-3.

66
 Figure 3-3 4WG-310 electro-hydraulic control schematic
Transmission case uses five solenoid valves to control all the gears, different combinations of solenoid valves

result in different gears. The gear combinations of solenoid valves are described in the transmission section.

ZF transmission allows gear shifting from forward gear 1 to backward gear 1, from forward gear 2 to

backward gear 2. To prolong the service life of transmission case and other drive components, the reverse

control is better carried out within gear 1. Under special circumstances, the reverse control may also be in

gear 2. In reversing, the remnants of the meshing speed only exist at the moment of reverse control. When

implementing reverse control, you’d better reduce engine speed.

Transmission case can achieve KD gear function. Select forward gear 2, the loader moves towards the

windrow, press the KD gear (do not turn the shift lever) when approaching the materials, vehicle speed will

automatically engage gear 1. When the bucket is full, move the shift lever back to backward gear, the vehicle

can automatically change from forward gear 1 to backward gear 2. Thereby it reduces the operating

procedures, reduces the work intensity and improves efficiency. Specific manipulation process is shown in

Figure 3-4. KD gear operation method is shown in Figure 3-5, you only press the joystick in the direction of

the arrow.

67
 KD Gear Move back to backward gear
2F 1F 2R

Figure 3-4

Figure 3-5
This machine can start the automatic protection function in gear engaging, that is, the engine can only start

when the transmission case is in neutral, and can not start when the transmission case engages gear (not

neutral). This reduces damage and accidents due to operational errors.

Too low oil pressure can cause the clutch plate to be burned and the gear shifting is not working. Insufficient

pressing force can cause the clutch continuously to slip, thus to be overheat.

Pressure and oil temperature test points are shown in Figure 3-6 (Interfaces 52 and 63 are M14x1.5, the rest

are M10x1)

51—Torque converter valve opening pressure test point 52—Torque converter back pressure test points (5bar)
(8.5bar)
+2 +2
53—KV clutch pressure test points (16 0 bar) 55—KR clutch pressure test points (16 0 bar)

+2 +2
56—K1 clutch pressure test points (16 0 bar) 57—K2 clutch pressure test points (16 0 bar)

+2 +2
58—K3 clutch pressure test points (16 0 bar) 60—K4 clutch pressure test points (16 0 bar)

68
63—Torque converter outlet oil temperature test point +2
65—Transmission system pressure test points (16 0 bar)

Figure 3-6
b) Transmission case control precautions

● Because oil in torque converter, oil cooler and the oil pipeline will all flow back into the tank when

stopping, it is necessary to make the engine idling and the torque converter at normal temperature before

checking the oil quantity. When oil temperature is 40℃, the oil level should be located at the lower

graduation line of the oil gauge, and when oil temperature is 80℃-90℃ the oil level should be located

at the upper graduation line of the oil gauge.

● If the engine has stopped, the oil level will rise. The increased heights are different due to different

installation location of the transmission case. When releasing oil, the hole can only release some oil

within the transmission case and torque converter.

Note that when replacing oil, you should also clean or replace the filter.

● When cleaning the main oil way filter, be careful not to let oil pollution and impurities enter into the oil

way. In addition, install one cover plate on the hand brake to prevent the oil entering into the hand brake

and affecting the braking effect. When installing filter, an external force should be avoided.

● When check the oil level, it must meet the accident prevention provisions developed by the power sector.

Place the parking brake in the braking position, block the wheels with something. Joystick is in neutral

position.

● You can only start the engine when the shift control lever is in neutral (N) position. To ensure safety, it is

recommended before starting the vehicle not to release the parking brake.

Before the loader runs, release the parking brake.

When the loader slides, the transmission case must not be placed in neutral position.

When the loader slides downhill, in order to ensure the transmission lubrication and cooling, the engine

speed should not be lower than 1200r/min.

When the loader stops, you should press the brake button to brake. When leaving the vehicle, put the block

under wheels to stop it, as an additional preventive measures.

In case of long downtime, you should enable the manipulation handle in neutral.

If the vehicle stops running, while the engine still drives the transmission case to operate, the engine could

automatically stop. However, at this time if the vehicle is on a flat level road it may start to move crawling,

because in the idling state the engine can produce a small amount of traction torque through the torque
69
converter. Therefore, the parking brake should be used.

We recommend not skipping gear in the driving. Under the influence of the braking, the engine speed will

rapidly change from low speed to high speed. Especially in the gear skipping manipulation, the engine speed

will change abruptly, which is very dangerous to the engine. Only when the low gear reaches the highest

speed, it should shift. If necessary, you should step on the brakes, shift gear at low speed.

When manipulate reversely at high speed, the engine speed should be reduced. The maximum speed in

reverse control should not exceed 10 km/h. When possible, reverse control can only carried out at gear 1 and

gear 2.

When dragging the machine, the drag speed shall not exceed 10 km/h, with drag distance no more than 10

kilometers. Otherwise it will damage the transmission case. When the distance is longer, it should be loaded

for delivery.

Normal operating temperature of torque converter is 80-110℃, can allow to reach to 120℃ in the short

time.

In a system without fault, the torque converter oil temperature will not reach the maximum temperature

120℃ in normal control. If the torque converter oil temperature exceeds 120℃, you must shut down the

engine, and at speed of 1200-1500r/min and transmission case in neutral check the external oil leakage

conditions. In this case, the torque converter oil temperature quickly (in 2-3 minutes) declines to normal

temperature. Otherwise, the system must have a failure, which must be excluded before continued use.

Transmission lubrication depends on the engine speed, so do not make the engine speed lower 1200r/min.

Speed should be achieved through the appropriate gear.

Speed control oil pressure should be concerned.

When the transmission case fails, you should stop it and consult a professional and technical personnel.

c) Maintenance

Oil: Use specified oil grade CH level 15W/40 diesel oil.

Oil quantity: about 64 liters, a reference, oil quantity should be determined according to the fuel oil gauge.

Oil change: The first oil change time is 100 hours, after that change oil every 1,000 hours of working time,

but at least once a year.

d) Drive axle

The drive axle is the MT-L3125II / MT-L3115II drive axle produced by German ZF Company. To increase

70
traction and improve operational performance, four-wheel drive is used.

The drive axle mainly consists of body case, the main driver, half-axle, wheel edge reducer and wet brakes.

The front axle body case is mounted on the vehicle chassis, bearing the loads from front frame, and

transmitting it to the wheels. The front axle body case is the installation body case of the main driver, wheel

edge reducer and wet brakes.

The rear axle body case is mounted on the rear frame support body, the center swing type, bearing the load

from the frame, and transmitting it to the wheels. The rear axle body case is the installation body case of the

main driver, wheel edge reducer and wet brakes.

The main reducer is a spiral bevel gear pair, and is mainly used to increase the torque of transmission system,

reduce the speed from the transmission, and change the motion transmission direction.

The wheel edge reducer is a planetary gear drive mechanism. Ring gear is fixed on the wheel supporting

shaft, planetary gear and rim are fixed together to rotate, the operation is driven by half-axle and the sun gear.

Its role is to further increase the torque of the motion system and reduce the speed of transmission system to

obtain the appropriate working speed.

Tire rim assembly is the main walking parts, and Michelin 29.5R25 tires without internal tires are adopted.

The flexibility and shock absorption properties are good, and ground specific pressure is small, with good

adhesion performance and off-road performance.

e) Drive shaft assembly

Because the transmission output axis and drive axle input axis are hard to coincide, coupled with uneven

roads and work sites during the loader operation, so that the relative position of two axes frequently changes.

Therefore, the transmission output shaft and drive axle input shaft can not use rigid connection, rather to use

universal drive shaft assembly.

The drive shaft assembly consists of a spline bushing, spline fork and universal joint assembly. The drive

shaft has passed dynamic balance test, and mark at the fork and the axis with arrows, therefore you should

pay attention to maintain their original relative position in assembly or maintenance, not to destroy the

balance. In the repair, generally assembly of the damaged shaft is not allowed. If to assembly, dynamic

balance test must be carried out, with imbalance of not more than 100g.cm at both ends, otherwise, replace

the drive shaft assembly.

After assembly of universal joint assembly and the casing, it should be free to rotate and slide, the locking

71
phenomenon is not allowed. The number of needle roller in needle roller bearing can not be arbitrarily

increased or decreased.

In order to reduce wear and tear, grease should be injected into the grease cups of universal joints needle

roller bearing, spline bushing and splined sleeve in the specified time, usually once every 50 hours.

Drive shaft bolts is made of alloy steel (40Cr). Do not mix them with other bolts, and not replace them with

other bolts.

f) Tire rim

Tire rim assembly is the main travel unit, and a low-pressure wide base tire is adopted. The section size is

large, flexibility and shock absorption properties are good, and ground specific pressure is small, with good

adhesion performance and off-road performance.

3.4.3 Hydraulic system

a) Overview

The hydraulic system includes the working hydraulic system, steering hydraulic system, and pilot control

system. Hydraulic system diagram is shown in Figure 3-7.

72
1. Working hydraulic system 2. Steering hydraulic system 3. Emergency steering system 4. Pilot control system 5.
Articulated pipeline system 6. Central pressure measurement system
Figure 3-7 Hydraulic system schematic

(1) Working Device Hydraulic System

The working device hydraulic system is used to control the motions of boom and bucket and is mainly

composed of hydraulic oil tank, working pump, multi-way reversing valve, boom cylinder, bucket cylinder,

and pipeline.

When the working device is not working, the distributor valve is at neutral position, in which case the main

pump barely has displacement.

When the bucket is used for digging or dumping, the bucket circuit valve core of multi-way reversing valve

moves to the working position and the pressure oil pumped from the working pump is supplied to the rear or

front chamber of bucket cylinder via multi-way reversing valve to rotate upward or downward the bucket.

When the lifting or lowering of boom is required, the boom circuit valve core of multi-way reversing valve

moves to working position and the pressure oil from working pump is supplied to the lower or upper
73
chamber of boom cylinder via multi-way reversing valve to lift or lower the boom and bucket. The

maximum pressure of working oil is controlled by the regulator valve in the plunger pump.

When the vertical floating of bucket is required (for loading and unloading of bulk materials), the floating

valve core in the multi-way reversing valve opens to interconnect the oil inlet and outlet lines of boom

cylinder. In such case, the working oil in the upper and lower chambers of cylinder is under low pressure

state and the bucket is under free floating state under action of dead weight so that the bucket is working

closely near the ground.

When the system pressure is higher than the design pressure of pump, the pump displacement is reduced.

When the bucket encounters an external impact load or has interference with other mechanism, the overload

valve opens to play the role of safety valve. The oil refilling valve is functioned for oil refilling, in order to

prevent the empty suction of specific cylinder chamber.

Meanwhile, this machine provides the boom lowering and pressure relief functions under stop state of engine.

The operations are as below:

When the engine is not running, rotate the key switch to position ON, turn on the pilot lock switch, and

operate the boom joystick to lower the boom onto the ground. Then, operate the bucket joystick to lower the

bucket or other attachment onto the ground. Operate the boom joystick to position FLOAT and LIFT and

operate the bucket joystick to position RETRACT and TIP, with 2s holding time for each position. Turn off

the pilot lock switch and turn off the key switch.

Stabilizing module system. If this system is installed on the machine, when the forward or backward driving

speed of the machine exceeds 7km/h, the stabilizing module is turned on automatically. In such case, the

boom will move slightly depending on the variation of road surface during the driving of machine to reduce

the machine impact, stabilize the material in the bucket, and improve the working efficiency. This stabilizing

module is automatically turned off when the driving speed of the machine doesn’t meet the above

requirement.

(2) Steering hydraulic system of loader

The steering hydraulic system of the loader is functioned to control the driving direction of the loader, stably

maintain the linear driving of loader, and flexibly change the driving direction during turns. The good and

stable performance of the steering hydraulic system is one important factor to guarantee the driving safety of

74
the loader, relieve the labor strength of the driver, and improve the working efficiency.

The main constituent parts for the steering hydraulic system include steering pump, steering gear, flow

amplifying valve, steering cylinder, and pipeline.

(3) Secondary steering system (also referred to as emergency steering system- optional function)

The secondary steering system can convey a pressure of up to 100bar. This pressure level means that a

sufficient steering pressure is provided to the driver for steering. To test the secondary steering system,

connect the pressure measurement device attached in the driver’s tool kit to the pressure measurement point,

adjust the pressure gauge of pressure measurement device to 40MPa measurement range, move but do not

start the engine, turn on the pressure measurement point of secondary steering system, operate the steering

motions, and observe the reading of the pressure gauge. This secondary steering system is normal if the

reading is within 100±10bar. Otherwise, the secondary steering system is malfunctioned. Solve the

malfunction of secondary steering system before operating the loader.

2nd steering
pressure
measurement
point

Notice: The secondary steering system (emergency steering system) is intended for use only in event of

emergency and shall be turned off during normal operations.

75
b) Multi-way change valve

(1) Model: M6-1488-30/3M6-22H

(2) Technical parameters:

Main safety valve set pressure Mpa 24±0.5Mpa

(3) Features

 Small control force, good handling proportion performance.

 The valve reset mechanism and the reset spring work immersed in oil, no corrosion.

 Large cross-section flow channel.

 Small mating clearance of valve core, with less internal leakage.

(4) Working principle

Multi-way valve has inside the rotating bucket valve stem and movable arm valve stem. The rotating bucket

valve stem has three positions neutral, forward and backward. The movable arm valve stem has four

positions neutral, lift, lower, and float. The motion of valve stem depends on oil, and return depends on

spring. The triple valve structure diagram is shown in Figure 3-8.

1. Valve body 5. Differential action backpressure valve 8. Spring chamber

2. Main valve core 6. Differential action refilling valve 9. Travel limiter
3. Pressure compensator 7. Overflow/refilling valve
4. Load holding valve

Figure 3-8 M6-1488-30/3M6-22H Multi-way change valve

 Neutral position

76
Without manipulation, the control valve core (1) is kept at the starting position by the backspring, in this

position, the connection between the pump and the working oil way is cut off, oil without the pressure flows

from port P to port T back to tank.

 Working position
When the pilot valve is in the working position, the pilot oil enters into a multi-way valve stem end, pushing

the valve stem to move right from left to the working position. The pilot oil at the other end of the valve stem

flows back to the pilot valve pilot back to the tank.

The pilot oil make one of the valve stems of multi-way valve moves to the working position. The working

oil from main pump opens the check valve in the multi-way valve, and flows from Port A to port B through

the oil way into the bucket oil cylinder or a chamber of the movable arm oil cylinder. The working oil in

another chamber of the oil cylinder flows back another port B or A of the multi-way valve, through the oil

path inside the valve flows back to the oil tank. The maximum pressure of working oil is controlled by the

main safety valve.

 The role of overload valve and oil fill valve

When the bucket is impacted by external or has interference other bodies, the overload valve is opened

playing a role of safety valve. The oil fill valve plays the oil filling role to prevent suction air of a chamber of

the oil cylinder.

(5) Dismantling requirement

 Clean the valve body, valve stem and all the parts using kerosene, and then use dry and clean lint felt to

mop up or use compressed air to blow them dry.

 Check the slotting, scratches and wear of valve hole and valve stem. Valve stem is installed in the

corresponding hole, and the clearance should not be felt by gently pressing. If the valve stem has

obvious wear, scratches and damage, or the valve hole is wear and the slotting is damaged, generally the

assembly should be replaced with new valve body and valve stem parts.

 Check the sealing of the guide valve conical surface and guide valve seat, if the sealing is adversely

affected by bad contact due to damage, crushing, and gaps, they should be grinded and repaired, replace

with new ones when the situation is severe.

 Check the sealing of the contact of check valve in the valve with the valve seat, if deformation and wear

affect the sealing, grind the valve seat, and replace with new check valve.

(6) Use and maintenance requirements:

77
 If you need to remove the valve core, simply open a cover of each valve core. The valve just needs to

open cover (2).

 One-step overflow valve (3) and two-step valve is designed to be screw thread cartridge structure,

therefore, when replacing or later installing, the valve body does not need to be disassembled. The reset

parts have corrosion protection.

 The maximum allowable oil contamination level of oil is 9 by NAS 1638. Here filters with minimum

filtration β10> 75 are recommended.

c) Pilot valve

Model: 4THF5K14-10

Technical parameters:
T port back pressure(bar) <3
Control oil flow rate(L/min) <16

Grade 9 by NAS 1638. Recommended

Oil cleanliness
filter filtering accuracy isβ10>75

(3)Working principles(see Figure 3-9)

Electromagnet lock-in

Oil port 4 Oil port 2

Figure 3-9 4THF5K14-10 pilot valve internal structure and working principle

78
A single joystick lever is composed by pilot valve bucket lever and moveable arm control lever.

Manipulation of the bucket has forward, neutral and backward three positions, and the moveable arm

joystick has lifting, neutral, declining and floating four locations. The lifting, floating and tipping back

position are equipped with solenoid position.

P is the inlet port, and T is the return oil port. Ports 1, 2, 3 and 4 are control ports and connect with the

corresponding control ports b1, a1, b2 and a2 in the multi-way valve, respectively.

When the joystick is in neutral position, the control lever (1) is kept at the neutral position by the backspring

(4), the oil port is connected with return oil port T through the hole (8).

When manipulating control lever (1), the plunger (5) is pressed down to contact with backsprings (4) and the

control spring (3). Control spring (3) starts to push down the control valve core (2) and close the connection

between the corresponding oil ports and return oil port T. At the same time, the corresponding oil port is

connected with oil port P through the hole (8).

When the pilot valve joystick moves the bucket to full lift or full draw position, the magnetic coil assembly

magnetism force fixed the joystick at full lift or full draw position, the pilot valve will lock (position) it, until

the bucket reached lift height limit or restricted the bucket angle, bucket limiter circuit is disconnected, the

coil is energized, the backspring pushes the bar up so that the joystick moves to neutral position.

Once the control valve core (2) is in the balance between the force of the control spring (3) and hydraulic

forces of the corresponding oil ports (1, 2, 3 or 4) pressure, the control stage starts. As the interaction between

the control valve core (2) and control spring (3), the pressure of the corresponding oil ports is proportional to

the stroke of plunger (5), and therefore is proportional to the angle of control lever (1).

d) BC449700 pilot oil source block

The BC449700 pilot oil source block is one of the pilot control units. The pilot oil flows into pressure

reducing proportional pilot valve via pilot oil source block to complete the lifting and tilting motions. The

shape and schematic diagram of the BC449700 pilot oil source block are shown in Figure 3-10.

79
 Figure 3-10 Shape and Schematic Diagram of BC449700 Pilot Oil Source Block

● During normal working of pilot valve, the incoming pilot oil is supplied through port P and is outputted

through port B via valve chamber to the pilot valve to complete the pilot control. The pressure of the

pilot control oil is controlled by the pressure reducing valve of DR in the valve.

● When the engine is stopped, the main system has no oil supply and there is no pressure oil supply at port

P. The accumulator can maintain the oil pressure to a certain extent. If the pilot valve is at neutral

position, the oil pressure of accumulator is cut off by the pilot slide valve. When the pilot valve slide

valve is at lowered position, the pressure oil at port B is connected to complete the tilting motion of

bucket and lowering motion of boom.

e) OSQA8 150F8001 priority type flow valve to enlarge

Flow enlarging valve is a hydraulic valve in the steering system. Pilot control oil from the steering device

through position limit valve to the control chamber of flow enlarging valve to move to the main valve core.

The oil from the steering pump flows to the steering cylinder to complete the turning action. In addition to

preferred supply for the steering system, it also can make the excess oil in the steering system to merge to the

working system, so that the work of the pump displacement can be reduced to meet the operating low

pressure and high flow conditions.

Flow enlarging valve’s structure is shown in Figure 3-11.

80
 Figure 3-11 OSQA8 150F8001 priority type flow valve structure diagram to enlarge

(1) Technical parameters

Nominal Pressure of Control
pressure overload valve spring force
Mpa Mpa Mpa

21 25 1.05

(2) Working principles

81
f) OSPCX 200 LS 150-8311 full-hydraulic steering gear

The steering gear is composed of a follow-up valve and one cycloidal-pin wheel engagement pair, featuring

flexible operations and compact structure.

OSPCX 200 LS 150-8311 hydraulic steering gear is of closed LS load-sensitive type, of which the structure

is shown in Figure 3-12.

1．Connection block 2. Front cover 3. Valve body 4．Leaf spring 5．Drawing pin 6. Valve sleeve 7. Valve core 8.
Linkage shaft 9. Rotor 10. Rear cover 11. Separator 12. Steel ball 13. Stator
Figure 3-12 OSPCX 200 LS 150-8311 hydraulic steering device structure

82
● In the figure, the valve core, sleeve and valve body compose servo rotary valve, playing a role of

controlling the direction of oil flow. Rotor and stator compose cycloid needle gear meshing pair, playing

a role of measuring motor in the power steering, to ensure that exports quantity of oil is proportional to

the steering wheel angle, and acts as a hand steering pump in manpower steering. In steering, the servo

rotary valve and the measuring motor work together to delver the oil to the flow enlarging valve.

● When the steering wheel does not move, the servo rotary valve is in neutral position, and the oil return

are all turned off. The inlet oil for the pilot valve flows back to tank through the overflow valve. When

turning the steering wheel, the inlet oil for pilot valve flows to the measuring motor through servo rotary

valve, driving the rotor to follow the rotation of the steering wheel. It delivers the pilot oil to one end of

the flow enlarging valve stem, resulting in displacement of valve stem and achieving steering. The oil at

the other end of the valve stem flows back to the tank through the servo rotary valve. When the steering

wheel rotates faster, the pilot oil flows to one end of the flow enlarging valve stem through the metering

motor increases, the stem displacement increases, the steering is faster.

● The steering wheel is connected together with the valve core, when the steering wheel rotates, the valve

core pass through a small angle, until the spring is pressed, the valve cover rotates follow it. Here the

valve core and cover set apart by a certain angle, connecting the oil way. At the same time, the linkage

shaft connected with the valve cover rotates, driving the rotor within the stator to rotate. It delivers the

pilot oil proportional to the steering wheel to the flow enlarging valve. The steering wheel stops rotating,

leaf spring makes the valve cover go back to the middle position, the oil way is closed.

g) BC356500 shuttle valve

The BC356500 shuttle valve is functioned to transmit the LS signal to control the flow of steering pump.

The diagram of BC356500 shuttle valve is shown in Figure 3-13.

Figure 3-13 BC356500 Shuttle Valve

83
h) Precautions of use and maintenance of Hydraulic system

● The hydraulic oil for the system is API CD/SF SAE10W, after use of 2000 hours the working oil of the

loader must be replaced. If the working environment is bad, the time between oil replacements should

be shortened. Oil replacement is according to the following way:

a. Manipulate the bucket to rotate upward and lift the moveable arm to highest position, shut down the

engine, and then the bucket and the moveable arm decline by self weight, so that the fuel in the tank

drains completely.

b. Release the waste oil before the oil temperature reduces, in order to release the dust and deposit together.

c. Open the drain plug at the bottom of the fuel tank and the hose at the bottom of the moveable arm and

bucket to discharge the waste oil, and clean the tank and oil filter with kerosene (diesel oil).

d. After adding the new oil, the moveable arm and the rotary bucket should be continuously manipulate

for several times to thoroughly discharge the system air.

● When dismantling and mounting the hydraulic components, you should ensure that the workplace must

be clean to prevent dust, dirt, debris falling into the component.

● Re-assemble hydraulic components after repair, the original rubber seal and O seal ring must be

checked. The ones that have changes, aging, gaps and scratches, thus affecting the sealing, should be

replaced with new ones. All the old gaskets also should be replaced.

● When dismantling and mounting the hydraulic components, beating and hitting are not allowed to avoid

damage to parts.

3.4.4 Brake system

The role of the brake system is to quickly slow down or stop the vehicle which is running, and stop the

complete machine on the ground or the ramp. This machine has two brake systems, and their principle is

shown in Figure 3-15.

84
 Figure 3-15
a) Traveling brake system

Used for regular speed control and parking in general driving and operating process. The traveling brake in

the vehicle adopts hydraulic wet brake, with advantages such as fast response, stable, safe, reliable, and

maintenance-free.

The main components of the traveling brake system include the pilot pump, overflow valve, filling valve,

brake, wet brake and accumulator. Pilot pump and steering pumps are double pumps, directly driven by the

engine through the transmission. High-pressure oil pumped from the pilot pump is directly delivered to the P

port of the filling valve. The hydraulic oil entering into the filling valve not only ensures the brake oil, but

also supply controls oil sources for the pilot system, which is adjusted by the by-pass valve core in the filling

valve. Step on the foot brake pedal, high pressure oil connects the wet brakes in the front and rear drive axles

through the two exports A in the brake valve to realize brake. The output brake pressure is proportional to the

brake pedal angle stepped. In order to stabilize the brake oil pressure and supply large quantity oil when

continuously stepping on the brake pedal, the ports A1 and A2 of the filling valve connects with two

accumulators to store and release energy. Accumulator is the gas load type, nitrogen pressure is 65bar.

85
b) Emergency and parking brake system

Emergency and parking brake system is used for brake when an emergency happens in the working of the

loader, and plays a role of safety protection when the brake oil pressure is too low. It can also be used for

keeping the loader in the original position after parking, to prevent movement due to inclined road or other

external force.

The main components of emergency and parking brake system are emergency parking brake block and

parking brake. When the solenoid valve is energized, the pressure oil enters into the parking brake oil

chamber through the solenoid valve, and the hand brake is in a release state. When the solenoid valve is

powerdown, the pressure oil in the brake oil chamber flows back the tank through the solenoid valve T port.

The brake oil chamber returns to the original position under the action of the spring, and the hand brake is in

the braking state.

Parking brake button switch is on the dashboard, which is a red button. Pressing is to brake. Loosen it in the

direction of the arrow is to release the brake. When the parking brake is in braking condition, the loader is cut

off the power. Only releasing the parking brake, the loader can be engaged gears to move forward or

backward.

When the traveling brake system fails, press the red button, using the hand brake to brake, in order to achieve

the purpose of emergency braking.

When the braking oil pressure is insufficient (less than 11Mpa), warning indicates the brake oil pressure. You

should check troubleshooting, to continue to work after eliminating the faults.

When the machine is not energized, the brake state automatically starts.

Therefore, this machine has gear engaging protection and low oil pressure protection functions.

When the machine needs to be dragged, you should release the parking brake. If the engine does not work,

the whole vehicle without electricity, electromagnetic valve stuck result in parking brake, you must release

the parking brake. The method is to unscrew the cover, loosen the adjusting nut. At this time the machine is

in no brake state, you should pay more attention to safety when dragging.

3.4.5 Electrical system

The electrical system consists of the charging part, starting part, and the signal lighting part. This system is

DC24V, a single wire system, with negative ground connection. The system principle is shown in Figure

3-16.

86
87
Figure 3-16 Principle of electrical system（1）
88
Figure 3-16 Principle of electrical system（2）
89
Figure 3-16 Principle of electrical system（3）
90
Figure 3-16 Principle of electrical system（4）
91
Figure 3-16 Principle of electrical system（5）
92
Figure 3-16 Principle of electrical system（6）
93
Figure 3-16 Principle of electrical system（7）
94
Figure 3-16 Principle of electrical system（8）
a) Charging part

This part mainly consists of battery, generators and cables. Requirements and precautions are as follows:

Battery

This machine uses two maintenance-free batteries in series connection. The negative electrode of the first

battery connects with the positive electrode of the second battery. The negative electrode of the second

battery connects with the ground, and the positive electrode of the first battery connects with the power

master switch, so that when the power switch starts to work, it can supply power to the vehicle. After the

battery is installed onto the battery box, it must be fixed firmly to avoid breaking in traveling. Cable

terminals and battery terminals must be kept in close contact. Do not use a screwdriver or wire directly to

check whether the battery has power by short circuit spark method, in order to prevent the instantaneous

current is too large and damaging to the battery.

b) Starting part

This part mainly consists of the ignition switch, power master switch, knife switch, and starter motors. When

starting, close the knife switch, the ignition switch is set in "ON" position, the power master switch starts to

work, then put the ignition switch in "START" position, the starter motor works, driving the engine flywheel

to rotate. When starting the engine, each starting time should not exceed 10 seconds; if the engine is not

started in 10 seconds, you should release the start switch, stop for a minute before starting again. If the engine

still can not start in 3 to 4 times, check the causes. Such as: Check for loose connections, falling off

phenomenon, the adequacy of battery power, diesel fuel supply, and whether the power switch is working

properly.

c) Lighting signal part

This machine is equipped with th front combined lamps (including low beam, high beam, front width lamp, turn lamp,

auxiliary illumination lamp), rear combined lamps (including rear width lamp, rear turn lamp, brake lamp, reverse lamp),

work lamps (cab front work lamp, cab rear work lamp, hood rear work lamp), cab top lamp, etc., with their specifications

shown below:

No. Name Quantity Bulb Specification

1 Headlamp 2 DC24V 75/70W
2 Front turn signal lamp 2 DC24V 21W
3 Front clearance lamp 2 DC24V 4W
4 Brake lamp 2 DC24V 21W

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5 Rear turn signal lamp 2 DC24V 21W
6 Reversing lamp 2 DC24V 21W
7 Rear clearance lamp 2 DC24V 5W
8 Working lamp (LED) 10 DC24V 24W
9 Roof lamp 1 DC24V 5W

96
d) Instrument Monitoring System

1. Front working lamp 12. Pilot joystick

2. Rotary warning lamp 13. A/C Control Panel

3. Transmission display (Optional) 14. Rocker switch

4. Gearshift lever 15. Power socket

5. Brake pedal 16. Parking brake switch

6. Horn button 17. Rear wiper

7. Front wiper 18. Rear working lamp

8. Combination instrument 19. Radio/audio player

9. Lighting combination switch 20. Electric fan

10. Reversing camera 21. Emergency stop switch

11. Accelerator pedal 22. Central distribution box

97
Layout and functional description of combination instrument:

Button

Functional Description
No. Features

G1 Pointer gauge 1 Tachometer

G2 Pointer gauge 2 Oil pressure gauge of engine
G3 Pointer gauge 3 Water temperature gauge
G4 Pointer gauge 4 Battery Voltage Gauge
G5 Pointer gauge 5 Transmission Oil Temp Gauge

98
List of warning lamps;
No. Name Symbol Color

Left turn signal Green

Right turn signal Green

Charging indicator Red

Low brake air pressure

Red
warning

Low engine oil pressure Red

Parking brake Red

Axle oil temperature Red

Preheating Red

Engine coolant temperature

Red
warning

Low fuel level warning Red

Low transmission oil

Red
pressure warning
Transmission oil temperature
Red
warning

Air filter blockage Red

Buzzer mute Red

Reserved fuel-water
TBD TBD
separator warning

Hydraulic oil filter blockage

Red
warning

Axle filter blockage warning Red

Engine maintenance Red

Inter-wheel differential lock Green

Waiting for start Red

99
 Hydraulic oil temperature Red

Power cutoff Yellow

Engine stop indicator Red

Engine diagnosis Yellow

Descriptions of working status for signal indicator lamps:

1. Left turn signal: This warning lamp turns on when the input is connected with the battery voltage.
2. Right turn signal: This warning lamp turns on when the input is connected with the battery voltage.
3. Charging indicator: This warning lamp turns on when the input is grounded.
4. Low brake air pressure warning: This warning lamp turns on when the input is grounded.
5. Low engine oil pressure: This warning lamp turns on when the engine oil pressure is less than 1bar.
6. Parking brake: This warning lamp turns on when the input is grounded.
7. Axle oil temperature: This warning lamp turns on when the input is grounded.
9. Water temperature warning: This warning lamp turns on when the coolant temperature is higher than
100ºC.
10. Low fuel level warning: This warning lamp turns on when the fuel level is less than 1/8.
12. Drive oil temperature warning: This warning lamp turns on when the transmission oil temperature is
higher than 120ºC.
13. Air filter blockage warning: This warning lamp turns on when the input is grounded.
14. Buzzer mute: This warning lamp turns on when one sound warning is muted.
18. Engine maintenance: This warning lamp turns on when the input is grounded. (This terminal is controlled
by engine ECU. If this lamp turns on, check the fuel-water separation pipeline for presence of water).
23. Engine stop indicator: This warning lamp turns on when a serious trouble code occurs in the engine or
transmission.
24. Engine diagnosis: This warning lamp turns on when a trouble code occurs in the engine or transmission.

100
 LCD display:

2 6、7、8、9、10、11、12
6、7、8、9、10、11、 1 1
12

1. Engine running time 2. Vehicle speed 3. Total mileage 4. Clock 5. Trouble code information
6. Fuel level 7. Battery voltage 8. Transmission oil temperature 9 Transmission oil pressure 10. Air
pressure 11. Engine oil pressure 12. Life time
Note: About malfunction code information

Malfunction Malfunction code Malfunction code

code ID SPN FMI

101
Method to acquire malfunction code: It indicates the presence of malfunction in engine or

transmission if the diagnostic indicator lamp/ turns on and it indicates the presence of serious

malfunction in the vehicle if the stop malfunction indicator lamp/ turns on. In such case,
make sure to stop the engine and vehicle, check the malfunction information, and troubleshoot
before restarting the vehicle. When any of the above-mentioned two indicator lamps turns on,
firstly cut off the power supply, press and hold the button near the LCD screen for more than 3s,
and at the same time rotate the key switch to power on (namely rotate the key switch to position
ON) and observe the malfunction code date. Press the button to circulate all malfunction code
information and troubleshoot one by one as per the information indicated in the attached table of
transmission and engine malfunction codes.
The combination instrument reads the data information from engine ECU and transmission TCU
via CAN bus technology and can accurately real-time inquire the working status and malfunction
code of the engine and the transmission. The complete malfunction code information include ID
address, SPN code, and FMI code, of which the ID:00 denotes the engine malfunction
information and 03 denotes the transmission malfunction information.
The SPN code and FMI code of the malfunction code indicated in the instrument panel LCD
screen are of hexadecimal code and the SPN code and FMI code of malfunction code listed in the
attached table of transmission and engine malfunction codes are of decimal code. This is why to
convert the SPN code and FMI code indicated on the instrument panel to decimal codes and
inquire the corresponding malfunction code in the Appendix.
As shown in above figure, the meaning of the malfunction code 00.0006F.02:
ID: 00 denotes engine malfunction code.
SPN code: 0006FThis data information is one hexadecimal value and it’s necessary to convert it
to decimal value 111.
FMI code: 02 This data information is one hexadecimal value and it’s necessary to
convert it to decimal value 02.
Look up the table of engine malfunction codes, find out the information of malfunction code
111/02, and troubleshoot as per the information description.

102
Back view of instrument panel
Buzzer alarm

A B

Connector A (Blue)

Connector B (green)

103
A Blue Connector

Pin Heavy Loader Cluster

01 Diesel Pre-heat
02 Engine Oil Pressure Low Warning
03 Body Ground
04
05 Sensor Ground
06
07
08
09 Transmission Oil Temp Sensor
10 Tachometer Signal
11 Battery Power Input
12
13 Ignition
14
15 Diagnostic
16 Charging Indication
17 Transmission Oil Pressure Low Warning
18 Park Brake
19
20 Air Filter Block Warning
21 Fuel Sensor Input
22 Right Turn
23 Coolant Temperature Sensor
24 Left Turn
25 Little Lamp Switch
26 Air Pressure Low Warning
27 Speed Signal Input
28 Engine Oil Pressure Sensor
29 Air Pressure Sensor
30
31 CAN L
32 CAN H

104
Green Connector:

Pin Heavy Loader Cluster

01
02
03
23 Waiting Start
24 Reserved Digital Input 1
25 Power Off
26 Axle Oil Temp
27 Maintain Reminder

Function description of alarm buzzers inside the instrument:

The alarm buzzer will continuously sound in case of low engine-oil pressure alarm, water temperature alarm,
low braking pressure alarm, and lit park braking indicator.

Low braking pressure alarm:

The buzzer will activate when the air pressure is below 4 bar or above 8 bar.

Engine-oil pressure alarm:

The buzzer will activate when the oil pressure is not exceeding 1 bar or above 6 bar and the engine speed is
above 100 rpm.

Water temperature alarm:

The buzzer will activate when the water temperature is not exceeding 100℃.

Park braking alarm:

The buzzer will activate when the park braking indicator is lit.

Priority of buzzer alarms

Low braking pressure alarm＞ engine-oil pressure alarm ＞ water temperature alarm ＞ park braking alarm
When the buzzer sounds, holding the button for 3s will screen off the audible alarm and so do all of other
alarms until another holding of the button is made for 3s to activate these alarms; or otherwise after the ignition
is reset, all audible alarms will be restored.

105
e) Switch control panel
Rocker switch:
The switch group 1 is located on the control box:

1. Independent radiator switch 2. Emergency signal switch 3. Pilot locking switch 4. Rear
hood working lamp switch 5. Cab front working lamp switch 6. Cab rear working lamp
switch 7. Differential locking switch 8. Transmission display backlight switch 9.
Manual/automatic gearshift switch 10. Intelligent power cutoff switch 11. Stabilizing module
switch 12. A/C water valve switch 13. Signal indicator lamp 14. Signal indicator lamp 15.
Blank cover plate

The switch group 2 is located on the right front corner of cab roof trim part:

16. Front washer switch 17. Rear washer switch 18. Roof lamp switch 19. Front wiper
switch 0. Rear wiper switch 21. Rotary warning lamp switch
Note
Note: 3 – Pilot locking switch

106
The hydraulic pilot system can actuate only after this switch is pressed and turned on. To turn off
this switch, push downward the upper button to lock this switch. The pilot joystick will not
actuate when this switch is turned off. Ensure that this switch is at position OFF when the
machine is to be left unused for a long time.
1. Cooling fan reversing switch

The above figure shows the state when the switch is pressed and held (reset once released). This
state is the manual reversing mode. When this switch is pressed and held for more than 2s, the
fan is working under manual reversing mode so that the fan rotates in reverse direction for 2min
and then returns to forward running mode.

f) Engine Trouble Diagnosis

● Engine trouble inspection
Inspection to the engine trouble should be done when the start-up key is at “ON” position while
the machine is running. If the trouble is detected, then there will be a trouble record in the store
unit. The detected trouble record shows some working parameters of the engine. Based on how
severe the trouble is, the outcome of certain types of trouble will have the Warning lamp ( yellow)
or STOP lamp ( red) light on.

● Codes for flashing troubles

The mode of “Codes for Flashing Troubles” can be accessible by diagnosis switch or accelerator
pedal. So, to access into this mode, the start-up key must be at its “ON” position and the engine
stops. In case of accessing into this mode by the diagnosis switch, after the diagnosis switch
being placed at “ON”, ECM will automatically flash the first trouble code. To view

107
forward/backward the trouble codes, you can move the current code forward or backward. In case
of accessing into this mode by means of the accelerator pedal, then you need to repeatedly step
down and release the accelerator pedal and have the accelerator capacity increase from 0 to 100%
for continuous 3 times. Once this mode comes out, repeatedly stepping down/ releasing the
accelerator can obtain the current trouble code. The following diagram shows an example of a
flashing trouble code.
Example of trouble
Trouble code code order P=
244： 暂停
WAR WAR WAR WAR WAR
NING S PNING S PNING S PNING S PNING S
Mainten
TOP Maintenan
TOP Maintenanc
TOP Maintenanc
TOP TOP
Maintenan
ance ce e e
ce
Flash once Flash twice Flash four Flash four Flash once
times times
Trouble code
112：
WAR WAR WAR WAR WAR
NING S NING S NING S NING S NING S
P P P P
TOP
Maintenance TOP
Maintenan TOP
Maintenan TOP
Maintenan TOP
Maintena
ce ce ce nce
1
次闪烁
● Trouble indication lamp
If the start-up switch is turned to “ON” position, but the trouble-diagnosis switch has to be turned
off, then these indication lamps will turn off after being on for 2 seconds, which is used for
checking if those indication lamp and their wiring work properly. Please see the following
diagram, which shows that the indication lamps will all turn on but will be off one by one.

Order of the warning

indicator lamp

Warning indicator lamp

Warning indicator lamp shows important operation information to the machine operator.
Therefore, the machine operator must attach much attention to those indicated information.
Warning indicator lamp can also show trouble diagnosis codes.
Machine-parking indication lamp
This lamp shows very emergent operation information, which requires the operator to take right
measures immediately. The machine-parking indication lamp is also used for showing the
flashing trouble codes.
108
● Troubles Indication Lamp
Trouble code for engine
Fault code/
ISO J1939
flash code

Fault Code P-Code SPN FMI Fault Description

Electronic control module (ECM) microprocessor fault – ECM

111 P0606 629 12
internal hardware fault
Engine speed sensor (ESS) circuit fault – engine speed and
115 P0008 612 2
crankshaft position signal is not detected
Intake manifold pressure sensor circuit fault – intake manifold
122 P0108 102 3
pressure signal too high
Intake manifold pressure sensor circuit fault – intake manifold
123 P0107 102 4
pressure signal too low.
Intake manifold pressure sensor signal too high – intake manifold
Not
124 102 16 pressure exceeds than the rated engine rated maximum, engine
Mapped
protection
Not Intake manifold pressure sensor signal too low – intake manifold
125 102 18
Mapped pressure exceeds than the rated engine rated minimum.
Accelerator position sensor 1 circuit fault – accelerator position
131 P2123 91 3
signal voltage too high
Accelerator position sensor 1 circuit fault – accelerator position
132 P2122 91 4
signal voltage too low.
Remote accelerator position sensor circuit fault – signal voltage too
133 P254D 974 3
high
Remote accelerator position sensor circuit fault – signal voltage too
134 P254C 974 4
low.
135 P0523 100 3 Engine oil pressure sensor circuit fault – signal voltage too high
141 P0522 100 4 Engine oil pressure sensor circuit fault – signal voltage too low.
Engine oil pressure sensor signal indicating that the oil pressure is
143 P0524 100 18
lower than engine protection lower limit
Coolant temperature sensor circuit fault – signal voltage on the
144 P0118 110 3
high side
Coolant temperature sensor circuit fault – signal voltage on the low
145 P0117 110 4
side
Coolant temperature sensor circuit fault – coolant temperature
146 P0217 110 16 exceeds than the engine protection limiting value, engine
protection
Not Accelerator position sensor 1 electric current frequency is too low
147 91 1
Mapped
Not Accelerator position sensor 1 fault – signal is effective, but higher
148 91 0
Mapped than normal working range
Coolant temperature sensor circuit fault – coolant temperature
151 P0217 110 0
exceeds than engine protection limit, engine protection

109
 Intake manifold temperature sensor circuit fault-signal voltage is
153 P0113 105 3
on the high side.
Intake manifold temperature sensor circuit fault – signal voltage is
154 P0112 105 4
on the low side
Not Intake manifold temperature sensor -Engine protection, intake
155 105 0
Mapped manifold air temperature exceeds than engine protection limit
Not Sensor supply circuit 2 fault – voltage is lower than normal
187 3510 4
Mapped working voltage
Engine coolant liquid level sensor circuit fault – signal voltage is
195 #N/A 111 3
on the high side
Engine coolant liquid level sensor circuit fault – signal voltage is
196 P2558 111 4
on the low side
Engine coolant liquid level sensor circuit fault –Engine protection,
197 P2560 111 18 coolant liquid level signal shows that the coolant liquid level is on
the low side
Engine oil temperature sensor circuit fault – signal voltage is too
212 P0198 175 3
high
Engine oil temperature sensor circuit fault – signal voltage is too
213 P0197 175 4
low
Not Engine oil temperature sensor – oil temperature exceeds than the
214 175 0
Mapped engine protection limit
Barometric pressure sensor circuit fault – signal voltage is on the
221 P2229 108 3
high side
Barometric pressure sensor circuit fault – signal voltage is on the
222 P2228 108 4
low side
Not Sensor supply circuit 2 fault – voltage is higher than the normal
227 3510 3
Mapped working voltage
Engine speed sensor (ESS) overspeed circuit fault – engine speed
234 P0219 190 0
signal shows that the engine speed has exceeded than the limit
Engine coolant liquid level sensor circuit fault – engine protection,
235 P2560 111 1 and coolant liquid level signal shows that the coolant liquid level is
on the low side
Not External speed command input (multi-ECU synchronization) signal
237 644 2
Mapped instable, interrupted or wrong.
Engine speed sensor power circuit fault – the engine speed sensor
238 P0642 3511 4
5V power line voltage is detected to be on the low side
Engine speed sensor power circuit fault – the engine speed sensor
239 P0643 3511 3
5V power line voltage is detected to be on the high side
Vehicle speed sensor circuit fault – vehicle speed signal instable,
241 P0501 84 2
interrupted or wrong.
Not Vehicle speed sensor circuit fault -Invalid or incorrect vehicle
242 84 10
Mapped speed signal is detected, and the signal is interrupted or disturbed.
245 P0480 647 4 Engine fan clutch circuit fault – fan clutch signal is wrong
Atmospheric temperature sensor circuit fault – signal voltage is
249 P0073 171 3
high
252 Not 98 2 Engine oil liquid level sensor circuit fault – invalid or incorrect oil
110
 Mapped liquid level sensor signal is detected, and the signal is interrupted
or disturbed
Not Engine oil liquid level sensor circuit fault – Engine protection, and
253 98 1
Mapped oil liquid level is lower than the limit
Not Oil cut-off circuit fault – voltage signal is on the low side
254 632 4
Mapped
Not Oil cut-off circuit fault – voltage signal is on the high side
255 632 3
Mapped
Atmospheric temperature sensor circuit fault – signal voltage is
256 P0072 171 4
low.
Oil cut-off valve driving mechanism – mechanical system does not
257 P000F 632 7
respond or needed to be adjusted
Fuel oil temperature sensor circuit fault – fuel oil temperature
263 P0183 174 3
signal voltage is on the high side
Fuel oil temperature sensor circuit fault – fuel oil temperature
265 P0182 174 4
signal voltage is on the low side
Fuel oil pressure sensor circuit fault – the fuel pressure in
268
accumulator does not change with the engine working conditions
Not Security password effectiveness indicator – data invalid,
269 1195 2
Mapped interrupted or wrong
Oil pump control solenoid valve circuit fault – signal voltage is too
271 P0253 1347 4
low
Oil pump control solenoid valve circuit fault – signal voltage is too
272 P0254 1347 3
high.
Oil pump element fault – mechanical component does not respond
281 P0252 1347 7
or needed to be adjusted
Not SAE J1939 PNG receives timeout – ECM receives PNG signal
285 639 9
Mapped timeout or can not receive signal
Not SAE J1939 bus transmission configuration fault – ECM can only
286 639 13
Mapped receive part of control unit signals
Not OEM vehicle ECU detects bus accelerator pedal fault
287 91 19
Mapped
Not OEM vehicle ECU detects remote accelerator fault
288 974 19
Mapped
Not Private protocol communication fault – refresh rate is abnormal,
291 625 9
Mapped and the anti-theft system can not work properly
Not Auxiliary temperature sensor input 1 – specially used for indication
292 441 14
Mapped
Not Auxiliary temperature sensor input 1 – Signal voltage is too high
293 441 3
Mapped
Not Auxiliary temperature sensor input 1 – Signal voltage is too high
294 441 4
Mapped
Barometric pressure sensor fault – signal instable, interrupted or
295 P2227 108 2
wrong
Not Auxiliary temperature sensor input 2 - specially used for indication
296 1388 14
Mapped

111
 Not Auxiliary temperature sensor input 2 – Signal voltage is too high
297 1388 3
Mapped
Not Auxiliary temperature sensor input 2 – Signal voltage is too low
298 1388 4
Mapped
1st cylinder oil atomizer drive fault – electric current is too large or
311 P0262 651 6
short circuit to the earth
5th cylinder oil atomizer drive fault – electric current is too large or
312 P0274 655 6
short circuit to the earth
3rd cylinder oil atomizer drive fault – electric current is too large or
313 P0268 653 6
short circuit to the earth
6th cylinder oil atomizer drive fault – electric current is too large or
314 P0277 656 6
short circuit to the earth
2nd cylinder oil atomizer drive fault – electric current is too large or
315 P0265 652 6
short circuit to the earth
Not Real-time clock power fault – number instable, interrupted or
319 251 2
Mapped wrong
4th cylinder oil atomizer drive fault – electric current is too large or
321 P0271 654 6
short circuit to the earth
1st cylinder oil atomizer drive fault – electric current is too small or
322 P0201 651 5
open circuited
5th cylinder oil atomizer drive fault –electric current is too small or
323 P0205 655 5
open circuited
3rd cylinder oil atomizer drive fault –electric current is too small or
324 P0203 653 5
open circuited
6th cylinder oil atomizer drive fault –electric current is too small or
325 P0206 656 5
open circuited
2nd cylinder oil atomizer drive fault –electric current is too small or
331 P0202 652 5
open circuited
4th cylinder oil atomizer drive fault –electric current is too small or
332 P0204 654 5
open circuited
Engine coolant temperature sensor fault – signal instable,
334 P0116 110 2
interrupted or wrong
Not Idling closing (vehicle accessories) relay driving circuit fault –
338 1267 3
Mapped voltage is too high
Not Idling closing (vehicle accessories) relay driving circuit fault –
339 1267 4
Mapped voltage is too low
343 P0607 629 12 ECM internal hardware fault
Not ECM calibrating procedure – invalid switch configuration
346 630 12
Mapped parameter setting
Not Transmission output shaft rotation speed – data valid and on the
349 191 16
Mapped high side
Not Oil atomizer control actuator power supply voltage is low
351 627 12
Mapped
Sensor power circuit 1 fault – sensor power voltage is on the low
352 P0652 3509 4
side

112
 Sensor power circuit 1 fault – sensor power voltage is on the high
386 P0653 3509 3
side
Engine oil pressure sensor fault – engine protection, and oil
Not
415 100 1 pressure signal shows that the oil pressure is far below the engine
Mapped
protection lower limit
Water of fuel oil (W/F) sensor circuit fault – water drainage is
418 P2269 97 15
needed for the fuel filter
Not Engine oil temperature sensor – fuel oil temperature exceeds the
421 175 16
Mapped engine protection limit
Not Engine oil temperature sensor – signal instable, interrupted or
425 175 2
Mapped wrong
Not SAE J1939 CAN network fault - signal instable, interrupted or
426 639 2
Mapped wrong
Not The communication between SAE J1939 Datalink – ECM and
427 639 9
Mapped other electric control unit is not available.
Water of fuel oil (W/F) sensor circuit fault – signal voltage is on
428 P2267 97 3
the high side
Water of fuel oil (W/F) sensor circuit fault – Signal voltage is on
429 P2266 97 4
the low side
Idling valid switch (IVS) circuit fault – the idling valid and
431 P2127 2
non-idling valid signals are also detected
Idling valid switch (IVS) circuit fault - the idling valid and
432 P2121 13 non-idling valid signals are not matched with accelerator position
signal
Engine oil pressure sensor fault - signal instable, interrupted or
435 P0521 100 2
wrong
436 P0111 105 2 Intake manifold temperature is instable, interrupted or wrong
Battery supply circuit fault – ECM service voltage value is valid
441 P0562 168 18
and lower than the normal working range (6-32V)
Battery supply circuit fault – ECM service voltage value is valid
442 P0563 168 16
and higher than the normal working range (6-32V)
Not Fuel oil pressure sensor circuit fault – fuel oil pressure exceeds
449 157 0
Mapped than the maximum limit of engine rated power
451 P0193 157 3 Fuel oil pressure sensor circuit fault – Signal valve is too high
452 P0192 157 4 Fuel oil pressure sensor circuit fault – Signal valve is too low
Not Turbocharger bypass-valve control circuit fault – voltage is too
465 1188 3
Mapped high
Not Engine oil liquid level sensor circuit fault – fuel oil liquid level is
471 98 17
Mapped lower than the limit
Not Intake manifold temperature sensor circuit fault – engine intake
488 105 16
Mapped manifold temperature exceeds than the engine protection limit
Not Transmission output shaft rotation speed – data is valid and on the
489 191 18
Mapped lower end
Not Multi-system synchronous switch fault – data instable, interrupted
497 1377 2
Mapped or wrong

113
 Not Engine oil liquid level sensor circuit fault – signal voltage is too
498 98 3
Mapped high
Not Engine oil liquid level sensor circuit fault – signal voltage is too
499 98 4
Mapped low
Not Sensor supply circuit 2 (coolant sensor) fault – sensor supply
515 3514 3
Mapped voltage is on the high side
Not Sensor supply circuit 2 (coolant sensor) fault – sensor supply
516 3514 4
Mapped voltage is on the low side
Not Auxiliary cruise/PTO speed switch confirmation fault - data
523 611 2
Mapped instable, interrupted or wrong
Not Auxiliary input and output 2 circuit fault – signal voltage is too
527 702 3
Mapped high
Not Auxiliary standby torque curve switch - data instable, interrupted
528 93 2
Mapped or wrong
Not Auxiliary input and output 3 circuit fault – signal voltage is too
529 703 3
Mapped high
535 P0181 174 2 Fuel oil temperature sensor - data instable, interrupted or wrong
Turbocharger bypass-valve fault – mechanical mechanism does not
545 P0234 1188 7
respond, or needed to be adjusted
Not Fuel oil supply pressure sensor circuit fault – signal voltage is on
546 94 3
Mapped the high side
Not Fuel oil supply pressure sensor circuit fault – signal voltage is on
547 94 4
Mapped the low side
Fuel oil orbit pressure – value is valid, but higher than the normal
553 P0088 157 16
working range
Fuel oil orbit pressure – value is invalid, interrupted or incorrect,
554 P0191 157 2 and fuel oil pressure does not change with the engine operating
condition
Crankcase pressure fault – crankcase pressure value is valid but
555 P1507 101 16
higher than normal working range
Crankcase pressure fault – crankcase pressure value is valid but
556 P1508 101 0
lower than normal working range
Fuel oil orbit pressure fault - value is valid, but lower than the
559 P0087 157 18
normal working range
Starter relay driving circuit fault – signal voltage is too high or
584 P0617 677 3
open circuited
585 P0616 677 4 Starter relay driving circuit fault – signal voltage is too low
Turbocharger rotation speed fault - value is valid, but higher than
595 P0049 103 16
normal working speed
596 P2504 167 16 Charging voltage fault – charging voltage is too high
597 P2503 167 18 Charging voltage fault – charging voltage is too low
Not Charging voltage fault – charging voltage is too low
598 167 1
Mapped
Not Auxiliary command output – specially used for indication
599 640 14
Mapped

114
 Not Turbocharger compressor intake pressure fault - value is valid, but
629 1176 18
Mapped lower than normal working pressure
Not Engine oil replacement time interval – prompt to replace engine oil
649 1378 31
Mapped and oil filter
Turbocharger rotation speed fault – signal instable, interrupted or
686 P2579 103 2
wrong
Turbocharger rotation speed fault – value is valid but lower than
687 P2580 103 18
normal working speed
Not Engine oil liquid level sensor circuit fault - value is valid but
688 98 0
Mapped higher than normal engine oil liquid level
Engine speed sensor circuit fault - signal instable, interrupted,
689 P0335 190 2
wrong or lost
Turbocharger compressor intake temperature sensor circuit fault –
691 P1193 1172 3
signal voltage is too high
Turbocharger compressor intake temperature sensor circuit fault –
692 P1192 1172 4
signal voltage is too low
Turbocharger compressor intake temperature sensor circuit fault –
693 P1191 1172 2
signal instable, interrupted or wrong
ECU temperature sensor circuit fault – signal voltage is too high or
697 P0669 1136 3
open circuited
698 P0668 1136 4 ECU temperature sensor circuit fault –signal voltage is too low
ECU temperature sensor circuit fault –signal instable, interrupted
699 P0667 1136 2
or wrong
Crankshaft position sensor and camshaft position sensor signal
fault – the position signal provided by the crankshaft position
731 P0016 723 7
sensor is not matched with that provided by the camshaft position
sensor
Not Turbocharger compressor intake temperature sensor circuit fault –
741 1176 3
Mapped signal voltage is too high
Not Turbocharger compressor intake temperature sensor circuit fault –
742 1176 4
Mapped signal voltage is too low
Not Turbocharger compressor intake temperature sensor circuit fault
743 1176 2
Mapped –signal instable, interrupted or wrong
Not Fuel oil orbit pressure fault – mechanical mechanism does not
755 157 7
Mapped respond
Camshaft position sensor fault – the signal of camshaft position
778 P0340 723 2
sensor can not be detected
Not Auxiliary equipment temperature sensor input 3 fault – unknown
779 703 11
Mapped fault cause
Not Cruise mode fault – data instable, interrupted or wrong
784 1590 2
Mapped
1117 P2509 627 2 ECM supply voltage after Key-ON is 0 or lower than 6.2V
1st cylinder oil atomizer drive fault – mechanical component does
1139 P020A 651 7
not respond or needed to be adjusted
2nd cylinder oil atomizer drive fault – mechanical component does
1141 P020B 652 7
not respond or needed to be adjusted
115
 3rd cylinder oil atomizer drive fault – mechanical component does
1142 P020C 653 7
not respond or needed to be adjusted
4th cylinder oil atomizer drive fault – mechanical component does
1143 P020D 654 7
not respond or needed to be adjusted
5th cylinder oil atomizer drive fault – mechanical component does
1144 P020E 655 7
not respond or needed to be adjusted
6th cylinder oil atomizer drive fault – mechanical component does
1145 P020F 656 7
not respond or needed to be adjusted
EGR valve position signal fault – signal instable, interrupted or
1228 P046C 27 2
wrong
Accelerator position sensor 2 circuit fault – signal pressure is too
1239 P2128 2623 3
high
Accelerator position sensor 2 circuit fault – signal pressure is too
1241 P2127 2623 4
low
Accelerator position sensor fault - signal instable, interrupted or
1242 P2121 91 2
wrong
1654 P0301 1323 31 Engine 1st cylinder misfires
1655 P0302 1324 31 Engine 2nd cylinder misfires
1656 P0303 1325 31 Engine 3rd cylinder misfires
1657 P0304 1326 31 Engine 4th cylinder misfires
1658 P0305 1327 31 Engine 5th cylinder misfires
1659 P0306 1328 31 Engine 6th cylinder misfires
Not Post processing system DOC fault – there is no oxidation catalyst
1664 4796 31
Mapped for the post processing system
SCR reagent (urea) liquid level sensor circuit fault – voltage signal
1668 P203C 1761 4
is on the low side
SCR reagent (urea) liquid level sensor circuit fault – voltage signal
1669 P203D 1761 3
is on the high side
SCR reagent (urea) liquid level sensor circuit fault – voltage signal
1671 P203F 1761 18
is on normal working level
SCR reagent (urea) liquid level sensor circuit fault – voltage signal
1673 P203F 1761 1
is on normal working level
SCR reagent (urea) liquid level sensor circuit fault – signal voltage
1677 P205C 3031 4
is too low
SCR reagent (urea) liquid level sensor circuit fault – signal voltage
1678 P205D 3031 3
is too high
Not SCR reagent (urea) liquid level sensor circuit fault –signal instable,
1679 3031 2
Mapped interrupted or wrong
Not SCR reagent (urea) spraying unit fault – control element fault
1681 3361 12
Mapped
Not SCR reagent (urea) spraying unit supply pipeline fault
1682 3362 31
Mapped
SCR reagent (urea) heater circuit fault – SCR reagent heating
1683 P202C 3363 3
sensor signal voltage is too high

116
 SCR reagent (urea) heater circuit fault – SCR reagent heating
1684 P202B 3363 4
sensor signal voltage is too low
Not SCR reagent (urea) control unit fault – control element fault
1688 3360 12
Mapped
Not Real-time clock power fault – data instable, interrupted or wrong
1689 251 2
Mapped
DOC efficiency fault – value is valid but DOC working efficiency
1691 P0420 5018 18
is too low
1694 P2201 3226 2 Nox sensor fault – Nox sensor signal instable, interrupted or wrong
Sensor power supply 5 fault – the sensor power supply circuit
1695 P0699 3513 3
voltage of OEM wiring harness is too high
Sensor power supply 5 fault – the sensor power supply circuit
1696 P0698 3513 4
voltage of OEM wiring harness is too low
Not Secondary air executive component fault – signal voltage is too
1697 3489 3
Mapped high
Not Secondary air executive component fault – signal voltage is too
1698 3489 4
Mapped low
SCR reagent (urea) liquid level sensor fault - signal instable,
1699 P203B 1761 2
interrupted or wrong
Not SCR reagent (urea) supply unit fault – supply quantity refresh rate
1711 3361 9
Mapped is abnormal
Not SCR reagent (urea) heater fault – value is lower than normal
1712 3363 18
Mapped working range
Not SCR reagent (urea) heater fault – value is higher than normal
1713 3363 16
Mapped working range
Not Auxiliary temperature sensor input 1 circuit fault – temperature is
1716 441 15
Mapped slightly high
1718 P0300 1322 31 Engine multi-cylinders misfire
Crankcase pressure sensor circuit malfunction -signal voltage is too
1843 P051D 101 3
high
Crankcase pressure sensor circuit malfunction -signal voltage is too
1844 P051C 101 4
low
Fuel water content (W/F) indicator malfunction - Value is valid but
1852 P0169 97 16
is beyond limit and the water drainage is required for fuel filter.
Incorrect pressure δ (pressure difference) of EGR valve. Key-ON
Not
1866 411 2 The EGR pressure signal malfunction is detected after Key-ON or
Mapped
the sensor fails during automatic reset test.
1867 P040B 412 2 EGR temperature error - Unstable, intermittent, or incorrect value
After-treatment system DPF pressure different sensor circuit
1879 P2455 3251 3
-signal voltage is too high
After-treatment system DPF pressure different sensor circuit
1881 P2454 3251 4
-signal voltage is too low
After-treatment system DPF pressure difference sensor - Value
1883 P2453 3251 2
error
1887 P2202 3226 4 NOx sensor circuit in after-treatment system exhaust pipe - Voltage

117
 is less than standard value or circuit is short circuited
Not EGR valve controller malfunction - EGR valve can’t adjust
1896 2791 13
Mapped automatically after key-on, requiring calibration
Not EGR valve pressure δ is incorrect or less than normal working
1899 411 18
Mapped range
Fuel rail pressure - Value is valid, but is higher than normal
1911 P0088 157 0
working range.
Over-high pressure difference between inlet and outlet of
1921 P2463 3251 16
after-treatment system DPF
Over-high pressure difference between inlet and outlet of
1922 P242F 3251 0
after-treatment system DPF and probable blockage of DPF
Not After-treatment DPF regenerative fuel cutoff valve circuit
1923 3482 3
Mapped malfunction - Signal voltage is too high
Not After-treatment DPF regenerative fuel cutoff valve circuit
1924 3482 4
Mapped malfunction -signal voltage is too low
Not After-treatment DPF regenerative fuel cutoff valve circuit
1925 3482 2
Mapped malfunction - Unstable, intermittent, or incorrect signal
Not After-treatment DPF regenerative fuel pressure sensor circuit
1926 3480 2
Mapped malfunction -Unstable, intermittent, or incorrect signal
Not After-treatment DPF regenerative fuel pressure sensor circuit
1927 3480 3
Mapped malfunction -signal voltage is too high
Not After-treatment DPF regenerative fuel pressure sensor
1928 3480 4
Mapped circuit malfunction - signal voltage is too low
Not After-treatment DPF regenerative fuel injector malfunction
1932 3556 2
Mapped -Unstable, intermittent, or incorrect signal
Malfunction of ECU output voltage 1 - VGT actuator voltage is too
1938 P006E 3597 18
low
Crankcase pressure malfunction - Value is unstable, intermittent
1942 P051B 101 2 value, or remains unchanged following change of engine working
condition
Atmospheric density - Atmospheric density is less than normal
Not
1943 3555 17 working condition and the engine torque is reduced while working
Mapped
under highland condition
High VGT driver temperature (calculated value) - High internal
1962 P006F 641 15
temperature of VGT actuator
After-treatment system DPF regenerative fuel cutoff valve 1 -
Not
1963 3482 7 After-treatment system DPF regenerative fuel cutoff valve is
Mapped
bonded against opening
Not Over-high crankcase pressure and maintenance necessity for
1974 101 15
Mapped ventilator
After-treatment system DPF regenerative fuel supply circuit
Not
1977 3556 5 malfunction - Under-low current, over-high resistance, or
Mapped
open-circuit
High pressure difference between inlet and outlet of after-treatment
1981 P1451 3936 15
system DPF and probable blockage of DPF
1993 P244A 4795 31 No detection of DPF system by ECM

118
 Engine exhaust brake control circuit malfunction - Over-high
2182 P0478 1072 3
signal voltage or open-circuit
Engine exhaust brake control circuit malfunction - Signal voltage is
2183 P0477 1072 4
too low
Circuit (accelerator position sensor) malfunction of sensor power
2185 P06A5 3512 3 supply 4 - Voltage at 5V power wire of accelerator position sensor
is too high
Circuit (accelerator position sensor) malfunction of sensor power
2186 P06A4 3512 4 supply 4 - Voltage at 6V power wire of accelerator position sensor
is too low
Not Engine protection indicator of auxiliary equipment sensor
2195 703 14
Mapped input 3
VGT actuator drive circuit malfunction - Communication
2198 P0046 641 11
malfunction between VGT controller and ECM
Not Fuel delivery pipeline pressure malfunction - Value is less than
2215 94 18
Mapped normal working pressure
Not Fuel delivery pipeline pressure malfunction - Value is more than
2216 94 16
Mapped normal working pressure
2217 P0604 630 31 ECM memory malfunction
Not Fuel rail pressure malfunction - Value is valid, but is less than
2249 157 1
Mapped normal working pressure
Electronic fuel lift pump circuit malfunction -signal voltage is too
2265 P0629 1075 3
high
Electronic fuel lift pump circuit malfunction -signal voltage is too
2266 P0628 1075 4
low
2272 P0405 27 4 EGR valve position signal malfunction -signal voltage is too low
Not EGR valve pressure difference sensor circuit malfunction - High
2273 411 3
Mapped signal voltage
Not EGR valve pressure difference sensor circuit malfunction - Low
2274 411 4
Mapped signal voltage
2288 P0049 103 15 Speed of turbocharger - High speed
Not
2311 633 31 Electronic fuel injection control valve circuit malfunction
Mapped
Crankshaft position sensor malfunction - Unstable, intermittent, or
2321 P0336 190 2
incorrect signal
Camshaft position sensor malfunction -Unstable, intermittent, or
2322 P0341 723 2
incorrect signal
2345 P2579 103 10 Speed malfunction of turbocharger 1 - Abnormal update rate
Not Turbocharger turbine intake temperature malfunction - Value is
2346 2789 15
Mapped valid, but higher than engine protection temperature
Not Turbocharger compressor exhaust temperature (ECM calculated
2347 2629 15
Mapped value) malfunction - Value is valid, but higher than normal range
Not EGR valve control circuit malfunction - Low current or
2349 2791 5
Mapped open-circuit
2351 P0489 2791 4 EGR valve control circuit malfunction - Low voltage

119
 EGR valve control circuit malfunction - High current or
2353 P0489 2791 6
short-circuit to ground
EGR valve control circuit malfunction - No reaction of mechanical
2357 P0404 2791 7
system
Not
2359 411 16 Over-high EGR valve pressure difference
Mapped
Not Circuit malfunction of engine brake actuator drive output 2 -
2363 1073 4
Mapped Under-low voltage
Not Circuit malfunction of engine brake actuator drive output 2 -
2367 1073 3
Mapped Over-high voltage
Not Engine exhaust brake drive circuit malfunction -signal voltage is
2369 1074 4
Mapped too low
Not Engine exhaust brake drive circuit malfunction -signal voltage is
2371 1074 3
Mapped too high
Not Pressure difference between inlet and outlet of fuel filter -
2372 95 16
Mapped Over-high pressure difference
Exhaust pressure sensor circuit malfunction -signal voltage is too
2373 P0473 1209 3
high
Exhaust pressure sensor circuit malfunction -signal voltage is too
2374 P0472 1209 4
low
EGR temperature sensor circuit malfunction -signal voltage is too
2375 P040D 412 3
high
EGR temperature sensor circuit malfunction -signal voltage is too
2376 P040C 412 4
low
2377 P0692 647 3 Fan control circuit malfunction - Over-high voltage
VGT actuator drive circuit malfunction - Mechanic malfunction of
2387 P2262 641 7
VGT drive motor
Atmospheric temperature sensor malfunction - Unstable,
2398 P0071 171 2
intermittent, or incorrect signal
2448 P2560 111 17 Coolant level malfunction - Under-low coolant level
Not
2449 641 13 VGT actuator malfunction - Requiring calibration
Mapped
Not Turbocharger turbine intake temperature malfunction -
2451 2789 16
Mapped Temperature is higher than engine protection limit
Exhaust pressure sensor malfunction - Unstable, intermittent, or
2554 P0471 1209 2
incorrect signal
Engine intake heating circuit malfunction - Over-high voltage of
2555 P0542 729 3
intake heater signal

2556 P0541 729 4

Engine intake heating circuit malfunction - Under-low
voltage of intake heater signal
Not Circuit malfunction of auxiliary pulse width modulation driver 1-
2557 697 3
Mapped Over-high voltage
Not Circuit malfunction of auxiliary pulse width modulation driver 1-
2558 697 4
Mapped Under-low voltage
2634 P00AF 641 12 VGT controller internal electronic unit malfunction

120
 Not
2635 641 31 VGT drive circuit malfunction
Mapped
VGT drive circuit malfunction - Abnormal update rate and no
2636 U010C 641 9
communication between VGT controller and ECM
Not Blockage of after-treatment system DOC intake end by soot
2637 5018 11
Mapped particles
Not Over-high pressure difference between front and rear ends of
2639 3251 15
Mapped after-treatment system DPF and DPF overload
Not Over-high coolant temperature. Closing of EGR valve is forced to
2646 110 31
Mapped cool down coolant
Not Over-high coolant temperature. Closing of EGR valve is forced to
2659 110 31
Mapped cool down coolant
Not Circuit malfunction (diethyl ether) of start enabling device 1 -
2738 626 3
Mapped Over-high voltage
Not Circuit malfunction (diethyl ether) of start enabling device 1 -
2739 626 4
Mapped Under-low voltage
Not Over-high intake pressure of after-treatment system DPF and thick
2754 81 16
Mapped engine exhaust gas
Not
2764 1209 16 Over-high exhaust pressure
Mapped
Not
2765 2797 13 Fuel injector barcode info error
Mapped
Not NOx sensor malfunction in after-treatment system exhaust pipe -
2771 3226 9
Mapped Abnormal signal update rate
Not NOx content in after-treatment system exhaust pipe - Value is
2772 3226 15
Mapped valid, but is higher than normal range
Not NOx content in after-treatment system exhaust pipe - Value is
2773 3226 0
Mapped valid, but is lower than normal range
Not EGR pressure difference sensor malfunction - Blockage of EGR
2774 3058 31
Mapped pressure difference sensor air pipe
Not
2777 3703 31 Actuation of DPF regenerative limit switch
Mapped
Not After-treatment system DPF regenerative fuel supply frequency
2778 3481 16
Mapped malfunction
Engine idling speed malfunction - Unstable, intermittent, or
2787 P0519 188 2
incorrect speed
Not
2789 110 18 Under-low coolant temperature
Mapped
Not After-treatment system DPF regenerative fuel pressure sensor -
2881 3480 17
Mapped Under-low fuel pressure
Not High EGR temperature (beyond engine protection temperature
2961 412 15
Mapped limit)
High EGR temperature (beyond engine protection temperature
2962 P2457 412 16
limit)
Coolant temperature malfunction - Value is valid, but higher than
2963 P0217 110 15
engine protection temperature limit
121
 Not
2964 105 15 High air temperature in intake manifold
Mapped
Intake manifold air pressure signal malfunction - Unstable,
2973 P0106 102 2 intermittent, or incorrect signal or high or low intake manifold
pressure signal detected by ECM
Not After-treatment SCR reagent (urea) temperature malfunction -
2976 3361 2
Mapped Unstable, intermittent, or incorrect signal
Not After-treatment DPF outlet pressure sensor circuit malfunction -
3133 3610 3
Mapped Signal voltage is too high
Not After-treatment DPF outlet pressure sensor circuit malfunction
3134 3610 4
Mapped -signal voltage is too low
After-treatment DPF outlet pressure sensor circuit malfunction
3135 P1122 3610 2
-Unstable, intermittent, or incorrect signal
Not EGR outlet pressure sensor circuit malfunction - signal voltage is
3136 5019 3
Mapped too high
Not EGR outlet pressure sensor circuit malfunction -signal voltage is
3137 5019 4
Mapped too low
Not EGR outlet pressure sensor circuit malfunction -Unstable,
3138 5019 2
Mapped intermittent, or incorrect signal
Not
3139 3667 3 Engine cutoff stop circuit malfunction - Over-high voltage
Mapped
Not
3141 3667 4 Engine cutoff stop circuit malfunction -Under-low voltage
Mapped
Not SCR intake temperature sensor circuit malfunction -signal voltage
3142 4360 3
Mapped is too high
Not SCR intake temperature sensor circuit malfunction -signal voltage
3143 4360 4
Mapped is too low
SCR intake temperature sensor circuit malfunction - Unstable,
Not
3144 4360 2 intermittent, or incorrect signal or no change following change of
Mapped
engine working condition
Not SCR intake temperature sensor circuit malfunction - Abnormal
3145 4360 10
Mapped signal update rate
Not SCR outlet temperature sensor circuit malfunction -signal voltage
3146 4363 3
Mapped is too high
Not SCR outlet temperature sensor circuit malfunction -signal voltage
3147 4363 4
Mapped is too low
SCR outlet temperature sensor circuit malfunction - Unstable,
Not
3148 4363 2 intermittent, or incorrect signal or no change following change of
Mapped
engine working condition
Not SCR outlet temperature sensor circuit malfunction - Abnormal
3149 4363 10
Mapped signal update rate
Not
3151 4794 31 No detection of SCR system by ECM
Mapped
Not Reversed exhaust temperature sensor signal at inlet end of SCR
3163 4360 13
Mapped with other sensor signal
3164 Not 4360 15 Over-high exhaust temperature at inlet end of SCR

122
 Mapped
Not
3165 4363 0 Over-high exhaust temperature at inlet end of SCR
Mapped
Not
3167 3556 18 Under-low fuel supply volume of after-treatment system
Mapped
Not Over-high regenerative fuel supply volume of after-treatment
3168 3936 16
Mapped system DPF
Not After-treatment system DPF regenerative fuel pressure sensor
3175 3480 18
Mapped malfunction - Under-low fuel pressure
Not After-treatment system DPF regenerative fuel pressure sensor
3176 3480 16
Mapped malfunction - Over-high fuel pressure
Not After-treatment system pump gas actuator circuit malfunction
3223 3490 4
Mapped -Under-low voltage
Not After-treatment system pump gas actuator circuit malfunction
3224 3490 3
Mapped -Over-high voltage
Not No reaction or adjustment necessity of after-treatment system
3225 3490 7
Mapped pump gas actuator mechanical part
Not
3231 4360 16 Over-high after-treatment system SCR intake temperature
Mapped
Not
3235 4363 15 High after-treatment SCR outlet temperature
Mapped
Not
3236 4363 16 Over-high after-treatment SCR outlet temperature
Mapped
Not Circuit malfunction of after-treatment system SCR reagent (urea)
3237 4340 3
Mapped pipeline heater 1-Over-high voltage
Not Circuit malfunction of after-treatment system SCR reagent (urea)
3238 4340 4
Mapped pipeline heater 1-Under-low voltage
Not Circuit malfunction of after-treatment system SCR reagent (urea)
3239 4342 3
Mapped pipeline heater 2-Over-high voltage
Not Circuit malfunction of after-treatment system SCR reagent (urea)
3241 4342 4
Mapped pipeline heater 2-Under-low voltage
Engine cooling system monitoring malfunction - Under-low
3243 P0128 3060 18
temperature
Not After-treatment DPF system malfunction - No reaction or
3245 3936 7
Mapped adjustment necessity of mechanical parts
Not
3246 3556 17 Low fuel supply volume of after-treatment system
Mapped
Not
3251 4765 16 Over-high after-treatment system DOC intake temperature
Mapped
Not
3252 4765 15 High after-treatment system DOC intake temperature
Mapped
Not
3253 3242 16 Over-high after-treatment system DPF intake temperature
Mapped
Not
3254 3242 15 High after-treatment system DPF intake temperature
Mapped

123
 Not
3255 3246 16 Over-high after-treatment system DPF outlet temperature
Mapped
Not
3256 3246 15 High after-treatment system DPF outlet temperature
Mapped
Not Circuit malfunction of after-treatment system SCR reagent (urea)
3258 4340 5
Mapped heater 1 - Under-low current
Not Circuit malfunction of after-treatment system SCR reagent (urea)
3261 4342 5
Mapped heater 2 - Under-low current
Not
3299 4765 0 Over-high after-treatment system DOC intake temperature
Mapped
Not
3311 3242 0 Over-high after-treatment system DPF intake temperature
Mapped
Not
3312 3246 0 Over-high after-treatment system DPF outlet temperature
Mapped
Not
3313 4765 4 Under-low after-treatment system DOC intake temperature
Mapped
Not After-treatment system DOC intake temperature sensor circuit
3314 4765 3
Mapped malfunction - Over-high signal voltage or open-circuit
After-treatment DOC intake temperature sensor circuit malfunction
Not - SCR intake temperature sensor circuit malfunction - Unstable,
3315 4765 2
Mapped intermittent, or incorrect signal or no change following change of
engine working condition
Not After-treatment DOC intake temperature sensor circuit malfunction
3316 3242 4
Mapped -signal voltage is too low
Not After-treatment DOC intake temperature sensor circuit malfunction
3317 3242 3
Mapped -signal voltage is too high
Not After-treatment DOC intake temperature sensor circuit malfunction
3318 3242 2
Mapped -Unstable, intermittent, or incorrect signal
Not After-treatment DPF outlet temperature sensor circuit malfunction
3319 3246 3
Mapped -signal voltage is too high
Not After-treatment DPF outlet temperature sensor circuit malfunction
3321 3246 4
Mapped -signal voltage is too low
After-treatment DPF outlet temperature sensor circuit malfunction
Not - SCR intake temperature sensor circuit malfunction - Unstable,
3322 3246 2
Mapped intermittent, or incorrect signal or no change following change of
engine working condition
Not Under-low after-treatment system DPF intake temperature against
3323 3242 17
Mapped DPF continuous regenerative temperature
Not Under-low after-treatment DPF intake temperature against normal
3324 3242 18
Mapped working temperature for stable regeneration
Not Reversed signal between DOC intake temperature sensor and DPF
3325 4765 13
Mapped intake temperature sensor
Not Abnormal update rate of CAN bus accelerator position sensor
3326 91 9
Mapped signal
Not
3327 597 9 Abnormal update rate of CAN bus brake switch signal
Mapped

124
 Not
3328 191 9 Abnormal update rate of transmission output shaft speed signal
Mapped
Not
3329 1231 2 J1939 Network #3 - Unstable, intermittent, or incorrect data
Mapped
Not
3331 1235 2 J1939 Network #4 - Unstable, intermittent, or incorrect data
Mapped
Not Under-low after-treatment DPF outlet air pressure against normal
3336 3610 16
Mapped pressure range
3337 P0507 188 16 High engine idling speed
3338 P0506 188 18 Low engine idling speed
3342 P2457 4752 18 Under-low EGR cooler efficiency
3343 P1120 2630 16 Over-high engine turbocharged inter-cooler outlet temperature
Not
3348 1176 1 Under-low turbocharger compressor intake pressure
Mapped
Not
3349 597 2 Unstable, intermittent, or incorrect CAN bus brake switch signal
Mapped
Not
3361 102 10 Abnormal update rate of intake manifold pressure signal
Mapped
Not
3366 111 18 Under-low coolant level
Mapped
Not
3367 4490 9 Humidity sensor malfunction - Abnormal update rate
Mapped
Not
3368 4490 19 Humidity sensor malfunction - Received network signal error
Mapped
Not Turbocharger compressor intake temperature sensor circuit
3369 1172 9
Mapped malfunction - Abnormal update frequency
Not Turbocharger compressor intake temperature sensor circuit
3371 1172 19
Mapped malfunction - Received network data error
Not Turbocharger compressor intake pressure malfunction - Abnormal
3372 1176 9
Mapped update frequency
Not Turbocharger compressor intake pressure malfunction - Received
3373 1176 19
Mapped network data error
Not 5204
3375 31 Over-frequent DPF regeneration
Mapped 46
Not
3376 5319 31 Incomplete DPF regeneration
Mapped
5204
3377 P1121 31 Disconnected crankcase ventilation hose
48
Not EGR system malfunction - Value is valid, but less than normal
3382 3058 18
Mapped working range
Not EGR system malfunction - Value is valid, but more than normal
3383 3058 16
Mapped working range
Not Humidity sensor malfunction - Unstable, intermittent, or incorrect
3386 4490 2
Mapped signal
3387 Not 4490 3 Humidity sensor circuit malfunction - Signal voltage is too high

125
 Mapped
Not
3388 4490 4 Humidity sensor circuit malfunction -signal voltage is too low
Mapped
Not
3389 3058 10 EGR system malfunction - Abnormal EGR change rate
Mapped
Not Circuit malfunction of after-treatment system SCR reagent (urea)
3422 4344 3
Mapped pipeline heater 3 -Over-high voltage
Not Circuit malfunction of after-treatment system SCR reagent (urea)
3423 4344 4
Mapped pipeline heater 3 -Under-low voltage
Not Circuit malfunction of after-treatment system SCR reagent (urea)
3425 4344 5
Mapped pipeline heater 3 - Under-low current or open-circuit
Not Circuit malfunction of after-treatment system SCR reagent (urea)
3426 4346 3
Mapped pipeline heater 4 -Over-high voltage
Not Circuit malfunction of after-treatment system SCR reagent (urea)
3427 4346 4
Mapped pipeline heater 4 -Under-low voltage
Not Circuit malfunction of after-treatment system SCR reagent (urea)
3429 4346 5
Mapped pipeline heater 4 - Under-low current or open-circuit
Unstable, intermittent, or incorrect engine inter-cooler outlet
3478 P007B 2630 2
temperature
Not Real-time clock malfunction - Unstable, intermittent, or incorrect
3492 251 10
Mapped data
Not
3497 1761 17 Low after-treatment system SCR reagent level
Mapped
Not
3498 1761 18 Under-low after-treatment system SCR reagent level
Mapped
Not 5204 Pressure holding failure or air content of after-treatment DPF
3548 31
Mapped 81 regenerative fuel injector supply pipeline
Not Unstable, intermittent, or incorrect after-treatment system SCR
3557 3360 2
Mapped reagent (urea) flow controller signal
Not After-treatment system SCR reagent (urea) flow controller - Signal
3558 3361 3
Mapped voltage is too high
Not After-treatment system SCR reagent (urea) flow controller - signal
3559 3361 4
Mapped voltage is too low
Not After-treatment system SCR reagent (urea) flow controller - Low
3561 3361 5
Mapped current
Not 5204 After-treatment system SCR reagent (urea) heater relay - Signal
3562 3
Mapped 83 voltage is too high
Not 5204 After-treatment system SCR reagent (urea) heater relay - Signal
3563 4
Mapped 83 voltage is too high
Not 5204 After-treatment system SCR reagent (urea) heater relay - Low
3564 5
Mapped 83 current
Not 5204 After-treatment system SCR reagent (urea) supply valve -
3565 3
Mapped 82 Over-high signal voltage
Not 5204 After-treatment system SCR reagent (urea) supply valve -signal
3566 4
Mapped 82 voltage is too low

126
 Not 5204 After-treatment system SCR reagent (urea) supply valve - Low
3567 5
Mapped 82 current
Not 5204 After-treatment system SCR reagent (urea) supply valve - No
3568 7
Mapped 82 reaction or adjustment necessity of mechanical parts
Not Mechanical malfunction or adjustment necessity of after-treatment
3569 3362 7
Mapped system DPF regenerative fuel injector supply pipeline
Not After-treatment system SCR reagent (urea) pressure sensor - Signal
3571 4334 3
Mapped voltage is too high
Not After-treatment system SCR reagent (urea) pressure sensor - signal
3572 4334 4
Mapped voltage is too low
Not
3574 4334 18 Under-low pressure of after-treatment system SCR reagent (urea)
Mapped
Not
3575 4334 16 Over-high pressure of after-treatment system SCR reagent (urea)
Mapped
Not After-treatment system SCR reagent (urea) heater - Under-low
3576 3363 5
Mapped current or open-circuit
Not After-treatment system SCR reagent (urea) return valve -signal
3577 4376 3
Mapped voltage is too high
Not After-treatment system SCR reagent (urea) return valve -signal
3578 4376 4
Mapped voltage is too low
Not After-treatment system SCR reagent (urea) return valve -
3579 4376 5
Mapped Under-low current
Not After-treatment system SCR reagent (urea) pressure sensor -
3596 4334 2
Mapped Under-low current
Not After-treatment system SCR reagent (urea) flow controller -
3597 3360 9
Mapped Abnormal update rate
Not After-treatment system SCR reagent (urea) flow controller -
3598 3360 19
Mapped Received bus data error
After-treatment system SCR reagent (urea) supply device
Not
3612 3361 7 malfunction - No reaction or adjustment necessity of mechanical
Mapped
parts

127
3.4.6 Air-conditioner system
a) Air conditioner structure and its working system
Cool air
Outputted into
1 - A/C compressor
cab
2 - Evaporator assembly (including
expansion valve)
3 - Liquid reservoir
4 - Condenser

Hot and moisture

air

Hot air High pressure liquid

Outputted to
outside of cab Low pressure liquid

Low pressure gas

High pressure gas

Head-on wind

A. Compression process
The vaporized low temperature (approximate 5ºC) and low pressure (0.15MPa) refrigerant is sucked in by the
compressor 1 from the evaporator 2 and is compressed to high temperature (70~80ºC) and high pressure
(1.3~1.5MPa) gas refrigerant before being conveyed to the condenser 4. This process consumes mechanical
energy.

B. Condensation process
After being conveyed into the condenser 4, the high temperature and high pressure gas refrigerant is forced for
heat dissipation to gradually become high temperature and high pressure liquid refrigerant (approximate 50ºC
and 1.3~1.5MPa) and then is conveyed into the fluid reservoir 3.

C. Throttling and expansion process

After being dried and filtered by fluid reservoir 3, the high temperature and high pressure liquid refrigerant is
conveyed under the action of air compressor to the evaporator assembly 2 (including expansion valve) and is

128
throttled and expanded by the expansion valve to become low temperature (approximate -5º) and low pressure
(0.15MPa) liquid. This process features the sharp reduction of pressure and temperature.

D. Evaporation process
The low temperature and low pressure vaporous refrigerant is vaporized by absorbing heat while flowing
through the evaporator 2 to cool down the ambient air within the machine. The heat absorbed and vaporized
refrigerant is sucked in by the compressor 1 once again. The above-mentioned processes are repeated
continuously to cool down the air within the machine.
Through the continuous running of the compressor, the above refrigerating process is repeated continuously to
carry away the internal heat of the cab continuously by the refrigerant within the evaporator to complete the
cooling and dehumidification of the whole machine.
E. Heating
The heating is achieved by utilizing the circulating coolant of the engine. When the heating is required, open
the hot water valve and turn on the A/C fan speed switch so that the engine coolant is circulated continuously
through radiator to blow out hot air continuously and realize the heating of air within the cab.

The electronic control principle is shown in the figure.

The symbols in the diagram denote:

F - 20A fuse ST - Temperature controller M1 - Evaporator fan motor
M2-1,M2-2 - Condenser fan motor YC - Compressor electromagnetic clutch Rt - Temperature sensor
R - Speed regulation resistor LED - Voltage type light-emitting diode (indicator lamp)
b) Overview of control panel
The control panel is one important part of full-automatic A/C control system.

129
c) Precautionary Points
● 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.
130
● Before running the air conditioner for heating performance, you should firstly let the engine
run for a while. 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.
d) Maintenance to the air conditioner
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.
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 signs
△
Cooling of cracks or damages. .
system Check that if each joint leaks or
Pipes △
not.
Check that if each clamp is
△
loose or damage or not.
Replace the cooling oil ( please
Cooling oil use the oil with correct brand as △
stated in the manual.).
Compressor Check the tension and wear of
Belt △
belt.
Compressor Check the bracket is reliable or
△
bracket not.
Check to see if it is clean and
Condenser core △
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 get
△
bracket loose or not.
Evaporator
Check that it is damaged or not. △
bracket
Inlet of cycling Check that if the ventilation is
Evaporator △
wind good or not.
Check to see if the motor can
Blow motor △
work properly.

131
 Coupler Check the coupler is ok or not. △
Electromagne-tic Check that if it can work
Electrical △
clutch properly.
system
Check that if it can work
Control switch △
properly.

Instructions for Air Conditioning Evaporator Filter Maintenance

Structure of evaporator

1-Fresh air filter screen 860152446 AX GAY 40097

2-Internal circulation filter screen 860152447 AX GAY
40098

Recommendations on filter maintenance:

The fresh air filter screen shall be cleaned once a week and replaced every two months; the internal
circulation filter screen shall be checked and cleaned every half month and replaced every three months.
Based on the actual working conditions, it is recommended to increase the frequency of cleaning and
replacement when under dusty working conditions.
Instructions for filter replacement:
1. Steps to clean and replace fresh air filter screen
① open the upper access port on the air conditioning cover

132
② Press the buckle and take out the fixing plate and the
screen of fresh air filter

③ Remove the filter screen to clean up dust or replace it

④ Put the filter screen and fixing plate back into the
clamping groove

⑤ Close the access port on the air conditioning cover

2. Clean or replace the internal circulation filter screen

① Open the access port on the side of air conditioning
cover and take out the internal circulation filter screen
buckle plate

133
② Pull out the filter screen through the paper tape on the
internal circulation filter screen

③ After cleaning or replacing the filter screen, insert the

filter screen into the evaporator again
④ Install the buckle plate of the internal circulation filter
screen and cover the access port on the side of the air
conditioning cover

Note: The tightness of the port clip of the

air-conditioning cover can be adjusted by rotating the
rubber head

134
3.4.7 Automatic fire-extinguishing system
3.4.7.1 System overview
Model: MUSTER II- LHD
This system adopts the Australian JSC special foam fire-extinguishing system, with the total
capacity of the agent tank at 110L, including 880ml aqueous film forming foam (AFFF) agent.
This system is functional within the 0ºC~+60ºC temperature range. LW1200KN onboard
automatic fire-extinguishing system is composed of agent storage, spray device, starter device,
and system detection parts.
Agent storage: Foam agent tank and foam agent tank bracket.
Spray device: Composed of spray hose, spray nozzle, and control valve subassembly.
Starter device: Remote starter.
System detection: Control panel and temperature-sensing cable. The work principle is shown in
figure below:

It features easy operations, quick reaction speed, timely fire-extinguishing, high storage volume
and extensive coverage of fire-extinguishing agent, high operation reliability, advanced
technology, and high economy and rationality. Regardless of the driving location of the vehicle, it
can effectively extinguish and control the fire and achieve outstanding performance especially for
the preliminary stage of fire accident in event of any fire accident on machine.
This system covers all dangerous protection zones of the loader. The main protection zones of
this system include engine, hydraulic pump, and starter motor. This system is designed with one
110L foam agent tank and 15 spray nozzles, of which 10 nozzles are distributed in the engine
zone, 4 nozzles are used to protect hydraulic pump and high pressure hoses, and 1 nozzle is used

135
to protect the starter motor. With rapid start function and 80s spray time, this system can achieve
outstanding performance to extinguish initial stage of fire accident. The temperature of the
turbocharger on the engine is really high and, in some cases, can even reach 557ºC. Once the high
pressure hydraulic oil sprayed from hydraulic pump or high pressure hoses is sprayed onto the
exhaust pipe, it will easily result in fire accident. In addition, the leakage of hydraulic oil tank and
diesel tank can also easily result in fire accident. Therefore, the above-mentioned parts are the
main protection zones. The main parts of the system are shown in figure below:

An innovative fire-extinguishing
system

Welcome to an all-new and innovative

fire-extinguishing system

3.4.7.2 Working Principle of System

This system adopts two modes, namely manual start and automatic start.
a) Automatic start.
In event of any fire accident, a full-monitoring fire sensing wire system MusterWire LHD (Wire
type temperature-sensing) is provided via cylinder valve. When the temperature reaches 180ºC,
the resistance of the terminal resistor changes along with the variation of environmental
temperature to guarantee sensitivity and stability. The warning panel within the cab issues a
warning tone to indicate the occurrence of fire accident. After a time lag, the system
automatically sprays the fire-extinguishing agent. After the triggering of the system is confirmed
and the fire is extinguished, press and hold the RESET button on the control box to cancel the
warning tone.

136
 MUSTER II MUSTERWIRE LHD electric-driven system

Automatic MUSTER II monitoring

system Warning
start

S
Double-core silicon cable
pray Including
remote actuator

MUSTE WIRE LHD detection

Resistor
connector
Stop procedure

MUSTER II cylinder
composition

MUSTER II remote
actuator

b) Manual start
The manual start is a full-mechanical start mode. A mechanical starter button is installed at an
easily accessible external position of the machine. Upon the confirmation of any fire accident, the
driver can directly press this button (Unplug the pin and press the starter) to trigger the starter and
thus open the agent tank of the fire-extinguishing system to extinguish the fire in the zone.
Another manual start button is the FIRE button on the control panel. Upon the confirmation of
any fire accident, the driver can directly press this button to directly start the whole
fire-extinguishing system.

MUSTER II MUSTERWIRE LHD electric-driven system

Automatic MUSTER II monitoring

system Warning
start

S Double-core silicon
Including
pray cable remote actuator

MUSTE WIRE LHD detection

Stop procedure

MUSTER II cylinder
composition

MUSTER II remote
actuator
Operation method for start of system:
1) In event of any fire accident, unplug the locking pin and press the manual starter button (Near the rear
counterweight of the machine). The system can start directly without any time lag. An alternative method

137
 is to press the FIRE button on the control panel of cab.
2) Upon receipt of the starter signal, the control panel transmits the signal to the electric valve subassembly.
3) The control panel drives the electric valve on the foam agent tank to open the tank body and spray the
agent.
3.4.7.3 Operation instruction
In event of any fire accident on the loader, for the consideration of own safety, the driver shall
stop the machine as soon as possible, stop the engine, press the switch of fire-extinguishing
system, and rapidly escape from the machine. Check the machine after the safety is confirmed. If
the fire is too fierce to be extinguished, keep away from the loader as far as possible and wait for
the arrival of the fire truck.
Emergency countermeasure in event of machine fire:
a) Park the vehicle in a safe place and stop the engine.
(i) In the initial stage of a mild fire accident, the system can react rapidly to extinguish the fire.
(ii) After the use of fire-extinguishing system, the residual heat from the fire will likely cause fire
again. Therefore, ensure to assign someone to hold a portable fire-extinguisher and observe in a
safe place nearby, until it’s confirmed that the fire is completely extinguished.
Treatment measure after extinguishing of fire:
Check the system as soon as possible and check and analyze the spray cause of the
fire-extinguishing system. Replace the damaged parts.
The table below lists the parts that must be replaced after the spray of system. The other parts
shall be replaced depending on the checking result.

No. Name Volume Note

Replace the agent upon
1 Foam agent 110L
expiration of one year.

3.4.7.4 Checking and maintenance procedure

To guarantee the operation safety and reliability of the automatic fire-extinguishing system on
your loader, ensure to check periodically once every half year and maintain the checking records.

138
3.5 Trouble and shootings
3.5.1 Power System
Fault Feature Fault Causes
1.The engine can’t be 1. Engine has trouble.
started. 2. The control lever has not been put at
neutral gear.
3.The fuse is burnt broken and the wire
is loose.
Engine keeps running Gears not being engaged.
but the machine could Hand brake is not released.
not move.
Oil pressure of transmission system t is
too low.
Oil level of the speeder is too low.
There is some thing wrong with the
torque converter.
The clutch or transmission part of the
transmission gets broken.
Oil pressure of There is something wrong with main
gear-shifting system safety valve.
is too low. Serious oil leakage from clutch oil
sealing.
Oil leakage from oil pipelines.
Failure with oil pump.
Oil filters being blocked.
Gears or certain gear Gear-locking not being released.
could not be engaged Low oil pressure for gear-shifting
system.
Oil pipelines being blocked.
Serious oil leakage from oil sealing
ring.
Hand brake not being released.
Low braking pressure makes hand
brake be locked.
Only have Gear I and The wire connection for the sensor of
II, and no Gear III and speeder tachometer gets loose.
IV. The speeder tachometer being broken.
Something wrong with gear-shifting
control handle or its electrical switch.
139
Troubleshooting
1. Refer to the engine manual.
2. Put the control lever at neutral gear.
3.Replace the fuse and engage the wire.
Engage the gear or check if the gear
engaged is correct or not.
Release the hand brake when air
pressure being up to regulated value.
Refill with new oil.
Please see Trouble No. 3.
Change the torque converter.
Check and repair the transmission.
Check and repair the control valve of
gear-shifting.
Replace the new sealing ring and
sealing seat.
Fasten the fittings for pipelines.
Replace the oil pump.
Replace the oil filter.
Operate the gear-shifting in correct
procedures.
See Trouble No. 3.
Clean or replace oil pipelines.
See Trouble No. 3.
Release the hand brake.
Please refer to Braking System.
Check the wires connection.
Replace the sensor.
Replace the control handle or its
electrical switch.
Not enough driving Not sufficient oil level or oil leakage Refill with new oil after checking and
power for transmission system. repairing.
Too low oil pressure for gear-shifting See Trouble No. 3.
system. Check and Adjust.
Improper adjustment for braking See Trouble No. 7.
system. Braking wrench or hand brake
not being completely released. Disassembly, clean and replace the
damaged disc.
Torque converter oil temperature being
too high. Check and repair diesel engine.
Improper clamping for driving and
driven discs of the clutch.
Diesel engine working abnormally.
Torque converter and Insufficient oil level or too much oil for As instructed, check oil level or make
transmission getting transmission system. adjustment.
over hot. Clutch getting sliding. Check and repair the clutch. And adjust
The oil getting dirt or deteriorated. gear-shifting pressure.

Water tank or radiator getting blocked Change the oil.

or broken. Make cleaning at regular interval, and
Too long continuous working time or replace it when it gets broken.
the machine working overloaded. Stop machine temporarily to have
machine temperature cool down. Avoid
being overloaded.
Disordered The gear-shifting control handle getting Check and repair or replace the
gear-shifting broken. gear-shifting control handle.
Electrical switch for gear-shifting being Change the electrical switch.
broken .

140
3.5.2 Steering System

Fault Feature Fault Causes Troubleshooting

1.Steering Pump internal leakage 1.Repair or replace

2.Filter Restriction 2.Clean or replace
Heavy steering
3.Diverter damage 3.Repair or replace
4.Flow amplification valve damage 4.Repair or replace
1.Flow amplification valve damage 1.Clean or replace relief valve
2.Steering Pump internal leakage 2.Repair or replace
3.Filter Restriction 3.Clean or replace
Steering slow 4.Relief valve low pressure 4.Clean ,adjust or replace
5.Diverter damage 5.Repair or replace
6.Steering cylinder damage 6.Repair or replace
7. Pilot pump damage 7.Repair or replace
1. Repair or replace
1.Flow amplification valve damage
2. Clean ,adjust or replace
2.Relief valve low pressure
3.Repair or replace
No steering 3. Pilot pump or steering pump damage
4.Repair or replace
4.Steering cylinder damage
5. Repair or replace
6.Diverter deadbolt fracture
6.Repair or replace

3.5.3 Hydraulic System

Fault Feature Fault Causes Troubleshooting
Cylinder seals damaged Replace
Multiple directional control valves internal Repair or replace
Lift or bucket Inability leakage Repair or replace
Working pump Internal leakage Clean or replace
Relief valve low pressure
Lift cylinder piston seal damage Replace
Multiple directional control valves internal Repair or replace
Movable arm sink leakage Repair or replace
Lift Cylinder’s Large chamber back oil check
valve leakage
Bucket cylinder seal damage Replace
Bucket automatic Bucket cylinder overload valve low pressure Clean or replace
rotation Multiple directional control valves internal Repair or replace
leakage

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3.5.4 Electrical System
Trouble Symptom Causes Remedies
1. After the key switch was The pilot wire connection for Fasten the pilot wire.
turned to “Start-up”, the engine starting –up electrical circuit gets Polish the contact point or
motor could not run. loose or disconnected. replace the electrical relay.
Poor electrical contact with starting Replace the solenoid switch.
relay, or wire coil gets burnt.
Put the gear in “Neutral”
Some problems with the solenoid position.
valve of the starting motor.
Replace the fuse.
The gear being not in “Neutral”
position. Replace or make repair.
Fuse getting broken. Recharge the battery.
The wire coil for starting motor
being broken.
Seriously insufficient electrolyte
with the battery.
2.Wrong display of gauges The wire connection gets loose or Fasten the wire connection.
disconnected. Replace the sensor.
The sensor being broken. Replace the gauges.
Gauges being broken.
3.Warning buzzer keeps The warning buzzer for monitoring Please see the instruction
sounding. gauge keeps sounding. manual of the monitoring
gauge.
4.The bulbs don’t light. The fuse is broken. Replace the fuse.
The bulb is broken. Change the bulb.
The wire connection gets Fasten the wire connection.
disconnected.
5.The generator doesn’t work, The wire connection for the engine Retighten the wire connection.
or its current is too little or too gets loose. Adjust the tension of the pulley
much. The pulley belt gets too loose. belt.
The regulator or the generator Replace the generator.
being broken.
3.5.5 Braking System

Fault Feature Fault Causes Troubleshooting

Air ingress in brake oil line Bleed air

Damage of brake valve Replace
1. Low foot braking force
Excessive wear of brake pad Replace

2. Insufficient parking Failure of parking brake cylinder return spring Replace

brake force Oil on parking brake plate Clean

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4. Transportation, Storage And Protection

4.1 Safe Transportation

4.1.1 Load Or Unload The Machine
Before loading the machine onto a carrier, clear the ice or snow from the carrier to avoid of
slippery.
If the loader should be transported to a cold area, ensure that its cooling system has good
anti-freezing ability.
Wedge the towing vehicle or locomotive before lifting the loader.
There is always a potential risk of danger during loading and unloading the machine, so special
care should be given. During loading and unloading the machine,
run the engine at low speed.
Moving the machine should be done on the hard ground, and the
machine should be kept at a safe distance from road side.
When loading or unloading the machine to or from a carrier
vehicle, you must be sure that the wheels of vehicles are securely
positioned, not moving. And put a wedge under the slope plate.

Use those slope plates which have enough strength, length

and width, so that it can be sure the slope plates are strong
and safe enough to load or unload the machine. The angle
between the slope plates and ground should not be larger than
15. And the gap between slope plates should be in
accordance with the wheel base of the machine to be loaded
or unloaded.

Make sure the slope plates are securely fastened and have same height.
Make sure the slope plates are free of grease, oil, ice and other loosing material. And also remove
away the dirt from the machine wheels.
Never make steering on the slope plates. But if the steering has to be done, at first get the
machine off from the slope plates. After steering, you can drive the machine onto the slope plates
again.
Perform following jobs after loading the machine:

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After loading the loader, engage the frame steering locking device to place front and rear frames
to appropriate position.
Drop the bucket down on the deck of carrier and put the gear-shift lever at neutral position.
Engage the parking brake.
Rotate the engine starter key switch to OFF to stop the engine and withdraw the key.
Move all hydraulic controlling lever to release pressure.
Lock the door of cab and take all safety measures.
Wedge all wheels of the loader.
Prepare enough ropes to prevent the loader from skidding during transporting.
Cover the exhausting nozzle.
4.1.2 Hoist or put down the machine
● When the loader has to be moved into a ship or other place, please use the lifting lugs which
is located on front and rear frame.
● The improper hoisting to the loader can result injury and damage to people and the machine,
therefore before hoisting the loader, please lock the frame to prevent the machine from
turning.
● When hoisting the loader, the rope only can pass through the lifting lugs.
● Please select those ropes and lifting devices which have enough solidity. Keep the loader
horizontal in the hoisting process. The girder of hoisting device must has enough width to
avoid colliding with the loader.
● Take the length, width, height and weight into consideration.
Prevent hydraulic pipes from being damaged.

CAUTION When lifting the loader, make sure that there is nobody standing under
the lifted machine.

4.1.3 Transporting The Loader On A Public Road

● When transporting this loader, please obey with those laws which regulate the weight, height,
width and length.
● Determine the transporting route with regarding to the weight, height, width and length of the
machine.
● Before passing through a bridge or a building, please ensure in advance that its strength can
support the weight of the machine. Obey with traffic rules when driving on a public road.

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● If the loader has to be dismantled for the purpose of being transported, please consult with
manufacturer or its agent.
4.1.4 Long-Distance Transfer Operation
Please notice the following issues during the long-distance high-speed transfer operation of
the loader:
 The driving speed shall not exceed 35km/h and the unloaded operation mode shall be taken.
Please notice the obstacles buried beneath the snow.
 Once every 45min continuous operation, rest for 15min to cool down the tires, drive system,
and brake system, in order to guarantee the normal operations of the system and avoid
reducing the life of the equipment.
 After the machine is stopped, keep all personnel away from the tires to safeguard the
personnel. In addition, it’s prohibited to touch the high temperature parts such as drive axle,
transmission, engine, in order to prevent scalding.
 Before restarting the operation, check the tires, drive system (Transmission, drive shaft, and
drive axle), and brake system. Upon detection of any damage, stop the operation and check
and repair before restarting operation.

4.2 Storage And Protection

4.2.1 Daily Parking
● Park the loader on a place, with its bucket resting on the ground horizontally. Try your best to
park the loader on a dry place, and avoid of moisture. If the machine has to be kept outside, a
shelter cloth must be used to cover it.
● Turn the ignition switch to “OFF” position, take out the key and keep it in a safe place.
● After the ignition key being pulled out. Operate slowly the control levers of the working
devices for 2 to 3 times, so as to release the remained pressure inside the cylinders and hoses,
and then leave them at their neutral positions.
● Place the gear-shifting lever at neutral position, and the parking brake must be engaged.
● Lock the front and rear chassis with the lock bar.
● Lock all the parts that have locking key. Pull out the keys and keep them safely.
● In winter or cold weather (when the ambient temperature below 0C ), anti-freezing addition
must be applied into the cooling water. Cooling water must be drained out completely for
those machines without anti-freezing addition in the cooling system, so that the engine can

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 be protected from being cracked by ice.
4.2.2 Long Time Storage
The storing period for the machine includes short-term storing and long-term storing. For
short-term, the storing period should not exceed two months. Over more than two months must
be taken as a long-term storing. The parking place for storing should be sheltered, ventilated and
dry and without any corrosive substances or gas.
Within one month:
Except those mentioned measures in the “Daily Parking”, the following procedures must be
noted:
● Start and drive the machine every week, and operate its working device to let it be ready for
work at any time.
Over one month:
Except those mentioned in “Daily Parking”, the following procedures must also be noted.
● Check all the oil levels and lubricating points to see if the oil being in the level as required.
● Considering the raining season, try your best to park the machine on a hard ground of a
higher place.
● The battery must be removed.
● Although the machine is indoor stored, if it is too hot or damp, the battery must be
dismounted to get it stored in a better place, and charge it once a week.
● Parts which moisture can easily get in (such as: ventilating device and air filter) should be
covered with a clothes.
● The inflating pressure of the tyres must be standard. Check the wear and damage status of the
tyres.
● In order to release the heavy load on the tyres, it is better to jack up the machine to let it be in
floating state.
● If the loader can’t not be jacked up, the inflation of the tyres must be checked every two
weeks to ensure the tyre pressure.
● Restore the machine into ready-work condition each week. Start the engine and let it warm
up, and then move the machine back and forth a little bit. If you think it is necessary to
activate the working device, before you do it, the grease on the cylinder rods must be cleaned
away. And after such attempt, apply grease to cylinder rods again.
4.2.3 After A Long Time Storage
● Move away all the protecting coverings.
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● Clean away the anti-rust grease on the exposed parts.
● Drain out the oil that is inside the engine, transmission and driving axle, and then wash them
and refill with new oil.
● Drain out the debris and water from hydraulic oil tank and fuel tank.
● Dismantle the pneumatic cylinder of the engine, and lubricate the valve and rocker shaft.
And check the performance of each valve.
● Fill the radiator with cooling water to the standard level.
● Charge the battery again and connect it to the wires.
● Adjust the inflation pressure of the tyres in accordance with the road condition.
● Follow the checking procedures before operating.
● Warm up the engine.

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