CLG856H Service Manual (LG AXLE, Q&V SYS) - 201408 [PDF]

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Service Manual CLG856H

Wheel loader

Applicable type and model: CLG856H

Contents Safety...................................................................................................... 1-1 Overview ............................................................................................. 2-1 Maintenance .................................................................................. 3-1 Power system ............................................................................... 4-1 Power train system ............................................................... 5-1 Quantitative & Variable hydraulic system.6-1 Electrical system ..................................................................... 7-1 Air conditioning system ................................................... 8-1 Frame ...................................................................................................... 9-1 Work implement...................................................................... 10-1 Cab system ................................................................................... 11-1 Engine hood system .......................................................... 12-1

1 Safety 1.1 Safety warning symbols ............................................................................................... 1-2 1.2 Safety operation of the machine .............................................................................. 1-11 1.3 Safety maintenance for the machine ...................................................................... 1-18

1-2 1.1 Safety warning symbols

1.1 Safety warning symbols

"WARNING" is set near the specified dangerous location. General notices is listed on the safety sign "CAUTION". •

General notices for safety

Safety warning symbols/mark will appear

Please read and be familiar with all safety rules

on the machine, safety sign, manual or any

to avoid the occurrence of severe damage or

other important safety informations. If the sym-

even death.

bol appeared, you should obey the instruction in

Only trained and qualified persons are permitted

the safety information, and guard for the possibility of personal injury or death. •

to operate and maintain the machine.

Words on safety sign

Words on safety sign such as "DANGER", "WARNING" or "CAUTION" appeared on the machine shall have the following definitions:

DANGER DANGER: this word means danger will occurred immediately, and if no avoidance, it may cause death or serious personal injury.

If you feel uncomfortable, feel sleepy after taking medicine or have drunk, do not operate the machine. In the case, it may cause your misjudgment and possibility of accidents. Before

WARNING

maintaining and repairing the machine, please

WARNING: this word means existing potential danger, and if no avoidance, it may cause death or serious personal injury.

hang the labels of “do not operate” or similar warnings on the starting switch or the operation lever.

:

O pe ra te r: ate

it may cause slight or medium per-

D

potential danger, and if no avoidance,

AR N

existing

W

means

!

word

d op o n er ot at e

Caution: this

IN

G

CAUTION

sonal injury. "CAUTION" is also used for reminding the safety attentions of unsafe operation possibly causing personal injury. "DANGER" represents the worst dangerous condition. Safety sign of "DANGER" or

Do not wear loose clothes, jewelries or long hair. Because they may be drawn into the control system or the mobile parts and lead to severe damage or even death.

1-3 1.1 Safety warning symbols

During the operating and maintaining the

If you work under loud noise, please wear

machine, please wear the cap, ear cover and

appropriate hearing protection devices, such as

safety glasses of hard material as well as safety

earmuff or earplug, to avoid damage to hearing

shoes, mask and gloves.

due to loud noise.

Goggles, safety glasses or mask can protect your eyes from the hazards of high-pressure fluid during the maintenance of the battery and the hazards of flying debris generated during the work of the engine and the operation of tools. Please wear the protection mask when to remove spring, elastic parts or add acid to the battery. Please wear the safety cap and goggles when to conduct welding operations or use the welding gun for cutting.

Ensure all guard plates and covers of the machine are fasten to the machine. Normally, the guard plates and covers are removed during the maintenance and repairing of the machine. If there is any damage, please repair it before the operation of the machine. Please ensure that there is no chip, greasy dirt, tool or other matters irrelevant to the machine on the machine, especially on the instrument panel. Put the irrelevant matters in place, such as the lunch boxes and tools. Prevent foreign matters from entering the components of the system when to inspect the opened oil tanks or water tanks. Please empty the clothes pockets and move spanneres and nuts with great care before the removing of the box.

1-4 1.1 Safety warning symbols

Compressed air may lead to death. When use the compressed air for cleaning, wear the mask, protection suits and shoes. Do not point the compressed air to others or oneself. The compressed air may penetrate the skin and lead to severe injury or even death. The maximum pressure of the compressed air for cleaning should be lower than 0.2MPa. • Learn about the gesture singles and the signal sources at the working site and only receive the signals from one person. Never keep the maintenance and repair solution in glass containers. Please observe relevant laws and regulations

High-pressure solution

Warning: when overhauling or replacing the pipes of hydraulic system, you shall check the system pressure had been released in order to prevent from scalding by high-pressure oil. hydraulic oil under pressure will damage your

when to dispose hazardous materials such as

skin severely when it spattered on you.

lubricant, fuel oil, coolant, solution, filter, battery

Take care when dismantle the hydraulic pipe-

and other materials.

lines or connectors. When the oil spouts, the

Take great care during the operation of the

released high-pressure oil may lead to the con-

cleaner. Do not use flammable materials as the

tinuous movement of the hoses.

cleaner of the parts, such as diesel oil, petro-

Normally, before shutting off the hydraulic pipe-

leum and other inflammables.

lines, place the relevant work implements in order and release the residue pressure from the pipelines. Otherwise, when to dismantle the hydraulic pipelines, the pressure provided by the loader to the work implements may lead to the spouting of the hydraulic oil. Please wear safety glasses and leather gloves when to check leakages. Do not use the naked hands to check the leakage but plate or paper

Report all necessary repair work in a timely manner. Persons without permission or authorization cannot stay onto or around the machine. It is prohibit to refit the machine without LiuGong's consent, and LiuGong will not responsible for the aftermath due to refit. •

Compressed air

plate.

1-5 1.1 Safety warning symbols

Even if the pressured liquid is leaked from a hole

•

Notices about the use of the accumulator

as small as a pin hole, it may penetrate the muscles and lead to death. If spattered by the

High-pressure nitrogen, a dangerous article, is

spouted high-pressure oil, please contact a doc-

mounted in the accumulator, therefore read the

tor and take a medical treatment immediately.

following requirements and properly use the accumulator. The accumulator must be checked before the charging of nitrogen. It is prohibited to charge the accumulator with air if the accumulate does not have a nameplate, or the words of the nameplate are missed and unable to be identified with

•

the kinds, or if the steel seal marks are incom-

Safe disposal of waste liquid

plete or cannot be read clearly, or if there is

Inappropriate disposal of waste liquid will

defect with the body and therefore cannot

endanger environment and ecology. Please

ensure safe use.

observe local laws and regulations when to dis-

The accumulator is only charged with nitrogen. It

pose the waste liquid.

is prohibited to charge the accumulator with oxy-

It is mandatory and necessary to collect the liq-

gen, compressed air or other flammable air to

uid spattered during the inspection, mainte-

avoid explosion.

nance,

Slowly charge the nitrogen into the accumulator

test,

adjustment

and

repair

with

containers.

to avoid the breakage of the capsule.

Before opening any fluid cavity or resolve the

The air valve of the accumulator shall be

parts containing liquid, the proper container

mounted upward vertically. The accumulator

shall be prepared well firstly.

must be stably fastened to the supporter. Do not

Use proper container when liquid draining. Do

use the welding method to fasten the accumula-

not use the food or drink containers because

tor.

they may be taken as drinks by others.

Do not drill the accumulator any time or carry open fire or heat sources close to the accumulator. Never conduct any welding operation on the accumulator. Since the accumulator is a high-pressure container, it must be replaced and repaired by professional operators. Release the air before discarding the waste accumulator. •

Asbestos

If sucked in asbestos dust, it will endanger your

1-6 1.1 Safety warning symbols

health. This product is not containing asbestos,

fix well the shield after the repair.

and LiuGong Machinery Co. Ltd recommended

For safety, you shall check all protectors, such

to use genuine LiuGong spare parts. If materials

as door, safety shield and hood, etc. to make

that you need to deal with containing asbestos

sure they are correctly installed to avoid from

fiber, please abide by the following rules:

the hurt caused by moving parts. e.g. revolving

•

Never use compressed gas when cleaning.

vane of engine has the risk of sharing the fin-

Water can be used for descending the dust.

gers, therefore shut down the engine or keeping

It can uses the vacuum cleaner with high

a safety distance when servicing. If any door,

•

filtering properties. •

Do not grind the materials containing asbestos dust.

•

hood and other protector damaged, it shall be repaired or replaced before operating the machine.

Please observe local laws and regulations when to dispose asbestos.

•

Bath your body after contacted with asbestos.

•

If required, it can uses effective protective mask.

Make sure there's no foreign matters in the vanes of engine fan. Fan vanes will throw or cut •

Prevention of extruding or cut off

Do not make your hands, arms or any other bodies placed among the moving parts. e.g. between work implement and cylinder, between machine and working implement. Working under the work implement, you shall support the machine properly. Do not support the work implement depending on hydraulic cylinder. If control mechanism moving or hydraulic oil line leaking, it will cause the work implement drops. If it is necessary to remove the shield, you must

out the tools and other things that dropped or pushed in it. Unless otherwise stated, any adjustment is not permitted to be performed when machine or engine is running. If the repair procedure must be performed when machine running, do not let the machine in an unattended status. Arrange one operator seated in the seat, and prepare to shut down the engine at all times. Do not use twisted or worn wire rope. Wear gloves when using and transporting. When forcing to extrude the bayonet, you shall

1-7 1.1 Safety warning symbols

make sure no one standing around it. You shall

do not make the hot oil and parts contacting with

wear safety goggles in order to protect you

your skin.

eyes. Knocking object with hammer, please make sure the flying debris will not hurt others. •

Prevent burns

Running for some time, parts of the machine will hot, and those parts shall be inspected or repaired after cooled down. •

Coolant

Under working temperature, the coolant of the engine has been pressed and at high temperature, the radiator and all the pipes connected to the radiator contain hot water or vapor, if you touch them, serious burn would occur.

Under working temperature, the hydraulic oil tank is hot and contains pressure. When opening oil filler cap of hydraulic oil tank, the engine shall be stopped, and cool the filler cap down until it can be opened by bare hands. Remove the tank cover slowly to release the pressure of hydraulic oil tank, averting scalded by hot oil. Before disassembling all pipes, connector, or relevant parts, relieve the system pressure. •

Refrigerant

Air conditioner pipeline should be removed and installed by professional personnel. If liquid During checking the cooling liquid level, the

refrigerant state splashed into eyes may lead to

engine shall be closed down and the filler cap

blind; Spraying on the skin results to frostbite.

shall be cooled to meet that it can be manually

The container for storing refrigerant can neither

screwed off.

be exposed under ambient temperature above

Slowly loosen the filler cap of cooling system to

50 ℃ or beside a heat radiating device or object,

release the pressure.

nor be directly exposed under the sun. In that

Coolant contains alkali which may causing

case, the temperature of the refrigerant easily

injury, and do not make it contact with your skin, eyes and mouth. •

Oil

Hot oil and parts will cause personnel injury, and

rises to cause increase in pressure in the container. When the pressure reaches high enough, the container may have leakage explosion. The refrigerant itself is non-toxic, but it cannot

1-8 1.1 Safety warning symbols

be in direct contact with open flames or heated

Clean and tight all electrode connector. Daily

metal, otherwise toxic gases will be produced.

inspect the wire for loose or wear. Before start,

•

Battery

make sure tighten the loosen power supply, and

Smog discharged from the battery may cause

repair or replace the worn electric wires.

explosion.

Scheduled inspect the electrical circuit to avoid

Battery and electrode may contains lead, and do

from overload or short circuit that will causing

not touch it with bare hands directly. Wash your

fire hazard.

hands just after battery repair.

Stored the fuel, lubricant into containers with rel-

Do not smoke when inspecting the level of bat-

evant marks, preventing from operating and

tery electrolyte.

used by non-staff personnel.

Electrolyte is a kind of acidic material, and

Put the cleaning cloth or other combustible

please do not let your skin and eyes touched by electrolyte. Once touched, you should use water to wash it and timely to seek medical advice. You shall wear safety goggles and glove when inspecting battery.

materials with oil impregnated into protective container, and set at a safe place. Do not perform welding or flame cutting onto the pipe containing flammable liquid. Before welding or cutting, the operation shall be perform until it is cleaned by flammable liquid. Accumulated combustible materials such as fuel, lubricant or junk on the machine shall be clean up. Do not operate the machine near open fire. Make sure the battery is far away from open fire and sparks, and do not smoke at the place of battery charing. Do not charge the frozen battery to avoid of

•

Protection for fire and explosion

All fuels, such as most of lubricants and some cooling agent, are flammables.

explosion. •

Diethyl ether

Warning: Diethyl ether is forbidden for

Fuel leaks on the hot surface or electrical ele-

starting machine.

ments may cause fire.

Any attempt action of using diethyl ether to start

No smoking when refilling or within refiling area,

the engine may cause serious damage of

and the place storing flammables.

engine or personnel injury or death.

1-9 1.1 Safety warning symbols

pressor, it is forbidden to be approached with open fire, or it will generate toxic gas, and result in poisoning. No smoking when maintaining and servicing, otherwise, the generated toxic gas will burn the body or sucked by human, and it also cause personal injury and death. •

Fire extinguisher and first aid kit

Fire extinguisher provided by the machine shall conform to the related local laws and regulations, and it shall be maintained and improved for satisfying the requirements. For more information, please contact your local authorities. •

Piping, pipe and hose

You should know how to do when fire occurred

Do not warp or knock the high-pressure pipe,

or human injured.

and do not install the abnormally warped or bro-

The construction site must have first-aid kit in

ken pipe or hose onto the machine.

stock. Regular inspection shall be performed,

Repair the pipe and hose of loosen or broken

supplemented some medicines if required.

fuel and lubricant circuit and hydraulic system in

Selected some contacts of phone number (such

time. Leakage will cause fire hazard, and if you

as doctor, first-aid center, fire station and so on)

need repair or replace, please contact the

use for communication in emergency. Paste the

authorized dealer by LiuGong Machinery Co.,

contact list onto specified location to ensure all

Ltd.

staff known that the contact information and cor-

If following problems occurred, it shall be

rect ways.

replaced. •

Damage or leakage of connector.

•

There is corrosion with the outer of the hose and the exposure of the reinforced steel wires.

•

Local eminence of hose.

•

Hose with obvious twisting or flattening.

•

Reinforced hose guide wire is embedded into the outer layer.

•

Misplacement of the end connectors.

Make sure all clamps, guard and heat shield are installed, for preventing from shaking or overheating by friction with other parts. When removing the connecting pipe of the com-

Inspect and maintain the fire extinguisher frequently. Follows the recommended method of application listed on the operation panel. •

Prevention of injury by thunder

Never try to access the machine when lightning near it. If you seating in the cab while the thunderstorm occurred, please keep inside the cab; and if

1-10 1.1 Safety warning symbols

you're on the ground, please stand away from the machine.

•

AT LEAST 15m(50ft)

AT LEAST 500m(1500ft)

Tyre

Maintenance, removal, repair and install of tyre and rim shall apply special tools and technology, therefore the maintenance and service shall be implemented by tyre repair shop.

It is suggested to inflate the tyre using dry nitrogen gas (N2). If tyre already has inflated air, it is suggested to use nitrogen for air pressure adjustment, and the nitrogen can be mixed with atmospheric gas. Tyre inflated with nitrogen can reduce the possibility of explosion due to nitrogen gas is noninflammable. In the same way, nitrogen is helpful to prevent from oxidation and rubber age deterioration and corrosion of rim parts. In order to prevent from over-inflation, it needs correct inflating device and operation trainings for the application. Because of incorrect device

Pneumatic tyre can explode due to the heating

or improper applications, it may cause tyre or

and the firing of its internal air. It is due to gas

rim broken.

expansion or burning because of heating

Incorrect tyre rim maintenance will cause tyre

caused by rim heating or electric welding, exter-

blow-out, and such a explosive power will result

nal flame, or frequent braking.

in serious death. Only trained personnel by

Power of tyre explosion is much bigger than that

proper tools and procedures can maintain and

of bleeding, the explosion will make the tyre, rim

service the tyre rim.

and drive parts burst apart for 500m away, and

•

Inner space of cab

the explosive force and debris will cause per-

This LiuGong device is equipped with and meet

sonnel injury and property loss.

the

Do not get close to the heated tyres. Ensure the

“ISO3411” cab, and standard provided the

distance to the minimum extent (at least 15

requirements to the cab space.

meters). (As shown in the figure) stand outside

Any refit of cab shall not occupy the specified

the shadow area.

space. Installation of added radio, fire extin-

industry

standard

of

“SAEJ154”

and

guisher and other devices must make the specified space kept well. Any object bringing in the cab shall not occupy the specified space. Lunch-

1-11 1.2 Safety operation of the machine

box or other things shall be fixed. When driving on uneven ground or tilting, those articles shall not strike the cab and damage it. •

Steering frame lock

1.2 Safety operation of the machine •

Getting on/off the machine

Connect steering frame lock when lifting and

Before getting on/off the machine, please clean

transporting machine.

the oil dirt and mud on handrail or stairs. In addi-

Connect steering frame lock when do mainte-

tion, broken parts shall be repaired, and the

nance near articulated joint

loosen bolt shall be tightened.

Separate steering frame lock before operating

Only the place with handrail or stairs can be

machine.

accessed.

Refer to “Steering frame lock” in operation for

When getting on/off the machine, you will face to

more details.

the machine, holding the handrail while stepping

•

Notices for accessories

stairs, to keep the three-point contact (two feet

It shall be installed and commissioned by

one hand or two hands one foot).

qualified personnel; the operator shall be trained, and his/her operation and maintenance shall be performed strictly according to the operation instructions for accessories. When installing and using the spare accessory, please read related instructions, manuals and informations about the accessories. Incorrect installation or purchase of accessories will not only cause safety issues, but also have

It is prohibited to jump out from machine.

the negative effect on service life and operation

It is prohibited to get on/off the machine during

of the machine.

operation.

Do not use the accessories unauthorized by

Never serve the control lever as handrail for get-

LiuGong. Using unauthorized accessories will

ting on/off the machine.

cause safety issues, adversing the normal oper-

Do not take tools or other things to climb up and

ation of machine and influencing its service life.

down the machine.

It is forbidden to make any refit on the accessories without permissions, otherwise all at your peril. LiuGong Machinery Co., Ltd will be not responsible for the Injury, accident and damage of machine due to using unauthorized accessories.

•

Know about your machine

You are able to operate all devices on the machine. Know about all the purposes of control system, instrument and indicator. Know about the rated load, velocity range, brake and steering characteristic, turning radius, and height of operating space. Remember that rain, snow, ice, broken stone,

1-12 1.2 Safety operation of the machine

soft ground and others will change the working

Check if electric wire harness is not worn or bro-

capacity of machine.

ken, the fuse is in good condition, and the con-

Study the safety signs (such as DANGER,

nector is firmly fastened.

WARNING, CAUTION) on the machine and

Check if the fluid level of engine and fuel system

other signs.

is normal, and drain out the water and sedi-

•

Know about your workspace

ments from oil-water separator. Discharge

Know about your future workspace in advance

waste liquid according to local regulations.

as far as possible. Please check: location of

Replace all broken or lost parts, and necessary

slope, ditch, falling objects or suspensions, soil

lubricating work shall be done in accordance

conditions (soft or hard), zone of accumulated

with the lubrication point listed on schedule

water and swamp, rocks and stumps, buried

maintenance table.

foundations, boundary of pillar or wall, boundary

Purge all loose masses out of cab, because the

of buried garbage or earth fill, voids, obstacles,

loose mass will affect the operation and result-

muds, amount of traffic, heavy dust, heavy

ing in accidents.

smoke, heavy fog, buried or hanging electricity,

Make sure all windows are cleaned and the wip-

gas, telephone, water, sewage or other utility

ers can work in normal.

pipelines' accurate positions. If necessary, you

Adjust the seat to appropriate position to make

shall invite a public service company to mark

the operator seated comfortably and easy to

them out before starting works, and close or

operate the machine. Check if the fixed device

move those facilities.

of seat belt and seat belt is not damaged. Seat

•

Before starting the engine

belt shall be replaced after three-year's applica-

You shall inspect your machine carefully before

tion.

working, and make all systems are in the good

Make sure illuminating systems of machine is in

operation conditions. And dispel all other per-

normal operation, and the working site have suf-

sonnels standing around your machine away

ficient lighting.

from the workspace.

Check to ensure steering lock is fixed in release

Keep the stairs and handrail clean. Before get-

position.

ting on the machine, please clear all dirt mud and tiny sands stuck on your shoes. Check if all structural parts and covering parts are not damaged due to collision. Check if all safety devices, such as door, guard, cover, etc., are installed properly so as to prevent from damaging by moving parts, and if broken, please repair it in time. Check if hydraulic system does not leak, and inspect the hose, steel pipe is not worn. Check if all fastener parts are not loosen or lost.

•

Engine starting

If warning sign of “do not operate” pasted on control lever, then the engine shall be not started.

1-13 1.2 Safety operation of the machine

they are in normal operation, and their readings are in working range.

O pe ra Da te r: te :

!

d op o n er ot at e

W AR

N

IN

G

Observe and listen carefully to the machine for any fault, if fault or abnormal condition existing, stop the machine immediately, and resolve the fault before further operation.

Make sure operator is seated and fastened the seat belt securely, and then start the machine.

Engine exhaust will cause decease or death. If it is necessary to start the engine in a closed or Before starting the engine, please make sure that the hydraulic control lever is at the neutral position, and the shift control lever is at he neutral position. When starting engine, you shall press the horn as a warning.

You shall start the engine only seated in the cab, and it is forbidden to short circuit the starter motor to start the engine. Such a operation will damage the electrical system of machine through bypass starting system, and even personnel injury or death. Observe the pressure gage, instrument and beacon after engine started, and make sure that

unventilated place, you need to open the windows and doors to guarantee the sufficient ventilation so as to prevent from poisoning of gas. If it still cannot providing sufficient ventilation after windows and doors opened, then you need to install a fan.

•

Before operating machine

No one is permitted to stay on/around the machine, and please fasten the seat belt firmly. Make sure all windows, lampshade, reverse mirror are clean, and fix the opened or closed window and door well. Adjust the position of rearview mirror for having the best visual field from the operator's seat,

1-14 1.2 Safety operation of the machine

especially the filed near the machine.

appropriate lights.

Clear all obstacles on the driving path of machine. Take care for the high-voltage line, canal and other dangers. Make sure all the horns, backup alarm (if equipped) and other warning devices can work normally. •

Machine operation

Before driving on a public road, please check this machine satisfy the requirements of local

If driving or operating the machine in a bad

laws and regulations, and acquired driving

vision or crowded region, please use signalman,

license on road from related authorities. Please

and keep the signalman inside your sight and

follow your local traffic laws when driving on a

coordinating with hand signals.

road.

Adjust the height of work implement to ground

You should confirm the safety conditions of your

clearance of 450~500 mm (17~20 in) beneath

surroundings before driving, and ascertain the

the boom lower hinge pin for traveling.

relationship between driving direction and driving pedal/control lever. Keep correct posture on the seat When you do not sit on the seat in correct posture or leave seat to operate machine, it may cause accidents. In case of extra seat, seat belt and Roll Over Protection System (ROPS), the accommodation of a passenger is strictly prohibited.

Prevent from working on the edge of cliff, under

Before starting formal work, you should drive the

the dike or dump, and on the road surface with

machine to a wide site, and check the working

insufficient support capacities, or at the over-

condition of all control levers and protectors are

hanging objects, in order to avoid collapse.

normal. If found out any item (such as noise, vibration, smell, incorrect display of instrument, air and oil leaks, etc) needed to be repaired during operation, you should make a report for the item needing repair immediately. Dust, heavy rain, dense fog and so on will blur your sight. Maintain the clean and good conditions of windows, mirrors and lights. When the visibility descended, please slow down and use

1-15 1.2 Safety operation of the machine

Bang Bang

Avoid any condition that may cause machine roll-over. Machine may roll over when working on hills, banks or slopes. The machine might also roll over when passing canals, dumps or other unexpected obstacles.

If the machine starting side lapsing from slopes, you shall unload materials and drive the machine downhill. In order to avoid machine roll-over or work The machine should work in straightly forward or

implement damaged, the load of machine shall

backward manner on a slope. Do not turn on the

be kept inside the specified maximum load.

slope or move in a crosswise way to avoid

When operating machine, do not exceed its

machine roll-over.

specified capacity.

1-16 1.2 Safety operation of the machine

Do not use bucket or boom for lifting operation.

If machine contacted with high voltage power

The machine only undertake the specified work,

supply:

and if exceeded its serviceable range for other

● Warning others for preventing from contact-

operation, it will damage the machine. For the

ing the machine and away from it.

specified operation, please refer to “Application”

● If connection portion can be separated, sepa-

and “Main technical performance and parameters”. Do not directly put sling on the bucket teeth for lifting heavy loads. Do not lift staff by loader. Do not take bucket as platform for operator, and do not allow anyone to ride on bucket. Pay more attentions to the works beside the high-voltage line. When machine is in the construction site with the danger of touching cable, please consult power company before operation. Contacting the cable will cause serious accident or casualties, therefore any part of the machine is not allow to approach the cables. You shall check the upper part of machine, in order to know the distance among cable, machine and ground is enough. If it is possible, the best way is to cut down the power supply, and requiring for the guide of signalman.

rate machine from high voltage power supply, and keep the machine away from the dangerous zone. ● If you cannot separate that point, please stay in the machine until power supply department cut down the power wire, and inform you the power has been disconnected. ● If encountered extreme cases that people is forced to escape (such as fire) caused by high voltage power, please jump out of the machine by two feet together as far as possible instead of walking step-by-step, and do not touch the earth with your hands. You shall continuously jump forward by two feet together until your reached the safety distance away from the machine and power supply. When towing, make sure trailers with sufficient strength. Trailer only can connect to the towing bar and hinges, and it is prohibited anyone stepping across the steel wire or similar devices between trailer and towed vehicle. Before towing, make sure no one is standing between the machine and trailer. Traction frame or traction pin of towing equipment shall centered align and connect with the towing bar on

1-17 1.2 Safety operation of the machine

the machine. •

Park the machine

or other work implements onto the ground, and applying parking brake (if equipped).

Level ground shall be selected for parking the

Place the hydraulic control lever at middle posi-

machine, and use parking brake (if equipped) to

tion, and the shift control level is placed in neu-

lower the work implement to the ground so as to

tral position.

prevent from machine moving and damage or

Apply parking brake (if equipped).

hurt.

Make the engine keeping idling for 5 minutes for

Consider for any possible hazard in high alti-

cooling down gradually.

tude, such as rolling rocks, high-tension cable,

Shut down the engine, place the safety handrail

etc.

at the lifting position, and remove the key.

Consider for road conditions. Do not park the

Turn the battery switch (-) to the OFF position in

machine at the cliff edge, uncovered excavation

order to prevent from battery being damaged

pits or sags.

and discharged due to the leakage of electricity

Consider the changes of environmental condi-

from some elements or short circuit of the bat-

tions, such as flood, heavy snow, heavy storm,

tery.

chilly weather and so on. Those extreme condi-

When leaving the machine, please lock up all

tions will damage the machine.

devices with the key. Remove the key and take

Considering that the place where the machine

it with you.

needed to approach and other potential emergency situations will not cause traffic block. If the machine needed to be parked on a slope, you shall lower the bucket and other work implements to the ground, and apply parking brake (if equipped), then shut down the engine. Place the block under the tyre in order to prevent machine moving. •

Lower down the work implement when engine cut-out

Notes: for the machine equipped with electric-hydraulic control

lever,

the

engine start switch shall be placed at ON position in order to lower the work implement. After it lowered down, the Know about all road regulations, if parking on the road, it may needs extra signal light or flash light for other people or vehicles. Before leave the machine, lower the attachment

start switch shall be turned to OFF position. Move all control levers to the “Down” position so as to lower the work imple-

1-18 1.3 Safety maintenance for the machine

ment down onto the ground or trailer. When the control lever released, they will return to the “Keep” position. •

Accessory storage

1.3 Safety maintenance for the machine •

Preparations for workspace

Store the accessories and tools safely to pre-

Select a region where has sufficient space, light,

vent serious injuries or death caused by over-

ventilating, clean and smooth to do repairing

turning. Keep the child and bystander standing

work. Clean the working floor, wipe off the fuel

or playing far away from the storage area.

oil, lubricant and water, and then sand some sands or other absorbing materials on slippery

Keep away

ground. Keep the workspace clean and dry. •

Correctly support the mechanism

During

operation,

accessories

or

general

assembly of mechanism are located at a lower position from the surface of earth, or fix and support the accessories on a certain platform. Use wedge to prevent the machine from moving during maintenance and service. If you must to work over/beneath the lifted mechanism, please support the machine or accessories safely. Never treat the hydraulic system as a support mechanism. The mechanism shall be supported on a stable support. Do not work under the mechanism supported with a single support only. •

Loading and unloading of the machine

It shall follows the state and local regulations for limits of weight, length, width and height of the materials when shipping. Know about the right procedure for loading and unloading. Load and unload on a level ground. Wedge the wheel of transport vehicle with wedge ① to make it unmovable.

1-19 1.3 Safety maintenance for the machine

● Do not inhale the flue dust of paint. ● It is prohibited to weld on or near the rubber hose, wire or pressure pipes. ● Release the excess pressure of the machine. Don't weld the concrete pipes of the machine. ● You should wear eyeshield and protective clothing during welding. Establish a warning board to keep out working area and warn spectators that welding work is carried out. ● Keep the ventilation of electric welding working floor in good condition. 1. Wedge 2. Block 3. Angle (maximum angle is no more than 15°) 4. Distance between ramp 5. Ramp Apply the ramp with fitted size, sufficient intensity, lower angle and fitted height. Make the ramp is anti-skid without muds or snow. Fix the machine with chain and block. Keep the bystander far away from it.

•

Regular cleaning machine

Fix all work implements, and place it on the

In order to prevent from hurt or damage, the

transport location.

machine shall be cleaned periodically, and

•

Weldment operation

remove all cumulative grease, oil or shatters for

Electric welding operator shall have professional

keeping the cleanliness of engine compartment,

certificate, and the work shall be performed at

radiator, battery, hydraulic pipe, fuel tank and

the place with appropriate equipment. Operator

cab.

shall follows the attentions below during weld-

You should wear antiskid shoe while cleaning, to

ing:

prevent from slipping down on the slippery sur-

● When the machine is welded, disconnect

face. And pay attention to the hazard of chemi-

main power switch and connector of instrument system, otherwise elements on the instrument panel may be burnt out. ● Clear the paints on the place where needed welding so as to prevent the generation of harmful gas.

cal substances, high-pressure water jetting and materials spattering, etc.

1-20 1.3 Safety maintenance for the machine

Do not directly spray the water onto sensor, connector and instrument of electric system, and if water entered the electric system, it may cause the hazard of explosion and failure.

2 Overview 2.1 The standard of general torque................................................................................ 2-2 2.2 Unit conversion table ................................................................................................. 2-5 2.3 Functions and major technical parameters (complete loader parameters)..... 2-7 2.4 Transportation of the machine................................................................................ 2-15 2.5 Hoisting of the machine............................................................................................ 2-17 2.6 Traction of the machine............................................................................................ 2-19

2-2 2.1 The standard of general torque

2.1 The standard of general torque Bolts involved in this machine shall be fastened in accordance with the torque requirements specified in the following table, unless special declaration. Standard thread torque in metric system Thread size

Standard torque lb·ft (N·m) Grade 8.8 strength Grade 10.9 strength

M6

7.7±1.1 （10.5±1.5）

　

M8

19±2.9 （26±4）

M10

38±5 （52±7）

　 53±4 （72±6）

M12

66±9 （90±12）

89±7 （120±10）

M14

107±15 （145±20）

144±11 （195±15）

M16

166±26 （225±35）

M18

229±33 （310±45）

225±18 （305±25） 306±26 （415±35）

M20

302±37 （410±50）

443±37 （600±50）

M22

443±59 （600±80）

590±52 （800±70）

M24

561±74 （760±100） 811±111 （1100±150）

752±74 （1020±100）

M27 M30

1106±148 （1500±200）

1106±74 （1500±100）

M33

1512±221 （2050±300）

1364±11 （1850±150） 2139±295 （2900±400）

M36

1955±258 （2650±350）

2286±184 （3100±250）

Standard thread torque in British system Thread size 1/4

Standard torque lb·ft (N·m)

5/16

18±5 （25±7）

3/8

33±5 （45±7）

7/16

52±11 （70±15）

1/2

74±11 （100±15）

9/16

110±15 （150±20）

9±3 （12±4）

5/8

148±18 （200±25）

3/4

266±37 （360±50）

7/8

420±59 （570±80）

1

645±74 （875±100）

2-3 2.1 The standard of general torque

Pipe thread in British system Thread

Torque of knurled nut (N.M)

G1/8”X28

Nov.12th

G1/4”X19

25-28

G3/8”X19

41-48

G1/2”X4

72-82

G5/8”X14

96-110

G3/4”X14

124-137

G1”X11

151-165

G1.1/4”X11

192-206

G1.1/2”X11

261-275

G2”X11

343-357

Standard torque of nut for hose connector Metric thread Thread

Torque of knurled nut (N.M)

M12X1.5

10-20

M14X1.5

20-35

M16X1.5

25-40

M18X1.5

30-45

M20X1.5

35-50

M22X1.5

40-70

M24X1.5

40-70

M26X1.5

60-100

M30X2.0

80-120

M36X2.0

100-150

M42X2.0

150-220

M45X2.0

180-250

2-4 2.1 The standard of general torque

JIC Thread in American system Thread

Torque of knurled nut (N.M)

7/16”X20

15-16

1/2”X20

19-21

9/16”X18

24-28

3/4”X16

49-53

7/8”X14

77-85

1.1/16”X12

107-119

1.3/16”X12

127-140

1.5/16”X12

147-154

1.5/8”X12

172-181

1.7/8”X12

215-226

2.1/2”X12

332-350

ORFS Thread in American system Thread

Torque of knurled nut (N.M)

9/16”X18

14-16

11/16”X16

27-27

13/16”X16

43-47

1”X14

60-68

ORFS Thread in American system (continuing) Thread

Torque of knurled nut (N.M)

1.3/16”X12

90-95

1.7/16”X12

125-135

1.11/16”X12

170-190

2”X12

200-225

2-5 2.2 Unit conversion table

2.2 Unit conversion table Name

Unit

Conversion unit

Conversion ratio

Inch (in)

Millimeter (mm)

25.4

Millimeter (mm)

Inch (in)

0.03937

Foot (ft)

Meter (m)

0.3048

Meter (m)

Foot (ft)

3.28084

Square Inch (in2)

Square centimeter (cm2)

6.4516

Square centimeter (cm2)

Square Inch (in2)

0.1550

UK gallons (gal)

Liter (L)

4.54609

Liter (L)

UK gallons (gal)

0.219969

US gallons (gal)

Liter (L)

3.78541

Liter (L)

US gallons (gal)

0.264172

Liter (L)

Cubic decimeter3

1

Pound (lb)

Kilogram (kg)

0.453592

Kilogram (kg)

Pound (lb)

2.204622

Lbf•in

N·m

0.112985

N·m

Lbf•in

8.85075

Length

Area

Volume

Mass

Torque

2-6 2.2 Unit conversion table

Name

Unit

Conversion unit

Conversion ratio

Pound force per square inch (psi)

Bar (bar)

0.06895

Bar (bar)

Pound force per square inch (psi)

14.5038

Pound force per square inch (psi)

MPa

0.006895

MPa

Pound force per square inch (psi)

145.038

MPa

Bar (bar)

10

Bar (bar)

MPa

0.1

Pascals (Pa)

Bar (bar)

10-5

Bar (bar)

Pascals (Pa)

105

Foot per second (ft/s)

Meter per second (m/s)

0.3048

Meter per second (m/s)

Foot per second (ft/s)

3.28084

UK gallons per minute (gal/min)

Liter per minute (l/min)

4.54609

Liter per minute (l/min)

UK gallons per minute (gal/min)

0.219969

US gallons per minute (gal/min)

Liter per minute (l/min)

3.78541

Liter per minute (l/min)

US gallons per minute (gal/min)

0.264172

Fahrenheit degree ℉

Centigrade °C

5/9*(Fahrenheit degree ℉ -32)

Centigrade °C

Fahrenheit degree ℉

Centigrade °C*9/5+32

N.m

Lbf•in

8.85075

Pressure

Speed

Flow

Temperature

2-7 2.3 Functions and major technical parameters (complete loader parameters)

2.3 Functions and major technical parameters (complete loader parameters) •

Functions

This loader is a large construction machine mainly intended to load and unload bulk materials. It is applicable to loading, unloading, bulldozing, hoisting and traction works in mine fields, ports and piers, infrastructures, road construction, iron and steel enterprises, etc. It is a kind of construction machinery with multiple purposes and high efficiency. This loader is a common construction machine and is not applicable to flammable, explosive, high-dust or toxic gas atmospheres. •

Working ambient requirements

1. Altitude: ≤ 3000m 2. Ambient temperature: -15 ℃ ~40 ℃ (no extra or auxiliary cooling start device) 3. Fording depth: ≤ 630mm Notes: precautions on operation, maintenance and safety operation regulations in this manual are applicable only when this machine is used as specified. If the machine exceeds the range of application specified in this manual, LiuGong Machinery Co., Ltd. will assume no safety responsibility, and all safety responsibilities in such operations will be assumed by user. Under no circumstance operations prohibited in this manual shall be carried out. •

Major technical parameters

All rated operational/lifting capacities of the machine are obtained when the machine operates on hard horizontal supporting surface. If the working ambient conditions of the machine are different from the above reference conditions (for example, working on soft or uneven ground or slopes), then operator shall consider these conditions. The table below lists technical parameter values for standard configuration, the technical parameter variations of other special configuration (such as enlarged bucket, extended jib, side dump bucket) are shown in the table attached to this section.

2-8 2.3 Functions and major technical parameters (complete loader parameters)

•

Overall dimension drawing

•

Complete vehicle parameters

Rated bucket capacity

m3

3

Rated load weight

kg

5000

Boom raise time (full load)

s

≤ 5.7

Sum of three items

s

≤ 10

2-9 2.3 Functions and major technical parameters (complete loader parameters)

Forward IV gear

km/h

40.7

Forward III gear

km/h

24.7

Forward II gear

km/h

12

Forward I gear

km/h

6.7

Reverse I gear

km/h

6.7

Reverse II gear

km/h

12

Reverse III gear

km/h

24.7

Maximum traction force

kN

161±10

Max. breakout force (tilting)

kN

173±10

°

27

A: Hinge shaft height in time of the

mm

4159±50

B: Unloading height

mm

3100±50

C: The net extending distance

mm

1126±50

D: Excavation depth

mm

85±10

E: Ground clearance

mm

431±20

F: Distance between swing center

mm

1660

G: Wheel base

mm

3320±20

H: Height (from the top of cab)

mm

3450±50

J: Wheel track

mm

2150±10

K: Width (over tyres)

mm

2750±50

L: Length (with the bucket)

mm

8253±100

M: Maximum steering angle

°

38±1

W: Bucket width

mm

2976±30

R1: Turning radius of the bucket in

mm

6914±140

R2: Minimum radius of turning

mm

5896±50

kg

17200±200

Highest speed at different gears

Maximum gradeability

Physical dimensions

Operating weight (with cab) Work implement

Single bucket lever reversed six-linkage

Driver’s seat

Above the frame hitch

2-10 2.3 Functions and major technical parameters (complete loader parameters)

•

Appendix: Variable part of technical parameters for specially configured model

Parameters of the special configuration

Standard bucket

Enlarged bucket (active blade)

Enlarged bucket

V-shape Rock bucket

Rated bucket capacity

m3

3.0

3.3

4.5

2.7

Max. breakout force (tilting)

KN

172

167

135

162

3100±50

3072±50

2882±50

3057±50

1126±50

1156±50

1346±50

1170±50

8253±100

8319±100

8330±100

8340±100

6914±50

6935±50

7002±50

6824±50

2976±30

2976±30

3150±30

2887±30

17200±200

17200±200

17200±200

17200±200

B: Unloading height C: The net extending distance during the maximum lifting (unloading distance) L: length (with the bucket) R1: Turning radius of the bucket in time of material transport W: Bucket width Complete machine working mass

mm

mm

mm mm mm kg

2-11 2.3 Functions and major technical parameters (complete loader parameters)

•

Components’ parameters Model Fuel consumption rate

Guang Kang 6LTAA9.3 g/kWh

Number and arrangement of cylinders

Power system

215 Inline six-engine

Cylinder bore × stroke

mm

Φ116.5X144.5

Total displacement

L

9.3

Compression ratio

18: 1

Ignition order

1-5-3-6-2-4

Air intake mode

Turbocharger & Air cooler

Engine Rated power

KW

162

Rated speed

r/min

2200

Maximum no-load speed

r/min

2376±100

Minimum no-load speed

r/min

800±50

Max. torque

N.m

940

Maximum torque speed

r/min

1400

Starter motor

24V-7.8KW

Alternator

28V-70A

2-12 2.3 Functions and major technical parameters (complete loader parameters)

Type

Single-turbine and threecomponent

Cooling mode

Air-cooling pressure circulation type

Type

Fixed shaft power gearshift

Gear range

Go forward when the gear is in the fourth position and reverse when the gear is in the third

Torque converter

Transmission Power train system

Working pressure of gear shift oil pump (gear pump) Drive axle

MPa

1.6~1.8

Main drive type

Spiral bevel gear one-stage reducer

Wheel speed reduction type

Super gear and planetary gear speed reduction

Type

4-wheel drive

Tyre

23.5-25PR16

Wheel

2-13 2.3 Functions and major technical parameters (complete loader parameters)

Articulated frame, full hydraulic steering

Type

Steering hydraulic system

Hydraulic system

Number of steering cylinder--internal radius X stroke Displacement of steering pump

mm

2-φ90×465

ml/r

83.9 (ration)/100 (variant)

Rated speed of the steering pump

r/min

2200

Working pressure of the system

MPa

18 (ration)/20.7 (variant)

Steering angle

38°±1°for both left and right sides

Type

Dual-pump converging hydraulic system

Number of boom cylinder － inner diameter × stroke Number of bucket tilting cylinder － inner diameter × stroke Working hydraulic system

mm

2-φ160×745

mm

1-φ180×571

Control valve

Pilot valve double (triple) stem

Displacement of working pump

ml/r

70.5

Rated speed of the working pump

r/min

2200

Working pressure of the system

MPa

20.7

Pressure of the pilot operation

MPa

3.5

Type Service brake Brake System Parking brake and emergent brake

Single pipe

Air pressure of the system

MPa

0.71~0.784MPa

Oil pressure of the system

MPa

12.3 MPa

Type

Flexible shaft controlled inner expansion shoe type brake

2-14 2.3 Functions and major technical parameters (complete loader parameters)

Air conditioning system

Electrical system

Heating capacity

W

5800

Heating air output

m3/h

900

Refrigerating capacity

W

5500

Cooling air output

m3/h

900

Refrigerant

Air conditioner

R134a

Voltage

V

24

Total power consumption

W

250

Compressor’s shaft power

KW

3

Voltage

V

24

System voltage

V

24

Battery

V

24

2-15 2.4 Transportation of the machine

2.4 Transportation of the machine Transport machine •

Shipment of machines

Notes: it shall follows the state and local regulations for limits of weight, length, width and height of the materials when shipping. Before the transportation, find the details about the passage height, width and permissible load. The total height, width and weight after the machine is placed onto the transportation vehicle cannot exceed those stipulated in the local relevant rules. Before the loading, remove ice, snow or other slippery matters on platform and vehicle. This will help to prevent slip during the loading and the movement during the transportation. 1. Before the loading and transportation, use wedges to secure the wheels of trucks or trailers (the figure shows a trailer).

2. When the machine is moved onto a truck or a trailer, direction change is prohibited in the process. 3. After the machine is successfully loaded, use the frame locking devices to fasten the front and back frames.

2-16 2.4 Transportation of the machine

4. Lower all bucket to the floor of the transportation vehicle, and change the shift control lever to the Neutral. 5. Rotate the pilot shutoff valve to the shutoff position. 6. Pull parking brake button switch. 7. Shut down the engine, and turn all switches to neutral or “OFF” position. Pull out the start switch key. 8. Close and lock all doors, take out the key. 9. Swift the negative switches of power supply to the shutdown position. 10. Wedge machine wheels and fix the machine with wire rope to prevent it from moving in transportation. 11. Cover the opening of the air emission device to avoid the rotation of the turbocharger like a windmill during the transportation and prevent the damage to the turbocharger.

2-17 2.5 Hoisting of the machine

2.5 Hoisting of the machine

WARNING Inappropriate hoisting and fastening will cause the load to move and lead to death.Install steering frame lock before the hoisting!

1. Use a lift frame in lifting. The dimensions of the frame shall be over 2.5 m~4 m in length and 1.7 m in width; The lifting weight of this machine shall consider the maximum carrying capacities of crane and lifting rope to ensure lifting safety.

2. The four hoisting ropes of the hoisting device should be of the same length to ensure the equal forces to the four hooks. 3. Swift the negative switches of power supply to the shutdown position. 4. There are marks of lifting point both on the front and rear frame of the machine. Position on diagram is position of lift spot of rear frame.

2-18 2.5 Hoisting of the machine

5. Before lifting, fix front and rear frames with a steering frame lock so that the machine cannot rotate.

1.Pin 2.Steering frame lock

6. The hoisting device should be stably fastened to the hoisting lugs with hoisting marks on the machine.

2-19 2.6 Traction of the machine

2.6 Traction of the machine

WARNING Incorrect towing of faulty machine may cause personnel injuries and deaths. Chock tyres to prevent free rolling before releasing brake. The brake failure may result to personnel injury. Make sure the machine has undergone all necessary repairs and adjustments before being towed to the maintenance location. Except for towing a faulty machine in emergencies, this machine shall not be towed. The machine is only towed to a location where it is accessible to repair. The towing distance of this machine cannot exceed 10 km, and the towing speed cannot exceed 10 km/h. If the machine needs to be moved for long distance, a trailer must be used to transport. In order to perform the towing steps correctly, obey the following suggestions: 1. If the machine cannot move due to braking caused by engine or brake system failure. At the moment, remove the pin connecting parking brake flexible shaft with parking brake linkage to force the release of parking brake.

Notes: chock the machine wheels to avoid machine movement before releasing the parking brake. Clear the wedge before drag & drop. 2. A safeguard must be provided on the towing machine so as to protect driver in case of accidental breakage of towing rope or tow bar.

2-20 2.6 Traction of the machine

3. No person is allowed to stand on the towed machine, unless a driver is needed to control steering or braking. 4. Make sure the towing rope or tow bar has enough strength to tow the machine before towing. The strength of the used towing rope or tow bar is at least 1.5 times of gross weight of towed machine. 5. Avoid using chain for hauling. Chain links may break to cause personal injuries. A rope with loops or wire rope with end rings shall be used as a towing tool. Assign an observer in the safety position. If the rope starts to break or ravel out, the observer shall stop towing. If the towing machine moves but the towed machine doesn’t move, stop towing. 6. The minimum angle between the towing rope and the right forward direction is maintained not to exceed 30°. 7. The engine rotating at high speed will lead to overload of towing cable or towing lever. This will result to breakage of towing cable or towing rod. Constant motion is more conducive to hauling. 8. In general, the trailer shall be the same size as the towed machine. Make sure the trailer has enough braking capacity, weight and power to control the uphill and driving distances and the like of these two machines. 9. In towing, all personnel shall be kept away from both sides of the towing rope to prevent injuries in case of rope breakage. 10. In order to provide enough control force and braking, a large machine may be needed to be connected on the faulty machine, so that the faulty machine can be prevented from losing control to roll while running downhill. 11. When the towed machine runs downhill, in order to provide enough control and braking capacities, a large trailer or other machines shall be connected behind the towed machine, so that the machine can be prevented from losing control to roll down. It is possible to point out requirements of all different situations one by one. For detailed information about the towing of faulty machine, please consult LiuGong agency. •

Haul when the engine is running

In engine operation, short-distance towing can be carried out in certain circumstances. At this moment, the power train and the steering system must be manipulated. Only haul for short distance/avoid hauling for long. For example, drag the machine out of mire or to the road side. Driver on the towed machine must operate the machine in the direction of the towing rope. Please strictly follow all instructions in the introduction of “Towing of Machine”.

3 Maintenance 3.1 New vehicle running-in................................................................................................. 3-2 3.2 Regular maintenance ................................................................................................... 3-4 3.3 Tyre inflation pressure.................................................................................................. 3-8 3.4 Technical specifications for lubricant ...................................................................... 3-10

3-2 3.1 New vehicle running-in

3.1 New vehicle running-in New vehicle running-in is of significant role to prolong the service life of the machine, eliminate potential failures and avoid the occurrence of great failures. Users must conduct the operation and maintenance of the machine in accordance with the new vehicle running-in instructions as stipulated in the Manual after purchasing the machine, and then use the machine normally. •

Requirements of new vehicle running-in

1. The new vehicle running-in period is 100 hours. 2. After starting, keep the machine idle away for 5 minutes at first. The machine should start at a steady and slow speed with small acceleration, and then its speed should be increased gradually. 3. During running-in, all forward and reverse gears shall be evenly arranged to run in. 4. Except in the urgent situations, there should be no sudden start, acceleration, steering or braking. 5. During running-in, it is appropriate to load bulk materials, and working shall not be too violent and hasty. During running-in, the loading weight shall not exceed 70% of rated capacity, and the running speed shall not exceed 70% of rated maximum speed. 6. Pay attention to the lubrication of the machine, and replace or fill the lubricant and grease in stipulated time and cycles. 7. Pay attention to the temperatures of the transmission, torque converter, front and rear axles, hubs, parking brake, central shaft, hydraulic oil, engine coolant and oil. If there is overheating, find out the reasons and eliminate them. 8. Check the fastening of bolts and nuts of different parts. •

Conduct following operations after 8 hours of the new vehicle running-in

Check the fastening of different parts fully. Especially the bolts of diesel engine cylinder head, the bolts of the exhaust pipe and the captive bolts of front and rear axles, the nuts of rims, the binder bolts of drive shaft, the captive bolts of diesel engine, the captive bolts of transmission, and the bolts at the hinge of the front and rear frames. 1. Check the tightening grade of the fan belt, engine belt and the belt of compressor of air conditioner. 2. Check the oil level of the transmission, drive axle and diesel engine. 3. Check whether there is any leakage with the hydraulic system and brake system. 4. Check the connection and fastening of the linkage of all control levers and accelerator linkage. 5. Check the temperatures and connection of different components of the electrical systems, the power supply of alternator the lighting and the working condition of turning signal lamps, etc. Notes: Please follow relevant operation procedures and regulations when checking different oil levels. •

Conduct following work when the new vehicle running-in completes

1. Check the fastening of different parts, i.e. nuts and bolts. Especially the bolts of diesel engine cylinder head, the bolts of the exhaust pipes and the captive bolts of front and rear axle, the nuts of rims, the

3-3 3.1 New vehicle running-in

binder bolts of drive shaft, the captive bolts of diesel engine, the captive bolts of transmission, and the bolts at the hinge of the front and rear frames. Check each part for one time. 2. Check the tightening grade of the fan belt, alternator belt and the belt of compressor of air conditioner. 3. Check whether there is any leakage with the hydraulic system and brake system. 4. Check the transmission oil of the transmission and the lubricant of the drive axles. 5. Replace the precision filter of the transmission and clean the rough filter of the transmission. 6. Wash the return oil filter element of the hydraulic oil tank. •

Notes: when to replace the transmission oil of the transmission and the lubricant of the drive axles as well as the precision filter of the transmission, the relevant procedures and regulations should be followed.

3-4 3.2 Regular maintenance

3.2 Regular maintenance •

Notes: read and understand all safety documents, warnings and instructions before conducting any operations or taking any maintenance steps.

LiuGong requires that the maintenance work must be conducted according to the time cycle that firstly expire in the working timer or the calender (date, week, month, etc.). In the working environment of extreme coldness, excessive dust or humidity, there should be more lubrication maintenance stipulated in “Regular maintenance”. During the maintenance, it is better to repeat the maintenance items listed in original maintenance items. For example, when conducting the maintenance for every 500 working hours or 3 months, there should be the maintenance for 250 working hours or 1 month, 50 working hours or every week and every 10 working hour or every day. •

Maintenance for 10 working hours or every day

•

Check engine oil level.

•

Check coolant level.

•

Check hydraulic oil level.

•

Check fuel level.

•

Remove the water and impurities from the oil pre-filter and the fuel filter of the engine.

•

Tour inspections.

•

Visual inspection of the engine fan and driving belt.

•

Check lighting and instrument.

•

Check the air pressure and damage of tyres.

•

Check the working performance of the backup alarm.

•

Push up hand water drain valve below air reservoir to drain water in the air reservoir.

•

Maintenance for 50 working hours or every week

Items must be added in addition to daily technique maintenance items: •

Check the oil level of the transmission.

•

Check the distance between brake drum and brake shoe at the first 50 working hours, and make adjustments if it is not proper. Check the wear condition of friction plate. Replace it in case of serious wear. Drain clamp air. Conduct the check every 250 working hours.

•

For a machine with air conditioner, debris and dust on air (evaporator return air) filter inside cab and air (fresh air) filter outside cab, and clean them when necessary; Check the tension of compressor driving belt, and check the condenser for oil stains, dirt and other foreign matters which will affect the heat dissipation of condenser.

•

Check the lubrications of all lubrication points, and add the lubricant grease to all lubrication points as

3-5 3.2 Regular maintenance

per the instructions of the machine lubrication figure pasted onto the machine. If a centralized lubrication system is equipped, artificially grease non-automatic lubricating points according to instructions in complete machine lubricating chart. •

Check the level of assistor grease fitting.

•

Check the nitrogen pre-charging pressure of the accumulator at the first 50 working hours.

•

Maintenance for 100 working hours or every two weeks

Besides daily and weekly technical maintenance items, the following items must be added: •

Add the grease to drive shafts as per the instructions of the machine lubrication figure pasted onto the machine.

•

During the first 100 working hour, tighten all binder bolts of drive shaft; later tighten all bolts every 2,000 working hours.

•

Replace transmission oil, transmission oil filter element and seal ring and clean rough filter inside transmission oil sump tank after the first 100 working hours. Afterwards, replace transmission oil, transmission oil filter element and seal ring and clean rough filter inside transmission oil sump tank every 1,000 working hours or every year, whichever is earlier.

•

Replace front and rear drive axle gear oil after the first 100 working hours. Afterwards, replace drive axle oil every 1,000 working hours or every year, whichever is earlier.

•

Clean the engine cylinder head.

•

Clean the radiator unit.

•

Clean and wash the fuel filling filter screen of the fuel tank.

•

Check the oil level of front and rear axles.

•

Check the nitrogen pre-charging pressure of the accumulator at the first 100 working hours.

•

Maintenance for 250 working hours or one month

Besides daily, weekly and fortnightly technical maintenance, the following items must be added: •

Check the state of the battery voltage.

•

Check the tightening torque of the captive bolts of rims.

•

Check the tightening torque of the mounting bolts of the engine.

•

Check whether there is crack and looseness with the force welding seams and captive bolts of work implement and front and rear frames.

•

Check air intake system of engine, air filter service indicator or air filter blockage alert indicator (if any). If yellow piston of indicator rises up to red zone or air filter blockage alert indicator goes on, clean or replace the air filter element.

•

Replace fuel pre-filter (oil-water separator) and fuel filter on engine.

•

Replace the engine oil and engine oil filter.

3-6 3.2 Regular maintenance

•

Change the coolant filter of the engine.

•

Check the tension and damage of the driving belt of the engine and the belt of the compressor of the air conditioner.

•

Check the service brake ability and parking brake ability.

•

Check the distance between brake drum and brake shoe , and make adjustments if it is not proper. Check the wear condition of friction plate. Replace it in case of serious wear. Drain clamp air.

•

Check the nitrogen pre-charging pressure of the accumulator at the first 250 working hours.

•

Maintenance for 500 working hours or three months

Besides daily, weekly, fortnightly and monthly technical maintenance, the following items must be added: •

Check the concentration of anti-freeze and the concentration of the coolant additive.

•

Tighten the binder bolts of the front and rear axles and frames.

•

Check whether the captive bolts of the frame hinge pin is loosened.

•

Check the nitrogen pre-charging pressure of the accumulator at the first 500 working hours.

•

Replace hydraulic system return oil filter element after the first 500 working hours. Afterwards, replace hydraulic system return oil filter element every 1,500 working hours.

•

Replace hydraulic system pilot oil filter element after the first 500 working hours. Afterwards, replace hydraulic system pilot oil filter element every 1,500 working hours.

•

Maintenance for 1,000 working hours or six months

Besides daily, weekly, monthly and quarterly technical maintenance, the following items must be added: •

Adjust valve clearance of the engine.

•

Check the tension pulley bearing and fan shaft housing of the engine.

•

Replace transmission oil, transmission oil filter element and seal ring and clean filter inside transmission oil sump tank.

•

Replace driving axle gear oil.

•

Clean and wash the fuel tank.

•

Screw up the captive bolts of the battery and clean the top of the battery.

•

Check the nitrogen pre-charging pressure of the accumulator at the first 1,000 working hours.

•

For the machine equipped with air conditioner, change the air filter outside the cab.

•

Maintenance for 1,500 working hours or six months

Besides daily, weekly, monthly and quarterly technical maintenance, the following items must be added: •

Replace the returning oil filter element of the hydraulic system.

•

Replace the pilot oil filter of hydraulic system.

•

Maintenance for 2,000 working hours or every year

3-7 3.2 Regular maintenance

Besides daily, weekly, monthly, quarterly and semiannually technical maintenance, the following items must be added: •

Replace the coolant and coolant filter, and clean the cooling system. Replace coolant every two years if the working hours are not reached.

•

Replace the hydraulic oil, clean the oil tank and check the oil suction pipes.

•

Check the working performance of the service brake system and the parking brake system. Remove the friction plate and check its corrosion when necessary.

•

Check the tightness of the control valve and the working cylinder through the measurement of the natural settlement of the cylinder.

•

For the machine equipped with air conditioner, check whether there is rupture and wear with the cooling pipes and water pipes of the air conditioning or the oil immersion of such system, and check whether pipe joints and clamps are loosened.

•

For the machine equipped with air conditioner, replace the air filter inside the cab.

•

Check the flexibility of the steering system.

•

Fasten all the binder bolts of all drive shafts;

•

Check the tightening torque of the mounting bolts of the transmission;

•

Check the nitrogen pre-charging pressure of the accumulator at the first 2,000 working hours. Conduct the check every 2,000 working hours.

3-8 3.3 Tyre inflation pressure

3.3 Tyre inflation pressure It is recommended to inflate the tyres with dry nitrogen and adjust the tyre pressures. This is applied to all the machines equipped with rubber tyres. Since nitrogen is a type of inert gas, it will not help to combust in the tyres. Using nitrogen (N2) can not only reduce risk of explosion but also help to prevent oxidation and rubber ageing as well as corrosion of rim parts. Notes: It is necessary to train the operators to use the inflatable equipment. Using improper tyre inflation technique can cause personal injury or even death! Don’t set the pressure of the inflatable equipment to be higher than the recommended tyre pressure by 140kPa (20 psi)! Check and adjust tyre inflation pressure. This should be done when tyres are fully cooled. Keep all other person away from the dangerous area (around the tyres). The pressure of the nitrogen–inflated tyres is the same as that of the air-inflated tyres. LiuGong suggests selecting tyre inflation pressure based on the service conditions of the machine. The table below lists inflation pressures under normal temperature in normal working conditions with rated effective load.

Tyre specification

Index of level or Front wheel inflation Rear wheel inflation strength pressure (MPa) pressure (MPa)

17.5-25 17.5-25 17.5R25 20.5-25 20.5-25 20.5R25 23.5-25 23.5-25 23.5-25 23.5R25

PR12 PR16 One asterisk PR16 PR20 One asterisk PR16 PR20 PR24 One asterisk

0.32-0.35

0.29-0.32

0.44-0.47

0.41-0.44

0.42-0.45

0.39-0.42

0.32-0.35

0.29-0.32

0.32-0.35

0.29-0.32

0.42-0.45

0.39-0.42

0.30-0.32

0.28-0.30

0.34-0.37

0.31-0.34

0.44-0.47

0.41-0.44

0.42-0.45

0.39-0.42

26.5R25 26.5R25 29.5R25 29.5R25 35/65-33

PR26 One asterisk PR28 Two asterisks PR30

0.42-0.45

0.39-0.42

0.42-0.45

0.39-0.42

0.42-0.45

0.39-0.42

0.42-0.45

0.39-0.42

0.44-0.47

0.41-0.44

3-9 3.3 Tyre inflation pressure

If the machine driving at freezing temperatures, the original tyre pressure at 18-21°C will change greatly. Even if the tyre has been inflated to the correct pressure at normal temperature, it will be under-inflated at freezing temperature. Low tyre pressure can shorten the tyre’s service life. When you are not sure about tyre inflation pressure, please consult LiuGong agency. Notes: If the machine runs at high speed for long time, then run at the speed of 45 km/h. Stop the vehicle for 30 minutes for full cooling of tyres.

3-10 3.4 Technical specifications for lubricant

3.4 Technical specifications for lubricant •

Interval between the change time of the lubricant and approximate filling volume.

Notes: During the check, maintenance, test and adjustment of the machine, when to remove any hydraulic oil lines or dismantle any parts that contain liquid, prepare proper containers to collect such liquid. Dispose all liquid properly as per local law and regulation. Category

Oil change interval (working hours)

Approximate filling volume (litre)

Torque converter, transmission oil

1000

45

Hydraulic oil

2000

236

Drive axle oil (front axle)

1000

33

Drive axle oil (rear axle)

1000

33

Engine oil

250

18

Cooling system

2000

44

Brake fluid

2×3.5

Fuel

•

300

Technical specification for oil

When various oils in this machine are supplemented and replaced, use specifications and grades specified in the table below to ensure normal use of the machine. Oil specification list Category Engine oil Engine fuel Hydraulic oil

Name

Parts

≥ -10 ℃

★ SAE15W/40CH-4

≤ -10 ℃

SAE5W/40CH-4 level

　 Diesel engine

≥4℃

0# light diesel oil

Diesel engine

≤4℃

-35# light diesel oil

Diesel engine

-15 ∽ 40 ℃

★ HM-46 Anti-wear hydraulic oil HV-46 low-temperature anti-wear hydraulic oil

Work hydraulic system, steering hydraulic system

★ 2# molybdenum disulfide lithium base grease (use 2# composite lithium base grease free of molybdenum disulfide if centralized lubrication system is equipped)

Roller bearing, slide bearing, pins of work implement, pins of steering cylinder, pins of frames, swing frame of rear axle, spline of drive shaft, universal joints, and water pump shafts etc.,

-25 ∽ 40 ℃

Grease

3-11 3.4 Technical specifications for lubricant

Category

Name

Parts

Torque converter oil

★ SAE15W-40 Mobil Delvac 1300

Torque converter and power shift gearbox

Gear oil

★ SAE85W-90 (APIGL-5) heavy-load wheel gear oil

Inner axle bevel gear and reducer

Brake fluid

★ Mobil DOT3

Assistor of the brake system

Notes: The oil marked with ★ is the oil filled when the machine is transported out of the factory. Notes: 1. The oil of the same specification but different brands cannot be used together. If another brand of oil is to be used, please clean the system first. 2. If the machine is used in low-temperature and extremely cold region, the hydraulic oil should be the HV46 anti-corrosion hydraulic oil. The transmission oil should use ATF220 or DEXRON-III or DonaxTC transmission oil. 3. The lubricant should be changed in a timely manner. Even though the lubricant is very clean, yet it may deteriorate if it is placed for a long time. 4. The selection of fuel should depend on the lowest temperature of the place where the machine is used.

3-12 3.4 Technical specifications for lubricant

4 Power system 4.1 Overview of power system .......................................................................................... 4-3 4.2 Main technical parameters of power system .......................................................... 4-7 4.3 Engine .............................................................................................................................. 4-9 4.4 Intake and exhaust system of engine ..................................................................... 4-10 4.4.1 Working principle of intake and exhaust................................................................ 4-11 4.4.2 Removal and installation of air pre-filter ................................................................ 4-14 4.4.3 Removal and installation of muffler ....................................................................... 4-16 4.4.4 Air filter .................................................................................................................. 4-20

4.5 Removal and installation of fan ................................................................................ 4-28 4.5.1 Removal of fan ...................................................................................................... 4-29 4.5.2 Installation of fan ................................................................................................... 4-32

4.6 Removal and installation of engine as ................................................................... 4-34 4.6.1 Removal and installation of engine mounting/....................................................... 4-36 4.6.2 Removal and installation of engine........................................................................ 4-44 4.6.3 Turbocharger ......................................................................................................... 4-48

4.7 Fuel system .................................................................................................................. 4-51 4.7.1 Function and working principle of fuel system....................................................... 4-51 4.7.2 Removal and installation of fuel lines .................................................................... 4-52

4.8 Throttle control system............................................................................................... 4-57 4.8.1 Throttle control system .......................................................................................... 4-57 4.8.2 Removal of throttle control system ........................................................................ 4-58 4.8.3 Installation of throttle control system ..................................................................... 4-59 4.8.4 Adjustment of throttle control system .................................................................... 4-60

4.9 Removal and installation of fuel tank as ................................................................ 4-61 4.9.1 Fuel tank as ........................................................................................................... 4-61 4.9.2 Removal of fuel tank.............................................................................................. 4-62

4-2

4.9.3 Installation of fuel tank .......................................................................................... 4-66 4.9.4 Cleaning of fuel tank ............................................................................................. 4-66

4.10 Cooling system ......................................................................................................... 4-67 4.10.1 Working principle of cooling system.................................................................... 4-67 4.10.2 Removal and installation of cooler lines.............................................................. 4-72 4.10.3 Removal and installation of radiator.................................................................... 4-80 4.10.4 Refilling and replacement of coolant................................................................... 4-95

4-3 4.1 Overview of power system

4.1 Overview of power system Power system has the function of converting chemical energy of fuel into mechanical energy to be supplied to the machine. Power system consists of engine system composed of engine, engine mounting as, intake and exhaust as, fuel line and throttle control system; cooling system composed of radiator mounting as and cooling line; and fuel tank as. Among them, the engine mounting consists of engine, and the radiator mounting as consists of radiator gp. Module structure of power system - Figure 1

Engine mounting as

Intake and exhaust as Engine system Fuel lines Throttle control system

Cooler mounting as Power system

Cooling system Cooler lines

Fuel tank as

4-4 4.1 Overview of power system

Position of power system in the machine - Figure2

1. Engine system 2. Cooling system

3. Fuel tank as

4-5 4.1 Overview of power system

Components of power system - Figure 3

S/N

Description

S/N

Description

1

Engine

5

Auxiliary tank

2

Fan

6

Muffler

3

Mounting support of the engine

7

Exhaust pipe

4

Fuel tank

8

Throttle control system

4-6 4.1 Overview of power system

Components of power system - Figure 4

S/N

Description

S/N

Description

9

Radiator gp

11

Air filter

10

Oil-water separator

12

Air pre-filter

4-7 4.2 Main technical parameters of power system

4.2 Main technical parameters of power system

Engine

Model

Cummins 6LTAA9.3

Type

Straight-six, four-stroke, turbocharged

Emission

China II

*Rated power

162kW/2200r/min

*Maximum no-load speed

2376±50r/min

*Minimum no-load speed

800±50r/min

Engine oil level

19.9L Clockwise (viewed from the fan end to flywheel housing end) Diameter of 780mm, 6 pieces of blades, air suction type 0.87:1

Direction of rotation Fan Cooling system

Transmission ratio of the fan pulley Thermostat

Opening temperature: 84 ℃ Full open temperature: 91 ℃

Oil system

Oil filter

Full flow type and replaceable (filter can rotate)

Preheating system

Preheating method

Intake grid heater (optional)

Core type

Plate-fin type

Core size (height × width × length)

1100mmX409mmX140mm

Core type

Plate-fin type

Core size (height × width × length)

1100mmX180mmX140mm

Core type

Plate-fin type

Core size (height × width × length)

1100mmX238.5mmX140mm

Core type

Plate-fin type

Core size (height × width × length)

1100mmX195.5mmX140mm

Water radiator Hydraulic oil cooler Torque converter oil cooler Air cooler

Notes: data marked with * is based on engine with fuel system and water pump under intake resistance of 250 mm H2O (atmospheric pressure is 2.449 kPa) and exhaust resistance of 50 mm Hg (atmospheric pressure is 7 kPa). Alternator, fan, optional configurations and drive components are excluded.

Notes on removal and installation: 1. Removal and installation must be carried out when engine is cool. In general, open engine hood after engine is shut down, and wait for 15 minutes before the engine is cooled down. 2. Measurement equipment and tools such as torque spanner, etc. shall have compliance certificates issued by metrological department; 3. Because many other related components on the complete machine are concerned

4-8 4.2 Main technical parameters of power system

during the removal and installation of each component, removed components (especially standard parts) shall be reasonably placed to avoid wrong installation, neglected installation, part missing, etc. in reassembly. 4. If the removal and installation of other components on the complete machine are concerned in the removal and installation of each component, tools are referred to the tool list for the removal and installation of other components and won’t listed in the tool list of this component; 5. If the expected effect can be reached in the ways of using open-end spanner, blower gun and socket as well as ratchet spanner and socket to remove and install, anyone can be chosen.

4-9 4.3 Engine

4.3 Engine Outside view of Cummins engine QSL9.3

S/N

Description

S/N

Description

1

Pulley system

7

Oil cooler

2

Turbocharger

8

Coolant filter

3

Fuel filter

9

Oil filter

4

Flywheel housing

10

Starting motor

5

Ventilating device for crankcase

11

Oil sump tank

6

Alternator

12

Air compressor

Engine installed on this machine is Cummins engine 6LTAA9.3. For all working principles, maintenance and service information, refer to Cummins Engine Operation and Service Manual. Cummins Inc. still owns the proprietary right of all information on the manual. During “three guarantees” period of engine, contact the Cummins dealer closest to the maintenance location for all maintenances. LiuGong Machinery Co., Ltd. will assume no responsibility for any loss caused by the user violating these instructions.

4-10 4.4 Intake and exhaust system of engine

4.4 Intake and exhaust system of engine Configuration scheme of engine intake and exhaust system

4-11 4.4 Intake and exhaust system of engine 4.4.1 Working principle of intake and exhaust

Part No.

Parts name

Quantity

Part No.

Parts name

Quantity

1

Alert indicator

1

20

Washer

8

2

Shim clamp

1

21

Washer

14

3

Intake pipe

1

22

Bolt

8

4

Turbine worm clamp

2

23

Air pre-filter

1

5

Hose clamp

1

24

Exhaust pipe

1

6

Washer

1

25

Muffler

1

7

Bolt

1

26

Nut

4

8

Washer

1

27

Washer

4

9

Hose

1

28

Bolt

4

10

Support

1

29

Washer

8

11

Bolt

6

30

Bolt

6

12

Washer

14

31

Washer

6

13

Washer

14

32

Shim clamp

1

14

Piping gp

1

33

Bolt

1

15

Bolt

5

34

Support

1

16

Plate

1

35

Exhaust pipe

1

17

Air filter

1

36

Bolt

2

18

Shim clamp

2

37

Clamp

1

19

Bellows

1

4.4.1 Working principle of intake and exhaust The functions of the intake and exhaust as are: 1. Supply clean and dry air with proper temperature for engine to combust so as to minimize engine wear and optimize engine performance; 2. Keep all exhaust gases safely away from engine and discharge them into atmosphere quietly while optimizing engine performance. 3. Supply clean and dry air for engine air compressor to be used for braking of complete machine. Working principle of intake and exhaust as is: Air is taken in through air pre-filter. There are rotating blades inside the air pre-filter, which can discharge big dust in intake air from the bottom of air pre-filter. Intake air reaches air filter, filter element removes small dust and moisture to obtain clean and dry air to be sent to turbocharger, the turbocharger is driven by engine exhaust to pressurize intake air and increase intake quantity, and sufficient combustion of fuel can be ensured. Air coming out of turbocharger goes through air cooler in cooling system and electric heater of engine itself to obtain proper temperature and then enters engine block to combust. Exhaust gas generated after combustion reaches turbocharger via exhaust manifold, drives turbocharger to pressurize

4-12 4.4 Intake and exhaust system of engine 4.4.1 Working principle of intake and exhaust

intake air and is then discharged to muffler to reduce exhaust noise. Exhaust gas is discharged into atmosphere via exhaust pipe after going through muffler. After intake air flows across air filter, one path enters air compressor intake line via filter junction so as to supply clean and dry air for air compressor. The air path graph of engine intake:

Hot gas Cold gas

4-13 4.4 Intake and exhaust system of engine 4.4.1 Working principle of intake and exhaust

The air path graph of engine exhaust:

Hot gas Cold gas

4-14 4.4 Intake and exhaust system of engine 4.4.2 Removal and installation of air pre-filter

Air path graph of air compressor intake:

Hot gas Cold gas

4.4.2 Removal and installation of air pre-filter Principle

1. Clean air 2. Impurity

4-15 4.4 Intake and exhaust system of engine 4.4.2 Removal and installation of air pre-filter

Air pre-filter is specially designed into rotary intake channel, and air passes through specially designed blade surfaces and rotates. When air rotates fast, it generates a certain centrifugal force to separate dust, water and other impurities from air. Dust and impurities are driven by intake air flow and blown to a special discharge outlet by a fast rotating rotator so as to achieve the action of air filtration.

Faults Fault mode: dust plugging; Troubleshooting: clear. Fault mode: the revolving shaft is locked; Troubleshooting: clean or replace.

Removal and installation Tool list Name Open-end spanner Plastic sealing membrane

Specifications 8mm, 13mm

Remarks:

Removal of air pre-filter: Picture

Removal objects

1. Unscrew the connecting clamp 32 of air filter and bellows.

Tool

Tool: Open-end spanner 8#

4-16 4.4 Intake and exhaust system of engine 4.4.3 Removal and installation of muffler

Picture

Removal objects

Tool

2. Remove the 4 captive bolts 22 of air filter Tool: 3. Remove the pre-filter 23 Open-end spanner 4. Seal every ports with 13# plastic sealing membrane as required

Installation of air pre-filter Installation is in the reverse order of removal.

4.4.3 Removal and installation of muffler Muffler has the main function of reducing noise caused by engine exhaust and satisfying machine noise level emission standard.

Maintenance Periodically and visually inspect the muffler. If clamps and bolts are loose, tighten them. In case of any cracks or erosion, the muffler must be replaced. Otherwise, noise may be higher than standard value, and cracked muffler has the possibility of spark leakage to cause fires.

Removal and installation Tool list Name Open-end spanner Travelling crane Wire rope with hooks Plastic sealing membrane Remarks:

Specifications 8mm, 13mm, 16mm, 18mm above 2t

4-17 4.4 Intake and exhaust system of engine 4.4.3 Removal and installation of muffler

Removal and installation steps Picture

Removal objects

1. Turn off the negative electrode switch, and hang on a "No operation" warning board.

CAUTION

No Operation

Tool

4-18 4.4 Intake and exhaust system of engine 4.4.3 Removal and installation of muffler

Picture

Removal objects

Tool

2. Remove 4 captive bolts 22 of exhaust pipe, and remove exhaust pipe 24.

Tool: Open-end spanner 13#

3. Remove the engine hood according to removal and installation requirements and steps of engine hood in Section 12.3.

Plastic sealing membrane Travelling crane Wire rope with hook

4. Remove the connecting clamp 37 of exhaust pipe and muffler.

Tool: Open-end spanner 18#

4-19 4.4 Intake and exhaust system of engine 4.4.3 Removal and installation of muffler

Picture

Removal objects

Tool

5. Remove the connecting clamp of turbocharger and exhaust pipe bracket.

Tool: Open-end spanner 13#

6. Remove binder bolts 36 for exhaust pipe and fixing plate, remove exhaust pipe 35, and shield both ends with plastic sealing films.

Tool: Open-end spanner 16#

Connecting clamp

4-20 4.4 Intake and exhaust system of engine 4.4.4 Air filter

Picture

Removal objects

7. Remove muffler captive bolts 28, remove muffler 25, and shield both ends with plastic sealing films.

Tool

Tool: Open-end spanner 16#, plastic sealing membrane

Installation of mufflers: Installation is in the reverse order of removal.

4.4.4 Air filter Principle Air filter ensures clean and dry air to enter engine through main filter element and safety filter element.

4-21 4.4 Intake and exhaust system of engine 4.4.4 Air filter

S/N

Description

S/N

Description

1

Air filter housing

5

Air filter cover

2

Safety filter element

6

Dusting bag

3

Main filter element

7

Locking handle

4

Spinning disk

When engine operates, air enters air filter through pre-filter, is filtered by main filter element and is then secondarily filtered by safety filter element. As the figure below:

Air filter plug of this machine is of electronic induction type. When the filter operates for a period of time, much dust is accumulated on filter element, and air resistance through filter is increased. When circulating air resistance is 1. Main filter element

2. Safety filter element

above 6.3 KPa, air filter blockage sensor

Spinning disk guides intake air and separates

installed between air filter and turbocharger will

large-particle dust in intake air by centrifugal

transmit signal to air filter alert indicator on

force to be discharged by dust collection bag.

instrument panel. When the indicator goes on, air filter shall be maintained.

4-22 4.4 Intake and exhaust system of engine 4.4.4 Air filter

Maintenance Air filter doesn’t need additional operations. However, when engine air filter alert indicator on instrument panel goes on, engine air filter shall be maintained.

1.Engine air filter alert indicator Filter element of air filter is divided into safety filter element and main filter element. Filter elements shall be maintained as follows: (1) Shut down engine, open engine hood, wait until engine is cooled down, and remove outer cover of air filter.

4-23 4.4 Intake and exhaust system of engine 4.4.4 Air filter

(5) Clean main filter element, back purge main filter element with compressed air (pressure not greater than 300 kPa) from inside to outside.

(2) Rotate and take out the main filter element along the direction of housing.

It is forbidden to purge main filter element with compressed air from outside to inside. It is also forbidden to use oil and water to wash main filter element! Notes: do not knock to avoid damages when main filter element is cleaned. (6) After cleaning the main filter element, use the electric light to inspect. If small hole or particle is found, replace with a new main filter element.

(3) Check the main filter element. ●

Replace main filter element if fold and gasket are damaged.

●

If the main filter element is not damaged, clean it.

(4) Clean the inner wall of air filter housing.

(7) Install clean main filter element in air filter housing. Make sure evenly seal and install main filter element and housing in place. (8) Clean and install cover of air filter. Make

4-24 4.4 Intake and exhaust system of engine 4.4.4 Air filter

sure gasket of air filter is in even contact with air filter housing. If filter housing cannot be assembled, it means filter element is not installed in place; Keep the dust collecting bag downward during installation of filter cover. Notes: replace main filter element which is cleaned and maintained for 4-5 times with a new one; Don't remove and install safety filter element when cleaning and maintaining main element. (9) Shutdown the engine hood. The replacement of safety filter element is the same to that of main filter element, except that safety filter element is only allowed to be replaced and shall not be cleaned for use. Main filter element shall be replaced when safety filter element is replaced. Faults 1. Fault: engine weakness and generating black smoke. Fault cause: blockage of filter element; Troubleshooting: blow the filter element dry or replace the filter element; Fault cause: empty filter sucked in paper scrap or rag and other things; Troubleshooting: clearing; Fault cause: rainwater into the empty filter; Troubleshooting: dry or replace filter element; 2. Fault: early wear of the engine. Fault cause: air intake short circuit; Troubleshooting: check for error proofing; Fault cause: filter element’s damage and failure; Troubleshooting: replace; Fault cause: the dusting bag lost efficacy; Troubleshooting: replace.

4-25 4.4 Intake and exhaust system of engine 4.4.4 Air filter

Removal and installation Tool list Name Open-end spanner Plastic sealing membrane

Specifications 8mm, 13mm, 16mm

Remark:

Removal of air filter: Picture

Removal objects

Tool

1. Remove air pre-filter according to removal and installation requirements and steps of air filter hereinafter.

2. Loosen clamp 32 connecting air filter and bellows with open-end spanner or blower gun (ratchet spanner) and socket, remove clamp and bellows 19, and seal each end with plastic sealing film as required.

Tool: Open-end spanner 8#

4-26 4.4 Intake and exhaust system of engine 4.4.4 Air filter

Picture

Removal objects

Tool

3. Loosen clamp 4 connecting air filter and intake pipe with openend spanner or blower gun (ratchet spanner) and socket, plug intake pipe 3 out of air filter end, and seal each end with plastic sealing film as required.

Tool: Open-end spanner 8#,13#

4. Loosen clamp 2 connecting air filter and air compressor intake hose with open-end spanner, remove captive clamp bolt 7 of air compressor intake hose, remove clamp 5, plug air compressor intake hose 9 out of branch end from air filter to air compressor, and seal each end with plastic sealing film as required.

Tool: Open-end spanner 16#

4-27 4.4 Intake and exhaust system of engine 4.4.4 Air filter

Picture

Removal objects

5. Remove captive bolts 15 of air filter with open-end spanner, and remove air filter 17.

Installation of air filter Installation is in the reverse order of removal.

Tool

Tool: Open-end spanner 8#

4-28 4.5 Removal and installation of fan 4.4.4 Air filter

4.5 Removal and installation of fan Tool list Name Open-end spanner Torque spanner

Specifications 13mm 72±4N.m

Steel ruler Remark: gap between fan and fan guard needs to be remeasured after replacing fan to ensure the gap is greater than 10 mm.

4-29 4.5 Removal and installation of fan 4.5.1 Removal of fan

4.5.1 Removal of fan Picture

Removal objects

1. Turn off the negative electrode switch, and hang on a "No operation" warning board. 2. Open engine hood.

CAUTION

No Operation

Tool

4-30 4.5 Removal and installation of fan 4.5.1 Removal of fan

Picture

Nut

Protection shield

Removal objects

Bolt

3. Hold captive nuts of protection shield with open-end spanner, remove captive bolts with open-end spanner or blower gun (ratchet spanner), rod and socket, and remove upper and lower protection shield from shroud.

Tool

Tool: Open-end spanner 13#

4-31 4.5 Removal and installation of fan 4.5.1 Removal of fan

Picture

Removal objects

Tool

Captive bolt

4. Remove captive bolts of fan with open-end spanner or blower gun (ratchet spanner), rod and socket, and remove fan from connecting shaft, and take it out from right gap of complete machine.

The right of the complete

Tool: Open-end spanner 13#

4-32 4.5 Removal and installation of fan 4.5.2 Installation of fan

4.5.2 Installation of fan Picture

Interior (concave) Exterior (convex)

Removal objects

Tool

1. If fan is damaged, it needs to be replaced with a new one having the same part number. Adopt the same parts as well when replace the parts on the fan. 2. This machine adopts suction fan, the inner side of arc surface of fan directly faces to engine, and the outer side of arc surface of fan directly faces to radiator. 3. Put the fan into the shroud from the right gap of complete machine. 4. Hang fan to connecting shaft, align fan fixing hole with threaded hole on connecting shaft, and install bolt. 5. Pre-tighten captive bolt of fan with open-end spanner, and tighten bolt to 72±10 N.m with torque spanner.

Tool: Open-end spanner 16#, 72±4N.m torque spanner

4-33 4.5 Removal and installation of fan 4.5.2 Installation of fan

Picture

Nut

Protection shield

Bolt

Removal objects

Tool

6. Hold captive nuts of protection shield with 13 mm open-end spanner, and install fan protection shield and its captive bolts with 13 mm open spanner or blower gun (ratchet spanner), rod and 13 mm socket. 7. Close the engine hood and take off the warning board "No operation".

Tool: Open-end spanner 13#

4-34 4.6 Removal and installation of engine as 4.5.2 Installation of fan

4.6 Removal and installation of engine as Engine mounting as has the function of realizing effective installation of engine. The working principle of engine as is as follows: engine is fixed on complete machine via engine mounting composed of mounting support and shock absorber, engine has excellent working environment through shock isolating action of shock absorber, vibration of engine transferred to complete machine is reduced, and riding comfort is improved. Generally, requirements for the engine as are as following. 1. Active and static loads can be supported under all working conditions, and engine as has displacements in all directions within acceptable range and does not interfere with other parts on chassis. Meanwhile, before repairing the engine, there are no damaged parts. 2. Vibration generated by engine can be sufficiently isolated from being transferred to frame and cab, and cab operating comfort and service life of complete machine components are improved. 3. Impact generated by uneven roads can be effectively isolated from being transferred to engine through engine mounting, and influence of road impact on engine is reduced.

4-35 4.6 Removal and installation of engine as 4.5.2 Installation of fan

Structural drawing of engine mounting assembly (version 40C5782000)

S/N

Parts name

Quantity

S/N

Parts name

Quantity

1

Bracket

1

6

Hard washer

4

2

Diesel engine

1

7

Cap

4

3

Shock absorber

2

8

Bolt

8

4

Locknut

2

9

Bracket

1

5

Bolt

2

10

Engine fan

1

1. Regularly measure with eyes engine mounting (including engine mounting support and shock absorber). Tighten the bolts if the looseness occurs. If safety seat of engine cracks, replace it. If the

4-36 4.6 Removal and installation of engine as 4.6.1 Removal and installation of engine mounting

shock absorber is cracked, damaged or rotted, replace it.

4.6.1 Removal and installation of engine mounting Tool list Name

Specifications 16mm, 30mm 120±6N.m, 1020±6N.m

Open-end spanner Torque spanner Plastic sealing membrane Travelling crane above 2t Wire rope with hooks Weight load over 840Kg Tool for measuring the clearance between shroud and fan Steel ruler Remarks: 1. In view of large M20 bolts during the removal and installation of engine mounting, it is recommended using a blower gun and a socket for easy removal and installation, as well as using an open-end spanner for auxiliary holding. 2. Re-measurement of fan clearances is needed after shock absorber is replaced. If possible, it is recommended using LiuGong shroud-fan clearance measuring tool; otherwise, a steel ruler can also be used for measurement.

4-37 4.6 Removal and installation of engine as 4.6.1 Removal and installation of engine mounting

The removal of engine mounting: Picture

Note

No Operation

Removal objects 1. Turn off the negative electrode switch, and hang on a "No operation" warning board. 2. Remove the engine hood top cover according to removal and installation requirements and steps of engine hood in Section 12.3. 3. Remove exhaust pipe, air pre-filter and connecting pipe thereof, and use plastic sealing film to seal each end as required, according to removal and installation requirements and steps of intake and exhaust system described in Section 4.4. 4. Remove the engine hood according to removal and installation requirements and steps of engine hood in Section 12.3. 5. Loosen captive bolts of transmission according to removal and installation requirements and steps of transmission described in Section 5.1.1.

Tool

Plastic sealing membrane

4-38 4.6 Removal and installation of engine as 4.6.1 Removal and installation of engine mounting

Picture

Lifting hole

Warranty clearance

Removal objects

Tool

6. Hold captive nut 4 of engine with an openend spanner, and remove captive bolt 5 of engine from under engine mounting support with a blower gun, a rod and a socket. And take down the shock absorber and its cover from the engine mounting support.

Tool: Open-end spanner 30#

7. Operate wire rope on travelling crane for lifting hook to pass hook through lifting hole at fan side of engine, and lift engine as slowly as possible. Lifting height should allow no interference between fan and shroud of engine. It is recommended lifting height is not larger than 5 mm.

Travelling crane Wire rope with hooks

4-39 4.6 Removal and installation of engine as 4.6.1 Removal and installation of engine mounting

Picture

Removal objects

Tool

8. Take out shock absorber 3 and cover 7 under the mounting support of the engine.

9. Loosen captive bolt 8 of engine mounting support and take it out with an open-end spanner or a blower gun (ratchet spanner), a rod and a socket, and then take down engine mounting support 9 and 1.

Tool: Open-end spanner 16#

4-40 4.6 Removal and installation of engine as 4.6.1 Removal and installation of engine mounting

The installation of engine mounting: Picture

Installation objects

1. Turn off the negative electrode switch, and hang on a "No operation" warning board.

CAUTION

No Operation

Tool

4-41 4.6 Removal and installation of engine as 4.6.1 Removal and installation of engine mounting

Picture

Installation objects 2. Install engine mounting support on engine with captive bolt for engine mounting support, and pretighten captive bolt with an open-end spanner or a blower gun (ratchet spanner), a rod and a socket. 3. Tighten mounting support captive bolt of engine with a torque spanner to torque of 120 ±50 N.m. 4. Place shock absorber and cover at upper and lower sides of engine mounting support respectively, and adjust shock absorber so that it is installed into hole of mounting support. 5. Assemble shock absorber, cover and engine mounting support together by passing engine fasteners such as captive bolt and nut through them.

Tool

Tool: Open-end spanner 16#, 120±6N.m torque spanner

4-42 4.6 Removal and installation of engine as 4.6.1 Removal and installation of engine mounting

Picture

Installation objects

Tool

Lifting hole

6. Lay down the engine slowly when maneuvering the vehicle and loose the lifting hook.

7. Hold nut with an open-end spanner, and pre-tighten captive bolt of engine from under engine mounting support with a blower gun, a rod and a socket. 8. Tighten captive bolt of engine with a torque spanner to torque of 1,020 ±6 N.m. 9. Re-tighten captive bolt of transmission with a torque spanner according to removal and installation requirements and steps of transmission described in Section 5.1.2.

Tool: Open-end spanner 16# 1,020±6N.m Torque spanner

4-43 4.6 Removal and installation of engine as 4.6.1 Removal and installation of engine mounting

Picture

Clearance between fan and shroud>10mm

Edge of the fan

Installation objects

Tool

10.Measure clearances between fan and shroud, protection shield. Clearance between fan and shroud should be larger than 10 mm, while that between fan and protection shield should be larger than 20 mm.

Tool for measuring the clearance of fan (steel ruler)

Inner edge of the protection shield

11. Install hood according to removal and installation requirements and steps of hood described in Section 12.3.

4-44 4.6 Removal and installation of engine as 4.6.2 Removal and installation of engine

Picture

Installation objects

Tool

12. Install exhaust pipe, air pre-filter and connecting pipe thereof according to removal and installation requirements and steps of intake and exhaust system described in Section 4.4. 13. Install engine hood according to removal and installation requirements and steps of engine hood hereinafter. 14. Close the engine hood and take off the warning board "No operation".

4.6.2 Removal and installation of engine Tool list Name Specifications Travelling crane Above 2t Wire rope with hooks Plastic sealing membrane Oil collecting basin Remarks: 1. In view of large M20 bolts during the removal and installation of engine mounting, it is recommended using a blower gun and a socket for easy removal and installation, as well as using an open-end spanner for auxiliary holding. 2. Re-measurement of fan clearances is needed after fan is removed and installed. If possible, it is recommended using LiuGong shroud-fan clearance measuring tool; otherwise, a steel ruler can also be used for measurement.

4-45 4.6 Removal and installation of engine as 4.6.2 Removal and installation of engine

Picture

CAUTION

No Operation

Removal objects 1. Turn off the negative electrode switch, and hang on a "No operation" warning board. 2. Remove the engine hood according to removal and installation requirements and steps of engine hood in Section 12.3. 3. Remove air filter, muffler and their connecting pipes according to removal and installation requirements and steps of intake and exhaust system described in Section 4.4; seal every terminal with plastic seal membrane as per the requirements. Whether to remove and install muffler bracket depends on specific conditions of an engine position under repair. 4. Remove feed and drain hoses and pipe, empty coolant into oil collecting basin for treatment together, and use plastic sealing film to seal each end as required, according to removal and installation requirements and steps of cooler lines described in Section 4.10.2.

Tool

4-46 4.6 Removal and installation of engine as 4.6.2 Removal and installation of engine

Picture

Removal objects 5. Remove protection shield according to removal and installation requirements in Section 4.10.3. 6. Remove engine fan and support thereof according to removal and installation requirements and steps of fan described in Section 4.5. 7. Remove electrical connector and wiring on engine according to removal and installation requirements and steps of electrical system described in Section 7. 8. Remove A/C pipe and warm air hose on engine, and use plastic sealing film to seal each end as required, according to removal and installation requirements and steps of air conditioning system described in Section 8.2. 9. Remove fuel hose and flexible throttle shaft on engine, and use plastic sealing film to seal each end as required, according to removal and installation requirements and steps of fuel lines and throttle control system described in Sections 4.7 and 4.8.

Tool

Plastic sealing membrane Oil collecting basin

4-47 4.6 Removal and installation of engine as 4.6.2 Removal and installation of engine

Picture

Lifting eye

Removal objects

Tool

10. Slowly operate travelling crane, hang lifting eye on engine with hook on wire rope, and tauten wire rope without lifting engine.

Travelling crane Wire rope with hooks

Lifting eye

11. Remove captive bolt in connecting surface of engine and torque converter according to removal and installation requirements and steps of transmission & torque converter as described hereinafter. 12. Remove captive bolt of engine according to removal and installation requirements and steps of engine mounting described hereinbefore.

4-48 4.6 Removal and installation of engine as 4.6.3 Turbocharger

Picture

Buttress

Removal objects

Buttress

Tool

13. Slowly operate travelling crane and hold both sides of engine in order to ensure that engine is slowly and steadily lifted out of complete machine and will not collide with other parts of complete machine.

Installation of engine Installation is in the reverse order of removal.

4.6.3 Turbocharger Turbocharger is mainly used to increase intake pressure and improve intake quantity (intake density), and finally improve engine power and economy. Installation location and its diagram of turbocharger

4-49 4.6 Removal and installation of engine as 4.6.3 Turbocharger

S/N

Description

S/N

Description

1

Exhaust pipe

6

Bearing

2

Nozzle ring

7

Diffuser

3

Turbine

8

Compressor impeller

4

Turbine housing

9

Compressor housing

5

Rotor shaft

10

Intake pipe

Maintenance Turbocharger is a precision machine running at a high speed, and thus random removal is forbidden. If severe wear or damage is found during a check, corresponding parts must be adjusted, repaired or replaced. If turbocharger is damaged or improperly adjusted, it cannot function sufficiently, that is, it cannot deliver sufficient air to engine. If malfunctions, go to Cummins maintenance center for repair. Proper operation: 1. Before lubricant pressure of engine is built, keep engine idle. 2. Before engine is stopped, gradually lower its temperature and revolutions from maximum values (for approximately 5 minutes). 3. Lubricate the turbocharger first. After replacement of lubricant or any services (including draining lubricant), pre-lubrication is required for turbocharger. Move crankshaft disc several times before engine starts. After engine starts and before it begins to run at a high speed, keep engine idling for a period so pressure of whole lubricant circulation can be built.

4-50 4.6 Removal and installation of engine as 4.6.3 Turbocharger

4. Be cautious when start the engine at low temperature. When ambient temperature is too low or vehicle is idle for a long period, engine’s ability to build proper lubricant pressure and flow will be affected. In that case, engine cannot but idle for several minutes after starting in order to work properly. 5. Avoid running the engine idle for a long time. In addition, whenever lubricant is replaced, oil filter is washed or engine is rest for a long period (approximately more than a week), loosen oil inlet joint of turbocharger and inject clean lubricant so turbocharger lubrication system is filled with lubricant. 6. For other maintenance information on turbocharger, see engine operation and service manual attached to machine. Faults Fault mode: air intake system blockage; Troubleshooting: check lines between air filter and air compressor, lines between air compressor outlet and intake pipe and intake pipe, and keep those positions clean and clear. Fault mode: leakage in air intaking; Troubleshooting: check lines between air filter and air compressor, lines between air compressor outlet and intake pipe, and joint between intake pipe and engine to see whether any part having a leak, a captive bolt able to be tightened, a gasket needing replacement, etc. exists. Fault mode: air exhaust system blockage; Troubleshooting: maintain or replace the related parts. Fault mode: leakage in air exhausting; Troubleshooting: check joints between exhaust pipe and engine, between turbine inlet and exhaust pipe, between turbine housing and middle housing as well as between turbine outlet and exhaust pipe. If any leak exists, defective sealing gasket can be replaced to tighten corresponding captive bolt. Fault mode: air compressor rotor collides with air compressor housing, and turbine collides with turbine housing; Troubleshooting: replace the assembly. Replace assembly: oil inlet or return pipe leakage; Troubleshooting: replace relevant parts. Removal and installation For the removal and installation of turbocharger, see Cummins Engine Service Manual.

4-51 4.7 Fuel system 4.7.1 Function and working principle of fuel system

4.7 Fuel system 4.7.1 Function and working principle of fuel system

Fuel inlet Fuel return

Working principle of fuel system 1.Fuel tank

2. Fuel-water separator

3. Fuel transfer pump

4. Fuel filter

5. Fuel injection pump

6. Injector

Fuel system acts to provide engine with clean and sufficient fuel, which thus ensures proper operation of engine. Its working principle is shown above: when engine works, fuel transfer pump 3 sucks fuel from fuel tank 1, then fuel-water separator 2 eliminates water from fuel, next fuel filter 4 eliminates impurities from fuel, and finally fuel enters fuel injection pump 5. After fuel is pressurized and metered in fuel injection pump, it is supplied into injector 6, and finally is injected into combustion chamber by injector. Return fuel from top of injector returns to fuel injection pump inlet, while spare fuel supplied by fuel transfer pump returns to fuel tank.

4-52 4.7 Fuel system 4.7.2 Removal and installation of fuel lines

4.7.2 Removal and installation of fuel lines Fuel lines comprise fuel inlet pipe, fuel return pipe, fuel-water separator, etc. See below diagram and list for details:

Part No.

Name

Quantity

Part No.

Name

Quantity

1

Fuel hose

1

12

Washer

4

2

Fuel hose

1

13

Bolt

3

3

Turbine worm clamp

6

14

Fuel hose

1

4

Support

1

15

Connector

1

5

Washer

6

16

Washer

10

4-53 4.7 Fuel system 4.7.2 Removal and installation of fuel lines

Part No.

Name

Quantity

Part No.

Name

Quantity

6

Washer

6

17

Connector

1

7

Bolt

6

18

Screw

5

8

Drain hose

1

19

Bolt

1

9

Fuel-water separator

1

20

Nut

1

10

Hose clamp

4

21

Connector

4

11

Washer

4

22

Pipe clamp

1

Tool list Name

Specifications 7#, 16#, 18#, 19#

Open-end spanner Waste oil tank Plastic sealing bag Remark: removed standard parts should be placed with relevant material together to avoid confusion.

Removal of fuel lines Picture

Steps

Tool

1. Remove fuel returnpipe 2 (line from fuel tank to fuel return joint of engine) a. Remove the hose clamp 10 fixing the fuel hose.

Tool: Open-end spanner 16#

4-54 4.7 Fuel system 4.7.2 Removal and installation of fuel lines

b. Unscrew turbine worm clamp 3 connecting fuel hose and engine fuel return port, take down fuel hose here and recover fuel flowing out of line and engine fuel return port through waste fuel drum. c. Block the engine return oil port with clean plastic bags.

Tool: Open-end spanner 7#, 19#, waste oil drum

d. Remove screw 18 connecting fuel hose and fuel tank end, take down fuel hose, and install screw back on fuel return port of fuel tank. Block the fuel hose with clean plastic bag.

Tool: Open-end spanner 7#, 19#, waste oil drum

4-55 4.7 Fuel system 4.7.2 Removal and installation of fuel lines

2. Remove fuel inlet pipe 14 (fuel-water separator to fuel hose of oil transfer pump): a. Disassemble the hose clamp 10 fixing the fuel hose. b. Remove screw 18 of fuel hose at oil transfer pump end, take down fuel hose, recover fuel in line through waste fuel drum and install screw back on fuel inlet of oil transfer pump. c. Remove screw 18 of fuel hose at fuel-water separator end, install screw back on fuel-water separator after taking down fuel hose, and mask fuel hose with clean plastic bag. 3. Remove fuel inlet pipe 1 (fuel tank to fuel-water separator fuel hose) a. Remove the fixed fuel hose clamp 10. b. Remove screw 18 of fuel hose at fuel-water separator end, take down fuel hose, and recover fuel in line through waste fuel drum. Then put bolt back onto fuel-water separator. c. Remove screw 18 of fuel hose at fuel tank end, install screw back on fuel tank after taking down fuel hose, and mask fuel hose with clean plastic bag.

Tool: Open-end spanner 16#, 19#, waste oil barrel

Tool: Open-end spanner 16#, 19#, waste oil barrel

4-56 4.7 Fuel system 4.7.2 Removal and installation of fuel lines

4. Remove fuel-water separator 9: Remove 4 bolts 7 on fuelwater separator mounting bracket, take down fuelwater separator and bracket, and put them away properly.

Installation of fuel lines Installation is in the reverse order of removal.

Tool: Open-end spanner 18#

4-57 4.8 Throttle control system 4.8.1 Throttle control system

4.8 Throttle control system 4.8.1 Throttle control system

Part No. 1

Name Throttle control system

Quantity

Part No.

1

2

Name

Quantity

Flexible shaft

Tool list Name Specifications Open-end spanner 10#, 13#, 16#, 22# Remark: removed standard parts should be placed with relevant material together to avoid confusion.

1

4-58 4.8 Throttle control system 4.8.2 Removal of throttle control system

4.8.2 Removal of throttle control system Picture

Steps

Tool

1. Remove the flexible shaft: Remove captive nuts on mounting bolts at both ends of flexible shaft, loosen fixing cap of jacket, and take flexible shaft down.

Tool: Open-end spanner 10#, 22#

2. Remove the throttle control system: Lift up floor mat, remove 4 captive bolts on throttle control system, and take down throttle control system.

Tool: Open-end spanner 16#

4-59 4.8 Throttle control system 4.8.3 Installation of throttle control system

4.8.3 Installation of throttle control system Picture

Steps

Tool

1. Install the throttle control system Screw the 4 captive bolts on the throttle control system.

Tool: Open-end spanner 16#

2. Accelerator flexible shaft installation (installation between flexible shaft and accelerator pedal joint) a. Fix end of accelerator flexible shaft to mounting hole corresponding to accelerator pedal, and tighten mounting nut. b. Adjust the positions of two nuts fixing flexible shaft, then fix them on the bracket and fasten them.

Tool: Open-end spanner 10#, 22#

4-60 4.8 Throttle control system 4.8.4 Adjustment of throttle control system

Picture

Steps

Tool

3. Accelerator flexible shaft installation (installation between flexible shaft and engine joint) a. Fix end of accelerator flexible shaft to mounting hole corresponding to accelerator linkage of engine, and tighten mounting nut. b. Adjust the positions of two nuts fixing flexible shaft, then fix them on the bracket and fasten them.

Tool: Open-end spanner 10#, 22#

4.8.4 Adjustment of throttle control system After accelerator flexible shaft is installed, under normal circumstances: accelerator pedal is free, and engine can be idling; accelerator pedal can be operated smoothly and freely, and when it is at the lowest point, engine is in maximum working conditions; Release the accelerator pedal, and the pedal can return automatically. If any exceptional conditions occur, that is, engine cannot idle, accelerator pedal operations are obviously tough, accelerator cannot reach maximum accelerator position, or accelerator cannot return, carry out mutual coordination and adjustment through installation steps 2b and 3b of throttle control system, until operation is normal.

4-61 4.9 Removal and installation of fuel tank as 4.9.1 Fuel tank as

4.9 Removal and installation of fuel tank as 4.9.1 Fuel tank as

Part No.

Name

Quantity

Part No.

Name

Quantity

1

Fuel tank

1

13

Filler tube

1

2

Drain plug

1

14

Strainer

1

3

O-ring

1

15

Tank cover as

1

4

Hard washer

8

16

Retainer

1

5

Locknut

4

17

Adjustable connector

1

6

Bolt

4

18

Turbine worm clamp

2

4-62 4.9 Removal and installation of fuel tank as 4.9.2 Removal of fuel tank

7

Washer

4

19

Fuel hose

1

8

Shock absorber cushion

4

20

Adjustable connector

1

9

Rubber washer

1

21

Suction flange

2

10

Washer

3

22

O-ring

2

11

Washer

3

23

Bolt

12

12

Bolt

3

24

Washer

12

Tool list Name

Specifications 7#, 16#, 18#, 19#, 20#, 24#, 30# Socket spanner, 24# socket

Open-end spanner Socket spanner, socket Clean oil basin, towel Plastic sealing bag Forklift Remark: removed standard parts should be placed with relevant material together to avoid confusion.

4.9.2 Removal of fuel tank Diagram

Removal objects

1. Drain diesel oil: Clean drain hole of fuel tank, place a clean oil container under the fuel tank, and unscrew drain plug 2. After fuel is drained, fix drain plug back to fuel tank. Drained fuel should be strictly sealed for preservation to prevent pollution to fuel.

Tool

Tool: 24# socket, socket spanner

4-63 4.9 Removal and installation of fuel tank as 4.9.2 Removal of fuel tank

Diagram

Removal objects

Tool

2. Remove the clamp: Remove the clamp bolt on the fuel tank, and take off the hose clamp.

Tool: Open-end spanner 16#, 18#

3. Remove the fuel lines of suction and return port: After fuel is drained, remove screw 23 of fuel hose at fuel tank end, take down fuel hose of that end, and fix the screw back to fuel return hole. Block the fuel hose with clean plastic bag.

Tool: Open-end spanner 19#

Hose clamp

4-64 4.9 Removal and installation of fuel tank as 4.9.2 Removal of fuel tank

Diagram

Removal objects

Tool

4. Remove the fuel sensor wire harness: Remove the harness connector of fuel tank sensor.

5. Remove fuel-water separator: a. Remove assembly joint screws of fuel hose at both ends of fuel-water separator, take down fuel hose close to fuel tank, and screen fuel hose with a clean plastic bag. b. Remove 4 bolts from mounting bracket of fuelwater separator, and take down fuel-water separator and its bracket.

Tool: Open-end spanner 19#, 18#

4-65 4.9 Removal and installation of fuel tank as 4.9.2 Removal of fuel tank

Diagram

Removal objects

Tool

6. Remove filler tube 13: a. Rotate loose turbine worm clamp 18 and take off the fuel hose. b. Remove 3 bolts 12 from filler tube flange, and remove filler tube.

Tool: Open-end spanner 18#, 7#

7. Remove fuel tank 1: Remove the mounting bolts 6 and nuts 5 on the 4 fuel tanks.

 CAUTION

Fuel tank is connected to frame through bolts and nuts in four mounting points. After mounting bolts are loosened, fuel tank will separate from frame. Before removal, use a reliable tool (e.g., forklift) with sufficient bearing capacity to support fuel tank.

 CAUTION

Before step 7, make sure steps 2-6 have been done; otherwise, corresponding parts will be damaged, and even a safety accident will occur.

Tool: Open-end spanner 30#, carrier tool or tooling

4-66 4.9 Removal and installation of fuel tank as 4.9.3 Installation of fuel tank

4.9.3 Installation of fuel tank Installation is in the reverse order of removal. Notes: fuel tank mounting bolt has tightening torque of 600 ±50 N·m.

4.9.4 Cleaning of fuel tank Remove suction flange cover in front of fuel tank, and wash internal surface of fuel tank. Unscrew drain plug at bottom of fuel tank to drain fuel (use a proper container to collect fuel). Rinse it by fuel repeatedly until the drained fuel is clean. Put drain plug back onto the floor of fuel tank.

4-67 4.10 Cooling system 4.10.1 Working principle of cooling system

4.10 Cooling system 4.10.1 Working principle of cooling system Cooling system comprises a radiatorr and corresponding connecting lines, where the radiator is composed of a water radiator, an air cooler, a hydraulic oil cooler and a torque converter oil cooler. Its function is to radiate heat produced by each part (or system) into the air along with cooling air in order to ensure each part works properly in appropriate temperature range. As shown below, diesel engine cooling system mainly comprises a radiator (water tank), a water pump, a fan, a thermostat, an engine oil cooler, water intake and outtake pipes, etc.

S/N

Name

S/N

Name

1

Outfall sewer

6

Water pump

2

Circulating tubule

7

Engine oil cooler

3

Thermostat

8

Water drain valve

4

Radiator

9

Heating valve

5

Fan

10

Water temperature sensor

Cooling system of this machine adopts engine to drive fan and adopts suction mode to cool. The system adopts forced closed circulating water cooling system. Working principle of system is as follows: water outlet at lower part of cooler is connected with water inlet of engine oil cooler via water hose, water outlet of engine oil cooler is connected with water pump via water hose, water pump pumps coolant into cylinder block water passage, coolant firstly cools cylinder through water jacket inside cylinder block, then flows up

4-68 4.10 Cooling system 4.10.1 Working principle of cooling system

to cool cylinder head, and is collected by water outlet header pipe to reach thermostat. When coolant temperature is lower than 84 ℃ , thermostat is closed, and all coolant is bypassed to water pump inlet. At the moment, coolant is only circulating between cylinder block and cylinder head, so that warm-up can be quickly realized. When coolant temperature is above 84 ℃ , thermostat starts to be opened, part of coolant flows to water inlet at upper part of cooler and enters radiator to be cooled by cooling fan. When coolant temperature is above 91 ℃ , thermostat is totally opened, bypass hole is closed, and all coolant is cooled by radiator. The coolant flowing direction at the moment is shown in the chart.

1.Engine

2. Water radiator

Fig. The cooling system of diesel engine

4-69 4.10 Cooling system 4.10.1 Working principle of cooling system

Air cooler Air cooler has the main function of cooling high-temperature high-pressure gas across turbocharger and reducing temperature of air entering engine combustion chamber to increase air density. Its working principle is shown in Fig. below. After air is pressurized by turbocharger, temperature rises up sharply, pressure is increased, air flows into air cooler from left air pipe and passes across core of air cooler, external cooling air flows by outside the core to bring away heat of air inside intercooler so as to reduce its temperature to be lower than 80 ℃ , and then, the air flows into engine intake manifold and cylinder from right air pipe of air cooler.

1.Booster air inlet

6.Intake manifold

2.Booster air outlet

7.Cylinder

3.Pressurized hot air

8.Exhaust gas

4.Air cooler radiator

9.Muffler

5.Pressurized cold air

4-70 4.10 Cooling system 4.10.1 Working principle of cooling system

The air cooler system of the vehicle arranged as the drawing below:

1.Air-air inter-cooler

2.Turbocharger

4-71 4.10 Cooling system 4.10.1 Working principle of cooling system

Hydraulic oil cooler Hydraulic oil cooler has the main function of radiating heat generated by hydraulic oil during the working of hydraulic system to avoid temperature of hydraulic oil line from being too high. Torque converter oil cooler Torque converter oil cooler has the main function of radiating heat generated by torque converter oil during the working of transmission and torque converter to avoid temperature of torque converter and transmission from being too high and ensure normal working of machine.

1. Hydraulic oil cooler

2. Torque converter oil cooler

4-72 4.10 Cooling system 4.10.2 Removal and installation of cooler lines

4.10.2 Removal and installation of cooler lines Cooler lines

4-73 4.10 Cooling system 4.10.2 Removal and installation of cooler lines

Part No.

Name

Quantity

Part No.

Name

Quantity

1

Water pipe

1

21

Turbine worm clamp

4

2

Hose clamp

3

22

Pipe clamp

2

3

Water pipe

1

23

Water pipe

1

4

Washer

3

24

Nut

1

5

Washer

18

25

Washer

2

6

Bolt

2

26

Bolt

1

7

Evaporator hose

1

27

Washer

2

8

Bolt

1

28

Intercooler steel tube

1

9

Nut

1

29

Intake hose

2

10

Washer

14

30

Heat shield

2

11

Nut

8

31

Bolt

1

12

U-clamp

2

32

Washer

1

13

Plate

1

33

Support

1

14

Bolt

6

34

Water drain valve

1

15

Turbine worm clamp

2

35

Water pipe

1

16

Clamp

8

36

Intercooler steel tube

1

17

Drain pipe

1

37

Water pipe

1

18

Steam hose

1

38

Plate

1

19

Refill hose

1

39

Support

1

20

Nylon strap

1

40

U-clamp

2

Tool list Name

Specifications 7#, 8#, 12#, 16#

Open-end spanner Clean container, rubber tube Plastic sealing bag Nipper plier Remark: removed standard parts should be placed with relevant material together to avoid confusion.

4-74 4.10 Cooling system 4.10.2 Removal and installation of cooler lines

Removal of cooler lines Picture

Steps

Tool

1. Park the complete machine: a. Park complete machine on flat ground, apply parking brake and shut down engine. Remove the antiTool: rotating bumper with a nipper plier, connect the Nipper plier bumper with the front and rear frames with its pin. b. Open engine hood, and turn disconnect switch to “OFF” position.

4-75 4.10 Cooling system 4.10.2 Removal and installation of cooler lines

Picture

Steps

Hydraulic oil drain valve

Drain valve of the torque converter

Tool

2. Draining (oil/water) a. Loosen water drain valve 34, select a proper container to recover antifreeze (total capacity of anti-freeze is about 45 L), or select a proper hose to introduce water flowing out of water drain valve into a container prepared in advance, and tighten water drain valve after emptying coolant.

Tool: Clean container, rubber tube

b. Loosen hydraulic oil cooler drain valve or torque converter oil cooler drain valve, select a proper container to recover oil (total capacity of hydraulic oil cooler is about 5 L/total capacity of torque converter oil cooler is about 7 L), or select a proper hose to introduce oil flowing out of drain valve into a container prepared in advance, and tighten drain valve after emptying oil.

Tool: Clean container, rubber tube

4-76 4.10 Cooling system 4.10.2 Removal and installation of cooler lines

Picture

Steps

Tool

3. Remove the auxiliary tank steam hose 18 of engine a. Remove the clamp 2 fixing the steam hose.

Tool: Open-end spanner 16#

b. Loosen turbine worm clamps at both ends of steam hose, and remove steam hose. Shield the port and steam hose with clean plastic bags.

Tool: Open-end spanner 7#

4-77 4.10 Cooling system 4.10.2 Removal and installation of cooler lines

Picture

Steps

4. Remove the auxiliary tank steam hose 7 of water radiator Remove clamp 2 from fixed hose. Loosen turbine worm clamp 21 at both ends of steam hose, and remove steam hose. Shield the port and steam hose with clean plastic bags.

Tool

Tool: Open-end spanner 7#, 16#

5. Remove refill hose 19 of auxiliary tank - water hose, and remove clamp 22 fixing Tool: refill hose. Loosen turbine worm clamps 15 at both Open-end ends of refill hose, and spanner 7#, 16# remove refill hose. Shield the port and water make-up pipe with clean plastic bags.

4-78 4.10 Cooling system 4.10.2 Removal and installation of cooler lines

Picture

Steps

Tool

6. Remove the water radiator pipe 1, 35 a. Loosen captive nut 11 of Uclamp, and remove Uclamp 12.

Tool: Open-end spanner 16#

b. Loosen shim clamp 16 of water hose, remove water hose, and shield ends and water hose with clean plastic bags.

Tool: Open-end spanner 8#

4-79 4.10 Cooling system 4.10.2 Removal and installation of cooler lines

Picture

Installation of cooler lines Installation is in the reverse order of removal.

Steps

Tool

7. Remove the intercooler steel tube 28, 36 a. Loosen captive nut 11 of Uclamp, and remove Uclamp 40.

Tool: Open-end spanner 16#

b. Loosen clamp 41 on intake hose connecting both ends of pipe, remove pipe and intake hose, and shield ends, pipe and intake hose with clean plastic bags.

Tool: Open-end spanner 12#

4-80 4.10 Cooling system 4.10.3 Removal and installation of radiator

4.10.3 Removal and installation of radiator 4.10.3.1 Removal and installation of radiator Tool list Name

Specifications 7#, 8#, 10#, 12#, 13#, 16#, 20#, 24# 160~680N·m 8mm

Open-end spanner Torque spanner Inner hexagon spanner Clean container, rubber tube, plastic sealing bag Nipper pliers, scissors, nylon ties and cross screwdriver Travelling crane and sling Remarks: removed standard parts should be placed with relevant material together to avoid confusion. Removal of radiator Diagram

Removal objects

Tool

1. Park the complete machine Refer to the first Step of removal and installation of cooler lines. 2. Draining (oil/water) Refer to the second Step of removal and installation of cooler lines. 3. Remove auxiliary radiator to steam hose of engine Refer to the third Step of removal and installation of cooler lines.

Tool: Open-end spanner 16#, 7#

4. Remove the refillhose Refer to the fifth step of removal and installation of cooler lines.

Tool: Open-end spanner 7#

5. Remove the water hose mounting bracket Refer to Step 6a of removal and installation of cooler lines.

Tool: Open-end spanner 8#

6. Remove the water pipe Refer to Step 6b of removal and installation of cooler lines.

Tool: Open-end spanner 16#

4-81 4.10 Cooling system 4.10.3 Removal and installation of radiator

Diagram

Removal objects

7. Remove air intake hose connecting air cooler Refer to Step 7b in removal and installation of cooling line (only intake hose at radiator end is removed).

Tool

Tool: Open-end spanner 12#

4-82 4.10 Cooling system 4.10.3 Removal and installation of radiator

Diagram

Removal objects

Tool

8. Remove fuse box Cut off nylon strap fixing wiring with scissors, loosen bolts fixing fuse box, remove fuse box, put it away properly.

Tool: Scissor, cross screwdriver

9. Remove of hose of hydraulic oil cooler Loosen screws on plate fixing hose, remove plate and hose, and shield ends and hose with clean plastic bags.

Tool: Inner hexagon spanner, 8mm

4-83 4.10 Cooling system 4.10.3 Removal and installation of radiator

Diagram

Removal objects

10. Remove the hose of torque converter oil cooler Loosen screws on plate fixing hose, remove plate and hose, and shield ends and hose with clean plastic bags.

Tool

Tool: Inner hexagon spanner, 8mm

4-84 4.10 Cooling system 4.10.3 Removal and installation of radiator

Diagram

Removal objects

Tool

11. Remove A/C compressor Remove compressor according to removal and installation requirements and steps of compressor hereinafter.

Tool: Open-end spanner 10#, 16#

12. Remove upper cover Remove engine hood according to removal and installation requirements and steps of engine hood hereinafter.

Tool: Open-end spanner #12, travelling crane

13. Remove the protection shield Remove protection shield according to removal and installation requirements and steps of shield hereinafter.

Tool: Open-end spanner 13#

4-85 4.10 Cooling system 4.10.3 Removal and installation of radiator

Diagram

Removal objects

14. Remove the radiator a. Install lifting eyes on lifting lugs on both sides of radiator, and screw them in at least by three turns. Splice and tighten the lifting tools to lifting eyes.

Tool

4-86 4.10 Cooling system 4.10.3 Removal and installation of radiator

Diagram

Removal objects

b. Unscrew the 4 mounting bolts 17 on the radiator. Slowly lift radiator onto special tool with traveling crane and lifting sling, and put away and collect shim.

Tool

Tool: Open-end spanner 24#

Installation of radiator Installation is in the reverse order of removal. Note: Make sure radial clearance between engine fan and shroud is not less than 10 mm in assembly. Tightening torque of radiator mounting bolts is 305±25 N.m.

4-87 4.10 Cooling system 4.10.3 Removal and installation of radiator

4.10.3.2 Removal and installation of radiator as Installation of radiator

4-88 4.10 Cooling system 4.10.3 Removal and installation of radiator

Part No.

Name

Quantity

Part No.

Name

Quantity

1

Radiator gp

1

17

Bolt

4

2

Shroud

1

18

Plate

1

3

Protection shield

2

19

Washer

8

4

Seal

2

20

Support

1

5

Washer

8

21

Support

1

6

Washer

8

22

Plate

1

7

Washer

8

23

Bolt

11

8

Nut

8

24

Nut

7

9

Bolt

8

25

Rubber plate

1

10

Plate

1

26

Auxiliary tank

1

11

Seal

2

27

Plate

1

12

Washer

37

28

Bolt

10

13

Washer

45

29

Seal

1

14

Bolt

24

30

Plate

1

15

Washer

4

31

Adjusting shim

4

16

Washer

4

Tool list Name

Specifications Open-end spanner 13#, 16# Remark: removed standard parts should be placed with relevant material together to avoid confusion.

4-89 4.10 Cooling system 4.10.3 Removal and installation of radiator

Removal of the radiator mounting Picture

Steps

Tool

1. Remove support 20, 21 Loosen 8 captive bolts 14 of left and right radiator supports, and remove supports.

Tool: Open-end spanner 16#

2. Remove auxiliary tank 26 Loosen 4 mounting bolts 14 of auxiliary tank, and remove auxiliary tank.

Tool: Open-end spanner 16#

4-90 4.10 Cooling system 4.10.3 Removal and installation of radiator

Picture

Steps

Tool

3. Remove protection shield 3 Unscrew the 8 mounting bolts 9 of the protective cover, and remove protection shield

Tool: Open-end spanner 13#

4. Remove shroud 2 Loosen 8 upper and lower captive bolts 14 of shroud, and remove shroud.

Tool: Open-end spanner 16#

4-91 4.10 Cooling system 4.10.3 Removal and installation of radiator

Picture

Steps

5. Remove the seal mounting board 22, 10, 18 and 30 Successively loosen captive bolts 14, 28 and 23 of upper, left, right and lower 4 plates on radiator, and remove seal mounting plate.

Assembly of the radiator mounting Installation is in the reverse order of removal.

Tool

Tool: Open-end spanner 16#

4-92 4.10 Cooling system 4.10.3 Removal and installation of radiator

4.10.3.3 Removal and installation of radiator gp Radiator gp

Part No.

Parts name

Quantity

Part No.

Parts name

Quantity

1

Water radiator

1

11

Washer

4

2

Sponge

2

12

Bolt

4

3

Air cooler

1

13

Connecting bracket

1

4

Sponge

2

14

Bracket-lh

1

5

Hydraulic oil cooler

1

15

Water drain valve

2

4-93 4.10 Cooling system 4.10.3 Removal and installation of radiator

6

2

16

Shock absorber cushion

16

1

17

Washer

6

8

Sponge Torque converter oil cooler Sponge

2

18

Washer

6

9

Bracket-rh

1

19

Bolt

6

10

Washer

4

20

Connecting bracket

1

7

Tool list Name

Specifications

Open-end spanner

16#, 18#

Screw driver Remark: removed standard parts should be placed with relevant material together to avoid confusion. Removal of the radiator mounting Picture

Steps

1. Disassemble the upper plate 20 Loosen and remove 6 captive bolts 19 of upper connecting plate, and remove upper connecting plate.

Tool

Tool: Open-end spanner 16#

4-94 4.10 Cooling system 4.10.3 Removal and installation of radiator

Picture

Steps

2. Unscrew the underneath plate 13 Loosen 4 captive bolts 12 (do not remove) of lower connecting plate, so that left and right supports 14, 9 can rotate around lower connecting plate by certain angle.

3. Remove water radiator 1, air cooler 3, hydraulic oil cooler 5 and torque converter oil cooler 7. Split left and right supports by certain angle with the aid of straight screw driver, successively take out water radiator, air cooler, hydraulic oil cooler and torque converter oil cooler, and collect sponge 2, 4, 6, 8 and shock absorber 16.

 CAUTION

Hold radiator gp by someone or use corresponding stabilizing equipment to prevent radiator components from tilting when above 1, 2 and 3 operations are carried out.

Tool

Tool: Open-end spanner 18#

Tool: screw driver

4-95 4.10 Cooling system 4.10.4 Refilling and replacement of coolant

4.10.4 Refilling and

Put a container with the capacity of about 35

replacement of coolant

L at rear left side of machine, connect one hose into water drain valve of drain hose,

1. Completely mix water and anti-freeze in

unscrew auxiliary tank cover, loosen water

advance according to selected cooling

drain valve so that coolant flows into the

proportion. (Cummins Engine Company

container, and tighten water drain valve after

suggests using mixed liquid of 50/50 purified

empting coolant.

soft water and completely proportioned anti-

6. Slowly open auxiliary tank cover (wait until

freeze or completely proportioned coolant to

engine coolant temperature drops to be

refill

Completely

below 50 ℃ ), slowly add coolant until coolant

proportioned anti-freeze or coolant must

level is within 1 cm higher than wellhead

conform to American Trucking Association

bottom,

Technical

minutes.

cooling

and

(TMCRP329

or

system.

Maintenance

Committee

TMCRP330

and

technical

specification). 2. Park machine on flat ground, apply parking brake and shut down engine. 3. Turn on the power switch (-); insert the key into the start switch and turn to 1st gear clockwise to power on the machine, pull the change-over

switch

of

air

conditioning

system to heating position. 4. Open engine hood, and turn water return valve to ON position (in ON position, valve handle is consistent with line route.

Wellhead bottom

5. (Only operate this step in replacing coolant.)

remain

stable

within

ten

4-96 4.10 Cooling system 4.10.4 Refilling and replacement of coolant

7. Tighten auxiliary tank cover, start engine, firstly operate it for 5 minutes at low idle speed, then operate it for 5 minutes at high idle

speed,

and

increase

coolant

temperature to be above 85 ℃ . 8. Check coolant level through inspection window once again, and after engine coolant temperature drops to be below 50 ℃ ), continue to refill coolant until level is within 1 cm higher than wellhead bottom. 9. Close the engine hood Notes: 1. Avoid only using the water for coolant 2. Do not refill coolant into hot engine to avoid possible damages to engine body. Wait until engine temperature is below 50 ℃ .

5 Power train system 5.1 Torque converter & transmission as ......................................................................... 5-3 5.1.1 Removal and installation of torque converter & transmission as............................. 5-4 5.1.2 Removal and installation of transmission as ......................................................... 5-14 5.1.3 Common faults and troubleshooting of torque converter & transmission as ......... 5-15

5.2 Drive axle system ........................................................................................................ 5-18 5.2.1 Removal and installation of front axle as............................................................... 5-19 5.2.2 Removal, installation and adjustment of the front axle main transmission as ....... 5-22 5.2.3 Removal, installation and adjustment of front and rear axle reducers................... 5-35 5.2.4 Removal and installation of rear axle as................................................................ 5-41 5.2.5 Removal and installation of swing frame ............................................................... 5-44 5.2.6 Removal, installation and adjustment of clamp ..................................................... 5-54

5.4 Tyre ................................................................................................................................. 5-60 5.5. Drive shaft .................................................................................................................... 5-63 5.5.1 Function of drive shaft ........................................................................................... 5-63 5.5.2 Removal and installation of drive shaft system ..................................................... 5-63

5-2

Major technical parameters of power train system listed in chart below: Table 1 Main technical parameters of power train system: System componen ts

Transmissi on

Items Model

ZF4WG200

Type

Fixed shaft type

Control mode

Semi-automatic control

Voltage of shift control system (V)

24

System pressure (MPa) of shift control valve Working pressure (MPa) of gear clutch

Torque converter

Drive axle

Tyre

1.6-1.8 Single-turbine and threecomponent

Effective diameter (mm)

340

Opening pressure (MPa) of safety valve Opening pressure (MPa) of back pressure valve

Remarks

1.6-1.8

Type

0.85 0.5

Transmission type

Spiral gear 1st reduction, wheel planetary gear reduction

Brake mode

Dry brake

Clamp operating pressure (Mpa)

12.3

Structure of tyre

Bias tyre with an inner tube

Specifications

23.5-25

level

16

Type of tread

L-3

Ordinary block

Front wheel

0.32-0.35

Rear wheel

0.29-0.32

Tire pressure (MPa) Rim

Parameters

Specifications

19.5-25

Tubeless and radial tires can be equipped

5-3 5.1 Torque converter & transmission as

5.1 Torque converter & transmission as For the composition and working principles of transmission & torque converter as, see Figures 5-1, 5-2, 53 and 5-4:

7

Figure 5-1 Front view of torque converter-transmission as

Figure 5-1 Front view of torque converter-transmission as

Figure 5-3 Rear view of Torque converter & transmission as

Figure 5-4 Torque converter & transmission as working principle

The transmission of this machine is a fixed shaft power shift transmission with 4 forward gears and 3 reverse gears. It is composed of 6 shift clutches, drive gears, shafts, bearings, a housing, a shift control valve, a shift control system, etc. Engine power is delivered to torque converter through input end, and converted power by torque converter is then delivered to transmission input shaft. Meanwhile, input shaft also drives oil pump, out of which some oil is used for heat exchange of torque converter, while other oil is used to control shift clutches for shifting through shift control valve. Transmission output shaft is respectively

5-4 5.1 Torque converter & transmission as 5.1.1 Removal and installation of torque converter & transmission as

coupled to front and rear drive axles and deliver power through drive shaft.

5.1.1 Removal and installation of torque converter & transmission as

Removal: 1. Unscrew transmission oil drain plug 1 with spanner, and drain oil; Open-end spanner: 21 Notes! Recycle the waste oil to avoid pollution to the environment

2. Remove coupling nuts 2 between transmission as and middle drive shaft as; Notes! Open-end spanner: 21 Two shaft yokes of drive shaft are coupled through sliding splines. Please avoid injuries due to spline dislocation!

5-5 5.1 Torque converter & transmission as 5.1.1 Removal and installation of torque converter & transmission as

3. Remove coupling bolts 3 and hard washers 4 between transmission Open-end spanner: 18 as and rear drive shaft as;

4.

Remove bolt 5 and washer 6 connecting filler pipe Open-end spanner: 13 and transmission; Notes! Block the oil port to avoid the transmission and the filler pipe from being contaminated.

5. Removal of the cab; 6. Remove the connecting hose assembly 7 and 8 of the transmission as; Open-end spanner: 41 Notes! Block the oil port to avoid the transmission and the hose assembly from being contaminated.

5-6 5.1 Torque converter & transmission as 5.1.1 Removal and installation of torque converter & transmission as

7.

Remove the connecting hose assembly 9 and 10 of Open-end spanner: 41 the transmission as; Notes! Block the oil port to avoid the transmission and the hose assembly from being contaminated.

8. Fix pull ring 14 on Lifting rig; transmission as with lifting equipment and Lifting rope; pre-lift transmission as;

5-7 5.1 Torque converter & transmission as 5.1.1 Removal and installation of torque converter & transmission as

9. Remove coupling bolts Open-end spanner: 46 11, washers 12 and Socket: 46 locknuts 13 between transmission mounting Blower gun bracket and frame;

10.Remove mounting hole Open-end spanner: 16 cover 15 on the transmission as;

5-8 5.1 Torque converter & transmission as 5.1.1 Removal and installation of torque converter & transmission as

11.Remove coupling bolts 16 and hard washers 17 between Open-end spanner: 16 transmission and engine flywheel housing;

12.Remove coupling bolts 18 and hard washers Open-end spanner: 16 19 between torque converter housing and engine housing;

5-9 5.1 Torque converter & transmission as 5.1.1 Removal and installation of torque converter & transmission as

13.Use lifting equipment and ropes to lift transmission & torque converter as through lifting ring 14 and place transmission & torque converter as into a safe area; Notes! As torque converter core and stator support are coupled in a non-fixed way, when lifting transmission & torque converter as, fix torque converter core and housing to avoid individual injuries due to torque converter pulling out during lifting.

Lifting rig Rope

Assembly: 1. Assemble the drain plug Open-end spanner: 21 and tighten it

5-10 5.1 Torque converter & transmission as 5.1.1 Removal and installation of torque converter & transmission as

2. Pass ropes through lifting ring on transmission as, and lift up transmission as with lifting equipment; Lifting rig; Rope; Notes! Make efforts to keep output shaft of transmission as parallel to the ground during lifting.

3. Move transmission as so that it fits with Lifting rig; engine flywheel Rope; housing, and tighten Open-end spanner: 16 bolts 16 and hard washers 17 after fitting.

5-11 5.1 Torque converter & transmission as 5.1.1 Removal and installation of torque converter & transmission as

4. Install and tighten coupling bolts 18 and hard washers 19 Open-end spanner: 16 between torque converter housing and engine housing;

5. Install the cover and tighten the fastening bolts

Open-end spanner; 16

5-12 5.1 Torque converter & transmission as 5.1.1 Removal and installation of torque converter & transmission as

6. Install and tighten coupling bolts 11, hard Open-end spanner: 41 washers 12 and Socket:41 locknuts 13 between mounting bracket of Blower gun; transmission as and frame;

7. Install the filler pipe and tighten fixing bolt 5 Open-end spanner: 13 and washer 6;

5-13 5.1 Torque converter & transmission as 5.1.1 Removal and installation of torque converter & transmission as

8. Align middle drive shaft and front output flange Open-end spanner; 18 of transmission, and install and tighten nuts 2;

9. Install and tighten fastening bolts 3 and hard washers 4 of rear Open-end spanner: 18 drive shaft as and rear output flange of transmission;

5-14 5.1 Torque converter & transmission as 5.1.2 Removal and installation of transmission as

10.Install the hose as 7 & 8;

Notes! Open-end spanner: 41 As oil filter has a flow direction, oil flows through oil filter from hose as 7, and flows back to transmission from hose as 8.

11.Install the hose as 9 & 10;

Notes! Hose as 10 is one from torque converter oil outlet to radiator inlet, and hose as 9 is for transmission oil return. Improper Open-end spanner: 41 installation will result in poor cooling performance of system. 12.Assemble cab and connect transmission wicking; 13.Refill the transmission oil as per the specified method and check the oil level;

5.1.2 Removal and installation of transmission as The transmission as of this machine is ZF4WG200 transmission. For removal and installation of transmission as, refer to “Assembly and Service Manual for ZFWG180 and WG200 Power Shift Transmission”.

5-15 5.1 Torque converter & transmission as 5.1.3 Common faults and troubleshooting of torque converter & transmission as

5.1.3 Common faults and troubleshooting of torque converter & transmission as Detection point layout of transmission & torque converter as is shown in Figure 5-5, and names and parameters of each detection point can be found in Table 2.

60

Figure 5-5 The layout of measuring point Parameter list of the measuring point in figure 2: Serial number of the measuri ng point 21 34 51 53 65 60

Name of the measuring point

Theoretical value

Serial number of the measurin g point

\

55

Input sensor of the transmission Output sensor of the transmission Inlet pressure of torque converter

\

58

Opening pressure: 0.85

56

Forward gear clutch

1.6-1.8MPa

57

1.6-1.8MPa

63

Shift control system pressure Clutch with forth position

Name of the measuring point Reverse gear clutch Clutch with third position Clutch with first position Clutch with second position Outlet pressure of torque converter

Theoretical value 1.6-1.8MPa 1.6-1.8MPa 1.6-1.8MPa 1.6-1.8MPa Opening pressure: 0.5

1.6-1.8MPa

Logical relations between gear states and working conditions of shift solenoid control valve can be found in Table 3:

5-16 5.1 Torque converter & transmission as 5.1.3 Common faults and troubleshooting of torque converter & transmission as

Table 3 Logical relations between gear states and working conditions of shift solenoid control valve: Electric condition of the solenoid valve Solenoid valve

Forward gear 1

2

3

Reverse gear 4

M1 M2

●

M3

●

●

M4

●

●

Neutral gear

1

2

3

●

●

●

●

1

2

3

4

●

● ●

●

●

●

●

M5 Clutch

KV

KV

KV

K4

KR

KR

KR

Clutch

K1

K2

K3

K3

K1

K2

K3

K3

Note: ●means the solenoid valve is with current; See chart 4 Common faults and troubleshooting: Chart 4 Common faults and troubleshooting:

Fault features

1

The engine can not start.

2

The shift pressure of all gears are low

3

Shifting time of all positions is too short.

Main reasons 1. Base machine start circuit (such as power voltage, electric lock, start relay and start motor) has faults. 2. The lever is not at the neutral position. 3. The fuse leading to the control circuit on the main machine was burn. 4. Poor contact of handle plug or failure of handle. 5. Poor contact of controller connector or controller failure 1. Oil temperature gauge failure. 2. The tightening torque for bolt of transmission control valve is insufficient 3. Spring of main pressure valve is broken 4. Wear of the gear shift pump 5. Fragments enter into shift control valve or valve pass 1. O-ring in throttle plug is damaged 2. The tightening torque of pressure control valve bolts is out of specified range

Troubleshooting

1.Check the base machine circuit. 2. Shift the handle to neutral position. 3. Replace the fuse. 4. Organize the plugs. 5. Organize the plugs.

1. Replace the oil pressure gauge 2. M8-8.8 bolt of shift control valve has tightening torque of 26 N·m. 3. Replace 4. Replace the gear shift pump 5. Replace filter, clean control valve 1. Replace the O-ring 2. M8-8.8 bolt of shift control valve has tightening torque of 26 N·m.

5-17 5.1 Torque converter & transmission as 5.1.3 Common faults and troubleshooting of torque converter & transmission as

4

Fault features Shifting time of all positions is too long.

Main reasons 1. Throttle plug 2.Pressure control valve block

5

The oil temperature of the torque converter is high

1. Oil temp sensor fault 2. The oil temperature gauge fails. Insufficient oil level 3. Insufficient oil level 4. Gas found in transmission oil cooler 5. Oil lines between torque converter and radiator is poor

6

The oil temperature of the torque converter is high

1. Lack of cooling capability of radiator 2. Counterbalance valve block of torque converter

No matter which position the gear is in, the vehicle is not moving.

1. Insufficient oil level 2. Elastic plate connecting engine and torque converter is torn, or power connection from torque converter to transmission input gear has faults. 3. Circuit failure of the vehicle 4. Shift pressure is too low 5. Solenoid valve is damaged 6. Shifting handle is damaged 7. Controller is damaged

7

Troubleshooting 1. Clean and dredge 2. Washing and checking 1. Replacement 2. Replacement 3. Check fuel level with sound approach 4. Exhaust 5. Check oil pipe from cooler to transmission and radiator for blockage. 1. Check whether cooling capability is sufficient, such as checking the degree of tightness for engine fan belt and dirt attached to outer surface of radiator. 2. Be careful to check hose connector from transmission to radiator. If hose connector enters housing too deeply, pushes spool of back pressure valve and cause valve to stick, oil line will be getting blocked. 1. Check oil level and oil following the right operation 2. Replace the elastic plate or replace the related damaged parts 3. Check the power pressure for being abnormal and the cable for damage. 4. Refer to the elimination methods above 5. Check the rated current of solenoid valve to make sure it is 830mA 6. Replace according to the process of eliminating handle failure. 7. Replace according to the process of eliminating controller failure.

5-18 5.2 Drive axle system 5.1.3 Common faults and troubleshooting of torque converter & transmission as

5.2 Drive axle system Structure composition diagram and drive sketch of drive axle are shown in Figures 5-6 and 5-7:

Reducer

Half shaft

Axle housing

Main drive

Figure 5-6 Structural drawing of drive axle Tyre

Clamp (service brake)

Ring gear

Planetary gear

Sun gear

Rim

Planetary carrier

Crown wheel

Bevel gear

Half shaft

Axle housing

Half shaft gear Driving spiral bevel gear

Figure 5-7 Transmission Diagram of Drive Axle Engine output power is converted by transmission, is input to drive axle through drive shaft, and is delivered to half shaft of drive axle after bevel gear of drive axle slows down further, increases torque and

5-19 5.2 Drive axle system 5.2.1 Removal and installation of front axle as

rotates drive shaft line by 90o. Power is input to drive axle reducer after being delivered by half shaft, is delivered to tire & rim as after further slowing down of differential and further increasing of toque, and drives machine to walk. The main function of drive axle differential is when machine makes a turn or is running on the uneven road, drive axle differential can roll sprockets-lh and sprockets-rh at different speeds to avoid tire slips which can accelerate tire wear and increase power consumption.

5.2.1 Removal and installation of front axle as

Removal: 1. Remove line connecting hose as 1 on brake system and front axle; Open-end spanner: 19 Notes! Recycle the waste oil to avoid pollution to the environment

5-20 5.2 Drive axle system 5.2.1 Removal and installation of front axle as

2. Remove coupling bolt 3 and hard washer 2 between front axle as and front drive shaft & bearing as;

Open-end spanner: 18

3. Prelift the front axle assembly with a lifting device and tighten it properly; 4. Remove coupling bolt 4, washer 6 and nut 6 between front axle as and frame; 5. Place the disassembled axle assembly in safe area.

Open-end spanner: 41 Socket:41 Blower gun Lifting rig

Assembly: 1. Use lifting equipment to lift axle as, align it with mounting hole of rear frame axle mounting support, and install and tighten bolt 4, hard washer 5 and locknut 6;

Open-end spanner: 41 Socket:41 Blower gun Lifting rig

5-21 5.2 Drive axle system 5.2.1 Removal and installation of front axle as

2. Install front drive shaft & bearing as, and tighten captive bolt 3 and locknut 2 of axle input flange;

Open-end spanner: 18

3. Install the connecting hose assembly of axle braking steel pipe and tighten it;

Open-end spanner: 19

5-22 5.2 Drive axle system 5.2.2 Removal, installation and adjustment of the front axle main transmission as

5.2.2 Removal, installation and adjustment of the front axle main transmission as 5.2.2.1 Disassembly of front axle main drive assembly

1. Place bevel gear on operation platform or ground in a steady way, and fix it on bracket with Tool: Sling bolts through the flange bolt hole 1 of carrier. Disassemble the thrust bolt 2

5-23 5.2 Drive axle system 5.2.2 Removal, installation and adjustment of the front axle main transmission as

2. Remove locking plate 1 of adjusting nuts-lh and rh, bearing support 2 and adjusting nut 3 (mark 2 with an Tool: Socket, assembly symbol before pneumatic impact removing it). spanner Check copper bush 5 of thrust bolt 4 for wear. If copper bush 5 has thickness of less than 16 mm, replace it.

3. Remove the differential as 1. 4. Remove fastening bolt 2 Tool: Socket, of differential housings- pneumatic impact lh and rh, and separate spanner differential housing-lh from right one.

5-24 5.2 Drive axle system 5.2.2 Removal, installation and adjustment of the front axle main transmission as

5. Take down spider 2, planetary bevel gear 3, half shaft gear 4, bevel gear gasket 5 and half shaft gear gasket 6, and check gear gaskets for cracks, cuts, dents, pitting and excessive wear. Replace them if necessary ； 6. Remove tapered roller Tool: Socket, bearing 7 of right and left differential housing pneumatic spanner, with a puller; Check the puller bearing for damage and replace it if necessary. 7. Remove bolt 9 fixing crown wheel on differential housing-rh 8, observe or mark assembly symbol in order to fit in original position during reassembly. Underneath crown wheel.

8. Unscrew the lock nut 1 Tool: Socket, to remove the input pneumatic impact flange 2. Take out the sealing cover 4 after the spanner bolt 3 is unscrewed out.

5-25 5.2 Drive axle system 5.2.2 Removal, installation and adjustment of the front axle main transmission as

Screw-in M10 bolt

Screw-in M10 bolt

9. Turn cover screw (M10) into screw hole of bearing bushing 5 to push up bevel pinion as (push up with copper bar from the other end when necessary). Support flange of bearing bushing 5, apply pressure to thread end of pinion 6 with a hold-down, and push it off bearing bushing 5.

Tool: Socket, pneumatic impact spanner and copper bar

10.Take down snap ring 7, and pull down tapered Tool: roller bearing 8 and cylindrical roller bearing Opening tong, puller 9 from bevel pinion with a puller.

Take out bearing cup 10 from bearing bushing 5 with copper rod; Check carrier and the hole of bearing bushing Tool: Copper bar for cracks, cuts, dents, and excessive wear. Replace them when necessary.

5-26 5.2 Drive axle system 5.2.2 Removal, installation and adjustment of the front axle main transmission as

5.2.2.3 Assembly of front axle main drive assembly a. Pinion as Assembly of pinion gp: install outer ring of bearing →install inner ring of bearing →install bearing →install bearing bushing gp →install bushing, etc. →detect rotating force of bearing

1. Install roller bearing cup 2 into bearing bushing 1 with copper bar through socket. Make sure installation reaches bottom of bearing bushing 1 without tilting. Tool: (Be careful of assembly directions of two outer Copper bar, rings of bearing: big-end holes of outer ring taper holes all face outward, and outer rings must be installed at bottom of bearing.)

2. Install cylindrical roller bearing 1 with above methods into a position close to small end of pinion Tool: 2; Install the snap ring 5; Socket, copper bar Install the bearing 3 with the big end close to the gear part of main spiral; Nest the spacer ring 4.

5-27 5.2 Drive axle system 5.2.2 Removal, installation and adjustment of the front axle main transmission as

3. Install bearing bushing 1, and press in cone 2 of tapered roller bearing outside.

Tool: Socket, copper bar

4. Adjustment: fix main spiral gp vertically, hook a hole on bearing bushing flange, and pull toward a horizontal direction steadily. When bearing bushing is rotated by pulling, its rotating force should be between 16.8 N and 29.7 N. Measure as Tool: shown in the figure. Spring balance, sleeve Notes: Replace the bushing for adjusting, if beyond the range. Adjusting method: When rotating force is too big, increase thickness of gasket or bushing; when rotating force is too small, reduce thickness of bushing. b).Differential assembly Assembly of differential gp: install housing-rh →install half shaft gear gasket and half shaft gear →install spider, bevel gear and bevel gear gasket →install half shaft gear and close housing-lh →install bolts in a symmetrically tightened way.

5-28 5.2 Drive axle system 5.2.2 Removal, installation and adjustment of the front axle main transmission as

1. Fasten crown wheel 1 to differential housing-rh 2 with new bolt & nut gp 3 to torque of 98-118 N·m.

2. Assemble half shaft gear gasket 1, half shaft gear 2 and glued bolt 3.

Tool: Socket, pneumatic impact spanner and torque spanner.

5-29 5.2 Drive axle system 5.2.2 Removal, installation and adjustment of the front axle main transmission as

3. Install planetary bevel gear 1 and gasket 2 on spider 3, and then place spider 3 into differential housing.

4. Fold differential housing edges according to original assembly symbol 2, and symmetrically install bolt & nut gp 1 to torque of 98-118 N·m. Rotate the half shaft gear with the inspection tool 3 for gear rotation,

Tool: Bushing, copper rod, inspection tooling, torque spanner.

Notes: This spot should be flexible without blocking.

5. Install cone of tapered roller bearing 1 into journal of differential housing with soft metal socket. Make sure installation reaches bottom without tilting.

Tool: Socket, copper bar and torque spanner

5-30 5.2 Drive axle system 5.2.2 Removal, installation and adjustment of the front axle main transmission as

c.Bevel Gear Assembly of drive axle insert as: install hanging bracket & carrier as → install pinion gp and cap gp →install differential gp →adjust contact pattern, backlash, etc. 1. Apply a cycle of continually closed flat sealant to the small end face of the support. Apply sealant around two oil holes 1 for one round according to above method, and place gaskets in position.

Notes: Keep coherent when applying sealant in order to ensure the sealing effect, and make sure sealant will not enter oil holes.

2. Install the well assembled drive spiral tapered roller bearing subassembly into support 2.

Notes: Align the oil hole 1 of bearing sleeve with the oil hole passage of carrier.

5-31 5.2 Drive axle system 5.2.2 Removal, installation and adjustment of the front axle main transmission as

3. Align sealing gasket 1 with hole to place sealing gasket 1 in position, and align cap gp 2 with locating step of bearing bushing to place cap gp 2 inside; Knock it in position with soft metal and screw the bolt subassembly 3.

Tool: Socket, copper bar and pneumatic impact spanner

4. Install flange 1, O-ring 2 and locknut 3 successively; Tighten locknut to the torque of 600-700 N·m, and knock shaft end of pinion with soft metal to relieve its stress, return bearing back to its original position, and make gear turn flexibly. Apply grease (yellow) when installing O-ring, and press O-ring into seal groove; Nylon nut must be screwed in 2-3.

Tool: Socket, pneumatic impact spanner

5. Turn over carrier, select matched crown wheel and Tool: differential gp 1 according to Sling pinion number, and lift them in position.

5-32 5.2 Drive axle system 5.2.2 Removal, installation and adjustment of the front axle main transmission as

6. Install roller bearing 1 cup, and make sure both inner and outer rings of bearing are produced by the same manufacturer. Screw adjusting nut 2 into bearing Tool: Socket, support, hard washer and monkey spanner bolt 3 then. Bearing supports at both sides cannot be exchanged for installation; Pre-tighten bolt, and rotate it back by 2 to 3 turns to adjust backlash. 7.

Adjustment method: (1) contact of dial indicator 1 must be perpendicularly pressed against edge face of big end of major spiral to check the maximum shaking amount of major spiral when main spiral is fixed; (2) Repeat 1 to check at trisection position of circumstance of major spiral. If it is not qualified, slightly adjust Tool: axial position of nut according to Dial indicator gap, and repeat the above steps; Backlash between major and minor spirals: 0.25-0.45 mm, backlash variation amount: ≤0.15 mm. (3) Evenly apply thin red lead to three positions on major spiral (3 teeth respectively), and reciprocate. Check contact spot according to marked control requirements. If it is unsatisfactory, adjust it through shim and adjusting nut. When contact circumstance exceeds normal circumstance, replace bevel gear pair or carrier as. There is no noise when rotating.

5-33 5.2 Drive axle system 5.2.2 Removal, installation and adjustment of the front axle main transmission as

8. Inspect the back run out value after the big spiral rotates a cycle with percent table 1. Requirements: