6 Fault diagnosis

6.1 Precautions for fault diagnosis ............................................................ 6-7

6.2 Basic fault detection before maintenance ........................................ 6-8
6.3 Classification of faults ........................................................................... 6-11
6.4 DTC ............................................................................................................... 6-13
6.4.1 DTC 101001 Extremely low battery voltage ......................................... 6-13
6.4.2 DTC 101003 High battery voltage ......................................................... 6-20
6.4.3 DTC 101017 Low battery voltage .......................................................... 6-24
6.4.4 DTC 111001 System charging fault ...................................................... 6-30
6.4.5 DTC 121015 Engine oil pressure switch OFF ...................................... 6-33
6.4.6 DTC 121018 Low engine oil pressure................................................... 6-36
6.4.7 DTC 121305 Hand pilot pressure switch OFF...................................... 6-38
6.4.8 DTC 121405 Foot pilot pressure switch OFF ....................................... 6-42
6.4.9 DTC 121604 Air filter switch shorted to the ground............................ 6-46
6.4.10 DTC 121615 Air filter clogging ............................................................ 6-49
6.4.11 DTC 131000 High engine speed .......................................................... 6-51
6.4.12 DTC 131005 Engine speed sensor fault ............................................. 6-54
6.4.13 DTC 131100 Extremely high coolant temperature............................. 6-57
6.4.14 DTC 131103 Coolant temperature sensor voltage above the 
range value ...................................................................................................... 6-59
6.4.15 DTC 131104 Coolant temperature sensor voltage below the 
range value ...................................................................................................... 6-62
6.4.16 DTC 131115 High coolant temperature .............................................. 6-65
6.4.17 DTC 131116 High coolant temperature .............................................. 6-67
6.4.18 DTC 1131200 Extremely high hydraulic oil temperature .................. 6-69
6.4.19 DTC 131203 Hydraulic oil temperature sensor voltage above 
the range value ................................................................................................ 6-71
6.4.20 DTC 131204 Hydraulic oil temperature sensor voltage below 
the range value ................................................................................................ 6-74
6.4.21 DTC 131215 High hydraulic oil temperature ...................................... 6-77
6-2
CLG922E
February 3, 2015

6.4.22 DTC 131216 Extremely high hydraulic oil temperature..................... 6-79

6.4.23 DTC 131303 Fuel level sensor voltage above the range value......... 6-81
6.4.24 DTC 131304 Fuel level sensor shorted to the ground....................... 6-86
6.4.25 DTC 131317 Low fuel level................................................................... 6-90
6.4.26 DTC 131603 Water-in-fuel sensor voltage above the range value ... 6-93
6.4.27 DTC 131604 Water-in-fuel sensor voltage below the range value ... 6-96
6.4.28 DTC 131605 Water-in-fuel sensor open-circuited.............................. 6-99
6.4.29 DTC 131615 Water-in-fuel .................................................................. 6-102
6.4.30 DTC 131703 Sensor power (5V) shorted to the battery................... 6-104
6.4.31 DTC 131704 Sensor power (5V) shorted to the ground .................. 6-106
6.4.32 DTC 141005 Pump proportional solenoid valve feedback open-
circuited.......................................................................................................... 6-109
6.4.33 DTC 141006 Pump proportional solenoid valve feedback 
overcurrent..................................................................................................... 6-112
6.4.34 DTC 141104 Pump proportional solenoid valve shorted to the 
ground ............................................................................................................ 6-115
6.4.35 DTC 141105 Pump proportional solenoid valve open-circuited 
or shorted to the battery ............................................................................... 6-118
6.4.36 DTC 151004 Attachment confluent solenoid valve shorted to the 
ground ............................................................................................................ 6-121
6.4.37 DTC 151005 Attachment confluent solenoid valve open-
circuited or shorted to the battery ............................................................... 6-124
6.4.38 DTC 151204 A2 Travel speed solenoid shorted to the ground....... 6-127
6.4.39 DTC 151205 A2 Travel speed solenoid open-circuited or 
shorted to the battery.................................................................................... 6-130
6.4.40 DTC 151304 A3 Flattening solenoid valve shorted to the ground . 6-134
6.4.41 DTC 151305 A3 Flattening solenoid valve open-circuited or 
shorted to the battery.................................................................................... 6-137
6.4.42 DTC 151404 A8 Digging solenoid valve shorted to the ground ..... 6-141
6.4.43 DTC 151405 A8 Digging solenoid valve open-circuited or 
shorted to the battery.................................................................................... 6-144
6.4.44 DTC 151504 A5 Flow adjusting solenoid shorted to the ground ... 6-148
6.4.45 DTC 151505 A5 Flow adjusting solenoid valve open-circuited or 
shorted to the battery.................................................................................... 6-151
 6-3
CLG922E
February 3, 2015

6.4.46 DTC 151605 A6 Flow adjusting solenoid open-circuited or 

shorted to the battery ................................................................................... 6-155
6.4.47 DTC 151704 A7 Transient power boosting solenoid valve 
shorted to the ground ................................................................................... 6-159
6.4.48 DTC 151705 A7 Transient power boosting solenoid valve open-
circuited or shorted to the battery............................................................... 6-162
6.4.49 DTC 151804 A4 Travel lifting solenoid valve shorted to the 
ground ............................................................................................................ 6-166
6.4.50 DTC 151805 A4 Travel lifting solenoid valve open-circuited or 
shorted to the battery ................................................................................... 6-169
6.4.51 DTC 151905 A5 or A6 solenoid valve feedback open-circuited ..... 6-173
6.4.52 DTC 151906 A5 or A6 solenoid valve feedback overcurrent.......... 6-176
6.4.53 DTC 171004 Battery relay shorted to the ground............................ 6-179
6.4.54 DTC 171104 Auto preheating relay shorted to the ground............. 6-182
6.4.55 DTC 171105 Auto preheating relay open-circuited or shorted to 
the battery ...................................................................................................... 6-186
6.4.56 DTC 171204 Start cut-off relay shorted to the ground.................... 6-190
6.4.57 DTC 171205 Start cut-off output open-circuited or shorted to 
the battery ...................................................................................................... 6-194
6.4.58 DTC 201004 Travel alarm shorted to the ground ............................ 6-198
6.4.59 DTC 211003 P1 pump pressure sensor voltage above the range 
value ............................................................................................................... 6-201
6.4.60 DTC 211004 P1 pump pressure sensor voltage below the range 
value ............................................................................................................... 6-204
6.4.61 DTC 211003 P2 pump pressure sensor voltage above the range 
value ............................................................................................................... 6-207
6.4.62 DTC 211104 P2 pump pressure sensor voltage below the range 
value ............................................................................................................... 6-210
6.4.63 DTC 211203 N1 negative flow pressure sensor voltage above 
the range value .............................................................................................. 6-213
6.4.64 DTC 211204 N1 negative flow pressure sensor voltage below 
the range value .............................................................................................. 6-216
6.4.65 DTC 211303 N2 negative flow pressure sensor voltage above 
the range value .............................................................................................. 6-219
6.4.66 DTC 211304 N2 negative flow pressure sensor voltage below 
6-4
CLG922E
February 3, 2015

the range value .............................................................................................. 6-222

6.4.67 DTC 211316 High N2 negative flow pressure................................... 6-225
6.4.68 DTC 211403 Pump pressure-reducing valve sensor voltage 
above the range value ................................................................................... 6-227
6.4.69 DTC 211404 Pump pressure-reducing valve sensor voltage 
below the range value ................................................................................... 6-230
6.4.70 DTC 221001 Actuator feedback voltage below the range value..... 6-233
6.4.71 DTC 221003 Actuator feedback voltage above the range value..... 6-236
6.4.72 DTC 221007 Actuator getting stuck .................................................. 6-239
6.4.73 DTC 221013 Actuator outside the calibrated range......................... 6-241
6.4.74 DTC 221104 Actuator AC1 terminal shorted to the ground ............ 6-245
6.4.75 DTC 221204 Actuator AC2 terminal shorted to the ground ............ 6-248
6.4.76 DTC 221305 Actuator AC1 terminal open-circuited......................... 6-251
6.4.77 DTC 221306 Actuator AC1 overcurrent ............................................ 6-254
6.4.78 DTC 221405 Actuator AC2 terminal open-circuited......................... 6-257
6.4.79 DTC 221406 Actuator AC2 overcurrent ............................................ 6-260
6.4.80 DTC 231012 Abnormal controller heartbeat..................................... 6-263
6.4.81 DTC 231014 CAN bus communication error .................................... 6-265
6.4.82 DTC 241014 Accelerator knob outside the measurement range.... 6-267
6.4.83 DTC 251004 Fuel pump relay shorted to the ground ...................... 6-270
6.4.84 DTC 251005 Fuel pump relay open-circuited or shorted to the 
battery............................................................................................................. 6-274
6.4.85 DTC 261011 GPS Antenna fault......................................................... 6-278
6.4.86 DTC 261111 GPS Module fault........................................................... 6-279
6.4.87 DTC 261211 GSM Signal fault............................................................ 6-279
6.4.88 DTC 261311 GPRS Connection fault................................................. 6-280
6.4.89 DTC 261411 SIM card read fault ........................................................ 6-281
6.4.90 DTC 261512 Abnormal GPS heartbeat.............................................. 6-282
6.4.91 DTC 261611 Level-1 automatic locking, abnormal GPS heartbeat, 
excavator restricted for use.......................................................................... 6-284
6.4.92 DTC 261614 Level-1 forced locking, overdue payment, 
excavator restricted for use.......................................................................... 6-286
6.4.93 DTC 261711 Level-2 automatic locking, abnormal GPS heartbeat, 
excavator restricted for use.......................................................................... 6-287
 6-5
CLG922E
February 3, 2015

6.4.94 DTC 261714 Level-2 forced locking, overdue payment, 

excavator restricted for use ......................................................................... 6-288
6.4.95 DTC 261814 Please pay the due loan promptly............................... 6-289
6.4.96 DTC 271304 Fan reversing solenoid valve shorted to the ground 6-290
6.4.97 DTC 271305 Fan reversing solenoid valve open-circuited or 
shorted to the battery ................................................................................... 6-293
6.4.98 DTC 271404 Fan drive solenoid valve shorted to the ground........ 6-296
6.4.99 DTC 271405 Fan drive solenoid valve open-circuited or 
shorted to the battery ................................................................................... 6-299
6.4.100 DTC 271505 Fan drive solenoid valve feedback open-circuited.. 6-302
6.4.101 DTC 271505 Fan drive solenoid valve feedback overcurrent....... 6-305
6.5 Fault diagnosis of electrical system ............................................... 6-308
6.5.1 E1-Troubleshooting for battery undervoltage ................................... 6-308
6.5.2 E2-Troubleshooting for abnormal battery ......................................... 6-310
6.5.3 E3-Automatic slowdown failed ........................................................... 6-312
6.5.4 E4-Engine start fault ............................................................................ 6-315
6.5.5 E5-Engine shutdown during operation .............................................. 6-325
6.5.6 E6-Engine non-shutdown .................................................................... 6-328
6.5.7 E7-Preheater fault................................................................................. 6-331
6.5.8 E8-All the work implements, revolving and travel unable to move . 6-335
6.5.9 E9-Display panel showing nothing..................................................... 6-339
6.5.10-Incorrectly displayed hydraulic oil temperature ............................. 6-342
6.5.11 E11-Fuel gauge unable to display correct value ............................. 6-345
6.5.12 E12-Windshield wiper uable to work ................................................ 6-351
6.5.13 E13-A/C panel unable to display....................................................... 6-355
6.5.14 E14-No wind or abnormal air volume of air conditioner................. 6-360
6.5.15 E15-Poor A/C refrigeration ................................................................ 6-362
6.5.16 E16-Abnormal alarm of the A/C E11 – Internal sensor wire 
broken ............................................................................................................ 6-365
6.5.17 E17-Abnormal alarm of the A/C E12- Internal sensor short-
circuited ......................................................................................................... 6-366
6.5.18 E18-Abnormal alarm of the A/C E15 – Water temperature 
sensor wire broken ....................................................................................... 6-367
6-6
CLG922E
February 3, 2015

6.5.19 E19-Abnormal alarm of the A/C E16 - Water temperature 

sensor short-circuited................................................................................... 6-369
6.5.20 E20-Abnormal alarm of the A/C E180 - Insolation sensor 
short-circuited................................................................................................ 6-371
6.5.21 E21-Abnormal alarm of the A/C E43 – Abnormal outlet 
ventilation doors............................................................................................ 6-373
6.5.22 E22-Abnormal alarm of the A/C E44 – Abnormal the air mixing 
door................................................................................................................. 6-375
6.5.23 E23-Travel alarm unable to sound .................................................... 6-377
6.6 Fault diagnosis of the hydraulic system and mechanical 
system .............................................................................................................. 6-380
6.6.1 System table of the hydraulic system and mechanical system ....... 6-380
6.6.2 H1-Excessive barking angle for slewing stop.................................... 6-381
6.6.3 H2-Abnormal noise of pump mounting position ............................... 6-382
6.6.4 H3-No responses for all operations when starting the engine......... 6-383
6.6.5 H4-Hydraulic oil emulsification ........................................................... 6-384
6.6.6 H5-Abnormal hydraulic oil temperature rise...................................... 6-385
6.6.7 H6-Slewing abnormally to left and right directions........................... 6-386
6.6.8 H7-No response for slewing single direction operation ................... 6-387
6.6.9 H8-Rotation unable to stop.................................................................. 6-388
6.6.10 H9-Fail to actuate unilateral travel mechanism ............................... 6-389
6.6.11 H10-Travel deviation........................................................................... 6-390
6.6.12 H11-Slow speed of the boom, arm or bucket................................... 6-391
6.6.13 H12-Weak actions of the boom, arm or bucket................................ 6-392
6.6.14 H13-Significantly reduced engine speed or engine stalling........... 6-393
 6-7
CLG922E 6.1 Precautions for fault diagnosis
February 3, 2015

6.1 Precautions for fault diagnosis

• Park the machine on the flat ground, check whether the locking pin, cushion block and parking
brake are fixed firmly.
• When two or more workers are operating, follow the agreed signal strictly, and any unautho-
rized people are not allowed to get close.
• If the radiator cover is removed when the engine is still hot, the hot coolant may spray out
which will cause scald. Therefore, start the fault diagnosis when the engine is cooled.
• Specially notice that do not touch any hot components or any jammed rotating components.
• When disconnecting the wire, be sure to disconnect the negative pole (-) of the battery first.
• Be sure to release the inner pressure when removing the plug or cover where the oil pressure,
water pressure or air pressure may exist. When installing the measuring device, make sure
that it is connected correctly.
6-8
6.2 Basic fault detection before maintenance CLG922E
February 3, 2015

6.2 Basic fault detection before maintenance

Do the following tests before having your authorized LiuGong dealer repair your excavator or when
your excavator is not functioning properly. Doing these tests can help the maintenance personnel
to repair your excavator as soon as possible.


Do the following tests when the engine is running and shuts down, respectively.
If the excavator operates in a closed space, be sure to discharge the exhaust gases before starting
the engine to maintain the excavator.
No irrelevant personnel is allowed to be close to the excavator working and detection area.
Some tests may be required to be done when the excavator is travelling. Therefore, before starting
any test, make sure the driver has been trained specially and has been qualified.

 Notice: Some tests may require the appropriate hearing protection devices.

Some tests may need the help of the specialized testing tools. Therefore, before starting any test,
make sure the operators understand these tools fully.
Before performing any of the following tests, make sure all routine examination items have been
completed.
Start the engine and do the testing by following the relevant guidance steps. When detecting the
hydraulic system components, make sure that the hydraulic system has been fully heated and all
hydraulic components have reached normal operating temperature.
 6-9
CLG922E 6.2 Basic fault detection before maintenance
February 3, 2015

S/N Test items Test requirements

Rotate the engine starting switch to "ON" position but do not start the
1
engine.

Shut down the engine, park Hydraulic oil state

the machine on a firm and 1. Check whether the oil level is within the normal range?
horizontal ground, and • Notice: Check before the engine is started.
make the machine in the 2. Check whether the oil level is between the MIN and MAX marks at
hydraulic oil testing state the end of the dipstick.
2
(all the arms are stretched
3. Check whether the cold hydraulic oil level is between the maximum
out, the bucket is
scale and the minimum scale of the dipstick?
withdrawn, and the work
attachment is lowered to the 4. Check the hydraulic oil lines or the connectors for damage or
ground). leakage?
5. Visually check the machine for wear or damage sign? Whether the
parts are damaged or lost? Whether the welding piece has cracks?
6. Check the parts for loss?
7. Check the track for obvious scratches or wear.
Horn Check the horn for ring. (Yes or No)
Wiper Check whether the front wiper works normally. (Yes or No)
Fan Check whether the internal circulation fan works? (Yes or No)
Lighting equipment (work
3 light, revolving signal light, Check whether the outdoor light and dome light works normally.
brake light, dome light, etc.)
Instrument, meter and Check whether all the indicators come on.
indicator If not, do not start the engine.
Operate all the switches and controls to check whether they can work
Switches and controls normally.
If not, do not start the engine.
Cab Check whether all the control levers are in the correct positions.
Check whether the safety warning labels on the machine can be seen
Safety warning label
clearly.
4 Check whether the cab windows and doors can be opened smoothly.
Gate lock and engine hood When the gate lock can be locked?
lock Check whether the engine hood can be closed. Whether the engine
hood can be locked?
6-10
6.2 Basic fault detection before maintenance CLG922E
February 3, 2015

S/N Test items Test requirements

Check the surrounding of the engine for obvious damage or oil
leakage sign.
Start the engine and listen to the engine for abnormal noise.
When the engine operates in idle speed, whether the oil pressure
indicator goes off?
5 Engine system Check whether the engine speed is normal. Whether the operation is
smooth?
After the engine operates for a period, check whether the engine
temperature is within the normal working range.
After the engine is preheated and started, observe whether the
exhaust gas is discharged. If any, what is color of the exhaust gas?
Grayish white, white or black?
Check whether the engine working temperature is within the normal
Engine operates in idle range.
6
speed After the engine operates in idle speed for several minutes, check
whether the air conditioner refrigerates.
Start the engine and check the system voltage. The voltage after
7 Charging of battery
starting should be more than that before starting (normally, >26V)
 6-11
CLG922E 6.3 Classification of faults
February 3, 2015

6.3 Classification of faults

In this chapter, the faults are divided into three categories
(1) DTC
If the excavator monitor shows DTC, perform the fault diagnosis corresponding to the code according to
the displayed DTC.
(2) Electrical system faults (for E series)
In the Electrical System Faults, the typical electrical faults are introduced. The location drawing for main
faulted parts, relevant circuit diagram and the detailed diagnosis procedures are equipped.

The faults introduced in this chapter are as follow

Fault SN Fault phenomenon Consequence

E1 Battery is undercharged The battery is damaged.
E2 The battery is abnormal The battery is damaged.
E3 Automatic slowdown failed Increased fuel consumption and noise
Engine cannot be started (the engine
E4 Failed to work.
does not rotate)
E5 Engine shuts down during operation. System fault
E6 The engine can not shut down System fault
E7 Preheater does not work Difficult to start or won’t start.
All the work implements, revolving and
E8 No motion, failed to work.
travel cannot move
E9 Display panel shows nothing It can not display the machine information.
Reducing the pump current and engine speed
Incorrectly displayed hydraulic oil can affect the overall performance, or cause
E10
temperature damage to the engine and hydraulic
components.
The fuel level display is inaccurate, and it
E11 Fuel gauge cannot display correct value
brings trouble to the work.
Foreign matters on glass cannot be removed;
E12 Windshield wiper does not work.
the sight for operator is poor.
E13 Failed A/C panel. Air conditioning system cannot work
Air conditioner blows no air or air
E14 The service effect of air conditioner is poor
volume is abnormal
The refrigeration effect of air conditioning
E15 Poor A/C refrigeration
system is poor
Abnormal A/C alarm E11 -- Internal
E16 The service effect of air conditioner is poor
sensor wire broken
6-12
6.3 Classification of faults CLG922E
February 3, 2015

Fault SN Fault phenomenon Consequence

Abnormal A/C alarm E12 -- Internal
E17 The service effect of air conditioner is poor
sensor short-circuited
Abnormal A/C alarm E15 -- Water
E18 The service effect of air conditioner is poor
temperature sensor wire broken
Abnormal A/C alarm E16 -- Water
E19 The service effect of air conditioner is poor
temperature sensor short-circuited
Abnormal A/C alarm E18 -- Insolation
E20 The service effect of air conditioner is poor
sensor short-circuited
Abnormal A/C alarm E43 -- Abnormal
E21 The service effect of air conditioner is poor
outlet ventilation doors
Abnormal A/C alarm E44 -- Abnormal air
E22 The service effect of air conditioner is poor
mixing doors
Alarm system is faulty, causing potential
E23 Travel alarm does not sound
safety hazard.
(3) Faults of hydraulic mechanical system (for H series)
The Faults of Hydraulic System and Mechanical System mainly introduces the diagnosis methods for the
common faults in the hydraulic system.

The faults introduced in this chapter are as followNotice

S/N Fault phenomenon
H1 Excessive braking angle for slewing stop
H2 Abnormal sound of pump mounting position
H3 When the engine is started, all operations are unresponsive.
H4 Hydraulic oil emulsification
H5 Abnormal hydraulic oil temperature rise
H6 Normal slewing cannot be achieved either in the left direction or in the right direction.
H7 Unidirectional slewing operation is unresponsive.
H8 Rotation cannot be stopped.
H9 Unilateral running gear fails to move completely.
H10 The excavator pulls to one side.
H11 Boom, arm or bucket moves slowly.
H12 Boom, arm or bucket is unable to move.
H13 Significantly reduced engine speed or engine stalling
 6-13
CLG922E 6.4 DTC
February 3, 2015 6.4.1 DTC 101001 Extremely low battery voltage

6.4 DTC
6.4.1 DTC 101001 Extremely low battery voltage

DTC Description of Fault Consequence

Extremely low battery voltage (The
101001 controller detects the battery voltage is It is difficult to start the engine.
extremely low (below 16V).)

System description
When the alternator does not work or generates a low voltage, the battery supplies power to the electrical
equipment. When the engine starts, the battery supplies power to the starter motor. When the engine is
started, the battery is charged by the alternator. When the electrical equipment needs more power simulta-
neously and the alternator is overloaded, the battery assists the alternator to supply power. The battery has
a rated voltage of 12V. The complete excavator is powered by two batteries in series.
6-14
6.4 DTC CLG922E
6.4.1 DTC 101001 Extremely low battery voltage February 3, 2015
 6-15
CLG922E 6.4 DTC
February 3, 2015 6.4.1 DTC 101001 Extremely low battery voltage

Component location

Front

Battery

Fault diagnosis and elimination procedures

Step 1 Check the battery terminals for looseness or rust.

 Be sure to turn off the electric lock before checking whether the battery cables are secured
reliably.
• Inspection method
Turn the battery terminals by hand or with the tools, and check them for looseness.
Visually check the terminals for rust.
• Whether the battery terminals become loose or rusty or not?
• Yes
Tighten or derust.
Turn to Step 6
• No
Turn to Step 2
6-16
6.4 DTC CLG922E
6.4.1 DTC 101001 Extremely low battery voltage February 3, 2015

Step 2 Check whether the battery voltage is low.

 Make sure the ignition switch is at the

OFF position before removing and
installing the battery cables. When
assembling, installed the positive termi-
nals before the negative terminals.
Removal is the reverse of installation.
This can avoid damage to the battery
terminals and the wrench due to short-
circuit spark. Black probe
Red probe

 During the detection period, turn the

start switch to the OFF position • Is the battery voltage too low?
• Inspection method • Yes
There are three possible causes for low bat- Charge or replace the battery.
tery voltage: Turn to Step 6
1. Prolongedly uncharged battery • No
2. Battery damage Turn to Step 3
3. Loss of power
• Check the battery in the following proce- Step 3 Check the charging harness for open-cir-
dures: cuit (whether the coupling ends become loose.).
1. Check the inspection window for the battery.
 Pay special attention to the following
If the inspection window becomes black, the bat-
when the engine is running:
tery needs to be charged. If the inspection win-
dow becomes white, the battery has been 1. Hot engine block can scald you seriously.
damaged. If the inspection window is in the 2. Prevent the harnesses, clothing and oth-
green status, the battery is good. ers from being drawn into the belts and the
2. Measure the battery voltage with the multime- flywheel.
ter. Turn the multimeter to its DC voltage func- 3. Do not let the excavator move.
tion (200V), and connect the red probe to the
 Correctly tie up harness and wire:
positive battery terminal and the black probe to
the negative battery terminal. See the schematic 1. Avoid folding or bending the harness forc-

diagram for detection as follows: ibly.

2. It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
3. Avoid friction with sharp metal edges.
4. Try to keep far way from oil and water.
 6-17
CLG922E 6.4 DTC
February 3, 2015 6.4.1 DTC 101001 Extremely low battery voltage

5. Try to keep far away from high tempera-

ture parts (e.g. engine body).
• Inspection method
1. Check the battery charging harness (No. 120)
for wear and its terminals for looseness.
2. Check the charging harness for open-circuit
with the multimeter:
Method A: Turn the ignition switch to the OFF
position. Turn the multimeter to its resistance Connect the red probe to Connect the black
the generator B+ probe to ground
function (200Ω), and measure the resistance of
the battery charging harness (No. 120) (nor-
mally, <10Ω). For the alternator location and the
starter motor location, see the figure. • Whether the charging harness is open-
circuited or not (whether the coupling
ends become loose)?
• Yes
Repair the harness or re-connect it.
Turn to Step 6
• No
Turn to Step 4

Start motor Alternator

Step 4 Check whether the alternator fails or its
Connect the multimeter probes to both ends
output voltage is low.
of the charging harness
 Pay special attention to the following
Method B: Turn the ignition switch to the ON when the engine is running:
position and turn the multimeter to its voltage 1. Hot engine block can scald you seriously.
function, and then measure the voltage between 2. Prevent the harnesses, clothing and oth-
the alternator terminal B and the grounding (nor- ers from being drawn into the belts and the
mally, about 25V (battery voltage).). flywheel.
3. Do not let the excavator move.
• Inspection method
After the engine is started, there are two pos-
sible causes for the alternator fault:
1. The belt is too loose.
2. Alternator fault
• Check the battery in the following proce-
dures:
6-18
6.4 DTC CLG922E
6.4.1 DTC 101001 Extremely low battery voltage February 3, 2015

1. Stop the engine and check whether the alter-

nator belt becomes loose.
2. Start the engine, and measure the voltage
between the alternator terminal B and the
grounding with the multimeter (normally, higher
than the battery voltage).
• Whether the alternator fails or its output
voltage is low?
Connect the black
probe to ground
• Yes
1. Tension or replace the drive belt. To the red probe

2. Contact your local authorized LiuGong dealer

or service center.
• Whether the controller power voltage is
Turn to Step 6
too low?
• No
• Yes
Turn to Step 5
Repair the harness or re-connect it.
Turn to Step 6
Step 5 Check whether the controller power volt-
• No
age is too low.
Turn to Step 6
 During the detection period, turn the
start switch to the OFF position Step 6 Check whether this fault is eliminated
• Inspection method • Inspection method
1. Check the controller power line for wear and Turn the start switch to the ON position and re-
the coupling ends for looseness. check the DTC.
2. Turn the multimeter to its DC voltage function
• Has this fault been eliminated?
(200V), and measure the voltage between the
• Yes
controller power terminal (J1-2, J1-3, J1-4, J1-5,
J1-6) and the grounding, respectively. Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-19
CLG922E 6.4 DTC
February 3, 2015 6.4.1 DTC 101001 Extremely low battery voltage

Figure

Alternator

Start motor
6-20
6.4 DTC CLG922E
6.4.2 DTC 101003 High battery voltage February 3, 2015

6.4.2 DTC 101003 High battery voltage

DTC Description of Fault Consequence

High battery voltage (The controller
101003 detects the battery voltage is extremely The engine may shut down.
high (above 30V).)

System description
When the alternator does not work or generates a low voltage, the battery supplies power to the electrical
equipment. When the engine starts, the battery supplies power to the starter motor. When the engine is
started, the battery is charged by the alternator. When the electrical equipment needs more power simulta-
neously and the alternator is overloaded, the battery assists the alternator to supply power. The battery has
a rated voltage of 12V. The complete excavator is powered by two batteries in series.
 6-21
CLG922E 6.4 DTC
February 3, 2015 6.4.2 DTC 101003 High battery voltage
6-22
6.4 DTC CLG922E
6.4.2 DTC 101003 High battery voltage February 3, 2015

Component location Normally, the battery (2 packs) voltage should

be about 25V.
• Whether the battery voltage is correct or
not?
Front

• Yes
Repair or replace the battery.
Turn to Step 3
• No
Turn to Step 2
Battery

Step 2 Check the alternator for fault.

 Pay special attention to the following

Fault diagnosis and elimination pro- when the engine is running:
cedures 1. Hot engine block can scald you seriously.
Step 1 Check the battery voltage for fault. 2. Prevent the harnesses, clothing and others
from being drawn into the belts and the flywheel.
 During the detection period, turn the
3. Do not let the excavator move.
start switch to the OFF position
• Inspection method:
• Inspection method:
Start the engine. Turn the multimeter to its DC
Measure the battery voltage with the multimeter. voltage function (200V), and connect the red
Turn the multimeter to its DC voltage function probe to the alternator B+ terminal and the black
(200V), and connect the red probe to the posi- probe to the grounding. Measure the voltage
tive battery terminal and the black probe to the between the alternator B+ terminal and the
negative battery terminal. See the schematic grounding (normally, no more than 30V). For the
diagram for detection as follows: alternator location, see the figure:

Connect the red probe to Connect the black

the generator B+ probe to ground
Black probe
Red probe
 6-23
CLG922E 6.4 DTC
February 3, 2015 6.4.2 DTC 101003 High battery voltage

• Whether a fault developing in the alter-

nator or not?
• Yes
Contact your local authorized LiuGong dealer or
service center.
Turn to Step 3
• No
Turn to Step 3

Step 3 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check the DTC.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.

Figure

Alternator
6-24
6.4 DTC CLG922E
6.4.3 DTC 101017 Low battery voltage February 3, 2015

6.4.3 DTC 101017 Low battery voltage

DTC Description of Fault Consequence

Low battery voltage (The controller detects
101017 It is difficult to start the engine.
the battery voltage is low (16V-18V).)

System description
When the alternator does not work or generates a low voltage, the battery supplies power to the electrical
equipment. When the engine starts, the battery supplies power to the starter motor. When the engine is
started, the battery is charged by the alternator. When the electrical equipment needs more power simulta-
neously and the alternator is overloaded, the battery assists the alternator to supply power. The battery has
a rated voltage of 12V. The complete excavator is powered by two batteries in series.
 6-25
CLG922E 6.4 DTC
February 3, 2015 6.4.3 DTC 101017 Low battery voltage
6-26
6.4 DTC CLG922E
6.4.3 DTC 101017 Low battery voltage February 3, 2015

Component location Step 2 Check whether the battery voltage is low.

 Make sure the ignition switch is at the

OFF position before removing and
Front installing the battery cables. When
assembling, install the positive termi-
nals before the negative terminals.
Removal is the reverse of installation.
This can avoid damage to the battery
terminals and the wrench due to short-
Battery
circuit spark.

 During the detection period, turn the

start switch to the OFF position.

Fault diagnosis and elimination pro- • Inspection method

cedures There are three possible causes for low bat-

tery voltage:
Step 1 Check the battery terminals for loose-
1. Prolongedly uncharged battery
ness or rust.
2. Battery damage
 Be sure to turn off the electric lock
3. Loss of power
before checking whether the battery
• Check the battery in the following proce-
cables are secured reliably.
dures:
• Inspection method 1. Check the inspection window for the battery.
Turn the battery terminals by hand or with the If the inspection window becomes black, the bat-
tools, and check them for looseness. tery needs to be charged. If the inspection win-
Visually check the terminals for rust. dow becomes white, the battery has been
• Whether the battery terminals become damaged. If the inspection window is in the
loose or rusty or not? green status, the battery is good.

• Yes 2. Measure the battery voltage with the multime-

ter. Turn the multimeter to its DC voltage func-
Tighten or derust.
tion (200V), and connect the red probe to the
Turn to Step 6
positive battery terminal and the black probe to
• No the negative battery terminal. See the schematic
Turn to Step 2 diagram for detection as follows:
 6-27
CLG922E 6.4 DTC
February 3, 2015 6.4.3 DTC 101017 Low battery voltage

3. Avoid friction with sharp metal edges.

4. Try to keep far way from oil and water.
5. Try to keep far away from high tempera-
ture parts (e.g. engine body).
• Inspection method
1. Check the battery charging harness (No. 120)
for wear and its terminals for looseness.
2. Check the charging harness for open-circuit
with the multimeter:
Black probe
Method A: Turn the ignition switch to the OFF
Red probe
position. Turn the multimeter to its resistance
function (200Ω), and measure the resistance of
If the voltage below 18V, this indicates the
the battery charging harness (No. 120) (nor-
battery voltage is low.
mally, <10Ω). For the alternator location and the
• Is the battery voltage too low?
starter motor location, see the figure.
• Yes
Charge or replace the battery.
Turn to Step 6
• No
Turn to Step 3

Step 3 Check the charging harness for open-cir-

cuit (whether the coupling ends become loose.).

 Pay special attention to the following Start motor Alternator

when the engine is running: Connect the multimeter probes to both ends
of the charging harness

1. Hot engine block can scald you seriously.

2. Prevent the harnesses, clothing and oth- Method B: Turn the ignition switch to the ON
ers from being drawn into the belts and the position and turn the multimeter to its voltage
flywheel. function, and then measure the voltage between
3. Do not let the excavator move. the alternator terminal B and the grounding (nor-
mally, the battery voltage should be 25 ± 0.5V.).
 Correctly tie up harness and wire:

1. Avoid folding or bending the harness forc-

ibly.
2. It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
6-28
6.4 DTC CLG922E
6.4.3 DTC 101017 Low battery voltage February 3, 2015

dures:
1. Stop the engine and check whether the alter-
nator belt becomes loose.
2. Start the engine, and measure the voltage
between the alternator terminal B and the
grounding with the multimeter (normally, higher
than the battery voltage).
• Whether the alternator fails or its output
Connect the red probe to Connect the black voltage is low?
the generator B+ probe to ground
• Yes
1. Tension or replace the drive belt.
2. Contact your local authorized LiuGong dealer
• Whether the charging harness is open-
or service center.
circuited or not (the coupling ends
become loose)? Turn to Step 6
• No
• Yes
Turn to Step 5
Repair the harness or re-connect it.
Turn to Step 6
Step 5 Check whether the controller power volt-
• No
age is too low.
Turn to Step 4
 During the detection period, turn the
Step 4 Check whether the alternator fails or its start switch to the OFF position
output voltage is low. • Inspection method

 Pay special attention to the following 1. Check the controller power line for wear and
the coupling ends for looseness.
when the engine is running:
2. Turn the multimeter to its DC voltage function
1. Hot engine block can scald you seriously.
(200V), and measure the voltage between the
2. Prevent the harnesses, clothing and oth-
controller power terminal (J1-2, J1-3, J1-4, J1-5,
ers from being drawn into the belts and the
J1-6) and the grounding, respectively.
flywheel.
3. Do not let the excavator move.
• Inspection method
After the engine is started, there are two pos-
sible causes for the alternator fault:
1. The belt is too loose.
2. Alternator fault
• Check the battery in the following proce-
 6-29
CLG922E 6.4 DTC
February 3, 2015 6.4.3 DTC 101017 Low battery voltage

Figure

Alternator

Start motor

Connect the black

probe to ground

To the red probe

If the voltage below 18V, this indicates the

power voltage is low.
• Whether the controller power voltage is
too low?
• Yes
Repair the harness or re-connect it.
Turn to Step 6
• No
Turn to Step 6

Step 6 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check the DTC.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
6-30
6.4 DTC CLG922E
6.4.4 DTC 111001 System charging fault February 3, 2015

6.4.4 DTC 111001 System System description

The engine is accompanied with the alternator,
charging fault
and the silicon rectifier circuit and voltage
adjuster with the frequency output are installed
Description of in the alternator. After the engine is started, the
DTC Consequence
Fault
alternator driven by the drive belt starts generat-
System charging
fault (The ing (nominal voltage 28V). The current from the
The battery is
111001 controller detects generating terminal (B+) flows through the No.
short of power.
the J2-28 port has 120 and No.108 wires and the battery relay to
0 voltage.)
the battery to charge it. The charging indicator
signal terminal (P) is connected to the controller
J2-28 via the wire (No. 928). The controller
checks whether the alternator is working prop-
erly through the signal terminal.

Controller J2(White)
Alternator
Battery charging
indicator switch

Start moter

GND
 6-31
CLG922E 6.4 DTC
February 3, 2015 6.4.4 DTC 111001 System charging fault

Component location Step 2 Check the harness for open-circuit

 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
Alternator
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Try to keep far away from high temperature
Front parts (e.g. engine body).
• Inspection method
Fault diagnosis and elimination pro- 1. Check the No. 928 harness (between the
cedures alternator P terminal and the J2-28 port) for
wear.
Step 1 Check the alternator P terminal for elec-
2. Disconnect the connectors from the P termi-
trical signal output (whether the alternator fails)
nal and the controller and check the harness for
• Inspection method
open-circuit. Turn the multimeter to its resis-
1. Stop the engine and check whether the alter- tance function, and measure the resistance of
nator belt becomes loose. the harness (No. 928) between the controller
2. Starts the engine and turn the multimeter to port J2-28 and the P terminal (normally, <10Ω).
its voltage function, and then measure the volt-
• Is the harness open?
age between the alternator P terminal and
• Yes
ground (Normally, about 14V)
Connect the harness again and wrap the har-
• Whether the alternator P terminal has no
ness.
electrical signal output (the alternator
Turn to Step 3
fails)?
• No
• Yes
Turn to Step 3
Tension or replace the belt.
Contact local LiuGong dealer and authorized
service center.
Turn to Step 3
• No
Turn to Step 2
6-32
6.4 DTC CLG922E
6.4.4 DTC 111001 System charging fault February 3, 2015

Step 3 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-33
CLG922E 6.4 DTC
February 3, 2015 6.4.5 DTC 121015 Engine oil pressure switch OFF

6.4.5 DTC 121015 Engine oil System description

The oil pressure switch is used for detecting the
pressure switch OFF
engine oil pressure. Normally, the pressure
switch contact is closed. When the pressure
Consequen
DTC Description of Fault reaches 0.07MPa or more, the contact is open,
ce
The display resulting in a safety overpressure less than
Engine oil pressure shows the 3.5MPa. Under normal circumstances, when the
121015
switch OFF. oil pressure engine is started, the engine oil pressure is
anomaly.
greater than 0.07MPa, and the pressure switch
contact should be open. The controller detects
the pressure switch signal. Then, if the engine
oil pressure is lower than 0.07MPa, the control-
ler will give alarm information via the display.

Controller J2(White) Oil Pressure SW

Engine oil
pressure switch
6-34
6.4 DTC CLG922E
6.4.5 DTC 121015 Engine oil pressure switch OFF February 3, 2015

Component location Step 2 Check the harness for open-circuit

 Correctly tie up harness and wire:

Engine oil pressure switch Avoid folding or bending the harness forci-
Front
bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).
• Inspection method
Fault diagnosis and elimination pro- 1. Check the harness (No. 902) and the ground-
cedures ing wire (No. 283) between the controller (J2-02)
and the engine oil pressure switch.
Step 1 Check the oil pressure switch for fault.
2. Disconnect the connectors from the engine oil
 When replacing the components, please pressure switch and the controller, and check
be sure to use LiuGong parts. the harness for open-circuit:
• Inspection method (a) Turn the multimeter to its resistance func-
Turn the start switch to the OFF position, tion, and measure the resistance between
and disconnect the oil pressure switch con- the grounding wire (No.283) switch terminal
nector: and the grounding (normally, <10Ω).

1. Check the connector pins for looseness, rust, (b) Turn the multimeter to its resistance func-
bending and damage. tion, and measure the resistance of the har-
2. Turn the multimeter to its resistance function, ness between the connector (J2-2)
and measure the resistance between the oil connected to the controller and the switch
pressure switch connector terminals 1 and 2 (normally, <10Ω).
(normally, <10Ω). • Is the harness open?
• Whether a fault developing in the oil • Yes
pressure switch or not? Connect the harness again and wrap the har-
• Yes ness.
Repair or replace the oil pressure switch. Turn to Step 4
Turn to Step 4 • No
• No Turn to Step 3
Turn to Step 2
 6-35
CLG922E 6.4 DTC
February 3, 2015 6.4.5 DTC 121015 Engine oil pressure switch OFF

Step 3 Check the connector for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Connect the oil pressure switch connector and
disconnect the controller connector. Turn the
multimeter to its resistance function, and mea-
sure the resistance between the connector C2-
02 connecting to the controller J2-02 and the
grounding (normally, <10Ω).
When the resistance is abnormal, this indi-
cates the connector is poorly contacted.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
6-36
6.4 DTC CLG922E
6.4.6 DTC 121018 Low engine oil pressure February 3, 2015

6.4.6 DTC 121018 Low engine System description

The engine oil pressure switch is used for
oil pressure
detecting the engine oil pressure. Normally, the
pressure switch contact is closed. When the
Description of pressure reaches 0.07MPa or more, the contact
DTC Consequence
Fault
is open, resulting in a safety overpressure less
Low engine oil
pressure - When than 3.5MPa. Under normal circumstances,
the engine is when the engine is started, the engine oil pres-
running, the signal If the excavator sure is greater than 0.07MPa, and the pressure
circuit of the oil is operated as
121018 pressure switch usual, the switch contact should be open. The controller
detects a low engine can be detects the pressure switch signal. Then, if the
engine oil damaged. engine oil pressure is lower than 0.07MPa, the
pressure (the
sensor contact is controller will give alarm information via the dis-
open). play.

Controller J2(White) Oil Pressure SW

Engine oil
pressure switch
 6-37
CLG922E 6.4 DTC
February 3, 2015 6.4.6 DTC 121018 Low engine oil pressure

Component location Step 2

 When replacing the components, please

Engine oil pressure switch be sure to use LiuGong parts.
Front
• Inspection method
When the oil pressure is normal, check the oil
pressure detection circuit or the oil pressure
switch for fault in accordance with the fault diag-
nosis of the 121015- Engine Oil Pressure Switch
OFF.
• Whether a fault developing in the engine
oil pressure monitoring system or not?
• Yes
Fault diagnosis and elimination pro- Repair the engine oil pressure detection circuit
or replace the engine oil pressure switch.
cedures
Turn to Step 3
Step 1
• No
• Inspection method
Turn to Step 3
1. Pull out the oil dipstick, and check whether
the oil level on the dipstick is below the MIN
Step 3
mark.
2. Check whether the engine oil pump is func- • Inspection method
tioning properly. Turn the start switch to the ON position and re-
3. Remove the engine oil pressure switch, and check for fault.
measure whether the engine oil pressure is low • Has this fault been eliminated?
with the pressure gauge. • Yes
• Whether the engine oil pressure is low Maintenance is over
or not?
• No
• Yes Troubleshoot the faults according to the steps
Troubleshoot and restore the oil pressure. again or contact the local LiuGong dealer and
Turn to Step 3 authorized service center.
• No
Turn to Step 2
6-38
6.4 DTC CLG922E
6.4.7 DTC 121305 Hand pilot pressure switch OFF February 3, 2015

6.4.7 DTC 121305 Hand pilot System description

The hand pilot pressure switch is used to detect
pressure switch OFF
the hand pilot pipeline pressure and the logic
signal input for the automatic idling function.
Description of After the engine is started, open the pilot shut-
DTC Consequence
Fault
off valve. Then, when the hand pilot control lever
Hand pilot
No automatic is not operated, the pressure switch contact
121305 pressure switch
idling.
OFF should be closed. When the hand pilot control
lever is operated, the pressure switch contact
should be open. The automatic idling function
can be achieved only when the controller
detects simultaneously the hand pilot switch and
foot pilot switch signals, that is, when one or two
pilot pressure switches are unplugged, the auto-
matic idling function will be invalid.

J1 (Black)
Controller
Hand pilot
pressure switch Hand pilot
pressure switch
J2(White)
Foot pedal
pressure switch

Foot pilot
pressure switch
 6-39
CLG922E 6.4 DTC
February 3, 2015 6.4.7 DTC 121305 Hand pilot pressure switch OFF

Component location

Front

Foot pilot
pressure switch Connect the multimeter probes to
two pins of the hand pilot pressure
Hand pilot pressure switch switch, respectively.

• Whether a fault developing in the hand

pilot pressure switch or not?
Fault diagnosis and elimination pro-
• Yes
cedures
Repair or replace the hand pilot pressure switch.
Step 1 Check the hand pilot pressure switch for
Turn to Step 4
fault.
• No
 When replacing the components, please
Turn to Step 2
be sure to use LiuGong parts.
• Inspection method Step 2 Check the harness for open-circuit
Turn the start switch to the OFF position,
and disconnect the connector from the hand
 Correctly tie up harness and wire:

pilot pressure switch. Avoid folding or bending the harness forci-

1. Check the connector pins for looseness, rust, bly.
bending and damage. It shall be kept away from moving compo-
2. Turn the multimeter to its resistance function, nents as far as possible to prevent tensile
and measure the resistance between the hand fault and wear.
pilot pressure switch connector terminals 1 and Avoid friction with sharp metal edges.
2 (normally, <10Ω). Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).
• Inspection method
1. Check the harness (No. 808) and the ground-
ing wire (No. 240) between the controller (J1-8)
and the hand pilot pressure switch for wear.
2. Disconnect the connectors from the hand pilot
6-40
6.4 DTC CLG922E
6.4.7 DTC 121305 Hand pilot pressure switch OFF February 3, 2015

pressure switch and the controller, and check ness.

the harness for open-circuit: Turn to Step 4
(a) Turn the multimeter to its resistance func- • No
tion, and measure the resistance between Turn to Step 3
the grounding wire (No.240) hand pilot
pressure switch terminal and the grounding
Step 3 Check the connector for fault.
(normally, <10Ω).
 When replacing the components, please
be sure to use LiuGong parts.
Black probe

• Inspection method
Connect the hand pilot pressure switch connec-
tor and disconnect the controller connector.
Turn the multimeter to its resistance function,
Gray wire and measure the resistance between the har-
ness at the controller port J1-8 and the ground-
Red probe

ing (normally, <10Ω).

(b) Turn the multimeter to its resistance func-

tion, and measure the resistance between
the connector port J1-8 and hand pilot
pressure switch harness (normally, <10Ω).

To the black probe

To the red probe To the black probe

To the red probe

White wire

When the resistance is abnormal, this indi-

cates the connector is poorly contacted.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• Is the harness open?
Yes • No

Connect the harness again and wrap the har- Turn to Step 4
 6-41
CLG922E 6.4 DTC
February 3, 2015 6.4.7 DTC 121305 Hand pilot pressure switch OFF

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
6-42
6.4 DTC CLG922E
6.4.8 DTC 121405 Foot pilot pressure switch OFF February 3, 2015

6.4.8 DTC 121405 Foot pilot System description

The foot pilot pressure switch used for detecting
pressure switch OFF
the foot pilot line pressure and the logic signal
input for automatic idling function. After the
Description of engine is started, open the pilot shut-off valve.
DTC Consequence
Fault
Then, when the foot pilot control lever is not
Foot pilot pressure No automatic
121405 operated, the pressure switch contact should be
switch OFF idling.
closed. When the foot pilot control lever is oper-
ated, the pressure switch contact should be
open. The automatic idling function can be
achieved only when the controller detects simul-
taneously the foot pilot switch and hand pilot
switch signals, that is, when one or two pilot
pressure switches are unplugged, the automatic
idling function will be invalid.

J1 (Black)
Controller
Hand pilot
pressure switch Hand pilot
pressure switch
J2(White)
Foot pedal
pressure switch

Foot pilot
pressure switch
 6-43
CLG922E 6.4 DTC
February 3, 2015 6.4.8 DTC 121405 Foot pilot pressure switch OFF

Component location

Front

Foot pilot
pressure switch Connect the multimeter probes to
two pins of the foot pilot pressure
Hand pilot pressure switch switch, respectively.

• Whether a fault developing in the foot

pilot pressure switch or not?
Fault diagnosis and elimination pro-
• Yes
cedures
Repair or replace the foot pilot pressure switch.
Step 1 Check the foot pilot pressure switch for
Turn to Step 4
fault
• No
 When replacing the components, please
Turn to Step 2
be sure to use LiuGong parts.
• Inspection method Step 2 Check the harness for open-circuit
Turn the start switch to the OFF position,
and disconnect the foot pilot pressure
 Correctly tie up harness and wire:

switch connector: Avoid folding or bending the harness forci-

1. Check the connector pins for looseness, rust, bly.
bending and damage. It shall be kept away from moving compo-
2. Turn the multimeter to its resistance function, nents as far as possible to prevent tensile
and measure the resistance between the foot fault and wear.
pilot pressure switch connector terminals 1 and Avoid friction with sharp metal edges.
2 (normally, <10Ω). Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).
• Inspection method
1. Check the harness (No. 913) and the ground-
ing wire (No. 240) between the controller (J2-13)
and the foot pilot pressure switch for wear.
2.Disconnect the connectors from foot pilot
6-44
6.4 DTC CLG922E
6.4.8 DTC 121405 Foot pilot pressure switch OFF February 3, 2015

pressure switch and the controller and check the ness.

harness is open-circuited. Turn to Step 4
(a) Turn the multimeter to its resistance func- • No
tion, and measure the resistance between Turn to Step 3
the grounding wire (No.240) foot pilot pres-
sure switch terminal and the grounding
Step 3 Check the connector for fault.
(normally, <10Ω).
 When replacing the components, please
be sure to use LiuGong parts.
Black probe

• Inspection method
Connect the foot pilot pressure switch connector
and disconnect the controller connector. Turn
the multimeter to its resistance function, and
Gray wire measure the resistance between the harness at
the controller port J2-13 and the grounding (nor-
Red probe

mally, <10Ω).

(b) Turn the multimeter to its resistance func-

tion, and measure the resistance between
the connector port J2-13 and foot pilot
pressure switch harness (normally, <10Ω).

To the black probe

To the red probe

White When the resistance is abnormal, this indi-

wire
cates the connector is poorly contacted.
• Whether a fault developing in the con-
nector or not?
To the red probe
• Yes
To the black probe
Replace the connector.
Turn to Step 4
• Is the harness open?
• No
• Yes
Turn to Step 4
Connect the harness again and wrap the har-
 6-45
CLG922E 6.4 DTC
February 3, 2015 6.4.8 DTC 121405 Foot pilot pressure switch OFF

Step 4 Check whether this fault is eliminated

Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
6-46
6.4 DTC CLG922E
6.4.9 DTC 121604 Air filter switch shorted to the ground February 3, 2015

6.4.9 DTC 121604 Air filter System description

The air prefilter is used to filter the dust and
switch shorted to the ground
large impurities in the air before entering the air
filter. The air filter mounted on the inside of the
Description of
DTC Consequence left door of the excavator is used to filter further
Fault
If the excavator the air from the prefilter, and keep the air clean
Air filter switch is operated as and dry through the main filter element and
121604 shorted to the usual, the safety filter element before entering into the
ground engine can be
damaged. engine cylinders for combustion. When the air-
flow through the air filter is blocked and the air
filter is needed to work, then if the engine is run-
ning, a high vacuum between the air filter and
the engine will produce. The vacuum can acti-
vate the electronic indicator (air filter switch) to
generate ground which is transmitted to the con-
troller. The display will show the current situation
to alert the operator.

J2(White)
Controller

Intake air filter alarm Filter alarm SW

 6-47
CLG922E 6.4 DTC
February 3, 2015 6.4.9 DTC 121604 Air filter switch shorted to the ground

Component location Step 2 Check the harness for short-circuit to

ground

 Correctly tie up harness and wire:

Front
Avoid folding or bending the harness forci-
bly.
It shall be kept away from moving compo-
Air filter switch
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).

Fault diagnosis and elimination pro- • Inspection method

cedures 1. Check the harness (No. 927) between the

controller (J2-27) and the air filter switch.
Step 1 Check the air filter switch for fault
2. Disconnect the connectors from the air filter
 When replacing the components, please switch and the controller. Turn the multimeter to
be sure to use LiuGong parts. its resistance function, and measure the resis-
• Inspection method tance between the harness (No. 927) switch ter-
minal and the grounding (normally, >100K).
Turn the start switch to the OFF position,
and disconnect the connector from the air fil- • Whether the harness is shorted to the
ter switch. ground or not?

1. Check the connector inside for moisture, oil Yes

dirt and other. Connect the harness again and wrap the har-
2. Turn the multimeter to its resistance function, ness.
and measure the resistance between the air fil- Turn to Step 4
ter switch terminals (normally, >100K). • No
• Whether a fault developing in the air fil- Turn to Step 3
ter switch or not?
• Yes
Repair or replace the air filter switch.
Turn to Step 4
• No
Turn to Step 2
6-48
6.4 DTC CLG922E
6.4.9 DTC 121604 Air filter switch shorted to the ground February 3, 2015

Step 3 Check the connector for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Connect the air filter switch connector and dis-
connect the controller connector. Turn the multi-
meter to its resistance function, and measure
the resistance between the controller port J2-27
and the grounding (normally, >100K).
When the resistance is abnormal, this indi-
cates there is an insulation fault in the con-
nector.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-49
CLG922E 6.4 DTC
February 3, 2015 6.4.10 DTC 121615 Air filter clogging

6.4.10 DTC 121615 Air filter System description

The air prefilter is used to filter the dust and
clogging
large impurities in the air before entering the air
filter. The air filter mounted on the inside of the
Description of
DTC Consequence left door of the excavator is used to filter further
Fault
Air filter clogging- the air from the prefilter, and keep the air clean
When the engine and dry through the main filter element and
is running, the If the excavator safety filter element before entering into the
signal circuit of the is operated as
121615 air filter switch usual, the engine cylinders for combustion. When the air-
detects the air filter engine can be flow through the air filter is blocked and the air
is clogged (the damaged. filter is needed to work, then if the engine is run-
sensor contact is
closed). ning, a high vacuum between the air filter and
the engine will produce. The vacuum can acti-
vate the electronic indicator (air filter switch) to
generate ground which is transmitted to the con-
troller. The display will show the current situation
to alert the operator.

J2(White)
Controller

Intake air filter alarm Filter alarm SW

6-50
6.4 DTC CLG922E
6.4.10 DTC 121615 Air filter clogging February 3, 2015

Component location Step 2 Check the air filter monitoring system for
fault.

 When replacing the components, please

Front
be sure to use LiuGong parts.
• Inspection method

Air filter switch

If the air filter is normal, check the air filter detec-
tion circuit or air filter alarm switch for fault in
accordance with the fault diagnosis of the
121604 - Air Filter Switch Shorted to the
Ground.
• Whether a fault developing in the air fil-
ter monitoring system or not?

Fault diagnosis and elimination pro- • Yes

cedures Repair the air filter detection circuit or replace

the air filter alarm switch.
Step 1 Check the air filter for clogging
Turn to Step 3
• Inspection method
• No
Check the air filter for clogging
Turn to Step 3
• Whether the air filter is clogged
• Yes Step 3 Check whether this fault is eliminated
Clean or replace the air filter.
• Inspection method
Turn to Step 3
Turn the start switch to the ON position and re-
• No check for fault.
Turn to Step 2 • Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-51
CLG922E 6.4 DTC
February 3, 2015 6.4.11 DTC 131000 High engine speed

6.4.11 DTC 131000 High engine System description

The speed sensor is used for detecting the
speed
engine speed which can be read on the display.
The speed sensor is an electromagnetic induc-
Description of
DTC Consequence tion sensor, which is mounted on the diesel
Fault
High engine speed engine flywheel housing. The diesel engine fly-
- When the engine If the excavator wheel cuts the magnetic field lines, resulting in
is running, the is operated as an EMF and output current. After starting the
131000 signal circuit of the usual, the
speed sensor engine can be engine, let it run at 1000-2270r/min, and then
detects the engine damaged. turn the multimeter to its AC voltage function,
speed is too high. and measure the speed sensor output voltage of
3-28V.

J1(Black)
Controller
Engine speed

J2(White)
Speed sensor
Sensor to ground
6-52
6.4 DTC CLG922E
6.4.11 DTC 131000 High engine speed February 3, 2015

Component location Step 2 Check whether the fuel is used properly.

 Be careful! Hot engine block and

Speed sensor
Front hydraulic oil can scald you seriously.
• Inspection method
Check whether the fuel being used is the speci-
fied one.
• Whether the fuel is used properly or
not?
• Yes
Replace the fuel.
Turn to Step 4
• No
Fault diagnosis and elimination pro- Turn to Step 3
cedures
Step 1 Check whether the operating method is Step 3 Check the detection circuit or speed sen-
correct. sor for fault.

 When replacing the components, please  When replacing the components, please
be sure to use LiuGong parts. be sure to use LiuGong parts.
• Inspection method • Inspection method
Check whether the operator’s operating method Check the speed detection circuit or speed sen-
is correct. sor for fault in accordance with the fault diagno-
• Whether the operating method is correct sis of the 131005 - Engine Speed Sensor Fault.
or not. • Check whether a fault developing in the
• Yes detection circuit speed sensor or not?
Tell the operator about the correct operating • Yes
method. Repair the detection circuit or replace the speed
Turn to Step 4 sensor.
• No Turn to Step 4
Turn to Step 2 • No
Turn to Step 4
 6-53
CLG922E 6.4 DTC
February 3, 2015 6.4.11 DTC 131000 High engine speed

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
6-54
6.4 DTC CLG922E
6.4.12 DTC 131005 Engine speed sensor fault February 3, 2015

6.4.12 DTC 131005 Engine System description

Used to detect the engine speed which can be
speed sensor fault
displayed on the display. The speed sensor is
an electromagnetic induction sensor, which is
Description of
DTC Consequence mounted on the diesel engine flywheel housing.
Fault
An abnormal The diesel engine flywheel cuts the magnetic
Engine speed
speed appears field lines, resulting in an EMF and output cur-
sensor fault (There
on the display. rent. After starting the engine, let it run at 1000-
131005 is a fault in the
The speed
speed sensor 2270r/min, and then turn the multimeter to its
calibration is
circuit.)
unsuccessful. AC voltage function, and measure the speed
sensor output voltage of 3-28V.

J1(Black)
Controller
Engine speed

J2(White)
Speed sensor
Sensor to ground
 6-55
CLG922E 6.4 DTC
February 3, 2015 6.4.12 DTC 131005 Engine speed sensor fault

Component location Step 2 Check the harness for open-circuit and

short-circuit.

Speed sensor
Front
 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).

Fault diagnosis and elimination pro- • Inspection method

cedures 1. Check the harnesses (No. 830 and No. 922)

between the controller (J1-30 and J2-22) and
Step 1 Check the speed sensor for fault
the speed sensor for wear, respectively.
• Inspection method 2. Disconnect the connectors from the speed
1. Check the sensor for looseness. sensor and the controller and check the har-
2. Disconnect the speed sensor connector: nesses for open-circuit. Turn the multimeter to
(a) Check the connector pins for looseness, its resistance function, and measure the resis-
rust, bending and damage. Check the con- tance of the harness (No. 830/No. 922) between
nector inside for moisture, oil dirt and other. the controller (J1-30/ J2-22) and the speed sen-
(b) Start the engine and turn the knob to sor, respectively (normally, <10Ω).
increase the accelerator gradually. Turn the 3. Disconnect the connectors from the speed
multimeter to its voltage function, and mea- sensor and the controller and check the har-
sure the voltage on the sensor output ports nesses for short-circuit. Turn the multimeter to
(normally, when the engine speed at 1000- its resistance function, and measure the resis-
2270r/min, the speed sensor outputs an AC tance between the harness (No. 830/No. 922)
voltage between 3-28V.). sensor terminal and the grounding, respectively
(normally, >100K).
• Whether a fault developing in the speed
sensor or not? • Is the harness open or short circuit?

• Yes • Yes
Tighten or repair, or replace the speed sensor. Connect the harness again and wrap the har-
Turn to Step 4 ness.
Turn to Step 4
• No
Turn to Step 2 • No
Turn to Step 3
6-56
6.4 DTC CLG922E
6.4.12 DTC 131005 Engine speed sensor fault February 3, 2015

Step 3 Check the connector for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Connect the speed sensor connector and dis-
connect the controller connector. Start the
engine and turn the knob to increase the accel-
erator gradually. Turn the multimeter to its volt-
age function, and measure the voltage between
the controller port J1-30 and J2-22 (normally,
when the engine speed at 1000-2270r/min, the
speed sensor outputs an AC voltage between 3-
28V.).
An abnormal voltage indicates that there is
fault in the connector.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-57
CLG922E 6.4 DTC
February 3, 2015 6.4.13 DTC 131100 Extremely high coolant temperature

6.4.13 DTC 131100 Extremely System description

The temperature sensor is made of NTC tem-
high coolant temperature
perature sensing material and is used for detect-
ing cooling water temperature. The temperature
Description of
DTC Consequence sensor is a negative temperature coefficient
Fault
Extremely high thermistor type, i.e., the lower the temperature,
coolant temperature the larger the resistance. Therefore, the tem-
If the excavator
- When the engine is perature change is converted into a resistance
is operated as
running, the signal
usual, this can voltage signal output to the controller which
131100 circuit of the engine
cause the
coolant temperature detects the temperature of the cooling water.
scuffing of
sensor detects that The temperature of the cooling water appears
cylinder bore.
the engine coolant is
overheating (108 °). on the connected display instrument. When the
water temperature is higher than a certain value,
an alarm signal is sent.

Temperature sensor
Controller

Coolant temperature

Sensor to ground
6-58
6.4 DTC CLG922E
6.4.13 DTC 131100 Extremely high coolant temperature February 3, 2015

Component location Step 2 Check the engine coolant temperature

monitoring system for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Coolant temperature
sensor
If the coolant temperature is normal, check the
coolant temperature detection circuit or coolant
temperature sensor for fault in accordance with
the fault diagnosis of 131103 - Coolant Tem-
perature Sensor Voltage Outside the Range
Front Value.
• Whether the engine coolant temperature
monitoring system is failed or not?
Fault diagnosis and elimination pro-
• Yes
cedures
Repair the coolant temperature detection circuit
Step 1 Check the engine coolant for overheat-
or replace the coolant temperature sensor.
ing.
Turn to Step 3
 Be careful! Hot engine block and cool- • No
ant can scald you seriously. Turn to Step 3
• Inspection method
Check the engine coolant for overheating with a Step 3 Check whether this fault is eliminated
thermometer. • Inspection method
• Whether the engine coolant overheat- Turn the start switch to the ON position and re-
ing or not? check for fault.
• Yes • Has this fault been eliminated?
Look for the cause for the engine coolant over- • Yes
heating. Maintenance is over
Turn to Step 3
• No
• No
Troubleshoot the faults according to the steps
Turn to Step 2 again or contact the local LiuGong dealer and
authorized service center.
 6-59
CLG922E 6.4 DTC
February 3, 2015 6.4.14 DTC 131103 Coolant temperature sensor voltage above the range value

6.4.14 DTC 131103 Coolant tem- System description

The temperature sensor is made of NTC tem-
perature sensor voltage above
perature sensing material and is used for detect-
the range value ing cooling water temperature. The temperature
sensor is a negative temperature coefficient
Description of thermistor type, i.e., the lower the temperature,
DTC Consequence
Fault the larger the resistance. Therefore, the tem-
The controller perature change is converted into a resistance
detects the coolant
If the excavator voltage signal output to the controller which
temperature
is operated as
sensor voltage is detects the temperature of the cooling water.
usual, this can
131103 higher than the The temperature of the cooling water appears
cause the
range value, that
scuffing of on the connected display instrument. When the
is, the detected
cylinder bore. water temperature is higher than a certain value,
voltage is above
4.9V. an alarm signal is sent.

Temperature sensor
Controller

Coolant temperature

Sensor to ground

Water temperature sensor parame-

ter table

Coolant temperature (Centigrade)

Resistance (Ohm)
6-60
6.4 DTC CLG922E
6.4.14 DTC 131103 Coolant temperature sensor voltage above the range value February 3, 2015

Component location Step 2 Check the harness for open-circuit

 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

bly.
It shall be kept away from moving compo-
Coolant temperature nents as far as possible to prevent tensile
sensor
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Try to keep far away from high temperature
Front
parts (e.g. engine body).
• Inspection method
Fault diagnosis and elimination pro- 1. Check the harnesses (No. 819 and No. 922)
cedures between the controller (J1-19 and J2-22) and
the coolant temperature sensor for wear,
Step 1 Check the coolant temperature sensor for
respectively.
fault.
2. Disconnect the connectors from the coolant
• Inspection method
temperature sensor and the controller. Turn the
Turn the start switch to the OFF position, multimeter to its resistance function, and mea-
and disconnect the sensor connector. sure the resistance of the harness (No. 819/No.
1. Check the connector for looseness, rust, 922) between the controller (J1-19 and J2-22)
bending and damage. and the sensor, respectively (normally, <10Ω).
2. Turn the multimeter to its resistance function • Is the harness open?
(20KΩ), and measure the resistance between
• Yes
the sensor connector terminals 1 and 2, compar-
Connect the harness again and wrap the har-
ing the result with the parameter table (normally,
ness.
<4K).
Turn to Step 4
• Whether a fault developing in the cool-
ant temperature sensor or not? • No
Turn to Step 3
• Yes
Repair or replace the sensor.
Turn to Step 4
• No
Turn to Step 2
 6-61
CLG922E 6.4 DTC
February 3, 2015 6.4.14 DTC 131103 Coolant temperature sensor voltage above the range value

Step 3 Check the connector for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Connect the coolant temperature sensor con-
nector and disconnect the controller connector.
Turn the multimeter to its resistance function,
and measure the resistance between the con-
troller port J1-19 and J2-22, comparing the
result with the parameter table (normally, <4K).
An abnormal resistance indicates that there
is poor contact in the connector
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
6-62
6.4 DTC CLG922E
6.4.15 DTC 131104 Coolant temperature sensor voltage below the range value February 3, 2015

6.4.15 DTC 131104 Coolant tem- System description

The temperature sensor is made of NTC tem-
perature sensor voltage below
perature sensing material and is used for detect-
the range value ing cooling water (hydraulic oil) temperature.
The temperature sensor is a negative tempera-
DTC Description of Fault Consequence ture coefficient thermistor type, i.e., the lower
Coolant temperature the temperature, the larger the resistance.
sensor voltage below Therefore, the temperature change is converted
the range value into a resistance voltage signal output to the
(When the engine is If the
running, the signal excavator is controller which detects the temperature of the
circuit of the engine operated as cooling water (hydraulic oil). The temperature of
131104 coolant temperature usual, this can the cooling water (hydraulic oil) appears on the
sensor detects that cause the
the engine coolant engine power connected display instrument. When the cooling
temperature is too down. water (hydraulic oil) temperature is higher than a
high (above certain value, an alarm signal is sent.
measurement
range).)

J1(Black)
Controller
Coolant temperature

Hydraulic oil
temperature
Temperature sensor

J2(White)
Sensor to ground

Hyd temperature sensor

Water temperature sensor parame-

ter table
Coolant temperature (Centigrade)

Resistance (Ohm)
 6-63
CLG922E 6.4 DTC
February 3, 2015 6.4.15 DTC 131104 Coolant temperature sensor voltage below the range value

Component location Step 2 Check the harness for short-circuit to

ground

 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

bly.
Coolant temperature It shall be kept away from moving compo-
sensor
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Front Try to keep far away from high temperature
parts (e.g. engine body).

Fault diagnosis and elimination pro- • Inspection method

cedures 1. Check the harnesses (No. 819 and No. 922)

between the controller (J1-19 and J2-22) and
Step 1 Check the coolant temperature sensor for
the coolant temperature sensor for wear,
fault.
respectively.
 When replacing the components, please 2. Disconnect the connectors from the coolant
be sure to use LiuGong parts. temperature sensor and the controller. Turn the
multimeter to its resistance function, and mea-
• Inspection method
sure the resistance between the harness (No.
Turn the start switch to the OFF position,
819 and No. 922) sensor terminal and the
and disconnect the sensor connector.
grounding, respectively (normally, >100K).
1. Check the connector for moisture, oil dirt and
• Whether the harness is shorted to the
other
ground or not?
2. Turn the multimeter to its resistance function
(20KΩ), and measure the resistance between • Yes
the sensor connector terminals 1 and 2, compar- Connect the harness again and wrap the har-
ing the result with the parameter table (normally, ness.
>10Ω). Turn to Step 4
• Whether a fault developing in the cool- • No
ant temperature sensor or not? Turn to Step 3
• Yes
Repair or replace the sensor.
Turn to Step 4
• No
Turn to Step 2
6-64
6.4 DTC CLG922E
6.4.15 DTC 131104 Coolant temperature sensor voltage below the range value February 3, 2015

Step 3 Check the connector for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Connect the coolant temperature sensor con-
nector and disconnect the controller connector.
Turn the multimeter to its resistance function,
and measure the resistance between the con-
troller port J1-19 and J2-22, comparing the
result with the parameter table (normally, >10Ω).
When the resistance is abnormal, this indi-
cates there is an insulation fault in the con-
nector
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-65
CLG922E 6.4 DTC
February 3, 2015 6.4.16 DTC 131115 High coolant temperature

6.4.16 DTC 131115 High coolant System description

The temperature sensor is made of NTC tem-
temperature
perature sensing material and is used for detect-
ing cooling water temperature. The temperature
Description of
DTC Consequence sensor is a negative temperature coefficient
Fault
High coolant thermistor type, i.e., the lower the temperature,
temperature - the larger the resistance. Therefore, the tem-
When the engine perature change is converted into a resistance
is running, the If the excavator
signal circuit of the is operated as voltage signal output to the controller which
engine coolant usual, this can detects the temperature of the cooling water.
131115
temperature cause the The temperature of the cooling water appears
sensor detects scuffing of
that the engine on the connected display instrument. When the
cylinder bore
coolant is water temperature is higher than a certain value,
overheating (102 an alarm signal is sent.
℃ ).

Temperature sensor
Controller

Coolant temperature

Sensor to ground
6-66
6.4 DTC CLG922E
6.4.16 DTC 131115 High coolant temperature February 3, 2015

Component location Step 2 Check the engine coolant temperature

monitoring system for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Coolant temperature
sensor
If the coolant temperature is normal, check the
coolant temperature detection circuit or coolant
temperature sensor for fault in accordance with
the fault diagnosis of 131103 - Coolant Tem-
perature Sensor Voltage Outside the Range
Front Value.
• Whether the engine coolant temperature
monitoring system is failed or not?
Fault diagnosis and elimination pro-
• Yes
cedures
Repair the coolant temperature detection circuit
Step 1 Check whether the engine coolant tem-
or replace the coolant temperature sensor.
perature is too high.
Turn to Step 3
 Be careful! Hot engine block and cool- • No
ant can scald you seriously. Turn to Step 3
• Inspection method
Check whether the engine coolant temperature Step 3 Check whether this fault is eliminated
is too high with a thermometer. • Inspection method
• Whether the engine coolant temperature Turn the start switch to the ON position and re-
is high or not? check for fault.
• Yes • Has this fault been eliminated?
Look for the cause for high coolant temperature. • Yes
Turn to Step 3 Maintenance is over
• No • No
Turn to Step 2 Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-67
CLG922E 6.4 DTC
February 3, 2015 6.4.17 DTC 131116 High coolant temperature

6.4.17 DTC 131116 High coolant System description

The temperature sensor is made of NTC tem-
temperature
perature sensing material and is used for detect-
ing cooling water temperature. The temperature
Description of
DTC Consequence sensor is a negative temperature coefficient
Fault
High coolant thermistor type, i.e., the lower the temperature,
temperature - the larger the resistance. Therefore, the tem-
When the engine perature change is converted into a resistance
is running, the If the excavator
signal circuit of the is operated as voltage signal output to the controller which
engine coolant usual, this can detects the temperature of the cooling water.
131116
temperature cause the The temperature of the cooling water appears
sensor detects scuffing of
that the engine on the connected display instrument. When the
cylinder bore
coolant is water temperature is higher than a certain value,
overheating (105 an alarm signal is sent.
℃ ).

Temperature sensor
Controller

Coolant temperature

Sensor to ground
6-68
6.4 DTC CLG922E
6.4.17 DTC 131116 High coolant temperature February 3, 2015

Component location Step 2 Check the engine coolant temperature

monitoring system for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Coolant temperature
sensor
If the coolant temperature is normal, check the
coolant temperature detection circuit or coolant
temperature sensor for fault in accordance with
the fault diagnosis of 131103 - Coolant Tem-
perature Sensor Voltage Outside the Range
Front Value.
• Whether the engine coolant temperature
monitoring system is failed or not?
Fault diagnosis and elimination pro-
• Yes
cedures
Repair the coolant temperature detection circuit
Step 1 Check whether the engine coolant tem-
or replace the coolant temperature sensor.
perature is too high.
Turn to Step 3
 Be careful! Hot engine block and cool- • No
ant can scald you seriously. Turn to Step 3
• Inspection method
Check whether the engine coolant temperature Step 3 Check whether this fault is eliminated
is too high with a thermometer. • Inspection method
• Whether the engine coolant temperature Turn the start switch to the ON position and re-
is high or not? check for fault.
• Yes • Has this fault been eliminated?
Look for the cause for overhigh coolant tem- • Yes
perature. Maintenance is over
Turn to Step 3
• No
• No
Troubleshoot the faults according to the steps
Turn to Step 2 again or contact the local LiuGong dealer and
authorized service center.
 6-69
CLG922E 6.4 DTC
February 3, 2015 6.4.18 DTC 1131200 Extremely high hydraulic oil temperature

6.4.18 DTC 1131200 Extremely System description

The temperature sensor is made of NTC tem-
high hydraulic oil temperature
perature sensing material and is used for detect-
ing hydraulic oil (cooling water) temperature.
Description of
DTC Consequence The temperature sensor is a negative tempera-
Fault
Extremely high ture coefficient thermistor type, i.e., the lower
hydraulic oil the temperature, the larger the resistance.
temperature - Therefore, the temperature change is converted
If the excavator
When the engine
is operated as into a resistance voltage signal output to the
is running, the
usual, this can controller which detects the temperature of the
131200 signal circuit of the
cause damage
hydraulic oil hydraulic oil (cooling water). The temperature of
to the hydraulic
temperature
components. the hydraulic oil (cooling water) appears on the
sensor detects
that the hydraulic connected display instrument. When the water
oil is high (95 ℃ ). temperature is higher than a certain value, an
alarm signal is sent.

Hyd temperature sensor

Controller

Hydraulic oil temperature

Sensor to ground
6-70
6.4 DTC CLG922E
6.4.18 DTC 1131200 Extremely high hydraulic oil temperature February 3, 2015

Component location Step 2 Check the hydraulic oil temperature mon-

itoring system for fault.

Front
 When replacing the components, please
be sure to use LiuGong parts.
• Inspection method
If the hydraulic oil temperature is normal, check
the hydraulic oil temperature detection circuit or
hydraulic oil temperature sensor for fault in
accordance with the fault diagnosis of 131203 -
Hydraulic Oil Temperature Sensor Voltage
Hydraulic oil
temperature sensor Above the Range Value.
• Whether a fault developing in the
hydraulic oil temperature monitoring
Fault diagnosis and elimination pro-
system or not?
cedures
• Yes
Step 1 Check whether the hydraulic oil tempera-
Repair the hydraulic oil temperature detection
ture is extremely high.
circuit or replace the hydraulic oil temperature
 Be careful! Hot engine block and sensor.
hydraulic oil can scald you seriously Turn to Step 3

• Inspection method • No

Check whether the hydraulic oil is overheating Turn to Step 3

with a thermometer.
• Whether the hydraulic oil temperature is Step 3 Check whether this fault is eliminated
extremely high or not? • Inspection method
• Yes Turn the start switch to the ON position and re-
Look for the cause for high coolant temperature. check for fault.
Turn to Step 3 • Has this fault been eliminated?
• No • Yes
Turn to Step 2 Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-71
CLG922E 6.4 DTC
February 3, 2015 6.4.19 DTC 131203 Hydraulic oil temperature sensor voltage above the range value

6.4.19 DTC 131203 Hydraulic oil System description

The temperature sensor is made of NTC tem-
temperature sensor voltage
perature sensing material and is used for detect-
above the range value ing hydraulic oil (cooling water) temperature.
The temperature sensor is a negative tempera-
Description of ture coefficient thermistor type, i.e., the lower
DTC Consequence
Fault the temperature, the larger the resistance.
The controller Therefore, the temperature change is converted
If the excavator
detects the coolant
is operated as into a resistance voltage signal output to the
temperature
usual, this can
sensor voltage is controller which detects the temperature of the
cause pump
131203 higher than the hydraulic oil (cooling water). The temperature of
power down
range value, that
and damage to the hydraulic oil (cooling water) appears on the
is, the detected
the hydraulic connected display instrument. When the water
voltage is above
components.
4.9V. temperature is higher than a certain value, an
alarm signal is sent.

Hyd temperature sensor

Controller

Hydraulic oil temperature

Sensor to ground

Hydraulic oil temperature sensor

parameter table
Coolant temperature (Centigrade)

Resistance (Ohm)
6-72
6.4 DTC CLG922E
6.4.19 DTC 131203 Hydraulic oil temperature sensor voltage above the range value February 3, 2015

Component location Step 2 Check the harness for open-circuit

 Correctly tie up harness and wire:

Front Avoid folding or bending the harness forci-
bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Try to keep far away from high temperature
Hydraulic oil
temperature sensor parts (e.g. engine body).
• Inspection method
Step 1 Check the hydraulic oil temperature sen- 1. Check the harnesses (No. 831 and No. 922)
sor for fault. between the controller (J1-31 and J2-22) and
• Inspection method the hydraulic oil temperature sensor for wear.
Turn the start switch to the OFF position, 2. Disconnect the connectors from the hydraulic
and disconnect the sensor connector. oil temperature sensor and the controller. Turn
1. Check the connector for looseness, rust, the multimeter to its resistance function, and
bending and damage. measure the resistance of the harness (No. 831/
No. 922) between the controller (J1-31/J2-22)
2. Turn the multimeter to its resistance function
and the hydraulic oil temperature sensor,
(20KΩ), and measure the resistance between
respectively (normally, <10Ω)
the sensor connector terminals 1 and 2, compar-
ing the result with the parameter table (normally, • Is the harness open?
<4K). • Yes
• Whether a fault developing in the Connect the harness again and wrap the har-
hydraulic oil temperature sensor or not? ness.
• Yes Turn to Step 4
Repair or replace the hydraulic oil temperature • No
sensor. Turn to Step 3
Turn to Step 4
• No
Turn to Step 2
 6-73
CLG922E 6.4 DTC
February 3, 2015 6.4.19 DTC 131203 Hydraulic oil temperature sensor voltage above the range value

Step 3 Check the connector for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Connect the hydraulic oil temperature sensor
connector and disconnect the controller connec-
tor. Turn the multimeter to its resistance func-
tion, and measure the resistance between the
controller port J1-31 and J2-22, comparing the
result with the parameter table (normally, <4K).
An abnormal resistance indicates that there
is poor contact in the connector
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
6-74
6.4 DTC CLG922E
6.4.20 DTC 131204 Hydraulic oil temperature sensor voltage below the range value February 3, 2015

6.4.20 DTC 131204 Hydraulic oil System description

The temperature sensor is made of NTC tem-
temperature sensor voltage
perature sensing material and is used for detect-
below the range value ing hydraulic oil (cooling water) temperature.
The temperature sensor is a negative tempera-
Description of ture coefficient thermistor type, i.e., the lower
DTC Consequence
Fault the temperature, the larger the resistance.
If the excavator Therefore, the temperature change is converted
Hydraulic oil
is operated as
temperature into a resistance voltage signal output to the
usual, this can
131204 sensor voltage
cause damage controller which detects the temperature of the
below the range
to the hydraulic hydraulic oil (cooling water). The temperature of
valve.
pipeline.
the hydraulic oil (cooling water) appears on the
connected display instrument. When the water
temperature is higher than a certain value, an
alarm signal is sent.

Hyd temperature sensor

Controller

Hydraulic oil temperature

Sensor to ground

Hydraulic oil temperature sensor

parameter table
Coolant temperature (Centigrade)

Resistance (Ohm)
 6-75
CLG922E 6.4 DTC
February 3, 2015 6.4.20 DTC 131204 Hydraulic oil temperature sensor voltage below the range value

Component location Step 2 Check the harness for short-circuit to

ground

Front
 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Hydraulic oil
temperature sensor Try to keep far away from high temperature
parts (e.g. engine body).

Fault diagnosis and elimination pro- • Inspection method

cedures 1. Check the harnesses (No. 831 and No. 922)

between the controller (J1-31 and J2-22) and
Step 1 Check the hydraulic oil temperature sen-
the hydraulic oil temperature sensor for wear.
sor for fault.
2. Disconnect the connectors from the hydraulic
 When replacing the components, please oil temperature sensor and the controller. Turn
be sure to use LiuGong parts. the multimeter to its resistance function, and
• Inspection method measure the resistance between the harness
(No. 831/No. 922) sensor terminal and the
Turn the start switch to the OFF position,
grounding, respectively (normally, >100K)
and disconnect the sensor connector.
• Whether the harness is shorted to the
1. Check the connector for moisture, oil dirt and
ground or not?
other
2. Turn the multimeter to its resistance function • Yes
(20KΩ), and measure the resistance between Connect the harness again and wrap the har-
the sensor connector terminals 1 and 2, compar- ness.
ing the result with the parameter table (normally, Turn to Step 4
>10Ω). • No
• Whether a fault developing in the Turn to Step 3
hydraulic oil temperature sensor or not?
• Yes
Repair or replace the sensor.
Turn to Step 4
• No
Turn to Step 2
6-76
6.4 DTC CLG922E
6.4.20 DTC 131204 Hydraulic oil temperature sensor voltage below the range value February 3, 2015

Step 3 Check the connector for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Connect the hydraulic oil temperature sensor
connector and disconnect the controller connec-
tor. Turn the multimeter to its resistance func-
tion, and measure the resistance between the
controller port J1-31 and J2-22, comparing the
result with the parameter table (normally, >10Ω).
When the resistance is abnormal, this indi-
cates there is an insulation fault in the con-
nector
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-77
CLG922E 6.4 DTC
February 3, 2015 6.4.21 DTC 131215 High hydraulic oil temperature

6.4.21 DTC 131215 High hydrau- System description

The temperature sensor is made of NTC tem-
lic oil temperature
perature sensing material and is used for detect-
ing hydraulic oil (cooling water) temperature.
Description of
DTC Consequence The temperature sensor is a negative tempera-
Fault
High hydraulic oil - ture coefficient thermistor type, i.e., the lower
When the engine the temperature, the larger the resistance.
is running, the If the excavator Therefore, the temperature change is converted
signal circuit of the is operated as
hydraulic oil usual, this can into a resistance voltage signal output to the
131215 controller which detects the temperature of the
temperature cause damage
sensor detects the to the hydraulic hydraulic oil (cooling water). The temperature of
hydraulic oil components.
temperature is the hydraulic oil (cooling water) appears on the
high (86 ℃ ). connected display instrument. When the water
temperature is higher than a certain value, an
alarm signal is sent.

Hyd temperature sensor

Controller

Hydraulic oil temperature

Sensor to ground
6-78
6.4 DTC CLG922E
6.4.21 DTC 131215 High hydraulic oil temperature February 3, 2015

Component location Step 2 Check the hydraulic oil temperature mon-

itoring system for fault.

Front
 When replacing the components, please
be sure to use LiuGong parts.
• Inspection method
If the hydraulic oil temperature is normal, check
the hydraulic oil temperature detection circuit or
hydraulic oil temperature sensor for fault in
accordance with the fault diagnosis of 131203 -
Hydraulic Oil Temperature Sensor Voltage
Hydraulic oil
temperature sensor Above the Range Value.
• Whether a fault developing in the
hydraulic oil temperature monitoring
Fault diagnosis and elimination pro-
system or not?
cedures
• Yes
Step 1 Check whether the hydraulic oil tempera-
Repair the hydraulic oil temperature detection
ture is too high
circuit or replace the hydraulic oil temperature
 Be careful! Hot engine block and sensor.
hydraulic oil can scald you seriously Turn to Step 3

• Inspection method • No

Check whether the hydraulic oil temperature is Turn to Step 3

high with a thermometer.
• Whether the hydraulic oil temperature is Step 3 Check whether this fault is eliminated
too high or not? • Inspection method
• Yes Turn the start switch to the ON position and re-
Look for the cause for high coolant temperature. check for fault.
Turn to Step 3 • Has this fault been eliminated?
• No • Yes
Turn to Step 2 Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-79
CLG922E 6.4 DTC
February 3, 2015 6.4.22 DTC 131216 Extremely high hydraulic oil temperature

6.4.22 DTC 131216 Extremely System description

The temperature sensor is made of NTC tem-
high hydraulic oil temperature
perature sensing material and is used for detect-
ing hydraulic oil (cooling water) temperature.
Description of
DTC Consequence The temperature sensor is a negative tempera-
Fault
Extremely high ture coefficient thermistor type, i.e., the lower
hydraulic oil the temperature, the larger the resistance.
temperature- Therefore, the temperature change is converted
When the engine
If the excavator into a resistance voltage signal output to the
is running, the
is operated as controller which detects the temperature of the
signal circuit of the
usual, this can
131216 hydraulic oil hydraulic oil (cooling water). The temperature of
cause damage
temperature
to the hydraulic the hydraulic oil (cooling water) appears on the
sensor detects the
components. connected display instrument. When the water
hydraulic oil
temperature is temperature is higher than a certain value, an
extremely high (88
alarm signal is sent.
℃ ).

Hyd temperature sensor

Controller

Hydraulic oil temperature

Sensor to ground
6-80
6.4 DTC CLG922E
6.4.22 DTC 131216 Extremely high hydraulic oil temperature February 3, 2015

Component location Step 2 Check the hydraulic oil temperature mon-

itoring system for fault.

Front
 When replacing the components, please
be sure to use LiuGong parts.
• Inspection method
If the hydraulic oil temperature is normal, check
the hydraulic oil temperature detection circuit or
hydraulic oil temperature sensor for fault in
accordance with the fault diagnosis of 131203 -
Hydraulic Oil Temperature Sensor Voltage Out-
Hydraulic oil
temperature sensor side the Range Value.
• Whether a fault developing in the
hydraulic oil temperature monitoring
Fault diagnosis and elimination pro-
system or not?
cedures
• Yes
Step 1 Check whether the hydraulic oil tempera-
Repair the hydraulic oil temperature detection
ture is extremely high.
circuit or replace the hydraulic oil temperature
 Be careful! Hot engine block and sensor.
hydraulic oil can scald you seriously Turn to Step 3

• Inspection method • No

Check whether the hydraulic oil temperature is Turn to Step 3

extremely high with a thermometer.
• Whether the hydraulic oil temperature is Step 3 Check whether this fault is eliminated
extremely high or not? • Inspection method
• Yes Turn the start switch to the ON position and re-
Look for the cause for high coolant temperature. check for fault.
Turn to Step 3 • Has this fault been eliminated?
• No • Yes
Turn to Step 2 Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-81
CLG922E 6.4 DTC
February 3, 2015 6.4.23 DTC 131303 Fuel level sensor voltage above the range value

6.4.23 DTC 131303 Fuel level System description

The fuel level sensor is a reed pipe type. The
sensor voltage above the range
magnetic float density is lower than the working
value medium (diesel) density, so the fuel level sensor
floats on the surface of the working medium and
Description of can slide up and down on the reed pipe. When
DTC Consequence
Fault the floater moves on the reed pipe, the on-off of
If the excavator the internal circuit of the reed pipe is controlled
is operated as
Fuel level sensor by a magnetic field to allow the resistance
usual, this can
131303 voltage above the
cause the between the two output leads of the connector
range value
engine shuts to change. Therefore, the fuel level change is
down.
converted into a resistance signal output to the
controller which detects the fuel level in the tank.
Then, the fuel level appears on the connected
display instrument.

Controller J2(White)

Fuel level
Fuel level sensor
6-82
6.4 DTC CLG922E
6.4.23 DTC 131303 Fuel level sensor voltage above the range value February 3, 2015

Fuel level sensor parameter table 2. Turn the multimeter to its resistance function,
and measure the resistance between the fuel
(For the details, see the figure.)
level sensor connector terminals 1 and 2 (nor-
Component location mally, <2K, for the specific resistance, see the
figure.).

Front

Fuel level sensor

Fault diagnosis and elimination pro-

cedures • Whether a fault developing in the fuel
level sensor
Step 1 Check the fuel level sensor for fault.
• Yes
 When replacing the components, please
Repair or replace the fuel level sensor
be sure to use LiuGong parts.
Turn to Step 4
 High temperature and high pressure oil • No
or water can cause personal injury! To Turn to Step 2
replace the sensor, please shut down
the engine first, wait until the engine Step 2 Check the harness for open-circuit.
and gearbox housing are sufficiently
cooled.  Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

 To install the fuel level sensor into the
bly.
fuel tank, wipe off its water and keep it
It shall be kept away from moving compo-
clean.
nents as far as possible to prevent tensile
• Inspection method fault and wear.
Turn the start switch to the OFF position, Avoid friction with sharp metal edges.
and disconnect the connector from the fuel
Try to keep far way from oil and water.
level sensor.
Try to keep far away from high temperature
1. Check the connector for looseness, rust,
parts (e.g. engine body).
bending and damage.
 6-83
CLG922E 6.4 DTC
February 3, 2015 6.4.23 DTC 131303 Fuel level sensor voltage above the range value

• Inspection method
1. Check the harness (No. 930) and the ground-
ing wire (No.227) between the controller (J2-30)
and fuel level sensor for wear.
2. Disconnect the connectors from the fuel level
sensor and the controller.Check the harness for
open-circuit:
White wire
(a) Turn the multimeter to its resistance func-
tion, and measure the resistance between
the grounding wire (No.227) sensor termi- To the black probe

nal and the grounding (normally, <10Ω). To the red probe

• Is the harness open?

• Yes
Connect the harness again and wrap the har-
ness.
Gray wire
Turn to Step 4
• No
Turn to Step 3

Step 3 Check the connector for fault.

 When replacing the components, please

(b) Turn the multimeter to its resistance func- be sure to use LiuGong parts.
tion, and measure the resistance between • Inspection method
the connector ports J2-30 and sensor har-
Connect the water-in-fuel sensor connector and
ness (normally, <10Ω).
disconnect the controller connector. Turn the
multimeter to its resistance function, and mea-
sure the resistance between the harness at the
controller port J2-30 and the grounding (nor-
mally, <2K, for the specific resistance, see the
figure ).
6-84
6.4 DTC CLG922E
6.4.23 DTC 131303 Fuel level sensor voltage above the range value February 3, 2015

Connect the black

probe to ground

Connect the red

probe to Pin 30

When the resistance is abnormal, this indi-

cates the connector is poorly contacted.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check the DTC.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-85
CLG922E 6.4 DTC
February 3, 2015 6.4.23 DTC 131303 Fuel level sensor voltage above the range value

Figure: Fuel level sensor parameter table

Floater position Floater position

Output Output resistance
(Refer to the place at (Refer to the place at
resistance (Ω) (Ω)
17.5mm) 17.5mm)
Below L1 1100±11.0 L11-L12 550±5.5
L1-L2 1050±10.5 L12-L13 500±5.0
L2-L3 1000±10.0 L13-L14 450±4.5
L3-L4 950±9.5 L14-L15 400±4.0
L4-L5 900±9.0 L15-L16 350±3.5
L5-L6 850±8.5 L16-L17 300±3.0
L6-L7 800±8.0 L17-L18 250±2.5
L7-L8 750±7.5 L18-L19 200±2.0
L8-L9 700±7.0 L19-L20 150±1.5
L9-L10 650±6.5 L20-L21 100±1.0
L0-L11 600±6.0

Oil level
6-86
6.4 DTC CLG922E
6.4.24 DTC 131304 Fuel level sensor shorted to the ground February 3, 2015

6.4.24 DTC 131304 Fuel level System description

The fuel level sensor is a reed pipe type. The
sensor shorted to the ground
magnetic float density is lower than the working
medium (diesel) density, so the fuel level sensor
Description of
DTC Consequence floats on the surface of the working medium and
Fault
If the excavator can slide up and down on the reed pipe. When
is operated as the floater moves on the reed pipe, the on-off of
Fuel level sensor
usual, this can the internal circuit of the reed pipe is controlled
131304 shorted to the
cause the
ground. by a magnetic field to allow the resistance
engine shuts
down. between the two output leads of the connector
to change. Therefore, the fuel level change is
converted into a resistance signal output to the
controller which detects the fuel level in the tank.
Then, the fuel level appears on the connected
display instrument.

Controller J2(White)

Fuel level
Fuel level sensor
 6-87
CLG922E 6.4 DTC
February 3, 2015 6.4.24 DTC 131304 Fuel level sensor shorted to the ground

Fuel level sensor parameter table 1. Check the connector for moisture, oil dirt and
other
(For the details, see the figure.)
2. Turn the multimeter to its resistance function
Component location (2K), and measure the resistance between the
fuel level sensor terminals 1 and 2 (normally,
Front
>10Ω, for the specific resistance, see the figure).

Fuel level sensor

Fault diagnosis and elimination pro-

cedures
Step 1 Check the fuel level sensor for fault. • Whether a fault developing in the fuel
level sensor
 When replacing the components, please
• Yes
be sure to use LiuGong parts.
Repair or replace the fuel level sensor
 High temperature and high pressure oil Turn to Step 4
or water can cause personal injury! To • No
replace the sensor, please shut down Turn to Step 2
the engine first, wait until the engine
and gearbox housing are sufficiently
cooled.

 To install the fuel level sensor into the

fuel tank, wipe off its water and keep it
clean.
• Inspection method
Turn the start switch to the OFF position,
and disconnect the connector from the fuel
level sensor.
6-88
6.4 DTC CLG922E
6.4.24 DTC 131304 Fuel level sensor shorted to the ground February 3, 2015

Step 2 Check the harness for short-circuit to Turn to Step 4

ground • No
 Correctly tie up harness and wire: Turn to Step 3

Avoid folding or bending the harness forci-

bly. Step 3 Check the connector for fault.

It shall be kept away from moving compo-  When replacing the components, please
nents as far as possible to prevent tensile be sure to use LiuGong parts.
fault and wear.
• Inspection method
Avoid friction with sharp metal edges.
Connect the sensor connector and disconnect
Try to keep far way from oil and water. the controller connector. Turn the multimeter to
Try to keep far away from high temperature its resistance function, and measure the resis-
parts (e.g. engine body). tance between the J2-30 port and the grounding
• Inspection method (normally, >10Ω).
1. Check the harness (No. 930) between the When the resistance is abnormal, this indi-
controller (J2-30) and fuel level sensor for wear. cates there is an insulation fault in the con-
2. Disconnect the connectors from the fuel level nector
sensor and the controller. Turn the multimeter to • Whether a fault developing in the con-
its resistance function, and measure the resis- nector or not?
tance between the harness (No. 930) sensor ter- • Yes
minal and the grounding (normally, >100K).
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

White wire Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• Whether the harness is shorted to the
ground or not? • No
Troubleshoot the faults according to the steps
• Yes
again or contact the local LiuGong dealer and
Connect the harness again and wrap the har-
authorized service center.
ness.
 6-89
CLG922E 6.4 DTC
February 3, 2015 6.4.24 DTC 131304 Fuel level sensor shorted to the ground

Figure: Fuel level sensor parameter table

Floater position Floater position

Output Output resistance
(Refer to the place at (Refer to the place at
resistance (Ω) (Ω)
17.5mm) 17.5mm)
Below L1 1100±11.0 L11-L12 550±5.5
L1-L2 1050±10.5 L12-L13 500±5.0
L2-L3 1000±10.0 L13-L14 450±4.5
L3-L4 950±9.5 L14-L15 400±4.0
L4-L5 900±9.0 L15-L16 350±3.5
L5-L6 850±8.5 L16-L17 300±3.0
L6-L7 800±8.0 L17-L18 250±2.5
L7-L8 750±7.5 L18-L19 200±2.0
L8-L9 700±7.0 L19-L20 150±1.5
L9-L10 650±6.5 L20-L21 100±1.0
L0-L11 600±6.0

Oil level
6-90
6.4 DTC CLG922E
6.4.25 DTC 131317 Low fuel level February 3, 2015

6.4.25 DTC 131317 Low fuel System description

The fuel level sensor is a reed pipe type. The
level
magnetic float density is lower than the working
medium (diesel) density, so the fuel level sensor
Description of
DTC Consequence floats on the surface of the working medium and
Fault
Low fuel level - can slide up and down on the reed pipe. When
When the start the floater moves on the reed pipe, the on-off of
switch is turned to the internal circuit of the reed pipe is controlled
If the excavator
the ON position
is operated as by a magnetic field to allow the resistance
(without starting
usual, this can
131317 the engine), the between the two output leads of the connector
cause the
signal circuit of the to change. Therefore, the fuel level change is
engine shuts
fuel level sensor
down. converted into a resistance signal output to the
detects that the
fuel level is low controller which detects the fuel level in the tank.
(below 10%). Then, the fuel level appears on the connected
display instrument.

Controller J2(White)

Fuel level
Fuel level sensor
 6-91
CLG922E 6.4 DTC
February 3, 2015 6.4.25 DTC 131317 Low fuel level

Fuel level sensor parameter table Step 2 Check the fuel level monitoring system
for fault.
(For the details, see the figure.)
Component location  When replacing the components, please
be sure to use LiuGong parts.
• Inspection method
Front
If the fuel level is normal, check the fuel level
monitoring system in accordance with the fault
diagnosis in the 131304 - Fuel Level Sensor
Shorted to the Ground.
• Whether a fault developing in the fuel
level monitoring system or not?
• Yes
Fuel level sensor
Repair or replace the fuel level sensor.
Turn to Step 3
• No
Fault diagnosis and elimination pro-
Turn to Step 3
cedures
Step 1 Check whether the fuel level is low.
Step 3 Check whether this fault is eliminated
• Inspection method
• Inspection method
Check the fuel level.
Turn the start switch to the ON position and re-
• Whether the fuel level is low or not? check for fault.
• Yes • Has this fault been eliminated?
Add fuel. • Yes
Turn to Step 3 Maintenance is over
• No • No
Turn to Step 2 Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
6-92
6.4 DTC CLG922E
6.4.25 DTC 131317 Low fuel level February 3, 2015

Figure: Fuel level sensor parameter table

Floater position Floater position

Output Output resistance
(Refer to the place at (Refer to the place at
resistance (Ω) (Ω)
17.5mm) 17.5mm)
Below L1 1100±11.0 L11-L12 550±5.5
L1-L2 1050±10.5 L12-L13 500±5.0
L2-L3 1000±10.0 L13-L14 450±4.5
L3-L4 950±9.5 L14-L15 400±4.0
L4-L5 900±9.0 L15-L16 350±3.5
L5-L6 850±8.5 L16-L17 300±3.0
L6-L7 800±8.0 L17-L18 250±2.5
L7-L8 750±7.5 L18-L19 200±2.0
L8-L9 700±7.0 L19-L20 150±1.5
L9-L10 650±6.5 L20-L21 100±1.0
L0-L11 600±6.0

Oil level
 6-93
CLG922E 6.4 DTC
February 3, 2015 6.4.26 DTC 131603 Water-in-fuel sensor voltage above the range value

6.4.26 DTC 131603 Water-in-fuel System description

The water-in-fuel sensor is used to detect water
sensor voltage above the range
content in the fuel. The more the water in the
value fuel, the smaller the resistance. Therefore, the
change in water content is converted into the
Description of resistance voltage signal output to the controller
DTC Consequence
Fault which detects the water content in the fuel and
Water-in-fuel gives a warning signal.
sensor voltage
above the range
value. The signal
The engine
131603 circuit of the water-
won’t start.
in-fuel sensor
detects the power
voltage is high
(above 4.3V).

Controller J2(White)

Water-in-fuel
sensor
Water-in-fuel sensor
6-94
6.4 DTC CLG922E
6.4.26 DTC 131603 Water-in-fuel sensor voltage above the range value February 3, 2015

Component location Step 2 Check the harness for open-circuit

 Correctly tie up harness and wire:

Front Avoid folding or bending the harness forci-

bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.

Fuel-in-water
Try to keep far away from high temperature
sensor
parts (e.g. engine body).
• Inspection method
Fault diagnosis and elimination pro- 1. Check the harness (No. 921) and the ground-
cedures ing wire (No. 254) between the controller (J2-21)
and the water-in-fuel sensor for wear.
Step 1 Check the water-in-fuel sensor for fault.
2. Disconnect the connectors from the water-in-
 When replacing the components, please fuel sensor and the controller. Check the har-
be sure to use LiuGong parts. ness for open-circuit:
• Inspection method (a) Turn the multimeter to its resistance func-
Turn the start switch to the OFF position, tion, and measure the resistance between
and disconnect the connector from the the grounding wire (No.254) sensor termi-
water-in-fuel sensor. nal and the grounding (normally, <10Ω).

1. Check the connector for looseness, rust, (b) Turn the multimeter to its resistance func-
bending and damage. tion, and measure the resistance of har-
2. Turn the multimeter to its resistance function, ness between the connector ports J2-21
and measure the resistance between the water- and sensor (normally, <10Ω).
in-fuel sensor connector terminals 1 and 2 (nor- • Is the harness open?
mally, <4.6M/306.5K). • Yes
• Whether a fault developing in the water- Connect the harness again and wrap the har-
in-fuel sensor or not? ness.
• Yes Turn to Step 4
Repair or replace the water-in-fuel sensor. • No
Turn to Step 4 Turn to Step 3
• No
Turn to Step 2
 6-95
CLG922E 6.4 DTC
February 3, 2015 6.4.26 DTC 131603 Water-in-fuel sensor voltage above the range value

Step 3 Check the connector for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Connect the water-in-fuel sensor connector and
disconnect the controller connector. Turn the
multimeter to its resistance function, and mea-
sure the resistance between the harness at the
controller port J2-21 and the grounding (nor-
mally, <4.6M/306.5K).
When the resistance is abnormal, this indi-
cates the connector is poorly contacted.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
6-96
6.4 DTC CLG922E
6.4.27 DTC 131604 Water-in-fuel sensor voltage below the range value February 3, 2015

6.4.27 DTC 131604 Water-in-fuel System description

The water-in-fuel sensor is used to detect water
sensor voltage below the range
content in the fuel. The more the water in the
value fuel, the smaller the resistance. Therefore, the
change in water content is converted into the
Description of resistance voltage signal output to the controller
DTC Consequence
Fault which detects the water content in the fuel and
Water-in-fuel gives a warning signal.
sensor voltage
below the range
There is white
value. The signal
smoke in the
131604 circuit of the water-
engine
in-fuel sensor
exhaust.
detects the power
voltage is low
(below 0.25V).

Controller J2(White)

Water-in-fuel
sensor
Water-in-fuel sensor
 6-97
CLG922E 6.4 DTC
February 3, 2015 6.4.27 DTC 131604 Water-in-fuel sensor voltage below the range value

Component location Step 2 Check the harness for short-circuit to

ground

Front
 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Fuel-in-water
sensor
Try to keep far away from high temperature
parts (e.g. engine body).

Fault diagnosis and elimination pro- • Inspection method

cedures 1. Check the harness (No. 921) between the

controller (J2-21) and the water-in-fuel sensor
Step 1 Check the water-in-fuel sensor for fault.
for wear.
 When replacing the components, please 2. Disconnect the connectors from the water-in-
be sure to use LiuGong parts. fuel sensor and the controller, respectively. Turn
• Inspection method the multimeter to its resistance function, and
measure the resistance between the harness
Turn the start switch to the OFF position, and
(No. 921) sensor terminal and the grounding
disconnect the connector from the water-in-fuel
(normally, >100K).
sensor.
1. Check the connector for moisture, oil dirt and • Whether the harness is shorted to the
other ground or not?

2. Turn the multimeter to its resistance function, • Yes

and measure the resistance between the water- Connect the harness again and wrap the har-
in-fuel sensor connector terminals 1 and 2 (nor- ness.
mally, >2.62K). Turn to Step 4
• Whether a fault developing in the water- • No
in-fuel sensor or not? Turn to Step 3
• Yes
Repair or replace the water-in-fuel sensor.
Turn to Step 4
• No
Turn to Step 2
6-98
6.4 DTC CLG922E
6.4.27 DTC 131604 Water-in-fuel sensor voltage below the range value February 3, 2015

Step 3 Check the connector for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Connect the water-in-fuel sensor connector and
disconnect the controller connector. Turn the
multimeter to its resistance function, and mea-
sure the resistance between the controller port
J2-21 and the grounding (normally, >2.62K).
When the resistance is abnormal, this indicates
there is an insulation fault in the connector
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-99
CLG922E 6.4 DTC
February 3, 2015 6.4.28 DTC 131605 Water-in-fuel sensor open-circuited

6.4.28 DTC 131605 Water-in-fuel System description

The water-in-fuel sensor is used to detect water
sensor open-circuited
content in the fuel. The more the water in the
fuel, the smaller the resistance. Therefore, the
Description of
DTC Consequence change in water content is converted into the
Fault
Water-in-fuel resistance voltage signal output to the controller
sensor open- which detects the water content in the fuel and
circuited (The gives a warning signal.
131605 signal circuit of the
water-in-fuel
sensor is open-
circuited).

Controller J2(White)

Water-in-fuel
sensor
Water-in-fuel sensor
6-100
6.4 DTC CLG922E
6.4.28 DTC 131605 Water-in-fuel sensor open-circuited February 3, 2015

Component location Step 2 Check the harness for open-circuit

 Correctly tie up harness and wire:

Front Avoid folding or bending the harness forci-

bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.

Fuel-in-water
Try to keep far away from high temperature
sensor
parts (e.g. engine body).
• Inspection method
Fault diagnosis and elimination pro- 1. Check the harness (No. 921) and the ground-
cedures ing wire (No. 254) between the controller (J2-21)
and the water-in-fuel sensor for wear.
Step 1 Check the water-in-fuel sensor for fault.
2. Disconnect the connectors from the water-in-
 When replacing the components, please fuel sensor and the controller. Check the har-
be sure to use LiuGong parts. ness for open-circuit:
• Inspection method (a) Turn the multimeter to its resistance func-
Turn the start switch to the OFF position, tion, and measure the resistance between
and disconnect the connector from the the grounding wire (No.254) sensor termi-
water-in-fuel sensor. nal and the grounding (normally, <10Ω).

1. Check the connector for looseness, rust, (b) Turn the multimeter to its resistance func-
bending and damage. tion, and measure the resistance of har-
2. Turn the multimeter to its resistance function, ness between the connector ports J2-21
and measure the resistance between the water- and sensor (normally, <10Ω).
in-fuel sensor connector terminals 1 and 2 (nor- • Is the harness open?
mally, <4.6M). • Yes
• Whether a fault developing in the water- Connect the harness again and wrap the har-
in-fuel sensor or not? ness.
• Yes Turn to Step 4
Repair or replace the water-in-fuel sensor. • No
Turn to Step 4 Turn to Step 3
• No
Turn to Step 2
 6-101
CLG922E 6.4 DTC
February 3, 2015 6.4.28 DTC 131605 Water-in-fuel sensor open-circuited

Step 3 Check the connector for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Connect the water-in-fuel sensor connector and
disconnect the controller connector. Turn the
multimeter to its resistance function, and mea-
sure the resistance between the harness at the
controller port J2-21 and the grounding (nor-
mally, <4.6M).
When the resistance is abnormal, this indicates
the connector is poorly contacted.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
6-102
6.4 DTC CLG922E
6.4.29 DTC 131615 Water-in-fuel February 3, 2015

6.4.29 DTC 131615 Water-in-fuel System description

The water-in-fuel sensor is used to detect water
Description of content in the fuel. The more the water in the
DTC Consequence
Fault fuel, the smaller the resistance. Therefore, the
Water-in-fuel- change in water content is converted into the
When the start
switch is turned to resistance voltage signal output to the controller
the ON position If the excavator which detects the water content in the fuel and
(without starting is operated as gives a warning signal.
131615 the engine), the usual, the
signal circuit of the engine power
water-in-fuel will reduce.
sensor detects
there is water in
the fuel.

Controller J2(White)

Water-in-fuel
sensor
Water-in-fuel sensor
 6-103
CLG922E 6.4 DTC
February 3, 2015 6.4.29 DTC 131615 Water-in-fuel

Component location Step 2 Check the water-in-fuel monitoring sys-

tem for fault.

Front
 When replacing the components, please
be sure to use LiuGong parts.
• Inspection method
If the fuel is normal, check the water-in-fuel
detection circuit or the water-in-fuel sensor for
fault in accordance with the fault diagnosis in the
131604- Water-in-Fuel Sensor Voltage Below
the Range Value or 131603 - Water-in-Fuel
Fuel-in-water
sensor Sensor Voltage Above the Range Value.
• Whether a fault developing in the water-
in-fuel monitoring system or not?
Fault diagnosis and elimination pro-
• Yes
cedures
Repair the water-in-fuel detection circuit or
Step 1 Check the fuel for water.
replace the water-in-fuel sensor.
• Inspection method Turn to Step 3
Check the oil-water separator for water. • No
• Whether water in the fuel or not? Turn to Step 3
• Yes
Drain the water in the fuel. Step 3 Check whether this fault is eliminated
Turn to Step 3 • Inspection method
• No Turn the start switch to the ON position and re-
Turn to Step 2 check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
6-104
6.4 DTC CLG922E
6.4.30 DTC 131703 Sensor power (5V) shorted to the battery February 3, 2015

6.4.30 DTC 131703 Sensor System description

The throttle control system consists of the
power (5V) shorted to the bat-
potentiometer (accelerator knob), controller and
tery actuator. The schematic diagram is shown
below. No. 907 and No. 904 are drive control
Description of lines. The controller is driven by two pins. If
DTC Consequence
Fault either pin is open-circuited, this can cause the
The accelerator accelerator system fault. The potentiometer is
Sensor power (5V)
actuator cannot
131703 shorted to the used to control the engine speed. As shown in
function
battery.
properly. the figure, Pin 1 of the R1 connector is con-
nected to the 5V power, Pin 2 is connected to
the controller-sensor ground and Pin 3 is con-
nected to the accelerator signal feedback termi-
nal. The actuator controls the engine accelerator
opening through the flexible shaft, thereby con-
trolling the engine speed. The terminals are
shown in the figure. Pin 3 of the M1 connector is
the controller power (5V), Pin 5 is grounded, Pin
2 is used for the accelerator feedback signal,
Pin 1 is used to control the accelerator motor’s
positive rotation and Pin 4 is used to control the
accelerator motor’s negative rotation.

Accelerator knob

Controller J1 (Black)
Accelerator motor 2 (ls ac2)

5V power supply
12-position throttle
potentiometer Accelerator actuato
Accelerator motor 1 (ls ac1)

J2(White)
Accelerator motor 2 (hs ac2)

Accelerator motor 1 (hs ac1)

Accelerator motor position
feedback
Sensor to ground
 6-105
CLG922E 6.4 DTC
February 3, 2015 6.4.30 DTC 131703 Sensor power (5V) shorted to the battery

Component location Re-connect the harness and wrap it or replace

the connector.
Turn to Step 2
Front
• No
Turn to Step 2

Step 2 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
Accelerator actuator check for fault.
• Has this fault been eliminated?
• Yes

Fault diagnosis and elimination pro- Maintenance is over

cedures • No
Troubleshoot the faults according to the steps
Step 1 Check the sensor power (5V) is shorted
again or contact the local LiuGong dealer and
to the battery.
authorized service center.
 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).
• Inspection method
Turn the start switch to the ON position and dis-
connect the controller connector to switch on the
switches of all electrical equipment, and then
measure the voltage between the J1-28 port
(No. 828) and ground (normally, 0V).
• Whether the sensor power (5V) is
shorted to the battery or not?
• Yes
6-106
6.4 DTC CLG922E
6.4.31 DTC 131704 Sensor power (5V) shorted to the ground February 3, 2015

6.4.31 DTC 131704 Sensor System description

The throttle control system consists of the
power (5V) shorted to the
potentiometer (accelerator knob), controller and
ground actuator. The schematic diagram is shown
below. No. 907 and No. 904 are drive control
Description of lines. The controller is driven by two pins. If
DTC Consequence
Fault either pin is open-circuited, this can cause the
The accelerator accelerator system fault. The potentiometer is
Sensor power (5V)
actuator cannot
131704 shorted to the used to control the engine speed. As shown in
function
ground
properly. the figure, Pin 1 of the R1 connector is con-
nected to the 5V power, Pin 2 is connected to
the controller-sensor ground and Pin 3 is con-
nected to the accelerator signal feedback termi-
nal. The actuator controls the engine accelerator
opening through the flexible shaft, thereby con-
trolling the engine speed. The terminals are
shown in the figure. Pin 3 of the M1 connector is
the controller power (5V), Pin 5 is grounded, Pin
2 is used for the accelerator feedback signal,
Pin 1 is used to control the accelerator motor’s
positive rotation and Pin 4 is used to control the
accelerator motor’s negative rotation.

Accelerator knob

Controller J1 (Black)
Accelerator motor 2 (ls ac2)

5V power supply
12-position throttle
potentiometer Accelerator actuato
Accelerator motor 1 (ls ac1)

J2(White)
Accelerator motor 2 (hs ac2)

Accelerator motor 1 (hs ac1)

Accelerator motor position
feedback
Sensor to ground
 6-107
CLG922E 6.4 DTC
February 3, 2015 6.4.31 DTC 131704 Sensor power (5V) shorted to the ground

Component location accelerator actuator.

Turn to Step 4
• No
Front
Turn to Step 2

Step 2 Check the harness for short-circuit to

ground

 Correctly tie up harness and wire:

Avoid folding or bending the harness forcibly.

Accelerator actuator
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Fault diagnosis and elimination pro- Avoid friction with sharp metal edges.
cedures Try to keep far way from oil and water.

Step 1 Check the accelerator knob or actuator Try to keep far away from high temperature
for fault. parts (e.g. engine body).
• Inspection method
 When replacing the components, please
1. Check the harnesses (No. 828 and No. 922)
be sure to use LiuGong parts.
between the controllers (J1-28 and J2-22) and
• Inspection method the accelerator knob or actuator for wear,
Turn the start switch to the OFF position and respectively.
disconnect the connectors from the acceler- 2. Disconnect the accelerator knob, the acceler-
ator knob and actuator: ator actuator connector and the controller con-
1. Check the connector for moisture, oil dirt and nector. Turn the multimeter to its resistance
other function, and measure the resistance between
2. Turn the multimeter to its resistance function, the terminal opposite to the harness (No. 828/
and measure the resistance between the accel- No. 922) controller and the grounding, respec-
erator knob connector terminals 1 and 2 (nor- tively (normally, >100K).
mally, >10Ω). • Whether the harness is shorted to the
3. Measure the resistance between the termi- ground or not?
nals 3 and 5 of the accelerator actuator connec- • Yes
tor (normally, >10Ω).
Connect the harness again and wrap the har-
• Whether a fault developing in the accel- ness.
erator knob or actuator or not? Turn to Step 4
• Yes • No
Repair or replace the accelerator knob and the Turn to Step 3
6-108
6.4 DTC CLG922E
6.4.31 DTC 131704 Sensor power (5V) shorted to the ground February 3, 2015

Step 3 Check the connector for fault. Step 4 Check whether this fault is eliminated

 When replacing the components, please • Inspection method

be sure to use LiuGong parts. Turn the start switch to the ON position and re-
check for fault.
• Inspection method
• Has this fault been eliminated?
1. Connect the accelerator knob connector and
disconnect the accelerator actuator and the con- • Yes
troller connector. Turn the multimeter to its resis- Maintenance is over
tance function, and measure the resistance • No
between the controller ports J1-28 and J2-22 Troubleshoot the faults according to the steps
(normally, >10Ω). again or contact the local LiuGong dealer and
2. Connect the accelerator actuator connector authorized service center.
and disconnect the accelerator knob and the
controller connector. Turn the multimeter to its
resistance function, and measure the resistance
between the controller port J1-28 and J2-22
(normally, >10Ω).
When the resistance in any step above is
abnormal, this indicates an insulation fault
develops in the connector.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4
 6-109
CLG922E 6.4 DTC
February 3, 2015 6.4.32 DTC 141005 Pump proportional solenoid valve feedback open-circuited

6.4.32 DTC 141005 Pump pro- System description

The pilot pump provides oil to the proportional
portional solenoid valve feed-
pressure-reducing valve on the main pump
back open-circuited directly. The proportional pressure-reducing
valve regulates the displacement of the main
Description of pump based on various operating conditions.
DTC Consequence
Fault
Pump proportional
The complete
solenoid valve
141005 excavator
feedback open-
moves slowly.
circuited

Pump proprtional
solenoid valve
Pump solenoid valve current
Main pump PWM signal
Pump solenoid valve current feedback
6-110
6.4 DTC CLG922E
6.4.32 DTC 141005 Pump proportional solenoid valve feedback open-circuited February 3, 2015

Component location Turn to Step 2

Step 2 Check the harness for open-circuit

Front
 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Pump proportional
solenoid valve
Try to keep far way from oil and water.
Try to keep far away from high temperature
Fault diagnosis and elimination pro- parts (e.g. engine body).

cedures • Inspection method

Step 1 Check the pump proportional solenoid 1. Check the harness (No. 905/No. 901)
valve for fault. between the controller and the pump propor-
tional solenoid valve for wear.
 When replacing the components, please
2. Disconnect the connectors from the pump
be sure to use LiuGong parts. proportional solenoid valve and the controller,
• Inspection method respectively. Turn the multimeter to its resis-
Turn the start switch to the OFF position and tance function, and measure the resistance of
disconnect the pump proportional solenoid the harness (No. 905/No. 901) between the con-
valve: troller and the solenoid valve, respectively (nor-
mally, <10Ω).
1. Check the connector for looseness, rust,
bending and damage. • Is the harness open?
2. Turn the multimeter to its resistance function, • Yes
and measure the resistance between the sole- Connect the harness again and wrap the har-
noid valve connector terminals 1 and 2 (nor- ness.
mally, 16-40Ω). Turn to Step 4
• Whether a fault developing in the pump • No
proportional solenoid valve or not? Turn to Step 3
• Yes
Repair or replace the pump proportional sole-
noid valve.
Turn to Step 4
• No
 6-111
CLG922E 6.4 DTC
February 3, 2015 6.4.32 DTC 141005 Pump proportional solenoid valve feedback open-circuited

Step 3 Check the connector for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Connect the pump proportional solenoid valve
connector and disconnect the controller connec-
tor. Turn the multimeter to its resistance func-
tion, and measure the resistance between the
controller ports J2-01 and J2-05 (normally, 16-
40Ω).
When the resistance is abnormal, this indi-
cates the connector is poorly contacted.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
6-112
6.4 DTC CLG922E
6.4.33 DTC 141006 Pump proportional solenoid valve feedback overcurrent February 3, 2015

6.4.33 DTC 141006 Pump pro- System description

The pilot pump provides oil to the proportional
portional solenoid valve feed- pressure-reducing valve on the main pump
back overcurrent directly. The proportional pressure-reducing
valve regulates the displacement of the main
Description of pump based on various operating conditions.
DTC Consequence
Fault
The engine
Pump proportional
gets stuck or
solenoid valve
141006 even shuts
feedback
down in a low
overcurrent
gear.

Pump proprtional
solenoid valve
Pump solenoid valve current
Main pump PWM signal
Pump solenoid valve current feedback
 6-113
CLG922E 6.4 DTC
February 3, 2015 6.4.33 DTC 141006 Pump proportional solenoid valve feedback overcurrent

Component location Turn to Step 2

Step 2 Check the harness for short-circuit

 Correctly tie up harness and wire:

Front
Avoid folding or bending the harness forci-
bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Pump proportional
solenoid valve Try to keep far away from high temperature
parts (e.g. engine body).
Fault diagnosis and elimination pro- • Inspection method
cedures 1. Check the harnesses (No. 901/No. 905)
between the controller (J2-01 and J2-05) and
Step 1 Check the pump proportional solenoid
the pump proportional solenoid for wear.
valve for fault.
Disconnect both the controller and the sole-
 When replacing the components, please noid valve
be sure to use LiuGong parts. 2. Check the two harnesses for short-circuit:
• Inspection method Turn the multimeter to its resistance function,
Turn the start switch to the OFF position and and measure the resistance of the harness (No.
disconnect the pump proportional solenoid 901/No. 905) between the solenoid valve termi-
valve: nals (normally, >100K).
1. Check the connector for moisture, oil dirt and 3. Check whether the harness is shorted to the
other battery. Turn the start switch to the ON position
2. Turn the multimeter to its resistance function, and switch on the switches of all electrical
and measure the resistance between the pump equipment, and then measure the voltage
proportional solenoid valve connector terminals between the harness (No. 901/No. 905) sole-
1 and 2 (normally, 16-40Ω). noid valve terminal and the grounding (normally,
0V).
• Whether a fault developing in the pump
proportional solenoid valve or not? • Is the harness short?

• Yes • Yes

Repair or replace the pump proportional sole- Connect the harness again and wrap the har-
noid valve. ness.

Turn to Step 4 Turn to Step 4

• No • No
6-114
6.4 DTC CLG922E
6.4.33 DTC 141006 Pump proportional solenoid valve feedback overcurrent February 3, 2015

Turn to Step 3

Step 3 Check the connector for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Connect the pump proportional solenoid valve
connector and disconnect the controller connec-
tor. Turn the multimeter to its resistance func-
tion, and measure the resistance between the
controller ports J2-01 and J2-05 (normally, 16-
40Ω).
When the resistance is abnormal, this indi-
cates there is an insulation fault in the con-
nector
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-115
CLG922E 6.4 DTC
February 3, 2015 6.4.34 DTC 141104 Pump proportional solenoid valve shorted to the ground

6.4.34 DTC 141104 Pump pro- System description

The pilot pump provides oil to the proportional
portional solenoid valve
pressure-reducing valve on the main pump
shorted to the ground directly. The proportional pressure-reducing
valve regulates the displacement of the main
Description of pump based on various operating conditions.
DTC Consequence
Fault
Pump proportional
solenoid valve
141104 Works slowly.
shorted to the
ground

Pump proprtional
solenoid valve
Pump solenoid valve current
Main pump PWM signal
Pump solenoid valve current feedback
6-116
6.4 DTC CLG922E
6.4.34 DTC 141104 Pump proportional solenoid valve shorted to the ground February 3, 2015

Component location Step 2 Check the harness for short-circuit to

ground

 Correctly tie up harness and wire:

Front
Avoid folding or bending the harness forci-
bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Pump proportional
solenoid valve
Try to keep far away from high temperature
parts (e.g. engine body).

Fault diagnosis and elimination pro- • Inspection method

cedures 1. Check the harnesses (No. 901 and No. 905)

between the controller (J2-01 and J2-05) and
Step 1 Check the pump proportional solenoid
the pump proportional solenoid valve for wear.
valve for fault.
2. Disconnect the connectors from the pump
 When replacing the components, please proportional solenoid and the controller. Turn
be sure to use LiuGong parts. the multimeter to its resistance function, and
• Inspection method measure the resistance between the harnesses
(No. 904 and No. 905) the solenoid valve termi-
Turn the start switch to the OFF position and dis-
nal and the grounding, respectively (normally,
connect the pump proportional solenoid valve:
>100K).
1. Check the connector for moisture, oil dirt and
other • Whether the harness is shorted to the
ground or not?
2. Turn the multimeter to its resistance function,
and measure the resistance between the pump • Yes
proportional solenoid connector terminals 1 and Connect the harness again and wrap the har-
2 (normally, 16-40Ω). ness.
• Whether a fault developing in the pump Turn to Step 4
proportional solenoid valve or not? • No
• Yes Turn to Step 3
Repair or replace the pump proportional sole-
noid valve.
Turn to Step 4
• No
Turn to Step 2
 6-117
CLG922E 6.4 DTC
February 3, 2015 6.4.34 DTC 141104 Pump proportional solenoid valve shorted to the ground

Step 3 Check the connector for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Connect the pump proportional solenoid valve
connector and disconnect the controller connec-
tor. Turn the multimeter to its resistance func-
tion, and measure the resistance between the
controller port J2-01 and the grounding (nor-
mally,16-40Ω).
When the resistance is abnormal, this indi-
cates there is an insulation fault in the con-
nector
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
6-118
6.4 DTC CLG922E
6.4.35 DTC 141105 Pump proportional solenoid valve open-circuited or shorted to the battery February 3, 2015

6.4.35 DTC 141105 Pump pro- System description

The pilot pump provides oil to the proportional
portional solenoid valve open-
pressure-reducing valve on the main pump
circuited or shorted to the bat- directly. The proportional pressure-reducing
valve regulates the displacement of the main
tery
pump based on various operating conditions.

Description of
DTC Consequence
Fault
Pump proportional
solenoid valve
The engine
141105 open-circuited or
gets stuck.
shorted to the
battery

Pump proprtional
solenoid valve
Pump solenoid valve current
Main pump PWM signal
Pump solenoid valve current feedback
 6-119
CLG922E 6.4 DTC
February 3, 2015 6.4.35 DTC 141105 Pump proportional solenoid valve open-circuited or shorted to the battery

Component location Turn to Step 2

Step 2 Check whether the harness is open-cir-

Front
cuited or shorted to the battery.

 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Pump proportional
solenoid valve
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.

Fault diagnosis and elimination pro- Try to keep far away from high temperature
parts (e.g. engine body).
cedures
• Inspection method
Step 1 Check the pump proportional solenoid
valve for fault. 1. Check the harness (No. 905/No. 901)
between the controller and the pump propor-
 When replacing the components, please tional solenoid valve for wear.
be sure to use LiuGong parts. Disconnect the connectors from the pump pro-
• Inspection method portional solenoid valve and the controller.
Turn the start switch to the OFF position and 2. Check whether the harness is shorted to the
disconnect the pump proportional solenoid battery. Turn the start switch to the ON position
valve: and switch on the switches of all electrical
1. Check the connector for looseness, rust, equipment, and then measure the voltage
bending and damage. between the harness (No. 901 and No. 905)
solenoid valve terminal and the grounding (nor-
2. Turn the multimeter to its resistance function,
mally, 0V).
and measure the resistance between the sole-
noid valve connector terminals 1 and 2 (nor- 3. Check the harnesses for open-circuit. Turn
mally, 16-40Ω). the multimeter to its resistance function, and
measure the resistance of the harnesses (No.
• Whether a fault developing in the pump
905 and No. 901) between the controller and the
proportional solenoid valve or not?
solenoid valve, respectively (normally, ＜ 10Ω).
• Yes
• Whether the harness open-circuited or
Repair or replace the pump proportional sole-
shorted to the battery or not?
noid valve.
• Yes
Turn to Step 4
Connect the harness again and wrap the har-
• No
ness.
6-120
6.4 DTC CLG922E
6.4.35 DTC 141105 Pump proportional solenoid valve open-circuited or shorted to the battery February 3, 2015

Turn to Step 4
• No
Turn to Step 3

Step 3 Check the connector for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Connect the pump proportional solenoid valve
connector and disconnect the controller connec-
tor. Turn the multimeter to its resistance func-
tion, and measure the resistance between the
controller ports J2-01 and J2-05 (normally, 16-
40Ω).
When the resistance is abnormal, this indi-
cates the connector is poorly contacted.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-121
CLG922E 6.4 DTC
February 3, 2015 6.4.36 DTC 151004 Attachment confluent solenoid valve shorted to the ground

6.4.36 DTC 151004 Attachment System description

The attachment confluent solenoid valve (shear
confluent solenoid valve
function solenoid valve, ATT function solenoid
shorted to the ground valve) (optional) is used to control realization of
hydraulic shear function.
Description of
DTC Consequence
Fault
Attachment
There is no
confluent solenoid
151004 hydraulic shear
valve shorted to
function.
the ground

Shear function solenoid (option)

Controller

ATT solenoid valve

6-122
6.4 DTC CLG922E
6.4.36 DTC 151004 Attachment confluent solenoid valve shorted to the ground February 3, 2015

Component location Turn to Step 2

Step 2 Check the harness for short-circuit to

Front ground

 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Attachment
confluent solenoid
valve (position) Avoid friction with sharp metal edges.
Try to keep far way from oil and water.

Fault diagnosis and elimination pro- Try to keep far away from high temperature
parts (e.g. engine body).
cedures
• Inspection method
Step 1 Check the attachment confluent solenoid
valve for fault. 1. Check the harness (No. 912) between the
controller (J2-12) and the attachment confluent
 When replacing the components, please solenoid valve for wear.
be sure to use LiuGong parts. 2. Disconnect the connectors from attachment
• Inspection method confluent solenoid valve and the controller. Turn
Turn the start switch to the OFF position and the multimeter to its resistance function, and
disconnect the attachment confluent sole- measure the resistance between the harness
noid valve connector: (No. 912) solenoid valve terminal and the
grounding (normally, >100K).
1. Check the connector for moisture, oil dirt and
other • Whether the harness is shorted to the
2. Turn the multimeter to its resistance function, ground or not?
and measure the resistance between the attach- • Yes
ment confluent solenoid connector terminals 1 Connect the harness again and wrap the har-
and 2 (normally, 16-40Ω). ness.
• Whether a fault developing in the attach- Turn to Step 4
ment confluent solenoid valve or not? • No
• Yes Turn to Step 3
Repair or replace the attachment confluent sole-
noid valve.
Turn to Step 4
• No
 6-123
CLG922E 6.4 DTC
February 3, 2015 6.4.36 DTC 151004 Attachment confluent solenoid valve shorted to the ground

Step 3 Check the connector for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Connect the attachment confluent solenoid
valve connector and disconnect the controller
connector. Turn the multimeter to its resistance
function, and measure the resistance between
the controller port J2-12 and the grounding (nor-
mally, 16-40Ω).
When the resistance is abnormal, this indi-
cates there is an insulation fault in the con-
nector
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
6-124
6.4 DTC CLG922E
6.4.37 DTC 151005 Attachment confluent solenoid valve open-circuited or shorted to the battery February 3, 2015

6.4.37 DTC 151005 Attachment System description

The attachment confluent solenoid valve (shear
confluent solenoid valve open-
function solenoid valve, ATT function solenoid
circuited or shorted to the bat- valve) (optional) is used to control realization of
hydraulic shear function.
tery

Description of
DTC Consequence
Fault
Attachment
confluent solenoid
There is no
valve open-
151005 hydraulic shear
circuited or
function.
shorted to the
battery

Shear function solenoid (option)

Controller

ATT solenoid valve

 6-125
CLG922E 6.4 DTC
February 3, 2015 6.4.37 DTC 151005 Attachment confluent solenoid valve open-circuited or shorted to the battery

Component location Turn to Step 2

Step 2 Check whether the harness is open-cir-

Front cuited or shorted to the battery.

 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Attachment
confluent solenoid
valve (position) Avoid friction with sharp metal edges.
Try to keep far way from oil and water.

Fault diagnosis and elimination pro- Try to keep far away from high temperature
parts (e.g. engine body).
cedures
• Inspection method
Step 1 Check the attachment confluent solenoid
valve for fault. 1. Check the harness (No. 912) or the grounding
wire (No. 252) between the controller and the
 When replacing the components, please attachment confluent solenoid valve for wear.
be sure to use LiuGong parts. Disconnect the connectors from the attachment
• Inspection method confluent solenoid valve and the controller.
Turn the start switch to the OFF position and 2. Check whether the harness is shorted to the
disconnect the attachment confluent sole- battery. Turn the start switch to the ON position
noid valve connector: and turn on all switches of the electrical equip-
ment, and then measure the voltage between
1. Check the connector for looseness, rust,
the harness (No. 912) solenoid valve terminal
bending and damage.
and the grounding (normally, 0V).
2. Turn the multimeter to its resistance function,
3. Check the harness for open-circuit. Turn the
and measure the resistance between the attach-
multimeter to its resistance function, and mea-
ment confluent solenoid valve connector termi-
sure the resistance of the harness (No. 912)
nals 1 and 2 (normally, 16-40Ω).
between the controller and the solenoid valve
• Whether a fault developing in the attach-
and that of the harness (No. 252) between the
ment confluent solenoid valve or not?
solenoid valve and the grounding (normally,
• Yes <10Ω).
Repair or replace the attachment confluent sole- • Whether the harness open-circuited or
noid valve. shorted to the battery or not?
Turn to Step 4
• Yes
• No
Connect the harness again and wrap the har-
6-126
6.4 DTC CLG922E
6.4.37 DTC 151005 Attachment confluent solenoid valve open-circuited or shorted to the battery February 3, 2015

ness. Step 4 Check whether this fault is eliminated

Turn to Step 4 • Inspection method
• No Turn the start switch to the ON position and re-
Turn to Step 3 check for fault.
• Has this fault been eliminated?
Step 3 Check the connector for fault. • Yes
 When replacing the components, please Maintenance is over
be sure to use LiuGong parts. • No

• Inspection method Troubleshoot the faults according to the steps

again or contact the local LiuGong dealer and
Connect the attachment confluent solenoid
authorized service center.
valve connector and disconnect the controller
connector. Turn the multimeter to its resistance
function, and measure the resistance between
the controller port J2-12 and the grounding (nor-
mally, 16-40Ω).
When the resistance is abnormal, this indi-
cates the connector is poorly contacted.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4
 6-127
CLG922E 6.4 DTC
February 3, 2015 6.4.38 DTC 151204 A2 Travel speed solenoid shorted to the ground

6.4.38 DTC 151204 A2 Travel System description

The controller outputs a signal to the travel
speed solenoid shorted to the
speed solenoid valve through the harness (No.
ground 910) to open the valve port.

Description of
DTC Consequence
Fault
Travel speed
There is no
solenoid valve
151204 travel speed
shorted to the
function.
ground.

Controller
Travel speed solenoid valve (valve A2)
A2 Travel speed
solenoid valve
6-128
6.4 DTC CLG922E
6.4.38 DTC 151204 A2 Travel speed solenoid shorted to the ground February 3, 2015

Component location Step 2 Check whether the power harness of the

travel speed solenoid valve is shorted to the
ground.
Front
 Shutdown operation is needed
A2-marked solenoid
valve can be located.
• Inspection method
1. Turn the start switch to the OFF position for
fault diagnosis.
2. Disconnect the connectors from the controller
(in the figure) and travel speed solenoid, and
measure the resistance between the power line
(No. 910) of travel speed solenoid and the
grounding. The resistance should be infinite.
• Whether the power harness of the travel
Fault diagnosis and elimination pro-
speed solenoid valve is shorted to the
cedures ground or not?
Step 1 Check the travel speed solenoid valve for
• Yes
fault.
Re-connect the harness, and wrap it.
 When replacing the components, please Turn to Step 4
be sure to use LiuGong parts. • No
• Inspection method Turn to Step 3
Turn the start switch to the OFF position and
disconnect the valve connector from the Step 3 Check the connectors for fault.
travel speed solenoid valve.
 Shutdown operation is needed.
1. Check the pins for moisture, oil dirt and other.
2. Measure the resistance between both ends of  When replacing the components, please
the travel speed solenoid valve. The resistance be sure to use LiuGong parts.
should be 16-40Ω.
• Inspection method
• Is there a fault in track shift solenoid? Connect the travel speed solenoid valve con-
• Yes nector and disconnect the controller connector.
Repair or replace the travel speed solenoid Turn the multimeter to its resistance function,
valve and measure the resistance between the har-
Turn to Step 4 ness at the controller port J2-10 and the ground-
• No ing (normally, 16-40Ω). When the resistance is
abnormal, this indicates there is a fault in the
Turn to Step 2
connector.
 6-129
CLG922E 6.4 DTC
February 3, 2015 6.4.38 DTC 151204 A2 Travel speed solenoid shorted to the ground

Figure
Definition of
connector pin
serial number

Controller

Controller connector
Front

• Whether a fault in the connector or not?

• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check the DTC.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
6-130
6.4 DTC CLG922E
6.4.39 DTC 151205 A2 Travel speed solenoid open-circuited or shorted to the battery February 3, 2015

6.4.39 DTC 151205 A2 Travel System description

The controller outputs a signal to the travel
speed solenoid open-circuited
speed solenoid valve through the harness (No.
or shorted to the battery 910) to open the valve port.

Description of
DTC Consequence
Fault
There is no
travel speed
A2 travel speed
function or the
solenoid valve
travel speed
151205 open-circuited or
solenoid valve
shorted to the
is uncontrolled
battery.
by the
controller.

Controller
Travel speed solenoid valve (valve A2)
A2 Travel speed
solenoid valve
 6-131
CLG922E 6.4 DTC
February 3, 2015 6.4.39 DTC 151205 A2 Travel speed solenoid open-circuited or shorted to the battery

Component location Step 2 Check the harness for open-circuit.

 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

Front
bly.
A2-marked solenoid
valve can be located.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).
• Inspection method
Fault diagnosis and elimination pro- 1. Check the harness (No. 910) and the ground-
cedures ing wire (No. 221) between the controller (J1-10)
(in the figure) and the travel speed solenoid
Step 1 Check the travel speed solenoid valve for
valve for wear.
fault.
2.Disconnect the connectors between travel
 When replacing the components, please speed solenoid and controller and check
be sure to use LiuGong parts. whether the harness is open-circuited:

• Inspection method (a) Turn the multimeter to its resistance func-

Turn the start switch to the OFF position and tion, and measure the resistance between
disconnect the connector from the travel the connector ports J2-10 and travel speed
speed solenoid valve. solenoid valve harness (normally, <10Ω).

1. Check the pins for looseness, rust, bending (b) Turn the multimeter to its resistance func-
and damage. tion, and measure the resistance between
the grounding wire (No.222) travel speed
2. Measure the resistance between both ends of
solenoid valve terminal and the grounding
the travel speed solenoid valve. The resistance
(normally, <10Ω).
should be 16-40Ω.
• Is there a fault in track shift solenoid?
• Yes
Repair or replace the travel speed solenoid
valve.
Turn to Step 5
• No
Turn to Step 2
6-132
6.4 DTC CLG922E
6.4.39 DTC 151205 A2 Travel speed solenoid open-circuited or shorted to the battery February 3, 2015

• No
Definition of Turn to Step 4
connector pin
serial number

Step 4 Check whether the travel speed solenoid

valve is shorted to the battery.
• Inspection method
Turn the start switch to the ON position for fault
diagnosis.
Disconnect the connectors from the controller
and A2 travel speed solenoid valve to switch on
the switches of all electrical equipment, and then
measure the voltage of the harness of A2 travel
• Is the harness open?
speed solenoid valve. The voltage should be 0.
• Yes
• Whether the travel speed solenoid valve
Connect the harness again and wrap the har- is shorted to the battery or not?
ness.
• Yes
Turn to Step 5
Find out the short circuit position and re-connect
• No
the harness and wrap it.
Turn to Step 3
Turn to Step 5
• No
Step 3 Check the connectors for fault.
Turn to Step 5
 When replacing the components, please
be sure to use LiuGong parts. Step 5 Check whether this fault is eliminated
• Inspection method • Inspection method
Connect the travel speed solenoid valve con- Turn the start switch to the ON position and re-
nector and disconnect the controller connector. check the DTC.
Turn the multimeter to its resistance function, • Has this fault been eliminated?
and measure the resistance between the har-
• Yes
ness (No.910) at the controller port J2-10 and
Maintenance is over
the grounding (normally, 16-40Ω). When the
resistance is abnormal, this indicates there is a • No
fault in the connector. Troubleshoot the faults according to the steps
• Whether a fault in the connector or not? again or contact the local LiuGong dealer and
authorized service center.
• Yes
Repair or replace the connector.
Turn to Step 5
 6-133
CLG922E 6.4 DTC
February 3, 2015 6.4.39 DTC 151205 A2 Travel speed solenoid open-circuited or shorted to the battery

Figure

Controller

Controller connector
Front
6-134
6.4 DTC CLG922E
6.4.40 DTC 151304 A3 Flattening solenoid valve shorted to the ground February 3, 2015

6.4.40 DTC 151304 A3 Flatten- System description

The controller outputs a signal to the flattening
ing solenoid valve shorted to
solenoid valve through the harness (No. 827) to
the ground open the valve port.

Description of
DTC Consequence
Fault
Flattening solenoid There is no
151304 valve shorted to flattening
the ground function.

Controller
Flattening solenoid valve (valve A3)
A3 arm speed
2nd gear proportional
solenoid valve
 6-135
CLG922E 6.4 DTC
February 3, 2015 6.4.40 DTC 151304 A3 Flattening solenoid valve shorted to the ground

Component location Step 2 Check whether the power line of the flat-
tening solenoid valve is shorted to the ground.

 Shutdown operation is needed

Front
• Inspection method
A3-marked solenoid
valve can be located.
For troubleshooting, turn the start switch to
the OFF position:
Disconnect the connectors from the controller
(in the figure) and the flattening solenoid valve,
and measure the resistance between the power
line (No. 827) of the flattening solenoid valve
and the grounding. The resistance should be
infinite.
• Whether the power line of the flattening
Fault diagnosis and elimination pro-
solenoid valve is shorted to the ground
cedures or not?
Step 1 Check the flattening solenoid valve for • Yes
fault.
Re-connect the harness, and wrap it.
 When replacing the components, please Turn to Step 4
be sure to use LiuGong parts. • No
• Inspection method Turn to Step 3
Turn the start switch to the OFF position and
disconnect the connector from the travel Step 3 Check the connectors for fault.
speed solenoid valve:
 Shutdown operation is needed.
1. Check the pins for moisture, oil dirt and other.
2. Measure the resistance between the both  When replacing the components, please
ends of the flattening solenoid valve. The resis- be sure to use LiuGong parts.
tance should be 16-40Ω. • Inspection method
• Whether a fault developing in the flatten- Connect the flattening solenoid valve connector
ing solenoid valve or not? and disconnect the controller connector. Turn
• Yes the multimeter to its resistance function, and
Repair or replace the flattening solenoid valve. measure the resistance between the harness
Turn to Step 4 (No.827)at the controller port J1-27 and the
grounding (normally, 16-40Ω). When the resis-
• No
tance is abnormal, this indicates there is a fault
Turn to Step 2
in the connector.
6-136
6.4 DTC CLG922E
6.4.40 DTC 151304 A3 Flattening solenoid valve shorted to the ground February 3, 2015

Figure
Definition of
connector pin
serial number

Controller

Controller connector
Front

• Whether a fault in the connector or not?

• Yes
Repair or replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check the DTC.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-137
CLG922E 6.4 DTC
February 3, 2015 6.4.41 DTC 151305 A3 Flattening solenoid valve open-circuited or shorted to the battery

6.4.41 DTC 151305 A3 System description

The controller outputs a signal to the flattening
Flattening solenoid valve open-
solenoid valve through the harness (No. 827) to
circuited or shorted to the bat- open the valve port.

tery

Description of
DTC Consequence
Fault
There is no
flattening
A3 Flattening
function or the
solenoid valve
flattening
151305 open-circuited or
solenoid valve
shorted to the
is uncontrolled
battery.
by the
controller.

Controller
Flattening solenoid valve (valve A3)
A3 arm speed
2nd gear proportional
solenoid valve
6-138
6.4 DTC CLG922E
6.4.41 DTC 151305 A3 Flattening solenoid valve open-circuited or shorted to the battery February 3, 2015

Component location Step 2 Check the harness for open-circuit.

 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

Front
bly.
A3-marked solenoid
valve can be located. It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).
• Inspection method
Fault diagnosis and elimination pro- 1. Check the harness (No. 827) and the ground-
cedures ing wire (No. 222) between the controller (J1-27)
and the flattening solenoid valve for wear.
Step 1 Check the flattening solenoid valve for
2. Disconnect the connectors from the flattening
fault.
solenoid valve and the controller. Check the har-
 When replacing the components, please ness for open-circuit:
be sure to use LiuGong parts. (a) Turn the multimeter to its resistance func-
• Inspection method tion, and measure the resistance between
Turn the start switch to the OFF position, and the connector ports J1-27 and flattening
disconnect the travel speed solenoid valve con- solenoid valve harness (normally, <10Ω).
nector; (b) Turn the multimeter to its resistance func-
1. Check the pins for looseness, rust, bending tion, and measure the resistance between
and damage. the grounding wire (No.222) flattening sole-
2. Measure the resistance between the both noid valve terminal and the grounding (nor-
ends of the flattening solenoid valve. The resis- mally, <10Ω).
tance should be 16-40Ω.
• Whether a fault developing in the flatten-
ing solenoid valve or not?
• Yes
Repair or replace the flattening solenoid valve.
Turn to Step 5
• No
Turn to Step 2
 6-139
CLG922E 6.4 DTC
February 3, 2015 6.4.41 DTC 151305 A3 Flattening solenoid valve open-circuited or shorted to the battery

• No
Definition of Turn to Step 4
connector pin
serial number

Step 4 Check whether the flattening solenoid

valve is shorted to the battery
• Inspection method
Turn the start switch to the ON position for fault
diagnosis.
Disconnect the connectors from the controller
and A3 flattening solenoid valve to switch on the
switches of all electrical equipment, and then
measure the voltage of the harness of A3 flat-
• Is the harness open?
tening solenoid valve. The voltage should be 0.
• Yes
• Whether the flattening solenoid valve is
Connect the harness again and wrap the har- shorted to the battery or not?
ness.
• Yes
Turn to Step 5
Find out the short circuit position and re-connect
• No
the harness and wrap it.
Turn to Step 3
Turn to Step 5
• No
Step 3 Check the connectors for fault.
Turn to Step 5
 When replacing the components, please
be sure to use LiuGong parts. Step 5 Check whether this fault is eliminated
• Inspection method • Inspection method
Connect the flattening solenoid valve connector Turn the start switch to the ON position and re-
and disconnect the controller connector. Turn check the DTC.
the multimeter to its resistance function, and • Has this fault been eliminated?
measure the resistance between the harness at
• Yes
the controller port J1-27 and the grounding (nor-
Maintenance is over
mally, 16-40Ω). When the resistance is abnor-
mal, this indicates there is a fault in the • No
connector. Troubleshoot the faults according to the steps
• Whether a fault in the connector or not? again or contact the local LiuGong dealer and
authorized service center.
• Yes
Replace the connector.
Turn to Step 5
6-140
6.4 DTC CLG922E
6.4.41 DTC 151305 A3 Flattening solenoid valve open-circuited or shorted to the battery February 3, 2015

Figure

Controller

Controller connector
Front
 6-141
CLG922E 6.4 DTC
February 3, 2015 6.4.42 DTC 151404 A8 Digging solenoid valve shorted to the ground

6.4.42 DTC 151404 A8 Digging System description

The controller outputs a signal to the digging
solenoid valve shorted to the
solenoid valve A8 through the harness (No. 825)
ground to open the valve port.

Description of
DTC Consequence
Fault
Digging solenoid There is no
151404 valve shorted to digging
the ground. function.

Controller
Digging solenoid valve (valve A8)
A8 Digging solenoid valve
6-142
6.4 DTC CLG922E
6.4.42 DTC 151404 A8 Digging solenoid valve shorted to the ground February 3, 2015

Component location Step 2 Check whether the power line of the dig-
ging solenoid valve is shorted to the ground.

 Shutdown operation is needed

Front
• Inspection method
A8-marked solenoid
valve can be located.
1. Turn the start switch to the OFF position for
fault diagnosis.
2. Disconnect the connectors from the controller
(in the figure) and the digging solenoid valve,
and measure the resistance between the power
line (No. 825) of the digging solenoid valve and
the grounding. The resistance should be infinite.
• Whether the power line of the digging
solenoid valve is shorted to the ground
Fault diagnosis and elimination pro-
or not?
cedures
• Yes
Step 1 Check the digging solenoid valve for
Re-connect the harness, and wrap it.
fault.
Turn to Step 4
 When replacing the components, please • No
be sure to use LiuGong parts. Turn to Step 3
• Inspection method
Turn the start switch to the OFF position and Step 3 Check the connectors for fault.
disconnect the connector from the digging sole-
 Shutdown operation is needed.
noid valve.
1. Check the pins for moisture, oil dirt and other.  When replacing the components, please
2. Measure the resistance between both ends of be sure to use LiuGong parts.
the digging solenoid valve. The resistance • Inspection method
should be 16-40Ω.
Connect the digging solenoid valve connector
• Whether a fault developing in the dig- and disconnect the controller connector. Turn
ging solenoid valve or not? the multimeter to its resistance function, and
• Yes measure the resistance between the harness
Repair or replace the digging solenoid valve. (No.825) at the controller port J1-25 and the
Turn to Step 4 grounding (normally, 16-40Ω). When the resis-
tance is abnormal, this indicates there is a fault
• No
in the connector.
Turn to Step 2
 6-143
CLG922E 6.4 DTC
February 3, 2015 6.4.42 DTC 151404 A8 Digging solenoid valve shorted to the ground

Figure
Definition of
connector pin
serial number

Controller

Controller connector
Front

• Whether a fault in the connector or not?

• Yes
Repair or replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check the DTC.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
6-144
6.4 DTC CLG922E
6.4.43 DTC 151405 A8 Digging solenoid valve open-circuited or shorted to the battery February 3, 2015

6.4.43 DTC 151405 A8 Digging System description

The controller outputs a signal to the digging
solenoid valve open-circuited
solenoid valve A8 through the harness (No. 825)
or shorted to the battery to open the valve port.

Description of
DTC Consequence
Fault
The digging
Digging solenoid
solenoid valve
valve open-
is open-
151405 circuited or
circuited or in
shorted to the
the digging
battery.
function state.

Controller
Digging solenoid valve (valve A8)
A8 Digging solenoid valve
 6-145
CLG922E 6.4 DTC
February 3, 2015 6.4.43 DTC 151405 A8 Digging solenoid valve open-circuited or shorted to the battery

Component location Step 2 Check the harness for open-circuit.

 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

Front
bly.
A8-marked solenoid
valve can be located. It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).
• Inspection method
Fault diagnosis and elimination pro- 1. Check the harness (No. 825) and the ground-
cedures ing wire (No. 225) between the controller (J1-25)
(in the figure) and the digging solenoid valve for
Step 1 Check the digging solenoid valve for
wear.
fault.
2. Disconnect the connectors from the digging
 When replacing the components, please solenoid valve and the controller, and check the
be sure to use LiuGong parts. harness for open-circuit:

• Inspection method (a) Turn the multimeter to its resistance func-

Turn the start switch to the OFF position and tion, and measure the resistance between
disconnect the connector from the digging sole- the controller port J1-25 and digging sole-
noid valve. noid valve harness (normally, <10Ω).

1. Check the pins for looseness, rust, bending (b) Turn the multimeter to its resistance func-
and damage. tion, and measure the resistance between
2. Measure the resistance between both ends of the grounding wire (No.225) digging sole-
the digging solenoid valve. The resistance noid valve terminal and the grounding (nor-
should be 16-40Ω. mally, <10Ω).

• Whether a fault developing in the dig-

ging solenoid valve or not?
• Yes
Repair or replace the digging solenoid valve.
Turn to Step 5
• No
Turn to Step 2
6-146
6.4 DTC CLG922E
6.4.43 DTC 151405 A8 Digging solenoid valve open-circuited or shorted to the battery February 3, 2015

• No
Definition of Turn to Step 4
connector pin
serial number

Step 4 Check whether the digging solenoid

valve is shorted to the battery.
• Inspection method
Turn the start switch to the ON position for fault
diagnosis.
Disconnect the connectors from the controller
and A8 digging solenoid valve to switch on the
switches of all electrical equipment, and then
measure the voltage of the harness of A8 dig-
• Is the harness open?
ging solenoid valve. The voltage should be 0.
• Yes
• Whether the digging solenoid valve is
Connect the harness again and wrap the har- shorted to the battery or not?
ness.
• Yes
Turn to Step 5
Find out the short circuit position and re-connect
• No
the harness and wrap it.
Turn to Step 3
Turn to Step 5
• No
Step 3 Check the connectors for fault.
Turn to Step 5
 When replacing the components, please
be sure to use LiuGong parts. Step 5
• Inspection method • Inspection method
Connect the digging solenoid valve connector Turn the start switch to the ON position and re-
and disconnect the controller connector. Turn check the DTC.
the multimeter to its resistance function, and • Has this fault been eliminated?
measure the resistance between the harness at
• Yes
the controller port J1-25 and the grounding (nor-
Maintenance is over
mally, 16-40Ω). When the resistance is abnor-
mal, this indicates there is a fault in the • No
connector. Troubleshoot the faults according to the steps
• Whether a fault in the connector or not? again or contact the local LiuGong dealer and
authorized service center.
• Yes
Repair or replace the connector.
Turn to Step 5
 6-147
CLG922E 6.4 DTC
February 3, 2015 6.4.43 DTC 151405 A8 Digging solenoid valve open-circuited or shorted to the battery

Figure

Controller

Controller connector
Front
6-148
6.4 DTC CLG922E
6.4.44 DTC 151504 A5 Flow adjusting solenoid shorted to the ground February 3, 2015

6.4.44 DTC 151504 A5 Flow System description

The controller outputs a signal to the flow adjust-
adjusting solenoid shorted to
ing solenoid valve through the harness (No.
the ground 908) which feeds back the valve port opening
through the harness (No. 924). The controller
Description of performs logical judgment and then adjusts the
DTC Consequence
Fault signal to control the valve port opening through
A5 flow adjusting There is no flow the harness (No. 908).
151504 solenoid is shorted adjusting
to the ground. function.

Controller

Accessory adjusting solenoid 2 valve A5

A5 Flow adjusting
Pql & PQ2 flow adjusting (valve A6 & A5) solenoid valve 2
 6-149
CLG922E 6.4 DTC
February 3, 2015 6.4.44 DTC 151504 A5 Flow adjusting solenoid shorted to the ground

Component location Step 2 Check whether the harness of A5 flow

adjusting solenoid valve is shorted to the
ground.

Front  Shutdown operation is needed

A5-marked solenoid
valve can be located. • Inspection method
1. Turn the start switch to the OFF position for
fault diagnosis.
2. Disconnect the connectors from the controller
(in the figure) and the A5 flow adjusting solenoid
valve, and measure the resistance between the
power line (No. 908) of the A5 flow adjusting
solenoid valve J2-8 and the grounding. The
resistance should be infinite.
Fault diagnosis and elimination pro-
cedures
Definition of
Step 1 Check the flow adjusting solenoid for connector pin
serial number
fault

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Turn the start switch to the OFF position, and
disconnect the connector from the flow adjusting
solenoid valve.
1. Check the pins for moisture, oil dirt and other.
2. Measure the resistance between both ends of • Whether the harness of A5 flow adjust-
the flow adjusting solenoid valve. The resistance ing solenoid valve is shorted to the
should be 16-40Ω. ground or not?
• Whether a fault developing in the flow • Yes
adjusting valve or not? Re-connect the harness, and wrap it.
• Yes Turn to Step 4
Repair or replace the flow adjusting solenoid • No
valve
Turn to Step 3
Turn to Step 4
• No
Turn to Step 2
6-150
6.4 DTC CLG922E
6.4.44 DTC 151504 A5 Flow adjusting solenoid shorted to the ground February 3, 2015

Step 3 Check the connectors for fault. Figure

 Shutdown operation is needed.

 When replacing the components, please

be sure to use LiuGong parts. Controller

• Inspection method
Connect the flow adjusting solenoid valve con-
nector and disconnect the controller connector.
Turn the multimeter to its resistance function,
and measure the resistance between the har-
ness at the controller port J2-8 and the ground- Controller connector

ing (normally, 16-40Ω). When the resistance is Front

abnormal, this indicates there is a fault in the

connector.
• Whether a fault in the connector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check the DTC.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-151
CLG922E 6.4 DTC
February 3, 2015 6.4.45 DTC 151505 A5 Flow adjusting solenoid valve open-circuited or shorted to the battery

6.4.45 DTC 151505 A5 Flow System description

The controller outputs a signal to the flow adjust-
adjusting solenoid valve open-
ing solenoid valve through the harness (No.
circuited or shorted to the bat- 908) which feeds back the valve port opening
through the harness (No. 924). The controller
tery
performs logical judgment and then adjusts the
signal to control the valve port opening through
Description of
DTC Consequence the harness (No. 908).
Fault
A5 flow adjusting
solenoid valve There is no flow
151505 open-circuited or adjusting
shorted to the function.
battery.

Controller

Accessory adjusting solenoid 2 valve A5

A5 Flow adjusting
Pql & PQ2 flow adjusting (valve A6 & A5) solenoid valve 2
6-152
6.4 DTC CLG922E
6.4.45 DTC 151505 A5 Flow adjusting solenoid valve open-circuited or shorted to the battery February 3, 2015

Component location Step 2 Check the harness for open-circuit.

 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

Front
bly.
A5-marked solenoid
valve can be located. It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).
• Inspection method
Fault diagnosis and elimination pro- 1. Check the harness (No. 908) and the feed-
cedures back wire (No. 924) between the controller (J1-
8) (in the figure) and the flow adjusting solenoid
Step 1 Check the flow adjusting solenoid for
valve for wear.
fault
2.Disconnect the connectors from flow adjusting
 When replacing the components, please solenoid valve and the controller. Check the har-
be sure to use LiuGong parts. ness for open-circuit:

• Inspection method (a) Turn the multimeter to its resistance func-

Turn the start switch to the OFF position, and tion, and measure the resistance between
disconnect the connector from the flow adjusting the connector ports J2-8 and flow adjusting
solenoid valve. solenoid valve harness (normally, <10Ω).

1. Check the pins for looseness, rust, bending (b) Turn the multimeter to its resistance func-
and damage. tion, and measure the resistance between
2. Measure the resistance between both ends of the feedback wire (No.924) flow adjusting
the flow adjusting solenoid valve. The resistance solenoid valve terminal and the grounding
should be 16-40Ω. (normally, <10Ω).

• Whether a fault developing in the flow

adjusting valve or not?
• Yes
Repair or replace the flow adjusting solenoid
valve
Turn to Step 5
• No
Turn to Step 2
 6-153
CLG922E 6.4 DTC
February 3, 2015 6.4.45 DTC 151505 A5 Flow adjusting solenoid valve open-circuited or shorted to the battery

• No
Definition of Turn to Step 4
connector pin
serial number

Step 4 Check whether the flow adjusting sole-

noid valve is shorted to the battery
• Inspection method
Turn the start switch to the ON position for fault
diagnosis.
Disconnect the connectors from the controller
and A5 flow adjusting solenoid valve to switch
on the switches of all electrical equipment, and
then measure the voltage of the harness of A5
• Is the harness open?
flow adjusting solenoid valve. The voltage
• Yes should be 0.
Connect the harness again and wrap the har- • Whether the flow adjusting solenoid
ness. valve is shorted to the battery or not?
Turn to Step 5
• Yes
• No
Find out the short circuit position and re-connect
Turn to Step 3 the harness and wrap it.
Turn to Step 5
Step 3 Check the connectors for fault.
• No
 When replacing the components, please Turn to Step 5
be sure to use LiuGong parts.
• Inspection method Step 5 Check whether this fault is eliminated

Connect the flow adjusting solenoid valve con- • Inspection method

nector and disconnect the controller connector. Turn the start switch to the ON position and re-
Turn the multimeter to its resistance function, check the DTC.
and measure the resistance between the har- • Has this fault been eliminated?
ness at the controller port J2-8 and the ground-
• Yes
ing (normally, 16-40Ω). When the resistance is
Maintenance is over
abnormal, this indicates there is a fault in the
connector. • No

• Whether a fault in the connector or not? Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
• Yes
authorized service center.
Replace the connector.
Turn to Step 5
6-154
6.4 DTC CLG922E
6.4.45 DTC 151505 A5 Flow adjusting solenoid valve open-circuited or shorted to the battery February 3, 2015

Figure

Controller

Controller connector
Front
 6-155
CLG922E 6.4 DTC
February 3, 2015 6.4.46 DTC 151605 A6 Flow adjusting solenoid open-circuited or shorted to the battery

6.4.46 DTC 151605 A6 Flow System description

The controller outputs a signal to the flow adjust-
adjusting solenoid open-cir-
ing solenoid valve through the harness (No.
cuited or shorted to the battery 909) which feeds back the valve port opening
through the harness (No. 924). The controller
Description of performs logical judgment and then adjusts the
DTC Consequence
Fault signal to control the valve port opening through
A6 flow adjusting the harness (No. 909).
solenoid valve There is no flow
151605 open-circuited or adjusting
shorted to the function.
battery.

Controller

Accessory adjusting solenoid valve 1(valve A6)

A6 Flow adjusting
Pq1 & PQ2 flow adjusting (valve A6 & A5) solenoid valve 1
6-156
6.4 DTC CLG922E
6.4.46 DTC 151605 A6 Flow adjusting solenoid open-circuited or shorted to the battery February 3, 2015

Component location Step 2 Check the harness for open-circuit.

 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

Front
bly.
A6-marked solenoid
valve can be located. It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).
• Inspection method
Fault diagnosis and elimination pro- 1. Check the harness (No. 909) and the feed-
cedures back wire (No. 924) between the controller (J2-
9) (in the figure) and the flow adjusting solenoid
Step 1 Check the flow adjusting solenoid for
valve for wear.
fault
2.Disconnect the connectors from flow adjusting
 When replacing the components, please solenoid valve and the controller. Check the har-
be sure to use LiuGong parts. ness for open-circuit:

• Inspection method (a) Turn the multimeter to its resistance func-

Turn the start switch to the OFF position, and tion, and measure the resistance between
disconnect the connector from the flow adjusting the connector ports J2-9 and flow adjusting
solenoid valve. solenoid valve harness (normally, <10Ω).

1. Check the pins for looseness, rust, bending (b) Turn the multimeter to its resistance func-
and damage. tion, and measure the resistance between
2. Measure the resistance between both ends of the feedback wire (No.924) flow adjusting
the flow adjusting solenoid valve. The resistance solenoid valve terminal and the grounding
should be 16-40Ω. (normally, <10Ω).

• Whether a fault developing in the flow

adjusting valve or not?
• Yes
Repair or replace the flow adjusting solenoid
valve
Turn to Step 5
• No
Turn to Step 2
 6-157
CLG922E 6.4 DTC
February 3, 2015 6.4.46 DTC 151605 A6 Flow adjusting solenoid open-circuited or shorted to the battery

• No
Definition of Turn to Step 4
connector pin
serial number

Step 4 Check whether the flow adjusting sole-

noid valve is shorted to the battery
• Inspection method
Turn the start switch to the ON position for fault
diagnosis.
Disconnect the connectors from the controller
and A6 flow adjusting solenoid valve to switch
on the switches of all electrical equipment, and
then measure the voltage of the harness of A6
Is the harness open?
flow adjusting solenoid valve. The voltage
• Yes
should be 0.
Connect the harness again and wrap the har-
• Whether the flow adjusting solenoid
ness.
valve is shorted to the battery or not?
Turn to Step 5
• Yes
• No
Find out the short circuit position and re-connect
Turn to Step 3
the harness and wrap it.
Turn to Step 5
Step 3 Check the connectors for fault.
• No
 When replacing the components, please Turn to Step 5
be sure to use LiuGong parts.
• Inspection method Step 5 Check whether this fault is eliminated
Connect the flow adjusting solenoid valve con- • Inspection method
nector and disconnect the controller connector. Turn the start switch to the ON position and re-
Turn the multimeter to its resistance function, check the DTC.
and measure the resistance between the har- • Has this fault been eliminated?
ness at the controller port J2-9 and the ground-
• Yes
ing (normally, 16-40Ω). When the resistance is
abnormal, this indicates there is a fault in the Maintenance is over
connector. • No
• Whether a fault in the connector or not? Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
• Yes
authorized service center.
Replace the connector.
Turn to Step 5
6-158
6.4 DTC CLG922E
6.4.46 DTC 151605 A6 Flow adjusting solenoid open-circuited or shorted to the battery February 3, 2015

Figure

Controller

Controller connector
Front
 6-159
CLG922E 6.4 DTC
February 3, 2015 6.4.47 DTC 151704 A7 Transient power boosting solenoid valve shorted to the ground

6.4.47 DTC 151704 A7 Transient System description

Sends a power boosting signal automatically or
power boosting solenoid valve
manually to control on-off of the solenoid valve
shorted to the ground port to achieve the power boost.

Description of
DTC Consequence
Fault
Transient power
There is no
boosting solenoid
151704 power boosting
valve shorted to
function.
the ground.

Controller
Transient power bossting solenoid valve valve A7
A7 Transient power
boosting solenoid
valve
6-160
6.4 DTC CLG922E
6.4.47 DTC 151704 A7 Transient power boosting solenoid valve shorted to the ground February 3, 2015

Component location Step 2 Check whether the power line of the

power boosting solenoid valve is shorted to the
ground.

Front  Shutdown operation is needed

A7-marked solenoid
valve can be located.
• Inspection method
1. Turn the start switch to the OFF position for
fault diagnosis.
2. Disconnect the connectors from the controller
(in the figure) and power boosting solenoid
valve, and measure the resistance between the
power line (No. 813) of the power boosting sole-
noid valve and the grounding. The resistance
should be infinite.
Fault diagnosis and elimination pro-
• Whether the power line of the power
cedures boosting solenoid valve is shorted to
Step 1 Check the power boosting solenoid valve the ground or not?
for fault. • Yes
 When replacing the components, please Re-connect the harness, and wrap it.
be sure to use LiuGong parts. Turn to Step 4

• Inspection method • No

Turn the start switch to the OFF position and Turn to Step 3
disconnect the connector from the power
boosting solenoid valve. Step 3 Check the connector for fault
1. Check the pins for moisture, oil dirt and other.  Shutdown operation is needed.
2. Measure the resistance between both ends of
the power boosting solenoid valve. The resis-  When replacing the components, please
tance should be 16-40Ω. be sure to use LiuGong parts.
• Whether the power boosting solenoid • Inspection method
valve for fault？ Connect the power boosting solenoid valve con-
• Yes nector and disconnect the controller connector.
Repair or replace the power boosting solenoid Turn the multimeter to its resistance function,
valve. and measure the resistance between the har-
Turn to Step 4 ness at the controller port J1-13 and the ground-
ing (normally, 16-40Ω). When the resistance is
• No
abnormal, this indicates there is a fault in the
Turn to Step 2
connector.
 6-161
CLG922E 6.4 DTC
February 3, 2015 6.4.47 DTC 151704 A7 Transient power boosting solenoid valve shorted to the ground

Figure
Definition of
connector pin
serial number

Controller

Controller connector
Front

• Whether a fault in the connector or not?

• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check the DTC.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
6-162
6.4 DTC CLG922E
6.4.48 DTC 151705 A7 Transient power boosting solenoid valve open-circuited or shorted to the battery February 3, 2015

6.4.48 DTC 151705 A7 Transient System description

Sends a power boosting signal automatically or
power boosting solenoid valve
manually to control on-off of the solenoid valve
open-circuited or shorted to the port to achieve the power boost.

battery

Description of
DTC Consequence
Fault
Transient power
There is no
boosting solenoid
power boosting
valve open-
151705 or the power
circuited or
boosting is
shorted to the
kept.
battery.

Controller
Transient power bossting solenoid valve valve A7
A7 Transient power
boosting solenoid
valve
 6-163
CLG922E 6.4 DTC
February 3, 2015 6.4.48 DTC 151705 A7 Transient power boosting solenoid valve open-circuited or shorted to the battery

Component location Step 2 Check the harness for open-circuit.

 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

Front bly.
A7-marked solenoid
valve can be located.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).
• Inspection method
Fault diagnosis and elimination pro- 1. Check the harness (No. 813) and the ground-
cedures ing wire (No. 224) between the controller (J1-13)
(in the figure) and the power boosting solenoid
Step 1 Check the power boosting solenoid valve
valve for wear.
for fault.
2. Disconnect the connectors from the power
 When replacing the components, please boosting solenoid valve and the controller, and
be sure to use LiuGong parts. check the harness for open-circuit:

• Inspection method (a) Turn the multimeter to its resistance func-

Turn the start switch to the OFF position and tion, and measure the resistance between
disconnect the connector from the power boost- the controller port J1-13 and power boost-
ing solenoid valve. ing solenoid valve harness (normally,
<10Ω).
1. Check the pins for looseness, rust, bending
and damage. (b) Turn the multimeter to its resistance func-
2. Measure the resistance between both ends of tion, and measure the resistance between
the power boosting solenoid valve. The resis- the grounding wire (No.224) power boost-
tance should be 16-40Ω. ing solenoid valve terminal and the ground-
ing (normally, <10Ω).
• Whether the power boosting solenoid
valve for fault？
• Yes
Repair or replace the power boosting solenoid
valve.
Turn to Step 5
• No
Turn to Step 2
6-164
6.4 DTC CLG922E
6.4.48 DTC 151705 A7 Transient power boosting solenoid valve open-circuited or shorted to the battery February 3, 2015

• No
Definition of Turn to Step 4
connector pin
serial number

Step 4 Check whether the power boosting sole-

noid valve is shorted to the battery
• Inspection method
Turn the start switch to the ON position for fault
diagnosis.
Disconnect the connectors from the controller
and A7 power boosting solenoid valve to switch
on the switches of all electrical equipment, and
then measure the voltage of the harness of A7
• Is the harness open?
power boosting solenoid valve. The voltage
• Yes should be 0.
Connect the harness again and wrap the har- • Whether the power boosting solenoid
ness. valve is shorted to the battery?
Turn to Step 5
• Yes
• No
Find out the short circuit position and re-connect
Turn to Step 3 the harness and wrap it.
Turn to Step 5
Step 3 Check the connectors for fault.
• No
 When replacing the components, please Turn to Step 5
be sure to use LiuGong parts.
• Inspection method Step 5 Check whether this fault is eliminated

Connect the power boosting solenoid valve con- • Inspection method

nector and disconnect the controller connector. Turn the start switch to the ON position and re-
Turn the multimeter to its resistance function, check the DTC.
and measure the resistance between the har- • Has this fault been eliminated?
ness at the controller port J1-13 and the ground-
• Yes
ing (normally, 16-40Ω). When the resistance is
Maintenance is over
abnormal, this indicates there is a fault in the
connector. • No

• Whether a fault in the connector or not? Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
• Yes
authorized service center.
Replace the connector.
Turn to Step 5
 6-165
CLG922E 6.4 DTC
February 3, 2015 6.4.48 DTC 151705 A7 Transient power boosting solenoid valve open-circuited or shorted to the battery

Figure

Controller

Controller connector
Front
6-166
6.4 DTC CLG922E
6.4.49 DTC 151804 A4 Travel lifting solenoid valve shorted to the ground February 3, 2015

6.4.49 DTC 151804 A4 Travel System description

The controller outputs an electric signal to the
lifting solenoid valve shorted to
travel lifting solenoid valve A4 through the har-
the ground ness (No. 826) to open the valve port.

Description of
DTC Consequence
Fault
Travel lifting
There is no
solenoid valve
151804 travel lifting
shorted to the
function.
ground.

Travel lifting solenoid valve (valve A4)

A4 Travel lifting
solenoid valve
 6-167
CLG922E 6.4 DTC
February 3, 2015 6.4.49 DTC 151804 A4 Travel lifting solenoid valve shorted to the ground

Component location Step 2 Check whether the power line of the

travel lifting solenoid valve is shorted to the
ground.

Front  Shutdown operation is needed

A4-marked solenoid
valve can be located. • Inspection method
1. Turn the start switch to the OFF position for
fault diagnosis.
Disconnect the connectors from the controller
(in the figure) and the travel lifting solenoid
valve, and measure the resistance between the
power line (No. 825) of the travel lifting solenoid
valve and the grounding. The resistance should
be infinite.
Fault diagnosis and elimination pro-
• Whether the power line of the travel lift-
cedures ing solenoid valve is shorted to the
Step 1 Check the travel lifting solenoid valve for ground.
fault. • Yes
 When replacing the components, please Re-connect the harness, and wrap it.
be sure to use LiuGong parts. Turn to Step 4

• Inspection method • No

Turn the start switch to the OFF position and Turn to Step 3
disconnect the connector from the travel lifting
solenoid valve. Step 3 Check the connector for fault
1. Check the pins for moisture, oil dirt and other.
 Shutdown operation is needed.
2. Measure the resistance between both ends of
the travel lifting solenoid valve. The resistance  When replacing the components, please
should be 16-40Ω. be sure to use LiuGong parts.
• Whether a fault developing in the travel • Inspection method
lifting solenoid valve. Connect the travel lifting solenoid valve connec-
• Yes tor and disconnect the controller connector.
Repair or replace the travel speed solenoid Turn the multimeter to its resistance function,
valve. and measure the resistance between the har-
Turn to Step 4 ness at the controller port J1-26 and the ground-
ing (normally, 16-40Ω). When the resistance is
• No
abnormal, this indicates there is a fault in the
Turn to Step 2
connector.
6-168
6.4 DTC CLG922E
6.4.49 DTC 151804 A4 Travel lifting solenoid valve shorted to the ground February 3, 2015

Figure
Definition of
connector pin
serial number

Controller

Controller connector
Front

• Whether a fault in the connector or not?

• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check the DTC.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-169
CLG922E 6.4 DTC
February 3, 2015 6.4.50 DTC 151805 A4 Travel lifting solenoid valve open-circuited or shorted to the battery

6.4.50 DTC 151805 A4 Travel System description

The controller outputs an electric signal to the
lifting solenoid valve open-cir-
travel lifting solenoid valve A4 through the har-
cuited or shorted to the battery ness (No. 826) to open the valve port.

Description of
DTC Consequence
Fault
There is no
travel lifting
Travel lifting
function or the
solenoid valve
travel lifting
151805 open-circuited or
solenoid valve
shorted to the
is uncontrolled
battery.
by the
controller.

Travel lifting solenoid valve (valve A4)

A4 Travel lifting
solenoid valve
6-170
6.4 DTC CLG922E
6.4.50 DTC 151805 A4 Travel lifting solenoid valve open-circuited or shorted to the battery February 3, 2015

Component location Step 2 Check the harness for open-circuit.

 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

Front
bly.
A4-marked solenoid
valve can be located.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).
• Inspection method
Fault diagnosis and elimination pro- 1. Check the harness (No. 826) and the ground-
cedures ing wire (No. 223) between the controller (J1-26)
(in the figure) and the travel lifting solenoid valve
Step 1 Check the travel lifting solenoid valve for
for wear.
fault.
2. Disconnect the connectors from the travel lift-
 When replacing the components, please ing solenoid valve and the controller, and check
be sure to use LiuGong parts. the harness for open-circuit:

• Inspection method (a) Turn the multimeter to its resistance func-

Turn the start switch to the OFF position and tion, and measure the resistance between
disconnect the connector from the travel lifting the controller port J1-26 and travel speed
solenoid valve. solenoid valve harness (normally, <10Ω).

1. Check the pins for looseness, rust, bending (b) Turn the multimeter to its resistance func-
and damage. tion, and measure the resistance between
2. Measure the resistance between both ends of the grounding wire (No. 223) travel lifting
the travel lifting solenoid valve. The resistance solenoid valve terminal and the grounding
should be 16-40Ω. (normally, <10Ω).

• Whether a fault developing in the travel

lifting solenoid valve.
• Yes
Repair or replace the travel speed solenoid
valve.
Turn to Step 5
• No
Turn to Step 2
 6-171
CLG922E 6.4 DTC
February 3, 2015 6.4.50 DTC 151805 A4 Travel lifting solenoid valve open-circuited or shorted to the battery

• No
Definition of Turn to Step 4
connector pin
serial number

Step 4 Check whether the travel lifting solenoid

valve is shorted to the battery.
• Inspection method
Turn the start switch to the ON position for fault
diagnosis.
Disconnect the connectors from the controller
and A4 travel lifting solenoid valve to switch on
the switches of all electrical equipment, and then
measure the voltage of the harness of A4 travel
• Is the harness open?
lifting solenoid valve. The voltage should be 0.
• Yes
• Whether the travel lifting solenoid valve
Connect the harness again and wrap the har- is shorted to the battery or not?
ness.
• Yes
Turn to Step 5
Find out the short circuit position and re-connect
• No
the harness and wrap it.
Turn to Step 3
Turn to Step 5
• No
Step 3 Check the connectors for fault.
Turn to Step 5
 When replacing the components, please
be sure to use LiuGong parts. Step 5 Check whether this fault is eliminated
• Inspection method • Inspection method
Connect the travel lifting solenoid valve connec- Turn the start switch to the ON position and re-
tor and disconnect the controller connector. check the DTC.
Turn the multimeter to its resistance function, • Has this fault been eliminated?
and measure the resistance between the har-
• Yes
ness (No. 826) at the controller port J1-26 and
Maintenance is over
the grounding (normally, 16-40Ω). When the
• No
resistance is abnormal, this indicates there is a
fault in the connector. Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
• Whether a fault in the connector or not?
authorized service center.
• Yes
Replace the connector.
Turn to Step 5
6-172
6.4 DTC CLG922E
6.4.50 DTC 151805 A4 Travel lifting solenoid valve open-circuited or shorted to the battery February 3, 2015

Figure

Controller

Controller connector
Front
 6-173
CLG922E 6.4 DTC
February 3, 2015 6.4.51 DTC 151905 A5 or A6 solenoid valve feedback open-circuited

6.4.51 DTC 151905 A5 or A6 System description

The controller sends a signal through which A5
solenoid valve feedback open-
or A6 adjusts the hydraulic flow.
circuited

Description of
DTC Consequence
Fault
A5 or A6 flow
adjusting solenoid The flow cannot
151905
valve open- be adjusted.
circuited.

Controller

Accesspry adjusting solenoid valve 2 valve A5

Accesspry adjusting solenoid valve 1 (valve A6)
Pq1 & PQ2 flow adjusting solenoid valve (valve A6 & A5)

A5 Flow adjusting solenoid valve 2

A1 Flow adjusting solenoid valve1

6-174
6.4 DTC CLG922E
6.4.51 DTC 151905 A5 or A6 solenoid valve feedback open-circuited February 3, 2015

Component location
Definition of
connector pin
serial number
Solenoid valve
assembly. Both
A5-marked solenoid
and A6-marked
solenoid can be
located

Front

• Is the harness open?

Fault diagnosis and elimination pro- • Yes

cedures Re-connect the harness and wrap it.

Turn to Step 3
Step 1 Check the harness for open-circuit.
• No
 Shutdown operation is needed
Turn to Step 2
Correctly tie up harness and wire
Avoid folding or bending the harness forci- Step 2 Check the connectors for fault.
bly.
Avoid friction with sharp metal edges.
 Shutdown operation is needed

Try to keep far way from oil and water. • Inspection method

Try to keep far away from high temperature Check the connectors between the A5/A6 flow
parts (e.g. engine body). adjusting solenoid valve for looseness and their
pins for rust, bending and damage one by one
• Inspection method
manually.
Turn the start switch to the OFF position,
Disconnect the controller connector and connect
Disconnect the connectors from the controller
the connector of A5 and A6 flow adjusting sole-
(in the figure), A5 and A6 flow adjusting solenoid
noid valves, and then measure the resistance
valves, and measure the resistance between the
among the controller connector ports J2-8, J2-9
J2-24 wire and the A5/A6 flow adjusting sole-
and J2-24. The resistance should be 16-40Ω.
noid valve. The maximum resistance should be
Otherwise, there is a fault in the connector.
10Ω.
• Whether a fault in the connector or not?
• Yes
Adjust or replace the connector.
Turn to Step 3
 6-175
CLG922E 6.4 DTC
February 3, 2015 6.4.51 DTC 151905 A5 or A6 solenoid valve feedback open-circuited

• No
Turn to Step 3

Step 3 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check the DTC.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.

Figure

Controller

Controller connector
Front
6-176
6.4 DTC CLG922E
6.4.52 DTC 151906 A5 or A6 solenoid valve feedback overcurrent February 3, 2015

6.4.52 DTC 151906 A5 or A6 System description

The controller sends a signal through which A5
solenoid valve feedback over-
or A6 adjusts the hydraulic flow.
current

Description of
DTC Consequence
Fault
A5 or A6 solenoid
The flow cannot
151906 valve feedback
be adjusted.
overcurrent.

Controller

Accesspry adjusting solenoid valve 2 valve A5

Accesspry adjusting solenoid valve 1 (valve A6)
Pq1 & PQ2 flow adjusting solenoid valve (valve A6 & A5)

A5 Flow adjusting solenoid valve 2

A1 Flow adjusting solenoid valve1

 6-177
CLG922E 6.4 DTC
February 3, 2015 6.4.52 DTC 151906 A5 or A6 solenoid valve feedback overcurrent

Component location Step 2 Check whether the harness is shorted to

the battery.

Solenoid valve  Shutdown operation is needed

assembly. Both
A5-marked solenoid
and A6-marked • Inspection method
solenoid can be
located Disconnect the connectors from the controller,
A5 and A6 solenoid valves, respectively.
Turn the multimeter to its voltage function
Front
(200V), and then measure the voltage between
the controller’s connector port (J2-24) (in the fig-
ure) and the ground. The voltage should be 0.

Definition of
connector pin
Fault diagnosis and elimination pro- serial number

cedures
Step 1 Check the pump proportional solenoid
for fault

 Shutdown operation is needed

• Inspection method
Turn the start switch to the OFF position, and
check the pins for moisture, oil dirt and other.
Measure the resistance of A5 or A6 flow adjust- • Whether the harness is shorted to the
ing solenoid valve. The resistance should be 16- battery or not?
40Ω.
• Yes
• Whether a fault developing in the pump
Re-connect the harness, and wrap it.
proportional solenoid valve or not?
Turn to Step 4
• Yes
• No
Replace solenoid valve
Turn to Step 3
Turn to Step 4
• No
Turn to Step 2
6-178
6.4 DTC CLG922E
6.4.52 DTC 151906 A5 or A6 solenoid valve feedback overcurrent February 3, 2015

Step 3 Check the connectors for fault. Figure

 Shutdown operation is needed

• Inspection method
Check the connectors between the A5/A6 flow Controller

adjusting solenoid valve for looseness and their

pins for rust, bending and damage one by one
manually.
• Whether a fault in the connector or not?
• Yes
Repair or replace the connector Controller connector

Turn to Step 4 Front

• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check the DTC.
Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-179
CLG922E 6.4 DTC
February 3, 2015 6.4.53 DTC 171004 Battery relay shorted to the ground

6.4.53 DTC 171004 Battery relay System description

When the B or L terminal is connected to the
shorted to the ground
positive pole of the power (24V) and the E termi-
nal to the negative pole, the energized coil gen-
Description of erates a magnetic field suction to move the
DTC Consequence
Fault
armature to pull in the contact, so that the con-
The alternator’s trolled circuit is switched on.
load dump may
Battery relay
burn electronic
171004 shorted to the
components
ground
and electrical
equipment.

Battery

IPC Controller

Power supply relay

Battery relay
6-180
6.4 DTC CLG922E
6.4.53 DTC 171004 Battery relay shorted to the ground February 3, 2015

Component location Step 2 Check the harness for short-circuit to

ground

 Correctly tie up harness and wire:

Front Avoid folding or bending the harness forci-

bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Battery relay

Try to keep far away from high temperature

parts (e.g. engine body).

Fault diagnosis and elimination pro- • Inspection method

cedures 1. Check the harness (No. 824) between the

controller (J1-24) and the battery relay for wear.
Step 1 Check the battery relay for fault.
2. Disconnect the relay connector and the con-
 When replacing the components, please troller connector. Turn the multimeter to its resis-
be sure to use LiuGong parts. tance function, and measure the resistance
between the harness (No. 824) relay terminal
• Inspection method
and the ground (normally, >100K).
Turn the start switch to the OFF position and
turn the multimeter to its resistance function • Whether the harness is shorted to the
(200Ω), and then measure the resistance ground or not?
between the relay terminals L and E (normally, • Yes
>10Ω, about 50Ω). Connect the harness again and wrap the har-
• Whether a fault developing in the battery ness.
relay or not? Turn to Step 3
• Yes • No
Replace the battery relay. Turn to Step 3
Turn to Step 3
• No
Turn to Step 2
 6-181
CLG922E 6.4 DTC
February 3, 2015 6.4.53 DTC 171004 Battery relay shorted to the ground

Step 3 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
6-182
6.4 DTC CLG922E
6.4.54 DTC 171104 Auto preheating relay shorted to the ground February 3, 2015

6.4.54 DTC 171104 Auto pre- System description

The controller needs to be preheated before log-
heating relay shorted to the
ical judgment. If the harness (No. 911) is ener-
ground gized, the automatic preheater K9 is energized
and the harness (No. 123) is connected to the
Description of harness (No. 190), then the harness (No. 190) is
DTC Consequence
Fault energized. As a result, the preheating relay is
Auto preheating The auto energized, so that the harness (No. 104) is con-
171104 relay shorted to preheating
the ground. function fails. nected to the harness (No. 185) which connects
the heater for heating.

Ignition switch

Auto preheating 10A

Auto preheating relay K9
Electric lock power supply

Battery

Preheating relay K3

Controller
Preheating relay
 6-183
CLG922E 6.4 DTC
February 3, 2015 6.4.54 DTC 171104 Auto preheating relay shorted to the ground

Component location

Open the fuse box.

K9 auto preheating
relay. It can be pulled
out during detection`
6-184
6.4 DTC CLG922E
6.4.54 DTC 171104 Auto preheating relay shorted to the ground February 3, 2015

Fault diagnosis and elimination pro- Step 2 Check the connectors for fault

cedures  Shutdown operation is needed.

Step 1 Check whether the harness connecting
the controller port J2-11 is shorted to the
 When replacing the components, please

ground. be sure to use LiuGong parts.

• Inspection method
 Shutdown operation is needed
Check manually the connectors between the
• Inspection method automatic preheater and the controller one by
For troubleshooting, turn the start switch to the one for moisture, oil dirt and other which may
OFF position. cause electric leakage.
Disconnect the connector from the controller (in • Whether a fault in the connector or not?
the figure) and pull out the auto preheating
• Yes
relay, and then measure the resistance between
Adjust or replace the connector.
the harness (No. 911) at the J2-11 port and the
Turn to Step 3
grounding. The resistance should be infinite.
• No
Turn to Step 3
Definition of
connector pin
serial number
Step 3 Check whether this fault is eliminated
• Inspection method
Turn the start switch to the ON position and re-
check the DTC.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
• Check whether the harness connecting Troubleshoot the faults according to the steps
the controller port J2-11 is shorted to again or contact the local LiuGong dealer and
the ground. authorized service center.

• Yes
Re-connect the harness, and wrap it.
Turn to Step 3
• No
Turn to Step 2
 6-185
CLG922E 6.4 DTC
February 3, 2015 6.4.54 DTC 171104 Auto preheating relay shorted to the ground

Figure

Controller

Controller connector
Front
6-186
6.4 DTC CLG922E
6.4.55 DTC 171105 Auto preheating relay open-circuited or shorted to the battery February 3, 2015

6.4.55 DTC 171105 Auto pre- System description

The controller needs to be preheated before log-
heating relay open-circuited or
ical judgment. If the harness (No. 911) is ener-
shorted to the battery gized, the automatic preheater K9 is energized
and the harness (No. 123) is connected to the
Description of harness (No. 190), then the harness (No. 190) is
DTC Consequence
Fault energized. As a result, the preheating relay is
Auto preheating energized, so that the harness (No. 104) is con-
relay open- The auto
171105 circuited or preheating nected to the harness (No. 185) which connects
shorted to the function fails. the heater for heating.
battery.

Ignition switch

Auto preheating 10A

Auto preheating relay K9
Electric lock power supply

Battery

Preheating relay K3

Controller
Preheating relay
 6-187
CLG922E 6.4 DTC
February 3, 2015 6.4.55 DTC 171105 Auto preheating relay open-circuited or shorted to the battery

Component location

Open the fuse box.

K9 auto preheating
relay. It can be pulled
out during detection`

Fault diagnosis and elimination pro- supply (24V), and measure the terminals 30 and
87 by turning the multimeter to its on-off func-
cedures
tion. The relay should switch on.
Step 1 Check the auto preheating relay for fault.
• Whether a fault developing in the auto
 When replacing the components, please preheating relay or not?
be sure to use LiuGong parts. • Yes
• Inspection method Replace the auto preheating relay.
For troubleshooting, turn the start switch to the Turn to Step 4
OFF position. No
Open the fuse box, and pull out the auto pre- Turn to Step 2
heating relay.
Measure the resistance between the ports 85
and 86 of the auto preheating relay coil. The
resistance should be 320-360Ω.
Connect the terminals 85 and 86 to the power
6-188
6.4 DTC CLG922E
6.4.55 DTC 171105 Auto preheating relay open-circuited or shorted to the battery February 3, 2015

Step 2 Check the harness for open-circuit Turn to Step 4

 Shutdown operation is needed • No

Turn to Step 3
 Correctly tie up harness and wire:

Avoid folding or bending the harness forci- Step 3 Check the connectors for fault
bly
 When replacing the components, please
Avoid friction with sharp metal edges
be sure to use LiuGong parts.
Try to keep far way from oil and water
• Inspection method
Try to keep far away from high temperature
Insert the auto preheating relay into the fuse box
parts (e.g. engine body) as far as possible
properly and disconnect the controller connec-
• Inspection method
tor, and then turn the multimeter to its resistance
For troubleshooting, turn the start switch to the function and measure the resistance between
OFF position. the harness at the controller port J2-11 and the
Disconnect the connector from the controller (in grounding. The resistance should be between
the figure) and pull out the auto preheating 320-360Ω. Otherwise, check the connector:
relay, and then measure the resistance between
(a) Check the connector at the grounding of
the harness (No. 911) at the J2-11 port and the
the relay for poor contact:
auto preheating relay. The maximum resistance
(b) Check the connector of the relay for loose-
should be 10Ω.
ness or damage.
Measure the resistance between the 85 port in
• Whether a fault in the connector or not?
the fuse box and the ground. The maximum
resistance should be 10Ω. • Yes
Adjust or replace the connector.
Turn to Step 4
Definition of
connector pin
serial number • No
Turn to Step 4

• Is the harness open?

• Yes
Re-connect the harness, and wrap it.
 6-189
CLG922E 6.4 DTC
February 3, 2015 6.4.55 DTC 171105 Auto preheating relay open-circuited or shorted to the battery

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check the DTC.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.

Figure

Controller

Controller connector
Front
6-190
6.4 DTC CLG922E
6.4.56 DTC 171204 Start cut-off relay shorted to the ground February 3, 2015

6.4.56 DTC 171204 Start cut-off System description

After the controller port 23 is energized, the har-
relay shorted to the ground
ness (No. 923) is energized, so that the ports 30
and 87A of the start cut-off relay K8 are
Description of
DTC Consequence switched off.
Fault
The start cut-off
Start cut-off valve
relay is not
171204 relay shored to the
controlled by
ground
the controller.

Controller

Start cutoff relay

Controller control start relay K8

Pilot control start relay K7
 6-191
CLG922E 6.4 DTC
February 3, 2015 6.4.56 DTC 171204 Start cut-off relay shorted to the ground

Component location

Open the fuse box.

Start cut-off relay K8

Fault diagnosis and elimination pro- Connect the terminals 85 and 86 to the power
supply (24V), and measure the terminals 30 and
cedures
87 by turning the multimeter to its on-off func-
Step 1 Check whether there is a fault in the start
tion. The relay should switch on.
cut-off relay.
• Check if there is a fault in the start cut-
 When replacing the components, please off valve relay.
be sure to use LiuGong parts. • Yes
• Inspection method Replace the start cut-off valve relay.
For troubleshooting, turn the start switch to the Turn to Step 4
OFF position: • No
Open the fuse box, and pull out the auto pre- Turn to Step 2
heating relay;
Measure the resistance between the ports 85
and 86 of the start cut-off relay coil. The resis-
tance should be 320-350Ω.
6-192
6.4 DTC CLG922E
6.4.56 DTC 171204 Start cut-off relay shorted to the ground February 3, 2015

Step 2 Check whether the power line of the start

cut-off relay is shorted to the ground.
Definition of


connector pin
Shutdown operation is needed serial number

• Inspection method
1. Turn the start switch to the OFF position for
fault diagnosis.
2.Disconnect the connectors from the controller
(in the figure) and the start cut-off relay, and
measure the resistance between the power line
(No. 923) of the start cut-off relay and the
grounding. The resistance should be infinite.
• Whether the power line of the start cut- • Whether a fault in the connector or not?
off relay is shorted to the ground or not. • Yes
• Yes Replace the connector.
Re-connect the harness, and wrap it. Turn to Step 4
Turn to Step 4 • No
• No Turn to Step 4
Turn to Step 3
Step 4 Check whether this fault is eliminated
Step 3 Check the connectors for fault • Inspection method
 Shutdown operation is needed. Turn the start switch to the ON position and re-
check the DTC.
 When replacing the components, please
• Has this fault been eliminated?
be sure to use LiuGong parts.
• Yes
• Inspection method
Maintenance is over
Connect the connector of the start cut-off relay
• No
and disconnect the controller connector, and
Troubleshoot the faults according to the steps
then turn the multimeter to its resistance func-
again or contact the local LiuGong dealer and
tion and measure the resistance between the
authorized service center.
harness at the controller port J2-23 and the
grounding (normally, 320-350Ω). If the resis-
tance is abnormal, this indicates that there is a
fault in the connector.
 6-193
CLG922E 6.4 DTC
February 3, 2015 6.4.56 DTC 171204 Start cut-off relay shorted to the ground

Figure

Controller

Controller connector
Front
6-194
6.4 DTC CLG922E
6.4.57 DTC 171205 Start cut-off output open-circuited or shorted to the battery February 3, 2015

6.4.57 DTC 171205 Start cut-off System description

After the controller port 23 is energized, the har-
output open-circuited or
ness (No. 911) is energized, so that the ports 30
shorted to the battery and 87A of the start cut-off relay K8 are
switched off.
Description of
DTC Consequence
Fault
Start cut-off
The start cut-
output open-
off relay is not
171205 circuited or
controlled by
shorted to the
the controller.
battery.

Controller

Start cutoff relay

Controller control start relay K8

Pilot control start relay K7
 6-195
CLG922E 6.4 DTC
February 3, 2015 6.4.57 DTC 171205 Start cut-off output open-circuited or shorted to the battery

Component location

Open the fuse box.

Start cut-off relay K8

6-196
6.4 DTC CLG922E
6.4.57 DTC 171205 Start cut-off output open-circuited or shorted to the battery February 3, 2015

Fault diagnosis and elimination pro- parts (e.g. engine body) as far as possible

cedures • Inspection method

Step 1 Check whether there is a fault in the start For troubleshooting, turn the start switch to the
cut-off relay. OFF position:
Disconnect the connector from the controller (in
 When replacing the components, please
the figure) and pull out the start cut-off relay, and
be sure to use LiuGong parts. then measure the resistance between the har-
• Inspection method ness (No. 923) at the J2-23 port and the start
For troubleshooting, turn the start switch to the cut-off relay. The maximum resistance should
OFF position: be 10Ω.
Open the fuse box, and pull out the start cut-off Measure the resistance between the 85 port in
relay. the fuse box and the ground. The maximum
Measure the resistance between the ports 85 resistance should be 10Ω.
and 86 of the start cut-off relay coil. The resis-
tance should be 320-360Ω. Definition of
connector pin
Connect the terminals 85 and 86 to the power serial number

supply (24V), and measure the terminals 30 and

87A by turning the multimeter to its on-off func-
tion. The relay should switch on.
• Check if there is a fault in the start cut-
off valve relay.
• Yes
Replace the start cut-off valve relay.
Turn to Step 5
• No • Is the harness open?
Turn to Step 2
• Yes
Re-connect the harness, and wrap it.
Step 2 Check the harness for open-circuit
Turn to Step 5
 Shutdown operation is needed • No
Turn to Step 3
 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

bly
Avoid friction with sharp metal edges
Try to keep far way from oil and water
Try to keep far away from high temperature
 6-197
CLG922E 6.4 DTC
February 3, 2015 6.4.57 DTC 171205 Start cut-off output open-circuited or shorted to the battery

Step 3 Check the connectors for fault • Whether the start cut-off relay is shorted
to the battery or not?
 When replacing the components, please
be sure to use LiuGong parts. • Yes
Find out the short circuit position and re-connect
• Inspection method
the harness and wrap it.
Insert the start cut-off relay into the fuse box
Turn to Step 5
properly and disconnect the controller connec-
tor, and then turn the multimeter to its resistance • No
function and measure the resistance between Turn to Step 5
the harness (No. 923) at the controller port J2-
23 and the grounding. The resistance should be Step 5 Check whether this fault is eliminated
between 320-360Ω. Otherwise, check the con- • Inspection method
nector:
Turn the start switch to the ON position and re-
(a) Check the connector at the grounding of check the DTC.
the start cut-off relay for poor contact.
• Has this fault been eliminated?
(b) Check the connector of the start cut-off
• Yes
relay for looseness or damage.
Maintenance is over
• Whether a fault in the connector or not?
• No
• Yes
Troubleshoot the faults according to the steps
Adjust or replace the connector. again or contact the local LiuGong dealer and
Turn to Step 5 authorized service center.
• No
Turn to Step 4 Figure

Step 4 Check whether the start cut-off relay is

shorted to the battery

 When replacing the components, please

Controller

be sure to use LiuGong parts.

• Inspection method
Turn the start switch to the ON position for fault
diagnosis.
Disconnect the connectors from the controller
Controller connector
and the start cut-off relay and turn on the Front

switches of all electrical equipment, and then

measure the voltage of the harness connecting
the start cut-off relay. The voltage should be 0.
6-198
6.4 DTC CLG922E
6.4.58 DTC 201004 Travel alarm shorted to the ground February 3, 2015

6.4.58 DTC 201004 Travel alarm System description

The travel alarm is used to beep for warning
shorted to the ground
when the excavator is moving, as shown in the
figure. One pin of the travel alarm is connected
Description of
DTC Consequence to the controller directly and the other pin is
Fault
Travel alarm grounded. When the excavator is moving, the
Travel alarm
201004 shorted to the controller receives the traveling signal and
fails to work.
ground allows the travel alarm to be energized through
its internal logic program.

(Black)

Travel alarm buzzer

Controller

Travel alarm (optional)

Component location

Front

Travel alarm
 6-199
CLG922E 6.4 DTC
February 3, 2015 6.4.58 DTC 201004 Travel alarm shorted to the ground

Fault diagnosis and elimination pro- controller connector. Turn the multimeter to its
resistance function, and measure the resistance
cedures
between the harness (No. 801) sensor terminal
Step 1 Check the travel Alarm for fault.
and grounding (normally, >100K).
 When replacing the components, please • Whether the harness is shorted to the
be sure to use LiuGong parts. ground or not?
• Inspection method • Yes
Turn the start switch to the OFF position, Connect the harness again and wrap the har-
and disconnect the travel alarm connector. ness.
1. Check the connector for moisture, oil dirt and Turn to Step 4
other. • No
2. Turn the multimeter to its resistance function, Turn to Step 3
and measure the resistance between the alarm
connector terminals 1 and 2 (normally, >10Ω). Step 3 Check the connector for fault.
• Check the travel Alarm for fault.
 When replacing the components, please
• Yes
be sure to use LiuGong parts.
Repair or replace the sensor.
• Inspection method
Turn to Step 4
Connect the attachment confluent solenoid
• No
valve attachment connector and disconnect the
Turn to Step 2
controller connector. Turn the multimeter to its
resistance function, and measure the resistance
Step 2 Check the harness for short-circuit to between the controller port J1-01 and the
ground grounding (normally, >10Ω).
 Shutdown operation is needed When the resistance is abnormal, this indicates
there is an insulation fault in the connector.
 Correctly tie up harness and wire:
• Whether a fault developing in the con-
Avoid folding or bending the harness forci- nector or not?
bly • Yes
Avoid friction with sharp metal edges Replace the connector.
Try to keep far way from oil and water Turn to Step 4
Try to keep far away from high temperature • No
parts (e.g. engine body) as far as possible
Turn to Step 4
• Inspection method
1. Check the harness (No. 801) between the
controller (J1-01) and the travel alarm for wear.
2. Disconnect the travel alarm connector and the
6-200
6.4 DTC CLG922E
6.4.58 DTC 201004 Travel alarm shorted to the ground February 3, 2015

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-201
CLG922E 6.4 DTC
February 3, 2015 6.4.59 DTC 211003 P1 pump pressure sensor voltage above the range value

6.4.59 DTC 211003 P1 pump System description

The pressure sensor (pressure transmitter) con-
pressure sensor voltage above
verts the detected hydraulic oil pressure param-
the range value eter into the current signal input to the controller
which detects the hydraulic oil pressure value
Description of which is displayed on the display instrument.
DTC Consequence
Fault
The P1 pump
pressure sensor
voltage is out of
the range value. Operating the
When the left/right excavator as
control lever is usual can
211003 operated, the cause the
current detected in engine gets
the signal circuit of stuck or even
the P1 pump shuts down.
pressure sensor is
extremely high
(above 20mA).

Controller J2(White)
P1 Left pump pressure transmitter
P1 left pump pressure
6-202
6.4 DTC CLG922E
6.4.59 DTC 211003 P1 pump pressure sensor voltage above the range value February 3, 2015

Pressure sensor parameters: Step 2 Check the harness for short-circuit to

battery
Output Current: 4-20mA
Working voltage: 8-30Vdc  Correctly tie up harness and wire:
Pressure range: 0-400bar Avoid folding or bending the harness forci-
bly.
Component location It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
P1 pump
pressure sensor
Try to keep far way from oil and water.
P2 pump
pressure sensor Try to keep far away from high temperature
parts (e.g. engine body).
• Inspection method
1. Check the harness (No. 931) between the
controller (J2-31) and the pump pressure sensor
for wear.
Front
2. Turn the start switch to the ON position and
disconnect the pump pressure sensor connector
Fault diagnosis and elimination pro- and the controller connector. Turn the multime-
cedures ter to its voltage function and measure the volt-
Step 1 Check the connector for fault. age between the harness (No. 931) sensor
terminal and the grounding (normally, 0V).
 When replacing the components, please
• Whether the harness is shorted to the
be sure to use LiuGong parts.
battery.
• Inspection method • Yes
Check the connector for moisture, oil dirt or Connect the harness again and wrap the har-
insulation fault. ness.
• Whether a fault developing in the con- Turn to Step 4
nector or not?
• No
• Yes Turn to Step 3
Repair or replace the connector.
Turn to Step 4
• No
Turn to Step 2
 6-203
CLG922E 6.4 DTC
February 3, 2015 6.4.59 DTC 211003 P1 pump pressure sensor voltage above the range value

Step 3 Check the pump pressure sensor for connect the controller connector, and then dis-
fault. connect the pump pressure sensor connector
and measure the current in the pump pressure
 When replacing the components, please
sensor signal circuit:
be sure to use LiuGong parts.
(a) Connect the measuring circuit as shown in
• Inspection method the schematic diagram.
Turn the start switch to the OFF position and

Connector matching P1 P1 left pump pressure transmitter

Controller J2(White)

P1 left pump pressure

Black probe Red probe

Multimeter

(b) Start the engine, and with the boom lifted, Step 4 Check whether this fault is eliminated
turn the multimeter to its current function, • Inspection method
and measure the current between the sen- Turn the start switch to the ON position and re-
sor connector male terminal and female check for fault.
terminal (Pin 1) (normally, 4-20mA).
• Has this fault been eliminated?
• Whether a fault developing in the pump
• Yes
pressure or not?
Maintenance is over
• Yes
• No
Replace the pump pressure sensor.
Troubleshoot the faults according to the steps
Turn to Step 4
again or contact the local LiuGong dealer and
• No authorized service center.
Turn to Step 4
6-204
6.4 DTC CLG922E
6.4.60 DTC 211004 P1 pump pressure sensor voltage below the range value February 3, 2015

6.4.60 DTC 211004 P1 pump System description

The pressure sensor (pressure transmitter) con-
pressure sensor voltage below
verts the detected hydraulic oil pressure param-
the range value eter into the current signal input to the controller
which detects the hydraulic oil pressure value
Description of which is displayed on the display instrument.
DTC Consequence
Fault
The P1 pump
pressure sensor
voltage is lower
than the range
value. When the
left/right control
Some hydraulic
lever is operated,
211004 actions cannot
the current
be achieved.
detected in the
signal circuit of the
P1 pump pressure
sensor is
extremely low
(below 4mA).

Controller J2(White)
P1 Left pump pressure transmitter
P1 left pump pressure
 6-205
CLG922E 6.4 DTC
February 3, 2015 6.4.60 DTC 211004 P1 pump pressure sensor voltage below the range value

Pressure sensor parameters: Turn to Step 2

Output Current: 4-20mA Step 2 Check the harness for open-circuit or

short-circuit to ground.
Working voltage: 8-30Vdc
Pressure range: 0-400bar  Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

Component location bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
P1 pump
pressure sensor
Avoid friction with sharp metal edges.
P2 pump
pressure sensor Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).
• Inspection method
1. Check the harness (No. 931) between the
controller (J2-31) and the pump pressure sensor
Front
and the power line (No. 121) for wear.
Turn the start switch to the ON position, and dis-
Fault diagnosis and elimination pro- connect the connectors from the pump pressure
cedures sensor and the controller, respectively.
Step 1 Check the connector for fault. 2. Check the harness for open-circuit:

 When replacing the components, please (a) Turn the multimeter to its voltage function,
and measure the voltage between the
be sure to use LiuGong parts.
power line (No. 121) sensor terminal and
• Inspection method the grounding (normally, 25±0.5V (battery
1. Check the connector at the sensor grounding voltage)).
for poor contact. (b) Turn the multimeter to its resistance func-
2. Check whether the connector becomes loose. tion, and measure the resistance of the har-
3. Check the connector pins for rust, bending or ness (No. 931) between the controller and
damage. the sensor (normally, <10Ω).
• Whether a fault developing in the con- 3. Check whether the harness is shorted to the
nector or not? ground:
• Yes Measure the resistance between the harness
Repair or replace the connector. (No. 931) sensor terminal and the grounding
Turn to Step 4 (normally, >100K).

• No • Whether the harness open-circuited or

shorted to the ground or not?
6-206
6.4 DTC CLG922E
6.4.60 DTC 211004 P1 pump pressure sensor voltage below the range value February 3, 2015

• Yes  When replacing the components, please

Connect the harness again and wrap the har- be sure to use LiuGong parts.
ness.
• Inspection method
Turn to Step 4
Turn the start switch to the OFF position and
• No
disconnect the pump pressure sensor connec-
Turn to Step 3 tor, and then connect the controller connector:
Step 3 Check the pump pressure sensor for
(a) Connect the current detection circuit as
fault.
shown in the schematic diagram:

Connector matching P1 P1 left pump pressure transmitter

Controller J2(White)

P1 left pump pressure

Black probe Red probe

Multimeter

(b) Turn the multimeter to its current function Step 4 Check whether this fault is eliminated
(200mA) and start the engine, and then • Inspection method
with the boom lifted, measure the current Turn the start switch to the ON position and re-
between the sensor connector male termi- check for fault.
nal and female terminal (Pin 1) (normally,
• Has this fault been eliminated?
4-20mA).
• Yes
• Check the pump pressure sensor for
Maintenance is over
fault.
• No
• Yes
Troubleshoot the faults according to the steps
Replace the pump pressure sensor.
again or contact the local LiuGong dealer and
Turn to Step 4
authorized service center.
• No
Turn to Step 4
 6-207
CLG922E 6.4 DTC
February 3, 2015 6.4.61 DTC 211003 P2 pump pressure sensor voltage above the range value

6.4.61 DTC 211003 P2 pump System description

The pressure sensor (pressure transmitter) con-
pressure sensor voltage above
verts the detected hydraulic oil pressure param-
the range value eter into the current signal input to the controller
which detects the hydraulic oil pressure value
Description of which is displayed on the display instrument.
DTC Consequence
Fault
P2 pump pressure
sensor voltage
above the range
value. When the Operating the
left/right control excavator as
lever is operated, usual can
211103 the current cause the
detected in the engine gets
signal circuit of the stuck or even
P2 pump pressure shuts down.
sensor is
excessive (above
20mA).

Controller J2(White)
P2 right pump pressure transmitter
P2 right pump pressure
6-208
6.4 DTC CLG922E
6.4.61 DTC 211003 P2 pump pressure sensor voltage above the range value February 3, 2015

Pressure sensor parameters: Step 2 Check the harness for short-circuit to

battery
Output Current: 4-20mA
Working voltage: 8-30Vdc  Correctly tie up harness and wire:
Pressure range: 0-400bar Avoid folding or bending the harness forci-
bly.
Component location It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
P1 pump
pressure sensor
Try to keep far way from oil and water.
P2 pump
pressure sensor Try to keep far away from high temperature
parts (e.g. engine body).
• Inspection method
1. Check the harness (No. 932) between the
controller (J2-32) and the pump pressure sensor
for wear.
Front
2. Turn the start switch to the ON position and
disconnect the pump pressure sensor connector
Fault diagnosis and elimination pro- and the controller connector. Turn the multime-
cedures ter to its voltage function and measure the volt-
Step 1 Check the connector for fault. age between the harness (No. 932) sensor
terminal and the grounding (normally, 0V).
 When replacing the components, please
• Whether the harness is shorted to the
be sure to use LiuGong parts.
battery.
• Inspection method • Yes
Check the connector for moisture, oil dirt or Connect the harness again and wrap the har-
insulation fault. ness.
• Whether a fault developing in the con- Turn to Step 4
nector or not?
• No
• Yes Turn to Step 3
Repair or replace the connector.
Turn to Step 4
• No
Turn to Step 2
 6-209
CLG922E 6.4 DTC
February 3, 2015 6.4.61 DTC 211003 P2 pump pressure sensor voltage above the range value

Step 3 Check the pump pressure sensor for connect the controller connector, and then dis-
fault. connect the pump pressure sensor connector
and measure the current in the pump pressure
 When replacing the components, please
sensor signal circuit:
be sure to use LiuGong parts.
(a) Connect the measuring circuit as shown in
• Inspection method the schematic diagram.
Turn the start switch to the OFF position and

Connector matching P2
P2 Left pump pressure transnmitter

Controller J2(White)

P2 left pump pressure

Black probe Red probe

Multimeter

(b) Start the engine, and with the boom lifted, Step 4 Check whether this fault is eliminated
turn the multimeter to its current function, • Inspection method
and measure the current between the sen- Turn the start switch to the ON position and re-
sor connector male terminal and female check for fault.
terminal (Pin 1) (normally, 4-20mA).
• Has this fault been eliminated?
• Check the pump pressure sensor for
• Yes
fault.
Maintenance is over
• Yes
• No
Replace the pump pressure sensor.
Troubleshoot the faults according to the steps
Turn to Step 4
again or contact the local LiuGong dealer and
• No authorized service center.
Turn to Step 4
6-210
6.4 DTC CLG922E
6.4.62 DTC 211104 P2 pump pressure sensor voltage below the range value February 3, 2015

6.4.62 DTC 211104 P2 pump System description

The pressure sensor (pressure transmitter) con-
pressure sensor voltage below
verts the detected hydraulic oil pressure param-
the range value eter into the current signal input to the controller
which detects the hydraulic oil pressure value
Description of which is displayed on the display instrument.
DTC Consequence
Fault

P2 pump pressure
sensor voltage
below the range
value. When the
left/right control
lever is operated,
No special
211104 the current
response.
detected in the
signal circuit of the
P2 pump pressure
sensor is
extremely low
(below 4mA).

Controller J2(White)
P2 right pump pressure transmitter
P2 right pump pressure
 6-211
CLG922E 6.4 DTC
February 3, 2015 6.4.62 DTC 211104 P2 pump pressure sensor voltage below the range value

Pressure sensor parameters: Step 2 Check the harness for open-circuit or

short-circuit to ground.
Output Current: 4-20mA
Working voltage: 8-30Vdc  Correctly tie up harness and wire:
Pressure range: 0-400bar Avoid folding or bending the harness forci-
Component location bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
P1 pump
pressure sensor
Avoid friction with sharp metal edges.
P2 pump
pressure sensor Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).
• Inspection method
1. Check the harness (No. 932) between the
controller (J2-32) and the pump pressure sensor
Front
and the power line (No. 121) for wear.
Turn the start switch to the ON position, and dis-
Fault diagnosis and elimination pro- connect the connectors from the pump pressure
cedures sensor and the controller, respectively.
Step 1 Check the connector for fault. 2. Check the harness for open-circuit:

 When replacing the components, please (a) Turn the multimeter to its voltage function,
and measure the voltage between the
be sure to use LiuGong parts.
power line (No. 121) sensor terminal and
• Inspection method the grounding (normally, 25±0.5V (battery
1. Check the connector at the sensor grounding voltage)).
for poor contact. (b) Turn the multimeter to its resistance func-
2. Check whether the connector becomes loose. tion, and measure the resistance of the har-
3. Check the connector pins for rust, bending or ness (No. 932) between the controller and
damage. the sensor (normally, <10Ω).
• Whether a fault developing in the con- 3. Check whether the harness is shorted to the
nector or not? ground:
• Yes Measure the resistance between the harness
Repair or replace the connector. (No. 932) sensor terminal and the grounding
Turn to Step 4 (normally, >100K).

• No • Whether the harness open-circuited or

shorted to the ground or not?
Turn to Step 2
• Yes
6-212
6.4 DTC CLG922E
6.4.62 DTC 211104 P2 pump pressure sensor voltage below the range value February 3, 2015

Connect the harness again and wrap the har-  When replacing the components, please
ness.
be sure to use LiuGong parts.
Turn to Step 4
• Inspection method
• No
Turn the start switch to the OFF position and
Turn to Step 3
disconnect the pump pressure sensor connec-
tor, and then connect the controller connector:
Step 3 Check the pump pressure sensor for
(a) Connect the current detection circuit as
fault.
shown in the schematic diagram:

Connector matching P2
P2 Left pump pressure transnmitter

Controller J2(White)

P2 left pump pressure

Black probe Red probe

Multimeter

(b) Turn the multimeter to its current function Step 4 Check whether this fault is eliminated
(200mA) and start the engine, and then • Inspection method
with the boom lifted, measure the current Turn the start switch to the ON position and re-
between the sensor connector male termi- check for fault.
nal and female terminal (Pin 1) (normally,
• Has this fault been eliminated?
4-20mA).
• Yes
• Check the pump pressure sensor for
Maintenance is over
fault.
• No
• Yes
Troubleshoot the faults according to the steps
Replace the pump pressure sensor.
again or contact the local LiuGong dealer and
Turn to Step 4
authorized service center.
• No
Turn to Step 4
 6-213
CLG922E 6.4 DTC
February 3, 2015 6.4.63 DTC 211203 N1 negative flow pressure sensor voltage above the range value

6.4.63 DTC 211203 N1 negative System description

The pressure sensor (pressure transmitter) con-
flow pressure sensor voltage
verts the detected hydraulic oil pressure param-
above the range value eter into the current signal input to the controller
which detects the hydraulic oil pressure value
Description of which is displayed on the display instrument.
DTC Consequence
Fault
N1 negative flow
pressure sensor
voltage above the
range value. The
The complete
current in the
211203 excavator
signal circuit of the
moves slowly.
N1 negative flow
pressure sensor is
excessively high
(above 20mA).

Controller J2(White)
N1 Negative flow N1 Negative flow pressure
pressure Left pump transmitter
6-214
6.4 DTC CLG922E
6.4.63 DTC 211203 N1 negative flow pressure sensor voltage above the range value February 3, 2015

Pressure sensor parameters: Step 2 Check the harness for short-circuit to

battery
Output Current: 4-20mA
Pressure range: 0-60bar  Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

Component location bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
Front
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).
• Inspection method
1. Check the harness (No. 919) between the
N1 Negative flow controller (J2-19) and the N1 negative flow pres-
pressure sensor
(position) sure sensor for wear.
2. Turn the start switch to the ON position and
Fault diagnosis and elimination pro- disconnect the N1 negative flow pressure sen-
cedures sor connector and the controller connector, and
Step 1 Check the connector for fault. then measure the voltage between the harness
(No. 919) sensor terminal and the grounding
 When replacing the components, please
(normally, 0V) using the multimeter.
be sure to use LiuGong parts.
• Whether the harness is shorted to the
• Inspection method battery.
Check the connector for moisture, oil dirt or
• Yes
insulation fault.
Connect the harness again and wrap the har-
• Whether a fault developing in the con- ness.
nector or not?
Turn to Step 4
• Yes
• No
Repair or replace the connector.
Turn to Step 3
Turn to Step 4
• No
Turn to Step 2
 6-215
CLG922E 6.4 DTC
February 3, 2015 6.4.63 DTC 211203 N1 negative flow pressure sensor voltage above the range value

Step 3 Check the N1 negative flow pressure sen- connect the controller connector, and then dis-
sor for fault. connect the N1 negative flow pressure sensor
connector and measure the current in the sen-
 When replacing the components, please
sor signal circuit:
be sure to use LiuGong parts.
(a) Connect the measuring circuit as shown in
• Inspection method the schematic diagram.
Turn the start switch to the OFF position and

Connector matching P4
N1 Negative flow pressure transmitter

Controller J2(White)

N1 Negative flow pressure

Black probe Red probe

Multimeter

(b) Start the engine, and with the boom lifted, Step 4 Check whether this fault is eliminated
turn the multimeter to its current function, • Inspection method
and measure the current between the sen- Turn the start switch to the ON position and re-
sor connector male terminal and female check for fault.
terminal (Pin 1) (normally, 4-20mA).
• Has this fault been eliminated?
• Check the N1 negative flow pressure
• Yes
sensor for fault.
Maintenance is over
• Yes
• No
Replace the N1 negative flow pressure sensor.
Troubleshoot the faults according to the steps
Turn to Step 4
again or contact the local LiuGong dealer and
• No authorized service center.
Turn to Step 4
6-216
6.4 DTC CLG922E
6.4.64 DTC 211204 N1 negative flow pressure sensor voltage below the range value February 3, 2015

6.4.64 DTC 211204 N1 negative System description

The pressure sensor (pressure transmitter) con-
flow pressure sensor voltage
verts the detected hydraulic oil pressure param-
below the range value eter into the current signal input to the controller
which detects the hydraulic oil pressure value
Description of which is displayed on the display instrument.
DTC Consequence
Fault
N1 negative flow
pressure sensor
voltage below the
Abnormal
range value. (The
hydraulic oil
current in the
211204 temperature
signal circuit of the
rise under no
N1 negative flow
load.
pressure sensor is
extremely low
(below 4mA)).

Controller J2(White)
N1 Negative flow N1 Negative flow pressure
pressure Left pump transmitter
 6-217
CLG922E 6.4 DTC
February 3, 2015 6.4.64 DTC 211204 N1 negative flow pressure sensor voltage below the range value

Pressure sensor parameters: Step 2 Check the harness for open-circuit or

short-circuit to ground.
Output Current: 4-20mA
Pressure range: 0-60bar  Correctly tie up harness and wire:

Avoid folding or bending the harness forcibly.

Component location It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Front
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).
• Inspection method
1. Check the harness (No. 919) between the con-
troller (J2-19) and the N1 negative flow pressure
N1 Negative flow sensor and the power line (No. 121) for wear.
pressure sensor
(position) Turn the start switch to the ON position, and dis-
connect the connectors from the N1 negative
Fault diagnosis and elimination pro- flow pressure sensor and the controller.
cedures 2. Check the harness for open-circuit:
Step 1 Check the connector for fault. (a) Turn the multimeter to its voltage function,
 When replacing the components, please and measure the voltage between the
power line (No. 121) sensor terminal and
be sure to use LiuGong parts.
the grounding (normally, 25±0.5V (battery
• Inspection method
voltage).
1. Check the connector at the sensor grounding
(b) Turn the multimeter to its resistance func-
for poor contact.
tion, and measure the resistance of the har-
2. Check whether the connector becomes loose. ness (No. 919) between the controller and
3. Check the connector pins for rust, bending or the sensor (normally, <10Ω).
damage. 3. Check whether the harness is shorted to the
• Whether a fault developing in the con- ground:
nector or not? Measure the resistance between the harness
• Yes (No. 919) sensor terminal and the grounding
Repair or replace the connector. (normally, >100K).
Turn to Step 4 • Whether the harness open-circuited or
• No shorted to the ground or not?

Turn to Step 2 • Yes

6-218
6.4 DTC CLG922E
6.4.64 DTC 211204 N1 negative flow pressure sensor voltage below the range value February 3, 2015

Connect the harness again and wrap the har- be sure to use LiuGong parts.
ness. • Inspection method
Turn to Step 4 Turn the start switch to the OFF position and
• No disconnect the N1 negative flow pressure sen-
Turn to Step 3 sor connector, and then connect the controller
Step 3 Check the N1 negative flow pressure connector:
sensor for fault. (a) Connect the current detection circuit as
shown in the schematic diagram:
 When replacing the components, please

Connector matching P4
N1 Negative flow pressure transmitter

Controller J2(White)

N1 Negative flow pressure

Black probe Red probe

Multimeter

(b) Turn the multimeter to its current function Step 4 Check whether this fault is eliminated
(200mA) and start the engine, and then • Inspection method
with the boom lifted, measure the current Turn the start switch to the ON position and re-
between the sensor connector male termi- check for fault.
nal and female terminal (Pin 1) (normally,
• Has this fault been eliminated?
4-20mA).
• Yes
• Check the N1 negative flow pressure
Maintenance is over
sensor for fault.
• No
• Yes
Troubleshoot the faults according to the steps
Replace the N1 negative flow pressure sensor.
again or contact the local LiuGong dealer and
Turn to Step 4
authorized service center.
• No
Turn to Step 4
 6-219
CLG922E 6.4 DTC
February 3, 2015 6.4.65 DTC 211303 N2 negative flow pressure sensor voltage above the range value

6.4.65 DTC 211303 N2 negative System description

The pressure sensor (pressure transmitter) con-
flow pressure sensor voltage
verts the detected hydraulic oil pressure param-
above the range value eter into the current signal input to the controller
which detects the hydraulic oil pressure value
Description of which is displayed on the display instrument.
DTC Consequence
Fault
N2 negative flow
pressure sensor
voltage above the
range value. (The
The complete
current in the
211303 excavator
signal circuit of the
moves slowly.
N2 negative flow
pressure sensor is
extremely high
(above 20mA)).

Controller J2(White)
N2 Negative flow N2 Negative flow pressure
pressure right pump
transmitter
6-220
6.4 DTC CLG922E
6.4.65 DTC 211303 N2 negative flow pressure sensor voltage above the range value February 3, 2015

Pressure sensor parameters: Step 2 Check the harness for short-circuit to

battery
Output current: 4-20mA
Pressure range: 0-60bar  Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

Component location bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
Front
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).
• Inspection method
1. Check the harness (No. 933) between the
N Negative flow controller (J2-33) and the N2 negative flow pres-
pressure sensor
(position) sure sensor for wear.
2. Turn the start switch to the ON position and
Fault diagnosis and elimination pro- disconnect the N2 negative flow pressure sen-
cedures sor connector and the controller connector. Turn
Step 1 Check the connector for fault. the multimeter to its voltage function and then
measure the voltage between the harness (No.
 When replacing the components, please
933) sensor terminal and the grounding (nor-
be sure to use LiuGong parts.
mally, 0V).
• Inspection method • Whether the harness is shorted to the
Check the connector for moisture, oil dirt or battery.
insulation fault.
• Yes
• Whether a fault developing in the con- Connect the harness again and wrap the har-
nector or not? ness.
• Yes Turn to Step 4
Repair or replace the connector. • No
Turn to Step 4 Turn to Step 3
• No
Turn to Step 2
 6-221
CLG922E 6.4 DTC
February 3, 2015 6.4.65 DTC 211303 N2 negative flow pressure sensor voltage above the range value

Step 3 Check the N2 negative flow pressure sen- connect the controller connector, and then dis-
sor for fault. connect the N2 negative flow pressure sensor
connector and measure the current in the sen-
 When replacing the components, please
sor signal circuit:
be sure to use LiuGong parts.
(a) Connect the measuring circuit as shown in
• Inspection method the schematic diagram.
Turn the start switch to the OFF position and

Connector matching P3
N2 Negative flow pressure transmitter

Controller J2(White)

N2 Negative flow pressure

Black probe Red probe

Multimeter

(b) Start the engine, and with the boom lifted, Step 4 Check whether this fault is eliminated
turn the multimeter to its current function, • Inspection method
and measure the current between the sen- Turn the start switch to the ON position and re-
sor connector male terminal and female check for fault.
terminal (Pin 1) (normally, 4-20mA).
• Has this fault been eliminated?
• Check the N2 negative flow pressure
• Yes
sensor for fault.
Maintenance is over
• Yes
• No
Replace the N2 negative flow pressure sensor.
Troubleshoot the faults according to the steps
Turn to Step 4
again or contact the local LiuGong dealer and
• No authorized service center.
Turn to Step 4
6-222
6.4 DTC CLG922E
6.4.66 DTC 211304 N2 negative flow pressure sensor voltage below the range value February 3, 2015

6.4.66 DTC 211304 N2 negative System description

The pressure sensor (pressure transmitter) con-
flow pressure sensor voltage
verts the detected hydraulic oil pressure param-
below the range value eter into the current signal input to the controller
which detects the hydraulic oil pressure value
Description of which is displayed on the display instrument.
DTC Consequence
Fault
N2 negative flow
pressure sensor
voltage below the
Abnormal
range value. (The
hydraulic oil
current in the
211304 temperature
signal circuit of the
rise under no
N2 negative flow
load.
pressure sensor is
extremely low
(below 4mA)).

Controller J2(White)
N2 Negative flow N2 Negative flow pressure
pressure right pump
transmitter
 6-223
CLG922E 6.4 DTC
February 3, 2015 6.4.66 DTC 211304 N2 negative flow pressure sensor voltage below the range value

Pressure sensor parameters: Step 2 Check the harness for open-circuit or

short-circuit to ground.
Output Current: 4-20mA
Pressure range: 0-60bar  Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

Component location bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
Front
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).
• Inspection method
1. Check the harness (No. 933) between the
N Negative flow controller (J2-33) and the N2 negative flow pres-
pressure sensor
(position) sure sensor and the power line (No. 121) for
wear.
Fault diagnosis and elimination pro- Turn the start switch to the ON position, and dis-
cedures connect the connectors from the N2 negative
Step 1 Check the connector for fault. flow pressure sensor and the controller.
2. Check the harness for open-circuit:
 When replacing the components, please
(a) Turn the multimeter to its voltage function,
be sure to use LiuGong parts.
and measure the voltage between the
• Inspection method
power line (No. 121) sensor terminal and
1. Check the connector at the sensor grounding the grounding (normally, 25-27V (battery
for poor contact. voltage)).
2. Check whether the connector becomes loose. (b) Turn the multimeter to its resistance func-
3. Check the connector pins for rust, bending or tion, and measure the resistance of the har-
damage. ness (No. 933) between the controller and
• Whether a fault developing in the con- the sensor (normally, <10Ω).
nector or not? 3. Check whether the harness is shorted to the
• Yes ground:
Repair or replace the connector. Measure the resistance between the harness
Turn to Step 4 (No. 933) sensor terminal and the grounding
(normally, >100K).
• No
• Whether the harness open-circuited or
Turn to Step 2
shorted to the ground or not?
6-224
6.4 DTC CLG922E
6.4.66 DTC 211304 N2 negative flow pressure sensor voltage below the range value February 3, 2015

• Yes  When replacing the components, please

Connect the harness again and wrap the har- be sure to use LiuGong parts.
ness.
• Inspection method
Turn to Step 4
Turn the start switch to the OFF position and
• No
disconnect the N2 negative flow pressure sen-
Turn to Step 3 sor connector, and then connect the controller
connector:
Step 3 Check the N2 negative flow pressure sen- (a) Connect the current detection circuit as
sor for fault. shown in the schematic diagram:

Connector matching P3
N2 Negative flow pressure transmitter

Controller J2(White)

N2 Negative flow pressure

Black probe Red probe

Multimeter

(b) Turn the multimeter to its current function Step 4 Check whether this fault is eliminated
(200mA) and start the engine, and then • Inspection method
with the boom lifted, measure the current Turn the start switch to the ON position and re-
between the sensor connector male termi- check for fault.
nal and female terminal (Pin 1) (normally,
• Has this fault been eliminated?
4-20mA).
• Yes
• Check the N2 negative flow pressure
Maintenance is over
sensor for fault.
• No
• Yes
Troubleshoot the faults according to the steps
Replace the N2 negative flow pressure sensor.
again or contact the local LiuGong dealer and
Turn to Step 4
authorized service center.
• No
Turn to Step 4
 6-225
CLG922E 6.4 DTC
February 3, 2015 6.4.67 DTC 211316 High N2 negative flow pressure

6.4.67 DTC 211316 High N2 neg- System description

The pressure sensor (pressure transmitter) con-
ative flow pressure
verts the detected hydraulic oil pressure param-
eter into the current signal input to the controller
Description of
DTC Consequence which detects the hydraulic oil pressure value
Fault
High N2 negative which is displayed on the display instrument.
flow pressure -
When the
excavator is
operated, the The complete
211216 pressure detected excavator
in the signal circuit moves slowly.
of the N2 negative
flow pressure
sensor is high
(above 4.2MPa).

Controller J2(White)
N2 Negative flow N2 Negative flow pressure
pressure right pump
transmitter
6-226
6.4 DTC CLG922E
6.4.67 DTC 211316 High N2 negative flow pressure February 3, 2015

Pressure sensor parameters: Step 2 Check the N2 negative flow pressure

monitoring system for fault.
Output Current: 4-20mA
Pressure range: 0-60bar  When replacing the components, please
be sure to use LiuGong parts.
Component location • Inspection method
When the pressure is normal, check the N2 neg-
ative flow pressure detection circuit or pressure
Front
sensor for fault, referring to the troubleshooting
in the 211303-N2 Negative Flow Pressure Sen-
sor Voltage Above the Range Value.
• Check the N2 negative flow pressure
monitoring system for fault.
• Yes
Check and repair N2 negative flow pressure
N Negative flow
detection circuit or replace the pressure sensor.
pressure sensor
(position) Turn to Step 3
• No
Fault diagnosis and elimination pro-
Turn to Step 3
cedures
Step 1 Check whether the N2 negative flow pres- Step 3 Check whether this fault is eliminated
sure is high.
• Inspection method
 Be careful! Hot engine block and Turn the start switch to the ON position and re-
hydraulic oil can scald you seriously check for fault.
• Inspection method • Has this fault been eliminated?
Using the manometer, check whether the N2 • Yes
negative flow pressure is high. Maintenance is over
• Check whether the N2 negative flow • No
pressure is high.
Troubleshoot the faults according to the steps
• Yes again or contact the local LiuGong dealer and
Pinpoint the cause for the high pump pressure. authorized service center.
Turn to Step 3
• No
Turn to Step 2
 6-227
CLG922E 6.4 DTC
February 3, 2015 6.4.68 DTC 211403 Pump pressure-reducing valve sensor voltage above the range value

6.4.68 DTC 211403 Pump pres- System description

The pressure sensor (pressure transmitter) con-
sure-reducing valve sensor
verts the detected hydraulic oil pressure param-
voltage above the range value eter into the current signal input to the controller
which detects the hydraulic oil pressure value
Description of which is displayed on the display instrument.
DTC Consequence
Fault
Pump pressure-
reducing valve
sensor voltage
above the range
value. (The
The complete
detected current in
211403 excavator
the signal circuit of
moves slowly.
the pump
proportional valve
pressure sensor is
too high (above
20mA)).

Controller J2(White)
Pump valve pressure
Pump valve pressure transmitter
transmitter
6-228
6.4 DTC CLG922E
6.4.68 DTC 211403 Pump pressure-reducing valve sensor voltage above the range value February 3, 2015

Pressure sensor parameters: Step 2 Check the harness for short-circuit to

battery
Output Current: 4-20mA
Pressure range: 0-60bar  Correctly tie up harness and wire:

Avoid folding or bending the harness forcibly.

Component location It shall be kept away from moving components
as far as possible to prevent tensile fault and
wear.
Front Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).
• Inspection method
1. Check the harness (No. 920) between the
controller (J2-20) and the pump pressure-reduc-
Pressure sensor for ing valve sensor for wear.
pump proportional
pressure-reducing valve 2. Turn the start switch to the ON position and
disconnect the pump pressure-reducing valve
Fault diagnosis and elimination pro- sensor connector and the controller connector.
cedures Turn the multimeter to its voltage function and
Step 1 Check the connector for fault. measure the voltage between the harness (No.
920) sensor terminal and the grounding (nor-
 When replacing the components, please
mally, 0V).
be sure to use LiuGong parts.
• Whether the harness is shorted to the
• Inspection method battery.
Check the connector for moisture, oil dirt or • Yes
insulation fault.
Connect the harness again and wrap the har-
• Whether a fault developing in the con- ness.
nector or not? Turn to Step 4
• Yes • No
Repair or replace the connector. Turn to Step 3
Turn to Step 4
• No
Turn to Step 2
 6-229
CLG922E 6.4 DTC
February 3, 2015 6.4.68 DTC 211403 Pump pressure-reducing valve sensor voltage above the range value

Step 3 Check the pump pressure-reducing valve disconnect the connector from the pump pres-
sensor for fault. sure-reducing valve sensor, and then measure
the current of the signal circuit of the pump pres-
 When replacing the components, please
sure-reducing valve sensor:
be sure to use LiuGong parts.
(a) Connect the measuring circuit as shown in
• Inspection method the schematic diagram.
Turn the start switch to the OFF position and

Connector matching P5
Pump valve pressure transmitter

Controller J2(White)
Pressure of pump proportional
pressure-reducing valve

Black probe Red probe

Multimeter

(b) Start the engine, and with the boom lifted, Step 4 Check whether this fault is eliminated
turn the multimeter to its current function, • Inspection method
and measure the current between the sen- Turn the start switch to the ON position and re-
sor connector male terminal and female check for fault.
terminal (Pin 1) (normally, 4-20mA).
• Has this fault been eliminated?
• Whether a fault developing in the pump
• Yes
pressure-reducing valve sensor?
Maintenance is over
• Yes
• No
Replace the pump pressure-reducing valve sen-
Troubleshoot the faults according to the steps
sor.
again or contact the local LiuGong dealer and
Turn to Step 4
authorized service center.
• No
Turn to Step 4
6-230
6.4 DTC CLG922E
6.4.69 DTC 211404 Pump pressure-reducing valve sensor voltage below the range value February 3, 2015

6.4.69 DTC 211404 Pump pres- System description

The pressure sensor (pressure transmitter) con-
sure-reducing valve sensor
verts the detected hydraulic oil pressure param-
voltage below the range value eter into the current signal input to the controller
which detects the hydraulic oil pressure value
Description of which is displayed on the display instrument.
DTC Consequence
Fault
Pump pressure-
reducing valve
sensor voltage
below the range
value. (The The engine
detected current in gets stuck or
211404
the signal circuit of even shuts
the pump down.
proportional valve
pressure sensor is
too low (below
4mA)).

Controller J2(White)
Pump valve pressure
Pump valve pressure transmitter
transmitter
 6-231
CLG922E 6.4 DTC
February 3, 2015 6.4.69 DTC 211404 Pump pressure-reducing valve sensor voltage below the range value

Pressure sensor parameters: Step 2 Check the harness for open-circuit or

short-circuit to ground.
Output Current: 4-20mA
Pressure range: 0-60bar  Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

Component location bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
Front fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).
• Inspection method
1. Check the harness (No. 920) and the power
Pressure sensor for line (No. 121) between the controller (J2-20) and
pump proportional
pressure-reducing valve the pump pressure-reducing valve sensor for
wear.
Fault diagnosis and elimination pro- Turn the start switch to the ON position, and dis-
cedures connect the connectors from the pump pres-
Step 1 Check the connector for fault. sure-reducing valve sensor and the controller,
respectively.
 When replacing the components, please
2. Check the harness for open-circuit:
be sure to use LiuGong parts.
(a) Turn the multimeter to its voltage function,
• Inspection method
and measure the voltage between the
1. Check the connector at the sensor grounding power line (No. 121) sensor terminal and
for poor contact. the grounding (normally, 25-27 V (battery
2. Check whether the connector becomes loose. voltage)).
3. Check the connector pins for rust, bending or (b) Turn the multimeter to its resistance func-
damage. tion, and measure the resistance of the har-
• Whether a fault developing in the con- ness (No. 920) between the controller and
nector or not? the sensor (normally, <10Ω).
• Yes 3. Check whether the harness is shorted to the
Repair or replace the connector. ground:
Turn to Step 4 Measure the resistance between the harness
(No. 920) sensor terminal and the grounding
• No
(normally, >100K).
Turn to Step 2
6-232
6.4 DTC CLG922E
6.4.69 DTC 211404 Pump pressure-reducing valve sensor voltage below the range value February 3, 2015

• Whether the harness open-circuited or  When replacing the components, please

shorted to the ground or not?
be sure to use LiuGong parts.
• Yes
• Inspection method
Connect the harness again and wrap the har-
Turn the start switch to the OFF position and
ness.
disconnect the connector from the pump pres-
Turn to Step 4
sure-reducing valve sensor, and then connect
• No the controller connector:
Turn to Step 3 1. Connect the current detection circuit as
Step 3 Check the pump pressure-reducing valve shown in the schematic diagram:
sensor for fault.

Connector matching P5
Pump valve pressure transmitter

Controller J2(White)
Pressure of pump proportional
pressure-reducing valve

Black probe Red probe

Multimeter

2. Turn the multimeter to its current function Turn to Step 4

(200mA) and start the engine, and then with the Step 4 Check whether this fault is eliminated
boom lifted, measure the current between the • Inspection method
sensor connector male terminal and female ter-
Turn the start switch to the ON position and re-
minal (Pin 1) (normally, 4-20mA).
check for fault.
• Whether a fault developing in the pump
• Has this fault been eliminated?
pressure-reducing valve sensor?
• Yes
• Yes
Maintenance is over
Replace the pump pressure-reducing valve sen-
• No
sor.
Turn to Step 4 Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
• No
authorized service center.
 6-233
CLG922E 6.4 DTC
February 3, 2015 6.4.70 DTC 221001 Actuator feedback voltage below the range value

6.4.70 DTC 221001 Actuator System description

The throttle control system consists of the
feedback voltage below the
potentiometer (accelerator knob), controller and
range value actuator. The schematic diagram is shown
below. No. 907 and No. 904 are drive control
Description of lines. The controller is driven by two pins. If
DTC Consequence
Fault either pin is open-circuited, this can cause the
Actuator feedback accelerator system fault. The potentiometer is
voltage below the
range value. (The used to control the engine speed. As shown in
detected voltage in The accelerator the figure, Pin 1 of the R1 connector is con-
221001
the actuator actuator fails. nected to the 5V power, Pin 2 is connected to
feedback signal
circuit is low the controller-sensor ground and Pin 3 is con-
(below 4.5V)). nected to the accelerator signal feedback termi-
nal. The actuator controls the engine accelerator
opening through the flexible shaft, thereby con-
trolling the engine speed. The terminals are
shown in the figure. Pin 3 of the M1 connector is
the controller power (5V), Pin 5 is grounded, Pin
2 is used for the accelerator feedback signal,
Pin 1 is used to control the accelerator motor’s
positive rotation and Pin 4 is used to control the
accelerator motor’s negative rotation.

Accelerator knob
(Black)
(Black)
Accelerator motor 2 (ls ac2)

5V power supply
12-position accelerator
potentiometer
Accelerator actuator
Accelerator motor 1 (ls ac1)

(White)
Accelerator motor 2 (hs ac2)

Accelerator motor 1 (hs ac1)

Accelerator motor position
feedback

Sensor to ground
6-234
6.4 DTC CLG922E
6.4.70 DTC 221001 Actuator feedback voltage below the range value February 3, 2015

Component location Repair or replace the accelerator actuator.

Turn to Step 4
• No
Front
Turn to Step 2

Step 2 Check the harness for open-circuit and

short-circuit.

 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

Accelerator actuator
bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
Fault diagnosis and elimination pro- fault and wear.

cedures Avoid friction with sharp metal edges.

Try to keep far way from oil and water.
Step 1 Check the accelerator actuator for fault
Try to keep far away from high temperature
 When replacing the components, please parts (e.g. engine body).
be sure to use LiuGong parts.
• Inspection method
• Inspection method 1. Check the harness (No. 828/No. 918)
Disconnect the connectors from the accelerator between the controller (J1-28/J1-18) and the
actuator: accelerator actuator for wear.
1. Check the connector pins for looseness, rust, Disconnect the connectors from the accelerator
bending and damage. Check the connector actuator and the controller, respectively.
inside for moisture, oil dirt and other. 2. Check the harness for open-circuit:
2. Turn the multimeter to its resistance function Turn the multimeter to its resistance function,
(20kΩ) and measure the resistance between the and measure the resistance of the harness (No.
actuator connector pins 3 and 5 (normally, 4- 828/No. 918) between the controller and the
5kΩ), and then, using the multimeter, measure accelerator actuator, respectively, (normally,
the resistance between the pins 2 and 3 and that <10Ω).
between the pins 2 and 5. The sum of the resis- 3.Check whether the harness is shorted to the
tance between the pins 2 and 3 and that ground;
between the pins 2 and 5 equals the resistance
Turn the multimeter to its resistance function,
between the pins 3 and 5.
and measure the resistance between the (No.
• Whether a fault developing in the accel- 828/No. 918) harness’s actuator coupling end
erator actuator? and the grounding (normally, >100K).
• Yes • Is the harness open or short circuit?
 6-235
CLG922E 6.4 DTC
February 3, 2015 6.4.70 DTC 221001 Actuator feedback voltage below the range value

• Yes Step 4
Connect the harness again and wrap the har- • Inspection method
ness. Turn the start switch to the ON position and re-
Turn to Step 4 check for fault.
• No • Has this fault been eliminated?
Turn to Step 3 • Yes
Maintenance is over
Step 3 Check the connector for fault. • No
 When replacing the components, please Troubleshoot the faults according to the steps
be sure to use LiuGong parts. again or contact the local LiuGong dealer and
authorized service center.
• Inspection method
Connect the actuator connector and disconnect
the controller connector. Turn the multimeter to
its resistance function and measure the resis-
tance between the controller port J1-28 and J2-
18 (normally, 4-5kΩ), and then measure the
resistance between the ports J1-28 and J2-22
and that between the ports J2-28 and J2-22.
(The sum of the resistance between the pins 2
and 3 and that between the pins 2 and 5 equals
the resistance between the pins 3 and 5).
An abnormal resistance indicates that there is
fault in the connector.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
No
Turn to Step 4
6-236
6.4 DTC CLG922E
6.4.71 DTC 221003 Actuator feedback voltage above the range value February 3, 2015

6.4.71 DTC 221003 Actuator System description

The throttle control system consists of the
feedback voltage above the
potentiometer (accelerator knob), controller and
range value actuator. The schematic diagram is shown
below. No. 907 and No. 904 are drive control
Description of lines. The controller is driven by two pins. If
DTC Consequence
Fault either pin is open-circuited, this can cause the
Actuator feedback accelerator system fault. The potentiometer is
voltage above the
range value, (The used to control the engine speed. As shown in
detected voltage in The accelerator the figure, Pin 1 of the R1 connector is con-
221003
the actuator actuator fails. nected to the 5V power, Pin 2 is connected to
feedback signal
circuit is too high the controller-sensor ground and Pin 3 is con-
(above 4.5V)). nected to the accelerator signal feedback termi-
nal. The actuator controls the engine accelerator
opening through the flexible shaft, thereby con-
trolling the engine speed. The terminals are
shown in the figure. Pin 3 of the M1 connector is
the controller power (5V), Pin 5 is grounded, Pin
2 is used for the accelerator feedback signal,
Pin 1 is used to control the accelerator motor’s
positive rotation and Pin 4 is used to control the
accelerator motor’s negative rotation.

Accelerator knob
(Black)
(Black)
Accelerator motor 2 (ls ac2)

5V power supply
12-position accelerator
potentiometer
Accelerator actuator
Accelerator motor 1 (ls ac1)

(White)
Accelerator motor 2 (hs ac2)

Accelerator motor 1 (hs ac1)

Accelerator motor position
feedback

Sensor to ground
 6-237
CLG922E 6.4 DTC
February 3, 2015 6.4.71 DTC 221003 Actuator feedback voltage above the range value

Component location Repair or replace the accelerator actuator.

Turn to Step 4
• No
Front
Turn to Step 2

Step 2 Check the harness for short-circuit and

open-circuit.

 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

Accelerator actuator
bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
Fault diagnosis and elimination pro- fault and wear.

cedures Avoid friction with sharp metal edges.

Try to keep far way from oil and water.
Step 1 Check the accelerator actuator for fault
Try to keep far away from high temperature
 When replacing the components, please parts (e.g. engine body).
be sure to use LiuGong parts.
• Inspection method
• Inspection method 1. Check the harness between the controller and
Disconnect the connectors from the acceler- the accelerator actuator for wear.
ator actuator: Disconnect the connectors from the accelerator
1. Check the connector pins for looseness, rust, actuator and the controller, respectively.
bending and damage. Check the connector 2. Check whether the harness is shorted to the
inside for moisture, oil dirt and other. battery:
2. Turn the multimeter to its resistance function Turn the start switch to the ON position and turn
(20kΩ) and measure the resistance between the on all switches of the electrical equipment, and
actuator connector pins 3 and 5 (normally, about then measure the voltage between the harness
4.29kΩ), and then, using the multimeter, mea- (No. 828/No. 928) solenoid valve terminal and
sure the resistance between the pins 2 and 3 the grounding (normally, 0V), respectively.
and that between the pins 2 and 5. (The sum of 3. Check the harness for open-circuit:
the resistance between the pins 2 and 3 and that Turn the multimeter to its resistance function,
between the pins 2 and 5 equals the resistance and measure the resistance of the harness (No.
between the pins 3 and 5). 922) between the controller port (J2-22) and the
• Whether a fault developing in the accel- solenoid valve (normally, <10Ω).
erator actuator? • Is the harness short or open circuit?
• Yes • Yes
6-238
6.4 DTC CLG922E
6.4.71 DTC 221003 Actuator feedback voltage above the range value February 3, 2015

Connect the harness again and wrap the har- Step 4

ness. • Inspection method
Turn to Step 4 Turn the start switch to the ON position and re-
• No check for fault.
Turn to Step 3 • Has this fault been eliminated?
• Yes
Step 3 Check the connector for fault. Maintenance is over
 When replacing the components, please • No
be sure to use LiuGong parts. Troubleshoot the faults according to the steps
• Inspection method again or contact the local LiuGong dealer and
authorized service center.
Connect the actuator connector and disconnect
the controller connector. Turn the multimeter to
its resistance function and measure the resis-
tance between the controller port J1-28 and J2-
18 (normally, 4-5kΩ), and then measure the
resistance between the ports J1-28 and J2-22
and that between the ports J2-28 and J2-22.
(The sum of the resistance between the pins 2
and 3 and that between the pins 2 and 5 equals
the resistance between the pins 3 and 5).
An abnormal resistance indicates that there is
fault in the connector.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4
 6-239
CLG922E 6.4 DTC
February 3, 2015 6.4.72 DTC 221007 Actuator getting stuck

6.4.72 DTC 221007 Actuator System description

The throttle control system consists of the
getting stuck
potentiometer (accelerator knob), controller and
actuator. The schematic diagram is shown
Description of
DTC Consequence below. No. 907 and No. 904 are drive control
Fault
Actuator getting The accelerator lines. The controller is driven by two pins. If
221007
stuck. actuator fails. either pin is open-circuited, this can cause the
accelerator system fault. The potentiometer is
used to control the engine speed. As shown in
the figure, Pin 1 of the R1 connector is con-
nected to the 5V power, Pin 2 is connected to
the controller-sensor ground and Pin 3 is con-
nected to the accelerator signal feedback termi-
nal. The actuator controls the engine accelerator
opening through the flexible shaft, thereby con-
trolling the engine speed. The terminals are
shown in the figure. Pin 3 of the M1 connector is
the controller power (5V), Pin 5 is grounded, Pin
2 is used for the accelerator feedback signal,
Pin 1 is used to control the accelerator motor’s
positive rotation and Pin 4 is used to control the
accelerator motor’s negative rotation.

Accelerator knob
(Black)
(Black)
Accelerator motor 2 (ls ac2)

5V power supply
12-position accelerator
potentiometer
Accelerator actuator
Accelerator motor 1 (ls ac1)

(White)
Accelerator motor 2 (hs ac2)

Accelerator motor 1 (hs ac1)

Accelerator motor position
feedback

Sensor to ground
6-240
6.4 DTC CLG922E
6.4.72 DTC 221007 Actuator getting stuck February 3, 2015

Component location Step 2 Check whether the accelerator actuator

gets stuck.

Front
 When replacing the components, please
be sure to use LiuGong parts.
• Inspection method
Turn the start switch to the OFF position, and
visually check whether the engine accelerator
flexible shaft (including its mounting plate)
becomes loose.
Accelerator actuator Start the excavator and turn the accelerator
knob, and then check whether the accelerator
flexible shaft is operating properly.
• Whether the accelerator actuator gets
Fault diagnosis and elimination pro-
stuck?
cedures
• Yes
Step 1 Check the harness connector for fault.
Repair or replace the accelerator actuator.
 When replacing the components, please Turn to Step 3
be sure to use LiuGong parts. • No
• Inspection method Turn to Step 3
Check the harness connector for looseness.
Check the harness connector pins for rust, Step 3 Check whether this fault is eliminated
bending and damage. • Inspection method
There is moisture, oil dirt or insulation fault in the Turn the start switch to the ON position and re-
connector. check for fault.
• Whether a fault developing in the con- • Has this fault been eliminated?
nector or not?
• Yes
• Yes
Maintenance is over
Re-connect or replace the connector.
• No
Turn to Step 3
Troubleshoot the faults according to the steps
• No again or contact the local LiuGong dealer and
Turn to Step 2 authorized service center.
 6-241
CLG922E 6.4 DTC
February 3, 2015 6.4.73 DTC 221013 Actuator outside the calibrated range

6.4.73 DTC 221013 Actuator System description

The throttle control system consists of the
outside the calibrated range
potentiometer (accelerator knob), controller and
actuator. The schematic diagram is shown
Description of
DTC Consequence below. No. 907 and No. 904 are drive control
Fault
Actuator outside lines. The controller is driven by two pins. If
The accelerator
221013 the calibrated either pin is open-circuited, this can cause the
actuator fails.
range accelerator system fault. The potentiometer is
used to control the engine speed. As shown in
the figure, Pin 1 of the R1 connector is con-
nected to the 5V power, Pin 2 is connected to
the controller-sensor ground and Pin 3 is con-
nected to the accelerator signal feedback termi-
nal. The actuator controls the engine accelerator
opening through the flexible shaft, thereby con-
trolling the engine speed. The terminals are
shown in the figure. Pin 3 of the M1 connector is
the controller power (5V), Pin 5 is grounded, Pin
2 is used for the accelerator feedback signal,
Pin 1 is used to control the accelerator motor’s
positive rotation and Pin 4 is used to control the
accelerator motor’s negative rotation.

Accelerator knob
(Black)
(Black)
Accelerator motor 2 (ls ac2)

5V power supply
12-position accelerator
potentiometer
Accelerator actuator
Accelerator motor 1 (ls ac1)

(White)
Accelerator motor 2 (hs ac2)

Accelerator motor 1 (hs ac1)

Accelerator motor position
feedback

Sensor to ground
6-242
6.4 DTC CLG922E
6.4.73 DTC 221013 Actuator outside the calibrated range February 3, 2015

Component location Step 2 Check the speed sensor for fault

 When replacing the components, please

Front
be sure to use LiuGong parts.
• Inspection method
1. Check the sensor for looseness.
2. Disconnect the speed sensor connector:
(a) Check the connector pins for looseness,
rust, bending and damage. Check the con-
nector inside for moisture, oil dirt and other.
Accelerator actuator
(b) Start the engine and turn the knob to
increase the accelerator gradually. Turn the
multimeter to its voltage function, and mea-
Fault diagnosis and elimination pro- sure the voltage on the sensor output ports
(normally, when the engine speed at 1000-
cedures
2270r/min, the speed sensor outputs an AC
Step 1 Check whether the number of teeth of the
voltage between 3-28V.).
flywheel is correct.
• Whether a fault developing in the speed
 When replacing the components, please sensor or not?
be sure to use LiuGong parts. • Yes
• Inspection method Tighten or repair, or replace the speed sensor.
Check whether the number of teeth of the fly- Turn to Step 6
wheel is correct in the control parameter. • No
• Whether the number of teeth of the fly- Turn to Step 3
wheel is correct or not?
• Yes
Re-adjust the number of teeth of the flywheel in
the control parameter.
Turn to Step 6
• No
Turn to Step 2
 6-243
CLG922E 6.4 DTC
February 3, 2015 6.4.73 DTC 221013 Actuator outside the calibrated range

Step 3 Check the harness for short-circuit to Step 4 Check whether the harness is open-cir-
ground cuited or shorted to the battery.

 Correctly tie up harness and wire:  Correctly tie up harness and wire:

Avoid folding or bending the harness forci- Avoid folding or bending the harness forci-
bly. bly.
It shall be kept away from moving compo- It shall be kept away from moving compo-
nents as far as possible to prevent tensile nents as far as possible to prevent tensile
fault and wear. fault and wear.
Avoid friction with sharp metal edges. Avoid friction with sharp metal edges.
Try to keep far way from oil and water. Try to keep far way from oil and water.
Try to keep far away from high temperature Try to keep far away from high temperature
parts (e.g. engine body). parts (e.g. engine body).
• Inspection method • Inspection method
1. Check the harness (No. 918) between the Disconnect the connectors from the accelerator
controller (J2-18) and the accelerator actuator actuator and the controller.
for wear. 1. Check the harness for open-circuit: Turn the
2. Disconnect the connectors from the accelera- multimeter to its resistance function, and mea-
tor actuator and the controller, respectively. sure the resistance of the harness (No. 918)
Turn the multimeter to its resistance function, between the controller and the actuator (nor-
and then measure the resistance between the mally, <10Ω).
harness (No. 918) actuator terminal and the 2. Check whether the harness is shorted to the
grounding (normally, >100K). battery. Turn the start switch to the ON position
• Whether the harness is shorted to the and turn on all switches of the electrical equip-
ground or not? ment, and then measure the voltage between
the harness (No. 918) actuator terminal and the
• Yes
grounding (normally, 0V).
Connect the harness again and wrap the har-
• Whether the harness open-circuited or
ness.
shorted to the battery or not?
Turn to Step 6
• Yes
• No
Connect the harness again and wrap the har-
Turn to Step 4
ness.
Turn to Step 6
• No
Turn to Step 5
6-244
6.4 DTC CLG922E
6.4.73 DTC 221013 Actuator outside the calibrated range February 3, 2015

Step 5 Check whether the harness is wrong.

 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).
• Inspection method
According to the throttle control system sche-
matics, check whether the sequence of the har-
nesses between the actuator and the controller
is correct.
• Whether the harness is wrong or not.
• Yes
Connect the harness again and wrap the har-
ness.
Turn to Step 6
• No
Turn to Step 6

Step 6 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-245
CLG922E 6.4 DTC
February 3, 2015 6.4.74 DTC 221104 Actuator AC1 terminal shorted to the ground

6.4.74 DTC 221104 Actuator System description

The throttle control system consists of the
AC1 terminal shorted to the
potentiometer (accelerator knob), controller and
ground actuator. The schematic diagram is shown
below. No. 907 and No. 904 are drive control
Description of lines. The controller is driven by two pins. If
DTC Consequence
Fault either pin is open-circuited, this can cause the
The actuator accelerator system fault. The potentiometer is
Actuator AC1 fails to work, so
221104 terminal shorted to the revolving used to control the engine speed. As shown in
the ground speed cannot the figure, Pin 1 of the R1 connector is con-
be governed. nected to the 5V power, Pin 2 is connected to
the controller-sensor ground and Pin 3 is con-
nected to the accelerator signal feedback termi-
nal. The actuator controls the engine accelerator
opening through the flexible shaft, thereby con-
trolling the engine speed. The terminals are
shown in the figure. Pin 3 of the M1 connector is
the controller power (5V), Pin 5 is grounded, Pin
2 is used for the accelerator feedback signal,
Pin 1 is used to control the accelerator motor’s
positive rotation and Pin 4 is used to control the
accelerator motor’s negative rotation.

Accelerator knob
(Black)
(Black)
Accelerator motor 2 (ls ac2)

5V power supply
12-position accelerator
potentiometer
Accelerator actuator
Accelerator motor 1 (ls ac1)

(White)
Accelerator motor 2 (hs ac2)

Accelerator motor 1 (hs ac1)

Accelerator motor position
feedback

Sensor to ground
6-246
6.4 DTC CLG922E
6.4.74 DTC 221104 Actuator AC1 terminal shorted to the ground February 3, 2015

Component location Step 2 Check the harness for short-circuit to

ground

Front
 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Accelerator actuator
Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).

Fault diagnosis and elimination pro- • Inspection method

cedures 1. Check the harness (No. 907) between the

controller (J2-07) and the accelerator actuator
Step 1 Check the accelerator actuator for fault
for wear.
 When replacing the components, please 2. Disconnect the connectors from the accelera-
be sure to use LiuGong parts. tor actuator and the controller, respectively.
• Inspection method Turn the multimeter to its resistance function,
and then measure the resistance between the
Turn the start switch to the OFF position and
harness (No. 907) actuator terminal and the
disconnect the accelerator actuator connectors:
grounding (normally, >100K).
1. Check the connector for moisture, oil dirt and
other • Whether the harness is shorted to the
ground or not?
2. Turn the multimeter to its resistance function,
and measure the resistance between the actua- • Yes
tor connector terminal 4 and the grounding (nor- Connect the harness again and wrap the har-
mally, >100K) ness.
• Whether a fault developing in the accel- Turn to Step 4
erator actuator? • No
• Yes Turn to Step 3
Repair or replace the accelerator actuator.
Turn to Step 4
• No
Turn to Step 2
 6-247
CLG922E 6.4 DTC
February 3, 2015 6.4.74 DTC 221104 Actuator AC1 terminal shorted to the ground

Step 3 Check the connector for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Connect the accelerator actuator connector and
disconnect the controller connector. Turn the
multimeter to its resistance function, and mea-
sure the resistance between the controller port
J2-07 and the grounding (normally, >100K).
When the resistance is abnormal, this indi-
cates there is an insulation fault in the con-
nector.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
6-248
6.4 DTC CLG922E
6.4.75 DTC 221204 Actuator AC2 terminal shorted to the ground February 3, 2015

6.4.75 DTC 221204 Actuator System description

The throttle control system consists of the
AC2 terminal shorted to the
potentiometer (accelerator knob), controller and
ground actuator. The schematic diagram is shown
below. No. 907 and No. 904 are drive control
Description of lines. The controller is driven by two pins. If
DTC Consequence
Fault either pin is open-circuited, this can cause the
The actuator accelerator system fault. The potentiometer is
Actuator AC2 fails to work, so
221204 terminal shorted to the revolving used to control the engine speed. As shown in
the ground speed cannot the figure, Pin 1 of the R1 connector is con-
be governed. nected to the 5V power, Pin 2 is connected to
the controller-sensor ground and Pin 3 is con-
nected to the accelerator signal feedback termi-
nal. The actuator controls the engine accelerator
opening through the flexible shaft, thereby con-
trolling the engine speed. The terminals are
shown in the figure. Pin 3 of the M1 connector is
the controller power (5V), Pin 5 is grounded, Pin
2 is used for the accelerator feedback signal,
Pin 1 is used to control the accelerator motor’s
positive rotation and Pin 4 is used to control the
accelerator motor’s negative rotation.

Accelerator knob
(Black)
(Black)
Accelerator motor 2 (ls ac2)

5V power supply
12-position accelerator
potentiometer
Accelerator actuator
Accelerator motor 1 (ls ac1)

(White)
Accelerator motor 2 (hs ac2)

Accelerator motor 1 (hs ac1)

Accelerator motor position
feedback

Sensor to ground
 6-249
CLG922E 6.4 DTC
February 3, 2015 6.4.75 DTC 221204 Actuator AC2 terminal shorted to the ground

Component location Step 2 Check the harness for short-circuit to

ground

Front
 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Accelerator actuator
Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).

Fault diagnosis and elimination pro- • Inspection method

cedures 1. Check the harness (No. 904) between the

controller (J2-04) and the accelerator actuator
Step 1 Check the accelerator actuator for fault
for wear.
 When replacing the components, please 2. Disconnect the connectors from the accelera-
be sure to use LiuGong parts. tor actuator and the controller, respectively.
• Inspection method Turn the multimeter to its resistance function,
and then measure the resistance between the
Turn the start switch to the OFF position and
harness (No. 904) actuator terminal and the
disconnect the accelerator actuator connectors:
grounding (normally, >100K).
1. Check the connector for moisture, oil dirt and
other • Whether the harness is shorted to the
ground or not?
2. Turn the multimeter to its resistance function,
and measure the resistance between the actua- • Yes
tor connector terminal 1 and the grounding (nor- Connect the harness again and wrap the har-
mally, >100K) ness.
• Whether a fault developing in the accel- Turn to Step 4
erator actuator? • No
• Yes Turn to Step 3
Repair or replace the accelerator actuator.
Turn to Step 4
• No
Turn to Step 2
6-250
6.4 DTC CLG922E
6.4.75 DTC 221204 Actuator AC2 terminal shorted to the ground February 3, 2015

Step 3 Check the connector for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Connect the accelerator actuator connector and
disconnect the controller connector. Turn the
multimeter to its resistance function, and mea-
sure the resistance between the controller port
J2-04 and the grounding (normally, >100K).
When the resistance is abnormal, this indi-
cates there is an insulation fault in the con-
nector.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-251
CLG922E 6.4 DTC
February 3, 2015 6.4.76 DTC 221305 Actuator AC1 terminal open-circuited

6.4.76 DTC 221305 Actuator System description

The throttle control system consists of the
AC1 terminal open-circuited
potentiometer (accelerator knob), controller and
actuator. The schematic diagram is shown
Description of
DTC Consequence below. No. 907 and No. 904 are drive control
Fault
Actuator AC1 lines. The controller is driven by two pins. If
The actuator fails
221305 terminal open- either pin is open-circuited, this can cause the
to work.
circuited accelerator system fault. The potentiometer is
used to control the engine speed. As shown in
the figure, Pin 1 of the R1 connector is con-
nected to the 5V power, Pin 2 is connected to
the controller-sensor ground and Pin 3 is con-
nected to the accelerator signal feedback termi-
nal. The actuator controls the engine accelerator
opening through the flexible shaft, thereby con-
trolling the engine speed. The terminals are
shown in the figure. Pin 3 of the M1 connector is
the controller power (5V), Pin 5 is grounded, Pin
2 is used for the accelerator feedback signal,
Pin 1 is used to control the accelerator motor’s
positive rotation and Pin 4 is used to control the
accelerator motor’s negative rotation.

Accelerator knob
(Black)
(Black)
Accelerator motor 2 (ls ac2)

5V power supply
12-position accelerator
potentiometer
Accelerator actuator
Accelerator motor 1 (ls ac1)

(White)
Accelerator motor 2 (hs ac2)

Accelerator motor 1 (hs ac1)

Accelerator motor position
feedback

Sensor to ground
6-252
6.4 DTC CLG922E
6.4.76 DTC 221305 Actuator AC1 terminal open-circuited February 3, 2015

Component location Step 2 Check the harness for open-circuit

 Correctly tie up harness and wire:

Front Avoid folding or bending the harness forci-

bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Accelerator actuator
Try to keep far away from high temperature
parts (e.g. engine body).
• Inspection method
Fault diagnosis and elimination pro- 1. Check the harness (No. 907/No. 904)
cedures between the controller and the accelerator actu-
ator for wear.
Step 1 Check the accelerator actuator for fault
2. Disconnect the connectors from the accelera-
 When replacing the components, please tor actuator and the controller, respectively.
be sure to use LiuGong parts. Turn the multimeter to its resistance function,
• Inspection method and then measure the resistance of the harness
(No. 907/ No. 904) between the controller and
Turn the start switch to the OFF position and
the actuator (normally, <10Ω).
disconnect the accelerator actuator connectors:
1. Check the connector for looseness, rust, • Is the harness open?
bending and damage. • Yes
2. Turn the multimeter to its resistance function, Connect the harness again and wrap the har-
and measure the resistance between the accel- ness.
erator actuator connector terminals 1 and 4 (nor- Turn to Step 4
mally, <100K) • No
• Whether a fault developing in the accel- Turn to Step 3
erator actuator?
• Yes
Repair or replace the accelerator actuator.
Turn to Step 4
• No
Turn to Step 2
 6-253
CLG922E 6.4 DTC
February 3, 2015 6.4.76 DTC 221305 Actuator AC1 terminal open-circuited

Step 3 Check the connector for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Connect the accelerator actuator connector and
disconnect the controller connector. Turn the
multimeter to its resistance function, and mea-
sure the resistance between the controller port
J2-07 harness and J2-04 (normally, <100K).
When the resistance is abnormal, this indi-
cates the connector is poorly contacted.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
6-254
6.4 DTC CLG922E
6.4.77 DTC 221306 Actuator AC1 overcurrent February 3, 2015

6.4.77 DTC 221306 Actuator System description

The throttle control system consists of the
AC1 overcurrent
potentiometer (accelerator knob), controller and
actuator. The schematic diagram is shown
Description of
DTC Consequence below. No. 907 and No. 904 are drive control
Fault
Actuator AC1 lines. The controller is driven by two pins. If
overcurrent either pin is open-circuited, this can cause the
The actuator
(actuator AC1 accelerator system fault. The potentiometer is
fails to work, so
terminal is shorted
221306 the revolving used to control the engine speed. As shown in
to the battery, with
speed cannot
a 3Ω circuit the figure, Pin 1 of the R1 connector is con-
be governed.
connected in nected to the 5V power, Pin 2 is connected to
series.)
the controller-sensor ground and Pin 3 is con-
nected to the accelerator signal feedback termi-
nal. The actuator controls the engine accelerator
opening through the flexible shaft, thereby con-
trolling the engine speed. The terminals are
shown in the figure. Pin 3 of the M1 connector is
the controller power (5V), Pin 5 is grounded, Pin
2 is used for the accelerator feedback signal,
Pin 1 is used to control the accelerator motor’s
positive rotation and Pin 4 is used to control the
accelerator motor’s negative rotation.

Accelerator knob
(Black)
(Black)
Accelerator motor 2 (ls ac2)

5V power supply
12-position accelerator
potentiometer
Accelerator actuator
Accelerator motor 1 (ls ac1)

(White)
Accelerator motor 2 (hs ac2)

Accelerator motor 1 (hs ac1)

Accelerator motor position
feedback

Sensor to ground
 6-255
CLG922E 6.4 DTC
February 3, 2015 6.4.77 DTC 221306 Actuator AC1 overcurrent

Component location Step 2 Check whether the harness is shorted to

the battery.

Front
 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Accelerator actuator
Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).

Fault diagnosis and elimination pro- • Inspection method

cedures 1. Check the harness (No. 907/No. 904)

between the controller (J2-07 and J7-04) and
Step 1 Check the accelerator actuator for fault
the accelerator actuator for wear respectively.
 When replacing the components, please Disconnect both the controller and the solenoid
be sure to use LiuGong parts. valve:
• Inspection method 2. Check the two harnesses for short-circuit:
Turn the start switch to the OFF position and Turn the multimeter to its resistance function,
disconnect the accelerator actuator connectors: and measure the resistance of the harness (No.
1. Check the connector for moisture, oil dirt and 907/No. 904) between the actuator terminals
other (normally, >100K).

2. Turn the multimeter to its resistance function, 3. Check whether the harness is shorted to the
and measure the resistance between the accel- battery. Turn the start switch to the ON position
erator actuator connector terminals 1 and 4 (nor- and switch on the switches of all electrical
mally, >10Ω) equipment, and then measure the voltage
between the harness (No. 907/No. 904) actuator
• Whether a fault developing in the accel-
terminal and the grounding (normally, 0V).
erator actuator?
• Whether the harness is shorted to the
• Yes
battery.
Repair or replace the accelerator actuator.
• Yes
Turn to Step 4
Connect the harness again and wrap the har-
• No
ness.
Turn to Step 2
Turn to Step 4
• No
6-256
6.4 DTC CLG922E
6.4.77 DTC 221306 Actuator AC1 overcurrent February 3, 2015

Turn to Step 3

Step 3 Check the connector for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Connect the accelerator actuator connector and
disconnect the controller connector. Turn the
multimeter to its resistance function, and mea-
sure the resistance between the controller port
J2-07 and J2-04 (normally, >10Ω).
When the resistance is abnormal, this indi-
cates there is an insulation fault in the con-
nector.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-257
CLG922E 6.4 DTC
February 3, 2015 6.4.78 DTC 221405 Actuator AC2 terminal open-circuited

6.4.78 DTC 221405 Actuator System description

The throttle control system consists of the
AC2 terminal open-circuited
potentiometer (accelerator knob), controller and
actuator. The schematic diagram is shown
Description of
DTC Consequence below. No. 907 and No. 904 are drive control
Fault
Actuator AC2 lines. The controller is driven by two pins. If
The actuator
221405 terminal open- either pin is open-circuited, this can cause the
fails to work.
circuited accelerator system fault. The potentiometer is
used to control the engine speed. As shown in
the figure, Pin 1 of the R1 connector is con-
nected to the 5V power, Pin 2 is connected to
the controller-sensor ground and Pin 3 is con-
nected to the accelerator signal feedback termi-
nal. The actuator controls the engine accelerator
opening through the flexible shaft, thereby con-
trolling the engine speed. The terminals are
shown in the figure. Pin 3 of the M1 connector is
the controller power (5V), Pin 5 is grounded, Pin
2 is used for the accelerator feedback signal,
Pin 1 is used to control the accelerator motor’s
positive rotation and Pin 4 is used to control the
accelerator motor’s negative rotation.

Accelerator knob
(Black)
(Black)
Accelerator motor 2 (ls ac2)

5V power supply
12-position accelerator
potentiometer
Accelerator actuator
Accelerator motor 1 (ls ac1)

(White)
Accelerator motor 2 (hs ac2)

Accelerator motor 1 (hs ac1)

Accelerator motor position
feedback

Sensor to ground
6-258
6.4 DTC CLG922E
6.4.78 DTC 221405 Actuator AC2 terminal open-circuited February 3, 2015

Component location Step 2 Check the harness for open-circuit

 Correctly tie up harness and wire:

Front Avoid folding or bending the harness forci-

bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Accelerator actuator
Try to keep far away from high temperature
parts (e.g. engine body).
• Inspection method
Fault diagnosis and elimination pro- 1. Check the harness (No. 907/No. 904)
cedures between the controller and the accelerator actu-
ator for wear.
Step 1 Check the accelerator actuator for fault
2. Disconnect the connectors from the accelera-
 When replacing the components, please tor actuator and the controller, respectively.
be sure to use LiuGong parts. Turn the multimeter to its resistance function,
• Inspection method and then measure the resistance of the harness
(No. 907/No. 904) between the controller and
Turn the start switch to the OFF position and
the actuator (normally, <10Ω).
disconnect the accelerator actuator connectors:
1. Check the connector for looseness, rust, • Is the harness open?
bending or damage. • Yes
2. Turn the multimeter to its resistance function, Connect the harness again and wrap the har-
and measure the resistance between the accel- ness.
erator actuator connector terminals 1 and 4 (nor- Turn to Step 4
mally, <100K) • No
• Whether a fault developing in the accel- Turn to Step 3
erator actuator?
• Yes
Repair or replace the accelerator actuator.
Turn to Step 4
• No
Turn to Step 2
 6-259
CLG922E 6.4 DTC
February 3, 2015 6.4.78 DTC 221405 Actuator AC2 terminal open-circuited

Step 3 Check the connector for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Connect the accelerator actuator connector and
disconnect the controller connector. Turn the
multimeter to its resistance function, and mea-
sure the resistance between the controller port
J2-07 harness and J2-04 (normally, <100K).
When the resistance is abnormal, this indi-
cates the connector is poorly contacted.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
6-260
6.4 DTC CLG922E
6.4.79 DTC 221406 Actuator AC2 overcurrent February 3, 2015

6.4.79 DTC 221406 Actuator System description

The throttle control system consists of the
AC2 overcurrent
potentiometer (accelerator knob), controller and
actuator. The schematic diagram is shown
Description of
DTC Consequence below. No. 907 and No. 904 are drive control
Fault
Actuator AC2 The actuator lines. The controller is driven by two pins. If
overcurrent fails to work, so either pin is open-circuited, this can cause the
221406 (actuator AC2 the revolving accelerator system fault. The potentiometer is
terminal is shorted speed cannot
to the battery). be governed. used to control the engine speed. As shown in
the figure, Pin 1 of the R1 connector is con-
nected to the 5V power, Pin 2 is connected to
the controller-sensor ground and Pin 3 is con-
nected to the accelerator signal feedback termi-
nal. The actuator controls the engine accelerator
opening through the flexible shaft, thereby con-
trolling the engine speed. The terminals are
shown in the figure. Pin 3 of the M1 connector is
the controller power (5V), Pin 5 is grounded, Pin
2 is used for the accelerator feedback signal,
Pin 1 is used to control the accelerator motor’s
positive rotation and Pin 4 is used to control the
accelerator motor’s negative rotation.

Accelerator knob
(Black)
(Black)
Accelerator motor 2 (ls ac2)

5V power supply
12-position accelerator
potentiometer
Accelerator actuator
Accelerator motor 1 (ls ac1)

(White)
Accelerator motor 2 (hs ac2)

Accelerator motor 1 (hs ac1)

Accelerator motor position
feedback

Sensor to ground
 6-261
CLG922E 6.4 DTC
February 3, 2015 6.4.79 DTC 221406 Actuator AC2 overcurrent

Component location Step 2 Check whether the harness is shorted to

the battery.

Front
 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Accelerator actuator
Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).

Fault diagnosis and elimination pro- • Inspection method

cedures 1. Check the harness (No. 907/No. 904)

Step 1 Check the accelerator actuator for fault between the controller (J2-07 and J7-04) and
the accelerator actuator for wear respectively.
 When replacing the components, please
Disconnect both the controller and the solenoid
be sure to use LiuGong parts. valve:
• Inspection method 2. Check the two harnesses for short-circuit:
Turn the start switch to the OFF position and Turn the multimeter to its resistance function,
disconnect the accelerator actuator connectors: and measure the resistance of the harness (No.
1. Check the connector for moisture, oil dirt and 907/No. 904) between the actuator terminals
other. (normally, >100K).
2. Turn the multimeter to its resistance function, 3. Check whether the harness is shorted to the
and measure the resistance between the accel- battery. Turn the start switch to the ON position
erator actuator connector terminals 1 and 4 (nor- and switch on the switches of all electrical
mally, >10Ω) equipment, and then measure the voltage
between the harness (No. 907 and No. 904)
• Whether a fault developing in the accel-
actuator terminal and the grounding (normally,
erator actuator?
0V).
• Yes
• Whether the harness is shorted to the
Repair or replace the accelerator actuator.
battery.
Turn to Step 4
• Yes
• No
Connect the harness again and wrap the har-
Turn to Step 2
ness.
Turn to Step 4
6-262
6.4 DTC CLG922E
6.4.79 DTC 221406 Actuator AC2 overcurrent February 3, 2015

• No
Turn to Step 3

Step 3 Check the connector for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Connect the accelerator actuator connector and
disconnect the controller connector. Turn the
multimeter to its resistance function, and mea-
sure the resistance between the controller ports
J2-07 and J2-04 (normally, >10Ω).
When the resistance is abnormal, this indi-
cates there is an insulation fault in the con-
nector.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-263
CLG922E 6.4 DTC
February 3, 2015 6.4.80 DTC 231012 Abnormal controller heartbeat

6.4.80 DTC 231012 Abnormal System description

The controller is the core part of the excavator’s
controller heartbeat
electrical control system and is responsible for
the complete excavator’s operation mode and
Description of
DTC Consequence status, information processing, and various elec-
Fault
Abnormal tronic control functions.
The excavator
231012 controller
fails to work.
heartbeat.

Tracker (optional)

Electric lock ON

Power -

Power +

Electric lock
Ground

Controller
(Black)
CAN 1/2 shield
CAN 1 low
CAN 1 high

Travel alarm buzzer Controller, Display 30A

Power
6-264
6.4 DTC CLG922E
6.4.80 DTC 231012 Abnormal controller heartbeat February 3, 2015

Component location is short of power.

Definition of
connector pin
serial number
Controller

Controller connector
Front

• No power to the controller or not?

Fault diagnosis and elimination pro-
• Yes
cedures
Check the harness for open-circuit, and re-con-
Step 1 Check the controller connector J1 for
nect it.
looseness.
Turn to Step 3
• Inspection method
• No
Manually check whether the controller connector
Turn to Step 3
for looseness or fall-off.
• Whether the controller connector J1
Step 3 Check whether this fault is eliminated
becomes loose or not?
• Inspection method
• Yes
Turn the start switch to the ON position and re-
Tighten the connector J1.
check the DTC.
Turn to Step 3
• Has this fault been eliminated?
• No
• Yes
Turn to Step 2
Maintenance is over

Step 2 Check whether there is no power to the • No

controller. Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
• Inspection method
authorized service center.
Dismantle the controller connector J1 (black).
Turn the multimeter to its voltage function, and
measure the voltage between J1’s port 2, 3, 4, 5
and 6 and ground, respectively. The voltage
should be about 24V. Otherwise, the controller
 6-265
CLG922E 6.4 DTC
February 3, 2015 6.4.81 DTC 231014 CAN bus communication error

6.4.81 DTC 231014 CAN bus System description

The CAN bus can achieve real-time data
communication error
exchange of various control units of the excava-
tor.
Description of
DTC Consequence
Fault
CAN bus The excavator
231014 communication cannot operate
error properly.

Monitor
Battery power

Battery power

Electric lock
Ground
Ground
supply

supply

ON

Power 12V Socket (Option)

Tracker (optional)

Electric lock ON

Power -

Power +

Electric lock
Ground
6-266
6.4 DTC CLG922E
6.4.81 DTC 231014 CAN bus communication error February 3, 2015

Component location Step 2 Check the display’s harness for fault.

• Inspection method
GPS antenna Dismantle the display connector C4 and the
GPS connector C3.
Display
Turn the multimeter to its on-off function, and
check the harness (No. 751/No. 752) between
the port 5 (C3) and the port 1 (C4) between the
GPS
port 8 (C3) and the port 8 (C4) for open-circuit.
• Is there a fault in display harness?
• Yes
Re-connect the harness.
Turn to Step 3
• No
Fault diagnosis and elimination pro-
Turn to Step 3
cedures
Step 1 Check the display connector for fault
Step 3 Check whether this fault is eliminated
• Inspection method
• Inspection method
Manually check the controller connector for
Turn the start switch to the ON position and re-
looseness or fall-off, and check the pins for
check the DTC.
bending.
• Has this fault been eliminated?
• Is there a fault in display connector?
• Yes
• Yes
Maintenance is over
Repair or tighten the connector.
• No
Turn to Step 3
Troubleshoot the faults according to the steps
• No
again or contact the local LiuGong dealer and
Turn to Step 2
authorized service center.
 6-267
CLG922E 6.4 DTC
February 3, 2015 6.4.82 DTC 241014 Accelerator knob outside the measurement range

6.4.82 DTC 241014 Accelerator System description

The throttle control system consists of the
knob outside the measurement
potentiometer (accelerator knob), controller and
range actuator. The schematic diagram is shown
below. No. 907 and No. 904 are drive control
Description of lines. The controller is driven by two pins. If
DTC Consequence
Fault either pin is open-circuited, this can cause the
Accelerator knob The gear accelerator system fault. The potentiometer is
outside the positions are
241014 used to control the engine speed. As shown in
measurement displayed
range abnormally. the figure, Pin 1 of the R1 connector is con-
nected to the 5V power, Pin 2 is connected to
the controller-sensor ground and Pin 3 is con-
nected to the accelerator signal feedback termi-
nal. The actuator controls the engine accelerator
opening through the flexible shaft, thereby con-
trolling the engine speed. The terminals are
shown in the figure. Pin 3 of the M1 connector is
the controller power (5V), Pin 5 is grounded, Pin
2 is used for the accelerator feedback signal,
Pin 1 is used to control the accelerator motor’s
positive rotation and Pin 4 is used to control the
accelerator motor’s negative rotation.

Accelerator knob
(Black)
(Black)
Accelerator motor 2 (ls ac2)

5V power supply
12-position accelerator
potentiometer
Accelerator actuator
Accelerator motor 1 (ls ac1)

(White)
Accelerator motor 2 (hs ac2)

Accelerator motor 1 (hs ac1)

Accelerator motor position
feedback

Sensor to ground
6-268
6.4 DTC CLG922E
6.4.82 DTC 241014 Accelerator knob outside the measurement range February 3, 2015

Component location Repair or replace the accelerator actuator.

Turn to Step 4
• No
Turn to Step 2

Step 2 Check the harness for short-circuit and

open-circuit.
Throttle Potentiometer

 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

bly.
Controller
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
Fault diagnosis and elimination pro- fault and wear.

cedures Avoid friction with sharp metal edges.

Try to keep far way from oil and water.
Step 1 Check the accelerator actuator for fault
Try to keep far away from high temperature
 When replacing the components, please parts (e.g. engine body).
be sure to use LiuGong parts.
• Inspection method
• Inspection method 1. Check the harness (No. 828/No. 829)
Disconnect the connectors from the acceler- between the controller (J1-28/J1-29) and the
ator actuator: accelerator actuator and the grounding wire (No.
1. Check the connector pins for looseness, rust, 922) for wear.
bending and damage. Check the connector 2. Check whether the harness is shorted to the
inside for moisture, oil dirt and other. battery:
2. Turn the multimeter to its resistance function Disconnect the connectors from the accelerator
(20kΩ) and measure the resistance between the actuator and the controller, respectively. Turn
actuator connector pins 3 and 5 (normally, 4- the multimeter to its voltage function, and mea-
5kΩ), and then, using the multimeter, measure sure the voltage between the harness (No. 828
the resistance between the pins 2 and 3 and that and No. 829) and the grounding, respectively
between the pins 2 and 5. (The sum of the resis- (normally, 0V).
tance between the pins 2 and 3 and that 3. Check the harness for open-circuit:
between the pins 2 and 5 equals the resistance Turn the multimeter to its resistance function,
between the pins 3 and 5). and measure the resistance between the (No.
• Whether a fault developing in the accel- 922) harness’s actuator coupling end and the
erator actuator? grounding (normally, <100K).
• Yes • Is the harness short or open circuit?
 6-269
CLG922E 6.4 DTC
February 3, 2015 6.4.82 DTC 241014 Accelerator knob outside the measurement range

• Yes Step 4 Check whether this fault is eliminated

Connect the harness again and wrap the har- • Inspection method
ness. Turn the start switch to the ON position and re-
Turn to Step 4 check for fault.
• No Has this fault been eliminated?
Turn to Step 3 • Yes
Maintenance is over
Step 3 Check the connector for fault. • No
 When replacing the components, please Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
be sure to use LiuGong parts.
authorized service center.
• Inspection method
Connect the actuator connector and disconnect
the controller connector.
1.Turn the multimeter to its resistance function,
and measure the resistance between the con-
troller port J2-28 and the grounding (normally, 4-
5kΩ).
2. Turn the multimeter to its resistance function,
and measure the resistance between the con-
troller ports J1-28 and J1-29 (normally, >10Ω).
An abnormal resistance indicates that there
is fault in the connector.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4
6-270
6.4 DTC CLG922E
6.4.83 DTC 251004 Fuel pump relay shorted to the ground February 3, 2015

6.4.83 DTC 251004 Fuel pump System description

Power on the electric lock to energize the bat-
relay shorted to the ground
tery relay, the harness (No. 133) and the har-
ness (No. 320), so that the fuel pump can
Description of
DTC Consequence operate. If the 6th port of the controller J2 sig-
Fault
The fuel pump nals and the harness (No. 906) is energized,
Fuel pump relay automatically then the fuel pump relay is energized, so that
251004 shorted to the stops and the harnesses (No. 133 and No. 320) are open-
ground refueling
function fails. circuited and the fuel pump automatically stops.

Controller
Fuel pump relay

Fuel pump (option)

Ignition switch

Electric lock power 20A Fuel pump fuse 20A (optional)

Fuel pump relay K11

Battery
 6-271
CLG922E 6.4 DTC
February 3, 2015 6.4.83 DTC 251004 Fuel pump relay shorted to the ground

Component location

Open the fuse box.

K11 auto preheating

relay. It can be pulled out
during detection.
6-272
6.4 DTC CLG922E
6.4.83 DTC 251004 Fuel pump relay shorted to the ground February 3, 2015

Fault diagnosis and elimination pro- Step 2 Check the connectors for fault

cedures  Shutdown operation is needed

Step 1 Check whether the harness connecting
the controller port J2-6 is shorted to the ground.
 When replacing the components, please
be sure to use LiuGong parts.
 Shutdown operation is needed
• Inspection method
• Inspection method Check manually the connectors between the
For troubleshooting, turn the start switch to the automatic preheater and the controller one by
OFF position. one for moisture, oil dirt and other which may
Disconnect the connector from the controller (in cause electric leakage.
the figure) and pull out the fuel pump relay, and • Whether a fault in the connector or not?
then measure the resistance between the har-
• Yes
ness (No. 906) at the J2-6 port and the ground-
Adjust or replace the connector.
ing. The resistance should be infinite.
Turn to Step 3
• No
Definition of
connector pin Turn to Step 3
serial number

Step 3 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check the DTC.
• Has this fault been eliminated?
• Yes
Maintenance is over
• Check whether the harness connecting • No
the controller port J2-6 is shorted to the Troubleshoot the faults according to the steps
ground. again or contact the local LiuGong dealer and
• Yes authorized service center.
Re-connect the harness, and wrap it.
Turn to Step 3
• No
Turn to Step 2
 6-273
CLG922E 6.4 DTC
February 3, 2015 6.4.83 DTC 251004 Fuel pump relay shorted to the ground

Figure

Controller

Controller connector
Front
6-274
6.4 DTC CLG922E
6.4.84 DTC 251005 Fuel pump relay open-circuited or shorted to the battery February 3, 2015

6.4.84 DTC 251005 Fuel pump System description

Power on the electric lock to energize the bat-
relay open-circuited or shorted
tery relay, the harness (No. 133) and the har-
to the battery ness (No. 320), so that the fuel pump can
operate. If the 6th port of the controller J2 sig-
Description of nals and the harness (No. 906) is energized,
DTC Consequence
Fault then the fuel pump relay is energized, so that
The fuel pump the harnesses (No. 133 and No. 320) are open-
Fuel pump relay
automatically
open-circuited or circuited and the fuel pump automatically stops.
251005 stops and
shorted to the
refueling
battery.
function fails.

Controller
Fuel pump relay

Fuel pump (option)

Ignition switch

Electric lock power 20A Fuel pump fuse 20A (optional)

Fuel pump relay K11

Battery
 6-275
CLG922E 6.4 DTC
February 3, 2015 6.4.84 DTC 251005 Fuel pump relay open-circuited or shorted to the battery

Component location

Open the fuse box.

K11 auto preheating

relay. It can be pulled out
during detection.
6-276
6.4 DTC CLG922E
6.4.84 DTC 251005 Fuel pump relay open-circuited or shorted to the battery February 3, 2015

Fault diagnosis and elimination pro- OFF position.

cedures Disconnect the connector from the controller (in

the figure) and pull out the fuel pump relay, and
Step 1 Check the fuel pump relay for fault.
then measure the resistance between the har-
 Shutdown operation is needed ness (No. 906) at the J2-6 port and the fuel
pump relay. The maximum resistance should be
• Inspection method
10Ω.
Turn the multimeter to its resistance function
Measure the resistance between the 85 port in
and measure the resistance between the termi-
the fuse box and the ground. The resistance
nals 85 and 86 of the fuel pump relay coil. The
should be less than 10Ω.
resistance should be between 350-360Ω.
Turn the multimeter to its on/off function, and
measure the terminals 30 and 87A of the relay. Definition of
connector pin
The relay should switch on and sound. serial number

Connect the terminals 85 and 86 to the power

supply (24V), and measure the terminals 30 and
87A. The relay should switch off and not sound.
• Whether the fuel pump relay fails or
not?
• Yes
Replace relay.
Turn to Step 4
• No • Is the harness open?
Turn to Step 2 • Yes
Re-connect the harness, and wrap it.
Step 2 Check the harness for open-circuit. Turn to Step 4

 Shutdown operation is needed. • No

Turn to Step 3
 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

bly.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body).
• Inspection method
For troubleshooting, turn the start switch to the
 6-277
CLG922E 6.4 DTC
February 3, 2015 6.4.84 DTC 251005 Fuel pump relay open-circuited or shorted to the battery

Step 3 Check the connector for fault Step 4 Check whether this fault is eliminated

 Shutdown operation is needed • Inspection method

Turn the start switch to the ON position and re-
• Inspection method
check the DTC.
Insert the fuel pump relay into the fuse box prop-
• Has this fault been eliminated?
erly and disconnect the controller connector,
and then turn the multimeter to its resistance • Yes
function and measure the resistance between Maintenance is over
the harness (No. 906) at the controller port J2-6 • No
and the grounding. The resistance should be Troubleshoot the faults according to the steps
between 320-360Ω. Otherwise, check the con- again or contact the local LiuGong dealer and
nector: authorized service center.
(a) Check the connector at the grounding of
the auto preheating relay for poor contact:
Figure
(a) Check the connector of the auto preheating
relay for looseness or damage.
• Whether the connector fails or not?
Controller
• Yes
Adjust or replace the connector.
Turn to Step 4
• No
Turn to Step 4

Controller connector
Front
6-278
6.4 DTC CLG922E
6.4.85 DTC 261011 GPS Antenna fault February 3, 2015

6.4.85 DTC 261011 GPS • Whether the antenna connector

becomes loose or falls off or not?
Antenna fault
• Yes
Tighten the antenna connector.
Description of
DTC Consequence Turn to Step 3
Fault
The excavator • No
cannot be
GPS antenna positioned and Turn to Step 2
261011
fault. connected to
the monitoring
Step 2 Check the antenna for damage.
center.
• Inspection method
System description
Remove the antenna, and re-install a new one
Use the GPS (Global Positioning System) to
to determine whether the antenna is damaged.
position the excavator and use the GSM mobile
• Whether the antenna is damaged or
communication network to achieve the two-way
not?
data exchange with the central control center to
realize remote monitoring and control. • Yes
Replace the antenna.
Turn to Step 3
Component location
• No
Turn to Step 3
GPS antenna

Display
Step 3 Check whether this fault is eliminated
• Inspection method
Turn the start switch to the ON position and re-
GPS
check the DTC.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No

Fault diagnosis and elimination pro- Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
cedures
authorized service center.
Step 1 Check the antenna connector for loose-
ness and fall-off.
• Inspection method
Manually check whether the antenna connector
becomes loose or falls off.
 6-279
CLG922E 6.4 DTC
February 3, 2015 6.4.86 DTC 261111 GPS Module fault

6.4.86 DTC 261111 GPS Module 6.4.87 DTC 261211 GSM Signal
fault fault

Description of Description of
DTC Consequence DTC Consequence
Fault Fault
GPS signals GSM signal is
261211 GSM signal fault
261111 GPS module fault cannot be weak.
received.
System description
System description
Use the GPS (Global Positioning System) to
Use the GPS (Global Positioning System) to position the excavator and use the GSM mobile
position the excavator and use the GSM mobile communication network to achieve the two-way
communication network to achieve the two-way data exchange with the central control center to
data exchange with the central control center to realize remote monitoring and control.
realize remote monitoring and control.

Component location
Component location
GPS and GSM antenna

GPS antenna
Display
Display

GPS

GPS

Fault diagnosis and elimination pro-

Fault diagnosis and elimination pro-
cedures
cedures
Step 1 Check the antenna connector for loose-
Step - Contact local LiuGong dealer and autho- ness and fall-off.
rized service center.
• Inspection method
Manually check whether the antenna connector
becomes loose or falls off.
• Whether the antenna connector
becomes loose or falls off or not?
6-280
6.4 DTC CLG922E
6.4.88 DTC 261311 GPRS Connection fault February 3, 2015

• Yes 6.4.88 DTC 261311 GPRS Con-

Tighten the antenna connector.
nection fault
Turn to Step 3
• No
Description of
Turn to Step 2 DTC Consequence
Fault
GPS cannot
GPRS connection
261311 operate
Step 2 Check the antenna for damage. fault
properly.
• Inspection method
System description
View the mobile signal strength. Compared with
GPRS is used to transmit information between
the GSM signal, if the mobile signal is strong,
GPS and mobile server.
the antenna is faulty.
• Whether the antenna is damaged or
not? Fault diagnosis and elimination pro-
• Yes cedures
Replace the antenna. Step - Contact local LiuGong dealer and autho-
Turn to Step 3 rized service center.

• No
Turn to Step 3

Step 3 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check the DTC.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-281
CLG922E 6.4 DTC
February 3, 2015 6.4.89 DTC 261411 SIM card read fault

6.4.89 DTC 261411 SIM card Fault diagnosis and elimination pro-
read fault cedures
Step 1 Check whether the SIM card becomes
loose.
Description of
DTC Consequence
Fault • Inspection method
GPS cannot
Turn the start switch to the OFF position, and
261411 SIM card read fault operate
properly. manually check whether the SIM card becomes
loose.
System description
• If the SIM card becomes loose?
The GPS positioning information is transmitted
• Yes
to the monitoring center through the SIM card.
Fix the SIM card.
Turn to Step 2
Component location
• No
Turn to Step 2
GPS and GSM antenna

Display
Step 2 Check whether this fault is eliminated
• Inspection method
Turn the start switch to the ON position and re-
GPS
(SIM card check the DTC.
inside GPS)

• Has this fault been eliminated?

• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
6-282
6.4 DTC CLG922E
6.4.90 DTC 261512 Abnormal GPS heartbeat February 3, 2015

6.4.90 DTC 261512 Abnormal System description

Use the GPS (Global Positioning System) to
GPS heartbeat
position the excavator and use the GSM mobile
communication network to achieve the two-way
Description of
DTC Consequence data exchange with the central control center to
Fault
Over time, the realize remote monitoring and control.
Abnormal GPS excavator is
261512
heartbeat limited to be
used.

Ignition switch

Tracker (optional)

Electric lock
ON

Power -

Power +

Electric lock
Ground
 6-283
CLG922E 6.4 DTC
February 3, 2015 6.4.90 DTC 261512 Abnormal GPS heartbeat

Component location Step 2 Check the harness (No. 149) for fault.
• Inspection method
GPS antenna Turn the start switch to the ON position

Display
Dismantle the GPS connector C3. Make sure no
pin of the connector is bent. Turn the multimeter
to its voltage function, and measure the voltage
between the connector port 4 and the ground-
GPS
ing. The voltage should be 24V. Otherwise, a
fault develops in the harness (No. 149).
• Is there a fault in the harness (No. 149)?
• Yes
Rewire
Turn to Step 3
Fault diagnosis and elimination pro-
• No
cedures
Turn to Step 3
Step 1 Check whether the GPS connector
becomes loose and falls off.
Step 3 Check whether this fault is eliminated
• Inspection method
• Inspection method
Manually check the GPS connector for loose-
Turn the start switch to the ON position and re-
ness or fall-off
check the DTC.
• Whether the GPS connector becomes
• Has this fault been eliminated?
loose and falls off?
• Yes
• Yes
Maintenance is over
Tighten the GPS connector
• No
Turn to Step 3
Troubleshoot the faults according to the steps
• No
again or contact the local LiuGong dealer and
Turn to Step 2 authorized service center.
6-284
6.4 DTC CLG922E
6.4.91 DTC 261611 Level-1 automatic locking, abnormal GPS heartbeat, excavator restricted for use February 3, 2015

6.4.91 DTC 261611 Level-1 auto- System description

Use the GPS (Global Positioning System) to
matic locking, abnormal GPS
position the excavator and use the GSM mobile
heartbeat, excavator restricted communication network to achieve the two-way
data exchange with the central control center to
for use
realize remote monitoring and control.

Description of
DTC Consequence
Fault
Level-1 automatic
locking, abnormal The excavator
261611 GPS heartbeat, is restricted for
excavator use
restricted for use

Ignition switch

Tracker (optional)

Electric lock
ON

Power -

Power +

Electric lock
Ground
 6-285
CLG922E 6.4 DTC
February 3, 2015 6.4.91 DTC 261611 Level-1 automatic locking, abnormal GPS heartbeat, excavator restricted for use

Component location Step 2 Check the harness (No. 149) for fault.
• Inspection method
GPS antenna Turn the start switch to the ON position

Display
Dismantle the GPS connector C3. Make sure no
pin of the connector is bent. Turn the multimeter
to its voltage function, and measure the voltage
between the connector port 4 and the ground-
GPS
ing. The voltage should be 24V. Otherwise, a
fault develops in the harness (No. 149).
• Is there a fault in the harness (No. 149)?
• Yes
Rewire.
Turn to Step 3
Fault diagnosis and elimination pro-
• No
cedures
Turn to Step 3
Step 1 Check whether the GPS connector
becomes loose and falls off.
Step 3 Check whether this fault is eliminated
• Inspection method
• Inspection method
Manually check the GPS connector for loose-
Turn the start switch to the ON position and re-
ness or fall-off
check the DTC.
• Whether the GPS connector becomes
• Has this fault been eliminated?
loose and falls off?
• Yes
• Yes
Maintenance is over
Tighten the GPS connector
• No
Turn to Step 3
Troubleshoot the faults according to the steps
• No
again or contact the local LiuGong dealer and
Turn to Step 2 authorized service center.
6-286
6.4 DTC CLG922E
6.4.92 DTC 261614 Level-1 forced locking, overdue payment, excavator restricted for use February 3, 2015

6.4.92 DTC 261614 Level-1

forced locking, overdue pay-
ment, excavator restricted for
use

Description of
DTC Consequence
Fault
Level-1 forced
locking, overdue The excavator
261614 payment, is restricted for
excavator use.
restricted for use

System description
Use the GPS (Global Positioning System) to
position the excavator and use the GSM mobile
communication network to achieve the two-way
data exchange with the central control center to
realize remote monitoring and control.

Fault diagnosis and elimination pro-

cedures
Step - Contact local LiuGong dealer and autho-
rized service center.
 6-287
CLG922E 6.4 DTC
February 3, 2015 6.4.93 DTC 261711 Level-2 automatic locking, abnormal GPS heartbeat, excavator restricted for use

6.4.93 DTC 261711 Level-2 auto- System description

Use the GPS (Global Positioning System) to
matic locking, abnormal GPS
position the excavator and use the GSM mobile
heartbeat, excavator restricted communication network to achieve the two-way
data exchange with the central control center to
for use
realize remote monitoring and control.

Code Faults Consequence

Level-2 automatic
locking, abnormal The excavator
261711 GPS heartbeat, is forbidden to
excavator be used.
restricted for use

Ignition switch

Tracker (optional)

Electric lock
ON

Power -

Power +

Electric lock
Ground
6-288
6.4 DTC CLG922E
6.4.93 DTC 261711 Level-2 automatic locking, abnormal GPS heartbeat, excavator restricted for use February 3, 2015

Component location Step 2 Check the harness (No. 149) for fault.
• Inspection method
GPS antenna Turn the start switch to the ON position

Display
Dismantle the GPS connector C3. Make sure no
pin of the connector is bent. Turn the multimeter
to its voltage function, and measure the voltage
between the connector port 4 and the ground-
GPS
ing. The voltage should be 24V. Otherwise, a
fault develops in the harness (No. 149).
• Is there a fault in the harness (No. 149)?
• Yes
Rewire.
Turn to Step 3
Fault diagnosis and elimination pro-
• No
cedures
Turn to Step 3
Step 1 Check whether the GPS connector
becomes loose and falls off.
Step 3 Check whether this fault is eliminated
• Inspection method
• Inspection method
Manually check the GPS connector for loose-
Turn the start switch to the ON position and re-
ness or fall-off
check the DTC.
• Whether the GPS connector becomes
• Has this fault been eliminated?
loose and falls off?
• Yes
• Yes
Maintenance is over
Tighten the GPS connector
• No
Turn to Step 3
Troubleshoot the faults according to the steps
• No
again or contact the local LiuGong dealer and
Turn to Step 2 authorized service center.
 6-289
CLG922E 6.4 DTC
February 3, 2015 6.4.94 DTC 261714 Level-2 forced locking, overdue payment, excavator restricted for use

6.4.94 DTC 261714 Level-2 6.4.95 DTC 261814 Please pay

forced locking, overdue pay- the due loan promptly
ment, excavator restricted for
Description of
DTC Consequence
use Fault
The excavator
Please pay the will be
Description of 261814
DTC Consequence due loan promptly. restricted for
Fault use if overdue.
Level-2 forced
locking, overdue The excavator System description
261714 payment, is restricted for
Remind the owner of payment to avoid unneces-
excavator use.
restricted for use sary faults.

System description
Fault diagnosis and elimination pro-
Use the GPS (Global Positioning System) to
position the excavator and use the GSM mobile cedures
communication network to achieve the two-way Step – Pay the loan on time.
data exchange with the central control center to
realize remote monitoring and control.

Fault diagnosis and elimination pro-

cedures
Step - Contact local LiuGong dealer and autho-
rized service center.
6-290
6.4 DTC CLG922E
6.4.96 DTC 271304 Fan reversing solenoid valve shorted to the ground February 3, 2015

6.4.96 DTC 271304 Fan revers- System description

The fan reversing solenoid valve (variable
ing solenoid valve shorted to
speed fan reversing solenoid valve) is used to
the ground control the fan’s positive and negative rotation.
To achieve that end, the controller receives the
Description of operation signal for the fan’s positive and nega-
DTC Consequence
Fault tive rotation from the instrument and controls the
Fan reversing solenoid valve through the J2-4 port.
solenoid valve The fan cannot
271304
shorted to the reverse.
ground

Fan reversing solenoid valve

Controller

Fan reversing solenoid valve

 6-291
CLG922E 6.4 DTC
February 3, 2015 6.4.96 DTC 271304 Fan reversing solenoid valve shorted to the ground

Component location Turn to Step 2

Step 2 Check the harness for short-circuit to

Front
ground

 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.

Fan reversing
Avoid friction with sharp metal edges.
solenoid valve
Try to keep far way from oil and water.

Fault diagnosis and elimination pro- Try to keep far away from high temperature
parts (e.g. engine body).
cedures
• Inspection method
Step 1 Check the fan reversing solenoid valve
for fault 1. Check the harness (No. 904) between the
controller (J2-04) and the fan reversing solenoid
 When replacing the components, please valve for wear.
be sure to use LiuGong parts. 2. Disconnect the connectors from the fan
• Inspection method reversing solenoid valve and the controller. Turn
Turn the start switch to the OFF position, and the multimeter to its resistance function, and
disconnect the fan reversing solenoid valve con- measure the resistance between the harness
nector. (No. 904) solenoid valve terminal and the
1. Check the connector for moisture, oil dirt and grounding (normally, >100K).
other. • Whether the harness is shorted to the
2. Turn the multimeter to its resistance function, ground or not?
and measure the resistance between the fan • Yes
reversing solenoid valve terminals 1 and 2 (nor- Connect the harness again and wrap the har-
mally, 16-40Ω). ness.
• Whether a fault developing in the fan Turn to Step 4
reversing solenoid valve or not? • No
• Yes Turn to Step 3
Repair or replace the fan reversing solenoid
valve.
Turn to Step 4
• No
6-292
6.4 DTC CLG922E
6.4.96 DTC 271304 Fan reversing solenoid valve shorted to the ground February 3, 2015

Step 3 Check the connector for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Connect the fan reversing solenoid valve con-
nector and disconnect the controller connector.
Turn the multimeter to its resistance function,
and measure the resistance between the con-
troller port J2-04 and the grounding (normally,
16-40Ω).
When the resistance is abnormal, this indi-
cates there is an insulation fault in the con-
nector.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-293
CLG922E 6.4 DTC
February 3, 2015 6.4.97 DTC 271305 Fan reversing solenoid valve open-circuited or shorted to the battery

6.4.97 DTC 271305 Fan System description

The fan reversing solenoid valve (variable
reversing solenoid valve open-
speed fan reversing solenoid valve) is used to
circuited or shorted to the bat- control the fan’s positive and negative rotation.
To achieve that end, the controller receives the
tery
operation signal for the fan’s positive and nega-
tive rotation from the instrument and controls the
Description of
DTC Consequence solenoid valve through the J2-4 port.
Fault
Fan reversing
solenoid valve
The fan cannot
271305 open-circuited or
reverse.
shorted to the
battery

Fan reversing solenoid valve

Controller

Fan reversing solenoid valve

6-294
6.4 DTC CLG922E
6.4.97 DTC 271305 Fan reversing solenoid valve open-circuited or shorted to the battery February 3, 2015

Component location Turn to Step 2

Step 2 Check whether the harness is open-cir-

Front
cuited or shorted to the battery.

 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.

Fan reversing
Avoid friction with sharp metal edges.
solenoid valve
Try to keep far way from oil and water.

Fault diagnosis and elimination pro- Try to keep far away from high temperature
parts (e.g. engine body).
cedures
• Inspection method
Step 1 Check the fan reversing solenoid valve
for fault 1. Check the harness (No. 904) or grounding
wire (No. 229) between the controller and the
 When replacing the components, please fan reversing solenoid valve for wear.
be sure to use LiuGong parts. Disconnect the connectors from the fan revers-
• Inspection method ing solenoid valve and the controller.
Turn the start switch to the OFF position and 2. Check whether the harness is shorted to the
disconnect the fan reversing solenoid valve con- battery. Turn the start switch to the ON position
nector: and turn on all switches of the electrical equip-
1. Check the connector for looseness, rust, ment, and then measure the voltage between
bending and damage. the harness (No. 904) solenoid valve terminal
2. Turn the multimeter to its resistance function, and the grounding (normally, 0V).
and measure the resistance between the fan 3. Check the harness for open-circuit. Turn the
reversing solenoid valve terminals 1 and 2 (nor- multimeter to its resistance function, and mea-
mally, 16-40Ω). sure the resistance of the harness (No. 904)
between the controller and the solenoid valve
• Whether a fault developing in the fan
and that of the harness (No. 229) between the
reversing solenoid valve or not?
solenoid valve and the grounding (normally,
• Yes
<10Ω).
Repair or replace the fan reversing solenoid
• Whether the harness open-circuited or
valve.
shorted to the battery or not?
Turn to Step 4
• Yes
• No
 6-295
CLG922E 6.4 DTC
February 3, 2015 6.4.97 DTC 271305 Fan reversing solenoid valve open-circuited or shorted to the battery

Connect the harness again and wrap the har- Step 4 Check whether this fault is eliminated
ness. • Inspection method
Turn to Step 4 Turn the start switch to the ON position and re-
• No check for fault.
Turn to Step 3 • Has this fault been eliminated?
• Yes
Step 3 Check the connector for fault. Maintenance is over
 When replacing the components, please • No
be sure to use LiuGong parts. Troubleshoot the faults according to the steps
• Inspection method again or contact the local LiuGong dealer and
authorized service center.
Connect the fan reversing solenoid valve con-
nector and disconnect the controller connector.
Turn the multimeter to its resistance function,
and measure the resistance between the con-
troller port J2-04 and the grounding (normally,
16-40Ω).
When the resistance is abnormal, this indi-
cates the connector is poorly contacted.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4
6-296
6.4 DTC CLG922E
6.4.98 DTC 271404 Fan drive solenoid valve shorted to the ground February 3, 2015

6.4.98 DTC 271404 Fan drive System description

The fan drive solenoid valve (variable speed fan
solenoid valve shorted to the
relief solenoid valve) is used to control the fan
ground speed. The controller provides the current
through Port J2-07 to control the relief valve
Description of which regulates the hydraulic oil pressure to
DTC Consequence
Fault drive the fan, thereby changing the fan speed.
Fan drive solenoid The fan speed
271404 valve shorted to cannot be
the ground governed.

Controller

Fan relief solenoid valve 1

Fan relief solenoid valve

Fan relief solenoid valve 2

 6-297
CLG922E 6.4 DTC
February 3, 2015 6.4.98 DTC 271404 Fan drive solenoid valve shorted to the ground

Component location Step 2 Check whether the harness is shorted to

the ground.

Front
 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.

Fan drive
Try to keep far way from oil and water.
solenoid valve
Try to keep far away from high temperature
parts (e.g. engine body).

Fault diagnosis and elimination pro- • Inspection method

cedures 1. Check the harnesses (No. 907 and No. 835)

between the controllers (J2-07 and J1-35) and
Step 1 Check the fan drive solenoid valve for
the fan drive solenoid valve for wear, respec-
fault
tively.
 When replacing the components, please 2. Disconnect the connectors from the fan drive
be sure to use LiuGong parts. solenoid valve and the controller. Turn the multi-
• Inspection method meter to its resistance function, and measure
between the harnesses (No. 907 and No. 835)
Turn the start switch to the OFF position and
the solenoid valve terminal and the grounding,
disconnect the fan drive solenoid valve connec-
respectively (normally, >100K).
tor.
1. Check the connector for moisture, oil dirt and • Whether the harness is shorted to the
other ground or not?

2. Turn the multimeter to its resistance function, • Yes

and measure the resistance between the termi- Connect the harness again and wrap the har-
nals 1 and 2 of the fan drive solenoid valve (nor- ness.
mally, 16-40Ω). Turn to Step 4
• Whether a fault developing in the fan • No
drive solenoid valve or not? Turn to Step 3
• Yes
Repair or replace fan drive solenoid valve.
Turn to Step 4
• No
Turn to Step 2
6-298
6.4 DTC CLG922E
6.4.98 DTC 271404 Fan drive solenoid valve shorted to the ground February 3, 2015

Step 3 Check the connector for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Connect the fan drive solenoid valve connector,
disconnect the controller connector, and then
turn the multimeter to its resistance function,
and measure the resistance between the con-
troller port J2-07 (normally, 16-40Ω).
When the resistance is abnormal, this indi-
cates there is an insulation fault in the con-
nector.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-299
CLG922E 6.4 DTC
February 3, 2015 6.4.99 DTC 271405 Fan drive solenoid valve open-circuited or shorted to the battery

6.4.99 DTC 271405 Fan drive System description

The fan drive solenoid valve (variable speed fan
solenoid valve open-circuited
relief solenoid valve) is used to control the fan
or shorted to the battery speed. The controller provides the current
through Port J2-07 to control the relief valve
Description of which regulates the hydraulic oil pressure to
DTC Consequence
Fault drive the fan, thereby changing the fan speed.
Fan drive solenoid The fan speed
271405 valve shorted to cannot be
the ground governed.

Controller

Fan relief solenoid valve 1

Fan relief solenoid valve

Fan relief solenoid valve 2

6-300
6.4 DTC CLG922E
6.4.99 DTC 271405 Fan drive solenoid valve open-circuited or shorted to the battery February 3, 2015

Component location Step 2 Check whether the harness is open-cir-

cuited or shorted to the battery.

Front
 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.

Fan drive
Try to keep far way from oil and water.
solenoid valve
Try to keep far away from high temperature
parts (e.g. engine body).

Fault diagnosis and elimination pro- • Inspection method

cedures 1. Check the harness (No. 907 and No. 835)

between the controller and the fan drive sole-
Step 1 Check the fan drive solenoid valve for
noid valve for wear.
fault
Disconnect the fan drive solenoid valve connec-
 When replacing the components, please tor and controller connector.
be sure to use LiuGong parts. 2. Check whether the harness is shorted to the
• Inspection method battery. Turn the start switch to the ON position
Turn the start switch to the ON position and dis- and switch on the switches of all electrical
connect the fan drive solenoid valve connector: equipment, and then measure the voltage
between the harness (No. 907 and No. 835)
1. Check the connector for looseness, rust,
solenoid valve terminal and the grounding (nor-
bending and damage.
mally, 0V).
2. Turn the multimeter to its resistance function,
3. Check the harnesses for open-circuit. Turn
and measure the resistance between the fan
the multimeter to its resistance function, and
drive solenoid valve terminals 1 and 2 (normally,
measure the resistance of the harnesses (No.
16-40Ω).
907 and No. 835) between the controller and the
• Whether a fault developing in the fan
solenoid valve, respectively (normally,<10Ω).
drive solenoid valve or not?
• Whether the harness open-circuited or
• Yes
shorted to the battery or not?
Repair or replace fan drive solenoid valve.
• Yes
Turn to Step 4
Connect the harness again and wrap the har-
• No
ness.
Turn to Step 2 Turn to Step 4
• No
 6-301
CLG922E 6.4 DTC
February 3, 2015 6.4.99 DTC 271405 Fan drive solenoid valve open-circuited or shorted to the battery

Turn to Step 3

Step 3 Check the connector for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Connect the fan drive solenoid valve and dis-
connect the controller connector, and then turn
the multimeter to its resistance function, and
measure the resistance between the controller
ports J2-04 and J1-35 (normally,16-40Ω).
When the resistance is abnormal, this indi-
cates the connector is poorly contacted.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
6-302
6.4 DTC CLG922E
6.4.100 DTC 271505 Fan drive solenoid valve feedback open-circuited February 3, 2015

6.4.100 DTC 271505 Fan drive System description

The fan drive solenoid valve (variable speed fan
solenoid valve feedback open-
relief solenoid valve) is used to control the fan
circuited speed. The controller provides the current
through Port J2-07 to control the relief valve
Description of which regulates the hydraulic oil pressure to
DTC Consequence
Fault drive the fan, thereby changing the fan speed.
Fan drive solenoid The fan speed
271505 valve feedback cannot be
open-circuited governed.

Controller

Fan relief solenoid valve 1

Fan relief solenoid valve

Fan relief solenoid valve 2

 6-303
CLG922E 6.4 DTC
February 3, 2015 6.4.100 DTC 271505 Fan drive solenoid valve feedback open-circuited

Component location Step 2 Check the harness for open-circuit.

 Correctly tie up harness and wire:

Front Avoid folding or bending the harness forci-
bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Fan drive Try to keep far away from high temperature
solenoid valve
parts (e.g. engine body).
• Inspection method
Fault diagnosis and elimination pro- 1. Check the harness (No. 907/No. 835)
cedures between the controller and the fan drive sole-
noid valve for wear.
Step 1 Check the fan drive solenoid valve for
fault 2. Disconnect the connectors from the fan drive
solenoid valve and the controller. Turn the multi-
 When replacing the components, please meter to its resistance function, and measure
be sure to use LiuGong parts. the resistance of the harnesses (No. 907 and
• Inspection method No. 835) between controller and the solenoid
Turn the start switch to the ON position and dis- valve (normally, <10Ω).
connect the fan drive solenoid valve connector: • Is the harness open?
1. Check the connector for looseness, rust, • Yes
bending and damage. Connect the harness again and wrap the har-
2. Turn the multimeter to its resistance function, ness.
and measure the resistance between the fan Turn to Step 4
drive solenoid valve terminals 1 and 2 (normally, • No
16-40Ω).
Turn to Step 3
• Whether a fault developing in the fan
drive solenoid valve or not?
• Yes
Repair or replace fan drive solenoid valve.
Turn to Step 4
• No
Turn to Step 2
6-304
6.4 DTC CLG922E
6.4.100 DTC 271505 Fan drive solenoid valve feedback open-circuited February 3, 2015

Step 3 Check the connector for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Connect the fan drive solenoid valve and dis-
connect the controller connector, and then turn
the multimeter to its resistance function, and
measure the resistance between the controller
ports J2-04 and J1-35 (normally,16-40Ω).
When the resistance is abnormal, this indi-
cates the connector is poorly contacted.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
 6-305
CLG922E 6.4 DTC
February 3, 2015 6.4.101 DTC 271505 Fan drive solenoid valve feedback overcurrent

6.4.101 DTC 271505 Fan drive System description

The fan drive solenoid valve (variable speed fan
solenoid valve feedback over-
relief solenoid valve) is used to control the fan
current speed. The controller provides the current
through Port J2-07 to control the relief valve
Description of which regulates the hydraulic oil pressure to
DTC Consequence
Fault drive the fan, thereby changing the fan speed.
Fan drive solenoid The fan speed
271506 valve feedback cannot be
open-circuited governed.

Controller

Fan relief solenoid valve 1

Fan relief solenoid valve

Fan relief solenoid valve 2

6-306
6.4 DTC CLG922E
6.4.101 DTC 271505 Fan drive solenoid valve feedback overcurrent February 3, 2015

Component location Step 2 Check the harness for short-circuit

 Correctly tie up harness and wire:

Front Avoid folding or bending the harness forci-
bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Fan drive Try to keep far away from high temperature
solenoid valve
parts (e.g. engine body).
• Inspection method
Fault diagnosis and elimination pro- 1. Check the harnesses (No. 904/No. 835)
cedures between the controllers (J2-04 and J1-35) and
the fan drive solenoid valve for wear, respec-
Step 1 Check the fan drive solenoid valve for
tively.
fault
Disconnect both the controller and the solenoid
 When replacing the components, please valve:
be sure to use LiuGong parts. 2. Check the two harnesses for short-circuit:
• Inspection method Turn the multimeter to its resistance function,
Turn the start switch to the ON position and dis- and measure the resistance of the harness (No.
connect the fan drive solenoid valve connector: 904/No. 835) between the solenoid valve termi-
nals (normally, >100K).
1. Check the connector for moisture, oil dirt and
other 3. Check whether the harness is shorted to the
battery. Turn the start switch to the ON position
2. Turn the multimeter to its resistance function,
and switch on the switches of all electrical
and measure the resistance between the fan
equipment, and then measure the voltage
drive solenoid valve terminals 1 and 2 (normally,
between the harness (No. 904/No. 835) sole-
16-40Ω).
noid valve terminal and the grounding (normally,
• Whether a fault developing in the fan
0V).
drive solenoid valve or not?
• Is the harness short?
• Yes
• Yes
Repair or replace fan drive solenoid valve.
Connect the harness again and wrap the har-
Turn to Step 4
ness.
• No
Turn to Step 4
Turn to Step 2
• No
 6-307
CLG922E 6.4 DTC
February 3, 2015 6.4.101 DTC 271505 Fan drive solenoid valve feedback overcurrent

Turn to Step 3

Step 3 Check the connector for fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Connect the fan drive solenoid valve connector,
disconnect the controller connector, and then
turn the multimeter to its resistance function,
and measure the resistance between the con-
troller ports J2-04 and J1-35 (normally, 16-40Ω).
When the resistance is abnormal, this indi-
cates there is an insulation fault in the con-
nector.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Turn the start switch to the ON position and re-
check for fault.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealer and
authorized service center.
6-308
6.5 Fault diagnosis of electrical system CLG922E
6.5.1 E1-Troubleshooting for battery undervoltage February 3, 2015

6.5 Fault diagnosis of elec-

trical system
6.5.1 E1-Troubleshooting for
battery undervoltage

Fault SN Faults Consequence

Battery is The battery is
E1
undercharged damaged

System description
The battery functions: Store the electric energy;
when the engine starts and powers the motor;
Fault diagnosis and elimination pro-
for gasoline engine, it can power the ignition cedures
system; stabilize the system voltage; when the Step 1 The battery needs to be charged.
motor does not generate electricity or the volt-
age is low, the battery powers the electric equip-
 Check the battery hydrometer color
when the start switch is in "OFF" posi-
ment; when the motor is overloaded because of
tion.
too many electric equipment, the battery assists
the motor to power; the battery is equivalent to a • Inspection method
big capacitor, it will protect the components and 1. Check the color of the battery hydrometer
parts in case of transient overvoltage. through the opening on the cover of the battery,
black means that the battery needs to be
charged.
2. Measure the battery voltage with the multime-
Hydrometer
ter. Turn the multimeter to its DC voltage func-
tion (200V), and connect the red probe to the
OK positive battery terminal and the black probe to
the negative battery terminal. Under the normal
Change
condition, the voltage is 24V. If the voltage is too
Replace
low, the battery needs to be charged.
• Whether the battery needs to be
charged or not?
• Yes
Charging of battery
Turn to Step 3
• No
Turn to Step 2
 6-309
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.1 E1-Troubleshooting for battery undervoltage

Step 2 The battery is aging and lack of power.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
The machine does not work for a long time and
the battery has not been charged so it is lack of
power seriously. Check it by referring to E2.
• Is the battery lack of power because of
aging?
• Yes
Replace it with a new one.
Turn to Step 3
• No
Turn to Step 3

Step 3 Check whether this fault is eliminated

• Inspection method
After replacing a new battery, connect the bat-
tery firmly.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealers and
authorized service centers.
6-310
6.5 Fault diagnosis of electrical system CLG922E
6.5.2 E2-Troubleshooting for abnormal battery February 3, 2015

6.5.2 E2-Troubleshooting for Component location

abnormal battery

Fault SN Faults Consequence

The battery is The battery is
E2
abnormal damaged

System description
The battery functions: Store the electric energy;
when the engine starts and powers the motor;
for gasoline engine, it can power the ignition
system; stabilize the system voltage; when the
motor does not generate electricity or the volt-
age is low, the battery powers the electric equip-
Fault diagnosis and elimination pro-
ment; when the motor is overloaded because of
too many electric equipment, the battery assists
cedures
the motor to power; as the battery is equivalent Step 1 Normal battery level
to a big capacitor, it will protect the components  Check the battery hydrometer color
and parts in case of transient overvoltage.
when the start switch is in "OFF" posi-
Common maintenance: The electric quantity
tion.
of the battery can be learned by the change
• Inspection method
of the hydrometer color. Green – normal,
black – requiring to be charged, white – the Check the color of battery hydrometer through
battery is scrap. the opening on the cover of the battery.
• Is the color of battery hydrometer
green?
• Yes
Hydrometer The battery level is normal.
Turn to Step 4
OK
• No
Change Turn to Step 2
Replace
 6-311
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.2 E2-Troubleshooting for abnormal battery

Step 2 The battery needs to be charged. Step 4 Check whether this fault is eliminated

 Check the battery hydrometer color • Inspection method

when the start switch is in "OFF" posi- Check the color of battery hydrometer through
tion. the opening on the cover of the battery.
• Has this fault been eliminated?
• Inspection method
Check the color of battery hydrometer through • Yes
the opening on the cover of the battery. Maintenance is over
• Is the color of battery hydrometer • No
black? Troubleshoot the faults according to the steps
• Yes again or contact the local LiuGong dealers and
authorized service centers.
Charging of battery
Turn to Step 4
• No
Turn to Step 3

Step 3 The battery is scrap.

 Check the battery hydrometer color

when the start switch is in "OFF" posi-
tion.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Check the color of battery hydrometer through
the opening on the cover of the battery.
• Is the color of battery hydrometer
white?
• Yes
Repair or replace battery
Turn to Step 4
• No
Turn to Step 4
6-312
6.5 Fault diagnosis of electrical system CLG922E
6.5.3 E3-Automatic slowdown failed February 3, 2015

6.5.3 E3-Automatic slowdown System description

When you are not operating the lever, pedal or
failed
attachment control lever, the engine speed will
Fault SN Faults Consequence
drop to the preset idle speed so as to achieve
Increased fuel the purpose of reducing fuel consumption or
Automatic
E3 consumption
slowdown failed noise. Once you are operating the lever, pedal
and noise
or attachment control lever, the engine speed
will immediately return to the point that the cur-
rent throttle knob corresponds to.

Engine controller

(Black)
Monitor
CAN 1/2 shield

CAN 1 low

CAN 1 high

Handle pilot
pressure switch
Engine speed dial
5V power supply
12-position throttle
potentiometer

(White)
Pedal pressure switch

Sensor to ground

Pressure switch

Pressure switch
 6-313
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.3 E3-Automatic slowdown failed

Component location Fault diagnosis and elimination pro-

cedures
Step 1 Operate the automatic idle speed control
Handle pressure switch
key to cancel the automatic idle speed function.
Pedal pressure switch
• Whether the idling speed function is
canceled or not?

Pressure switch
• Yes
of appurtenances
Operate the control key of automatic idle speed
to enable the automatic idle speed function.
Turn to Step 4
• No
Turn to Step 2

Step 2 Select mode L.

• Inspection method
Display
Accelerator knob
Check the display for automatic idle speed icon
and no icon means the automatic idle speed
function is canceled.
• Whether the idling speed function is
canceled or not?
• Yes
Operate the control key of automatic idle speed
to enable the automatic idle speed function.
Turn to Step 4
• No

ECU controller
Turn to Step 3
6-314
6.5 Fault diagnosis of electrical system CLG922E
6.5.3 E3-Automatic slowdown failed February 3, 2015

Step 3 121305, 121405, 231012, 231014 alarm

appears on the display.
• Inspection method
Turn “ON” the start switch, and then check the
alarm on the display.
• Whether 121305, 121405, 231012,
231014 alarm appears on the display or
not?
• Yes
Overhaul the machine in accordance with the
corresponding fault diagnosis and exclusion
step of the DTC.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Operate the machine, and check whether each
action is normal.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Find out the engine system fault or contact the
local LiuGong dealers or authorized service cen-
ters.
 6-315
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.4 E4-Engine start fault

6.5.4 E4-Engine start fault System description

In the condition where there is no fault on the
Fault SN Faults Consequence machine and the excavator is started in the cor-
Engine cannot be rect steps, and when the electric lock is
E4 started (the engine Failed to work switched to “Start” position, the start relay is
does not rotate)
jointly driven by the actuating signal controlled
by ECM, IPC and handle control signal of pilot
actuating. Send the power supply signal to the
start power end of the start motor, so as to start
the engine.

Start relay K1

Battery
To ignition switch B2

Battery moter

Battery relay

Engine earthing
6-316
6.5 Fault diagnosis of electrical system CLG922E
6.5.4 E4-Engine start fault February 3, 2015

Ignition witch
Pilot solenoid valve switch

IPC Controller
Engine start
To battery relay B

Start cut-off valve relay

Engine controller

Start protection

Preheating ground wire

 6-317
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.4 E4-Engine start fault

Electric lock power

supply 20A

Pilot cut-off 10A

Satety relay K11 Pilot control start relay K7 Controller control start relay K8 ECM control start relay K9
6-318
6.5 Fault diagnosis of electrical system CLG922E
6.5.4 E4-Engine start fault February 3, 2015

Component location Fault diagnosis and elimination pro-

cedures
Step 1 Immobilization alarm appears on the dis-
Ignition switch IPC controller
play.
• Inspection method
Turn “ON” the start switch, and then check the
alarm on the display.
• Is the alarm with the DTC of
261711.261714 appears on the display?

Pilot cut-off
Fuse box • Yes
valve switch
Overhaul the machine in accordance with the
corresponding fault diagnosis and exclusion
step of the DTC.
Turn to Step 15
• No
Starting motor Turn to Step 2

Step 2 Fuel level is too low.

• Inspection method
Check the fuel level.
• Whether the fuel level is low or not?
• Yes
Refuel.
Turn to Step 15
• No
ECU controller Turn to Step 3
 6-319
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.4 E4-Engine start fault

Step 3 Battery voltage is too low. Step 4 Blowing of fuse.

 When replacing the components, please  The start switch is in OFF state.
be sure to use LiuGong parts.
 When replacing the components, please
• Inspection method
be sure to use LiuGong parts.
1.Turn “ON” the start switch, and then check the
• Inspection method
display for the alarm with the DTC of
1. Open the electronic control unit, remove the
101001.101017.
fuse, visibly check whether the fuse blows or
2. Measure the battery voltage with the multime-
check whether both ends of the fuse are con-
ter. Turn the multimeter to its DC voltage func-
nected by the multimeter on the diode gear.
tion (200V), and connect the red probe to the
2. Open the fuse box, unplug the fuses 1 and 14
positive battery terminal and the black probe to
by a fuse clip, and observe by visual inspection
the negative battery terminal. See the schematic
whether the fuse is blown or turn the multimeter
diagram for detection as follows:
to its diode function to measure whether both
ends of fuse are connected.
Notice: There may be ground fault, so please
refer to step 14.
• Is fuse blown?
• Yes
Replace fuse
Turn to Step 15
• No
Black probe Turn to Step 5
Red probe

Voltage value is 24V in the normal condition.

• Whether the battery voltage is too low or
not?
• Yes
Overhaul the machine in accordance with the
corresponding fault diagnosis and exclusion
steps of the DTC, or charge the battery or
replace the battery.
Turn to Step 15.
• No
Turn to Step 4
6-320
6.5 Fault diagnosis of electrical system CLG922E
6.5.4 E4-Engine start fault February 3, 2015

Step 5 Start switch fault • Whether the disconnecting switch of

pilot solenoid valve fails or not?
 Remove the battery cable (-).
• Yes
 When replacing the components, please
Repair or replace the pilot solenoid cut-off
be sure to use LiuGong parts. switch
• Inspection method Turn to Step 15
Measure the resistance between the start switch • No
B1 and S with multimeter. Turn to Step 7
1. When the start switch is turned to OFF state,
the resistance between B1 and S is infinite. Step 7 Safety relay K11 fault
2. When the start switch is turned to START
state, the resistance between B1 and S is less
 When replacing the components, please

than 10Ω. be sure to use LiuGong parts.

• Is there fault on the start switch? • Inspection method

• Yes Measure the resistance among all contacts of

safety relay K11 with a multimeter.
Replace the start switch
Remove safety relay K11, and then measure the
Turn to Step 15
resistance among all contacts.
• No
• The resistance between 85 and 86 (coil
Turn to Step 6
resistance) is about 353-358Ω.
• The resistance between 30 and 87 is
Step 6 Pilot solenoid start switch fault
infinite.
 The start switch is in OFF state.
• The resistance between 30 and 87a is less
 When replacing the components, please than 10Ω.
2. Switch on 24V power to both ends of 85 and
be sure to use LiuGong parts.
86, and measure the resistance between each
• Inspection method
two contacts.
Measure the resistance between the pilot sole-
• The resistance between 30 and 87 is less
noid cut-off switch S13 (1) and X33 (3) with mul-
than 10Ω.
timeter.
• The resistance between 30 and 87a is
1. When the switch of pilot solenoid valve is
infinite.
turned to Locked state, the resistance between
S13 (male 1) and S13 (male 3) is less than 10Ω. • Whether safety relay K11 fails or not？
2. When the switch of pilot solenoid valve is • Yes
turned to Unlocked state, the resistance Replace the safety relay.
between S13 (male 1) and S13 (male 3) is Turn to Step 15
infinite. • No
 6-321
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.4 E4-Engine start fault

Turn to Step 8 Step 9 start relay K8 controlled by controller

fails.
Step 8 Pilot control start relay K7 fails.  When replacing the components, please
 When replacing the components, please be sure to use LiuGong parts.
be sure to use LiuGong parts. • Inspection method
• Inspection method Measure the resistance among all contacts of
Measure the resistance among all contacts of start relay K8 controlled by controller with a mul-
pilot control start relay K7 with a multimeter. timeter.
1. Remove pilot control start relay K7, and then 1. Remove start relay K8 controlled by control-
measure the resistance among all contacts. ler, and then measure the resistance among all
contacts.
• The resistance between 85 and 86 (coil
resistance) is about 353-358Ω. • The resistance between 85 and 86 (coil
resistance) is about 353-358Ω.
• The resistance between 30 and 87 is
infinite. • The resistance between 30 and 87 is
infinite.
• The resistance between 30 and 87a is less
than 10Ω. • The resistance between 30 and 87a is less
2. Switch on 24V power to both ends of 85 and than 10Ω.
86, and measure the resistance between each 2. Switch on 24V power to both ends of 85 and
two contacts. 86, and measure the resistance between each
two contacts.
• The resistance between 30 and 87 is less
than 10Ω. • The resistance between 30 and 87 is less
than 10Ω.
• The resistance between 30 and 87a is
infinite. • The resistance between 30 and 87a is
infinite.
• Whether pilot control start relay K7 fails
or not? • Whether start relay K8 controlled by
controller fails or not?
• Yes
Replace the pilot control start relay. • Yes

Turn to Step 15 Replace the start relay controlled by a controller.

Turn to Step 15
• No
Turn to Step 9 • No
Turn to Step 10
6-322
6.5 Fault diagnosis of electrical system CLG922E
6.5.4 E4-Engine start fault February 3, 2015

Step 10 ECM controller start relay K9 fails. Step 11 start relay K1 fails.

 When replacing the components, please  When replacing the components, please
be sure to use LiuGong parts. be sure to use LiuGong parts.
• Inspection method • Inspection method
Measure the resistance among all contacts of Measure the resistance among all contacts of
ECM controller start relay K9 with a multimeter. start relay K1 with a multimeter.
1. Remove ECM controller start relay K9, and 1. Remove the start relay K1, and then measure
then measure the resistance among all con- the resistance among all contacts.
tacts. • The resistance of coil is about 79-81Ω.
• The resistance between 85 and 86 (coil • The resistance of the main contact is
resistance) is about 353-358Ω. infinite.
• The resistance between 30 and 87 is 2. Supply 24V power to both ends of the coil and
infinite. measure the resistance between two main con-
• The resistance between 30 and 87a is less tacts.
than 10Ω. The resistance between two main contacts is
2. Switch on 24V power to both ends of 85 and less than 10Ω.
86, and measure the resistance between each • Whether start relay K1 fails or not?
two contacts. • Yes
• The resistance between 30 and 87 is less Replace the starter relay.
than 10Ω. Turn to Step 15
• The resistance between 30 and 87a is • No
infinite.
Turn to Step 12
• Whether ECM controller start relay K9
fails or not?
• Yes
Replace the ECM controller start relay.
Turn to Step 15
• No
Turn to Step 11
 6-323
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.4 E4-Engine start fault

Step 12 Internal fault of starter motor switch to OFF position, measure the resistance
of the following circuit, and the resistance shall
 Remove the wiring on the input end 50
be all less than 10Ω in normal condition.
and end 30 on the start motor.
1. Wire 137 on the main contact of battery relay
 When replacing the starter motor, - wire 136 of the main contact of start relay K1.
please be sure to use the LiuGong parts. 2. Wire 182 on the main contact of start relay K1
- end 30 of starter motor.
• Inspection method
3. Wire 004 on the main contact of battery relay
1. Turn the start switch to ON position, and then
- X2(8) - X1(5) - end B1 of start switch.
measure the voltage to earth of wire 108 on the
end 50, and make sure it is 24V. 4. End S of start switch - X2(2) - end 30 of start
relay K7 controlled by pilot.
2. Turn the start switch to START position, and
then measure the voltage to earth of wire 182 on 5. End 87 of start relay K7 controlled by pilot -
the end 30, and make sure it is 24V. start relay K8 (30-87A) controlled by controller -
ECN control start relay K9k8 (30-87A) - X1(19) -
If the input signals are normal, but the starter
wire 181 on the start relay K1.
motor does not rotate, it can be judged that
there is an internal fault in the starter motor. 6. Wire 260 on the start relay K1 - frame ground
(GND)
• Whether the start motor has internal
7. Wire 102 on the main contact of battery relay
fault or not？
- end 30 of the safety relay K11.
• Yes
8. End 87 of safety relay K11 - X1(21) - switch of
Replace the start motor. pilot shut -off valve (3-1) - X2(3) - end 86 of start
Turn to Step 15 relay K7 controlled by pilot.
• No 9. Wire 85 on the start relay K7 controlled by
Turn to Step 13 pilot - frame ground (GND).
10. End B2 of start switch - X1(28) - end 86 of
Step 13 Open circuit of wire in harness or poor safety relay K11.
connector contact. 11. Wire 85 on the safety relay K11 - frame
ground (GND).
 Correctly tie up harness and wire.
12. J2(female 23) - X2(15) - end 86 of the start
Avoid folding or bending the harness forci- relay K8 controlled by controller.
bly. 13. End 85 on the start relay K8 controlled by
It shall be kept away from moving compo- controller - frame ground (GND).
nents as far as possible to prevent tensile 14. J2 (female 9) - X2(11) - end 86 of the start
fault and wear. relay K7 controlled by ECM.
Avoid friction with sharp metal edges. 15. End 86 of the start relay K7 controlled by
Try to keep far way from oil and water. ECM - X2(9) - J22 (female 57).
• Inspection method 16. End S of start switch - J1 (female 10).
Remove the battery cable (-), and turn the start 17. End B2 of start switch - End of battery relay.
6-324
6.5 Fault diagnosis of electrical system CLG922E
6.5.4 E4-Engine start fault February 3, 2015

18. End E of battery relay - frame ground (GND). Connect the harness again and wrap the har-
• Is the harness open? ness

• Yes Turn to Step 15

Connect the harness again and wrap the har- • No

ness Turn to Step 4
Turn to Step 15
• No Step 15 Check whether this fault is eliminated

Turn to Step 14 • Inspection method

Operate the machine, and check whether each
Step 14 The inside conductor of harness 14 action is normal.
forms a short circuit with earthing cable. • Has this fault been eliminated?

 Shutdown operation is needed • Yes

Maintenance is over
• Inspection method
• No
Remove the battery cable (-), and turn the start
Troubleshoot the faults according to the steps
switch to OFF position, check whether the fol-
again or contact the local LiuGong dealers and
lowing circuit forms a short circuit with the
authorized service centers.
ground, and normally the resistance between
any check point and the ground shall be greater
than 1MΩ.
1. Wire 137 on the main contact of battery relay
- main contact of start relay K1 - end 30 of the
start motor.
2. Wire 004 on the main contact of battery relay
-X1(5)- start switch (B1-S) - X2(2) - relay
K7.K8.K9 (main contact) -X1(19)- wire 181 on
the coil contact of start relay K1.
3. Start switch (B1-B2) - X2(28) - end 86 of
safety relay K11.
4. Wire 102 on the main contact of battery relay
-X2(12) - safety relay K11 (main contact) -
X1(21) - switch of pilot shut-off valve (3-1) -
X2(3) - end 86 of start relay K7 controlled by
pilot.
5. Start switch (B1-S)-J1 (female 10).
• Is the harness short?
• Yes
 6-325
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.5 E5-Engine shutdown during operation

6.5.5 E5-Engine shutdown System description

During the operation, the engine may be choked
during operation
because of overload, or because of open circuit
in the power circuit of the engine controller. The
Fault SN Faults Consequence
supply circuit of engine controller is shown in the
Engine shutdown
E5 System fault following figure.
during operation.

Ignition switch

Engine controller

Ignition
Switch ON
Engine controller 5A
Power -
Engine controller 30A Power -
Power -
Electric lock power 20A Power +

Power +
Power +
6-326
6.5 Fault diagnosis of electrical system CLG922E
6.5.5 E5-Engine shutdown during operation February 3, 2015

Component location 2. When the start switch is turned to ON posi-

tion, the resistance between B1 and S is less
than 10Ω.
• Is ignition switch damaged?
Ignition switch
• Yes
Replace the start switch
Turn to Step 5
• No
Turn to Step 2

Fuse box
Step 2 Blowing of fuse.

 The start switch is in OFF state.

 When replacing the components, please

be sure to use LiuGong parts.
ECU controller
• Inspection method
1. Open the electronic control unit, remove the
fuse, visibly check whether the fuse blows or
check whether both ends of the fuse are con-
nected by the multimeter on the diode gear.
2. Open the fuse box, unplug the fuses 12, 13
and 14 by a fuse clip, and observe by visual
inspection whether the fuse is blown or turn the
multimeter to its diode function to measure
Fault diagnosis and elimination pro- whether both ends of fuse are connected.

cedures Notice: There may be ground fault, so please

refer to step 4.
Step 1 Start switch fault (internal open circuit)
• Is fuse blown?
 Remove the battery cable (-).
• Yes
 When replacing the components, please Replace fuse
be sure to use LiuGong parts. Turn to Step 5

• Inspection method • No

Measure the resistance between the start switch Turn to Step 3

B1 and B2 with multimeter.
1. When the start switch is turned to OFF state,
the resistance between B1 and B2 is infinite.
 6-327
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.5 E5-Engine shutdown during operation

Step 3 Open circuit of wire in harness or poor Step 4 Conductor in harness -- short circuit with
connector contact. ground wire

 Correctly tie up harness and wire.  Shutdown operation is needed

Avoid folding or bending the harness forci- • Inspection method

bly. Remove the battery cable (-), and turn the start
It shall be kept away from moving compo- switch to OFF position, check whether the fol-
nents as far as possible to prevent tensile lowing circuit forms a short circuit with the
fault and wear. ground, and normally the resistance between
Avoid friction with sharp metal edges. any check point and the ground shall be greater
Try to keep far way from oil and water. than 1MΩ.

• Inspection method 1. Fuse terminal 50 - X2(8) - X1(5) - end B1 of

start switch.
Remove the battery cable (-), and turn the start
switch to OFF position, measure the resistance 2. X2 (male8)-X1(2)-J22 (female 1, female 3,
of the following circuit, and the resistance shall female 5).
be all less than 10Ω in normal condition. 3. End B2 of start switch - X1(28) - X2(1) - J22
1. Fuse terminal 50 - X2(8) - X1(5) - end B1 of (female 15).
start switch. • Is the harness short?
2. X2 (8) - X1(2) - J(22)(1, 3, 5) • Yes
3. End B2 of start switch - X1(28) - X2(1) - J22 Connect the harness again and wrap the har-
(female 15). ness
4. J22 (female 2, female 4, female 6) - frame Turn to Step 5
ground (GND). • No
• Is the harness open? Turn to Step 5
• Yes
Connect the harness again and wrap the har- Step 5 Check whether this fault is eliminated
ness • Inspection method
Turn to Step 5 Operate the machine, and check whether each
• No action is normal.
Turn to Step 4 • Has this fault been eliminated?
• Yes
Maintenance is over
• No
Find out the engine system fault or contact the
local LiuGong dealers or authorized service cen-
ters.
6-328
6.5 Fault diagnosis of electrical system CLG922E
6.5.6 E6-Engine non-shutdown February 3, 2015

6.5.6 E6-Engine non-shutdown System description

While the machine is operating, start switch is
Fault SN Faults Consequence turned from ON to OFF to shut off the start sig-
Engine non- nal of engine controller, so that the engine shuts
E6 System fault
shutdown down. The supply circuit of engine controller is
shown in the following figure.

Ignition switch

Engine controller

Ignition
Switch ON
Engine controller 5A
Power -
Engine controller 30A Power -
Power -
Electric lock power 20A Power +

Power +
Power +
 6-329
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.6 E6-Engine non-shutdown

Component location Fault diagnosis and elimination pro-

cedures
Step 1 Start switch fault (internal short circuit)

Ignition switch  Remove the battery cable (-).

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Measure the resistance between the start switch
Fuse box
B1 and B2 with multimeter.
1. When the start switch is turned to OFF state,
the resistance between B1 and B2 is infinite.
2. When the start switch is turned to ON posi-
tion, the resistance between B1 and S is less
than 10Ω.
ECU controller
• Is ignition switch damaged?
• Yes
Replace the start switch
Turn to Step 3
• No
Turn to Step 2

Step 2 Harness fault.

 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
• Inspection method
Remove the battery cable (-), and turn the start
switch to OFF position, check whether the fol-
lowing circuit forms a short circuit with the bat-
6-330
6.5 Fault diagnosis of electrical system CLG922E
6.5.6 E6-Engine non-shutdown February 3, 2015

tery (+), and normally the resistance between

any check point and the battery (+) shall be
greater than 1MΩ.
End B2 of start switch - X1(28) - X2(1) - J22
(female 15).
• Is there fault in the harness?
• Yes
Connect the harness again and wrap the har-
ness
Turn to Step 3
• No
Turn to Step 3

Step 3 Check whether this fault is eliminated

• Inspection method
Operate the machine, and check whether each
action is normal.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Find out the engine system fault or contact the
local LiuGong dealers or authorized service cen-
ters.
 6-331
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.7 E7-Preheater fault

6.5.7 E7-Preheater fault System description

The preheat function is divided into manual pre-
Fault SN Faults Consequence heat and automatic preheat. Manual preheat
It is difficult to means to turn the start switch from OFF position
E7 Preheater fault start or won’t to HEAT position, preheat relay K3 is close, and
start.
the battery supplies power to the preheater of
the engine. Automatic preheat means that the
engine controller can make judgment based on
the external environment to determine whether it
requires preheat or not. When preheat is
required in accordance with the judgment, the
output of J22-31 on engine controller is 24V, the
driving automatic preheat relay K10 is close to
make preheat relay K3 powered, so that the pre-
heat relay K3 is close and the battery supplies
power to the engine. The figure below is the
electrical circuit diagram of engine preheater.

Preheating relay K3

Grid heater

Battery relay Diode

Auto preheating 10A

Engine controller

Air intake
preheating (+)
Preheating
ground wire

Ignition switch

Auto preheating relay K10

6-332
6.5 Fault diagnosis of electrical system CLG922E
6.5.7 E7-Preheater fault February 3, 2015

Component location Fault diagnosis and elimination pro-

cedures
Step 1 Start switch fault

Ignition switch  Remove the battery cable (-).

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Measure the resistance between the start switch
Fuse box
B1 and G1 with multimeter.
1. When the start switch is turned to OFF state,
the resistance between B1 and G2 is infinite.
2. When the start switch is turned to HEAT posi-
tion, the resistance between B1 and G1 is less
Preheater
than 10Ω.
• Is ignition switch damaged?
• Yes
Replace the start switch
Turn to Step 7
• No
Turn to Step 2
Engine controller

Step 2 Preheating relay fault (internal fault)

 When replacing the preheating relay,

please make sure to use LiuGong parts.
• Inspection method
Measure the resistance among all contacts of
preheat relay K3 with a multimeter.
1. Remove the preheat relay K3, and then mea-
sure the resistance among all contacts.
• The resistance of coil is about 61-63Ω.
• The resistance of the main contact is
infinite.
2. Supply 24V power to both ends of the coil and
measure the resistance between two main con-
 6-333
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.7 E7-Preheater fault

tacts.  Correctly tie up harness and wire.

The resistance between two main contacts is
Avoid folding or bending the harness forci-
less than 10Ω.
bly.
• Is there a fault in the preheating relay?
It shall be kept away from moving compo-
• Yes nents as far as possible to prevent tensile
Replace the preheating relay. fault and wear.
Turn to Step 7 Avoid friction with sharp metal edges.
• No Try to keep far way from oil and water.
Turn to Step 3 • Inspection method
Remove the battery cable (-), and turn the start
Step 3 Blowing of fuse. switch to OFF position, measure the resistance
 The start switch is in OFF state. of the following circuit, and the resistance shall
be all less than 10Ω in normal condition.
 When replacing the components, please 1. Wire 105 on the main contact of battery relay -
be sure to use LiuGong parts. wire 104 of the main contact of preheat relay K3.
• Inspection method 2. Wire 185 on the main contact of preheat relay
1. Open the electronic control unit, remove the K3 - terminal of the preheater.
fuse, visibly check whether the fuse blows or 3. End G1 of start switch - wire 190 on the coil of
check whether both ends of the fuse are con- preheat relay K3.
nected by the multimeter on the diode gear. 4. Wire 260 on the preheat relay K3 - frame
2. Open the fuse box, unplug the fuses 2 by a ground (GND).
fuse clip, and observe by visual inspection 5. End 87 of automatic preheat relay - X1(20) -
whether the fuse is blown or turn the multimeter wire 190 on the coil of preheat relay K3.
to its diode function to measure whether both 6. Wire 102 on the main contact of battery relay
ends of fuse are connected. - X2(12) - end 30 of the automatic preheat relay
Notice: There may be ground fault, so please K10.
refer to step 5. 7. End 86 of the automatic preheat relay K10 -
• Is fuse blown? X2(7)-J22 (female 31).
8. End 85 of the automatic preheat relay K10 -
• Yes
X2(9)-J22 (female 57).
Replace fuse
• Is the harness open?
Turn to Step 7
• Yes
• No
Connect the harness again and wrap the harness
Turn to Step 4
Turn to Step 7

Step 4 Open circuit of wire in harness or poor • No

connector contact. Turn to Step 5
6-334
6.5 Fault diagnosis of electrical system CLG922E
6.5.7 E7-Preheater fault February 3, 2015

Step 5 Conductor in harness - short circuit with Step 6 Preheater fault

ground wire.
 When replacing the preheater, please be
 Shutdown operation is needed sure to use LiuGong parts.
• Inspection method • Inspection method
Remove the battery cable (-), and turn the start Turn the start switch to HEAT position, when the
switch to OFF position, check whether the fol- voltage measured between the terminal of pre-
lowing circuit forms a short circuit with the heater and the ground is 24V, if the preheater
ground, and normally the resistance between still does not work, it can be determined as the
any check point and the ground shall be greater internal fault of the preheater.
than 1MΩ. • Is there a fault in the preheater?
1. Wire 105 on the main contact of battery relay • Yes
- main contact of preheat relay K3 - terminal of
Replace the preheater.
preheater.
Turn to Step 7
2. End G1 of start switch - wire 190 on the coil of
• No
preheat relay K3.
3. Wire 102 on the main contact of battery relay Turn to Step 7

- X2(12) - automatic preheat relay K10 (main

contact) - X1(20)- wire190 on the coil of preheat Step 7 Check whether this fault is eliminated
relay K3. • Inspection method
• Is the harness short? Operate the machine, and check whether each
• Yes action is normal.

Connect the harness again and wrap the har- • Has this fault been eliminated?
ness • Yes
Turn to Step 7 Maintenance is over
• No • No
Turn to Step 6 Find out the engine system fault or contact the
local LiuGong dealers or authorized service cen-
ters.
 6-335
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.8 E8-All the work implements, revolving and travel unable to move

6.5.8 E8-All the work imple- System description

Power on, pull up the disconnection switch of
ments, revolving and travel
pilot solenoid valve to connect wire 300 and
unable to move 481, at this time, the electrical circuit of pilot of
pilot cut-off solenoid valve is established, and
Fault SN Faults Consequence the oil path of the pilot cut-off solenoid is open,
All the work so the hydraulic system starts running. The fol-
implements, swing No motion, lowing is the electrical circuit diagram cut by the
E8
and travel unable failed to work.
to move pilot.

Pilot solenoid valve switch

Ignition switch

Pilot cut-off solenoid valve

Pilot cut-off 10A

Satety relay K11

Battery relay
6-336
6.5 Fault diagnosis of electrical system CLG922E
6.5.8 E8-All the work implements, revolving and travel unable to move February 3, 2015

Component location Fault diagnosis and elimination pro-

cedures
Step 1 Check whether the fuses 1 are blown
Ignition switch
 When replacing the components, please
be sure to use LiuGong parts.
• Inspection method
Unplug the fuse 1 by a fuse clip, observe by
visual inspection whether fuse is blown or turn
the multimeter to its diode function to measure
Fuse box whether both ends of fuse are connected.
Pilot cut-off valve switch
Notice: There may be ground fault, so please
refer to step 5.
• Is fuse 1 is blown?
• Yes
Replace fuse
Turn to Step 6
• No
Turn to Step 2

Step 2 Pilot solenoid cut-off switch fault

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
While pulling the cut-off switch of pilot solenoid
valve, the pin 2 and pin 3 on the cut-off switch of
pilot solenoid valve are connected, and at this
time measure the cut-off switch with a multime-
ter on the diode position.
• Is the switch closed?
• Yes
Repair or replace the cut-off switch of the
pilot solenoid valve.
Turn to Step 6
• No
 6-337
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.8 E8-All the work implements, revolving and travel unable to move

Turn to Step 3 Step 4 Open circuit of wire in harness or poor

connector contact.
Step 3 Check whether the safety relay fails or  Correctly tie up harness and wire.
not.
Avoid folding or bending the harness forci-
 When replacing the components, please bly.
be sure to use LiuGong parts. It shall be kept away from moving compo-
• Inspection method nents as far as possible to prevent tensile
Measure the resistance among all contacts of fault and wear.
safety relay K11 with a multimeter. Avoid friction with sharp metal edges.
Remove safety relay K11, and then measure the Try to keep far way from oil and water.
resistance among all contacts. Inspection method
• The resistance between 85 and 86 (coil Remove the battery cable (-), and turn the start
resistance) is about 320-360Ω. switch to OFF position, measure the resistance
• The resistance between 30 and 87 is of the following circuit, and the resistance shall
infinite. be all less than 10Ω in normal condition.
1. Wire 102 on the main contact of battery relay
• The resistance between 30 and 87a is less
- end 30 of the safety relay K11.
than 10Ω.
2. End 87 of safety relay K11 - X1(21) - S13
2. Switch on 24V power to both ends of 85 and
(female 3) of pilot cut-off valve switch.
86, and measure the resistance between each
3. S13 (female 2) of pilot cut-off valve switch -
two contacts.
pilot cut-off solenoid valve A1 (female 1).
• The resistance between 30 and 87 is less
4. Pilot cut-off solenoid valve A1 (female 1)-
than 10Ω.
frame ground (GND).
• The resistance between 30 and 87a is
5. End B2 of start switch - X1(28) - end 86 of
infinite.
safety relay K11.
• Is there a fault in the safety relay? 6. End 85 on the safety relay K11 -X2(16) -
• Yes frame ground (GND).
Replace the safety relay. • Is the harness open?
Turn to Step 6 • Yes
• No Connect the harness again and wrap the har-
Turn to Step 4 ness
Turn to Step 6
• No
Turn to Step 5
6-338
6.5 Fault diagnosis of electrical system CLG922E
6.5.8 E8-All the work implements, revolving and travel unable to move February 3, 2015

Step 5 Wire fault in harness -- short circuit to

ground wire.

 Shutdown operation is needed

• Inspection method
Remove the battery cable (-), and turn the start
switch to OFF position, check whether the fol-
lowing circuit forms a short circuit with the
ground, and normally the resistance between
any check point and the ground shall be greater
than 1MΩ.
1. Wire 102 on the main contact of battery relay
- end 30 of the safety relay K11.
2. End 87 of safety relay K11 - X1(21) - pilot
shut-off valve switch (3-2) - pilot shut-off sole-
noid valve A1 (female 1).
3. End B2 of start switch - X1(28) - end 86 of
safety relay K11.
• Is the harness short?
• Yes
Connect the harness again and wrap the har-
ness
Turn to Step 6
• No
Turn to Step 6

Step 6 Check whether this fault is eliminated

• Inspection method
Operate the machine, and check whether each
action is normal.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealers and
authorized service centers.
 6-339
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.9 E9-Display panel showing nothing

6.5.9 E9-Display panel showing System description

Protect the constant power end by fuse 15, con-
nothing
trol the energy power by start switch, and if the
power circuit is normal, turn on the display.
Fault SN Faults Consequence
It can not
Display panel display the
E9
showing nothing machine
information.

Display
Ignition switch

Electric lock ON
Battery power

Battery power

Ground

Ground
supply

supply

(Black) (Gray)

Controller,
display 30A

Battery relay
6-340
6.5 Fault diagnosis of electrical system CLG922E
6.5.9 E9-Display panel showing nothing February 3, 2015

Component location Step 2 Open circuit of wire in harness or poor

connector contact.

 Correctly tie up harness and wire.

Display Ignition switch

Avoid folding or bending the harness forci-
bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.

Fuse box
Try to keep far way from oil and water.
• Inspection method
Remove the battery cable (-), and turn the start
Fault diagnosis and elimination pro- switch to OFF position, measure the resistance
of the following circuit, and the resistance shall
cedures
be all less than 10Ω in normal condition.
Step 1- Blowing of fuse 15
1. Wire 004 on the main contact of battery relay
 When replacing the components, please -X2(8)-X1(1)-X3(6)- C4(female 6) of the display.
be sure to use LiuGong parts. 2. X1(female 1)-X4(7)-C4 (female 7) of the dis-
play.
• Inspection method
3. C4 (female 5)-X4(5) of the display - frame
Unplug the fuse 15 by a fuse clip, observe by
ground (GND).
visual inspection whether fuse is blown or turn
4. C4 (female 10)-X3(10) of the display - frame
the multimeter to its diode function to measure
ground (GND).
whether both ends of fuse are connected.
5. End S of start switch -X3(8)- C4(female 26) of
Notice: There may be ground fault, so please
the display.
refer to step 3.
• Is the harness open?
• Is fuse 15 is blown?
• Yes
• Yes
Connect the harness again and wrap the har-
Replace fuse.
ness
Turn to Step 5
Turn to Step 5
• No
• No
Turn to Step 2
Turn to Step 3
 6-341
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.9 E9-Display panel showing nothing

Step 3 Ground fault of wire in harness - short to Step 4 Display fault

ground wire.
 When replacing the components, please
 Shutdown operation is needed. be sure to use LiuGong parts.
• Inspection method • Inspection method
Remove the battery cable (-), and turn the start Turn the start switch to ON position, check the
switch to OFF position, check whether the fol- power supply with the multimeter, when all the
lowing circuit forms a short circuit with the following conditions are satisfied, if the display is
ground, and normally the resistance between still off, it can be determined as internal fault of
any check point and the ground shall be greater the display.
than 1MΩ. 1. The voltage to ground of the display C4 (6) is
1. Wire 004 on the main contact of battery relay 24V.
-X2(8)-X1(1)-X3(6)- C4(female 6) of the display. 2. The voltage to ground of the display C4 (7) is
2. X1(female 1)-X4(7)-C4 (female 7) of the dis- 24V.
play. 3. The voltage to ground of the display C4 (26)
3. End S of start switch -X3(8)- C4(female 26) of is 24V.
the display. 4. The voltage to ground of the display C4 (5) is
• Is the harness short? 0V.
• Yes 5. The voltage to ground of the display C4 (10)
is 0V.
Connect the harness again and wrap the har-
ness • Is there a fault in the display?
Turn to Step 5 • Yes
• No Replace the display.
Turn to Step 4 Turn to Step 5
• No
Turn to Step 5

Step 5 Check whether this fault is eliminated

• Inspection method
Operate the machine, and check whether each
action is normal.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Contact local LiuGong dealers and authorized
service centers.
6-342
6.5 Fault diagnosis of electrical system CLG922E
6.5.10-Incorrectly displayed hydraulic oil temperature February 3, 2015

6.5.10-Incorrectly displayed System description

The hydraulic oil temp sensor monitors the
hydraulic oil temperature
actual temperature, and outputs different resis-
Fault SN Faults Consequence
tance to the engine controller; the engine con-
Reducing the pump
current and engine troller sends the hydraulic oil temperature to the
Incorrectly speed can affect the display through CAN wire, so the hydraulic oil
displayed overall performance, temperature can be displayed on the display.
E10
hydraulic oil or cause damage to
temperature the engine and
hydraulic
components.

Engine controller

Oil temperature
Oil
temperature
ground

Hyd temperature Sensor

Hydraulic oil temperature sensor

parameter table
Coolant temperature 
50 60 70 80 85 90 95 100 105 110 115
(℃)
Resistance (ohms) 3509 2401 1678 1195 1015 865.5 741.2 637.1 549.8 476.3 414
 6-343
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.10-Incorrectly displayed hydraulic oil temperature

Component location Step 2 Open circuit of wire in harness or poor

connector contact

Front
 Correctly tie up harness and wire:

Avoid folding or bending the harness forci-

bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Hydraulic oil
temperature • Inspection method
sensor
Remove the battery cable (-), and turn the start
Fault diagnosis and elimination pro- switch to OFF position, measure the resistance
of the following circuit, and the resistance shall
cedures
be all less than 10Ω in normal condition.
Step 1 The fault of hydraulic oil temp sensor
1. J22 (female 48) of engine controller - P7
 When replacing the components, please (female 1) of hydraulic oil temp sensor.
be sure to use LiuGong parts. 2. J22 (female 45) of engine controller - P7
• Inspection method (female 2) of hydraulic oil temp sensor.

Turn the knob start switch to OFF position • Is the harness open?
and disconnect sensor connector. • Yes
1. Check the connector for looseness, rust, Connect the harness again and wrap the har-
bending and damage. ness
2. Turn the multimeter to its resistance function Turn to Step 4
(20KΩ), and measure the resistance between • No
the sensor connector terminals 1 and 2, compar-
Turn to Step 3
ing the result with the parameter table (normally,
<4K).
• Whether the hydraulic oil temp sensor
fails or not?
• Yes
Replace the hydraulic oil temp sensor.
Turn to Step 4
• No
Turn to Step 2
6-344
6.5 Fault diagnosis of electrical system CLG922E
6.5.10-Incorrectly displayed hydraulic oil temperature February 3, 2015

Step 3 Ground fault of wire in harness ----short Step 4 Check whether this fault is eliminated
to ground wire • Inspection method
 Shutdown operation is needed. Operate the machine, and check whether each
action is normal.
• Inspection method
• Has this fault been eliminated?
Remove the battery cable (-), and turn the start
switch to OFF position, check whether the fol- • Yes
lowing circuit forms a short circuit with the Maintenance is over
ground, and normally the resistance between • No
any check point and the ground shall be greater Contact local LiuGong dealers and authorized
than 1MΩ. service centers.
J22 (female 48) of engine controller - P7
(female 1) of hydraulic oil temp sensor.
• Is the harness open?
• Yes
Connect the harness again and wrap the har-
ness
Turn to Step 4
• No
Turn to Step 4
 6-345
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.11 E11-Fuel gauge unable to display correct value

6.5.11 E11-Fuel gauge unable to System description

The fuel level sensor is a reed pipe type. The
display correct value
magnetic float density is lower than the working
medium (diesel) density, so the fuel level sensor
Fault SN Faults Consequence
floats on the surface of the working medium and
The fuel level
Fuel gauge unable display is can slide up and down on the reed pipe. When
E11 to display correct inaccurate, and the floater moves on the reed pipe, the on-off of
value it brings trouble the internal circuit of the reed pipe is controlled
to the work
by a magnetic field to allow the resistance
between the two output leads of the connector
to change. Therefore, the fuel level change is
converted into a resistance signal output to the
controller which detects the fuel level in the tank.
Then, the fuel level appears on the connected
display instrument.

IPC Controller
Fuel level

Fuel level sensor

6-346
6.5 Fault diagnosis of electrical system CLG922E
6.5.11 E11-Fuel gauge unable to display correct value February 3, 2015

Fuel level sensor parameter table 2. Turn the multimeter to its resistance function,
and measure the resistance between the fuel
(For the details, see the figure.)
level sensor connector terminals 1 and 2 (nor-
Component location mally, ＜ 2K, for the specific resistance, see the
figure.).

Front

Fuel level sensor

Fault diagnosis and elimination pro-

cedures • Whether a fault developing in the fuel
Step 1 Check the fuel level sensor for fault. level sensor
• Yes
 When replacing the components, please
Repair or replace the fuel level sensor
be sure to use LiuGong parts.
Turn to Step 4
 High temperature and high pressure oil • No
or water can cause personal injury! To Turn to Step 2
replace the sensor, please shut down
the engine first, wait until the engine
and gearbox housing are sufficiently
cooled.

 To install the fuel level sensor into the

fuel tank, wipe off its water and keep it
clean.
• Inspection method
Turn the start switch to the OFF position,
and disconnect the connector from the fuel
level sensor.
1. Check the connector for looseness, rust,
bending and damage.
 6-347
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.11 E11-Fuel gauge unable to display correct value

Step 2 Check the harness for open-circuit (b) Turn the multimeter to its resistance func-
tion, and measure the resistance between
 Correctly tie up harness and wire:
the connector ports J2-30 and sensor har-
Avoid folding or bending the harness forci- ness (normally, <10Ω).
bly.
It shall be kept away from moving compo-
nents as far as possible to prevent tensile
fault and wear.
Avoid friction with sharp metal edges.
Try to keep far way from oil and water.
Try to keep far away from high temperature
parts (e.g. engine body) as far as possible. White wire

• Inspection method
1. Check the harness (No. 930) and the ground- To the black probe

ing wire (No.227) between the controller (J2-30) To the red probe

and fuel level sensor for wear.

2. Disconnect the connectors from the fuel level • Is the harness open?
sensor and the controller.Check the harness for • Yes
open-circuit: Connect the harness again and wrap the har-
(a) Turn the multimeter to its resistance func- ness.
tion, and measure the resistance between Turn to Step 4
the grounding wire (No.227) sensor termi- • No
nal and the grounding (normally, <10Ω).
Turn to Step 3

Gray wire
6-348
6.5 Fault diagnosis of electrical system CLG922E
6.5.11 E11-Fuel gauge unable to display correct value February 3, 2015

Step 3 Check the connector for fault. Step 4 Check whether this fault is eliminated

 When replacing the components, please • Inspection method

be sure to use LiuGong parts. Turn the start switch to the ON position and re-
check the DTC.
• Inspection method
• Has this fault been eliminated?
Connect the water-in-fuel sensor connector and
disconnect the controller connector. Turn the • Yes
multimeter to its resistance function, and mea- Maintenance is over
sure the resistance between the harness at the • No
controller port J2-30 and the grounding (nor- Troubleshoot the faults according to the steps
mally, <2K, for the details, see the figure). again or contact the local LiuGong dealers and
authorized service centers.
Connect the black
probe to ground

Connect the red

probe to Pin 30

When the resistance is abnormal, this indicates

the connector is poorly contacted.
• Whether a fault developing in the con-
nector or not?
• Yes
Replace the connector.
Turn to Step 4
• No
Turn to Step 4
 6-349
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.11 E11-Fuel gauge unable to display correct value

Figure: Fuel level sensor parameter table

Floater position Floater position

(Refer to the place at Output resistance (Ω) (Refer to the place at Output resistance (Ω)
17.5mm) 17.5mm)
Below L1 1100±11.0 L11-L12 550±5.5
L1-L2 1050±10.5 L12-L13 500±5.0
L2-L3 1000±10.0 L13-L14 450±4.5
L3-L4 950±9.5 L14-L15 400±4.0
L4-L5 900±9.0 L15-L16 350±3.5
L5-L6 850±8.5 L16-L17 300±3.0
L6-L7 800±8.0 L17-L18 250±2.5
L7-L8 750±7.5 L18-L19 200±2.0
L8-L9 700±7.0 L19-L20 150±1.5
L9-L10 650±6.5 L20-L21 100±1.0
L0-L11 600±6.0

Oil level
6-350
6.5 Fault diagnosis of electrical system CLG922E
6.5.12 E12-Windshield wiper uable to work February 3, 2015

6.5.12 E12-Windshield wiper System description

The following diagram is the electrical circuit fig-
uable to work
ure is wiper system: when the switch is in posi-
tion 0, M4(1) and M4(3) are connected, wiper
Fault SN Faults Consequence
motor stops and resets to the original position;
Foreign matters
on glass cannot when the switch is in position 1, M4(3) and the
Windshield wiper
E12 be removed; power are connected, and the wiper motor oper-
unable to work.
the sight for ates in the low speed state; when the switch is
operator is poor
turned to position 2, M4(2) and the power are
connected, and the wiper motor operates in the
high speed state.

Wiper switch Wiper motor

Wiper switch

(Gray) (Black)

Wiper, washer 10A

Wiper relay K6

Battery relay
 6-351
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.12 E12-Windshield wiper uable to work

Component location Step 2 Wiper switch fault

 When replacing the components, please

be sure to use LiuGong parts.
Wiper switch
• Inspection method
Disconnect connector S1, check the connection
condition of pins with the multimeter when the
wiper switch is turned to different positions,
when there is no fault in the wiper switch, the
connection condition of pins are shown as fol-
Wiper motor
lows:
1. When the wiper switch is in the 0 position, the
Fuse box
resistance between pin 5 and pin 7 of S1 is less
than 10Ω, the resistance between pin 1 and pin
Fault diagnosis and elimination pro- 3 is infinite, and the resistance between pin 5
cedures and pin 3 is infinite.
Step 1 Check whether the fuses 9 are blown 2. When the wiper switch is in the 1 position, the
resistance between pin 5 and pin 3 of S1 is less
 When replacing the components, please
than 10Ω, the resistance between pin 1 and pin
be sure to use LiuGong parts.
3 is infinite, and the resistance between pin 7
• Inspection method and pin 3 is infinite.
Unplug the fuse 9 by a fuse clip, observe by 3. When the wiper switch is in the 2 position, the
visual inspection whether fuse is blown or turn resistance between pin 1 and pin 3 of S1 is less
the multimeter to its diode function to measure than 10Ω, the resistance between pin 5 and pin
whether both ends of fuse are connected. 3 is infinite, and the resistance between pin 7
Notice: There may be ground fault, so please and pin 3 is infinite.
refer to step 4. • Is the wiper switch damaged?
• Is fuse 9 is blown? • Yes
• Yes Replace the wiper switch
Replace fuse Turn to Step 6
Turn to Step 6 • No
• No Turn to Step 3
Turn to Step 2
6-352
6.5 Fault diagnosis of electrical system CLG922E
6.5.12 E12-Windshield wiper uable to work February 3, 2015

Step 3 Open circuit of wire in harness or poor Step 4 Wire fault in harness - short circuit with
connector contact ground wire

 Correctly tie up harness and wire:  Shutdown operation is needed

Avoid folding or bending the harness forci- • Inspection method

bly. Remove the battery cable (-), and turn the start
It shall be kept away from moving compo- switch to OFF position, check whether the fol-
nents as far as possible to prevent tensile lowing circuit forms a short circuit with the
fault and wear. ground, and normally the resistance between
Avoid friction with sharp metal edges. any check point and the ground shall be greater
Try to keep far way from oil and water. than 1MΩ.

• Inspection method 1. Wiper switch S1 (female 1) - X3 (3) - wiper

motor M4 (female 2).
Remove the battery cable (-), and turn the start
2. Wiper switch S1 (female 5) - X3 (2) - wiper
switch to OFF position, measure the resistance
motor M4 (female 3).
of the following circuit, and the resistance shall
be all less than 10Ω in normal condition. 3. Wiper switch S1 (female 7) - X3 (1) - wiper
motor M4 (female 1).
1. Wiper switch S1 (female 1) - X3 (female3)-
wiper motor M4 (female 2). 4. Wire 102 on the main contact of battery relay
- X2(14) - main contact and end 86 of wiper
2. Wiper switch S1 (female 5) - X3 (2) - wiper
relay K6 - X1(24) - wiper switch S1 (female 3) -
motor M4 (female 3).
X3(4)- wiper motor M4 (female 6).
3. Wiper switch S1 (female 7) - X3 (1) - wiper
motor M4 (female 1). • Is the harness short?

4. Wire 102 on the main contact of battery relay • Yes

- X2(14) - main contact and end 86 of wiper Connect the harness again and wrap the har-
relay K6 - X1(24) - wiper switch S1 (female 3) - ness
X3(4)- wiper motor M4 (female 6). Turn to Step 6
5. End 85 on the wiper relay K6 - X2(4) - X5(1) - • No
door control wiper switch- X5(2) - frame ground Turn to Step 5
(GND).
• Is the harness open?
• Yes
Connect the harness again and wrap the har-
ness
Turn to Step 6
• No
Turn to Step 4
 6-353
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.12 E12-Windshield wiper uable to work

Step 5 Wiper motor fault

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Turn the start switch to ON position, check the
power supply with the multimeter; when all the
following conditions are satisfied, if the wiper
motor is still off, it can be determined as internal
fault of the wiper motor.
1. When the wiper switch is in position 0, the
voltage to ground of M4 (female 6) is 24V, and
the voltage to ground of M4 (female 4) is 0V.
2. When the wiper switch is in position 1, the
voltage to ground of M4 (female 3) is 24V.
3. When the wiper switch is in position 2, the
voltage to ground of M4 (female 2) is 24V.
• Is the wiper motor damaged?
• Yes
Replace the wiper switch
Turn to Step 6
• No
Turn to Step 6

Step 6 Check whether this fault is eliminated

• Inspection method
Operate the wiper system and check whether all
actions are normal.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Troubleshoot the faults according to the steps
again or contact the local LiuGong dealers and
authorized service centers.
6-354
6.5 Fault diagnosis of electrical system CLG922E
6.5.13 E13-A/C panel unable to display February 3, 2015

6.5.13 E13-A/C panel unable to System description

(1) Electrical schematic diagram of air condition-
display
ing system, see the figure.
(2) The evaporator as arrangement schematic
Fault SN Faults Consequence
diagram
Air conditioning
A/C panel unable a. Front view
E13 system cannot
to display
work

Air-mixing servo motor

Vent

Vent servo
motor

Foot vent

Water tempera-
ture sensor

Warm water Warm water

outlet inlet
 6-355
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.13 E13-A/C panel unable to display

b. Bottom view

Internal air
sensor
Expansion valve
inlet

Internal-to-external
air switching motor

Fan speed control

resistance

Expansion valve
outlet
6-356
6.5 Fault diagnosis of electrical system CLG922E
6.5.13 E13-A/C panel unable to display February 3, 2015

c. Rear view

Frost-prevention
probe
Switch

Fan motor
 6-357
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.13 E13-A/C panel unable to display

Fault diagnosis and elimination pro- • No

cedures Find out the reason according to Step 3

Step 1 Base machine power fault Turn to Step 3

 When replacing the components, please

Step 3 A/C 30A fuse is blown.
be sure to use LiuGong parts.
• Inspection method
 When replacing A/C fuse, please make
sure to use LiuGong parts.
Check whether the voltage of the mutually
plugged A/C harness and base machine har- • Inspection method

ness – harness 128 in the cab is 24V with a Check A/C 30A fuse, and observe by visual
multimeter. inspection whether the fuse is blown or turn the
multimeter to its diode function to measure
• Whether there is 24V voltage at No. 128
whether both ends of fuse are connected.
wire?
• Is A/C 30A fuse blown?
• Yes
• Yes
Find out the reason according to Step 2.
Replace A/C 30A fuse.
Turn to Step 2
Turn to Step 6
• No
• No
Check whether A/C 30A fuse is damaged.
Find out the reason according to Step 4.
Turn to Step 3
Turn to Step 4

Step 2 Wire grounding fault - failed to connect

with the earthing cable. Step 4 5A fuse of the A/C panel is damaged.

 When replacing the components, please  When replacing A/C fuse, please make

be sure to use LiuGong parts. sure to use LiuGong parts.

• Inspection method • Inspection method

Check whether the ground connection of the Check 5A fuse of the evaporator as wire har-
mutually plugged A/C harness and base ness in the cab. Visually observe whether the
fuse is fused or use a multimeter and a diode to
machine harness – harness 210 in the cab is in
check whether both ends of the fuse are con-
good condition with a multimeter.
nected.
• Is there an open circuit in the ground
• Is A/C panel fuse damaged?
wire?
• Yes
• Yes
Replace 5A fuse of the A/C panel
Check the ground circuit of base machine har-
Turn to Step 6
ness.
Turn to Step 6 • No
Turn to Step 5
6-358
6.5 Fault diagnosis of electrical system CLG922E
6.5.13 E13-A/C panel unable to display February 3, 2015

Step 5 A/C panel fault.

 When replacing A/C panel, please make

sure to use LiuGong parts.
• Inspection method
Press the blowing rate switch, display air volume
in the A/C panel, and turn on the LCD; after
pressing other keys, indicators come on or cor-
responding icons are displayed on the LCD.
• Is there a fault in the A/C panel?
• Yes
Replace the A/C panel
Turn to Step 6
• No
Turn to Step 6

Step 6 Check whether this fault is eliminated

• Inspection method
Operate the machine, and check whether each
action is normal.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Look for the electrical system fault or contact
local LiuGong dealers and authorized service
centers.
 6-359
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.14 E14-No wind or abnormal air volume of air conditioner

6.5.14 E14-No wind or abnormal Step 2 Power transistor fault.

air volume of air conditioner  When replacing the components, please

be sure to use LiuGong parts.

Fault SN Faults Consequence • Inspection method

No wind or The service Press the air regulation switch on the A/C panel,
abnormal air effect of air
E14 and feel whether outlet airflow is changed with
volume of air conditioner is
conditionerl poor adjustment of the blowing rate switch.

Fault diagnosis and elimination pro- • Whether outlet airflow is changed with
adjustment of the blowing rate switch?
cedures
• Yes
Step 1 Blower main relay fault.
Turn to Step 3
 When replacing the A/C relay, please
• No
make sure to use LiuGong parts. Replace the power transistor
• Inspection method Turn to Step 6
Use the multimeter to measure the resistance
value between all contacts of the fan main relay Step 3 Blower motor fault.
according to the table below and judge whether
relay is damaged the resistance value provided.
 When replacing the components, please
be sure to use LiuGong parts.
Code for both • Inspection method
Standard
Relay ends of wire
value Unplug the blower of the evaporator as, and
(contact)
Unplug the relay Measure coil check whether there is short circuit or open cir-
240±10Ω
and measure the resistance cuit of blower coil winding with a multimeter.
resistance
between the • Whether the blower fails?
contacts of the E-3 Contact Infinite
• Yes
relay
Replace the blower
• Whether the blower main relay fails?
Turn to Step 6
• Yes
• No
Replace the blower main relay.
Find out the reason according to Step 4
Turn to Step 6
Turn to Step 4
• No
Turn to Step 2
6-360
6.5 Fault diagnosis of electrical system CLG922E
6.5.14 E14-No wind or abnormal air volume of air conditioner February 3, 2015

Step 4 A/C circuit fault. Step 6 Check whether this fault is eliminated

 When replacing the blower, please make • Inspection method

sure to use LiuGong parts. Operate the machine, and check whether each
action is normal.
• Inspection method
• Has this fault been eliminated?
Check whether connectors of A/C harness are
connected stably, and whether there is open cir- • Yes
cuit or short circuit caused by damage of wires. Maintenance is over
• Whether A/C wiring is abnormal? • No

• Yes Look for the A/C system fault or contact local

LiuGong dealers and authorized service cen-
Check circuit fault points and repair them.
ters.
Turn to Step 6
• No
Turn to Step 5

Step 5 A/C panel fault.

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
If the A/C panel is checked to be normal through
step 1 to step 4, it may have been damaged.
• Is there a fault in the A/C panel?
• Yes
Replace the A/C panel.
Turn to Step 6
• No
Turn to Step 6
 6-361
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.15 E15-Poor A/C refrigeration

6.5.15 E15-Poor A/C Step 2 Internal sensor fault.

refrigeration  When replacing the components, please

be sure to use LiuGong parts.

Fault SN Faults Consequence • Inspection method

The The internal sensor may fail and diagnose the
refrigeration
Poor A/C fault of internal sensor.
E15 effect of air
refrigeration
conditioning • Whether the internal sensor fails?
system is poor
• Yes
Fault diagnosis and elimination pro- Replace the internal sensor.
cedures Turn to Step 8
Step 1 Compressor relay fault • No

 When replacing the components, please Find out the reason according to Step 3
Turn to Step 3
be sure to use LiuGong parts.
• Inspection method
Step 3 High-low voltage protection switch fault.
Check whether the electromagnetic coil circuit of
the compressor clutch relay is open with a multi-  When replacing the components, please
meter. be sure to use LiuGong parts.
• Whether the compressor clutch relay • Inspection method
fails? Unplug the pressure protection switch wiring
• Yes harness on the high-pressure side connector of
Replace the compressor clutch relay the expansion valve, and use a multimeter to
Turn to Step 8 check whether both ends of the pressure switch
is connected. When the system pressure is
• No
larger than 0.196 MPa and less than 3.14 MPa,
Check in accordance with Step 2.
the pressure switch shall be connected.
Turn to Step 2
• Whether the high and low voltage pro-
tection switch is damaged?
• Yes
Replace the high and low voltage protection
switch.
Turn to Step 8
• No
Find out the reason according to Step 4
Turn to Step 4
6-362
6.5 Fault diagnosis of electrical system CLG922E
6.5.15 E15-Poor A/C refrigeration February 3, 2015

Step 4 Compressor clutch fault Step 6 A/C circuit fault

 When replacing the components, please  When replacing the components, please
be sure to use LiuGong parts. be sure to use LiuGong parts.
• Inspection method • Inspection method
Unplug the compressor clutch, and use a multi- Check whether connectors of A/C harness are
meter to check whether the compressor clutch connected stably, and whether there is open cir-
coil is open. Whether the compressor earthing cuit or short circuit caused by damage of wires.
cable is in good condition? • Is there a fault in the A/C wiring?
• Whether the compressor earthing cable • Yes
fails?
Check circuit faults and repair them.
• Yes Turn to Step 8
Replace the A/C compressor. • No
Turn to Step 8 Find out the reason according to Step 7
• No Turn to Step 7
Find out the reason according to Step 5
Turn to Step 5 Step 7 A/C panel fault.

Step 5 Compressor fault

 When replacing the components, please
be sure to use LiuGong parts.
 When replacing the components, please
• Inspection method
be sure to use LiuGong parts.
If the A/C panel is checked to be normal through
• Inspection method step 1 to step 7, it may have been damaged.
Remove the A/C belt, and rotate the A/C com- • Is there a fault in the A/C panel?
pressor pulley by hand to check whether clamp-
• Yes
ing stagnation and abnormal noise happens on
Replace the A/C panel.
the compressor A/C pulley.
Turn to Step 8
• Whether the compressor fails?
• No
• Yes
Turn to Step 8
Replace the A/C compressor.
Turn to Step 8
• No
Find out the reason according to Step 6
Turn to Step 6
 6-363
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.15 E15-Poor A/C refrigeration

Step 8 Check whether this fault is eliminated

• Inspection method
Operate the machine, and check whether each
action is normal.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Look for the refrigerating system fault or contact
local LiuGong dealers and authorized service
centers.
6-364
6.5 Fault diagnosis of electrical system CLG922E
6.5.16 E16-Abnormal alarm of the A/C E11 – Internal sensor wire broken February 3, 2015

6.5.16 E16-Abnormal alarm of Check whether the internal sensor to the A/C
panel is open-circuited with a multimeter.
the A/C E11 – Internal sensor • Whether the internal sensor is open cir-
wire broken cuit?
• Yes
Fault SN Faults Consequence Check fault points and repair them
Abnormal A/C The service Turn to Step 4
alarm E11 - effect of air
E16 • No
Internal sensor conditioner is
wire broken poor Turn to Step 3
Fault diagnosis and elimination pro-
cedures Step 3 A/C panel fault.

Step 1 Internal sensor fault.  When replacing the components, please

 When replacing the components, please be sure to use LiuGong parts.

be sure to use LiuGong parts. • Inspection method

• Inspection method If open circuit is not found through checking by

step 1.2, it may be internal fault of the A/C
1. Press OFF on the A/C panel, the LCD does
panel.
not display, and the A/C stops running;
• Is it internal fault of the A/C panel?
2. Press the increase and decrease keys of the
temperature setting switch in the meantime for • Yes
over 3 seconds, the LCD will display DTCs; Replace the A/C panel
3. If E11 DTC occurs, check whether the circuit Turn to Step 4
of the internal sensor located in the air outlet is • No
open with a multimeter. Turn to Step 4
• Whether the circuit of the internal sen-
sor is open?
Step 4 Check whether this fault is eliminated
• Yes
• Inspection method
Replace the internal sensor. Operate the machine, and check whether each
Turn to Step 4 action is normal.
• No • Has this fault been eliminated?
Turn to Step 2
• Yes
Maintenance is over
Step 2 Internal sensor open circuited.
• No
 When replacing the components, please Look for the A/C system fault or contact local
be sure to use LiuGong parts. LiuGong dealers and authorized service cen-
• Inspection method ters.
 6-365
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.17 E17-Abnormal alarm of the A/C E12- Internal sensor short-circuited

6.5.17 E17-Abnormal alarm of Check whether the internal sensor to the A/C
panel is short-circuited with a multimeter.
the A/C E12- Internal sensor
• Whether the internal sensor is short-cir-
short-circuited cuited?
• Yes
Fault SN Faults Consequence Check fault points and repair them
Abnormal A/C The service Turn to Step 4
alarm E12 - effect of air
E17
Internal sensor conditioner is • No
short-circuited poor
Turn to Step 3
Fault diagnosis and elimination pro-
cedures Step 3 A/C panel fault.

Step 1 Internal sensor fault.  When replacing the components, please

 When replacing the components, please be sure to use LiuGong parts.

be sure to use LiuGong parts • Inspection method

• Inspection method If short circuit is not found through checking by

Step 1 and 2, it may be internal fault of the A/C
1. Press OFF on the A/C panel, the LCD does
panel.
not display, and the A/C stops running;
2. Press the increase and decrease keys of the • Is it internal fault of the A/C panel?
temperature setting switch in the meantime for • Yes
over 3 seconds, the LCD will display DTCs; Replace the A/C panel
3. If E12 DTC occurs, check the internal sensor Turn to Step 4
located in the air outlet for short circuit with a • No
multimeter.
Turn to Step 4
• Whether the internal sensor is short-cir-
cuited?
Step 4 Check whether this fault is eliminated
• Yes
• Inspection method
Replace the internal sensor.
Operate the machine, and check whether each
Turn to Step 4 action is normal.
• No • Has this fault been eliminated?
Turn to Step 2
• Yes
Maintenance is over
Step 2 Internal sensor short-circuited.
• No
 When replacing the components, please Look for the A/C system fault or contact local
be sure to use LiuGong parts. LiuGong dealers and authorized service cen-
• Inspection method ters.
6-366
6.5 Fault diagnosis of electrical system CLG922E
6.5.18 E18-Abnormal alarm of the A/C E15 – Water temperature sensor wire broken February 3, 2015

6.5.18 E18-Abnormal alarm of Step 2 Water temperature sensor open-cir-

cuited.
the A/C E15 – Water tempera-
 When replacing the components, please
ture sensor wire broken be sure to use LiuGong parts.
• Inspection method
Fault SN Faults Consequence
Check whether the water temperature sensor to
Abnormal A/C the A/C panel is open-circuited with a multime-
The service
alarm E15 -- Water
effect of air ter.
E18 temperature
conditioner is
sensor wire • Whether the water temperature is open-
poor
broken
circuited?
Fault diagnosis and elimination pro- • Yes
cedures Check fault points and repair them
Step 1 Water temperature sensor fault Turn to Step 4

 When replacing the components, please • No

be sure to use LiuGong parts. Turn to Step 3

• Inspection method
Step 3 A/C panel fault.
1. Press OFF on the A/C panel, the LCD does
not display, and the A/C stops running;  When replacing the components, please
2. Press the increase and decrease keys of the be sure to use LiuGong parts.
temperature setting switch in the meantime for • Inspection method
over 3 seconds, the LCD will display DTCs;
If open circuit is not found through checking by
3. If E15 DTC occurs, check whether the water
step 1.2, it may be internal fault of the A/C
temperature sensor circuit located in the inflow
panel.
side of the warm wind radiator is open with a
• Is it internal fault of the A/C panel?
multimeter.
• Yes
• Whether the water temperature sensor
Replace the A/C panel.
is open-circuited?
Turn to Step 4
• Yes
• No
Replace the water temperature sensor.
Turn to Step 4
Turn to Step 4
• No
Turn to Step 2
 6-367
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.18 E18-Abnormal alarm of the A/C E15 – Water temperature sensor wire broken

Step 4 Check whether this fault is eliminated

• Inspection method
Operate the machine, and check whether each
action is normal.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Look for the A/C system fault or contact local
LiuGong dealers and authorized service cen-
ters.
6-368
6.5 Fault diagnosis of electrical system CLG922E
6.5.19 E19-Abnormal alarm of the A/C E16 - Water temperature sensor short-circuited February 3, 2015

6.5.19 E19-Abnormal alarm of Step 2 Water temperature sensor short-cir-

cuited.
the A/C E16 - Water tempera-
 When replacing the components, please
ture sensor short-circuited be sure to use LiuGong parts.
• Inspection method
Fault SN Faults Consequence
Abnormal A/C Check whether the water temperature sensor to
The service the A/C panel is short-circuited with a multime-
alarm E16 - Water
effect of air
E19 temperature ter.
conditioner is
sensor short-
poor • Whether the water temperature sensor
circuited
is short-circuited?
Fault diagnosis and elimination pro-
• Yes
cedures
Check fault points and repair them
Step 1 Water temperature sensor fault
Turn to Step 4
 When replacing the components, please • No
be sure to use LiuGong parts. Turn to Step 3
• Inspection method
1. Press OFF on the A/C panel, the LCD does Step 3 A/C panel fault.
not display, and the A/C stops running;
 When replacing the components, please
2. Press the increase and decrease keys of the
be sure to use LiuGong parts.
temperature setting switch in the meantime for
over 3 seconds, the LCD will display DTCs; • Inspection method

3. If E16 DTC occurs, check whether the water If short circuit is not found through checking by
temp sensor circuit located in the inflow side of Step 1 and 2, it may be internal fault of the A/C
panel.
the warm wind radiator is short with a multime-
ter. • Is it internal fault of the A/C panel?

• Whether the water temperature sensor • Yes

is short-circuited? Replace the A/C panel
• Yes Turn to Step 4
Replace the water temperature sensor. • No
Turn to Step 4 Turn to Step 4
• No
Turn to Step 2
 6-369
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.19 E19-Abnormal alarm of the A/C E16 - Water temperature sensor short-circuited

Step 4 Check whether this fault is eliminated

• Inspection method
Operate the machine, and check whether each
action is normal.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Look for the A/C system fault or contact local
LiuGong dealers and authorized service cen-
ters.
6-370
6.5 Fault diagnosis of electrical system CLG922E
6.5.20 E20-Abnormal alarm of the A/C E180 - Insolation sensor short-circuited February 3, 2015

6.5.20 E20-Abnormal alarm of Step 2 Insolation sensor short-circuited.

the A/C E180 - Insolation sen-  When replacing the components, please
be sure to use LiuGong parts.
sor short-circuited
• Inspection method
Check whether the insolation sensor to the A/C
Fault SN Faults Consequence
Abnormal A/C The service panel is short-circuited with a multimeter.
alarm E18 - effect of air • Whether the insolation sensor is short-
E20
Insolation sensor conditioner is
circuited?
short-circuited poor
• Yes
Fault diagnosis and elimination pro-
Check fault points and repair them
cedures Turn to Step 4
Step 1 Insolation sensor fault
• No
 Be sure to use LiuGong parts in replac- Turn to Step 3
ing the insolation sensor.
• Inspection method Step 3 A/C panel fault.

1. Press OFF on the A/C panel, the LCD does  When replacing the components, please
not display, and the A/C stops running; be sure to use LiuGong parts.
2. Press the increase and decrease keys of the
• Inspection method
temperature setting switch in the meantime for
If short circuit is not found through checking by
over 3 seconds, the LCD will display DTCs;
Step 1 and 2, it may be internal fault of the A/C
3. If E18 DTC occurs, check whether the circuit
panel.
of the insolation sensor is short with a multime-
ter. • Is it internal fault of the A/C panel?

• Whether the internal sensor is short-cir- • Yes

cuited? Replace the A/C panel

• Yes Turn to Step 3

Replace the insolation sensor. • No

Turn to Step 4 Turn to Step 3

• No
Turn to Step 2
 6-371
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.20 E20-Abnormal alarm of the A/C E180 - Insolation sensor short-circuited

Step 4 Check whether this fault is eliminated

• Inspection method
Operate the machine, and check whether each
action is normal.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Look for the A/C system fault or contact local
LiuGong dealers and authorized service cen-
ters.
6-372
6.5 Fault diagnosis of electrical system CLG922E
6.5.21 E21-Abnormal alarm of the A/C E43 – Abnormal outlet ventilation doors February 3, 2015

6.5.21 E21-Abnormal alarm of Step 2 Circuit fault of the air-out servo motor

the A/C E43 – Abnormal outlet  When replacing the components, please
be sure to use LiuGong parts.
ventilation doors
• Inspection method
Check whether the circuit from the air-out servo
Fault SN Faults Consequence
motor harness to the A/C panel is short or
Abnormal A/C The service
alarm E43 - effect of air open with a multimeter.
E21
Abnormal outlet conditioner is • Whether the air-out servo motor circuit
ventilation doors poor
fails?
Fault diagnosis and elimination pro- • Yes
cedures Check fault points and repair them
Step 1 Air-out servo motor fault Turn to Step 4

 When replacing the components, please • No

be sure to use LiuGong parts. Turn to Step 3

• Inspection method
Step 3 A/C panel fault.
1. Press OFF on the A/C panel, the LCD does
not display, and the A/C stops running;  When replacing the components, please
2. Press the increase and decrease keys of the be sure to use LiuGong parts.
temperature setting switch in the meantime for
• Inspection method
over 3 seconds, the LCD will display DTCs;
If short circuit is not found through checking by
3. If E43 DTC occurs, check whether the air-out
Step 1 and 2, it may be internal fault of the A/C
servo motor on the evaporator as is short-cir-
panel.
cuited or open-circuited with a multimeter.
• Is it internal fault of the A/C panel?
• Whether the air-out servo motor fails?
• Yes
• Yes
Replace the A/C panel
Replace the air-out servo motor.
Turn to Step 3
Turn to Step 4
• No
• No
Turn to Step 3
Turn to Step 2
 6-373
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.21 E21-Abnormal alarm of the A/C E43 – Abnormal outlet ventilation doors

Step 4 Check whether this fault is eliminated

• Inspection method
Operate the machine, and check whether each
action is normal.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Look for the A/C system fault or contact local
LiuGong dealers and authorized service cen-
ters.
6-374
6.5 Fault diagnosis of electrical system CLG922E
6.5.22 E22-Abnormal alarm of the A/C E44 – Abnormal the air mixing door February 3, 2015

6.5.22 E22-Abnormal alarm of Step 2 Circuit fault of the servo motor of the air
mixing door (A/M).
the A/C E44 – Abnormal the air
 When replacing the components, please
mixing door be sure to use LiuGong parts.
• Inspection method
Fault SN Faults Consequence
Check whether the circuit from the servo motor
Abnormal A/C The service
alarm E44 - effect of air harness of the air mixing door to the A/C panel
E22
Abnormal air conditioner is is short or open with a multimeter.
mixing doors poor
• Whether the servo motor circuit of the
Fault diagnosis and elimination pro- air mixing door (A/M) fails?
cedures • Yes
Step 1 Air mixing door (A/M) servo motor fault. Check fault points and repair them

 When replacing the components, please Turn to Step 4

be sure to use LiuGong parts. • No

Turn to Step 3
• Inspection method
1. Press OFF on the A/C panel, the LCD does
Step 3 A/C panel fault.
not display, and the A/C stops running;
2. Press the increase and decrease keys of the  When replacing the components, please
temperature setting switch in the meantime for be sure to use LiuGong parts.
over 3 seconds, the LCD will display DTCs;
• Inspection method
3. If E44 DTC occurs, check whether the circuit
If short circuit is not found through checking by
of the air-out servo motor on the evaporator as
Step 1 and 2, it may be internal fault of the A/C
is short or open with a multimeter.
panel.
• Whether the air-out servo motor fails?
• Is it internal fault of the A/C panel?
• Yes
• Yes
Replace the servo motor of the air mixing door
Replace the A/C panel
(A/M)
Turn to Step 3
Turn to Step 4
• No
• No
Turn to Step 3
Turn to Step 2
 6-375
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.22 E22-Abnormal alarm of the A/C E44 – Abnormal the air mixing door

Step 4 Check whether this fault is eliminated

• Inspection method
Operate the machine, and check whether each
action is normal.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Look for the A/C system fault or contact local
LiuGong dealers and authorized service cen-
ters.
6-376
6.5 Fault diagnosis of electrical system CLG922E
6.5.23 E23-Travel alarm unable to sound February 3, 2015

6.5.23 E23-Travel alarm unable System description

The figure below is the travel alarm electrical cir-
to sound
cuit diagram. Operators can cancel or enable
the travel alarm function by operating buttons on
Fault SN Faults Consequence
the display. The main controller (IPC controller)
Alarm system is
Travel alarm faulty, causing judges whether the complete machine is on
E23
unable to sound potential safety travel status in accordance with the foot con-
hazard. trolled oil circuit pressure switch. If it is in travel
status, J1-1 foot of the main controller (IPC con-
troller) outputs 24 V voltage to the travel alarm.
If not, J1-1 foot of the main controller (IPC con-
troller) outputs 0 V voltage to the travel alarm.

IPC Controller (Black)

Display
CAN 1/2 shield
CAN 1 low
CAN 1 high

Travele alarm buzzer

(White)

Foot pedal pressure switch

Travel alarm (Option)

Pressure switch
 6-377
CLG922E 6.5 Fault diagnosis of electrical system
February 3, 2015 6.5.23 E23-Travel alarm unable to sound

Component location (female 2) - frame GND.

• Is the harness open?
• Yes
Front
Connect the harness again and wrap the har-
ness
Turn to Step 4
• No
Turn to Step 2

Traveling alarm Step 2 Ground fault of conductor in harness --

short circuit to ground wire.

 Shutdown operation is needed.

Fault diagnosis and elimination pro- • Inspection method
cedures Remove the battery cable (-), and turn the start
Step 1 Open circuit of wire in harness or poor switch to OFF position, check whether the fol-
connector contact. lowing circuit forms a short circuit with the
ground, and normally the resistance between
 Correctly tie up harness and wire:
any check point and the ground shall be greater
Avoid folding or bending the harness forci- than 1MΩ.
bly. 1. Main controller J1 (female 1) – travel alarm
It shall be kept away from moving compo- N3 (female 1)
nents as far as possible to prevent tensile 2. Main controller J2 (female 13) – foot con-
fault and wear. trolled oil circuit pressure switch P10 (female 1).
Avoid friction with sharp metal edges. • Is the harness short?
Try to keep far way from oil and water. • Yes
• Inspection method Connect the harness again and wrap the har-
Remove the battery cable (-), and turn the start ness
switch to OFF position, measure the resistance Turn to Step 4
of the following circuit, and the resistance shall • No
be all less than 10Ω in normal condition.
Turn to Step 3
1. Main controller J1 (female 1) – travel alarm
N3 (female 1)
2. Travel alarm N3 (female 2) – frame ground.
3. Main controller J2 (female 13) – foot con-
trolled oil circuit pressure switch P10 (female 1).
4. Foot controlled oil circuit pressure switch P10
6-378
6.5 Fault diagnosis of electrical system CLG922E
6.5.23 E23-Travel alarm unable to sound February 3, 2015

Step 3 Travel alarm fault

 When replacing the components, please

be sure to use LiuGong parts.
• Inspection method
Start the complete machine but do not pull up
the pilot shut-off valve switch, unplug connector
P10 of the foot controlled oil circuit pressure
switch, and measure the voltage value of N3
(female 1) over the ground with a multimeter..
The voltage is 24 V under normal conditions.
• Whether the travel alarm fails?
• Yes
Replace the travel alarm.
Turn to Step 4
• No
Turn to Step 4

Step 4 Check whether this fault is eliminated

• Inspection method
Operate the machine, and check whether each
action is normal.
• Has this fault been eliminated?
• Yes
Maintenance is over
• No
Find out the engine system fault or contact the
local LiuGong dealers or authorized service cen-
ters.
 6-379
CLG922E 6.6 Fault diagnosis of the hydraulic system and mechanical system
February 3, 2015 6.6.1 System table of the hydraulic system and mechanical system

6.6 Fault diagnosis of the 6.6.1 System table of the

hydraulic system and hydraulic system and mechani-
mechanical system cal system

Arm 1 Arm
Arm 2 cylinder

Bucket
cylinder Bucket Spare

Boom Boom
Boom 1 Boom 2 cylinder
cylinder

Travel Swing
motor-lh Travel-lh Swing motor

Straight Travel
Travel-rh motor-rh
travel

P2 (from the pilot

valve XB1)
6-380
6.6 Fault diagnosis of the hydraulic system and mechanical system CLG922E
6.6.2 H1-Excessive barking angle for slewing stop February 3, 2015

6.6.2 H1-Excessive barking

angle for slewing stop

Excessive braking angle for

slewing stop

Yes

Check whether the slewing

No Slewing relief valve fault
overflow pressure is normal.

Yes

Check whether the anti-reversing No Anti-reversing valve fault

valve is functioning properly.

Yes

Check the slewing pilot Clean and replace the pilot line
valve for clogging Yes

No

Check whether the pilot valve Pilot valve fault

is functioning properly No

Yes

Check whether the

slewing valve element No Spring fault
spring is normal

Yes

Swing motor fault

 6-381
CLG922E 6.6 Fault diagnosis of the hydraulic system and mechanical system
February 3, 2015 6.6.3 H2-Abnormal noise of pump mounting position

6.6.3 H2-Abnormal noise of

pump mounting position

Abnormal sound of pump

mounting position

Yes

Check the flywheel inside Coupling components:

Yes
for foreign matters Removal and repair

No

Check the coupling hub spline for

Replace the hub or tighten
wear and the adjusting screw for Yes the adjusting screw.
fixing the hub for looseness.

This abnormal sound may be

caused by the hydraulic pump or
No the engine itself. Refer to the
operating instructions of the
device and the engine.
6-382
6.6 Fault diagnosis of the hydraulic system and mechanical system CLG922E
6.6.4 H3-No responses for all operations when starting the engine February 3, 2015

6.6.4 H3-No responses for all

operations when starting the
engine
When the engine is
started, all operations
are unresponsive.

Yes

Check whether the

Add oil to the specified
hydraulic oil level is No level as required.
normal.

No
The hydraulic pump Hydraulic pump fault:
sounds abnormally. Yes Remove and repair it.
Check whether the abnormal Yes
sound comes from the
hydraulic pump or pump
installation position. Yes

The pump installation position Troubleshoot by

No sounds abnormally. Yes referring to H2.

Check whether the pilot Check whether any oil flows Pilot relief valve fault:
pressure is normal. No out from the pilot pump. Yes
Repair or replace it

Pilot pump fault:

Remove and repair it.

No

Pilot valve or main

Check the pilot line for No control valve fault:
clogging or leakage.
Remove and repair it.

Clean the pilot line or

Yes
repair it.
 6-383
CLG922E 6.6 Fault diagnosis of the hydraulic system and mechanical system
February 3, 2015 6.6.5 H4-Hydraulic oil emulsification

6.6.5 H4-Hydraulic oil

emulsification

Hydraulic oil
emulsification

Yes

Sample the oil and drop the Let the hydraulic oil sit
This may be due
sample droplets onto the hot for a period of time, and
Yes to water in the
iron plate, and then check remove the water or
hydraulic oil.
for bubbles. replace the oil.

Check the suction line

This may be due and the return line, and
Yes
to air in the cut off the air-mixed
hydraulic oil. source.
6-384
6.6 Fault diagnosis of the hydraulic system and mechanical system CLG922E
6.6.6 H5-Abnormal hydraulic oil temperature rise February 3, 2015

6.6.6 H5-Abnormal hydraulic oil

temperature rise
Abnormal hydraulic oil
temperature rise

Yes

Check whether the

Add oil to the specified
hydraulic oil level is No level as required.
normal.

Yes

Check the oil cooler for Clean the oil cooler to

Yes keep the air ventilated.
clogging.

No

Check whether the fan

Adjust the belt tension
belt tension is No or replace the belt.
appropriate or not.

Yes

Check whether the pressure

of the main relief valve, the Adjust the setting
port relief valve and the Yes pressure again.
motor relief valve is lower
than the standard value.

No

Check whether the oil

No The check valve is
return check valve is
failed. Replace it.
normal.
 6-385
CLG922E 6.6 Fault diagnosis of the hydraulic system and mechanical system
February 3, 2015 6.6.7 H6-Slewing abnormally to left and right directions

6.6.7 H6-Slewing abnormally to

left and right directions
Slewing abnormally to
left and right directions

Yes

Whether other Troubleshoot it by referring to the

operation is Yes method that for Unidirectional
unresponsive or not? Revolving Operation Is Unresponsive.

No

Check whether the Check whether the The swing valve

swing pilot pressure is Yes swing valve element Yes element gets stuck:
normal. gets stuck. Remove and repair it.

No

Check whether the Repair or replace the

swing relief valve is No swing relief valve.
functioning properly.
No

Yes

Swing motor and

reducer fault: Repair
or replace it.

Check whether the Swing pilot valve fault:

No
swing pilot valve is Remove, repair or
functioning properly. replace it.

Yes

Clogging or leakage Yes

Clean or replace the
inside the pilot line pilot line.
6-386
6.6 Fault diagnosis of the hydraulic system and mechanical system CLG922E
6.6.8 H7-No response for slewing single direction operation February 3, 2015

6.6.8 H7-No response for

slewing single direction opera-
tion

No reponse for
slewing single
direction opeation

Yes

Check whether the

left swing pilot Check the pilot line inside Pilot valve fault:
No No
pressure is the same for clogging or leakage. Remove and repair it.
as the right one.

Yes Yes
Clogging or Clean or repair the
leakage occurs. pilot line.

Check whether the

The swing valve element
swing valve element Yes
gets stuck: Remove it,
gets stuck.

Swing relief valve fault:

No
Remove, repair or replace it.
 6-387
CLG922E 6.6 Fault diagnosis of the hydraulic system and mechanical system
February 3, 2015 6.6.9 H8-Rotation unable to stop

6.6.9 H8-Rotation unable to

stop

Rotation unable to stop

Yes

Check whether the swing Check whether the swing valve

No No Spring fault: Remove or replace it.
valve element is in the element spring is normal
neutral position.
Yes

Check whether the swing valve The swing valve element gets stuck:
element gets stuck. Yes Remove or replace it.

No

Check whether the swing pilot Swing pilot valve fault:

No
pressure is normal. Remove or replace it.

Yes

Check whether the pilot Pilot relief valve fault:

No
pump pressure is normal. Remove, repair or replace it.

No Pilot pump fault:

Remove and repair it.

Check whether the

swing relief valve Swing relief valve fault:
No Remove or replace it.
pressure is normal.
6-388
6.6 Fault diagnosis of the hydraulic system and mechanical system CLG922E
6.6.10 H9-Fail to actuate unilateral travel mechanism February 3, 2015

6.6.10 H9-Fail to actuate unilat-

eral travel mechanism

Fail to actuate
unilateral travel
mechanism

Yes

Whether other Check whether the The travel valve

operation is No travel valve element Yes element gets stuck:
unresponsive or not? gets stuck. Remove and repair it.

No

Check whether the Clean or replace the pilot

travel pilot pressure is Travel pilot line and
No line. Travel pilot valve fault:
normal. pilot valve fault
Remove, repair or replace it.

Yes

Yes Check whether the The travel motor balance

travel motor balance Yes valve gets stuck: Remove,
valve gets stuck. repair or replace it.

No

Travel motor and

reducer fault: Remove
and repair it.

Troubleshoot
according to H3.
 6-389
CLG922E 6.6 Fault diagnosis of the hydraulic system and mechanical system
February 3, 2015 6.6.11 H10-Travel deviation

6.6.11 H10-Travel deviation

Travel deviation

Yes

Let both left and right sides of

the excavator travel at the same
Check whether the travel spool Travel spool fault: Remove and
time in the same direction+ any Yes Yes
gets stuck. repair
movement on the upper part,
whether pulling one side or not?
No

Check whether the travel pilot Travel pilot line and pilot valve fault:
pressure is normal. No Clean, repair and replace it.

Yes

No Check whether the center joint is Center joint fault: Remove,

No
functioning properly. repair or replace it.
No
Yes

Check whether the travel motor Travel motor fault:

No Remove and repair it.
is functioning properly.

Yes

Main control valve fault:

Remove, repair or replace it.

Exchange the left pump output

hose and negative feedback
Hydraulic pump fault:
hose with the right ones, and Yes Remove and repair it.
check whether the fault
phenomenon transfers.
6-390
6.6 Fault diagnosis of the hydraulic system and mechanical system CLG922E
6.6.12 H11-Slow speed of the boom, arm or bucket February 3, 2015

6.6.12 H11-Slow speed of the

boom, arm or bucket

Slow speed of the boom,

arm or bucket

Yes

Whether the engine Adjust the engine

No
speed is normal speed.

Yes

Check whether the left Check whether both the

and right traveling left speed and the right Yes Main pump fault:
No
speeds are normal. speed are slow. Remove and repair it.

No

Check whether the Check the pilot line

Clean or repair
boom, arm or bucket No inside for clogging or Yes the pilot line.
pilot pressure is normal. leakage.

Yes No

Check whether the pilot valve is Pilot valve fault:

No
functioning properly Remove and repair it.

Check whether the

Check whether the pilot Just as above-mentioned,
confluence is normal when
the boom rising or the arm No pressure of the boom (2) No check the pilot line and
expanding. or the arm (2) is normal. pilot valve.

Yes
Check whether the
Check whether the
confluent valve element
above-mentioned valve Yes
spring is functioning
element gets stuck.
properly.
No
Yes
Confluent valve element
gets stuck: Remove and No Replace spring
repair it.

Check whether the boom, Check the pilot line Pilot valve fault:
arm or bucket pilot pressure No inside for clogging or No Remove and repair it.
is normal. leakage.

Clean or repair the

Yes Yes pilot line.

Check whether the Valve element gets

above-mentioned valve Yes stuck: Remove or
element gets stuck. replace

No
Check whether the main
relief valve and the port relief Relief valve fault: Remove,
valve are functioning No repair or replace it.
properly.

Cylinder inside damage:

Yes Remove and repair it.
 6-391
CLG922E 6.6 Fault diagnosis of the hydraulic system and mechanical system
February 3, 2015 6.6.13 H12-Weak actions of the boom, arm or bucket

6.6.13 H12-Weak actions of the

boom, arm or bucket

Weak actions of the

boom, arm or
bucket

Yes

Check whether the Main relief valve fault: Adjust

main relief valve No the pressure, and repair or
pressure is normal. replace the valve.

Yes

Check whether the Port relief valve fault: Adjust

port relief valve No the pressure, and repair or
pressure is normal. replace the valve.

Yes

Check whether the cylinder Cylinder fault:

No
leakage rate is normal. Remove and repair it.

Troubleshoot according to
Yes
the H11 fault.
6-392
6.6 Fault diagnosis of the hydraulic system and mechanical system CLG922E
6.6.14 H13-Significantly reduced engine speed or engine stalling February 3, 2015

6.6.14 H13-Significantly reduced engine speed or engine stalling

Precautions:
(1) Turn off the engine, make preparations, rotate the engine at high speed and then take fault diagnosis.
(2) Check for loose harness connectors in advance.

Significantly reduced engine

speed or engine stalling,
Check whether the system
shutdown Yes No Main relief valve fault
pressure is normal.

Yes

Check whether the main Pump proportional

pump proportional valve is No valve fault: Repair
functioning properly. or replace it.

Yes

Engine or electronic control

system fault