LL 506 22x80 ZL50G WHEEL LOADER ETE TH SERVICE MANUALCONTENTS 1 Preface 4.1 Preface 1.2 How To Use This Manual -» 1.3 Hoisting Instruction ---- 1.4 Standard Fastening Torque ‘Standard Fasten Torque of Bolts And Nuts Fastening Torque for Separate Flange Mounting Bolts: 2 Safety Notice 2.4 Safety Notice- 2.2 General Safety Preventive Measures: 2.4 Safety Preventive Measures During Operating 3 General Regulations 3.1 Assembly Drawing of the Machine 03-01 3.2 Specifications and Technical Data - 08-08 3.3 Table of Components Weight 3.3.1 List of Oil, Water and Lubricant -~ 3.3.2 Applicable Temperature for Different Grade of Oil- 3.33 Special Reminding----- 4 Dismounting and Assembling Using method of this handbook: + 04-01 Notices when dismounting:---+------ . . sess 04201 List of common tools: List of special tools: Dismounting of rear hood uni 04-03, Assembling of the rear hood unit 04-06 Dismounting the front hood + 04-06 Assembling of the front hood unit Dismounting of the radiator uni 04-08Assembling of the radiator unit Dismounting of the combination (engine, gearbox and torque converter) - Assembling of the combination (engine, gearbox and torque convertor) Dismounting of the front axle unit Assembling of the front axle unit Dismounting of the rear axle unit Assembling of the rear axle uni Dismounting and assembling of C216NZS-1, C216NZT-taxl Dismounting of the steering cylinder unit - Assembling of the steering cylinder unit-~ Dismounting of the tilt cylinder unit Assembling of the tilt cylinder ui Dismount the lift cylinder uni Assembling of the lift cylinder unit-~ Dismounting of the working device unit - ‘Assembling of the working device unit: Dismounting of the counterweight Assembling of the counterweight - Dismounting of the fuel tank uni Assembling of the fuel tank unit --- Dismounting of the left trestle------~ Assembling of the left trestle Dismounting of the right trestle: Assembling of the right trestle Dismounting of the hydraulic oil tank unit: Assembling of the hydraulic oil tank unit ~ Assembling of the central pin ~ Dismount 9 of the working pump- Assembling of the working pump «~~~ Dismounting of the multi-path steering valve ‘Assembling of the multi-path steering valve: Dismounting of the two-way flow pump of leading and steeringAssembling of the two-way flow pump of leading and stecring Dismounting of flow amplifier valve: Assembling of the flow amplifier valve Dismounting of limit valve~ Assembling of the limit valve Dismounting of the select valve-- Assembling of the select valve Dismounting of the leading vaive-~ Assembling of the leading valve Dismounting of the leading overflow valve-- Assembling of the leading overflow valve - Dismounting of the steering-gear-~ Assembling of the steering-gear Dismounting of the brake valve--- Assembling of the brake valve = Dismounting of combination valve of oil-water separator: Assembling of the combination valve of oll-water separator---- Dismounting of air reservior- Assembling of the air reservior Dismounting of brake cylinder: Assembling of brake cylinder: Dismounting of the driver's cab-----~ Assembling of the driver's cab: Dismounting of the AIG Assembling of the A/C: 5 Test And Adjustment General Notes: Measure Engine Rotation Speed--- Test Exhaust Emission Color Measure Et ssion Temperature: Test Accelerator Pedal -~- Operation Angle of Accelerator Pedal:----Test Oll Pressure in Gearbox And Torque Converter: Measure Clearance between Rims and Tires--~ Test And Adjust Steering-Wheel -- Measure Operation Force for Steering-Wheel Measure Operation Time for Steering-Wheel: Test And Adjust Steering Angle: Measure Operation Force And Travel Limit of Braking Pedal ~ Testing Brake Performance: Test Parking Brake Performance ‘Test Multi-Way Valve Overflow Pressure: Test Hydraulic Pressure & Oil Leakage ‘Test Working Speed of Working Mechanism «+ z Test And Adjustment for Bucket Self-Leveling Approximate Switch ~ Test And Adjustment for Driving Axle Gears Engagement ~ 6 Troubles, Trouble Diagnosis And Trouble-Shooting Remedies Preface-. 6.1 Troubles Phenomena And Troubles Causes: 6.1.1 Troubles Phenomena: 6.1.2 Trouble Causes:s---s--sersstssren 6.2 Trouble Diagnosis And Trouble-Shooting: 6.2.1 Instruction to Trouble-Shooting 6.2.2 General Process for Trouble-Shooting 6.2.3 Process of Trouble-Shooting 6.2.4 Methods for Trouble Diagnosis - 6.2.5 Trouble Diagnosis Examples 6.2.6 The diagnosis Process Charts for Other types of Problems on the Wheel Loader 6.2.7 Problems Analysis Process Charts for the Main Components: 6.3 Causes And Remedies for Common Troubles: 6.3.1 Power system 6.3.2 Transmission system. 6.3.3 Hydraulic System-6.3.4 Braking System + 06-34 6.3.5 Electrical System---- + 06-35, 6.3.6 Air -conditioner system « + 06-37 7 Maintenance 7.4 Instruction on Maintenance: 5 “07-01 7.1.1 Maintenance Instruction for Hydraulic System, “07-01 7.1.2 Maintenance Instruction for Electrical System: + 07-03 7.2 Maintenance And Service to the Machine: + 07-08 7.2.1 Main Measures for Reducing Machine Breakdown + 07-08 7.2.2 Daily Checks And Periodical Maintenance: + 07-09 7.3 Maintenance for Key Working System: 07-12 7.3.1. Maintenance for Transmission System-~ O72 7.3.2 Maintenance for Hydraulic System: 07-17 7.3.3 Maintenance for Operation Mechanism: 07-19 7.3.4 Maintenance for Electrical System=--- “07-19 7.4 Maintenance for Wheel Loader Under Special Environment: “07-21 7.5 Maintenance Standard: 07-22 7.5.1 Standard for Filling Oil Liquid And Engine Coolant 07-22 7.5.2 Maintenance Standard for Key Working System And Components 07-23, 8 Accessories Specifications and List of Easy-worn Parts 8.1 Working Range::--+s+-sssssessernseeseese see 08-01 8.2 Table of Accessories for Different Working Apparatus: 08-02 8.3 Table of Bucket Types and Applications---- ++ 08-08 8.4 List of Easy-worn Parts Within 500 hr-~ 08-04 8.5 List of Easy-worn Parts Within 1000 hn + 08-05 8.6 List of Easy-worn Parts Within 1500hr: 08-07 8.7 List of Easy-worn Parts Within 2000hr---- 08-09 9 Brief Introduction of Maintenance 9.1Classification of Maintenances 09-01 9.2 Examples of Sovoral Familiar Maintenanc 09-029.2.1 Repairs of crack welding seam and stee! material: 9.2.2 Repairs of severely worn pin shafts, shaft sleeves and pin shaft holes: 9.2.3 Repairs of hydraulic oil cylinder1. Preface1.1 Preface ‘This manual is designed to help service people understand the machine structure and its working components, guiding service people how to make correct breakdown diagnosis and give trouble-shooting remedies to the machine, This manual also outlines the standards on maintenance and service for the ‘machine under the normal and special working condition, so that it will help service people improve service quality for the machine. ‘This manual totally consists of the following chapters: “Preface” is consisted of How To Use This Manual, Instruction on Hoisting and Standard Fastening Torque. "Safety Precautions" mainly includes General Safety Precautions and Safety Measures To Be Taken Before ‘And During Service Work. "General Profile” includes the Assembly Diagram, Technical Specification, Component Weight and Oil Liquid List And Grease. "Disassembling And Assembling" mainly describes the process and methods to be taken for machine ‘components dismounting and assembly as well as the tools, lifting methods and precautions that should be taken during the process of dismounting and assembly of the machine. “Test And Adjustment” mainly illustrates the practices and process on testing the machine components performance and machine technical data. This chapter will give helpful reference for maintaining the proper performance of the machine. “Trouble And Trouble-Shooting Remedies’ mainly describes the trouble phenomena, trouble causes, ‘rouble diagnosis and trouble-shooting remedies. It also outlines the trouble diagnosis process by giving some examples of normal-seen troubles, which is very helpful to improve the service people qualification. ‘The troubles, troubles causes and trouble-shooting remedies for some normal-seen problems are also listed in this chapter. "Maintenance And Its Standards" mainly provides the machine operators with the illustration on the ‘maintenance guidance and relative precautions for hydraulic system, electrical system and other working ‘mechanism, as well as the special maintenance for the machine under the special working condition and ‘maintenance standards (e.g: articulation holes, bearing clearance and torques, etc.), which is totally consisted of 3 parts “Attachment Specification And Wearing Parts List" mainly gives the models and specification of some other working attachments of the machine, and outlines the wearing parts list for specific 500 working hours, 1000 working hours, 1500 working hours and 2000 working hours. "Basic Service Knowledge” mainly describes the basic knowledge of general service, and gives the some examples of service practices for welding seam, steel plate cracking, pin shafts, shaft sleeves and holes ‘wearing as well hydraulic cylinders. ortIf you have any comment to this manual or good suggestion for improvement, please don't he te to contact us, We will reserve the right to make improvement modification on the machine without giving prior notification. 1.2 How to Use This Manual (J) Printing method: This manual is printed in the page sequence. The page number of this manual is shown at the bottom of each page. (2) The following diagram shows how to read this manual. — % L_| 05, page sequence number for the chapter L | Chapter number (3) Adding pages:Behind the page number, itis shown with a mark of "(-)" and adding pages. Following is the example, 04.05 04-05-01 04.05.02, 04-06 (4) Edition Modification Number ‘When it is needed to modify the current manual, edition number (1, 2, 3--.)will be shown at the bottom of the cover page, (5) All the modification or complimentary information will be sent to XCMG dealers. Before carrying out any work with this type of machines, please inquire the latest technical information about the machines from authorized XCMG dealers. (6 Symbols ‘The symbols as shown in the table 01-01 will be used for highlighting the safety and quality instruction. ‘Table 01-01: Symbols Symbols | Description Notes ‘ Safety Safety measures must be taken and followed during executing works. Caution | Technical precautionary measures or other service means as mst be then ding wodng. 0102_—____ EMG To show the weight of machine component or working Ka) meee system, Care should be taken when selecting hoisting | ropes and operation methods, © To show that the required fastening torque should be Fastening Torque we Tong applied during the assembly. Coatin ‘To show the area or points that need to be coated with a sealing globe or grease. wW Waerand oi | 7 stow the working system that needs to be replenish with oil, water oF fuel. t ‘To show that water drainage or water drainage must be ees Drainage made at some parts of the machine, 1.3 Hoisting Instruction Ay The heavy components (25kg plus) must be hoisted with crane machine. In thchapter of "Dismounting And Assembly’, explicit marks are given for the machine parts with weight of 25kg or 25kg plus. 4. Hoisting fa part of the machine could not be removed away by using u crane hook, then make the following checks: (1) Check to see if all the mounting bolts on the part have been removed avray @) Check to see if there is any conflict between the part which is being removed away and other machine parts. 2, Steel Ropes (1) According to the weight of the part which needs to be hoisted, select the proper steel ropes. Steel Ropes (standard S-shape steel rope) Steel ropes diameter (mm) Allowable loading capacity (t) 10 10 14 22 16 28 18 3.6 20 44 30 10.0 40. 18.0 50 28.0 60 40.0Note: {() The allowable loading capacity as shown in the above table is estimated on the basis of 1/6-1/7 steel rope breaking strength, (2) The steel rope should be suspended in the middle of the hoisting hook, Otherwise, it will cause the risk of sever safety hazards if the steel rope is very near to the hook edge and possibly falls down from the ‘hook. Bear it in mind that the most strong strength of the hook is at its middle. bbe 100% 80% 79% 71% am @) Itis recommended to use more than one steel rope when hoisting a machine part. AX? hoisting a machine part with only one steel rope could possibly have the part turn, steel rope get Joose or slide away from the part during the process of hoisting, which will cause sever accident hazards. (4) Never let the steel ropes hoist @ machine part in a large angle during hoisting, And please know that ‘when hoisting the machine part with two or more steel ropes the loading force on each stel rope willbe enlarged with the increasing of hoisting angle. The following diagram shows the changing allowable hoisting capacity of each steel ropes when hoisting & machine part with two stel ropes. In tis example, tho allowable hoisting weight of each steel rope is 1000kg. When the two steel ropes hoist a heavy staff in perpendicular angle, the total hoisting weight can be 2000kg. However, when hoisting a staff in an angle of 120° the maximum allowable hoisting weight can only be 1000kg, Let's we consider this issue from another point of view: if two steel ropes are used to hoist, in the angle of 150° , a heavy staff with weight of 2000kg, then the maximum loading capacity of each steel rope should be up to 4000kg. mn 0s) foo gw el 5 00 g 30 = = @ b Rising angle (unit:* dagree ) 01.041. Preface —_— ©XCMG 1.4 Standard Fastening Torque Standard Fasten Torque of Bolts And Nuts ‘Table 01-02 lists the standard fastening torque of mounting bolts and nuts. The spcial torque as stated in the chapter "Dismounting And Assembly” is not shown here, ‘Table 01-02: Standard Fastening Torque Bolts thread diameter Sane retin Fastening Torque (mm) (mm) Kgm Nam 6 10 1352015 132214 eae B 32203 314229 10 16 67207 6.7268 2 18. 115210 112498 4 21 180220 mz [is m4 28543 279429 is 21 3924 383239 7 20 30 5626 549458 2 4 768 TS £78 a 36 94510 927498 30 46 175220 1720+ 190 23 50 225425 2210 240 36 35 28030 2750290 Note: (1) The fastening torques as listed in this table don' apply to the bolts with Nylon pads or other metal pads ‘or other special bolts with designed fastening torques. Q)1Kg:m=9.8Nm Fastening Torque for Separate Flange Mounting Bolts ‘The mounting bolts for separate flanges should adopt the fastening torques as listed in table 01-03. ‘Table 01-03: Fastening Torque Bolts thread diameter Spanner open-idth Fastening Torque (am) (om) Kem Nam 10 16 6.7407 65.7268 2 18 113#10 112298 4 21 18020 1TE19 16 wa 28.523 279+292. Safety NoticeSafety 2.1 Safety Notice Important safety notice: Proper services are very important for safe operations of the machine! In order to prevent personal injury.signals with Ald in this handbook represent safety measures which should be observed strictly; if dangerous situation occurs or may occur, safety should be considered first and take necessary preventive measures according to the real situation atthe site. 2.2 General Safety Preventive Measures Incorrect operations are very dangerous, Read the safety notice in the Service Handbook carefully before ‘operating the machine, (1) Before lubricating or servicing, please read all the safety preventive measures specified on the tags and labels stuck or tied on the machine. (2) When doing any operations, safety shocs and helmet should be put on, loose work clothes or those with ‘missing buttons should not be allowed. Besides: (© Have the goggles on when hammering the parts, ‘¢ Have the goggles on when grinding the pars @) If welding is necessary, only skillful welders after being trained are allowed to do it, ‘welding gloves, goggles, helmets and proper welding clothes when welding. (4) When two or more workers are doing operations on the machine, consult the operation steps with each ‘other before doing anything; let your partner know before you start any operation. Hang the label of " On Service" on the control lever in the cab before doing any operations or services. (5) Keep all tools in good condition, and learn how to use them correctly. (6) In the service workshop, a proper arca should be specified for keeping tools and disassembled parts. ‘Tools and parts should be stored in a right place, and the working site should be kept clean and no dust or oily dirt on the ground, Smoking is only allowed in specified area. No smoking when working. 2.3 Preparations (1) Before adding oil or doing services, stop the machine on a stable and horizontal ground, and put a ind put on the ‘wedge under the wheels in order to prevent the machine from moving. 2) Before doing services, lower the bucket or other distortional working apparatus to the ground, If being unable to do this, insert safety pins or fix on the service supporting apparatus 50 as to prevent the working apparatus from falling down which may cause accidents; meanwhile, make sure that all the control levers should be locked and hang the safety signs on them, (G3) Support the machine with a heel block, jack or bracket before doing any dismounting or assembling. (4) Clear away all mud and oil on the ladder or other steps for getting on or down the machine; use the handrail, ladder or footplate for getting on or down the machine, do not allow jumping up or down the machine directly. If it is impossible to use a handrail, ladder or footplate, make a platform as a safe treadboard instead, 202. Safety Notice 2.4 Safety Preventive Measures During Operating (1) Slowly loose oil caps, oil drainage plugs or plugs for measuring oil pressure at hydraulic mouthes in ‘case oil may splash out; when dismounting the components of the oil, water or air pipelines, release pressure inside first. (2) When the engine is extinguished, water and oil inside of the pipelines are very hot, be careful not to be scalded. Only after the oil and water is getting cooled can service be made on the pipelines. G) Disconnect wires from the battery cell before operating, wires on the negative pole should be always disconnected first. (4) Use a hoist or crane when lifting up heavy components. Check whether the steel wires, chains and lifting hooks are broken. Lifting equipment with enough capacity should be used. Place the lifting equipment at a correct position, and operate the hoist or crane slowly in case of colliding with other components. Do not work on any components which are lifted up by a hoist or crane, (5) When dismounting caps which are bearing the inside pressure or spring pressure, leave two bolls at the symmetrical position and release the pressure slowly, then loose the bolts slowly for dismounting, (© When dismounting component units, be careful not to break off or damage the electrical wires which ‘may cause electrical fire. ( When dismounting pipelines, be careful not to sprinkte fuel or engine oil on the ground and wipe away if necessary. Any fuel or engine oil on the ground may cause you slip and fall and even @ fire. (8) Normally do not use gasoline for cleaning components, especially for electrical components. (9) When assembling, make sure that all the components are assembled to their origianl position and change with new ones for those broken; special reminding is that when assembling hoses or wires, be careful not to collide with other components in case of lacerating or damaging. (10) Do not twist the high pressure hoses when assembling; broken hoses are very dangerous, so check carefully when assembling the high pressure return hoses; especially check whether the assemblies to the connecting components are correct. (11) Adopt required torque when assembling or fixing components with fasteners. Especially for assembling the safety protection components, such as protection shield and components which are severely shaking or high-speed rotating, check whether their assemblies are correct, (12) When aligning two holes, do not use your finger or hand, be careful not to insert your finger into holes. (13) When measuring the hydraulic pressure, check whether the measuring tools are precise first. 2023. General Regulations3. General Regulations 3.1 Assembly Dra 1. Bucket Assembly 2.Tyre 3. Boom 4, Rocker 5. Tilt Cylinder 6. Front Axle 7. Cylinder of Boom 8, Front Framework 9, Front Transmission Shaft 10, Steering Cylinder 11 Instrument Panel 12. Shift Selector 13, Steering Wheel 14, Control Lever of Boom Cylinder 15. Control Lever of Tilt Cylinder 16. Cab 17, Brake Pedal 18. Accelerator Pedal 19, Seat 20. Working Pump 21, Two-way Flow Pump of Leading and Steering 22. Gearbox 23. Torque Converter 24, Rear Transmission Shaft 25. Hood 26. Engine Assembly 27. Rear Axle 28, Rear Framework 29, Radiator Assembly 30. Counterweight 31. Hydraulic Oil Box oso8. Gonoral Regulations WXCMG Assembly Drawing of the Machine (Fig. 03-02)8. General Regulations ____ WI XCMG 3.2 Specifications and Technical Data (Table 03-01) Model ZLS0G yp of working appara Rog, [Sanaa Iara vn Operating weight (Kg) 175 000 | 175 000 | 175 000 Distribution (front) (Kg) 7850 |7850 |7850 Distribution (reat) (Kg) I9650_|9650 | 9650 Bucket capacity (fully loaded) (my ns |30 |35 Rated load (Ka) [5.000 | 5000 [5000 ‘Traveling speed Forward Ist (km/h) 65 Forward 2nd (km) 110 Forward 3rd (awh) 240 Forward 4th (kami) 38.0 Feature Reverse Ist (km/h) 65 Reverse 2nd (km/h) 110 Reverse 3rd (km/h) 240 Max. gradesbility (eg) 28.0 Max. drawing force (Nik) 15000005 000 Min, steering] At the center of outside tre (mm) 6700 radius __|Atthe outside of the bucket (mm) 7.300 Overall length (mm) 8200 ‘Overall width (chassis) (am) 2.800 Bucket width (mm) 3.000 Overall height (roof of the cab) (am) 3.485 (Bucket at full it) (nm) 5.365 ‘Wheel base (mm) 3300 Min, ground clearance (nm) 450 seca Articulated pin height of bucket (am) 4100 Dumping clearance (edge of bucket teeth) (mam) 2955 Dumping reach(edge of bucket teth) (mm) 1205 | Dumping angle of bucket (deg) 45 Drawing back angle of bucket 49 (at conveying position) (eg) Digging depth(slope to 10 degree) (xm) 50 03.033. General Regulations Model ZLS0G Model: Cummins 6CTAAB3-C ‘Type 4-stroke water cooling direct injection, pressurized, air-to-air intercooling Number of eylinders- inner diameter X stroke(mm): | 6-114mm x 135mm Displacement (L): 83 Horsepower of flywheel 153(208)/2 200 (KWEPSy/epm): Engine Max. torque /rotate speed 991101 400 (N.m(kgmyepm): Rating fuel consumption S241 ghWh (KW): High idle speed (rpm): 2.460 Low idle speed (pm) 850 Start motor : 2av 7.S5KW AC generator: 24V SOA Storage battery: 12V 120Abx2 Torque converter: Single-stage, single-phase three-element Power | Gearbox: Fixed shaft electro-hydraulie gear shifting train ‘Type of main reducer: spiral bevel gear single-stage reducing, ‘Type of hub reducer: single-stage planetary reducing Driving type: wheel driving Front axle: Fixed with the machine body - Rear axle: Swing type me Tyre: 23.5-25-16PR(L-3) axleand No inner tube 23.5-25-20PR wheels . Inflating pressure: Front wheel (KPa) 310-340 Rear wheel (KPa) 280.310 Foot pedal: Single pedal, air pushing oil, clamp disc brake. Parking brake: Soft shaft control, energy is accumulated through Brake spring, inner expanding shoe type. The brake is ‘controlled though pushing the brake button. Brake pressure (KPa) 686-784 Steering system | Type: Articulated fully hydraulic flow amplified steering 02-043. General Regulations @XCMG Seine oa Max, steering angle (deg): Left or right 35 ‘Max, operating pressure (MPa): 15 Model ZLS0G Type of hydraulic pump: Gear pump Displacement Working oilpump: 100 (nl) Steering oil pump: 68 ‘Max. operating pressure of workingdevice to. Control | (vtPa) 175 valve _|Max. pressure of steering system Hydraulic (Pay 15 system : !Boom cylinder Hydraulic ‘number-inner diameter X stroke(mm)} Reciprocating piston 2-160 840 cylinder | Bucket cylinder number-inner diameter X stroke(mmm)| Reciprocating piston 1-200 x 585 Steering cylinder Jnumber-inner diameter x stroke(mm) | Reciprocating piston 2-90 350 Working ‘Type of connecting rod: Single connecting rod device Bucket: Bucket teeth ‘Working medium of warm wind: Coolant of diesel engine Heating capacity: 5000 keal AIC system Working medium of cold wind: Refrigerant (R134a) Refrigerating capacity: 4000 keal ‘Working voltage: pe24v Options _[Retating alarm lamp, triple valve, wood pliers, rock bucket, high dumping device, side tilting device8. General Regulations WXCMG 3.3 Table of Components Weight (Table 03-02) ‘This table is only a reference for transportation or repairing and moving these components. (unit in the following table is ke/piece) Model ZLS0G Engine 617 (Commins) “Torque converter and gearbox 425 Front transmission shaft 70 ‘Rear transmission shaft 21 Front axle 1050 Rear axle 1096 ‘Tyre 335 Rim 180 ‘Working oil pump 37 ‘Two-way flow pump of leading and steering 39 Multiple combined valve @ Flow amplified valve 2B Tilteylinder 250 Lift eylinder 178 Steering cylinder 25 Front framework 1800 Rear framework 1670 Rear mounting rack 216 Boom 1190 Rocker 346 Connecting rod 2 Bucket (2.5m) 1375 Bucket 3m) 1300 Bucket 3.5 m') 1350 Left westle 80 Right trestle 100 4 Fuel tank 205 “iydraulic ol tank 140 Counterweight 1500 Front engine hood 90 ‘Rear engine hood 150 Driver's cab 350 (Standard) 710 (FOPS & ROPS) 03-063, General Regulations Seat 25 Storage battery 243 AIC evaporator 46 AIC condensator 30 AIC compressor 105 ‘AIC compressor bracket 2 Radiator 200 | __ Front differential 135 Rear differential 135 Front serapper 23 Front framework pin of tilt eylinder 10 Fron framework pin of boom eylinder 2 Front framework pin of boom 25 3.3.1 List of Oil, Water and Lubricant (Table 03-03) I Name and grade Filing amount Parts and components for Cagory Summer Winter | ofl vate) ‘filling oil (water) of, 10% | 108, 35% Fue : 230L Fuel tank light dieset_| tight diesel ‘Varieties:API CG-8/SG Engine oi Sar taWidd once ai 20L Engine oil sump Geaiboxoil | CF-4 15W/40 engine oil 5oL Gearbox, torque converter , L-HIM46 (summer) Hydra oit 2001 Hydraulic ol tank “ L-HM32 (winter) a ‘Total $4 | Main transmission of driving axle Lincluding: and hub reducer Gear cit GL sswis0 2 Front axle aL Rear axle Cooling sytem Water aL Water tank Brake liquid | 719 synthesized brake liquid og Oil cup very anicuaed point and pn of working device, front framework, steering cylinder, a oe dug [COU of framework and rear ase inc mounting bracket, cross shafls of every srease(GB7631.8-90) transmission shaft and spline, bearings of engine fan and wetee pur, and connecting point of evry conrling kno, os073. General Regulations __ @XEMG 3.3.2 Applicable Temperature for Different Grade of Oll (Table 03-04) Category Grade Applicable Temperature (C) | Remarks 10# light diese 15 light diese 28 108 light dieset 24 Fuel 104 light diesel a5 GB252-1994 204 light diesel 4 354 light diesel 229 50 light diesel Bad Viscosity grade 15W/40 engine oi 2010+ 50 Engine oil | Viscosity grade 10W/40 engine oil -30 10+ 50 6B11122-1997 Viscosity grade 10W/30 engine oil -30t0 +40 Viscosity grade SW/30 engine oil -40 t0-+40 3.3.3 Special Reminding Other requirements, selecting principle and notes concerning oil grade for Cummins pressurized engine, ZE gearbox - torque converter and Meritor drive axle should be strictly observed according to the attached operation manuals of themselves; no lower grade of oil compared with those recommended in the operation manuals of engine, gearbox and driving axle should be selected in principle ® When the sulfur content in the fuel is less than 0.5%, please refer to the specifications of periodic maintenance stated in the attached operation manual of the wheel loader and change the fuel at every time of periodic maintenance. [If the sulfur content in the fuel is more than 0.5%, please change it according to the following table: Sulfur content in the fuel Intervals for changing the fuel 0.5% to 1.0% 1/2 of the normal intervals Higher than 1.0% 1/4 of the normal intervals @ When starting the engine at the temperature lower than O°C, make sure that SAEIOW/30, SABIOW/40 and SAEISW/40 engine oil are used, even when the temperature goes up to around 10°C at daytime. @ The filling amount is the total amount, which including the oil in this component and also the oil in every pipeline © If the ambient temperature is lower than O°C, antifreeze should be added into the cooling system in time; ‘meanwhile, cooling water should be drinkable because impure water may have lots of foreignmatters which may cause blockage on the engineand the radiator, thus may decrease the radiating and lead oil temperature go up. 03.086, Genera Reguiatons @XCMG © Under special geographical environment conditions, proper grad of oil should be selected according to the local air temperature; if the climate environment is very atrocious, some accessional protection devices are necessary, ploase contact with your local dealer of XCMG. © Xugong Science & Technology Co., Ltd. recommend our customers to use the hydraulic oil which is confected by Xugong and approved to be used on hydraulic components and equipment, and specially approptiative for Xugong's products. Notes for symbols in the above table: SAB: Society of Automotive Engineers. ‘API; American Petroleum Institute 03.094. Dismounting and Assembling4. Dismounting and Assembling _ @XCMG Using method of this handbook 1. Dismounting and assembling of components (1) When dismounting or assembling of components, dismounting procedures and methods are available in this article, but no procedures for assembling, (2) For example: Dismounting XXX AW xxx “Title of operation “Notice related to safety when operating 1) Xxx: Operating procedure 2) XXX: Operating procedure A xxx itle of operation Assembling of XXX ‘Title of operation, Procedures for assembling are quite opposite to those of dismounting, A xxx oe ‘Notice when operating 3) General notices are provided for dismounting and assembling, meanwhile, notices for operation are also listed. When taking operation, itis a must to follow these notices 2. List of common tools Names, specifications and amounts required for common tools during operation refer to the section of "List of common tools". 3. List of special tools Names, specifications and amounts required for special tools during operation refer to the section of "List of special tools". Notices when dismounting When dismounting and assembling of the system or the components, the following notices should be observed, 1. Notices when dismounting components from the wheel loader: © Lift equipment with enough strength is needed for lifting the components; © A container with proper capacity should be prepared whien draining out the lubricants or fuel: 1 the coolant has anti-freeze in it, dispose it properly;; «¢ When dismounting hoses or hard pipes, sel the mouths of these pipes to prevent any dirts or dusts coming in; Tie labels on dismounted wires and hoses and explain their assembling position so as to prevent mistakes ‘when re-assembling; Before dismounting any components from the wheel loader, set matching signs at necessary places so as to prevent mistakes when re-assembling; 04014, Dismounting and Assembling ‘© When dismounting strengthful bolts of any component, itis necessary to loose the bolts alternately; ‘© Check the amount and thickness of the adjusting pads and keep them in a safe place; ‘© Before dismounting any component, clean the place where you would lay it on; and fix a protection cover ‘on the component so as to prevent dirt and dust may come inside; © When lifting any component, lifting equipment with enough strength should be adopted. 2. Notices when assembling: ¢ Tighten all bolts and muts to specified tight moment; @ Distortion or interference is not allowed for assembling of hoses; © Change all sealing pads, O-rings, split pins and locking washers; ¢ Bend split pins and locking washers carefully and assemble them properly; © After assembling of split rings, check whether they are firmly fixed in the slot or not; © When tightening the separate flange, tighten from both sides alternately in case of one side is over tightened; © When it is necessary to daub agglutinants, clean the component first to clear away all the oil and lubricant on its surface and then daub 2~3 drops of agglutinants on the serew thread © When js necessary to daub sealing glue on washers, clean the surface of the component and clear away all oil and lubricant, and then daub sealing glue on it evenly; ‘© When connecting plugs of wires, clean the plugs first to clear away all the oil, dust and water, and then connecting them firmly; ‘© Daub lubricants on the rotating parts and gliding parts; © All the assembling parts should be cleaned and all the broken parts should be repaired: © When using fly ring bolts, check whether they are distorting or broken, tighten them with screws and then align them with the lifting hook; AX After re-assembling of the repaired cylinder, the air inside of it should be drained away according to the following method atthe first time of operation: (1) Start the engine and run it at low speed and in neutral gear; (2) Use the control lever of the working device to make the hydraulic oil cylinder act for 4~5 times and stop at the 100 em to the end of the strokes (3) Then make the cylinders of steering, bucket and boom act for 3~4 times to the end of the stroke; (4) Increase the speed of the engine, and repeat the procedure of 3) to drain away the air for several times until there is no air coming out from the draining plug; (5) After finishing the above procedures, run the engine at the normal speed A\ After repair of the loader, or atthe first time of re-operation after not being used for a long time, the hydraulic equipment should be drained out of air according to the above procedures as well. 3. Notices after assembling: © If the coolant has already been drained away, tighten the drainage valve first, fll water to the specified level, run the engine to circulate the water in the system and then check the water level agains 0402@LXCMG If the hydraulic component is re-assembled after being dismounted, the hydraulic oil should be filled to the specified level, run the engine to circulate the oil in the system and then check the oil level again; IF pipes or hydraulic components (such as hydraulic oil cylinder, pump or motor) are dismounted for repair, they should be drained out of air after being re-assembled; ‘© Add lubricants with specified amount at the lubricating points of the working device and every 4. Dismounting and Assembling articulating joint. List of common tools No. Name Specifications Quantity i Split spanners 12 pieweshset set [2 Double offset ring spanner B piocesist Tset 3 ‘Adjustable spanners 30%250 (10" 1 [4 Adjustable spanners 55450 (18") 1 5 Screw driver 150%7 6") 1 6 Screw driver 3009 (12%) 1 7 Hammer Ike 1 8 Slip joint pliers 200 (8") 1 9 Grease gun 400m 1 10 ‘Tyre barometer 0-0.8MPa 1 List of special tools No. Name Quantity Remarks 1 Pinch bar | 1 2 Box spanner I 1 Foraxle Box spanner | 1 [ Foraxle | Dismounting of rear hood unit Ay Bie» ine toaderon a horizontal ground, lower the bucket to the ground and stop the engine. Use the parking brake and place a wedge behind the wheels to prevent the machine from moving. Ad cox oft: power irom the negative pole ofthe battery cll 1. Rear blocking hood (1) Cutoff the socket connector of the reat large light; 4.034, Dis mounting and Assembling (2) Loose the nut for fixing the rear light, and then take down tte rear large light; (3) Take down the assembling bolts and then the rear blocking hood. 2. Lift device (1) Put the direction control handle of oil pump at $ and take down the two hoses which connected with oil pump. Drain ‘out all the hydraulic oi in oil pump ane pipes. (2) Take down the two hoses connected with lift cylinder. 04-04@LXCMG (3) Take down the fixing bolt of upper and lower articulation pin of lift cylinder, pull out the articulation pin and take down the lift cylinder, 3. Side door (1) Take down the assembly bolts for connecting the left and right side doors with the framework; (2) Take down the chain and then the side doors. 4, Rear hood (1) Take down the assembly bolts for fuel tank cover, cut off the ‘wires of bugle and take down the fuel tank cover. 04-054, Dismounting and Assembling (2) Take down the assembly bolts for connecting the brackets of the rear hood with the framework; (3) Cross nylon rope over the lifting bolt, and then connect with the lifting chains to hang the hood away from the machine, (Rear hoo unit ofthe engine 105g AX When using lifting bolts for hanging the engine rear hood, the dimension ofthe serew thread is M2O. Assembling of the rear hood unit Adopt the opposite sequences of dismounting for assembling AX When assembling the rear hood, add a litte of grease at the inside holes of the left and right brackets, and fix the bearing to the inside hole, then coat the inside and outside of the bearing with enough ‘grease (marker of the bearing is outward). A When assembling the lift device, add grease at both the up and down pins Dismounting the front hood 1. Main switch of the power and start-up relay (1) Cut off the socket connectors of the main power switch and start-up relay; 0408(2) Take down the assembling bolts and then the main power ‘witch and start-up relay. 2. Air filter (1) Loose the hoop for fixing the water proof eap, and then take down the water proof cap; (2) Loose the fixing bolts on the cover plate of the front hood, sxltha ke down th re y (3) Loose the T-hoop for connecting the air inlet pipe with the inlet port of the engine(@L12) ‘The following steps should be done after the ont hood is lifted away from the machine (4) Loose the Tshoop for connecting the air filter(0165), and then take down the air inet pipes (5) Loose the bolts on the bracket of the air filter(MS x SO}and those for fixing the bracket(MS x 25) (6) Take down the air filter. o1o74, Dismounting and Assembling WXCUG 3. Front hood (1) Loose the bolts for connecting the front hood and the framework; (2) Cross a nylon rope over the front hood, and connect to the lifting chains, then hang the hood away from the machine. (64) Front nod uni ofthe engine 45k Assembling of the front hood unit ‘Adopt the opposite sequences of dismounting for assembling, Dismounting of the radiator unit Ad 3009 ine loader on a horizontal ground, lower the bucket to the ground and stop the engine, Use the parking brake and place a wedge behind the wheels to prevent the machine from moving. Mirren tx sec pcan eit tt poe. Lift up the front part ofthe bucket for 30~50mm and down the rear part (0 the ground by operating the knob, and then stop the engine ‘Then check whether the whole underside of the bucket touch the ground or not. ‘Tum the filler cap of the hydraulic oil tank slowly to release the inside pressure. Then operating the ‘knob for several times to release the remnant pressure in the hydraulic pipelines. Ad curt te power from the negative poe of the battery cel 1. Cap Loose the cap of the hydraulic oil tank slowly to release the inside pressure in case of any oil may come out. 04.08_. 4, Dismounting and Assembling 2. Water drainage Loose the water drainage valve to drain away the coolant. \ tthe coolant has anti-freeze in it, proper dispose of it wie Coolant: 451. 3. Hydraulic oll drainage Loose the drainage valve of the hydraulic oil radiator to drain the hydraulic oil, Loose the drainage valve of the gearbox radiator to drain the hydraulic oil. 4. Hoses of water tank radiator (1) Disconnect the hoses for linking the upside of the water tank radiator with the engine (three pieces, respectively are permeability hose of the engine, up water hose and water filling hose); (2) Disconnect the hos for linking the downside of the water tank radiator with the engine (down water hose). AX inorder to prevent water leaking from the water tank, bend the end of the hose and tie up with a belt. FA ca i cf a | laeAt 5. Hoses of intercooler (1) Disconnect the hoses for linking the upside of the intercooler with the engine (air inlet hose of the intercooler); (2) Disconnect the hoses for linking the downside of the intercooler with the engine (air outlet hose of the intercooler). A\ The end of the hoses should be covered in case water or dust may come inside. 4.094, Dismounting and Assembling 6. Hoses of the gearbox radiator Disconnect the hoses for linking the gearbox radiator with the gearbox (two pieces: oil inlet hose andoutlet hose); A\ The end of the hoses should be covered in case water or dusty come inside, 7. Hoses of hydraulic oil radiator Disconnect the hoses for linking the hydraulic oil radiator with the hydraulic oil tank (two pieces: oil inlet hhose and outlet hose); RARANRERARE! A The end of the hoses should be covered in case water or ‘dust may come inside. 8. Cover of the fan Loose the bolts for connecting the fan cover and the windshied and then take down the fan cover. 04-10srouning ard Assembling WXCMG 9. Radiator ‘Take down the assembling bolts for connecting the radiator and the framework and lift the radiator away. (LTE Radiator unit: 200kg. AA When taking down the radiator, please note that the radiator-fans should not damaged, Assembling of the radiator unit Adopt the opposite sequences of dismounting for assembling. AX Run the engine to circulate the water in the system and then check the water level A When fixing hoses, itis not allow to distort or enwind these hoses. A\ Be careful, do not damage the radiator-fans. When fixing, the distance between the fan and the radiator should be well-proportioned. Fully tighten the bolts for fixing the radiator. 4. Re-filling with oil (1) Fill oi to the required level through the filler for the gearbox. AX Run the engine to circulate the oil inthe system and check the level again. (2) Fill oil tothe required level for the hydraulic oil tank Dismounting of the combination (engine, gearbox and torque converter) AiSiep the loader on 1 horizontal ground, lower the bucket to the ground and stop the engine. Use the parking brake and place wedge behind the wheel to preven the machine fom moving, Metis te rormant pressure inside ofthe ppines. Lit up the fron par ofthe bucket for 30-50mm and down the rear pat othe ground by operating the nob, and then stop the engine, ‘Then check whether the whol underside ofthe bucket touch the ground o ot ‘Turn the filler cap ofthe hydraulic il tank slowly to release the inside pressure, Then operating the ‘nob for evra times o release the rernant pressure inthe hydraulic ppelns Mca: ost ie poser om te negative pole ofthe batery el 4. AIC compressor unit ‘Take down the AJC compressor. Please refer to the section of "Dismounting of A/C compressor” for details,4. Dismounting and Assembiing WXCMG 2. Radiator unit “Take down the radiator unit Please refer tothe section of "Dismounting of radiator unit" for details. 3. Driver cab ‘Take down the driver cab, Please refer to the section of "Dismounting of driver cab" for details. 4, Hoses for connecting the water tank and intercooler with the engine (1) Disconnect and take down the hoses for linking the end of engine with the radiator of the water tank (permeability hose of the engine, up water hose, down water hose and water filling hose); (2) Disconnect and take down the hoses for linking the engine with the intercooler (air inlet hose and ‘outlet hose). 5, Hoses of hydraulic oil Disconnect and take down the hoses for linking the gearbox with its radiator (oil inlet hose and outlet hose);4. Dismounting and Assembling WXCMG 6. Fuel hoses (2) Disconnect the fuel hoses from the end of the fuel tank (oil inlet hose and outlet hose); (2) Disconnect the wire linker of the level sensor of the fuel tank. 7. Wires Disconnect the follow wires. AN When disconnecting wires, please tie labels on them for future identification. (1) Disconnect wires from the main power switch and the start-up relay; (2) Disconnect cables from the end of the start-up motor; (3) Disconnect wires from the sensor of the gearbox, 8. Front and rear transmission shafts Loose the bolts for connecting the front transmission shaft and the front axle; [Loose the bots for connecting the middle transmission shaft and the gearbox and those for fixing the axle bracket, and then take down the front and middle transmission shafts; on134. Dismounting and Assembling W@XCMG Loose the bolts for connecting the rear transmission shaft, the rear axle and the gearbox, and then take down the front and rear transmission shafts; A Make matching signs to indicate the assembly posi re ee @ — Rear transmission shaft: 21kg. 9. Air filter unit ‘Take down the air filter unit. Please refer to the section of "Dismounting of the front hood" for details 10. Silencer unit ‘Take down the hoop and bolts for connecting with the turbocharger, and then lift up the silencer. 11. Oil draining pipeline of engine ‘Take down the bolts for fixing the connector of oil draining pipeline of engine. oad4. Diemounting and Assembling WMG 12. Combination of the engine, the torque convertor and the gearbox 1) Use special lifting tools to lift up this combination, and then take down the assembling bolts of both sides, A Keep this combination at horizontal status when lifting it up. AX Check the assembling method of the shock pads and liners ofthe engine and the gearbox for reference ‘when re-assembling, 2) Keep this combination at a horizontal status after taking down all the bolts, and move it backwards for around 30mm, and then lift it away from the machine, A Check ifthe engine unit is blocked by any other objects when lifting it up. Engine unit: 617kg (Cummins Engine) ‘Torque convertor and gearbox: 425kg. Assembling of the combination (engine, gearbox and torque convertor) Adopt the opposite sequences of dismounting for assembling 1. Assembling of the A/C compressor Please refer to the section of “Assembling of the A/C compressor" for details. 2. Assembling of the radiator unit Please refer to the section of "Assembling of the radiator unit” for details. 3. Assembling of the driver cab lease refer to the section of "Assembling of the driver cab" for details. 4. Connect the wires and the socket connectors of the electrical equipment firmly. 045mounting and Assembling WXCMG 5. Connect the hoses and oil pipelines based on their labels. AN When connecting the transmission shafts, clean the surface of the cross joints and the couplings, and then fix them on after well engaged. Re-filling with oil 1) Fill hydraulic ol to the required level forthe hydraulic oil tank; 2) Fill oil to the required level through the filler for the gearbox. Run the engine to circulate the oil in the system and then check the oil level again, Dismounting of the front axle unit Ais: the loader on a horizontal ground, lower the bucket to the ground and stop the engine. Use the connecting rod to lock the front and rear frameworks. Use the parking brake and place a wedge behind the wheels to prevent the machine from moving. Ad Reiease he remnant pressure inside ofthe pipetnes. ‘Turn on the power and step the brake pedal slowly and continuously until the brake pressure give out alarm, then turn off the power. Loose the exhaust bolts on the front and rear brake to release the brake oil pressure, Acar oir ine power from the negative pole ofthe battery cel Use a jack to lift up the axle, and place a wood under the front framework. 4. Tyres and wheels Lift and hold the left and right tyres and ri RG) Tyres and rm: 585K (23.5-25 ere) 2. Transmission shaft Please refer to the section of "Dismounting of the combination" for details.4, Dismounting and Assembling 3. Brake pipelines (1) Dismount the cover at the front framework and then the brake pipes between the brake valve and the T-connector; (2) Dismount the brake pipe between the T-connector tothe left and right wheels. AN Insert plug to the pipe in case of any dust or dirt may ide after dismounting, (1) Lift and hold one end ofthe front axle shel, and place a jack under the other end (2) Place a jack under the differentia 4. Front axle €) Dinning tno, ey aloe yang cre adj nd en i A\ Be careful, do not let the T-conneetor at the bottom of the (4) Pull out the front axle from the underside of the framework, Assembling of the front axle unit Adopt the opposite sequences of dismounting for assembling. A\ Drain out air from the brake oil pipeline and make brake testing, A\ Fill oil t the required level through the filler forthe hydraulic ol tank Dismounting of the rear axle unit Stop the loader on a horizontal ground, lower the bucket to the ground and stop the engine. Use the ‘connecting rod to lock the front and rear frameworks. Use the parking brake and place a wedge behind the wheels to prevent the machine from moving. : Ad ketease the semoant pressure inside ofthe pipelines. ‘Tum on the power and step the brake pedal slowly and continuously until the brake pressure give out Jarm, then turn off the power, Loose the exhaust bolts on the front and rear brake to release the brake oil pressure, Mic ofr ie power fom the negative poe ofthe batery cel Use a jack to lift up the axle, and place a wood under the front framework ont?4. Dismounting and Assembling 1. Tyres and wheels Lift and hold the left and right tyres and rims, dismount the nats, and then take them down, ‘Tyros and rims: S35kg (23.5-25 Wyre) 2. Transmission shaft Please refer to the section of "Dismounting of the combination” for details. 3. Brake pipelines (1) Dismount the brake pipeline between the boost pump and the T-connector; (2) Dismount the brake pipe between the T-connector to the left and right wheels. A\ Insert a plug to the pipe in ease of any dust or dirt may ‘come inside after dismounting. 4. Grease pipeline Dismount the grease pipeline from the assembly bracket of the rear axle. 5. Rear axle and the assembly bracket (1) Fix the assembly bracket and the rear axle by chains; (2) Dismount the left and right bolts; Rear axle: 1065kg, (G) Pull out the rear axle and the assembly bracket together from the chassis and then put them down A\ Keep its balance when putting down the rear axle. Assembling of the rear axle unit Adopt the opposite sequences of dismounting for assembling. AX Assemble the rear axle first, and then the fuel tank. Please refer to the section of "Assembling of the fuel tank" for details. AX O-rings and liners should be new ones. AN Drain out air from the brake oil pipeline and make brake testing. ont4.Dismounting and Assembiing CMG Dismounting and assembling of C216NZS-1, C216NZT-1axle 1. Dismounting and disassembling Note: (1) Take protection when dismount and disassemble, The protection includes glove, protecting shoe and lasses. (2) Don't dismount the serew and fasten by cold chisel and hammer. Warning (1) Part and person may be damaged and injured caused by dismounting the screw fasten by cold chisel and hammer. (2) Support the drive axle firmly before dismounting, which can prevent part damaging and personal injury caused by axle sliding and tilting Discharge the lubrication oil from axle (1) The oil discharging should be done just after the machine stops working and the machine still has high temperature (2) Discharge the oil from the to rim reducers of axle and! main reducer located on the middle of axe, @) Release the air pressure inside the axle before oil discharging. The air releasing ean be done through dismounting the air plug 4.1 Dismounting of the brake clamp (2) Unscrew off the bolts for fastening the anti-dust cover of brake clamp and take down the anti-dust cover of brake clamp. (This item is specially point to C216NZS-1 axle, )4, Dismounting and Assembling brake clamp. (3) Take down the brake clamp. 4.2 Dismounting of the rim reducer 1.2.1 Dismounting of side cover, half shaft and sun wheel (1) Unscrew off the upper plug on the end side of rim reducer to release the air pressure inside the drive axle, then screw the plug again, Note: If discharge oil without releasing the air pressure, the oil will spout out. (2) Unscrew off the lower drain plug to discharge oil 04204, Dismounting and Assembiing WMG (3) Take down the bolis for fastening the rim end cover. (4) Take down the rim end cover. (5) Take down the ring from the half shaft, then take down the sun wheel. (6) Take out the half sha. 1.2.2 Dismounting of planetary wheel bracket (Q) Take down the three bolts for fastening the planetary wheel bracket. oat4, Dismounting and Assembling (2) Screw the M16 bolts into the two screw holes on the planetary whee! bracket to push out the planetary wheel bracket, and the orientation hole should disengage. (3) Screw the M16 bolts into the wo screw holes on the planetary wheel bracket to disengage the orientation hole between planetary wheel bracket and hub. (4) Fasten the planetary whee! bracket by safety belt and lift it away form rim, 1.2.3 Dismounting of hub and serew. (2) Take down the lock nut and retainer washer. onze4. Dismountng and Assembing @XCMG (G) Insert the screw into the open slot of taper cap, take down | the taper cap from the lock nut of ring supporter. (4) Take down the O-ring on the hub. (5) Take down the ring unit. Note: When take down the ring unit, please hang the hub by safety _ rope to keep it in level. (©) Lif the hub away by safety belt. 4.3 Take down the main reducer (1) Take down the assembling bolts of main reducer. 04.234, Dismounting and Assembling (2) Take down the main reducer by suitable rope or clamp. 4.4 Dismounting of the main reducer 1.44 Dismounting of the differentia (1) Open the safety of lock plate on the back-stopping bolt by ‘hammer and screw. (2) Unscrew the back-stopping boll, (3) Take down the iron wire on the cover of main reducer by pliers (4) Take down the lock plate for cover. 04.244, Dismounting and Assembling (5) Screw off the fastening bolts on the cover of main reducer. (6) Dismount the adjusting nut on the differentia (7) Make mark on the cover and the main reducer. Dismount the bolts for fastening the cover and take down the cover, (8) Lift out the differential form the shell by suitable rope. 1.4.2 Dismount the spiral bevel gear (1) Open the safety on tock nut of drive spiral bevel gear by hammer and serew. 04.28Dismounting and Assembling (2) Take down the lock nut, (3) Take down the input flange. (4) Take down the bolts for fastening the oil seal cover. (5) Screw the jacking screw to push out the oil seal cover, (6) Take down the oil seal cover. 04284, Dismounting and Assembling WXCMG (7) Screw into the dismounting jacking screw of bearing base to push out the bearing base. (8) Take out the bearing base and main drive spiral bevel gear 1.4.3 Dismounting of driven spiral bevel gear (1) Take down the lock nut of driven spiral bevel gear. (2) Take down the fastening bolt of driven spiral bevel gear by copper stick. (3) Take down the driven spiral bevel gear by copper stick.4, Dismounting and Assembling 1.44 Dismounting of differential unit (1) Take down the lock nut of differential shell. (2) Take down the fastening nut of differential shell by copper stick. (3) Take down the small shell of differential. (4) Take out the half shaft gear, cross shat and planetary gear. 2. Reinstalling and final assembly (1) Prepare the part before assembly Note: 1) Obey with the manufacturer manual when clean the parts with strong. solvent and alkalescence solvent. 2) The soap and water can be used to clean the non-mental part. 0428_. 4: Dismounting and Assembling W@W XCMG Warning: 1) Take glassed and protection clothes when clean the parts. 2) Do the job at a proper place with good ventilating condition, 3) The gasoline and the solvent containing gasoline should not be used, the gasoline can incur exploding. (2) The cleaning and drying to parts Remove the remaining glue away from the parts before assembling and clean the parts completely. Avoid of the parts collide each other. The cleaned parts should have no iron scraps, rust spot, rust trace and burr, The tetrachloride , emulsification oil and cleanser epurated form petroleum can be used to clean the parts. Clearly paper, clearly cloth and compressed air can be used to dry the part, Daub some grease on the parts which should be assembled at once to prevent them from rusting. Take anti- corrosion treatment for those parts that should be stored. (3) Checking and repairing for the parts ‘Check all the parts before assemble them. The checking method as follows. 1) As for the bearing, check that the inner ring, outside ring and roller has scratch, weariness, crack or deformation or not. Ifthe damaged has been found, the bearing should not be used again, 2) As for the gear, check that if the tooth has over weariness, crack, peeling and abnormal distortion or not. The damaged part should not be used again, 3) As for the shell, check that if the effected surface has crack, dent and over weariness or not. 4) As for the joint, check that if the serew has distorted tooth, collision and abnormal distortion o not. '5) As for the lock shim and oil seal, they can't be used again after dismounted. 6) As for the burr or collision mark on the unimportant surface, repair it then use it. (4) Take care in the progress of assembly _. 1) Take protection measures, for example gloves, protection shoe and protection glasses, when assembling. 2) The screwing torque to bolt must comply with relative standards. 3) Daub the 262 glue onto the screw of fasten and Letai 598 glue on the plane connection when assembling 4) When assemble the bearing, install all the parts in place by sleeve and copper hammer. 5) Assemble the rolling needle in planetary gear according to group, the needle from different batch should not be assembled into a planetary gear. Warning: 1) Tooling and rubber hammer is necessary when install the oil seal, otherwise the oil seal should leak oil for the sake of improperly assembly. 2) Screw all fastener with enough torque, otherwise the O-ring and other oil seal will leak oil, even whole ‘wheel can move outward to incur incident, 3) The moving an lifting to part should be smooth and reliable, ‘The sliding, tilting and falling of part can injury personal and damage machine. ———4, Dismounting and As 244 Assembly of hub (1) Daub 262 glue onto the bolt and install the brake dise, then fasten the bolt (The serew torque 380~450Nm,). (2) Press it into the outside ring of hub bearing, then install the inner ring of bearing. Take care that assemble the part in place. 3) Press and install the oil ring in place. (4) Daub some grease onto the hub hole and daub a litle grease ‘on the outside ring of oil seal and daub some grease on the ‘mouth of oil seal. Make the stot of oil seal face to the bearing, press and fix the single lip oil seal and double lip oil seal. Keep level and assemble firmly 2.2 Assembly of planetary wheel bracket (1) Assembling the planetary wheel ‘Daub a layer of lithum base grease into the inner hole of planetary wheel 3. dispose the rolling needle 1 ‘on one end of the inner hole evenly, then install the spacer 2. Assemble the rolling needle on another end of inner hole. 0430 ) a4:DismountingandAssembing RD IG 12 3 RS NS RS per] (2) Assemble the planetary wheel 1 pad and planetary wheel unit Place the planetary whee! bracket 3 levelly, put the planetary wheel pad 1 on the lower side of the hole of planetary wheel bracket, then put the planctary wheel unit 2 on a pad, put another pad on the planetary ‘wheel unit and make hole of wheel bracket and planetary gear in a direct line. G) Press the planetary wheel shaft into the hole of wheel bracket and planetary gear. After assembling, the planetary ‘heel can be turned freely ont4, Diamounting and Assembling WW XCMG 2.3 Assembly if gear ring supporter and bearing Heat the bearing until its temperature reach to 90-100°C and keep the temperature for 30 minutes. Install the bearing onto the gear ring supporter while the bearing is hot, ensure the installation is in plice. 2.4 Assembly of main reducer 2.4.1 Assembly if differential (1) Press and install the differential bearing 1) The big and small shell of differential should be used in pair. Daub a thin layer of grease on the fixing place of differential shell 2) Press and install the inner ring of bearing into the shaft neck of big and small shell of differential, ensure install it in place. (2) Assembly of cross shaft Install a planetary gear and a pad on every arm of the cross shat 04s(3) Assembly of half shaft gear, half gear pad and cross shaft unit. 1) Install the half shaft gear pad into the big shell of differential ‘and make the side with oil slot face to air, daub some oil. 2) Put into the half shaft gear, put the assembled cross shaft into the cross hole of differential big shell by bearing it lightly select the half shaft gear pad, ensure the engagement clearance is 0.18-0.23mm. 3) Assemble and inspect the small shell of differential with the same method (4) Install the flange bolt and lock nut. 1) Daub oil on the planetary gear and align the big and small shell. Cross through the big shell of differential or beat the bolt lightly with hammer to make assembly in place. 2) Daub glue on the screw evenly, then screw into the nut and, fasten it. The fastening torque is 206-245Nm. 04334, Dismounting and Assembling 3) Screw into the nut. The fastening torque is 206~245Nm, 4) Check the rotation of half shaft gear and planetary gear. The half shaft gear and planetary gear can be turned freely. (3) Install the big spiral bevel, lock bolt an mut. 1) Align the big spiral taper gear (o the bolt hole of differential big shell, ensure the assembly is firm. 2) Daub glue onto the screw, screw the nut 19 and fasten it. The fastening torque is 150~180Nm, 2.4.2 Assembly if gear ring supporter and bearing Daub a thin layer of grease on the outer ring of oil seal 2 and 3. install the oil seal 2 and 3 into the hole of oil seal cover, make the slot downwards, Note: Dau 3 lithium base grease onto the lip of oil seal, fill enough grease between two oil seals. 14.Dismounting and Assembling WXCMG 2.4.3 Assembly of bearing base and the selection of adjusting spacer (1) Press the bearing into the bearing base. (2) Overturn the bearing base and put it on a platform, put the bearing 3 on the bearing base. Record value B. = ( I \ YW Z ay h 3) 0.02~0,05mm.Choose the proper adjusting spacer with stitable thickness, Make the bearing clearance is 0.02~0,05mm. 2.4.4 Press the drive spiral bevel gear unit (2) Press and install the bearing base to the drive spiral bevel gear,4, Dismounting and Assembling (2) Daub seal glue evenly on the plane between bearing base And shell of main reducer. (3) Press and install the inner ring to the drive, don't install it in place, (4) Install a ring on the bearing outer ring near the small end of small bevel, press an install it into the main reducer, daub, seal glue onto the end section of main reducet shell. (5) Calculate the thickness of lower adjusting shim of bearing base: ‘A-The deviation to the theoretic value of main reducer shell B--The deviation tothe bearing base. N--Deviation to the engaging center marked on the small spiral bevel. ph shane Ata sete an rene she. gear erg, 2160500 LTTE Theor so4, Dismounting and Assembiin (© Put the small spiral bevel into the main reducer shell, choose a adjusting pad with suitable thickness and put it between main reducer shell and bearing base (7) Press and install the drive spiral taper gear in place. 24.5 Assembly of cover unit (Oil seal and oil seal base) (1) Daub seal glue evenly on the bearing base. (2) Place the cover unit and make the hole of cover aligning to the hole of bearing base. Serew the bolt M14 X 1.5 and M12 x L.5,4. Dismounting and Assembling (3) Screw every bolt tightly. The fastening torque to M14 x 1.5 bolt is 120~130N.m. The fastening torque to MI2% 1.5 bolt is 80~100N.m. (@) Engage the spline which connecting the flange spline and spiral taper gear, beat it with tooling and copper stick to make it in place. (5) Daub seal glue evenly on the end side of flange Pes corresponding to lock mut. (6) Screw lock nut to the small spiral taper gear, the fastening torque is 800-850Nm. If the 75500269 lock slot mut has been adopted, the 75500231 washer should be used. The flange should rotate freely when be tumed by hand, (7) Assemble the inner ring of bearing in place with tooling sleeve and hammer.4. Dismounting and Assembling 2.4.6 Assembly of differential and adjustment of gear clearance (1) Lift and install the differential into the main reducer shell (2) Lift the differential and install the outer ring of bearing, adjust the gear clearance and touching area of main drive taper gear ‘couple by adjusting the differential nut. (3) Check the gear clearance: ‘Tum the big spiral taper gear and inspect the clearance with dial indicator, the gear clearance must be 0.3~0.4mm. the. clearance between two bearing on differential must be 0. If the clearance exists please adjust it repeatedly, and atthe same time, check the engaging clearance. (4) Check the contacting area: ‘Use a brush to paint red lead powder on three teeth faces evenly divided on the helical cone gear. Turn the hetical cone gear to make contact prints. Make some adjustment to have an print equal or more than 1/2 ofthe total tooth length, from the upper end of the teeth to middle of the teeth. Ifthe contact print is irregular, choose the suitable adjustment shim and adjust the position of differential nut 1. (5) Screw the bolt 24, the fastening torque is 410~450Nm, 04.394. Dismounting and Assembing WXCMG (6) Fix the lock shim on the tile by bol, the fastening torque is, 40-50Nm. Knock the claw of lock shim into the groove of

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