Service Manual of Wheel Loader

Contents
9 Working hydraulic system ...................................................................................................................... 1
91 Overview of working hydraulic system..................................................................................................... 1
92 Measurement and adjustment of working hydraulic system .................................................................. 3
921 Measurement of system working pressure...................................................................................... 3
922 Overload pressure measurement of rotating bucket cavity .......................................................... 5
923 Primary pressure measuring of pilot control ................................................................................. 6
924 Secondary pressure measuring of pilot control .............................................................................. 8
925 Settlement detection of cylinder .................................................................................................... 10
926 Pressure adjustment of safety valve ...............................................................................................11
93 Precautions for repairing the hydraulic system ..................................................................................... 12
94 Introduction to hydraulic components.................................................................................................... 13
941 Hydraulic oil tank ........................................................................................................................... 13
942 Working pump ................................................................................................................................ 13
943 multi-way valve ............................................................................................................................... 15
944 pilot valve.................................................................................................................................... 19
945 Pressure selector valve .................................................................................................................... 23
95 Fault diagnosis and troubleshooting of hydraulic system ..................................................................... 24
951 Bucket falling .................................................................................................................................. 24
952 Boom settlement .............................................................................................................................. 26
953 Slow lift of the boom ....................................................................................................................... 27
954 Inability of boom lift ....................................................................................................................... 30
955 Blow bucket movement .................................................................................................................. 31
956 Inability bucket movement ............................................................................................................ 31

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9 Working hydraulic
system
91 Overview of working hydraulic
system
working hydraulic system adopts a pilot valve
for control. Its system working pressure is
19Mpa. Its working principle is shown in the
figure below:

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Figure 9-1 Schematic diagram of L958F working hydraulic system

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92 Measurement and adjustment of

working hydraulic system
921 Measurement of system working
pressure
Measurement of oil temperature: 45 - 55℃.
Pressure measuring tool: 40Mpa pressure gauge,
pressure connector (4120002945), piezometric tube
(4030000368).
Pressure measuring standard: 18.7-19.2Mpa
Pressure measuring position: Pressure measuring
hydraulic oil port near the oil inlet of the multi-way valve.
Fig. 9-3 4030000370 pressure gauge
Pressure measuring process:
1. Place the working device on the ground. Press
the button of parking brake. Wedge the tire
with wood or stone. Turn off the engine.
2. Manipulate the control handle and the steering
wheel for 10 times and about 5 times
respectively to release residual pressure in the
hydraulic oil pipe. Prepare tools for pressure
measuring.
3. Remove the pressure measuring plug screw on
the oil inlet of the multi-way valve.
4. Install the pressure measuring joint to the
pressure port of the multi-way valve.
5. Tighten piezometric tube on the pressure
measuring joint.
Fig. 9-4 pressure measuring joint
6. Connect the pressure gauge to the pressure
measuring hose.
7. Start the engine and place the control handle of
the rotating bucket in the close position. After
the bucket is placed in position and moved to
the limit position, gradually accelerate to the
maximum (2200/rpm). Observe the oil
pressure gauge to obtain the stable pressure,
which is the current working pressure of the
working device hydraulic system of the tested
loader.
Note: To confirm measurement accuracy, the
control handle of the boom might be moved to
lifting or falling positions for repeated
measurements.
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Fig. 9-5 4030000368 pressure measuring hose

Fig. 9-6 Measurement location of system pressure

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922 Overload pressure measurement of

rotating bucket cavity
Note: This pressure measuring method is only
applicable to fault diagnosis. Servicemen are
prohibited to adjust the overload valve on the
machine.
Measurement of oil temperature: 45 - 55℃.
Pressure measuring tool: 40Mpa pressure gauge
(4030000370), pressure connector (4120002945),
piezometric tube (4030000368). See 921
Measurement of system working pressure
Pressure measuring standard: 21±0.5 Mpa.
Pressure measuring position: Plug screw on the
steel pipe of the rotating bucket cavity
Pressure measuring process:
1. Place the working device on the ground. Press
the button of parking brake. Wedge the tire
with wood or stone. Turn off the engine.
2. Manipulate the control handle and the steering
wheel for 10 times and about 5 times
respectively to release residual pressure in the
hydraulic oil pipe. Prepare tools for pressure
measuring.
3. Remove the plug screw of pressure measuring
on the steel pipe of the rotating bucket cavity.
4. Install the pressure measuring joint to the
pressure port of the multi-way valve.
5. Tighten piezometric tube on the pressure
measuring joint.
6. Start the engine. Lift the boom to the highest
position. Run the diesel engine at idle speed.
Manipulate the control handle of the rotating
bucket to the maximum. Return to the neutral
position. Operate the control handle to lower
the boom. The current maximum pressure of
the pressure gauge is the overload pressure of
the overload valve of the rotating bucket
cylinder cavity. (The maximum stress appears
after the bucket reaches the limit position)
Note: The measurement might be repeated for
confirmation.
Fig. 9-7 Measurement position of overload valve pressure

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923 Primary pressure measuring of

pilot control
Note: This operation is applicable to model of pilot
control only.
Measurement of oil temperature: 45 - 55℃.
Pressure measuring tool: 6Mpa pressure gauge
(6410003106), pressure connector (4120001751),
T-junction (4120001100) and piezometric tube
(4030000368).
Pressure measuring standard: 4 Mpa.
Pressure measuring position: Oil inlet of pilot filter.
Fig. 9-8 6410003106 pressure gauge
Measurement process:
1. Place the loader in the service location. Lay
the bucket on the ground. Pull up the parking
brake. Shut down the engine. Operate the
handle of the working device handle 3 - 5
times to release residual stress in the hydraulic
oil pipe.
2. Remove the inlet pipe of the pilot filter. Install
the T-junction on the location of removal.
Install the test joint and oil pipe on the
T-junction.
3. Connect one end of the test hoes to the joint
and the other end to the pressure gauge.
Fig. 9-9 T-junction and test joint
4. Start the engine. Move the pilot handle to the
limit position. Gradually accelerate to observe
the pressure gauge for a stable pressure value.
5. The control handle might be moved to other
limit position to repeat the measurement to
guarantee accuracy of test data.
6. After test, repeat step 1 of pressure releasing.
Remove the T-junction and install the oil pipe.
7 Wipe hydraulic oil leaking in the removal.
Fig. 9-10 4030000368 pressure measuring hose

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Fig. 9-11 Primary pressure measuring position of pilot control

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924 Secondary pressure measuring of

pilot control
Note: This operation is applicable to model of pilot
control only.
Measurement of oil temperature: 45 - 55℃.
Pressure measuring tool: 6Mpa pressure gauge
(6410003106), pressure connector, T-junction and
piezometric tube (4030000368).
Pressure measuring standard: 2Mpa.
Pressure measuring position: Pilot pipe joint of
multi-way valve.
Fig. 9-12 6410003106 pressure gauge
Pressure measuring process:
1. Place the loader in the service location. Lay
the bucket on the ground. Pull up the parking
brake. Shut down the engine. Operate the
handle of the working device handle 3-5 times
to release residual stress in the hydraulic oil
pipe.
2. Remove the pilot oil pipe as shown in Figure
9-15. Install the T-junction on the location of
removal. Install the test joint and pilot oil pipe
on the T-junction.
3. Connect one end of the test hoes to the test
joint and the other end to the pressure gauge.
Fig. 9-13 T-junction and test joint
4. Start the engine. Manipulate the pilot handle to
move the bucket to the limit position. And then
gradually accelerate to the maximum.
Observer the oil pressure gauge to obtain the
stable pressure value, which is the pilot
pressure at the back joint position of the tested
loader.
Measurement methods of other joints are similar to
it.

Fig. 9-14 4030000368 pressure measuring hose

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5. The control handle might be moved to boom
lift position to repeat the measurement to
guarantee accuracy of test data.
6. After test, repeat step 1 of pressure releasing.
Remove the T-junction and install and remove
the oil pipe. Wipe hydraulic oil leaked.

Fig. 9-15 Pilot pressure measurement point of back joint

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925 Settlement detection of cylinder

Measurement of oil temperature: 50 ±3℃.
Pressure measuring tool: Timer and meter ruler.
Measurement standard:
Cylinder of rotating bucket ≤20mm/h;
Lift cylinder ≤50mm/h.
Measuring position: Boom cylinder or bucket
cylinder
Measurement process:
1. Load the bucket to the rated working mass and
reverse it backward. Operate the boom
cylinder to lift the bucket to the highest
position. Move the multi-way valve to the
neutral position and turn off the engine.
2. Measure the extension length of boom cylinder
and bucket cylinder every 15 minutes and
record the data in corresponding table. The
total test duration is 3h.

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926 Pressure adjustment of safety

valve
If any pressure abnormity after pressure
measurement of the hydraulic system, adjust the
pressure of the safety valve. The set pressure of the
main safety valve on the multi-way valve decides
the working pressure of the system. The set
pressure of the safety valve on the pilot pump
decides the primary pressure of the pilot pump.
Now it is to introduce how to adjust the set value of
safety pressure with the main safety valve as an
example.

Fig. 9-16 Position of main safety valve

Adjustment process:
1. Remove the lead sealing and protection cover
at the end surface of the pressure regulating
screw .
2. Loosen locknut with a wrench.
3. Rotate the pressure regulating screw with a
socket head wrench. The pressure increases
when the screw is rotated clockwise. The
pressure decreases when the screw is rotated
anticlockwise. Adjust to the proper pressure
and fasten locknut. Reference value: The
adjustment amount for rotating the adjusting
screw by a circle is 4Mpa.
4. Penetrate a fine steel wire into the hole on the
pressure regulating screw 3 and then penetrate
into the protection cover. Seal it with a lead
sealing.
1 2 3
Fig. 9-17 Main safety valve
1 Locknut 2 Pressure regulating screw
3 Protection cover

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93 Precautions for repairing the hydraulic system

1. Avoid adding hydraulic oil or replacing filter
or preparing the machine in rains or places of
strong wind or much dust.
2 The hydraulic device should be disassembled
and maintained in a special dust-free workshop.
In addition, its performance should be tested
with special test devices.
3. Pay attention to openings of the seal.
4. It is suggested to replace the oil when the oil
temperature is hot. Used oil should be
discharged thoroughly in oil replacement.
5. In disassembly, assembly of hydraulic
equipment or oil replacement, rinse pollutant,
fatlute and used oil in the hydraulic oil with
flushing oil. Rinse twice in normal
circumstances: Rinse the first time with
flushing oil; rinse the second time with
specified hydraulic oil.
6 In the process of dismantling and maintenance
of hydraulic system, it is required to fasten
according to the torque required in the manual.
Excessive or insufficient torque might cause
leakage of hydraulic oil.
7 Pressure of the system should be released
according to steps below before maintaining
the hydraulic system:
(1) Start the engine. Drive the vehicle to a flat
and wide ground. Move the boom to the
highest position. Retrovert the bucket.
(2) Push the control handle of the pilot valve
backward slowly. Antevert the bucket to
discharge oil in the bucket cylinder.
(3) After the bucket is moved in place, push the
handle forward slowly to lower the boom
gradually to discharge oil in the boom cylinder.
Place the bucket on the ground. Move the
control handle all around 5-6 times to release
the oil pressure in the system.

Fig. 9-19 Pressure relief of the system

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94 Introduction to hydraulic
components
941 Hydraulic oil tank
It is used to supply oil to the whole hydraulic
system. An oil return filter tank is set in the oil tank
to remove impurities in the hydraulic system to
guarantee cleanliness of hydraulic oil. The air
change filter installed on top of the hydraulic oil
tank can prevent damages to the oil tank during the
process of using due to imbalance of internal and
external pressure of the tank

Fig. 9-20 Hydraulic oil tank

942 Working pump

L956F loader (T3 engine + VRT transmission)
The working pump is a duplex gear pump,
where the first pump is used to feed oil to the
working hydraulic system and the second one is
used to feed oil to the transmission system. The
working pump is connected with the power
take-off hole of the transmission. It converts the
mechanical energy input by the transmission
into pressure energy of oil, and then input the
pressure energy to the system in forms of
pressure and flow. The working pump is a
150/50 duplex pump.

Table 9-3 Parameters of pump

Name Parameter

Connection type Rectangular spline

Figure 9-24 Working pump Direction of turning Rightward

Nominal
150/50ml/r
displacement

Revolution range 2,200r/min

Rated air pressure 21/25Mpa

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Table 9-1 Fault Diagnosis of the Working Pump

No. Fault phenomenon Fault cause Elimination methods
Oil leakage on pump body O-ring is damaged or bolts Replace the O-ring or
1
junction surface are loose fasten the bolts
Inspect and replace the
2 Pump body oil leakage Pump body defect
working pump
Excessive wear of the Replace the spline shaft
spline shaft or working pump
Excessive wear of the side Replace the side plate or
plate working pump
Abnormal sound of the working
3 Oversize of the spline
pump Replace the spline shaft
shaft, holding against the
or working pump
shaft
Replace the bearing or
Damage of bearing
working pump
Replace the
Slow motion due to lack of flow Excessive wear of the gear
4 corresponding parts or
of the working pump or side plate
working pump

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943 multi-way valve

loader uses a pilot valve as its multi-way valve,
which enables the valve stem to move through
the pilot oil. This valve mainly consists of valve
body, movable arm slide valve, rotating bucket
slide valve, main overflow valve, overload
valve, and various check valves. The two slide
valves connect with each other in series.

Table 9-4 Main parameters of multi-way valve

Item Name

Model KM300-II-19

Code 4120006636

Nominal pressure (MPa) 19

Nominal flow rate (L/min) 300

Pressure of the main relief valve (MPa) 19.2～19.7

The pressure of the rotating A2 21±0.5

bucket overload valve (MPa)
B1 12±0.5

Figure 9-25 Structure of multi-way valve

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Figure 9-5 Structure and position of multi-way valve

No. Name No. Name

1 Low-pressure overflow valve xA1 Control forward tilting of the bucket

2 Overload valve (12±0.5) MPa xB1 Control backward tilting of the bucket

3 Main relief valve xA2 Control rising of the movable arm

4 Overload valve (21±0.5) MPa xB2 Control falling of the movable arm

P Main oil inlet xP Oil outlet of the pressure selector valve

A1 Connect the large cavity of the bucket xT Connect the tank for oil return
cylinder

B1 Connect the small cavity of the bucket xF Connect the oil inlet/outlet via logic
cylinder valve

A2 Connect the large cavity of the movable B2 Connect the small cavity of the movable
arm arm

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KM300 Fault and troubleshooting of multi-way

valve
1. Floating position failure
Phenomenon: Although the floating control
pressure reaches 3MPa, the valve rod fails in
reaching the floating position.
Method 1: Unscrew the screw-plug on one side
of the valvelet body, take out its core, and
inspect whether the core can freely move in the
valvelet opening during the process of taking it
out. If it is stuck, inspect whether there are burrs
on valvelet rod and opening; and if it is still
stuck after removing the burrs, replace the
valvelet rod. Inspect whether there are too many
adjusting washers in the screw-plug, and then
assemble the valvelet core, spring and
screw-plug after removing the adjusting
washers.
Method 2: Loosen the nut for fastening the
valvelet body, and take off the check ring and
valvelet body. Unscrew screw-plug of the end
cap with a special tool, and take out the spring
and floating piston; during taking out the
floating piston, inspect whether it can freely
move in the end cap, and replace a new one if it
is stuck.
2. Valve rod is stuck or oil leakage appears at
both ends of the valve rod
Remove the bolts on limit end cap (hydraulic
control) of the stuck valve rod (moveable arm
chip as the end cap), remove the limit end cap
(hydraulic control), and then pull out the valve
rod; meanwhile, inspect whether the valve rod
can freely move in the valve opening, if it is
stuck, inspect whether there are burrs on valve
rod and opening; and if it is still stuck after
removing the burrs, replace the valve rod.
If both ends of the valve rod subject to oil
leakage, inspect and replace sealing elements at
both ends of the valve rod according to the
methods mentioned above.
3. Serious internal leakage
Inspect whether the valve rod is slightly stuck
that may affect length of the seal belt according
to the methods mentioned above; if there is no
abnormal phenomenon, inspect whether the

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valve rod and opening subject to abnormal wear.
If there is abnormal wear in the valve opening, it
shall be repaired in a specialized plant, and
replace with the appropriate valve rod.
If the valve rod is slightly worn, it can be
recovered by electroplating.
4. Safety valve (overload valve) failure or
low pressure
When the system does not act or the operation
speed is significantly reduced, inspect whether
there are foreign matters in the overflow valve,
whether the pressure regulating lock nuts are
loose, and whether the pressure adjusting spring
is subject to residual deformation, and remove
and adjust the corresponding elements.
5. Setting of safety valve and overload valve
Safety valve: First remove the nut cap on the
safety valve, loosen the lock nut, next set the
system pressure at a value being higher than
settling pressure of the safety valve, then fully
open the safety valve, and finally set the flow
passing through the safety valve as 320L/min; at
this time, adjust pressure of the main safety
valve to the required value with a slot type
screwdriver; the clockwise adjusting refers to
pressure rise, and anticlockwise adjusting refers
to pressure reduction. After such adjustment,
tighten the lock nut and nut cap. Fully open the
overload valve, and set the flow passing through
the overload valve as 35L/min; at this time,
adjust pressure of the overload valve to the
required value with a special tool, the clockwise
adjusting refers to pressure rise, and
anticlockwise adjusting refers to pressure
reduction. After such adjustment, tighten the
lock nut and nut cap.
6. Oil cleanliness of the system
The failure of the control valve is mostly caused
by poor oil cleanliness. When the cleanliness
cannot meet the requirement, the oil shall be
timely replaced and working medium shall be
filtered; the filter shall also be replaced or
cleaned.
Matters needing attention during installation,
debugging and operation of the complete
machinery
1. Ensure that the flatness of the installation
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plane is less than 0.1, to avoid valve sticking due
to the uneven plane.
2. Prevent dirt from entering into the inner
chamber during removal.
3. Before pilot run, ensure that the working
medium is filled into the component. First
implement no-load operation at low speed for 5
min., to inspect whether the air in the system is
fully exhausted; if there are too many bubbles in
the oil tank, and there is abnormal noise, inspect
whether the oil suction and pipe are subject to
air leakage.
4. Inspect the motion of the control valve
under no-load operation at low speed, when the
executive component acts normally, implement
high-speed running for 5 min.
Recommended tightening torque of spare
parts:
160Nm for screw-plugs of the main safety valve,
overload valve, and one-way valve, and G1"
plug of the return opening;
35Nm for M8 bolts on the end cap, and Loctite
thread fastening adhesive shall be coated;
20Nm for stop screw on the valve rod, and
Loctite thread fastening adhesive shall be
coated;
40Nm for screw-plugs on the floating control
valve blocks and plugs at the pressure detecting
points;
160Nm for M24 nuts on the floating control
valve blocks, and Loctite thread fastening
adhesive shall be coated;
Other parts needing to be tightened shall be free
from oil leakage after being tightened.

944 pilot valve

Pilot valve model of L958F is PCL403-35-B.
The pilot valve is installed at the right of the
driver seat in the cab, and the driver can control
the boom spool or rotating bucket spool valve
within the multi-way valve through controlling
the pilot control rod, so as to control working
devices of the vehicle.

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Figure 9-26 Oil mouth at the bottom of pilot valve

Figure 9-27 Schematic diagram of pilot valve

Table 9-7 Technical parameters of pilot

valve

Item Parameter

Model PCL403-35-B

Nominal pressure 4.31Mpa

Nominal flow 7.6～19L/min

rate

Operating voltage DC24V

of electromagnet start control pressure2.3゜terminate control pressure14゜ compulsion turn on
pressure15.5゜

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Faults and solutions

Phenomenon 1: Abnormal noise.
Solution: Exhaust air from the system, and loosen
the relevant connectors to exhaust the air in
necessity.
Phenomenon 2: Oil cylinder subjects to stick-slip.
Solution: Exhaust air in the system, and loosen the
relevant connectors to exhaust the air in necessity.
Phenomenon 3: Abnormal action.
Solution: Inspect whether the oil inlet, return
opening and working port are correctly connected.
Inspect whether the valve rod is stuck.
Phenomenon 4: No floating position.
Solution: Inspect whether the pressure of control
port A reaches the pressure of the floating position,
and inspect whether the valve rod is stuck.
Phenomenon 5: There is pressure oil at the service
ports (A\B\C\D) when the handle is at the neutral
position, or the motion of the handle is sluggish.
Solution: Loosen the nuts on the pressure plate with
a wrench, and adjust the height of the pressure plate
with a special tool, to equalize the strength at four
directions of the handle, and make it automatically
return to the neutral position without
electromagnetic force.
Phenomenon 6: When the handle is pushed forward
to the position of the steel ball, the output pressure
at port A is higher than the designed value, namely
when the handle is pushed forward to the position of
the steel ball, valve rod of the movable arm chip has
reached the floating position.
Solution: Replace the spring or reduce the pressure
adjusting washers: remove the four bolts on the
valve body, and the handle, as well as the pressure
plate, pivot assembly, pallet, solenoid assembly,
push rod assembly, and spring. Remove the four
bolts in the upper valve body, to separate the upper
valve body from valve body; take out the plunger
assembly and valve rod assembly (port A). Put the
valve rod assembly on a dedicated device to remove
its screws, next take out the spring, and then reduce
the pressure adjusting washers or replace the softer
spring. Install the spring seat, tighten the screws to
the required torque, install the valve rod assembly
into the valve body, place the plunger assembly,

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cover the valve body, and tighten the four bolts to
the required torque. Install the spring, push rod
assembly, pallet, pivot assembly, and solenoid
assembly, then tighten the four bolts to the required
torque, and finally cover the protective jacket.
Phenomenon 7: The handle is stuck during
operation; when it is pushed to a direction, the
resistance is uneven, being sometimes large and
sometimes small.
Solution: Inspect whether the cleanliness of
hydraulic oil meets the drawing requirements; if not,
replace the hydraulic oil.
Phenomenon 8: When the handle is pushed to a
direction (the direction absorbed by electromagnet),
the electromagnet does not act.
Solution: Inspect whether the connection plug
connecting with the electromagnet is correctly
installed; whether there are foreign matters on the
contact surface between the electromagnet and push
rod assembly; if there is no abnormal phenomenon,
replace the electromagnet.
Phenomenon 9: The valve core is stuck.
Solution: Dismantle and inspect the valve core, to
see whether there are foreign matters; it shall be
cleaned or replaced.

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945 Pressure selector valve

The pressure selector valve is installed in the pilot
oil-way. It is mainly composed of valve body, valve
element, spring, etc. The pressure selector valve
role is to provide control oil of certain pressure to
the pilot valve and guarantee to place the boom on
the ground even if the diesel engine has flameout.
The model of the pressure selector valve is SF8-D.
Its nominal pressure is 20Mpa. The exit pressure of
the relief port is 4±0.2MPa.

Fig. 9-26 Appearance of pressure selector valve

Fig. 9-27 Section of pressure selector valve Fig. 9-28 Schematic diagram of pressure selector
valve

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95 Fault diagnosis and

troubleshooting of hydraulic system
951 Bucket falling
Fault phenomenon: the bucket automatically
anteverts (falling) when the control handle of the
pilot valve is in the neutral position.
Fault analysis: when the bucket is in the closed
state and the control handle of the pilot valve is in
the neutral position, dead load of the bucket causes
the bucket cylinder suffer pressure from the large
cavity. At this point, the bucket anteverts
automatically as long as the pressure oil in the big
cavity pressure has leakage against the return
opening.
Fault causes:
1. Pipeline fault: There is apparent leakage in
pipe fittings, joints of cylinder large cavity and
multi-valve and junction surface of
installation.
2 Oil cylinder fault: Besides inner leakage of the
rotating bucket cylinder, the small cavity of
the rotating bucket cylinder also leaks
compared with the return opening.
3. Multi-way valve or pilot valve fault:
 The reversing slid valve of the rotating
Filter valve bucket fails to return the neutral position
so that the small cavity of the rotating
bucket cylinder is connected to Port P of
multi-way valve, large cavity and returning
opening.
Rotating
bucket valve  The overload pressure of the overload
valve for the large cavity of the rotating
bucket cylinder on the multi-way valve.
Rotating bucket  The oil supplementary valve of the large
slide valve of cavity of the rotating bucket cylinder leaks
multi-way valve
oil.
 Valve element or valve hole of the
reversing valve is excessively worn so that
the fit clearance of valve element and valve
hole is much higher than the design value.
As a result, pressure oil in the large cavity
of the rotating bucket cylinder leaks.
Fig. 9-29 Schematic diagram of rotating bucket joint

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Fault detection and troubleshooting
1. Check the pipeline for leakage: Start the
machine and raise the boom to a certain height
to return the bucket to the maximum. Observe
whether there is apparent leakage on pipes,
joints from the large cavity of rotating bucket
cylinder to the multi-way valve and the
junction surface of installation, etc.
2. Judge whether the pilot valve has fault: If no
external leakage, raise the boom to the highest
position by operating the pilot valve handle.
After the bucket is raised to the maximum,
close the engine and remove pilot pipes on
both ends of the slide valve of the multi-way
valve rotating bucket joint The bucket does not
fall, it might be the pilot valve which cause
that the slide valve of the multi-way valve
rotating bucket fails to return the neutral
position and thus causes bucket falling.
Dismount, check and clean or replace the pilot
valve. Or otherwise, continue the following
steps for judgment.
3 Judge whether the oil cylinder leaks: Operate
the handle of the pilot valve to lower the boom
to the lowest position and retrovert the bucket
to the maximum. Close the engine and
disconnect the hose for the small cavity of the
rotating bucket and lead it back to the
hydraulic oil tank. Then, start the machine and
operate the handle of the pilot valve to
retrovert the bucket. Observe whether the oil
port of the large cavity of the rotating bucket
cylinder leaks hydraulic oil constantly. If yes,
the rotating bucket cylinder has serious
leakage. It is required to dismount, check and
repair or replace the cylinder. If oil cylinder
has no leakage, continue the next step for
judgment.
4. Judge whether the overload valve and oil
supplementary valve is damaged: Connect a
40mpa pressure gauge to the pressure
measuring port of the large cavity of the
rotating bucket cylinder. Start the machine.
Operate the handle of the pilot valve to make
the bucket in the most forward position. Step
on the accelerator and operate the handle of
the pilot. Observe whether the reading of the
pressure gauge reaches the design value during
the lifting process of the boom. If not,

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 Service Manual of Wheel Loader
dismount, check and clean the overload valve
or oil supplementary valve of the large cavity
of the rotating bucket cylinder.
5. Check whether the slide valve of the
multi-way valve is damaged: If the above
situations are excluded, stop the machine and
lower the boom and the bucket to the bottom.
Remove the rotating bucket slid valve of the
multi-way valve and check the valve rod and
valve holes carefully for fitness. Valve element
or valve hole of the reversing valve is
excessively worn so that the fit clearance of
valve element and valve hole is much higher
than the design value. As a result, pressure oil
in the large cavity of the rotating bucket
cylinder leaks.
952 Boom settlement
Fault phenomenon: when the control handle of the
pilot valve is in the neutral position, the boom
lowers automatically and exceeds the settlement
Connected by pressure selector valve standard of the cylinder.
Fault analysis: when the boom is lifted and kept at
any height, dead load of the boom makes
corresponding oil pressure be reserved in the large
cavity of the boom cylinder. At this point, the boom
lowers automatically as long as the pressure oil in
Boom the big cavity pressure has leakage compared with
cylinder the return opening.

Fig. 9-30 Schematic diagram of boom joint

Fault cause:
1. Pipeline fault: There is apparent leakage in
pipe fittings, joints of cylinder large cavity and
multi-valve and junction surface of
installation.
2. Oil cylinder fault: Besides inner leakage of the
boom cylinder, the small cavity of the boom
also leaks compared with the return opening.
3. Multi-way valve or pilot valve fault:
 The boom reversing valve rod of the
multi-way valve fails to return the neutral
position so that the small cavity of the
boom cylinder is connected to pump port,
large cavity and returning opening.

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Service Manual of Wheel Loader
 Valve element or valve hole of the
reversing valve is excessively worn so that
the fit clearance of valve element and valve
hole is much higher than the design value.
As a result, pressure oil in the large cavity
of the boom cylinder leaks.
Fault detection and troubleshooting
1. Check the pipeline for leakage: Start the
machine and raise the boom to the highest
position to return the bucket to the maximum.
Observe whether there is apparent leakage on
pipes, joints from the large cavity of boom
cylinder to the multi-way valve and the
junction surface of installation, etc.
2. Judge whether the pilot valve has fault: If no
external leakage, raise the boom to the highest
position by operating the pilot valve handle.
After the bucket is raised to the maximum,
close the engine and disconnect pilot pipes on
both ends of the slide valve of the multi-way
valve boom slide valve. If the boom does not
settle, it might be the pilot valve which causes
that the slide valve of the multi-way valve
boom slide valve fails to return the neutral
position and thus causes boom settlement.
Dismount, check and clean or replace the pilot
valve. Or otherwise, continue the following
steps for judgment.
3 Judge whether the oil cylinder leaks: Raise the
boom to the maximum. Close the engine and
open the hose of the small cavity of the boom
cylinder to lead it back to the hydraulic oil
tank. Start the machine and operate the handle
of the pilot valve. Observe whether the oil port
of the small cavity of the boom cylinder leaks
hydraulic oil constantly. If yes, the boom
cylinder has inner leakage. It is required to
dismount, check and repair or replace the
cylinder. If oil cylinder has no inner leakage, it
is required for analyze further.
4. Judge fault of multi-way: Lower the boom and
bucket to the bottom. Remove boom valve rod
of the multi-way valve. Check the valve rod
and the valve hole carefully for fitness.
953 Slow lift of the boom
Fault phenomenon: operate the handle of the pilot
valve at the rated speed of the diesel engine. The
time required to lift the boom from the bottom to
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Service Manual of Wheel Loader
the highest position is longer than the standard
lifting time.
Fault analysis: according to the characteristics of
the hydraulic power component, the cause for slow
lifting of the boom is: the flow delivered from the
pump to the hydraulic oil cylinder is insufficient.
Fault cause:
 Joints, pipes and valves from the pump
opening to the large cavity of the boom
cylinder and other junction surfaces have
severe leakage.
 The hydraulic oil contains a large amount
of air bubbles or appears black, gets severe
deterioration and loses the corresponding
viscosity.
 The suction filter is blocked or interior
rubber of the fuel sucking pipe falls out
and thus causes the fuel sucking pipe be
blocked. As a result, severe insufficient oil
suction causes insufficient output flow of
the working pump.
 The work pump has severe inner leakage
which causes insufficient output flow.
 The boom cylinder has severe inner
leakage.
 Main safety valve pressure of the
multi-way valve is too low.
 There is severe inner leakage between the
oil inlet passage and return passage of the
multi-way valve body.
 Reversing valve or hole of the multi-way
boom is excessively worn so that the fit
clearance of valve element and valve hole
is much higher than the design value. As a
result, pressure oil leaks from the large
cavity of the boom cylinder.
 The opening degree of the multi-valve rod
is insufficient.
Fault detection and troubleshooting
1. Check for outer leakage: Start the machine and
lift the boom. Observe whether joints, pipes
and valves from the pump opening to the large
cavity of the boom cylinder and other junction
surfaces have severe leakage.
2. Check the oil: In case of no outer leakage,
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Service Manual of Wheel Loader
conduct basic inspections: whether the
hydraulic oil level in the oil tank is above the
lowest level; whether the hydraulic oil
contains large amount of bubbles or turns
black.
3. Check sound: It is required to start the
machine to judge whether the hydraulic oil is
abnormal. Operate the pilot valve to add load
to the hydraulic system. Meanwhile, it is
required to pay attention to judge whether
there is any squeal in the working pump. If yes,
it means that the oil suction of the working
pump is woefully inadequate. Check the oil
suction filter and hose.
4. Check the working pump for inner leakage: If
the working pump has no squeal, operate the
pilot valve to make the pump loaded for 1-2
minutes. Close the engine. Touch the shell of
the working pump with hand carefully. It the
shell is very hot. It could be judged that the
working pump has severe inner leakage, which
causes insufficient output flow.
5. Test pressure: Connect a 40MPa pressure
gauge to the pressure measuring opening of
the multi-way valve Port P. Start the engine
and operate the handle of the pilot valve to
press the hydraulic system. Meanwhile,
observe the pressure gauge. Its reading should
reach the design pressure. Conduct the
following inspections if it fails to reach the
design pressure.
6. Test the oil cylinder for inner leakage: Start the
machine. Operate the handle of the pilot valve
to lower the boom to the lowest position and
retrovert the bucket to the maximum. Close the
engine and disconnect the hose for the large
cavity of the boom cylinder and lead it back to
the hydraulic oil tank. Then, start the machine
and operate the handle of the pilot valve to
lower the boom. Observe whether the oil port
of the large cavity of the boom cylinder leaks
hydraulic oil constantly. If yes, the boom
cylinder has serious leakage. It is required to
dismount, check and repair or replace the
cylinder.
7. Check the main safety valve: disassemble,
check and clean the main safety valve. The
main safety valve should be replaced in case of
irreparable issues such as deformation of valve
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Service Manual of Wheel Loader
element, hole, etc.
8. Check the multi-way valve: If the system
pressure still fails to reach the design pressure
after the above attempts. It is suggested to
disassemble and check the boom valve rod of
the multi-way valve. Check the valve body,
valve rod, valve hole as well as valve rod and
valve hole for fitness carefully.
9. If the pressure of the hydraulic system reaches
the design value and the slow lifting issue of
the boom still exists, it is required to conduct
the inspections and troubleshooting below:
Operate the pilot valve to lower the boom and the
bucket to the lowest position. Open the end cover of
the slide valve end without spring of the multi-way
valve boom. Move the valve rod axially. Pay
attention to observe whether the movement distance
of the valve rod is proper and whether the return is
free.
Exchange the pilot pipes controlling the rotating
bucket valve rod and the boom valve rod. Start the
machine and operate the pilot valve. Observe
whether the boom lift is normal. If yes, disassemble,
check and clean the boom valve block of the pilot
valve.
954 Inability of boom lift
Fault phenomenon: operate the handle of the pilot
valve to lift the boom with full load at the rated
speed of the diesel engine, but it fails to lift the
boom.
Fault analysis: the most direct cause for inability of
the boom lift is the excessive low pressure in the
large cavity of the boom cylinder.
Fault cause:
The overload pressure of the main safety valve of
the multi-way valve is too low.
The working pump has severe inner leakage which
disables the system to form pressure or reach the
design pressure.
The boom cylinder has severe inner leakage.
There is severe inner leakage between the oil inlet
passage and return passage of the multi-way valve
body. It disables the system to form pressure or
reach the design pressure.
Fault detection and troubleshooting

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Service Manual of Wheel Loader
As for troubleshooting of inability of boom lift, it is
required to focus the above four points and refer to
the fault detection of troubleshooting of "slow
boom lift".
955 Blow bucket movement
Analyze and solve referring to slow boom lift.
956 Inability bucket movement
Analyze and solve referring to inability of boom
lift.

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