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Lonking LG50HCG Repair Manual

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LG50HCGⅧ.00Ⅰ
Wheel loader
Repair Manual
:
Code
68000009355
1

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Summary of Contents for Lonking LG50HCG

  • Page 1 LG50HCGⅧ.00Ⅰ Wheel loader Repair Manual Code 68000009355...
  • Page 2 Foreword Thank you for selecting the high-performance Lonking loader! The LG50HC Wheel Loader Repair Manual has been prepared to provide the dealers and service stations of Lonking with a better understanding of the Lonking LG50HC (China IV) wheel loaders. This Manual focuses on structure and function, testing and adjustment, installation and removal, dismantling and repair, and troubleshooting, and hopefully covers the basics needed for the repair service.
  • Page 3 Contents I. Safety Precautions ......................... 5 II. Pictures and Parameters of the Machine..................7 III. Maintenance Schedule of Whole Machine .................. 9 IV. Data Sheet ..........................10 V. Main Components ........................15 5.1 A/C System ........................16 5.1.1 Main Composition and Parameters ................ 16 5.1.2 Principle and Schematic Diagram of Cooling and Heating........
  • Page 4 5.7.3 Disassembly and Repair ..................68 5.7.4 Faults and Troubleshooting ..................81 5.8 Torque Converter ......................83 5.8.1 Structure and Function ................... 83 5.8.2 Test and Adjustment ....................85 5.8.3 Removal and Installation ..................85 5.8.4 Disassembly and Repair ..................85 5.9 Transmission ........................
  • Page 5 I. Safety Precautions (I) Safety Precautions before Repair/Maintenance Safety Precautions during Repair/Maintenance 1. Repair/maintenance shall be carried out on a level and solid ground or a specialized site, away from working 1. Set up a repair sign during repair/maintenance of the machines and personnel;...
  • Page 6 14. When disassemble the engine and torque converter & 6. Adjust the indication direction of rearview mirror to transmission assembly, the core components of the torque be correct; converter may fall off and hurt people, so protective 7. Check the original safety signs on the machine and if measures shall be taken;...
  • Page 7 II. Pictures and Parameters of the Machine Fig. 2-01-01 Overall dimensions: Code Dimension Description 8650 mm Length of whole machine Wheel base 3300 mm Minimum ground clearance 398mm Maximum total height of main 3400mm engine Height of pin shaft at 4520mm maximum lifting Unloading height...
  • Page 8 Standard specification Item Specification Performance Bucket capacity 3.0 m Performance Rated load 5000kg Performance ≤5.6s Lift arm lifting time Performance ≤10.5s Sum of three items Performance Maximum speed of Forward gear I 11km/h each gear Performance Maximum speed of Reverse gear I 14km/h each gear Performance...
  • Page 9 III. Maintenance Schedule of Whole Machine Maintenance Schedule of Loader Maintenance Cycle Maintenance Parts Maintenance Contents Specification and Model Quantity Replacement Period Remarks 50H 100H 250H 500H 1000H 1500H 2000H Engine oil CK-4 15W/40 (ordinary) CK-4 5W/40 (low Engine temperature) First 50h, every 250h Note the brand of oil used in winter and summer Oil filter element...
  • Page 10 IV. Data Sheet 1. Tightening torque of ordinary bolts Bolt Nominal diameter of bolt (mm) Yield strength grade strength Tightening torque (N.m) (N/mm) 10~12 20~25 36~45 55~70 90~110 120~150 170~210 12~15 25~32 45~55 70~90 110~140 150~190 210~270 17~23 33~45 58~78 93~124 145~193 199~264...
  • Page 11 2. Recommended grades, prescribed amounts and filling amounts (in international grades and units of measurement) of engine oil, transmission oil, hydraulic oil, drive axle oil, pin grease, diesel, antifreeze for the smaller temperature ranges within the general range of -30 to +50° C Ambient temperature acity type...
  • Page 12 3. Comparison of domestic and foreign oil products Oil Product Name China Models International Models General CK-4 15W/40 China IV CK-4 15W-40 Diesel engine oil Engine oil Low temperature CK-4 5W/40 or CK-4 OW/40 CK-4 5W-40 Diesel engine oil China IV Engine oil General 0# Diesel oil...
  • Page 13 5. Definition of VDO instrument pins [Connector-Pins assignment] Functional Description Blue Connector： Define Remark Glow Input Digital Input 1 Neutral Gear Input Digital Input 2 Chassis Ground KL31 Sensor Ground All Analogue Inputs Negative Pole Back To Oil Filter Warning Input Digital Input 3 Back To Oil Filter Warning Input Transmission Oil Temperature Input...
  • Page 14 Low engine coolant level Fuel Level Input PR [AI 1-Fuel Level Input] Turning Right Input Digital Input 10 Water Temperature Sensor Input PR [AI 2-Engine Coolant Temperature Input] Turning Left Input Digital Input 11 High Beam Input Digital Input 12 Engine operating condition Digital Input 13 Speed Signal Input...
  • Page 15 V. Main Components Section 1 A/C System Contents 5.1.1 Main Composition and Parameters 5.1.2 Principle and Schematic Diagram of Cooling and Heating 5.1.3 Electrical Schematic Diagram 5.1.4 Installation Guidelines and Precautions 5.1.5 Maintenance Guidelines and Precautions 5.1.6 Analysis and Troubleshooting of Common Faults 5.1.7 Fault Detection Method...
  • Page 16 5.1 A/C System 5.1.1 Main Composition and Parameters Main components of A/C: The A/C is mainly composed of condensing unit, air vent, switch panel, evaporation unit, compressor and refrigeration pipeline. The following is a schematic diagram of the main components of the A/C on the loader.
  • Page 17 5.1.2 Principle and Schematic Diagram of Cooling and Heating 1. Overview of refrigeration principle ① Compression process (compressor): The compressor operates to suck low-temperature and low-pressure gaseous refrigerant in the evaporator, compress it into high-temperature and high-pressure gaseous refrigerant and discharge ②...
  • Page 18 2. Overview of heating principle The heating system of the A/C is water-heating type, using engine coolant as heat source. This system has a simple structure and is environmentally friendly and economical. The coolant generated by the engine enters the heater core through the warm water pipe.
  • Page 19 5.1.3 Electrical Schematic Diagram of A/C Fig. 5-01-04...
  • Page 20 5.1.4 Installation Guidelines and Precautions (I) Filling amount of compressor oil A certain amount of oil shall be injected into the A/C system for lubrication. The compressor oil is dissolved in the refrigerant and circulates throughout the system. When the A/C system is turned off, the compressor oil will stay in various components of the system.
  • Page 21 Precautions for test run of compressor 1. The test run shall be carried out when the engine is idling (at a speed of 750 rpm), and the A/C shall run for more than 10 min; 2. During the test run, it is absolutely forbidden to increase the speed halfway;...
  • Page 22 (IV) Precautions for pipeline connection (V) Use of antifreeze 1. The dust cover on the pipe joint must be removed The heating principle of the A/C system is that the during installation to prevent moisture and other engine coolant goes through the pipeline and the heater impurities from entering;...
  • Page 23 (VI) Vacuumizing There shall be no moisture inside the A/C unit. The refrigerant used in the A/C is easily soluble in water. If a very small amount of moisture remains in the unit, it will cause faults such as icing of expansion valve hole and rusting of compressor valve during use.
  • Page 24 Refrigerant Filling (VII) Refrigerant filling Charge refrigerant from the low-pressure side: Note: Refrigerant must be filled by personnel with The low-pressure side of the refrigeration system can be specialized training. charged with gaseous refrigerant by means of a manual 1. Filling method and amount of refrigerant: low-pressure valve on the manifold pressure gauge as follows: Confirm the type of refrigerant to be filled: R134a...
  • Page 25 Check the A/C duct for leakage Preparation for inspection: 1. Start the engine 2. Open all doors, turn the A/C switch to "ON", the blower switch to "MAX" and the temperature control switch to "COOL". 3. Keep the compressor speed at 1800rpm. Check the refrigerant charge with naked eyes according to the refrigerant flow rate through the observation window.
  • Page 26 (II) Maintenance cycle of A/C Maintenance cycle Item Contents Weekly Monthly Quarterly √ Whether the blower operates abnormally Evaporation unit √ Whether the core surface is dirty and blocked √ Whether the drainage is smooth √ Whether the fastening bolts are loose Compressor √...
  • Page 27 system, and the compressor can not work (when the low pressure in the system is below 1 kg, or the high pressure is above 21 kg, the A/C pressure switch does not conduct, and the compressor stops working). Do not start the machine when checking the system pressure.
  • Page 28 watch/touch/listen Clutch does not engage/lines failures Start the A/C, and there is Test it with a pressure gauge Handle or replace no change in system and observe the pressure; the faulty parts pressure watch/listen Broken or no belt Compressor does not compress or seizes due to internal damage Loose connectors...
  • Page 29 The heater water The heater hose is hot and hot Touch the heater Close the water valve or replace valve is not closed air blows out of the air outlet water pipe by hand, or leaks or feel the air outlet temperature;...
  • Page 30 Loose belt Harsh noise is heard and the Watch/listen Adjust the belt rotating speed of the compressor does not rise The expansion valve The system does not cool Test it with a Replace the expansion valve is blocked down after working for a pressure gauge and and drying bottle, vacuumize it period of time, with low...
  • Page 31 5.1.7 Fault Detection Method Manifold pressure gauge method After the engine is warmed up, read the pressure value of manifold pressure gauge under the following specific conditions. The temperature at the air inlet is 30~35 ° C. The engine speed is 1800 rpm (reference). Set the fan speed to the high position and the temperature control to the coldest position.
  • Page 32 3. Poor circulation of refrigerant Condition: Insufficient refrigeration Symptoms Cause Diagnosis Troublesh analysis ooting refrigerati on system Pressure is Dirt in the Replace low at both reservoir reservoir is the high- hinders blocked. reservoir. refrigerant low-pressur flow. e sides. The pipes from the component to the...
  • Page 33 Excessive refrigerant charging insufficient condensation Condition: insufficient refrigeration Symptoms Cause Diagnosis Troublesh analysis ooting refrigerati on system Pressure is Refrigeran Excessive Clean the too high at t is refrigerant condenser the high- excessive in the and check in the system: low-pressur system, excessive...
  • Page 34 V. Main Components Section 2 Pilot Valve Contents 5.2.1 Schematic Diagram of Pilot Valve 5.2.2 Introduction to Working Principle 5.2.3 Fault and Troubleshooting 5.2.4 Precautions for Installation and Use...
  • Page 35 5.2 Pilot Valve CRV Pilot Valve Parts Brochure and Exploded View Diagrams Figure No. Description Qty. DXS-01y-00a Handle assembly GB/T6170-2000 Nut M12 CRV-12 Dust cover CRV-11 Thick nut CRV-09 Pad disc GB/T6170-2000 Nut M6 XDF3-28 Gasket CRV-08 Ejector rod head assembly XDF3-20 Gasket CRV-10...
  • Page 36 XDF3-13 Shaft sleeve CRV-06y1 Mounting plate Fig. 5-02-01 Fig. 5-02-01...
  • Page 37 Technical parameters Maximum pressure: 5MPa Nominal flow: 10L/min Oil return back pressure: MAX≤0.3 MPa Electromagnet resistance: 117±10 Ω Working voltage of electromagnet: DC24 V Rated attraction force of electromagnet: 320± 20 N Working current of electromagnet: 0.19-0.23 A Operating temperature of electromagnet: -40 - 121 ° C Control pressure range: tilt joint: 0.5-1.9 MPa Lift arm joint: 0.5-1.9 MPa 5.2.1 Schematic Diagram of Pilot Valve...
  • Page 38 When the control lever is pulled, it pushes the contact to move downward, so that the pressure regulating spring pushes the valve element to move downward to cut off the passage between the control chamber and the oil return chamber, and connect the oil inlet chamber with the control oil chamber. In this way, the pilot pressure oil can be output to the multi-way valve control port, and pushes the multi-way valve stem to move, thus realizing direction switching action.
  • Page 39 hydraulic oil, and replace the dust cover. The electromagnet is damaged Replace the electromagnet Floating function The valve element is stuck Clean the parts failure Spring deformation Replace the spring External leakage O-ring is damaged Replace the seal Oil leakage of dynamic seal Replace the dynamic seal sleeve assembly List of Wearing Parts...
  • Page 40 ③ Loosen the M6 bolts with an S5 Allen wrench, and remove the mounting plate, cover plate, electromagnet, etc. ④ Loosen the M5 bolts with an S4 Allen wrench and remove the transition block. ⑤ Replace the copper sleeve assembly. Replace the valve element ①...
  • Page 41 ③ Loosen the M6 bolts with an S5 Allen wrench, and remove the mounting plate, cover plate, electromagnet, etc. ④ Loosen the M5 bolts with an S4 Allen wrench and remove the transition block. ⑤ Take out the copper sleeve, spring and valve element assembly and clean them as well as the valve body, and then reinstall the parts into the valve Replace the ejector rod assembly...
  • Page 42 ③ Replace the ejector rod assembly. Replace the handle ① Disengage the upper end of the dust cover from the handle positioning groove, and remove the handle with S18 and S24 open-end wrenches. ② Install the new handle into the pilot valve and tighten it with S18 and S24 open-end wrenches.
  • Page 43 ③ In the dust cover, install the new handle into the pilot valve, and tighten the handle with S18 and S24 open-end wrenches; finally, clamp the upper and lower ends of the dust cover into the cover plate and the handle positioning groove respectively.
  • Page 44 V. Main Components Section 3 Multi-way Valve Contents 5.3.1 Structural Diagram 5.3.2 Schematic Diagram 5.3.3 Introduction to Working Principle 5.3.4 Installation and Use 5.3.5 Fault and Troubleshooting...
  • Page 45 5.3 Multi-way Valve Technical parameters Oil makeup nominal diameter: 25 mm; Nominal pressure: 25 MPa, nominal diameter: 32 mm; Oil makeup opening pressure: ≤0.3 bar; Nominal flow: 250L/min; Maximum set pressure of overload valve: 31.5 MPa; 5.3.1 Structural Diagram Fig. 5-03-01 Parts Catalog 1: Main overflow valve (assembly) 9: Lift arm makeup valve (assembly)
  • Page 46 5.3.2 Schematic Diagram Pressure measuri ng port Fig. 5-03-02 Parts Catalog P: Oil outlet connected to oil pump B2: To small cavity of lift arm cylinder A1: To large cavity of tilt cylinder T: To oil return tank B1: To small cavity of tilt cylinder a1, b1: Tilt pilot control oil port A2: To large cavity of lift arm cylinder a2, b2: Lift arm pilot control oil port...
  • Page 47 (II) The lift arm reversing valve is a 5.3.3 Introduction to Working Principle four-position six-way valve, which can control the lifting, closing, lowering and floating of the In the multi-way valve, port P is the oil inlet, T is the oil return port, ports A1 and B1 are connected with the large lift arm.
  • Page 48 5.3.5 Fault and Troubleshooting Remark Fault Cause Solutions The high-pressure overload Remove and clean or replace the Automatic tipping, valve element is jammed high-pressure overload valve falling or weak Excessive leakage in the tilt Consult the cylinder manufacturer for retracting of bucket cylinder details The low-pressure overload...
  • Page 49 Outline schematic diagram Fig. 5-03-03...
  • Page 50 V. Main Components Section 4 Booster Pump Contents 5.4.1 Purpose 5.4.2 Working Principle 5.4.3 Fault Diagnosis...
  • Page 51 5.4 Booster Pump 5.4.1 Purpose The air booster pump is suitable for the air-over-hydraulic brake systems of the engineering machinery loader, bulldozer, excavator and heavy-duty vehicle to convert the low pressure from the air brake valve into the high hydraulic pressure required by the brake. 5.4.2 Working Principle 1.
  • Page 52 List of Wearing Parts Description Figure No. Qty. Air piston rubber ring SL409-35100023C O-ring SG509-3510011 Hydraulic rubber ring SL409-3510052MF Y-ring SL409XG-3510024A O-ring ZL20A-3510034 Dust ring SL409XG-3510026A Precautions for maintenance Main technical parameters ① The brake fluid used shall conform to national Rated working air pressure: Pressure ratio: 1 : standards and shall not be adulterated.
  • Page 53 5. If the ratio of pressure value between hydraulic gauge 5.4.3 Fault Diagnosis and barometer reaches 90% of pressurization ratio, it indicates that the performance of booster is normal. 1. Use a special oil pressure and air pressure gauge to measure the air pressure and oil pressure at both ends of 6.
  • Page 54 the joint 2. The O-ring is damaged assembly to 25+5 N· m between 2. Replace the O-ring hydraulic cylinder block and connecting cover Oil leakage at O-ring is deformed or damaged Replace the O-ring the joint between oil cup and hydraulic cylinder block Oil spreading of 1.
  • Page 55 V. Main Components Section V Air Brake Valve Contents 5.5.1 Working Principle 5.5.2 Purpose 5.5.3 Analysis and Troubleshooting of Non-braking Air Leakage 5.5.4 Analysis and Troubleshooting of Full Brake Air Leakage 5.5.5 Analysis and Troubleshooting of Jamming...
  • Page 56 5.5 Air Brake Valve 5.5.1 Working Principle When the driver depresses the brake pedal, a certain pressure is applied to the balance spring through the ejector rod, so as to push the piston to move downward to open the air intake valve. Compressed air is then output from the air inlet to the air outlet.
  • Page 57 Main technical parameters When it is suspected that there is air leakage in a Rated working air 784kPa non-braking state, there is no need to remove the air pressure Working medium brake valve. When about 800kPa of air pressure is charged into the air inlet, immerse the exhaust port Operating temperature -30～+80℃...
  • Page 58 5.5.3 Analysis and Troubleshooting of Non-braking Air Leakage ① Unscrew the dust cover assembly ② Remove the retainer ring with retainer pliers ③ Remove the parts at the non-braking end, clean the interior of the valve body and its components, and replace the wearing parts.
  • Page 59 Failure mode of non-braking air leakage of air brake valve (III) Repair method: Adjust the M6 bolt at the bottom of the pedal with a solid wrench 8-10 to ensure that the roller is in contact with the ejector rod and can be rotated by hand, and then lock the nut.
  • Page 60 5.5.4 Analysis and Troubleshooting of Full Brake Air Leakage ① Remove the three M8 bolts with a pneumatic impact wrench. ② Remove the parts at the full braking end, clean the interior of the valve body and its components, and replace the wearing parts.
  • Page 61 5.5.5 Analysis and Troubleshooting of Jamming 1. When the air brake valve is jammed, if the pedal cannot return automatically or cannot be depressed with foot, it indicates that the piston is jammed. 2. When the air brake valve charge air to the air inlet in a non-braking state, if the air is quickly discharged from the exhaust port, it indicates that the lower valve is jammed.
  • Page 62 V. Main Components Section VI Unloading Valve Contents 5.6.1 Purpose 5.6.2 Working Principle 5.6.3 Correct Use and Maintenance Methods 5.6.4 Common Faults, Fault Analysis and Troubleshooting Methods...
  • Page 63 5.6 Unloading Valve 5.6.1 Purpose Wearing parts The unloading valve is suitable for the brake system of engineering vehicles and automobiles, which is used to Description Figure No. Qty. automatically adjust the working pressure in the brake system and can automatically discharge the filtered oil, Check valve SLKJ-3512019 water and other impurities through unloading.
  • Page 64 5.6.4 Common Faults, Fault Analysis and Troubleshooting Methods Common faults Fault analysis Troubleshooting method O-ring on the exhaust valve stem is Replace the O-ring on the Air leakage at the exhaust damaged exhaust valve stem port Exhaust valve is damaged Replace the exhaust valve Iron filings on the exhaust valve Clean the pipeline...
  • Page 65 V. Main Components Section VII Drive Axle Contents 5.7.1 Structure and Function 5.7.2 Removal and Repair 5.7.3 Disassembly and Repair 5.7.4 Faults and Troubleshooting...
  • Page 66 5.7 Drive Axle (III) Structure and principle of wheel reducer: 5.7.1 Structure and Function Fig. 5-07-02 The wheel reducer is mainly composed of sun gear, planetary gear, planetary gear bracket and ring gear. Planetary transmission principle of wheel reducer assembly: The axle shaft drives the sun gear integrated with spline to rotate at the speed and direction of the sun gear, while the planetary gear meshed with the sun gear Fig.
  • Page 67 with the front and rear drive axles; connect the tee joint Tools used: steel pipe assembly on the axle; connect the flange surface of the axle with the drive shaft; finally, install the 1. Two 10t traveling 7. Sleeve 46 tire on the drive axle.
  • Page 68 5.7.3 Disassembly and Repair (I) Disassembly of drive axle 1. Disassembly of wheel reducer assembly ① Place the drive axle horizontally on the tooling rack, rotate the gear brackets on both sides to make the two wheel-hub screw plugs at the lowest point of the circumference, and place two oil collecting devices right below the wheel-hub screw plugs.
  • Page 69 ⑦ Remove the ring gear. ⑧ Unscrew the 8 fixing bolts M20× 1.5× 56 of brake caliper with a wrench, and remove 4× 20 spring washers. Remove the brake caliper carefully. ⑨ Remove the inner ring of bearing 32221. ⑩ Hook the bolt hole of the wheel housing with a lifting appliance and slowly remove the wheel housing assembly.
  • Page 70 ② Remove the two cotter pins from the key-bolt with needle-nose pliers, then remove the key-bolt, and finally remove the two brake pads and put them aside. ③ Unscrew the deflating valves on the two inner calipers with a wrench, and then take out the two Φ9 steel balls in the deflating valve holes and put them aside.
  • Page 71 (II)Repair of drive axle Before assembling, all disassembled components shall be cleaned; worn or damaged parts, especially sealing parts, shall be replaced; for the positions sealed with sealant, such as the joint between axle housing and bracket flange surface, the sealant shall be scraped clean. 1.Repair of planetary gear bracket assembly ①...
  • Page 72 ② Install the oil seal assembly into the wheel housing with 6 bolts M8× 16 and washers. ③ Install the oil seal assembly into the wheel housing with 6 bolts M8× 16 and washers. ④ Assemble the brake disc onto the wheel housing assembly with 20 bolts M20×...
  • Page 73 ③ Press the double combined oil seal 62× 93× 20.5 into the sealing cover with an oil press, and assemble the paper pad and sealing cover assembly onto the driving spiral bevel gear assembly. ④ Assemble the input flange welded part, washer and lock nut to the driving gear assembly.
  • Page 74 ⑧ Assemble the bevel gear and bevel gear gasket onto the cross shaft in turn. ⑨ Place the assembled cross shaft on the right housing of the differential, and assemble the left and right housings in pairs. ⑩ Tighten it with the 8 differential bolts M14× 1.5× 139 and nuts M14×...
  • Page 75 ⑭ Cover the bearing cap, and adjust the meshing clearance and bearing play of driving and driven spiral bevel gears with adjusting nuts. The adjustment requirement is 0.2 ~ 0.35, and the clearance between two 32215 bearings shall be 0.08 ~ 0.012. After adjusting the clearance, tighten 4 bolts M22×...
  • Page 76 ② Install the 32221 bearing inner ring. During installation, apply a layer of grease to the 32221 bearing outer ring to ensure lubrication of the bearing. ③ Sleeve the ring gear into the support shaft first, and then install the round nut. When adjusting the wheel hub pre-tightening force, tighten the round nut until the wheel hub assembly can only be barely rotated, and then rotate the round nut for 1/10 turn.
  • Page 77 ⑦ Install the assembled brake assembly. The brake assembly and the brake caliper bracket are connected with 8 bolts M20× 1.5× 56 to a tightening torque of 370 ~ 450 N· m. ⑧ Check whether there is any foreign matter in the inner chamber of the axle housing.
  • Page 78 ① Install the rectangular seal ring into the sealing groove below the caliper body inner hole, and install the dust cover into the groove above the caliper body inner hole. ② Evenly apply silicone grease to the dust cover and inner holes of rectangular seal ring for a full circle, so as to ensure that there is silicone grease on the surfaces of dust cover and rectangular seal ring.
  • Page 79 ⑥ Put the two friction discs on the brake caliper assembly with the friction surface facing inward. Insert two bolt pins φ10×125 and lock them with two pins 3.2×26. 6. Air test, air pressure 0.2~0.3 Mpa Air pressure: 0.2~0.3 Mpa; tighten the screw plug after injecting gear oil, and apply 567 pipe thread sealant onto the screw plug.
  • Page 80 Attachment: Tools, equipment and supplies for disassembly and repair of drive axle 1. Drive axle assembly placement rack 14. Wheel-hub bearing press-fitting tooling 2. Pneumatic wrench 15. Oil press 3. Iron rod (with a diameter slightly smaller than the 16. Copper rod (with a diameter of 40~50mm and length screw hole of planetary gear bracket and a length about of about 300 mm) 300 mm)
  • Page 81 5.7.4 Faults and Troubleshooting (I) Insufficient driving force (III) Abnormal noise from main drive Fault characteristics: The loader has normal pressure Fault characteristics: The noise is more obvious when response in all gears, with sudden weakness during the machine runs in a straight line at high speed during operation, but it runs normally on the road.
  • Page 82 V. Main Components Section VIII Torque Converter Contents 5.8.1 Structure and Function 5.8.2 Test and Adjustment 5.8.3 Removal and Installation 5.8.4 Disassembly and Repair...
  • Page 83 5.8 Torque Converter 5.8.1 Structure and Function The torque converter is connected with the diesel engine. It can automatically adjust the output torque and speed, so that the loader can automatically change its speed and traction according to road conditions and resistance to adapt to changing working conditions.
  • Page 84 The torque converter is mainly composed of four working The torque converter impeller and cover pulley are impellers: impeller, first-stage turbine, second-stage integrated with the diesel engine flywheel through turbine and guide wheel. Its working chamber is filled with elastic plates, and run at the same speed as the diesel working oil.
  • Page 85 Torque converter pressure measuring port: Fig. 5-08-03 5.8.2 Test and Adjustment The torque converter and the transmission are installed on the machine as a whole, so the "Testing and Adjustment" of the torque converter after installation is incorporated into the "Testing and Adjustment" section for the transmission.
  • Page 86 Disassembly of torque converter (I) Disassembly of torque converter assembly ① Remove the six fastening bolts from the housing with a wrench, and remove the gasket and elastic plate. ② Remove the connecting bolts and nuts between the cover pulley and the pump pulley with a wrench. ③...
  • Page 87 ⑦ Erect the housing, remove the fixing screws of the guide wheel base, and take out the guide wheel base from the housing. ⑧ Remove the rotating oil seal on the guide wheel base and check whether the oil seal is damaged. Replace the oil seal if it is damaged or worn.
  • Page 88 ④ Use a hammer and a special iron rod to knock out the 8 elastic pins connecting the first-stage turbine with the turbine cover, and take out the first-stage turbine. ⑤ Remove the second-stage turbine with a thin iron rod. ⑥...
  • Page 89 ② Tap the pump pulley gently with a hammer to remove the transfer gear and bearing. ③ Gently knock out the bearings in the pump pulley and transfer gear with a copper rod. Repair of torque converter (I) Cleaning of parts Clean all parts of the torque converter with a brush in cleaning fluid.
  • Page 90 ③ Install the first-stage turbine. ④ Align the first-stage turbine with the pin hole on the turbine cover, and then hammer in 8 elastic pins. ⑤ Check the rotation of the second-stage turbine. ⑦ Assemble the cover pulley and first-stage turbine assembly and second-stage turbine assembly: Install the O-ring into the groove on the end face of the cover pulley.
  • Page 91 (III) Assembly of torque converter assembly ① Install the oil inlet and outlet valve, and control it between 0.45 MPa and 0.8 MPa. ② Check the quality of rotating oil seal, and pay special attention to whether the interface is firm. Install the rotating oil seal on the guide wheel base and check whether it is flexible.
  • Page 92 ⑥ Install the pump pulley, gasket and locking gasket. Tighten the hexagon bolt with a wrench and put away the locking gasket wrap angle. ⑦ Install the guide wheel, and then install the check ring to fix it ⑧ Turn over the cover pulley by 180° , install two lifting bolts into the screw holes of the cover pulley, hold the lifting bolts with hands to install the cover pulley and first-stage turbine assembly and second-stage turbine...
  • Page 93 V. Main Components Section IX Transmission Contents 5.9.1 Structure and Function 5.9.2 Test and Adjustment 5.9.3 Removal and Installation 5.9.4 Disassembly and Repair 5.9.5 Faults and Troubleshooting...
  • Page 94 5.9 Transmission 5.9.1 Structure and Function The transmission is composed of main parts such as box body, overrunning clutch, planetary transmission mechanism, friction disc clutch, cylinder piston, transmission pump, transmission operating valve, oil filter, shaft and gear. Fig. 5-09-01 This transmission is a hydraulic shift transmission with 3.
  • Page 95 Fig. 5-09-02 1. During the operation of the whole machine, check the 7. Adjust the working oil temperature of torque tightness of each oil line interface every day. If any oil converter transmission: maximum oil leakage is found, repair it in time. temperature during general operation and driving shall not exceed 120°...
  • Page 96 Schematic Diagram of Assembly Transmission Fig. 5-09-03 5.9.3 Removal and Installation As the torque converter and transmission are installed on the machine as a whole, the removal and installation of the transmission described here already includes the torque converter. The specific details of removal and installation of transmission (including torque converter) are as follows: (I) Introduction to position of torque converter &...
  • Page 97 The torque converter & transmission assembly is connected with the front and rear drive axles through the front drive shaft and the rear drive shaft. The torque converter is connected with the diesel engine by internal hinge and external hinge. (II) Disassembly steps 1.
  • Page 98 ① Remove the two M8×25 bolts, Φ8 enlarged flat washers and spring washers connecting the fuel filler pipe assembly bracket to the frame with a wrench. ② Remove the rubber hose and oil tank steel pipe connected to the working pump and steering pump with a wrench (Note: Before removal, please open the oil drain plug at the bottom of the transmission to completely discharge the transmission oil, then loosen the steel pipe...
  • Page 99 ⑥ Remove the twelve M10× 1 nuts used for inner hinge of torque converter and engine with a wrench; remove the M12 × 45 bolts, nuts and flat washers used for outer hinge of torque converter and engine with a wrench. ⑦...
  • Page 100 (III) Commissioning requirements Commissioning shall be carried out by designated personnel (if required); (IV) Installation 1. Install the torque converter & transmission assembly in the following order: ① Lift the transmission onto the frame with a special lifting appliance; ② The torque converter & transmission assembly shall be hinged with the inside and outside of the engine;...
  • Page 101 Parts used for cab installation Material name Material code Quantity of material Remarks Cab weldment 30812116480 Base plate 30812115784 Shock absorber 30812013457 Bolt 51210172914 Nylon self-locking (nut) 51342001119 M18× 1.5 Equipment and tools used 1. One 10t traveling crane; 5. 5044 jackhammer; 2.
  • Page 102 the intermediate output shaft) 4. Puller 11. Socket wrench 18. Lifting bolt and iron wire (lift the reverse planetary carrier assembly) 5. Jackscrew (jack out the rear end 12. Hexagon socket (install and 19. Box wrench (install and remove cover) remove the rear output flange the second gear friction disc screw, fastening nut)
  • Page 103 ④ Unscrew the fixing bolts of oil pan with a wrench, remove the oil pan and gasket, and take down the filter. ⑤ Unscrew the fixing bolts of transmission distribution valve and speed sensor with a wrench. Remove the transmission distribution valve and take down the gasket.
  • Page 104 ⑦ Remove the cotter pin with pliers. ⑧ Remove the fastening nut and gasket with a wrench, and take out the front output flange. ⑨ Remove the oil seal seat and frame oil seal with a...
  • Page 105 puller. ⑩ Remove the snap ring, frame oil seal and O-ring with a snap ring plier. 10. Remove the snap ring, frame oil seal and O-ring with a snap ring plier. ⑪ Take out the gasket and check ring with a snap ring plier.
  • Page 106 5.9.5 Faults and Troubleshooting Inspection steps or handling methods (I) Transmission oil temperature and water temperature rise too fast Premise I: Confirm the working condition. Or special working environment such as paper mill. Fault description: Premise II: Confirm the operation method. It is not Under normal use of the loader, the transmission oil advisable to operate under heavy load for a long time or temperature will exceed 120°...
  • Page 107 operation, the main reason is the first gear clutch itself. 3. The transmission operating valve has internal leakage Inspection steps of transmission parts: or the valve element and spring are stuck. 1. Check whether the oil temperature gauge and sensor are 4.
  • Page 108 5. After taking out the clutch, check whether the end cover 5. Remove the transmission end cover and check bolts are loose. Then disassemble the second gear clutch whether the O-ring and oil seal of the end cover are and check whether the piston returns. If it does not return damaged.
  • Page 109 5. Internal leakage of transmission operating valve. (VI) Under normal use of the loader, the transmission oil temperature will exceed 120° C 6. The oil suction pipe of the transmission pump is blocked in a short time or the working efficiency of the transmission pump decreases.
  • Page 110 3. Bad air flow. Inspection steps or handling methods: 4. The oil inlet valve of torque converter is damaged or the 1. Check the cleanliness of transmission oil. There is too adjusting pressure is relatively high. much oil dirt. During oil suction, the dirt will gather at the oil outlet of the oil pan, blocking the oil outlet and 5.
  • Page 111 V. Main Components Section X Instrument Cluster Contents 5.10.1 Instrument Assembly 5.10.2 Function Description 5.10.3 Instrument Display Indicator...
  • Page 112 5.10 Instrument Cluster All monitoring instruments, alarm and steering indication systems of the loader are integrated in the instrument assembly under the steering wheel. The instrument system displays multiple items such as engine coolant temperature, engine oil pressure, engine speed, brake air pressure, fuel quantity, transmission oil temperature, system voltage, charging indicator, low braking pressure alarm, low transmission oil pressure alarm, working hour meter of the whole machine, left and right turn signal indicators, high beam indicator, etc.
  • Page 113 5.10.2 Function Description Functional description V1.0 Pointer gauge Pointer gauge 1 (G1): brake air pressure gauge Pointer gauge 2 (G2): fuel gauge Pointer gauge 3 (G3): oil pressure gauge Pointer gauge 4 (G4): engine coolant temperature gauge See details below Sound Sound emitting device: buzzer There are 4 buttons on the instrument, namely Up, Down,...
  • Page 114 Input signal List of digital input signal: 1. Hydraulic oil cleanliness fault alarm 2. Neutral 3. Parking brake 4. Preheating (reserved) 5. Clearance lamp 6. Air filter blockage fault alarm (reserved) 7. Low coolant level alarm (reserved) 8. Hazard indicator (reserved) 9.
  • Page 115 5.10.3 Instrument Display Indicator Description Symbol Color Input signal Left turn Green +24V Right turn Green +24V Low fuel level alarm Yellow Sensor Preheating Yellow +24V（开关量预 留） Clearance lamp Green +24V High beam Blue +24V Hazard indicator +24V, reserved SVS fault indicator Yellow OBD lamp Yellow...
  • Page 116 Charging indication Analog quantity High water temperature alarm Neutral Green +24V, GND dual control Air filter blockage fault +24V alarm Reserved Fault alarm for cleanliness of hydraulic oil filter Fault alarm for cleanliness of oil filter of torque converter and transmission Driver performance limit 预留...
  • Page 117 Low coolant level alarm 预留 Brake air pressure fault Sensor alarm Low oil pressure alarm Oil-water separation fault alarm Liquid crystal – LCD layout Fig. 5-10-03 If there is an alarm, the alarm and text prompt area will display the alarm text, which will alternately display the alarm of analog quantity and switching value during operation;...
  • Page 118 1. Alarm and text prompt ❖ Display conditions and corresponding text: as shown in the following table Alarm Index Alarm Conditions Alarm text CAN signal cannot be received within 10s Communication with engine ECU failed! Fuel quantity <20% Low fuel level, please check! Transmission oil pressure <...
  • Page 119 Urea level ≤10% The level of urea solution is too low, please check! Urea temperature ≥100°C The temperature of urea solution is too high, please check! 2. Digital signal input Description Activation signal Connector pin Hydraulic oil cleanliness fault alarm Neutral +24V A3 to +24V, A1 to GND...
  • Page 120 3. Analog signal input Description Activation signal Connector pin Hydraulic oil temperature sensor signal A8 (reserved) Fuel quantity sensor signal Fuel quantity <20% Transmission oil pressure < 1.0 Transmission oil pressure sensor signal Mpa, speed ≥ 100 rpm and parking (and low transmission oil pressure alarm) brake not activated Vehicle speed sensor signal...
  • Page 121 If a DTC appears, press F2 to view the specific code, as (I) Press F2 key to enter the main menu interface. shown in the following figure: The main menu has 6 submenus, namely: engine DTC, operating parameters, main machine information, user settings, instrument information and system settings, which will be introduced separately below.
  • Page 122 Fig. 5-10-10 In the user settings menu, press F2 to enter the 1st submenu - language settings. After entering, Simplified Chinese and English are available for selection. Press F3 to select up and F4 to select down, and press F2 to select required language.
  • Page 123 ⑥ System settings Press F2 in the main menu to enter the 6th menu of the main menu interface. Password is required to enter this menu. The password is 1111, as shown in the following figure: Fig. 5-10-15 ② Main machine information settings Main machine information can be modified in this submenu, as shown in the following figure: Fig.
  • Page 124 V. Main Components Section XI Steering Gear Contents 5.11.1 Structure and Function 5.11.2 Removal and Installation 5.11.3 Disassembly and Repair...
  • Page 125 5.11 Steering Gear 5.11.1 Structure and Function 5.11.2 Removal and Installation (I) Function 1. Introduction to the position of steering gear on product The control element of the vehicle steering system realizes the steering function of the vehicle through the steering wheel.
  • Page 126 4. Installation ① Pay attention to the assembling direction of steering gear during installation, with 4 sets of oil port ends pointing to the rear side of vehicle body; ② Check whether the connecting paper pad is in good condition, and replace it if damaged; ③...
  • Page 127 5.11.3 Disassembly and Repair 1. Disassembly process ① Place the steering gear on the workbench ② Remove the two bolts of the joint seat ③ Remove the joint seat. ④ Remove the four seal rings on the joint seat ⑤ Remove the outer plug, copper gasket and inner plug on the joint seat ⑥...
  • Page 128 ⑦ Remove the four bolts of upper end cover. ⑧ Remove the upper end cover ⑨ Remove the joint connecting the steering column in the upper end cover. ⑩ Remove the two seal rings on the upper end cover ⑪ Remove the seven bolts on the lower end cover ⑫...
  • Page 129 ⑭ Remove the gear and jacking pipe in the gear ⑮ Remove the seal ring assembly from the gear ⑯ Remove the universal joint shaft, oil distribution disc and steel balls on the oil distribution disc ⑰ Remove the seal ring ⑱...
  • Page 130 2. Repair process Clean all parts and check whether they are damaged. If any, replace them with new ones. However, rubber seals, whether damaged or not, shall be replaced with new ones after removal. ① Assemble the valve element and valve sleeve ②...
  • Page 131 ⑦ Install the seal ring ⑧ Install the universal joint shaft, oil distribution disc and steel balls on the oil distribution disc ⑨ Install the seal ring assembly on the gear ⑩ Install the gear and jacking pipe in the gear ⑪...
  • Page 132 ⑭ Install the two seal rings on the upper end cover ⑮ Install the joint connected to steering column ⑯ Install the upper end cover and its four bolts ⑰ Install the outer plug, copper gasket, inner plug and four seal rings on the other side of the joint seat onto the joint seat.
  • Page 133 V. Main Components Section XII Gear Pump Contents 5.12.1 Working Principle 5.12.2 Analysis of Common Faults...
  • Page 134 5.12 Gear Pump Oil trapping: 5.12.1 Working Principle When one pair of gears has not been disengaged, but the The closed volume formed by the gear and pump housing other pair of gears have entered into meshing, there will is changed to complete the function of the pump. The flow be a moment when two pairs of gears are meshed at the distribution device is not required, so it is invariant, with same time, forming a closed volume between the tooth...
  • Page 135 5.12.2 Analysis of Common Faults Fault Cause Troubleshooting method Pressure measurement, Reduced hydraulic oil and increased Damaged oil seal replacement of oil seal or transmission oil working pump Pressure measurement, Increased hydraulic Damaged oil seal replacement of oil seal or decreased transmission oil transmission pump Oil leakage at the joint surface of...
  • Page 136 V. Main Components Section XIII Hydraulic Cylinder Contents 5.13.1 Storage and Handling 5.13.2 Use of Hydraulic Cylinder 5.13.3 Replacement of Spare Parts 5.13.4 Troubleshooting for Maintenance and Repair of Oil Cylinder...
  • Page 137 5.13 Hydraulic Cylinder 5.13.1 Storage and Handling Availability validation When storing hydraulic cylinders, it is necessary to If the hydraulic cylinder is stored for more than one year, distinguish between short-term storage and long-term or if the actual storage conditions cannot meet the storage.
  • Page 138 ⑥ Welding on the hydraulic cylinder is not allowed; ③ Use reliable lifting equipment and soft slings that can bear the weight of hydraulic cylinder. Make sure that the ⑦ Reliable lifting equipment shall be used to meet the distribution of hoist points is reasonable and hoisting is weight requirements hydraulic...
  • Page 139 ⑥ After the components are disassembled, take out the 5.13.4 Troubleshooting for Maintenance and seals and then clean all parts with degreasing medium; Repair of Oil Cylinder (IV) General guidance on installation process ① Only professionally trained personnel can maintain The cleanliness of all parts and the correctness of the hydraulic cylinder;...
  • Page 140 Troubleshooting Fault phenomenon Causes Troubleshooting method 1. The oil line is blocked or has serious 1. Clean the pipeline and block leakage leakage 2. Clean or replace the overflow valve The hydraulic 2. The overflow valve is opened due to cylinder does not 3.
  • Page 141 VI. Hydraulic Schematic Diagram...
  • Page 142 VII. Electrical Schematic Diagram...