XC8-C2570 Manual de Servicio

Service Manual
XC8-C2570
Backhoe Loader
Xuzhou Construction Machinery Group Co., Ltd.
Version 1.0
04.2024 Page 1 / 630

BHL XC8-C2570 Service Manual
04.2024 Page 1 / 630

Introduction
This Service Manual is designed for the benefit of XCMG Distributor

Service Engineers or authorized specialists who are receiving, or
have received, training by XCMG Technical Training Department.
These personal should have s sound knowledge of workshop, safe

procedures, and general techniques associated with the maintenance
and repair of backhoe loaders.
The configuration, structural principles and maintenance information

provided in this manual may change at any time without prior notice.
04.2024 Page 2 / 630

Table of Content
0 Table of Content...........................................................................................................
1 Foreword.......................................................................................................................
1.1 How to read and use this manual..........................................................................
1.2 Lifting instructions.................................................................................................
2 Safety............................................................................................................................
2.1 Safety signs..........................................................................................................
2.2 Safety precautions................................................................................................
2.3 Daily safety...........................................................................................................
2.4 Operation safety....................................................................................................
2.5 Maintenance safety...............................................................................................
3 General information...................................................................................................
3.1 Machinery structure.............................................................................................
3.2 Main technical parameters of machinery............................................................
3.2.1 Overall dimensions...............................................................................14
3.2.2 Steering dimensions.............................................................................14
3.2.3 Loader and backhoe dimensions..........................................................15
3.2.4 Performance.........................................................................................16
3.2.4.1 Weights...............................................................................................................
3.2.4.2 Engine.................................................................................................................
3.2.4.3 Driving performance............................................................................................
3.2.4.4 Hydraulic performance........................................................................................
3.3 Fluid recommended and fill capacity...................................................................
3.4 19
3.5 Bolt tightening torques........................................................................................
4 Faults and Troubleshooting......................................................................................

4.1 Power system.....................................................................................................
4.2 Transmission system..........................................................................................
4.3 Front axle............................................................................................................
4.4 Rear axle.............................................................................................................
4.5 Hydraulic system.................................................................................................
4.6 Brake system......................................................................................................
4.7 Electric system....................................................................................................
4.8 Air condition system............................................................................................
5 Power system.............................................................................................................
6 Transmission system................................................................................................
7 Hydraulic system.......................................................................................................
1 / 630
7.1 液压系统原理......................................................................................................
7.2 工作液压系统......................................................................................................
7.3 转向液压系统......................................................................................................
8 Braking system..........................................................................................................
8.1 Service brake......................................................................................................
8.2 Parking brake......................................................................................................
9 Work devices..............................................................................................................
9.1 Loading work devices..........................................................................................
9.1.1 基本组成............................................................................................... 51
9.1.2 装载端油缸的拆卸与更换......................................................................51
9.1.3 装载端的润滑........................................................................................52
9.1.4 安全杆的拆卸与安装..............................................................................54
9.2 Backhoe work devices........................................................................................
9.2.1 基本组成............................................................................................... 56
9.2.2 挖臂的拆卸与更换.................................................................................56
9.2.3 斗杆的拆卸与更换.................................................................................58
9.2.4 回转体的拆卸与更换..............................................................................60
9.2.5 挖掘工作装置润滑点..............................................................................61
10 Electric system...........................................................................................................
11 Cab..............................................................................................................................
11.1 Controls in cab....................................................................................................
11.1.1 General overview..................................................................................65
11.1.2 Front Control Panel...............................................................................66
11.1.2.1 Front Display Screen...........................................................................................
11.1.2.2 Front Control Console.........................................................................................
11.1.3 Side Control Panel................................................................................69
11.1.3.1 Side Display Screen............................................................................................
11.1.3.2 Side Control Console..........................................................................................
11.1.3.3 Right Rocker Switch Panel..................................................................................
11.1.3.4 Power Socket......................................................................................................
11.1.4 Air conditioning control panel................................................................79
11.1.5 Travelling Control Zone.........................................................................81
11.1.5.1 Steering Column..................................................................................................
11.1.5.2 Gear Lever..........................................................................................................
11.1.5.3 Light Control Lever..............................................................................................
11.1.5.4 Accelerator Pedal................................................................................................
11.1.5.5 Brake Pedals.......................................................................................................
11.1.5.6 Handbrake lever..................................................................................................
11.1.5.7 reading lamp.......................................................................................................
11.1.5.8 Radio Control Panel............................................................................................
11.1.6 Operation control levers........................................................................89
11.1.6.1 Loader Operation Control lever...........................................................................
2 / 630
11.1.6.2 Backhoe Control levers.......................................................................................
11.1.6.3 Stabilizer Control Levers.....................................................................................
11.1.6.4 Hand throttle Knob..............................................................................................
11.2 Removal and replacement of side console.........................................................
11.3 Removal and replacement of front console.........................................................
12 Air condition system...............................................................................................

12.1 General instruction............................................................................................
12.1.1 General instruction..............................................................................100
12.1.2 Technical specification........................................................................100
12.1.3 Working principle................................................................................100
13 Hood..........................................................................................................................
13.1 Removal and replacement of hood...................................................................
3 / 630
Preface
This Maintenance Manual is prepared to help maintenance
personnel understand the structural principle and functions of
each system (component) of the machine, guide them to
correctly diagnose and eliminate machine faults according to the
fault symptoms of the machine, and provide maintenance
standards for the machine under general and special
environmental conditions, so as to improve the repair quality
and level.
This Maintenance Manual consists of the following chapters:

Foreword includes how to read and use this manual and lifting
instructions;
Safety mainly includes safety signs, safety precautions, daily safety,
operation safety and maintenance safety;
General Provisions includes the overall structure of the machine, liquid
material and volume table, tightening torque of hydraulic pipelines, standard
tightening torque of bolts and nuts, and tightening torque of mounting bolts of
split flanges;
Causes and Common Troubleshooting Methods of General Faults
includes the cause analysis and common troubleshooting methods of
1-1
common faults in power system, powertrain system, hydraulic system,
electrical system, air conditioning system and other systems.
Power System briefly outlines the engine structure and functions, engine
testing and adjustment, radiator installation and removal sequence to provide
technical reference for diagnosing and troubleshooting machine faults;
Powertrain System mainly introduces the structural composition,
functional principle and maintenance precautions of transmission system;
Hydraulic System mainly provides the machine operator with knowledge
and precautions for testing and adjustment, removal and installation as well
as maintenance of hydraulic system or components;
Brake System mainly describes the composition, working principle and
commissioning method of brake system;
Operating Devices mainly provides the machine operator with knowledge
and precautions for testing and adjustment, removal and installation as well
as maintenance of loading and excavating devices.
Electrical System mainly introduces the electrical system, circuit,
monitoring system and switch as well as troubleshooting;
1-2
Cab System mainly introduces the instruments and control elements in the cab, as
well as removal and installation methods and precautions.
Air Conditioning System mainly introduces the working principle, operation and
use, installation, commissioning and maintenance of air conditioning system.
Covering Parts System mainly includes the removal and installation of engine
hood.
Mistakes and errors in this Manual are inevitable. We sincerely ask all
peer experts and readers to raise criticism and correction, and we will
make improvement when reprinting.
1-1
1.1 How to Read and Use this Manual
1. Binding method: bind in the correct order according to the page number at the
bottom of each page;
2. The following examples indicate how to read the page numbers of this Manual.
05 —- 06
05, Chapter Page S/N
Chapter No. (05, Power System)
3. Supplementary page number: It is indicated by hyphen (I) and supplementary

page number after the page S/N. Bind according to the following example.
04-05
04-05-01
04-05-02
04-06
4. Modified version No.
When the manual is modified, the version number (1, 2, 3 ...) is indicated at the
bottom of the back cover page.
5. Any supplement or change information will be transmitted to XCMG dealer, and
you should ask for the latest technical change data from the dealer before starting
work.
6. Symbols
The important safety and quality control parts of this Maintenance Manual are
marked with symbols in Table 01-01:
1-2
Table 01-01: Symbols
Symb
Item Notes
ol
Special safety preventive measures must be taken at
Safety
work.
Special technical preventive measures or the

Caution preventive measures of other maintenance standards
must be taken at work.
Weight of part or system.

Weight Attention must be paid to the selection of lifting ropes
and the determination of operating posture.
Tighten During assembly, special attention shall be paid to the

Torque place where tightening torque is used.
Application Places where sealant or lubricating oil is required.
Places where oil, water or fuel need to be added and

Oil, water
their capacities.
Places where oil or water must be drained and their

Emission
discharge amount.
1.2 Lifting Instructions
Heavy parts (25kg or above) must be lifted by crane, etc. In the section of
disassembly and assembly, each part weighing 25kg or above is clearly marked with
symbols.
Lifting
If the parts cannot be smoothly moved away from the machine with hooks, check as
follows:
1. Check whether all fastening bolts connected with relevant parts are removed.
2. Check whether there are other parts that interfere with the parts to be removed.
Steel wire rope
1. According to the weight of lifted parts, select appropriate steel wire ropes with
reference to the following table:
Steel Wire Rope (Standard S-shaped Steel Wire Rope)
1-3
Diameter of steel wire rope (mm) Allowable load (t)
10 1.0
14 2.2
16 2.8
18 3.6
20 4.4
30 10.0
40 18.0
50 28.0
60 40.0
Note: The allowable load in the above table is estimated according to

1/6~1/7 of the breaking strength of steel wire rope.
2. Hang the steel wire rope in the middle of the hook. When hanging, if the steel
wire rope is close to the hook edge, it will slide out of the hook and cause serious
safety accidents. The strength in the middle of the hook is the highest.
3. Do not lift the parts with only one steel wire rope, but use two or more steel wire
ropes to symmetrically wind the parts.
When a steel wire rope is used to lift parts, the parts may rotate, and the steel
wire rope may be twisted loose or slide away from the original position of the wound
parts, resulting in serious accidents.
4. It is not allowed to hang heavy objects at a large angle between the steel wire
rope and the hook. When two or more steel wire ropes are used for lifting heavy
objects, the force borne by each steel wire rope increases with the increase of the
lifting angle. The following figure shows the variation of allowable load at different
lifting angles when two steel wire ropes are used for lifting. The allowable lifting weight
of each steel wire rope is 1,000kg. When the two steel wire ropes are used to lift a
heavy object vertically, the total weight that can be lifted can reach 2,000kg. However,
when two steel wire ropes form a lifting angle of 120°, only 1,000kg can be lifted; from
another perspective, if two steel wire ropes are used to lift a 2,000kg heavy object at a
lifting angle of 150°, the maximum force borne by each steel wire rope is 4,000kg.
1-4
1-5
Safety
Safety signs
There are many safety signs in this Manual and on the machine. At the beginning of
each safety sign, there is an obvious warning word with the following meanings:
Danger
It indicates an extremely dangerous condition which, if proper preventive measures
are not taken, is highly likely to cause death or permanent injury to you or others.
Warning
It indicates danger. If proper preventive measures are not taken, there is a high risk of
injury or death to you or others.
Caution
It indicates to pay attention to operation safety, and may also remind you that unsafe
operation may hurt people or damage the machine.
2.2 Safety precautions

All engineering machinery may be dangerous. When the machine is correctly operated
and maintained, the backhoe loader is a safe machine. However, careless operation or
negligent maintenance will cause danger to you (driver) and others.
Do not use the machine until you are sure that you can operate it.
Before starting the machine, make sure that you and others around are safe.
If you are uncertain about the machine and its operation, be sure to ask someone who
understands it. Don't take it for granted!
Remember!
– Be careful
– Always be alert
– Always be safe
In addition to the safety warnings given on the following pages, there are some special
warnings in other chapters of this Manual. This chapter gives safety rules for daily use
and operation of the machine and maintenance practices.
Note: This chapter contains some operational safety information. However, remember
that whenever you operate a machine or controller, you are the actual operator.
1-6
Therefore, be sure to read and understand the information given in this Operation
Manual before operating the machine or controller.
2.3 Daily Safety
Warning
Labels
The labels on the machine warn you of specific hazards. Failure to follow the safety
guidelines on the labels may result in injury.
Each label is affixed near a potentially hazardous part of the machine. Make sure that
the required warning labels are on the replaced components.
Keep all labels legible. Replace illegible missing labels with new ones. Each label is
printed with a part number, which is used to purchase new labels from the XCMG
dealer.
Warning
Keep alert
Always be careful and vigilant when working on the machine to avoid danger.
Warning
Clothing
Improper clothing may cause casualties. Loose clothing may be twisted into the
machine. Be sure to wear protective clothing when operating the machine, such as
safety helmets, safety shoes, safety goggles, overalls, ear protectors and industrial
gloves, tighten cuffs, do not wear tie or scarf, and please roll up long hair.
Warning
Lifting equipment
The use of faulty lifting equipment may cause injury. Ensure that the lifting equipment
is in good condition, ensure that the slings comply with local regulations and are
suitable for the lifting operation to be carried out, and ensure that the lifting capacity of
the lifting equipment meets the work requirements.
Warning
Accessories at height
The lifted accessories may fall and hit people. Do not walk and work under the lifted
accessories unless it is safely supported.
1-7
2.4 Operation Safety
Warning
Status of machine
A faulty machine may hurt people. Do not use a machine with faults or missing parts.
Ensure that the machine is maintained according to the requirements of this Manual
before use.
Warning
Control lever
Pulling the control lever from outside the cab will cause serious personal injury or
death to you or others. Do seat correctly in the cab before using the control lever.
Warning
Limits of the machine
Using the machine beyond its design limits can damage the machine and is also very
dangerous. Do not operate beyond the limits of the machine, and do not make
unauthorized modifications to improve machine performance
Warning
Engine/Control fault
In case of engine or control fault, stop the machine as soon as possible. Do not
operate the machine before the fault is solved.
Warning
Engine
There are rotating parts in the engine. Do not open the hood when the engine is
running, and do not leave the hood open when using the machine.
Warning
Entry/Exit
It is allowed to enter or exit the cab or cockpit only where there are handrails and
pedals. When entering or exiting the machine, face the machine and ensure that the
pedals, handrails and soles of your shoes are clean and dry. Do not jump off the
machine, do not use the control lever as a handrail, and be sure to use the handrail.
Warning
Exhaust gas
1-8
Breathing in machine exhaust is harmful or even fatal to you. When operating the
machine in a confined space, ensure good ventilation. If possible, add an extension
pipe to the exhaust pipe. If you begin to feel drowsy, stop the machine immediately
and get some fresh air out of the cab.
Warning
The machine is equipped with a rollover protection system (ROPS) and falling object
protection system (FOPS). If ROPS/FOPS is damaged or lost, operating the machine
may cause death or serious injury. In case of ROPS/FOGS accident, do not use the
machine before the structure is replaced. Modification and repair without the
manufacturer's permission may be dangerous, and will invalidate ROPS/FOPS
verification.
Warning
Communications
Poor communication will lead to accidents. Make sure that everyone around you
knows what you're doing. If two or more people are working on the same machine at
the same time, make sure that everyone understands your sign language. It will be
noisy on the construction site, and it is impossible to communicate only by language.
Warning
Ramp and trailer
Make sure that there is no water, mud, ice, grease and oil on the unloading ramp or
trailer, which will cause accidents. Make sure that the surface is clean before driving
on a ramp or trailer, and be extremely careful when driving.
Danger
Sparks
Sparks from the exhaust pipe or electrical system may cause explosion and fire. Do
not use the machine in a confined space with flammable materials, vapors or dust.
Warning
Power Shift Gearbox
1-9
When the machine is moving, please do not suddenly shift from high gear to low gear
(such as 4th gear to 1st gear) in a time. Otherwise, the machine will decelerate rapidly,
which may cause death or serious injury to you or others. When selecting a low gear,
slow down the engine before each shift.
2.5 Maintenance Safety
Warning
Repair
Do not carry out any repair when you do not know the machine. Ask a professional
engineer for repair to avoid personal injury or damage to the machine.
Warning
Modification and welding
Unauthorized modifications can cause damage to the machine or personal injury.
Contact your XCMG dealer before modifying the machine
Warning
Metal fragments
When installing and removing the metal pin, flying debris may hurt people. Therefore,
be sure to use a hammer or punch with low surface hardness and wear safety goggles
during installation and removal.
Warning
Circuit
Understand the circuit before connecting or disconnecting an electronic component.
An incorrect connection may cause personal injury or damage to the machine.
Warning
If you try to charge a frozen battery, or boost start the engine and run it, the battery
may explode. Do not use the battery if its electrolyte is frozen. Fully charging the
battery can prevent the battery electrolyte from freezing.
1 - 10
Warning
Battery gas
Explosive gases can escape from the battery. Keep the battery away from fire and
sparks. Do not smoke near the battery. Ensure that there is a good ventilation
environment near the place where the battery is used and charged. Do not check the
battery charging by metal short circuit, but use a hydrometer and voltmeter.
Warning
Battery electrode
The negative electrode of the machine is grounded. Always keep the negative
electrode grounded.
When connecting the battery, connect the negative electrode finally.
When disconnecting the battery, disconnect the negative electrode first.
Warning
High-pressure liquid flow
A fine jet of hydraulic oil under high pressure can penetrate the skin, keep skin and
hands away from high-pressure liquids, and wear protective goggles. Take a piece of
cardboard close to the place where leakage may occur. Check flow marks. If the fluid
penetrates your skin, seek medical treatment immediately.
Warning
Pressure of hydraulic system
Before disconnecting or connecting the hydraulic hose, stop the engine and pull the
control lever to release the high pressure on the hose. When disconnecting the
hydraulic hose, make sure that the engine cannot be started.
Warning
Diesel fuel
Diesel is flammable, keep open flames away from the fuel system. Do not smoke
during refueling or near the fuel system, and do not refuel when the engine is running.
Failure to observe these precautions will cause fire or injury.
Warning
1 - 11
Oil is poisonous. If you have swallowed any oil, do not attempt to vomit it out, please
seek medical treatment. Used engine oil contains toxic pollutants, which can cause
skin cancer. Do not dispose of the used engine oil too much. Always use skin cream
and wear gloves to prevent contact between the skin and oil. Wash off skin
contaminants thoroughly with oil in warm soapy water. Do not use gasoline, diesel or
kerosene to clean your skin.
Warning
Soft ground
The machine will sink on soft soil. Never work under the machine on soft soil.
Warning
Tire and rim
Overinflated or heated tires will explode. Inflate the tire according to the instructions in
this Manual. Do not weld or cut the rim. Ask a tire/wheel specialist for repair.
Warning
Hot coolant
When the engine is hot, the cooling system is pressurized. When you move the oil filler
cap, hot coolant can be ejected. Cool down the system before moving the oil filler cap.
To remove the cap, turn it to the first notch and release the system pressure before
moving the cap.
Warning
Always wear safety goggles when disassembling and assembling the components
included. This will protect the eyes from injury caused by accidental flying of
components.
Caution
Cylinder
If there is solidified dirt on the cylinder, cylinder efficiency will be affected. Regularly
clean the dirt around the cylinder. When leaving or parking the machine, close all
cylinders as much as possible to reduce the possibility of weather corrosion.
Caution
Clean
Cleaning metal components with wrong solvent will cause corrosion. Use only
recommended cleaning agents and solvents.
1 - 12
Caution
O-rings, seals and gaskets
Improper installation, as well as damage or corrosion of O-rings, seals and gaskets will
lead to leakage and accidents. Unless otherwise specified, replace the defective parts.
Do not use trichloroethane and paint thinner near O-rings and seals.
Warning
Live
If your machine is provided with a fire extinguisher, check it regularly. Keep it in the
cab unless use. If the machine catches fire, do not extinguish fire with water. You may
expand the oil fire or get knocked down by electric shock. Use carbon dioxide, dry
powder or foam extinguishers. Get in touch with the nearest fire service department as
soon as possible.
Warning
Jack
If the wheels are not wedged, the machine may roll off the jack and hit you. Wedge the
wheels with skids on the other side of the jacked machine, and do not work under the
machine supported only by a jack. Before working under the machine, support the
machine jacked up on the drive axle support.
Warning
Hydraulic hose
Damaged hoses can be fatal. Regularly check the following parts of hoses:
– Whether the hose joint is damaged
– Check whether the outer layer of the hose is scratched
– Whether the exterior bulges
– Whether the hose is squeezed or twisted
– Whether the hose is punctured by foreign matters
– Whether the hose joint is connected incorrectly
Warning
It is prohibited to work or walk under the accessories at height before the machine is
supported by mechanical devices. If the hydraulic system fails or the control lever is
operated (even if the engine stops running), the equipment supported by hydraulic
devices only will fall and hurt you.
1 - 13
Warning
Lifted machine
It is prohibited to stand or place any part of your body under a lifted machine that is not
properly supported. If the machine is moved inadvertently, you may be hit and
seriously injured or killed.
Caution
The anticorrosive coating waxoyl contains a turpentine substitute, which is flammable.
Keep away from flames during drying when using anticorrosive coating waxoyl.
Do not weld in the area around the paint during drying. Be as careful as engine oil, and
be careful to keep the anti-corrosive paint waxoyl away from your skin. Do not breathe
smoke. Use in a well-ventilated area.
Warning
Ensure the safety of the machine when working under the machine. Park the machine
on a solid and flat ground, and lower the accessories to the ground. Apply the parking
brake, shift the transmission to neutral gear and stop the engine. All four wheels are
stopped on both sides of the disc.
Disconnect the battery when you are walking under the machine to prevent the engine
from starting.
Warning
To avoid burning, wear protective gloves when handling hot components. To protect
your eyes, wear goggles when cleaning components with a wire brush.
1 - 14
General information
Machinery structure
Item Description Item Description

1 Loader bucket 8 Arm
2 Lift arm 9 Backhoe bucket
3 Cylinder, bucket 10 Hydraulic oil tank
4 Cylinder, lift 11 Stabilizer
5 Cab 12 Main frame
6 Fuel tank 13 Swing frame
7 Boom
1 - 15
Main technical parameters of machinery
Overall dimensions
Code Item Unit Parameter

A Overall length mm 7340
B Shovel width mm 2350
C Overall height mm 3437
D Cab roof height mm 2868
E Wheelbase mm 2180
F Front axle clearance mm 318
G Front wheel width mm 2207
H Rear wheel width mm 2279
Steering dimensions
Cod Item Unit Parameter(unbrake Parameter(braked)

e d)
R1 Turning radius (Shovel m 5.8 5.4
Side)
R2 Turning radius (Front m 4.4 4
Tire)
1 - 16
Loader and backhoe dimensions
Loader dimensions:
Code Item Unit Parameter
I Dig depth mm 74
J Roll back at ground ° 42
K Dump height mm 2776
L Reach at full height fully dumped mm 832
M Dump angle ° 45
N Max. Operating height mm 4366
O Loader hinge pin height mm 3495
Backhoe dimensions:
Code Item Unit Parameter Parameter Parameter
(Stardard) (Extradig (Extradig
Ret) Ext)
P Bucket rotation ° 208 208 208
Q Reach-ground level mm 5426 5481 6606
to slew centre
R Max. Dig depth mm 4440 4497 5698
S Max. Loadover mm 3541 3490 4240
height
U Operating height mm 5397 5257 6007
1 - 17
Performance
Weights
Item Unit Parameter
Operating weight kg 7600-9000
Engine
Item Unit Parameter
Model —— 904J-E36TA
Manufacturer —— Perkins
Rated Power kw 74.5
Rated Speed r/min 2200
Peak Torque N.m 450
Number of Cylinders —— 4
Bore mm 98
Stroke mm 120
Configuration —— Vertical in line
Displacement L 3.621
Aspiration —— Turbocharged
Compression Ratio —— 17:1
Driving performance
Item Unit Parameter
Model —— MYF110
Manufacturer —— XCMG
Transmission
Type —— Power shift
Gear Selection —— Power shift
Model —— A1092(Ⅲ)
manufacturer —— XCMG
Front Axle Static load rating kg 22500
Dynamic load rating kg 9000
Oscillation angel ° 16
Model —— WA1080(Ⅲ)
Rear axle manufacturer —— XCMG
Static load rating kg 18750
Dynamic load rating kg 7500
Gear 1(forward) km/h 6
Driving Speed Gear 4(forward) km/h 38
Gear 1(reverse) km/h 8
Front Tire —— 12.5/80-18
Rear Tire —— 19.5L-24
Braking distance m ≤12
Hydraulic performance
Item Unit Parameter
Type —— Open center
Pump Model —— HP5V105/AV10RC4S3MA
-L1/1-EO-D1-T181
1 - 18
Manufacturer —— HENGLI
Type —— Variable Flow, Axial Piston
Max. pump L/min 160
capacity
Loader bar 240
System
Backhoe bar 240
pressure
Steering bar 160
Fluid recommended and fill capacity

Use listed below or equivalent only. Do not mix different brand oils.
Capacity Ambient temperature ℃ / °F

Service Kind of
L(imperi -40 -30 -20 -10
SAE 0 10 20 30
point fluid SAE5W-30
0W-30
al gal) 40 50
-40 -22 -4 14 32 50 68 86
SAE 5W-40
SAE 0W-40
SAE 10W-30
8-
Engine oil Engine
10.6(1.76
pan oil(1)
- 2.33)
SAE 10W-40
SAE 15W-40
GL-5 75W-90
Main Front
reducer axle:
and 5.7(1.25)
Gear oil +0.7(0.15
wheel GL-5
)×2; ISO VG 32 85W-90
hub of
Rear
drive axle axle: ISO VG 46
Hydraulic Hydraulic 95(20.9)

oil tank oil
ISO VG 68
1 - 19
5#
0#
-10#
-20#
-35#
Diesel 166(36.5
Fuel tank fuel(2) 1) -50#
NLGI No.1
Grease As
Grease
fitting required
NLGI No.2
Cooling 12.5(2.75 Add antifreeze

Coolant (50% antifreeze-50% distilled water)
system )
Mobil 424
Transmis
Gearbox 15(3.3)
sion oil
Adblue(32.5%)
DEF tank DEF(3) 19(4.18)
(1).Engine oil should be used according to the following specification: API CJ-4; API
CK-4; ACEA E9; ECF-3.
(2). Diesel fuel must be ultra low sulphur diesel. Sulfur content ≤15 ppm.
(3).DEF must meet the specification of ISO 22241-1.
Do not store DEF in direct sunlight.
Recommend that all DEF taken from storage should be checked to ensure that the
DEF meets ISO 22241-1.
Store Temperature Expeceed DEF life
Below 25° C (77° F) 18 months
25° C (77° F) to 30° C (86° F) 12 months
1 - 20
30° C (86° F) to 35° C (95° F) 6 months
Above 35° C (95° F) test quality before use
Bolt tightening torques

Size of Torque [Nm]
socket Size of inner
Bolt Size wrench hexagonal 10.9 8.8
wrench mm class class
Mm
M5 7 4 8 6
M6 8 5 13 9
M8 10 6 30 22
M10 13 8 70 50
M12 15 10 120 90
M14 18 12 195 140
M16 21 14 300 210
M18 27 —— 410 300
M20 30 17 600 400
M22 34 —— 800 550
M24 36 19 1000 700
M27 41 —— 1500 1050
M30 46 22 1850 1450
M36 55 27 3000 2450
Bolt Wrench Torque

S/N Item Size. Qty size
mm Nm
mm
Fixing bolts of engine
1 vibration isolating M16*120 2 21 300
rubber gasket
Fixing bolts of M12*30 8 15 90
2
engine bearer
3 Fixing bolts of air M12*25 3 15 90
1 - 21
intake filter
Fixing bolts of
transmission M16*120 2 21 300
4
vibration isolating
rubber gasket
Fixing bolts of
flywheel housing of M10*30 12 13 70
5
engine and
transmission
Fixing bolts of front
6 cardon shaft and M14*1.5*45 4 18 140
front axle
Fixing bolts of rear M20*240 8 30 600
7
axle
Fixing nuts of front M18*1.5 16 30 380~450
8
wheel
Fixing nuts of rear M22*1.5 20 34 740~880
9
wheel
Fixing bolts of rear M10*1.25*4
10 cardon shaft and 4 13 70
5
rear axle
11
hydraulic pump
12
excavating valve
13
loading valve
14
hydraulic oil tank
Fixing bolts of fuel M20*40 6 30 600
15
tank
16
steering pump
Fixing bolts of side
17 shift kingpost M24*190 12 36 1000
carriage
Fixing bolts of
18 swing cylinder M20*105 6 17 400
plate
19 Fixing bolts of cab M16*120 4 21 300
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Faults and
Troubleshooting
Power system
Trouble Cause Solution

Gear is not in neutral Check and operate to
positon neutral positon
Broken fuse Replace the fuse
The ignition switch is
Check and replace
damaged
Engine is not Check and charge or
Trouble of battery
responding when start replace
Trouble of starting relay Repair or replace
Repair of replace the
Trouble of starting motor
starting motor
Start line open circuit Check and repair
Trouble of ECM Check and replace
Engine rotates, but No fuel Add fuel
cannot start or has Check and use water
trouble to start properly. Air in fuel separator to drain air from
fuel
Check the connection of fuel
Leakage of fuel system
system.
Empty the oil tank, clean the
Wrong fuel fuel system and adopt the
correct fuel.
Empty the oil tank, clean the
Polluted fuel fuel system and adopt the
correct fuel.
Charge or attach a new
Low capacity of battery
battery.
Clean and fix the connection
Poor contact of circuit of battery and starting
motor.
Check and clean or replace
Blockage of air system
the air filter.
Low level of engine oil Add engine oil.
Drain the oil, and adopt the
Wrong engine oil
correct oil.
Trouble of starting motor Replace the starting motor.
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Connect XCMG distributor
Trouble in engine
or engine distributor
Blockage of fuel filter Repair or replace
Low temperature of coolant Check or replace thermostat
Popping noises, of Water, dirt or air exists in Drain the air from fuel
engine running or fuel system system, and clean fuel tank.
stopping
abnormally Trouble of engine
Dirt or trouble of nozzle
Off-time of injection pump
the air filter.
Blockage of fuel pipe Repair or replace the fuel
pipe.
Polluted fuel Empty and clean the fuel
tank, and add new fuel
Blockage of fuel filter Repair or replace
Blockage of fuel tank cover Clean or replace a new
vent hole cover.
Wrong fuel Empty the oil tank, clean the
fuel system and adopt the
The engine can’t
correct fuel.
function properly.
Wrong engine oil Drain the oil, and adopt the
correct oil.
Blockage of emission Remove the muffler, run the
engine and check
Overheating or
See below
undercooling of engine
Trouble of engine
Dirt or trouble of fuel
nozzle
Trouble of turbo charger
Overheat of engine Check the level and add
Low level of coolant
coolant
Blockage of radiator core Clean the radiator and oil
and oil cooler core cooler.
Blockage of radiator mesh
Clean the mesh enclosure.
enclosure
Damage of fan Check and replace
Loosening of engine belt Tension the belt or attach a
new belt.
Damage of radiator cap Check and replace
Wear of belt pulley Replace the belt pulley
Dirty of cooling pipe Flush the cooling pipe.
1 - 24
Trouble of thermostat
Other reasons
Damage of water
temperature sensor
Damage of silicon oil clutch
or its controller
Damage of engine cable
Wrong engine oil Drain the oil, and adopt the
correct oil.
Leak of engine oil Check and repair
Excessive consumption Overheat of engine See above
of engine oil Check and clean or replace
the air filter.
Wear of inner parts of Connect XCMG distributor
engine or engine distributor
the air filter.
Excessive consumption fuel system and adopt the
of engine fuel correct fuel.
Dirt or trouble of fuel
nozzle
correct fuel.
Exhaust has excessive the air filter.
black smoke Dirt or trouble of fuel
nozzle Connect XCMG distributor
Off-time of injection pump or engine distributor
Trouble of turbocharge
Other reasons
correct fuel.
Run the engine until it
Exhaust has excessive Low temperature of engine
becomes hot.
white smoke
Off-time of injection pump Connect XCMG distributor
Leak of coolant into the or engine distributor
cylinder of engine
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Inspect the alernator drive
Trouble of alternator drive
belts and the belt tension
belt
and replace
Trouble alternaror Inspect the alternator
mounting bracket mounting bracket and repair
Trouble of the alternator
Check and repair
drive pulley
Chariging problem and
Wear of the alternator
or noisy operation Check and repair
bearings
Operation of the alternator
Check and repair
or regulator
Trouble of the charging
Check and clean or repair
circuit
Other reasons
Incorrect installation of Nox
Check and reinstall
sensors
Diagnostic trouble code
Exhaust leak between the
3217-16 or 3227-16 for
turbocharger and the tail Check and repair
clean emissions module
pipe
has high oxygen level
Other reasons
Trouble of engine oil cooler
Trouble of cylinder head
gasket Connect XCMG distributor
Coolant contains oil
Trouble of cylinder head or engine distributor
Troubl of cylinder block
Other reasons
Restriction of the DEF lines Clean or replace
Diagnostic trouble code Restriction of the DEF
Check or replace
4334-15 or 4334-16 for pump
DEF pressure is high Connect XCMG distributor
Other reasons
Diagnostic trouble code Blockage of the DEF tank
Check and clean
4334-7or 4334-18 or filter cap
5392-31 for DEF Trouble of DEF gauge Check and repair
pressure is low Leak of the DEF lines Check and repair
The DEF quality is poor Check and replace
Restriction of the DEF lines Clean or replace
Leak of the manifold on the
Check and replace
DEF tank
Restriction of the DEF Check and replace
pump filter
1 - 26
Other reasons
Low DEF level in DEF tank Check and refill
Trouble of DEF gauge Check and repair
Diagnostic trouble code Loose or disconnect of the
Check and repair
1761-1 or 1761-17 or electrical connect
1761-18 for DEF tank Trouble of the DEF tank
Check and repair
level is low head
Other reasons
Loose or disconnect of the
Check and repair
electrical connect
Incorrect installation of the
coolant supply and return Check and reinstall
3031-16 for DEF
lines
temperature is high
The DEF quality is poor Check and replace
Other reasons
Check the level and add
coolant
Check for coolant leaks and
Leak of coolant
repair
Loose or disconnect of the
3031-7 or 3031-18 or
electrical connection at the Check and repair
5798-7 for DEF
DEF tank header
temperature is low
The coolant temperature is
Check and repair
too low
Other reasons
Leak of exhaust between
Diagnostic trouble code the turbocharge and the Check and repair
4565-17 for diesel clean emissions module
oxidation catalyst has Missing or damaged
Check and repair
incorrect inlet exhaust system insulation
temperature Connect XCMG distributor
Other reasons
Leak of oil between the
Diagnostic trouble code turbocharge and the clean Check and repair
5298-17 for diesel emissions module
oxidation catalyst has Ensure the specification of
Use of high sulphur fuel
low conversion fuel and replace
efficiency Connect XCMG distributor
Other reasons
Diagnostic trouble code Leak oil in the exhaust Check and repair
3251-16 or 3714-31 or system
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3715-31 or 3719-16 or Ensure the specification of
Use of high sulphur fuel
3719-0 for diesel fuel and replace
particulate filter collect Connect XCMG distributor
Other reasons
execssive soot or engine distributor
Leak of exhaust between
Diagnostic trouble code the turbocharge and the Check and repair
3251-1 or 3251-18 for clean emissions module
diesel particulate filter Missing or damaged DPF
Check and replace
has low inlet brick
temperature Connect XCMG distributor
Other reasons
Incorrect installation or
loose of the temperature Check and repair
3242-18 for diesel
sensor
particulate filter
temperature is low Other reasons
Incorrect maintennance
Check and replace
interval
Incorrect oil Check and replace
Contaminated engine oil Check and replace
Engine has early wear
Leaks in air intake sysytem Check and repair
Dirt in fuel Check and replace
Other reasons
loose of the ECM J1/P1 Check and repair
Engine has mechanical and the J2/P2
noise(knock) Wrong Fuel or its quality Check and replace
Other reasons
No fuel Add fuel
Check and use water
Air in fuel separator to drain air from
fuel
Restriction of the vent in
Check and clean
Engine misfires, runs the fuel cap
rough or is unstable Water in the water
Check and drain
separator
Restriction of the fuel
Check and clean
supply and return lines
Other reasons
Engine shutdown
occurs intermittently
and the J2/P2
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Poor power and ground
Check and repair
connections to the ECM
No fuel Add fuel
Check and use water
fuel
Check and clean
the fuel cap
Water in the water
Check and drain
separator
Check and clean
Trouble of keyswitch Check and repair
Trouble of engine
Check and repair
speed/timing sensors
Other reasons
Diagnostic trouble code Restart the engine if
Normal operation
593-31 or 594-0 or 594- necessary
31 for engine shutdown Connect XCMG distributor
Other reasons
while idling or engine distributor
Excessive load on the
Check and repair
engine
No fuel Add fuel
Check and use water
fuel
Check and clean
Engine stalls at low the fuel cap
RPM Water in the water
Check and drain
separator
Check and clean
Wrong Fuel or its quality Check and replace
Trouble of water separator Check and replace
Other reasons
Engine top speed is not Excessive load on the
Check and repair
obtained engine
Blockage of air system Check and repair
Restrictions of air inlet and Check and repair
exhaust system
1 - 29
Check and use water
fuel
Check and clean
the fuel cap
Water in the water
Check and drain
separator
Check and clean
Other reasons
Mounts or brackets are
Check and fasten or replace
Engine vibration is loose or broken
excessive Connect XCMG distributor
Other reasons
Cylinder head gasket leak
Exhaust system Cylinder head has cracks Connect XCMG distributor
contains coolant NRS cooler leak or engine distributor
Other reasons
Failed turbocharger seals
Worn valve guide seals or
Exhaust system faulty valve guide seals Connect XCMG distributor
contains oil Worn valve guides or engine distributor
Worn piston rings
Other reasons
Fuel leakage Check and repair
Wrong oil or its quality Check and replace
Prolonged operation at idle
Charify
speed
Fuel consumption is Check and clean or replace
excessive the air filter.
Blockage of exhaust
Cheak and repair
system
Damage of fan Check and replace
Trouble of thermostat Connect XCMG distributor
Other reasons or engine distributor
More water in water Drain water from water
separator separator
97-15 or 97-16 for fuel
contains water Other reasons
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and the J2/P2
Poor installation of the
connector for the flow
Check and reinstall
control valve on the high-
Diagnostic trouble code pressure fuel pump
157-16 or 157-18 o
Trouble of water separator Replace
5571-0 for fuel rail
Fuel leakage Check and repair
pressure problem
Check and use water
fuel
Other reasons
Fuel level in the tank is low Check and refill
Fuel tank is close to a heat Check and shield the fuel
Diagnostic trouble code source tank from the heat source
174-16 for fuel Blockage of the return fuel
Check and clean
temperature is high lines
Other reasons
Trouble of air intake
Check and repair
precleanere
Blockage of air filter Check and clean or replace
element the air filter.
107-15 or 107-16 for
Restriction of air inlet
inlet air is restricted Check and repair
piping
Other reasons
102-16 for intake Connect XCMG distributor
Trouble of engine
manifold air pressure is or engine distributor
high
Blockage of air filter Check and clean or replace
Diagnostic trouble code element the air filter.
102-18 for intake Restriction of air inlet
Check and repair
manifold air pressure is sysytem
low Connect XCMG distributor
Other reasons
Diagnostic trouble code Check the level and add
105-15 or 105-16 or coolant
105-0 for intake Blockage or damage of air-
Check and clean or repair
manifold air to-air aftercooler
temperature is high Damage of fan Check and replace
1 - 31
Check and repair
sysytem
Restriction of exhaust
Check and repair
sysytem
Operate the engine at
High ambient temperature reduced speed or reduced
power
Operate the engine at
High altitude reduced speed or reduced
power
Other reasons
Check and reinstall
loose of the NOX sensors
Diagnostic trouble code The DEF quality is poor Check and replace
3516-11 or 3516-15 or Leakage of DEF lines Check and repair
3516-18 or 4364-2 or Wrong Fuel or its quality Check and replace
4364-18 or 7105-31 for Check the level and add
NOX conversion is low coolant
Other reasons
Diagnostic trouble code Check the level and add
412-15 or 412-16 for coolant
NRS exhaust gas Connect XCMG distributor
Other reasons
temperature is high or engine distributor
loose of the connectors for
Check and repair
the compoments in the
NRS system
Poor ground connection of
Check and repair
the ECM
Diagnostic trouble code Check and repair
sysytem
2659-7 for NRS mass
flow rate problem Check and repair
sysytem
coolant
Leakage of the coolant
Check and repair
system
Other reasons
Leakage of oil Check and repair
Oil consumption is Restriction of engine
Check and repair
excessive crankcase breather
High level of oil Check and repair
1 - 32
Check and repair
sysytem
Check and repair
sysytem
Other reasons
Leakage of engine oil
Check and repair
cooler
Oil contains coolant
Other reasons
Oil contains fuel Trouble of engine
Diagnostic trouble code Low level of coolant
coolant
98-17 or 98-18 or 98-1
for oil level is low Other reasons
Low level of oil Check the level and add oil
Diagnostic trouble code Wrong oil or its quality Check and replace
100-1 for oil pressure is Blockage of oil filter Check and replace
low Connect XCMG distributor
Other reasons
and the J2/P2
No fuel Add fuel
Check and use water
fuel
Power is intermittently Restriction of the vent in
Check and clean
low or power cutout is the fuel cap
intermittent Water in the water
Check and drain
separator
Check and clean
Other reasons
Diagnostic trouble code Leakage between the
4360-10 or 4360-16 or turbocharger and the Check and repair
4360-17 or 4360-18 for exhaust tail pipe
SCR catalyst has
incorrect inlet Other reasons
temperature
1 - 33
5246-15 or 5246-16 or Connect XCMG distributor
Trouble of engine
5246-0 for SCR warning or engine distributor
system problem
Transmission system

Check the gear selector
Not on the gear
circuit and gear accuracy
Add oil to recommended
Oil level is too low
level
Insufficient oil supply
The engine is running
caused by damage or Check oil sealing and
normally, but can't drive
leakage of variable speed replace
oil pump
Faulty torque converter,
elastic plate or cardon Check and repair
shaft
The brake signal enters the
No forward or backward gearbox controller, which
Check and adjust the brake
1 or 2 gear, only have 3 interferes with the normal
stroke
gear operation of the 1st and
2nd gears of the controller
Increase the system
Low main pressure pressure adjustment pad in
(theoretical value 17-20 the combined valve (1mm
bar) gasket boost
0.8- 1bar)
Check the gearbox oil level;
Insufficient driving replace the filter; check
force Low oil pressure at the
whether the main pressure
torque converter inlet
regulating valve and related
solenoid valves are normal.
Check main pressure, gear
Clutch slip
pressure and piston seal
Engine failure Check the engine
Clean or replace the control
Gear control oil Spool stuck
pressure is low valve
and unstable Check the oil level, oil
Variable speed pump
passages and solenoid
sucks in air
valve filter for blockage
Variable speed pump Replace a new pump
failure
1 - 34
Clutch seal leakage Check and repair
Transmission oil level is Add oil to recommended
too high or too low level
Breathable cap clogged Check the breathable cap
Check main pressure, gear
Transmission oil Clutch slip
pressure
temperature is too high
Bearing burnout, poor oil Replace burnt parts, check
path oil circuit and oil pump
Check or replace the oil
Damaged oil cooler
cooler
Gear selector failure Replace the gear selector
The solenoid valve is Check and replace solenoid
damaged valve
No gears, unclear gears Poor contact of the wiring Check the contact condition
or shifts harness socket of each socket
The electrical system of the Check the electrical system
machine is faulty or the of the machine and measure
voltage is unstable the voltage
Front axle

Loose adjustment nut Fasten nuts and bolts
Fasten the nut of shate end
Improper bearing preload or reduce the number of
shims
Main reducer gear wear
Gear meshing gap is too
Adjust to requirements
large or too small
Improper oil or insufficient
Change or replenish oil
oil
Bearing damage
shims
Quality defects Replace
large or too small
oil
Abnormal noise
Bearing damage Replace
Spiral umbrella tooth
Replace in pairs
damage
Half shaft gear damage Replace in pairs
Wheel hub gear damage Replace
1 - 35
Improper oil or insufficient Change or replenish or drain
oil or too much oil oil
Axle temperature Gear meshing gap is too
is too high small
Bearing preload is too
large
Oil seal quality problem Replace
Blocked vent Clean
Oil leak
Poor joint surface, foreign
Repair or clean
matter in the sealing area
The steering limit bolt is
Steering angle is too
loose or improperly Fasten or adjust
small
adjusted
The steering limit bolt is
Steering angle is too
loose or improperly Fasten or adjust
large
adjusted
Rear axle

shims
Main reducer gear wear
large or too small
oil
Differential lock cannot Insufficient pressure Check the pressure
be locked Shaft sleeve damage Replace
The pressure is not
Check the pressure
Differential lock cannot eliminated
be unlocked Spring stuck Replace
Shaft sleeve damage Replace
Bearing damage
shims
Quality defects Replace
Abnormal noise Adjust to requirements
large or too small
oil
Bearing damage Replace
1 - 36
Spiral umbrella tooth
Replace in pairs
damage
Half shaft gear damage Replace in pairs
Wheel hub gear damage Replace
The differential lock sleeve
Replace
is not fully returned
Improper oil or insufficient Change or replenish or drain
oil or too much oil oil
small
Bearing preload is too
Axle temperature is too Adjust to requirements
large
high
The service brake piston
Replace the driven disc or
stroke is small or the piston
piston
is stuck
Small parking brake
Adjust
clearance on one side
Oil seal quality problem Replace
Blocked vent Clean
Oil leak
Poor joint surface, foreign
Repair or clean
matter in the sealing area
Hydraulic system

Low level of hydraulic oil Check and add
Leakage or hydraulic oil Check and replace
Poor engine power Check and repair
Improper setting of main
Check and repair
Insufficient power for safety valve
hydraulic components Poor ventilation of
Check and repair
hydraulic tank
Low pump flow Check and repair
The filter is not working
Check or replace
properly
Low pump flow Check and repair
Improper setting of main
Check and repair
safety valve
cylinders move Poor ventilation of
Check and repair
slowly hydraulic tank
The filter is not working
Check or replace
properly
Leakage of pipe Check and replace
1 - 37
Leakage, blockage or
Check and repair
damage of related piping
Unable to perform Leakage of related cylinder Check and repair
an action
Leakage of related valve Check and repair
Piston rod bent Check and repair
Poor engine power Check and repair
Engine stalls on
Unload valve pressure set
hydraulic load Check and repair
too high
Oil temperature abnormally
Check and repair
high
Spool stuck The hydraulic oil is dirty. Clean and replace the oil
Too high.pressure Check and adjust
Return spring is broken. Check and replace
Hydraulic oil cooler
Check and clean
Hydraulic oil abstruced
temperature abnormally Restriction in circuit lines Check and repair
high The filter is not working
Check or replace
properly
1 - 38
Brake system

Air in oil Drain air
Change or replenish
The braking effect is oil
not good Insufficient pressure Check and repair
Braking pump damage Repair or replace
Friction plate wear Replace
Damaged seal Replace
Braking pump leakage
Improper adjustment Adjust and replace
Electric system

Loose connection of
Tighten or replace
charge cable
Check and charge or
Trouble of battery
Insufficient capacity of replace
battery Broken fuse Replace the fuse.
Tension the belt or attach a
Loose of engine belt
new belt.
Trouble of generator Repair or replace
Trouble of the battery
Check and repair
charging circuit
Verify if the battery is no
Trouble of battery longer able to hold a charge
Diagnostic trouble code and repair
168-31 for battery Check if an auxiliary device
problem has drained the battery by
Auxiliary device
being left in the on position
and repair
Other reasons
Air condition system
1 - 39
There is water in the
Replace the liquid reservoir,
system, causing the
re-evacuate, and charge
expansion valve to be
refrigerant
blocked by ice
Refrigeration Thermostat failure Repair or replace
intermittent work
Bad grounding Check and repair
Poor contact of control
Check and repair
switch
Bad relay contact Check and repair
The belt is too loose Adjust or replace
Compressor bracket is
Adjust and tighten
loose
The system makes an Loose evaporator fan
Adjust and tighten
abnormal sound wheel
Clutch slip Repair or replace
Internal wear of the Repair or replace
compressor
The hot water valve is not
Open the hot water valve
open
Clogged pipeline Repair
Insufficient heating
The hot water temperature Turn on when the
is not high temperature rises
Leak in the pipeline Repair or replace
The plug falls off Check and connect
Not cooling(The Broken belt Replace
evaporator fan is Leaking or insufficient
Check and add refrigerant
normal, but the refrigerant
compressor is not Overcharged refrigerant Moderate release
working) The thermostat is damaged Replace
Compressor damage Replace
Not cooling(The Leaking or insufficient
Check and add refrigerant
evaporator fan is refrigerant
normal, and the
Overcharged refrigerant Moderate release
compressor is working)
Not cooling(The Poor ground connection Check and repair
evaporator fan is not Fuse blown Check and replace
working, and the
compressor is not The power switch is broken Check and replace
working)
The evaporator fan is
Not cooling(The Check and replace
broken
evaporator fan is not
Fuse blown Check and replace
working, and the
The wind gear switch is
compressor is working) Check and replace
broken
1 - 40
The belt is too loose Adjust or replace
Leaking or insufficient Check and add refrigerant
refrigerant
The hot water valve is
Close the hot water valve
open
The cooling effect is not
Condenser fins blocked Clean
good.( The evaporator
Overcharged refrigerant Moderate release
fan is normal.)
Expansion valve blocked Clean or replace
Blocked reservoir Replace
Blocked pipe Repair of replace
Compressor failure Repair of replace
Clogged evaporator Repair of replace
The cooling effect is not Blocked air inlet Clean
good.( Insufficient Blocked air outlet Clean
evaporator air.) Evaporator frosting Shutdown and defrost
1 - 41
Power system
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Transmission system
Gerbox
一、 Precautions for
disassembly and
assembly
In this section it gives the safety precautions and other precautions for disassembly
and assembly of MYF110 gearbox, and lists the main steps, procedures and methods
for disassembly and assembly. During disassembly and assembly, be sure to follow
the following precautions.
1.1 Safety precautions during disassembly from the complete machine
Stop the excavator and loader on the level ground, lower the bucket to the ground
and stop the engine. Use the parking brake and place a block behind the wheel to
prevent the excavator and loader from moving;
Release the residual pressure in the relevant pipe;
Operate the handle, raise the front part of the bucket by 30-50mm, lower the rear
part to the ground, and then stop the engine;
After operating the handle, check whether the whole bottom surface of the bucket is
in contact with the ground;
Slowly loosen the cap of the hydraulic oil tank filler in order to release the air
pressure inside the hydraulic oil tank. Then operate the control handle several times to
release the residual pressure in the hydraulic pipeline;
Disconnect the power supply from the negative pole of the battery
1.2 Other precautions during disassembly
 When it is necessary to hoist a component, be sure to use hoisting equipment with
sufficient strength;
 When discharging lubricating oil or fuel oil, prepare a container with appropriate
capacity to hold the oil;
 If it contains antifreeze in the coolant, it must be disposed of correctly in
accordance with environmental protection and cleaning requirements;
 When dismantling the hard pipe or hose, its mouth shall be sealed to prevent dirt
and dust from entering;
1 - 398
 Labels shall be attached to the removed wires and hoses to indicate their
installation positions to prevent errors during assembly;
 All parts dismantled from the gearbox must be matched with marks and placed in
categories to prevent errors during assembly. Even parts with the same drawing
number cannot be interchanged (except standard parts);
 When removing the strong bolts of components, loosen them alternately;
 Check the number and thickness of adjusting shims and keep them in a safe place
 Before disassembling a part, the place where the part is placed shall
be cleaned; A protective cover shall be installed on the part to prevent
dirt and dust from entering during storage;
 Be sure to wear protective articles during disassembly.
 It is forbidden to disassemble threaded fasteners with chisel and
hammer;
 Drain the oil in the gearbox before dismantling!
Release the air pressure in the gearbox before draining the oil (by loosening or
removing the nut on the vent plug); If the oil is drained before releasing the air
pressure, it may cause oil splashing.
★ Warning：
1） Removing threaded fasteners with a chisel and hammer may cause damage to
parts or personal injury.
2) Before disassembly, the gearbox shall be firmly fixed to avoid sliding and tilting
during disassembly, resulting in damage to parts or personal injury.
1.3 Precautions during assembly
 Tighten all screws, bolts and nuts to the specified tightening torque;
Table for tightening torque of bolts
Screw and thread Tightening torque
No.
Spec Grade 8.8 Grade 10.9
1 M6 10-12 N.m
2 M8 25-30 N.m
3 M10 49-59 N.m
4 M16 214-256 N.m 295-350 N.m
Table for tightening torque of screw plug and plug
No. Thread Spec Tightening torque
M14 螺塞
1 50-60 N.m
M14 screw plug
2 VSTI10×1EDCF(J) 20-25 N.m
1 - 399
3 VSTI14×1.5EDCF(J) 45 N.m
6 Lock nut M27x2 550-600 N.m
 After installing the retaining ring, check whether the ring is firmly installed in the
groove;
 When it is necessary to apply adhesive, first clean the parts, remove all the oil and
lubricating oil on the surface, and then apply 2 ~ 3 drops of adhesive on the thread
part;
 When it is necessary to apply gasket sealant, first clean the surface of
components, remove all oil and lubricating oil, and then apply gasket sealant
evenly;
 When connecting the wire plug, clean the connecting plug, remove all oil, dust and
water, and then connect them firmly;
 Apply lubricating oil on rotating parts and sliding parts;
 When using eyebolts, check whether there is deformation or damage, tighten them
with screws, and then align them with the direction of the hook.
1 - 400
1.4 List of common tools required during disassembly and assembly
No. Names Spec Qty
1 Allen wrench 1Set
2 Constant torque wrench 1Set
3 Socket wrench 1Set
4 Circlip pliers 1
5 Chisel 1
6 Hammer 1
7 Screwdriver 1
8 Copper bar 1kg 1
9 Plum wrenches 8 pieces / set 1Set
10 Slip joint pliers 200(8”) 1
11 Crowbar 2
1 - 401
二、Disassembly steps and procedures of MYF110 gearbox
In this section it mainly gives the disassembly steps of MYF110 gearbox (see the
figure below for the assembly).
1. Loosen the magnetic oil drain plug at the bottom of the box, remove the plug and
drain the oil in the gearbox.
Plug Oil drain plug
1 - 402
2. Remove the external oil pipe assemblies and joints
KF gear hose
Joints (4)
CF gear hose
C1 gear hose
FA gear hose
3. Remove screws and filter assembly
Screw M8×80 (1)
Filter assembly
Screw M8×35 (1)
1 - 403
4. Remove screws, combination valve and frame mounting bracket
Screw M10×30 (4)

Screw M6×65 (4)
Combination valve
Mounting bracket
1 - 404
5. Remove the upper and lower integrated valve assembly (be careful not to break the
ring gasket)
Gasket
M8×50（7 个）
Screw M8×50 (7)
Upper integrated
valve
Lower integrated
valve
Screw M8×50 (8)
Gasket
6. Remove the nut, gasket and output flange assembly
Output flange assembly
1 - 405
7. Remove movement assembly of the torque converter
Movement assembly of the torque

converter
8. Remove the plug and fixing bolts of torque converter’s housing.
Screw M10×30 (40)
VSTI22×1.5EDCF(J)Plug
Screw M10×100 (1)
VSTI14×1.5EDCF(J)Plug
1 - 406
9. Remove the torque converter’s housing
Torque converter’s
housing
10. Remove the two cylindrical pins and the filter screen
Cylindrical pins
Filter screen
1 - 407
11. Loosen the tightening screws of the main and auxiliary housings.
(10 screw M10×50; 15 screw M10×30)
Screw M10×50) Screw M10×50)
Screw M10×30)
Screw M10×30)
Screw M10×50)
Screw M10×50)
Screw M10×30)
Screw M10×50)
12. Knock the FA shaft with a plastic hammer to remove the auxiliary housing and FA
dust cover
Dust cover
Auxiliary housing
1 - 408
13. Lift out KF hub assembly with lifting hook
KF
14. Slightly lift the C2/O hub assembly and remove the C1 hub assembly
C1
C2/O
1 - 409
15. Separate the CF hub and N/CR hub from the bearing outer ring and lift them out
in turn.
N/CR
CF
16. Remove the C3, FA and C2/O hubs together with the shield.
FA
C2/O
C3
Shield
1 - 410
17. Remove the PTO and retaining ring with a plastic hammer
PTO
Retaining ring
.
18. Remove the bearing and sealing ring on the PTO
Bearing 6009C3
Sealing ring
1 - 411
19. Remove the O-ring, plug and bearing outer ring from the main housing, and pay
attention to the matching of the inner and outer rings of the bearing.
O-ring 17x1.8 Outer rings of the bearing
O-ring 21.2x2.65
plug
20. Remove the oil suction pipe and bearing outer ring of the auxiliary housing.
oil suction pipe
Outer rings of the

bearing
Glued bolt M8×18
1 - 412
21. Remove the variable speed pump assembly, plug, purging plug assembly and oil
baffle cover.
Plug Screw M8×60 (8) Variable speed pump
Purging plug
Oil baffle cover
Variable speed pump assembly, drawing No.:

MYF110.3
O-ring 3×135 (inner diameter), GB3452.1
22. Take N/CR clutch assembly as an example to illustrate the disassembly

procedures. For other clutches, please refer to this.
1) Remove the sealing ring.
Sealing ring
2) Remove the hub gear and bearing LM48548 / LM48510 with special tools, and
remove the CR hub gear, together with needle bearing, thrust bearing, retaining
ring and other parts
1 - 413
Retaining ring
1.
Bearing LM48548/LM48510
2.
Thrust bearing
3.
Hub gear
4.
5.
Needle bearing
6.
3) Remove the friction plate retainer ring and platen
Retainer ring
Platen
1 - 414
4) Remove the driving friction plate, slave driven friction plate and disc spring
assembly in turn.
Driven friction plate
Slave driven friction plate
Disc spring assembly
5) Use tooling and snap ring pliers to remove the shaft retaining ring, compression
spring and spring seat.
Retaining ring
Spring seat
Compression spring
6) Inject compressed gas into the clutch and blow out the piston assembly.
Piston assembly
Compressed gas
1 - 415
7) Remove the sealing ring and bearing on the other side.
Sealing ring
Bearing
1 - 416
三、Assembly steps and procedures of MYF110 gearbox
In this section it mainly gives the assembly steps and procedures of MYF110
gearbox.
3.1 Precautions:
▲ Attentions:
1) When cleaning parts with strong dissolving agent or alkaline solvent, carefully follow
the instructions of the manufacturer.
2) Non metallic parts can be cleaned with soap and water.
★ Warnings:
1) Work in a well ventilated place
2) It is not recommended to use gasoline or solvent containing gasoline, which may cause
explosion.
3.2 Cleaning and drying of parts

The parts shall be cleaned of residual glue before assembly, and then cleaned. During
cleaning, the parts shall not collide with each other. The inner cavity and surface of the cleaned
parts shall be free of iron filings, rust spots, rust marks and burrs; Tetrachloride, emulsified oil
series or petroleum refining detergent can be used.
The cleaned parts can be dried with clean paper, cloth or compressed air. For the parts that
need to be assembled immediately, coat the parts with lubricating oil to prevent corrosion; For
the parts to be stored, anti-corrosion materials shall be used.
3.3 Inspection and repair of parts:
All parts must be inspected and confirmed before assembly. The specific inspection is
as follows:
1) For bearing parts, check whether the inner ring, outer ring, cage and roller are
scratched, worn, cracked and deformed. If any of the above conditions is found, the
bearing can not be reused.
2) For gear parts, check whether the teeth of the parts are excessively worn, glued, peeled
and abnormally deformed. Once the above problems are found, the parts can not be
used again.
3) For friction plate parts, check whether the parts are excessively worn, glued, peeled
and abnormally deformed. Once the above problems are found, the parts can not be
used again.
4) For the sealing rings at the shaft end and the inner and outer seals, O-rings and other
parts on the piston, check whether there are scratches, deformation, wear and other
phenomena. Once the above problems are found, the parts can not be used again.
1 - 417
5) For housings, check whether the stressed surface has cracks or dents and excessive
wear.
6) For fastening connectors, check whether the thread has tooth damage and whether the
thread has cracks, bumps and abnormal deformation.
7) The self-locking nut, oil seal and gasket shall not be reused after disassembly.
8) For burrs and bumps on non important surfaces of parts, they shall be repaired before
continuing to be used.
3.4 Attention shall be paid to the following during part assembly and final
assembly:
1) The tightening torque of threaded fasteners must comply with relevant requirements.
2) During assembly, apply thread sealant on the threads of fasteners and plane sealant on
the joints.
3) The bearing must be assembled in place with a sleeve and a copper hammer.
Warnings:
1) When installing the oil seal, be sure to use tooling or rubber hammer,
otherwise oil leakage at the oil seal will be caused by improper assembly.
2） All fasteners must meet the requirements of tightening torque, otherwise oil
leakage at O-ring and oil seal will be caused. The workpiece shall be
transported or hoisted stably and firmly to avoid sliding, tilting and falling
during working, which will result in machine damage and personal injury.
1 - 418
3.5 Assembly
3.5.1 Assembly tooling equipment
1 Press MYF110.923-9-000 retaining ring D40 press tooling
2 Press MYF110.923-11-00 retaining ring D50×2 press tooling
3 Press MYF110.923-24-000 retaining ring press tooling
4 Press MYF110.923-26-000 piston press tooling
5 Bearing 15126A /15245 assembly aids
6 Bearing 25877/25281 assembly aids
7 Bearing LM48548/LM48510 assembly aids
8 Bearing 32010 assembly aids
9 Bearing M88046/88010AS assembly aids
10 Bearing 32206 assembly aids
11 Oil pressure pulse tool PT040-T6000-S10S (22-40)
12 Oil pressure pulse tool PT070-T4000-S13S（32-70）
15 MYF110.902-2-000 transmission assembly transfer frame
16 MYF110.903-3-001 bench
17 MYF110.903-3-002 platen
18 MYF110.911-3-000MYF110 shaft assembly lifting tooling 1
19 MYF110.911-4-000MYF110 shaft assembly lifting tooling 2
MYF110.911-5-000 MYF110 shaft assembly lifting and pre

20
assembly platform 1
MYF110.911-6-000 MYF110 shaft assembly lifting and pre

21
assembly platform 2
1 - 419
22 MYF110.919-1-000MYF110 torque converter fixing tooling
23 MYF110.923-14-00 bearing 6009C3 press tooling
24 MYF110.923-15-00 bearing 15126A/1524 outer ring press tooling
25 MYF110.923-16-000 bearing 32010 outer ring press tooling
26 MYF110.923-17-00 bearing 32206 outer ring press tooling
27 MYF110.923-18-00 bearing 25877/25821 outer ring press tooling
MYF110.923-19-00 bearing LM48548/LM48510 outer ring press

28
tooling
29 MYF110.923-21-00 oil seal FB40 press tooling
30 MYF110.923-22-000 oil seal FB40 press tooling aids
31 MYF110.923-23-000 oil seal FB60 press tooling
32 MYF110.923-25-000 sealing sleeve press tooling
33 MYF110.923-27-000 tooling for bearing clearance measurement
3.5.2 Assembly of clutch component
i. Assemble CF hub assembly

1. Install the piston into the inner and outer O-rings.
Inner O-ring
Outer O-ring
2. Apply a layer of lubricating oil on the inner and outer O-ring surfaces of the piston.
Apply lubricating oil
3. Assemble the piston assembly into the CF hub.
1 - 420
Piston assembly
1 - 421
4. Assemble the above parts in the CF hub in the order of compression spring and
spring seat
Spring seat
Compression spring
5. Assemble retaining ring 40x1.75
Retaining ring
40x1.75
MYF110.923-24-000
retaining ring press
tooling
6. Assemble the disc spring assembly, 10 pairs of friction plates (driven+slave

driven), platen, retaining ring and other parts in place in turn.
Retaining ring
Platen
Drive friction plate
Slave drive friction plate
7. Inject 1.8MPa gas from the oil passage hole to make the piston move up and down
for several times, cut off the gas, and measure the distance L1 from the end face
of the piston to the end face of the hub when the piston is not working; The
compressed air is injected from the oil passage hole, the piston moves up to the
1 - 422
working state, and the air is not cut off. Measure the distance L2 from the end face
of the piston to the end face of the hub when the piston (during the actual
measurement, the L1 and L2 values increase the thickness of the gauge block).
Measure it for three times to calculate the average, and calculate the piston stroke
S= L1-L2. The piston stroke S shall be within 3.7 (+0.6, -0.2) mm. If it is not within
the specified range, replace the retaining ring until the requirements are met.
Inject with an air

gun
1 - 423
8. Assemble needle bearing, thrust bearing and CF hub gear.
Thrust bearing
Needle bearing
CF hub gear
9. Assemble inner ring of bearing M88046/88010AS (heated)
Inner ring of bearing M88046/88010A
10. Turn over the hub assembly and assemble the inner ring of bearing
15126A/15245
Inner ring of bearing 15126A/15245
ii. Assemble N/CR hub assembly

1 - 424
Inner O-ring
外O圈
Outer O-ring
3. Blow air with an air gun to check whether there is air leakage at the oil passage
hole. If it is qualified, assemble the piston assembly into the hub assembly.
Piston assembly
4. Assemble the above parts in the hub in the order of compression spring and spring
seat
Spring seat
Compression spring
1 - 425
Retaining ring
40x1.75 MYF110.923-24-000
retaining ring press
tooling
1 - 426
6. Assemble the disc spring assembly, 10 pairs of friction plates (driven+slave driven),
platen, retaining ring and other parts in place in turn.
Retaining ring
Platen
Driven friction plates
Slave driven friction plates
for several times, cut off the gas, and measure the distance L1 from the end face of
the piston to the end face of the hub when the piston is not working; The
Inject with an air

gun
8. Assemble needle bearing, thrust bearing and CF hub gear.
1 - 427
Thrust bearing
CF hub gear
Needle bearing
9. Assemble the inner ring of bearing LM48548/LM48510 (heated)
Inner ring of bearing LM48548/LM48510
10. Turn over the hub assembly and assemble the inner ring of bearing 32010
Inner ring of bearing 32010
1 - 428
iii. Assemble KF hub assembly
Inner O-ring
Outer O-ring
Piston assembly
1 - 429
seat
Spring seat
Compression spring
Retaining ring MYF110.923-24-000

40x1.75 retaining ring press
tooling
Retaining ring
Platen
Driven friction plates

1 - 430
Inject with an air

gun
8. Assemble needle bearing, thrust bearing and KF hub gear.
Thrust bearing
KF hub gear
Needle bearing
1 - 431
9. Assemble the inner ring of bearing 15126A/15245 (heated)
10. Turn over the hub assembly and assemble the inner ring of bearing 25877/25281
Inner ring of bearing 25877/25281
1 - 432
iv. Assemble C1 hub assembly
Inner O-ring
Outer O-ring
Piston
assembly
1 - 433
seat
Spring seat
Compression spring

tooling

Retaining ring
Platen

1 - 434
Inject with an air

gun
1 - 435
8. Assemble needle bearing, thrust bearing and C1 hub gear
Thrust bearing
C1 hub gear
Needle bearing
10. Turn over the hub assembly and assemble the inner ring of bearing 25877/25281
inner ring of bearing 25877/25281
1 - 436
v. Assemble C2/O hub assembly
Inner O-ring
Outer O-ring
Piston assembly
1 - 437
4. Assemble the above parts in the hub in the order of disc spring and washer
Washer
Disc spring

Retaining ring
40x1.75 MYF110.923-9-000 retaining
ring D40 press tooling

Retaining ring
Platen

1 - 438
Inject with an air

gun
1 - 439
8. Assemble needle bearing, spacer sleeve, thrust bearing and C2/O hub gear
Thrust bearing
C2/O hub gear
Needle bearing
spacer sleeve
10. Turn over the hub assembly and assemble the inner ring of bearing 32010.
1 - 440
vi Assemble C3 hub assembly
Inner O-ring
Outer O-ring
Piston assembly
1 - 441
seat
Spring seat
Compression spring

tooling
Retaining ring
Platen

1 - 442
Inject with an air

gun
1 - 443
8. Assemble needle bearing, thrust bearing, spacer sleeve and C3 hub gear
Thrust bearing
C3 hub gear
Needle bearing
Spacer sleeve
9. Assemble the inner ring of bearing 32206 (heated)
10. Turn over the hub assembly and assemble the inner ring of bearing
15126A/15245
1 - 444
vii Assemble FA hub assembly
Inner O-ring
Outer O-ring
Piston assembly
1 - 445
4. Assemble the above parts in the hub in the order of disc spring and gasket
Gasket
Disc spring
5. Assemble retaining ring 50x2
Retaining ring MYF110.923-11-000 retaining ring D50x2

50x2 press tooling

Retaining ring
Platen

1 - 446
Inject with an air

gun
1 - 447
8. Assemble FA hub gear (quickly install after heating) and shaft ring.
Shaft ring
FA hub gear
10. Turn over the hub assembly and assemble the inner ring of bearing 32010.
1 - 448
3.5.3 Assemble the box component
i. Assemble the auxiliary housing assembly
1. Hoist the auxiliary housing onto the tooling bench, and fix the housing with bolts and
platen.
MYF110.903-3-001 bench
Bolt M14x75
MYF110.903-3-002 platen
2. Assemble the oil suction pipe: put the O-ring on the oil pipe and apply
an appropriate amount of lubricating oil on the O-ring. The tightening
torque of M8x18 bolt is 25 ~ 30N.m.
7.
8. O-ring
9.
10. Glued bolt M8×18
11.
12. Oil suction pipe
13.
14.
1 - 449
3. Assemble the purging plug and oil baffle. Note: Apply thread sealant to
M8 nuts. When tightening M8 nuts, the tightening torque is 25 ~ 30N.m.
Glued nut M8
15.
Bolt M8×20 Purging plug assembly

Oil baffle
16.
4. Assemble plug, filter screen and oil baffle cover. The tightening torque
of plug is 20-25N.m. When assembling the oil baffle cover, first assemble
the O-ring on the oil baffle cover, apply an appropriate amount of
lubricating oil, and then install it; After it is assembled in place, limit it with
retaining ring.
65 Retaining ring 65
Oil baffle cover
O-ring 43.7x3.55
Plug
Filter screen
1 - 450
5. Assemble dowel pin
6. Apply flat anaerobic sealant on the mating surface of the auxiliary

housing and the torque converter’s housing, assemble the torque converter’s
housing, and the tightening torque of screw is 49-59N.m.
Screw M10×30 (40)
Screw M10×100 (1)
7. Assemble the plugs. The tightening torque of VSTI14×1.5EDCF(J) plug

is 45N.m; and the tightening torque of VSTI22×1.5EDCF(J) plug is
125N.m.
VST122×1.5EDCF(J) Plug
VST144×1.5EDCF(J) Plug
17.
1 - 451
8. Assemble the variable speed pump assembly. Before assembly, apply
lubricating oil at the chamfer of the torque converter’s housing and the O-ring
of the variable speed pump; Guide the pump with two auxiliary screws and
knock with a copper rod during assembly. The assembly process of variable
speed pump shall be stable and safe. Be careful not to scratch the O-ring.
Screw M8×60
For
18. auxiliary positioning
9. Tighten the screws. Pay attention to apply thread tightening sealant

before assembly. There are 8 M8x60, 2 screw M8x16, 2 screw M8x35.
Beware of missing and wrong installation. The tightening torque of the screw
is 25-30N.m. Then turn the bench over and remove the auxiliary screws.
Screw M8×60 (8)
Screw M8×16 (2) Screw M8×35 (2)
1 - 452
ii. Assemble the main housing assembly
1. Assemble the plugs. The tightening torque of VSTI10×1EDCF(J) plug is
20-25N.m; and the tightening torque of VSTI18×1.5EDCF(J) plug is 55N.m.
VSTI10×1EDCF(J) plug
VSTI10×1EDCF(J) plug
VSTI18×1.5EDCF(J) plug
2. Fix the mounting bracket on the main housing with 4 M16x35 bolts.
MYF110 mounting
bracket
Bolt M16×35
1 - 453
iii. Assemble the PTO and valve assembly
1. Assemble the PTO assembly: first assemble the sealing ring, then
assemble the bearing (heated), and limit with the retaining ring
19.
Retaining ring 45x1.75
20.
21. Bearing 6009C3
22.
Sealing ring
23.
24.
2. Assemble the upper integrated valve assembly. Pay attention that the
tightening torque of the screw M6x12 is 10-12N.m.
25.
Two-position four-way Two-position five-way solenoid valve assembly
solenoid valve assembly
Screw M5x10 (4)
gasket
gasket
Screw M6X12 (1)
3. Assemble the lower integrated valve assembly. Pay attention that the
tightening torque of the screw M6x12 is 10-12N.m.
Two-position three-way solenoid valve
Two-position four-way assembly
Gasket (1)
Two-position five-way
Gasket (3)
Screw M5x10 (6)

Screw M6X12 (1)
1 - 454
iv.Assemble the housing
1. Fix the main housing assembly on the assembly bench with 4 M20x65 bolts and
M20 nuts.
Bolt M20×65
Nut M20
2. Install plugs, perforated plug M14 and magnetic oil drain plug. The tightening
torque of VSTI22×1.5EDCF (J) plug is 125N.m; The tightening torque of magnetic
oil drain plug is 50-60N.m; The tightening torque of VSTI10×1EDCF(J) plug is 20-
25N.m; The tightening torque of VSTI14×1.5EDCF(J) plug is 45N.m;The tightening
torque of VSTI18×1.5EDCF(J) plug is 55N.m.
Perforated plug M14 VSTI18×1.5EDCF(J) plug (3)
VSTI14×1.5EDCF(J) plug (4)
VSTI10×1EDCF(J) plug (8)
VSTI22×1.5EDCF
Magnetic oil drain plug
(J) plug（1 个）
3. Assemble solenoid valve, the tightening torque of the screw M6x16 is 10-12N.m.
Two-position three-way solenoid valve

assembly (2)
Platen
Screw M6X16 (2)
1 - 455
v. Assemble the hub assembly
1. Measure the bearing spacing H of each hub assembly and record the measured
values on the corresponding hub. During the measurement, press with the
counterweight, and rotate the hub assembly. Measure it for three times to calculate
the average as the final H. Record the distance B from the end face of the bearing
of the corresponding main housing to its joint surface.
2. Assemble the O-ring and the outer ring of the bearing

Outer ring of the bearing
15126A/15245
O-ring 17x1.8
O-ring 21.2x2.65
Outer ring of the

bearing 32010
Outer ring of the

bearing 32206
1 - 456
3. Assemble the snap seal ring φ30x2 (5) and sealing ring 50x2.5 (4).
Snap sealing ring φ30x2
Sealing ring
50x2.5
4. Assemble C3 hub assembly, C2/0 hub assembly, FA hub assembly and shield
Shield
5. Assemble CF hub assembly, N/CR hub assembly and KF hub assembly
6. Assemble C1 hub assembly
1 - 457
vii. Adjust the clearance
1. Record the distance A between the end face of the bearing of the auxiliary housing
and its joint surface, and bearing spacing of closer D= A + B. Calculate bearing
clearance ΔL=D-H；It is required ΔL is between -0.12 ~ 0.09; Adjust the clearance
by adding adjusting pad or returning to the factory for processing.
2. Assemble the outer ring of the bearing of the auxiliary housing.
Bearing 15126A/15245 (outer ring)

Bearing M88046/88010AS (outer
ring)
Bearing LM48548/LM48510
(outer ring)
Bearing 25877/25281 (outer ring)
Bearing 32010 (outer ring)
1 - 458
viii. Mould assembling of main and auxiliary housings
1. Assemble the snap seal ring Snap sealing φ30x2 (6)
Snap sealing 35x2.5 (1)
2. Assemble the dowel pin, and apply flat anaerobic sealant on the mating surfaces
of the main and auxiliary housings.
Dowel pin Dowel pin
3. When hoisting the auxiliary housing assembly, the spline end of N/CR hub
assembly shall pass through the hole of variable speed pump assembly to prevent
the spline from being knocked. The screw are M10x30 (15), M10x50 (10). The
tightening torque of the screws is 49-59N.m.
Screw M10X50 Screw M10X50
Screw M10X30
Screw M10X30
Screw M10X50
Screw M10X50
Screw M10X30
Screw M10X50
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4. Assemble the frame oil seal FB40x62x7 and FA dust cover.
FA 防尘罩
FA dust cover
骨架油封 FB40×62×7
Frame oil seal FB40x62x7
1 - 460
ix. Assemble the valve assembly
1. Place the gasket on the combination valve and fix the combination valve to the
auxiliary housing with screws. The tightening torque of screw M8x50 is 25-30N.m,
The tightening torque of screw M6x65 is 10-12N.m.
Screw M8x50
Gasket
Screw M6x65
2. Assemble filter assembly, The tightening torque of screw M8x35, M8x80 is 25-
30N.m. Do not scratch the O-ring during assembly.
Screw M8x80
Screw M8X35
Filter
3. Assemble the upper integrated valve assembly, place the gasket on the upper
surface of the main housing, and fix the upper integrated valve assembly to the
main housing with screws, The tightening torque of screw M8x50 is 25-30N.m.
Screw M8X80 (7)
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4. Assemble the lower integrated valve assembly, place the gasket on the lower
surface of the main housing, and fix the lower integrated valve assembly to the
main housing with screws, The tightening torque of screw M8x50 is 25-30N.m.
Screw M8X50 (8)
5. Assemble the joints and hose assembly. Note: Just screw the joint into the
corresponding threaded hole by hand without force；The tightening torque of
hollow bolts is 55N.m.
CF gear hose assembly
Joints
KF gear hose assembly
C1 gear hose
assembly Hollow bolts Washer 16
FA gear hose
assembly
1 - 462
x. Assemble the flange assembly
1. Assemble the PTO
Retaining ring 75x2.5
PTO
2. Assemble the frame oil seal
MYF110.923-23-000 oil seal FB press tooling
Frame oil seal
1 - 463
3. Assemble the output flange assembly, assemble the O-ring on the flange, and
apply an appropriate amount of lubricating oil.
4. Assemble and tighten the lock nut, and smash the thin wall of the lock nut into the
shaft notch with a chisel for limit.
Lock nut
Washer
O-ring
Output flange
xi. Assembly movement

1. Hoist the torque converter’s movement assembly, assemble it into the torque
converter’s housing (push the torque converter’s movement to the bottom), and
tighten and fix it with tooling, M10 nuts and M10x100 bolts.
M10 Nut
Bolt M10×100
1 - 464
2. Assemble the label at the position shown in the auxiliary housing
Label
3. Remove the gearbox from the assembly bench, remove the MYF110 mounting
support, assemble support I, support II, and the tightening torque of bolt M16X35
is 295-350N.m.
Glued bolt
Support II Support I
1 - 465
Axle
6.2.1 Structure, principle and function
The drive axle is divided into front and rear axles. The front axle is a swing steering
axle, and the rear axle is a rigid fixed axle. The drive axle is mainly composed of axle
housing assembly, main reducer assembly, hub reducer assembly and brake
assembly. The main transmission is a one-stage bevel spiral gear reduction, and the
differential is composed of straight axle shaft gears and bevel planetary gears. The left
and right shafts of the front axle are articulated, those of the rear axle are fully floating,
and the hub reduction mechanism is planetary gear type. The ring gear and hub
supporting shaft are fixed, while the planetary gear carrier and the rim are fixed as a
whole. The sun gear receiving half shaft torque drives the planetary carrier to drive the
wheels to rotate.
The front axle is a steering drive axle, which is driven by two-stage reduction. The
wheel hub and the main reducer are connected through an articulated half shaft, and
the left and right steering linkage is realized through an external cylinder. The axle has
no brake;
The rear axle is a rigid fixed drive axle. Wet brake and hydraulic fork differential lock
are built in at the main reducer, which can improve the trafficability of the differential on
muddy roads and increase the traction force of the whole machine. The wet brake is a
brake half shaft structure with small volume. The half shaft and hub sun gear are
integrated into one to provide compact and reasonable structure. The rear axle is
equipped with external caliper-disc parking brake, which is convenient for
maintenance.
The drive axle decelerates the power from the gearbox through the main
transmission, increases the torque, changes the rotation axis to the transverse
direction, and then transmits it to the differential. Then, after passing through the
planetary gear, half shaft gear and half shaft in the differential, the power is transmitted
to the final drive gear for further deceleration and torque increase, and then
transmitted to the drive wheels to make the machine run.
See the figure below for the front and rear axle assemblies:
1 - 466
Fig. 1 A1092III Front Axle
1. Main reducer assembly 2. Axle housing assembly 3. Left wheel hub 4. Right wheel hub 5. Nameplate 6.
Linkage mechanism 7. Oil cylinder
Fig. 2 WA1080III Rear Axle

1. Hub assembly 2. Main reducer assembly 3. Left axle housing assembly 4. Right axle housing assembly 5.
Nameplate
1.1 Introduction to Main Reducer
Fig. 3 Main Reducer Assembly of A1092III Front Axle
1 - 467
Fig. 4 Main Reducer Assembly of WA1080III Rear Axle
The main reducer of A1092III/WA1080III drive axle is composed of a pair of
spiral bevel gears. The driving spiral bevel gear is integrated with the shaft and
supported by cantilever, with one end supported on two tapered roller bearings
on the main reducer housing. The driven spiral bevel gear is fixed on the flange
of differential housing I by bolts. The left and right differential housings are
bolted together and then installed in the seat holes of the bracket assembly by
two tapered roller bearings. The main reducer housing is fastened on the drive
axle body by bolts to form a closed housing. An appropriate amount of
lubricating oil is filled in the axle housing, and the lubricating oil splashes to
lubricate gears and bearings with the help of gear rotation.
The differential is composed of bevel gear, half shaft gear, straight shaft and
differential housing. Install the left and right half shaft gears with half shaft gear
gaskets and then install them into the left and right differential housing seat
holes. After installing planetary bevel gears (two for front axle and four for rear
axle) on the straight shaft and bevel gear gaskets, install the straight shaft into
the round hole of the differential housing, with its centerline coincident with the
interface between the left and right differential housings. Then fix the left and
right housings together with bolts and support them in the main reducer
housing with two tapered roller bearings.

Installation instructions for main reducer:
1 - 468
1) Clean the parts before assembly, and apply gear lubricating oil to the half shaft
gear, half shaft gear gasket, planetary bevel gear and bevel gear gasket when
assembling.
2) Adjust the rolling bearing with adjusting gasket and lock nut to obtain a
resistance torque of 3-6N.m when the driving spiral gear rotates.
3) Apply high-strength thread locking agent to the bolts fastening the driven spiral
bevel gear, and the tightening torque is 49~59 N·m for front axle and 86~103
N·m for rear axle.
4) Apply 3# lithium-based grease evenly to the frame oil seal.
5) After assembling, the half shaft gear and planetary gear shall be able to rotate
lightly by hand without jamming. The minimum side clearance of gear
engagement is 0.15~0.20mm for front axle and 0.18-0.23mm for rear axle.
6) Adjust the lock nut and adjusting gasket to ensure that the meshing backlash of
spiral gear pair is 0.20-0.30mm for front axle and 0.20~0.30mm for rear axle,
and the variation tolerance of gear pair backlash is ≤0.1mm.
7) 1> The meshing spot of spiral bevel gear shall be 35%~50% of the tooth length
along the tooth length direction and 40%~70% of the tooth height along the tooth
height direction. The meshing spot of working tooth surface must be controlled in
the middle smaller end of the tooth, preferably 2~7mm; and that of non-working
tooth surface must be controlled in the middle of the tooth;
2> The meshing spot of bevel gear transmission shall be ≥50% along the tooth
length and height directions.
1.2 Introduction to Hub Assembly

The hub assembly is used to reduce the speed of power from the main transmission again,
increase the torque and transmit it to the drive wheels for mechanical running or various
operations; realize vehicle braking (rear axle).
See the figure below for the structural composition of axle hub assembly:
1 - 469
Fig. 5 Left/Right Hub Assembly of A1092III Front Axle Fig. 6 Hub Assembly of WA1080III Rear Axle
1) A1092III front axle hub is divided into left and right hubs. They are all
composed of hinged half shaft, steering knuckle, hub, ring gear, planetary
gear, planetary carrier and planetary shaft. The difference is that the directions
of hinge holes of steering knuckles are different.
2) WA1080III rear axle hub is composed of sun gear shaft, hub, ring gear,
planetary gear, planetary carrier and planetary shaft.
3) The hub reduction mechanism is composed of three planetary gears evenly
distributed on the ring gear assembly. There are needle rollers between the
planetary gears and the planetary gear shaft to reduce frictional resistance.
The three planetary gears mesh with the sun gear shaft and the ring gear
assembly, and the ring gear support assembly is installed on the steering
knuckle (front axle)/axle housing (rear axle) through bolts. When the sun gear
shaft rotates, it forces the planetary gear to roll on the ring gear assembly, thus
driving the planetary gear carrier and hub to rotate and making the main
engine run. The wheel hub does not have a braking structure.
Instructions for wheel hub installation:
4) Needle rollers shall be assembled in groups, and the difference between the
maximum and minimum inner diameters of the same group shall be less than
0.003mm;
5) Apply sealant around the mating surface between planetary shaft and
planetary carrier;
6) Apply grease evenly when assembling the oil seal;
7) After installing the hub assembly and gear ring assembly, tighten the 4
uniformly distributed bolts on the gear ring, rotate the hub forward and
backward by hand for 3 ~ 5 turns respectively, and measure the tension at the
rim bolt with a tension meter to keep it at 90~150N;
8) The tightening torque of bolts fixing the ring gear assembly shall be 110~130
N.m for front axle and 215~235 N.m for rear axle, 25~30 N.m for planetary
carrier, 72~85 N.m for planetary shaft and planetary cover plate; apply Loctite
262 thread locking agent to the bolts;
9) Adjust the axial clearance of sun gear to 1~2mm by selecting and adjusting
struts;
6.2.2 Operation, maintenance and repair
2.1 Production Safety
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Generally, maintenance personnel are responsible for their own production safety
during product maintenance.
The premise of all effective safety systems and laws and regulations is to avoid
damage to people and products under maintenance. Maintenance personnel must be
familiar with these laws and regulations. Maintenance of the product shall be carried
out by maintenance personnel who have received professional training and mastered
maintenance skills.
The following safety references apply to this Maintenance Manual:
: This icon indicates the working process, method and auxiliary tool to be paid
attention to in this document;
: This icon indicates that lack of safety awareness may cause personal injury or
product damage.
Reference
1> Before inspection and maintenance, read this Maintenance Manual carefully;
2> Illustrations, drawings and components may differ from the original version and are
not drawn to scale,
It cannot be used as a reference for dimension and weight;
3> After completion of the maintenance and performance test, the staff shall
confirm that the product can work normally.
2.2 Adjustment of Meshing Spots of Spiral Bevel Gear Pair
Fig. 1 Gear Meshing Contact and Adjustment Method
1 - 471
Surface contact
position of driven Adjustment Movement
gear methods direction
Forward Revers of gears
e
Move the driven
Driven spiral gear closer to
bevel gear the driving gear.

If the backlash is
too small, move
the driving gear
Driving outward
surface Move the driven
gear away from
the driving gear.
Driven surface If the backlash is
too large, move
the driving gear
Drive spiral inward
bevel gear Move the driving
gear closer to
the driven gear.
Driving surface
If the backlash is
too small, move
the driven gear
Driven surface outward
2.3 Lubrication and Move the driving
Maintenance gear away from
2.3.1 Oil specification:
the driven gear.
85W/90GL-5 heavy-duty
If the backlash is
vehicle gear oil.
too small, move
the driven gear 1 - 472
inward
2.3.2 Replacement of oil
When replacing oil, place the main engine on a flat ground. All oil drain holes, oil
filler holes and oil level holes must be cleaned before opening.
A1092 III front axle
WA1080III rear axle
Legend:
1: When the arrow direction of the oil drain hole is horizontal, it is the filler position; when the arrow direction is
vertically downward, it is the oil drain position
2: Oil level hole M26×1.5
3: Final drive oil drain hole M12×1.25 (front), M24×1.5 (rear)
4: Brake oil inlet M16×1.5
5: Vent pipe M10×1
6: Brake exhaust valve M16×1.5
1 - 473
2.3.2.1 Oil draining
1) It is better to drain oil when the axle has just finished working and the
machine internal temperature is high;
2) Drain oil respectively at the wheel rims at both ends of the axle and the
final drive in the middle of the axle;
3) The air pressure in the axle shall be relieved before oil drain. If the oil is
drained before the air pressure is released, it may cause oil splashing;
4) Remove the plugs 1 and 3 to drain oil.
2.3.2.2 Refueling
1) Adjust the red arrow 1 at both wheel rims to be horizontal;
2) The oil filler amount shall be controlled based on the oil level hole of the axle.
When the arrow is horizontal, it is the oil filler position. During oil filling, the oil level
line is at the lower busbar of the screw hole opening, and a small amount of oil
spillage will be allowed. The total oil filling volume is about 7.1L for the front axle
(about 5.7L for final drive and about 0.7L for single wheel rim) and about 13L for the
rear axle (about 10L for final drive and about 1.5L for single wheel rim). The actual
oil filling volume shall be subject to the observation of the lower busbar of the screw
hole;
2.3.2.3 Check the oil level
1) Check the oil level after 5 min. of oil filling until the oil level reaches the specified
level; check the lubricating oil level in the final drive and wheel rim once a month,
add it in time to maintain the required oil level.
2) Install the wheel rim and final drive position plug (be sure to check whether there
are wear cracks on the combined washer before tightening the plug, and replace
it in time if any).
2.3.2.4 Oil replacement interval
First oil replacement: the new vehicle runs for one month or works for 250 h;
Periodic oil replacement: every 1,000 working hours thereafter (at least once a year).
2.3.2.5 Inspection of breather pipe
Remove oil stains, soil and dust frequently, and keep the breather pipe unblocked.
2.3.2.6 Brake oil
L-HM antiwear hydraulic oil (32, 46). When the machine runs for 4000~5000 h, it is
necessary to check the brake oil pressure.
2.3.2.7 Brake exhaust
1> Unscrew the exhaust valve;
1 - 474
2>Gently depress the brake pedal until fluid flows out from the exhaust valve;
3> Tighten the exhaust valve;
4> Gently depress the brake pedal and hold it for several seconds (the brake piston is
displaced, the brake cylinder is filled with oil, and residual air is distributed on the
upper part of the cylinder);
5> Release the brake pedal to release the braking state (the reset piston presses air
from the upper part of the cylinder into the brake pipeline);
6> Unscrew the exhaust valve;
7> Gently depress the brake pedal until oil overflows from the exhaust valve (Note:
Repeat steps 3 to 7 until no air overflows from the exhaust valve)
2.3.2.8 Greasing position and amount
1 > Upper and lower grease nipples of front axle steering knuckle, and hinged joint
between the middle of front axle and rack (five in total)
Greasing equipment: manual pump grease model: #2 extreme pressure lithium-
based grease
Grease filler amount: Inject grease from the grease nipple until the grease oozes
out of the disc spring on the contact surface. New grease must also be filled before
and after the machine stops running for a long time.
Greasin
g
Greasin
g
position
2> Greasing cycle

Add grease once a day before work.
2.5 Plates
1 - 475
2
3
1: Supplier code;
2: Material code;
3: Product origin;
4: Ex-factory batch.
2.6 Unit Conversion Table

2.7 Bolt Tightening Torque Standard
When the tightening torque requirements are not indicated, refer to the table below
(tightening torque of common bolts)
Bolt Bolt nominal diameter (mm)
Yield
strengt 6 8 10 12 14 16 18 20
strength
h
N/mm 2
Tightening torque (N.m)

Class
4.6 240 4-5 10-12 20-25 36-45 55-70 90-110 120-150 170-210
5.6 300 5-7 12-15 25-32 45-55 70-90 110-140 150-190 210-270
6.8 480 7-9 17-23 33-45 58-78 93-124 145-193 199-264 282-376
8.8 640 9-12 22-30 45-59 78-104 124-165 193-257 264-354 376-502
10.9 900 13-16 30-36 65-78 110-130 180-201 280-330 380-450 540-650
12.9 1080 16-21 38-51 75-100 131-175 209-278 326-434 448-597 635-847
Bolt Bolt nominal diameter (mm)

Yield
strengt 22 24 27 30 33 36 39
strength
h
N/mm 2
Tightening torque (N.m)

Class
928-1237
1160-
230-290 1546
4.6 240 300-377 450-530 540-680 670-880 900-1100
290-350 1559-
5.6 300 370-450 550-700 680-850 825-1100 1120-1400
384-512 2079
6.8 480 488-650 714-952 969-1293 1319-1759 1694-2259
512-683 2923-
8.8 640 651-868 952-1269 1293-1723 1759-2345 2259-3012
740-880 3898
10.9 900 940-1120 1400-1650 1700-2000 2473-3298 2800-3350
864- 4111-
12.9 1080 1098-1464 1606-2142 2181-2908 2968-3958 3812-5082
1152 5481
4933-
6577
1 - 476
6.2.3 Introductions to Disassembly
3.0 Removal and Disassembly
Caution:
1) Be sure to wear protective equipment such as protective
gloves, shoes and goggles during removal and disassembly;
2) It is strictly prohibited to remove threaded fasteners with chisel and
hammer;
3) The removed parts shall be kept clean, and fasteners and other
smaller parts shall be well kept to prevent loss and damage.
Warning:
1) Remove threaded fasteners with a chisel and hammer, which may cause
damage to parts or personal injury;
2) Before removal, the drive axle shall be firmly supported to avoid sliding
and tilting during removal and installation, which may cause damage to
parts or personal injury.
Drain the lubricating oil in the axle
1) It is better to drain oil when the axle has just finished working and the
machine internal temperature is high;
2) Drain oil respectively at the wheel rims at both ends of the axle and the
final drive in the middle of the axle;
3) The air pressure in the axle shall be removed before oil drain (by
removing the breather plug, etc.); if the oil is drained before the air
pressure is released, it may cause oil splashing.
3.1 Removal of Front Axle
3.1.1 Removal of spherical hinge and cylinder
3.1.1.1 Loosen the nuts
fastening the right-angle
spherical hinge and between
the right-angle spherical hinge
and the spherical hinge, and
remove the 2 types of
spherical hinges.
Fig. 3.1
1 - 477
3.1.1.2 Loosen the bolts connecting
the cylinder and axle housing, and
remove the cylinder.
Fig. 3.2
3.1.2 Removal of wheel rim
3.1.2.1 Loosen the screws connecting

the planetary carrier and the hub, lift
the planetary carrier with a safety belt,
and lift it away from the wheel rim.
The lifting rope must be firm and

reliable. It is strictly prohibited to lift the workpiece with rubber belts.
The position of the lifting rope must be made reasonable and reliable,
and attention shall be paid to lifting safety.
Fig. 3.3
3.1.2.2. Loosen the bolts connecting the

ring gear support and steering knuckle, and
remove the retainer ring and gasket.
Fig. 3.4
3.1.2.3 Take out the ring gear assembly.
1 - 478
Fig. 3.5
3.1.2.4 Remove the flange shafts I and II.
Fig. 3.6
3.1.2.5 Remove the hub together with

the steering knuckle. Remove the shaft
sleeve and oil seal from the hinged axle
shaft.
Fig. 3.7
3.1.3 Removal of final drive assembly
3.1.3.1.Take out the hinged axle shaft.
1 - 479
Fig. 3.8
3.1.3.2 Remove the final drive assembly

connecting bolts. Take out the final drive
assembly with safety belt lifting rope and
lifting ring.
The lifting rope must be firm and reliable.

It is strictly prohibited to lift the workpiece
with rubber belts. The position of the
lifting rope must be made reasonable
and reliable, and attention shall be paid to lifting safety.
Fig. 3.9
3.1.4 Disassembly of final drive assembly
3.1.4.1 Place the final drive assembly on the support and mark the bearing
pedestal and
final drive housing.
Fig. 3.10
1 - 480
3.1.4.2 Remove the mounting bolts of bearing pedestal.
Fig. 3.11
3.1.4.3 Remove the bearing pedestal
after removing the locking plate.
Fig. 3.12
3.1.4.4 Remove the adjusting nut, and
use a rope to
carefully lift the differential out of the
housing.
Fig. 3.13
3.1.4.5 Remove the oil seal cover and oil seal.
3.1.4.6 Remove the lock nut and gasket.
1 - 481
3.1.4.7 Remove the small spiral bevel
gear with appropriate tools.
Do not damage the spline, and place

a wooden plate under the final drive
housing,
to prevent the force generated by the
heavy hammer from hurting the small
spiral bevel gear.
Fig. 3.14
3.1.4.8 Take out the bearing inner
ring.
Fig. 3.15
3.1.4.9 Remove the adjusting gasket.
3.1.4.10 Remove the spacer sleeve and driving spiral bevel gear.
Fig. 3.16
1 - 482
3.1.4.11 Mark the outside of differential
housing assembly.
Fig. 3.17
3.1.4.12 Unscrew the bolts on the end

face of driven spiral bevel gear, and
remove differential housing I, driven
spiral gear and bearing.
Fig. 3.18
3.1.4.13 Remove the axle shaft gear
and its gasket.
Fig. 3.19
1 - 483
3.1.4.14 Remove the straight shaft,
differential planetary bevel gear and
bevel gear gasket.
Fig. 3.20
3.1.4.15 Remove the axle shaft gear

and its gasket from the differential
housing.
Fig. 3.21
3.2 Removal of Rear Axle
3.2.1 Removal of wheel rim assembly
3.2.1.1 Loosen the plug right above
(turn the plug to 12 o'clock
direction), release the air pressure
in the axle, and re-screw the plug.
If the oil is drained before exhausting, it will cause oil
splashing.
1 - 484
Fig. 3.22
3.2.1.2 Unscrew the bottom oil drain
plug to drain oil (turn the plug to 6
o'clock direction)
Fig. 3.23
3.2.1.3 Remove the 2 fastening

screws M8×20.
Fig. 3.24
1 - 485
3.2.1.4 Hoist the planetary gear carrier with a safety belt and lift it away
from the wheel rim.
The lifting rope must be firm and
reliable. It is strictly prohibited to
lift the workpiece with rubber
belts. The position of the lifting
rope must be made reasonable
and reliable, and attention shall be
paid to lifting safety.
Fig. 3.25
3.2.1.5 Remove the planetary gear,

planetary shaft, needle roller, gasket
and axle shaft in turn.
Fig. 3.26
3.2.1.6 Remove the ring gear
1 - 486
Fig. 3.27
3.2.1.7 Remove the hub, bearing and
floating oil seal in turn.
The lifting rope must be firm and reliable.
It is strictly prohibited to lift the workpiece
with rubber belts. The position of the
lifting rope must be made reasonable and
reliable, and attention shall be paid to
lifting safety.
Fig. 3.28
3.2.2 Removal of final drive assembly
3.2.2.1 Remove the connecting bolts

between axle body and final drive assembly.
Fig. 3.29
3.2.2.2 Lift the axle body and internal

friction lining and spline sleeve with safety
belts, and safely lift them away from the
final drive assembly.
Fig. 3.30
1 - 487
The lifting rope must be firm and reliable. It is strictly prohibited to lift
the workpiece with rubber belts. The position of the lifting rope must be
made reasonable and reliable, and attention shall be paid to lifting safety.
3.2.2.3 Repeat steps 1 and 2 to remove the axle body on the other side.
3.2.3 Disassembly of rear axle final drive assembly
3.2.3.1 Loosen the lock nut at the driving

spiral gear end, and remove the flange
assembly, 310 brake, brake support, seal ring
and bearing in turn.
Fig. 3.31
3.2.3.2 Loosen the 3 fastening screws and
lock nuts on the brake housing, and remove
the brake housing together with the piston.
Fig. 3.32
3.2.3.3 Remove the differential housing
assembly and its internal axle shaft gear,
bevel gear, gasket, shaft sleeve, retainer
ring, etc.
1 - 488
Fig. 3.33
3.2.3.4 Remove the driving spiral gear,
bearing, gasket and spacer sleeve.
Fig. 3.34
3.2.3.5 Remove the support, cover plate, shift

fork assembly, piston, spring and other parts
on both sides in turn.
Fig. 3.35
1 - 489
3.2.3.6 Marking on the outside of differential
assembly
Fig. 3.36
3.2.3.7 Unscrew the bolts on the end face of

driven spiral bevel gear, and remove the
differential housing I, driven spiral gear and
bearing.
Fig. 3.37
3.2.3.8 Remove the axle shaft gear and its gasket.
Fig. 3.38
1 - 490
3.2.3.9 Remove the straight shaft,
differential planetary bevel gear and bevel
gear gasket.
Fig. 3.39
3.2.3.9 Remove the axle shaft gear and its
gasket from the differential housing.
Fig. 3.40
3.2.3.10 Remove the shaft sleeve, retainer ring, lock pin and O-ring.
.
4. Assembly Instructions
4.0 Preparations before Assembly and Precautions
4.0.1 Preparation of Parts before Assembly
1) When strong solvents or alkaline solvents are used for cleaning, the
manufacturer's instructions shall be followed carefully.
2) Non-metallic parts can be cleaned with soap and water.
3) Wear eye and clothing protective equipment during cleaning.
4) Work in a well-ventilated area.
1 - 491
5) It is not recommended to use gasoline or solvent containing gasoline
which may cause explosion.
4.0.2 Cleaning and drying of parts
Before assembling the parts, remove the residual sealant and then clean them.
During cleaning, avoid collision between the parts. The inner cavity and surface of
the cleaned parts shall be free of any scrap iron, rust spots, rust stains and burrs.
Tetrachloride, emulsified oil series or petroleum refined detergent can be used.
Cleaned parts can be dried with clean paper, cloth or compressed air.
The parts to be assembled immediately shall be applied with grease to prevent
corrosion, and anti-corrosion materials shall be used for the stored parts to prevent
corrosion.
4.0.3 Inspection and repair of parts
All parts must be inspected before assembly and can only be reused after
confirmation. The specific inspection for the following parts is as follows:
1) For parts such as bearing, check the inner ring, outer ring and roller for
scratch, wear, crack and deformation. The bearing with any of the above
defects shall not be reused.
2) For gear parts, check whether there is excessive wear, gluing, crack, peeling
and abnormal deformation on the teeth of the parts. Once the above problems
are found, then the parts cannot be used anymore;
3) For shell parts, check whether there are cracks or dents and excessive wear
on the stressed surface;
4) For fastening connectors, check whether the thread is damaged, cracked,
bumped and deformed abnormally;
5) Lock gaskets and oil seals are not allowed to be reused after removal;
6) The burrs and bumps on the non-important surfaces of parts shall be trimmed
before continued use.
4.0.4 Precautions during subassembly and final assembly
1) Protective equipment must be worn during assembly. Such as protective
gloves, shoes and goggles;
2) The tightening torque of threaded fasteners must meet relevant
requirements;
3) During assembly, apply Loctite 262 to the fastener threads and Loctite
598 to the plane joint;
4) The bearing must be assembled in place with a sleeve and copper
hammer;
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5) Needles in planetary gears shall be selected and matched in groups, and
needle rollers of different batches are not allowed to be installed in the
same planetary gear;
6) Use tooling or rubber hammer when installing the oil seal; otherwise, oil
leakage would be caused at the oil seal due to improper assembly;
7) All fasteners must meet the requirements of tightening torque, otherwise it
would cause oil leakage at O-ring and oil seal, or cause even serious
accidents such as outward displacement and falling off of the whole
wheel;
8) Workpieces shall be handled or hoisted stably and firmly to avoid sliding,
tilting and falling during work, which may cause damage to the machine
and personal injury.
4.1 Front Axle Assembly

4.1.1 Assemble the hub assembly
4.1.1.1 Measure the distance N1

between the two bearing mounting
surfaces of the hub, and measure the
heights N2 and N3 of both the inner
and outer rings of the two bearings.
Fig. 4.1
4.1.1.2 First, put the big end of hub
upwards and install it into the bearing
outer ring by cooling or pressing; then turn
the small end upwards to install the
bearing outer ring, and then install the
bearing inner ring.
Fig. 4.2
4.1.1.3 Install the frame oil seal
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Apply grease to the outer ring of oil seal before assembling.
Fig. 4.3
4.1.1.4 Press-fit the rim bolts.
Fig. 4.4
4.1.2 Assembling of planetary carrier assembly

First, the needle rollers are grouped into groups of 28, and the difference between
the maximum and minimum values of the average diameter of each needle roller in
each group
is less than 0.003. After the assembly is completed, it should rotate freely without
jamming.
4.1.2.1 Apply lubricating grease evenly

in the planetary gear, and assemble
needle rollers (28 in a group) to the
inner holes on the upper and lower
end faces of the planetary gear.
1 - 494
Fig. 4.5
4.1.2.2 Place the small end face of
the planetary carrier upward, install
the plug and O-ring into the
planetary carrier, cool the planetary
shaft and assemble it on the inner
hole of the planetary carrier, and
then turn over the planetary carrier
180° to make its big end face
upward.
Fig. 4.6
4.1.2.3 Assemble the lifting pin to
the planetary gear carrier.
4.1.2.4 Install the planetary gear

subassembly on the planetary shaft.
Install gaskets and retainer rings at
the planetary shaft ends
respectively.
Fig. 4.7
4.1.3 Assemble the differential housing assembly
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4.1.3.1 Assemble a bevel gear and a bevel gear gasket on the cross shaft in
turn.
Fig. 4.8
4.1.3.2 Apply lubricating grease to the

mating surfaces of differential housings I
and II and axle shaft gear gasket, and
install the axle shaft gear gasket and
axle shaft gear into the differential
housing in turn.
4.1.3.3 Assemble the cross shaft

assembly into the differential housing, measure and adjust the clearance
between planetary bevel gear and axle shaft gear to 0.15-0.20 mm.
Fig. 4.9
4.1.3.4 Install the pin 6×40 into the pin hole of differential housing II, and
assemble the differential housing.
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Fig. 4.10
4.1.3.5 Preheat the driven spiral gear

and assemble it on the differential
housing I, and tighten it with bolts
M10×75.
Tightening torque: 49~59 N.m

Apply Loctite 620 retaining adhesive
to bolts before assembling.
Fig. 4.11
4.1.4 Assemble the final drive assembly
4.1.4.1 Mark the bearing cap and bracket

on the bracket assembly, unscrew the
bolts and remove the bearing cap.
Fig. 4.12
4.1.4.2 Place the bracket on the
workbench with its large side facing
upwards. Install the 31308 bearing inner
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and outer rings in the bracket, measure the distance L1 from the bracket lug
to the end face of the bearing inner ring, and calculate the thickness δ of the
gasket.
δ=L1-mounting distance of driving spiral gear, where the mounting distance

of spiral gear = printed value at shaft end of driving spiral gear +107.2. The
value of L1 is measured at three points in the circumferential direction and is
averaged.
Fig. 4.13
4.1.4.3 Assemble the gasket with a
thickness of δ and the inner ring of
bearing 31308 on the driving spiral bevel
gear in turn. Then assemble it on the
bracket and fix it with tooling.
4.1.4.4 Turn over the workbench so that

the small side of the bracket can face
upward. Measure the distance from the
small end face of bracket to the bearing mounting surface H1.
Fig. 4.14
4.1.4.5 Press-fit the outer ring of bearing 31308

and assemble the spacer sleeve. Measure the
distance H2 from the small end face of bracket to
spacer sleeve. Calculate the thickness B of gasket.
B=H3-(H1-H2), where H3 is the height difference
between inner and outer rings of bearing 31308.
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Note: The above measured values should be all measured at 3 points in
the circumferential direction, and the average value is calculated.
Fig. 4.15
4.1.4.6 Assemble the calculated gasket on the main bevel gear, and then
assemble the inner ring of bearing 31308, washer and lock nut in turn. After
tightening the lock nut, measure its torque value with a torque wrench to
ensure it is 3-6 N.m.
4.1.4.7 Apply lubricating grease to the inner hole and O-ring groove of the oil
seal cover, and assemble the lip seal ring and O-ring into the oil seal cover in
turn. Then apply a thin layer of grease around the seal ring.
4.1.4.8 Install the oil seal cover and seal ring

together on the bracket.
4.1.4.9 Turn over the workbench so that the big
end face of the bracket can face upward, and
install the differential housing assembly. Install
the shaft sleeve, bearing cap and differential nut,
and fix them with bolts.
Installation direction: Keep the driven spiral gear away from the final
drive oil drain plug!
Fig. 4.16
4.1.4.10 The meshing clearance of spiral bevel
gear pair is 0.2-0.3 mm by adjusting the upper
nuts of differentials on both sides.
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4.1.4.11 Tighten the bolts on the bearing cap with a torque of 170-200 N.m.
Assemble the locking plate and tighten it.
4.1.4.12 Assemble the plug and washer.
Fig. 4.17
4.1.5 Installation of axle housing assembly
4.1.5.1 Install the shaft sleeve and oil
seal into the shaft holes at both ends
of the axle housing;
Fig. 4.18
4.1.5.2 Install the shaft sleeve and

knuckle bearing (after cooling) into the
steering knuckle shaft holes on both
sides of the axle housing respectively.
Fig. 4.19
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4.1.5.3 Install the shaft sleeve into the long pin hole on the axle housing.
Fig. 4.20
4.1.6 Installation of final drive assembly
4.1.6.1 Install the pin into the hole on
the final drive mounting surface on the
axle housing, and apply plane sealant
evenly and continuously onto the final
drive mounting surface.
Fig. 4.20
4.1.6.2 Put the final drive assembly into
the axle housing and tighten it with
flange bolts, with a tightening torque of
95-110 N·m.
1 - 501
Fig. 4.21
4.1.7 Installation of left and right steering knuckles

4.1.7.1 Assemble the hinged axle shaft into the axle housing.
Fig. 4.22
4.1.7.2 Install the shaft sleeve and oil seal into

the left and right steering knuckle shaft holes.
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Fig. 4.23
4.1.7.3 Install 2 flange shafts on the left and

right steering knuckles respectively, and then
fasten them with bolts. Tightening torque: 140-
170 N.m. Assemble the oil cups to the flange
shaft respectively.
4.1.7.4 Assemble the steering knuckle to the

axle housing, and assemble the disc spring between the axle housing and
the steering knuckle mounting surface.
Fig. 4.24
4.1.8 Installation of hub and ring gear
4.1.8.1 Assemble the bearing inner ring

onto the outer circle of steering knuckle;
Fig. 4.25
4.1.8.2 Install the hub assembly on the

steering knuckle;
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Fig. 4.26
4.1.8.3 Assemble the bearing inner ring to

the outer circle of steering knuckle.
4.1.8.4 Assembling of ring gear assembly
4.1.8.5 Install the ring gear assembly and

locating sleeve on the steering knuckle,
and tighten them with bolts to 110-130
N·m.
Fig. 4.27
4.1.9 Installation of planetary carrier assembly
4.1.10 Assembling of cylinder and spherical hinge
Fig. 4.29
4.2 Rear Axle Assembly
4.2.1 Assembling of hub assembly
4.2.1.1 Measure the distance N1

between two bearing mounting
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surfaces of hub, and measure the heights N2 and N3 of inner and outer
rings of two bearings.
Fig. 4.30
4.2.1.2 First, put the big end of hub
upward and install it into the bearing
outer ring by cooling or pressing;
then turn over the small end upward
and install the bearing outer ring, and
finally install the bearing inner ring.
Fig. 4.31
4.2.1.3 Installation of frame oil seal
Apply grease to the outer ring of oil seal before
assembling.
Fig. 4.32
4.2.1.4 Press-fit the rim bolts.
1 - 505
Fig. 4.33
4.2.2 Assembling of planetary carrier assembly
First, the needle rollers are grouped into
31 groups, and the difference between
the maximum and minimum values of the
average diameter of each needle roller in each
group
is less than 0.003. After the assembly is
completed, it should rotate freely without jamming.
4.2.2.1 Apply lubricating grease evenly in the planetary

gear, and assemble needle rollers (31 in a group) to the inner holes
on the upper and lower end faces of the planetary gear.
Fig. 4.34
4.2.2.2 Place the small end face of the
planetary carrier upward, install the
plug and O-ring into the planetary
carrier, cool the planetary shaft and
assemble it on the inner hole of the
planetary carrier, and then turn over the
planetary carrier 180° to make its big
end face upward. Install the lifting pin
into the planetary gear carrier.
Fig. 4.35
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4.2.2.3 Install the planetary gear subassembly on the planetary shaft.
Install gaskets and retainer rings at the planetary shaft ends respectively.
Fig. 4.36
4.2.3 Assemble the differential housing assembly
4.2.3.1 Assemble 2 straight shafts into a cross shaft.

Assemble a bevel gear and a bevel gear gasket on the
cross shaft in turn.
Fig. 4.37
4.2.3.2 Apply lubricating grease to the mating
surfaces of differential housings I and II and
axle shaft gear gasket, and then install the
axle shaft gear gasket and axle shaft gear in
turn.
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Fig. 4.38
4.2.3.3 Install the cross shaft assembly into
the differential housing, measure and adjust
the clearance between planetary bevel gear
and axle shaft gear to 0.18-0.23 mm
Fig. 4.39
4.2.3.4 Preheat the driven spiral gear and

then assemble it on the differential housing I.
Then tighten the driven spiral gear,
differential housing I and differential housing
II with bolts.
Tightening torque: 68-103 N.m

Apply Loctite 620 retaining adhesive to
bolts before assembling.
Punch and rivet both ends of the locating pin to prevent the pin from falling
off
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Fig. 4.40
4.2.3.5 Assemble the O-ring to the lock pin and install it into the pin hole of
differential housing II in turn.
4.2.3.6 Assemble the shaft sleeve, retainer ring and bearing at the small end
of differential housing II.
4.2.4 Assemble the brake housing

4.2.4.1 Assemble the seal ring and retainer ring
into the piston groove.
4.1.3.5
Fig. 4.41
4.2.4.2 Assemble the seal ring and retainer ring

into the groove of brake housing.
Fig. 4.42
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4.2.4.3 Screw the threaded ends of the 3 threaded rods into the piston.
Fig. 4.43
4.2.4.4 Assemble the piston into the brake

housing.
Fig. 4.44
4.2.4.5 Install compression springs, spacer

sleeves and retainer rings at the other ends of
3 threaded rods respectively. Install the O-ring
on the brake housing.
Fig. 4.45
4.2.5 Installation of shift fork subassembly
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4.2.5.1 Assemble the retainer ring into the slot
in the middle of the shaft, and install the shift
fork on the shaft;
Fig. 4.46
4.2.5.2 Install the shaft together with the shift
fork on the final drive housing so that the right
end can extend out of the final drive housing.
Install bushing and compression spring at the
protruding end of shaft.
Fig. 4.47
4.2.5.3 Install the O-ring into the groove of

the cover, then assemble the cover to the
final drive housing and tighten it with bolts.
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Fig. 4.48
4.2.5.4 Assemble the compression spring,

shaft bushing and retainer ring at the left
end of the shaft in turn.
Fig. 4.49
4.2.5.5 Install 2 O-rings in the groove of

piston. Install the O-ring into the groove on
the end face of the support. Then install the
piston into the support.
Fig. 4.50
4.2.5.6 Install the support on the final
drive housing and tighten it with bolts.
Finally, assemble the plug and washer
on the support.
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Fig. 4.51
4.2.6 Assemble the final drive assembly
26. 4.2.6.1 Optional gasket: Assemble

the outer ring of bearing 30309 to the
final drive housing, place the inner ring
as required, measure dimensions H1 and
H2, calculate the gasket thickness δ1, and
optionally select a gasket.
Fig. 4.52
27. 4.2.6.2 Install the optional gasket and

bearing inner ring on the driving spiral bevel
gear, and then install them into the final
drive housing.
Fig. 4.53
4.2.6.3 After assembling the spacer sleeve,
measure dimensions H5 and H4 and bearing
dimension H3, and calculate the thickness δ2
of gasket II.
4.2.6.4 Assemble the bearing, flange
assembly, washer and lock nut in turn.
Measure the resistance torque of lock nut to
ensure it is 3-6 N.m.
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4.2.6.5 Measure the upper Φ95 seam allowance runout of flange assembly
to ensure that the runout is less than 0.08, and make matching marks on the
flange assembly and driving spiral bevel gear.
Fig. 4.54
4.2.6.6 Remove the lock nut, gasket and flange
assembly; assemble the brake support.
Fig. 4.55
4.2.6.7 Successively press in the lip seal rings.
4.2.6.8 Assemble the rim bolts to the flange

assembly. Assemble the flange assembly,
washer and lock nut in turn.
Fig. 4.56
4.2.6.9 Install the differential housing assembly

into the final drive housing. Note: Fit between
the shaft sleeve on differential housing
assembly and shift fork.
Note: The driven spiral bevel gear is located on the lower side of the sight
glass after assembly.
1 - 514
Fig. 4.57
4.2.6.10 Install the brake housing assembly on

the final drive housing. Pay attention to
distinguishing the left and right brake housing
assemblies. Secure with screws.
Fig. 4.58
4.2.7 Assembly of axle body
4.2.7.1 Superimpose 6 driven plates

and 5 driving plates on the workbench
in turn, and measure dimension L2;
press the piston to the bottommost end, and measure the distance L2
between the piston plane and the flange surface of brake housing; measure
the distance L3 between the fitting
surface of axle body friction lining
and the flange surface; calculate the
piston stroke Δ=L3-L2-L1
(theoretical value: about 1.5~1.7
mm).
Fig. 4.59
1 - 515
4.2.7.2 Install the retainer ring, driven plate, driving plate, driven plate and
driving plate in turn. Assemble the retainer ring to the spline sleeve; pay
attention to aligning the teeth of the driven plate.
Fig. 460
4.2.7.3 Assemble 3 pins to the axle
body, and then assemble the friction
lining assembled in the previous step
to the axle body.
Fig. 4.61
4.2.7.5 Connect the axle assembly

with the final drive housing
assembly. Pay attention to
distinguishing the left and right axle
bodies.
1 - 516
Fig. 4.62
4.2.7.6 Assemble the exhaust valve
and bonnet on the brake housing.
4.2.7.7 Pressure holding test
4.2.7.8 Install the oil inlet plug on the
brake housing and the oil level plug on
the left axle body.
4.2.7.9 Assemble the breather pipe
assembly and label.
Fig. 4.63
4.2.8 Installation of hub and gear ring
4.2.8.1 Measure the distance N4 from the small

end face of axle body to the bearing mounting
surface. Calculate the thickness of adjusting
gasket t=N4-N1-N2-N3, where N1, N2 and N3
are the data measured and recorded in the hub
assembly step.
Fig. 4.64
4.2.8.2 Shrink-fit one bearing inner ring to
the axle body.
1 - 517
Fig. 4.65
4.2.8.3 Lift the hub assembly and assemble
it on the axle body. Assemble the other
bearing inner ring to the axle body.
Fig. 4.66
4.2.8.4 Press-fit the locating sleeve to the gear ring assembly.

4.2.8.5 Install the adjusting gasket
calculated in step 4.2.7.1 on the end face of
gear ring, and then assemble the gear ring
assembly to the axle body. 6 locating
sleeves are press-fitted in place and fixed
with bolts, with a tightening torque of
215~235 N.m
1 - 518
Fig. 4.67
4.2.9 Assembling of planetary carrier
4.2.9.1 Adjust the axial clearance of sun gear: 1) Measure the distance X1
from the outer plane of sun gear to the mating surface with planetary carrier
on hub; 2) Measure the distance X2 from the mating surface with hub on
planetary carrier; 3) Ensure the axial clearance of sun gear is 1~2 mm,
calculate the protrusion height c=X2-X1-(1~2) of adjusting strut, and
optionally install the adjusting strut based on the calculation results.
Fig. 4.68
4.2.9.2 Assemble adjusting strut to the sun

gear shaft.
Torque of planetary cover bolt: 72~85 N.m
Fig. 4.69
4.2.8.3 Install the planetary carrier
assembly in place.
1 - 519
Fig. 4.70
4.2.10 Brake assembling
4.2.10.1 After the whole axle is
painted, assemble 310 parking brake.
Assemble the flat washer 12, spring

washer 12 and bolt M12X40 in turn,
and tighten them crosswise
symmetrically with a tightening torque
of 110~130 N.m
The clearance between the friction

lining and both sides of the brake disc shall be consistent, with a clearance of
> 0.5 and < 0.66 mm
Fig. 4.71
After assembling, confirm that the flange assembly can rotate flexibly, pull up
the parking brake lever, and ensure that the friction linings on both sides of
the brake can contact the brake disc at the same time
Do not drive until the parking brake is released!
1 - 520
If the parking brake is not released before driving, the brake and brake
disc will be burnt out!
5.0 Test Run
1.>Remove the plug screws on the final drive and wheel rim, and inject
85W/90GL-5 heavy-duty vehicle gear oil. The filling amount shall be
controlled based on the oil level hole of the axle. When the red arrow on
the wheel rim planetary carrier is downward, it is the oil drain position;
when the arrow is horizontal, it is the oil filler position.
The oil level line is at the lower busbar of the screw hole opening, and a
small amount of oil spillage will be allowed. The total oil filling volume is
about 7.1L for the front axle (about 5.7L for final drive and about 0.7L for
single wheel rim) and about 13L for the rear axle (about 10L for final drive
and about 1.5L for single wheel rim). The actual oil filling volume shall be
subject to the observation of the lower busbar of the screw hole;
Filling
position
Oil
drain
2. > Tighten the plug (be sure to check whether the combined washer has
wear and cracks before tightening the plug, and replace it in time if any)
3.>Start the machine and run it (forward and backward for 5 s
respectively). Observe the rotation direction of the drive axle. When the
front axle faces the flange, the clockwise rotation of the driving spiral
gear is the forward direction; when the rear axle faces the flange on the
back, the counterclockwise rotation of the driving spiral gear is the
1 - 521
forward direction. The drive axle shall operate smoothly without jamming
or abnormal sound, and there shall be no obvious noise from the final
drive and wheel rim. If any, analyze and eliminate it in time.
4. > Observe whether there is oil leakage in each part; if any, analyze
and eliminate it.
5.>Start the machine and run it (forward and reverse rotation for 5 min.
respectively). It shall run smoothly without abnormal sound and local
overheating.
1 - 522
Hydraulic system
Principle of the Hydraulic System
液
Working principle of hydraulic system
Relevant information of reserved hydraulic pipeline:
Loading end pressure 24±10%MPa，flow 144l/min；steering pressure
16±10%MPa，flow 144l/min。
Working Hydraulic System
1 - 523
1. Bucket cylinder 2. Arm cylinder 3. Boom cylinder
4.Right leg cylinder 5. Digging valve 6. Left boom cylinder
7. Left tipping bucket cylinder 8. Right tipping bucket cylinder
9. Right boom cylinder 10. Hydraulic fuel tank 11.Plunger pump
12. Loading valve 13. Left leg cylinder
Digging valve
T2 接油箱 A1 右支腿缸大腔 A2 斗杆缸大腔 A3 挖臂缸大腔

A4 挖斗缸大腔 A5 左回转缸小腔 A6 左支腿缸小腔 P1 接装载阀 P1
口 B6 左支腿缸大腔 B5 左回转缸大腔 B4 挖斗缸小腔 B3 挖
臂缸小腔
B2 斗杆缸小腔 B1 右支腿缸小腔 L 接油箱 S 接油箱
LS 接柱塞泵 PL 口
1 - 524
装载阀
T2 接油箱回油 A1 翻斗缸小腔钢管B1 翻斗缸大腔钢管

A2 动臂缸小腔钢管
B2 动臂缸大腔钢管 P1 接柱塞泵 P 口
L 接油箱 S 接油箱 LS 接柱塞泵 PL 口
V 口接柱塞泵 Pr 口
Hydraulic oil tank
1 - 525
1
3 4
6 7
65
1. Refueling air filter

2. Liquid level gauge
3. Oil return connector (loading valve and digging valve)
4. Return oil filter element
5. Oil suction connector (Plunger pump)
6. Oil return connector (priority valve)
1 - 526
7. Oil drain port
Refueling air filter
The product is installed above the fuel tank, which can
not only filter the air entering and leaving the hydraulic fuel
tank, but also fill hydraulic oil through this port.
Due to the pressure and closure of the fuel tank, if the oil
level in it drops, a negative pressure will be generated. At
this time, the atmosphere enters the fuel tank through the
air filter to prevent the generation of negative pressure. When the oil
circuit is operated by raising or lowering the oil level and raising the
temperature, and if the pressure in the hydraulic fuel tank rises, the
atmosphere in the fuel tank is discharged through the air cleaner to
release the pressure in the hydraulic fuel tank. It ensures the pressure
stability in the hydraulic fuel tank.
Liquid level thermometer

A liquid level gauge is installed right in front of the fuel tank, through which
the hydraulic oil level can be observed when the machine stops.
Oil return filter element

THE OIL FILTER ELEMENT IS INSIDE THE HYDRAULIC FUEL TANK AND PLAYS A
ROLE IN CLEANING THE WHOLE HYDRAULIC SYSTEM. IF THE RETURN OIL FILTER
ELEMENT IS BLOCKED, THE OIL IN THE HYDRAULIC SYSTEM WILL NOT BE
FILTERED, WHICH COULD SERIOUSLY ENDANGER THE NORMAL OPERATION OF
THE HYDRAULIC SYSTEM.
1 - 527
转向液压系统
1.Steering gear
2. Priority valve
1 - 528
Function overview
The steering hydraulic system of the backhoe loader is used to control
the driving direction, so that the machine can stably keep running in a
straight line and flexibly change the driving direction when turning. Good
and stable performance of the steering hydraulic system is an important
factor to ensure safe driving of the loader, reduce driver's labor intensity
and improve operation efficiency.
Steering gear
T: Connected to oil return tank R: Connected to right port of front

axle
Ls: Connected to priority valve port Ls L: Connected to left port of
front axle
P: Connected to EF port of priority valve
Priority valve
CF: to steering gear port P
1 - 529
EF: Connected to port E of crushing valve
P: Connected to gear pump outlet
T: to oil return tank
Ls: Connected to steering gear port Ls
1 - 530
Braking system
The brake system is used for deceleration or braking during traveling and
long-time parking on flat ground or slopes.
8.1 Service Braking
1. Pedal assembly 2. Hose assembly 3. Dual-chamber booster

The service brake system is used for regular speed control and
parking in progress, and frequent general driving. The brake of the
machine is a kind of full hydraulic braking, which is stable, safe and
reliable.
1 - 531
When the pedal is depressed, the pressure oil from the brake booster
pump will be led to the left and right full-disc wet brakes in the rear axle,
thus realizing simultaneous deceleration or braking of both rear wheels.
Caution: In case of emergency braking, it is necessary to brake for
several times in a row (depress the brake pedal twice or more
continuously) to increase the brake system pressure, shorten the braking
distance of the machine and ensure safety.
Parking brake
1 - 532
1. Hand brake controller 2. Hand brake flexible shaft support 3. Rear
axle
The parking brake system has manual release and tension braking,
which is convenient and fast to operate.
The parking brake system is shown in the figure and consists of the hand
brake controller, hand brake flexible shaft support, rear axle, etc. The
moment arms on both sides of the main drive of the drive axle are pulled
by the hand brake controller to drive the wet brake of the drive axle to
work, and the half shaft of the drive axle stops rotating under the action of
friction force, achieving the braking effect. Convenient, fast and easy to
maintain.
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Work devices
Loading work devices

Basic composition
1-Safety lever; 2-Boom cylinder; 3-Rocker arm; 4-Boom; 5-Bucket; 6-

Bucket connecting rod; 7-Boom connecting rod; 8-Tipping bucket cylinder
The basic structure of the loading working device is shown in Fig. 9-1,
which consists of the safety lever, boom cylinder, rocker arm, tipping
bucket cylinder, boom, boom connecting rod, bucket connecting rod,
bucket, etc. The working device has eight-connecting rod mechanism and
has automatic leveling function.
装载端油缸的拆卸与更换
拆卸：
1. 启动停车制动器，同时将变速箱回到空挡上；
2. 如有安装，需要拆卸装载端的机具（如铲斗），如果机具采用液压控制，断开连接机具的软管或
插头，关闭发动机，并且操作控制杆，将软管中的压力排出；
如果没有使用支架和/或吊索对动臂提供支撑，请不要在举起的动臂
下方工作。
3. 拆卸发动机罩，参见发动机罩拆卸与更换；
4. 举起动臂，可以接触到动臂油缸和销轴 5；
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5.将吊索固定在图中所示的 13 位置，当吊索处于拉紧状态时，吊索承受动臂的重量；
6. 关闭发动机，操作装载端操控杆前后移动几次，确保停留在装载工作装置液压软管中的压力排出；
7. 拆卸动臂油缸销轴 5；
注：拆卸动臂油缸销轴时要格外小心，拆下销轴后油缸会自动落下，可以提前用吊索将油缸吊住，
或者可以在拆卸前让一个人顶住油缸。
8. 使用吊索将动臂缓慢放至地面，动臂油缸完全收回，并确保在收回油缸时油缸不会堵塞；
9. 确保软管内的压力已经全部排出，按照图中所示 1 位置，拆下动臂的液压软管，并立即塞住软管
端口加上盖子；
10. 拆卸弹簧垫圈 2 和垫片 3;
11. 拆卸销轴 4；
12. 对应的另一侧动臂油缸的拆卸步骤请重复步骤 7 至步骤 11；
13. 断开铲斗的复位开关（若安装）；
14. 按照图中所示 12 位置，拆下铲斗的液压软管，并立即塞住软管端口加上盖子；
15. 拆下弹簧垫圈 6 和垫片 7；
16.拆卸销轴 8；
17.拆卸弹簧垫圈 9 和垫片 10；
18.拆卸销轴 11；
19.拆下销轴螺栓之后，小心的将其从装载端中取出；
20.对应另一侧铲斗油缸的拆卸步骤请重复步骤 15 至步骤 19；
更换
更换步骤与拆卸步骤相反，但要注意以下方面：
1.将销轴螺栓安装到机器外面的抽出孔中；
2.检查铲斗复位开关（若安装）；
3.在所有动臂的镗孔中涂上润滑油；
4.在所有销轴螺栓上涂上防锈油。
Lubrication of loading end

To make the machine work efficiently, it must be lubricated regularly,
which can prolong its service life.
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The machine must be lubricated after pressure cleaning or steam
cleaning.
28. Before working closely by the machine, it is necessary to lower the

machine as much as possible and pull out the starter key to prevent the
engine from being started. Disconnect the battery and ensure that the
parking brake has been activated nearby.
Stop the four wheels before working under the machine.
The lubrication points of the machine should be lubricated with a grease
gun. Generally, it should be required to press the grease gun twice (gas
piston stroke). Lubrication shall be stopped when new lubricating oil
overflows at the lubrication point.
In the figure below, all lubrication points have been numbered properly.
Check each lubrication point and cover the dust cover after lubrication.
Each lubrication point in the figure has a corresponding other lubrication
point on the other side of the machine.
There are 22 lubrication points in total.
Four-in-one bucket:
Three lubrication points at each end, 6 in total.
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Loading hopper quick changer:
Each wheel has 2 lubrication points, and 4 in total.
Removal and Installation of Safety Lever

Installation of safety lever
The installation of boom safety lever is described in detail below
Warning
It is forbidden to walk or work under the lifted boom before it is
supported by the safety lever. If the hydraulic unit or operation
controller fails (even if the engine stops running), the equipment
supported only by the hydraulic unit will fall and even hurt people
under the boom.
1. Empty the bucket and lift the boom to the highest possible position;
2. Stop the engine and remove the starter key.
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Warning
29. Serious injury or death may be caused if the loading work device
could be operated accidentally. When releasing the safety lever, it must
be ensured that no one is near the machine.
3. Release the safety lever
a. Loosen the fastener 1;
b. Remove the safety lever 3 from the rack.

4. Installation of safety lever
a. Press the safety lever 3 onto the cylinder piston rod;
b. Fix the safety lever at corresponding position with belt 2.
5. Lower the hydraulic cylinder onto the safety lever.
a. To prevent the boom from hurting fingers during descending, the boom
should be carefully placed on the safety lever as shown in the figure.
b. Start the engine and slowly lower the boom onto the safety lever. When
the boom passes through the safety lever, stop the movement of the
boom immediately.
Note: When lowering the bucket, operate the control lever carefully and
slightly move it to make it descend slowly.
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Removal of safety lever:
1. Lift the boom completely to remove the weight borne by the
safety lever;
2. Stop the engine and pull out the starter key.
Warning
30. Serious injury or death may be caused if the loading work device
could be operated accidentally. When releasing the safety lever, it must
be ensured that no one is near the machine.
3. Remove the safety lever

a. Loosen the belt 2;
b. Remove the safety lever 3 from the cylinder piston rod.
4. Placement of safety lever
Secure the support to the rack with fastener 1.
1 - 539
Backhoe work devices
Basic composition
STRUCTURAL DIAGRAM OF LOADING WORKING DEVICE
1-Hook; 2-Slewing body connecting rod 1; 3-Boom 2; 4-Arm; 5-Rocker

arm; 6-Connecting rod; 7-Bucket;
The digging working device is located at the rear end of the frame and
equipped with a 0.25 m³ bucket as standard, which can rotate left and
right.
Removal and replacement of excavator arm
Disassembly
This procedure describes the removal of the excavator arm when it is
installed with the arm cylinder. If necessary, these components can be
removed separately before removing the excavator arm. Please refer to
reasonable removal and replacement procedures.
1. Remove the bucket at the digging end and place it in a safe area;
2. Lower the stabilizer leg;
3. Shut down the engine and disconnect the power supply (to prevent
the engine from starting);
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4. Operate the control lever at the digging end to move forward and
backward several times to discharge the pressure in the hydraulic
hose;
Warning
31. The pressure in the hydraulic system may cause injury to persons.
Before disconnecting or connecting the hydraulic hose, it is necessary to
shut down the engine and shake the digging control lever back and forth
to release the pressure in the hose. Do not start the engine when the hose
is opened.
32.
5. Disconnect the hydraulic hose from the slewing diaphragm. Before
disconnecting the hose, mark the hydraulic hose to ensure it can be
reassembled correctly later, and plug or cover the open end of the
hose to prevent dust from entering and hydraulic oil from flowing
out.
6. Remove the arm. See Section 9.2.3 Removal and Replacement of
Arm for details;
7. Surround the upper sling around the excavator arm according to 3
shown in the figure, and ensure that the weight of the excavator arm
is borne by the sling before removing the pin shaft;
8. Remove the spring washers 4 and gaskets 5 on both sides of the
connection between the slewing body and the excavator arm, and
remove the pin shaft 6;
9. Remove the spring washer 7, gasket 8 (1 on each side) and pin
shaft 10, and mark the gasket so as to install them at the same
position;
10. Take out the excavator arm from the slewing body assembly;
Warning
33. The ejected fluid under high pressure will penetrate the human skin.
So, protect your face and hands from contacting the high-pressure fluid
1 - 541
and wear protective glasses. Take a card close to the suspected leakage
area and check whether there is any trace of fluid on it. If the fluid is
ejected onto your skin, please seek medical care immediately.
Replace
The replacement procedure is generally reverse to that for the removal.
When installing the excavator arm on the slewing bearing, make sure
that the gasket 5 is reinstalled in its original position and replace all pin
shaft seals as required.
Removal and replacement of arm

Disassembly
This procedure describes the removal of the arm when the bucket (if
installed) and the arm cylinder are still installed. If necessary, this part can
also be removed before removing the arm. Please refer to the reasonable
removal and replacement procedures.
1 - 542
1. Disassemble the bucket and place it in the right position;
2. Drop the stabilizer leg;
3. Shut down the engine and disconnect the power supply (in case of
engine starting);
4. Operate the control lever at the digging end and shake it back and
forth for several times to release the pressure in the hose;
Warning
34. Fluid under hydraulic system pressure may cause injury to people.
Before disconnecting or connecting the hydraulic hose, shut down the
engine and operate the control lever to release the pressure in the hose.
Do not start the engine when the hose is opened.
5. Disconnect the hydraulic hoses 2 as shown in the figure, and mark

them before disconnection to ensure that they can be correctly reinstalled.
Plug or cover the open end of hose to prevent dust from entering and
liquid from flowing out;
6. Place a suitable support under the arm cylinder at 3 as shown in
the figure;
7. Surround the upper sling around the arm as shown in Fig. 4 to
ensure that the weight of the arm is borne by the sling before removing
the pin shaft;
8. Remove the nut 5, bolt 7 and pin shaft 6;
9. Remove the nut 10, bolt 8 and pin shaft 9;
10. Take out the arm from the boom;
Warning
The ejected fluid under high pressure will penetrate the human skin. So,
protect your face and hands from contacting the high-pressure fluid and
wear protective glasses. Take a card close to the suspected leakage area
and check whether there is any trace of fluid on it. If the fluid is ejected
onto your skin, please seek medical care immediately.
1 - 543
Replace
The replacement order is generally reverse to that for the removal. When installing the arm on the excavator arm,
make sure that gasket 11 is installed as shown in the figure and replace all pin shaft gaskets as required
Removal and replacement of slewing body

Disassembly
1. Rotate the center pillar to the central position, and remove the boom
and arm from the slewing body.
Warning
35. Fluid under hydraulic system pressure may cause injury to people.
Before disconnecting or connecting the hydraulic hose, shut down the
engine and operate the control lever to release the pressure in the hose.
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Do not start the engine when the hose is opened.
2. Starting from the bottom, disconnect the hydraulic hoses at the

digging end separately and make sure that each one is marked
before disconnection to ensure correct reassembly later;
3. Plug or cover the open end of hose to prevent dust from entering
and hydraulic oil from flowing out;
4. Remove the nuts 22 (2 pcs.), and remove the fixing bolts 10 (2 pcs.)
of pin shaft;
5. Remove the pin shafts 13 (2 pcs.) of slewing cylinder;
6. Attach a suitable lifting belt to the slewing body assembly;
7. Remove the excavator arm locking assembly. See Section 9.2.2
Removal and Replacement of Arm;
8. Remove the fixing pin shaft 3;
9. Remove the pin shaft 2 at the top of center pillar;
10. Remove the bolt 14 and gasket 15;
11. Remove the pin shaft 16 at the bottom of center pillar;
12. Remove the center pillar casting 11 from the rear rack, and
remove the washer 21 at the same time;
Check
Inspect bearings 1, 12, 18, 19 and 20 for damage, wear, scratches or
notches etc. Use a spindle (locally produced) to help remove the bearings.
Replace
The replacement procedure is generally reverse to the removal
procedure; however, attention should be paid to the following aspects:
Check and remove burrs and sharp edges on bores, bearings and pin
shafts to minimize assembly damage;
If necessary, use oil or suitable lubricating oil to facilitate bearing
installation process and reduce the number of scratches on contact
surfaces;
1 - 545
If the bearing has a lead-in inner diameter (with an obvious small step),
install the smaller one into the bore first;
Ensure that the boom bottom pad 12 is installed completely in the boom
bottom bore;
Make sure that all holes and pins are clean, lubricated during assembly
and greased at each joint before starting the machine when assembly is
complete.
Lubrication points for excavating working device

As shown in the figure below, there are 22 lubrication points for the
excavating working device.
1 - 546
Lubrication points of telescopic bucket rod:
Warning
36. Lubricating wax is flammable and therefore needs to be kept away
from open flames when used, and it takes several weeks for the
lubricating wax to become completely dry and so it shall be kept away
from open flames during drying.
37. Do not carry out welding operation in the surrounding area during its
drying. Avoid contact between lubricating wax and skin. Use it in a well-
ventilated environment to avoid inhaling the gas volatilized by
lubricating wax.
Apply lubricating oil (in the direction indicated by the arrow) to the
slideway of telescopic bucket rod as shown in the figure.
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Quick change at digging end:
Warning
38. Lubricating wax is flammable and therefore needs to be kept away
from open flames when used, and it takes several weeks for the
lubricating wax to become completely dry and so it shall be kept away
from open flames during drying.
39. Do not carry out welding operation in the surrounding area during its
drying. Avoid contact between lubricating wax and skin. Use it in a well-
ventilated environment to avoid inhaling the gas volatilized by
lubricating wax.
There are 4 lubrication points for quick change at the digging end, as
shown in the following figure:
1 - 548
1 - 549
Electric system
目录
维修工具
图号索引
工具详细参考
电路图
电气系统主要构成
电源电路
起动电路
仪表检测电路
照明电路
故障报警电路
辅助电路
1 - 550
维修工具
图号索引
表格中所列的工具是用来实施本某些工具以工具包形式供应。可
章节所述程序的专用工具。参考所给的工具表。
这些工具可向 JCB 维修部购买。注：表格中未列出的工具也可能
需要这样的常用工具能从所有装
备完好的工厂或当地优质工具供
应商处获得
工具详细参考
1 - 551
1 电气维修工具包 C 3
2 :7212/000 2 路插头外壳 5 :7214/000 4 路插孔外壳

A 2 D 1
2 :7212/000 2 路插头固定器 6 :7216/000 6 路插头外壳

B 4 A 2
2 :7212/000 2 路插孔固定器 6 :7216/000 6 路插头固定器

C 3 B 4
2 :7212/000 2 路插孔外壳 6 :7216/000 6 路插孔固定器

D 1 C 3
3 :7213/000 3 路插头外壳 6 :7216/000 6 路插孔外壳

A 2 D 1
3 :7213/000 3 路插头固定器 7 :7218/000 8 路插头外壳

B 4 A 2
3 :7213/000 3 路插孔固定器 7 :7218/000 8 路插头固定器

C 3 B 4
3 :7213/000 3 路插孔外壳 7 :7218/000 8 路插孔固定器

D 1 C 3
4 :7213/000 3 路插头外壳 DT 7 :7218/000 8 路插孔外壳

A 6 D 1
4 :7213/000 3 路插头固定器 DT 8 :7219/000 10 路插头外壳

B 8 A 2
4 :7213/000 3 路插孔固定器 DT 8 :7219/000 10 路插头固定器

C 7 B 4
4 :7213/000 3 路插孔外壳 DT 8 :7219/000 10 路插孔固定器

D 5 C 3
5 :7214/000 4 路插头外壳 8 :7219/000 10 路插孔外壳

A 2 D 1
5 :7214/000 4 路插头固定器 9 :7219/000 14 路插头外壳

B 4 A 6
5 :7214/000 4 路插孔固定器 9 :7219/000 14 路插头固定器
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B 8
9 :7219/000 14 路插孔固定器
C 7
9 :7219/000 14 路插孔外壳
D 5
1 :7210/000 空塞
0 1
1 :7210/000 导线密封（1.4-2.2 毫
1 2 米直径）
1 :7210/000 导线密封（2.2-2.9 毫
2 3 米直径）
图 2. 电气维修工具包
图 3. 993/85700
1 - 553
电路图
电气系统主要构成
电气系统的主要功用是起动发动机并完成照明、信号指示、仪表监测、
电控设备（包括各种电磁控制阀等）和其他辅助用电设备（主要包括空调、
刮水器、暖风机、收放机）等的供电工作，它对提高装载机的经济性、使
用性和安全性起到重要作用。该系统具有低压直流电源供电、单线制电气
线路以及负极搭铁等特点。
电气系统包括蓄电池、启动马达、发电机、调节器等，主要有五个组成
部分：电源起动部分、照明信号部分、仪表检测部分、电子监控部分和辅
助部分。各部分的组成关系如图 10-1 所示：蓄电池给启动马达供电，由启
动马达的直流电动机产生动力，经传动机构带动发动机曲轴转动，从而实
现发动机的起动；通过皮带传动，带动发电机发电，供给所有用电设备电
能，并给蓄电池充电。调节器控制发电机输出稳定的电压。
1 - 554
电源电路
由蓄电池、交流发电机（包括电枢、磁场、内置调节器等）、电源总开
关、继电器组等组成，为整车提供所需的电能。
1.蓄电池（两个蓄电池并联，标称电压为 12V）的电压便通过连接蓄电池
正极到启动马达处，再通过 F2 号导线、100A 保险以及 F4 号导线、20A 保
险到达钥匙开关的电源端。
2.开电锁（将电锁拧至 ON），F4 号导线与 L1 号导线接通，电流通过 6
号导线、电源总开关线圈至电池负极。
3. 电源总开关线圈得电后，触点开关闭合，主电源线接通，通过继电器
保险盒主电源线到达各路分保险，整车电路接通，L1 此时分成两路：①经
过 30A 保险到 F5 号线给空调和仪表、按键开关供电。②过 20A 保险到 F6
号线给电源插座和喇叭供电。同时接通发电机的充电指示灯，到发电机的
励磁端，励磁完成。（注意：我公司均规定地线为 0 号线，以下不再重
复。）
起动电路
包括：起动电机、蓄电池、起动继电器、钥匙开关等。|
1.将钥匙拧至起动（START）档：
（1）电流经 9 号线至发动机点火启动 ECU 端口（在 ON 档时，ECU 已
得电，此时空挡继电器 R04 线圈已得电，空挡继电器开关 R04 闭合。），
起动机控制档得电。
（2）起动电机带动发动机飞轮旋转，发动机起动。发动机起动后，发电
机在传动皮带的带动下开始发电（标称电压 14V），发电机一方通过一根
10 平方的充电线到启动机，再通过电缆给蓄电池充电，一方面通过 L1，L2
号导线给整车负载供电。
1 - 555
2. 发动机起动后，司机松开电锁钥匙，电锁自动复位至“ON”档，9 号导
线断电，4 号导线断电，5 号导线断电，起动电机停止工作，发动机继续运
转。
3. 关电锁（将电锁拧至“OFF”档），6 号导线断电，燃油油路关闭，发
动机熄火，发电机不再发电；同时，电源总开关圈断电，触点断开，整车
电器负载断电
1 - 556
仪表检测电路
主要包括仪表和传感器，用来显示发动机的水温，转速，发动机机油压
力等发动机参数等。以燃油表为例，由 L3 号线供电，信号线是 21 号线，
传感器搭铁接地。其余各表原理相同，此处不再重复介绍。
1 - 557
照明电路
一般由开关控制，包括：远、近光灯，前、后工作灯，前、后转向灯，
行车灯，倒车灯，刹车灯等。
举例介绍前工作灯。电源经 F12 到控制器 A01，给前工作灯供电，翘板
开关按下，电流到达 AA08 号线，进入前工作灯，经 0 号线进入蓄电池负极，
前工作灯亮。
1 - 558
故障报警电路
主要为报警指示灯和各种传感器及压力开关（如油温传感器、液压油温
开关）等，集中在前仪表盘。仪表监测冷却水温、变矩油温、燃油油量、
发动机转速。报警灯在进行左右转向、手制动、液压油温低等报警。
1 - 559
辅助电路
主要由前后雨刮器，喇叭等组成。
1 - 560
Cab
Controls in cab
General overview
Devices in driver's cab consist of display, indicator lamp assembly, switch assembly,
control mechanism, steering wheel and seats, etc. refer to Figure 11-1.
.
Figure 11-1 Arrangement in the driver's cab
No. Name No. Name
1 Front control panel 4 Side control panel
Travelling control Air conditionding control

2 5
zone panel
3 Operation control levers
1 - 561
Front Control Panel
Front Display Screen
− Front display screen shows the basic status of driving and operations in loader
protion.
− The arrangement and identification in front display screen are shown as Figure 11-
2.
− The symbols comply with ISO 6405-1 and ISO 6405-2.
Figure 11-2 Front Display Screen
Symbols Meaning and description
Clearance lights; position lights

To indicate that the position lights is on.
Work light
To indicate that the front work light is on.
High beam headlight (blue)

To indicate that the hign beam headlight is on.
Parking brake (red)

To indicate that the parking brake has been
pulled up.
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Hazard warnig (red)

To indicate that the hazard warning is on.
Turn signals (Green)

To indicate that the turn signal light is on, and
shows the movement direction of machine
Left stabilizer and Right stabilizer

To indicate the lowing status of stabilizer.
Front Control Console

− Front control concole integrates the functions as follow:
Figure 11-3 Front control console
− The symbols comply with ISO 6405-1.

Windscreen washer
Press to sprays washing fluid on the windshield.
After release it would be resets automatically and
stop spraying washing fluid.
1 - 563
Cruise control(optional)
Press to activates cruise control, which could
keep the engine speed until a braking or
accelerating operation or until press this button
again.
Windscreen wiper
Press once, the wipers will clean windshield at a
low speed.
Press twice, the wipers will clean windshield at a
high speed.
Press third time, the wipers will stop work.
Work light
Press to activate the work light in the
driving/loader operation position.
 Do not turn on the work
lights when driving on
the road, because you
may dazzle other
drivers and cause an
accident.
All-wheel drive 4X4

The default drive mode is all-wheel drive.
Rear-axle drive 4X2

The default drive mode is all-wheel drive.
Press to activate rear axle drive, the backlight of
this button will be lighted simultaneously.
Hazard warnig (red)

Press to activite hazard warning lights.
The hazard waring indicator will on, and the
turn signal lights will flash at a fixed
frequency.
 Whenever the machine
may cause danger, this
hazard warning light
shall be turned on.
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Side Control Panel
− The right control planel integrates the functions and display information needed by
the both operation positions.
− The arrangement of the side control panel is shown as Figure 11-4Error: Reference
source not found.
− All the symbols comply with ISO 6405-1 and ISO 6405-2.
Key:
1 Side Display Screen 2 Aircondition control
3 Side control console 4 Engine Key Switch
5 Power Socket 6 Side Rocker Switch Panel
Figure 11-4 Arrangement of Side Control Panel
− The Side Display Screen (1) provides the status of the machine. Be careful of the
warning symbols on it.
CAUTION! Pay Attention to the warning symbols on the

screen- Ignore this rule may cause damage to
the machine
− During operation or driving, if any of the warning lights are on, please turn off the
engine immediately.
− Do not start the engine until the problem is solved and the warning symbols
disappear.
− The aircondition control (2) provides the AC-control and display of temperature in
the cab.
− The right console (3) provides the operation functions that needed in both operation
position.
− The engine key switch (4) is the main power supply for this machine.
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− The power socket (5) can provide power for external electrical devices.
− The side rocker awitch panel (6) provides the operation functions that needed in
bothe operation position.
Side Display Screen
2 3
1 4
Figure 11-5 Side Display Screen
− This screen is located at the right-hand side of the seat (loader operation position).
− The four main display areas on the screen are descripted as follow:
Displa Symbols Meaning and description

y Area
1
Fuel meter
Provides the information about the quantity
of fuel in the tank.
 Refuel as soon as
possible, when the
indicator points to the
red area.
 Never let the fuel tank
run out of fuel,
otherwise air will enter
the fuel system.
2
Voltmeter
Provides the information about electrical
potential of battery.
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Displa Symbols Meaning and description
y Area
3
Engine coolant temperature
Provides the information about the engine
coolant temperature
4
Engine tachometer
Provides the information about current
engine speed
− Rear working light indicates the rear working light is on. This symbol is green.
Rear working light

Indicate that rear working light is on.
− Special stauts symbols on the screen includes as follow. These symbols are yellow.
Waiting for start

Low temperature start aid
DPF regeneration underway

To indicate that active regeneration of DPF is
underway and engine operation can be
affected.
Engine emission system, failure or
malfunction
− Failure warning symbols on the screen includes as follow. These symbols are red.
 Stop working, turn all the controls into the neutral postion
and shut down the engine immediately.
 After dealing with the problem, restart the engine and
check the failure warning symbols.
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 Only when the warning symbol is off, normal working can
be carried out.
Low fuel level

Indicate the fuel level is low.
Refuel as soon as possible.
Low pressure of engine lubricating oil

Indicate the low pressure of lubricating oil.
Contact your service personnel to deal with this
situation.
High temperature of hydraulic oil
Indicate the high temperature of hydraulic oil.
Contact your service personnel to deal with this
situation.
Engine intake air filter
Indicate the unusual status or service-needed of
the engine intake air filter.
Water in fuel
Indicate the water content in the fuel has
reached a specified concentration.
Battery charging condition

Indicate whether the battery is charging or low-
level charge of battery.
Engine emission filter active regeneration

disable
To indicate that the aftertreatment regen has
been inhibited due to the inhibit switch.
Engine emission filter active regeneration
required
To indicate that active regeneration of the DPF
is required.
Engine stop
To indicate engine shutdown required for
severe system faults/events.
When the key switch is moved to the ON
position, the indicator will come on for 2
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seconds and then go off.

If the indicator will not illuminate during indicator
check or stay illuminated or flash, contact your
service personnel to deal with this situation.
Engine failure or malfunction
To indicate engine and emissions system
diagnostics.
When the key switch is moved to the ON
position, the indicator will come on for 2
seconds and then go off.
If the indicator will not illuminate during indicator
check or stay illuminated or flash, contact your
service personnel to deal with this situation.
− Display switch buttons are located on the bottom of the Side Display Screen.
− These buttons could switch the information on the screen.

− Press any button of F1-F4, and then press the button which provide the information
you need.
o F1: Display the current parameters information of the machine

o F2: Display the current fault information of the machine
o F3: Main menu
o F4: Turn off or on the alarm sound
− Find the details as follow:
o F1: Current Parameters. After entering this menu, F1 is Page Down. F2 is Page Up. F3 is
Enter. F4 is Return.
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o F2: Current Fault information. After entering this menu, F1 is Page Down. F2 is Page Up.
F3 is Enter. F4 is Return.
o F3: Main Menu. After entering this menu, F1 is Page Down. F2 is Page Up. F3 is Enter. F4
is Return.
The Structure of main menu is as follow:
No. Menu Content Note
1 Information of
Use
1.1 Operating Parameters Same contents as F1

Button
1.2 Information of modes, series number,

Instrument etc.
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No. Menu Content Note
1.3 Information of modes, series number,

Controller etc.
2 Instrument Only be used by trained

Adjustment personnel
3 User Setting
3.1 Language Option: English,

Chinese, Portuguese
etc.
3.2 Brilliance F1: Decrease

F2: Increase
F3: Enter
F4: Return
Side Control Console
− The functions in the side control console are as follow:
Figure 11-6 Side control console
Clearance lights; position lights

Press to turn on the position lights.
Rear working light

Press to turn on the rear woring light
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Backhoe, boom side shift（optional）

Press to unlock the movement of boom
laterally, which allow operation of the boom and
bucket from the offset right or offset left
position.
Press again to lock the boom in a fixed position
to prevent it from shifting left or right.
Rear window washer

Press to sprays washing fluid on the rear window.
After release it would be resets automatically and
stop spraying washing fluid.
Hydraulic speed control

switch(optional)
Press to slow down the operating speed of the
machine.
Warning beacon
Press to turn on a rotating or blinking light
ISO/SAE Habit Switch

Switch between the operation custom of ISO and
SAE.
Default habit is SAE custom operation.
Press once, change to ISO custom operation.
Rear window wiper

Press once, the wipers will clean rear window at a
low speed.
Press twice, the wipers will clean rear window at a
high speed.
Press third time, the wipers will stop work.
Right Rocker Switch Panel

− The functions in the right rocker switch panel are as follow:
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Figure 11-7 Right Rocker Switch Panel
Switch Symbols Meaning and description
Engine emission filter active

regeneration required
To indicate that active regeneration of
the DPF is required.
Multifunctional continuous oil

supply switch
When operate the attachment need
continuous oil supply, press the switch
to supply continuous oil without
holding the operating roller open.
Load or backhoe multi-function

circuit switch
when use the attachment need sigle
circuit, should choose the sigle circuit
positon, e.g. breaker; and when use
the attachment need double circuit,
should choose the double circuit
positon, e.g. auger or multipurpose
Bucket.
Loader/ Backhoe portion
Activation Switch
To activate the loader or backhoe
portion.
 Without this
activation, the
control devices in
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Switch Symbols Meaning and description
the corresponding
portion would be
invalid.
 This switch and
seat switch are the
safety protective
devices to prevent
inadvertent
operation out of
your vision, when
you work in another
portion of this
machine.
Object handling application of

backhoe portion
switch(optional)
When use the backhoe for object
handling applcation, you should control
the swtich to “LMI“ positon.
Power Socket
− Open the lid of the power socket , you can insert external electrical appliances such
as cigarette lighter, teacup heating socket, external reading light, etc.
CAUTION! Attention to the use of electrical socket, if avoid this

instruction, could result in damage to machine.
− Do not leave the external device in the socket before turning off the engine.
− When the engine starts, the external device and socket may be burned under the
impact start-up current.
− Use external device while the engine is tured off may cause low battery power and
affect the start of machine.
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a) Close the lid b) Open the lid
Figure 11-8 Power Socket
Air conditioning control panel
NOTICE!- Maintain the air conditioning system
− Replace the filter of the air conditioner regularly.
− Air conditioning control panel’s arrangement is shown as follow:
Key:
1 Air Flow adjusting knob
2 “Hot” button
3 “Cool” button
4 “Fresh Air” button
5 Temperature adjusting knob
6 Temperature display screen
Figure 11-9 Air conditioning Control Panel
− Press “Fresh Air” button allows fresh air to enter the operator cabin from outside.
− Refrigeration shall follow this instruction:
o Start the engine;
o Turn the Temperature adjusting knob (5) to the temperature you need;
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o Press the “Cool” button (3);
o Turn the Air Flow adjusting knob (1) to high (3 position) for several minutes;
o If the temperature in the cab reaches your requirement, turn the air flow adjusting
knob (1) to low (1 position).
 Air flow adjustment has three positions, 1 is the lowest
flow, 3 is the highest flow.
 Adjust the air outlet can change the angle and direction of
the blowing.
NOTICE!- Attention to use the “cool” air conditioning system
− Do not turn to 1 position when start the refrigeration to prevent the evaporator from
frosting and affect the cooling effect.
− Do not turn on “Hot” and “Cool” simultaneously.
− Heating shall follow this instruction:

o Start the engine;
o Turn the Temperature adjusting knob (5) to the temperature you need;
o Press the “Hot” button (2);
o Turn the Air Flow adjusting knob (1) to high (3 position) for several minutes;
o If the temperature in the cab reaches your requirement, turn the air flow adjusting
knob (1) to low (1 position).
 Air flow adjustment has three positions, 1 is the lowest
flow, 3 is the highest flow.
 Adjust the air outlet can change the angle and direction of
the blowing.
 The heat of aircondition is from the engine coolant, which
flows through the evaporator of the aircondition.
CAUTION! Special Attention to ultimate environment temperature, -

if avoid this instruction, could result in damage to
machine.
− Fill the coolant with antifreeze.

− Follow the instruction in Error: Reference source not found to empty the coolant
tank, if the environment temperature is lower than the temperature limits of
machine. Otherwise the pipes may be frozen and break-up.
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Travelling Control Zone
− Travelling control zone of the machine integrates gear lever, light control lever,
steering wheel, pedals and handbrake. Its arrangement is shown as follow.
Steering Wheel
Light Control
Gear Lever Lever
Horn Button
Height Adjusting
Handler
Tilt Adjusting
Pedal
Pedal Control
Accelerator
Pedal
Figure 11-10 Steering column
Steering Column
− The steering column is the integration of steering wheel and its support struture.
− The height of the column could be adjusted by the adjusting handler. Pull the
handler out and adjust the height of column as you need. Push the handler back
and ensure the column is locked.
− The tilt of steering column could be adjusted by the adjusting pedal. Press and hold
the pedal to adjust the tilt of the column before operation or driving. Release and
ensure the column is locked.
CAUTION! Attention of adjusting steering column
− After adjustment, ensure that the steering column is locked to prevent its
unexpected movement during travelling.
− Do not adjust the steering column during travelling.
− The horn button is under the logo of the steering wheel.

− The horn (warning device) is located under the frame of the machine. Its sound
level is greater than 93dB at 7 m from the most front-end forward and from backhoe
swing centre to the rear.
− Press the horn button to sound the horn.
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CAUTION! Use horn to waring the bystanders
− Press horn TWICE to warning the bystanders before driving or operation of

backhoe portion.
Gear Lever
− The gear lever is located on the left-hand side of steering column.
− The gear lever is used to control the travel direction of the machine and also used
as gear selector.
Figure 11-11 Gear Lever
− The top position (F) is FORWARD. Lift the lever and push completely forward to
travel forward.
− The center position (N) is NEUTRAL.
 Make sure the gear lever is in NEUTRAL before you start
the engine or before you operate the backhoe.
− The bottom position (R) is REVERSE. Lift the lever and pull completely rearward, to
travel in reverse.
 An audible alarm in the backhoe portion will be
automatically activated while in reverse.
− There are 4 gears in this machine. 1 is the lowest speed and 4 is the highest speed.
− Turn the lever counter-clockwise to increase the gear.
DANGER! Pay attention while using gear lever!
− Suddenly change direction without warning (horn) may cause injury or

death to the driver himself or bystanders.
− Not respecting the rules presented hereafter may cause serious injuries or death
hazards to change travel direction:
o Recommend not choose REVERSE when the machine is in 3 or 4 gears.
o Before change direction of machine, press the brake pedal until the machine
totally stop and the engine speed drops to idle speed. Lift and pull the gear
lever to change the travel direction. Release the brake pedal and accelerate.
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− Stop the engine before you leave the seat to prevent inadvertent activity of gear
lever.
Light Control Lever

− The light control lever is located on the right side of the steering column.
− This lever is used to adjust headlight, position light, turn signals light.
− Light control lever is shown as Figure 11-12
B A
Figure 11-12 Light control lever
− Turning (A) of the lever could select from 0-3 position:

o 0: turnoff all the lights
o 1: turn on the position lights and the “position lights” indicator in the Front
Display Screen (see )
o 2: turn on the low beam headlight
o 3: turn on the high beam headlight and the “high beam” indicator in the
Front Display Screen (see )
− Push (B) the lever up or down could select the turn signals:
o UP: turn on the left turn signal light and the “left turn” indicator in the Front
Display Screen (see )
o DOWN: turn on the right turn signal and the “right turn” indicator in the
Front Display Screen (see )
1.
1 - 579
Accelerator Pedal
Accelerator
Pedal
Figure 11-13 Accelerator Pedal
CAUTION! Beware of using the pedals – hazards due to loss of skid

resistance
− Clean the pedals and its surrouding after working daily to prevent inadvertent
action during operation.
− Do not operate with poor anti-slip shoes (e.g. slippers), or even without shoes.
− The accelerator pedal is locted on the right-foot side under the steering column.
− The default position of accelerator pedal is idle engine speed.
− Depress the accelerator pedal will increase the fuel supply for engine, and increase
the engine speed.
− Release the accelerator pedal will decrease the fuel supply for engine, and
decrease the engine speed.
 Do not adjust the engine speed with hand throttle, but with
accelerator pedal, during travelling.
Figure 11-14 Accelerator Pedal
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Brake Pedals
Brake Pedals
Figure 11-15 Brake Pedals
CAUTION! Beware of using the pedals – hazards due to loss of skid

resistance
− Clean the pedals and its surrouding after working daily to prevent inadvertent
action during operation.
− Do not operate with poor anti-slip shoes (e.g. slippers), or even without shoes.
− The brake pedals are located on the left-foot side under the steering column.
− The brake pedals are used to decelerate or stop the machine.
− The brake pedals are engaged with brake lights, which could automatically lighten
while braking.
 Do not drive or operate the machine, if the brake lights fail.
− Recommand use brake pedals to control the speed of machine while going
downhill.
− The brake pedals are dual-pedal braking of this machine.
o The left pedal controls the brake on the left rear wheel.
o The right pedal controls the brake on the right rear wheel.
o The two pedals could be locked together with a lock lever to work
simultaneously.
o Lock the two pedals - Turn the lock lever upwards, push it to left and turn
downward to lock, as shown in Error: Reference source not found, a).
o Unlock the two pedals – Turn the lock lever upwars, push it to right and
turn downward to lock, as shown in Error: Reference source not found, b).
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a) Lock b)Unlock
Figure 11-16 Lock and unlock between brake pedals
DANGER! Pay attention while braking! - Hazards of tip-over or

uncontrolled movement may causes injuries or even
death of driver himself or bystanders!
− Do not unlock the two pedals unless in special operation situation, such as in
narrow space.
− Do not unlock two pedals while operate the machine with 3 or 4 gears or
travelling.
− Unware of locking the two brake pedals as this instruction may cause hazards.
− Press one pedal while the machine is travelling in a high speed, may cause tip-
over or uncontrolled movement.
Handbrake lever
− The handbrake lever is located on the right-side of the driver’s seat (loader portion).
− The handbrake is always used for parking the machine.
− The handbrake is engaged with the “park” indicator in the Front Display Screen.
− Handbrake can be used as the emergency brake.
 Do not use handbrake to slow down the machine unless in
a emergency situation.
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Handbrake lever
Figure 11-17 Handbrake Lever
− PARK: Pull up the handbrake to park the machine.

− RELEASE: Press the button on the top of the handbrake and press down the
handbrake lever simultaneously to release the handbrake.
DANGER! Beware of parking machine before leave! – May cause

injuries and even death hazards to bystanders!
− Turn the gear lever to Neutral and pull up the handbrake to park.
− Leave machine without parking may cause unexpected movement.
reading lamp
− One reading lamp is placed at the roof, on the left side above the operator’s seat.
− Turn on the lamp for reading this manual or other information, when the illuminance
in the cab is insufficient.
− Turn off the lamp before driving in the night or leave the cab.
Figure 11-18 Reading Lamp

Radio Control Panel
CAUTION! Beware of the use of radio.
1 - 583
− Do not turn the volume of the radio too loud.
− Ensure that you can hear the sound of alarms from machine at any time.
− Ignore the rules may cause accidents during travelling or operation.
− The radio control panel is located on the top of the cab interior.
Figure 11-19 Radio Control Panel
− The functions of these buttons are descripted as follow:

1. Power button: press to open/close the radio.
2. ZERO: press to reset the time (minute) to zero.
This reset is effective only when it’s at 01-05 minutes or 55-59 minutes.
3. BAND: Press to switch between FM1, FM2 and AM (MW) band.
4. AUX: Press to switch between radio and external input audio, such as MP3,
U disk or SD card.
5. VOL(∨): Press to decrease the volume of tone. Keep press, the volume can
decrease rapidly.
6. VOL(∧): Press to increase the volume of tone. Keep press, the volume can
increase rapidly.
7. TUNE(∨): In the radio mode, press once to skip to the next lower frequency
tune. Keep press for 3 seconds to search tunes automatically. In the external
input audio, this button is used to adjust the “Hour” of time.
8. TUNE(∧): In the radio mode, press once to skip to the next higher frequency
tune. Keep press for 3 seconds to the search tunes automatically. In the
external input audio, this button is used to adjust the “Minute” of time.
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9. AST/USB/SD: Automatic search tune and save the tunes into -.
In the external input audio, if USB and SD card are both linked, this button
can switch between USB and SD.
10. DISP: Press to switch between the display of time and radio frequency.
11. /PREV: Press 3 seconds to save current radio frequency in this button. In the
external input mode, press to the previous audio.
12. /PLAY/PAUSE: Press 3 seconds to save current radio frequency in this
button. In the external input mode, press to play or pause the current audio.
13. /STOP: Press 3 seconds to save current radio frequency in this button. In the
external input mode, press to stop.
14. /NEXT: Press 3 seconds to save current radio frequency in this button. In the
external input mode, press to the next audio.
15. /REPEAT: Press 3 seconds to save current radio frequency in this button. In
the external input mode, press to repeat plays the current audio.
16. /EQ: Press 3 seconds to save current radio frequency in this button. In the
external input mode, press to switch the sound effects.
Each botton of -could store 3 radio frequencies in FM1, FM2 and AM (MW).
17. USD: Insert U disk. Only MP3 could be recognized.
18. SD: Insert SD card. Only MP3 could be recognized.
19. LCD monitor: Display the content of the audio being played.
− Reset all settings: Press 9.AST/USB/SD and 4.AUX bottons simultaneously, and
press 15./REPEAT more than 1 second to reset all settings of radio.
Operation control levers
− There are two control levers on the both side of the seat.
− Engaged with activation switch and seat switch, the control levers would be
activated to operate the equipments of loader portion or backhoe portion.
NOTICE!- Attention to the difference response of levers and equipment
− The operating lever will return to the neutral position after you release it.
− The equipments would keep its position after you release the levers.
− The operating levers could be moved to four directions, forward and backward,
towards the left and right.
− If the operating lever is moved to two directions simultaneously, the machine
would operate a combined movement. For example, move the lever to left-rear
would raise the arm and rollback the bucket simultaneously if at loader portion.
1 - 585
Left-hand Right-hand
Control Control
Lever Lever
Figure 11-20 Operation control levers
Loader Operation Control lever

− When the operator’s seat is in the loader operation position, and the Loader/
Backhoe portion Activation Switch in the loader positon, the loader operation control
lever would be activated.
− Loader operation control lever is the right-hand control lever.
− This control lever integrates most of the funcitons of loading operation, which allows
the operator to operate with one hand conveniently.
− Loader operation control lever is consisted of two buttons in obverse side and one
button in reverse side, one roller and an operating lever.
− The first button in obverse side is “return-to-dig”, which could return the loader
bucket to the dig position.
− The second butoon in obverse side is “float”, which could allow the bucket move up
and down depending on the contour of the ground. When press the “float” button
and Push the right-hand control lever to the front ,can implement the “float” function.
− The button in reverse side of control lever is “clutch”, which could stop travelling
and supply more power to loader operation.
− The roller is an option funciton in loader operation, which could be selected
personalized, such as four-in-one bucket, sweeper, etc.
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AUX
Figure 11-21 Right-hand Control Lever in loader portion
− The left-hand control lever could provide horn and differential lock.
− The first button in the obverse side of left-hand control lever is “horn”, which could
works in both loader and backhoe portion.
− The button in the reverse side of left-hand control lever is “differential lock”, which
forces both wheels to rotate at the same speed.
Figure 11-22 Left-hand Control Lever in loader portion
− The opration and movement are described as follow:
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Symbols and Meaning and description
Operating
Return to Dig
Let the loader bucket return to dig position.
Float
Allow the bucket move up and down depending to
the contour of the ground
Lower of Loader bucket

Push the operating lever forward to lower the
loader lift arms.
 Move the lever to left-front
could lower the arm and
rollback the bucket.
 Mover the lever to right-
front could lower the arm
and dump the bucket.
Raise of the loader bucket

Pull the operating lever backward to raise the
loader lift arms.
With a completely roll backed bucket, the angle
between the bucket and the ground would
remain the same as the bucket raise.
The rising speed of loader arm is related to the
engine speed.
Rollback of loader bucket
Push the operating lever to left to retract the
bucket cylinder and turn the bucket to carry
material.
Dumpt of loader bucket

Push the operating lever to right to extent the
bucket cylinder and turn the bucket to dump its
contents.
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Symbols and Meaning and description
Operating
Clutch
Stop travelling and supply more power to loader
operation.
Horn
Warning device
Differential Lock
Lock the differential of axel, force the two
wheels to rotate at the same speed.
Backhoe Control levers

− When the operator’s seat is in the backhoe operation position, and the Loader/
Backhoe portion Activation Switch is in the backhoe positon, the backhoe operation
control lever would be activated.
− Backhoe portion would be operating by both left and right-hand control levers.
− The left-hand control lever has two buttons. The first one is horn, another is an
option button, the roller on this lever is an option funciton in backhoe operation,
such as breaker, auger etc.
− The right-hand control lever has one roller. Roll up would extend the backhoe
extendable arm. Roll down would retract the backhoe extendable arm.
NOTICE!- Attention to the movement different of operating lever and the

equipment
− The operating lever would return to the neutral position after you release it.
− The equipments would keep its position after you release the levers.
− The operating levers could be moved to four directions, forward and backward,
towards the left and right.
− If one operating lever is moved to two directions simultaneously, the machine
would operate a combined movement.
− Both control levers could be used simultaneously to operate combined
movements.
− Before operate the lever, please verify the operating mode under safe
conditions.Before verify the mode, can not operate.
1 - 589
Figure 11-23 The functions in the control levers of backhoe portion
− In order to adapt different operators’ habit, there are two operating modes of
backhoe portions.
− One is SAE operating mode, and another is ISO operating mode.
− Operating mode could be selected from the Side Control Console (see ). The
default mode is SAE mode.
− The operating and corresponding movement of the equipments are descripted as
follows.q
o SAE Operating Mode (left lever and right lever)
o ISO Operating Mode (left lever and right lever)
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− The meanings of these symbols are as follow:
Lower of backhoe boom
Push the operating lever (left lever with SAE
mode, or right lever with ISO mode) forward to
lower the boom of the backhoe.
 Pay more attention while
lowering the boom to
prevent crushing injuries to
bystander or damage to
property.
Raise of backhoe boom

Pull the operating lever (left lever with SAE
mode, or right lever with ISO mode) backward to
raise the boom of backhoe.
rising the boom to prevent
crushing obstacles upside.
Left swing of backhoe boom

Pull the left operating lever to left to swing the
boom to the left.
 Pay more attention to the
size of different
attachments.
 Swing the boom too much
may cause crushing
between attachments and
outriggers.
1 - 591
Right swing of backhoe boom
Pull the left operating lever to right to swing the
boom to the right.
Outward of backhoe arm

Push the operating lever (right lever with SAE
mode, left lever with ISO mode) forward to move
the arm outward away from the machine by
increasing the angle between the boom and
arm.
moving outward to prevent
crushing injuries to
bystander or damage to
property.
Inward of backhoe arm

Pull the operating lever (right lever with SAE
mode, left lever with ISO mode) backward to
move the arm toward the machine by
decreasing the angle between the boom and
arm.
 Pay more attention to the
size of different
attachments.
 Move the backhoe arm
inward too much may cause
crushing between
attachments and arm.
Rollback of backhoe bucket

Pull the right lever to left to move the tip of the
bucket away from vertical to rollback the bucket
for dig, lift or carry materials.
Dump of backhoe bucket

Pull the right lever to right to move the tip of the
bucket toward vertical to dump its contents.
1 - 592
Retract of backhoe extendable arm
Roll the roller of the right lever upwards to
extend the arm and increase the reach of the
hoe equipment.
Extent of backhoe extendable arm

Roll the roller of the right lever downwards to
retract the arm and decrease the reach of the
hoe equipment.
Stabilizer Control Levers

− Stabilizer control levers (Error: Reference source not found, A and B) is located at
the left-hand side of backhoe protion.
− Swerve the seat to backhoe operation position and press the Loader/ Backhoe
portion Activation Switch (see ) in the backhoe positon to activate the stabilizer
control levers.
− Push the Lever A forward (to the direction of backhoe equipment) will lower the left-
stabilizer. Pull the Lever A backward (reverse direction of backhoe equipment) will
raise the left-stabilizer.
− Push the Lever B forward (to the direction of backhoe equipment) will lower the
right-stabilizer. Pull the Lever B backward (reverse direction of backhoe equipment)
will raise the right-stabilizer.
Figure 11-24 Stabilizer Control Levers
1 - 593
CAUTION! Attention about using stabilizers
− Lower the stabilizers and loader bucket on the ground before the backhoe
operation to prevent oscillate and overload of tires.
− If necessary, the stabilizers could be lowered with the help of backhoe bucket’s
support on ground.
 The whole machine shall be horizontal and stable after the
lowering of stabilizers and bucket.
− Lever A and Lever B are independent.

o The two stabilizers can have different extensions in oder to keep the machine
horizontal and stable due to special ground condition.
o Restract BOTH stabilizers completely before travelling.
o If any stabilizer is not completely restracted, its indicator will be on in the front
display screen. In this case, warning alarm will sound when the gear lever is not on
the neutral position.
Hand throttle Knob

Hand throttle knob is used to supply oil continuely to maintain the engine speed.
− Hand throttle knob is located at the left-hand side of backhoe protion.
− Swerve the seat to backhoe operation position and press the Loader/ Backhoe
portion Activation Switch in the backhoe positon could activate the hand throttle
knob.
− Turn the throlttle knob clockwisely to increase the engine speed.
− Turn the throlttle knob counter-clockwisely to decrease the engine speed.
− Hand throttle is only used for backhoe operation. About 1600 r/min engine
speed is recommended for digging work.
Figure 11-25 Hand throttle Knob
1 - 594
Removal and replacement of side console
Removal
− Park the machine on firm level ground, apply the parking brake. Lower the
loader arms and excavator to the ground, switch OFF the engine and remove
the starter key.
− Disconnect the battery.
− Remove the fixing at the top of the instrument panel and carefully lift the panel
forward to revel theconnections at the back as shown.
− Disconnect the electrical connectors at the rear of the instrument panel, then
remove the instrument panel assembly clear of the side console. Label the
connectors and controls cables before disconnecting to ensure correct
replacement.
Replacement
− Replacement is the reverse of the removal sequence.
− Take care when removing/replacing the console panel to ensure that
harnesses do not become snagged and that no other connections have been
disturbed.
− After re-fitting, operate the side console controls and check all function
correctly.
Removal and replacement of front console

Removal
the starter key.
− Remove the steering wheel.
− Remove the fixing and take off the steering column cover.
− Remove the gear lever and the light control lever.
− Remove the front panel.
− Remove the fixing and carefully lift up the steering column.
Replacement
− Take care when removing/replacing the console panel to ensure that
harnesses do not become snagged and that no other connections have been
disturbed.
1 - 595
− After re-fitting, operate the front console controls and check all function
correctly.
1 - 596
12 Air Conditioning System
12.1 Overview of A/C System

12.1.1 Overview
The A/C system consists of evaporator, condenser, compressor,
receiver dryer, controller and pipeline. The compressor is driven by the
engine through a belt, and the A/C power supply is provided by the vehicle
power supply. The air conditioning system has stable and reliable
performance and good seismic resistance, which can be used by various
vehicles such as construction vehicles, trucks and special vehicles.
12.1.2 Technical parameters
Applicable -40°C~43°C (partially adapted to T3 working

temperature condition, depending on specific vehicle
range configuration)
Working 12V or 24V

voltage
Total power ≤750W (with condenser fan)/300W (without

consumption condenser fan)
Refrigerant R134a
Refrigeration PAG100
oil
Shaft power ≤2000W

consumption
of
compressor
12.1.3 Working principle
1. Refrigeration system
1 - 597
The system is designed with a circulating vapor-compression
refrigeration mechanism and mainly contains four working processes.
A. Compression process
The compressor operates to suck low-temperature and low-pressure
gaseous refrigerant in the evaporator, compress it into high-temperature
and high-pressure gaseous refrigerant and discharge it.
B. Condensation process
The high-temperature and high-pressure gaseous refrigerant from the
compressor enters the condenser for condensation and heat dissipation,
and gradually becomes a medium-temperature and high-pressure liquid
refrigerant.
C Throttling expansion process
The medium-temperature and high-pressure liquid refrigerant reaches
the expansion valve after being dried and filtered by the receiver dryer.
After throttling expansion, its pressure and temperature drop sharply and
enter the evaporator in the form of atomized small droplets.
D. Evaporation process
The mist refrigerant with a boiling point far lower than the temperature
in the evaporator absorbs heat and vaporizes in the evaporator, then turns
1 - 598
into low-temperature and low-pressure gas and enters the compressor for
the next cycle.
2. Heating system
The heating system of the A/C is a water-heating type, using engine
cooling circulating water as a heat source. This system has a simple
structure and is environmentally friendly and economical.
Note: Some models have oil heaters for heating.
3. Automatic system protection

A. Pressure protection
The system pressure is controlled by high and low pressure switches,
and the normal working pressure range of the system is
0.196MPa~3.14MPa (2.65MPa for some models). When the system
pressure is too high or too low, the high and low pressure switch will be
automatically disconnected and the compressor will stop running to
protect the system.
B. Temperature protection
When the temperature of the working medium in the receiver-drier
reaches 102-110°C, the fusible plug on the receiver-drier melts and the
working medium in the system is discharged into the atmosphere to
protect the system.
12.2 Operation Instruction

Select the operation content shown in the following figure according to
the controller style of specific vehicle model configuration.
Mechanical A/C controller
The mechanical A/C controller is mostly used for cooling-only air
conditioners. When it is used for heating-cooling air conditioners, it
cooperates with manual water valves or electric control water valves to
realize heating function control.
1 - 599
(1) Introduction to panel
Controllers have three working modes: refrigeration, heating and
ventilation, as well as the functions of displaying fresh air and room
temperature.
Controllers
(2) Operation Method of Styles II and III Controllers
1) Start the main engine.
2) Air volume switch: Rotate the magnetic switch to a comfortable
air speed (there are three levels of air speed: 3/high, 2/medium and
1/low), and shut down at level 0.
3) Temperature control switch: Rotate this switch to set the return
air temperature of A/C, with a setting range of 18°C~30°C. This knob
shall be used in conjunction with the cooling and heating buttons.
4) Heating button: Press this button to turn on the electric water
control valve of the A/C heating system, and the heating will be turned
on. This button shall be used together with the temperature knob.
When the temperature knob is set to 30, the heating effect is best:
5) Refrigeration button: Press this button to turn on the compressor
of A/C refrigeration system and start refrigeration. This button needs to
be used together with the temperature knob. When the temperature
knob is set to 18°C, the cooling effect is best.
6) Fresh air button: internal circulation by default. Press this button
to switch to external circulation and turn on fresh air of the A/C.
1 - 600
7) Temperature display: It displays the indoor (return air)
temperature.
(3) System fault diagnosis
The meanings of DTC indication are as follows:
ERI high voltage fault
ER2 low voltage fault
ER3 receiver-drier pressure fault
ER4 Defrosting sensor fault
ER5 return air sensor fault
12.3 Install
Caution:
A. The installer shall have knowledge of the vehicle A/C system.
B. Read this manual before installation.
C. The components shall be free of bumps and damages, with good
tightness and dry and clean internals.
D. The working environment shall be clean and moisture-proof to
prevent dirt, moisture, and other substances from entering the system.
5.1 Installation of compressor
a) The compressor clutch belt groove and the engine belt groove
shall be in the same plane.
b) Add a tensioning device to the compressor belt, and adjust the
tightness of the belt (the belt should drop by about 10-12mm when a force
of 98N is applied to the belt).
c) The compressor interface shall face upwards and rotate leftward or
rightward by 45°.
d) The clearance between compressor fixing feet and support fixing
feet shall be less than 0.1m.
5.2 Installation of evaporator
a) Handle the evaporator with care to prevent damage to the topcoat.
1 - 601
b) Install the evaporator at the reserved position of the main engine,
so that the fixing holes and leakage pipes correspond to the reserved
holes in the cab one by one and are installed firmly.
c) When installing the evaporator, pay attention to smooth air inlet
and outlet so as not to affect the air volume as well as the cooling and
heating effects.
5.3 Install the condenser
a) The condenser shall be installed to ensure smooth ventilation.
b) In general, the condenser inlet pipe joint (thick pipe) shall be above
and the outlet pipe (thin pipe) shall be below.
c) The installation shall be firm without damaging the fin and fan, and
the wire connectors shall be well connected.
Note: When fixing the condenser, do not unscrew the connector plug
cap to prevent dirt from entering and causing adverse effects on the A/C
system.
5.4 Installation of Receiver Drier
The receiver drier shall be installed vertically in a well-ventilated
position, and the pipeline connection shall be carried out immediately after
the sealing cap on the receiver drier is opened to prevent the desiccant
from failing due to long-term exposure to moisture.
Note: The inlet and outlet of the receiver drier have directions, and the
condenser outlet pipe is connected to the inlet of the receiver drier, which
cannot be reversed.
5.5 Schematic Diagram for Installation of Refrigeration Pipeline (the
joint form shall be subject to the physical object)
1 - 602
a) Connect the refrigeration pipeline according to the operation steps
in Fig. VIII. The O-ring on the joint must be coated with refrigerant oil, and
the remaining refrigerant oil in the cylinder is poured into the compressor
from the low-pressure port (thick pipe orifice).
b) When connecting the pipeline, the pipe joint with the seal ring must
ensure that the sealing ring completely enters the butt pipe joint, and at
the same time, over-cutting of the sealing ring shall be prevented. Tighten
the nut by hand first, and then use a wrench. Do not tighten it forcibly
before tightening it by hand or putting the nut in place.
c) Tightening torque: (based on steel nut and aluminum joint)
M16x1.5 thread 14±2Nm

5/8- 18 UNF thread 14±2Nm
1 - 603
12.4 Commissioning
After the system installation or maintenance, carry out the system
commissioning (the commissioning must be operated by professionals).
Caution:
A. The operating environment shall be clean and moisture-proof to
prevent dirt and water from entering the system, and operations on rainy
days shall be avoided as far as possible
B. The refrigerant shall be R134a, and other refrigerants such as R12
are strictly prohibited.
6.1 Vacuumizing
Vacuum pumping is to remove moisture and air from the system, and
is an extremely important process in the air conditioner service.
Commonly used vacuuming tools are manifold pressure gauges (see Fig.
9) and vacuum pumps.
6.1.1 Connect the two HP and LP hoses on the manifold pressure
gauge to the HP and LP filling ports on the compressor respectively, and
ensure that the HP and LP manual valves on the manifold pressure gauge
are closed at this time.
1 - 604
6.1.2 Connect the intermediate hose of manifold pressure gauge to
the vacuum pump intake.
6.1.3 Open the manual HP and LP valves on the manifold pressure
gauge, start the vacuum pump, observe the two pressure gauges, and
vacuum-pump the system to a pressure of -0.1MPa.
6.1.4 Close the HP and LP manual valves on the manifold pressure
gauge, turn off the vacuum pump, and check the system pressure after
maintaining the pressure for 30min. If the system pressure rises
significantly, it indicates that there are leaks in the system, and leak
detection and repair are required. If the system pressure is still -0.1MPa,
i.e. the pointer of the pressure gauge does not move, open the manual
high and low-pressure valves, start the vacuum pump to continue
vacuuming for 15~30min, so that the pointer of the vacuum pressure
gauge is stable.
6.1.5 Close the HP and LP manual valves on the manifold pressure
gauge.
6.1.6 Turn off the vacuum pump.
Note: ① Firstly close the manual HP and LP valves, and secondly
close the vacuum pump to prevent air from entering the system.
1 - 605
②Time for vacuum-pumping operation must be determined as
required, to ensure to eliminate moisture from the system. Repeated
vacuum-pumping operation shall be carried out in damp days.
6.2 Leakage Detection

The common leakage detection methods of the A/C system include
electronic leak detector, pressure leak detection, refrigerant filling leak
detection, and appearance leak detection. The following is a description of
the leakage detection method of the electronic leak detector.
6.2.1 Fill the system with refrigerant to 0.1MPa.
6.2.2 Power on the electronic leak detector and preheat it for 10 min.
6.2.3 Turn the switch to the detection mode and place the probe at
the detected part. If there is leakage beyond the sensitivity range, the
alarm bell will sound.
6.2.4 After all the leaks are found out, repair them.
6.2.5 After the repair, maintain the pressure and test for leak, until
eliminating all leaks.
6.3. Fill the refrigerant
After completing the vacuum-pumping operation, maintaining the pressure
and confirming no more leaks after inspection, fill refrigerant into the
system. There are three ways to fill the refrigerant: filling from HP end,
1 - 606
filling from LP end and filling from both HP and LP ends. Filling refrigerant
from both HP and LP ends features a fast speed and is therefore most
commonly used for installation and commissioning. This way is described
as follows:
6.3.1 The connection between manifold pressure gauge and
compressor is the same as that in 6.1.1.
6.3.2 Connect the intermediate hose of manifold pressure gauge to
the joint of the refrigerant tank filling valve.
6.3.3 Make sure that the air conditioner is turned off and the engine is
shut down.
6.3.4 Open the bottle opening valve of the refrigerant tank, loosen the
exhaust valve on the manifold pressure gauge to let the refrigerant drive
out the air in the intermediate hose for 2~3s, and then tighten the exhaust
valve.
6.3.5 Unscrew the manual HP valve of the manifold pressure gauge,
invert the refrigerant tank and fill liquid refrigerant from the HP side.
6.3.6 After the liquid refrigerant is injected from the high-pressure
side for a while if the weight of the refrigerant tank no longer drops or the
pointer of the manifold pressure gauge is constant but the refrigerant has
not reached the specified amount, close the high-pressure manual valve
and erect the refrigerant tank.
6.3.7 Start the engine, keep the speed at 1250~1500r/min, turn on
the A/C refrigeration switch, select the maximum gear of the air volume
switch, and open the low-pressure manual valve to let gaseous refrigerant
into the system.
6.3.8 During refrigerant filling, observe the flow state of refrigerant
through the sight glass on the receiver/dryer. When there are just no
bubbles in the hole and the liquid flows stably, it indicates that the amount
of injected refrigerant is appropriate (at this time, the system pressure
value displayed by the manifold pressure gauge meets the system
1 - 607
pressure parameters specified in 6.6); observe occasional bubbles, it
indicates insufficient refrigerant; when there are no bubbles in the hole
and the liquid flows rapidly, it indicates excessive refrigerant filling.
Insufficient or excessive refrigerant in the system will affect the
refrigeration effect of A/C.
6.3.9 After filling, close the refrigerant tank, and then close the low-
pressure manual valve to stop the air conditioner and the engine. Wait for
1~3min, and quickly remove the two joints of the manifold pressure
gauge. The joints shall be removed quickly to avoid excessive refrigerant
leakage. The original plug cap of the system filling interface shall be
sealed.
6.3.10 When replacing the refrigerant tank during filling, close the
manual valve on the filling side, wait for 1-3 min, and then quickly unscrew
the open-bottle valve and replace it with another tank of refrigerant. After
replacement, repeat the operation steps in 6.3.4, and then continue to fill
according to the filling state before tank replacement.
Caution:
●When opening the high-pressure manual valve for filling at the
high pressure end, it is absolutely not allowed to start the compressor to
prevent liquid hammer.
●Wear gloves when removing the pipe to prevent frostbite, and
wear protective glasses if necessary.
6.4 Refill Refrigerant
6.4.1 Manifold pressure gauge shall be used for supplementary
refrigerant equipment, and its connection mode is the same as 6.3.1 and
6.3.2.
6.4.2 After the pipeline connection is completed, exhaust air from the
intermediate hose according to the operation method in 6.3.4.
6.4.3 Start the engine, turn on the air conditioner, set the air volume
to the maximum, and open the low-pressure manual valve to let the
1 - 608
refrigerant enter the low-pressure pipe in a gaseous state (at this time, the
refrigerant tank shall be placed vertically) until the pressure of the A/C
system reaches the specified value (the judgment method is the same as
that in 6.3.8). 6.4.4 After the filling is completed, close the low-
pressure manual valve to stop the A/C and engine. Wait for 1~3 minutes
and quickly remove the two connectors of the manifold pressure gauge.
Remove the connector quickly to avoid excessive refrigerant leakage. The
original plug cap of the system filling interface shall be sealed
Caution:
●At this time, the refrigerant tank shall be placed vertically.
●The high-pressure manual valve shall be closed and must not be
opened.
6.5 Refrigerant Discharge
Excessive refrigerant filled in the A/C system will affect the refrigeration
effect of the A/C. Therefore, when excessive refrigerant is found in the
system (judged according to the method in 6.3.8), excess refrigerant shall
be discharged. The operation steps are as follows:
6.5.1 Refrigerant shall be recovered directly with recovery equipment
as far as possible. When there is no recovery equipment, a manifold
pressure gauge can be used to discharge the refrigerant.
6.5.2 Connect the high and low-pressure hoses of the manifold
pressure gauge to the high and low-pressure filling valves of the A/C
system respectively, and place the intermediate pipe at the bottom of the
vehicle.
6.5.3 Open the high and low-pressure manual valves slightly, observe
the reading of the pressure gauge, and close them when they meet the
values specified in 6.6 Pressure Parameter Table of System at Different
Temperatures.
1 - 609
6.5.4 When it is necessary to discharge all refrigerant for
maintenance of the air conditioning system, observe that the reading on
the pressure gauge indicates zero (u).
Note: When discharging refrigerant, the operator shall stay away from
the refrigerant discharge port to prevent frostbite.
6.6 Pressure Parameters of the System at Different Temperatures
12.5 Repair and Maintenance

The service life of air conditioners for construction vehicles depends to
a large extent on the correct maintenance by users.
7.1 Daily Maintenance of Air Conditioner:
a) Check and clean the air-conditioning condenser. It is required that
the radiator is clean, and there is no blockage in the radiator. Cold water
or compressed air shall be used for cleaning, and hot water and hot air
shall not be used.
b) Check the amount of refrigerant in the cooling system, that is,
observe the reservoir observation window. Under normal circumstances,
no air bubbles shall be seen through the observation window and only a
few of air bubbles will be seen when the engine speed changes.
c) Check the tension of compressor drive belt.
d) Check whether the hose appearance is normal and whether each
joint is firm.
e) Check whether the power supply of cooling system is firmly
connected and whether there is open circuit or short circuit.
Caution:
●Regardless of whether the air conditioner is used or not, lines and
other devices shall be inspected and maintained regularly.
●If the air conditioner is not used for a long period, it should be turned
on once a month for about 10 minutes each time to facilitate the normal
operation of the system;
1 - 610
●A/C with heating function. The circulating water for heating must be
added with antifreeze to prevent the core or pipeline from freezing and
cracking. 7.2 Regular Maintenance of Air Conditioner
7.2 Regular Maintenance of Air Conditioner
Maintenance cycle
Once
Maintenance
System components half
work Monthly Annually
a
year
Check whether
Refrigeration pipes are worn
√
pipe and kept in
good condition
Check whether
there is
leakage (oil
Joint stains will be √
seen in general
Refrigeration in case of
system leakage)
Check the
Condenser condition of √
cooling fins
Check the
Receiver service
√
drier condition or
replace it
Refrigerant Check the √
1 - 611
refrigerant
condition
through the
observation
window.
Check the
fixation and
Main body of installation
air condition of the √
conditioner main body (it
should not be
loose).
Check the
sealing
System condition of the
√
seals vehicle body
and air
conditioner.
Check the
Magnetic
clutch √
clutch
engagement
Check the
intactness and
Compressor Belt √
tension of the
belt.
Check the
Fixing
fixation and √
bracket
installation
1 - 612
condition.
Check whether
Compressor the running
√
running sound is
abnormal
Check the
Wire circuit for wear √
and intactness.
Check it for
Circuit
Connector contact and √
system
intactness.
Check it for
The control
contact and √
switch
intactness.
1 - 613
1 - 614
1 - 615
1 - 616
1 - 617
1 - 618
Hood
Removal and replacement of hood
Figure 13-26 hood
Removal
the starter key.
− Open the front hood A with hood key and remove the fornt hood.
− Toggle the switch B and open the hood C fully.
− Loose the fixings of the gas spring D.
− Loose the fixing bolts E.
− Remove the hood C.
Replacement
1 - 619

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Service Manual

Xuzhou Construction Machinery Group Co., Ltd.

04.2024 Page 1 / 630

04.2024 Page 1 / 630

This Service Manual is designed for the benefit of XCMG Distributor

These personal should have s sound knowledge of workshop, safe

The configuration, structural principles and maintenance information

04.2024 Page 2 / 630

4 Faults and Troubleshooting......................................................................................

12 Air condition system...............................................................................................

This Maintenance Manual is prepared to help maintenance

personnel understand the structural principle and functions of

each system (component) of the machine, guide them to

correctly diagnose and eliminate machine faults according to the

fault symptoms of the machine, and provide maintenance

standards for the machine under general and special

environmental conditions, so as to improve the repair quality

This Maintenance Manual consists of the following chapters:

05, Chapter Page S/N

Chapter No. (05, Power System)

3. Supplementary page number: It is indicated by hyphen (I) and supplementary

Special technical preventive measures or the

Weight of part or system.

Tighten During assembly, special attention shall be paid to the

Application Places where sealant or lubricating oil is required.

Places where oil, water or fuel need to be added and

Places where oil or water must be drained and their

1.2 Lifting Instructions

Steel Wire Rope (Standard S-shaped Steel Wire Rope)

Note: The allowable load in the above table is estimated according to

2.2 Safety precautions

2.3 Daily Safety

2.5 Maintenance Safety

Item Description Item Description

Code Item Unit Parameter

Cod Item Unit Parameter(unbrake Parameter(braked)

Fluid recommended and fill capacity

Capacity Ambient temperature ℃ / °F

Hydraulic Hydraulic 95(20.9)

Cooling 12.5(2.75 Add antifreeze

DEF tank DEF(3) 19(4.18)

Store Temperature Expeceed DEF life

Below 25° C (77° F) 18 months

25° C (77° F) to 30° C (86° F) 12 months

Above 35° C (95° F) test quality before use

Bolt tightening torques

Bolt Wrench Torque

Trouble Cause Solution

Trouble Cause Solution

Trouble Cause Solution

Trouble Cause Solution

Trouble Cause Solution

Trouble Cause Solution

Trouble Cause Solution

Air condition system

Trouble Cause Solution

Plug Oil drain plug

3. Remove screws and filter assembly

Screw M8×80 (1)

Screw M10×30 (4)