1

Important Safety Information

Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should
also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair on this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintain and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"WARNING" as shown following.

The meaning of this safety alert symbol is as follows:

Attention. Be alert. Your safety is involved.
The message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
LiuGong cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are therefore not all inclusive. If a tool, procedure, work
method or operating technique not specifically recommended by LiuGong is used, you must satisfy
yourself that it is safe for you and others. You should also ensure that the product will not be damaged or
made unsafe by the operation, lubrication, maintenance or require procedures you choose.
The information, specification, and illustrations in this publication are on the basis of information
available at the time when it was written. The specification, torques, pressures, measurements,
adjustments, illustrations, and other items can change at any time. These changes can affect the service
given to the product. Obtain the complete and most current information before starting any job. LiuGong
has the most current information available.

CALIFORNIA PROPOSITION 65

Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer,
birth defects and other reproductive harm.
Battery post, terminal and related accessories contain lead and lead compounds, Always wash hands
after handling.
 1
Preface

Preface Safety

The safety section lists basic safety precautions.

In addition this section identifies the text and
This manual includes important instructions locations of warning signs and labels used on the
concerning operation, lubrication, checking machine.
testing, adjusting the machine and permanent
key components. Read and understand the basic precautions
listed in the safety section before operating or
This manual should always be kept safe, clean performing lubrication, maintenance or repairs
and with the machine where it is convenient to on this machine.
find for operators to use. This manual should not
be separated from the machine even when Operation
reselling or leasing.
Some photographs and illustrations in this The operation section is a reference for the new
manual show details of attachments that may be operator and a refresher for the experienced
different from your machine. Guards and covers operator. Read, understand and reference it
may have been removed for the purpose of when ever neccessary. This section includes a
illustration. description of gauges, machine controls,
switches and other controls at the operators
Read this manual carefully and follow all staion. It also provides transportation and towing
instructions for proper operation and information.
maintainance of this machine. Instructions in this
manual should help the reader avoid possible Photographs and illustrations guide the operator
personal injury or damage to the machine. The through correct procedures of checking, starting,
operator should proficiently and correctly operate operating and stopping the machine.
the machine to ensure safety. Operating techniques outlined in this publication
Use this machine only for the purpose described are basic. Skill and techniques develop as the
in this manual. Contact your LiuGong dealer for operator gains knowledge of the machine and its
approval before making any modifications or capabilities.
adding attachments to the machine. The addition
of any unauthorized attachment may cause Maintenance
operation of the machine to become unsafe and
reduce the service life of the machine. Guangxi The maintenance section is a guide for
LiuGong accepts no liability for any damage equipment care. The illustrated, step-by-step
resulting from the use of unapproved instructions are grouped by servicing intervals.
attachments or working practices. Items without specific intervals are listed under
the "When Required" service interval. Items in
Only trained or experienced personnel should be the "Maintenance Intervals" are referenced to
allowed to operate or maintain this machine. detailed instructions that follow.
Correctly record the machine type, serial
number, engine serial number and all major
component serial numbers for your reference
when ordering parts or in the event of theft.
Record the correct numbers to both the
operators manual and a secure place outside the
machine.
2
Preface

Maintenance Intervals

Use the service hour meter to determine

servicing intervals. Calendar intervals shown
(daily, weekly, monthly, etc) can be used instead
of service hour meter intervals if they provide
more convenient servicing schedules and
approximate the indicated service hour meter
reading. Recommended service should always
be performed at the interval that occurs first.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified in the "Maintenance Intervals" may be
necessary.
Perform service on items at multiples of the
original requirement. For example, at every 500
service hours, also service those items listed
under every 250 service hours, 50 service hours
and every 8 service hours or daily.
All the information, figures, tables and
specifications are the latest product information
obtainable at the time of publication. Guangxi
LiuGong Company will reserve the right to make
change without notice.

Certified Engine Maintenance

Correct maintenance and repair methods are

essential to keeping the engine and machine
systems operating correctly. As the owner, you
are responsible for performance of required
maintenace listed in the Maintenance Manual for
this machine. It is prohibited for person engaged
in the business of repairing, serviceing, selling,
leasing or trading engines or machines to
remove, alter or render inoperative any
emmissions related device or element of design
installed on or in an engine or machine that is in
compliance with the regulations. Certain
elements of the machine such as exhaust
system, fuel system, electrical system, air intake
system and cooling system may be emmision
related and should not be altered unless
approved by LiuGong.
 3
Preface

Main Components

Z-bar

on

OFF

1. Front and rear lever 10. Rear wheel

2. Tilting cylinder 11. Ladder
3. Front frame 12. Front fender
4. Front floodlight, front position light, turn signal light 13. Front wheel
5. Cab 14. Boom cylinder
6. Engine hood 15. Boom
7. Counterweight 16. Bucket
8. Rear frame
9. Rear fender
4
Preface

8-bar

on

OFF

1. Front and rear lever 10. Rear wheel

2. Tilting cylinder 11. Ladder
3. Front frame 12. Front fender
4. Front floodlight, front position light, turn signal light 13. Front wheel
5. Cab 14. Boom cylinder
6. Engine hood 15. Boom
7. Counterweight 16. Bucket
8. Rear frame
9. Rear fender
 5
Safety Information
Safety Decals and Decal Locations

Safety Information "Caution" is also used to indicate safety

information relating to unsafe operations which
may cause personal injuries. "Danger"
represents the most dangerous conditions. The
Safety Symbol safety signs "Danger" or "Warning" are placed
near particular dangerous places. General notice
information is placed on the safety sign
The symbol for safety alerting appears
"Caution."
on machines, safety signs, manuals or
for important safety information at
other places. When you see this Safety Decals and Decal
symbol, you should follow the instructions in the
safety information, guarding against any Locations
possibility of personal injuries or death.
There are several specific safety decals on your
Safety Signs machine. The exact location of and description of
the hazards are reviewed in this section. Please
take time to read, understand and familiarize
Definitions of the safety signs with the words yourself with each and every one of these safety
"Danger", "Warning" and "Caution" which appear decals.
in this manual and on the machine are as
follows: Make sure that you can read all safety decals.
Clean or replace if you cannot read the words or
see the pictures. When cleaning the decals use a
cloth, water and soap. Do not use solvent,
gasoline, or other harsh chemicals to clean the
● Danger: this word denotes an impending safety decals. Solvents, gasoline or hash
danger, failure to observe instructions could chemicals could loosen the adhesive backing of
result in death or serious injuries. decals causing them to fall off the machine.
You must replace a decal if it is damaged,
missing or cannot be read. If a decal is on a part
that is replaced, make sure a new decal is
● Warning: this word denotes potential danger, installed on the replacement part. Pay attention
failure to observe instructions could result in to the notice decals located in the cab before
death or serious injuries. starting.

● Caution: this word denotes potential danger,

failure to observe instructions could result in
minor to medium degree of injury.
6
Safety Information
Safety Decals and Decal Locations

Decal location(Z-bar)

14
22
7 4A
 7
Safety Information
Safety Decals and Decal Locations

7 4A
22
14
8
Safety Information
Safety Decals and Decal Locations

Decal location(8-bar)

Impro pe r en gag ement

o f w o rk tool s could
re sul t in in ju ry or death.
D o no t o pe rate this
ma ch in e un ti l you have
po si ti ve i nd ic ation that
th e di ve rter val ve is in
A ux il i ary posi tion and
th e qu ic k coupler
s wi tc h is in L ocked
po si tion.
To l o ck a nd unl ock
co up l er, atta chment
mu st be o ff gro un d and
i n a ro ll ed-back
po si tion.
R oll bac k bu cket ful ly
w he n l ock ing
aIns
tta pe
ch ct
ment. cou pl er l ock pin
Fai
exlteure
ns ioto nc before
omply could
reopsul t in
era dea th or
ti ng.
sCou
erio us
pl erinjl ock
ury. pi ns w il l
ex te nd to locked
p os iti on w he n swi tch i s
i n l oc ke d po sition and
wh en e l ectri cal power i s
sh ut-off.

14
7 4A22
 9
Safety Information
Safety Decals and Decal Locations

74
A22
14
10
Safety Information
Safety Decals and Decal Locations

Decal Information(Used for ISO market)

Fig.1 WARNING DECAL

(Located near the crush area)
CRUSH HAZARD. Keep clear.

74A3167

Fig. 2 DANGER DECAL

(Located on the arm)
CRUSH HAZARD. Keep away from raised
loader arm or bucket.

74A3153
 11
Safety Information
Safety Decals and Decal Locations

Decal Information(Used for ISO market)

Fig. 3 DANGER DECAL

(Located on the arm or arm cylinder)
CRUSH HAZARD. Install arm support before
maintenance or repair with loader arm raised.

74A3165
Fig. 5 WARNING DECAL
(Located in the cab)
Read and understand Operation and
Maintenance Manual before operating or
performing maintenance on this machine,
death or serious injury could result. It is your
responsibility to be aware of and follow all
local laws and regulations.Operate only from
operator's seat.Do not carry riders on
machine. Before starting machine, make sure
hydraulic control lever is in lockout position
and all control levers are in neutral.Sound
horn to alert people. Ensure bystanders and
obstacles are clear of machine before moving
machine or its attachment. Before leaving
operator's compartment, park on level
ground, lower attachments to ground, make
sure hydraulic control lever is in lockout
position. All control levers are in neutral.
Engage parking brake. Never operate
machine downhill with stalled engine and
gear in neutral. Avoid contacting overhead
obstacles when operating or hauling
machine. 74A3160
12
Safety Information
Safety Decals and Decal Locations

Decal Information(Used for ISO market)

Fig. 6 NOTICE DECAL
(Located in the cab)
To Start Machine:
Semi Automatic Transmissions
1. Move F-N-R lever on steering column to "N"
position
2. Turn key to "start" position
Fully Automatic Transmissions
1. Turn key to "on" position
2. Press the "N" button on the control Paddle
3. Confirm "N2" is displayed in display panel
4. Turn key switch to "start" position
To Move Machine From Neutal To Drive:
Semi Automatic Transmissions
1. Move the F-N-R lever to "F"or"R" position as
desired
2. Release park brake
Fuly Automatic Transmissions
1. Apply foot brake and hold
2. Release park brake(P)
3. Press the K.D button located on the front of the
control paddle,at the same time,press ↑ or ↓
button as desired
4. Release foot brake and press accelerator To
move from ↑ to ↓ will not require the use of
K.D button. 74A2835

Fig. 9 NOTICE DECAL

(Located in the cab)
Do not clean inside of cab with water under
pressure, electrical component damage will
result. Prevent loss of electrical power, turn
battery disconnect switch to off position when
machine not in use or being parked overnight. 74A3235
 13
Safety Information
Safety Decals and Decal Locations

Decal Information(Used for ISO market)

Fig. 10 NOTICE DECAL

(Located in the cab)
Avoid damaging electronic components when
welding: Position machine on level ground,
engage parking brake. Shut off engine and
turn off battery disconnect switch. Remove
electrical connectors from transmission,
engine control units and instrument panel
plug.

74A2840

Fig. 11 CAUTION DECAL

(Located on the hot surface)
Hot surface, keep clear.

74A3168
14
Safety Information
Safety Decals and Decal Locations

Decal Information(Used for ISO market)

Fig. 12 WARNING DECAL

(Located on the engine)
RUNOVER HAZARD. Start engine from
operator's seat, transmission in NEUTRAL.

74A3183

Fig. 13 WARNING DECAL

(Located near the engine belt)
ENTANGLEMENT HAZARD. Keep clear or
stop engine before servicing.

74A3171
 15
Safety Information
Safety Decals and Decal Locations

Decal Information(Used for ISO market)

Fig.16 DANGER DECAL

(Located near the battery)
Fumes given off by batteries are combustible.
Keep flame and sparks away, do not store
tools or metal objects near batteries. Risk of
explosion if metal objects cause a short
circuit. Sulphuric acid contained in batteries is
poisonous, do not allow acid to contact skin,
clothing or your eyes. If you spill acid on
yourself, immediately: Flush your skin with
water. Apply a neutralizing agent such as
lime. Flush eyes with water for 10-15 minutes.
Immediately seek medical attention.
74A3188

Fig. 17 WARNING DECAL

(Located at the frame articulation joint )
CRUSH HAZARD. Keep clear.

74A3163
16
Safety Information
Safety Decals and Decal Locations

Decal Information(Used for ISO market)

Fig.18 WARNING DECAL

(Located near the articulation joint)
CRUSH HAZARD. Engage articulation lock
before service or transport.

74A3176

Fig. 20 WARNING DECAL

(Located near the ladder)
Whenever mounting or dismounting machine,
face machine and maintain 3 points of
contact. Never jump from machine. Ensure
steps are clean.

74A3169

Fig. 21 DANGER DECAL

(Located on arm or arm support)
CRUSH HAZARD. Install arm support before
maintenance or repair with loader arm raised.

74A3407
 17
Safety Information
Safety Decals and Decal Locations

Decal Information(Used for ISO market)

Fig. 24 WARNING DECAL
(Located near the battery)
Only attempt to use jumper cables from an
operating machine with a 12 volt negative
ground system, failure to observe could result
in serious injury. Follow this procedure when
attaching jumper cables. Confirm positive
terminal(+) of each machine. Positive(+)
terminal has a red cable connected to
machine starter motor not to other battery.
Connect a jumper cable to positive terminal
(+) of disabled machine and connect other
end to positive terminal (+) of operating
machine. Connect a second jumper cable to
machine frame of operating machine and
connect other end of jumper cable to disabled
machine frame or engine block as far away
from batteries as possible. Start operating
machine from operator seat only. Start
disabled machine from operator seat only.
Once disabled machine is started remove
jumper cables in reverse order. 74A3086

Fig. 28 WARNING DECAL

(Located on the engine hood )
Do not step on this surface.

74A3192

Fig. 30 WARNING DECAL

(Located near the coolant filler cap)
Hot liquid under pressure, service when cool.

74A3180
18
Safety Information
Safety Decals and Decal Locations

Decal Information(Used for ISO market)

74A2868

Fig. 31 NOTICE DECAL

(Located near the coolant filler on engine
hood)
Engine coolant contains antifreeze protection
to -15°C\-30°C\-45°C. Change coolant
annually.
74A2867

74A2863

Fig. 35 WARNING DECAL

(Located in the cab)
CRUSH HAZARD. Use seat belt. Do not jump
if machine tips.

74A3179
 19
Safety Information
Safety Decals and Decal Locations

Decal Information(Used for ISO market)

Fig. 37 WARNING DECAL

(Located on the tail of machine)
RUNOVER HAZARD. Keep clear.

74A3178

Fig. 39 WARNING DECAL

(Located near the engine fan)
CUTTING HAZARD. Keep clear or stop
engine before servicing.

74A3161
Fig. 40 WARNING DECAL
(Located near the joint of coupler)
CRUSH HAZARD. Inspect coupler locking
pins extension before operating. Bucket
engaged, indicators point towards each other
at top. Bucket disengaged, indicators point
away from each other at top. Improperly
locked attachment could release and cause
serious injury. Failure to comply could result
in death or serious injury. Only use
attachments specifically degigned for and
approved for use with the coupler fitted.If the
attachment is damaged or can not be secured
to the coupler it must not be used. Never
move the machine with attachments not
secured. 74A3184
20
Safety Information
Safety Decals and Decal Locations

Decal Information(Used for ISO market)

Fig. 41 WARNING DECAL
(Located in the cab)
Improper engagement of work tools could
result in serious injury or death. Do not
operate this machine unitl you have positive
indication that: 1.Tool is firmly attached to
coupler. 2.Handle of diverter valve is in Aux
position as picutured. 3. Mechanical lock on
control lever of coupler is in locked position.
Never operate machine without locks in
locked position. To change tool, turn hydraulic
diverter valve to Coupler position. Ensure that
work area is clear of personnel.Tool must be
in rolled back position and indicators visible to
operator. Release mechanical interlock on
control lever and withdraw locking pins.
Lower tool to ground and roll forward to
release. When attaching tool, roll back fully
and extend locking pins. Check attachment
by rolling tool forward against ground. Tool
should remain attached. Bucket engaged,
indicators point towards each other at top.
Bucket disengaged, indicators point away
from each other at top.Relock the mechanical
interlock on the coupler control lever and
reset the hydraulic diverter valve to Aux
position. Do not operate machine with a faulty
coupler or with the mechanical interlock on
the control lever not engaged at all times. 74A3185
Fig. 42 DECAL
1. Refer to the manufacturer plate on the
machine for the machine mass.
2. The steering frame lock must be in place
for lifting.
3. Use proper rated cables and slings for
lifting .position crane for level machine lift.
4. Spreader bar witch should be sufficient to
prevent contact with machine. 74A4255
 21
Safety Information
Safety Decals and Decal Locations

Decal Information(Used for North America market)

Fig. 1 WARNING DECAL

(Located near the crush area)
CRUSH HAZARD. Keep clear.

74A2804

Fig. 2 DANGER DECAL

(Located on the arm)
CRUSH HAZARD. Keep away from raised
loader arm or bucket.

74A2828
22
Safety Information
Safety Decals and Decal Locations

Decal Information(Used for North America market)

Fig. 3 DANGER DECAL

(Located on the arm)
Crush hazard. Install arm support before
maintenance or repair with loader arm raised.

74A2829

Fig. 4 WARNING DECAL

(Located at front below of the cab)
Pressurized system. Relieve pressure before
maintenance.

74A2856
 23
Safety Information
Safety Decals and Decal Locations

Decal Information(Used for North America market)

Fig. 6 WARNING DECAL
(located in the cab)
Read and understand Operation and
Maintenance Manual before operating or
performing maintenance on this machine,
death or serious injury could result. It is your
responsibility to be aware of and follow all
local laws and regulations.Operate only from
operator's seat.Do not carry riders on
machine. Before starting machine, make sure
hydraulic control lever is in lockout position
and all control levers are in neutral.Sound
horn to alert people. Ensure bystanders and
obstacles are clear of machine before moving
machine or its attachment. Before leaving
operator's compartment, park on level
ground, lower attachments to ground, make
sure hydraulic control lever is in lockout
position. All control levers are in neutral.
Engage parking brake. Never operate
machine downhill with stalled engine and
gear in neutral. Avoid contacting overhead
obstacles when operating or hauling
machine. 74A2815
24
Safety Information
Safety Decals and Decal Locations

Decal Information(Used for North America market)

Fig. 7 NOTICE DECAL
(Located in the cab)
To Start Machine:
Semi Automatic Transmissions
1. Move F-N-R lever on steering column to "N"
position
2. Turn key to "start" position
Fully Automatic Transmissions
1. Turn key to "on" position
2. Press the "N" button on the control Paddle
3. Confirm "N2" is displayed in display panel
4. Turn key switch to "start" position
To Move Machine From Neutal To Drive:
Semi Automatic Transmissions
1. Move the F-N-R lever to "F"or"R" position as
desired
2. Release park brake
Fuly Automatic Transmissions
1. Apply foot brake and hold
2. Release park brake(P)
3. Press the K.D button located on the front of the
control paddle,at the same time,press ↑ or ↓
button as desired
4. Release foot brake and press accelerator To
move from ↑ to ↓ will not require the use of
K.D button. 74A2835
Fig. 10 NOTICE DECAL
(Located in the cab)
Do not clean inside of cab with water under
pressure, electrical component damage will
result. Prevent loss of electrical power, turn
battery disconnect switch to off position when
machine not in use or being parked overnight. 74A3235
 25
Safety Information
Safety Decals and Decal Locations

Decal Information(Used for North America market)

Fig. 11 NOTICE DECAL

(Located in the cab)
Avoid damaging electronic components when
welding: Position machine on level ground,
engage parking brake. Shut off engine and
turn off battery disconnect switch. Remove
electrical connectors from transmission,
engine control units and instrument panel
plug.

74A2840

Fig. 12 CAUTION DECAL

(Located on the hot surface)
Hot surfce,keep clear.

74A2814
26
Safety Information
Safety Decals and Decal Locations

Decal Information(Used for North America market)

Fig. 13 WARNING DECAL

(Located on the engine)
RUNOVER HAZARD. Start engine from
operator's seat, transmission in NEUTRAL.

74A2839

Fig. 14 WARNING
(Located near the engine belt)
ENTANGLEMENT HAZARD. Keep clear or
stop engine before servicing.

74A2837
 27
Safety Information
Safety Decals and Decal Locations

Decal Information(Used for North America market)

Fig. 17 WARNING DECAL

(Located near the battery)
CALIFORNIA Propositin65. Battery posts,
terminals and related accessories contain
lead and lead compounds, chemicals known
to the State of California to cause cancer and
reproductive harm. Wash hands after
handling.

74A2966

Fig. 18 WARNING DECAL

(Located at the frame articulation joint )
CRUSH HAZARD. Keep clear.

74A2833
28
Safety Information
Safety Decals and Decal Locations

Decal Information(Used for North America market)

Fig. 19 WARNING DECAL

(Located at the frame articulation joint )
CRUSH HAZARD. Engage articulation lock
before service or transport.

74A2852

Fig. 21 WARNING DECAL

(Located on the high-pressure gas container)
CONTAINS HGHT PRESSURE GAS. To
avoid explosion and personal injury, do not
expose to fire, do not weld, do not drill.
Relieve pressure before discharging.
74A2869

Fig. 22 WARNING DECAL

(Located near the ladder)
Whenever mounting or dismounting machine,
face machine and maintain 3 points of
contact. Never jump from machine. Ensure
steps are clean.

74A2809
 29
Safety Information
Safety Decals and Decal Locations

Decal Information(Used for North America market)

Fig. 23 WARNING DECAL

RUNOVER HAZARD. Block wheels to
prevent machine movement before
disengaging parking brake for repair or
maintenance.

74A2854

Fig. 24 DANGER DECAL

(Located on arm or arm support)
CRUSH HAZARD. Install arm support before
maintenance or repair with loader arm raised.

74A2887
30
Safety Information
Safety Decals and Decal Locations

Decal Information(Used for North America market)

Fig. 27 WARNING DECAL
(Located near the battery)
Only attempt to use jumper cables from an
operating machine with a 24 volt negative
ground system, failure to observe could result
in serious injury. Follow this procedure when
attaching jumper cables. Confirm positive
terminal(+) of each machine. Positive(+)
terminal has a red cable connected to
machine starter motor not to other battery.
Connect a jumper cable to positive terminal
(+) of disabled machine and connect other
end to positive terminal (+) of operating
machine. Connect a second jumper cable to
machine frame of operating machine and
connect other end of jumper cable to disabled
machine frame or engine block as far away
from batteries as possible. Start operating
machine from operator seat only. Start
disabled machine from operator seat only.
Once disabled machine is started remove
jumper cables in reverse order. 74A2995

Fig. 31 WARNING DECAL

(Located on the engine hood)
No step.

74A2807
 31
Safety Information
Safety Decals and Decal Locations

Decal Information(Used for North America market)

Fig. 33 WARNING DECAL

(Located near the coolant filler cap)
Hot liquid under pressure, service when cool.

74A2841

74A2868

Fig. 34 NOTICE DECAL

(Located near the coolant filler on engine
hood)
Engine coolant contains antifreeze protection
to -15°C\-30°C\-45°C. Change coolant
annually.
74A2867

74A2863
Fig. 38 WARNING DECAL
(Located in the cab)
CALIFORNIA Proposition 65 Diesel engine
exhaust and some of its constituents are
known to the State of California to cause
cancer,birth defects,and other reproductive
harm. 74A2996
32
Safety Information
Safety Decals and Decal Locations

Decal Information(Used for North America market)

Fig. 39 WARNING DECAL

(Located in the cab)
CRUSH HAZARD. Use seat belt. Do not jump
if machine tips.

74A2850

Fig. 40 WARNING DECAL

(Located in the cab)
EXPLOSION HAZARD. Do not use ether.
Machine is equipped with electrical cold
weather start aid device.

74A2853

Fig. 43 WARNING DECAL

(Located on the tail of machine)
RUNOVER HAZARD. Keep clear.

74A2846
 33
Safety Information
Safety Decals and Decal Locations

Decal Information(Used for North America market)

Fig. 44 WARNING DECAL

(Located near the engine fan)
CUTTING HAZARD. Keep clear or stop
engine before servicing.

74A2826
Fig. 45 WARNING DECAL
(Located near the joint of coupler)
Crush hazard. Inspect coupler locking pins
extension before operating. Bucket engaged,
indicators point towards each other at top.
Bucket disengaged, indicators point away
from each other at top. Improperly locked
attachment could release and cause serious
injury. Failure to comply could result in death
or serious injury. Only use attachments
specifically degigned for and approved for
use with the coupler fitted.If the attachment is
damaged or can not be secured to the
coupler it must not be used. Never move the
machine with attachments not secured. 74A2942
34
Safety Information
Safety Decals and Decal Locations

Decal Information(Used for North America market)

Fig. 46 WARNING DECAL
(Located in the cab)
Improper engagement of work tools could
result in serious injury or death. Do not
operate this machine unitl you have positive
indication that: 1.Tool is firmly attached to
coupler. 2.Handle of diverter valve is in Aux
position as picutured. 3. Mechanical lock on
control lever of coupler is in locked position.
Never operate machine without locks in
locked position. To change tool, turn hydraulic
diverter valve to Coupler position. Ensure that
work area is clear of personnel.Tool must be
in rolled back position and indicators visible to
operator. Release mechanical interlock on
control lever and withdraw locking pins.
Lower tool to ground and roll forward to
release. When attaching tool, roll back fully
and extend locking pins. Check attachment
by rolling tool forward against ground. Tool
should remain attached. Bucket engaged,
indicators point towards each other at top.
Bucket disengaged, indicators point away
from each other at top.Relock the mechanical
interlock on the coupler control lever and
reset the hydraulic diverter valve to Aux
position. Do not operate machine with a faulty
coupler or with the mechanical interlock on
the control lever not engaged at all times. 74A2903
Fig. 47 DECAL
1. Refer to the manufacturer plate on the
machine for the machine mass.
2. The steering frame lock must be in place
for lifting.
3. Use proper rated cables and slings for
lifting .position crane for level machine lift.
4. Spreader bar witch should be sufficient to
prevent contact with machine. 74A4255
 35
Safety Information
General Hazard Information

General Hazard Information

Be familiar with all safety cautions, failure to

observe could result in property damage,
serious injury or even death.
Only trained and qualified personnel should be
allowed to operate or maintain the machine.

Wear relevant personal protective equipment

(PPE) such as a hard hat, ear protection, safety
glasses, safety shoes and gloves when
operating or servicing the machine.

Do not operate the machine if you feel sick,

sleepy or after taking some medication. Check
with your doctor if unsure. Never operate
machinery while under the influence of drugs or
alchohol.
Attach a DO NOT OPERATE or similar warning
tag to start switch or control levers before
servicing or repairing the machine.

Using goggles, safety glasses or full face mask

can protect your eyes from being injured by high
G

pressure liquids, when maintaining storage

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electrolyte to batteries, you should wear a full

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face protective mask. When carrying out welding

operations or gas cutting operations with a
Do not wear loose fitting clothing, dangling
welding torch, wear specific safety goggles
jewelry or long hair that can catch on controls or
suitable for the task being performed. Consult
in other moving parts of the machine.
your welding equipment dealer for more
information.
36
Safety Information
General Hazard Information

Pay attention when opening fluid compartments,

prevent foreign materials from entering the
system. Always remove loose materials from
near caps and plugs.

When working under high noise conditions, wear

appropriate safety equipment to protect your
hearing, such as approved earmuffs or plugs.
Avoid the damage caused by exposure to high Know the appropriate worksite hand signals and
noise on your hearing. who gives them. Accept signals from one person
only.
Never put maintenance fluids into glass
containers.
Observe the relevant laws and regulations when
handling harmful articles such as lubricants,
fuels, coolants, solvents, filters, batteries and
other matterials.
Use all cleaning solutions with care. Do not use
any flammable material to wash components, for
example, diesel oil or gasoline. They may easily
catch fire.
Make sure all protective guards and covers are
secured in place on the machine. Always replace
protective guards and covers removed for
servicing or maintenance. Repair damaged
guards and covers before operation.
Keep the machine, especially the panels,
accesses, step and ladders, free of foreign
material, such as debris, oil, tools and other
items which are not part of the machine.
Secure all loose items such as lunch boxes, tools
and others.
Report all required repairs in time.
Do not allow unauthorized personnel on or
around the machine.
Guangxi Liugong bear no resposibility for failures
caused by modifications to machine structure
without Liugong’s permission.
 37
Safety Information
General Hazard Information

Compressed Air Even a pin-hole size leak can cause serious

injury, If you are hit by spraying high-pressure oil,
Compressed air can cause personal injury. When see a doctor for treatment at once.
using compressed air for cleaning, wear a
protective face shield, protective clothing,
hearing protection and protective shoes. Never
direct compressed air at yourself or others.
Compressed air could penetrate your skin and
cause serious injury or death. The maximum air
pressure used should not exceed 25psi(0.2Mpa).

High-pressure Fluid

WARNING: Avoid injury from high-

Disposal of Waste Fluids
pressure oil. When repairing hydraulic lines,
ensure that system pressure is completely
Improper handling of the waste fluid will cause
released before beginning the repair.
pollution of the environment. Obey all local
Hydraulic oil under pressure contacting the
regulations for disposal of waste fluids.
skin could cause serious injury or damage.
Collect all waste fluids when performing
Use cautiion before disconnecting hydraulic lines inspections, maintenance, testing, adjusting and
or connectors. High pressure oil that is released repairs to the machine.
can cause a hose to whip.
Prepare to collect fluids with suitable containers
Always support attachments and release before opening any compartment or
residual pressure before attempting to disassembling any component that contains
disconnect hydraulic lines. Pressure applied by fluids.
loads on attachments could cause hydraulic oil to
Use suitable containers to collect waste fluids.
spray when lines are removed.
Do not use food containers or beverage bottles
Wear safety glasses and leather gloves. Never as they could mislead people to drink the
check for a high-pressure leaks with your contents.
unprotected hand. Use a board or cardboard
when checking for leaks.

Cautions about Accumulators

High-pressure nitrogen is contained in the

accumulators making them dangerous articles.
Read the following requirements and pay
attention to the proper use of accumulators.
38
Safety Information
Crushing and Cutting Prevention

Check accumulators before charging with Shower after contact with asbestos.
nitrogen. Safe use cannot be guaranteed if there
Wear an approved respirator if there is no other
is not a nameplate attached to the accumulator.
way to control the dust. .
Never charge accumulators that have an
incomplete nameplate or that are of an
unidentified type.
Accumulators are charged with nitrogen. The
use of oxygen, compressed air or other
flammable air in the accumulator could cause an
explosion and possible injury, death and damage
to the machine.
When charging accumulators with nitrogen, care
should be taken not to damage the diaphragm.
The accumulator's valve should be installed Crushing and Cutting Preven-
facing vertically upward. Do not attempt to fix
accumulators by welding them. tion
Do not drill any hole in the accumulator or close
a hole by welding. Don't put hands, arms, or any other parts of the
body in the way of removable parts.
Do not weld a boss on the accumulator.
Support equipment and attachments properly
Accumulators are high-pressure vessels and when working beneath them. Do not depend on
should be repaired only by trained specialized hydraulic cylinders to hold up the implement/
personnel. attachment. The implement/attachment can fall if
Always release pressure in the accumulator a control lever is accidentally moved, or if a
before disposing of it. hydraulic line breaks.
If it is necessary to remove shields in order to
Asbestos Danger perform maintenance, always install the shields
after the maintenance is performed.
Breathing asbestos dust can be hazardous to
your health. Equipment and replacement parts Check all protective devices for safety such as
shipped from Liugong have no asbestos in them. doors, safety guards and covers. Ensure they
Liugong recommends the use of genuine factory have been installed correctly so as to avoid any
spare parts only. Observe the following rules if possible injury caused by moving parts, for
you are handling any spare parts that contain example: prevent fans from causing injury by
asbestos or asbestos fibers: cutting. Keep clear or stop engine before
servicing. If any door, guard or cover are
Never use compressed air to clean up asbestos. damaged, they should be repaired or replaced
Use a wet method in order to clean up asbestos before using the machine.
materials. Water the area down to clear asbestos
dust.
A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be
used.
Do not grind materials that contain asbestos.
Obey environmental regulations for the disposal
of asbestos.
 39
Safety Information
Burn Prevention

Keep hands and objects away from moving fan Check the coolant level only after the engine has
blades. They can throw or cut any object that been stopped and the coolant filler cap is cool
contacts the moving blades. enough to remove with your bare hand.
Never attempt adjustments while the machine is Remove the cooling system filler cap slowly to
moving or the engine is running unless otherwise relieve pressure.
specified.
Coolant contains alkali that can cause personal
If the machine must be repaired with engine injury. Avoid contact with the skin, eyes and
running, make sure that a qualified operator is mouth.
available in the cab to shut down the engine if
required. Oil
Do not use a kinked or frayed wire cable. Wear
Hot oil and components can cause personal
gloves when handling wire cables.
injury. Do not allow hot oil or components to
Retainer pins, when struck with force, can fly out contact the skin.
and injure nearby persons. Make sure the area is
clear of people when driving retainer pins. Wear
protective glasses when striking a retainer pin to
avoid injury to your eyes.
Chips or other debris can fly off objects when
struck. Make sure no one can be injured by flying
debris before striking any object.

Burn Prevention At operating temperature the hydraulic oil tank is

hot and can be under pressure.

Some parts of the machine become hot during Remove the hydraulic oil tank cap only after the
normal operation. Use caution when maintaining engine has been stopped and the cap is cool
the engine and hydraulics. Allow the machine to enough to remove with your bare hand.
cool after it has been operating for a long period Remove the hydraulic oil tank oil filling cap
of time. slowly to relieve pressure.
Relieve all residual pressure in air, oil, fuel or
Coolant
cooling systems before any lines, connectors or
related items are disconnected or removed.
At operating temperature, the engine coolant is
hot and under pressure. The radiator and all
Batteries
lines to heaters and the engine contain hot water
or steam. Any contact can cause severe burns.
Batteries give off flammable fumes which can
explode.
Batteries and battery terminals may contain lead,
do not touch batteries with your bare hands.
Always wash your hands right after maintaining a
battery.
Do not smoke when observing the battery
electrolyte levels.
40
Safety Information
Fire & Explosion Prevention

Electrolyte is an acid and causes personal injury Store all oily rags or other flammable materials in
if it contacts skin or eyes. If contact occurs flush a protective container away from naked flames
with water and seek medical attention right away. or other sources of ignition. Do not weld or flame
cut pipes that contain flammable fluids. Remove
Always wear protective glasses and gloves when
them from the machine and clean them
checking batteries.
thoroughly with nonflammable solvent before
welding or flame cutting on them.
Remove all flammable materials such as fuel,
lubrication and other debris before they
accumulate on the machine.
Do not operate the machine near an open flame.
Keep all open flames or sparks away from the
battery. Do not smoke in battery charging areas.
Do not charge a frozen battery. This may cause
an explosion.

Fire & Explosion Prevention Ether

WARNING: Do not attempt to ether-start

All fuels, most lubrications and some coolant
this machine.
mixtures are flammable.
Fuel leaked or spilt onto hot surfaces or electrical Starting the machine by use of ether could result
components can cause a fire. in serious damage to the engine or personal
injury or death.
Do not smoke while refueling or in a refueling
area, or where flammable materials are stored.

Clean and tighten all electrical connections.

Check daily for loose or frayed electrical wires. Cautions Concerning Lines, Tubes and
Have all loose or frayed electrical wires Hoses
tightened, repaired or replaced before operating
the machine. Do not bend or strike high-pressure lines. Do not
Check the electric circuit periodically to avoid fire install bent or damaged tubes or hoses.
caused by overload or short circuit. Tighten any loose fuel or oil pipes, hydraulic
Keep all fuels and lubrications stored in properly system tubes or hoses. Repair any damaged fuel
marked containers and away from all or oil lines, tubes or hoses. Leaks can cause
unauthorized persons. fires. Contact Liugong or your Liugong Dealer for
factory authorized replacement parts.
If you see evidence of any of the following
situations, replace the part before using:
 41
Safety Information
Fire Extinguishers and First-aid Kit

● Connectors damaged or leaking. Keep telephone numbers of doctors, first-aid

centers or fire stations etc with you so you can
● Outer covering frayed or cut and reinforcing
contact them in case of an emergency. Post the
wire exposed.
contact telephone numbers in regulated places.
● Outer covering ballooning. Ensure that all persons know where the
telephone numbers are located and know the
● Evidence of kinking or crushing.
correct contact method.
● Reinforcing steel wire of the hose embedded
in the outer covers.
● Connectors incorrectly fitted or tensioned.
Make sure that all clamps, guards and heat
shields are properly installed. During operation
this will prevent vibration, abrassion, friction with
other parts and guard from excessive heat.
Before removing or servicing any lines of the air
conditioning system, always ensure there is not
an open fire nearby, any escaping gas coming Inspect and service the fire extinguisher
into contact with fire could result in poisonous regularly. Obey the recommendations on the
fumes. Never smoke when servicing or repairing instruction plate and all local laws and
the air conditioning system, any escaping gas regulations relating to fire extinguishers.
that burns and inhaled can cause bodily harm or
death. Electrical Storm Injury Pre-
vention
Fire Extinguishers and First-
aid Kit When lightning is striking in the vicinity of the
machine, the operator should never attempt to
A fire extinguisher that meets with all local fire mount and dismount the machine.
extinguisher laws and regulations should be If you are in the cab during an electrical storm,
available on the machine. stay in the cab. If you are on the ground during
Maintain the fire extinguisher in accordance with an electrical storm, stay away from the machine.
all local laws and regulations. Contact your local
fire department for further information.
Know how to use the fire extinguisher and first-
aid kit.
A first-aid kit should be available at the work site.
Periodically check the contents of the kit and
replace used medical supplies as necessary.
42
Safety Information
Tire Explosion Prevention

Tire Explosion Prevention Dry nitrogen is recommended for inflation of

tires. If the tires were originally inflated with air,
nitrogen is still preferred for adjusting the
Maintenance, removal, repair and installation of pressure. Nitrogen mixes properly with air.
the tires and wheel rims must be performed with Nitrogen inflated tires reduce the potential of a
special equipment and a trained repairer. tire explosion because nitrogen does not aid
Therefore, it is better to repair and maintain the combustion. Nitrogen helps to prevent oxidation
tires in a tire service shop. of the rubber, deterioration of rubber, and
corrosion of rim components.

ROPS/FOPS

ROPS/FOPS of Guangxi Liugong Machinery

Co., Ltd are located above the operator's
compartment and secured to the machine.
The strength of the structure will be reduced if it
is damaged due to a rollover. ROPS are certified
structures and cannot be repaired. Any damage
Explosions of tires have resulted from gas heat- to the ROPS structure will require replacement of
induced and combustion inside the tires. the structure to retain the certification.
Explosions can be caused by heat that is Always fasten your seat belt when you operate
generated by welding, by heating rim the machine.
components, by external fire, or by excessive
use of brakes. It is forbidden to drill holes or weld inside or
outside or change anything of the cab. This will
A tire explosion is much more violent than a damage the integrity of the ROPS structure.
blowout. The explosion can propel the tire, the
rim components, and the drive train components If the cab is to be modified in any way, contact
as far as 500 m (1500 ft) or more from the your local Liugong dealer to avoid damaging the
machine. Both the force of the explosion and the ROPS structure.
flying debris can cause property damage,
personal injury, or death.
Do not approach a warm tire. Maintain a
minimum distance, as shown. Stay outside the
shadow area.

AT LEAST 15m(50ft) AT LEAST 500m(1500ft)

 43
Safety Information
Operator Station

Operator Station It is forbidden to modify the machine or any

attachments without permission from your
Liugong dealer.
This machine is equipped with a cab that meets
with industry standard: SAE J154 and ISO 3411. Liugong bears no responsibility for injuries,
accidents or machine damage resulting from the
Any modifications or aditional equipment added use of unauthorized attachments.
to the inside of the operator station should not
project into the operator space. The addition of a
radio, fire extinguisher and other equipment must Cautions about Machine
be installed so that the defined operator space is Operation
maintained. Any item that is brought into the cab
should not project into the defined operator
space. A lunch box or other loose items must be Mounting and Dismounting
secured. Objects must not pose an impact
hazard during travel over rough terrain or in the Before mounting or dismounting the machine,
event of the machine tipping. check the condition of handrails, ladders and
steps. Clean them of grease, lubricants and dirt
before use. Repair any damaged parts and
Steering Frame Lock tighten loose bolts.
Mount and dismount the machine only where
Connect steering frame lock when the machine there are handrails, steps or ladders.
is being lifted and shipped. Also connect the
Face the machine when getting on or off, grab
steering frame lock when performing repairs
the handrails with both hands and step onto the
near the articulation joint.
steps or ladders. Touch three points
Disassemble the steering frame lock before simultaneously (two feet and one hand or two
operating the machine. hands and one foot) to ensure stability of the
body.
More information refers to Steering Frame Lock
in Operation Manual.

Attachment Cautions

Attachments should only be installed by

authorized people who have been trained to
operate and maintain the attachment according
to the operator’s manual. Never jump off the machine.

Refer to the instructions in the operation manual Never get on or off a moving machine.
and any other related information when installing Be careful not to touch any control levers when
and using attachments. getting on or off the machine.
Incorrect installation of attachments or optional Do not try to climb on or off the machine when
parts not only will result in safety problems, but carrying tools or supplies. Use a rope to pull
also will negatively influence the operation and equipment up onto the platform or have an
sevice life of the machine and the attatchments. assistant pass them to you.
44
Safety Information
Cautions about Machine Operation

Understand Your Machine Check the condition of safety guards such as

doors, guards and covers. Repair any damage
Be able to operate all the equipment on your as necessary.
machine.
Check the hydraulic system for oil leakage.
Understand the purpose of all control systems, Check the condition of hoses and pipes.
instruments and indicators.
Check all fasteners for security.
Understand the rated load, speed range, the
Check the condtion of electrical wiring harness
characteristics of braking and steering, turning
and fuses, replace or repair as neccessary. Also
radius and the space clearance for operation.
check the connectors for good connection.
Remember that rain, snow, ice, gravel and soft
Check the fuel level and fuel system for normal
earth may change the performance of the
condition, drain any water or sediment in the
machine.
water/fuel separator. Dispose of fluids in
Understand the safety signs on the machine accordance with local regulations.
(Danger, Warning, Caution) and any other signs.
Replace all damaged or lost parts and carry out
lubrication according to the maintenance interval
Understand Your Working Area
schedule.
Before starting, inspect the area where you will Remove all loose objects from the cab. Loose
be working. You should check: adequate objects may affect the operation and cause
ventilation the position of any slopes, visible accidents.
ditches, falling or hanging objects, conditions of
Make sure that all the windows if fitted are clean
soils (soft or hard), accumulated water and
and the screenwiper works normally.
swamp areas, rocks or stumps, hidden
groundwork, posts or the outer limits of walls, the Adjust the operators seat to a position that is
outer limits of the areas where garbage is buried most comfortable and provides for easiest
or that are filled in with earth, holes or openings, operation of the machine. Check the seat belt
obstacles, mud or ice, traffic, heavy dust, heavy and the condition of mounting hardware. Repair
smoke, heavy fog, the exact locations of cables or replace any items that are damaged. Replace
or pipes for power supply, gas supply, phone the seat belt after three years of use or any time
service, water supply, sewage disposal and other the belt shows signs of wear or damage.
utilities that are hidden or hung. If necessary Check all the illumination equipment before
before starting work you should ask the utility operation in low light, and ensure that the
companies to mark out, close or move out these illumination system is in good condition.
utilities.
Check to make sure the steering frame lock is in
Before Starting the Engine the RELEASED position.

Inspect the machine carefully before starting the

engine, ensure all systems are in good
operational condition. Make sure nobody is on or
around the machine before starting the engine.
Keep the steps and handrail clean. Clear any dirt
and sands from your shoes before mounting the
machine.
Check all structural members, covers and
fenders for deformation or damaged.
 45
Safety Information
Cautions about Machine Operation

Engine Starting After the engine is started, you should observe,

instruments and warning lights, and make sure
Do not start the engine if there is a DO NOT that they work and every reading is within
OPERATE or similar tag attached to the start working range.
switch or control levers.
Observe machine movements and listen
carefully for unusual noises. If there is any fault
or abnormality, you should stop the engine
immediately. Locate the source of the problem
G

and fix before further operation.

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Do not start the engine until seated in operators

seat and the seat belt is firmly fastened.

Never run the engine in a closed or poorly

ventilated environment. If working inside a
building, open the doors and windows to ensure
enough ventilation and try to prevent exhaust
gas poisoning. Use a power exhaust system
when working in an enclosed area.

Ensure the hydraulic control levers are all in the

NEUTRAL position and the shift control lever is
in the NEUTRAL position before starting the
engine.
Sound the horn to alert personnel before starting
the engine.

Before Operating the Machine

Make sure the machine is free of personnel and

fasten the seat belt before operation.
Keep all the windows, lightshades and rearview
mirrors clean. Secure doors and windows in
either the open or close position.
Only start the engine from the operators seat in
Adjust the rearview mirrors for best vision,
the cab. Never start the engine by short-circuiting
especially close to the machine.
the starter motor terminals. Starting the engine
by short-circuiting could result in damage of the Clear all obstacles from where the machine will
electrical system, personal injury or death. be working. Be aware of hazards such as high
voltage wires, ditches, etc.
46
Safety Information
Cautions about Machine Operation

Make sure the horn, backup alarm (if equipped) Dust, heavy rain, and heavy fog will blur your
and all other alert devices are working properly. vision. You should keep windows, mirrors and
lights clean and in good condition. When the
visibility decreases, you should decrease the
speed and apply the proper lights.
Machine Operation

Before operating the machine on roads, check

whether the machine meets the requirements of
the local laws and regulations for road operation.
Make sure that you get the road operating
permission from relevant road administration
offices. Observe the local traffic regulations when
driving the machine on roads.
Before driving the machine, you should carefully
observe the surroundings, and find out the If driving or operating the machine with a bad
relations between the direction that you want to view or in a crowded area, you should work with
go in and the pedal/operating lever. a signalman, keep the signalman within the field
Do not allow another person to sit on the of your vision, and coordinate your hand signal.
machine unless equipped with an additional When traveling with a load in the bucket, set the
seat, seat belt and Rollover Protective Structure load height at 17" ~20" (450?500mm) from the
(ROPS) ground level to below the boom articulation joint.

Before working the machine, you should operate Do not go close to the edge of a cliff, a dyke, or a
the machine slowly to an open area, check for hillock to avoid collapse.
proper operation of all control levers and all
protective devices.
Note any needed repairs during machine
operation such as an abnormal noise, vibration,
smell, wrong reading of gauges, gas or oil
leakage, etc., stop what you are doing and report
any needed repairs.
 47
Safety Information
Cautions about Machine Operation

If the machine begins to sideslip on a slope,

immediately remove the load and turn the
machine downhill.
To prevent the machine from tipping over or
damaging the attachment due to overloading,
never exceed the machines rated capacity.

Avoid any conditions that can lead to the

machine tipping. The machine can tip when you
work on hills, on banks and on slopes. Also, the
machine can tip when the machine goes across
ditches, hillocks or other unexpected
obstructions.

Do not use the bucket or boom for lifting. The

machine can only be used within its capability.
Any operation beyond its capability will bring
damage to the machine. Refer to Specification
section for the stipulation.
Never hoist heavy articles by directly hanging
slings on the bucket teeth.
Never use the loader to lift people. Do not use
Avoid operating the machine across the slope. If the bucket as a work platform for people. Never
possible, drive the machine in reverse when allow people to ride in the bucket.
going down the slope with a load, and run
forward when going up the slope. Be careful when working beside high voltage
wire. If it is possible to contact the electrical wire
while working, consult the Electricity Company
before working.
48
Safety Information
Cautions about Machine Operation

The contact with electrical wire may cause Parking the Machine
accidents, such as injury or death, do not make
any part of the machine close to electrical wire. When possible choose flat level ground to park
Check the area above the machine, and learn the machine, apply the parking brake (if
about the exact distance between electrical wire, equipped), always lower any attachment to the
machine and ground. If possible, you’d better cut ground and ensure the machine will not move,
off the power supply. If it is impossible to cut off possibly causing damage or injury.
the power supply, you should ask a signalman to
Consider any overhead hazards such as the
guide you.
posibility of falling rocks, any powerlines or any
other overhead hazards that may exist.
Consider the ground conditions. Do not park the
machine near the edge of a cliff, close to an open
excavation or pit.
Consider environmental conditions such as the
posibility of flooding, heavy snow fall, electrical
storms and exposure to wind and cold. Any of
these conditions may cause damage to the
machine.
If the machine has contacted the high voltage
wire: Do not cause an obstruction, consider the site
access and other emergency conditions the
● Alert all personnel to keep away from the machine may obstruct.
machine.
If it is necessary to park the machine on a slope
● If you can disconnect the contact point, or incline, lower the implement to the ground,
separate the high voltage wire from the engage the parking brake and shut off the
machine and leave. engine. Place chocks under the wheels at the
● If you can not disconnect the contact point, downhill side on both sides to prevent the
stay inside the cab until the Electricity machine from moving.
Company cuts off the power and you are
informed to go out.
● If a fire occurs, hold your feet as close as
possible and jump off the machine without
touching ground with your hands. Try to jump
into a safe place.
When transporting, make sure that the hooks
and the towing devices are adequate. Connect
trailing equipment to a drawbar or hook only.
Never straddle a wire rope cable or similar
device, nor allow others to do so.
No personal should be between the machine and Understand and obey all regulations relating to
trailing equipment when maneuvering to connect public roads, if the machine is parked on a public
them. Block the tongue or hook of trailing road. Additional signage or lighting may be
equipment to align it with the drawbar or hook. required.
Always lower attachments or other equipment
before leaving the machine, apply the parking
brake (if equipped).
 49
Safety Information
Cautions about Machine Maintenance

Put the hydraulic control levers to NEUTRAL Store Accessories Safely

position and the shift control lever to NEUTRAL
position. Store accessories and tools safely so as to
prevent them from falling and causing serious
Engage the parking brake (if equiped).
injury or death. Keep playful children and
Keep the engine running at idle speed for five bystanders away from the storage area or any
minutes to let the engine cool down gradually. area accessories are being stored while in use.
Stop the engine, and take out the key from the
switch.
Turn the battery disconnect switch to OFF
position to avoid battery discharge.
When leaving the machine lock all equipment
covers and doors with the key. Remove the key
and keep it with you.

Cautions about Machine

Maintenance
Lowering the Attachment/ Implement with Prepare the Working Area
Engine Stopped
Please choose a clean and flat area with
CAUTION: For a machine controlled by adequate space, enough light, and good
electro-hydraulically control lever, in order to ventilation to carry out any repair work. Clean the
lower the implement, the engine start switch ground surface, wipe up fuel, lubricating oil and
must be on ON position .Turn the engine start water, and spread sands or other absorptive
switch to OFF position after lowering the materials on the slippery ground. Keep the work
implement. area clean and dry.

In order to lower the implement to the ground or Support the Machine Correctly
trailer, move all control levers to DOWN position.
When release them, they will return to HOLD Lower to the ground or support any attachments
position. with stands or other methods. Ensure that any
attachment can not move during maintenance or
repair work, use wheel chocks or other devices
to prevent machine movement.
Do not work under any part of the machine or
attachment that is not adequately supported. Do
not rely on hydraulic systems as support. Use
stands or other measures that are secure and
can support the weight being applied to them.
50
Safety Information
Cautions about Machine Maintenance

Transportation Information Welding Operation

Obey the appropriate laws that govern the Any personnel engaging in welding operations
parameters of the load (weight, length, width, must have occupational certificates and carry out
and height). the operation at a place with appropriate devices
equipped, When carrying out the welding
Understand the correct procedures for loading
operation, the personnel must follow the
and unloading.
instructions below:
Carry out the loading and unloading operations
Before carrying out the welding operation, turn
on flat ground.
off the battery isolator switch, disconnect the
Chock the wheel of the trailer to make it unable battery, disconnect the controllers, GPS and
to move. other electrical parts.
Remove all paint from the place to be welded, so
as to prevent harmful gas from being produced.
Do not inhale smoke produced buy burning paint.
Never weld pipes, close to rubber hose and
electrical wires.
5
Always remove residual pressure from the
machine. Never weld pipes that are fitted to the
1 machine.
4
3 2
Always wear correct PPE for welding, protect
bystanders by using screens and signs advising
1. Wedge of the operation being performed.
2. Block
3. Angle (Max. angle is 15°) Ensure good ventilation.
4. Distance between the ramps
5. Ramp Remove all the flammable materials, supply the
Use loading ramps appropriate for the machine work area with a fire extinguisher.
being moved. Consider: size, strength, departure
angle and proper height. Make sure that the
loading ramp is anti-slip and free of mud and
snow.
Use chains and blocks to secure the machine to
the trailer.
Keep the bystanders away.
Place all the working equipment in the
transportation position, secure all the equipment
and attachments or additional equipment with
chains or other secure methods to prevent
accidental movement. Clean the Equipment Periodically

To avoid possible injury or damage to the

machine, all the oil and scraps accumulated
should be removed. The engine, radiator,
storage battery, hydraulic hose, fuel tank and cab
should be kept clean.
 51
Safety Information
Sound and Vibration

When carrying out the cleaning operation, wear The hands and arms are exposed to a weighted
suitable PPE. Consider exposure to: chemicals, root mean square acceleration that is less than
slippery surfaces, high pressure water spray and 2.5 m/s2.
material splash.
The whole body is exposed to a weighted root
mean square acceleration that is less than 0.5 m/
s2.
Mesurements are obtained on a representative
machine using the procedures in the following
standards:
''ISO 2631-1"
"ISO 5349-1"
"ISO 5349-2"

Do not spray the water directly onto sensors,

connectors or instruments of the electrical
system. If water enters the electrical system
malfunction may occur.

Sound and Vibration

Sound

The sound performance offered for this machine

is the standard in European Union countries and
in countries that adopt the EU Directives.
A-Weighted emission sound pressure level, L at
the operator's position measured according to
work cycle procedures specified in "ISO 6396" is
75 dB(A), for the cab offered by Liugong.
The sound level outside the cab is 106dB (A).

Vibration Level

NOTICE: Whole body vibrations

generated by construction machines, are to a
high degree, influenced by different factors,
e.g. working methods, ground conditions and
traveling speed selected by the operator.

This machine is equipped with an operator's

seat, which meets the criterion in standard ISO
7096. This seat is tested with the input spectral
class EM3 and has a Seat Amplitude
Transmissibility factor SEAT=0.95.
52
Safety Information
Sound and Vibration
 53
Engine System
Work Principle

Engine System Air drawn into the engine passes through a pre-
cleaner. The pre-cleaner uses air speed and
direction to separate large dirt particles. Pre-
cleaned air then flows throught the center of the
Work Principle pre-cleaner to the air filter assembly. Smaller
particles of dirt are removed by the primary and
secondary air filters as air passes through.
Engine
Clean air is then drawn into the turbo charger
where it is compressed. This process creates
This machine is equiped a Cummins QSB6.7 heat. Heated air leaving the turbo charger under
engine. Please refer to the enclosed disc for all pressure passes through an inter-cooler cooling
work principle, maintanence and repair the air to a suitable temperature. The cooled air
information. The Cummins Company maintains under pressure is forced into the intake manifold
ownership of all information provided on the disc. and then the engine cylinder.
Please contact your nearest Cummins dealer for
During compression stroke of the piston the air is
all repairs during the engine warranty period.
further compressed and heated. Atomize diesel
Guangxi Liugong Machinery Co., Ltd. accepts no oil is injected at high pressure and combusts.
liability resulting from the failure of the customer Rapid expansion of the gasses produced push
to follow this instruction. on the piston moving it away. The piston is
attached by a connecting rod to the crankshaft.
The linear motion of the piston is translated into a
Intake and Exhaust System rotary motion at the crankshaft.

Intake System Exhaust System

1. Pre-filter 2. Air filter 3. Diesel engine

Exhaust gases produced by the combustion
4. Inter-cooler 5. Muffler 6. Exhaust pipe
process pass into the exhaust manifold and
turbo-charger. Turbo charger design uses the
heated gas to rotate a turbine that inturn
compresses inlet air. Exhaust gasses then
leaving the turbo pass through a silencer
(muffler) and out to the atmosphere.
54
Engine System
Work Principle

Cooling System Inter-Cooler Cooling

1. Diesel engine 2. Inter-cooler Intake air temperature and pressure are greatly
3. Oil radiator of torque 4. Fan increased after the air is boosted by the
converter Turbocharger. To remove heat the air flows
5. Hydraulic motor 6. Motor bracket through an inter-cooler. Air flowing around the
7. Shroud 8. Water radiator intercooler reduces the temperature of the
9. Hydraulic oil radiator 10. Oil drain device heated air inside to a value less than 80°C .
Cooled air flows from the intercooler into the
engine intake manifold and engine cylinder.
Cooling is provided by a hydraulically driven
cooling fan. The fan is located at the rear of the Hydraulic Oil Radiator Cooling
machine and draws air through the coolers. The
motor and fan are connected to the radiator
group by the motor bracket and shroud. The
radiator group is distributed longitudinally: the
inter-cooler and hydraulic oil radiator are
distributed in tandem at first level; water radiator,
inter-cooler and oil radiator at second level; the
oil radiator of torque converter and water radiator
at the third level; and last, the fan and oil radiator
of torque converter at the rear side.
The cooling air is sucked in from direction of left,
right, top and bottom of the radiator group by the
fan to flow to the inter-cooler, hydraulic oil
radiator, then to the water radiator and oil
radiator of torque converter, and finally exhausts
out of the shroud. Hydraulic oil flows into the bottom of the
hydraulic oil cooler element. Air flowing around
the element reduces the temperature of the
heated oil inside to a value less than 80°C.
Cooled hydraulic oil flows from the top of the
cooler and returns to the hydrulic oil tank.
 55
Engine System
Work Principle

Water Radiator Cooling Torque Converter Oil Radiator Cooling

When the engine coolant temperature is less Torque converter oil flows to the converter oil
than 88°C, the coolant is cooling inside the radiator element through the top inlet port on
engine by means of lesser circulation; But when right hand of the torque converter oil radiator.
the engine coolant temperature is more than Exterior cooling air flows around the element to
88°C, the engine thermostat is opened. Some of take way the heat in torque converter oil to lower
the coolant goes into the upper water chamber of temperature to a value less than 110°C. Finally,
the water radiator through the upper hose of the converter oil returns back to the gearbox
engine; then to the lower water chamber through through the top outlet port on left hand of the
the water radiator element. Exterior cooling air torque converter oil radiator.
flows around the element to take way the coolant
heat to lower temperature. Then the coolant
flows into the engine through the lower hose to
finish the major cycle. When the coolant
temperature reaches to 96°C, thermostat will
close the lesser circulation passage, so all
coolant will circulate through the major cycle.
56
Transmission System
Specifications

Transmission System

Specifications

Transmission Torque Converter

1. Clamp assembly 2. Elbow assembly: radiator inlet oil

3. Hose assembly: nominal diameter 4. Transmission torque converter assembly: ZF 4WG200
5. Oil filler assembly 6. Shock absorber: CB-1125-2
7. Transmission mounting bracket 8. Hose assembly: nominal diameter
9. Clamp 10. Elbow assembly: radiator outlet oil
11. Torque converter oil radiator
 57
Transmission System
Specifications

Transmission Torque Converter

Assembly

1. Bolt tightening torque 52±7 N·m

2. Bolt tightening torque 42±4 N·m

About the detail component specifications and

technique illumination of transmission torque
converter assembly, please refer to the parts list
of power shift gearbox ZF 4WG200 in ZF
Company that provided together with this
manual.
58
Transmission System
Work Principle

Work Principle

Transmission torque converter system drawing

1. Elbow assembly (radiator inlet oil) 2. Hose assembly 3. Engine connection

4. Transmission torque converter assembly 5. Front output flange 6. Oil filler assembly
7. Rear output flange 8. Hose assembly 9. Hose assembly (radiator outlet oil)
10. Torque converter oil radiator
 59
Transmission System
Work Principle

In the system, the engine power transfers to the

transmission torque converter assembly through
engine connection, then passes to the front and
rear drive axles respectively through the front
and rear output flanges. In order to increase
more torque, the output power from the drive
axle half shaft transmits to the wheels so as to
drive the machine after decelerated by the hub
reducer. About the principles of transmission
torque converter assembly and front, rear drive
axles, please refer to the operation, installation,
and maintenance manuals of power shift
gearbox ZF 4WG200 and drive axles in ZF
Company that provided together with this
manual.
Through the engine connection, the engine
drives the variable-speed pump in the power
transmission torque converter assembly to suck
the oil continuously from the oil tank of the
transmission torque converter assembly, and
provide oil to the power variable-speed control
valve and torque converter of the transmission
torque converter system. About the principles of
the power variable-speed control valve and
torque converter, please refer to the operation,
installation, and maintenance manuals of power
shift gearbox ZF 4WG200 in ZF Company that
provided together with this manual. The oil from
the torque converter produces abundant heat
due to the rapid, complicated flow inside the
torque converter, and this oil is transported to the
torque converter oil radiator through hose
assembly and elbow assembly. Under the effect
of the torque converter oil radiator, oil
temperature declined and the oil flows back to
the power transmission torque converter
assembly through elbow assembly and hose
assembly, and perform lubrication on the clutch
and bearing in the transmission.
The oil will be consumed or lost continuously
during the operation of the transmission torque
converter, which can be refilled through the oil
filler assembly. About the oil grade and oil filling
operation detail illustration of the power
transmission torque converter, please refer to the
operation, installation, and maintenance
manuals of power shift gearbox ZF 4WG200 in
ZF Company that provided together with this
manual.
60
Working Hydraulic System
Specifications

Working Hydraulic System

Specifications Breather Filter

Part No.:53C0232
Hydraulic Tank

Part No.:21C0144

1. Air filter 2. Oil strainer

Filter accuracy: 40 μm

Torque for the gauge: 10±2 N·m 7.38±1.48 lb.ft

 61
Working Hydraulic System
Specifications

Return Oil Filter Oil Suction Strainer

Part No.:53C0162 Part No.:53C0163

Filter accuracy 150 μm

Fliter area 15568 cm2

Filter 12 μm
1. Filter accuracy
Rated flow 630 L/min 166Gal./min

2. Bypass Pressure 0.4 MPa 58Psi

valve setting
62
Working Hydraulic System
Specifications

Vane Pump (Implement) Vane Pump

Part No.: 11C0297 Part No.: 11C0298

1. Torque for the bolt 187 N·m 138 lb.ft 1. Torque for the bolt 68 N·m 50 lb.ft
2. Shaf SAE C spline 2. Torque for the bolt 187 N·m 138 lb.ft
3. Shaf SAE C spline
Test at Full Speed
Pump speed at rated Test at Full Speed
2100 rpm
engine speed
Pump speed at rated
Output 153.95 L/min 41Gal./min 2100 rpm
engine speed
Pressure 20 MPa 2900.76 Psi Front pump output 153.95 L/min 41Gal./min
Input power of pump Front pump pressure 20 Mpa 2900.76 Psi
58.2 kW
at main relief
Rear pump output 33.2 L/min 8.8Gal./min
Rear pump pressure 15 Mpa 2175.6 Psi
 63
Working Hydraulic System
Specifications

Main Control Valve

Part No.: 12C0100

1. Port to rod end of lift cylinder 2. Port to head end of lift cylinder
3. Relief valve 4. Tilt control valve
5. Port for pilot pressure to control auxiliary cylinder 6. Auxiliary control valve
7. Port to rod end of auxiliary cylinder 8. Port to head end of auxiliary cylinder
9. Pump port 10. Port for pilot pressure to control auxiliary cylinder
11. Lift control valve 12. Port to rod end of tilt cylinder
13. Relief valve for rod end of tilt cylinder 14. Port to head end of tilt cylinder
15. Relief valve for head end of tilt cylinder 16. Tank port
17. Port to float 18. Port for pilot pressure to control head end of lift cylinder
19. Relief valve for auxiliary cylinder 20. Relief valve for auxiliary cylinder
21. Port for pilot pressure to control rod end of lift cylinder 22. Port for pilot pressure to control head end of tilt cylinder
23. Port for pilot pressure to control rod end of tilt cylinder

3. Pressure setting 20 +0.5-0.2 MPa 2900.76+73-29 Psi

13. Pressure setting at 38 L/min 22 MPa 3190.83 Psi

15. Pressure setting at 38 L/min 22 MPa 3190.83 Psi

64
Working Hydraulic System
Specifications

Pilot Valve Pilot Oil Supply Valve

Part No.: 12C0372 Part No.: 12C0785

1. Torque for the bolt 12 N·m 8.85 lb.ft 1. Relief valve 4.5 MPa 652.67 Psi
pressure setting
Lifetime- 150000
resistive load at cycles 2. Check valve
24 VDC/5A opening pressure 0.03 MPa 4.35 Psi
2. Microswitch setting
Lifetime- 200000
inductive load at Volume 0.4 L
cycles
24VDC/1.25A
3. Accumulator Precharge at 21 °C
3. Torque for the 1.5 N·m 1.11 lb.ft temperature
screw (dead engine
lower)
Precharge 0.8+0.2 MPa
4. Torque for the nut 40 N·m 29.5 lb.ft
pressure with 116+29 Psi
5. Torque for the nut 40 N·m 29.5 lb.ft dry nitrogen
6. Torque for the nut 10 N·m 7.38 lb.ft 4. Reduce valve 3.5 MPa 507.6 Psi
pressure setting
7. Torque for the 40 N·m 29.5 lb.ft
screw 5. Shuttle valve
8. Torque for the bolt 8 N·m 5.9 lb.ft
Pilot oil flow up to 16 L/min
 65
Working Hydraulic System
Specifications

Ride Control Valve Ride Control Accumulator

Part No.: 12C0443 Part No.: 15C0104

1. Capacity of the 5.7 L 1.5 Gal

chamber for the oil

2. Capacity of the
chamber for the dry 5.8 L 1.53 Gal
nitrogen

Pressure of oil at
maximum working 35 MPa 5076 Psi
pressure
1. Drain plug for emergency Normal operating -30 to 75 °C
temperature
2. Electrical connector 24 VDC Precharge at 21 °C
plug control voltage
temperature
3. Relief valve Precharge pressure
31.5 MPa 4568.7 Psi 2.0+0.2 MPa 290+29 Psi
pressure setting
with dry nitrogen
Relief valve maximum
300 L/min 79.3Gal./min
flow
66
Working Hydraulic System
Specifications

Cooling Pump Cooling Motor

Part No.: 11C0258 Part No.: 11C0256

1. Shaft: SAE B spline

Test at Full Speed

1. Output 58 L/min 15.3Gal./min
2. Pressure 16 MPa 2320.6 Psi
3. Pump speed at rated 2100 rpm
engine speed
4. Input power of pump 17.6 kW
at main relief

1. Shaft TB Taper 1:5

Max. torque 90 N·m 66.4 lb.ft

2. Torque for the nut 80+20 N·m 59+14.8 lb.ft

 67
Working Hydraulic System
Specifications

Lift Cylinder Tilt Cylinder

Part No.: 10C0023 Part No.: 10C0024

1. Torque for the nut 3600±360 N·m 2655±266 1. Torque for the nut 3600±360 N·m 2655±266
lb.ft lb.ft
2. Outside diameter of 80 (-0.03, -0.076) mm 2. Outside diameter of 80 (-0.03, -0.076) mm
a new cylinder rod a new cylinder rod
3. Inside diameter of 160 (+0.063,0) mm 3. Inside diameter of 180 (+0.063,0) mm
the cylinder bore the cylinder bore
4. Inside diameter of a 80.4 (+0.087,0) mm 4. Inside diameter of a 80.4 (+0.087,0) mm
new cylinder head new cylinder head
5. Cylinder stroke 794 mm 5. Cylinder stroke 540 mm
Pin to pin length of a 1434 mm Pin to pin length of a 1088 mm
retracted cylinder retracted cylinder
Lubricate the sealing lips with a minimal amount of the Lubricate the sealing lips with a minimal amount of the
lubricant that is being sealed lubricant that is being sealed

Quick Coupler Cylinder

Part No.: 10C0316

Rod diameter: 40 mm Cylinder bore: 63 mm

Cylinder stroke: 256 mm Pin to pin length with a retracted cylinder: 496 mm
68
Working Hydraulic System
Operation Section

Operation Section
General Information

1. Ride control valve 2. Solenoid 3. Ride control accumulator

4. Relief valve 5. Manual valve 6. Spool valve rod
7. Check valve 8. Main control valve (3-function) 9. Spool valve rod (lift)
10. Relief valve (head end of tilt 11. Relief valve (rod end of tilt 12. Spool valve rod (tilt)
cylinders) cylinders) 15. Spool valve rod (third-function)
13. Relief valve (third-function) 14. Relief valve (third-function) 18. Motor (hydraulic fan)
16. Main relief valve 17. Hydraulic cooler 21. Pilot valve
19. Shuttle valve 20. Manual pressure reducing valve 24. Manual pressure reducing valve
22. Manual pressure reducing valve (lift lower & float) (tilt back)
(tilt dump) 23. Manual pressure reducing valve 27. Pilot shutoff valve switch
25. Manual pressure reducing valve (lift raise) 30. Relief valve
(third-function) 26. Manual pressure reducing valve 33. Gear pump (hydraulic fan)
28. Oil filter (third-function) 36. Strainer
31. Accumulator (oil supply valve) 29. Oil supply valve (pilot valve) 40. Quick coupler cylinder
34. Return oil filter 32. Check valve 41. Relief valve
37. Vane pump (hydraulic system) 35. Hydraulic tank 42. Tilt cylinder
38. Unload valve 39. Cut-off valve 43. Lift cylinder
 69
Working Hydraulic System
Operation Section

Note: Illustration shows a machine with the ● Gear pump

optional equipments (quick coupler and ride
Vane pump is located under the cab. It supplies
control). Machines without the optional
oil to main control valve. A remote pressure tap
equipments are not equipped with quick coupler
for measuring implement pressure is located on
cylinder, cut-off valve, ride control valve and ride
the left side of the machine.
control accumulator. A z-bar machine is only
equipped one tilt cylinder but no the relief valve. Hydraulic tank is located on the right side of the
machine.
The hydraulic system is composed of the
following systems: Relief valve is located on the main control valve
of 8- bar machine. If head end pressure of the
● Main hydraulic system
boom cylinder exceeds16Mpa, relief valve will
● Pilot pipes actuate.
● Ride control system Unload valve is located at left side of the rear
frame. If the implement pressure is above
● Hydraulic fan system
16MPa, unload valve will drain the oil from
Hydraulic tank is common to all of the system. steering system to the hydraulic tank.
The main hydraulic system is made up of the Cut-off valve is located on the quick coupler. Use
following components: this valve to connect the quick coupler cylinder
hoses or any other auxiliary lines. This valve is
● Main control valve
used to connect other auxiliary lines under
● Tilt cylinders normal condition.
● Lift cylinder The ride control system provides a means for
● Unload valve dampening the bucket forces which produce a
pitching motion as the machine travels over a
● Cut-off valve rough terrain.
● Relief valve Main control valve is mounted on the front end
● Vane pump frame.

The pilot pipes are made up of the following

components:
● Pilot valve
● Pilot shutoff valve switch 1
● Oil filter
● Oil supply valve
The ride control is made up of the following
components:
● Ride control valve
1. Pilot shutoff valve switch
● Ride control accumulator
● Lift cylinders
The hydraulic fan system is made up of the
following components:
● Hydraulic fan motor
70
Working Hydraulic System
Operation Section

Pilot shutoff valve switch, joystick control, and Pilot Oil Supply Valve
auxiliary control are located on right side of the
operator’s seat.

2. Hydraulic fan pump

Hydraulic fan pump is located on the left of the
engine. The fan pump supplies high pressure oil 1. Relief valve 2. Check valve
to fan motor. The hydraulic oil cooler are located 3. Pilot oil accumulator 4. Pressure reducing valve
to the rear of the engine. 5. Check valve 6. Check valve

The pilot oil supply valve provides the pressure

oil to the hydraulic pilot valve.
3
A part of pressure oil flow to the pilot oil supply
valve inlet P from the service brake accumulator.
The pressure oil flow to the pressure reducing
valve through the check valve, the oil pressure is
reduced to 3.5MPa by the pressure reducing
valve, then charge fluid to the accumulator by
flowing the check valve. The check valve can
4
prevent the fluid of the accumulator
countercurrent to the pressure reducing valve
when no charging. The accumulator provides the
pressure oil to the hydraulic pilot valve by the
fitting A. The relief valve can protect the
accumulator when the pressure reducing valve is
3. Strainer 4. Return oil filter damage.
Strainer is located in hydraulic tank. Return oil
filter is located on hydraulic tank.
 71
Working Hydraulic System
Operation Section

Implement Control System B point is resistance point before the pressure

changes to oil inlet pressure.

Use the hydraulic pilot valve to control the valve

rod of the main hydraulic valve movement,
thereby controlling the implement action and
speed.
Use the hydraulic pilot valve lever to control the
oil pressure, the fitting of the hydraulic pilot valve
is connected to two ends of the main valve rod.
The hydraulic oil pressure of the hydraulic pilot
valve will increase, the main valve rod movement
largens, the fitting open degree largens between
the stem and the valve, the flow of the hydraulic
oil increases and the movement speed of the Illustration shows the relation between the
implement increases when the hydraulic pilot movement angle of hydraulic pilot lever at tilting
valve lever movement angle largens. The back & dumping position and the pressure
pressure is zone when the hydraulic pilot valve variety of hydraulic pilot valve oil outlet. The
lever is at NEUTRAL position; the implement has hydraulic pilot valve raise or lower oil outlet
no movement at this time. pressure is 3.1bar when turn the pilot lever to 2°
The movement angle direction of the hydraulic from NEUTRAL. Keep turning the pilot lever from
pilot lever can control the different valve rods in 2° to 17°, the oil pressure of outlet will increase
the main valve and two ends fitting of valve rod linearly from A point 3.1 bar to C point 24 bar.
thereby controlling implement. B point is resistance point before it changes to
the highest pressure point.

Illustration shows the relation between the raise/

lower angle of the hydraulic pilot lever and the
pressure variety of hydraulic pilot valve oil outlet.
The hydraulic pilot valve raise or lower oil outlet
pressure is 3.9bar when turn the pilot lever to 2°
from NEUTRAL. Keep turning the pilot lever from
2° to 4°, the oil pressure of outlet will increase
linearly from A point 3.9 bar to B point 18 bar.
The pilot valve oil outlet will be equal to inlet D
point if the pilot lever keeps turning.
72
Working Hydraulic System
Operation Section

Pilot Control Lever & Auxiliary The up arrow refers to the LOWER position.
Then down arrow refers to the RAISE position.
Control Lever l The right arrow refers to the DUMP position. The
left arrow refers to the TILT BACK position. The
Full auto-shift pilot control lever up arrow refers to the auxiliary control at OPEN
position. The down arrow refers to the auxiliary
control at CLOSE position.

Common pilot control lever

1. Pilot control lever 2. Auxiliary control lever

The above illustrations show the full auto-shift
pilot control lever and the common pilot control
lever.
 73
Working Hydraulic System
Operation Section

The pilot equipment with THF6 works according

to the direct operated pressure reducing valve
theory.
It mostly consists of the control lever, 4 pressure
reducing valves, 1 housing and the lock device.
Every pressure reducing valve is controlled by
the control spool, control spring, reset spring and
plug.
The control lever is kept at NEUTRAL position by
the reset spring. Connect oil outlet (1, 2, 3, 4) to
oil outlet T by hole.
Push down the plug to tip the reset spring and
control spring when turn the control lever. The
control spring starts to push the control spool
down and close the corresponding oil outlet &
the connections under the return oil outlet. At the
same time, connect the corresponding oil outlet
to oil outlet P by the hole.
When the control spool is balanced between
control spring force and hydraulic pressure at
ports (port 1, 2, 3, 4), the control stage will start.
The corresponding oil outlet pressure proportion
with the plug journey due to the mutual effect of
the control spool and the control spring, thus
proportion with control lever location.
Control the main valve hydraulic proportion
through the control lever location and the control
spring characteristic pressure.
The fifth oil outlet 5 can be used to control
floating. The spool overcomes the spring to
move under the oil outlet 1 pressure when oil
outlet 1 pressure is 22 bar, the oil outlet 5
communicates to T outlet.

1. Control lever 2. Control spool

3. Control spring 4. Reset spring
5. Plug 6. Housing
7. Auxiliary spring 8. Hole
9. Rubber bushing 10. Ring
11. Magnet gag bit 12. Dishing washer
14. Spool 15. Spring
74
Working Hydraulic System
Operation Section

Magnet Lock

Add the auxiliary spring pre-pressure under the

dishing washer in order to let the plug and the
control lever journey approach end point then
warning. The ring touches the magnet gag bit
once beyond this point. The magnet powers off,
the lock self-release if keep the magnet control
lever at end position.

1. Unload valve 2. Check valve

The hydraulic system used hydraulic pump and
steering pump (double pumps interflow) provides
oil to the cylinder. The unload valve don’t start,
the hydraulic system provides oil to the cylinder
together with the hydraulic steering pump whose
oil from outlet A to outlet B by the check valve to
the hydraulic system when the hydraulic system
pressure is less than 16MPa. The unload valve
starts, the hydraulic steering pump oil flows to
outlet T and returns to tank from outlet A through
the unload valve when hydraulic system
pressure is not less than 16MPa. At the same
time, the steering system pressure is just equal
to back pressure returning to tank, the pressure
is so low that the hydraulic steering system
power is very low in order to save the energy
source. The check valve can prevent the
hydraulic pump oil from returning oil to tank by
the unload valve when unloading.
 75
Working Hydraulic System
Operation Section

Main Control Valve

1. Hydraulic-control 2. Lift valve rod
check valve
1 3. Boom filling oil check 4. Head end of tilt
valve cylinder safety valve
5. Rod end of tilt 6. Rod end of tilt
cylinder filling oil cylinder safety valve
7. Tilt join valve rod 8. Tilt join filling oil
check valve
2
9. Auxiliary join oil inlet 10. Auxiliary join oil inlet
A3 safety valve B3 safety valve
11. Auxiliary join valve 12. Auxiliary join filling oil
rod check valve
13. Main relief valve 14. Tilt cylinders
15. Lift cylinders
The supply oil flows from the implement vane
3
pump and steering system to the main control
1. Control valve (Auxiliary) 2. Control valve (Tilt) valve at point (P). The main control valve
3. Control valve (Lift) controls the flow of hydraulic oil to the cylinders.
Most of the supply oil flows to control valves for
the implement circuits. Oil returns from the
control valve and flows to the tank at point (T).
The supply oil flows to the following components:
auxiliary control valve, tilt control valve, and lift
control valve.
76
Working Hydraulic System
Operation Section

Boom join valve rod NEUTRAL, tilt join valve rod tilting position

1. Tilt join valve rod tilting chamber 2. Spring 3. Spring

4. Rod end of tilt cylinder safety 5. Oil way(Oil outlet B1, to rod end 6. Oil way(Oil outlet A1, to head end
valve filling oil check valve of tilt cylinder) of tilt cylinder)

7. Oil way 8. Spring 9. Tilt join filling oil check valve

10. Work pump filling oil way 11. Tilt join valve rod 12. Tilt join valve rod dumping cavum
13. Oil way 14. Oil way 15. Main valve return oil way (Oil
outlet T)

16. Boom join valve rod

 77
Working Hydraulic System
Operation Section

Tilt Join Valve Rod at NEUTRAL Bucket Tilting Dump Operation

The tilt join valve rod is at NEUTRAL under the The hydraulic pilot pressure reducing valve (22)
spring 2 when two ends of the main valve tilt join starts when use the pilot to dump. The hydraulic
valve rod have no pilot oil pressure. The work oil flows into the dump cavum of left side of the
pump provides oil to the boom from oil way (10) main valve’s tilt join valve rod from outlet 2
to oil way (7). Tow oil ways (5) & (6) of head/rod through the pilot hose when the hydraulic oil
end of tilt cylinder two ends connecting to the pressure of the pilot oil supply valve is decreased
main valve are blocked out by the tilt join valve by the pressure reducing valve (22). Tilt cavum
rod, the tilt cylinder holds on. The work pump oil (1) oil of right side of the tilt join valve rod flows to
connects the main valve return oil way (15) to the tank by the pilot control valve. The tilt join valve
tank by the oil way (14), (13) if the boom join rod under the oil pressure overcomes the spring
valve rod is at NEUTRAL. (2) force to move right and open the hatch of oil
way (5) & oil way (7) connecting with the rod end
of tilt cylinder. The pressure oil of work pump
Bucket Tilting Operation flows to the rod end of tilt cylinder from oil way
(7) after it pushes the tilt join filling oil check
The pressure reducing valve (24) starts when valve (9). Oil of the head end of tilt cylinder from
operate the hydraulic pilot valve lever for tilting. oil way (6) flows to tank through oil way (13)&
The hydraulic oil of the pilot oil supply valve flows return oil way (15). Bucket tilting realizes
from outlet 4 through the pilot hoses to the tilt dumping when the tilt cylinder piston draws back.
cavum(1) of right side of the tilt join valve rod During dumping, if the retractile speed of piston
after reducing pressure by the reducing pressure rod is more than flow speed of work pump oil, the
valve (24). The dump cavum(12) oil of left side of rod end of tilt cylinder safety valve filling oil check
the tilt join valve rod flows to the return oil tank by valve (4) is opened and supply oil to rod end of
the pilot control valve. The tilt join valve rod tilt cylinder by the oil way (13) after overtaking
overcomes the spring (2) force to move left the spring (3) force, which can avoid bring air
under the oil pressure effect. Open the oil way pocket in cylinder.
(6) & (7) connecting to the head end of tilt
cylinder. The pressure oil of work pump flows to The boom can’t work due to its pressure oil can’t
the head end of tilt cylinder through the oil way flow into boom join when the tilt join valve rod
(7) & (6) after the pressure oil of pump push the moves right and to max dumping position.
tilt join filling oil check valve (9). The oil of rod
end of tilt cylinder flows to oil tank from oil way
(5), (13) and main valve return oil way (15). The
bucket realizes tilting when the tilt cylinder piston
rod holds out.
The pressure oil of work pump can not flow into
the boom join valve cavum, the boom can not
work when the tilt join valve rod move left and to
max tilting angle.
78
Working Hydraulic System
Operation Section

Tilt join valve rod at NEUTRAL, boom join valve rod at RAISE

10. Work pump filling oil way 11. Tilt join valve rod 13. Oil way
14. Oil way 15. Main valve return oil way(Oil 16. Boom join valve rod
outlet T)
17. Boom join valve rod lift cavum 18. Spring 19. Hydraulic-control check valve
20. Oil outlet K 21. Spring 22. Oil way(Oil outlet B2,to rod end of
boom cylinder)
23. Oil way(Oil outlet A2,to head end 24. Oil way 25. Boom join filling oil check valve
of boom cylinder)
26. Spring 27. Boom join valve rod lower cavum
 79
Working Hydraulic System
Operation Section

Boom Join Valve Rod at Boom lower

NEUTRAL The pressure reducing valve (20) will start under
the circumstances that the tilt join don’t work
The boom join valve rod is at NEUTRAL under when use the pilot lever for lowering the boom.
the force of the reset spring18 when the tilt join The hydraulic oil of pilot oil supply valve flows to
valve rod don’t work and two sides of the boom lower cavum (27) of main valve’s boom join valve
join valve rod17 & 18 have no pilot pressure oil. rod left side from oil outlet 1 passing pilot hose
The oil of work pump flows into oil way14 from oil after hydraulic oil of the pilot oil supply valve is
way 10 and tilt join. Two oil way 23 & 24 through the pressure reducing valve (20). The oil
connecting main valve which are located on two of the lift cavum (17) of boom join valve rod flows
ends of head end of boom cylinder/rod end of to tank passing the pilot control valve. The boom
boom cylinder is closed by boom join valve rod, join valve rod under oil pressure which
the boom cylinder holds on. The work pump oil overcomes force of valve rod reset spring (18)
flows to tank from oil way 14 & 13 passing the and move right opens hatch of oil way (22)
return oil way 15 of main valve. connecting with rod end of boom cylinder and oil
way (24). The work pump pressure oil flows to
rod end of boom cylinder from oil way (24) after
Boom Lift the pressure oil pushes boom join filling oil check
valve (25). Oil of head end of boom cylinder
The pressure reducing valve (23) will start under flows to tank from oil way (23),(13) & (15). The
the circumstances that the tilt join don’t work boom realizes lowering when the boom cylinder
when use the pilot lever for lifting the boom. The piston rod draws back.
hydraulic oil of pilot oil supply valve flows to tilt Boom Float
cavum (17) of main valve’s tilt join valve rod right
side from oil outlet 3 passing pilot hose after The pressure of oil outlet 1 of pilot valve is max
hydraulic oil of the pilot oil supply valve is when use the pilot lever form LOWER to FLOAT,
through the pressure reducing valve (23). The oil the pressure oil of outlet 1 can overcome the left
of the lower cavum (27) of left side of boom join side spring force of sequence valve (19) for
valve rod flows to tank passing the pilot control moving the sequence valve (19) rod left, the oil of
valve. The boom join valve rod under the oil spring cavum of hydraulic-control check valve
pressure which overcomes force of valve rod (19) inside of boom join returns to tank from
reset spring (18) and move left opens hatch of oil outlet K, (20), pilot hose to pilot oil outlet 5 and
way (23) connecting with head end of boom passing the sequence valve (19). Oil way (22)
cylinder and oil way (24). The work pump pressure or oil way (13) hydraulic oil can let the
pressure oil flows to head end of boom cylinder hydraulic-control check valve (19) overcomes the
from oil way (24) after the pressure oil pushes spring (21) and open the hydraulic-control check
boom join filling oil check valve (25). Oil of rod valve (19) when the hydraulic-control check
end of boom cylinder flows to tank from oil way valve(19) is under the oil way (22) pressure or
(22) &(13) passing the return oil way (15) of main due to boom lowering oil way (22) brings
valve. The boom realizes lifting when the boom pressure less than atmospheric pressure. At the
cylinder piston rod holds out. same time, oil of return oil outlet can mix with oil
of rod end of boom cylinder passing the oil way
(15), (13) hydraulic-control check valve (19), oil
way (22). The position of boom join valve rod is
the same to LOWER during boom floating, head
end of boom cylinder is connected to return oil
outlet. The boom realizes floating when the head
end of boom cylinder & rod end of boom cylinder
are all connected to tank.
80
Working Hydraulic System
Operation Section

Filling Oil Check Valve

1. Inlet 2. Valve seat
The boom & tilt join filling oil check valve can 3. Spool 4. Taper valve spool
prevent oil of boom or tilt cylinder returning for 5. Retainer 6. Pressure adjustment screw
avoiding cylinder block. For example, the work 7. Plug 8. Return oil outlet
pump oil pushes the check valve 9 to oil way 7
9. Return oil way 10. Reset spring
then to head end of tilt cylinder when the tilt join
valve rod tilts the bucket. The check valve is 11. Spring cavum 12. Pressure adjustment spring
closed under the oil pressure of head end of tilt The main control valve is equipped with one load
cylinder and check valve spring 8 if output oil sensing signal relief valve which limits the oil
pressure of work pump is lower than head end of pressure to the main hydraulic system from the
tilt cylinder. Keep the head end of tilt cylinder implement pump.
close in order to prevent the tilt cylinder drawing
When the pressure at the inlet of the main control
back for avoiding tilt roll.
valve exceeds the pressure setting of the load
There is a filling oil check valve (4) connecting to sensing signal relief valve, the relief valve opens.
rod end of tilt cylinder inside tilt join. The The excess hydraulic oil then flows through the
pressure of rod end of tilt cylinder is less than the relief valve to the hydraulic tank.
tank when the retractile speed of tilt cylinder
Implement system oil flows through inlet into
piston rod exceeds output flow speed of work
spring cavum. When the oil pressure in the
pump, the check valve moves upwards and
spring cavum is less then the relief valve setting,
opens. Replenish oil to rod end of tilt cylinder
the force of reset spring on spool keeps spool in
from tank passing oil way (13) in order to make
contact with valve seat. No oil will be allowed to
sure oil sufficient of tilt cylinder for avoiding the
flow to the hydraulic tank.
cylinder bring air pocket.
When the oil pressure of the circuit is greater
Realize replenishing oil to rod end of tilt cylinder
than the relief valve setting value, the oil
if the tilt cylinder suffers from outside force
pressure of spring cavum overcomes the force of
impact even though the tilt cylinder doesn’t work.
spring (12). This causes taper valve spool to
The hydraulic-control check valve (19) has the move off the seat. This allows spool to move off
same effect with rod end of tilt cylinder filling oil valve seat. The oil then flows through outlet (8) to
check valve (4) during the boom floating. Refer the hydraulic tank. Otherwise, the part oil in pilot
to the boom join float operation instruction. spring chamber will flow through pilot oil outlet
Relief valve (load sensing signal) (9) to the hydraulic tank.
The relief valve setting can be adjusted by
changing the force of pilot spring (12). Loosen
plug and turn adjustment screw clockwise in
order to increase the relief valve setting. Turn
adjustment screw counterclockwise in order to
decrease the relief valve setting.
 81
Working Hydraulic System
Operation Section

Safety Valve

1. Poppet 2. Spring
3. Locking nut 4. Adjustment screw

In the poppet, a group of unload valve is installed

respectively on the large chamber and small
chamber of the tilt cylinder.
Pressure oil acts on the poppet. When the oil
pressure increases to overcome the spring force,
then poppet will move and the pressure oil
connects with return oil.
The unload valve that connects to the tilt cylinder
is used to limit the maximum pressure of the tilt
cylinder when the poppet group on the control
valve is at neutral position. When there is any
external force acts on the tilt cylinder, if the
pressure inside the cylinder exceeds the pre-set
pressure value of the unload valve, then the
unload valve will open to connect the cylinder
with oil tank to return oil. Piston of the tilt cylinder
will move to avoid component damage from the
high pressure.
82
Working Hydraulic System
Operation Section

Ride Control System

The ride control system provides the means for

absorbing forces from the lift cylinders while the
machine is traveling. Those forces cause the
machine to pitch when the machine is moving
over rough terrain. The main components of the
ride control system are ride control valve,
accumulator, and the lift cylinder.

1
2

1. Ride control valve 2. Accumulator

Ride control accumulator is located at the
articulation joint on the left side of the front end
frame. The accumulator contains a precharge of 1. Accumulator 2. Relief valve
nitrogen. Ride control valve will control the flow 3. Manual valve rod 4. Valve rod
of oil between the ride control accumulator and 5. Boom cylinder 6. Check valve
the lift cylinders. 7. Throttle valve 8. Valve rod
When the ride control system is activated and The ride control valve is made up of the following
the machine travels over rough terrain with a components: relief valve, manual valve rod,
loaded implement, the forces of the load act valve rod, check valve, throttle valve, valve rod.
against the lift cylinders. When the load acts
against the head end of the lift cylinders, oil from
the head end will try to flow into the accumulator.
The accumulator will act as a shock absorber.
 83
Working Hydraulic System
Operation Section

. The Control Switch is at ON Position

The solenoid charges, its valve rod is at down

position when the control switch is at ON
position. The hydraulic oil of ride control
accumulator flows to left side of control valve
passing the solenoid, check valve and throttle
hole, the control valve rod moves right to 4
position under the left/right ends hydraulic oil and
spring force, the head end of boom cylinder is
connected with the hydraulic tank. The hydraulic
oil from head end of boom cylinder charges to
the ride control accumulator when the boom
vibrates, owing to obstruct form the ride control
accumulator nitrogen, the ride control
accumulator weakens the boom vibration. During
9 the boom vibration, the hydraulic oil of rod end of
boom cylinder flows to hydraulic tank, and that
9. Ride control switch
the hydraulic oil of hydraulic tank can flow to rod
The ride control system is controlled by ride end of boom cylinder.
control switch. The ride control switch is a two-
Manual valve is used for servicing. The hydraulic
position switch that is located on the right side
oil of ride control accumulator flows to hydraulic
control panel in the cab. The two positions of the
tank from the manual valve when push the
ride control switch are OFF and SERVICE.
manual valve left, the pressure of ride control
accumulator is zero.
The Control Switch is at OFF Position
The relief valve restricts the max pressure of ride
The solenoid discharges, its valve rod is at top control system thereby protecting every hydraulic
position when the control switch is at OFF component safety.
position. The control oil cavum of left side of the
control valve is connected with hydraulic tank by
the check valve, throttle valve and the solenoid.
The control valve rod is at 1 position when the
ride control accumulator pressure is so low.
Charge the ride control accumulator passing the
control valve if pressure of head end of boom
cylinder is greater than pressure of the ride
control accumulator. A part of oil from ride control
accumulator is used to right side of control valve,
the control valve rod move left to 2 position under
the pressure oil of ride control accumulator and
left/right spring forces when the pressure of ride
control accumulator raises to corresponding
value, oil from head end of boom cylinder to the
ride control accumulator is cut off, the oil of ride
control accumulator is also blocked. The ride
control system can’t absorb vibration.
84
Working Hydraulic System
System Test and Adjustment

Unload Valve System Test and Adjustment

The hydraulic oil of steering pump inside of the Hydraulic System Pressure--
interflowing hose is released to tank by the
unload valve for saving energy sources.
Release
When operate the machine, if no steering, the
steering pump together with work pump provide
oil to the control valve. When the work hydraulic
system pressure is greater than 16Mpa, the Sudden movement or accidental starting of
steering pump oil returns to hydraulic tank by the the machine can cause personal injury or
unload valve, the hydraulic steering system death to persons on or near the machine.
pressure is zero, the power is about zero, only To prevent personal injury or death, perform
hydraulic pump provides oil in the hydraulic the following:
system, and only consume the power of
hydraulic system. Although use the unload valve Park the machine on a smooth, level surface.
drain the hydraulic pump oil, the hydraulic Lower the work tool to the ground and
system pressure still raise to rated value 20Mpa, engage the parking brake.
just running speed of hydraulic cylinder will
reduce. Stop the engine and remove the key.
Block the wheels and install the steering
frame lock.
Tilt Cylinder Relief Valve
1. Move the machine to a smooth horizontal
Install a relief valve on main valve of the 8-bar location. Move away from working machines
machine, which can be connected to head end of and personnel. Lower the work tools to the
tilt cylinder for restricting the max hydraulic ground.
pressure of rod end of tilt cylinder.
2. Allow only one operator on the machine.
When pressure of head end of tilt cylinder is Keep all personnel away from the machine or
greater 16Mpa, the relief valve opens, the in the view of the operator.
hydraulic oil of head end of tilt cylinder returns to
tank for preventing the pressure of head end of 3. Engage the parking brake.
tilt cylinder exceeding 16MPa, thereby protecting 4. Turn the engine start switch key to the ON
the implement rod from suffering force. position
5. Move ride control switch to the ON position.
6. Move the lift control lever to the FLOAT,
RAISE, DUMP, TILT BACK position. Relieve
all of the hydraulic pressure.
7. Press the pedal for several times to release
the service brake system pressure.
8. Press down and pull up the parking brake
button for several times to release the
parking brake system pressure.
9. Turn the engine start switch key to the OFF
position
10. Move ride control switch to the OFF position.
 85
Working Hydraulic System
System Test and Adjustment

Hydraulic Oil Contamination--Test The hydraulic oil in this system is HM-46. If the
oil becomes contaminated, premature
component failure could result. Contaminated oil
can also contribute to overheating. Use the
following procedure to sample the oil in the
steering system.
Personal injury or death can result from
machine articulation or movement. 1. Install the steering frame lock in the LOCKED
position.
Machine frames can move and a person can
be crushed. 2. Start the engine and run the engine at high
idle. Allow the oil temperature to reach the
Connect the steering frame lock link between
normal operating temperature.
the front and rear frames before working on
machine. 3. Operate the machine for a few minutes
before you obtain the oil sample. This will
thoroughly mix the oil for a more accurate
sample.
4. Stop the engine.
5. Move all control levers and brake pedals
Sudden movement or accidental starting of through all positions in order to release any
the machine can cause personal injury or pressure in the hydraulic system.
death to persons on or near the machine.
6. In order to relieve all of the pressure in the
To prevent personal injury or death, perform hydraulic tank, open the oil filler cap of the oil
the following: tank.
Park the machine on a smooth, level surface. 7. Ensure that the control levers are in the
Lower the work tool to the ground and HOLD position.
engage the parking brake. 8. Sample 50 ml oil from the oil filler. The level
Stop the engine and remove the key. of contaminants must be lower than the
values in the following table.
Block the wheels and install the steering
frame lock. Hydraulic Oil Contamination
Particle Maximum Number of
CAUTION: Care must be taken to ensure ISO Code
Size(Microns) Particles Per I ml Sample
that fluids are contained during performance 18 5 2500
of inspection, maintenance, testing,
15 15 320
adjusting and repair of the product. Be
prepared to collect the fluid with suitable Note: The concentration of the particles by size
containers before opening any compartment should be monitored over a series of samples.
or disassembling any component containing This information can be used in order to spot
fluids. abnormal wear before a failure occurs. A
Required Tools: spectrographic analysis of the samples can be
used in order to identify the composition of the
Description Quantity particles. The analysis of the oil sample may be
Probe Assembly 1 used in order to identify the components that are
failing.
Fluid Sampling Bottle 1
86
Working Hydraulic System
System Test and Adjustment

Implement Cycle Time--Check Cycle Time--Check

Raise 6.5

Implement Cycle Times Lower 3.5

(Seconds) for CLG856III z Float 4
Sudden movement or accidental starting of bar Tilt back
the machine can cause personal injury or
Dump 1.5
death to persons on or near the machine.
Raise 6.5
To prevent personal injury or death, perform Lower 3.5
the following: Implement Cycle Times
(Seconds) for CLG856III 8 Float 4
Park the machine on a smooth, level surface. bar Tilt back
Lower the work tool to the ground and Dump 2.5
engage the parking brake.
Stop the engine and remove the key. Raise

Block the wheels and install the steering 1. Move the work tool to the TILT BACK
frame lock. position.
2. Lower the work tool completely.
The implement cycle time can be checked in 3. Increase the engine RPM to high idle.
order to verify a complaint about slow implement
4. Move the lift control lever to the RAISE
speed. This test will also help to determine
position. Hold the lift control lever in this
whether all functions are slow or only one
position until the lift cylinder reaches the end
function is slow.
of travel. Record the amount of time that is
Note: For all cycle time tests, the work tool must required for the work tool to travel from the
be empty. ground to the full RAISE position.
Refer to above table for the correct cycle time for
Machine Preparation the machine that is being serviced.
1. Perform the torque converter stall test in Lower
order to verify that the engine is developing
adequate power. 1. Position the work tool so that the work tool is
flat on the ground.
2. Perform the calibration of the main control
valve in order to ensure that pressure of 2. Raise the work tool to the maximum height.
hydraulic system is right. 3. Increase the engine RPM to high idle.
3. Move the machine to an open area so that 4. Move the lift control lever to the full LOWER
the work tool can be fully raised. position and hold.
4. Shift the transmission to neutral. Note: Ensure that the lift control lever is NOT in
5. Warm the hydraulic oil to normal operating the FLOAT position.
temperature. The hydraulic oil must be at a Record the time from the full LIFT position to the
temperature of 65 ± 3°C (150 ± 5°F) in order ground. Refer to above table for the correct
to obtain accurate results. cycle time.
 87
Working Hydraulic System
System Test and Adjustment

Float Lift and Tilt Cylinder Drift--Check

1. Position the work tool so that the work tool is
flat on the ground. Lift Cylinder Drift--Check
2. Raise the work tool to the maximum height.
3. Increase the engine RPM to high idle.
4. Move the lift control lever to the FLOAT/
Sudden movement or accidental starting of
DETENT position and hold.
the machine can cause personal injury or
Record the time from the full LIFT position to the death to persons on or near the machine.
ground. Refer to above table for the correct cycle
To prevent personal injury or death, perform
time.
the following:
Tilt Back Park the machine on a smooth, level surface.
1. Position the lift linkage at the midpoint of Lower the work tool to the ground and
travel. engage the parking brake.
2. Position the work tool in the full dump Stop the engine and remove the key.
position.
Block the wheels and install the steering
3. Move the tilt control lever to the full TILT frame lock.
BACK position. Hold the tilt control lever in
this position until the work tool is against the
stop.
Record the time from the level position to the full
TILT BACK position. Refer to above table for the
correct cycle time. Personal injury or death can result from
sudden movement of the lift cylinders or the
Dump tilt cylinders. Do not stand under the work
1. With the lift cylinders in the fully extended tool when you are testing or adjusting the lift
position, tilt back the work tool as far as cylinders or the tilt cylinders.
possible. Do not stand under the lift arms when you are
2. Increase the engine RPM to high idle. testing or adjusting the lift cylinders or the tilt
cylinders.
3. Move the tilt control lever to the full DUMP
position. Hold the tilt control lever in this This test will check the drift rate of the lift
position until the work tool is at the full DUMP cylinders. The drift rates will change according to
position. Record the time to the full DUMP many conditions (hydraulic oil temperature, type
position. of bucket, load in the bucket, etc). The values in
Refer to above table for the correct cycle time for the table are for an empty bucket.
the machine that is being serviced. 1. Park the machine on a smooth, level surface.
2. Move the transmission direction control
switch to the NEUTRAL position.
3. Engage the parking brake.
4. Place the steering frame lock in the LOCKED
position.
88
Working Hydraulic System
System Test and Adjustment

5. Start the engine. Warm the hydraulic oil to

normal operating temperature of
approximately 49 to 65°C (120 to 150°F).
6. To check the lift circuit, raise the bucket to the Personal injury or death can result from
maximum height and move the control lever sudden movement of the lift cylinders or the
to the HOLD position. tilt cylinders. Do not stand under the work
7. Turn the engine start switch to the OFF tool when you are testing or adjusting the lift
position. cylinders or the tilt cylinders.
8. Measure the distance of cylinder rod Do not stand under the lift arms when you are
movement. The maximum permissible drift is testing or adjusting the lift cylinders or the tilt
10 mm per 5 minutes. cylinders.
9. If the amount of cylinder drift is within the This test will check the drift rate of the tilt
specification, this lift circuit is not causing a cylinders. The drift rates will change according to
drift problem. many conditions (hydraulic oil temperature, type
10. If there is too much drift, check the anti-drift of bucket, load in the bucket, etc). The values in
valve for the lift function and check the ride the table are for an empty bucket.
control balance spool. If replacement of lift 1. Park the machine on a smooth, level surface.
cylinder is required, refer to Disassembly and
Assembly, "Lift Cylinder--Remove and 2. Move the transmission direction control
Install". switch to the NEUTRAL position.

11. Start the engine. Lower the bucket to the 3. Engage the parking brake.
ground. Turn the engine start switch to the 4. Place the steering frame lock in the LOCKED
OFF position. position.
Note: Auxiliary cylinders will drift in the CLOSE 5. Start the engine. Warm the hydraulic oil to
(LOWER) direction because of an orifice in the normal operating temperature of
rod end line. The orifice connects to the tank. approximately 49 to 65°C (120 to 150°F).
6. To check the tilt circuit, raise the bucket to the
Tilt Cylinder Drift--Check
maximum height, and keep the bottom of the
bucket parallel to the ground. Move the
control lever to the HOLD position.
7. Turn the engine start switch to the OFF
Sudden movement or accidental starting of position.
the machine can cause personal injury or
death to persons on or near the machine. 8. Measure the distance of rod movement.
Refer to Table 30 for the maximum distance.
To prevent personal injury or death, perform The maximum permissible drift is 6 mm per 5
the following: minutes.
Park the machine on a smooth, level surface. 9. If the amount of cylinder drift is within the
Lower the work tool to the ground and specification, this tilt circuit is not causing a
engage the parking brake. drift problem.

Stop the engine and remove the key.

Block the wheels and install the steering
frame lock.
 89
Working Hydraulic System
System Test and Adjustment

10. If there is too much drift, check the anti-drift Pilot Pressure to the Main Control
valve for the tilt function and check the tilt
back line relief valves. If replacement of tilt
Valve--Check
cylinder is required, refer to Disassembly and
Assembly, "Tilt Cylinder--Remove and Required Tools:
Install".
Description Quantity
11. Start the engine. Lower the bucket to the
ground. Turn the engine start switch to the Pressure Gauge 1
OFF position.
Note: Auxiliary cylinders will drift in the CLOSE
(LOWER) direction because of an orifice in the
rod end line. The orifice connects to the tank.
Personal injury can result from hydraulic oil
pressure and hot oil.
Hydraulic oil pressure can remain in the
hydraulic system after the engine has been
stopped. Serious injury can be caused if this
pressure is not released before any service is
done on the hydraulic system.
Make sure all of the attachments have been
lowered, oil is cool before removing any
components or lines. Remove the oil filler
cap only when the engine is stopped, and the
filler cap is cool enough to touch with your
bare hand.

Sudden movement or accidental starting of

the machine can cause personal injury or
death to persons on or near the machine.
To prevent personal injury or death, perform
the following:
Park the machine on a smooth, level surface.
Lower the work tool to the ground and
engage the parking brake.
Stop the engine and remove the key.
Block the wheels and install the steering
frame lock.
90
Working Hydraulic System
System Test and Adjustment

CAUTION: Care must be taken to ensure 3. Run the engine at low idle speed. Turn the
that fluids are contained during performance pilot control lever to TILK BACK position.
of inspection, maintenance, testing,
4. Observe the pressure gauge while the bucket
adjusting and repair of the product. Be
is on the full rolled-back position and the pilot
prepared to collect the fluid with suitable
control lever on the TILT BACK position.
containers before opening any compartment
or disassembling any component containing 5. The pressure reading should be at least 3.5 ±
fluids. Dispose of all fluids according to local 0.3 MPa (508 ± 44 psi).
regulations and mandates.
6. If the pilot oil pressure is correct, position the
work tool on the ground, turn the engine start
Machine Preparation switch to the OFF position.
1. Park the machine on a smooth, level surface. (a) Operate the pilot lever forwards,
Move the machine away from other operating backwards, leftwards and rightwards for
machines and away from personnel. several times to release the hydraulic
pressure.
2. Permit only one operator on the machine.
Keep all other personnel away from the (b) Remove the test equipment from the
machine or in the operator's sight. machine.
3. Position the work tool on the ground. 7. If the pilot oil pressure is not correct, turn the
engine start switch to the OFF position. If the
4. Engage the parking brake. pressure reading is not within specifications,
5. Place the steering frame lock in the LOCKED there are several possible causes:
position. (a) The pressure reducing valve for the oil
supply valve system needs to be
Pilot Oil Pressure--Test adjusted.

Pressure Reducing Valve--Adjust

1. Pressure reducing valve reduces the

pressure to the pilot system.
2. Before adjusting pressure reducing valve,
release the hydraulic system pressure and
1
the accumulators for the parking brake
system and the service brake system. Refer
to "Hydraulic System Pressure--Release " on
page 84.

1. Pressure tap

1. Install a Pressure Gauge from 0-6 MPa

Pressure Gauge Group or a 0-6 MPa Digital
Pressure Indicator to pressure tap on the left
of the machine.
2. Start the engine and warm the hydraulic oil to
a normal operating temperature of
approximately 49 to 65°C (120 to 150°F).
 91
Working Hydraulic System
System Test and Adjustment

3. Ensure that the work tool is on the ground. Pilot Oil Valve Accumulator--
Turn the engine start switch to the OFF
position.
Check and Charge

Machine Preparation

1. Park the machine on a smooth, level surface.

Move the machine away from other operating
machines and away from personnel.
2. Permit only one operator on the machine.
3. Keep all other personnel away from the
machine or in the operator's sight.
4. Position the work tool on the ground.
5. Engage the parking brake.
6. Place the steering frame lock in the LOCKED
1. Shim 2. Plug 3. Spring position.
4. Spool 5. Plug 6. Shim
The following procedure can be used in order to
7. Spring 8. Spool 9. Accumulator
test the pilot oil valve accumulator. The
10. Cap accumulator maintains pressure in the pilot
4. Adjust thickness of shim 1 to adjust the hydraulic system. It allows you to lower the boom
reducing valve pressure. The output pressure and the work tools with a stopped engine.
of the reducing valve is bigger when
When you test or charge the pilot oil valve
thickness of the shim is increased; and the
accumulator, the pressure in the pilot hydraulic
output pressure is smaller when the shim
system must be released. The temperature of
thickness is reduced.
the nitrogen gas must also be taken into account.
5. Loose plug 2, remove it. The pressure and volume of nitrogen gas varies
with temperature.
6. Change shim 1 or add a new shim to it with
proper thickness.
Accumulator Charge Pressure--Check
7. Install the plug and tighten it.
8. Refer to "Pilot Oil Pressure--Test " on page Required Tools:
38. Test the pilot oil valve pressure. If the
Description Quantity
pressure value is inconsistency with the
standard, repeat step 1-7 to adjust pressure Gauge 1
until the system pressure meets the
standard. 1. Release hydraulic system pressure. Refer to
"Hydraulic System Pressure--Release " on
page 32.
2. Loose the cap.
92
Working Hydraulic System
System Test and Adjustment

Relief Valve (Load Sensing

Signal)--Test and Adjust

Personal injury can result from hydraulic oil

pressure and hot oil.
Hydraulic oil pressure can remain in the
hydraulic system after the engine has been
stopped. Serious injury can be caused if this
pressure is not released before any service is
done on the hydraulic system.
1. Shim 2. Plug 3. Spring Make sure all of the attachments have been
4. Spool 5. Plug 6. Shim lowered, oil is cool before removing any
7. Spring 8. Spool 9. Accumulator
components or lines. Remove the oil filler
cap only when the engine is stopped, and the
10. Cap
filler cap is cool enough to touch with your
3. Connect the gauge to test pressure. Charge bare hand.
the accumulator if the nitrogen pressure in
the accumulator is lower than 0.7 MPa.

Accumulator--Charge

1. Release hydraulic system pressure. Refer to

"Hydraulic System Pressure--Release " on Sudden movement or accidental starting of
page 32. the machine can cause personal injury or
death to persons on or near the machine.
2. Loose the cap.
To prevent personal injury or death, perform
3. Connect the gauge and slowly turn on the the following:
charging valve of the nitrogen bottle to
charge with nitrogen. Park the machine on a smooth, level surface.
4. When reading in the gauge reaches to Lower the work tool to the ground and
0.8+0.2 0MPa, turn off the charging valve of engage the parking brake.
the nitrogen bottle and remove the gauge. Stop the engine and remove the key.
Charging is finished.
Block the wheels and install the steering
5. Install the cap. frame lock.

CAUTION: Care must be taken to ensure

that fluids are contained during performance
of inspection, maintenance, testing,
adjusting and repair of the product. Be
prepared to collect the fluid with suitable
containers before opening any compartment
or disassembling any component containing
fluids. Dispose of all fluids according to local
regulations and mandates.
 93
Working Hydraulic System
System Test and Adjustment

Machine Preparation 4. Release the hydraulic system pressure.

Refer to "Hydraulic System Pressure--
1. Move the machine to a smooth horizontal Release " on page 32.
location. Move away from working machines
and personnel. Lower the work tools to the
ground.
2. Allow only one operator on the machine.
Keep all personnel away from the machine or
in the view of the operator.
3. Engage the parking brake.

5. Connect Pressure Gauge Group on the

pressure tap. The pressure tap is located on
the left side of the machine.

4. Place the steering frame lock in the LOCKED 1

position.

Relief Valve--Test and Adjust

Required Tools: 1. Pressure tap

Note: In the following steps, do not keep the pilot
Description Quantity control lever in the RAISE position for more than
Pressure Gauge Group 1 five seconds while the pressure is at the relief
setting.
1. Start the engine and run the engine at high 6. Start the engine. Raise the work tool to the
idle. Operate the control levers and move all maximum height. Hold the pilot control lever
the cylinders in order to increase the in the full RAISE position.
temperature of the hydraulic oil to normal
operating temperature of approximately 49 to 7. Increase the engine speed to high idle.
65°C (120 to 150°F). Observe the pressure gauge with the pilot
control lever in the RAISE position. The
2. Lower the lift arms to the ground. pressure setting for the load sensing relief
3. Turn the engine start switch to the OFF valve should be 20+0.5 -0.2 MPa (2900+72 -
position. 29 psi).
8. If the pressure setting of the load sensing
relief valve is not correct, proceed with the
following steps.
94
Working Hydraulic System
System Test and Adjustment

(a) Position the work tool on the ground. Turn 9. If the pressure setting is correct, position the
the engine start switch to the OFF work tool on the ground.
position.
10. Turn the engine start switch to the OFF
position.
11. Release the hydraulic system pressure.
Refer to "Hydraulic System Pressure--
Release " on page 32.
12. Remove the test equipment.
13. Install the front guard group on the machine.
14. Start the engine, position the work tool on the
ground. Turn the key start switch to the OFF
position.

(b) Remove the front guard group in order to

access the load sensing relief valve.

15. Place the steering frame lock in the STORE

position.

1. Adjustment screw 2. Locknut

(c) Loosen locknut. Turn adjustment screw
clockwise in order to increase the
pressure setting. Adjust screw
counterclockwise in order to decrease the
pressure setting of the relief valve.
(d) After adjustment screw is turned for an
adjustment, hold adjustment screw in
place and tighten locknut.
(e) Repeat Steps 6 and 7.
 95
Working Hydraulic System
System Test and Adjustment

Ride Control Accumulator--Test

and Charge

Personal injury can result from hydraulic oil

pressure and hot oil.
Dry nitrogen is the only gas approved for use Hydraulic oil pressure can remain in the
in the accumulators. The charging of oxygen hydraulic system after the engine has been
gas in an accumulator will cause an stopped. Serious injury can be caused if this
explosion. pressure is not released before any service is
done on the hydraulic system.
Do not rely on color codes or other methods
of identification to tell the difference between Make sure all of the attachments have been
nitrogen and oxygen cylinders. In any lowered, oil is cool before removing any
application, never use an adapter to connect components or lines. Remove the oil filler
your nitrogen charging group to a valve cap only when the engine is stopped, and the
outlet used on both nitrogen, oxygen, or filler cap is cool enough to touch with your
other gas cylinders. BE SURE YOU USE DRY bare hand.
NITROGEN (99.8% purity).

Sudden movement or accidental starting of

the machine can cause personal injury or
Personal injury or death can result from death to persons on or near the machine.
escaping fluid under pressure.
To prevent personal injury or death, perform
Escaping fluid under pressure, even a very the following:
small pin-hole size leak, can penetrate body
Park the machine on a smooth, level surface.
tissue and cause serious injury and possible
death. If fluid is injected into your skin, it Lower the work tool to the ground and
must be treated immediately by a doctor engage the parking brake.
familiar with this type of injury.
Stop the engine and remove the key.
Always use a board or cardboard when
Block the wheels and install the steering
checking for a leak.
frame lock.

CAUTION: Care must be taken to ensure

that fluids are contained during performance
of inspection, maintenance, testing,
adjusting and repair of the product. Be
prepared to collect the fluid with suitable
containers before opening any compartment
or disassembling any component containing
fluids. Dispose of all fluids according to local
regulations and mandates.
96
Working Hydraulic System
System Test and Adjustment

Shutdown Procedure 10. Disconnect the hydraulic lines for servicing,

as needed.
1. Start the engine and move the machine to a
hard, level surface. Accumulator--Discharge
2. Move the transmission control lever to the
If the accumulator must be replaced, first perform
NEUTRAL position.
the "Shutdown Procedure". Then perform the
3. Engage the parking brake. following steps.

1. Ride control switch

1
4. Move ride control switch to the ON position.
1. Cap of accumulator charger
5. Lower the bucket to the ground.
Note: The ride control accumulator is located on
6. Turn the engine start switch key to the OFF the left side of the machine on the engine end
position. frame near the articulated joint.
7. Move the lift control lever to the FLOAT Required Tools:
position. This will relieve all of the hydraulic
pressure in the accumulator. For more Description Quantity
information about releasing the hydraulic
Nitrogen Charging Group 1
pressure in the system, refer to "Hydraulic
System Pressure--Release " on page 32. 1. Remove the cap of accumulator charger.
8. Move ride control switch to the OFF position. 2. Connect the charger with accumulator.
9. Loose screw; turn the spool which is located 3. Open the charger valve to release the
under the screw counterclockwise for 2 nitrogen in accumulator completely.
circles.
Accumulators--Charge
2
Required Tools:

Description Quantity
Nitrogen Charging Group 1

1. Start the engine and move the machine to a

hard, level surface.
2. Screw 2. Move the transmission control lever to the
NEUTRAL position.
 97
Working Hydraulic System
System Test and Adjustment

3. Engage the parking brake. 13. Connect connector 1 with connector of the
accumulator.

1. Ride control switch

4. Move ride control switch to the ON position. 4
5. Lower the bucket to the ground.
4. Connector of the accumulator
6. Turn the engine start switch key to the OFF 14. Connect gauge to connector 1 and its other
position. side to nitrogen bottle valve.
7. Move the lift control lever to the FLOAT
position. This will relieve all of the hydraulic
pressure in the accumulator. For more
information about releasing the hydraulic
pressure in the system, refer to "Hydraulic
System Pressure--Release " on page 84.
8. Move ride control switch to the OFF position.
9. Operate the manual valve to completely
release the accumulator pressure.
10. Disconnect the hydraulic lines for servicing, 5
as needed.
11. Remove the cap of the accumulator charger.
12. Install spring in pin, then install the pin into 5. Gauge
the connector. See the following figure. 15. Slowly open the nitrogen bottle valve to
charge with nitrogen gas.
16. Turn off the nitrogen bottle valve and remove
gauge and connector 1 when reading in the
gauge reaches to MPa.
17. Install cap of the accumulator charger.

Ride Control Valve--Test

1 2 3
The following procedure is used to determine
1. Connector 2. Pin
whether the valve is operating correctly. Perform
3. Spring this test after the ride control accumulator is
charged.
98
Working Hydraulic System
System Test and Adjustment

1. Start the machine. Unload Valve--Test and Adjust

2. Move ride control switch to the OFF position.
3. Place the bucket in the full DUMP position. The unload valve is located at the left side of rear
Lift the front wheels off the ground by moving frame, closed to articulation pin.
the lift control lever to the LOWER position.
4. When the front wheels are off the ground,
place the lift control lever in the HOLD
position. In approximately 5 seconds, the ride
control switch is moved to the ON position.
The front wheels should lower to the ground.
5. If the wheels do not lower to the ground, the
shuttle valve spool has not shifted to the ON
position. The following conditions are
probable causes:
(a) The ride control switch is faulty.
(b) The solenoid coil on the ride control valve
is faulty.
(c) The shuttle valve spool sticks.
Personal injury can result from hydraulic oil
pressure and hot oil.
Road Test
Hydraulic oil pressure can remain in the
Note: 5MPa is recommended for machines with hydraulic system after the engine has been
typical buckets. For machines with heavy stopped. Serious injury can be caused if this
buckets, the nitrogen pressure may need to be pressure is not released before any service is
increased in order to keep the accumulator done on the hydraulic system.
piston from striking an internal stop during Make sure all of the attachments have been
normal roading while the ride control system is lowered, oil is cool before removing any
activated. However, raising the nitrogen pressure components or lines. Remove the oil filler
will result in a stiffer ride. cap only when the engine is stopped, and the
1. Put a typical load in the bucket. filler cap is cool enough to touch with your
bare hand.
2. Move the ride control switch to the ON
position.
3. Drive the machine over a rough road surface.
4. If the machine bounces too much or the
accumulator piston is striking the stop, the
nitrogen precharge pressure must be
increased.
5. Increase the nitrogen precharge pressure by
0.5 MPa (72 psi) and perform the road test
again.
 99
Working Hydraulic System
System Test and Adjustment

3. Engage the parking brake.

Sudden movement or accidental starting of

the machine can cause personal injury or
death to persons on or near the machine.
To prevent personal injury or death, perform
the following:
Park the machine on a smooth, level surface.
Lower the work tool to the ground and
engage the parking brake.
Stop the engine and remove the key.
Block the wheels and install the steering 4. Place the steering frame lock in the LOCKED
frame lock. position.

CAUTION: Care must be taken to ensure Unload Valve--Test and Adjust

that fluids are contained during performance
of inspection, maintenance, testing, Required Tools:
adjusting and repair of the product. Be
prepared to collect the fluid with suitable Description Quantity
containers before opening any compartment
Pressure Gauge Group 1
or disassembling any component containing
fluids. Dispose of all fluids according to local
1. Start the engine and run the engine at high
regulations and mandates.
idle. Operate the control levers and move all
the cylinders in order to increase the
Machine Preparation temperature of the hydraulic oil to normal
operating temperature of approximately 49°C
1. Move the machine to a smooth horizontal to 65°C (120°F to 150°F).
location. Move away from working machines
and personnel. Lower the work tools to the 2. Put a typical load in the bucket.
ground. 3. Lower the lift arms to the ground.
2. Allow only one operator on the machine. 4. Turn the engine start switch to the OFF
Keep all personnel away from the machine or position.
in the view of the operator.
100
Working Hydraulic System
System Test and Adjustment

5. Connect Pressure Gauge Group on the (d) Repeat Steps 7.

pressure tap. The pressure tap is located on
9. If the pressure setting is not correct, repeat
the left side of the machine.
Steps 8.
6. Start the engine. Run the engine at high idle.
10. If the pressure setting is correct, position the
Raise the work tool to the maximum height.
work tool on the ground.
7. During boom raising period, check the
11. Turn the engine start switch to the OFF
pressure gauge to see whether the reading is
position.
slowly raising to 16±0.5 MPa (2320±72Psi)
and then dropping to Zero quickly, then this 12. Release the hydraulic system pressure.
reading is the correct load pressure value. Refer to "Hydraulic System Pressure--
Release " on page 32.
8. If the reading is not 16±0.5 MPa
(2320±72Psi)or the reading does not drop to 13. Remove the test equipment.
Zero quickly during raising the boom, then
adjust the unload valve. Adjustment steps
are as follows:
(a) Position the work tool on the ground. Turn
the engine start switch to the OFF
position.

1. Adjustment screw 2. Locknut

(b) Loosen locknut. Turn adjustment screw
clockwise in order to increase the
pressure setting. Adjust screw
counterclockwise in order to decrease the
pressure setting of the relief valve.
(c) After adjustment screw is turned for an
adjustment, hold adjustment screw in
place and tighten locknut.
 101
Steering Hydraulic System
Specifications

Steering Hydraulic System

Specifications Breather Filter

Hydraulic Tank Part No.:53C0232

Part No.:21C0144

1. Air filter 2. Oil strainer

Filter accuracy: 40 μm

Torque for the gauge 10±2 N·m 7.4 lb.ft

102
Steering Hydraulic System
Specifications

Vane pump (Steering) Secondary Steering Pump and

Electric Motor
Part NO.:11C0298
Part NO.:11C0255

The rotation of the shaft is counterclockwise

when the rotation of the shaft is viewed from the
drive end. 1. Secondary steering motor 2. Inlet
The steering pump is a Fixed Displacement Vane 3. Secondary steering pump 4. Ground terminal
Pump. 5. Positive terminal 6. Outlet

Displacement 79.5 ml/rev 7. Relief Valve

Output 164±7 L/min 43±2 Gal./min 4. Torque for the nut 13 ± 1 N·m 9.6±0.7 lb.ft
Pump speed 2200 rpm 5. Torque for the nut 13 ± 1 N·m 9.6±0.7 lb.ft
Engine speed 2200 rpm Test at Full Speed (24 VDC)
Relief pressure 20 MPa 2900.76 Psi
Output 22-25 L/min 5.8-6.6Gal./min
Pressure relief valve
16 MPa 2320.6 Psi
setting
Max. pump inlet pressure 0.2 MPa 29 Psi
Motor normal operating
20°C (70°F)
temperature
Oil SAE 10 oil
Oil temperature 38°C (100°F)

Note: The secondary relief valve is built into the

secondary steering pump.
 103
Steering Hydraulic System
Specifications

Steering Cylinder Steering Metering Pump

Part No.: 10C0031 Part No.: 44C0208

1. Inside diameter of a 50.5 (+0.1,0) mm

new cylinder head
2. Outside diameter of 50 (-0.025,-0.05) mm
a new cylinder rod
3. Inside diameter of 90 (+0.054,0) mm
the cylinder bore

4. Torque for the nut 1560 ±200N·m 1151±148

lb.ft
5. Cylinder stroke 485 mm Main technology parameter
Pin to pin length of a 806 mm Max system pressure 17.2 MPa 2494.6 Psi
retracted cylinder
Max back pressure 2.1 MPa 304.6 Psi
Lubricate the sealing lips with a minimal amount of the
lubricant that is being sealed Max system operating
93°C
temperature
Max differential temperature
28°C
between SCU and system
Power input torque (with 6.3
2.8-4.0 N·m 2.1-3.0 lb.ft
Bar back pressure)
QAM 1000 ml/r: 2
Max manual input torque 136 N·m 100 lb.ft
Oil cleanliness level ISO18/13
104
Steering Hydraulic System
Specifications

Priority Valve Unload Valve

Part No.: 12C0220 Part No.: 12C0786

Main technology parameter

Rated flow 160 L/min 42 Gal./min
Setting of the pressure
17.2 MPa 2494.6 Psi
relief valve
Control pressure 0.86 MPa 124.7 Psi

Main technology parameter

Rated flow 160 L/min 42 Gal./min
Setting of the pressure
16 MPa 2320.6 Psi
relief valve
System operating
-20~80°C
temperature
Oil cleanliness level ISO18/13

Shuttle Valve
 105
Steering Hydraulic System
Specifications

Part No.: 12C0570

Main technology parameter

Pressure 20 MPa 2900.76 Psi
System operating
-20~80°C
temperature
Oil cleanliness level ISO18/13
106
Steering Hydraulic System
Operation Section

Operation Section

Primary Steering System

When replacement parts are required for this
(Steering) (HMU Steering) product Liugong recommends using Liugong
replacement parts or parts with equivalent
specifications including, but not limited to,
physical dimensions, type, strength and
material.
Failure to heed this warning can lead to
premature failures, product damage,
personal injury or death.

The primary steering system is made up of a

high pressure circuit. When a machine is
equipped with the secondary steering
attachment, the steering system includes one
additional circuit.
Metering pump is attached to the bottom of the
steering column, and located under the floor of
the operator's cab.
Primary control valve is located on the left side of
the machine under the operator's cab. Hydraulic
oil tank is located on the right side of the
machine.
Steering pump is located under the operator's
cab on the left side of the machine.

High Pressure Circuit

The high pressure circuit consists of the following

components. Primary control valve, left steering
cylinder, right steering cylinder, steering pump,
backup relief valve, and hydraulic oil tank.
The high pressure circuit provides the high
pressure oil for the steering cylinders. Oil is
drawn from hydraulic oil tank by steering pump.
Steering pump is a vane pump.
 107
Steering Hydraulic System
Operation Section

When the Metering pump is turn .The Metering

pump's pilot oil moves Primary control valve's
spool. The pressure oil is directed to the
Metering pump P port from priority control valve
CF port. When a right turn is made, the pressure
oil flows to the head end of steering cylinder. The
pressure oil also flows to the rod end of steering
cylinder. This causes the machine to turn right.
When a left turn is made, the pressure oil flows
to the head end of steering cylinder. The high
pressure oil also flows to the rod end of steering
cylinder. This causes the machine to turn left.
108
Steering Hydraulic System
Operation Section

Secondary Steering System Secondary steering valve is located on the upper

left frame. Secondary steering valve is also
(HMU Steering) located above secondary steering pump.
Metering pump is attached to the bottom of the
steering column, and located under the floor of
the operator's cab.
Steering control valve is located below the
operator's cab. Steering control valve is also
located between the engine and the operator's
cab.
During normal machine operation, check valve is
off the seat, while check valve is seated. Check
valve prevents pressure oil from flowing back to
secondary steering pump.
If steering pump fails or the engine fails, the
primary steering pressure switch changes the
state. The primary steering pressure switch
changes the state due to low oil pressure in the
steering system. The primary steering pressure
switch sends a signal to the monitoring system.
The monitoring system then causes a Warning
Category 3 alarm to occur.

CAUTION: The alarm system indicates

that the primary steering system has failed.
Continuing to operate the machine could
result in additional damage to the steering
system components.

Use the secondary steering system to steer the

machine to a safe stop immediately. When the
machine comes to a complete stop, turn the start
switch key to the OFF position and remove the
key. Investigate the cause of the problem before
resuming operation.

Note: The secondary steering system is an Do not use the secondary steering system as a
attachment for these machines. The secondary limphome mode procedure.
steering system should only be used if there is a Do not use the secondary steering system for
failure of the primary steering system. steering the machine when the machine is being
Additionally, only use the secondary steering towed.
system to steer the machine off the road.
A Warning alerts the operator that engine
The secondary steering circuit consists of the shutdown should occur as soon as possible. This
following components. Secondary steering valve, helps prevent injury to the operator and potential
metering pump, steering control valve, left damage to the machine.
steering cylinder, right steering cylinder,
secondary steering pump and electric motor, and
hydraulic oil tank.
 109
Steering Hydraulic System
Operation Section

Secondary steering pump draws oil from

hydraulic oil tank. The oil then flows to secondary
steering valve. This causes check valve to
unseat. The oil pressure then causes check
valve to seat. This prevents pressure oil from
flowing back to steering pump. The pressure oil
then flows to primary control valve.
The oil that is pumped from the secondary
steering pump causes the secondary steering
pressure switch to change the state. The
secondary steering pressure switch activates
secondary steering indicator.
Note: The machine can be articulated during the
three second test.
The secondary steering system can be manually
tested. Test switch for the secondary steering
system is located on the upper left console. Test
switch is a momentary on, normally open switch.
Push test switch in order to determine if
secondary steering pump and secondary
steering indicator are operational. When test
switch is pushed, secondary steering pump runs.
This causes secondary steering indicator to turn
on. This also causes the action alarm to sound.
Relief valve is for the secondary steering pump.
Relief valve limits the amount of oil pressure in
the secondary steering circuit.
110
Steering Hydraulic System
System Test and Adjustment

System Test and Adjustment 1. Park the machine on a smooth, level surface.
Move away from other operating machines
and away from personnel. Lower the
implements to the ground. Stop the engine.
2. Permit only one operator on the machine.
When replacement parts are required for this Keep all other personnel away from the
product Liugong recommends using Liugong machine or in sight of the operator.
replacement parts or parts with equivalent 3. Engage the parking brake. Put blocks in front
specifications including, but not limited to, of the wheels and behind the wheels.
physical dimensions, type, strength and
material. 4. Install steering frame lock in the LOCKED
position so the machine can not articulate.
Failure to heed this warning can lead to
premature failures, product damage, Steering frame lock in the LOCKED position
personal injury or death.

Personal injury or death can result from

escaping fluid under pressure. Escaping fluid
under pressure, even a very small pin-hole
size leak, can penetrate body tissue and
cause serious injury and possible death. If
fluid is injected into your skin, it must be
treated immediately by a doctor familiar with
this type of injury. Always use a board or
cardboard when checking for a leak.
Sudden movement of the machine or release 5. Depress the brake pedal repeatedly. This will
of oil under pressure can cause injury to relieve any pressure that may be present in
persons on or near the machine. the brake hydraulic system.
In order to prevent possible injury, perform 6. Move the implement control levers through
the following procedure before testing and the full range of travel. This will relieve any
adjusting any of the machine hydraulic pressure that may be present in the
systems. implement hydraulic system. Place the lift
control lever in the HOLD position. Place the
tilt control lever in the HOLD position.
CAUTION: Care must be taken to ensure
that fluids are contained during performance 7. Turn the steering wheel several times in both
of inspection, maintenance, testing, directions in order to relieve the pressure in
adjusting and repair of the product. Be the steering system.
prepared to collect the fluid with suitable
containers before opening any compartment
or disassembling any component containing
fluids. Dispose of all fluids according to local
regulations and mandates.
 111
Steering Hydraulic System
System Test and Adjustment

Visual Inspection CAUTION: Care must be taken to ensure

that fluids are contained during performance
of inspection, maintenance, testing,
adjusting and repair of the product. Be
prepared to collect the fluid with suitable
Personal injury can result from hydraulic oil containers before opening any compartment
pressure and hot oil. or disassembling any component containing
fluids. Dispose of all fluids according to local
Hydraulic oil pressure can remain in the
regulations and mandates.
hydraulic system after the engine has been
stopped. Serious injury can be caused if this A visual inspection of the systems is one of the
pressure is not released before any service is first steps when you are troubleshooting a
done on the hydraulic system. Make sure all problem. Before any tests are performed,
of the work tools have been lowered to the visually inspect the systems for oil leaks and for
ground, and the oil is cool before removing damaged parts.
any components or lines. Remove the oil
1. When possible, talk to the operator. Ask
filler cap only when the engine is stopped,
about the symptoms of the problem: machine
and the filler cap is cool enough to touch with
performance, noises, smells, and frequency
your bare hand.
of the problem.
2. Prepare the machine for troubleshooting.
Refer to Testing and Adjusting, "Machine
Personal injury or death can result from Preparation for Troubleshooting" for the
escaping fluid under pressure. machine that is being serviced.

Escaping fluid under pressure, even a very 3. Check the display of the monitoring system
small pin-hole size leak, can penetrate body for the following machine conditions: alert
tissue and cause serious injury and possible indicators, warnings, and service codes.
death. If fluid is injected into your skin, it 4. Be aware of the work environment. An
must be treated immediately by a doctor extreme work environment can greatly affect
familiar with this type of injury. the symptoms of a machine.
Always use a board or cardboard when 5. Check the hydraulic oil level in the sight
checking for a leak. gauge.
6. Look for air in the hydraulic tank oil
immediately after the engine is stopped. Use
a clear container to obtain a sample of the oil.
Sudden movement or accidental starting of Look for air bubbles in the oil in the container.
the machine can cause personal injury or
death to persons on or near the machine. 7. Remove the hydraulic oil filter and cut the
filter open with a filter cutter. Look for
To prevent personal injury or death, perform particles in the filter elements. A magnet will
the following: separate the ferrous particles such as iron
Park the machine on a smooth, level surface. and steel from the nonferrous particles such
as brass, aluminum and rubber.
Lower the work tool to the ground and
engage the parking brake. 8. Check all oil lines and all connections for
damage and for leaks.
Stop the engine and remove the key.
9. Inspect all of the hydraulic cylinders for
Block the wheels and install the steering damage and leaks.
frame lock.
112
Steering Hydraulic System
System Test and Adjustment

10. Inspect all of the control linkages for This section provides probable causes to a
components that are bent, broken, or known problem. Since there may be several
damaged. probable causes, specific inspections or specific
instrument tests may be recommended. These
inspections and tests will help to identify the
Troubleshooting cause that is most probable.
Note: Make sure that you use hydraulic oil with
the correct viscosity for the ambient temperature
and for the operating conditions.
Personal injury or death can result from For additional information about the various
machine articulation or movement. lubricant viscosities for your machine, refer to
Machine frames can move and a person can "Lubrication Specifications" in the Operation and
be crushed. Maintenance Manual of your machine.

Connect the steering frame lock link between Command Control Steering
the front and rear frames before working on
machine. Problem List

1. Turning the steering wheel is difficult.

2. The steering wheel will not return to the
Personal injury or death can result from
NEUTRAL position. The machine is steering
escaping fluid under pressure.
all of the time.
Escaping fluid under pressure, even a very
3. The impact at full articulation is too high.
small pin-hole size leak, can penetrate body
tissue and cause serious injury and possible 4. The machine turns too slowly in one
death. If fluid is injected into your skin, it direction.
must be treated immediately by a doctor
5. The machine turns too slowly in both
familiar with this type of injury.
directions.
Always use a board or cardboard when
6. The machine turns too slowly in both
checking for a leak.
directions only when the machine turns
against a load.
CAUTION: Care must be taken to ensure 7. The machine does not turn when the steering
that fluids are contained during performance wheel is turned.
of inspection, maintenance, testing,
8. The machine turns but the operator does not
adjusting and repair of the machine. Be
turn the steering wheel.
prepared to collect the fluid with suitable
containers before opening any compartment 9. The machine turns too quickly in order to
or disassembling any component containing make small steering corrections when the
fluids. Dispose of all fluids according to local machine moves at fast speeds.
regulations and mandates.
Performance tests for the steering system can be
used for a diagnosis of poor performance and for
finding the source of oil leaks inside the hydraulic
system.
 113
Steering Hydraulic System
System Test and Adjustment

Problem 1: Turning the steering wheel is Problem 5: The steering wheel turns with
difficult. slight resistance but the machine does not
turn.
Probable causes:
1. The oil is cold. Probable causes:

2. There is a leak or blockage in the load 1. Oil is leaking from the steering crossover
sensing line. relief valve.
3. There is a leak or blockage in the steering 2. A seal in the piston has worn out.
pump,Steering pump pressure is low.
4. Bolts are too tight for the metering section of Problem 6: The machine turns slowly in both
the steering metering pump. directions only when the machine turns
against a load (high resistance).
5. The check valve for the steering metering
pump is missing. Probable causes:

Problem 2: The machine does not turn 1. Oil is leaking from the relief valve seat or
evenly. from the seals.

Probable causes: 2. The backup relief valve setting of the steering

control valve is set too low.
1. The steering metering pump is sticking. 3. The steering pump's high pressure cutoff
2. The margin pressure of the steering pump is setting is too low.
set too high.
Problem 7: The machine does not turn when
3. The steering control valve spool is sticking. the steering wheel is turned.

Problem 3: The machine turns slowly in both Probable causes:

directions.
1. The steering control valve spool is sticking.
Probable causes:
2. There is a mechanical failure in the steering
1. Springs for the steering metering pump are 3. The steering pump's high pressure cutoff
not adjusted correctly. setting is too low.
2. There is not enough flow from the steering
pump. Problem 8: The machine turns but the
operator does not turn the steering wheel.
3. The main control spool does not move all the
way. Probable causes:
4. The margin pressure setting for the steering
pump is too low. 1. The spool in the steering control valve does
not return to the NEUTRAL position correctly.
Problem 4: The machine turns too slowly in 2. The bolts for the end covers of the steering
one direction. control valve are too tight.

Probable causes:

1. Flow balance adjustment of main control

spool is not correct.
114
Steering Hydraulic System
System Test and Adjustment

Note: This cause may be corrected on some

machines by removing the spool. Then, install
the opposite end of the spool first. The spring,
the retainer, and the shims must be installed on
the opposite end of the spool. An adjustment to
the timing of the steering may be necessary.
3. The orifices in the steering control valve are
plugged.
4. Springs for the steering metering pump are
broken or damaged.

Problem 9: The machine turns too quickly in

order to make small steering corrections
when the machine moves at fast speeds.

Probable causes:

1. The adjustment of the steering metering

pump is not correct.
2. The main control valve spool does not move
freely.
3. The orifices in the steering control valve are
plugged.
4. The margin pressure of the steering pump is
set too high.

Problem 10: The pump makes noise and the

steering cylinder rod does not move freely.

Probable causes:

1. There is air in the steering hydraulic circuit.

2. The steering pump has too much wear.
3. There is a loose connection of the oil line on
the inlet side of the steering pump.
4. The viscosity of the oil is incorrect.
5. The oil level in the hydraulic oil tank is low.
 115
Brake Hydraulic System
Specifications

Brake Hydraulic System Brake Valve

Part No.: 12C0360

Specifications

Vane Pump

Part No.: 11C0298

Maximum brake pressure 6 MPa 870 Psi

Cut-off pressure of charging 15 MPa 2175.6 Psi
Cut-in pressure of charging 12.3 MPa 1784 Psi
Start pressure from P port
0.5 MPa 72.5 Psi
to N port
Maximum flow P→S 4.5 L/min 1.2 Gal./min
Maximum flow P→N 70 L/min 18.5 Gal./min

1. Torque for the bolt 68 N·m 50 lb.ft

2. Torque for the bolt 187 N·m 138 lb.ft
3. Shaf SAE C spline

Test at Full Speed

Pump speed at rated
2100 rpm
engine speed
Front pump output 135.95 L/min 36 Gal./min
Front pump pressure 20 Mpa 2900.76 Psi
Rear pump output 33.2 L/min 8.8 Gal./min
Rear pump pressure 15 Mpa 2175.6 Psi
116
Brake Hydraulic System
Specifications

Accumulators Parking Cylinder

Part No.: 13C0193 Part No.: 13C0189

Fully release pressure 5.2 MPa 754.2 Psi

Maximum spring force 6422 N 1443.7 lbf
Nominal capacity 1L 0.26 Gal Stroke 45 mm
Nominal pressure 31.5 MPa 4568.7 Psi Rated displacement 42 ml 0.01 Gal
Charging gas Nitrogen Work pressure 15 MPa 2175.6 Psi
Work media Petroleum base hydraulic oil
Work temperature -10°C~70°C
Charging pressure of 5.5MPa at 797.7 Psi at
accumulator II, III 20°C 68°F
Charging pressure of 9.2MPa at 1334 Psi at
accumulator I 20°C 68°F
Charging pressure of 1784~2175.6
12.3~15 MPa
accumulator II, III Psi
Charging pressure of
15 MPa 2175.6 Psi
accumulator I
 117
Brake Hydraulic System
Work Principle

Work Principle

Parts No.: 20E0151

Brake system schematic

1. To service brake low pressure alert swith (NC, respond when pressure below 10MPa) ( 0171-460-02-1-002)
2. To parking brake low pressure alert swith (NC, respond when pressure below 11.7MPa) ( 0169-420-02-1-014)
3. Paking brake cylinder
4. To service brake clutch cut-off swith (NO, respond when pressure aboce 1.5MPa) ( 0166-412-02-1-042).
5. To brake light swith (NO, respond when pressure above 0.5MPa) ( 0166-407-02-1-026).
6. Solenoid valve control swith (NO, respond when pressure above 7MPa) (0169-419-02-1-010).
118
Brake Hydraulic System
Work Principle

The brake system is used to reduce speed or

stop the machine when the machine is running
and parking on a level ground or slope for a long
period.
This machine is provided with full hydraulic dual-
circuit wet brake. The brake principle is as
follows:
The brake system is composed of two brakes:
Service brake system (foot brake): it is
commonly used for regular running speed control
and stopping when the machine is running. The
service brake adopts full hydraulic dual-circuit
wet brake. It has advantages of stable brake,
sensitive response, convenient operation, safety
& reliability and the brake performance which is
not affected by operation environment etc.
Parking/emergency brake system (namely
manual brake): It is used for brake after parking,
or when a malfunction occurs in the service
brake. It is controlled by parking brake solenoid
valve. Besides, when a failure happens to the
system, oil pressure of the accumulators in the
service brake circuit is below 7MPa, it can
automatically cut off power of parking brake
solenoid valve to engage the transmissions to
neutral position, the loader urgently stops to
ensure safety running.
The machine adopts full hydraulic dual-circuit
wet brake; refer to Fig. 2 for the principle. The
brake system is composed of brake pump (used
with pilot hydraulic system), brake valve,
accumulator, parking brake cylinder, pressure
switch and pipes. The brake valve consists of
four functional units, namely, charging valve,
dual-check valve, service brake valve and
parking brake solenoid valve. When oil pressure
in the accumulators of the brake system reaches
15MPa, the charging valve stops supplying oil for
the brake and changes to supply oil to hydraulic
pilot oil lines. When oil pressure inside the
accumulators is below 12.3MPa, the charging
valve then supplies oil to the brake system again.
 119
Brake Hydraulic System
Work Principle

Part No.: 20E0152

Brake System Composition Schematic

1. Brake Valve 2. Accumulator I 3. Accumulator II

4. Accumulator III 5. Parking Brake Cylinder
Oil from the brake pump is directed to
accumulators both in the service brake and in
parking brake circuit through the charging valve
inside the brake valve. Accumulator I is used for
the parking brake circuit and accumulator II& III
are used for the service brake circuit. Depress
down the brake pedal, high pressure oil stored in
the accumulators in the service brake circuit is
directed to the axle wheel brake to engage the
wheels. After the brake pedal is released to
remove brake, hydraulic oil inside the axle wheel
brake returns to oil tank through the combination
valve.
120
Brake Hydraulic System
Work Principle

Clutch Cut-off Function (Brake to When starting the engine, the service brake low
pressure alert indicator could illuminate in a short
Release Gear Function) time, the warning buzzer will sound. This is
because oil pressure of the accumulators in the
When the shift control lever is turned at forward service brake circuit is below warning pressure
first & second gear or reverse first & second (10MPa), the alarm will stop after oil pressure of
gear, when clutch cut-off switch is turned on (the the accumulators is higher than warning
button lamp illuminates), depress down the foot pressure. Push down the parking brake button
brake, the electrical control box sends signal to only after the alarm stops. During operation, if oil
engage the transmissions to neutral and shut pressure of the accumulators in the service
down power output. When shift control lever is brake circuit is below 10MPa due to a
turned at forward first & second gear or reverse malfunction occurs in the system, the service
first & second gear, and clutch cut-off switch is brake low pressure alert indicator blinks, the
turned off (the button lamp goes out), the buzzer sounds at the same time. Stop operation,
transmissions power output is not shut down. and stop the machine for checking. When
checking the machine, park the machine on a
The clutch cut-off switch is fitted with a locking
level ground and engage the parking brake
buckle; refer to the Operation and Maintenance
button.
Manual for particular using method.
The brake to release gear function only acts on
at forward or reverse first & second gear. When
the loader is at high speed shift gear, in order to
ensure the running safety, the electrical control
box will not send any power shutdown command
when engaging brake, no matter the clutch cut-
off switch is turned on or off; this is determined
by running features of the loader.

If the shift control lever is turned to F1, F2 or 1. Parking brake button 2. Clutch cut-off switch
R1, R2 gear when the machine is running, do Push down the park braking button, the solenoid
not turn off the clutch cut-off switch, valve is energized, the valve port is opened, and
otherwise brake and power train system will oil outlet pressure is 15MPa. High pressure oil
be damaged. Only when foot brake is needed stored in the accumulators in the parking brake
for uphill operation can this function be used circuit flows to the park braking cylinder through
to ensure running safety. park braking solenoid valve to disengage the
parking brake. When parking brake button is
pushed down, the parking brake low pressure
alert indicator will blink. This is because oil
pressure in the parking brake circuit is lower than
the warning pressure(11.7 MPa). Start the
machine after the parking brake low pressure
alert indicator goes out.
 121
Brake Hydraulic System
Work Principle

Pull up the parking brake button, the solenoid Brake Pump

valve is de-energized, hydraulic oil inside the
parking brake cylinder flows back to the oil tank
through the parking brake solenoid valve to Parts No: 11C0298
engage brake. During operation, if oil pressure in Steering and pilot tandem gear pump
the accumulator I is below 11.7Mpa due to a
failure occurs in the parking brake circuit, and
then the parking brake low pressure alert
indicator will blink. Stop working and check the
machine. When checking the machine, park the
machine on a level ground, lower the
attachments to the ground, pull up the parking
brake button and block the wheels with wedges
to stop the machine from moving.

The pump used in brake system is the same with

that used in pilot hydraulic system. Refer to
system manual for detailed information.

1. Service brake low 2. Parking brake low

pressure alert pressure alert

If oil pressure of the accumulators in the service

brake circuit is below 7Mpa due to a malfunction
occurs in the system, then clutch cut-off switch of
the system will automatically shut down power
output so that the transmissions is engaged at
neutral. At the same time, the solenoid valve is
de-energized, and then hydraulic oil in parking
brake cylinder flows back to the oil tank through
parking brake solenoid valve to engage brake, to
drive the loader stops immediately.

Do not use the parking brake when the

machine is moving, except for emergencies.
Use the parking brake in normal operation
will cause serious damages to the brake and
power train system.
122
Brake Hydraulic System
Work Principle

Brake Valve

Parts No: 12C0360

Brake valve schematic

Brake valve

The brake valve is installed at the left front side

of the cab. It is controlled by left foot.
 123
Brake Hydraulic System
Work Principle

Principle of the Brake Valve

This brake valve is an integrated valve; it

integrates all control valves of the brake system
of the whole machine. Refer to Fig. 5 for the
principle diagram; it consists of charging valve,
low pressure alert switch, dual check valve, two-
circuit brake valve, brake light switch, check
valve and parking brake solenoid valve etc.
Parts No: 12C0360
Outside view of brake valve

Port P To brake pump

Port T To oil tank
To combination valve inlet of the hydraulic
Port N
system
Port S1 To accumulator III
Port S2 To accumulator II
Port S3 To accumulator I
Port DS1 To brake light switch
To service brake low pressure warning
Port DS2
switch
Port BR1 To front axle
Port BR2 To rear axle
Port BR3 To brake cylinder
124
Brake Hydraulic System
Work Principle

When any accumulator pressure in the brake Under the effect of return spring of valve spool, it
system is below 12.3MPa, charging valve spool is normal if pressure at port BR2 is 0.5MPa lower
is actuated, the spool is located at working than that at port BR1 when brake circuit is
position 1 & 4, return oil of the charging valve working. The first time to depress down the
closes, port T and port N is partially connected. brake valve pedal, port T is disconnected from
Oil from the brake pump is directed to port P and port BR1 and BR2. Depress down the pedal
charging valve to charge the accumulators again, port S1and S2 connects respectively with
through check valve or dual-check valve with 5L/ port BR1 and BR2 to engage brake for the whole
min (1.3 Gal./min) of flow till pressure inside all machine. Bigger pedal force will increase
accumulators reaches 15MPa. Charging valve pressure of port BR1 and BR2 till the pedal force
spool is then actuated, valve spool is located at keeps balance with the hydraulic feedback force.
the working position 2 & 3, charging will stop.
Release the pedal, the valve will return to free
Then return oil port of the charging valve is
condition, port T connects with port BR1 and
connected to port T, port P is completely
BR2. When the pedal is depressed down to
connected to port N, oil from the brake pump is
engage brake of the machine, so long as
directed to port P and port N to supply oil to the
pressure at port DS1 is bigger than 0.5MPa, the
pilot hydraulic system. When the brake system
brake light switch is actuated, the brake light will
pressure (port DS2)is below 10MPa, the service
illuminate. Check valve is fixed to keep pressure
brake warning switch will be actuated, the
of the accumulators.
warning buzzer sounds.
When the magnet of parking brake solenoid
When the system is working, if there is a fault
valve is energized, port S3 connects with port
occurs in any one of the two brake circuits, (this
BR3, but port T disconnects from port BR3 so
circuit may fail to build up pressure due to
that the parking brake is disengaged, then the
leakage etc.), dual-check valve then are
machine can run. When magnet of parking brake
actuated at once to close the passage between
solenoid valve is de-energized due to
the other normal circuit and charging valve in
emergency, port S3 will disconnect from port
order to ensure the brake ability of the other
BR3 and port T connect with port BR3, then the
normal circuit. At this moment, the failed circuit is
machine is kept at brake condition.
connected to the charging valve to cause
pressure drop at port DS2, then the service
brake low pressure alert switch is actuated and
the warning buzzer sounds. Stop the machine
and check at once. Therefore, the function of
check valve and dual-check valve is to prevent
two brake circuits from disturbing each other.
Output pressure of two-circuit brake valve(that is
pressure of port BR1& BR2) is proportional to the
pedal force, that is, the bigger the pedal force is,
the bigger pressure of the brake port BR1and
BR2 will be, but maximum value is adjusted at
6MPa at ex-factory.
 125
Brake Hydraulic System
Work Principle

Two-circuit brake valve .

Two-way brake valve structure diagram
1. Principle Instructions

When the pedal (9) is depressed down, piston

(10) moves downward so that spring (13) drives
spool (6) & (4) to overcome the force of spring (3
& 5) to move downward, port T disconnects from
port BR1 and port BR2. Port S1 is connected to
port BR1 and port S2 is connected to port BR2.
Pressure oil from accumulator III flows through
port S1 to port BR1, then through orifice of spool
(6) to spring (5) chamber to act on the bottom of
spool(6) so that spool (6) moves upward. When
hydraulic force which is acting on the bottom of
spool (6) and spring (5) force is balanced with
the pedal force, spool (6) will stop moving, port
S1 is disconnected from port BR1. Pressure oil
from accumulator II flows to port BR2 through
port S2, then the oil goes to spring (3) chamber
through orifice of spool (4) to act on the bottom of
spool (4) so that spool (4) moves upward. When
hydraulic force which is acting on the bottom of
spool (4) and spring (3) force is balanced with 1. Brake lamp switch 2. Spring support
hydraulic force of spring (5) chamber and spring 3. Spring 4. Spool
(5) force, spool (4) will stop moving. Then port S2 5. Spring 6. Spool
is disconnected from port BR2. As the pedal
7. Nut 8. Bolt
force increases, output pressure of port BR1 and
9. Pedal 10. Piston
port BR2 increase too. When the pedal force
disappears, spool (4) and spool (6) move upward 11. Spring 12. Spring support
under force of spring (3) till it returns to the 13. Spring 14. Support
original condition. Then port T is connected with 15. Mounting support 16. Valve body
port BR1 & BR2; port S1 is disconnected from
port BR1 and port S2 also is disconnected from 2. Adjustment of brake pressure
port BR2.
When maximum output pressure at port BR1
doesn't meet the setting value (6MPa) which is
adjusted at ex-factory, then readjustment can be
carried out as following: make sure that all
external pipes of the brake valve is properly
connected→Fix a pressure gauge with
measuring range of 0~10MPa at port
BR1→Release nut (7)→Start the
machine→Depress down the pedal till reading of
the pressure gauge is 6MPa→Adjust bolt (8) till it
contacts to the pedal→Release the pedal→Lock
nut (7)→Stop engine→Remove the pressure
gauge→Connect hoses at port BR1. Only adjust
the pressure when accumulator III pressure is
within 12.3~15MPa.
126
Brake Hydraulic System
Work Principle

Dual-check valve Charging valve

When pressure of accumulator III or 1. Principle instructions
accumulatorII is below 12.3MPa, pressure oil
from port S of the charging valve is directed to oil As shown in the figure, chamber D is connected
inlet of dual check valve to open check valve (5) to port T. When any accumulator pressure in the
or check valve (2) to charge accumulator III or system is below 12.3MPa, spool (12) moves
accumulator II. Charging will stop when pressure upward to the position as shown in the Fig. 11
of accumulator III or accumulator II reaches to 15 under the force of spring (18). Port T id
MPa (2175.6 Psi). Then both port S1 and port S2 disconnected from chamber E through chamber
are connected to oil inlet of dual check valve. D; chamber F is connected to chamber E
When pressure of port S1 is not equal to that of through the radial orifice on the valve pocket (11)
port S2, the check valve at the port with big via the flute of spool (12). Oil from the brake
pressure is closed under hydraulic force. This pump is directed to port P and acts on the top of
dual-check valve mainly consists of check valve spool (22), then goes to chamber B through
(5) and check valve (2), which is combined throttle valve (21) to open the check valve (4) in
together through stem (4). The dual check valve order to act on top of spool (9). Meanwhile, the
is adjusted at ex-factory and can't be adjusted oil flows to chamber F through internal oil
again. passage of valve body (2). Chamber E is
Dual check valve structure diagram connected to chamber F, pressure oil from port P
is directed to chamber C through radial orifice on
the spool (12) to act on the top of spool (12) and
spool (9). Pressure oil in chamber E is directed to
chamber G via internal oil passage to push spool
(25) to enter spring (23) chamber to act on the
bottom of spool (22). Under hydraulic force and
spring (23) force, spool (22) overcomes hydraulic
force on the top and moves upward to reduce
port P connection to port N. The brake pump
charges accumulators via spring (5). When
pressure of accumulators reaches 15MPa, under
hydraulic force on the top of spool (12), spool
(12) overcomes the force of spring (18) and
moves downward till the passage from chamber
F to chamber E is closed. Chamber E is
connected to chamber D through the radial
orifice on the spool (10) and the flute of spool
(12), then spool (12) stops moving. Meanwhile,
pressure oil from spring (23) chamber opens
spool (25) to enter chamber G, then goes to
chamber E to unload to port T (port T is
1. Valve body 2. Check valve connected to oil tank) through internal passage.
3. Valve pocket 4. Stem Spool (22) overcomes spring (23) force and
5. Check valve 6. Plug moves downward so that port P is completely
connected to port N, then charging will stop. At
7. O-ring
this moment, pressure at port P is the pressure
of combination valve of the hydraulic system.
 127
Brake Hydraulic System
Work Principle

2. Adjustment of maximum charging Structure of charging valve

pressure

When maximum output pressure at port P

doesn't meet the set value (15MPa) which is
adjusted at ex-factory, then readjustment can be
carried out as follows: make sure that all external
pipes of the brake valve is properly connected
→fix inflator CQJ-25 according to measuring
method of air pressure of accumulator bladders
(refer to Bladder Accumulators section for using
method →Remove screw cap (13)→Release nut
(14)→Start the machine →Repeatedly depress
down the pedal→Adjust screw(15) till reading of
the pressure gauge of the inflator reaches to
15MPa→Release the pedal→tighten nut
(14)→Stop The engine→Remove the
inflator→Connect protective caps of
accumulators.
Parking brake solenoid valve
This valve is a two-position three-way valve and
adopts spool valve structure. When the machine
runs, the solenoid valve is energized, pressure
oil from accumulator I is directed to the brake
cylinder through port BR3, then the parking
brake is disengaged. When the electromagnet is
de-energized due to parking or emergency case,
pressure oil from accumulator I is disconnected
from port BR3, port T is connected with port BR3, 1. Plug 2. Valve body
the machine is at brake condition. 3. Valve support 4. Check valve
5. Spring 6. Spring support
7. Spring 8. Valve pocket
9. Spool 10. Valve pocket
The complicated structure of the brake valve 11. Valve pocket 12. Spool
asks for a professional assembly and 13. Screw cap 14. Nut
accurate adjustment. Do not allow any 15. Adjusting screw 16. Spring support
unauthorized personnel to remove and adjust
17. Support 18. Spring
the brake valve. The pressure value of the
19. Spring support 20. Plug
brake valve is adjusted ex-factory. If trouble
occurs or adjusting pressure is improper, 21. Throttle Valve 22. Spool
please contact the manufacturer or dealer. 23. Spring 24. Support
25. Spool 26. Spring support
27. Plug 28. Plug
128
Brake Hydraulic System
Work Principle

Accumulators Structure and Principle of Accumulator

Accumulators in the service brake and parking

Parts No: 13C0193 brake circuits are bladder accumulators as
Accumulator structure diagram shown above. The function of the bladder
accumulators is to store pressure oil for brake
use. Its principle is to store fluid under pressure
in a sealed housing with the bladder with preset
pressure. Under different pressure, fluid which is
absorbed or released is used for brake. When
the brake pump works, it inputs pressured fluid to
the accumulators through charging valve to store
energy, then air from bladder is compressed so
that fluid pressure is equal to air pressure of the
bladder to obtain energy. Air inflated in the
bladder is non-flammable nitrogen.
The housing of bladder accumulators is made of
even and seamless housing. It has bottle-like
body and ball-like heads. Openings are provided
at one side of the housing and air inflation valves
are fixed. The flexible pear-like bladders made of
synthetic rubber are fixed at the opening on the
other side. The bladders are mounted inside the
accumulators and fixed at the upper side of the
housing with the locking nut. Oil inlet and outlet
are fixed at the bottom of the housing. Besides, a
spring bracket type valve body (mushroom
valve) is fixed at the bottom of the housing to
control the flowing fluid in order to prevent the
bladder from being squeezed out of the housing.
The special feature of the bladder accumulators
is that bladders provide a permanent interlayer
between air and fluid to obtain absolute seal
between air and fluid.
1. Protective cap 2. Inflation valve
3. O-ring 4. O-ring
5. Locknut 6. Gland nut
7. Support ring 8. Rubber ring
9. Housing 10. Bladder
11. Mushroom valve 12. Rubber ring
13. Support ring 14. O-ring
15. Pressing ring 16. Back-up ring
17. Spring 18. Valve body
19. Locknut 20. Piston
21. Locknut 22. Locknut
 129
Brake Hydraulic System
Work Principle

2. Remove the air valve protection cap from the

Accumulators accumulators.
3. Connect one end of the inflator with the
4 pressure gauge to the air valve on the top of
the accumulators, the other end to nitrogen
bottle.
4. Turn on the switch on the nitrogen bottle,
when pressure of the pressure gauge is
stable, slowly turn on the switch eject up the
air inflation valve to charge the accumulators.
on the air inflator, that is,
5. The pressure could be reached in a short
1
2 time, turn off the nitrogen bottle switch; see if
3
6 5 the pressure of the pressure meter is stable.
If pressure is insufficient, re-inflate it again. If
pressure is too high, deflate air by removing
the air plug on the inflator till pressure drops
to the proper value.
1. Accumulator I 2. Accumulator II
3. Accumulator III 4. Inflation valve 6. After desired pressure is inflated, first turn off
5. Connector 6. Joint the nitrogen bottle switch, then turn off the
inflator switch.
As shown in above picture, the three
accumulators are located at the outer side of the 7. Remove the inflator.
frame and at the left lower part of the cab. 8. If the accumulators are leaked (apply engine
Accumulator I is used for parking brake circuit oil to the top of the accumulator valve,
and accumulator II & III are used for service bubbles mean leakage), gently strike the air
brake circuit. valve of the accumulator with a hammer or
Only inflate nitrogen into the accumulators, do small screwdriver to lower it first then quickly
not inflate oxygen, compressed air or other return ti to the original position let the seal
flammable gas. Always inflate nitrogen into surface completely contacted.
accumulators with special inflating tool. 9. Install the protection cover of the air valve of
the accumulator.
Inflating Method of Accumulators
10. Inflate other two accumulators according to
1. First stop the machine but do not turn off the the steps above.
start switch. Continuously depress down the
brake for about 20 times, then repeatedly
engage the parking brake solenoid valve for
about 20 times to discharge high pressure oil
in the accumulators. Then slowly release the
exhaust plug on the oil outlet beneath the
accumulators. At this moment, there may be
pressure oil still exists in the accumulators,
pay attention not to allowing the residual
pressure oil in the accumulators to spray
personal body.
130
Brake Hydraulic System
Work Principle

Maintenance of Accumulators Always release the residual nitrogen n with the

inflator before discarding the accumulators. The
Directly check inflation pressure inside discarded accumulators should be handled by
accumulator bladder with the inflator(it is specialized person from distributors or special
unnecessary to connect the nitrogen bottle by repair stations.
just check the inflation pressure). As for newly-
produced accumulators, check the bladder
pressure in the first week from the date when the
accumulators are produced. After that, check the
bladder pressure within the first month; later
check the inflation pressure once every half a
year. Periodically check the inflation pressure
can ensure optimal use condition, find out
leakage as early as possible and repair for use in
time.

Notices to Use Accumulators

Always check accumulators before charging with

nitrogen. Do not charge with nitrogen if the
accumulator is not equipped with nameplate or
the words on the nameplate has dropped which
causes trouble to identify the accumulator type;
or the steel mark is not completed or hard to
identify, or the housing is defective from which
the safety can not be guaranteed.
The accumulators are inflated and repaired only
by specialized person from dealers or special
repair stations.
The accumulators are only charged with
nitrogen, never use oxygen, compressed air or
other flammable air so as to avoid explosion.
Slowly charge the accumulators with nitrogen to
avoid burst of bladder.
The accumulators should be installed vertically
toward up. Fix it on the support firmly; do not fix
the accumulators by welding. Do not weld any
boss on the accumulators.
Before removing the accumulators, always drain
pressure oil first; then use charging tools to
exhaust residual nitrogen in the bladders, after
that, remove each part of them.
Do not drill any holes on the accumulators or
close the accumulators by carrying any open fire
or heat to it.
 131
Brake Hydraulic System
Work Principle

Brake Cylinder When no oil pressure in the system or the

parking brake button is engaged, then no
pressure oil will go to the left chamber of the
Part No: 13C0189 brake cylinder. Spring 5 support and piston 3 are
Brake cylinder pushed to left end. Then brake is engaged by
pushing the parking brake button to realize brake
function.
When oil pressure of the system reaches
operating pressure and parking brake button is
pushed down, pressure oil is directed to left
chamber of brake cylinder to compress spring 5
to push spring support and piston 3 rightwards
and push the parking brake button to disengage
brake. After that, the machine can run as normal.
When oil pressure inside the accumulators in the
service brake circuit is below 7MPa, then clutch
cut-off switch of the system is actuated to cut off
power of solenoid valve. Hydraulic oil inside the
brake cylinder returns to oil tank through parking
brake solenoid valve. Spring 5 support and
piston 3 is pushed leftwards under the force of
spring 2 to pull up the parking brake button to
engage the brake. At the same time, the
transmission is turned to neutral gear to actuate
parking brake for the loader.
The machine is fitted with springs and hydraulic-
controlled parking brake (work through brake
cylinder). If the engine, hydraulic system or brake
system fails to work, then brake is actuated to
stop the machine from running. If a trailer is
needed, firstly remove pin shaft 6 of the brake
cylinder, as shown in above picture, and tow the
machine only after the parking brake is
disengaged.
1. Cylinder AS 2. Seal
3. Piston 4. Spring support
5. Spring 6. Pin roll
The brake cylinder is located on the front left side
of transmission housing.
Refer to the picture above for the brake cylinder
structure; its working pressure is 15MPa.
Engagement and disengagement of the parking
brake is controlled by the brake cylinder. The rod
of the brake cylinder is connected to cam rod of
the brake.
132
Brake Hydraulic System
Work Principle

Personal injury or death could result when

towing a disabled machine incorrectly.
Block the machine with wedges before the
towed machine is released to avoid
movement of the machine. Failing to obey
this instruction will cause danger from a
moving machine.
Always slowly to tow the machine. If the
machine has lost brake ability, when tow the
machine downhill, a big trailer or other
machines is needed behind the towed
machine to avoid rolling when it is out of
control.
 133
Brake Hydraulic System
Work Principle

Diagram of brake cylinder clamp

1. Nut 2. Pressure plate 3. Stud screw 4. Spring 5. Bolt

Brake Cylinder--Remove Use the clamp too when installing the brake
cylinder, refer to the methods that mentioned
The spring of the parking brake has big elasticity, above, the step is just on the opposite.
use special tools when installing and removing,
otherwise danger could be easily caused.
Refer to above picture for removal of the brake
cylinder. Do not allow unauthorized personnel to
remove the brake cylinder by themselves.
1. Prepare two pressing plates and M14 & Only allow specialized personnel from
L=400 stud screws by yourselves as shown dealers or special repair stations to remove
in the figure. the brake cylinder. Design a special clamp for
2. Remove pin shaft and connecting fork. the brake cylinder as shown in above picture.

3. Put stud screw 3 through two pressing plates

and tighten two ends of the screw with nut
4. After tightening, completely release bolt 5 of
the brake cylinder with a spanner.
5. After completely removing bolt 5, slowly turn
two right bolts 1 with the spanner by turns till
the spring is completely released.
6. Remove the spring and spring support.
7. Remove the piston.
134
Brake Hydraulic System
Work Principle

Parking Brake

As shown in the figure, the parking brake is an

automatic boost and internal expanding brake; it
is engaged and disengaged by brake cylinder.
The parking brake is an attached component of
ZF4WG200 converter & transmission assembly.
It is fixed on the output flange of the
transmission.
Refer to Maintenance Manual of ZF Axles and
Transmissions for maintenance of the parking
brake.
 135
Brake Hydraulic System
Work Principle

System Exhaust 1. Park the machine on a flat surface.

2. Turn the shift control lever to neutral position.
Exhaust nozzles of wheel brake Start the engine and let it run at idle speed;
pull up the parking brake button. Stop the
engine after the service brake low pressure
alert indicator and parking brake low
pressure alert indicator go out, and then turn
on the start switch again.
3. Connect a transparent hose on the exhaust
nozzles of the left and right wheel brake of
the front axle and put the other side of the
hose into the oil collector.
4. Get two people to work together, one people
releases exhaust nozzles and observe
exhausting conditions; other people depress
down the brake pedal for several times.
Release the brake pedal until no air bubbles
After checking and repairing the brake system,
are exhausted from oil. Tighten the exhaust
air existence in the pipes could affect brake
nozzle.
performance. Therefore, exhaust the system
after checking, repairing and replacing parts. 5. Exhaust the rear axle with the same method.
Exhaust nozzles are provided at the left and right 6. After exhausting the front and rear axles,
wheel brakes of axles and oil outlet of continuously pull up and push down the
accumulators. As shown in the figure. Follow the parking brake button for 3~4 times to exhaust
method below to exhaust the system at these the parking brake pipes.
positions:
7. Carefully and slowly release the exhaust plug
Exhaust nozzles of accumulators
under the accumulators until there is oil
comes out of the exhaust plug thread.
Meanwhile, there may be air bubble also
comes out. Tighten the plug when no bubble
appears.

Be careful when exhausting the system

because high pressure oil exists in the wheel
brake and accumulators. Do not completely
screw out the exhaust nozzles and exhaust
plug and do not approach the exhaust
nozzles with eyes and body to avoid personal
injury due to the spraying oil.
136
Brake Hydraulic System (MICO valve)
Specifications

Brake Hydraulic System Charge Valve

(MICO valve) Part No:13C0218

Specifications

Vane Pump

Part No.: 11C0298

Allowable maximum
20.7MPa 3002.3 Psi
system pressure
Charging cut-out
15.9±0.35MPa 2306±50.8 Psi
pressure
Charging cut-in
12.8±0.35MPa 1856.5±50.8 Psi
pressure
Charging speed 10.2±1.9L/min 2.7±0.5Gal./min

1. Torque for the bolt 68 N·m 50 lb.ft

2. Torque for the bolt 187 N·m 138 lb.ft
3. Shaf SAE C spline

Test at Full Speed

Pump speed at rated
2100 rpm
engine speed
Front pump output 153.95 L/min 41Gal./min
Front pump pressure 20 Mpa 2900.76 Psi
Rear pump output 33.2 L/min 8.8 Gal./min
Rear pump pressure 15 Mpa 2175.6 Psi
 137
Brake Hydraulic System (MICO valve)
Specifications

Brake Valve Accumulators

Part No:13C0219 Part No:13C0193

Nominal capacity 1L 0.26 Gal

Nominal pressure 31.5 MPa 4568.7 Psi
Charging gas Nitrogen
Work media Petroleum base hydraulic oil
Work temperature -10°C~70°C
Allowable maximum Charging pressure of 5.5MPa at 797.7 Psi at
20.7 MPa 3002.3 Psi
system pressure accumulator II, III 20°C 68°F
Maximum brake Charging pressure of 9.2MPa at 1334 Psi at
5.3±0.35 MPa 768.7±50.8 Psi
pressure accumulator I 20°C 68°F
Pedal force under Charging pressure of 12.8~15.9 1856.5~2306
maximum pressure 250N 56.2 lbf accumulator II, III MPa Psi
(approximate)
Charging pressure of
Pedal stroke 15.9 MPa 2306 Psi
15° accumulator I
(approximate)
138
Brake Hydraulic System (MICO valve)
Specifications

Parking Cylinder

Part No.: 13C0189

Fully release pressure 5.2 MPa 754.2 Psi

Maximum spring force 6422 N 1443.7 lbf
Stroke 45mm
Rated displacement 42 ml 0.01 Gal
Work pressure 15 MPa 2175.6 Psi
 139
Brake Hydraulic System (MICO valve)
Work Principle

Work Principle

Parts No: 20E0217

Brake system schematic

1. To secondary brake control swith (NC, respond when pressure below 5.5 MPa)( PMN80ANZN)
2. Valve assembly
3. To service brake low pressure alert swith (NC, respond when pressure below 9MPa) ( PMN150CNZN)
4. To parking brake clutch cut-off swith (NO, respond when pressure above 6MPa)( PMN80CNZN)
5. To parking brake low pressure alert swith (NC, respond when pressure below 6MPa) ( PMN80CNZN)
6. Parking brake cylinder
7. Front axle
8. To service brake clutch cut-off swith (NO, respond when pressure above 1.5MPa)( PMN20ANZN)
9. To brake light swith (NO, respond when pressure above 0.5MPa) (PMN10ANZN)
10. Mico pedal tandem modulating valve (4.8±0.3MPa) (06-466-245)
11. Mico oual charge valve with relief (H-15.9MPa; L-12.8MPa; 10.2L/min)
12. Rear axle
140
Brake Hydraulic System (MICO valve)
Work Principle

The brake system is used to reduce speed or The service brake system is composed of pump
stop the machine when the machine is running (used with hydraulic system), two-way charging
and parking on a level ground or slope for a long valve, accumulator, two-way brake valve,
period. pressure switch and pipes. The system pressure
oil is provided by the pump and enters the
This machine is provided with full hydraulic dual-
charging valve, when the system pressure is
circuit wet brake. The brake principle is as
below 12.8 MPa, two-way charging valve opens
follows:
to charge oil for the system; When the system
The brake system is composed of two brakes: pressure is over 15.9 MPa, two-way charging
valve is shut down to stop charging oil for the
Service brake system (foot brake): it is
system, oil from the pump is used to radiate the
commonly used for regular running speed control
hydraulic system. Two-way charging valve is
and stopping when the machine is running. The
fitted with low pressure warning switch, when the
service brake adopts full hydraulic dual-circuit
system pressure is below 6 MPa, the system
wet brake. It has advantages of stable brake,
sends an alarm, indicating a malfunction to two-
sensitive response, convenient operation, safety
way charging valve occurs, stop the machine
& reliability and the brake performance which is
and remove troubles. When the system charges
not affected by operation environment etc.
oil, pressure oil enters accumulators in the front
Parking/emergency brake system (namely and rear circuit, two circuits are independent
manual brake): It is used for brake after parking, each other, when leakage trouble occurs in one
or when a malfunction occurs in the service circuit, pressure in the other circuit will not
brake. It is controlled by emergency brake reduced so as to improve relative reliability.
solenoid valve. Besides, when a failure happens
Depress down the brake pedal, high pressure oil
to the system, oil pressure of the accumulators in
stored in accumulators in the service brake
the service brake circuit is below 5.5MPa, it can
circuit enters axel wheel brake to brake wheels.
automatically cut off power of emergency brake
After releasing brake pedal to remove brake,
solenoid valve to engage the transmissions to
hydraulic oil inside the axel wheel brake flows
neutral position, the loader urgently stops to
back to oil tank through two-way brake valve.
ensure safety running.
Output oil pressure of two-way brake valve is
proportional to the control force acted on the
brake pedal. A little control force can obtain
5.3MPa of brake oil pressure necessary for
complete brake.
 141
Brake Hydraulic System (MICO valve)
Work Principle

Clutch Cut-off Function (Brake to When starting the engine, the service brake low
pressure alert indicator could illuminate in a short
Release Gear Function) time, the warning buzzer will sound. This is
because oil pressure of the accumulators in the
When the shift control lever is turned at forward service brake circuit is below warning pressure
first & second gear or reverse first & second (9MPa), the alarm will stop after oil pressure of
gear, when clutch cut-off switch is turned on (the the accumulators is higher than warning
button lamp illuminates), depress down the foot pressure. Push down the parking brake button
brake, the electrical control box sends signal to only after the alarm stops. During operation, if oil
engage the transmissions to neutral and shut pressure of the accumulators in the service
down power output. When shift control lever is brake circuit is below 9MPa due to a malfunction
turned at forward first & second gear or reverse occurs in the system, the service brake low
first & second gear, and clutch cut-off switch is pressure alert indicator blinks, the buzzer sounds
turned off (the button lamp goes out), the at the same time. Stop operation, and stop the
transmissions power output is not shut down. machine for checking. When checking the
machine, park the machine on a level ground
The clutch cut-off switch is fitted with a locking
and engage the parking brake button.
buckle; refer to the Operation and Maintenance
Manual for particular using method.
The brake to release gear function only acts on
at forward or reverse first & second gear. When
the loader is at high speed shift gear, in order to
ensure the running safety, the electrical control
box will not send any power shutdown command
when engaging brake, no matter the clutch cut-
off switch is turned on or off; this is determined
by running features of the loader.

1. Parking brake button 2. Clutch cut-off switch

If the shift control lever is turned to F1, F2 or Push down the park braking button, the solenoid
R1, R2 gear when the machine is running, do valve is energized, the valve port is opened. High
not turn off the clutch cut-off switch, pressure oil stored in the accumulators in the
otherwise brake and power train system will parking brake circuit flows to the park braking
be damaged. Only when foot brake is needed cylinder through park braking solenoid valve to
for uphill operation can this function be used disengage the parking brake. When parking
to ensure running safety. brake button is pushed down, the parking brake
low pressure alert indicator will blink. This is
because oil pressure in the parking brake circuit
is lower than the warning pressure (6 MPa). Start
the machine after the parking brake low pressure
alert indicator goes out.
142
Brake Hydraulic System (MICO valve)
Work Principle

Pull up the parking brake button, the solenoid Brake Pump

valve is de-energized, hydraulic oil inside the
parking brake cylinder flows back to the oil tank
through the parking brake solenoid valve to Parts No: 11C0298
engage brake. During operation, if oil pressure in Steering and pilot tandem gear pump
the accumulator I is below 6Mpa due to a failure
occurs in the parking brake circuit, and then the
parking brake low pressure alert indicator will
blink. Stop working and check the machine.
When checking the machine, park the machine
on a level ground, lower the attachments to the
ground, pull up the parking brake button and
block the wheels with wedges to stop the
machine from moving.

The pump used in brake system is the same with

that used in pilot hydraulic system. Refer to
system manual for detailed information.

1. Service brake low 2. Parking brake low

pressure alert pressure alert

If oil pressure of the accumulators in the service

brake circuit is below 7Mpa due to a malfunction
occurs in the system, then clutch cut-off switch of
the system will automatically shut down power
output so that the transmissions is engaged at
neutral. At the same time, the solenoid valve is
de-energized, and then hydraulic oil in parking
brake cylinder flows back to the oil tank through
parking brake solenoid valve to engage brake, to
drive the loader stops immediately.

Do not use the parking brake when the

machine is moving, except for emergencies.
Use the parking brake in normal operation
will cause serious damages to the brake and
power train system.
 143
Brake Hydraulic System (MICO valve)
Work Principle

Charge Valve

Parts No: 11C0298

Two-way Charging Valve

1. Stem 2. Spring 3. Seal 4. Valve element 5. Valve body

6. Nut 7. Spring 8. Stem 9. Steel ball 10. Seal
11. Valve element 12. Seal 13. Steel ball 14. Stem 15. Nut
16. Screw 17. Spring 18. Valve element 19. Valve seat 20. Valve element
21. Spring 22. Spring 23. Valve element 24. Seal 25. Valve seat
26. Seal 27. Valve seat 28. Valve element 29. Spring
144
Brake Hydraulic System (MICO valve)
Work Principle

Two-way charging valve is fixed under the cab

and right inner side of the rear frame.
Refer to above picture for main composition of
two-way charging valve. Port P is connected to
the pump, port A1 & A2 to the service brake
accumulator, port SW to the brake valve block
port P, port T to oil tank, port O to hydraulic
radiation system.
When pressure of any accumulator in the system
is below 12.8Mpa, the spring 21 pushes stem 14
upward to close port T and connect cavity W to
cavity H; Valve element 4 moves downward
under the spring 2 to reduce opening of port P
and port O, one way oil from the pump enters
cavity G through small hole, the other way oil
pushes check valve element 18 to enter cavity W
and push valve element 23 and valve element
28, check valve F1 & F2 open to charge oil to
accumulators. When pressure of accumulators is
above 15.9Mpa, joint force of oil pressure in the
cavity W and spring 7 is bigger than the force of
spring 19, the valve element 11 moves
downward to push vale gate under valve element
11, oil from cavity H flows back to oil tank,
pressure drops, at that time, pressure G is bigger
than joint force of spring 2 and oil of cavity H,
valve element 4 moves upward, port P is
completely connected to port O to stop charging
oil, all oil from the pump is used cool down
hydraulic system. When accumulator pressure is
below 12.8Mpa, oil is charged to accumulators
again.
The function of dual check valve F1 & F2 is to
make sure that two brake circuits don't disturb
each other. When a malfunction to one circuit
occurs, pressure drops, the port with bigger
pressure corresponds to valve F1 or F2 is closed
under hydraulic force. The effective brake circuit
can conduct brake function. At that time, failed
circuit is connected to the charging valve, port
SW pressure drops, the service brake low
pressure warning switch is actuated, the buzzer
sounds, at that time, stop the machine and check
again.
 145
Brake Hydraulic System (MICO valve)
Work Principle

Maximum Charging Pressure-- CAUTION: Always connect port T pipes

and joints after every adjustment to avoid oil
Adjust leakage from oil vent.
CAUTION:Because of complicated
When maximum charging pressure doesn't meet structure of the two-way charging valve and
the setting value (15.9±0.35MPa) at ex-factory, high requirement of fixing and adjustment,
the following adjustment is made: no non-specialized personnel remove and
1. Make sure that all exterior pipes of two-way adjust at will without authorization. The
charging valve are properly connected. pressure value of the two-way charging valve
is adjusted before leaving the factory. If a
2. Connect exact pressure gauge at pressure
failure occurs or adjusting pressure is
testing joint as shown below.
improper, contact the factory or distributor.

1 2

1. Pressure testing joint 2. Two-way charging

Pressure gauge

3. Start the machine, the charging valve is

allowed to work after about one minute, stop
oil supply when pressure of testing pressure
gauge continues to rise, oil supply stops.
4. Remove pipes at port T and joints.
5. Slowly turn nut 15 until maximum reading of
the pressure gauge is 15.9±0.35Mpa.
Pressure is set at the correct position only
after nut 15 is adjusted for many times.
146
Brake Hydraulic System (MICO valve)
Work Principle

Brake Valve

Parts No: 12C0360

Brake valve schematic

1. Spring 2. Valve body 3. Lower valve element 4. Valve body

5. Upper valve element 6. Steel ball 7. Spring support 8. Balance spring
9. Star seal ring 10. Y seal ring 11. Return spring 12. Adjusting gasket
13. Balance spring 14. Piston 15. Roller 16. Pedal
l
 147
Brake Hydraulic System (MICO valve)
Work Principle

The brake valve is installed at the left front side Under brake condition, output oil pressure of
of the cab. It is controlled by left foot. two-way brake valve proportional to control force
on the brake pedal is realized by balance spring
Refer to above schematic for main composition
8 &13. When applied force of the pedal is fixed,
of two-way brake valve, port P1 & P2 are
the force applied to the balance is also fixed
respectively connected to accumulators II & III,
value, after port P1 & P2 are opened, pressure
port A2 & A1 are respectively connected to
oil also enters cavity C & D of lower cavity of
wheel brake of the front and rear axels. When
valve element through small hole, when oil
the brake valve is released, valve element 5 and
pressure applied to oil pressure of lower cavity of
3 are pushed to maximum position under spring1
valve element is below tension of the balance
force, port P1 & P2 are respectively
spring, the balance spring is compressed, the
disconnected to A1 & A2, port A1 & A2 are
valve element moves upward till P1 & P2 are
connected to port T and is not at brake condition.
closed, at that time, the force applied to valve
Depress down the brake valve, certain pressure element by oil pressure keeps balance with
is applied to balance spring through piston14 to pressure applied to the balance force by the
push valve element 5 & 3 downward, port A1, pedal, oil pressure output by the brake valve is
port A2 and port T are closed, port P1 is certain value. When pressure applied to the
connected to port A1, port P2 to port A2, high balance spring by the pedal is increased, the
pressure oil stored in two accumulators (II & III) valve element moves downward again to open
respectively enter the front and rear axe wheel P1& P2 again. When oil pressure of lower cavity
brake to engage brake, also the brake lamp of the valve element increases to certain value,
switch is actuated, the brake lamp will illuminate. the force applied to the valve element keeps
Two circuits of two-way brake valve are balance with pressure applied to the balance
independent each other, when a malfunction spring, port P1 & P2 are closed again, oil
occurs in one brake circuit and the other circuit pressure output keeps unchanged and higher
still properly works. than original oil pressure. That is to say, oil
pressure output by the brake valve is
proportional to compressed distortion of the
balance spring, namely it is proportional to stroke
of the pedal.

Maximum Brake Pressure--Adjust

If maximum brake pressure value of two-way

brake valve is 5.3±0.35Mpa, if it is not like this, it
can be adjusted by increasing or reducing
adjusting washer 12.

CAUTION:Because of complicated
structure of the two-way charging valve and
high requirement of fixing and adjustment,
no non-specialized personnel remove and
adjust at will without authorization. The
pressure value of the two-way charging valve
is adjusted at ex-factory. If trouble occurs or
adjusting pressure is improper, contact the
factory or distributor.
148
Brake Hydraulic System (MICO valve)
Work Principle

Accumulators Structure and Principle of Accumulator

Accumulators in the service brake and parking

Parts No: 13C0193 brake circuits are bladder accumulators as
Accumulator structure diagram shown above. The function of the bladder
accumulators is to store pressure oil for brake
use. Its principle is to store fluid under pressure
in a sealed housing with the bladder with preset
pressure. Under different pressure, fluid which is
absorbed or released is used for brake. When
the brake pump works, it inputs pressured fluid to
the accumulators through charging valve to store
energy, then air from bladder is compressed so
that fluid pressure is equal to air pressure of the
bladder to obtain energy. Air inflated in the
bladder is non-flammable nitrogen.
The housing of bladder accumulators is made of
even and seamless housing. It has bottle-like
body and ball-like heads. Openings are provided
at one side of the housing and air inflation valves
are fixed. The flexible pear-like bladders made of
synthetic rubber are fixed at the opening on the
other side. The bladders are mounted inside the
accumulators and fixed at the upper side of the
housing with the locking nut. Oil inlet and outlet
are fixed at the bottom of the housing. Besides, a
spring bracket type valve body (mushroom
valve) is fixed at the bottom of the housing to
control the flowing fluid in order to prevent the
bladder from being squeezed out of the housing.
The special feature of the bladder accumulators
is that bladders provide a permanent interlayer
between air and fluid to obtain absolute seal
between air and fluid.
1. Protective cap 2. Inflation valve
3. O-ring 4. O-ring
5. Locknut 6. Gland nut
7. Support ring 8. Rubber ring
9. Housing 10. Bladder
11. Mushroom valve 12. Rubber ring
13. Support ring 14. O-ring
15. Pressing ring 16. Back-up ring
17. Spring 18. Valve body
19. Locknut 20. Piston
21. Locknut 22. Locknut
 149
Brake Hydraulic System (MICO valve)
Work Principle

3. Connect one end of the inflator with the

Accumulators pressure gauge to the air valve on the top of
the accumulators, the other end to nitrogen
4 bottle.
4. Turn on the switch on the nitrogen bottle,
when pressure of the pressure gauge is
stable, turn on the switch on the air inflator
slowly, that is, eject up the air inflation valve
to charge the accumulators.
5. The pressure could be reached in a short
time, turn off the nitrogen bottle switch; see if
the pressure of the pressure meter is stable.
2 If pressure is insufficient, re-inflate it again. If
1 3
6 5 pressure is too high, deflate air by removing
the air plug on the inflator till pressure drops
to the proper value.
6. After desired pressure is inflated, first turn off
1. Accumulator I 2. Accumulator II the nitrogen bottle switch, then turn off the
3. Accumulator III 4. Inflation valve inflator switch.
5. Connector 6. Joint 7. Remove the inflator.
As shown in above picture, the three
8. If the accumulators are leaked (apply engine
accumulators are located at the outer side of the
oil to the top of the accumulator valve,
frame and at the right lower part of the cab.
bubbles mean leakage), gently strike the air
Accumulator I is used for parking brake circuit
valve of the accumulator with a hammer or
and accumulator II & III are used for service
small screwdriver to lower it firstly then
brake circuit.
quickly return it to the original position let the
Only inflate nitrogen into the accumulators, do seal surface completely contacted.
not inflate oxygen, compressed air or other
9. Install the protection cover of the air valve of
flammable gas. Always inflate nitrogen into
the accumulator.
accumulators with special inflating tool.
10. Inflate other two accumulators according to
Inflating Method of Accumulators the steps above.

1. First stop the machine but do not turn off the

start switch. Continuously depress down the
brake for about 20 times, then repeatedly
engage the parking brake solenoid valve for
about 20 times to discharge high pressure oil
in the accumulators. Then slowly release the
exhaust plug on the oil outlet beneath the
accumulators. At this moment, there may be
pressure oil still exists in the accumulators,
pay attention not to allowing the residual
pressure oil in the accumulators to spray
personal body.
2. Remove the air valve protection cap from the
accumulators.
150
Brake Hydraulic System (MICO valve)
Work Principle

Maintenance of Accumulators Always release the residual nitrogen n with the

inflator before discarding the accumulators. The
Directly check inflation pressure inside discarded accumulators should be handled by
accumulator bladder with the inflator (it is specialized person from distributors or special
unnecessary to connect the nitrogen bottle by repair stations.
just check the inflation pressure). As for newly-
produced accumulators, check the bladder
pressure in the first week from the date when the
accumulators are produced. After that, check the
bladder pressure within the first month; later
check the inflation pressure once every half a
year. Periodically check the inflation pressure
can ensure optimal use condition, find out
leakage as early as possible and repair for use in
time.

Notices to Use Accumulators

Always check accumulators before charging with

nitrogen. Do not charge with nitrogen if the
accumulator is not equipped with nameplate or
the words on the nameplate has dropped which
causes trouble to identify the accumulator type;
or the steel mark is not completed or hard to
identify, or the housing is defective from which
the safety can not be guaranteed.
The accumulators are inflated and repaired only
by specialized person from dealers or special
repair stations.
The accumulators are only charged with
nitrogen, never use oxygen, compressed air or
other flammable air so as to avoid explosion.
Slowly charge the accumulators with nitrogen to
avoid burst of bladder.
The accumulators should be installed vertically
toward up. Fix it on the support firmly; do not fix
the accumulators by welding. Do not weld any
boss on the accumulators.
Before removing the accumulators, always drain
pressure oil first; then use charging tools to
exhaust residual nitrogen in the bladders, after
that, remove each part of them.
Do not drill any holes on the accumulators or
close the accumulators by carrying any open fire
or heat to it.
 151
Brake Hydraulic System (MICO valve)
Work Principle

Parking Brake Valve Block Push down the emergency brake button, the
emergency brake button solenoid valve is
energized, valve port is opened, pressure oil
Parts No.: 45C0182 stored in the accumulator I in the parking brake
Parking brake valve block circuit enters the parking brake through
emergency brake solenoid valve to remove
parking brake. The instant the emergency brake
button is pressed, the parking brake low
pressure warning lamp will illuminate. This is
because oil pressure in the parking brake circuit
is lower than the warning pressure(10MPa). Start
the machine after the parking brake low pressure
warning lamp goes out. Push down the
emergency brake button, emergency brake
solenoid valve is not energized, hydraulic oil of
the parking brake flows back to the oil tank
through emergency brake solenoid valve to
engage parking brake. During operation, if a
malfunction occurs in the parking brake circuit,
when oil pressure in the accumulator I is below
10Mpa, the parking brake low pressure warning
lamp will illuminate. At that time, stop operation
at once and stop the machine and check.
When a malfunction occurs in the system, oil
pressure of the accumulator in the service brake
circuit is below 5.5MPa, it can automatically cut
1. Parking brake power 2. Parking brake low off power of emergency brake solenoid valve to
cut-off switch pressure warning
switch engage the transmissions at the neutral, the
3. Solenoid valve block 4. Pressure testing joint
loader urgently stops to ensure safety running.

5. Emergency brake 6. Service brake low Oil pressure in the accumulator I can be
control switch pressure warning measured when a pressure gauge is fixed at the
switch pressure testing joint.
The parking brake valve block is located at the
right inner side of the rear frame and under the
two-way charging valve. Port P is connected to
port W of the charging valve, port T to oil tank,
port A to accumulator I and port B to the brake. A
check valve is provided between port P and port
A to prevent oil from accumulator I from flowing
back to the charging valve.
152
Brake Hydraulic System (MICO valve)
Work Principle

Brake Cylinder When no oil pressure in the system or the

parking brake button is engaged, then no
pressure oil will go to the left chamber of the
Part No: 13C0189 brake cylinder. Spring 5 support and piston 3 are
Brake cylinder pushed to left end. Then brake is engaged by
pushing the parking brake button to realize brake
function.
When oil pressure of the system reaches
operating pressure and parking brake button is
pushed down, pressure oil is directed to left
chamber of brake cylinder to compress spring 5
to push spring support and piston 3 rightwards
and push the parking brake button to disengage
brake. After that, the machine can run as normal.
When oil pressure inside the accumulators in the
service brake circuit is below 6MPa, then clutch
cut-off switch of the system is actuated to cut off
power of solenoid valve. Hydraulic oil inside the
brake cylinder returns to oil tank through parking
brake solenoid valve. Spring 5 support and
piston 3 is pushed leftwards under the force of
spring 2 to pull up the parking brake button to
engage the brake. At the same time, the
transmission is turned to neutral gear to actuate
parking brake for the loader.
The machine is fitted with springs and hydraulic-
controlled parking brake (work through brake
cylinder). If the engine, hydraulic system or brake
system fails to work, then brake is actuated to
stop the machine from running. If a trailer is
needed, firstly remove pin shaft 6 of the brake
cylinder, as shown in above picture, and tow the
machine only after the parking brake is
disengaged.
1. Cylinder AS 2. Seal
3. Piston 4. Spring support
5. Spring 6. Pin roll
The brake cylinder is located on the front left side
of transmission housing.
Refer to the picture above for the brake cylinder
structure; its working pressure is 15MPa.
Engagement and disengagement of the parking
brake is controlled by the brake cylinder. The rod
of the brake cylinder is connected to cam rod of
the brake.
 153
Brake Hydraulic System (MICO valve)
Work Principle

Personal injury or death could result when

towing a disabled machine incorrectly.
Block the machine with wedges before the
towed machine is released to avoid
movement of the machine. Failing to obey
this instruction will cause danger from a
moving machine.
Always slowly to tow the machine. If the
machine has lost brake ability, when tow the
machine downhill, a big trailer or other
machines is needed behind the towed
machine to avoid rolling when it is out of
control.
154
Brake Hydraulic System (MICO valve)
Work Principle

Diagram of brake cylinder clamp

1. Nut 2. Pressure plate 3. Stud screw 4. Spring 5. Bolt

Brake Cylinder--Remove Use the clamp too when installing the brake
cylinder, refer to the methods that mentioned
The spring of the parking brake has big elasticity, above, the step is just on the opposite.
use special tools when installing and removing,
otherwise danger could be easily caused.
Refer to above picture for removal of the brake
cylinder. Do not allow unauthorized personnel to
remove the brake cylinder by themselves.
1. Prepare two pressing plates and M14 & Only allow specialized personnel from
L=400 stud screws by yourselves as shown dealers or special repair stations to remove
in the figure. the brake cylinder. Design a special clamp for
2. Remove pin shaft and connecting fork. the brake cylinder as shown in above picture.

3. Put stud screw 3 through two pressing plates

and tighten two ends of the screw with nut.
4. After tightening, completely release bolt 5 of
the brake cylinder with a spanner.
5. After completely removing bolt 5, slowly turn
two right bolts 1 with the spanner by turns till
the spring is completely released.
6. Remove the spring and spring support.
 155
Brake Hydraulic System (MICO valve)
Work Principle

Parking Brake

As shown in the figure, the parking brake is an

automatic boost and internal expanding brake; it
is engaged and disengaged by brake cylinder.
The parking brake is an attached component of
ZF4WG200 converter & transmission assembly.
It is fixed on the output flange of the
transmission.
Refer to Maintenance Manual of ZF Axles and
Transmissions for maintenance of the parking
brake.
156
Brake Hydraulic System (MICO valve)
Work Principle

System Exhaust 1. Park the machine on a flat surface.

2. Turn the shift control lever to neutral position.
Exhaust nozzles of wheel brake Start the engine and let it run at idle speed;
pull up the parking brake button. Stop the
engine after the service brake low pressure
alert indicator and parking brake low
pressure alert indicator go out, and then turn
on the start switch again.
3. Connect a transparent hose on the exhaust
nozzles of the left and right wheel brake of
the front axle and put the other side of the
hose into the oil collector.
4. Get two people to work together, one people
releases exhaust nozzles and observe
exhausting conditions; the other people
depress down the brake pedal for several
times. Release the brake pedal until no air
After checking and repairing the brake system,
bubbles are exhausted from oil. Tighten the
air existence in the pipes could affect brake
exhaust nozzle.
performance. Therefore, exhaust the system
after checking, repairing and replacing parts. 5. Exhaust the rear axle with the same method.
Exhaust nozzles are provided at the left and right 6. After exhausting the front and rear axles,
wheel brakes of axles and oil outlet of continuously pull up and push down the
accumulators. As shown in the figure. Follow the parking brake button for 3~4 times to exhaust
method below to exhaust the system at these the parking brake pipes.
positions:
7. Carefully and slowly release the exhaust plug
Exhaust nozzles of accumulators
under the accumulators until there is oil
comes out of the exhaust plug thread.
Meanwhile, there may be air bubble also
comes out. Tighten the plug when no bubble
appears.

Be careful when exhausting the system

because high pressure oil exists in the wheel
brake and accumulators. Do not completely
screw out the exhaust nozzles and exhaust
plug and do not approach the exhaust
nozzles with eyes and body to avoid personal
injury due to the spraying oil.
 157
Air Conditioning System
Work Principle

Air Conditioning System

Illustration of air conditioning system

1. A/C panel 2. Evaporator As 3. Ventilation device 4. Hose

5. Compressor 6. Tensioner As 7. Tank receiver 8. Condenser As

The air conditioner is used to adjust the air

temperature inside the cab to provide a
comfortable operating environment for the
operator. HFC134 refrigerant is used in this air
conditioner system. Do not use any other
Main Performance Specifications
refrigerant except HFC134a to avoid
Refrigerating output 4300W damaging the air conditioner system.
Cool air capacity 420m3/h
Heat output 5520W
Warm air capacity 380m3/h
Voltage 24VDC
Total power ≤380W
Refrigerant HFC134a
Filling capacity for
950g±50g
refrigerant
158
Air Conditioning System
Specifications

Specifications The compressor used in this machine is a swash

plate type, which compresses the vaporous
refrigerant at low temperature and low pressure
Compressor into vaporous refrigerant at high temperature and
high pressure. It compresses and conveys the
refrigerant steam to ensure the normal cooling
Part No.:46C0752 effect.

1 Use ND-OIL8# refrigerating oil only for the

3
compressor. Do not use any other
refrigerating oil except ND-OIL8#, otherwise
2 the compressor may be affected and lead to a
fault to cooling system.

5 4
A/C Panel

Part No.:46C1525
1. Pulley 2. Compressor air
intake port 1 2 3 4 5
3. Compressor exhaust 4. Compressor Body
port
5. Electromagnetic Clutch

2. Torque for hose 8~12 N·m 5.9~8.85 lb.ft

captive bolt M6
3. Torque for hose 8~12 N·m 5.9~8.85 lb.ft
captive bolt M6
7 6
Technical Parameters and Specifications
1. Power switch 2. Cooling switch
Model 10S15C 3. Wind setting buttons 4. Internal circulation
button
Displacement 167.3cc/r
5. External circulation 6. Temperature adjusting
Shaft power consumption 3.02KW button button
Refrigerant HFC134a 7. Fan speed adjusting
button
Lubricant ND-OIL8 180cm
Rev 700~3000rpm The air conditioner control panel is used to
control the temperature, fan speed, internal/
Clutch model L50T(no protective cover)
external air change and cooling state and so on.
Pulley A-single groove
Power consumption ≤40W
 159
Air Conditioning System
Specifications

Condenser As Ventilation Device

Part No.:46C1000 Part No.:46C1691

1
2

2 3

1. Condenser 2. Condenser fan

3. Refrigerant inlet 4. Refrigerant outlet
1. Ventilation box 2. Air door
3. Motor of air door
3. Torque for hose
connection thread 20~25 N·m 14.8~18.4 lb.ft The ventilation device is used to control the fresh
M22×1.5 air input capacity through controlling the air door
4. Torque for hose by the motor to exchange internal circulation with
connection thread 15.7~24.5 N·m 11.6~18.1lb.ft external circulation.
M16×1.5

The condenser assembly is composed of Tank Receiver

condenser and blower. It is a double-stroke type.
The function for the condenser is to release the
high-temperature and high-pressure vaporous Part No.:46C0758
refrigerant from the compressor out of the cab to
condense the vaporous refrigerant into high-
temperature and high-pressure liquid refrigerant.

When storing the condenser, do not open the

cap of refrigerant inlet and outlet to prevent
wet air and foreign matters coming in.
When installing and carrying the condenser,
make sure that the condenser lines and fins
are free from damage. 1. Refrigerant inlet 2. Refrigerant outlet
Tightening torque: 8~12N·m (5.9~8.85 lb.ft)
160
Air Conditioning System
Specifications

Technical Parameters:
Quality capacity 370cc
Absorption capability 32g

The tank receiver is used to store the liquid

refrigerant, and to dry and filter the refrigerant.
Meanwhile, the refrigerant level can be viewed
from the liquidometer on the tank receiver
connector.

During tank receiver storage period, do not

open the plug on the tank receiver to avoid
wet air going into the dryer to damage it.

Tensioner As

Part No.: 46C0754

1. Nut 2. Cover
3. Pulley 4. Bushing
5. Shaft 6. Screw rod
The pulley is used to regulate the tension of the
compressor belt to ensure the compressor can
work normally.
 161
Air Conditioning System
Specifications

Evaporator As
8. Torque for hose
connection thread 29.4~34.3 N·m 21.7~25.3 lb.ft
Part No.: 46C1726 M24×1.5
9. Torque for hose
connection thread 12~15 N·m 8.85~11 lb.ft
M16×1.5
10. High pressure
protective shutoff 3.14 MPa 455.4 Psi
pressure
10. Low pressure
protective shutoff 0.196 MPa 28.4 Psi
pressure

Evaporator is mainly composed of evaporator

housing, cooling unit, expansion valve, pressure
protecting switch, temperature sensor, motor of
air door, evaporator blower, return air screen and
heating unit. Its function is to vaporize the liquid
refrigerant, which has been throttled and
reduced, to absorb the hot air around the
evaporator to lower temperature. Then
evaporator blower blows the cool air through air
duct into cab to lower the cab temperature.

1. Motor of air door 2. Compressor clutch relay

3. Evaporator blower 4. Speed adjusting module
5. Evaporator 6. Hot water outlet
7. Hot water inlet 8. Refrigerant outlet
9. Refrigerant inlet 10. High/low pressure switch
11. Return air screen 12. Evaporator blower relay
(low speed)
13. Evaporator blower 14. Evaporator blower
relay(medium relay(high-speed)
speed)
15. Condenser fan
relay
162
Air Conditioning System
Work Principle

Work Principle

Cooling System

Parts No: 23E0135

Cooling system schematic

1. Expansion valve 2. Evaporator 3. Compressor

4. Condenser 5. Tank receiver
 163
Air Conditioning System
Work Principle

The air conditioner system of this machine is Heating System

vapor-compression type, which is mainly
composed of compressor, expanded valve,
condenser, dryer and evaporator. Its work The heating system use residual heat as its
principle can be divided into fours processes. power. The heat source of the heating system in
air conditioner comes from residual heat from
(1) Compression Process: the refrigerant turns engine cooling water.
into low-temperature and low-pressure
vaporous refrigerant after heat is absorbed Open the warm water valve on engine and turn
into the evaporator. Then the low- on the air conditioner switch, then cooling water
temperature and low-pressure vaporous in engine will flow through the evaporator to the
refrigerant converts into high-temperature heating unit. Warm air then will be blown out by
and high-pressure state after sucked in by the evaporator blower to supply heat for the cab.
the compressor, then this high-temperature
and high-pressure vaporous refrigerant is
sent to the condenser.
(2) Condensing Process: after the high-
temperature and high-pressure vaporous
refrigerant enters into the condenser, the
refrigerant turns into high-temperature and
high-pressure liquid refrigerant when the
condenser fan drives the air flows through
condenser to bring heat away.
(3) Throttle Process: after filtered by dryer, the
high-temperature and high-pressure liquid
refrigerant then goes through expansion
valve to narrow its flow and reduce
temperature and pressure to turn into low-
temperature and low-pressure liquid
refrigerant, finally the refrigerant goes into
evaporator.
(4) Evaporating Process: Low-temperature and
low-pressure liquid refrigerant which is
throttled by the expansion valve vaporizes in
evaporator. Driven by evaporator blower, air
in cab flows through the evaporator surface,
then the refrigerant absorbs hot air to lower
the cab temperature and release condensed
water at the same time. The refrigerant then
turns into low-temperature and low-pressure
vaporous refrigerant. Sucked in and
compressed by compressor again, the
refrigerant will recycle the cooling process.
164
Air Conditioning System
Work Principle

Electrical Schematic Diagram of Air Conditioner

 165
Electrical System
Preface

Electrical System Use the color filling line to describe the current
flow direction in the electronic system principle
drawing for better expression when introduce the
electronic system principle.
Preface Think over the relationships between the unit and
individual when distinguish the fault
This manual is written according to the main phenomenon, which can be fast, right and simple
functions introduced sequence of the electronic when deal with the electronic fault.
system, which is convenient to find the When test by the multimeter, there may be a little
corresponding section of the fault when service difference between the described value in this
the machine. The service person should have manual and the actual value due to the
the special technology in order to understand the measurement error exits in the digital multimeter.
service manual although the technical
description in this manual can be understood For example, when use the 200Ω range of the
easily. multimeter to measure the object with 0
resistance value, the red probe and the black
When introduce the module, firstly, introduce probe should be short circuit, measure the down-
module function, secondly, introduce main lead resistance value, then use the actual
components, then, introduce the main measuring resistance value minus the lead
components' principle, function, electronic resistance value, the loop lead resistance value
system principle drawing, introduce the operation and the receptacle contact resistance value,
of module function after introducing the finally, contrast the resistance value with the
component, finally, introduce module fault description resistance value in this manual. The
diagnostic and test. loop lead resistance and the receptacle contact
The principle drawing symbol of the component resistance can be neglected in this manual, the
shows the denotation method of the component differences doesn't exceed 10Ω between the
in the principle drawing, Most of components' measuring resistance value and the actual
principle drawing symbols denote the actual resistance value.
principle drawings of the component, but there Test the electronic system fault without
are some special symbols, which will be also introduction in this manual, comply with the
introduced in detail. It will be helpful to following steps:
distinguish the component's fault phenomenon.
● Supply voltage
Introduce partial components fault test method in
this manual when introduce the component. The ● Short to ground
test method only aims to component. ● Short from probe to probe
Disassemble the component from the machine
before test. Test the component according to ● Open circuit
above introduction unless the component is ● Function check
disassembled from the machine. Judge the
component condition refer to the fault test
method introduced after the system,
disassemble the component if it is necessary.
The module fault diagnosis and test don't contain
all faults phenomenon, so the service person
must think over and accumulate experience
during operation.
166
Electrical System
Usages of Special Probes

Usages of Special Probes

Pricker inside the probe

During the inspection of electrical equipments,

sometimes, special probes are needed in
checking with electricity, and under the condition
of linker connection.
The special probe can be inserted into the wire,
contacting with the copper core of the wire.
Measure the parameter of the electrical
equipment when the power and the linker are
ON.
The inspect steps introduced in this manual refer
to the usage of special probes, so we will When check and use the probe normally, hold
introduce the use methods of special probes in the end of probe by palm, then use the forefinger
this section. and middle finger to fasten the extrusion seat,
The special probes divide into red probe and press it toward the end of the probe, the direction
black probe, which are the same as the meter is showed as the illustration. The pinhead of the
pens of the digital multimeters. During probe has been undrawn, the pricker and prick
measurement, if the inspected object has the device are exposed at this time. Put the wire in,
polarity requirement, generally, the red probe the pinhead of the probe resets after releasing,
connects with the positive terminal, and the black the pricker inside the probe gets into the wire.
probe connects with the negative terminal. But if See the following steps:
the inspected object does not have the polarity Step 1
requirement, the red and black probes can
connect with each terminal of the inspected
object at will.
The red and black probes

Step 2

Pull out the pinhead of the special probe, and

then you can see the wiry pricker. During
measurement, use the pricker to impale the
insulating layer of the wire to contact the inside
copper core. The hole on the insulating layer is
very small, and it does not impact the wire
insulation
 167
Electrical System
Power-Supply System

Power-Supply System
Step 3

Introduction

The power supply system of the machine

supplies power for all the electrical appliances.
Battery supplies power before starting the diesel
engine; battery and alternator supply power
together after starting the engine.
Under normal condition, power can be supplied
to all the appliances by turning on the start switch
or starting the engine.
Use the red probe and black probe to connect
Under certain condition, turn start switch to P
with wires separately, and adjust the digital
position can supply electricity to some
multimeter to the appropriate position and range.
appliances, which including radio, hazard
Insert the red meter pen and the black meter pen
flashers (front and rear, left and right turn signal
into the inspection point of red and black probes
lights), dome light, rotating beacon and horn.
for inspection. The standard inspection point of
red and black probes can be connected with The lift system power is not controlled by the
other electronic measure instruments. start switch.
The inspection point of red and black probes
168
Electrical System
Power-Supply System

Main Components

Start Switch

Part No.: 34B0359

Start Switch Terminals

Six terminals are provided for the start switch, 15- for turning on the power supply for whole
namely, "30"; "58"; "15"; "17"; "19"; "50", see the machine. When the start switch at I position and
above picture. Terminals that used in this III position, terminal 30 is connected with
machine: terminal 15.
30- for power supply 17-for engine starting. When the start switch is at
III position, terminal 30 is connected with
58-for P position. When start switch is at P
terminal 17.
position, terminal 30 is connected with terminal
58.
 169
Electrical System
Power-Supply System

Test Procedure 7. Turn the start switch to III position. The start
switch can not hold automatically at this
1. Remove all the connectors that connect to position. Use the two probes of the
the start switch terminals to disconnect the multimeter to test the six terminals of the start
start switch from the whole circuit. switch with two terminals for each time, as
the same procedures in step 3. when testing
2. Turn the digital multimeter to Ω position for
terminals [30,15]; [30,17],[30,50]; [15,17];
200 Ω.
[15,50]; [17,50],reading in the multimeter is 0,
3. Turn the start switch to O position. Use the and reading of other terminals is 1.
two probes of the multimeter to test the six
Finally, we can judge that the start switch works
terminals of the start switch with two
normally if reading in the multimeter is identical
terminals for each time. There are 15 groups
with that in the procedures after finish the above-
for test, namely, [30,58]; [30,15]; [30,17];
mentioned test procedure.
[30,19]; [30,50]; [58,15]; [58,17]; [58,19];
[58,50]; [15,17],[15,19]; [15,50]; [17,19];
[17,50]; [19,50]. Reading "1" is shown in the
multimeter which indicates the resistance
between the two terminals is infinite.
4. Turn the start switch to P position. Use the
two probes of the digital multimeter to test the
six terminals of the start switch with two
terminals for each time, as the same
procedures in step 3. when testing terminal
[30,58], the reading in the multimeter is 0,
which indicates the resistance between the
two terminals is 0, but reading of other
terminals is "1".
5. Turn the start switch to I position, use the two
probes of the multimeter to test the six
terminals of the start switch with two
terminals for each time, as the same
procedures in step 3. When testing terminal
[30,15], the reading in the multimeter is 0,
which indicates the resistance between the
two terminals is 0, but reading of other
terminals is "1".
6. Turn the start switch to II position; use the
two probes of the multimeter to test the six
terminals of the start switch with two
terminals for each time. When testing
terminal [30,15]; [30,19]; [15,19], the reading
in the multimeter is 0, which indicates the
resistance between those terminals is 0, but
reading of other terminals is "1".
170
Electrical System
Power-Supply System

Control Box

Part No.: 46C1665

 171
Electrical System
Power-Supply System
172
Electrical System
Power-Supply System

The control box is located at the rear left side of

the seat. It is composed of fuse, relay,
breadboard, box housing and so on. All of these
units are the main components of it. The power
supply for all the electrical appliances is
controlled by turning the breadboard and relay
on or off. Fuses and all the relays can be
removed or replaced respectively. A
corresponding nameplate is sticked to the control
box to show the usage for all the relevant
components. A safety clip is equipped to the
control box which makes it easier to change the
slice fuse. Refer to following introduction for
various fuses and relays function in the circuit.

Part No.: 37B0298 AMG fuse holder and 37B0299 AMG fuse
 173
Electrical System
Power-Supply System

Part No.: 37B0352 one-way fuse holder and fuse

Part No.: 37B0422 (AMI 80A) bolt fuse

174
Electrical System
Power-Supply System

Part No.: Slice Fuse

 175
Electrical System
Power-Supply System

Fuses are used to protect the circuit when a Test Procedure

short circuit or overcurrent happens.
Check the fuse by using the check methods for
All kinds of fuses including slice fuses and bolt
the melted bolt fuse.
fuses are used in the machine power-supply
system. The current for one kind of the bolt fuses Steps for checking the bolt fuse:
is 80 A, which is used for main circuit. The
1. Adjust the digital multimeter to 200Ω range
current for the slice fuses is
at Ω position.
30A,20A,15A,10A,7.5A,5A, which is used for the
branch circuit. When the control box is 2. Connect the two probes of the multimeter to
energized, if a slice fuse is melted, the relevant both ends of the fuse.
fuse indicator will turn on to indicate the fuse is
3. If the reading in the multimeter is "1", which
melted. Change the melted fuse. Another bolt
indicates the fuse is melted and need to
fuse is used in electric auxiliary heating start with
change; if the reading in the multimuter is "0",
a current specification of 150 A. refer to following
which indicates that the fuse is in normal
figure for the fuse shape, illustration and principle
condition.
symbol. Search the desired fuse according to its
specifications.
Specifications for all of the fuses are labeled on
the fuse housing, which can be checked by
eyeballing easily.
The color of slice fuse is related to its
specifications. See the following table for the
color and specifications of the slice fuses, and
Liugong part numbers.

Part No.(Liugong) Specification Color

37B0359 5A Tawny
37B0360 7.5A Brown
37B0361 10A Red
37B0362 15A Light blue
37B0363 20A Yellow
37B0364 30A Green

CAUTION: The specification of the fuses

is work out from circuit design. Replace the
melted fuse with a new one with the same
specification. Do not change the fuse with
different specification.

If the new fuse is still melted after installing it

into the circuit, need to check the circuits that
controlled by the fuse to find out the trouble
reason and eliminate it.
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Electrical System
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Relays

Part No.: 31B0095 (0 332 209 211)

14 relays are used in this machine and six for the The normal open contact for the rated current of
power-supply system to control different circuits. this relay contact circuit is 30A, and the normal
These six relays including power-supply relay closed contact is 10A.
K1, K2, K3, K4, gear/start interlock relay K11 and
Apply a voltage of +24 V to relay coil. Then the
work relay K14 for P position of start switch. The
electromagnetic force that produced from the
specification and work principle schematic is
energized coil attracts the magnet inside the
provided on the relay housing. Pay attention to
relay to turn on the normal open contact and turn
its general purpose when using it.
off the normal closed contact.
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Electrical System
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Part No.: 31B0113 (JQ212D)

A relay is used to control the starting circuit in Test Procedure

this machine. It only has one group normal open
contact without normal closed contact. It is the 1. Remove the relay from the relay holder.
K5 start relay in the principle schematic.
2. Turn the digital multimeter to 2KΩ range at Ω
Specification and inner principle schematic are
position.
provided on the relay housing.
3. Connect the red probe of the multimeter to
The normal open contact for the rated current of
terminal 86 and the black probe to terminal
this relay contact circuit is 60A. Apply a voltage
85.
of +24 V to relay coil. Then the electromagnetic
force that produced from the energized coil (a) 3.1 As to relay 31B0095, the reading in
attracts the magnet inside the relay to turn on the the multimeter should be about "255".
normal open contact.
(b) 3.2 As to 31B0113 relay, the reading in
the multimeter should be about "155"
4. Turn the multimeter to 200Ω range at Ω
position.
5. Connect one probe of the mulitimeter to
terminal "30" of the relay, and another one to
terminal "87". The reading in the multimeter
should be "1". Move the probe for terminal
"87" to terminal "87A", the reading in the
multimeter should be "0".
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Electrical System
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6. Connect the positive pole of the +24V power

supply to terminal "86" and the negative pole
to terminal "85"'; meanwhile, connect one
probe of the multimeter to terminal "30" of the
relay, and another one to terminal "87" , the
reading in the multimeter should be "0". Move
the probe for terminal "87" to terminal "87A",
the reading in the multimeter should be "1".
After finish the above-mentioned steps, if the
reading in the multimeter is the same with that
described in the above steps, then the relay can
be judged to be good.
As to the serious damaged normal open contact
and normal closed contact, the above-mentioned
steps are not suitable for checking.
Note: When testing relay 31B0113, it is
unnecessary to check terminal "87a".

Alternator There are 3 terminals for the alternator, namely,

Battery Positive, Ground, and Indicator Lamp.
The alternator supplied for this machine is one of
Alternator is the main power-supply device of the
the units of CUMMINS diesel engine assembly.
entire machine. It converts the diesel engine
Its voltage and current is 24V/70A. It is the 24SI
energy into electrical energy for all the electrical
series alternator of DelcoRemy Company, which
appliances.
is inbuilt with electronic regulator.
Outside view and schematic of alternator Alternator and batteries compose the power-
supply system of the machine. Before starting
the diesel engine, batteries supply electricity for
the appliances; but after starting the engine, the
alternator will supply electricity instead of the
batteries and simultaneously, it charges the
batteries. When the energy provided by the
alternator can not meet the need of appliances,
both alternator and batteries will supply power at
the same time.
 179
Electrical System
Power-Supply System

2. Rectify the current by the unilateral

Inside schematic of altemator conduction function of the silicon diode. At
any moment, only the positive diode which
has highest potential and connects with the
one-phrase winding is conducting; also, only
the negative diode which has lowest potential
and connects with one-phrase winding is
conducting. On this way, the six diodes
conduct in turn, and then a stable impulsive
direct voltage is available at its both sides.
3. The terminal voltage of the alternator is
proportional to the engine speed. Therefore,
the terminal voltage will change greatly
because the engine rotates at different
speed. Equip with a regulator because the
terminal voltage can not meet the
requirement for constant voltage of the
electrical appliances.
4. The regulator controls the excitation current
through the inner electrical circuit to stabilize
the alternator output voltage by controlling
Work Principle
the magnetic filed.
The alternator is composed of rotator, stator,
CAUTION: Without batteries, do not
engine belt and pulley, fan, front and rear end
allow the engine supplies power for the
caps electrical brush and so on. Generally, the
electrical appliances only.
excitation winding circles on the rotator. The
stators are bound in "?" shape. The rectifier is
During the operation of diesel engine, do not
six-pipe bridge type, rectifies in full-wave.
allow any metal tools or other metal conductors
1. When the direct current acts on both sides of close to the "B+" (Battery Positive) terminal and
FIELD COIL, magnetic filed will produce from "Ground" terminal of the alternator to avoid short
the current. Under driven by the diesel circuit. A short circuit on alternator could cause a
engine, the magnetic filed is rotating with the serious result!
rotator, that's so-called rotating magnetic
field. Under the effect of rotating magnetic
field, the three-phrase symmetric winding of
the stator will produce three-phrase sine
electrodynamic force which has the same
frequency and amplitude, but different in
angle for 120°
180
Electrical System
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Test Procedure

Do not remove the alternator for checking when

checking the alternator trouble. It should be
checked on the machine, which is different from
the checking methods of other components.
The following steps are not suitable for checking
the alternator if the electricity of batteries is
insufficient and the terminal voltage reaches 28V.
1. Turn the digital multimeter to 200 V range at
its voltage position.
2. Turn on the disconnect switch of the
machine. Do not start the diesel engine.
Connect the red probe of the multimeter to
"B+" terminal of the alternator, the black
probe to "Ground" terminal of the alternator.
Keep a record of the multimeter reading. The
normal reading should be between "24" and
"26".
3. Start the diesel engine. The checking
methods are the same with the instruction in
step 2. Record the reading in the multimeter
again. The reading should higher than that in
step 2. which indicates that the alternator
works normally.
The above-mentioned steps should be carried
out when the machine unloads. (Unload means
all of the electrical appliances are not turned on
when turning on the start switch)
If reading in the multimeter does not change after
step 2 and step 3, turn off the start switch and
check the engine again according to the
following steps:
1. Check the alternator drive belt according to
the instructions in operation manual. If it is
loose, adjust it.
2. Check the connection terminals of the
alternator. If they are loose, tighten them with
a spanner.
If it still doesn't work after check, please consult
with liugong dealers and CUMMINS service
station.
 181
Electrical System
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Start Motor

Outside view and schematic of start motor

The start motor is one of the units of CUMMINS

diesel engine assembly. Its specification is 24V/
5.8KW. It is the 38MT-HD series motor of
DelcoRemy Company; air-tight structure.
The direct current motor inside the start motor
can convert the electrical energy into mechanical
energy. Then the inner gear drives the flywheel
to work. Last, the engine is started.
182
Electrical System
Power-Supply System

Work Principle

Start motor structure

1. Electromagnetic switch 2. Big contact of start motor 3. Yoke

4. Rotator windings of start motor 5. Stator windings of start motor

The start motor is composed of electromagnetic the start motor. The rotator winding is energized
switch, direct current motor, yoke and drive gear. and produces electrodynamic force to rotate
The electromagnetic switch of start motor is under the magnetic filed effect of the stator
controlled by the start contact. When the start winding. Meanwhile, the iron of the
switch is turned to III position (start position), the electromagnetic switch moves rightwards to
start contact starts to work. The normal open push the yoke on the start motor move leftwards,
contact is energized with the power supply of to drive the drive gear of the start motor move left
electromagnetic switch to turn on the to engage with the engine flywheel. Then the
electromagnetic switch. After the start motor drives the flywheel to rotate, the
electromagnetic switch turns on, the inner diesel engine is starting to work.
electromagnetic coil produces suction and
makes the iron move rightwards to push the
tactile disc running. Then the two big contacts of
the starter motor are energized. Current from the
batteries goes through the two big contacts and
reaches the rotator winding and stator winding of
 183
Electrical System
Power-Supply System

Schematic of the start motor

FROM START RELAY

HOLD IN
SOLENOID WINDINGS FULL IN WINDINGS

FROM BATTERY
PLUNGER
CONTACTS

TO MOTOR
WINDINGS
SHIFT
LEVER

STARTING
MOTOR

Starter Solenoid

CAUTION: Check the terminals of the Especially, keep the above-mentioned

start motor frequently for good connection. terminals away from the fuel pipes near the
Turn off the disconnect switch when start motor or other conducting material
checking. during a long period operation and running to
avoid inter-contact or conflict, otherwise the
Make sure that the start motor is shut down whole machine could be in serious start
after start the engine, otherwise the drive trouble.
gear of the start motor will be damaged and
the start motor will be burnt. Besides, the
batteries capacity and service life is seriously
affected!

After the disconnect switch is turned to I

position, do not allow any conducting
material to close battery terminal and switch
terminal.
184
Electrical System
Power-Supply System

Test Procedure Sometimes the start motor can start when

turning the start switch to III position, but the
Judge the start motor for normal condition from engine can not run. The possible reason may be
its running noise. When the start switch is turned from the abnormal engagement of the drive gear
to III position (start) position, if you find that no inside the start motor, or the injection pump of
noise comes out, or the engine can not be the engine has trouble or other troubles in the
started, then check the start motor and the engine. Please contact with Liugong dealer and
starting circuit. CUMMINS service station.
Do not remove the start motor for checking.
Ensure that the start motor is equipped on the
machine and the secondary parking brake
should be engaged and the control lever is at
Neutral position when checking the start motor.
The start switch can not hold at III position for a
long time due to its auto-reposition function,
therefore, an assistor may be needed to help to
check the start motor.
1. Turn the digital multimeter to 50V range at its
voltage position.
2. Turn the start switch to III (start) position until
step 2 is finished. Connect the black probe of
the multimeter to any metal units on the
frame, the red probe to the big contact
terminal of the start motor (see Illustration1-
19 "TO MOTOR WINDINGS" terminal in work
schematic of start motor). Reading in the
multimeter should be about "24". If the start
motor has no response even though the
reading is correct, then the start motor is in
failure. If the reading is incorrect, continue to
check by following the below steps.
3. Turn the start switch to III (start) position
again; hold the start switch until step 3 is
finished. Connect the black probe of the
multimeter to any metal units on the frame,
the red probe to SWITCH TERMINAL on the
start motor. Reading in the multimeter should
be about "24". If the start motor has no
response even though the reading is correct,
then the start motor is in failure. If the reading
is incorrect, check the circuits that controlled
by start motor continuously. Refer to system
trouble test section for the circuit trouble
information.
 185
Electrical System
Power-Supply System

Disconnect Switch Turn off the disconnect switch when welding

on the machine.

Test Procedure

1. Remove the cables that connect to the

disconnect switch.
2. Turn the digital multimeter to 200 Ω range at
Ω position.
3. Turn the disconnect switch to I position
according to the symbol. Connect the two
probes of the multimeter respectively to the
two terminals on the back of the disconnect
switch. Reading in the multimeter should be
The disconnect switch is used to control the "0".
connection between battery negative pole and 4. Turn the disconnect switch to O position
frame of the machine. When the disconnect according to the symbol. Connect the two
switch is at "O" (OFF) position, the power-supply probes of the multimeter respectively to the
of the machine is cut off. The electrical two terminals on the back of the disconnect
appliances can not work even though the start switch. Reading in the multimeter should be
switch is turned on. When the disconnect switch "1".
is at "I" (On) position, the negative pole of the
power-supply is energized. Then the connection If reading in the multimeter is the same with the
between the electrical appliances and power - above-mentioned value after finish all of these
supply can be controlled by the start switch and steps, then we can conclude that the disconnect
the engine can be started now. switch is at good condition.
If the inner contact (plate) of the disconnect
CAUTION: Turn off the disconnect switch is abraded seriously, do not use the above
switch after finish each operation and checking steps
running. Otherwise, electricity leakage could
happen and results in serious damage.

Do not turn off the disconnect switch during

operation of the machine, or it will result in
serious damage to the electronic system!

Turn off the start switch firstly, then turn off

the disconnect switch when stop the
machine.

Turn on the disconnect switch firstly, then

turn on the start switch when start the
machine.

Turn off the disconnect switch when

connecting the battery cables, tighten the
battery cable terminals or remove the battery
cables.
186
Electrical System
Power-Supply System

Battery Battery--Charge

Charge the battery if the hydrometer appears

black.
As to a clear hydrometer, there may be bubbles
exist in the hydrometer. Remove all the
connected cables on the battery. Shake the
battery slightly after the battery cools down, if the
hydrometer is still clear, discard it.
1. Turn the disconnect switch to O position and
turn the start switch to O position then take
off the key.
2. Remove the battery from the machine. When
Two batteries are connected in series to produce removing the battery, disconnect the negative
+24V power supply in this machine. The rated cable firstly and then disconnect the positive
capacity of the battery is 120 Ah, and the starting cable.
current at low temperature is 850 CCA. 3. Clean the battery terminals and surface with
As reversible direct current, the battery connects a clean cloth. Remove the oxide on the
with the engine in series to supply power to all surface.
the electrical appliances. It can supply high 4. Under normal room temperature, connect the
current to motor starting in a short time to start positive pole (+) clamp of the charger to the
the engine. It is also a large capacitor which can position terminal (+) of the battery; the
absorb the overvoltage that could happen at any negative pole (-) clamp of the charger to the
time in the circuit in order to protect all the negative terminal (-) of the battery. Make sure
electrical appliances of the machine. that the battery terminals are clean and the
charge circuit is at good connection.
Battery--Check
5. Charge the battery with constant voltage
Check the hydrometer of the battery under good charger of 16.0 V (Max. does not exceed
condition. Judge the charge status or take 16.2 V) till the hydrometer of the battery turns
relevant measures according to the color of the green. A green hydrometer indicates that the
hydrometer. battery is full of electricity.
6. Charge the battery with constant current if it
Hydrometer
Green Black Clear can not be charged with constant voltage.
color
Charge the battery with 12A constant current
Status or Charge the till the battery hydrometer turns green. A
Good Replace
measures battery green hydrometer indicates that the battery is
full of electricity.
Check the battery hydrometer periodically or
under abnormal condition (especially the
machine has start trouble). If the hydrometer
appears clear, judge its status according to
"Battery-Charge" section, and change the battery
immediately if it turns clear.
 187
Electrical System
Power-Supply System

Table of charging time and battery voltage Do not charge the battery if its terminal cracks.
Discard it.
Battery 12.45~12 12.45~1 12.35~1 12.20~1
Voltage .55V 2.35V 2.20V 2.05V Do not charge the battery if it is swelled by over-
Charge charged or over-discharged. Discard it,
2h 3h 4h 5h
Time
If the hydrometer is still black after charging for a
Battery 12.05~11. 11.95~11 11.80~11 11.65~11 while, please check the charge connection for
Voltage 95V .80V .65V .50V
tightness, the connection point for cleanness and
Charge check whether the charge voltage reaches 16V.
6h 7h 8h 9h
Time
Battery 11.50~11. 11.30~11 Below Notice of operation
Voltage 30V .00V 11.00V
Charge
10h 12h 14 h All operations to the battery must comply with the
Time warning label requirements pasted on the
surface of the battery.
7. When the battery power loss is severe, the
battery may not be charged at the initial It is not permitted to use different type or brand
stages. The battery charge current can batteries in series, and also can not use the
resume step by step along with the charge same type and brand batteries with very different
process. It may take about 14 hours for terminal voltages in series.
charging the battery.
Turn off the disconnect switch before assembly
8. During charging, if the battery temperature and disassembly the battery cables. Assemble
exceeds 45°C, stop charging the battery until the positive cables firstly, then the negative
the battery temperature drops down to room cables when assembly. Disassemble the
temperature, halve the current, and keep negative cables firstly, then the positive cables
charging. when disassembly.
9. Check the hydrometer state one time per The battery must be fixed hard in order to avoid
hour during charge the battery. Stop charging damages caused by the jounce when the
if the hydrometer of the battery turns green. machine is running.
10. It is recommended to apply Vaseline on the The jounce will cause the connection loose
battery terminals to avoid electric corrosion between the battery terminals and cables when
after charging. operation and driving the machine. Therefore,
check the connection terminals and the
Notice of Charge grounding points of the battery cables and the
disconnect switch frequently. If there is
Do not charge two batteries in series. looseness, must close the disconnect switch,
and tighten them with tools.
Keep ventilation when charging the battery at
normal temperature. There are lagging in the battery terminals, cover
the lagging for protection the terminals after
Stop charging immediately to check the reason if
connecting the battery or checking and servicing
the battery exhaust spurts acid during the
the battery.
charging process.
Pay attention not to let the metal conductor
Carry out the electrification in good ventilation
contacts with the positive/negative of the battery
area. Pay attention to safety.
terminals, otherwise it will cause short circuit and
Do not charge the battery if the battery housing damage the battery.
cracks or leaks acid. Discard it.
188
Electrical System
Power-Supply System

Test Procedure Function Operation

The machine is at parking brake state, and the
shift control lever is at Neutral position. The color The power supply system can realize the
of densimeter inside the battery is green. Doing following functions:
these testing steps need associate's help.
1-A Turn on the power supply
1. Turn the disconnect switch to O position.
2. Adjust the digital multimeter to 200V range of The following components are needed for
voltage function. realizing turning on the power supply:

3. Connect the red probe of the multimeter to 1. Disconnect switch

the positive terminal of one battery; connect 2. Battery
the black probe to the negative terminal of
the other battery. Pay attention not to contact 3. Start switch
the cable terminals. The digital multimeter 4. All kinds of fuses
reading is between 24V and 31V.
5. Power supply contactor
4. Hold the two probes of the digital multimeter.
Turn the disconnect switch to I position. Turn 6. Diode group
on the start switch and start the engine.
1-B Start the diesel engine
5. The digital multimeter reading is between
20V and 24V when the start motor is at The following components are needed for
starting instant, and return to the reading realizing the start of the machine:
described in step 3 after the diesel engine
started smoothly. 1. Electrical diesel engine ECM

The battery is good if the above steps can be 2. Disconnect switch

finished, and the engine can be started 3. Battery
successfully. If the above steps couldn't be
finished, please continue with testing according 4. Start switch
to the following steps: 5. Start motor
1. Remove all the connection cables of 6. Power supply contactor
batteries, two batteries connections are
disconnedcted completely at this time. 7. Start contactor

2. Adjust the digital multimeter to 200V range of 8. Neutral/start interlock relay

voltage function. 9. Diode group
3. Connect the red probe of the multimeter to 10. Fuse
the positive terminal of one battery, connect
the black probe to the negative terminal of 1-C Power supply of all the electro-devices
the other battery, the digital multimeter on the machine
reading is about 12-16V.
4. Check the other battery according to step 3, The following components are needed for
the reading is the same with step 3. realizing the power supply of all the electro-
devices on the machine after starting the diesel
Replace the battery if the testing steps couldn't engine:
be finished.
1. Disconnect switch
2. Battery
 189
Electrical System
Power-Supply System

3. Start switch The electrical lift system is the only one electro-
device which can realize lift function but not
4. All kinds of fuses
through the control of the start switch.
5. Power supply contactor
6. Diode group Troubleshooting
7. Alternator
The battery supplies power separately which will In this section, the description about the fault
be changed after starting the diesel engine, the diagnosis and test methods of the power supply
alternator will be the main power supply of the system is focus on the function introduced in
machine. The energy comes from the diesel Funciton Operation section. Other faults are
engine. routine.
The function operation devices will be marked
1-D Start switch P supplies power according to step A or B in the principle
schematic. Sign step+No. on the operation
The following components are needed for devices in the same step, for example, B1; B2;
realizing work at start switch P. B3 etc..
1. Disconnect switch The experienced service personnel can test the
2. Battery system faults according to the judgement steps
in the flow schematics.
3. Start switch
4. Fuse
5. P work relay
6. Diode group
Start switch P supplies power which is used
when the machine is in maintenance or on other
special occasions. Turn the start switch left to P
position on above occasions. The workable
electro-devices including the radio, hazard
flashers (front-rear L/R turning indicators), dome
light, rotating beacon, horn. Their power supply
comes from the battery, therefore, can not use
start switch P to supply power to above electro-
devices for a long time.

1-E Power supply of the electrical lift system

The following components are needed for

realizing power supply of the electrical lift
system:
1. Disconnect switch
2. Battery
3. Breaker
4. Fuse
190
Electrical System
Power-Supply System

Principle schematic
 191
Electrical System
Power-Supply System
192
Electrical System
Power-Supply System

1-A Principle of Machine Power Supply One way voltage forms current loop through
No.120 wire→No. 86 terminal of K1 main
Step A: As shown in the principle schematic, relay→the realy winding→No.212 wire→ground,
when the disconnect switch is at I position, the K1 main relay works, its NO contact closes. The
voltage of batteries supplies power to No.100 voltage reaches K1 through No.176 wire in step
through the alternator. A, and then reaches No.185 wire and the fuse
generatrix through K1 NO contact to supply
The voltage is divided into two ways after
power to all branch ways fuses. The branch way
passing No.100 wire→XH4 receptacle→XA4
fuses controlled by K1 relay are: secondary
receptacle→80A fuse terminal, one way passes
steering 10A, parking brake 5A, the grid heating
No.176 wire and reaches K1, K2, K3, K4 power
relay 10A, the instrument 5A, the centralized
relay, the other way passes No.177 wire→XH4
lubrication system 10A, the shift control system
receptacle→XA4 receptacle→alternator, and
7.5A, the bucket positioner 5A, the boom shock
does excitation to the alternator.
absorption 5A, the stabilized power supply 10A,
At the same time, the voltage reaches No.87 the counterweight system 5A, start switch power
terminal of K9 start switch P work relay. supply 5A, the fan reversal solenoid 5A. K1 relay
will supply power to the corresponding electro-
The voltage reaches the fuse from third branch
devices by the branch way fuses.
way of No.100 wire→XH4→XA4 receptacle , and
enters into the engine system from 5A fuse of the One way voltage forms current loop through
eingine indicator through No.121 wire; then No.120 wire→No.86 terminal of K2 main
enters into No.30 terminal of the start switch from relay→the relay winding→No.212 wire→ground,
10A fuse of the start switch through No.111 K2 main relay works, its NO contact closes. The
wire→XA5 receptacle→XY1 receptacle to voltage reaches K1 through No.176 wire in step
prepare for the start switch. A, and then reaches No.186 wire and the fuse
generatrix through K1 NO contact and supplies
Step B: When the operator turns on the start
power to the branch way fuses. The branch way
switch and turns it to I position, the voltage which
fuses controlled by K2 relay are: A/C 20A, A/C
reaches No.30 terminal is divided into 5 ways
5A, the wiper 20A, the lighter 10A. K2 relay
through No.15 terminal→No.120 wire→XY1
supplies power to the corresponding electro-
receptacle→XA2 receptacle. As shown in above
devices by the branch way fuses.
illustration.
One way voltage forms current loop through
One way voltage enters into the diode through
No.120 wire→No.86 terminal of K3 main
No.120 wire→No.86 terminal of K14 start switch
relay→the relay winding→No.212 wire→ground,
P work relay→the relay winding→No.212
K3 main relay works, its NO contact closes. The
wire→ground, which forms the current loop, the
voltage reaches K1 through No.176 wire in step
K9 start switch P work relay works, its NO
A, and then reaches No.187 wire and the fuse
contact closes, NC contact opens. Voltage
generatrix through K1 NO contact and supplies
reaches No.87 terminal of K9 start switch P work
power to the branch way fuses. The branch way
relay in step A and supplies power to horn, radio,
fuses controlled by K3 relay are: the backup
flasher relay through NO contact of K9→No.30
alarm 10A, the brake light 10A, the electric seat
terminal→No.402 wire→the generatrix of fuse
5A, the positioner light 10A, the front floodlight
and 10A fuse; And supplies power to the rotating
l15A, the rearviewer 10A. K3 relay supplies
beacon, the dome light through 5A fuse; Turn on
power to the corresponding electro-devices by
the corresponding switches for work after above
the branch way fuses.
devices realized power supply.
 193
Electrical System
Power-Supply System

One way voltage forms current loop through

No.120 wire→No.86 terminal of K4 main
relay→the relay winding→No.212 wire→ground,
K4 main relay works, its NO contact closes. The
voltage reaches K1 through No.176 wire in step
A, and then reaches No.188 wire and the fuse
generatrix through K1 NO contact and supplies
power to the branch way fuses. The branch way
fuses controlled by K4 relay are: the work light
20A, the rear floodlight 15A, and the defroster
20A. K4 relay supplies power to the
corresponding electro-devices by the branch way
fuses.
Step C: The engine can be started when the
operator turns the start switch to III gear. The
voltage reached No.30 terminal of the start
switch passes No.17 terminal→No.180
wire→XY1 receptacle→XA5 receptacle→No.87
terminal of K11 gear start interlock relay. As
shown in above illustration.
The shift control unit supplies power to No.584
wire when the shift control lever is at NEUTRAL
state, the voltage forms current loop through
No.584→XA5 receptacle→No.86 terminal of K11
gear start interlock relay→relay
winding→No.212 wire→ground, K11 gear start
interlock relay works, its NO contact closes.
The voltage forms current loop from No.87
terminal of K11 gear start interlock relay→No.30
terminal of K11 gear start interlock
relay→No.182 wire→No.86 terminal of K start
relay→relay winding→No.212 wire→ground, K5
start relay works, its NO contact closes. The
voltage reached K5 through No.176 terminal in
step A, reaches No.183 terminal through K5 NO
contact→XA3 receptacle→XH3
receptacle→No.50 terminal of start motor
induction switch control terminal→ground, forms
current loop, its NO contact closes, the start
motor works, starting the engine.
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1-A-F1 Main Electro-devices Power Supply Fault Test Procedure

1-A-F1 the main

electro-devices
have no power
supply

1. Check the disconnect switch

Voltage of battery for damage according to
No
positive terminal to
component instruction。2. Judge
ground is +24V？ TEST STEP1
battery for power loss。

Yes

Turn on start Is still melting

10A start Eliminate the line
switch, main power No Yes after replacing Yes
switch fuse for
supply relay has 10A start switch short circuit fault。
melting or not
Fault has sound or not TEST STEP2 TEST STEP6 fuse? TEST STEP11
eliminated No No
Fault has
No Yes
eliminated

Eliminate line Yes Is still melting after No.120 wire of main

Yes 80A fuse melts Yes Check the main power
replacing 80A fuse or power supply
short circuit fault or not supply relay for damage
not voltage is +24V？
TEST STEP13
TEST STEP3 TEST STEP7
No No

No 176 wire of Check No.120 Check No.111

The relay The line fault or connector
Check the main power supply No main power wire of start Yes wire of start Yes
generatrix Yes loose from start switch to
relay for damage according to supply relay switch voltage switch voltage
voltage is main power supply relay
component instruction voltage is for +24V？ TEST STEP8 for +24V？
+24V？ TEST STEP12
TEST STEP14 +24V？ TEST STEP4 No
Yes No No Start switch
is damage
Fault has eliminated
No.100 wire of
The line fault or connector
fuse generatrix Yes
loose from fuse to main
voltage is
+24V？ start switch relay
Replace the centralized control TEST STEP9
box housing when 80A fuse to No.176 wire, No.100
Yes No
main power supply relay lines have wire of 80A fuse
voltage are +24V？
fault
TEST STEP5 No.100 wire of The line fault or connector
No start motor Yes loose from start motor to fuse
voltage is
Line fault from start or XH4, XA5 receptacles fault
motor No.100 wire to +24V？
TEST STEP10
80A fuse line or No
XH4、XA5
receptacles fault
Battery positive
cable connector
loosens or line fault

Fault phenomenon definition: 2. Turn the disconnect switch to I position (turn

on the disconnect switch)
Turn the disconnect switch and the start switch to
3. Open the battery box, and undraw the
I position, each instrument doesn't respond, the
lagging of the battery positive terminal.
electro-devices on the machine (except radio;
Connect the red probe of the digital
horn; flasher; beacon/doom lamp) don't respond
multimeter to the battery positive terminal,
( e.g, the light doesn't work when turn on the light
the black probe to the nearby machine
switch; the wiper doesn't move when operate the
housing (grounding).
wiper, etc).
Test result:
Step1. Test the voltage of battery positive
terminal to the nearby ground.
The reading of the digital multimeter is between
24V and 31V.
1. Adjust the digital multimeter to 200v range of
voltage function.
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Conclusion: Conclusion:

If the result does OK, please turn to step 2. If the fuse melted, please turn to step13.
If the result doesn't OK, please test as follows: If the fuse doesn't melt, please turn to step 4.
1. First, make sure every cable connection of
Step4. Test No.176 wire connection voltage of
the battery and the grounding of the
main relay
disconnect switch are good.
2. Then, measure the voltage between the 1. Hold the disconnect switch and start switch at
positive terminal and the negative terminal of I position.
the battery. The battery is deficient in power if
2. Adjust the digital multimeter to 200V range of
the digital multimeter reading is the same to
voltage function.
step1; please charge the battery according to
the battery charging procedure. 3. Connect the red probe of the digital
multimeter to No.30 terminal of No.176 wire
3. Otherwise, check the disconnect switch and
on main relay, the black probe to the the
judge whether it is damaged or not according
nearby machine housing (grounding).
to the test methods introduced in Main
Component section if the digital multimeter
Test result:
reading is different with step1.
The digital multimeter reading is between 24V
Step2. Listen to the engaged sound of the
and 31V.
main power supply relay
Conclusion:
1. Turn the disconnect switch and the start
switch to I position.
If the result does OK, please turn to step14.
2. Pay attention to the engaged sound of the
If the result doesn't OK, please turn to step 5.
main power supply relay under the left side of
driver seat in cab.
Step5. Test the connection voltage between
No.176 wire and No.100 wire of the main fuse.
Conclusion:
1. Hold the disconnect switch and the start
If the result does OK, please turn to step 3.
switch at I position
If the result doesn't OK, please turn to step 6.
2. Adjust the digital multimeter to 200V range of
voltage function.
Step3. Test 80A fuse for melting.
3. Connect the red probe of the digital
1. Hold the disconnect switch and the start multimeter to the plug terminal of No.176 wire
switch at I position on main relay, the black probe to the nearby
machine housing (grounding).
2. Open the electronic control box under the left
side of driver seat in cab. 4. Connect the red probe of the digital
multimeter to the plug terminal of No.100 wire
3. Find two ways 80A bolt type fuse on the
on main relay, the black probe to the nearby
electronic control box, and observe 80A bolt
machine housing (grounding).
type fuse for melting. If it couldn't be judged
from this, please use Ω function of the digital
multimeter to test melting according to Main
Component section instruction.
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Test result: 3. Connect the red probe of the digital

multimeter to No.86 terminal of No.120 wire
The digital multimeter reading is between 24V on main relay, the black probe to the nearby
and 31V. machine housing (grounding).

Conclusion: Test result:

If the result does OK,, there is connection fault The digital multimeter reading is between 24V
from No.176 wire connection of main fuse in the and 31V.
electronic centralized control box to the main
power supply relay connection, please replace Conclusion:
the housing of the electronic centralized control
box. If the result does OK, please test the main relay
according to Main Component section
If the result doesn't OK, there are two
instruction.
probabilities. First, 80A fuse is melted if there is
voltage in No.100 wire but not in No.176 wire, If the result doesn't OK, please turn to step 8.
please replace the 80A fuse. Second, please
1. Step8. Test No.120 wire connection voltage
turn to step 9 if there isn't voltage in No.100 wire.
of start switch
Step6. Test 10A fuse of start switch for 2. Hold the disconnect switch and the start
melting switch at I position.
3. Adjust the digital multimeter to 200V range of
1. Hold the disconnect switch and the start
voltage function.
switch at I position.
4. Connect the red probe of the digital
2. Open the electronic control box, find the
multimeter to No.120 wire connection
electronic centralized control box and 10A
terminal of start switch, the black probe to the
start switch fuse according to nameplate and
nearby machine housing (grounding).
pull it out.
3. Observe 10A fuse for melting, if it couldn't be Test result:
judged, please use Ω function of the digital
multimeter to test melting according to Main The digital multimeter reading is between 24V
Component section instruction. and 31V.

Conclusion: Conclusion:

If the fuse melted, please turn to step11. If the result does OK, please turn to step12.
If the fuse doesn't melt, please turn to step7. If the result doesn't OK, please turn to step9.

Step7. Test No.120 wire connection voltage of Step9. Test No.100 wire connection voltage of
main relay winding terminal start switch fuse

1. Hold the disconnect switch and the start 1. Hold the disconnect switch and the start
switch at I position. switch at I position.
2. Adjust the digital multimeter to 200V range of 2. Adjust the digital multimeter to 200V range of
voltage function. voltage function.
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3. Connect the red probe of the digital Step11. Replace 10A start switch fuse
multimeter to No.100 wire connection
terminal of start switch fuse, the black probe 1. Hold the disconnect switch and the start
to the nearby machine housing (grounding). switch at I and O position.
2. Replace 10A start switch fuse.
Test result:
3. Turn the start switch to I position.
The digital multimeter reading is between 24V
and 31V. Conclusion:

Conclusion: If the fuse melted, the line has short circuit fault,
please test it according to 1-A-F3 test method.
If the result does OK, the line from the fuse to
If the fuse doesn't melt, there isn't fault.
start switch has fault or the connector has
loosened.
Step12. Test No.111 wire connection voltage
If the result doesn't OK, please turn to step10. of start switch

Step10. Test No.100 wire connection voltage 1. Hold the disconnect switch and the start
of start motor switch at I position.
2. Adjust the digital multimeter to 200V range of
1. Hold the disconnect switch and the start
voltage function.
switch at I position.
3. Connect the red probe of the digital
2. Adjust the digital multimeter to 200V range of
multimeter to No.111 wire connection
voltage function.
terminal of start switch, the black probe to the
3. Connect the red probe of the digital nearby machine housing (grounding).
multimeter to No.100 wire plug terminal of
main relay, the black probe to the nearby Test result:
machine housing (grounding).
The digital multimeter reading is between 24V
Test result: and 31V.

The digital multimeter reading is between 24V Conclusion:

and 31V.
If the result does OK, the line from No.111 wire
Conclusion: connection of start switch to No.111 wire
connection of start switch fuse has fault.
If the result does OK, there are two probabilities.
If the result doesn't OK, check the start switch
First, the line from No.100 wire connection of
according to Main Component section
start motor to No.100 wire connection of fuse has
instruction, and replace it if it is damaged.
fault or the connector has loosened, please
check them carefully. Second, XH4 receptacle
Step13. Replace 80A main fuse of the
has fault, please pull out and insert over again.
electronic centralized box
Pull the wire connecting with the XH4 receptacle
slightly by hand in order to judge whether the
1. Hold the disconnect switch and the start
inside connector has loosened, and replace the
switch at I and O position.
connector if it has loosened.
2. Replace 80A fuse.
If the result doesn't OK, the positive cable
connection of battery has loosened. 3. Turn the start switch to I position.
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Conclusion:

If the fuse melted, the line has short circuit fault,

test it according to 1-A-F3 test method.
If the fuse doesn't melt, there isn't fault.

Step14. Test the connection terminal voltage

of fuse generatrix

1. Hold the disconnect switch and the start

switch at I position.
2. Adjust the digital multimeter to 200V range of
voltage function.
3. Connect the red probe of the digital
multimeter to the connection terminal of fuse
generatrix, the black probe to the nearby
machine housing (grounding).

Test result:

The digital multimeter reading is between 24V

and 31V.

Conclusion:

If the result does OK, the line may be open circuit

inside the centralized control box, please replace
the housing of the centralized control box.
If the result doesn't OK, test K1, K2, K3 and K4
main relays according to Main Component
section instruction. Replace them if they are
damaged.
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1-A-F2 Electro-devices Power Supply Fault Test Procedure

Fault phenomenon definition: Step1. Test the condition of other electro-

devices.
Turn the disconnect switch and the start switch to
I position. Turn on the switches of radio, horn, 1. Turn the disconnect switch and the start
hazard flasher, rotating beacon and dome light, switch to I position.
their corresponding electro-devices don't
2. Turn on the other switches (e.g. the front
respond, except these electro-devices, the other
floodlight switch, A/C switch) except the
electro-devices on the machine can work
switches of radio, horn, hazard flasher,
normally.
rotating beacon and dome light, and judge
The power supply used in 1-A-F1 is different whether the electro-devices can work.
from this step. Inside the fuse, they use the
different generatrixs to supply power. Therefore, Conclusion:
if there is electro-devices power supply fault after
turned on the start switch, need to distinguish If the electro-devices can work, please turn to
what kind of power supply the electro-devices step2.
used, and if it is the fuse generatrix power
If the electro-devices couldn't work, please test
supply, please refer to 1-A-F1 fault test steps.
them according to 1-A-F1 test steps.
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Step2. Test the condition of K9 start switch P Step4. Test No.176 wire connection voltage of
work relay. K9 start switch P work relay contact terminal.

1. Hold the disconnect switch at I position. 1. Adjust the digital multimeter to 200V range of
voltage function.
2. Open the electronic control box, find K9 start
switch P work relay, contacting the plastic 2. Open the electronic control box, and pull out
housing of the relay by hand slightly. K9 start switch P work relay.
3. Turn the start switch to I position. Turn on 3. Turn the disconnect switch and the start
and turn off the start switch, please try to feel switch to I position.
whether there is obvious vibration during the
4. Find No.176 wire connection of K9 start
relay contact action at that moment.
switch P work relay contact terminal. Insert
the red probe of the digital multimeter into
Conclusion:
No.100 wire plug on the back side of the
relay base, pay attention to contact with the
If the result does OK, please turn to step3.
inner copper. Connect the black probe to the
If the result doesn't OK, please turn to step5. nearby machine housing (grounding).

Step3. Test No.402 wire connection voltage of Test result:

K9 start switch P work relay contact terminal.
The digital multimeter reading is between 24V
1. Turn the disconnect switch and the start and 31V.
switch to I position.
Conclusion:
2. Adjust the digital multimeter to 200V range of
voltage function.
If the result does OK, please check or eliminate
3. Open the electronic control box. the line fault from No.176 wire connection of K9
start switch P work relay to that of other wiring
4. Find the fuse generatrixs of radio, horn,
harness in the cab.
flasher, rotating beacon and dome light,
insert the red probe into the generatrixs, and If the result doesn't OK, please check K9 start
pay attention to contact with the inner copper. switch P work relay according to Main
Connect the black probe to the nearby Component section instruction. Replace it if it is
machine housing (grounding). damaged.

Test result: Step5. Test the voltage between No.466 wire

and No.212 wire of K9 start switch P work
The digital multimeter reading is between 24V relay winding terminal.
and 31V.
1. Adjust the digital multimeter to 200V range of
Conclusion: voltage function.
2. Open the electronic control box, find K9 start
If the result does OK, check whether each
switch P work relay and pull it out from the
branch way fuse is melted.
relay base.
If the result doesn't OK, please turn to step 4.
3. Turn the disconnect switch and the start
switch to I position.
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4. Insert the red probe of the digital multimeter

into No.86 terminal (No.466 wire connection)
of the relay base, and insert the black probe
into No.85 terminal (No.212 wire connection)
of the relay base.

Test result:

The digital multimeter reading is between 24V

and 31V.

Conclusion:

If the result does OK, please check K9 start

switch P work relay according to Main
Component section instruction. Replace it if it is
damaged.
If the result doesn't OK, please turn to step 6.

Step6. Test No.212 wire grounding condition

of K9 start switch P work relay.

1. Turn the disconnect switch to I position. Turn

the start switch to O position.
2. Adjust the digital multimeter to 200Ω range.
3. Open the electronic control box, find K9 start
switch P work relay, and pull it out from the
relay base. Insert one probe of the digital
multimeter into No.85 terminal (No.212 wire
connection) of the relay base, the other one
into the nearby machine housing
(grounding).

Test result:

The digital multimeter reading is"0"Ω.

Conclusion:

If the result does OK, the test is finished.

If the result doesn't OK, please check the
grounding line and eliminate the grounding fault.
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1-A-F3 Main Line Short Circuit Test Procedure

Fault phenomenon definition: Test result:

Turn the disconnect switch and the start switch to The digital multimeter reading is 0 or not.
I position. The main fuse or the start switch fuse
melted, the new fuse keeps melting after Conclusion:
replaced.
If the result is NO, please turn to step5.
Step1. Test whether 80A main fuse
If the result is YES, please turn to step2.
connection terminal of electronic control box
gets short circuit to ground?
Step2. Test whether the main relay contact
terminal of the control box gets short circuit
1. Turn the disconnect switch to O position (turn
to ground?
off the disconnect switch).
2. Adjust the digital multimeter to 200Ω range. 1. Turn the disconnect switch to O position (turn
off the disconnect switch).
3. Open the control box, find 80A bolt type main
fuse, and pull it out from the centralized 2. Adjust the digital multimeter to 200Ω range.
control box. Connect one probe of the digital
multimeter to 80A main fuse connection
terminal of the control box, another probe to
the nearby machine housing (grounding).
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3. Open the control box, find K1, K2, K3, K4 2. Remove No.177 wire from B+ terminal of the
main relays, and pull them out from the alternator.
centralized control box. Connect one probe
3. Adjust the digital multimeter to 200Ω range.
of the digital multimeter to No.30 contact
terminal of the original main relay on the 4. Connect one probe of the digital multimeter
control box, another probe to the nearby to No.177 wire terminal, another probe to the
machine housing (grounding). nearby machine housing (grounding).

Test result: Test result:

The digital multimeter reading is 0 or not. The digital multimeter reading is 0 or not.
Conclusion:
Conclusion:
If the result is NO, please turn to step5.
If the result is NO, please turn to step5.
If the result is YES, the lines inside the control
box get short circuit, please replace the control If the result is YES, No.177 wire gets short circuit
box housing. inside the wiring harness, please check whether
the wiring harness has worn and eliminate the
Step3. Test whether B+ terminal of the short circuit fault.
alternator gets short circuit to ground?
Step5. Test whether No.111 wire of start
1. Turn the disconnect switch to O position (turn switch fuse gets short circuit to ground?
off the disconnect switch).
1. Turn the disconnect switch to O position (turn
2. Remove No.177 wire from B+ terminal of the
off the disconnect switch).
alternator.
2. Pull out XA5 receptacle.
3. Adjust the digital multimeter to 200Ω range.
3. Adjust the digital multimeter to 200Ω range.
4. Connect one probe of the digital multimeter
to B+ terminal of the alternator, another 4. Connect one probe of the digital multimeter
probe to the nearby machine housing to No.111 wire terminal of start switch fuse,
(grounding). another probe to the nearby machine
housing (grounding).
Test result:
Test result:
The digital multimeter reading is 0 or not.
The digital multimeter reading is 0 or not.
Conclusion:
Conclusion:
If the result is NO, please turn to step5.
If the result is NO, please turn to setp8.
If the result is YES, the lines inside the alternator
get short circuit, please replace the alternator. If the result is YES, No.111 wire gets short circuit
inside the control box, please replace the control
Step4. Test whether No.177 wire gets short box housing.
circuit to ground?

1. Turn the disconnect switch to O position (turn

off the disconnect switch).
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Step6. Test whether No.111 wire of No.14 pin Step8. Test whether ther winding of K1, K2,
on XA5 receptacle plug terminal gets short K3 and K4 main power supply relays gets
circuit to ground? short circuit?

1. Turn the disconnect switch to O position (turn 1. Turn the disconnect switch to O position (turn
off the disconnect switch). off the disconnect switch).
2. Pull out XA5 receptacle. 2. Pull out K1, K2, K3, and K4 main power
supply relays from relay base.
3. Adjust the digital multimeter to 200Ω range.
3. Adjust the digital multimeter to 200Ω range.
4. Connect one probe of the digital multimeter
to No.111 wire terminal of No.14 pin on XA5 4. Connect both probes of the digital multimeter
receptacle plug, another probe to the nearby separately to No.85, and No.86 terminals of
machine housing (grounding). K1, K2, K3, K4 main power supply relays.

Test result: Test result:

The digital multimeter reading is 0 or not. The digital multimeter reading is 0 or not.

Conclusion: Conclusion:

If the result is NO, please turn to step8. If the result is NO, please turn to step9.
If the result is YES, No.111 wire gets short circuit If the result is YES, the correspondting main
inside the wiring harness, please check whether power supply relay is damaged, please replace
it has worn and eliminate the short circuit fault. it.

Step7. Test whether No.120 wire of No.14 pin Step9. Test whether the contact terminals of
on XA2 receptacle plug terminal gets short K1, K2, K3 and K4 main power supply relays
circuit to ground? get short circuit to ground?

1. Turn the disconnect switch to O position (turn 1. Turn the disconnect switch to O position (turn
off the disconnect switch). off the disconnect switch).
2. Pull out XA2 receptacle. 2. Pull out K1, K2, K3, and K4 main power
supply relays from relay base.
3. Adjust the digital multimeter to 200Ω range.
3. Adjust the digital multimeter to 200Ω range.
4. Connect one probe of the digital multimeter
to No.120 wire terminal of No.14 pin on XA2 4. Connect both probes of the digital multimeter
receptacle plug, another probe to the nearby separately to No.85, and No.86 terminals of
machine housing (grounding). K1, K2, K3 and K4 main power supply relays.

Test result: Test result:

The digital multimeter reading is 0 or not. The digital multimeter reading is 0 or not.

Conclusion: Conclusion:

If the result is NO, please turn to step8. If the result is NO, the test is finished.
If the result is YES, No.120 wire gets short circuit If the result is YES, the line gets short circuit
inside the wiring harness, please check whether inside the control box, please replace the control
it has worn and eliminate the short circuit fault. box housing.
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1-A-F4 Engine Fault Test Procedure

Fault phenomenon definition: 3. Connect the red probe of the digital

multimeter to the positive terminal of the
Turn the disconnect switch to I position, turn the battery, the black probe to the negative
start switch clockwise to III position, the engine terminal of the battery, and don't connect to
can't start. the connection cable terminal.

Step1. Confirm whether the fault comes from Test result:

the main electro-devices power supply
connection faults. The digital multimeter reading is between 24V
and 27V or not.
1. If it is the main electro-devices power supply
connection fault, please check the fault Conclusion:
according to 1-A-F1 about the main electro-
devices power supply faults. If the result is YES, please turn to step3.
2. If the main electro-devices power supply can If the result is NO, the battery electricity is not
be connected, please turn to step2. enough, please replace the battery.

Step2. Test whether the battery electricity is Step3. Test No.183 wire voltage of start motor
enough. terminal.

1. Turn the disconnect switch to O position. 1. Turn the disconnect switch to I position.
2. Adjust the digital multimeter to 200V range. 2. Turn the start switch clockwise to III position.
3. Adjust the digital multimeter to 200V range.
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4. Connect the red probe of the digital Step5. Test No.86 terminal voltage of Neutral/
multimeter to No.183 wire of start motor start interlock relay in the centralized control
terminal, the black probe to the nearby box.
machine housing (grounding).
1. Pull out the Neutral/start interlock relay from
Test result: the centralized contro box.
2. Turn the disconnect switch to I position.
The digital multimeter reading is between 24V
and 27V or not. 3. Turn the start switch clockwise to I position.
4. Adjust the digital multimeter to 200V range.
Conclusion:
5. Connect the red probe of the digital
If the result is NO, please turn to step4. multimeter to No.86 terminal of original
Neutral/start interlock relay in the centralized
If the result is YES, perhaps the start motor has
control box, the black probe to the nearby
inner fault, please check the start motor
machine housing (grounding).
according to Main component section
instruction.
Test result:
Step4. Test No.86 terminal voltage of
The digital multimeter reading is between 24V
centralized control box start relay
and 27V or not.
1. Pull out the start motor from the centralized
Conclusion:
control box.
2. Turn the disconnect switch to I position. If the result is NO, please check the fault
according to the shift control system service
3. Turn the start switch clockwise to III position.
manual.
4. Adjust the digital multimeter to 200V range.
If the result is YES, perhaps the Neutral/start
5. Connect the red probe of the digital interlock relay has inner fault, please check the
multimeter to No.86 terminal of original start fault according to Main Component section
relay in the centralized control box, the black instruction, and replace the Neutral/start interlock
probe to the nearby machine housing relay if it is damaged.
(grounding).
Step6. Test No.30 terminal voltage of Neutral/
Test result: start interlock relay in the centralized control
box.
The digital multimeter reading is between 24V
and 27V or not. 1. Pull out the Neutral/start relay from the
centralized control box.
Conclusion:
2. Turn the disconnect switch to I position.
If the result is NO, please turn to step5. 3. Turn the start switch clockwise to III position.
If the result is YES, perhaps the start relay has 4. Adjust the digital multimeter to 200V range.
inner fault, please check the start relay according
5. Connect the red probe of the digital
to Main component section instruction, and
multimeter to No.30 terminal of original
replace the start relay if it is damaged.
Neutral/start interlock relay in the centralized
control box, the black probe to the nearby
machine housing (grounding).
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Test result:

The digital multimeter reading is between 24V

and 27V or not.

Conclusion:

If the result is NO, please turn to step7.

If the result is YES, the test is finished.

Step6. Test No.120 wire terminal voltage of

start switch.

1. Turn the disconnect switch to I position.

2. Turn the start switch clockwise to III position.
3. Adjust the digital multimeter to 200V range.
4. Connect the red probe of the digital
multimeter to No.120 wire terminal of start
switch, the black probe to the nearby
machine housing (grounding).

Test result:

The digital multimeter reading is between 24V

and 27V or not.

Conclusion:

If the result is NO, the start switch has inner fault,

please check the start switch according to Main
Component section instruction, and replace the
start switch if it is damaged.
If the result is YES, the test is finished.

NOTICE: If the fault couldn't be eliminated

according to above steps, please test by refer
to Chapter 3-Electrical Engine System in this
manual. The engine starting fault maybe the
mechanical failure, so please refer to the
engine system service manual if the fault still
exists after eliminating the electronic system
faults.
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Electrical System
Instrument System

Instrument System In addition, the instrument also has extended

function interface of alert and indicator. For
example, axle oil pressure alert, water in fuel
Introduction alert indicator. But these extended function
interfaces are not available for all III series wheel
loader. Outer connection of above extended
The instrument fixed on the machine is electronic functions can be obtained from electronic
combination type. principle drawing of III series wheel loaders.
The sensor and pressure switch connected to
the instrument system will be introduced in this
section.

Main Components

Instrument Panel

The instrument combination contains 3 displays.

There are 19 alarms and indicators on the left
panel. They are the left turn indicator, right turn
indicator, front floodlight high beam indicator,
clutch cut-off indicator, lubrication running
indicator, secondary steering running indicator,
steering system fault indicator, start state
indicator, parking brake low pressure alert
indicator, service brake low pressure alert
indicator, engine oil pressure alert indicator,
transmission oil pressure alert indicator,
hydraulic oil temperature alert indicator, hydraulic
oil filter alert indicator, engine coolant level alert
indicator, charge indicator, main fault alert
indicator etc.
The lubrication fault alert indicator, hydraulic oil
temperature alert indicator, hydraulic oil filter
alert indicator, engine coolant level alert indicator
are not available for CLG856III.
There are electronic diesel engine state
indicators, engine tachometer, and LCD
speedometer on the central instrument.
There are the engine coolant temperature
gauge, the torque converter oil temperature
gauge and the fuel level gauge on right side of
the instrument.
 209
Electrical System
Instrument System

The description of outer signal source will be The instrument system can be divided into micro-
introduced in detail in fault test and service controller mode, input mode and output mode
section. etc. according to the function. The control
principle drawing as follows:

TIMED
POWER MICRO-CONTROLLER MOTOR
(SOFTWARE, DRIVER
SIGNAL
INSPECTION, ALERT AND
FILTER WAVE, INDICATOR LIGHTS
CONNECTOR

FAILURE ILLUMINATION
DIAGNOSE, ALERT LUMINOUS
DISCRETE
AND INDICATOR PARTS
SIGNAL INPUT
DRIVER
LIGHTS CONTROL,
TIMED MOTOR
CONTROL,
ARITHMETIC,
ETC.)
CONTINUOUS DISPLAY
SIGNAL INPUT DRIVER

The icons used on the instrument system comply Buzzer alert

with the correlative ISO standard.
The instrument system has the buzzer alert
CAUTION: Pull out NO.36 core output, connected to the small type buzzer. The
receptacle of the instrument system before buzzer will beep when any of the steering system
weld or maintain the machine. Otherwise, the fault indicator, engine oil pressure alert indicator,
strong impacted current may burn the parking brake low pressure alert indicator,
combination instrument. And connect No. 36 service brake low pressure alert indicator is
core receptacle after welding,or the machine lightened.
won't work normally.
NOTICE: When the main fault alert indicator
No.36 core receptacle of instrument system flashes and the buzzer beeps, the machine
has the severe fault and needs to be stopped
to check, the operator can operate the
machine after eliminating the fault. It is
convenient & quick to find the fault system
according to the alert items in the instrument
system.

When the main fault alert indicator flashes

but the buzzer doesn't beep, the machine has
fault and needs to be stopped to check, the
operator can drive the machine to the service
station, finds the fault system according to
the alert items in the instrument system and
operates the machine after eliminate the fault.
210
Electrical System
Instrument System

Temperature Sensor Work Principle

This machine has two temperature sensors, one

is coolant temperature sensor, and another is
torque converter oil temperature sensor.
Their exteriors look very similar, but the
electronic parameters and installation sizes are
different, the part numbers are carved on the The temperature sensor used in the machine is
copper housing for distinguish. Pay attention the contact type and resistance type
when use them. thermometer of negative temperature coefficient.

Screw Measurement Keep the copper housing of the temperature

Part No. Name sensor contacting with the measured medium
thread range (°C)
when use it, the resistance value of the
Coolant temperature sensitive component changes along
30B0065 temperature Z1/2 55~105
with the measured medium temperature variety
sensor
due to the good diathermancy of the copper, the
Torque
measured medium temperature is higher, the
converter oil
30B0100
temperature
M14×1.5 60~130 resistance value of the temperature sensitive
sensor component is lower. This character of resistance
variety will be translated into that of voltage
variety along with temperature variety. The
variational voltage signal enters into the micro-
contoller of the instrument system, after
calculation and disposal, exports signals and
drives the timed motor instrument to indicate
temperature.

NOTICE: Turn off the start switch when

replace the temperature sensor, replace it
after the machine cooling completely. There
is liquid overflow when loosen the
temperature sensor, replenish the liquid after
replacing the temperature sensor.
 211
Electrical System
Instrument System

Pressure Switch See above table, NC shows there is one group

contacts inside the pressure switch; the contact
condition is NC when the system isn't
pressurized. NO shows there is one group
contacts inside the pressure switch; the contact
condition is NO when the system isn't
pressurized. NC/NO shows there are two groups
contacts inside the pressure switch, one is NO,
the other one is NC.
Some pressure switches are used in this
machine for each system pressure alarm, their Work Principle
exteriors look very similar, but action values,
withstand pressure values and installation sizes According to the different inner configurations,
are all different. The part numbers are carved on the pressure switches are divided into
the housing of pressure switch for distinguish. dissepiment type pressure switch and piston
Pay attention when use them. type pressure switch. But they have the same
The pressure switch parameter table below lists work principle no matter what types they are.
in detail all pressure switches types and
parameters, refer to this table straightly if it is
needed, or the unit is the imperial standard.
Hereinafter, just illuminate the pressure switches
used in this system.

Pressure Switch Parameter

Action
Part No. Name Contact
value(MPa)
Parking brake
30B0139 low pressure NC 11.5
alert switch 1. Pressure switch connection 2. Dissepiment
Steering system 3. Compression spring 4. Piston
30B0292 low pressure NC 0.6 5. Contact disc 6. Contact
alert switch
7. Adjusting pole
Service brake
30B0182 low pressure NC/NO 10 See above illustration, left side is the
alert switch dissepiment type pressure switch which has one
Transmission oil group NO contacts; right side is the piston type
30B0132 pressure alert NC 1.45 switch which has one group NC contacts. Now,
switch use the left illustration as an example to
Secondary illuminate the work principle of the pressure
30B0291 steering running NO 0.6 switch.
switch
Engine oil
30B0131 pressure alert NC 0.059
switch
212
Electrical System
Instrument System

The measured medium acts on the dissepiment Transmission oil pressure alert switch
through the pressure switch connection, the
piston will drive the contact disc to move if the In normal condition, the transmission system
measured medium pressure is bigger than the doesn't build pressure or system pressure
pre-pressure of the compression spring, thereby doesn't reach the action value when operator
closes the circuit with contact. The switch will turns on the start switch, the transmission oil
open again if the measured medium pressure pressure alert switch keeps NC state, the
degressive degree is bigger than the stagnant transmission oil pressure alert indicator of the
loop. instrument system is lightened. The system
pressure will rise until the pressure oil of action
For the pressure switch of NC contacts, the
value pushing inner NC contact of pressure
function of the contacts is opposite.
switch after turn on the start switch. The
Regulate the pressure switch action pressure by transmission oil pressure alert indicator of the
adjusting pole. The action pressure of the instrument system will go out.
pressure switch has been adjusted before leave
When the transmission system has fault, and
the factory and use red paint for sign. Do not
makes the system pressure too low, the pressure
adjust the pole optionally, otherwise which will
switch contact will close newly, the transmission
change the action value and cause accidents.
oil pressure alert indicator of the instrument
system will lighten for alarm.
Engine oil pressure alert switch
CAUTION: When the transmission oil
In normal condition, the engine system doesn't
pressure alert indicator lightens, and the
build pressure or system pressure doesn't reach
main fault alert indicator lightens, please
the action value when operator turns on the start
drive the machine to the service factory for
switch, the contact of engine oil pressure alert
check, and operate the machine after
switch keeps NC state, the engine oil pressure
eliminate the faults.
alert indicator of the instrument system is
lightened. The system pressure will rise until the
Service brake low pressure alert switch
pressure oil of action value pushing inner NC
contact of pressure switch after turn on the start
The service brake low pressure alert switch is a
switch. The engine oil pressure alert indicator of
switch with double contacts, but just one group
the instrument system will go out.
NC contact is used in this machine. It can be
When the engine system has fault, and makes used as a single contact NC pressure switch.
the system pressure too low, the pressure switch
The check point of service brake low pressure
contact will close newly, the engine oil pressure
alert switch is connected to the battery, the
alert indicator of the instrument system will
pressure oil will push NC contact of service
lighten for alarm.
brake low pressure alert switch if the battery
pressure is normal, the service brake low
CAUTION: When the engine oil pressure
pressure alert indicator of the instrument system
alert indicator lightens, the main fault alert
will go out, which shows that the system
indicator lightens and the buzzer beeps, must
pressure is normal.
stop the machine immediately and check the
faults, and operate the machine after
CAUTION: When the service brake low
eliminate the faults.
pressure alert indicator lightens, the main
fault alert indicator lightens and the buzzer
beeps, must stop the machine immediately
and check the faults, and operate the
machine after eliminate the faults.
 213
Electrical System
Instrument System

Parking brake low pressure alert switch When the operator starts the engine, the steering
pump runs, the steering oil line is connected.
The parking brake low pressure alert switch is a When the pressure reaches the stated value, the
NC contact pressure switch. pressure oil will push the NC contact of steering
system low pressure alert switch, and the
When operator turns on the start switch, the
steering system low pressure alert indicator of
parking brake oil line doesn't build pressure, the
the instrument system will go out, which shows
parking brake low pressure alert switch is at
that the system pressure is normal.
close state, and the parking brake low pressure
alert indicator of the instrument system will When the engine goes out abnormally, the
lighten. steering system pressure descends quickly or
the steering system has fault and makes the
The operator presses the parking brake switch
system pressure too low; the pressure switch
and starts the diesel engine; the brake oil enters
contact will close newly, and the steering system
into the parking brake oil line. When the pressure
low pressure alert switch of the instrument
reaches the stated value, the pressure oil will
system will lighten newly. The CUP in the
push the NC contact of the parking brake low
instrument system will execute the secondary
pressure alert switch, and the parking brake low
steering.
pressure alert indicator of the instrument system
will go out, which shows that the system
CAUTION: When the steering system low
pressure is normal.
pressure alert indicator lightens, the main
When the parking brake system has fault and fault alert indicator lightens and the buzzer
makes the system pressure too low, the pressure beeps, place the machine straightly
switch contact will close newly, the parking brake immediately after start the secondary
low pressure alert switch of the instrument steering pump and turn off the engine. Check
system will act newly. the faults immediately, and operate the
machine after eliminate the faults.
CAUTION: When the parking brake low
pressure alert indicator lightens, the main Secondary steering running switch
fault alert indicator lightens and the buzzer
beeps, must stop the machine immediately The secondary steering running switch is NO
and check the faults, and operate the contact pressure switch.
machine after eliminate the faults.
When the CUP in the instrument system exports
order and starts the secondary steering, the
Steering system low pressure alert switch
secondary steering pump works, the secondary
steering oil line builds pressure and the NO
The steering system low pressure switch is a NC
contact of secondary steering running switch
contact pressure switch.
closes. The secondary steering running indicator
When the operator turns on the start switch, the in the instrument system will lighten.
steering pump doesn't run, the steering oil line
doesn't build pressure, the steering system low CAUTION: When the secondary steering
pressure alert switch is at close state, and the running indicator lightens, there are 60s
steering system low pressure alert indicator of working hours in the secondary steering
the instrument system will lighten. pump, place the machine straightly in 60s,
check the faults, and operate the machine
after eliminate the faults.
214
Electrical System
Instrument System

Fuel level sensor Function Operation

All kinds of sensors and pressure switches in the

instrument system belong to inspection
components. The sensors measure the system
work information and show them by gauges
when the machine works. The pressure switches
monitor the system normal work condition, they
act when the system has fault, the instrument
system gives alarm.
Work principle The instrument system is a window implement
which collects and indicates the variational work
The fuel level sensor is a capacitance type information of the machine.
sensor, which has double layer canister wall.
There is a small hole at the bottom of the outer The followings are all electronic components
canister wall, and the fuel can flow into inner which execute this function; in general, the
canister wall from this hole. The middle of sensor components in every function reflect the real
is empty, and the fuel also can flow into the condition of the system straightly. Think over the
sensor from the big hole. The double layer system fault that resulted in those questions
canister walls of the sensor are equal to two when the instrument system alert indicators give
electrodes of the capacitance. alarm or have abnormal problem.

The liquid level of two terminals of the 2-A Engine coolant temperature gauge
capacitance will be changed along with the
variety of fuel level, then the capacitance value The following electronic components are needed
will be changed, which will affect the voltage for realizing engine coolant temperature gauge
value to change finally. See the result by the fuel indication.
level gauge.
1. 5A fuse
The voltage of the fuel level sensor signal is DC
1.5-4.5V linearity arrangement. 2. Instrument system
3. Coolant temperature sensor

2-B Torque converter oil temperature gauge

The following electronic components are needed

for realizing torque converter oil temperature
gauge indication.
1. 5A fuse
2. Instrument system
3. Torque converter oil temperature sensor

2-C Fuel level gauge

The following electronic components are needed

for realizing fuel level gauge indication.
1. 5A fuse
 215
Electrical System
Instrument System

2. Instrument system 2-H Front floodlight high beam indicator

3. Fuel level sensor
The following electronic components are needed
for realizing front floodlight high beam indication.
2-D Speed LCD
1. 5A fuse
The following electronic components are needed
2. Instrument system
for realizing speed indication.
3. 10A front floodlight fuse
1. 5A fuse
4. Position light & front floodlight switch
2. Instrument system
5. Combination switch
3. ZF shift control system EST control unit
2-I Clutch cut-off indicator
2-E Engine speedometer
There are other components have the clutch cut-
The following electronic components are needed
off function, which will be introduced in detail in
for realizing engine rev indication.
chapter 6 Parking Brake and Clutch Cut-off of
1. 5A fuse this service manual.
2. Instrument system The clutch cut-off indicator in this instrument
system just shows No.600 wire state of ZF shift
3. CUMMINS electrical diesel engine ECM
control system, the clutch cut-off indicator will
lighten when the grounding voltage of No.600
2-F Turn left indicator
wire is about +24V, the shift control system
executes the clutch cut-off function. The clutch
The following electronic components are needed
cut-off indicator will go out when the grounding
for realizing turn left indication.
voltage of No.600 wire is 0V. The shift control
1. 5A fuse system doesn't execute the clutch cut-of
function.
2. 10A FLASH fuse
The following electronic components are needed
3. Instrument system
for realizing clutch cut-off indication.
4. K15 flashing relay
1. 5A fuse
5. Combination switch
2. Instrument system
2-G Turn right indicator 3. ZF shift control system

The following electronic components are needed 2-J Lubrication running indicator
for realizing turn right indication.
The lubrication running indicator is the piston
1. 5A fuse
pump work indicator of the lubrication system.
2. 10A FLASH fuse The indicator will lighten when the piston pump
3. Instrument system runs, the indicator will go out when the piston
pump doesn't work.
4. K15 flashing relay
The following electronic components are needed
5. Combination switch for realizing lubrication system running
indication.
1. 5A fuse
216
Electrical System
Instrument System

2. Instrument system 2-O Service brake low pressure alert

indicator
3. Auto-return lubrication system
The following electronic components are needed
2-K Secondary steering running indicator
for realizing service brake low pressure alert
indication.
The following electronic components are needed
for realizing secondary steering running 1. 5A fuse
indication.
2. Instrument system
1. 5A fuse
3. Service brake low pressure alert switch
2. Instrument system
2-P Engine oil pressure alert indicator
3. Secondary steering running switch
The following electronic components are needed
2-L Steering system fault indicator
for realizing engine oil pressure alert indication.
The following electronic components are needed 1. 5A fuse
for realizing steering system fault indication.
2. Instrument system
1. 5A fuse
3. Engine oil pressure alert switch
2. Instrument system
2-Q Transmission oil pressure alert indicator
3. Steering system low pressure alert switch
The following electronic components are needed
2-M Start state indicator
for realizing transmission oil pressure alert
indication.
The following electronic components are needed
for realizing start state indication. 1. 5A fuse
1. 5A fuse 2. Instrument system
2. Instrument system 3. Transmission oil pressure alert switch
3. Start motor
2-R Engine intake air filter alert indicator
2-N Parking brake low pressure alert
The following electronic components are needed
indicator
for realizing engine intake air filter alert
indication.
The following electronic components are needed
for realizing parking brake low pressure alert 1. 5A fuse
indication.
2. Instrument system
1. 5A fuse
3. Engine intake air filter alert switch
2. Instrument system
2-S Alternator charge indicator
3. Parking brake low pressure alert switch
The following electronic components are needed
for realizing alternator charge indication.
1. 5A fuse
2. Instrument system
 217
Electrical System
Instrument System

3. Alternator 1. 5A fuse
4. Battery 2. Instrument system

2-T Buzzer 2-V Instrument system background

illumination
The following electronic components are needed
for realizing buzzer beeping indication. The following electronic components are needed
for realizing the instrument system background
1. 5A fuse
illumination.
2. Instrument system
1. 5A fuse
3. Mute switch
2. Instrument system
4. Buzzer
3. Position light & front floodlight switch
2-U Instrument system works normally

The following electronic components are needed

for realizing the instrument system works normal
indication.

Instrument system signal source and execution components

218
Electrical System
Instrument System

When turn on the start switch but not start the

machine, as the diesel engine hasn't been
started, the hydraulic, brake, shift control
systems don't build pressure, most of the alert
indicators will flash. Start the engine, every
system runs normally, these indicators will go out
one by one.
But when the machine operates or runs normally,
the instrument system appears alert signals,
mulst check the faults carefully. Some possible
faults may occur with high frequency are listed in
the following tables, but which don't include all
the faults, so please dispose the fault according
to the practical condition.
 219
Electrical System
Instrument System

Item Sign Fault description Fault point Remark

Start relay fault

The indicator doesn’t Neutral/start interlock relay fault

lighten when start the ZF system fault
Start state engine Start switch fault
indicator
Indicator damage
The engine doesn’t Start motor fault
go out after starting Start relay fault
Observe oil level condition from engine Read fault code from
oil dipstick electrical engine state and
Does engine oil pump run normally fault indicator state, dispose
Engine oil
Give alarm during fault according to CUMMUS
pressure CUMMIUS electrical system fault
operation engine fault code disc if has
alert indicator
143 fault. The engine oil
Engine oil pressure switch damage pressure switch is damage if
doesn’t appear 143 code.
Intake air
Air filter blocks, replace it. The details
filter alert Alert
see operation & maintenance manual
indicator
Read fault code from
electrical engine state and
Engine Observe coolant level, fill the coolant if
fault indicator state, dispose
coolant level Alert not enough. The details see operation &
fault according to CUMMUS
alert indicator maintenance manual.
engine fault code disc if has
197 fault.
Observe transmission oil level from oil
Transmission dipstick, fill oil if not enough.
Give alarm during Refer to Transmission of
oil pressure
operation Shift control valve fault service manual
alert indicator
ZF system fault
Check the battery according to Brake of
service manual if the battery pressure is
Service not enough. Pay attention leakage.
Give alarm during Refer to Brake of service
brake alert Check battery according to Brake of
operation manual
indicator service manual if the brake valve has
fault.
The line has fault
Check battery according to Brake of
service manual if the battery pressure is
Parking not enough. Pay attention leakage.
Give alarm during Refer to Brake of service
brake alert Check battery according to Brake of
operation manual
indicator service manual if the brake valve has
fault.
The line has fault

Steering Engine starts abnormally

Give alarm during
system fault Steering pump damages
operation
indicator The line has fault
220
Electrical System
Instrument System

The indicator doesn’t Engine damages

lighten before Line fault
Engine starting engine
charge The indicator damages
indicator The indicators don’t
go out after starting The engine damages
engine
The indicator doesn’t Control mode of instrument system
Secondary
lighten when engine damages
steering
goes out abnormally
running
or steering pump The indicator damages
indicator
damages

Troubleshooting
 221
Electrical System
Instrument System

This illustration just marks the related branch

way and direction, other irrespective parallet
connection branch ways aren't marked.
222
Electrical System
Instrument System

Core Instruction

Input Signal Instruction

Core No. Function Outer signal source Singal control state Wire No.
Parking brake low pressure See signal instruction of
2 Parking brake alet indicator 300
alert switch instrument system
Engine oil pressure alert Engine oil pressure alert See signal instruction of
3 301
indicator switch instrument system
Front floodlight high beam See signal instruction of
4 Combination switch 403
indicator instrument system
See signal instruction of
5 Turn right indicator Combination switch 404
instrument system
See signal instruction of
6 Turn left indicator Combination switch 405
instrument system
See signal instruction of
8 Lubrication running indicator Lubrication system input 411
instrument system
Service brake low pressure See signal instruction of
10 Service brake alert indicator 303
alert switch instrument system
Steering system low See signal instruction of
11 Steering system fault 312
pressure alert switch instrument system
Parking brake clutch cut-off
See signal instruction of
12 Clutch cut-off indicator pressure switch and parking 600
instrument system
brake button
Engine water temperature Engine water temperature
13 701
sensor sensor
See signal instruction of
14 Intake air filter alert indicator Intake air filter alert switch 310
instrument system
Axle oil pressure alert See signal instruction of
14 Axle oil pressure alert switch 304
indicator instrument system
Lubrication system fault alert
17 Lubrication system output 305
indicator
Engine coolant level alert CUMMINS electrical ECM See signal instruction of
18 306
indicator output instrument system
CUMMINS electrical ECM See signal instruction of
19 Warning indicator 320
output instrument system
Torque converter oil Torque converter oil
20 702
temperature sensor temperature sensor
Transmission oil pressure Transmission oil pressure See signal instruction of
21 307
alert indicator alert switch instrument system
Hydraulic oil filter alert See signal instruction of
22 Hydraulic oil filter alert switch 308
indicator instrument system
CUMMINS electrical ECM See signal instruction of
23 Wait to start indicator 321
output instrument system
See signal instruction of
24 Engine charge indicator L terminal of engine output 800
instrument system
 223
Electrical System
Instrument System

Core No. Function Outer signal source Singal control state Wire No.
CUMMINS electrical ECM See signal instruction of
25 Service indicator 322
output instrument system
CUMMINS electrical ECM See signal instruction of
26 Fuel in water indicator 323
output instrument system
CUMMINS electrical ECM See signal instruction of
27 Stop indicator 324
output instrument system
Hydraulic oil temperature Hydraulic oil temperature See signal instruction of
28 309
alert indicator switch instrument system
See signal instruction of
29 Start state indicator 50 terminal of start motor 407
instrument system
Secondary steering running Secondary steering running See signal instruction of
30 408
indicator switch instrument system
31 Engine rev signal 704
ZF shift control system
32 Speed signal 705
output
34 Fuel level sensor earthing Fuel level sensor earthing 201
35 Fuel level sensor signal Fuel level sensor signal 703

Power Supply Signal Introduction

Core No. Function Remark Power supply signal Wire No.

+24V IN (Electrical engine
1 +24V IN(Electrical) 121
indicator)
Background light power of +24V IN. Position light power
7 Instrument lights 416
instrument supply
+24V IN power supply of
9 +24V IN 122
instrument system
Use it when instrument +24V IN from battery power
15 Battery power +24V 114
returns supply
16 Ground Instrument system ground 200

Output Signal Introduction

Core No. Function Remark Outer circuit Wire No.

33 Buzzer output Buzzer 417
Secondary steering output
36 Secondary steering relay 409
control
224
Electrical System
Instrument System

Instrument system signal

Alert Signal

Alert Inout signal Inout signal

Item indicator Flash or not level at level at alert Sign Remark
color normal state state

Turn left
Green Flash Hang in the air Flash signal
indicator

Turn right
Green Flash Hang in the air Flash signal
indicator

Front floodlight
high beam Blue No Hang in the air +24V
indicator

Clutch cut-off
Yellow No Hang in the air +24V
indicator

Lubrication
Green No Hang in the air +24V
running indicator

Secondary
steering running Yellow No Hang in the air +24V
indicator

Steering system
Red No
fault indicator

Start state
Yellow No Ground +24V
indicator

Parking brake
Red No Hang in the air Earthing
alert indicator

Servicec brake
Red No Hang in the air Earthing
alert indicator

Engine oil
pressure alert Red No Hang in the air Earthing
indicator
Transmissionoil
pressure alert Red No Hang in the air Earthing
indicator
Engine intake air
filter alert Red No Hang in the air Earthing
indicator
 225
Electrical System
Instrument System

Alert Inout signal Inout signal

Item indicator Flash or not level at level at alert Sign Remark
color normal state state
Lubrication Not available
system fault Red No Hang in the air Earthing for this
alert indicator machine
Hydraulic oil Not available
tempertaure Red No Hang in the air Earthing for this
alert indicator machine
Hydraulic oil Not available
filter alert Red No Hang in the air Earthing for this
indicator machine
Engine coolant
level alert Red No Hang in the air Earthing
indicator
Not available
Axle oil pressure
Red No Hang in the air Earthing for this
alert
machine

Engnie charge D+ terminal of D+ terminal of From

Red No
indicator engine engine alternator

Electrical Engine Indicators

Alert Inout signal Inout signal

Item indicator Flash or not level at level at alert Sign Remark
color normal state state

Stop indicator Red No Hang in the air Earthing

Warning
Yellow No Hang in the air Earthling
indicator

Maintenance
Blue No Hang in the air Earthing
indicator

Wait to start
White No Hang in the air Earthing
indicator

Water in fuel
Blue No Hang in the air Earthing
indicator
226
Electrical System
Instrument System

Instrument Signal

Indication area Sensor

Item Connection
Sign
Yellow area Green area Red area Part No.
screw thread
Engine water
temperature 40-55°C 55-100°C 100-120°C 30B0065 1/2NPTF
gauge

Torque converter
oil temperature 40-60°C 60-130°C 130-150°C 30B0100 M14X1.5
gauge

Fuel level gauge 1-0.2 0-0.2 30B0279

Scale indication area Signal source

Item Sign Remark
Normal area Red area
Impule signal comes form
Engine
0~25 scale 25~30 scale CUMMINS electrical engine ECM X100RPM
speedometer

LCD display area Unit Signal source

Item
1 2 3 4 Impule signal comes
individual 1 digit after radix Km/h form ZF shift control
Speedometer Decimal radix point system
digits point
 227
Electrical System
Instrument System

2-A-F Engine Water Temperature Gauge 2. Disassemble the steering column assembly,
Fault Test Procedure pull out the receptacle of the instrument
system, and wrap one terminal of the lead
Fault phenomenon definition: prepared in step a with the lead copper
connector of the disassembled water
Test the fault of the engine water temperature temperature sensor, another terminal is
gauge in the instrument system if it doesn't have connected to the cab.
indication or the indication isn't on time. 3. Pull slightly No.701 wire connected to No.13
core of instrument system, judge the
Step1. Test engine water temperature gauge connecting condition, use the special tool to
is damaged or not (need another person). connect newly if it is loosened.

1. Turn on the start switch, the engine water 4. Adjust the digital multimeter to 200Ω range of
temperature gauge pin should turn and Ω function, connect one probe to the lead
indicate the min read of yellow area. Turn off inside the cab, another probe to No.13 core
the start switch, the read of pin drops down to of the instrument system.
limit value from the min read. The instrument
system has damaged if the water Test result:
temperature pin doesn't move.
The digital multimeter reading is 0Ω.
2. Turn off the start switch, and disassemble the
lead copper connector of water temperature Conclusion:
sensor from the engine.
3. Turn on the start switch, the lead copper If the result does OK, the line doesn't have fault,
connector of water temperature sensor please turn to step3.
contacts with engine metal housing or whole If the result doesn't OK, the line has fault,
machine metal housing (the place without disassemble the interior decoration assembly
paint). The pin of water temperature gauge and cup map on the left-rear side of the cab.
will indicate the max read.
(1) Check the loose condition of No.3 core of
4. Hang the lead copper connector of water XK4 receptacle.
temperature sensor in the air; the pin of water
temperatue gauge will indicate the min read. (2) Check the condition of wiring harnesses from
engine water temperature gauge receptacle
Conclusion: to the sensor.

If the result does OK, please turn to step3. Step 3. Test water temperature sensor is
damaged or not.
If the result doesn't OK, please turn to step2.
1. The water temperature sensor may be
Step2. Test whether there is fault in the line damaged if above test doesn't have fault.
from engine water temperatue gauge to the
sensor. 2. Turn off the start switch, disassemble the
watetr temperature sensor and replace it
1. Prepare one 10m lead, Divest insulation after the engine cooling, there is coolant
layer about 10-20mm of the lead two overflow during replacing, replenish the
terminals. coolant according to overflow coolant
quantity.
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Electrical System
Instrument System

3. Replace the instrument system if the water 3. Turn on the start switch, the lead copper
temperature gauge pin indicates incorrectly connector of torque converter oil temperature
again after eliminate the fault. sensor contacts with the whole machine
metal housing (the place without paint). The
Conclusion: pin of torque converter oil temperature gauge
will indicate the max read.
The cab environment is needed to judge the
4. Hang the lead copper connector of torque
water temperature sensor parameter is correct or
converter oil temperature sensor in the air;
not. Please replace with a new water
the pin of torque converter oil temperatue
temperature sensor if doubted that it has
gauge will indicate the min read.
damaged. Then deliver the bad sensor back to
the factory for test.
Conclusion:

If the result does OK, please turn to step 3.

Disassemble the water temperature sensor If the result doesn't OK, please turn to step 2.
after the engine cooling adequately! High
temperature water and oil will injure human Step 2. Test whether there is fault in the line
body; Please wear guard glasses and gloves from torque converter oil temperature gauge
if it is necessary. to the sensor.

1. Prepare one 10m lead, Divest insulation

2-B-F Torque Converter Oil layer about 10-20mm of the lead two
Temperature Gauge Fault Test terminals.
Procedure 2. Disassemble the steering column assembly,
pull out the receptacle of the instrument
Fault phenomenon definition: system, and wrap one terminal of the lead
prepared in step a with the lead copper
Test the fault of the troque converter oil connector of the disassembled torque
temperature gauge in the instrument system if it converter oil temperature sensor, another
doesn't have indication or the indication isn't on terminal is connected to the cab.
time.
3. Pull slightly No.702 wire connected to No.20
Step 1. Test the torque converter oil core of the instrument system, judge the
temperature guage is damaged or not (need connecting condition, and use the special
another person). tool to connect newly if it is loosened.
4. Adjust the digital multimeter to 200Ω range of
1. Turn on the start switch, the torque converter Ω function, connect one probe to the lead
pin should turn and point to the min read in inside the cab, another probe to No. 20 core
Yellow area. Turn off the start switch; the pin of the instrument system.
drops down to the limit value from the min
read. The instrument system has damaged if Test result:
the torque converter oil temperature gauge
pin doesn't move. The digital multimeter reading is 0Ω.
2. Turn off the start switch, and disassemble the
lead copper connector of torque converter oil Conclusion:
temperature sensor.
If the result does OK, the line doesn't have fault,
please turn to step 3.
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Electrical System
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If the result doesn't OK, the line has fault, 2-C-F Fuel Level Gauge Fault Test
disassemble the interior decoration assembly Procedure
and cup map on the left-rear side of the cab.
(1) Check the loose condition of No.2 core of Fault phenomenon definition:
XK4 receptacle.
Test the fault of the fuel level gauge in the
(2) Check the condition of wiring harnesses from combination instrument if it doesn't have
torque converter oil temperature gauge indication or the indication isn't on time.
receptacle to the sensor.
Step 1. Test the fuel level gauge is damaged
Step 3. Test the torque converter oil or not.
temperature sensor is damaged ro not.
1. Turn on the start switch, the fuel level gauge
1. The torque conveter oil temperature sensor pin should turn and point to the min read in
may be damaged if above test doesn't have red area. Turn off the start switch; the pin
fault. drops down to the limit value from the min
2. Turn off the start switch, disassemble the read.
torque conveter oil temperature sensor and
replace it after the engine cooling, there is Conclusion:
coolant overflow during replacing, replenish
the coolant according to overflow coolant If the result does OK, please turn to step 2.
quantity. If the result doesn't OK, the instrument system
3. Replace the instrument system if the oil has damaged if the fuel level gauge pin is
temperature gauge pin indicates incorrectly incorrect.
again after eliminate the fault.
Step 2. Test whether the voltage of XG1
Conclusion: receptacle is +24V.

The cab environment is needed to judge the 1. Turn off the start switch, find XG1 receptacle
torque converter oil temperature sensor at the fuel level sensor on the diesel engine
parameter is correct or not. Please replace with a case and pull out.
new oil temperature sensor if doubted that it has 2. Adjust the digital multimeter to 50V range of
damaged. Then deliver the bad sensor back to voltage function. Connect the red probe to
the factory for test. No.122 copper of No.1 core of XG1
receptacle wiring harness terminal, the black
probe to No.201 copper of No.2 core. Turn on
the start switch, and observe the reading of
Disassemble the water temperature sensor the digital multimeter.
after the engine cooling adequately! High
temperature water and oil will injure human Test result:
body; please wear guard glasses and gloves
if it is necessary. The digital multimeter reading is between 24V
and 31V.

Conclusion:

If the result does OK, please turn to step 5.

If the result doesn't OK, please turn to step 3.
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Electrical System
Instrument System

Step 3. Test whether the voltage of No.122 Step 5. Test whether the voltage of XG1
wire is +24V. receptacle is +1.5V-+4.5V.

1. Keep the measurement in step2. Connect the 1. Turn off the start switch, prepare two pins,
red probe to No.122 copper of No.1 core of plug XG1 receptacle. Insert one pin into
XG1 receptacle wiring harness terminal, the No.703 lead near XG1 receptacle wiring
black probe to the machine (the place without harness terminal, make sure the pin contacts
paint). with the copper of No.703 wire. Insert
another pin into No.201 wire near XG1
Test result: receptacle wiring harness terminal and make
sure the pin contacts with copper of No.201
The digital multimeter reading is between 24V wire. Please notice that two pins can't contact
and 31V. with each other. Otherwise the instrument
system will be damaged.
Conclusion:
2. Adjust the digital multimeter to 50V range of
voltage function. Turn on the start switch,
If the result does OK, please turn to step 4.
connect the red probe of the digital
If the result doesn't OK, if the instrument system multimeter to the pin inserted into No.703
indicators lighten, other meters or warning wire, connect the black probe of the digital
indicators lighten, No.122 line has fault from the multimeter to the pin inserted into No.201
fuse to XG1 receptacle. If the whole instrument wire, please notice that two pins can't contact
system doesn't reflect, please check the with each other, observe the reading of the
condition of 5A fuse. digital multimeter.
3. Turn off the start switch, remove the fixing
Step 4. Test the grounding resistance of
bolt of the fuel level sensor, and lift the fuel
No.201 wire.
level sensor for about 100mm-200mm height.
Turn on the start switch, and test the voltage
1. Keep the measurement in step3. Adjust the
between No.703 wire and No.201 wire.
digital multimeter to 200Ω range of Ω
function. Connect the red probe to No.201
Test result:
copper of 2 core of XG1 receptacle wiring
harness terminal, the black probe to the
The digital multimeter reading is +1.5 to +4.5.
machine (the place without paint).
The reading will change when the fuel level
sensor is lifted.
Test result:
Conclusion:
The digital multimeter reading is 0Ω.
If the result does OK, please turn to step 6.
Conclusion:
If the result doesn't OK, the fuel level sensor is
There are two reasons which cause the No.201 damaged.
wire grounding resistance value isn't 0: one is
No.201 wire is open circuit, another is instrument
system has inner fault.
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Electrical System
Instrument System

Step 6. Test whether the voltage of the 2-D-F Speed LCD Fault Test Procedure
instrument system receptacle is +1.5V-+4.5V.
Do not turn on the start witch, if the speed LCD
1. Turn off the start switch, put the fuel level leaks liquid, the black spot can be observed by
sensor to original position, don't fix bolt. eye on the speed LCD, which shows the
Disassemble the steering column assembly, instrument system is damaged.
and pull out the instrument system from the
Observe the speed LCD when turn on the start
fixing position. Prepare two pins, insert one
switch, the instrument system is damaged if the
pin into No.703 wire copper near instrument
speed LCD doesn't have reflection or the LCD
system receptacle, and make sure the pin
doesn't show the whole content.
contacts with No.703 wire copper. Insert
another pin into No.201 wire near instrument The rev sensor is used to check transmission
system receptacle, and make sure the pin output gear rev when running, then let rev signal
contacts with No.201 wire copper. Please translate into the impulse signal, input EST
notice that two pins can't contact with each electronic control unit. EST electronic control unit
other. Otherwise the instrument will be exports the transmission impulse signal into the
damaged. instrument system through the outer lead. CPU
inside the instrument system calculates the input
2. Adjust the digital multimeter to 50V range of
impulse signal number and sends to the speed
voltage function. Turn on the start switch,
LCD for show after converted into speed signal.
connect the red probe of the digital
multimeter to the pin inserted into No.703 The original signal of the speed signal comes
wire, connect the black probe of the digital from the rev sensor, through EST electronic
multimeter to the pin inserted into No.201 control unit and CPU of the instrument system,
wire, please notice that two pins can't contact reaches the speedometer finally. The special
with each other, observe the reading of the implement is needed if inspect the signal source,
digital multimeter. but the field maintenance doesn't have the
condition to inspect signal source. A new spare
3. Turn off the start switch, lift the fuel level
instrument system is needed to do the following
sensor for about 100mm-200mm height, and
test steps.
test the voltage between No.703 wire and
No.201 wire. LCD normal work temperature is 0~50°C
(0~122°F) in the instrument system, please keep
Test result: the indoor temperature at normal work
temperature when operate the machine in cold
The digital multimeter reading is +1.5 to +4.5. weather.
The reading will change when the fuel level
sensor is lifted. Falut phenomenon definition:

Conclusion: The speed LCD doesn't show reading during

running, just shows 0.
If the result does OK, the instrument system is
damaged.
If the result doesn't OK, No.703 wire has fault.
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Electrical System
Instrument System

Step 1. Test whether the machine can shift 4. Adjust the digital multimeter to 200Ω range of
successfully and run normally. Ω function, one probe contacts with No.32
core copper of the instrument system,
Conclusion: another probe contacts with the copper core
of the instrument system.
If the result does OK, the machine can shift
successfully and run normally which shows ZF Test result:
shift control system doesn't have fault, the rev
seonsor works normally, the signal source is The digital multimeter reading is 0Ω.
normal.
Conclusion:
If the result doesn't OK, please check as follows:
(1) Did replace the rev sensor? If it has been If the result does OK, the line doesn't have fault,
replaced, please adjust the gap between rev please turn to step 3.
sensor and thransmission gear until the
If the result doesn't OK, the line has open circuit,
whole machine can shift successfully (refer to
check No.705 wire carefully, especially the
the shift control system section for details).
receptacle, the round place, the active place
(2) If didn't replace the rev sensor, use the digital contacts with the metal plate.
multimeter 2000Ω range of Ω function, pull
out the plug of the rev sensor, connect the Step 3. Replace the instrument system
probes of the digital multimeter to two pins of
the rev sensor, the multimeter reading is 1. Turn off the start switch, disassemble the
1020±100Ω. Otherwise the rev sensor is steering column assembly, and replace the
damaged, please replace it. old instrument system of the machine with a
new one.
(3) The rev sensor signal wire of ZF shift control
system is broken or not. 2. Assemble the steering column, turn on the
start switch, and operate the machine.
Step 2. Test the line fault Observe if the speed LCD works normally.

1. Prepare one 10m lead, divest the insulation Conclusion:

layer for about 10-20mm of the lead two
terminals. OK
2. Turn off the start switch, disassemble the If the result doesn't OK, there is fault in the lines
steering column assembly, and pull out the of ZF system.
receptacle of the instrument system.
Disassemble the interior decoration
assembly and cup map on the left-rear side
of the cab, pull slightly No.705 wire of X5
receptacle (one plug and one socket), judge
the connecting condition between No.705
wire and copper, use the special tool to
connect over again if the connection is not
tight. And turn to the next step if it is tight.
3. Pull out X5 receptacle, and keep contacting
one terminal of 10m lead with No.705 wire
copper until finish the measurement, another
terminal is connected to the instrument
system.
 233
Electrical System
Instrument System

2-E-F Engine Tachometer Fault Test 3. Adjust the digital multimeter to 200Ω range of
Procedure Ω function, one probe contacts with the pin
(No.704 wire), another probe contacts with
The tachometer signal of the engine comes from the lead copper core of the engine.
CUMMINS engine ECM which is impulse signal,
the signal source of CUMMINS engine ECM Test result:
comes from crankshaft speed sensor. The
special test instrument is needed if test the signal The digital multimeter reading is 0Ω.
source.
Conclusion:
CUMMINS engine ECM is the control centre of
the engine system, which has self-check If the result does OK, the line doesn't have fault,
function. The electrical engine state indicator please turn to step 2.
group on the instrument system will give alarm
when the engine system has fault. If the result doesn't OK, the line has open circuit,
check No.704 wire carefully, especially the
The engine state indicator group will give alarm receptacle, the round place, the active place
signal if the engine system has fault and makes contacts with the metal plate.
the rev gauge doesn't indicate or the indication
value is incorrect. To the opposite, if the engine Step 2. Replace the instrument system
state indicator group doesn't give alarm signal,
the signal source doesn't have fault. Turn off the start switch and remove the steering
column assembly. Replace the old combination
Falut phenomenon definition: instrument with a new one.
The rev gauge doesn't have indication, and need Install the steering column, turn on the start
to test its fault. switch and run the machine to check whether the
engine speedometer works normally.
Step 1. Test the line fault
Conclusion:
1. Prepare one 10m lead, divest insulation layer
for about 10-20mm of the lead two terminals, OK
and prepare one pin. If the result doesn't OK, check the engine state
2. Turn off the start switch, disassemble the indicator for warning signal, check the fault code
steering column assembly, and put out the according to the engine fault code table in the
plug of the instrument system. Insert one service manual, examine & repair the engine
terminal of the lead into No.31 core of according to the fault table.
receptacle wiring harness of the instrument
system, and make sure the lead core
connects well to No.31 copper, pull another
terminal from the cab to 50-pin receptacle.
Find No.704 wire of 50-pin receptacle, pull
slightly No.704 wire by hand, judge the tight
condition between lead and copper, use the
special tool to connect newly if the
connection is not tight. Insert pin into No.704
wire if it is tight, make sure the connection
between the pin and No.704 wire.
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Electrical System
Instrument System

2-F-F Left Turn Indicator Fault Test 2. Assemble the steering column, turn on the
Procedure start switch, push the combination switch
forwards to turn left, observe whether the left
Falut phenomenon definition: turn indicator works normally.

The front-left turn indicator and rear-left turn Conclusion:

indicator lighten normally, but the left turn
indicator on the instrument system doesn't If the result does OK, the left turn indicator of the
lighten. instrument system is damaged, please replace
the instrument system, and send the old
Check the lights according to lights subassembly instrument system to the factory for service. The
section in this service manual if the front-left turn maintenance should be carried out in the clean
indicator and rear-left indicator don't lighten anti-static room, do not disassemble the
normally. instrument system without permission.

Step 1. Test the line fault 2-G-F Right Turn Indicator Fault Test
Procedure
1. Turn off the start switch, disassemble the
steering column, and pull out the receptacle
Refer to 2-F-F right turn indicator fault test steps,
of the instrument system. Find the receptacle
the tested lead is No.404 wire.
in the steering column of the instrument
system.
2-H-F Front Floodlight High Beam
2. Adjust the digital multimeter to 200Ω range of Indicator Fault Test Procedure
Ω function, one probe contacts with No.405
wire of the combination switch, another probe Falut phenomenon definition:
contacts with No.5 core of the instrument
system (No.405 wire). The front floodlight high beam indicator doesn't
indicate when the front floodlight is on high
Test result: beam.

The digital multimeter reading is 0Ω. Check the lights according to this service manual
if the front floodlight isn't on high beam.
Conclusion:
Step 1. Test the line fault
If the result does OK, the line doesn't have fault,
please turn to step 2. 1. Turn off the start switch, disassemble the
steering column, and pull out the receptacle
If the result doesn't OK, the line has open circuit, of the instrument system. Find the receptacle
check No.405 wire carefully, especially the of steering column of the instrument system.
receptacle, the round place, the active place
contacts with the metal plate. 2. Pull slightly No.403 wire connected to No.4
core of the instrument system; judge its loose
Step 2. Replace the instrument system. condition, using the special tool to connect
newly if it is loosed.
1. Turn off the start switch, disassemble the 3. Adjust the digital multimeter to 200Ω range of
steering column, and replace the old Ω function, one probe contacts with No.403
combination instrument with a new one. wire of the instrument system, another probe
contacts with No.4 core (No.403 wire) of the
instrument system.
 235
Electrical System
Instrument System

Test result: The clutch cut-off indicator lightens or not is only

related to No.600 wire state no matter how many
The digital multimeter reading is 0Ω. components are related to clutch cut-off function,
the clutch cut-off indicator will lighten when the
Conclusion: grounding voltage of No.600 wire is +24V, the
clutch cut-off indicator will go out when the
If the result does OK, the line has no fault, please grounding voltage of No.600 wire is 0.
turn to step 2.
Step 1. Send clutch cut-off order to the
If the result doesn't OK, the line has open circuit,
machine, and check the grounding voltage of
check No.403 wire carefully, especially the
No.600 wire of the instrument system
receptacle, the round place, the active place
contacts with the metal plate.
1. Turn off the start switch, and pull out 36-pin
receptacle of the instrument system.
Step 2. Replace the instrument system
2. Turn on the start switch, don't start the
1. Turn off the start switch, disassemble the engine, press down the parking brake button.
steering column, and replace the old
3. Adjust the digital multimete to 50V range of
instrument system with a new one.
voltage function. The red probe contacts with
2. Assemble the steering column, turn on the No.12 core of the instrument system, the
start switch, push the combination switch black probe contacts with the metal housing
forwards for floodlight high beam, observe (the place without paint) of the cab (or
whether the front floodlight high beam contacts with No.200 wire of No.16 core of
indicator works normally. the instrument system)

Conclusion: Test result:

If the result does OK, the high beam indicator The digital multimeter reading is between 24V
inside the instrument system is damaged, please and 31V.
send the damaged instrument system back to
the factory for service. The maintenance should Conclusion:
be carried out in the clean anti-static room, do
not disassemble the instrument system without If the result does OK, please turn to step 2.
permission.
If the result doesn't OK, please turn to step 3.
2-I-F Clutch Cut-off Indicator Fault Test Step 2. Replace the instrument system.
Procedure
1. Turn off the start switch, disassemble the
Fault phenomenon definition: steering column, and replace the old
instrument system with a new one.
Turn on the start switch, and pull up the parking
brake button, but the clutch cut-off indicator 2. Assemble the steering column, turn on the
doesn't lighten. start switch, don't start the engine, pull up the
parking brake, observe the clutch cut-off
The clutch cut-off indicator doesn't lighten when indicator lightens or not.
the operator presses KD button.
236
Electrical System
Instrument System

Conclusion: 3. No.600 wire and No.170 wire of the parking

brake switch don't have voltage, No.170 wire
If the result does OK, the high beam indicator of has fault if ZF shift control system works
the instrument system is damaged, please normally, 7.5A shift control fuse may melt if
replace it, and send the old instrument system ZF shift control system doesn't work.
back to the factory for service. The maintenance
should be carried out in the clean anti-static 2-J-F Lubrication Running Indicator
room, do not disassemble the instrument system Fault Test Procedure
without permission.
Falut phenomenon definition:
Step 3. Test the grounding voltage of No.600
wire, No.170 wire in turn. The lubrication running indicator doesn't lighten
when the lubrication system piston pump runs.
1. Pull the parking brake and hold it, turn off the
start switch, disassemble the fixing bolt of the Check the lubrication system piston pump
parking brake button plate, pull up the according to this service manual if the piston
parking brake assembly slightly. Put the pump doesn't run.
assembly on the control box, please notice
that the copper connector can't contact with Step 1. Test the line fault
the metal housing of the machine.
1. Turn off the start switch, disassemble the
2. Adjust the digital multimeter to 50V range of steering column, and pull out the receptacle
voltage function. Turn on the start switch, the of the instrument system. Find No.411 wire
red probe contacts with No.600 wire copper connected to No.8 core of the instrument
connector of the parking brake button, the system, pull it slightly by hand to judge it is
black probe contacts with the metal housing loosed or not, use the special tool to connect
(the place without paint) of the cab. The it if it is loosed.
digital multimeter reading is between 24V
and 31V. 2. Pull out XK7 receptacle connected to the
lubrication system, find No.411 wire connecte
3. The red probe contacts with No.170 wire to No.3 core, pull it slightly by hand to judge it
copper connector of the parking brake is loosed or not, and use the special tool to
button, the black probe contacts with the connect it if it is loosed.
metal housing (the place without paint) of the
cab. The digital multimeter reading is 3. Prepare one 10m lead, divest insulation layer
between 24V and 31V. for about 10-20mm of the lead two terminals,
one terminal of the lead is connected to No.8
Conclusion: core, another is connected to XK7 receptacle
of the lubrication system.
1. No.600 wire of the parking brake switch has 4. Adjust the digital multemter to 200Ω range of
voltage, please check No.600 wire circuit Ω function, one probe contacts with 3 core of
carefully, especially the receptacle, the round XK7 receptacle of the lubrication system,
place and the active parts contacts with the another is connected to the lubrication
metal plate. system lead. Observe the multimeter
2. No.600 wire of the parking brake switch reading.
doesn't have voltage, but No.170 wire has
voltage, which shows the parking brake is Test result:
damaged.
The digital multimeter reading is 0Ω.
 237
Electrical System
Instrument System

Conclusion: 2-K-F Secondary Steering Running

Indicator Fault Test Procedure
If the result does OK, the line doesn't have fault,
please turn to step 2. Fault phenomenon definition:
If the result doesn't OK, the line has open circuit,
check No.411 wire carefully, especially the The secondary steering indicator doesn't lighten
receptacle, the round place, the active place when the secondary steering motor runs.
contacts with the metal plate. Check the secondary steering motor according
to the service manual if the secondary steering
Step 2. Test the grounding voltage of No.411 motor can't run normally.
wire of the instrument system.
Step 1. Test whether the voltage of No.122
1. Turn off the start switch, disassemble the wire of the secondary steering pressure
steering column, take out the instrument switch is +24V.
system and pull out 36-pin of the instrument
system. 1. Pull out two receptacles of the secondary
2. Adjust the digital multimeter to 50V range of steering pressure switch.
voltage function. Turn on the start switch, and 2. Turn on the start switch, and adjust the digital
press the KD button to start the piston pump. multimeter to 50V range of voltage function.
The red probe contacts with No.8 core of the The red probe contacts with No.122 wire
instrument system. The black probe is copper receptacle. The black probe is
connected with the metal housing (the place connected with the metal housing (the place
without paint) of the cab. without paint) of the cab.

Test result: Test result:

The digital multimeter reading is between 24V The digital multimeter reading is between 24V
and 31V. and 31V.

Conclusion: Conclusion:

If the result does OK, the lubrication running If the result does OK, please turn to step 2.
indicator of the original instrument system is
damaged. Send the instrument system back to If the result doesn't OK, please check as follows:
the factory for service. The maintenance should (1) Judge the instrument system has electricity
be carried out in the clean anti-static room, do or not, all indicators lighten or not, 5A fuse
not disassemble the instrument system without melts if the instrument system doesn't
permission. electrify.
If the result doesn't OK, the lubrication system (2) No.122 wire has fault if the instrument
has inner fault. system works normally, check No.411 wire
carefully, especially the receptacle, the round
place, the active place contacts with the
metal plate.
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Electrical System
Instrument System

Step 2. Judge the pressure switch is 2-L-F Steering System Fault Indicator
damaged or not. Fault Test Procedure
1. Open the electronic control box, pull out the Fault phenomenon definition:
secondary steering relay in order to make
sure not to start the secondary steering The steering system fault indicator doesn't
piston pump during testing. lighten at all times when the secondary steering
2. Connect No.122 wire and No.408 wire, and pump has run.
make sure the copper has good contact. The steering system fault indicator doesn't
Observe the secondary steering running lighten when the secondary steering pump
indicator lightens or not. doesn't run.

Conclusion: Step 1. The steering system fault indicator

doesn't lighten when the secondary steering
If the result does OK, the secondary steering pump has run. Replace the instrument
pressure switch is damaged. system.
If the result doesn't OK, please turn to step 3.
Please turn to step2 if the secondary steering
Step 3. Replace the instrument system. pump doesn't run.

1. Turn off the start switch, disassemble the Step 2. Test whether No.312, No.231 wires
steering column, and replace the old have the line fault.
instrument system with a new one..
1. Turn off the start switch, disassemble the
2. Assemble the steering column, turn on the steering column, and pull out the receptacle
start switch, and keep No.122 wire short in of the instrument system. Find No.312 wire
step 2 connecting with No.408 wire. Observe connected to No.11 core of the instrument
the secondary steering indicator lightens or system, pull the wire slightly by hand, judge it
not. is loosed or not, use the special tool to
connect it if it is loosed.
Conclusion:
2. Find the steering pressure alert switch on the
If the result does OK, the secondary steering bottom of the cab, pull out its two
indicator of the original instrument system is receptacles, push the copper connector,
damaged. Send the instrument system back to connect two copper together in order to
the factory for service. The maintenance should connect No.312 wire to No.231 wire.
be carried out in the clean anti-static room, do 3. Adjust the digital multimeter to 200Ω range of
not disassemble the instrument system without Ω function, one probe contacts with 11 core
permission. of the instrument system, another probe
If the result doesn't OK, the line has open circuit, contacts with 16 core of the instrument
check No.411 wire carefully, especially the system. (grounding)
receptacle, the round place, the active place
contacts with the metal plate. Test result:

The digital multimeter reading is 0Ω.

 239
Electrical System
Instrument System

Conclusion: Conclusion:

If the result does OK, the line doesn't have fault, If the result does OK, the steering pressure alert
please turn to step 3. switch is damaged when the steering system
fault indicator lightens.
(1) If the result doesn't OK, the line has opern
circuit. Check No.312 wire carefully, If the result doesn't OK, the instrument system is
especially the receptacle, the round place, damaged when the steering system fault
and the active place contacts with the metal indicator doesn't lighten.
plate. Secondary steering start control
(2) Check the grounding condition of No.231
wire carefully. The grounding resistance is +24VIN TURN ON THE
0Ω or not. START SWITCH TURN OFF THE
START SWITCH
STEERING SYSTEM
FAILURE INDICATOR/ INPUT START FAILURE
Step 2. Test the steering pressure alert switch
is damaged or not. SECONDARY STEERING
OUTPUT CONTROL/ OUTPUT
60S (AVAILABLE)

1. Connect the receptacle of the instrument

system. See above illustration, grounding can be
considered as low level, +24V as high level. The
2. Connect two coppers of the steering first line is the voltage wave shape of the power
pressure alert switch to each other in order to supply system. The second line is the voltage
connect No.312 wire to No.231 wire. wave shape of the steering pressure alert switch
3. Disassemble the interior decoration namely the voltage condition of No.11 core of the
assembly and cup mat on the left-rear side of instrument system. The third line is the
the cab, observe the electronic centralized secondary steering output control voltage
controller, find K6 secondary steering relay condition namely the voltage condition of No.36
on the electronic centralized controller and core of the instrument system.
pull it out. Keep monitoring the instrument system from the
4. Adjust the digital multimeter to 50V range of steering pressure alert switch signal. The
voltage function. Find No.85 and No.86 steering system doesn't build voltage before turn
terminals on the relay socket according to the on the start switch, close the NC contact of the
sign on the relay, they are the sockets of steering pressure alert switch and earthing by
No.409 wire and No.212 wire. Insert red outer circuit, the level is low level, as shown in
probe into No.86 terminal of the relay socket, the second line of above illustration.
the black probe into No.85 terminal. Turn on the start switch, and start the engine, the
5. Turn on the start switch, observe the steering steering system pressure is built step by step,
system fault indicator of the instrument the NC contact of the steering pressure alert
system lightens or not, and observe the switch has been pushed open, the signal rises
digital multimeter reading. from low level to high level by the resistance
action inside the instrument system.
Test result: The steering pressure alert switch NC contact
closes newly and earthing by outer circuit when
The digital multimeter reading is between 24V operating and running the machine, the steering
and 31V. system pressure loses due to the fault, the
resistance action inside the instrument system is
counteracted. The signal declines from high level
to low level. The steering system fault indicator
lightens on the instrument system.
240
Electrical System
Instrument System

CPU inside the instrument system collects the 4. Adjust the digital multimeter to 200Ω range of
signal condition from the power supply system Ω function, one probe contacts with No.407
and the steering pressure alert switch, when the wire of the instrument system, another probe
low level signal of the steering pressure alert is connected to the lead copper core in the
switch reaches, the secondary steering exports cab.
+24V voltage to drive the secondary steering
control relay and then drives the steering motor. Test result:
As shown in the third line of above illustration.
The digital multimeter reading is 0Ω.
The battery power will be consumed rapidly due
to the big work current after the secondary
Conclusion:
steering motor starting to work. The work time of
the secondary steering motor is 60s which is
If the result does OK, the line doesn't have fault,
setup by CPU in the instrument system.
please turn to step 2.
Therefore, it will stop work automatically after
working for 60s. If the result doesn't OK, The line has open circuit,
check No.407 wire carefully, especially the
2-M-F Start State Indicator Fault Test receptacle, the round place, the active place
Procedure contacts with the metal plate.

Fault phenomenon definition: Step 2. Replace the instrument system.

The start state indicator doesn't lighten when 1. Turn off the start switch, disassemble the
starting the engine and running the motor. steering column, and replace the old
instrument system with a new one.
Check the start motor according to this service
manual if the start motor doesn't run. 2. Assemble the steering column, turn on the
start switch, start the engine, observe the
Step 1. Test the line fault. start state indicator lightens or not.

1. Turn off the start switch, disassemble the Conclusion:

steering column, and pull out the receptacle
of the instrument system. Find the receptacle If the result does OK, the start state indicator of
in the steering column of the instrument the original instrument system is damaged. Send
system. the old instrument system back to the factory for
service. The maintenance should be carried out
2. Pull No.407 wire connected to No.29 core of in the clean anti-static room, do not disassemble
the instrument system slightly by hand, judge the instrument system without permission.
its loose condition, and use the special tool to
connect it if it is loosed.
3. Prepare one 10m lead, divest the insulation
layer for about 10-20mm of the lead two
terminals, one terminal of the lead is
connected to No.407 wire or the copper
connector of No.183 wire, another is
connected to the receptacle of the instrument
system in the cab.
 241
Electrical System
Instrument System

2-N-F Parking Brake Low Pressure Alert 3. Adjust the digital multimeter to 200Ω, one
Indicator Fault Test Procedure probe contacts with No.2 core of the
instrument system, another probe is
Falut phenomenon definition: connected to No.16 core of the instrument
sysem (grounding).
The parking brake low pressure alert indicator
doesn't lighten when press the parking brake Test result:
button.
The digital multimeter reading is 0Ω.
The parking brake low pressure indicator doesn't
lighten when turn on the start switch, press the Conclusion:
parking brake button.
If the result doesn't OK, the line doesn't have
Step 1. Test the parking brake pressuren alert fault, the parking brake low pressure alert
switch is damaged or not. indicator inside the original the instrument
system is damaged. Send the instrument system
1. Turn off the start switch, find the parking back to the factory for service. The maintenance
brake pressure alert switch on the parking should be carried out in the clean anti-static
brake cylinder, pull out its two terminals, and room, do not disassemble the instrument system
push out the copper connector inside the without permission.
switch. Connect two copper connectors in
order to connect No.300 wire to No.231 wire. (1) If the result doesn't OK, the line has open
circuit. Check No.300 wire carefully,
2. Turn on the start switch, pull up the parking especially the receptacle, the round place,
brake and observe the parking brake and the active place contacts with the metal
pressure alert indicator lightens or not. plate.

Conclusion: (2) Check the grounding condition of No.231

wire carefully. The grounding resistance
If the result does OK, the parking brake pressure value is 0Ω or not.
alert switch is damaged.
If the result doesn't OK, please turn to step 2.

Step 2. Test whether No.300, No.231 wires

have line fault.

1. Turn off the start switch, disassemble the

steering column, and pull out the receptacle
of the instrument system. Find No.300 wire of
No.2 core. Pull No.300 wire connected to
No.2 core of the instrument system slightly by
hand, judge it is loosed or not, use the
special tool to connect it if it is loosed.
2. Keep connecting two coppers of the parking
brake pressure alert switch to each other in
order to connect No.312 wire to No.231 wire.
242
Electrical System
Instrument System

2-O-F Service Brake Low Pressure Alert 3. Adjust the digital multimeter to 200Ω, one
Indicator Fault Test Procedure probe contacts with No.10 core of the
instrument system, another probe is
Falut phenomenon definition: connected to No.16 core of the instrument
sysem (grounding).
The service brake low pressure indicator doesn't
lighten when the service brake system pressure Test result:
is low.
The digital multimeter reading is 0Ω.
For the machine stops for a long time, the
service brake low pressure indicator doesn't Conclusion:
lighten when turn on the start switch.
If the result doesn't OK, the line doesn't have
Step 1. Check the service brake low pressure fault, the service brake low pressure alert
alert switch is damaged or not. indicator inside the original instrument system is
damaged. Send the instrument system back to
1. Turn off the start switch, and find the service the factory for service. The maintenance should
brake low pressure alert switch on the pedal be carried out in the clean anti-static room, do
under the cab. Pull out two receptacles, push not disassemble the instrument system without
out the copper connector, and connect two permission.
copper connectors together in order to
connect No.303 wire to No.214 wire. (1) If the result doesn't OK, the line has open
circuit. Check No.303 wire carefully,
2. Observe the service brake low pressure alert especially the receptacle, the round place,
switch lightens or not when turn on the start the active place contacts with the metal plate.
switch but don't start the engine.
(2) Check the grounding condition of No.214
Conclusion: wire carefully. The grounding resistance
value is 0 Ω or not.
If the result does OK, the service brake low
pressure alert switch is damaged. 2-P-F Engine Oil Pressure Alert
Indicator Fault Test Procedure
If the result doesn't OK, please turn to step 2.
Falut phenomenon definition:
Step 2. Test whether No.303, No.214 wires
have line fault.
The engine oil pressure alert indicator doesn't
lighten when the engine oil pressure is low.
1. Turn off the start switch, disassemble the
steering column, pull out the receptacle of the The engine oil pressure alert indicator doesn't
instrument system. Find No.303 wire of lighten when turn on the start switch but don't
No.10 core. Pull No.303 wire connected to start the engine.
No.10 core of the instrument system slightly
by hand, judge its loose condition, and use Step 1. Test the engine oil pressure switch is
the special tool to connect it if it is loosed. damaged or not.
2. Keep connecting two copper connectors of
1. Turn off the start switch, and find the engine
the service brake low pressure alert switch
oil pressure alert switch under the engine
together in order to\ connect No.303 wire to
base housing, push out the copper
No.214 wire.
connector. Connect two copper connectors
together in order to connect No.301 wire to
No.229 wire.
 243
Electrical System
Instrument System

2. Turn on the start switch but don't start the (2) Check the grounding condition of No.229
engine, observe the engine oil pressure alert wire carefully. The grounding resistance
indicator lightens or not. value is 0Ω or not.

Conclusion: 2-Q-F Transmission Oil Pressure Alert

Indicator Fault Test Procedure
If the result does OK, the engine oil pressure
switch is damaged. Falut phenomenon definition:
If the result doesn't OK, please turn to step 2.
The transmission oil pressure alert indicator
Step 2. Test whether No.301, No.229 wires doesn't lighten when the transmission oil
have line fault. pressure is low.
The transmission oil pressure alert indicator
1. Turn off the start switch, disassemble the doesn't lighten when turn on the start switch but
steering column, pull out the receptacle of the don't start the engine.
instrument system. Find No.301 wire of No.3
core. Pull No.301 wire connected to No.3 Step 1. Test transmission oil pressure alert
core of the instrument system slightly by switch is damaged or not.
hand, judge its loose condition, and use the
special tool to connect it if it is loosed. 1. Turn off the start switch, find the transmission
2. Keep connecting two copper connectors of oil pressure alert switch under the
the service brake low pressure alert switch transmission. Pull out two receptacles, push
together in order to connect No.301 wire to out the copper connector, and connect two
No.229 wire. copper connectors together in order to
connect No.307 wire to No.231 wire.
3. Adjust the digital multimeter to 200Ω, one
probe contacts with No.3 core of the 2. Turn on the start switch but don't start the
instrument system, another probe is engine, observe the transmission oil pressure
connected to No.16 core of the instrument alert indicator lightens or not.
sysem (grounding).
Conclusion:
Test result:
If the result does OK, the transmission oil
The digital multimeter reading is 0Ω. pressure alert switch is damaged.
If the result doesn't OK, please turn to step 2.
Conclusion:
Step 2. Test whether No.307, No.231 wires
If the result doesn't OK, the line doesn't have have line fault.
fault, the engine oil pressure alert indicator inside
the original instrument system is damaged. Send 1. Turn off the start switch, disassemble the
the instrument system back to the factory for steering column, pull out the receptacle of the
service. The maintenance should be carried out instrument system. Find No.307 wire of
in the clean anti-static room, do not disassemble No.21 core. Pull No.307 wire connected to
the instrument system without permission. No.21 core of the instrument system slightly
(1) If the result doesn't OK, the line has open by hand, judge its loose condition, and use
circuit. Check No.301 wire carefully, the special tool to connect it if it is loosed.
especially the receptacle, the round place,
amd the active place contacts with the metal
plate.
244
Electrical System
Instrument System

2. Keep connecting two copper connectors of Step 1. Test the engine intake air filter alert
the transmission oil pressure alert switch switch is damaged or not.
together in order to connect No.307 wire to
No.231 wire. 1. Turn off the start switch, and find the engine
intake air filter alert switch on the engine air
3. Adjust the digital multimeter to 200Ω, one
filter. Pull out two receptacles, push out the
probe contacts with No.21 core of the
copper connector, and connect two copper
instrument system, another probe is
connectors together in order to connect
connected to No.16 core of the instrument
No.310 wire to No.229 wire.
sysem (grounding).
2. Turn on the start switch but don't start the
Test result: engine, observe the engine intake air filter
alert indicator lightens or not.
The digital multimeter reading is 0Ω.
Conclusion:
Conclusion:
If the result does OK, the engine intake air filter
If the result doesn't OK, the line doesn't have switch is damaged.
fault, the engine oil pressure alert indicator inside
If the result doesn't OK, please turn to step 2.
the original instrument system is damaged. Send
the instrument system back to the factory for
Step 2. Test whether No.310, No.229 wires
service. The maintenance should be carried out
have line fault.
in the clean anti-static room, do not disassemble
the instrument system without permission.
1. Turn off the start switch, disassemble the
(1) If the result doesn't OK, the line has open steering column, and pull out the receptacle
circuit. Check No.307 wire carefully, of the instrument system. Find No.310 wire of
especially the receptacle, the round place, No.14 core. Pull No.310 wire connected to
the active place contact with the metal plate. No.14 core of the instrument system slightly
by hand, judge its loose condition, and use
(2) Check the grounding condition of No.231
the special tool to connect it if it is loosed.
wire carefully. The grounding resistance
value is 0Ω or not. 2. Keep connecting two copper connectors of
engine intake air filter alert switch together in
2-R-F Engine Intake Air Filter Alert order to connect No.310 wire to No.229 wire.
Indicator Fault Test Procedure 3. Adjust the digital multimeter to 200Ω, one
probe contacts with No.14 core of the
Falut phenomenon definition: instrument system, another probe is
connected to No.16 core of the instrument
The engine intake air filter indicator doesn't sysem (grounding).
lighten when the engine air filter blocks.
When operating the machine, there is serious Test result:
black smoke (not includes the instants of starting
and step on the gas), must stop the machine to The digital multimeter reading is 0Ω.
check the engine air filter, the engine intake air
filter blocks but the alert indicator doesn't lighten.
 245
Electrical System
Instrument System

Conclusion: 3. Turn on the start switch and start the engine.

Observe the digital multimeter reading.
If the result doesn't OK, the line doesn't have
fault, the engine intake air filter alert indicator Test result:
inside the original instrument system is
damaged. Send the instrument system back to The digital multimeter reading is between 24V
the factory for service. The maintenance should and 31V.
be carried out in the clean anti-static room, do
not disassemble the instrument system without Conclusion:
permission.
If the result doesn't OK, the line doesn't have
(1) If the result doesn't OK, the line has open
fault, the engine charge indicator inside the
circuit. Check No.310 wire carefully,
original instrument system is damaged. Send the
especially the receptacle, the round place,
instrument system back to the factory for service.
and the active place contacts with the metal
The maintenance should be carried out in the
plate.
clean anti-static room, do not disassemble the
(2) Check the grounding condition of No.229 instrument system without permission.
wire carefully. The grounding resistance
If the result doesn't OK, No.800 wire has open
value is 0Ω or not.
circuit, check No.800 wire carefully, especially
the receptacle, the round place, the active place
2-S-F Engine Charge Indicator Fault contact with the metal plate.
Test Procedure
2-T-F Buzzer Fault Test Procedure
Fault phenomenon definition:
Fault phenomenon definition:
The voltage/service meter works normally after
starting the engine, the engine charge indicator When any one of the steering system fault
doesn't lighten when the service meter works indicator, engine oil pressure alert indicator,
normally. parking brake low pressure alert indicator and
Check it according to this service manual if the the service brake low pressure alert indicator
service meter of voltage/service meter doesn't lightens, the mute switch is at OFF state (not
time. mute), the buzzer doesn't beep.

Step 1. Test the voltage of No.800 wire on the Step 1. Test the voltage of No.417 wire of the
instrument system. mute switch.

1. Turn off the start switch, disassemble the 1. Turn off the start switch, use the screwdriver
steering column, and pull out the receptacle to prize the 8-joint pendant switch from the
of instrument system. Find No.800 wire of steering column (disassemble the steering
No.24 core. Pull No.800 wire connected to column if it can't be prized), find No.417 wire
No.24 core of the instrument system slightly of mute switch on the 8-joint pendant switch,
by hand, judge its loose condition, and use the mute switch is at OFF state (not mute).
the special tool to connect it if it is loosed. 2. Adjust the digital multimeter to 50V range.
2. Adjust the digital multimeter to 50V range. Insert red probe into No.417 wire hole of the
Insert red probe into No.24 core (No.800 mute switch receptacle, keep contacting with
wire) of the instrument system, the black copper piece inside No.417 wire. The black
probe is connected to No.16 core of the probe contacts with the metal housing (the
instrument sysem (grounding). place without paint) of the cab (grounding).
246
Electrical System
Instrument System

3. Turn on the start switch, pull up the parking 2-U-F Fault Test When the Instrument
brake button, and bserve the digital System Can't Work
multimeter reading.
Falut phenomenon definition:
Test result:
The guage pin doesn't return to 0, parts of
The digital multimeter reading is between 24V indicators don't give alarm after turning on the
and 31V. start switch.

Conclusion: Step 1. Test the voltage of No.122 wire of the

instrument system.
If the result does OK, please turn to step 2.
If the result doesn't OK, the instrument system 1. Turn off the start switch, disassemble the
has inner fault. steering column, find No.122 wire of No.9
core and No.200 wire of No.16 core, pull
Step 2. Test the voltage of No.418 wire of the them slightly by hand and judge their loose
mute switch. condition, use the special tool to connect
them if they are loosed.
4. Continue with step1, insert red probe of the 2. Prepare two pins, insert one into No.122 wire
digital multimeter into No.418 wire hole of the of No.9 core and make sure the pin contacts
mute switch receptacle, keep contacting with with the wire, insert another pin into No.200
copper piece inside No.418 wire, the black wire of No.16 core and make sure the pin
probe contacts with the metal housing (the contacts with the copper core. Please notice
place without paint) of the cab (grounding). that two pins don't contact with each other.

Test result: 3. Turn on the start switch and observe the

digital multimeter reading.
The digital multimeter reading is between 24V
and 31V. Test result:

Conclusion: The digital multimeter reading is between 24V

and 31V.
If the result does OK, the buzzer is damaged.
Conclusion:
If the result doesn't OK, the mute switch is
damaged. If the result does OK, the line doesn't have fault,
the instrument system has inner fault.
If the result doesn't OK, please check as follows:
(1) Check 5A fuse melts or not.
(2) Check the grounding resistance of No.200
wire is 0Ω or not.
(3) Check No.122 wire has fault or not.
 247
Electrical System
Instrument System

2-V-F Fault Test When the Instrument

System Can't Realize the Background
Illumination

Falut phenomenon definition:

Turn on the position light after turn on the start

switch, the instrument system background light
doesn't lighten and can not realize the
background illumination.

Step 1. Test the voltage of No.416 wire on the

instrument system.

1. Turn off the start switch, disassemble the

steering column, find No.416 wire of No.7
core and No.200 wire of No.6 core, pull them
slightly by hand and judge their loose
condition, use the special tool to connect
them if they are loosed.
2. Prepare two pins, insert one into No.416 wire
of No.7 core and make sure the pin contacts
with the copper core, insert another pin into
No.200 wire of No.16 core and make sure the
pin contacts with the copper core. Please
notice that two pins don't contact with each
other.
3. Turn on the start switch and observe the
digital multimeter reading.

Test result:

The digital multimeter reading is between 24V

and 31V.

Conclusion:

If the result does OK, the line doesn't have fault,

the instrument system has inner fault.
If the result doesn't OK, please check as follows:
(1) Check the grounding resistance of No.200
wire is 0Ω or not.
(2) Check No.122 wire has fault or not.
248
Electrical System
Electronic Diesel Engine System

Electronic Diesel Engine Electronic pedal accelerator provides

parameters for ECU by the changes of travel.
System ECU controls the fuel injection quantity and the
throttle open/close degree according to the
parameters provided by the electronic pedal
Introduction accelerator to adjust speed.
Enter into the fault code diagnostic mode by the
The electronic fuel injection system (EFI system)
electronic pedal accelerator, read the fault codes
which used electronic control unit (ECU) as the
forward sequencely by depressing down and
control center to test every parameter of the
releasing the pedal circularly, and read the
engine through various sensors installed on the
specific code number by the stop indicator on the
different positions of the engine. This system can
panel assembly. Please refer to the following
check all kinds of faults, give the users warning
STOP INDICATOR instruction for the read
through the corresponding warn indicators on the
methods.
panel, and display the corresponding fault code,
in order to maintain, service the machine and
Electronic Diesel Engine ECU
make sure it works normally.

Main Components

Electronic Pedal Accelerator

Part No.: 23C0075

CUP is the hard core in ECU, which has the

compute and control functions. ECU collects
every sensor signals, and computes, and then
transforms the results into control signals in
order to control the operation of the controlled
objects.
 249
Electrical System
Electronic Diesel Engine System

Data Diagnostic Interface

The communication mode of the data diagnostic

interface is J1939, it can communicate and
diagnose by using the computer installed with
After open the cover of the data diagnostic CUMMINS INSITE software after connected
interface (see illustration 3-4, 3-5), the computer successfully.
installed with CUMIMINS INSITE software
communicates with ECU straightly by the data Control Switches
diagnostic interface. It can read the fault code,
the fault content, the fault analysis, also can test
the various faults of the electronic diesel engine
system, and demarcate the ECU parameters at
the same time.

1 2

1. Diagnostic ON/OFF switch

2. Idle/diag (diagnostic) inc /dec switch
250
Electrical System
Electronic Diesel Engine System

Diagnostic ON/OFF switch Idle/diag (diagnostic) inc /dec switch

The idle/diag (diagnostic) inc /dec switch is at Press the idle/diag (diagnostic) inc/dec switch
idle set function when the diagnostic switch is at (this switch is reset switch) up/down to adjust the
OFF position. This switch is a pendant switch engine idle when the diagnostic switch is at OFF
contains self-lock, which is locked at OFF position, and the adjust range is 600-1200rev.
position, and must pull the buckle if turn it to ON When the diagnostic switch is at ON position, if
position. This design is to prevent the false the engine has more than two fauls, press up/
operation. When the diagnostic switch is at ON down the idle/diag (diagnostic) inc /dec switch to
position. If the engine has fault, the fault codes transform the engine fault codes, and the fault
will be displayed through the warn indicator on codes will be displayed through the warn
the panel assembly. indicator on the panel assembly.

NOTICE: Make sure this switch is usually at

OFF position.

The idle/diag (diagnostic) inc /dec switch is at

diagnostic inc/dec function when the diagnostic
switch is at ON position.
 251
Electrical System
Electronic Diesel Engine System

Electronic Diesel Engine Indicators The flash mode of diagnostic code is available
through the diagnostic ON/OFF switch or
accelerator pedal. The start switch must at ON
position and the engine shut off if need to enter
1
the fault code flash mode. Use the diagnostic
ON/OFF switch to enter this mode, ECM will
flash the 1st fault code automatically when the
diagnostic ON/OFF switch is at ON position.
Press the idle/diag (diagnostic) inc /dec switch
up/down for adjusting forward or backward the
fault code. Depress and release the accelerator
pedal circularly in order to enter the fault code
diagnostic mode, and let accelerator oil valve
open from 0% to 100% for three times. Once
entering into the diagnostic mode, depress down
and release the accelerator pedal circularly will
2 3 4 5 6 find the current fault code forwards in sequence.
Stop indicator displays the fault code illustration:
1. Engine speedometer Obtain No. 244 fault code.
Stop indicator displays as follows:
Flicker twice continuously→Stop→Flicker four
MAIN. times continuously→Stop→Flicker four times
STOP WARN. WTS WIF
continuously
Display progress of a diagnostic code (244) is
completed through the above order. Repeatly
display this code progress if there isn't choice to
display next code. Press the Idle/diag
(diagnostic) inc /dec switch up and down in
2. Stop indicator order to transform the engine fault codes if there
3. Warn indicator
4. Wait to start indicator are more than two fault codes. The fault code
also will be displayed through the stop indicator.
Stop Indicator The fault code description refers to the appendix.

The stop indicator symbol is STOP. This indicator NOTICE: If the stop indicator flashes fault
provides emergency information of the operator. code during operating, please contact with
These informations require the operator to your dealer and provide the fault code to the
respond quickly and take correct measure. The dealer for specific analysis.
operator needs to stop the machine and turn off
the engine to check. If the machine can not be Warn Indicator
stopped timely, the system will force the machine
to stop automatically according to the fault The warn indicator symbol is WARN. The warn
serious degree. This indicator also can be used indicator provides important information of the
for the fault code flash diagnosis. operator, and denotes the system faults, which
require the operator to notice these informations
in time. The warn indicator also can describe the
diagnostic fault codes.
252
Electrical System
Electronic Diesel Engine System

If the warn indicator flickers during operation, Wait to start indicator

please stop the machine immediately, and turn
off the start switch to shut off the engine. Then The symbol is WTS. When the operation
turn on the start switch again, turn the start temperature that the system tested inside the
switch to I position, and read the fault code machine is lower than 18°C, the machine will
according to DIAGNOSTIC ON/OFF SWITCH switch on the cold boot secondary device (the
section instruction. At last, consult with the grid heater) automatically for quicker warm-up of
technical service center in time to eliminate the the engine, and the indicator lightens at this time.
fault. The indicator goes out means that the
temperature has reached the desired
The warn indicator is also used as maintenance
requirement, the operator can start the engine
warn indicator. The warn indicator will lighten and
now.
the machine needs maintenance when the
service time is arrived at preset time (the default
NOTICE: MAIN indicator and WIF. indicator
system maintenance interval is 250 hours). It is
are not available for this machine.
not the fault warning, and no fault code displayed
although the warn indicator lightens.

Principle schematic
 253
Electrical System
Electronic Diesel Engine System

Work Principle (c) The pre-heating signal arrives at No.86

terminal of the grid heating realy through
Deutsh 50-pin connector and No.478
1. Two branches of battery provide power to the wire. No.85 terminal of the grid heating
electronic diesel engine system after turning relay groundings and forms current loop
on the battery disconnect switch. through NO.252 wire, Therefore, the
(a) The voltage passes No.101 wire and current brings magnetic field after
arrives at 30A fuse inside the electronic passing the grid heating relay winding
control box through XZ1 receptacle, then and then makes the relay contact
supplies power to ECU after passing XZ1 closed.The voltage reaches No.30
receptacle to No.113 wire and reaches terminal through No.87 terminal, then
XH7 Deutsh 4-pin connector. reaches the control winding terminal of
K14 heating contactor through No.489
(b) The voltage passes No.102 wire and wire, the heating contactor control
arrives at 150A fuse inside the electronic winding brings magnetic field and makes
control box, then reaches the contact of the contact closed. No.103 wire and
K14 heater through No.103 wire. No.488 wire connected, and the grid
2. Start the start switch, and turn it to I position, heater starts heating when the voltage
the power supply is on. Every branch fuse in arrives at the grid heater (see illustration
the control box has voltage, and two-way 3-14 for the installation position of the grid
fuses are related to the electronic diesel heater).
engine system among them. ECU stops power supply to No.487 wire
(a) The voltage arrives at No.160 wire and automatically after about 20s, the pre-heating is
No.161 wire through the electronic fuse, finished. ECU gives off signal to release the
and then divided into two branches. One WTS WARN, the indicator goes out, and the
way passes through No.160 wire to the operator can start the machine.
receptacle XJ6 and arrives at 9-pin data
diagnostic interface as the power supply
of the interface. The other way passes
through No.161 wire to XH1 and Deutsh
50-pin connector then arrives at
electronic diesel engine ECU for power
supply.
(b) The voltage arrives at No.172 wire
through the grid heating relay 10A fuse,
and passes XH1 receptacle to No.87
terminal of the grid heating relay inside
the electronic control box. (See
illustration 3-13, 3-14 for the installation
position of electronic control box, and the
installation of the fuse inside the
electronic control box and the relay). if
the operation temperature that ECU You can see the inner fuse and relay after open
system tested inside the machine is lower the cover of the electronic control box, the
than 18°C, ECU will give off pre-heating installation position illustration shows below:
signal and wait to start signal to panel
assembly indicator for clewing the users
that the machine is at WTS state.
254
Electrical System
Electronic Diesel Engine System

4. ECU measures various work parameters of

the engine by the sensors installed on the
engine, then arrives at the panel assembly to
2 provide the corresponding warning signal
1 after passing Deutsh 50-pin connector,
No.320,321,324 wire and XY3 receptacle.
The indicator will be lightened after receiving
the signal.
3
The corresponding warning signal of each wire
as follows:

320 Alarm signal

321 Wait to start signal
4
324 Stop signal
The engine rev signal ECU tested reaches the
panel assembly through No.704 wire, XY3
receptalce.
The speedometer displays the current engine rev
after the panel receiving ECU rev signal, the user
1. Heating relay 2. Grid heating relay can observe the variety of rev straightly.
3. 30A fuse 4. 150A fuse
See illustration 3-11 for the speedometer
installation position.
5. ECU arrives at the diagnostic ON/OFF switch
after passing Deutsh 50-pin connector
No.905 wire and XY3 receptacle, and adjusts
the idle speed by the idle/diag (diagnostic)
inc /dec switch or read the fault code by the
stop alert indicator on the panel assembly.
ECU arrives at the idle /diag inc/dec switch after
passing Deutsh 50-pin connector No.906,
No.907 wire and XY3 receptacle, and adjusts the
idle speed or read the fault code by the idle/diag
inc/dec switch.
6. ECU provides signal to the data diagnostic
interface after passing Deutsh 50-pin
3. ECU provides +5V voltage to the accelerator
connector No.750 wire and No.751 wire and
pedal by No.756 wire and No.758 wire, and
XH1, XJ4 receptacle. Through the straight
the accelerator pedal returns the feedback
communication between the data diagnostic
voltage to ECU through No.756 wire. This
interface and ECU, the user can read the
feedback voltage changes along with the
fault code and content.
accelerator pedal position. ECU controls the
oil spraying quantity accurately according to
the feedback signal in order to make the
engine gets the different rev.
 255
Electrical System
Electronic Diesel Engine System

7. Cooling water position switch is installed on 2. Test the voltage between No.756 wire and
the cooling water tank of engine, see the No.758 wire at XL3 with the voltmeter after
following picture. connecting the wire. The standard voltage is
5V. The wire may be off if there isn't voltage.

Step2. Check 5A fuse

1. Check the 5A fuse of the start switch power

inside the control box in the cab, and replace
the corresponding fuse if the fuse has
melted.

Step3. Check the accelerator

1. Firstly, check whether the voltage is 5V

between No.756 wire and No.758 wire at XL3
with the voltmeter?
2. Secondly, check the voltage between No.757
wire and No.758 wire, the normal value
The cooling water position switch closes when should be among 0.5V-4V along with the
the cooling water quantity reduces, and the water change of the accelerator position, the
level is lower than desired position. The cooling accelerator may be damaged if not.
water signal arrives at Deutsh 50-pin connector
by XH8. ECU warns and clews the users to fill Step4. Replace the accelerator
the cooling water after receiving the cooling
water position switch signal. Pay attention to the correspondence between
the wire colour and number of XL3 receptacle
Electrical Wiring Troubleshooting when replacing the accelerator.

Indicator Fault Test Procedure

Accelerator Fault Test Procedure
Fault phenomenon definition:
Fault phenomenon definition:
Turn on the start switch, 5 indicators should flash
The engine rev can't be increased, the engine firstly then go out in normal condition, there are
keeps idle when depressing down the faults if the indicators, especially the stop
accelerator. indicator, warn indicator don't lighten.

Step1. Check the wiring Fault test steps:

1. Check the wire connection, check No.756 1. Check the wire connection, check No.320
wire, No.757 wire, No.758 wire connection wire, No.321 wire, No.322 wire, No.323 wire,
condition from engine XH5 Deutsh 50-pin No.324 wire and No.704 wire connection
connector to XL3 receptacle, Connect the condition from the engine Deutsh 50-pin
wires again if they have loosened and make connector to XY5 receptacle of panel
sure the connection reliability assembly. Connect the wires again if they
have loosened and make sure the
connection reliability
256
Electrical System
Electronic Diesel Engine System

2. Check the 5A fuse of the start switch power

inside the control box in the cab, and replace
the corresponding fuse if the fuse has
melted.
3. Check the indicators. Electrify all indicators,
the indicators are damaged if they don't
lighten, replace the damaged indicators.

Typical Fault Codes

Typical fault codes are: 131, 132, 364, and 391;

131: Accelerator position sensor circuit -HV
short circuit;
132: Accelerator position sensor circuit -LV short
circuit;
The accelerator maybe invalid when there is
either 131 fault code or 132 fault code.
197: The engine cooling water level warning. The
engine cooling water level is low, please fill the
cooling water.
364: CAN communication error of fuel pump
control module - abnormal update rate.
391: The power supply voltage of fuel shut off
valve is wrong.
See "Engine Fault Code" on page 93 for detailed
electrical diesel engine fault codes.
 257
Electrical System
Electronic Diesel Engine System

Engine Fault Code

FAULT CODE LAMP COLOR CUMMIMUS DESCRIPTION

Engine Control Module Critical internal failure - Bad intelligent Device
111 Red
or Component
Engine Speed/Position Sensor Circuit lost both of two signals from the
115 Red magnetic pickup sensor - Data
Erratic, Intermittent, or incorrect
Intake Manifold Pressure Sensor Circuit – Voltage
122 Amber
Above Normal, or Shorted to High Source
Intake Manifold Pressure Sensor Circuit – Voltage
123 Amber
Below Normal, or Shorted to Low Source
Accelerator Pedal or Lever Position Sensor Circuit - Voltage Above
131 Red
Normal, or Shorted to High Source
Accelerator Pedal or Lever Position Sensor Circuit - Voltage Below
132 Red
Normal, or Shorted to Low Source
Remote Accelerator Pedal or Lever Position Sensor Circuit – Voltage
133 Red
Above Normal, or Shorted to High Source
Remote Accelerator Pedal or Lever Position Sensor Circuit – Voltage
134 Red
Below Normal, or Shorted to Low Source
Oil Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High
135 Amber
Source
Oil Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low
141 Amber
Source
Oil Pressure Low – Data Valid but Below Normal
143 Amber
Operational Range - Moderately Severe Level
Coolant Temperature Sensor Circuit – Voltage Above
144 Amber
Normal, or Shorted to High Source
Coolant Temperature Sensor Circuit – Voltage Below
145 Amber
Normal, or Shorted to Low Source
Coolant Temperature High - Data Valid but Above
146 Amber
Normal Operational Range - Moderately Severe Level
Accelerator Pedal or Lever Position Sensor Circuit – Abnormal
147 Red
Frequency, Pulse Width, or Period
Accelerator Pedal or Lever Position Sensor Circuit – Abnormal
148 Red
Frequency, Pulse Width, or Period
Coolant Temperature Low - Data Valid but Above
151 Red
Normal Operational Range - Most Severe Level
Intake Manifold Air Temperature Sensor Circuit - Voltage Above
153 Amber
Normal, or Shorted to High Source
Intake Manifold Air Temperature Sensor Circuit - Voltage Below
154 Amber
Normal, or Shorted to Low Source
Intake Manifold Air Temperature High – Data Valid but Above Normal
155 Red
Operational Range - Most Severe Level
Sensor Supply Voltage #2 Circuit – Voltage Below
187 Amber
Normal, or Shorted to Low Source
258
Electrical System
Electronic Diesel Engine System

FAULT CODE LAMP COLOR CUMMIMUS DESCRIPTION

Coolant Level Sensor Circuit - Voltage Above Normal, or Shorted to
195 Amber
High Source
Coolant Level Sensor Circuit - Voltage Below Normal, or Shorted to
196 Amber
Low Source
Coolant Level - Data Valid but Below Normal
197 Amber
Operational Range - Moderately Severe Level
211 None Additional Auxiliary Diagnostic Codes logged - Condition Exists
Engine Oil Temperature Sensor 1 Circuit - Voltage
212 Amber
Above Normal, or Shorted to High Source
Engine Oil Temperature Sensor 1 Circuit - Voltage
213 Amber
Below Normal, or Shorted to Low Source
Engine Oil Temperature - Data Valid but Above
214 Red
Normal Operational Range - Most Severe Level
Barometric Pressure Sensor Circuit – Voltage Above
221 Amber
Normal, or Shorted to High Source
Barometric Pressure Sensor Circuit – Voltage Below
222 Amber
Normal, or Shorted to Low Source
Sensor Supply Voltage #2 Circuit – Voltage Above
227 Amber
Normal, or Shorted to High Source
Coolant Pressure Sensor Circuit - Voltage Above
231 Amber
Normal, or Shorted to High Source
Coolant Pressure Sensor Circuit - Voltage Below
232 Amber
Normal, or Shorted to Low Source
Coolant Pressure - Data Valid but Below Normal
233 Amber
Operational Range - Moderately Severe Level
Engine Speed High - Data Valid but Above Normal
234 Red
Operational Range - Most Severe Level
Coolant Level Low - Data Valid but Below Normal
235 Red
Operational Range - Most Severe Level
External Speed Input (Multiple Unit Synchronization) - Data Erratic,
237 Amber
Intermittent, or Incorrect
Sensor Supply Voltage #3 Circuit – Voltage Below
238 Amber
Normal, or Shorted to Low Source
241 Amber Vehicle Speed Sensor Circuit - Data Erratic, Intermittent, or Incorrect
Vehicle Speed Sensor Circuit tampering has been detected – Abnormal
242 Amber
Rate of Change
Fan Control Circuit - Voltage Below Normal, or
245 Amber
Shorted to Low Source
Ambient Air Temperature Sensor Circuit - Voltage
249 Amber
Above Normal, or Shorted to High Source
Ambient Air Temperature Sensor Circuit - Voltage
256 Amber
Below Normal, or Shorted to Low Source
Engine Fuel Temperature - Data Valid but Above
261 Amber
Normal Operational Range - Moderately Severe Level
Engine Fuel Temperature Sensor 1 Circuit - Voltage
263 Amber
Above Normal, or Shorted to High Source
 259
Electrical System
Electronic Diesel Engine System

FAULT CODE LAMP COLOR CUMMIMUS DESCRIPTION

Engine Fuel Temperature Sensor 1 Circuit - Voltage
265 Amber
Below Normal, or Shorted to Low Source
268 Amber Fuel Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect
High Fuel Pressure Solenoid Valve Circuit – Voltage
271 Amber
Below Normal, or Shorted to Low Source
High Fuel Pressure Solenoid Valve Circuit – Voltage
272 Amber
Above Normal, or Shorted to High Source
Fuel Pumping Element (Front) – Mechanical System
275 Amber
Not Responding Properly or Out of Adjustment
High Fuel Pressure Solenoid Valve #1 – Mechanical System Not
281 Amber
Responding Properly or Out of Adjustment
Engine Speed/Position Sensor (Crankshaft) Supply Voltage Circuit -
284 Amber
Voltage Below Normal, or Shorted to Low Source
285 Amber SAE J1939 Multiplexing PGN Timeout Error - Abnormal Update Rate
SAE J1939 Multiplexing Configuration Error – Out of
286 Amber
Calibration
SAE J1939 Multiplexing Accelerator Pedal or Lever Sensor System
287 Red
Error - Received Network Data In Error
SAE J1939 Multiplexing Remote Accelerator Pedal or
288 Red
Lever Data Error - Received Network Data In Error
Auxiliary Temperature Sensor Input # 1 Circuit - Voltage Above Normal,
293 Amber
or Shorted to High Source
Auxiliary Temperature Sensor Input # 1 Circuit - Voltage Below Normal,
294 Amber
or Shorted to Low Source
Barometric Pressure Sensor Circuit - Data Erratic, Intermittent, or
295 Amber
Incorrect
Auxiliary Pressure Sensor Input 1 - Special
296 red
Instructions
Auxiliary Pressure Sensor Input # 2 Circuit - Voltage
297 Amber
Above Normal, or Shorted to High Source
Auxiliary Pressure Sensor Input # 2 Circuit - Voltage
298 Amber
Below Normal, or Shorted to Low Source
Real Time Clock Power Interrupt - Data Erratic, Intermittent, or
319 Maint
Incorrect
Injector Solenoid Cylinder #1 Circuit – Current Below
322 Amber
Normal, or Open Circuit
Injector Solenoid Cylinder #5 Circuit – Current Below
323 Amber
Normal, or Open Circuit
Injector Solenoid Cylinder #3 Circuit – Current Below
324 Amber
Normal, or Open Circuit
Injector Solenoid Cylinder #6 Circuit – Current Below
325 Amber
Normal, or Open Circuit
Injector Solenoid Cylinder #2 Circuit – Current Below
331 Amber
Normal, or Open Circuit
Injector Solenoid Cylinder #4 Circuit – Current Below
332 Amber
Normal, or Open Circuit
260
Electrical System
Electronic Diesel Engine System

FAULT CODE LAMP COLOR CUMMIMUS DESCRIPTION

Coolant Temperature Sensor Circuit – Data Erratic, Intermittent, or
334 Amber
Incorrect
Idle Shutdown Vehicle Accessories Relay Driver Circuit - Voltage
338 Amber
Above Normal, or Shorted to High Source
Idle Shutdown Vehicle Accessories Relay Driver Circuit - Voltage Below
339 Amber
Normal, or Shorted to Low Source
341 Amber Engine Control Module data lost - Data Erratic, Intermittent, or Incorrect
Electronic Calibration Code Incompatibility - Out of
342 Red
Calibration
Engine Control Module Warning internal hardware failure - Bad
343 Amber
Intelligent Device or Component
Injector Power Supply - Bad Intelligent Device or
351 Amber
Component
Sensor Supply Voltage #1 Circuit – Voltage Below
352 Amber
Normal, or Shorted to Low Source
Sensor Supply Voltage #1 Circuit – Voltage Above
386 Amber
Normal, or Shorted to High Source
Accelerator Pedal or Lever Position Sensor Supply Voltage Circuit -
387 Amber
Voltage Above Normal, or Shorted to High Source
Oil Pressure Low – Data Valid but Below Normal
415 Red
Operational Range - Most Severe Level
Water in Fuel Indicator High - Data Valid but Above
418 Maint.
Normal Operational Range – Least Severe Level
422 Amber Coolant Level - Data Erratic, Intermittent, or Incorrect
Engine Oil Temperature - Data Erratic, Intermittent, or
425 Amber
Incorrect
Water in Fuel Sensor Circuit - Voltage Above Normal, or Shorted to
428 Amber
High Source
Water in Fuel Sensor Circuit - Voltage Below Normal, or Shorted to Low
429 Amber
Source
Accelerator Pedal or Lever Idle Validation Circuit - Data Erratic,
431 Amber
Intermittent, or Incorrect
432 Red Accelerator Pedal or Lever Idle Validation Circuit - Out of Calibration
Intake Manifold Pressure Sensor Circuit - Data
433 Amber
Erratic, Intermittent, or Incorrect
434 Amber Power Lost without Ignition Off - Data Erratic, Intermittent, or Incorrect
435 Amber Oil Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect
Battery #1 Voltage Low - Data Valid but Below Normal Operational
441 Amber
Range – Moderately Severe Level
Battery #1 Voltage High - Data Valid but Above Normal Operational
442 Amber
Range – Moderately Severe Level
Accelerator Pedal or Lever Position Sensor Supply Voltage Circuit -
443 Amber
Voltage Below Normal, or Shorted to Low Source
Fuel Pressure High - Data Valid but Above Normal
449 Red
Operational Range – Moderately Severe Level
 261
Electrical System
Electronic Diesel Engine System

FAULT CODE LAMP COLOR CUMMIMUS DESCRIPTION

Injector Metering Rail #1 Pressure Sensor Circuit - Voltage Above
451 Amber
Normal, or Shorted to High Source
Injector Metering Rail #1 Pressure Sensor Circuit - Voltage Below
452 Amber
Normal, or Shorted to Low Source
Intake Manifold 1 Temperature - Data Valid but Above
488 Amber
Normal Operational Range - Moderately Severe Level
Multiple Unit Synchronization Switch Circuit - Data
497 Amber
Erratic, Intermittent, or Incorrect
OEM Intermediate (PTO) Speed switch Validation - Data Erratic,
523 Amber
Intermittent, or Incorrect
Auxiliary Input/Output 2 Circuit - Voltage Above
527 Amber
Normal, or Shorted to High Source
Auxiliary Alternate Torque Validation Switch - Data
528 Amber
Erratic, Intermittent, or Incorrect
Auxiliary Input/Output 3 Circuit - Voltage Above
529 Amber
Normal, or Shorted to High Source
Accelerator Pedal or Lever Idle Validation Circuit - Voltage Below
551 Amber
Normal, or Shorted to Low Source
Injector Metering Rail #1 Pressure High – Data Valid but Above Normal
553 Amber
Operational Range - Moderately Severe Level
554 Amber Fuel Pressure Sensor Error - Data Erratic, Intermittent, or Incorrect
Injector Metering Rail #1 Pressure Low – Data Valid but Below Normal
559 Amber
Operational Range - Moderately Severe Level
Starter Relay Circuit - Voltage Above Normal, or
584 Amber
Shorted to High Source
Starter Relay Circuit - Voltage Below Normal, or
585 Amber
Shorted to Low Source
Turbocharger #1 Speed High - Data Valid but Above Normal
595 Amber
Operational Range – Moderately Severe Level
Electrical Charging System Voltage High – Data Valid but Above
596 Amber
Normal Operational Range - Moderately Severe Level
Electrical Charging System Voltage Low – Data Valid but Below Normal
597 Amber
Operational Range - Moderately Severe Level
Electrical Charging System Voltage Low – Data Valid but Below Normal
598 Red
Operational Range - Most Severe Level
649 Maint Change Lubricating Oil and Filter – Condition Exists
Turbocharger #1 Speed Low - Data Valid but Below Normal Operational
687 Amber
Range – Moderately Severe Level
Primary Engine Speed Sensor Error – Data Erratic, Intermittent, or
689 Amber
Incorrect
Turbocharger #1 Compressor Inlet Temperature Sensor Circuit –
691 Amber
Voltage Above Normal, or Shorted to High Source
Turbocharger #1 Compressor Inlet Temperature Sensor Circuit –
692 Amber
Voltage Below Normal, or Shorted to Low Source
ECM Internal Temperature Sensor Circuit - Voltage
697 Amber
Above Normal, or Shorted to High Source
262
Electrical System
Electronic Diesel Engine System

FAULT CODE LAMP COLOR CUMMIMUS DESCRIPTION

ECM Internal Temperature Sensor Circuit - Voltage
698 Amber
Below Normal, or Shorted to Low Source
Extended Crankcase Blow-by Pressure Circuit - Voltage Above
719 Amber
Normal, or Shorted to High Source
Extended Crankcase Blow-by Pressure Circuit - Voltage Below Normal,
729 Amber
or Shorted to Low Source
Engine Speed/Position #2 mechanical misalignment between camshaft
and crankshaft sensors - Mechanical System Not Responding Properly
731 Amber
or
Out of Adjustment
Engine Speed/Position #2 Camshaft sync error - Data
753 Amber
Erratic, Intermittent, or Incorrect
757 Amber Electronic Control Module data lost - Condition Exists
Engine Speed Sensor (Camshaft) Error – Data
778 Amber
Erratic, Intermittent, or Incorrect
Warning Auxiliary Equipment Sensor Input # 3 (OEM Switch) - Root
779 Amber
Cause Not Known
Cylinder Power Imbalance Between Cylinders - Data
951 None
Erratic, Intermittent, or Incorrect
1117 None Power Lost With Ignition On - Data Erratic, Intermittent, or Incorrect
Injector Cylinder #1 - Mechanical System Not
1139 Amber
Responding Properly or Out of Adjustment
Injector Cylinder #2 - Mechanical System Not
1141 Amber
Responding Properly or Out of Adjustment
Injector Cylinder #3 - Mechanical System Not
1142 Amber
Responding Properly or Out of Adjustment
Injector Cylinder #4 - Mechanical System Not
1143 Amber
Responding Properly or Out of Adjustment
Injector Cylinder #5 - Mechanical System Not
1144 Amber
Responding Properly or Out of Adjustment
Injector Cylinder #6 - Mechanical System Not
1145 Amber
Responding Properly or Out of Adjustment
Accelerator Pedal or Lever Position Sensor 2 Circuit - Voltage Above
1239 Amber
Normal, or Shorted to High Source
Accelerator Pedal or Lever Position Sensor 2 Circuit - Voltage Below
1241 Amber
Normal, or Shorted to Low Source
Accelerator Pedal or Lever Position Sensor 1 and 2 - Data Erratic,
1242 Red
Intermittent, or Incorrect
Control Module Identification Input State Error - Data
1256 Amber
Erratic, Intermittent, or Incorrect
Control Module Identification Input State Error - Data
1257 Red
Erratic, Intermittent, or Incorrect
Injector Metering Rail 1 Pressure - Data Valid but Above Normal
1911 Amber
Operational Range - Most Severe Level
Coolant Temperature 2 Sensor Circuit - Voltage
2111 Amber
Above Normal, or Shorted to High Source
 263
Electrical System
Electronic Diesel Engine System

FAULT CODE LAMP COLOR CUMMIMUS DESCRIPTION

Coolant Temperature 2 Sensor Circuit - Voltage
2112 Amber
Below Normal, or Shorted to Low Source
Coolant Temperature 2 - Data Valid but Above
2113 Amber
Normal Operational Range - Moderately Severe Level
Coolant Temperature 2 - Data Valid but Above
2114 Red
Normal Operational Range - Most Severe Level
Coolant Pressure 2 Circuit - Voltage Above Normal, or Shorted to High
2115 Amber
Source
Coolant Pressure 2 Circuit - Voltage Below Normal, or
2116 Amber
Shorted to Low Source
Coolant Pressure 2 - Data Valid but Below Normal
2117 Amber
Operational Range - Moderately Severe Level
Sensor Supply Voltage #4 Circuit – Voltage Above
2185 Amber
Normal, or Shorted to High Source
Sensor Supply Voltage #4 Circuit – Voltage Below
2186 Amber
Normal, or Shorted to Low Source
Auxiliary Equipment Sensor Input 3 Engine Protection
2195 Red
Critical - Special Instructions
Fuel Pump Delivery Pressure - Data Valid but Below Normal
2215 Amber
Operational Range - Moderately Severe Level
Fuel Pump Delivery Pressure - Data Valid but Above Normal
2216 Amber
Operational Range – Moderately Severe Level
ECM Program Memory (RAM) Corruption - Condition
2217 Amber
Exists
Injector Metering Rail 1 Pressure - Data Valid but Below Normal
2249 Amber
Operational Range - Most Severe Level
Fuel Priming Pump Control Signal Circuit – Voltage
2265 Amber
Above Normal, or Shorted to High Source
Fuel Priming Pump Control Signal Circuit – Voltage
2266 Amber
Below Normal, or Shorted to Low Source
Fuel Inlet Meter Device - Data Valid but Above
2292 Amber
Normal Operational Range - Moderately Severe Level
Fuel Inlet Meter Device flow demand lower than expected - Data Valid
2293 Amber
but Below Normal Operational Range - Moderately Severe Level
2311 Amber Fueling Actuator #1 Circuit Error – Condition Exists
Engine Speed / Position Sensor #1 - Data Erratic, Intermittent, or
2321 None
Incorrect
Engine Speed / Position Sensor #2 - Data Erratic, Intermittent, or
2322 None
Incorrect
Turbocharger speed invalid rate of change detected - Abnormal Rate of
2345 Amber
Change
Turbocharger Turbine Inlet Temperature (Calculated)
2346 None - Data Valid but Above Normal Operational Range – Least Severe
Level
264
Electrical System
Electronic Diesel Engine System

FAULT CODE LAMP COLOR CUMMIMUS DESCRIPTION

Turbocharger Compressor Outlet Temperature
2347 None (Calculated) - Data Valid but Above Normal
Operational Range – Least Severe Level
Engine Brake Actuator Circuit #1 – Voltage Below
2362 Amber
Normal, or Shorted to Low Source
Engine Brake Actuator Circuit #2 – Voltage Below
2363 Amber
Normal, or Shorted to Low Source
Engine Brake Actuator Circuit #1 – Voltage Above
2366 Amber
Normal, or Shorted to High Source
Engine Brake Actuator Circuit #2 – Voltage Above
2367 Amber
Normal, or Shorted to High Source
Fan Control Circuit - Voltage Above Normal, or
2377 Amber
Shorted to High Source
VGT Actuator Driver Circuit - Voltage Below Normal, or Shorted to Low
2384 Amber
Source
VGT Actuator Driver Circuit - Voltage Above Normal, or Shorted to High
2385 Amber
Source
Intake Air Heater #1 Circuit - Voltage Above Normal, or Shorted to High
2555 Amber
Source
Intake Air Heater #1 Circuit - Voltage Below Normal, or Shorted to Low
2556 Amber
Source
Auxiliary PWM Driver #1 - Voltage Above Normal, or
2557 Amber
Shorted to High Source
Auxiliary PWM Driver #1 - Voltage Below Normal, or
2558 Amber
Shorted to Low Source
Engine Coolant Temperature High - Data Valid but
2963 None Above Normal Operational Range - Least
Severe Level
Intake Manifold Temperature High - Data Valid but
2964 None Above Normal Operational Range - Least
Severe Level
Intake Manifold Pressure Sensor Circuit - Data
2973 Amber
Erratic, Intermittent, or Incorrect
 265
Electrical System
Shift Control System (Fully-Automatic)

Shift Control System (Fully-

Transmission electrical control system
Automatic) components

SHIFT SOLENOID
Introduction LEVER GROUP

SPEED BACKUP
This machine uses ZF transmission and axle. SENSOR ALARM
OUTPUT
The transmission is electro-hydraulic 4WG-200. TRANSMISSION
SPEED ELECTRONIC
This manual introduces electronic control SENSOR NEUTRAL
CONTROL STARTING
component of transmission, called the shift OUTPUT
control system. POWER
SHUT OFF
The shift control system of CLG856III wheel SPEEDMETER
loader has two optional modes, one is fully-auto HARNESS
shift control mode, another is manual shift control INFORMATION
EXCHANGE
mode, and they belong to the different serial AND
number of the machine. The users can select the DIAGNOSE
suitable machine mode according to their TERMINAL

operation habits.
This section mainly introduces the shift control
system full-automatic mode. The next section will
introduce the manual shift control mode.
EST-25T electronic control unit of the shift
control sytem receives the outer signals from the
gear selector, the speed sensor, KD key,
disposes these signals and sends them into the
computer to calculate. CPU will judge the
machine running state according to contrast
signals of two speed sensors and other signals
and drive the shift control valve on the
transmission for getting the desired gear by
output circuit. This gear may be lower than the
operator selecting gear but not exceeding the
operator selecting gear according to the running
state.
The difference with the semi-automatic mode is:
the machine load condition and real speed
decide the transmission output speed but not
operator pre-selective speed.
266
Electrical System
Shift Control System (Fully-Automatic)

Main Components pilot control lever with shift control lever together.
In this section, just introduce shift control function
ERGO-II gear selector of ERGO-II gear selector, and its pilot control
function will be introduced at electronic section
(auto reset section) of service manual.
The ERGO-II gear selector is located on the pilot
valve of right side of cab, which is integrated the The operation button's fucntion on the ERGO-II
gear selector panel shows as below.

Shift control lever

 267
Electrical System
Shift Control System (Fully-Automatic)

Work Principle The inner micro-switches run when the operator

selects the gear and direction, these variational
The gear selector contains many micro-switches gears and direction signals enter into EST-25T
inside. electronic control unit through the wiring harness
connection.

Principle schematic
268
Electrical System
Shift Control System (Fully-Automatic)

See above illustration, it is the gear selector ERGO-II gear selector fault test
inner principle drawing; the following illustration
is the micro-switch action connection drawing. The inner micro-switches of gear selector are all
Use the digital multimeter to check the gear instant switches. It needs to keep connectiong
selector fault accroding to above illustration. But condition manually during measurement. See the
this method is not suitable for checking the following methods, use the resistance function of
damage condition of micro-switches' contacts digital multimeter to measure fault, test them if
inside the gear selector. It will show no fault by doubt that ERGO-II gear selector has fault. This
the digital multimeter measurement, but it section will introduce the method of fault test by
doesn't work normally due to the inner contacts using the voltage function of digital multimeter.
damage.
1. Turn off the start switch, open the pilot valve
control box under the ERGO-II gear selector,
pull out X2,X3 receptacles.
2. Refer to above illustration. Adjust the digital
multimeter to 200Ω range of resistance
function. Insert probe into the corresponding
core of lead combinations under the
receptacle of gear selector (the color
delegates the lead color): [RED,YELLOW],
[RED,PINK],[RED,BROWN], the digital
multimeter reading is 0.
3. Insert one probe of multimeter into the
corresponding core of receptacle red lead,
insert another probe into the corresponding
core (measure [RED,WHITE] combination) of
white lead, the digital multimeter reading is 1.
Press F button on the ERGO-II gear selector
by hand, the multimeter reading turns to 0,
but after releasing the button, the multimeter
reading turns back to 1 again. With the same
principle, measure [RED,YELLOW]
Generally, ERGO-II gear selector has lock combination and press F button, the
function in order to prevent error operation, multimeter reading changes from
unlock ERGO-II gear selector firstly when shift "0"→"1"→"0".
the machine. The unlock is setup by the 4. Insert one probe of multimeter into the
software, sometimes press KD button long time, corresponding core of receptacle red lead,
sometimes press KD button+F button (or R insert another probe into the corresponding
button) on the gear selector at the same time. core (measure [RED,WHITE] combination) of
There are different unlock methods for each white lead, the digital multimeter reading is 1.
machine, the details refer to the machine Press R button on the ERGO-II gear selector
operation manual, CLG856III wheel loader by hand, the multimeter reading turns to 0,
maybe have not gear selector lock function. but after releasing the button, the multimeter
reading turns back to 1 again. With the same
principle, measure [RED,PINK] combination
and press R button, the multimeter reading
changes from "0"→"1"→"0".
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5. Insert one probe of multimeter into the

corresponding core of receptacle red lead,
insert another probe into the corresponding
core (measure [RED,BROWN] combination)
of brown lead, the digital multimeter reading
is 0. Press N button on the ERGO-II gear
selector by hand, the multimeter reading
turns to 1, but after releasing the button, the
multimeter reading turns back to 0 again.
6. Insert one probe of multimeter into the
corresponding core of receptacle red lead,
insert another probe into the corresponding
core (measure [RED,BLUE] combination) of
blue lead, the digital multimeter reading is 1.
Press "+"button on the ERGO-II gear selector
by hand, the multimeter reading turns to 0,
but after releasing the button, the multimeter
reading turns back to 1 again.
7. Insert one probe of multimeter into the
corresponding core of receptacle red lead,
insert another probe into the corresponding
core (measure [RED,ORANGE] combination)
of orange lead, the digital multimeter reading
is 1. Press "-" button on the ERGO-II gear
selector by hand, the multimeter reading
turns to 0, but after releasing the button, the
multimeter reading turns back to 1 again.
8. Insert one probe of multimeter into the
corresponding core of receptacle red lead,
insert another probe into the corresponding
core (measure [RED,PURPLE] combination)
of purple lead, the digital multimeter reading
is 1. Press KD button on the ERGO-II gear
selector by hand, the multimeter reading
turns to 0, but after releasing the button, the
multimeter reading turns back to 1 again.
Most of the ERGO-II gear selectors that passed
the above tests successfully are good selectors.
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Display

1. Display of the operator select gear 2. Forward driving driection 3. Display of fault codes and real gear
4. Symbol for error in the system 5. Reverse driving direction

The display is located on right side of the front The middle area shows the real gear of
panel, which the operator can observe by eye. transmission during normal machine operation.
The display is used for display the select gear of In full-auto shift control system, the selected gear
the operator in normal driving, the real gear of of transmission lies on the load condition and the
machine driving and driving direction. The real speed but not the operator pre-select gear.
display is also used to show service information N shows NEUTRAL gear in this area. NN shows
and fault codes when the shift control system NO NEUTRAL gear. F+ number shows
has fault. FORWARD gear, No.1, 2, 3, 4 show gears. For
example, F3 shows FORWARD III gear. R+
The display uses CAN to realize the data
number shows REVERSE gear, No.1, 2, 3, 4
communication.
show gears. For example, R3 shows REVERSE
In the display, Left area is composed by upwards III gear. The middle area shows the fault codes
arrow, downwards arrow and four middle bars. when the shift control system has fault. Refer to
The upwards arrow lightens, which means the Function Operation in this section for details.
machine driving direction is forward, and vice
versa. Four middle bars show the operator pre-
select gear, and each bar shows one gear. For
example, the operator pre-select gear is III gear
if there are 3 bars lightened at the same time.
Right area shows service symbols, the shift
control system has fault when the spanner
symbol appears, which needs repair.
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Speed sensor l The speed sensor is composed by winding,

permanent magnet, and pole. The winding is
wraped around the pole, which is connected to
permanent magnet. The magnetic force line of
magnetic field produced around the permanent
magnet passes through the air gap, the teeth of
gear, and forms closed magnetic circuit.
Sometimes the magnetic field effects on teeth
1 gap, sometimes on teeth during the gear rotation
2 SPEED SENSOR for changing the air gap, and the flux is changing
along with the air gap. The variational flux
induces the proportionable sine signal with rev in
The full-auto shift control system machine is the winding, which was delivered into electronic
assembled with two speed sensors, which are control unit for disposal by wiring harness
used separately to test the input gear speed and connection.
the output gear speed of transmission. See
solenoid and clutch action drawing for the Installation of the Speed Sensor
specific location. EST-25T electronic control unit
needs these two speeds to judge the states of The installation of the speed sensor is very
the diesel engine and the real speed, and important. Generally, keep L value at
analyze the load condition and the speed 0.5+0.3mm. See above illustration, if the size of
condition for deciding the real machine gear. L is bigger, the effect of the magnetic field will
decrease along with the increasing distance due
Principle schematic
to the magnetic field's limited effect, and the
winding can't induce the signal. If the distance is
too close, the speed sensor will be damaged by
the gear in high speed rotation due to the
mechanism error.
Obseve the speed sensor fixing hole by eye and
find the tooth top before installation in lab, use
the vernier caliper to measure the distance from
installation surface to tooth top, and select the
suitable washer for the speed sensor according
to the measuring value. Then install it.
If replace and repair on the machine,
Work Principle disassemble the old speed sensor, clean the
fixing washer, and install it on the new speed
The speed sensor is installed on the tansmission sensor. Then screw the speed sensor into its
housing for testing the output gear rev of the fixing hole.
transmission. If the electronic control unit still can't induce the
sensor signal after installation, must install the
speed sensor over again. The steps as follows:
1. Remove the speed sensor. Align a gear tooth
directly in the center of the threaded sensor
opening.
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2. By hand, screw the sensor into the hole until

the end of the sensor just makes contact with
the gear tooth.
3. Turn the sensor back out 1/2 turn(180°in the
counterclockwise direction). This sets air gap
(L) to 0.5+0.3mm.
4. Measure the gap between the transmission
fixing surface and speed sensor fixing
surface, select the suitable washer,
disassemble the speed sensor, and put the
washer on it, then assemble it over again.

CAUTION: The receptacle wiring harness

connected to the speed sensor must
downward lest rain water should inflow the
receptacle along with wiring harness and
corrupt the core of the receptacle and the pin
of the speed sensor.

Measurement of the Speed Sensor CAUTION: When the machine needs

weld maintenance, must pull out X1
Use the digital multimeter to test the speed receptacle of EST-25T electronic control unit,
sensor, the resistance value is 1020±100Ω. otherwise the electronic control unit may be
Use the resistance range of multimeter to test, burnt due to the strong impulse current
remove the receptacle of the wiring harness caused by welding. Connect X1 receptacle
connected to the speed sensor (thread after welding, otherwise the machine couldn't
connection), measure the resistance value be started.
between two column pins of the speed sensor,
EST-25T Electronic control unit switch
the value should be about 1020Ω. Otherwise, the
speed sensor is damaged.

Electronic Control Unit EST

EST-25T electronic control unit is the core

component of the shift control system. See
illustration 4-1, the pre-select gear signal, speed
sensor signal, KD signal, transmission clutch cut-
off signal are delivered into EST-25T electronic
control unit for disposal and calculation. EST-25T
outputs control signals to drive solenoid group for
combination and finish each clutch switching,
then finish transmission clutch switching finally
after disposal. At the same time, EST-25T
outputs NEUTRAL signal to drive Neutral/start
interlock relay action when ERGO-II gear
selector is at NEUTRAL. It also output reverse
warning signal to drive the reverse warning relay.
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Solenoid
Shift control valve

The shift control valve contains 5 solenoids, M1-

M5, their positions show as above illustration.
The solenoid group is controlled by EST-25T
electronic control unit, which gives off the
corresponding gear signals according to the
operator pre-select gear signal, KD button
condition, clutch cut-off condition, the machine
running speed and load condition, and realizes
through output the driving voltage to solenoid. In
the transmission, shift or direction change are
realized through turn on and off the oil flow to the
clutches.
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Electrical System
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Solenoid and clutch action drawing

"●"The corresponding solenoid works.

"○"The corresponding solenoid works, but the corresponding solenoid is cut off temporarily when the machine executes
clutch cut-off function.
See above illustration for each gear solenoid in the transmission at the same time.
work condition and the corresponding mating
See above illustration, two speed sensors are
clutch work condition. For example, M2, M3, M4
assembled in the fully-auto shift control system.
solenoids in the shift control valve work when the
machine is at F1 gear, and K1, KV clutches mate
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Oil circulation diagram 4WG 200

Contrast illustration 4-12 oil circulation diagram The transmission clutch cut-off function is just
4WG-200 with illustration 4-11 solenoid and used at gear I& II, whatever the machine is at
clutch action drawing, through which can get the FORWARD and REVERSE gear. Their actions in
control relationship between the solenoid and the the transmission show: solenoid M3 or M1 is cut
clutch. It is basically that: solenoid M5 controls off when execute clutch cut-off order, namely KV
the clutch K4, M3 controls KV, M1 controls KR, or KR clutch is cut off. Because KV and KR
the solenoid is electrified and the clutch works. clutches are separately the Forward or Reverse
Solenoids M2 and M4 control the clutch K1, K2, clutches, therefore, the performance of the
K3 together. M4 is electrified, M2 isn't electrified, transmission clutch cut-off order is realized by
and K2 clutch works. M2 and M4 are electrified cut-off direction clutch.
together, K1 clutch works. M2 and M4 aren't
electrified, K3 clutch works.
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Electrical System
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Solenoid test

The solenoids' resistances are about 90Ω, X9

located on the shift control valve is solenoid
group receptacle. Remove X9 receptacle, and
observe A, B, C, D, E, F cores from faucet, F is
the common core of 5 solenoids.
Use the digital multimeter's resistance function to
test X9 receptacle (the terminal of shift control
valve), the resistance values of A-F, B-F, C-F, D-
F, E-F should be about 85-100Ω. Otherwise, the
solenoid is damaged.

Function Operation

The shift control system can complete the

following operations.
1
4-A Shift and Change Running Direction

The operator selects the running direction and

gear by operating ERGO-II gear selector; these
signals are sent into EST-25T electronic control
unit, which also received the signals from the
speed sensor, KD button and transmission clutch
cut-off at the same time. The electronic control
unit disposes these signals and drives the shift
control valve on the transmission combination 2
action by output circuit for getting desired gear
and running direction.
1. Input speed sensor position
2. Output speed sensor
See the following illustration for the fixing
positions of the shift control units on the
machine.
Display EST-25 electronic control unit
Shift control valve
ERGO-II gear selector
Output speed sensor and input speed sensor
(transmission is not assembled on the machine in this
illustration, input speed sensor just has fixing position
but not assembly)
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Electrical System
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The following illustration is the component 4-B Neutral/Start Interlock Protection

connection drawing of fully-auto control function. Function
Fully-auto shift control system
Neutral/start interlock relay and start relay

1. Output speed sensor 2. Input speed sensor

3. Shift control valve 4. EST-25T electronic
control unit The machine can be started when ERGO-II gear
5. Connection wiring 6. ERGO-II gear selector selector is at NEUTRAL, which is the special
harness Neutral/start interlock protection function.
7. Display
The following components are needed for
Transmission 4WG-200 fixed on the machine is realizing this function:
4-gear transmission, which contains F1, F2, F3, 1. Neutral/start interlock relay
F4 and R1, R2, R3. EST-25T electronic control
unit outputs R3 control signal when ERGO-II 2. ERGO-II gear selector
gear selector is at R4. 3. EST-25T electronic control unit
4. Start switch
5. Start relay
6. Fuse
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Electrical System
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4-C Transmission Clutch Cut-off

Function Transmission clutch ON/OFF switch

The operator can select transmission clutch cut-

off function when the machine runs on the flat
ground.
The transmission clutch cut-off unction can be
realized by pressing the transmission clutch ON/
OFF switch inside the cab.
The transmission power output is cut off when
close the transmission clutch ON/OFF switch
during the machine brake, which not only can
increase the machine brake performance, but
also can protect the transmission and the power
train. Moreover, the power from the transmission
is used at the hydraulic system and improves the
work efficiency. 1

The transmission clutch cut-off function is

cancelled when the transmission clutch ON/OFF
switch is at OFF position, the transmission power
output is not cut off when the machine brakes. 1. Lock buckle
EST-25T electronic control unit disposes the See illustration 4-17, the upper picture shows
transmission clutch cut-off order. The electronic that the transmission clutch ON/OFF switch is at
control unit executes the shift order by solenoid ON position; the underside picture shows that
on the shift control valve when the machine runs the transmission clutch ON/OFF switch is at OFF
or operates. The transmission clutch cut-off order position.
is sent and transmited into the electronic unit
In general, the transmission clutch ON/OFF
when the machine is at F1, F2 or R1, R2, the
switch is at ON position. When running or
electronic control unit will cut off power supply of
operating, the transmission clutch ON/OFF is at
solenoid which controls the direction, thereby cut
OFF position. According to above illustration, pull
off the clutch which controls the direction for
the lock buckle downward and press it down at
realizing the purpose of cut off the transmission
the same time in order to reach OFF position.
power output.
The transmission clutch ON/OFF switch has a
The transmission clutch cut-off function is just
lock buckle to prevent wrong operation. In
used at F1, F2 or R1, R2. EST-25T electronic
general, the switch is locked at ON position. The
control unit doesn't execute the transmission
switch is at OFF position when driving or
clutch cut-off order even if the transmission
operating the machine.
clutch ON/OFF switch is at ON position during
the brake in order to pretect the running safety
CAUTION: The transmission clutch ON/
when the machine is at high speed gear.
OFF switch has the lock device, turn off the
switch according to the requirement. Force to
disconnect the switch will cause damages.
The transmission clutch cut-off function is
just used at the machine F1, F2 or R1, R2. It is
not used when the machine is at high speed
gear.
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Electrical System
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CAUTION: Do not use the transmission 4-E Start Speed Limit Function
clutch cut-off function for operator's safety
when driving or operating the machine on the Start the machine at or under gear II.
ramp.
The machine can be started successfully when
the operator starts the machine at F1, F2 or R1,
The transmission clutch cut-off switch
R2. EST-25T electronic control unit doesn't
should be at ON position when driving or
execute this order when the start speed of the
operating the machine on the flat ground,
machine is higher than gear II, but will send out
otherwise it will affect the brake performance,
gear II starting order. The electronic control unit
shortening the service life of brake system
will allow the transmission to execute the
and the power train.
operator's desired gear according to the
feedback signals of the speed sensor on the flat
The following components are needed for
ground.
realizing the transmission clutch cut-off function:
1. Fuse 4-F Downshift Control
2. Transmission clutch ON/OFF switch
The downshift switch is only active when the
3. EST-25T electronic control unit ERGO-II shift lever is set to second gear. Press
4. ERGO-II gear selector and release the downshift switch will make the
transmission remain in first gear until the shift
5. Shift control valve (transmission) lever is moved; either speed or direction is
changed.
4-D Direct Forward/Reverse Change
Release the KD function by the following steps:
Function
1. Press KD button again;
ERGO-II gear selector hasn't direct forward/
2. Change the running direction;
reverse change interlock; the operator can
execute the direct forward/reverse change 3. Turn the lever to change gear;
straightly. The details are as follows:
4. Exceed the speed limited range.
1. In the speeds 1 and 2, direct reversing is
KD function will stop automatically once turn the
realized at any time.
lever to NEUTRAL position.
(1F<=>1R & 2F<=>2R)
Refer to ERGO-II Gear selector outline drawing
2. When the operator changes the direction at for KD button position.
gear III or IV and the machine running speed
exceeds the highest limited speed 14Km/H
that allowed by EST-25T electronic control
unit, which will descend the current running
speed to the limited value and change
direction, shift to the desired gear finally.
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Electrical System
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4-G System Self-protection Function Finally, there are still errors, which are not
directly critical. In this case, no RESET will be in-
EST-25T electronic control unit executes the itiated, i.e. the transmission-control program is
self-test operation of the shift control system running on with limitations; the error will be only
firstly when the operator turns on the start switch displayed after the shifting to Controller-Neutral,
but doesn't start the diesel engine. EST-25T and are only cancelled again with the shifting
electronic control unit doesn't send out neutral from Neutral:
starting order if the system has faults. These Failure of the turbine speed sensor 02(42*)
faults contain ERGO-II gear selector fault, the
Failure of the output speed sensor 10(50*)
shift control valve solenoid fault, the speed
sensor fault, electronic control unit software and Interruption/Foreign power supply of only
21(61*)
hardware faults etc. less critical outputs

In case of unrecoverable errors, the system (*): If the optional display is used, the errors can
shuts down completely (RESET; New start only be issued on this one as error number. In this
through key switch OFF/ON). case, these error number 02, 10 and 21 are also
displayed if they had occurred only temporatily
To it belong especially output line interruption and disappeared again in the mean time.
and outside supply at lines to the speed solenoid
valves. The value of the error number for such sporadic
errors is then increased for +40, therefore to 42,
There errors CANNOT be displayed. 50 resp.61.
Another error category is leading to an Still another NOTE concerning the Display:
immediate RESET, whereas however, the
electronics is still indicating the errors as error At a very short-time OFF/ON switching of the
number as long as a) these are still present and/ power supply(key switch), wrong error messages
or b) the controller is not yet in position "Neutral" can be issued on the display, because after the
(Status"Waiting for neutral") , the electronics is switching off the key switch, the microprocessor
starting the transmission-control program and is still "hunting".
clears the error display. If requested, the error indication on the display
To this belong the following Error classes/Error can therefore be completely suppressed.
numbers:
Invalid Controller input-line combination 22
Short circuit of an output against ground 23
Defective voltage supply 24
Error in the data field 31
Error in the program operation 32
Error in the processor-RAM 33
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Troubleshooting

Shift control system principle schematic

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Electrical System
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PR-68 penetrometer is the special tool of shfit CAUTION: The fault may be caused by
control system, which can be used to test EST- mechanism fault if the electronic control part
25T electronic control box inside the shift control of shift control system is normal after
system, DW-3 gear selector, the speed sensor, inspection. For example, the shift control
the shift control valve solenoid and lines rapidly& valve is blocked, and the shift oil line has
easily and judge the faults. Assemble PR-68 leakage, etc.. Please refer to the transmission
penetrometer for the machine if it is possible. fault test section of this service manual.
PR-68 Penetrometer
X5 and X12 receptalces are very important, they
are the electronic connection interfaces between
ZF shift control system and OEM (machine
manufacturer), and their connection relations
are:

Core
Function
No. numbe Signal
description
r
170 X12-A +24V power
170 X12-B +24V power
228 X12-E - power
228 X12-F - power
PR-68 penetrometer usage is very convenient, it
584 X12-C +24V Neutral/start interlock
has a conversion connector. Pull out X1
output signal output
receptacle which is connected to EST-25T +24V Backup alarm signal
electronic control unit, and insert the connector 588 X5-F
output output
of PR-68 penetrometer into EST-25T electronic 592 X5-D Digital input KD button
control unit, then insert X1 receptalce into PR-68
705 X5-A Impulse Rev signal output
penetrometer. Refer to the accessory manual of
output
PR-68 penetrometer for other operations (need The system executes
to order in addition, and please remark English transmission clutch
edition or German edition), and this manual cut-off order when has
doesn't describe again. 600 X5-E +24V input +24V voltage input;
and doesn’t execute
Check the transmission oil level at starting the order when has 0V
condition according to manual requirement when voltage input.
the shift control system has faults and couldn't
drive. Too high or too low oil level can result in
transmission abnormality and the machine
couldn't run. The shift control system can work
normally only the transmission oil level is at
normal value.
The shift control system has faults when the
transmission oil level is normal, and there isn't
PR-68 penetrometer, please check it according
to the instruction in this section.
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4-A-F1 Machine Starting Fault Test Conclusion:

Procedure
If the result does OK, EST-25T electronic control
Fault phenomenon definition: unit of shift control system has exported Neutral/
start interlock signal, the start fault of the diesel
The operator turns on the start switch and turns engine is not related to shift control system,
ERGO-II gear selector to NEUTRAL position, please check according to the power supply
then starts the diesel engine when the whole system section of this service manual.
machine electrifies, but there isn't any respond in If the result doesn't OK, please turn to step2.
the diesel engine. Consider whether the shift
control system has sent out the Neutral/start Step2. Test whether No.86 terminal of Neutral/
interlock signal firstly. start interlock relay socket and grounding
In general, EST-25T electronic unit couldn't pass terminal have +24V?
the self-test, which shows the shift control
system has fault. The purpose of the following 1. Keep on test of step1, hold red probe
steps is to eliminate the faults of the measurable connection, insert black probe into the
components in the system through the digital common grounding terminal on the left-rear
multimeter. floor of the cab.

Step1. Test whether No.85, No.86 terminals of Test result:

Neutral/start interlock relay socket have
+24V? The digital multimeter reading is between 24V
and 31V.
1. Turn off the start switch, disassemble the left-
rear decoration assembly and cup mat on the Conclusion:
left-rear side of the cab. Pull out Neutral/start
interlock relay from the electronic control box. If the result does OK, the connection between
the ground wire of Neutral/start interlock relay
2. Turn on the start switch, turn ERGO-II gear socket and the whole machine grounding
selector to NEUTRAL position, and pull out terminal is not good.
the parking brake switch, and then adjust the
digital multimeter to 50V range of voltage If the result doesn't OK, please turn to step3.
function. Insert red probe into No.86 terminal
of relay socket (contrast it with Neutral/start Step3. Test whether the power supply of shift
interlock relay, the pin of relay is marked with control system at X1 receptacle has +24V?
terminal number), and keep contacting with
the inner copper receptacle; insert black 1. Turn off the start switch, and plug the Neutral/
probe into No.85 terminal of relay socket, start interlock relay over again. Pull out X1
and keep contacting with the inner copper receptacle of EST-25T electronic control unit.
receptacle. 2. Turn on the start switch, measure the power
supply of shift control system according to
Test result: the shift control system principle drawing and
the following table.
The digital multimeter reading is between 24V
and 31V.
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Test power supply at X1 receptacle:

EST-25T electronic control unit X1 (35-PIN)
POS PIN WIRE POS PIN
receptacle drawing and shift control system lead
X1 1 682 X14 +24V
X1 2 654 X14 +24V
X12 A 612 X14 +24V
X12 B 616 X14 +24V
X1 18 666 X15 -
X1 35 678 X15 -
X12 E 632 X15 -
X12 F 636 X15 -

See above table, it lists the function of X1

receptacle core, which comes from the right side
table of the following illustration 5-21, the
comprehension method is the same as the
following right talbe.
See the following illustration, left side is the
number position of X1 receptacle core, right side
is the lead connection table of shift control
system. For example, "X1 31 430 X9 A" shows
that No.430 wire connects No.31 core of X1
receptacle to A core of X9 receptacle. Refer to
the principle drawing, this is the lead from EST-
25T electronic control unit to shift control valve
solenoid.
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3. Refer to the principle drawing, X14 is "+ Step4. Test whether ERGO-II gear selector of
"short circuit terminal of power supply, X15 is shift control system has fault? (Need another
"-"short circuit terminal of power supply. All person).
leads that connected to the short circuit
terminals are connected. So No.1, No.2 1. Turn off the start switch, assemble the
cores of X1 receptacle are connected to A receptacle over again. Turn on the start
core, B core of X12 receptacle, that is switch, and pull out the parking brake button.
connected to No.170 wire, which is the power Measure the condition of ERGO-II gear
line of shift control system. Therefore, there selector in the shift control system according
is +24V voltage of grounding at No.1, No.2 to the shift control system principle drawing
cores of X1 receptacle. No.18, No.35 cores and the following table (refer to illustration 4-
of X1 receptacle are " - " short circuit 3).
terminals power supply of shfit control
Test ERGO-II gear selector at X2 and X3
system. Adjust the digital multimeter to 50V
receptacles, "●" shows high level, "○" shows low
range of voltage function. Measure
level:
[1,18],[1,35],[2,18],[2,35] core combinations
of X1 receptacle separately, Please notice VP+ F R N C-S T- T+ KD
that only insert red probe into No.1, No.2 504 512 520 516 532 528 524 536
cores, black probe into No.18, No.35 cores. RD YL PK BR WH OR BL VK
F ● ○ ●
Test result:
R ● ○ ●
The digital multimeter readomg is between 24V N ● ○
and 31V. T+ ● ●
T- ● ●
Conclusion:
K
● ●
D
If the result does OK, please turn to step4.
If the result doesn't OK, please test as follows:
2. Adjust the digital multimeter to 50V range of
(1) Check the condition of 7.5A ZFshift fuse, voltage function. Connect the black probe to
replace it if it is melted. If the new fuse still the cab housing (grounding). Insert the red
melts, please check the short circuit fault. probe into A core of X2 receptacle (No.504
(2) Check the short circuit fault from fuse to X5 wire), and contacts with the copper piece in A
receptacle, X5 receptacle to X1 receptacle if core. The digital multimeter reading is
7.5A ZF shift fuse doesn't melt. between 24V and 31V. Hold the black probe,
and insert red probe into B core of X2
(3) Check the grounding condition of No.666 receptacle (No.512 wire), C core (No.520
wire, No.678 wire, No.632 wire, No.636, WIRE) and D core (No.516 wire) separately,
No.228 wire of X5 and X1 receptacles. and contacts with the copper pieces in B, C
and D cores. The digital multimeter reading is
between 24V and 31V.
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3. Connect the black probe to the cab housing 7. Keep the connection between the black
(grounding). Insert the red probe into B core probe and cab housing (grounding). Insert
of X2 receptacle (No.512 wire), and contacts red probe into C core (No.524 wire) of X3
with inner copper piece. Press F button of receptacle, and contacts with inner copper
ERGO-II gear selector, the digital multimeter piece. Press T+ button of ERGO-II gear
reading is 0. Release F button, the digital selector, the digital multimeter reading is
multimeter reading is between 24V and 31V. between 24V and 31V. Release T+ button,
Insert the red probe into A core (No.532 wire) the digital multimeter reading is 0.
of X3 receptacle, and contacts with inner
8. Keep the connection between the black
copper piece. Press F button again, the
probe and cab housing (grounding). Insert
digital multimeter reading is between 24V
red probe into D core (No.536 wire) of X3
and 31V. Release F button, the digital
receptacle, and contacts with inner copper
multimeter reading is 0.
piece. Press KD button of ERGO-II gear
4. Keep the connection between the black selector, the digital multimeter reading is
probe and cab housing (grounding). Insert between 24V and 31V. Release KD button,
red probe into C core (No.520 wire) of X2 the digital multimeter reading is 0.
receptacle, and contacts with inner copper
piece. Press R button of ERGO-II gear Conclusion:
selector, the digital multimeter reading is 0.
Release R button, the digital multimeter Generally, the self-test of EST-25T electronic
reading is between 24V and 31V. Hold the control unit couldn't check the faults of ERGO-II
black probe, insert red probe into A core gear selector completely. It just can check the
(No.532 wire) of X3 receptacle, and contacts current gear of ERGO-II gear selector before
with the inner copper piece. Press R button starting. The instruction in this step can check all
again, the digital multimeter reading is functions of ERGO-II gear selector. Therefore, it
between 24V and 31V. Release R button, the is allowed to check the current gear of ERGO-II
digital multimeter reading is 0. but not needed to check all gears when dispose
the machine's start fault. It is necessary to check
5. Keep the connection between the black
ERGO-II function completely if there isn't any
probe and cab housing (grounding). Insert
fault of the gear after starting the machine.
red probe into D core (No.516 wire) of X2
receptacle, and contacts with inner copper If the result does OK, please turn to step5.
piece. Press N button of ERGO-II gear
If the result doesn't OK, please test as follows:
selector, the digital multimeter reading is 0.
Release N button, the digital multimeter (1) Check whether there is open circuit or any
reading is between 24V and 31V. other fault in the line from ERGO-II gear
selector to EST-25T electronic control unit.
6. Keep the connection between the black
probe and cab housing (grounding). Insert (2) Replace ERGO-II gear selector.
red probe into B core (No.528 wire) of X3
receptacle, and contacts with inner copper Step5. Test whether the shift control valve
piece. Press T- button of ERGO-II gear solenoid has fault at X1 receptacle.
selector, the digital multimeter reading is
between 24V and 31V. Release T- button, the 1. Refer to shift control system principle
digital multimeter reading is 0. drawing and illustration 4-20. Turn off the
start switch, and remove X1 receptacle.
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Test shift control valve solenoid at X1 receptacle: 2. Adjust the digital multimeter to 2KΩ range of
Ωfunction, use the probe positive or negative
Corresponding
X1 core Resistance
X9 receptacle to measure the core combinations in above
table [17-27] and [9-34].
31-35 A-F
33-35 B-F Test result:
15-35 85~100Ω C-F
32-35 D-F The digital multimeter reading is between 920Ω
14-35 E-F and 1120Ω.

2. Adjust the digital multimeter to 200Ω range of Conclusion:

Ω function, use the probes positive or
negative to measure the core combinations If the result does OK, test the machine after
separately in above table [31-35], [33-35], replaced with new EST-25T electronic control
[15-35], [32-35], [14-35]. unit.
If the result doesn't OK, please test as follows:
Test result:
(1) Check whether there is open circuit or any
The digital multimeter reading is between 85Ω other fault in the line from speed sensor to
and 100Ω. EST-25T electronic control unit.
(2) Replace the speed sensor.
Conclusion:
4-A-F2 Fault Test Procedure of the
If the result does OK, please turn to step6.
Machine Without Any Gear after
If the result doesn't OK, please test as follows: Starting
(1) Check whether there is open circuit or any
other fault in the line from shift control valve Fault phenomenon definition:
to EST-25T electronic control unit.
The machine couldn't run whatever gear the
(2) The inner solenoid of shift control valve is operator turns after starting the diesel engine.
damaged if the line hasn't fault. The test of 5
couples of combinations corresponds with 5 Step1. Test the transmission oil level when
solenoids separately in the shift control valve. the machine is running.
Maintain the shift control valve if the test
value of any couple is not in the range of 1. Turn on the start switch, and start the diesel
measurement. engine, let the machine runs for about
10mins. Test the transmission oil level.
Step6. Test whether the speed sensor of shift
control system has fault at X1 receptacle. Test result:

1. Refer to shift control system principle The transmission oil level should in the normal
drawing and illustration 4-20. range of oil dipstick when the machine is
Test the speed sensor at X1 receptacle: running.
Corresponding X10 Conclusion:
X1 core Resistance
receptacle
17-27 920~1120Ω 1-2 HIGH-Drain oil
9-34 920~1120Ω 1-2
LOW-Fill oil
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If it is OK, please turn to step2. Conclusion:

Step2. Test ERGO-II gear selector according If the result does OK, the machine is at
to step4 introduced in 5-A-F1. transmission clutch ON position if the line has
fault, and the machine couldn't be started.
Conclusion: Please turn to step2.
If the result doesn't OK, please turn to step3.
If the result does OK, please replace with new
EST-25T electronic control unit.
Step2. Turn the transmission clutch ON/OFF
If the result doesn't OK, please test as follows: switch to ON position, observe whether the
indicator on the panel is going out.
(1) Check whether there is open circuit or any
fault in the line from ERGO-II gear selector to
1. Turn on the start switch, don't start the diesel
EST-25T electronic control unit.
engine, and turn the transmission clutch ON/
(2) Replace ERGO-II gear selector. OFF switch to ON position.
2. Insert the parking brake clutch cut-off switch
5-A-F3 Fault Test Procedure of the receptacle over again.
Machine Without I, II Gear after Starting
Test result::
Fault phenomenon definition:
Observe whether the indicator on the panel is
The machine could't be started when the shift going out.
control lever is at F1/F2 or R1/R2 after starting
the diesel engine. Conclusion:

Step1. Disconnect the transmission clutch If the result does OK, the parking brake clutch
cut-off signal (the voltage of No.600 wire is 0), cut-off switch is damaged.
judge whether the machine has gear I, II.
If the result doesn't OK, the service brake clutch
1. Turn the transmission clutch ON/OFF switch cut-off switch or the transmission clutch ON/OFF
to OFF position, remove No.600 wire switch is damaged.
receptacle from the parking brake clutch cut-
off switch. Turn on the start switch and turn Step3. Pull out the parking brake button, and
ERGO-II gear selector to NEUTRAL position. press down. The clutch cut-off indicator on
Press down the parking brake button for the panel will lighten and then go out.
releasing the parking brake. Observe
whether the clutch cut-off indicator on the 1. Turn on the start switch, don't start the diesel
panel is going out. engine, pull out and press down the parking
brake button.
2. Start the diesel engine at I, II gear. Judge
whether the machine can start normally. 2. Insert the receptacle of parking brake clutch
cut-off switch over again.
Test result:
Test result::
The machine starts when the indicator goes out.
Observe whether the indicator on the panel
lightens and then goes out.
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Conclusion: 2. Turn on the start switch, pull up the parking

brake switch, start the diesel engine, and pull
If the result does OK, please replace EST-25T ERGO-II gear selector to R1, R2. Adjust the
electronic control unit. digital multimeter to 50V range of voltage
function. Insert red probe into F core (No.588
If the result doesn't OK, the parking brake switch
wire) of X5 receptacle, keep contacting with
is damaged.
the inner copper core of receptacle. Insert
black probe into E core or F core (No.288
5-A-F4 Fault Test Procedure of the wire) of X12 receptacle, keep contacting with
Machine Without III, IV Gear after the inner copper of receptacle.
Starting
Test result::
Fault phenomenon definition:
The digital multimeter reading is between 24V
The machine's speed couldn't reach the desired and 31V.
gear when the shift control lever is at F3, F4 or
R3, R4 after starting the machine and the ground Conclusion:
condition is good.
If the result does OK, EST-25T electronic control
Conclusion: unit of shift control system has exported the
backup alarm signal, the backup alarm is
The gear III, IV have fault, if it is the line fault, the damaged or its line has fault if the backup alarm
display may not show the fault code, which need doesn't beep, please check it carefully.
to be checked carefully. The display will show
fault code if the shift control system has fault. If the result doesn't OK, please turn to step2.
Replace the corresponding speed sensor
according to display clue, and pay attention to Step2. Test ERGO-II gear selector according
the fixing gap of the speed sensor. to step4 introduced in 5-A-F1.

Conclusion:
5-A-F5 Fault Test Procedure of the
Backup Alarm When the Shift Control If the result does OK, please replace EST-25T
Lever is at R after Starting the Machine electronic control unit

Fault phenomenon definition: If the result doesn't OK, ERGO-II gear selector is
damaged.
The backup alarm doesn't beep when the shift
control lever is at R after starting the machine. CAUTION: When execute parking brake
to the machine, Start the diesel engine, and
Step1. Test whether No.588 wire has +24V? shift to test and service, please pay attention
to safety. Make sure the open place and the
1. Turn off the start switch, disassemble the left- efficiency of the parking brake, and ensure
rear interior decoration assembly and cup that the machine doesn't run.
mat on the left-rear side of the cab, find X5
and X12 receptacles. Sometimes it needs to change gear for
operating during test the machine, please
make sure the test is carried out on the flat
ground and won't hurt the other people.
Resume the machie complete state after
maintenance.
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Shift Control System (SEMI- Main Components

AUTOMATIC)
DW-3 Gear Selector
Introduction Shift control lever

This machine uses ZF transmission and axle.

The transmission is electro-hydraulic 4WG-200.
This manual introduces electronic control
component of transmission, called the shift
control system.
This section mainly introduces the shift control
system semi-auto mode. The operator shifts the
control lever to the scheduled gear through
controlling the transmission.
The shift lever is designed for the mounting on
EST117 electronic control unit of the shift control the steering column left side. By a rotative
sytem receives the outer signals from the gear motion, the positions (speeds) 1 to 4 are
selector, the speed sensor, KD key, disposes selected by tilting the lever, the driving direction
these signals and sends them into the computer (Forward (F) - Neutral (N) - Reverse (R).
to calculate. CPU drives the shift control valve on
the transmission for getting the desired gear by The DW-3 shift lever is also available with
output circuit. integrated KD button.
Transmission electronic control system For the protection from unintended start off, a
components Neutral interlock is installed:
Position "N" - Controller lever blocked in this
SHIFT SOLENOID position
LEVER GROUP
Position "D" - Driving
SPEED
SENSOR BACKUP
ALARM
TRANSMISSION
OUTPUT
KD ELECTRONIC
CONTROL
NEUTRAL
POWER
STARTING
SHUT OFF
OUTPUT

HARNESS
SPEEDMETER
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Work Principle The inner micro-switches run when the operator

selects the gear and direction, these variational
The gear selector contains many micro-switches gears and direction signals enter into EST117
inside. electronic control ulnit through the wiring
harness connection.

Principle schematic
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Electrical System
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See above illustration, the upper half part is the mean gears separately. "●"means connec-
gear selector inner principle drawing, the lower tion. The gear/digital combination reflects the
half part is the micro-switch action connection outer shift signal. For example, when the
drawing. Use the digital multimeter to check the operator turn the shift control lever to F1
gear selector fault accroding to above illustration. (FORWARD 1), AD4 is connected according
But this method is not suitable for checking the to above illustration, AD1, AD3 are con-
damage condition of micro-switches' contacts nected. Therefore, AD4, AD1 and AD3 are
inside the gear selector. In general, it will show connected together when the shift control
no fault by the digital multimeter measurement, lever is at F1. In addition, AD3 and ED1 are
but it doesn't work normally due to the inner connected forever.
contacts damage.
4. AD1, AD3, AD6 ED1 outputs are connected
when DW-3 is at I gear of NEUTRAL
DW-3 Gear Selector Troubleshooting
position, its inner micro-switch S4 contact is
closed, S1 normal close contact is closed.
Using the digital multimeter to check the gear
The corresponding blue wire, black wire, gray
selector fault is a very straight and convenient
wire, red wire should be connected, the
method, the details show as follows:
resistance value between each two wires is
1. Turn off the start switch, open the steering 0. Insert two probes of the digital multimeter
column assembly, and pull out the X2 separately into the corresponding color cores
receptalce connected to DW-3 gear selector of combination colors listed in step 2.
and wiring harness. [BLACK,BLUE], [BLACK,GRAY],
[BLACK,RED], [BLUE,RED], [BLUE,GRAY],
2. Adjust the digital multimeter to 200Ω range of
[RED,GRAY ], the digital multimeter reading
resistance function. Inspect the following
of the above combinations is 0, and the
groups when pull one gear of DW-3 gear
reading of the other combinations is 1.
selector (the following colors show the wire
colors): [BLACK,GREEN], [BLACK,BLUE], 5. AD3,AD6,ED1 outputs are connected when
[BLACK,PURPLE], [BLACK,RED], DW-3 is at gear II of NEUTRAL position, its
[BLACK,GRAY], [BLACK,YELLOW], inner micro-switch S1 normal close contact is
[BLACK,PINK], [GREEN,BLUE], closed. The corresponding black wire, gray
[GREEN,PURPLE], [GREEN,RED], wire, red wire should be connected, the
[GREEN,GRAY], [GREEN,YELLOW], resistance value between each two wires is
[GREEN,PINK], [BLUE,PURPLE], 0. Insert two probes of the digital multimeter
[BLUE,RED], [BLUE,GRAY], separately into the corresponding color cores
[BLUE,YELLOW], [BLUE,PINK], of combination colors listed in step 2.
[PURPLE,RED], [PURPLE, GRAY], [BLACK,GRAY], [BLACK,RED], [RED,GRAY
[PURPLE,YELLOW], [PURPLE,PINK], ], the digital multimeter reading of the above
[RED,GRAY], [RED,YELLOW], [RED,PINK], combinations is 0, and the reading of the
[GRAY,YELLOW], [GRAY,PINK]. other combinations is 1.
3. See the principle drawing, output AD3 6. AD3,AD2,AD6,ED1 outputs are connected
(corresponding) →black wire, AD2→green when DW-3 is at gear III of NEUTRAL
wire, AD1→blue wire, AD7→purple wire, position, its inner micro-switch S5 contact is
ED1→red wire, AD6→gray wire, closed, S1 normal close contact is closed.
AD4→yellow wire, AD5→pink wire. The red The corresponding black wire, green wire,
wire and the black wire are connected. See gray wire and red wire should be connected,
the left downside corner in above illustration, the resistance value between each two wires
F means FORWARD, N means NEUTRAL, R is 0. Insert two probes of the digital
means REVERSE; see the right downside multimeter separately into the corresponding
conrner in above illustration, "1", "2", "3", "4" color cores of combination colors listed in
 293
Electrical System
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step 2. [BLACK,GREEN], [BLACK,RED], 9. AD3,AD4,ED1 outputs are connected when

[RED,GRAY ] , [GREEN,RED], DW-3 is at F2, its inner micro-switch S4
[GREEN,GRAY], [RED,GRAY], the digital contact is closed, S1 normal open contact is
multimeter reading of the above combina- closed, S2 normal open contact is closed.
tions is 0, and the reading of the other combi- The corresponding black wire, yellow wire
nations is 1. and red wire should be connected, the
resistance value between each two wires is
7. AD3,AD2,AD1,AD6,ED1 outputs are
0. Insert two probes of the digital multimeter
connected when DW-3 is at gear IV of
separately into the corresponding color cores
NEUTRAL position, its inner micro-switch S4,
of combination colors listed in step 2.
S5 contact is closed. The corresponding
[BLACK,RED], [BLACK,YELLOW],
black wire, green wire, blue wire, gray wire
[RED,YELLOW], the digital multimeter
and red wire should be connected, the
reading of the above combinations is 0, and
resistance value between each two wires is
the reading of the other combinations is 1.
0. Insert two probes of the digital multimeter
separately into the corresponding color cores 10. AD3,AD2,AD4,ED1 outputs are connected
of combination colors listed in step 2. when DW-3 is at F3, its inner micro-switch S5
[BLACK,GREEN], [BLACK,BLUE], contact is closed, S1 normal open contact is
[BLACK,RED], [BLACK,GRAY], closed, S2 normal open contact is closed.
[GREEN,BLUE],[GREEN,RED], The corresponding black wire, green wire,
[GREEN,GRAY], red wire and yellow wire should be
[BLUE,RED],[BLUE,GRAY],[RED,GRAY], the connected, the resistance value between
digital multimeter reading of the above each two wires is 0. Insert two probes of the
combinations is 0, and the reading of the digital multimeter separately into the
other combinations is 1. corresponding color cores of combination
colors listed in step 2. [BLACK,GREEN],
8. AD3,AD1,AD4,ED1 outputs are connected
[BLACK,RED], [BLACK,YELLOW],
when DW-3 is at F1, its inner micro-switch S4
[GREEN,RED], [GREEN,YELLOW],
contact is closed, S1 normal open contact is
[RED,YELLOW], the digital multimeter
closed, S2 normal open contact is closed.
reading of the above combinations is 0, and
The corresponding black wire, blue wire,
the reading of the other combinations is 1.
yellow wire and red wire should be
connected, the resistance value between 11. AD3,AD2,AD1,AD4,ED1 outputs are
each two wires is 0. Insert two probes of the connected when DW-3 is at F4, its inner
digital multimeter separately into the micro-switch S4, S5 contacts are closed, S1
corresponding color cores of combination normal open contact is closed, S2 normal
colors listed in step 2. [BLACK,BLUE], open contact is closed. The corresponding
[BLACK,RED], [BLACK,YELLOW], black wire, green wire, blue wire, yellow wire
[BLUE,RED],[BLUE,YELLOW],[RED,YELLO and red wire should be connected, the
W], the digital multimeter reading of the resistance value between each two wires is
above combinations is 0, and the reading of 0. Insert two probes of the digital multimeter
the other combinations is 1. separately into the corresponding color cores
of combination colors listed in step 2.
[BLACK,GREEN], [BLACK,BLUE],
[BLACK,YELLOW], [BLACK,RED],
[GREEN,BLUE],[GREEN,RED],
[GREEN,YELLOW],
[BLUE,RED],[BLUE,YELLOW],[RED,YELLO
W], the digital multimeter reading of the
above combinations is 0, and the reading of
the other combinations is 1.
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Electrical System
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12. AD3,AD1,AD5,ED1 outputs are connected 15. AD3,AD2,AD1,AD5,ED1 outputs are

when DW-3 is at R1, its inner micro-switch connected when DW-3 is at R4, its inner
S4 contact is closed, S1 normal open contact micro-switch S4, S5 contacts are closed, S1
is closed, S3 normal open contact is closed. normal open contact is closed, S3 normal
The corresponding black wire, blue wire, pink open contact is closed. The corresponding
wire and red wire should be connected, the black wire, green wire, blue wire, pink wire
resistance value between each two wires is and red wire should be connected, the
0. Insert two probes of the digital multimeter resistance value between each two wires is
separately into the corresponding color cores 0. Insert two probes of the digital multimeter
of combination colors listed in step 2. separately into the corresponding color cores
[BLACK,BLUE], [BLACK,PINK], of combination colors listed in step 2.
[BLACK,RED], [BLACK,GREEN], [BLACK,BLUE],
[BLUE,PINK],[BLUE,RED],[PINK,RED], the [BLACK,PINK], [BLACK,RED],
digital multimeter reading of the above [GREEN,BLUE],[GREEN,RED],
combinations is 0, and the reading of the [GREEN,PINK],
other combinations is 1. [BLUE,PINK],[BLUE,RED],[RED,PINK], the
digital multimeter reading of the above
13. AD3,AD5,ED1 outputs are connected when
combinations is 0, and the reading of the
DW-3 is at R2, its inner micro-switch S4
other combinations is 1.
contact is closed, S1 normal open contact is
closed, S3 normal open contact is closed. 16. Press KD button and hold it which will
The corresponding black wire, pink wire and increase AD7 output connection no matter
red wire should be connected, the resistance DW-3 is at any position. For example, press
value between each two wires is 0. Insert KD button and hold it when DW-3 is at R2,
two probes of the digital multimeter AD3,AD5,ED1,AD7 outputs are connected,
separately into the corresponding color cores the corresponding black wire, pink wire, red
of combination colors listed in step 2. wire and purple wire should be connected,
[BLACK,PINK], [BLACK,RED], [PINK,RED], the resistance value between each two wires
the digital multimeter reading of the above is 0. Insert two probes of the digital
combinations is 0, and the reading of the multimeter separately into the corresponding
other combinations is 1. color cores of combination colors listed in
step 2. [BLACK,PINK], [BLACK,RED],
14. AD3,AD2,AD5,ED1 outputs are connected
[PINK,RED], [BLACK,PURPLE],
when DW-3 is at R3, its inner micro-switch
[PINK,PURPLE], [RED,PURPLE], the digital
S5 contact is closed, S1 normal open contact
multimeter reading of the above
is closed, S3 normal open contact is closed.
combinations is 0, and the reading of the
The corresponding black wire, green wire,
other combinations is 1.
red wire and pink wire should be connected,
the resistance value between each two wires DW-3 gear selector is good if it can completed
is 0. Insert two probes of the digital the above tests successfully.
multimeter separately into the corresponding
color cores of combination colors listed in
step 2. [BLACK,GREEN], [BLACK,RED],
[BLACK,PINK], [GREEN,RED],
[GREEN,PINK], [RED,PINK], the digital
multimeter reading of the above
combinations is 0, and the reading of the
other combinations is 1.
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Electrical System
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Solenoid Group
Shift control valve

The shift control valve contains 5 solenoids, M1-

M5, their positions show as above illustration.
The signal from DW-3 gear selector is sent into
EST117 electronic control unit when the operator
selects the direction and gear signal, the
electronic control unit gives off the corresponding
shift signals according the software calculation
and realizes through output the driving voltage to
solenoid. The purpose of the solenoids is to turn
on and off the oil flow to the clutches in the
transmission and realize the transmission shift or
change direction.
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Electrical System
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Solenoid and clutch action drawing

"●" The corresponding solenoid works.

"○" The corresponding solenoid works, but the corresponding solenoid will be cut off during executing transmission clutch
cut-off function.
See above illustration for each gear solenoid in the transmission at the same time.
work condition and the corresponding mating
In above illustration, actually, the semi-auto shift
clutch work condition. For example, M2, M3, M4
control system of this machine is assembled with
solenoids in the shift control valve work when the
the output speed sensor, but without the input
machine is at F1 gear, and K1, KV clutches mate
speed sensor.
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Electrical System
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Oil circulation diagram 4WG-200

Contrast oil circulation diagram 4WG-200 with The transmission clutch cut-off function is just
solenoid and clutch action drawing, through used at gear I& II, whatever the machine is at
which can get the control relationship between FORWARD and REVERSE gear. Their actions in
the solenoid and the clutch. It is basically that: the transmission show: solenoid M3 or M1 is cut
solenoid M5 controls the clutch K4, M3 controls off when execute clutch cut-off order, namely KV
KV, M1 controls KR, the solenoid is electrified or KR clutch is cut off. Because KV and KR
and the clutch works. Solenoids M2 and M4 clutches are separately the Forward or Reverse
control the clutch K1, K2, K3 together. M4 is clutches, therefore, the performance of the
electrified, M2 isn't electrified, and K2 clutch transmission clutch cut-off order is realized by
works. M2 and M4 are electrified together, K1 cut-off direction clutch.
clutch works. M2 and M4 aren't electrified, K3
clutch works.
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Electrical System
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Solenoid test
Principle schematic
The solenoids' resistances are about 90Ω, X9
located on the shift control valve is solenoid
group receptacle. Remove X9 receptacle, and
observe A, B, C, D, E, F cores from faucet, F is
the common core of 5 solenoids.
Use the digital multimeter's resistance function to
test X9 receptacle (the terminal of shift control
valve), the resistance values of A-F, B-F, C-F, D-
F, E-F should be about 85-100Ω. Otherwise the
solenoid is damaged.

Output Speed Sensor

Installation of the Speed Sensor

The installation of the speed sensor is very

important. Generally, keep L value at about
0.5+0.3mm. See above illustration, if the size of
L is bigger, the effect of the magnetic field will
decrease along with the increasing distance due
to the limited magnetic field effect, and the
winding can't induce the signal. If the distance is
too close, the speed sensor will be damaged by
the gear in high speed rotation due to
mechanism error.
Observe the condition inside fixing hole of the
Work Principle speed sensor by eye before installation, use the
vernier caliper to measure the distance from the
The output speed sensor is fixed at the fixing surface to the gear top, and select the
transmission housing for testing the output gear suitable fixing washer for the speed sensor
rev of the transmission. according to the measuring value, then fix it.
The speed sensor is composed by the winding, If replace and repair on the machine,
permanent magnet, the pole. The winding is disassemble the old speed sensor, clean the
wraped around the pole, which is connected to fixing washer and install it on the new speed
the permanent magnet. The magnetic force line sensor, screw the new speed sensor into its
of magnetic field produced around the fixing hole.
permanent magnet passes through the air gap,
the teeth of gear, and forms closed magnetic If the electronic control unit still can't induce the
circuit. Sometimes the magnetic field effects on sensor signal after installation, must install the
teeth gap, sometimes on teeth during the gear speed sensor over again. The steps as follows:
rotation for changing the air gap, and the flux is (1) Remove the speed sensor. Align a gear tooth
changing along with the air gap. The variational directly in the center of the threaded sensor
flux induces the proportionable sine signal with opening.
rev in the winding, which was delivered into
electronic control unit for disposal by wiring (2) By hand, screw the sensor into the hole until
harness connection. the end of the sensor just makes contact with
the gear tooth.
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(3) Turn the sensor back out 1/2 turn(180°in the

counterclockwise direction). This sets air gap
(L) to 0.5+0.3mm.
(4) Measure the distance between the
transmission fixing surface and the sensor
fixing surface, select the suitable washer,
disassemble the speed sensor, and put the
washer on it, then assemble it over again.

CAUTION: The receptacle X10 connected

to the speed sensor must downward lest rain
water should inflow the receptacle along with
the wiring harness and corrupt the core of
the receptacle and the pin of the speed
sensor.

Measurement of the Speed Sensor

Use the digital multimeter to test the speed

sensor, its resistance value is 1020±100Ω.
CAUTION: When the machine needs
Disassemble X10 receptacle connected to the weld maintenance, must pull out X1
speed sensor and the wiring harness when use receptacle of EST117 electronic control unit,
the resistance function of multimeter to measure otherwise the electronic control unit may be
the speed sensor, measure the resistance value burnt due to the strong impulse current
between two column pins of speed sensor, the caused by welding. Connect X1 receptacle
resistance value should be about 1020Ω. after welding, otherwise the machine couldn't
Otherwise, the speed sensor is damaged. be started.

Electronic Control Unit EST117 EST117 Electronic control unit switch

EST117 electronic control unit is the core

component of the shift control system. See
illustration 5-1, the gear signal, the speed sensor
signal, KD signal, transmission clutch cut-off
signal are delivered into EST117 electronic
control uint for disposal and calculation. EST117
will export the control signals to drive the
solenoid after disposal, then finish shifting finally.
At the same time, EST117 exports NEUTRAL
signal to drive Neutral/start interlock relay action
when DW-3 gear selector is at NEUTRAL.
EST117 exprots backup alarm signal to drive the
backup alarm relay.
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Function Operation

The shift control system can complete the

following operations.

5-A Shift and Change Running Direction

The operator selects the running direction and

gear by operating DW-3 gear selector; these
signals are sent into EST117 electronic control
unit, which also received the signals from the
speed sensor, KD button and transmission clutch
cut-off.at the same time. The electronic control
unit disposes these signals and drives the shift
control valve on the transmission combination
action by output circuit for getting desired gear
and running direction.
See the following components:
1
EST117 electronic control
DW-3 gear selector
uint
Shift control valve
KD button (additional)
Output speed sensor

1. Input speed sensor position

2. Output speed sensor
See above illustration, it is real fixing position
drawing of shift control system components. The
following illustration is the component connection
drawing of semi-auto control function.
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The machine can be started when DW-3 gear

Semi-auto shift control system selector is at NEUTRAL, which is the special
Neutral/start interlock protection function.
The following components are needed for
realizing this function:
1. Neutral/start interlock relay
2. DW-3 gear selector
3. EST117 electronic control unit
4. Start switch
5. Start relay
6. Fuse

1. Shift control valve 2. KD button (additional) 5-C Neutral/Lock Function

3. DW-3 gear selector 4. EST117 electronic
control unit On the CLG856III wheel loader, the Neutral/lock
switch on the top of the gear selector has the
5. Connection wiring 6. Output speed sensor
harness same function with the switch on the steering
column assmelby because DW-3 gear selector is
Transmission 4WG-200 fixed on the machine is wraped inside the steering column.
4-gear transmission, which contains F1, F2, F3,
F4 and R1, R2, R3. EST117 electronic control DW-3 gear selector is locked at NEUTRAL,
unit exports R3 control signal when DW-3 gear which can't be pushed forwards or pulled
selector is at R4. backwards for changing the direction of the
machine.
5-B Neutral/Start Interlock Protection Neutral/lock switch (locked)
Function
Neutral/start interlock relay and start relay

1. The switch is locked

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EST117 electronic control unit disposes the

Neutral/lock switch (unlocked) transmission clutch cut-off order. The electronic
control unit executes the shift order by solenoid
on the shift control valve when the machine runs
or operates. The transmission clutch cut-off order
is sent and transmited into the electronic unit
2 when the machine is at F1, F2 or R1, R2, the
electronic control unit will cut off power supply of
solenoid which controls the direction, thereby cut
off the clutch which controls the direction for
realizing the purpose of cut off the transmission
power output.
2. The switch is unlocked The transmission clutch cut-off function is just
used at F1, F2 or R1, R2. EST117 electronic
5-D Transmission Clutch Cut-off control unit doesn't execute the transmission
Function clutch cut-off order even if the transmission
clutch ON/OFF switch is at ON position during
The operator can select transmission clutch cut- the brake in order to pretect the running safety
off function when the machine runs on the flat when the machine is at high speed gear.
ground. The transmission clutch ON/OFF switch has a
The transmission clutch cut-off function can be lock buckle for preventing accident operation, in
realized by pressing the transmission clutch ON/ general, the switch is locked at ON position. The
OFF switch inside the cab. switch is at OFF position when running or
operating the machine.
The transmission power output is cut off when
close the transmission clutch ON/OFF switch Transmission clutch ON/OFF switch
during the machine brake, which not only can
increase the machine brake performance, but
also can protect the transmission and the power
train. Moreover, the power from the transmission
is used at the hydraulic system and improves the
work efficiency.
The transmission clutch cut-off function is
cancelled when the transmission clutch ON/OFF
switch is at OFF position, and the transmission
power output is not cut off when the machine
brakes.

1. Lock buckle
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See illustration 5-17, the upper picture shows 5-E Direct forward/reverse chang
that the transmission clutch ON/OFF switch is at function
ON position, and the underside picture shows
that the transmission clutch ON/OFF switch is at DW-3 gear selector hasn't direction forward/
OFF position. reverse change interlock; the operator can
In general, the transmission clutch ON/OFF execute the direct forward/reverse change
switch is at ON position. When running or straightly. The details are as follows:
operating, the transmission clutch ON/OFF is at ● In the speeds 1 and 2, direct reversing is
OFF position. According to above illustration, pull realized at any time. (1F<=>1R & 2F<=>2R)
the lock buckle downward and press it down at
the same time in order to reach OFF position. ● When the operator changes the direction at
gear III or IV and the machine running speed
CAUTION: The transmission clutch ON/ exceeds the highest limited speed 14Km/H
OFF switch has the lock device, turn off the that allowed by EST117 electronic control
switch according to the requirement! Force unit, which will descend the current running
to disconnect the switch will cause speed to the limited value and change
damages!! direction, shift to the desired gear finally.

CAUTION: The transmission clutch cut- 5-F Start speed limit function
off function is just used at the machine F1, F2
or R1, R2. It is not used when the machine is Start the machine at or under gear II.
at high speed gear. The machine can be started successfully when
the operator starts the machine at F1, F2 or R1,
CAUTION: Do not use the transmission R2. EST117 electronic control unit doesn't
clutch cut-off function for operator's safety execute this order when the start speed of the
when driving or operating the machine on the machine is higher than gear II, but will send out
ramp. gear II starting order. The electronic control unit
will allow the transmission to execute the
CAUTION: The transmission clutch cut- operator's desired gear according to the
off switch should be at ON position when feedback signals of the speed sensor on the flat
driving or operating the machine on the flat ground.
ground, otherwise it will affect the brake
performance, shortening the service life of 5-G Downshift control
brake system and the power train!
The downshift switch is only active when the
The following components are needed for DW-3 shift lever is set to second gear. Press and
realizing the transmission clutch cut-off function:
release the downshift switch will make the
Fuse transmission remain in first gear until the shift
lever is moved; either speed or direction is
Transmission clutch ON/OFF switch
changed.
EST117 electronic control unit
Release the KD function by the following steps:
DW-3 gear selector
1. Press KD button again;
Shift control valve (transmission)
2. Change the running direction;
3. Turn the lever to change gear;
4. Exceed the speed limited range.
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KD function will stop automatically once turn the Troubleshooting

lever to NEUTRAL position.
There are two KD button on the machine, they PR-68 penetrometer is the special tool of shfit
have the same function. control system, which can be used to test
See the following illustration, KD button is EST117 electronic control box inside the shift
located on the pilot control lever. control system, DW-3 gear selector, the speed
sensor, the shift control valve solenoid and lines
KD button located on the pilot control lever rapidly& easily and judge the faults. Assemble
PR-68 penetrometer for the machine if it is
possible.
PR-68 penetrometer usage is very convenient, it
has a conversion connector. Pull out X1
receptacle which is connected to EST117
electronic control unit, and insert the connector
of PR-68 penetrometer into EST117 electronic
control unit, and then insert X1 receptalce into
PR-68 penetrometer. Please refer to the
KD button located on the end of the shift control accessory manual (need to order in addition) of
lever (refer to DW-3 gear selector outline PR-68 penetrometer for the other operations.
drawing for KD button position). This manual doesn't describe again.

5-H System self-protection function PR-68 Penetrometer

EST117 electronic control unit executes the self-

test operation of the shift control system firstly
when the operator turns on the start switch but
doesn't start the diesel engine, EST117
electronic control unit doesn't send out neutral
starting order if the system has faults. These
faults contain DW-3 gear selector fault, the shift
control valve solenoid fault, the speed sensor
fault, electronic control unit software and
hardware faults etc.
EST117 electronic control unit keeps monitoring
above signals when driving and operating the Check the transmission oil level at starting
machine. If the signals are abnormal, EST117 condition according to manual requirement when
electronic control unit will decide to lock output or the shift control system has faults and couldn't
not according to the fault degree. EST117 will drive. Too high or too low oil level can result in
export the fault code if the machine is assembled transmission abnormality and the machine
with optional LCD of shift control system, the couldn't run. The shift control system can work
operators and service people will look for the normally only the transmission oil level is at
corresponding faults according to the fault normal value.
codes.
The shift control system has faults when the
transmission oil level is normal, and there isn't
PR-68 penetrometer, please check it according
to the instruction in this section.
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CAUTION: The fault may be caused by

mechanism fault if the electronic control part
of shift control system is normal after
inspection. For example, the shift control
valve is blocked, and the shift oil line has
leakage, etc.. Please refer to the transmission
fault test section of CLG856III service
manual.

X5 receptalce is very important, which is the

electronic connection interface between ZF shift
control system and OEM (machine
manufacturer). Its connection relationship is:
Core
No. signal Function description
number
+24V Neutral/start interlock
584 2
output signal output
+24V Backup alarm signal
588 3
output output
Digital
592 4 KD button
input
Impulse
705 1 Rev signal output
output
The system executes
transmission clutch cut-
off order when has
+24V +24V voltage input; the
600 6
input system doesn’t execute
the transmission clutch
cut-off order when has
0V voltage input.
170 9 +24V power
170 10 +24V power
228 14 - power
228 15 - power

Shift control system principle schematic

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5-A-F1 Starting fault test of the machine Conclusion:

Fault phenomenon definition If the result does OK, EST117 electronic control
unit of shift control system has exported Neutral/
The operator turns on the start switch and turns start interlock signal, the start fault of the diesel
DW-3 gear selector to NEUTRAL position, then engine is not related to shift control system,
starts the diesel engine when the whole machine please inspect it according to the power supply
electrifies, but there isn't any respond in the system section of this service manual.
diesel engine. Consider whether the shift control If the result doesn't OK, please turn to step2.
system has sent out the Neutral/start interlock
signal firstly. Step2. Test whether No.86 terminal of Neutral/
In general, EST117 electronic unit couldn't pass start interlock relay socket and grounding
the self-test, which shows the shift control terminal have +24V.
system has fault. The purpose of the following
steps is to eliminate the faults of the measurable Keep on test of step1, and hold red probe
components in the system through the digital connection not changed, insert black probe into
multimeter. common grounding terminal on the left-rear floor
of the cab.
Step1. Test whether No.85, No.86 terminals of
Neutral/start interlock relay socket have Test result:
+24V.
The digital multimeter reading is between 24V
1. Turn off the start switch, disassemble the and 31V.
interior left-rear decoration assembly and cup
mat on the left-rear of the cab. Pull out Conclusion:
Neutral/start interlock relay from the
electronic control box. If the result does OK, the connection between
the ground wire of Neutral/start interlock relay
2. Turn on the start switch, turn DW-3 gear socket and the whole machine gounding terminal
selector to NEUTRAL position, and pull out is not good.
the parking brake switch, adjust the digital
multimeter to 50V range of voltage function. If the result doesn't OK, please turn to step3.
Insert red probe into No.86 terminal of relay
socket (contrast it with the relay, the pin of Step3. Test whether the power supply of shift
relay is marked with terminal number), and control system at X1 receptacle has +24V.
keep contacting with the inner copper
receptacle; insert black probe into No.85 1. Turn off the start switch, and plug the Neutral/
terminal of relay socket, and keep contacting start interlock relay over again. Pull out X1
with the inner copper receptacle. receptacle of EST117 electronic control unit.
2. Turn on the start switch, measure the power
Test result: supply of shift control system according to
the shift control system principle drawing and
The digital multimeter reading is between 24V the following table.
and 31V.
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Test power supply at X1 receptacle: EST117 electronic control unit X1 (35-PIN)

POS PIN WIRE POS PIN
X1 1 682 X14 +24V
X1 2 654 X14 +24V
X5 9 612 X14 +24V
X5 10 616 X14 +24V
X1 18 666 X15 -
X1 35 678 X15 -
X5 14 632 X15 -
X5 15 636 X15 -

See above table, it lists the function of X1

receptacle core, which comes from the right table
of the following illustration 5-21, the
comprehension method is the same as the
following right table.
See the following illustration, left side is the
number position of X1 receptacle core, right side
is the lead connection table of shift control
system. For example, "X1 31 430 X9 A" shows
that No.430 wire connects No.31 core of X1
receptacle to A core of X9 receptacle. Refer to
the principle drawing, this is the lead from
EST117 electronic control unit to shift control
valve solenoid.
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3. Refer to the principle drawing, X14 is "+ Check DW-3 gear selector at X1 receptacle, "●"
"short circuit terminal of power supply, X15 is shows connection:
"-" short circuit terminal of power supply. All
25 5 8 23 26 29 24 19
leads that connected to the short circuit
terminals are connected. So No.1, No.2 N1 ● ● ● ●
cores of X1 receptacle are connected to No.9 N2 ● ● ●
core, No10 core of X5 receptacle, that is
N3 ● ● ● ●
connected to No.170 wire, which is the power
line of shift control system. Therefore, there N4 ● ● ● ● ●
is +24V voltage of grounding at No.1, No.2 F1 ● ● ● ●
cores of X1 receptacle. No.18, No.35 cores
F2 ● ● ●
of X1 receptacle are " - " short circuit
terminals power supply of shfit control F3 ● ● ● ●
system. Adjust the digital multimeter to 50V F4 ● ● ● ● ●
range of voltage function. Measure R1 ● ● ● ●
[1,18],[1,35],[2,18],[2,35] core combinations
of X1 receptacle separately. Please notice R2 ● ● ●
that only insert red probe into No.1, No.2 R3 ● ● ● ●
cores, black probe into No.18, No.35 cores. R4 ● ● ● ● ●
Test result: KD ● ● ●

The digital multimeter readomg is between 24V 2. Adjust the digital multimeter to 200 Ω range
and 31V. of Ω function, measure the following
combinations when pulling each gear of DW-
3 gear selector,
Conclusion:
[25,5],[25,8],[25,23],[25,26],[25,29],[25,24],[2
5,19],[5,8],[5,23],[5,26],[5,29],[5,24],[5,19],[8,
If the result does OK, please turn to step4.
23],[8,26],[8,29],[8,24],[8,19],[23,26],[23,29],[
If the result doesn't OK, please test as follows: 23,24],[23,19],[26,29],[26,24],[26,19],[29,24],
[29,19],[24,19], there are 28 couples of
1. Check the condition of 7.5A ZFshift fuse,
combinations.
replace it if it is melted. If the new fuse still
melts, please check the short circuit fault. 3. Turn DW-3 gear selector to N1, refer to
above table, 25,26,29,19 of X1 receptacle
2. Check the short circuit fault from fuse to X5
are connected each two at N1, use the probe
receptacle, X5 receptacle to X1 receptacle if
positive or negative of the multimeter to
7.5A ZF shift fuse doesn't melt.
measure the resistances of 28 couples of
3. Check the grounding condition of No.666 combinations.
wire, No.678 wire, No.632 wire, No.636, [25,26],[25,29],[25,19],[26,29],[26,19],[29,19]
No.228 wire of X5 and X1 receptacles. , the digital multimeter reading of the above
combinations is 0, and the reading of the
Step4. Test whether DW-3 gear selector of other combinations is 1.
shift control system has fault at X1
receptacle.

1. Turn off the start switch, measure the

condition of DW-3 gear selector in the shift
control system according to the shift control
system principle drawing and illustration 5-
21.
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4. Turn DW-3 gear selector to N2, refer to 8. Turn DW-3 gear selector to F2, refer to above
above table, 25,29,19 of X1 receptacle are table, 25,23,19 of X1 receptacle are
connected each two at N2, use the probe connected each two at F2, use the probe
positive or negative of the multimeter to positive or negative of the multimeter to
measure the resistances of 28 couples of measure the resistances of 28 couples
combinations. [25,29],[25,19],[29,19], the combinations. [[25,23],[25,19],[23,19], the
digital multimeter reading of the above digital multimeter reading of the above
combinations is 0, and the reading of the combinations is 0, and the reading of the
other combinations is 1. other combinations is 1.
5. Turn DW-3 gear selector to N3, refer to 9. Turn DW-3 gear selector to F3, refer to above
above table, 25,8,29,19 of X1 receptacle are table, 25,8,23,19 of X1 receptacle are
connected each two at N3, use the probe connected each two at F3, use the probe
positive or negative of the multimeter to positive or negative of the multimeter to
measure the resistances of 28 couples measure the resistances of 28 couples
combinations. combinations.
[25,8],[25,29],[25,19],[8,29],[8,19],[29,19], [25,8],[25,23],[25,19],[8,23],[8,19],[23,19],
the digital multimeter reading of the above the digital multimeter reading of the above
combinations is 0, and the reading of the combinations is 0, and the reading of the
other combinations is 1. other combinations is 1.
6. Turn DW-3 gear selector to N4, refer to 10. Turn DW-3 gear selector to F4, refer to above
above table, 25,8,26,29,19 of X1 receptacle table, 25,8,23,26,19 of X1 receptacle are
are connected each two at N4, use the probe connected each two at F4, use the probe
positive or negative of the multimeter to positive or negative of the multimeter to
measure the resistances of 28 couples measure the resistances of 28 couples
combinations. combinations.
[25,8],[25,26],[25,29],[25,19],[8,26],[8,29],[8, [25,8],[25,23],[25,26],[25,19],[8,23],[8,26],[8,
19],[26,29],[26,19],[29,19], the digital 19],[23,26],[23,19],[26,19], the digital
multimeter reading of the above multimeter reading of the above
combinations is 0, and the reading of the combinations is 0, and the reading of the
other combinations is 1. other combinations is 1.
7. Turn DW-3 gear selector to F1, refer to above 11. Turn DW-3 gear selector to R1, refer to
table, 25,23,26,19 of X1 receptacle are above table, 25,5,26,19 of X1 receptacle are
connected each two at F1, use the probe connected each two at R1, use the probe
positive or negative of the multimeter to positive or negative of the multimeter to
measure the resistances of 28 couples measure the resistances of 28 couples
combinations. combinations.
[25,23],[25,26],[25,19],[23,26],[23,19],[26,19] [25,5],[25,26],[25,19],[5,26],[5,19],[26,19],
, the digital multimeter reading of the above the digital multimeter reading of the above
combinations is 0, and the reading of the combinations is 0, and the reading of the
other combinations is 1. other combinations is 1.
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12. Turn DW-3 gear selector to R2, refer to Conclusion:

above table, 25,5,19 of X1 receptacle are
connected each two at R2, use the probe Generally, the self-test of EST117 electronic
positive or negative of the multimeter to control unit couldn't check the faults of DW-3
measure the resistances of 28 couples gear selector completely. It just can check the
combinations. [25,5],[25,19],[5,19], the digital current gear of DW-3 gear selector before
multimeter reading of the above starting. The instruction in this step can check all
combinations is 0, and the reading of the functions of DW-3 gear selector. Therefore, it is
other combinations is 1. allowed to check the current gear of DW-3 but
not needed to check all gears when dispose the
13. Turn DW-3 gear selector to R3, refer to
machine's start fault. It is necessary to check
above table, 25,5,8,19 of X1 receptacle are
DW-3 function completely if there isn't any fault
connected each two at R3, use the probe
of the gear after starting the machine.
positive or negative of the multimeter to
measure the resistances of 28 couples If the result does OK, please turn to step5.
combinations.
If the result doesn't OK, please test as follows:
[25,5],[25,8],[25,19],[5,8],[5,19],[8,19], the
digital multimeter reading of the above 1. Check whether there is open circuit or any
combinations is 0, and the reading of the other fault in the line from DW-3 gear selector
other combinations is 1. to EST117 electronic control unit.
14. Turn DW-3 gear selector to R4, refer to 2. Replace DW-3 gear selector.
above table, 25,5,8,26,19 of X1 receptacle
are connected each two at R4, use the probe Step5. Test whether the shift control valve
positive or negative of the multimeter to solenoid has fault at X1 receptacle.
measure the resistances of 28 couples
combinations. 1. Refer to shift control system principle
[25,5],[25,8],[25,26],[25,19],[5,8],[5,26],[5,19] drawing and illustration 5-21.
,[8,26],[8,19],[26,19], the digital multimeter Test shift control valve solenoid at X1 receptacle:
reading of the above combinations is 0, and
the reading of the other combinations is 1. Corresponding X9
X1 core Resistance
receptacle
15. Press KD button of DW-3 gear selector and
hold it, refer to above table, 25,24,19 of X1 31-35 A-F
receptacle are connected each two at KD 33-35 B-F
function, use the probe positive or negative
15-35 85~100Ω C-F
of the multimeter to measure the resistances
of 28 couples combinations. 32-35 D-F
[25,24],[25,19],[24,19], the digital multimeter 14-35 E-F
reading of the above combinations is 0, and
the reading of the other combinations is 1. 2. Adjust the digital multimeter to 200 Ω range
of Ω function, use the probes positive or
negative to measure the core combinations
separately in above table [31,35],
[33,35],[15,35],[32,35],[14,35].

Test result:

The digital multimeter reading is between 85Ω

and 100Ω.
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Conclusion: 5-A-F2 Fault test of the machine without

any gear after starting
If the result does OK, please turn to step6.
If the result doesn't OK, please test as follows: Fault phenomenon definition:

1. Check whether there is open circuit or any The machine couldn't run whatever gear the
other fault in the line from shift control valve operator turns after starting the diesel engine.
to EST117 electronic control unit.
2. The inner solenoid of shift control valve is Step1. Test the transmission oil level when
damaged if the line hasn't fault. The test of 5 the machine is running.
couples of combinations corresponds with 5
solenoids separately in the shift control valve. 1. Turn on the start switch, and start the diesel
Maintain the shift control valve if the test engine, let the machine runs for about
value of any couple is not in the range of 10mins. Test the transmission oil level.
measurement.
Test result:
Step6. Test whether the speed sensor of shift
control system has fault at X1 receptacle. The transmission oil level should in the normal
range of oil dipstick when the machine is
1. Refer to shift control system principle running.
drawing and illustration 5-21.
Conclusion:
Test the speed sensor at X1 receptacle:
Corresponding X9 HIGH-Drain oil
X1 core Resistance
receptacle LOW-Fill oil
17-27 920~1120Ω 1-2 If it is OK, please turn to step2.
2. Adjust the digital multimeter to 2K Ω range of
Step2. Test DW-3 gear selector at X1
Ω function, use the probe positive or
negative to measure the core combinations receptacle according to step4 introduced in
in above table [17,27]. 5-A-F1.

Test result: Conclusion:

The digital multimeter reading is between 920Ω If the result does OK, please replace with new
and 1120Ω. EST117 electronic control unit.
If the result doesn't OK, please test as follows:
Conclusion:
1. Check whether there is open circuit or any
If the result does OK, test the machine after fault in the line from DW-3 gear selector to
replaced with new EST117 electronic control EST117 electronic control unit.
unit. 2. Replace DW-3 gear selector.
If the result doesn't OK, please test as follows:
1. Check whether there is open circuit or any
other fault in the line from speed sensor to
EST117 electronic control unit.
2. Replace the speed sensor.
314
Electrical System
Shift Control System (SEMI-AUTOMATIC)

5-A-F3 Fault test of the machine without Test result:：

I, II gear after starting
Observe whether the indicator on the panel is
Fault phenomenon definition: going out.

The machine couldn't be started when the shift Conclusion:

control lever is at F1/F2 or R1/R2 after starting
the diesel engine. If the result does OK, the parking brake clutch
cut-off switch is damaged.
Step1. Disconnect the transmission clutch If the result doesn't OK, the service brake clutch
cut-off signal, judge whether the machine has cut-off switch or the transmission clutch ON/OFF
gear I, II. switch is damaged.

1. Turn the transmission clutch ON/OFF switch Step3. Pull out the parking brake button, and
to OFF position, remove No.600 wire press down. The clutch cut-off indicator on
receptacle from the parking brake clutch cut- the panel will lighten and then go out.
off switch. Turn on the start switch and turn
DW-3 gear selector to NEUTRAL position. 1. Turn on the start switch, don't start the diesel
Press down the parking brake switch for engine, pull out and press down the parking
releasing the parking brake. Observe brake button.
whether the clutch cut-off indicator on the
panel is going out. 2. Insert the receptacle of parking brake clutch
cut-off switch over again.
2. Start the diesel engine at I, II gear. Judge
whether the machine can start normally. Test result:：

Test result:： Observe whether the indicator on the panel

lightens and then goes out.
The machine starts when the indicator goes out.
Conclusion:
Conclusion:
If the result does OK, please replace EST117
If the result does OK, the machine is at electronic control unit
transmission clutch ON position if the line has
fault, and the machine couldn't be started. If the result doesn't OK, the parking brake switch
Please turn to step2. is damaged.

If the result doesn't OK, please turn to step3.

Step2. Turn the transmission clutch ON/OFF

switch to ON position, observe whether the
indicator on the panel is going out.

1. Turn on the start switch, don't start the diesel

engine, and turn the transmission clutch ON/
OFF switch to ON position.
2. Insert the parking brake clutch cut-off switch
receptacle over again.
 315
Electrical System
Shift Control System (SEMI-AUTOMATIC)

5-A-F4 Fault test of the machine without Conclusion:

III, IV gear after starting
If the result does OK, EST117 electronic control
Fault phenomenon definition: unit of shift control system has exported the
backup alarm signal, the backup alarm is
The machine's speed couldn't reach the desired damaged or its line has fault if the backup alarm
gear when the shift control lever is at F3, F4 or doesn't beep, please check it carefully.
R3, R4 after starting the machine and the ground If the result doesn't OK, please turn to step2.
condition is good.
Step2. Test DW-3 gear selector according to
Conclusion: step4 introduced in 5-A-F1.

Replace the speed sensor after make sure the Conclusion:

line hasn't fault. Pay attention to the fixing gap of
the speed sensor when fixing. If the result does OK, please replace EST117
electronic control unit
5-A-F5 Fault test of the backup alarm
If the result doesn't OK, DW-3 gear selector is
when the shift control lever is at R after
damaged.
starting the machine
CAUTION: When execute parking brake
Fault phenomenon definition: to the machine, Start the diesel engine, and
shift to test and service, please pay attention
The backup alarm doesn't beep when the shift to safety. Make sure the open place and the
control lever is at R after starting the machine. efficiency of the parking brake, and ensure
that the machine doesn't run.
Step1. Test whether No.588 wire has +24V.
CAUTION: Sometimes it needs to change
1. Turn off the start switch, disassemble the left- gear for operating during test the machine,
rear interior decoration assembly and cup please make sure the test is carried out on
mat on the left-rear side of the cab, find X5 the flat ground and won't hurt the other
receptacle. people. Resume the machie complete state
2. Turn on the start switch, pull up the parking after maintenance.
brake switch, start the diesel engine, and pull
DW-3 gear selector to R1, R2. Adjust the
digital multimeter to 50V range of voltage
function. Insert red probe into No.3 core
(No.588 wire) of X5 receptacle, keep
contacting with the inner copper core of
receptacle. Insert black probe into No.14
core or No.15 core (No.288 wire) of X5
receptacle, keep contacting with the inner
copper of receptacle.

Test result:

The digital multimeter reading is between 24V

and 31V.
316
Electrical System
Parking Brake and Transmission Clutch Cut-off System

Parking Brake and Parking brake switch location

Transmission Clutch Cut-off

System

Introduction

Use the parking brake and transmission clutch

cut-off system to control parking brake and shut
off transmission power. Realize manual brake by
the parking brake switch controlling the brake
solenoid, realize transmission clutch cut-off
protection function when the machine is running
by transmission clutch ON/OFF switch. 2. Transmission clutch ON/OFF switch: it is a
pendant switch, see chapter 7 THE LIGHTS
Main Components for the configuration principle. This switch
has a self-lock button; the self-lock will be
locked at ON position after connecting the
1. Parking brake switch: this switch is switch, pull the self-lock button before turn off
composed by the button and two contacts this switch. Keep this switch at ON position
(one is normal open, another is normal when the machine is running, shut off the
close). Pull out the button, the normal close power output of the transmission gear I, and
contact is on, the normal open contact is off; gearII for protecting the gear when depress
press the button, the normal close is off, the down the brake. Turn off this switch only at
normal open is on. See the illustration 6-1. the special condition, such as up and down
See the illustration 6-2 for installation slopes, at this time, the transmission power
location. output is normal when depressing down the
Parking brake switch outline brake. See illustration 6-3 for the installation
location.
Transmission clutch ON/OFF switch installation
location
 317
Electrical System
Parking Brake and Transmission Clutch Cut-off System

3. Parking brake clutch cut-off switch: this Service brake clutch cut-off switch installation
switch consists of two contacts, one is normal location
open, another is normal close, three
terminals, and the middle terminal is the
common terminal of these two contacts. The
normal close contact is off, the normal open
contact is on when the pressure is higher
than 11.5MPva; the normal close contact is
on, the normal open contact is off when the
pressure is lower than11.5MPva.
Parking brake clutch ON/OFF switch installation
location

5. Parking brake solenoid: this solenoid is the

accessory of brake valve, the brake solenoid
function is: produces electromagnetism force
when the electromagnetism winding has
been electrify, so as to impulse the spool and
connect the hydraulic oil line and then
provides pressure to impulse the parking
brake cylinder. The resistance of its solenoid
winding is 40 ohm. It is normal to judge its
damage condition by measuring the
resistance.
Parking brake solenoid installation location

4. Service brake clutch cut-off switch: this

switch consists of two normal open contacts.
The pressure will rise when depress down
the brake, and the normal open contact is on
when the pressure is higher than 1.5MPa,
the normal open contact is off when pressure
is lower than 1.5MPa.
318
Electrical System
Parking Brake and Transmission Clutch Cut-off System

Work Principle NOTICE: Understand the shift control system

rules firstly, viz No.600 wire is the clutch cut-
1. Turn on the start switch, 5A fuse of parking off signal wire of shift control system. When
brake electrifies and supplies power to No.600 wire inputs high level to control unit
No.136 wire; 7.5A fuse of shift control lever EST-25 of shift control system, the shift
electrifies and supplies power to No.170 wire. control lever is at 1st, 2nd gear, the
transmission clutch comes away, no power
2. Pull out the parking brake switch, No.170
output, the transmission is at NEUTRAL.
wire and No.600 wire are connected, 24V
voltage signal supplies power to No.600 wire
Parking brake and clutch cut-off system principle
after passes from No.170 wire to No.11 coil of
XA1 receptacle, and reaches parking brake
switch. No.600 wire high level signal is
inputted to shift control unit EST-25, thereby
cut-off the power output of transmission gear
I, and gearII. At this time, No.600 wire high
level signal is inputted into the gauge, the
clutch cut-off indicator of the gauge lightens.
3. Press the parking brake switch, No.136 wire
and No.478 wire are connected. If the
pressure of the parking brake clutch cut-off
switch is lower than 11.5Mpa, its normal
close contact is on (No.478 wire and No.600
wire are connected), 24V signal is inputted to
the control unit EST-25T through No.600 wire
at X5 receptacle, thereby cut-off the power
output of transmission gear I, and gearII. At
this time, No.486 wire hasn't electricity, the
parking brake solenoid doesn't work, and the
machine is at parking brake state. If the
pressure of the parking brake clutch cut-off
switch is higher than 11.5Mpa, its normal
open contact is on (No.478 wire and No.486
wire are connected ), No.486 wire electrifies,
the parking brake solenoid works and the
parking brake is released; at the same time,
No.600 wire hasn't electricity and the
transmission power outputs normally.
4. The service brake clutch cut-off switch
contact is closed when depress the brake.
No.170 wire and No.602 wire are connected,
No.602 wire electrifies. At this time, No.600
wire electrifies and inputs power to control
unit by receptacle X5 if the transmission
clutch ON/OF pendant switch is closed. If the
transmission clutch ON/OFF pendant switch
is disconnected, No.600 wire hasn't
electricity and transmission power outputs
normally.
 319
Electrical System
Parking Brake and Transmission Clutch Cut-off System

Troubleshooting Step 1. Test the voltage of No.600 wire at X5

receptacle.

6-A-F Fault test of the machine without 1. Turn on the start switch, and press the
I, II gear parking brake button after the engine starting
for 30 seconds, use 200V voltage function of
Fault phenomenon definition: multimeter to measure whether the
grounding voltage of No.600 wire at X5
The machine can drive forward and backward receptacle is between 24V and 31V.
normally when the shift control lever is at ?, ?
gear, but can't drive forward and backward at I,II 2. Please turn to step 2 if the voltage is between
24V and 31V.
gear.
3. If the voltage is 0, please refer to
Fault test cause analysis: transmission system service manual to
eliminate faults; or refer to shift control
Fault can be caused by 24V abnormal voltage at system section to eliminate faults.
No.600 wire when the machine runs normally.
This fault appears when the machine operates
normally, it may be caused by the transmission
mechanical fault if the grounding voltage of
No.600 wire is 0, please consult with the
TRANSMISSION SYSTEM SERVICE MANUAL
to eliminate the faults; or may be caused by the
shift control system, consult with the SHIFT
CONTROL SYSTEM section to eliminate the
faults.
320
Electrical System
Parking Brake and Transmission Clutch Cut-off System

Step 2. Test whether the parking brake clutch 2. press the parking brake button, use the
cut-off switch is god. resistance function of multimeter to measure
the resistance of parking brake button normal
1. Turn on the start switch, and press the open contact, the resistance should be 0,
parking brake button after the engine starting measure the normal close contact resistance,
for 30 seconds, pull out No.600 wire from the the resistance value should be infinity.
parking brake clutch cut-off switch. If the
3. Please turn to step 4 if the test resistance
clutch cut-off indicator is still on, so the
value meets the demand.
parking brake clutch cut-off switch hasn't
problem; if the clutch cut-off indicator is off, 4. If the test resistance value can't meet the
please check the parking brake clutch cut-off demand, the parking brake button is
switch is damaged or not. damaged, please replace it, and finish the
test; but if the fault still exists, please turn to
2. Turn on the start switch, press the parking
step 4.
brake button after the engine starting for 30
seconds, pull out No.600 wire and No.478
Step 4. Test whether the service brake clutch
wire from the parking brake clutch cut-off
cut-off switch is good.
switch, use the resistance function of
multimeter to measure parking brake clutch
1. Use the resistance function of multimeter to
cut-off switch normal close contact (two
measure the contact resistance of service
contacts connected to No.478 wire and
brake clutch cut-off switch, the resistance
No.600 wire formerly), if the resistance is 0,
value should be infinity.
use pressure gauge to check whether the
pressure of the parking brake clutch cut-off 2. If the resistance is 0, the service brake clutch
switch is higher than 11.5MPa. The parking cut-off switch is damaged, please replace it,
brake clutch cut-off switch is damaged if it is, stop checking if the faults are repaired; but if
please replace the parking brake clutch cut- the fault still exists, please turn to step 5.
off switch, and finish checking if the fault is
3. If the resistance is infinity, please turn to step
repaired. Check the brake system faults if the
5.
pressure is lower than 11.5MPa, please refer
to the brake system section in the service Step 5. Test whether No.600 wire is short
manual. Please turn to step 3 if the fault still circuit to power supply
exists.
1. Turn on the start switch, don't start the
Step 3. Test whether the parking brake button
engine, pull up the parking brake button, pull
is good.
out No.600 wire from parking brake clutch
cut-off switch, use 200V voltage function of
1. Turn off the start switch, pull out the parking
multimeter to measure whether the
brake button, use the resistance function of
grounding voltage of No.600 wire at X5
multimeter to measure the resistance of the
receptacle is between 24V and 26V.
parking brake button normal open contacts
(two contacts connected to No.136 wire and 2. If the voltage is between 24V and 26V,
No.478 wire), the resistance value should be please check whether the wiring harness is
infinity; measure the resistance of normal damaged, and eliminate the short circuit
close contacts (two contacts connected to fault; stop checking if the faults are repaired.
No.170 wire and No.600 wire), the resistance 3. If the voltage is 0, please refer to
value should be 0. transmission system or shift control system
service manual to eliminate the faults.
 321
Electrical System
Parking Brake and Transmission Clutch Cut-off System

Fault test steps:

Step 1. Test whether 5A parking brake fuse

has damaged?
High pressure brake oil may cause injury and
death! Never disassemble the parking brake 1. Check whether 5A parking brake fuse has
clutch cut-off pendant switch and the parking damaged. Replace the corresponding fuse if
brake solenoid before without discharging this fuse has burnt, and stop checking after
the brake pressure. Please discharge the replacing the fuse if the fault is repaired. But
brake pressure firstly according to BRAKE if the fault still exists, please turn to step 2.
SYSTEM SERVICE MANUAL instruction if it is
necessary to replace the service brake clutch Step 2. Test whether the parking brake
cut-off switch, the parking brake clutch cut- solenoid electrifies.
off switch and the parking brake solenoid
during maintenace. 1. Turn on the start switch; remove the
receptacle of the parking brake solenoid after
Wear the guard glasses and gloves when the engine starting for 30 seconds, use 200V
disassembly. voltage function of multimeter to measure
whether the voltages of No.486 wire and
6-B-F Fault test of the machine without No.214 wire are between 24V and 31V.
any gear 2. Please turn to step 3 if the voltage is between
24V and 31V.
Fault phenomenon definition:
3. Please turn to step 4 if the voltage is 0.
The machine can't drive forward and backward
Step 3. Test whether the parking brake
normally when the shift control lever is at I, II, ?,
solenoid is good.
? gear, press down and pull up the parking brake
button at the same time when the machine drives
1. Use the resistance function of multimeter to
normally, the parking brake cylinder doesn't
measure the resistance of two pins of the
move up and down.
parking brake solenoid, the normal value is
about 40 ohm.
Fault test cause analysis:
2. The parking brake solenoid is damaged if the
This fault appears when the machine operates resistance is infinity, replace the parking
normally, it may be caused by the abnormal brake solenoid; stop checking if the faults are
electrify or damages of the parking brake repaired. Please turn to step 4 if the fault still
solenoid. Moreover, it may be caused by the exists.
transmission mechanical fault. Please consult
3. Please turn to step 4 if the resistance is about
with the TRANSMISSION SYSTEM SERVICE
40 ohm.
MANUAL to eliminate the faults.
322
Electrical System
Parking Brake and Transmission Clutch Cut-off System

Step 4. Test whether the parking brake clutch 4. The parking brake button is damaged if the
cut-off switch is good resistance value can't meet the demand,
please replace it, and stop checking if the
1. Turn on the start switch, press the parking faults are repaired. Please turn to step 6 if the
brake button after the engine starting for 30 fault still exists.
seconds, remove No.486 wire and No.478
wire form the parking brake clutch cut-off Step 6. Check whether the wiring is
switch, use the resistance function of disconnected?
multimeter to measure the normal open
contact resistance of the parking brake clutch 1. Check the resistance value of No.486 wire is
cut-off switch (two contacts connected to 0 or not by 3m lead from the parking brake
No.478 wire and No.486 wire). clutch cut-off switch to parking brake
solenoid, it is normal if the resistance value is
2. If the resistance is infinity, check whether the
0. Check No.486 wire carefully for abrasion if
pressure of the parking brake clutch cut-off
the resistance value is infinity, or check the
switch is higher than 11.5Mpa by the
connecting condition of XH2 receptacle,
pressure meter, the parking brake clutch cut-
repair the wiring.
off switch is damaged if the pressure is
higher than 11.5MPa, please replace it, and 2. Check the resistance value of No.478 wire is
stop checking if the faults are repaired. 0 or not by 3m lead from the parking brake
Please turn to step 4 if the fault still exists. clutch cut-off switch to parking brake button,
Check the brake system faults if the pressure it is normal if the resistance value is 0. Check
is lower than 11.5MPa, please refer to No.478 wire carefully for abrasion if the
BRAKE SYSTEM section service manual. resistance value is infinity, or check the
connecting condition of XH2 receptacle,
3. Please turn to step 5 if the resistance value is
repair the wiring.
0.
3. Check the resistance value of No.136 wire is
Step 5. Test whether the parking brake clutch 0 or not by 3m lead from 5A fuse of parking
cut-off switch is good condition brake to parking brake button, it is normal if
the resistance value is 0. Check No.136 wire
1. Turn off the start switch, pull up the parking carefully for abrasion if the resistance value
brake switch, use the resistance function of is infinity, or check the connecting condition
multimeter to measure the resistance of the of XA1, XK4 receptacle, repair the wiring.
parking brake switch normal open contacts Stop checking if the faults are repaired.
(two contacts connected to No.136 wire and
No. 478 wire), the resistance value should be
infinity; measure the resistance of the normal
close contacts (two contacts connected to
No.170 wire and No.600 wire), the resistance
value is 0.
2. Press the parking brake button, use the
resistance function of the multimeter to
measure the resistance of the parking brake
button normal open contact, the resistance
value should be 0, the resistance value of the
normal close contact should be infinity
3. Please turn to step 6 if the resistance value
meets the demand.
 323
Electrical System
Lights

Lights The work light is mainly used for operation

illumination of the machine.
The interior light is used for illumination or
Introduction
reading in the cab at night.
Turn on the corresponding light switch for The rotating beacon is used for operation
realizing the illumination of the whole machine. indication of the machine.
The machine has the following lights:
Main Components
Name Qty Composing
Left-front Front floodlight-left front
combination 1 position light-left front turn Dome light
light signal light-left
Right-front Front floodlight-right front
Dome light and principle drawing symbol
combination 1 position light-right front turn
light signal light-right
Interior light 1
Work light 4
Rear floodlight 2
Rotating
1
beacon
Left-rear Backup light, brake light, rear
combination 1 position light-left, rear turn
light signal light-left
Right-rear Backup light, brake light, rear
combination 1 position light-right, rear turn Bulb specification of dome light:
light signal light-right
Rated Bulb Rated
Function
voltage specification power
All kinds of lights functions DOME
24V Bulb T10 10W
LIGHT
The backup light is used for illuminating the back
area of the machine when reverse it. This The bulbs used in this machine all accord with
machine is fixed with the backup alarm, the SAE standard except for the dome light bulbs are
backup light and the backup alarm work at the Chiese standard bulbs.
same time when reverse the machine.
The brake light is used to warn the machines
behind this machine that it is braking.
The turn signal light indicates the turning
direction and the potential danger signal of the
machine (used as the hazard flasher).
The front/rear position lights are used during
running or operation at night, which indicate the
relative position of the machine.
The front/rear floodlights are used for running or
operation illumination of the machine.
324
Electrical System
Lights

Rear combination light NOTICE: The rear combination light uses the
seal receptacle, the jacket of the receptacle
Rear combination light and principle drawing marked with receptacle core numbers.
symbol Perform the connection according to the core
numbers in above illustration and the wire
colors if it is necessary.

Work light and rear floodlight

Work light and rear floodlight and principle

drawing symbol

See above illustration, the rear combination light

is the left-rear combination light, and the right-
rear combination light appears after mirrior
image in above illustration.
Bulb specification of rear combination light:
Rated Bulb Rated Chimney
Fuction
voltage spec. power Color Bulb specification of work light and rear
BACK UP floodlight:
24V P21W 21W White
Light
TURN Rated Bulb Rated
Function
SIGNAL 24V P21W 21W Orange voltage Spec. power
Light WORK LIGHT
BRAKE REAR FLOOD 24V H3 70W
AND LIGHT
24V P21/5W 21/5W Red
POSITIO
N Light
Front combination light
Brake light and position light use the chimney,
inside of which is double filament bulb. Bulb specifications of front combination light:
Function illustration of rear combination light Rated Bulb Rated
Function
voltage spec. power
FRONT FLOOD
24V H4 75/70W
LIGHT
TURN SIGNAL
24V T4W 4W
LIGHT
POSITION LIGHT 24V P21W 21W

See the following illustration, the front

combination light is the left-front combination
light, the right-rear combination light appears
after mirrior image in the following illustration.
 325
Electrical System
Lights

Front combiantion light and pricipal drawing Combination Switch

symbol
Combination switch and principal drawing
symbol

The combination switch can realize the following

functions;
NOTCIE: The rear combination light uses the (Refer to the Operation manual along with the
seal receptacle, the jacket of the receptacle machine for more details)
marked with the receptacle core numbers.
Perform the connection according to the 1. Left turn signal
receptacle core numbers in above illustration 2. Right turn signal
and the wire color if it is necessary.
3. Front floodlight low/high beam switch
Rotating Beacon 4. Horn

Rotating beacon and principal drawing symbol 5. Front window washer

6. Front wiper I
7. Front wiper II

NOTICE: The combination switch realizes the

linkage with the exterior operation through
the cooperative action between the inside
minitype and jiggle switchs and the
mechanism. So the current that the inner
contacts withstood is relative small, needs to
connect the outer relay for realizing the
Bulb specification of rotating beacon: function control except for the left turn
signal, right turn signal, front floodlight high
Rated Bulb Rated beam and the front floodlight low beam.
Function
voltage Spec power
ROTARY
24V H1 70W
REACON
326
Electrical System
Lights

The Combination Light Fault Test Procedure (a) When the wiper is at O, use a probe of
the digital multimeter to connect the
The combination switch is composed by the corresponding copper of BR/WH wire,
inner separate switches, so can use the another probe connected to the
multimeter resistance function to check the corresponding copper of RD/BK wire, the
combination switch. This method is not available digital multimeter reading is 0. use two
for the switch with some damaged contacts, this probes to contact the corresponding
kind of switches look like normal but can't use coppers of the following each wire colour
when connecting to the circuit. This section won't group separately [BU,BK], [BU,BR/WH],
introduce this question due to its low occurrence [RD/BK,BK], [GN,BK], [GN,BR/WH], the
frequency, please replace it with a new multimeter reading is 1.
combination switch if it has such faults. This
(b) Turn the wiper to J, use a probe of the
section will just introduce the general test
multimeter to contact GN wire, another
methods.
probe contacts with BK wire, the
Replace with a new combination switch multimeter reading is 0. Then contact a
assembly when the combination switch is probe with the corresponding copper of
damaged, Liugong doesn't approve to repair the RR/WH wire, another probe contacts with
combination switch because the assembly of the the corresponding copper of RD/BK wire,
combination switch needs the special technics the multimeter reading is 0. Use two
guarantee. probes to contact the corresponding
coppers of the following each wire colour
Judgement steps of whether the combination
group separately [BU,BK],[BU,BR/
switch is damaged:
WH],[RD/BK,BK],[GN,BR/WH], the
1. Adjust the digital multimeter to 200 Ω range multimeter reading is 1.
of Ω function. (c) Turn the wiper to I, use a probe of the
2. Open the steering column assembly, and multimeter to contact RD/BK wire,
disassemble the combination switch from the another probe contacts with BK wire, the
steering column and pull out its receptacle multimeter reading is 0. Use two probes
from the wiring harness. Use either the to contact the corresponding coppers of
positive or negative terminal of the probe, the the following each wire colour group
measure position of the digital multimeter is separately [BU,BK],[BU,BR/WH],[RD/
the copper terminal of the combination switch BK,BR/WH],[GN,BK],[GN,BR/WH], the
receptacle. Distinguish from the wiring color multimeter reading is 1.
because there isn't definition about the
(d) Turn the wiper to II, use a probe of the
receptacle core numbers of the combination
multimeter to contact BU wire, another
switch on the combinantion switch principle
probe contacts with BK wire, the
drawing.
multimeter reading is 0, use two probes
3. Wiper function measurement: to contact the corresponding coppers of
the following each wire colour group
separately [BU,BR/WH],[RD/BK,BK],[RD/
BK,BR/WH],[GN,BK],[GN,BR/WH], the
multimeter reading is 1. Turn the wiper to
O position after measuring.
 327
Electrical System
Lights

4. Horn function measurement: press the horn 7. Front floodlight function measurement: use
and hold it. The horn switch is a reposition the probes of the digital multimeter to contact
switch, it will reposition after releasing. Keep the corresponding coppers of the following
this switch at PRESS position when wire colour groups [WH/BK,YL] or [WH/
measuring, can't let it reposition, which needs BK,WH], the multimeter reading of one group
another person to help. Use a probe of the is 0, the other group is 1. Pull the switch one
digital multimeter to contact the time along with the installation direction of the
corresponding copper of BK wire, the combination switch, the multimeter reading
multimeter reading is 0, but its reading is 1 changes from 0 to 1 or changes from 1 to 0.
after releasing.
The combination switch is good if it can complete
5. Front window washer function measurement: above steps. In addition, it is not necessary to
see the instruction, push the front window operate according to above steps when check,
washer and hold it, refer to step 4, this switch check the corresponding functions firstly if doubt
is a reposition switch. Keep it at washing that some functions have problems.
position when measuring. Use a probe of the
digital multimeter to contact the Brake Light Switch
corresponding copper of GY wire, another
probe contacts with the corresponding Brake light swigch and principle drawing symbol
copper of BK wire, the multimeter reading is
0, and the reading is 1 after releasing.
Replenish washing liquid in time after
measuring.
6. Turn signal measurement:
(a) Push the combination switch handle
forwards. Use a probe of the digital
The brake switch is a pressure switch, which is
multimeter to contact the corresponding
fixed inside the brake valve, the brake oil line
copper of BL/WH wire, another probe
filling oil when the operator depressing down the
contacts with the corresponding copper of
pedal, the oil pressure increases. When the
BK/WH/GN wire, the multimeter reading
pressure reaches the action pressure of the
is 0, and its reading is 1 when turn the
pressure switch, the normal open contacts of the
combination switch to NUEUTRAL
pressure switch will close and connect the circuit
position.
of the contacts.
(b) Push the combination switch handle
The brake light switch operation value is 0.5MPa,
backwards. Use a probe of the digital
and the contact state is ON.
multimeter to contact the corresponding
copper of BK/BR wire, another probe
NOTICE: Make sure the cleanness of the
contacts with the corresponding copper of
screw thread hole before install the pressure
BK/WH/GN wire, the multimeter reading
switch.
is 0, and its reading is 1 when turn the
combination switch to NEUTRAL
Brake Light Switch Fault Test Procedure
position.
The brake switch is a pressure switch, the switch
can operate only connecting it into the medium
loop and let the medium pressure reach the
operation pressure, so it is not available to judge
the pressure switch condition according to the
usual measurement by the resistance.
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The brake light doesn't lighten when the operator Backup Alarm Fault Test Procedure
depresses down the brake pedal. If the brake
switch has fault, it is not necessary to The backup alarm is a buzzer, this buzzer is
disassemble the brake switch from the barke controlled by the inner electrical wire, so can't
valve, just need to simulate its action state. The use the digital multimeter simply to measure the
details as follows: outer characteristic from the receptacle of the
backup alarm.
1. Turn DW-3 gear selector to NEUTRAL
position, pull the parking brake button, and The backup light lights but the backup alarm
disassemble two receptacles of the brake doesn't sound when turn the shift control lever to
light from the swich, connect their coppers REVERSE gear, the general test methods as
together. Simulate the open operation of the follows:
brake light switch.
1. Turn DW-3 gear selector to NEUTRAL
2. Turn on the start switch, the brake switch is position, pull up the parking brake button,
damaged if the brake light is lightened, the turn on the start switch and start the diesel
brake light line doesn't has fault. If the brake engine, turn the shift control lever to R1 gear.
light still not be lightened, the loop of the
2. Adjust the digital multimeter to voltage
brake light has fault, which is not related to
function (50V). Open the left-rear position
the brake light switch.
light- chimney, and pull out the backup alarm
receptacle XI4. Use two probes of the digital
CAUTION: The above operation is only
multimeter to measure the voltage between
for the test of the diesel engine at close state.
two coppers of the receptacle of the harness
Resume rapidly once finishing the test. Never
terminal (not the backup alarm terminal), the
do these operations when the machine is
multimeter reading is between 24V and 31V.
running or working, otherwise it will threat
the machine operation safety. The backup alarm is damaged if the multimeter
reading is the same to step 2, and need to
Backup Alarm replace the backup alarm. If the multimeter
reading is not in this range, please check the
Backup alarm and principle drawing symbol backup alarm lines for other problems.

The backup alarm is an intermittent beep buzzer,

it works together with the backup light when the
operator reverses the machine.
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Flash Relay Pendant Swtich

Flash relay and principle drawing symbol Pendant switch and principle drawing symbol

The flash relay rated load is 40-130W, the See above illustration, work light switch, rear
flashing frequency is 60-120 time/min; when the floodlight switch, hazard flasher switch are the
load changes (decreases), the flashing same with the pendant switch. The work light
frequency increases but doesn't exceed 140time/ and the rear floodlight switch use the principle in
min. illustration 1. The hazard flasher switch uses the
principle in illustration 2. They all are the double-
The flash relay determines the flashing
position switches, and hold at ON position.
frequency of the turn signal light, when the main
turn signal light has fault, the flashing frequency If the back light inside the pendant switch is
of other turn signal lights will increase due to the damaged, disassemble it from the pendant
ralay's effect. switch and replace it, shown as below:
Pendant switch assembly
Flash Relay Fault Test Procedure

The turn signal light and turn signal indicator

don't lighten or flash when steering or parking the
machine, if 10A fuse doesn't melt, the flasher has
fault. The disposal method as follows:
Open the electrical control box, replace the flash
relay with a new one, the flash relay is damaged
if the turn signal gets right. If the turn signal still
doesn't get right after replacement, please check
the turn signal lines for other problems.
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Pendant Switch Fault Test Procedure Position Light & Front Floodlight
Switch
The pendant switch is usually centralized
assembled at the compositive switch groove and Position light & front floodlight switch and
forms the different join number. The principle drawing symbol
subassembly installed with 8 pendant switches
named 7-join pendant switch. The work light,
rear floodlight switch, hazard flasher switch,
position light&front floodlight switch involved in
this section are all installed at 8-join switch
located on the steering column.
1. Take out the pendant switch group from the
switch hole, and don't damage the buckle of
the compositive switch groove. Pull out WH
8-core receptacle on the back of the pendant
switch, and let the copper on the back of the
switch expose.
2. Adjust the digital multimeter to Ω function
(200 Ω ). The position light & front floodlight switch is 3-
3. Hold the pendant switch at OFF position, use position pendant switch, which hold at ON
either the positive or negative of the probe of position.
the digital multimeter to measure [1,5]
copper combination on the back of the Position Light & Front Floodlight Switch
pendant switch, and need to measure [2,6] Fault Test Procedure
copper combination if measure the hazard
flasher switch. The digital multimeter reading 1. Take out the 8-joijn pendant switch group
is 1. from the switch hole, and don't damage the
buckle of the compositive switch groove. Pull
4. Hold the pendant switch at ON position, use out WH 8-core receptacle on the back of the
either the positive or negative of the probe of pendant switch, and let the copper on back of
the digital multimeter to measure [1,5] the switch expose.
copper combination on the back of the
pendant switch, and need to measure [2,6] 2. Adjust the digital multimeter to Ω function
copper combination if measure the hazard (200 Ω ).
flasher switch. The digital multimeter reading 3. Hold the pendant switch at OFF position, use
is 0. either the positive or negative of the probe of
The pendant switch is normal if it can complete the digital multimeter to measure
above testing, otherwise the pendant switch is [1,3],[2,6],[2,8] copper combinations on the
damaged. back of the pendant switch. The digital
multimeter reading is 1.
4. Hold the pendant switch at ON position, use
either the positive or negative of the probe of
the digital multimeter to measure
[2,6],[2,8],[1,3] copper combinations on the
back of the pendant switch. The digital
multimeter reading of [2,6],[2,8] combinations
is 0. The digital multimeter reading of [1,3]
combination is 1.
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5. Hold the pendant switch at ON position, use Operation steps:

either the positive or negative of the probe of
the digital multimeter to measure 1. Press the front floodlight button of position
[2,6],[2,8],[1,3] copper combinations on the light & front floodlight switch.
back of the pendant switch. The digital
2. The floodlight of the front combination light
multimeter reading is 0.
can lighten.
The position light & front floodlight switch is
3. Pull the front floodlight low/high beam switch
normal if it can complete above testing,
to change the light. The high beam indicator
otherwise the position light & front floodlight
will lighten when the switch is at high beam,
switch is damaged.
which shows the front light is at high beam
state.
Function Operation Front floodlight switch position

7-A Dome light operation

The following electronic components are needed

for realizing dome light illumination.
1. Fuse
2. Dome light
Dome light switch

7-B Front floodlight operation

The following electronic components are needed

for realizing front floodlight operation.
1. Fuse
2. High beam indicator
3. Left-front combination light
4. Right-front combination light
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7-C Turn signal light and hazard flasher Turn signal light component position (the
operation demonstration machine is CLG856III with 8-bar
front frame)
The following electronic components are needed
for realizing steering.
1. Fuse
2. Left-front combination light
3. Right-front combination light
4. Left-rear combination light
5. Right-rear combination light
The following electronic components are needed
for realizing the hazard flasher operation.
1. Fuse
2. Hazard flasher switch
3. Left-front combination light
4. Right-front combination light
5. Left-rear combination light
6. Right-rear combination light

Operation steps:

1. Press the turn signal light switch forwards 7-D Position light operation
when the machine turns left, the left turn
signal light of the left-front combination light The following electronic components are needed
and the left-rear combination light will lighten; for realizing the position light operation.
the left turn signal indicator on the central 1. Fuse
function panel will lighten at the same time.
2. Position light & front floodlight switch
2. Press the turn signal light switch backwards
when the machine turns right, the right turn 3. Left-front combination light
signal light of the right-front combination light 4. Right-front combination light
and the right-rear combination light will
lighten; the right turn signal indicator on the 5. Left-rear combination light
central function panel will lighten at the same 6. Right-rear combination light
time.
7. Central instrument panel
3. Park the machine beside the road when the
emergency happens to the machine. Open 8. Each pendant switch
the hazard flasher switch, the left-front turn
signal light, right-front turn signal light, left- Operation steps:
rear turn signal light, right-rear turn signal
light, left turn signal indicator and right turn 1. Press the position light switch of the position
signal indicator located on the panel will light & front floodlight switch.
lighten at the same time, which warns other
vehicles that this machine is at hazard state.
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2. The front position light of the front Operation steps:

combination light will lighten. The rear
position light of the rear combination light will 1. Press the position light & front floodlight
lighten. switch to position light position or front
floodlight position.
3. The indicator on the central instrument panel
will lighten for realizing background 2. Press the work light switch.
illumination.
3. The work light relay works, four work lights
4. Every pendant switch indicator lightens for on the top of the cab realize illumination
realizing background illumination. together.
Position light component position Work light component position

7-E Work light operation

The following electronic components are needed 7-F Rear floodlight operation
for realizing the work light operation.
1. Fuse The following electronic components are needed
for realizing the work light operation.
2. Position light & front flood light switch
1. Fuse
3. Work light switch
2. Position light & front flood light switch
4. Work light
3. Read flood light switch
5. K9 work light relay
4. K7 read flood relay
5. Read flood relay
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Electrical System
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Operation steps: Rotating beacon component position

1. Press the position light & front floodlight

switch to position light position or front
floodlight position.
2. Press the rear floodlight switch.
3. The rear floodlight relay works for realizing
illumination.
Rear floodlight component positon

7-H Brake light operation

The following electronic components are needed

when the brake light lightens.
1. Fuse
2. Service brake pedal
3. Brake valve (BRAKE LIGHT SWITCH)
4. K10 brake light relay
5. Brake light

Operation steps:

The brake light will lighten when the operator

depresses down the brake pedal during
operating the machine.

7-G Rotating beacon operation

The following electronic components are needed

for realizing the rotating beacon operation.
1. Fuse
2. Rotating beacon switch
3. Rotating beacon

Operation steps:

The rotating beacon starts working when press

the rotating beacon switch.
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Electrical System
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Brake light component position Backup light component position (the

demonstration machine is CLG856III of semi-
auto control)

7-I Backup light operation

The following electronic components are needed

when the backup light lightens.
1. Fuse
2. Shift control lever
3. EST117 or EST-25 electronic control unit
4. K12 Backup relay
5. Backup light
6. Backup alarm

Operation steps:

Push the shift control lever to REVERSE gear

when reverse the machine, the reverse signal
enters into ZF electronic control unit through
wiring harness at this time. Then the electronic
control unit exports the backup signal to backup
relay after processing the data at MPU, the
backup relay drives the backup light and the
backup alarm sounds.
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Electrical System
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Troubleshooting Dome light fault test flow chart 7-A-F

In this section, the description about the

lights'fault diagnosis and test method surrounds
mainly the function of FUNCTION OPERATION.
The professional service personnel can test
according to the judgement steps in the flow
chart (if has).

7-A-F Dome light fault test

See above illustration, it is dome light line

principle drawing. The dome light switch is
located on the dome light. When turn on the
dome light, it doesn't lighten, please test it
according to the test steps and the flow chart.
Step 1. Test whether 10A dome light fuse
melts.

1. Open the electronic control box, find the

dome light fuse according to its nameplate
indication and check its melting condition.

Conclusion:

If the fuse melts, open the dome light switch

newly after replacing 10A fuse, if the fuse melts
continuously, please turn to step 6. If the fuse
doesn't melt, and the dome light lightens, the
fault is eliminated.
If the fuse doesn't melt, please turn to step 2.

Step 2. Test the dome light bulbs.

1. Open the dome light chimney, and notice that

the dome light has two bulbs, left/right each.
Check the dome light bulb is damaged or not.
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Electrical System
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Conclusion: Conclusion:

The bulb has fault, please replace the bulb. If the result does OK, please turn to step 5.
The bulb is good, please turn to step 3. If the result doesn't OK, please eliminate the
ground wire fault.
Step 3. Test the voltage of dome light.
Step 5. Test the dome light line
1. Adjust the digital multimeter to voltage
function (50V range). 1. Adjust the digital multimeter to voltage
function (50V range).
2. Turn the disconnect switch and start switch to
I gear (turn on the start switch). 2. Turn the disconnect switch and start switch to
I gear (turn on the start switch).
3. Disassemble the fixing bolt of the dome light,
pull out XD8 receptacle. 3. Check the grounding voltage of XE4-4core,
XK6-1 core, No.139 wire of 10A dome light
4. Use the digital multimeter to measure the
according to the incidental receptacle
voltage of No.1 core and No.2 core in XD8
position distributing drawing of this manual.
receptacle of wiring harness.
Test result:
Test result:
The digital multimeter reading is between 24V
The digital multimeter reading is between 24V
and 31V.
and 31V.
Conclusion:
Conclusion:
If the result doesn't OK, please eliminate the
If the result does OK, replace the dome light
relative line fault.
assembly or open it for service.
If the result doesn't OK, please turn to step 4. Step 6. Test the dome light line

Step 4. Test the ground wire of dome light for 1. Adjust the digital multimeter to Ω function
fastness (200Ω range).
2. Turn the disconnect switch and the start
1. Adjust the digital multimeter to Ω function
switch to 0 gear.
(200Ω range).
3. Disconnect XD8, XE4, XK5 receptacles in
2. Turn the disconnect switch and start switch to
turn according to the incidental receptacle
I gear (turn on the start switch).
position distributing drawing of this manual.
3. Check the groungind resistance of XE2-5
4. Check the grounding resistance of No.1 core
core, XK6-1 core, and XE3-1 core according
and No.2 core of XD8 receptacle, XE4-4
to the incidental receptacle position
core, XK5-3 core, and XA1-13 core.
distributing drawing of this manual.
Test result:
Test result:
The digital multimeter reading is 1
The digital multimeter reading is 0 Ω.
338
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Conclusion:

If the result does OK, please replace the dome

light or eliminate the short circuit fault inside the
dome light.
If the result doesn't OK, please eliminate the
short circuit fault of relative lines.
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7-B-F Front floodlight fault test

Front floodlight, turn light, position light, work light, rear floodlight principle drawing1
340
Electrical System
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Front floodlight, turn light, position light, work light, rear floodlight principle drawing2

The red line is front floodlight current access, the The fault test methods of each light in the light
green line is work light current access, the blue group are very similar. This section will describe
line is rear floodlight current access, the yellow the principles of various lights in detail, and list
line is position light is position light current the flow chart as the reference to fault test, but
access, the purple line is turn light current not describe the fault test steps again. The
access, the ground line that current passed specific test steps are similar to those introduced
through doesn't mark any sign. in dome light section, please refer to that section.
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7-B-F Front floodlight work principle Illustration 7-26 Front floodlight fault test flow
description chart 7-B-F

1. See the red line in the pinciple drawing, press

the position light & front floodlight switch to
front floodlight position, No.125 wire of front
floodlight power supply from 15A fuse
passing XA5 and XY1 receptacles to the
inner contacts of the position light & front
floodlight switch and connecting with No.413
wire.
2. No.413 wire is the front floodlight power line
of the steerig column switch, connected to
No.56 terminal, No.56 terminal connects to
No.56a terminal when the steering column
switch is at original position, and then No.403
wire connects No.413 wire, +24V supplies
power to front floodlight high beam filament
after passing through No.403 wire and XY2
→ XQ8 → XQ1 and XQ6 receptacles, then to
the ground by the filament for realizing the
front floodlight high beam illumination.
Another way passes the panel system, and
the high beam indicator on the panel lightens
indicating the front floodlight is at high beam
state.
3. Pull the steering column switch upwards, the
No.56 terminal and No.56a terminal are 7-C-F Turn light fault test
disconnected, No.57b terminal is connected,
No.406 wire and No.413 wire are also 7-C-F Turn light work principle description
connected, +24V supplies power to front
floodlight low beam filament after passing 1. See the purple line in the principle drawing,
through No.406 wire and XY2 → XQ8 → No.128 wire of the turn light power supply is
XQ1 receptacles, then to the ground by the educed from 10A fuse and enters into the
filament for realizing the low beam flash relay for realizing the flashing, bring
illumination. No.428 wire → XA5 receptacle → XY2
receptacle from the flash relay to the steering
The front floodlight can't be lightened when turn column switch, final to the hazard flasher
on the front floodlight switch, please check the switch.
fault according to the flow chart.
342
Electrical System
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2. When turn the machine left, push the steering Turn light fault test flow chart 7-C-F1
column swich forwards, No.428 wire
connects No.405 wire by inner contacts of
the steering column switch, +24V supplies
power to the left-front turn light filament after
passing through No.405 wire and XY2 →
XQ8 → XQ7 receptacles, then to the ground
by the filament; the other way reaches the
left-rear turn light filament after passing
through XY4 → XI7 receptacles and final
passes the filament to the ground, the left-
fornt turn light and the left-rear turn light
lighten. At the same time, another way enters
into the panel system, and the left turn signal
indicator on the panel will lighten. The
machine is turning left.
3. Push the steering column swich backwards,
No.428 wire connects No.404 wire by inner
contacts of the steering column switch when
turn the machine right, +24V supplies power
to the right-front turn light filament after
passing through No.404 wire and XY2 →
XQ8 → XQ2 receptacles, then to ground by
the filament; the other way reaches te right-
rear turn light filament after passing through
XY4 → XI3 receptacles and final passes the
filament to ground, the right-fornt turn light
and the right-rear turn light lighten. At the
same time, another way enters into the panel
system, the right turn signal indicator on the
panel will lighten. The machine is turning
right.
4. The operator will turn on the parking light
switch when the machine needs emergency
parking, No.428 wire connects No.404 wire
and No.405 wire together by the inner
contacts of the parking brake switch, +24V
supplies power to the left-front turn light, the
left-rear turn light and the left turn signal
indicator on the panel by No.405 wire; also
supplies power to the right-front turn light, the
right-rear turn light and the right turn signal
indicator on the panel by No.404 wire. The
above lights are all lightened.
The turn light can't be lightened when turn on the
turn light switch or hazard flasher switch, please
check the fault according to the flow chart.
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Hazard flasher fault test flow chart 7-C-F2 3. +24V power supply is divided into 6 ways
after No.416 wire electrifies, one way passing
XY2 → XQ8 to XQ1 and XQ6, the front
position light of left/right front combination
light will lighten. One way passing XY4 to XI2
and XI6, the rear position light of left/right
rear combination light will lighten. One way
enters into instrument system and supplies
the background illumination to instrument.
One way supplies power to the backboard
diode of each pendant switch for realizing
background illumination of the pendant
switch. One way enters into work light switch
and becomes the switch power supply. One
way enters into the rear floodlight switch and
becomes the switch power supply.
Press the position light &front floodlight switch to
position light position, the position light can't be
lightened, please check the fault according to the
flow chart.

7-D-F Position light fault test

7-D-F Position light work principle

description

1. See the yellow line in the principle drawing,

No.126 wire of the position light power supply
is educed from 10A fuse passing XA5
receptacle → XY1 receptacle to position light
& front floodlight switch
2. Press the position light& front floodlight
switch to position light position. At this time,
No.126 wire passes inner contacts of the
switch and connects with No.416 wire.
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Electrical System
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Position light fault test flow chart 7-D-F 2. Press the work light switch, No.416 Wire
Connects No.415 Wire, +24V power supply
passing No.415 wire → XY2 → XA5 → work
light relay, the relay works, its normal open
contacts close. No.131 power supply wire
from 20A fuse passing the close contacts of
the work light relay and connects with No.482
wire, then reaches XD1, XD2, XD3, XD4 by
XA5, XK6 XE3 receptacles. Four work lights
on the top of the cab electrify and realize
illumination.
The work light can't be lightened when turn on
the work light switch, please check the fault
according to the flow chart.

7-E-F Work light fault test

7-E-F Work light work principle description

1. See the green line in the principle drawing,

press the position light & front floodlight
switch to position light position. No.416 wire
from the position light & front floodlight switch
turns into the work light power supply line.
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Electrical System
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Work light fault test flow chart 7-E-F 7-F-F Rear floodlight fault test

7-F-F Rear floodlight work principle

description

1. See the blue line in the principle drawing,

press the position light & front floodlight
switch to position light position. No.416 wire
from the position light & front floodlight switch
becomes the rear floodlight switch
background power supply line.
2. Press the rear floodlight switch, No.416 wire
connects No.419 wire, +24V power supply
passing No.419 wire → XY2 → XA5 → rear
floodlight relay, rear floodlight relay works, its
normal open contacts close, No.127 power
supply wire from 15A fuse passing the rear
floodlight relay close contacts and connects
with No.418 wire, then passing XA5, XK5,
XE4 receptacles to XD5, XD6. Two rear
floodlights on the top of the cab electrify and
realize illumination.
The rear floodlight can't be lightened when turn
on the rear floodlight switch, please check the
fault according to the flow chart.
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Electrical System
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Rear floodlight fault test flow chart 7-F-F 7-G-F Rotating beacon fault test

Principle drawing 7-G

7-G-F Rotating beacon work principle

description

1. See the principle drawing, the rotating

beacon power supply is brought out from 10A
fuse by No.152 wire, passing XA2 receptacle
→ XJ1 receptacle to rotating beacon switch.
2. Press the rotating beacon, No.152 wire
connects No.472 wire, +24V power passing
XJ1 → XK5 → XE4 → rotating beacon, then
to ground through the filament, the rotating
beacon gives off the frequency flashing
signal and realizes warning.
3. The rotating beacon can't be lightened when
turn on the rotating beacon switch, please
check the fault according to the flow chart.
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Rotating beacon fault test flow chart 7-G-F

348
Electrical System
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7-H-F Brake light fault test

Principle drawing 7-H-F

7-H-F Brake light work principle description 3. The normal open contacts of the brake light
close, No.155 wire connects No.481 wire,
1. See the principle drawing, the blue line is supplies power to the brake light relay by
brake light control loop, the red line is brake XA5 receptacle, the brake light relay works,
light loop. its normal open contacts close, No.155 wire
connects No.479 wire. +24V power supply
2. No.155 wire of the brake light power supply
provides power to two brake lights after
wire reaches the brake light relay contact
terminal from 10A fuse, passing XA2 passing through No.479 wire → XA5 → XH2
and reaches XI2 and XI6. The left/right brake
receptacle to brake light switch. The brake
lights are lightened at the same time.
light switch is installed on the brake valve,
the brake light normal open contacts close The brake light can't be lightened when the
when the operator depresses down the brake operator depresses down the brake pedal,
pedal. please check the fault according to the flow
chart.
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Brake light fault test flow chart 7-H-F

CAUTION: The short connection operation of the brake light switch receptacle is only for the
test of the diesel engine at close state. Resume rapidly once finishing the test. Never do these
operations when the machine is running or working, otherwise it will threat the machine
operation safety.
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7-I-F Backup light fault test

Principle drawing 7-I

7-I-F Backup light work principle description into XJ3 voltage/service meter and
instrument assembly as L terminal of the
1. See the purple line in the principle drawing, alternator The positive of the charging
No.171 wire exports +24V power supply from indicator in the instrument assembly
10A fuse after turn on the start switch, connects with the power supply of the
passing the backup alarm control relay and instrument assembly, the negative connects
No.800 wire → XA5 receptacle → XH2 with the ground by No.800 wire, then the
receptacle → L terminal of the alternator then indicator is lightened.
to ground by inner circuit of the alternator.
The backup alarm control relay works, its
normal close contacts is disconnected, cut-
off the connection between No.350 wire and
No.212 wire. At this time, No.800 wire enters
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2. L terminal potential of the alternator is bulit

after starting the diesel engine to drive the
alternator for running and the alternator
obtains the desired rev. No.800 wire builds
+24V potential, at this time, two terminals of
the backup alarm control relay winding have
the equal potential, the relay never works, its
normal close contacts close newly, No.350
wire connects No.212 wire and grounding.
The charging indicator loop in the instrument
assembly is cut off after No.800 wire has built
the voltage, and the charging indicator goes
out, which indicates the machine is at
charging state. The service meter starts
timing since No.800 wire has built the
voltage, which indicats the accumulative total
work time of the machine.
3. See the bule line in the principle drawing,
operator drives the machine for reverse
operation, the reverse signal is exported from
gear controller to EST electronic control unit
of ZF shift control system, EST control unit
exports the backup signal by No.588 wire.
The backup relay works, its normal open
contacts close when No.588 wire reaches the
backup relay, such as No.350 wire grounding
in No.2 description of this section.
4. See the red line in the principle drawing, the
backup relay works, No.156 wire connects
No.480 wire, +24V power supply is educed
from No.156 wire of 10A fuse → backup relay
contact → XA5 receptacle → XH2 receptacle
→ XI2, XI4, XI6, receptacles, then reaches
the backup light and the backup alarm then
to the ground through them. The backup light
is lightened, the backup alarm beeps
5. The backup light and the backup alarm just
work after starting the diesel engine. If turn
on the start switch, but not start the diesel
engine, they can't work when shift to reverse
gear. The service hour meter calculates the
work hour of the diesel engine not the hour of
machine electrifying power supply.
352
Electrical System
Lights

The backup light and backup alarm can't work

when operate machine at reverse gear, please
check the fault according to the flow chart.
 353
Electrical System
Lights

Backup light fault test flow chart 7-I-F

354
Electrical System
Secondary Steering System

Secondary Steering System Secondary steering running indicator, steering

system fault indicator
Secondary steering running indicator, steering
Introduction system fault indicator

The secondary steering system is exactly a

safety protection measurement. When the 1 2
normal steering system pressure is too low or
there isn't pressure to turn, the secondary
steering system will start automatically for
protecting, it also can be started by manual
operation.

Main Components

Secondary Steering Motor

1. Secondary steering running indicator
2. Steering system fault indicator
Secondary steering motor
Secondary Steering Running Switch

Part NO.: 30B0291

Secondary steering running switch

Secondary Steering Switch

Secondary steering switch

 355
Electrical System
Secondary Steering System

Steering System Low Pressure Alert (a) The steering system low pressure alert
Switch indicator turns on (see illustration 8-5)
when the system pressure is under
Part NO.: 30B0292 0.6Mp→No. 312 wire electrifies→the
steering system fault indicator lights (see
Steering system low pressure alert switch illustration 8-3)→the gauge No.36 pin
outputs +24V?32V voltage (the time is 40
sec)→No 409 wire electrifies→the
secondary steering relay works→No 465
wire electrifies→the secondary steering
motor works→the secondary steering
motor drives the secondary steering
pump and supplies the power output to
steering system→secondary steering
running switch turns on→No 408 wire
connected to the grounding wire→the
secondary steering running indicator
lights
Secondary steering system principle drawing
Secondary steering system principle:

1. Manual operation
(a) Turn on the start switch, and press the
secondary steering switch (see
illustration 8-2).
(b) No.409 wire electrifies→the secondary
steering relay works (in the wiring control
box) →No.465 wire electrifies→the
secondary steering motor works→the
secondary steering motor drives the
secondary steering pump and supplies
the power output to steering system→the
secondary steering running switch (see
illustration 8-4) turns on→No.408 wire
connected to the grounding wire→the
secondary steering running indicator
lights (see illustration 8-3).
2. Automatic operation
356
Electrical System
Secondary Steering System
 357
Electrical System
Secondary Steering System

Troubleshooting steering motor doesn't work automatically.

2-A Observe whether the steering system fault

Secondary steering motor manual no indicator lights?
work
Yes: please turn to 2-D
1-A Test whether 10A secondary steering system No: please turn to 2-B
fuse has melted?
2-B Test whether 10A secondary steering system
Yes: please replace the secondary steering fuse has melted?
system fuse
Yes: please replace the secondary steering
No: please turn to 1-B system fuse.
1-B Press the secondary steering switch when No: please turn to 2-C
the start switch is OFF, use the resistance
2-C Turn on the start switch, check the steering
function of the multimeter to measure whether
system low pressure alert switch, use DC voltage
No.1 pin and No. 5 pin of the secondary steering
function of the multimeter to measure whether
switch are connected?
the grounding voltage of No. 408 wire on the
Yes: please turn to 1-C alert switch is between 24V and 32V?
No: the secondary steering switch is damaged, Yes: please turn to 2-D
please replace the switch.
No: the steering system low pressure alert switch
1-C Test whether the secondary steering relay (in is damaged; please replace the steering system
the control box) is damaged? low pressure alert switch.
Yes: please replace the secondary steering relay. 2-D Turn on the start switch, use the DC voltage
function of the multimeter to measure whether
No: please turn to 1-D
the grounding voltage of the gauge receptacle
1-D Turn on the start switch, press the secondary No.36 pin (No.409 wire) is between 24V and
steering switch, use the DC voltage function of 32V?
the multimeter to measure whether the
Yes: please turn to 1-C
grounding voltage of No. 465 wire on the
secondary steering motor is between 24V and No: the gauge has fault, please replace it.
32V?
2. The secondary steering motor can work
Yes: please turn to 1-E
normally but can't turn
No: please turn to 1-F
Test the fault of the hydraulic system.
1-E Test whether the secondary steering motor is
damaged?
Yes: please replace the secondary steering
motor.
No: please turn to 1-F
1-F Test the receptacle condition according to
the system principle.

1. When the pressure of the steering system

is too low or there isn't pressure, the steering
system can not turn and the secondary
358
Electrical System
Wiper and Washer System

Wiper and Washer System Wiper

Introduction

The front, rear wiper motors of this machine are

permanent magnet motors and negative
controlled. The wiper motor drives the wiper to
work.

Main Components

Combination Switches

Combination switches Rear Wiper and Washer Switches

1 2

1 2

1. Front wiper switch

2. Front washer switch
1. Rear wiper switch
Wiper motor 2. Rear washer switch

Kettle with Washer Motor

 359
Electrical System
Wiper and Washer System

Front Wiper I, II and Washer Relays 1. Front wiper I relay

2. Front wiper II relay
3. Washer relay

2 1 3

Principle schematic
360
Electrical System
Wiper and Washer System

Common Fault Test The reset wire is connected to the power supply
wire when the wiper runs to the first position, the
wiper motor' low gear armature gets short circuit,
Wiper Work Principle the motor keeps running under the inertia action
and generates electricity, then produces the
The wiper motor drives the wiper to work (see electromagnetism brake torque and stops
illustration 9-2). The front, rear wiper motors of running immediately, the wiper stops working
the machine are magnet motors and negative when it runs to O gear.
controlled.
There are 5 wires connected outward to the rear
There are 5 wires connected outward to the front wiper motor, the red is power supply wire (the
wiper motor, the red is power supply wire (the common brush leads of high gear armature and
common brush leads of high gear armature and low gear armature connected to No. 129 wire),
low gear armature connected to No. 129 wire), the black is negative wire (connected to the
the black is negative wire (connected to the ground by the motor housing, connected to No.
ground by the motor housing, connected to No. 205 wire), the blue is another brush lead of high
213 wire), the blue is another brush lead of high gear armature (connected to No. 337 wire), the
gear armature (connected to No. 330 wire), the green is another brush lead of low gear armature
green is another brush lead of low gear armature (connected to No. 338 wire), the white is reset
(connected to No. 331 wire), the white is reset wire (connected to No. 339 wire).
wire (connected to No. 329 wire).
No. 129 wire electrifies (+24V) after starting the
No. 129 wire electrifies (+24V) after starting the start switch. When the rear wiper switch (see
start switch. When the combination lever wiper illustration 9-5) is at 1st gear, No. 3 pin is
switch (see illustration 9-1) is at I gear, No. 328 connected to No.5 pin, and the motor runs at low
wire is connected to No. 202 grounding wire, gear.
which makes the wiper motor 1st gear relay K7
(see illustration 9-6) works, that is the motor runs When the rear wiper switch is at 2nd gear, No.3
at low gear when No. 331 wire is connected to pin is connected to No.1 pin, and the motor runs
No. 213 grounding wire. at high gear.

When the combination lever wiper switch is at II If turn off the wiper switch (that is turn the switch
gear, No. 327 wire is connected to No. 202 wire, to O gear from 1st or 2nd gear), No.5 pin and No.
which makes the wiper 2th gear relay K8 works, 7 are connected. At the moment of turn off the
that is the motor runs at high gear when No. 330 switch, the wiper doesn't stop at the first position,
wire is connected to No. 213 grounding wire. the current passes by No. 129 lead-low gear
armature-wiper switch No.5 pin-wiper switch
If turn off the wiper switch (that is turn the switch No.7 pin-white reset wire-ground (illustration:
from I gear or II gear to O gear through J gear), there is a auto reset device in the motor, make
when turn the switch to J gear, if the wiper sure the wiper can always stop at the first
doesn't stop at the first position, the current position, the reset wire is connected to the power
passes by No. 129 lead-No. 328 lead of low gear supply wire when the wiper is at the first position,
armature-wiper switch-white reset No. 329 lead- otherwise the reset wire is connected to the
ground (illustration: there is a reset device in the negative wire) the motor runs continuously.
motor, make sure the wiper brush can always
stop at the first position, the reset wire is
connected to the power supply wire when the
wiper is at the first position, otherwise the reset
wire is connected to the negative wire), the motor
runs continuously.
 361
Electrical System
Wiper and Washer System

The reset wire is connected with the power 1-C Turn off the start switch, turn the
supply wire when the wiper runs to the first combination switch to I gear, pull out No.328 wire
position, the wiper motor' low gear armature gets on the wiper I gear relay, use the resistance
short circuit, the motor keeps running under the function of the multimeter to measure whether
inertia action and generates electricity, then No.328 wire is connected to the ground?
produces the electromagnetism brake torque
Yes: please turn to 1-D
and stops running immediately, the wiper stops
working when it runs to O gear. No: the front wiper switch is damaged, please
replace the combination switch.
The measuring methods of wiper motor 1-D Test whether the front wiper I gear relay is
in short circuit and open circuit: damaged?

Disconnect the connection between the wiper Yes: please replace the front wiper I gear relay.
motor and the whole machine wiring, and use the No: please turn to 1-E
resistance function of the multimeter to measure
the wiper motor resistance between red wire and 1-E Turn on the start switch, turn the combination
blue wire or green wire. If the resistance is switch to I gear, use the voltage function of the
infinity, it is open circuit. Use the resistance multimeter to measure whether the voltage
function of multimeter to measure the resistance between No.1 pin (No.129 wire) and No.4 pin
between the red wire and any other wire; if the (No.331 wire) of XJ2 receptacle is between 24V
resistance is limited, it is short circuit. and 32V?
Yes: please turn to 1-F
Washer Work Principle
No: please turn to 1-G
Turn on the start switch, 20A wiper fuse 1-F Test whether the front wiper motor gets short
electrifies (+24V), the front washer switch (see circuit or open circuit?
illustration 9-1) and the rear washer switch (see
Yes: please replace the front wiper assembly.
illustration 9-4) are connected, the front washer
relay K13 (see illustration 9-6) works, the front, No: please turn to 1-G
rear washer motors (see illustration 9-5) work by 1-G Test whether the receptacles have loosened
No.420. 421 wires, water in the kettle is taken out and the wiring harnesses have worn according to
to the nozzle (installed under the front, rear the principle of the wiper and washer systems.
windows) and spray to the windshield.
2. Front wiper II gear doesn't work
Fault Test Procedure of the Wiper and
Washer Systems 2-A Turn on the start switch, the front wiper I
gear works normally?
1. Front wiper I gear doesn't work
Yes: please turn to 2-C
1-A Turn on the start switch, the front wiper II No: please turn to 1-B
gear works normally?
2-B Test whether 20A fuses of the wiper and the
Yes: please turn to 1-C washer systems have melted?
No: please turn to 1-B Yes: please replace the fuse.
1-B Test whether 20A fuses of wiper and washer No: please turn to 2-C
systems have melted?
Yes: please replace the fuse
No: please turn to 1-C
362
Electrical System
Wiper and Washer System

2-C Turn off the start switch, turn the 3-D Turn on the start switch, turn the rear wiper
combination switch to II gear, pull out No.327 switch to I gear, use the DC voltage function of
wire on the wiper II gear relay, use the resistance multimeter to measure whether the voltage
function of the multimeter to measure whether between No.1 pin (No.129 wire) and No.4 pin
No.328 wire is connected to the ground? (No.338 wire) of XJ8 receptacle is between 24V
and 32V?
Yes: please turn to 2-D
Yes: please turn to 3-E
No: the front wiper switch is damaged, please
replace the combination switch. No: Test whether the receptacle have loosened
and the wiring harnesses have worn according to
2-D Test whether the front wiper II gear relay is
the principle of the wiper and washer systems.
damaged?
3-E Test whether the front, rear wiper motor gets
Yes: please replace the front wiper II gear relay.
short circuit or open circuit?
No: please turn to 2-E
Yes: please replace the rear wiper assembly.
2-E Turn on the start switch, turn the combination
No: Test whether the receptacles have loosened
switch to II gear, use the DC voltage function of
and the wiring harnesses have worn according to
the multimeter to measure whether the voltage
the principle of the wiper and washer systems.
between No.1 pin (No.129 wire) and No.3 pin
(No.330 wire) of XJ2 receptacle is between 24V
4. Rear wiper II gear doesn't work
and 32V?
Yes: please turn to 1-F 4-A Turn on the start switch, the rear wiper I gear
works normally?
No: Test whether the receptacles have loosened
and the wiring harnesses have worn according to Yes: please turn to 4-C
the principle of the wiper and washer systems
No: please turn to 4-B
3. Rear wiper I gear doesn't work 4-B Test whether 20A fuses of the wiper and
washer systems have melted?
3-A Turn on the start switch, the rear wiper II
Yes: please replace the fuses
gear works normally?
No: please turn to 4-C
Yes: please turn to 3-C
4-C Turn off the start switch, turn the rear wiper
No: please turn to 3-B
switch to II gear, use the resistance function of
3-B Test whether 20A fuses of the wiper and the multimeter to measure whether No.3 pin and
washer systems have melted? No.1 pin of rear wiper switch are connected?
Yes: please replace the fuse. Yes: please turn to 4-D
No: please turn to 3-C No: the rear wiper switch is damaged; please
replace the rear wiper switch.
3-C Turn off the start switch, turn the
combination switch to I gear, use the resistance 4-D Turn on the start switch, turn the rear wiper
function of the multimeter to measure whether switch to II gear, use the DC voltage of the
the voltage between No.1 pin (No.129 wire) and multimeter to measure whether the voltage
No.3 pin (No.330 wire) of XJ2 receptacle is between No.1 pin (No.129 wire) and No.3 pin
between 24V and 32V? (No.337 wire) of XJ8 receptacle is between 24V
and 32V?
Yes: please turn to 3-D
Yes: please turn to 3-E
No: the rear wiper is damaged; please replace
the rear wiper switch.
 363
Electrical System
Wiper and Washer System

No: Test whether the receptacles have loosend

and the wiring harnesses have worn according to
the principle drawing of the wiper and washer
systems..

5. The washer nozzle doesn't work

5-A Observe whether the motor runs and sprays

normally?
5-B Test the water line has disconnected or not
(water hose has disconnected or is bundled too
tightening)
5-C Test the nozzle is jammed or not.
364
Electrical System
Sound System

Sound System

Introduction

Turn on the power supply can play the radio or

the tape.

Main Components

Radio

Part NO.: 37B0242

1. Preselected Key1 2. Preselected key2 3. Preselected Key3 4. Preselected Key4

5. Preselected Key5 6. Preselected Key6 7. Switch 8. Sound Mode Key
9. Volume Key 10. Radio Key 11. Auto-memory 12. FM/AM Switch
13. LCD
 365
Electrical System
Sound System

Radio location Antenna

Part NO.: 37B0243

Notice: Refer to the sound instruction for the Sound System principle schematic
operation details of the radio.

Speaker

Part NO.: 38B0047

366
Electrical System
Sound System

Troubleshooting 2. Check the negative connection condition.

3. Adjust manually if the station signal is too
1. The main control panel displays normally, weak.
but there isn't sound or the sound is too low.
4. Display wiring harness "TAPE ERR"
1. Make sure the system is in receiving or
playing condition of the radio, check whether 1. Check the tape
the positive/negative pole of the speaker has
voltage. Check the speaker if it has voltage. 5. No alt or loss track when playing the tape
Judge the speaker condition by checking the
resistance value of the speaker's positive/ 1. Clean the tape head
negative pole. The methods as follows:
6. Tape looseness
(a) Unplug XD9 and XE1 receptacles, test
their resistance values. The values 1. Check and make sure the tape is in good
should be (or close to) the nominal condition. The tape ungirds may damage the
values. If the resistance value is zero or sound system and tape. Use a pencil or other
the circuit is open, the speaker is tools to tighten the tape.
damaged. If the positive/negative pole of
the speaker hasn't voltage, please check 7. The speaker volume reduces
the condition of the receptacles and the automatically
wiring harnesses.
2. Check the left/right balance set of the 1. The safety circuit inside will prevent the
speaker. sound system interior temperature from
exceeding the stated value.
3. Check the antenna and connector.
2. Increase the volume when the temperature is
2. Start the sound, the LCD doesn't display. reduced.

1. Check whether No. 153 line at XD7

receptacle has voltage;
2. If No. 153 wire hasn't voltage (24V), check
whether 10A fuse of the radio has melted in
the electronic centralized control box, change
the fuse if it has burnt.
3. Check the condition of XA2, XK5, XE4
receptacles if the fuse doesn't burn.
4. Check the condition of the red lead 5A fuse if
No. 153 line has voltage at XD7 receptacle
and XD7 contact is in good condition. If the
fuse is good, the sound has fault and replace
it.

3. Receive the wrong station

1. Check the spread and connect condition of

the antenna.
 367
Electrical System
Auto-Return System

Auto-Return System Single handle control lever and the pilot valve

Introduction

This machine auto return system consists of the

bucket positioner and the boom lift kickout. The
bool float function will be introduced in this
section since the boom float solenoid, the bucket
positioner solenoid, and the boom lift kickout
solenoid are installed in the pilot valve.
Push the control lever forward or backward for
boom lifting or lowering, the control lever will
keep at FORWARD or BACKWARD position
automatically. When the boom reaches the lifting
limit position, the control lever will return to the
middle position automatically; when the boom
lowers to the limit position, the control lever will
not return to the middle position automatically,
The pilot valve is fixed under the single handle
the operator needs to pull it to the middle
control lever, there are three group windings
position.
inside, which control the boom lift kickout, the
Push the control lever left for bucket tilting back, boom float and the bucket positioner functions
the control lever will keep at left position until separately.
reaches the bucket positioner, the control lever
These windings can lock the single handle
returns to the middle position automatically.
control lever at operation position when the
operator controls the lever for lifting the boom,
Main Components floating the boom and tilting the bucket. The
single handle control lever can return to the
middle position automatically when the boom lift
Single Handle Control Lever and Pilot kickout and the bucket positioner are at the limit
Valve (available for CLG856III with position.
semi-auto shift control)
The pilot valve solenoid electronic parameter:
The single handle control lever integrates the the temperature is 25°C, the winding resistance
boom, the bucket operation as a whole. is 100±5Ω.

Pilot valve solenoid fault check method:

1. Open the single handle control lever side

cover, and pull out the electronic receptacle
of the pilot valve solenoid.
2. Adjust the digital multimeter to 200 Ω
function.
3. Use the digital multimeter probe to connect
two probes of the pilot valve solenoid
receptacle separately.
368
Electrical System
Auto-Return System

4. The pilot valve solenoid condition is good These windings can lock the single handle
when the digital multimeter reading is about control lever at operation position when the
100. The pilot valve solenoid has burnt off, operator controls the lever for lifting the boom,
and needs replacement when the digital floating the boom and tilting the bucket. The
multimeter reading is 0. The pilot valve single handle control lever can return to the
solenoid may be short circuit between the middle position automatically when the boom lift
coils when the digital multimeter reading is kickout and the bucket positioner are at the limit
less than 70, please replace it. position.
The pilot valve solenoid electronic parameter:
Single Handle Control Lever and Pilot the temperature is 25°C, the winding resistance
Valve (available for CLG856III with full- is 100±5Ω.
auto shift control)
Pilot valve solenoid fault check method:
The single handle control lever in this machine
integrates the shift control, the boom and the 1. Open the single handle control lever side
bucket operation as a whole. cover, and pull out the electronic receptacle
The single handle boom and bucket operation of the pilot valve solenoid.
functions will be introduced in this section, but 2. Adjust the digital multimeter to 200 Ω
the shift control function will be introduced in the function.
corresponding section.
3. Use the digital multimeter probe to connect
Single handle control lever and pilot valve two probes of the pilot valve solenoid
receptacle separately.
4. The pilot valve solenoid condition is good
when the digital multimeter reading is about
100. The pilot valve solenoid has burnt off
and needs replacement when the digital
multimeter reading is 0. The pilot valve
solenoid may be short circuit between the
coils when the digital multimeter reading is
less than 70, please replace it.

Boom Magnet

The boom magnet is welded on the boom, close

to the articulation position of the boom. It is the
boom lifting limit magnet, and provides the
magnetic field for the approach switch. The
permanent magnet is installed in the white line
frame.
The pilot valve is fixed under the single handle
The boom magnetic field intensity is at the place
control lever, there are three group windings
13mm above the central axes of the magnet, the
inside, which control the boom kickout, the boom
magnetic field intensity is not less than
float and the bucket positioner functions
225G(Gauss).
separately.
 369
Electrical System
Auto-Return System

Boom magnet exterior drawing Boom lift kickout and bucket positioner approach
switches exterior drawing symbol

The boom lift kickout and bucket positioner

approach switches used in this machine are both
Bucket Magnet the magnetic field inducing sensor, which
installed with Hall switch inside.
The bucket magnet is installed in the pin
The boom lift kickout switch and bucket
connects the rocker and buckt tilting cylinder. It is
positioner switch look the same but use them
the bucket positioner magnet, and provides the
carefully due to the different installation positions
magnetic field for the approach switch. The
and quantities of Hall switches.
permanent magnet is installed in the white line
frame. The approach switch work principle is: check the
existence condition of the even magnetic field
The boom magnetic field intensity is at the place
intensity, and send the electrical signal to control
13mm above the central axes of the magnet, the
the circuit ON/OFF by Hall switch. During
magnetic field intensity is not less than
installation and adjustment, when the boom lift
225G(Gauss).
kickout switch and the bucket positioner switch
Bucket magnet exterior drawing close to the magnetic article, the magnetic field
intensity of Hall switch is located in the center of
magnetic field, in which can protect the switches
sensitivity.
The boom lift kickout approach switch has
restriction current protection function.
The induction relationship between the boom lift
kickout switch and the boom magnet

Boom Lift Kickout Approach Switch

The boom lift kickout approach switch looks the

same with the bucket positioner approach
switch, but they have the different interior See above illustration, the induction point
configuration, so must pay attention to their position is Hall switch position inside the boom
model differences during installation or lift kickout switch, the green indicator on the
replacement. approach switch shows the power supply state,
and the red one shows the work state of the
approach switch.
370
Electrical System
Auto-Return System

In above illustration, the plastic or wooden block 3. Disassemble the boom lift kickout switch
layer is used to test, its thickness is 4-6mm, from the fixing hood, observe the red
during test, this layer is not used, keep the indicator condition after put the boom lift
distance between the burst magnet and kickout switch induction surface close to the
induction surface for 4-6mm. boom magnet up to 4-6mm away from it.
The red indicator and green indicator lighten at Remove the boom lift kickout switch away if
the red indicator doesn't go out, and closing
the same time when the switches are switched
up the boom magnet again 2s later, observe
on, input +24V power to the pilot valve solenoid.
Hall switch checks the magnetic field existence the red indicator condition, the indicator is
damaged if it doesn't go out. Remove the
when the magnet is close to the inducton point of
boom lift kickout switch away if the red
the switch, Hall switch exports signals to drive
the inner electrical circuit and shut off the output indicator goes out, observe whether the red
indicator lightens again after 2s. The boom lift
voltage of the approach switch when the
kickout switch is damaged if it can't lighten
magnetic field intensity reaches to desired value,
newly.
the red indicator goes out at this time. The red
indicator lightens newly 1-2s later after the The above operation must be carried out under
magnet being moved and starts next work the safety condition.
circulation.
Bucket Positioner Approach Switch
NOTICE: During adjustment, when the boom
lift kickout switch is close to the boom See the boom lift kickout switch instruction for
magnet, must make the induction surface the bucket positioner switch exterior drawing and
distance is 4-6mm. principle drawing. Its outline is the same to the
boom lift kickout switch.
During installation, when the boom lift
kickout switch is close to the boom magnet, Refer to the boom lift kickout approach switch
must make the induction surface center work principle instruction for the bucket
corresponding to the magnet center. positioner approach switch work principle.
The induction relationship between the bucket
Boom lift kickout switch fault test method positioner switch and the bucket magnet

The switch interior wires are separate, can't test

the resistance and voltage according to the
traditional method. Test them according to the
following methods if doubt the switch has fault,
need a second to help if use this method to test.
1. Turn on the start switch, observe the red
indicator and green indicator, if there is one See above illustration, the induction point
indicator doesn't lighten, the switch is position is Hall switch position inside the bucket
damaged, and please replace it. Carry out positioner approach switch. It is different that the
the following steps if two indicators lighten. bucket positioner switch has two Hall switches,
2. Lower the boom slowly and level the bucket but the boom lift kickout switch just has one Hall
on the ground. switch. The gree indicator on the approach
switch shows the power supply state, the red
indicator shows the work state of the approach
switch.
 371
Electrical System
Auto-Return System

See above illustration, use the plastic or wooden 3. Disassemble the boom lift kickout switch
block layer to measure, its thickness is 4-6mm, from the fixing hood (use the spare magnet to
during test, this layer is not used, keep the test, note the process direction is opposite to
distance between the burst magnet and the the return direction), observe the red
induction surface for 4-6mm. indicator condition after put the bucket
The red indicator and green indicator lighten at positioner switch induction surface close to
the boom magnet according to the above
the same time when the switches are switched
illustration induction direction (the indicator
on, input +24V power to the pilot valve solenoid.
Hall switch exports signals to drive the inner wire as the reference)-first left induction point-then
right induction point. Observe the red
and cut off the switch output voltage when the
indicator lightens newly from goes out when
magnet is close to the right side induction point
of the approach switch from process direction→ the switch is close to the magnet according to
the above illustration induction direction-first
left side induction point, the red indicator goes
right induction point-then left induction point.
out at this time. The red indicator lightens newly
(The reference is switch, the motion object is
and starts next work circulation after remove
magnet, so the direction is opposite to the
away the magnet, see above illustration, closing
real operation process direction and return
up the left side induction point of the approach
direction). Repeat this step for 2-3 times, the
switch from return direction→right side induction
switch which can complete the test
point.
successfully is good.
The bucket positioner approach switch has
The above operation must be carried out under
restriction current protection function.
the safety condition.
NOTICE: During adjustment, when the boom
lift kickout switch is close to the boom Function Operation
magnet, must make the induction surface
distance is 4-6mm.
The system function has the boom float function,
During installation, when the boom lift the boom lift kickout return function, the bucket
kickout switch is close to the boom magnet, positioner return function.
must make the induction surface center
corresponding to the magnet center. 11-A Boom Float Function Operation

Bucket positioner switch fault test method Push the single handle control lever forward for
lowering the boom, keep pushing it to limit
The switch interior wires are separate, can't test position for floating the boom.
the resistance and voltage according to the Realize the boom float function during bucket
traditional method. Test them according to the loading, the bucket is generally used to scrap
following methods if doubt the switch has fault, operation and it will undulate along with the
need a second to help if use this method to test. ground condition; the boom will lower as quick as
1. Turn on the start switch, observe the red possible under deadweight if using the boom
indicator and green indicator, if there is one float function to lower the boom, but this
indicator doesn't lighten, the switch is operation must be carried out under the safety
damaged, and please replace it. Carry out condition.
the following steps if two indicators lighten. Keep the single handle control lever at float
2. Lower the boom slowly and level the bucket position when do floating operation, pull the lever
on the ground. to NEUTRAL position for stopping boom floating.
372
Electrical System
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The following electronic components are needed Illustration 11-9 Main components positions (the
for realizing this function: demonstration machine is CLG856III with full-
auto control)
1. Single handle control lever and pilot valve
2. 5A fuse
Main components positions (the demonstration
machine is CLG856III with full-auto control)

11-B Boom Lift Kickout Function

Operation

Push the single handle control lever backward

for boom lifting, push it to limit position, the
control lever can keep at the limit position (1) Boom magnet
(2) Switch (with fixing hood)
automatically, the signle handle control lever will (3) Indicator observe window
return to NEUTRAL position automatically when
lift the boom to the limit height. 11-C Bucket positioner function
The following components are needed for operation
realizing this function:
Push the single handle control lever left for
● Single handle control lever and pilot valve
realizing bucket tilting, push it to the limit
● 5A fuse position, the lever can keep at limit position
automatically; the lever will return to NEUTRAL
● Boom lift kickout switch
position automatically when the bucket tilts back
● Boom magnet to the leveling position, keep pushing the lever
left, the bucket will tilt back to the limit position.
The following components are needed for
realizing this function:
● Single handle control lever and pilot valve
● 5A fuse
● Bucket positioner switch
● Bucket magnet
 373
Electrical System
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Illustration 11-10 Main components positions (the

demonstration machine is CLG856III with full-
auto control)

(1) Boom magnet

(2) Switch (with fixing hood)
(3) Indicator observe window
374
Electrical System
Auto-Return System

Troubleshooting

Auto-reposition system schematic

System test and service When the start switch is ON, No.135 wire obtains
+24V voltage from 5A fuse, passing XA1→XK1
11-A Boom float function principle receptacle to the boom float solenoid then to the
description ground. The magnetic field is produced around
the solenoid when the solenoid electrifies. The
Lower the boom when push the single handle magnetic field produced by the solenoid
control lever forward, when push it to limit electrifying can't make the close magnetic circuit
position the lever will keep at limit position due to the pilot valve's special configuration
automatically, realize this function by the boom when the single handle control lever keeps at
float solenoid inside the pilot valve. NEUTRAL position. The close magnetic circuit is
produced around the pilot valve boom float
solenoid in order to decrease the magnetic circuit
spacing when the operator pushes the single
handle control lever forward to the limit position.
So the control lever can be kept at the limit
position
 375
Electrical System
Auto-Return System

Pull the single handle control lever to NEUTRAL Conclusion:

position manually to disconnect the close
magnetic circuit. If it can keep, please check as follows:
(1) Check No.209 wire grounding condition.
11-A-F Fault test when the control lever can't
be locked at boom float position (2) Check the connecting condition between
No.135 wire of XK1 and total No.135 wire.
Fault phenomenon definition:
If it can not keep, please check as follows:
The single handle control lever can't keep at float (1) Check 5A fuse for melting condition.
position automatically when push it forward to
(2) Check X1 receptacle connecting condition.
the limit position and do floating operation.
(3) Check No.135 wire connecting condition at
Fault test steps: No.32 fuse.

Step 1. Test whether there is +24V voltage Step 3. Test the resistance of the boom
between two cores of XK1 receptacle. floating solenoid

a.Adjust the digital multimeter to voltage function a.Adjust the digital multimeter to Ω function (200
(50V). Ω ).
b.Turn off the start switch, open the side cover of b.Use the digital multimeter probes to connect
fixing base of the pilot valve, find and unplug XK1 two pins of XK1 receptacle of the pilot valve
receptacle, measure XK1 receptacle terminal of solenoid terminal separately.
the cab wiring harness.
Test result:
c.Turn on the start switch, use red probe of the
digital multimeter to connect the corresponding
The digital multimeter reading is between 90Ω
core of No.135 wire, use black probe to connect and 100Ω.
the corresponding core of No.209 wire.
Conclusion:
Test result:
If the result does OK, the pilot valve has inner
The digital multimeter reading is between 24V
fault.
and 31V.
If the result doesn't OK, the boom float solenoid
Conclusion: is damaged.

If the result does OK, please turn to step 3

If the result doesn't OK, please turn to step 2

Step 2. Test whether the boom lift kickout

position and bucket leveling position can
keep automatically?

a.Push the single handle control lever to boom

lift position or bucket leveling position, observe
whether the lever can keep automatically.
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Electrical System
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The control lever can't be locked at boom floating

position fault test flow chart 11-A-F

11-B Boom lift function principle description

The boom will be lift when push the control lever

backward, the lever will be kept at this position
when push it to the limit position, realize this
function through the boom lift kickout solenoid
inside the pilot valve.
 377
Electrical System
Auto-Return System

When the start switch is ON, No.135 wire obtains Fault test steps:
+24V voltage from 5A fuse, passing
XA1→XQ8→XQ3 receptacle to the boom lift Step 1. Test the red indicator of the boom lift
kickout switch then to the ground. The switch kickout switch lightens or not when electrify?
exports +24V voltage to the boom lift kickout
solenoid then to the ground passing a.Turn on the start switch, observe the red
No.476→XQ3→XQ8→XK2 when the red indicator lightens or not from the observe window
indicator and green indicator lighten. The of the fixing hood on the boom kickout switch.
magnetic field is produced around the solenoid
b.Turn off the start switch if it doesn't lighten, pull
when the solenoid electrifies. The magnetic field
out and insert XQ8 and XQ3 receptacle newly,
produced by the solenoid electrifying can't make
pull No.135 wire and No.219 wire of XQ8
the close magnetic circuit due to the pilot valve's
receptacle and XQ3 receptacle two terminals
special configuration when the single handle
slightly by hand to check their connecting
control lever keeps at NEUTRAL position. The
condition.
close magnetic circuit is produced around the
pilot valve boom lift kickout solenoid in order to c.Turn on the start switch and observe the red
decrease the magnetic circuit spacing when the indicator condition if they don't loosen.
operator pushes the single handle control lever
backward to the limit position. So the control Conclusion:
lever can be kept at the limit position. The boom
magnet is close to the boom lift kickout switch If the result does OK, please turn to step 2.
slowly when the boom reaches to the limit If the result doesn't OK, please turn to step 5.
position, the lift kickout switch output is cut off,
No.476 wire doesn't have voltage output when Step 2. Test the green indicator of the boom
the the switch reaches the best position. The red lift kickout switch lightens or not when
indicator goes out. The single handle control electrify?
lever returns to NEUTRAL position automatically
when the pilot valve kickout solenoid stops a.Turn on the start switch, observe the green
working. indicator lightens or not from the observe window
Lower the boom by control lever reversely, of the fixing hood on the boom kickout switch.
separate the boom magnet and boom lift kickout This step should be carried out when the boom
switch, the switch exports +24V voltage to the kickout switch and the boom magnet are not at
boom kickout solenoid newly by No.476 wire the action position.
after the switch stops output for 2s, the winding b.Turn off the start switch if it doesn't lighten, pull
electrifies, the red indicator lightens newly, start out and insert XQ8 and XQ3 receptacle newly,
next circulation. pull No.135 wire, No.219 wire and No.476 wire of
XQ8 receptacle and XQ3 receptacle two
11-B-F1 Fault test when the control lever terminals slightly by hand to check their
can't be locked at boom lifting position connecting condition.

Fault phenomenon definition: c.Turn on the start switch and observe the green
indicator condition if they don't loosen.
The single handle control lever can't keep at
boom lifting position automatically when push the Conclustion:
lever backward to the limit position during boom
lifting. If the result does OK, please turn to step 3.
If the result doesn't OK, the boom kickout switch
is damaged.
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Electrical System
Auto-Return System

Step 3. Test whether there is +24V voltage Step 5. Test whether the boom float position
between two cores of XK2 receptacle wiring and bucket leveling position can keep
harness. automatically?

a.Adjust the digital multimeter to voltage function a.Push the single handle control lever to the
(50V). boom float position or bucket leveling position,
b.Remove XK2 receptacle, turn on the start observe whether the lever can keep
switch. automatically. Please to step 6 if it can keep
automatically.
c.Use red probe of the digital multimeter to
connect No.476 wire corresponding core of XK2 b.If it can't keep automatically, please turn off the
receptacle, use black probe to connect another start switch, open the electronic control box
copper piece of XK2 receptacle. inside the cab, and find 5A fuse then observe its
melting condition.
Test result:
Conclusion:
The digital multimeter reading is between 24V
and 31V. If it has melted, please replace 5A fuse. If the
new fuse melts again, please eliminate the short
Conclusion: circuit fault.
If it doesn't melt, please turn to step 6.
If the result does OK, please turn to step 4
If the result doesn't OK, please turn to step 7 Step 6. Test whether there is +24V voltage
between two cores of XQ3 receptacle wiring
Step 4. Test the resistance of the boom harness.
kickout solenoid
a.Adjust the digital multimeter to voltage function
(50V).
a.Adjust the digital multimeter to Ω function (200
Ω ). b.Remove XQ3 receptacle, turn on the start
b.Use the probe of multimeter to connect two switch.
pins of XK2 receptacle of the pilot valve solenoid c.Use red probe of the digital multimeter to
terminal. connect No.135 wire corresponding core of
XQ32 receptacle, use black probe to connect
Test result: another copper piece of XQ3 receptacle.

The digital multimeter reading is between 90Ω Test result:

and 100Ω.
The digital multimeter reading is between 24V
Conclusion: and 31V.

If the result does OK, the pilot valve has inner Conclusion:
fault.
If the result does OK, the boom kickout switch is
If the result doesn't OK, the boom kickout
damaged.
solenoid is damaged.
If the result doesn't OK, judge the grounding
condition of No.219 wire firstly, if the grounding
condition is good, please check the line fault
between 5A fuse and XQ3 receptacle.
 379
Electrical System
Auto-Return System

Step 7. Test whether there is open circuit in d.Use two probes of the multimeter to connect
the line between XK2 and XQ3 receptacles. separately with two copper receptacles of XK2
receptacle of the cab wiring harness.
a.Turn off the start switch, remove XQ3 and XQ2
receptacles. Test result:
b.Insert a 80mm long lead which shucks off two
The digital multimeter reading is about 0 Ω.
sides insulation layer each 10mm into No.2
(No.476 wire)and No.1 core (No.219 wire) of
Conclusion:
XQ3 receptacle connecting with front frame
wiring harness, please pay attention to contact
If the result does OK, the boom kickout switch is
the lead copper wire with the copper receptacle
damaged.
of XQ3 receptacle well.
If the result doesn't OK, please check the
c.Adjust the digital multimeter to Ω function (200
grounding condition of No.210 wire, and check
Ω ).
the open circuit phenomenon in the lines.
Fault test flow chart 11-B-F1 when the control lever can't be locked at boom lifting position

11-B-F2 Fault test when the boom reaches at The control lever keeps at boom lifting position
lifting limit position, the control lever can't when push the lever backward to the limit
return to NEUTRAL position position during boom lifting, the lever can't return
to NEUTRAL position when the boom reaches
Fault phenomenon definition: the limit position.
380
Electrical System
Auto-Return System

Fault test steps: Fault test flow chart 11-B-F2 when the boom lifts
to the limit position, it can't return to NEUTRAL
Step 1. Test the clearance between the boom position automatically
kickout switch and the boom magnet.

a.Turn off the start switch, disassemble the boom

kickout switch from switch receptacle. Or prepare
one spare magnet.
b.Turn on the start switch, push the single handle
control lever to the boom lifting position, the
control lever keeps at lifting position. Close up
the boom kickout switch to the boom magnet
manually or close up the spare magnet to the
switch manually. Observe the control lever
returns to NEUTRAL position or not.

Conclusion:

If it returns, please adjust the clearance between

boom kickout switch and boom magnet over
again, and reaches 4-6mm in order to make sure
the control lever can return successfully.
11-C Bucket positioner principle description
If it doesn't return, please turn to step 2.
Operate the bucket tilting when push the single
Step 2. Connect XK2 receptacle and boom handle control lever left, the control lever will
floating position solenoid, observe the boom keep at this position automatically when push at
floating position returns or not. desired position, realize this function by the
bucket positioner solenoid inside the pilot valve.
a.Turn off the start switch, and turn the pilot valve
switch to OFF position. Remove XK2 receptacle
and XK1 receptacle and connect them across.
b.Turn on the start switch, push the single handle
control lever forward to the limit position, the
lever will keep at boom floating position, close up
the boom kickout switch to the boom magnet
manually, and close up the spare magnet to the
switch manually. Observe the control lever
returns to NEUTRAL position automatically or
not.
c.Pull out XK2 and XK1 receptacles after
checking.

Conclusion:

If it returns, the pilot valve has inner fault.

If it doesn't return, the boom kickout switch is
damaged.
 381
Electrical System
Auto-Return System

Turn on the start switch, No.135 wire obtains Fault test steps:
+24V voltage from 5A fuse, passing
XA1→XQ8→XQ1 receptacle to the bucket Step 1. Test the red indicator of the bucket
leveling switch then to the ground. The switch positioner switch lightens or not when
exports +24V voltage to the bucket leveling electrify?
solenoid then to the ground passing No.477
wire→XQ4→XQ8→XK3 when the red indicator a.Turn on the start switch, observe the red
and green indicator lighten. The magnetic field is indicator lightens or not from the observe window
produced around the solenoid when the solenoid of the fixing hood on the bucket positioner
electrifies. The magnetic field produced by the switch.
solenoid electrifying can't make the close
b.Turn off the start switch if it doesn't lighten, pull
magnetic circuit due to the pilot valve's special
out and insert XQ8 and XQ4 receptacle newly,
configuration when the single handle control
pull No.135 wire and No.219 wire of XQ8
lever keeps at NEUTRAL position. The close
receptacle and XQ4 receptacle two terminals
magnetic circuit is produced around the pilot
slightly by hand to check their connecting
valve bucket leveling solenoid in order to
condition.
decrease the magnetic circuit spacing when the
operator pushes the single handle control lever c.Turn on the start switch and observe the
left to the limit position. So the control lever can condition of the red indicator if they don't loosen.
be kept at the limit position. The bucket magnet
is close to the bucket positioner switch slowly Conclusion:
when the bucket reaches to leveling position, the
positioner switch output is cut off, No.477 wire If the result does OK, please turn to step 2.
doesn't have voltage output when the the switch If the result doesn't OK, please turn to step 5.
reaches the best position. The red indicator goes
out. The single handle control lever returns to Step 2. Test the green indicator of the bucket
NEUTRAL position automatically when the pilot positioner switch lightens or not when
valve bucket positioner switch stops working. Tilt electrify?
the bucket left, the bucket magnet closes up the
bucket positioner switch. a.Observe the green indicator lightens or not
Operate the single handle control lever reversely from the observe window of the fixing hood on
for dumping, the bucket magnet contacts with the the bucket positioner switch when turn on the
bucket positioner switch newly, the positioner start switch. This step should be carried out
switch exports +24V voltage to the bucket when the bucket positioner switch and the bucket
leveling solenoid by No.477 wire, the winding magnet are not at positioner switch action
electrifies working, the red indicator lighten position.
newly. The next circulation starts. b.Turn off the start switch if it doesn't lighten, pull
out and insert XQ8 and XQ4 receptacle newly,
11-C-F1 Fault test when the control lever pull No.135 wire and No.219 wire of XQ8
can't be locked at HOLDING position. receptacle and XQ4 receptacle two terminals
slightly by hand to check their connecting
Fault phenomenon definition: condition.

Push the control lever to the desired position, the c.Turn on the start switch and observe the
lever can't hold at this position automatically condition of the green indicator if they don't
during leveling bucket. loosen.
382
Electrical System
Auto-Return System

Conclusion: If the result doesn't OK, the bucket leveling

solenoid is damaged.
If the result does OK, please turn to step 3
Step 5. Test whether the boom lifting position
If the result doesn't OK, the bucket positioner
or boom floating position can keep
switch is damaged.
automatically?
Step 3. Test whether there is +24V voltage
a.Observe the single handle control lever can
between two cores of XK3 receptacle wiring
harness terminal. keep automatically or not when push the control
lever to the floating position or bucket leveling
position. Please turn to step 6 if it can hold.
a.Adjust the digital multimeter to voltage function
(50V). b.Turn off the start switch, open the electronic
control box inside the cab, find 5A fuse and
b.Remove XK3 receptacle, turn on the start
observe the melting condition if it can't hold.
switch.
c.Use red probe of the digital multimeter to Conclusion:
connect No.477 wire corresponding core of XK3
receptacle, use black probe to connect another If it has melted, please replace 5A fuse, If the
copper piece of XK3 receptacle. new fuse melts again, please eliminate the short
circuit fault.
Test result:
If it doesn't melt, please turn to step 6.
The digital multimeter reading is between 24V
and 31V. Step 6. Test whether there is +24V voltage
between two cores of XQ4 receptacle wiring
Conclusion: harness terminal.

If the result does OK, please turn to step 4 a.Adjust the digital multimeter to voltage function
(50V).
If the result doesn't OK, please turn to step 7
b.Remove XQ4 receptacle, turn on the start
Step 4. Test the resistance of the bucket switch.
positioner solenoid c.Use the red probe of the digital multimeter to
connect No.135 wire of XQ4 receptacle
a.Adjust the digital multimeter to Ω function (200 corresponding copper piece, the black probe
Ω ). connects to another copper piece of XQ4
receptacle.
b.Use the probe of the digital multimeter to
connect two probes of XK3 receptacle of the pilot
Test result:
valve solenoid terminal separately.
The digital multimeter reading is between 24V
Test result:
and 31V.
The digital multimeter reading is between 90Ω
Conclusion:
and 100Ω.
If the result does OK, the bucket positioner
Conclusion:
switch is damaged.
If the result does OK, the pilot valve has inner
fault.
 383
Electrical System
Auto-Return System

If the result doesn't OK, judge the grounding c.Adjust the digital multimeter to Ω function (200
condition of No.219 wire firstly, and please check Ω ).
the line fault between 5A fuse and XQ4
d.Use the probe of the digital multimeter to
receptacle if the grounding condition is good.
connect two copper pieces of XK3 receptacle of
the cab harness separately.
Step 7. Test the wire connecting condition
between XK3 and XQ4. Test result:
a.Turn off the start switch, remove XQ4 and XK3 The digital multimeter reading is about 0 Ω.
receptacles.
b.Insert a 80mm long lead which shucks off two Conclusion:
sides insulation layer each 10mm into No.2
(No.476 wire)and No.1 core (No.219 wire) of If the result does OK, the bucket positioner
XQ3 receptacle connecting with the front frame switch is damaged.
harness, please pay attention to contact the lead
If the result doesn't OK, please check the
copper wire with the copper receptacle of XQ3
grounding condition of No.211 wire, and check
receptacle well. the open circuit among the lines.
Fault flow chart 11-C-F1 when the control lever can't be locked at bucket leveling position
384
Electrical System
Auto-Return System

11-C-F2 Fault test when the bucket reaches b.Turn on the start switch, push the single handle
leveling position, the control lever can't control lever forward to the limit position, the
return to NEUTRAL position control lever will keep at boom floating position,
close up the bucket positioner switch to bucket
Fault phenomenon definition: magnet manually. Or close up the magnet to the
switch manually. Observe the control lever
Push the control lever inside and hold it at this returns or not?
position when tilt the bucket back, the control
c.Pull out XK3 and XK1 receptacles after
lever can't return to NEUTRAL position when the
checking, and return to the condition before test.
bucket tilts back to leveling position.
Conclusion:
Fault test steps:
If it returns, the pilot valve has inner fault.
Step 1. Test the clearance between the
positioner switch and the bucket magnet If it doesn't return, the bucket positioner switch is
damaged.
a.Turn off the start switch, disassemble the Fault flow chart 11-C-F2 when the control lever
bucket positioner switch from the switch can't return to NEUTRAL position after the
receptacle. Or prepare one spare magnet. bucket tilting to leveling position
b.Turn on the start switch, push the single handle
control lever to the bucket tilting position, the
control lever will keep at tilting position
automatically. Close up the bucket positioner
switch to bucket magnet manually. Or prepare
one spare magnet, and close up the spare
magnet to the switch manually. Observe the
control lever returns or not?

Conclusion:

If it returns, adjust the clearance between the Bucket positioner

bucket positioner switch and the bucket magnet switch is damaged ?

over again, and reaches 4-6mm in order to make

sure the control lever can return successfully.
If it doesn't return, please turn to step 2.

Step 2. Connect XK3 receptacle and boom

floating position, observe the boom floating
position returns or not?

a.Turn off the start switch, and turn the pilot valve
switch to OFF position. Pull out XK3 receptacle
and XK1 receptacle, and connect the pilot valve
solenoid with the receptacles across.
 385
Electrical System
Lubrication system

Lubrication system This cycle will be stopped when turn off the start
switch in the stop machine time or lubrication
time cycle, but time will be stored. The operation
Introduction will proceed from the last stored stop time when
turn on the start switch.
This machine uses Germany VOGEL central This machine's set when leave the factory: the
lubrication device for automatic lubricating. The lubrication interval time: 1h, one lubrication
grease used in central lubrication device is 1# running time: 12min.
MOS2 or 2# grease or grease level≤NLG1
grade2, the oil tank capacity has 2L. The grease
Main Components
choice is relative to area environmental
temperature, eg, need 1# MOS2 at 0°C (32°F)
area. Piston pump
The lubrication cycle starts after turn on the start
switch firstly, the lubrication pump motor starts, 15C0018 (KFGS1-5+924) electromotion
the lubrication system works. The lubrication lubrication pump has 2L capacity tank, which has
pump motor turn off automatically after the inner-set controller, the pump element has
lubrication cycle time reaches the preestablished collocated as a unit with piston pump in the
time, stop machine time starts, the next manufactory. The controller inside the
lubrication cycle starts after stop time reaches electromotion lubrication piston pump controls
the preestablished time. All of lubrication work the electronic controlling of the lubrication
will proceed according to the preestablished time system.
program.
Controller inside the piston pump
386
Electrical System
Lubrication system

Inner set controller LED display instruction:

Time mode when the pump stops
The inner set controller is located inside the tPA
running, reading unit is hour
piston pump, which has collocated as a unit with
Pulse count mode when the pump
piston pump before leaving the manufactory. It cPA
stops running
has very important function as the control core of
Time mode under the pump running,
the whole auto-lubrication system, so introduce it tCO
reading unit is min
as a separate component from piston pump
Pluse count mode under the pump
section. cCO
running
Controller panel COP Pump running monitoring set mode
OFF No pump running monitoring
CS Cycle switch test mode
FLL Lowest oil level alert indication
FCS No pulse signal fault indication
Oh Work time calculagraph
Fh Fault time calculagraph
Show fault signal when the fault time
bLo
exceeds 3 pump running cycles

Panel symbol instruction:

PAUSE Pause time
CONTACT Pump running time
CS System test with cycle switch
System test with pressure switch
PS
(not available for advanced system)
FAULT Fault signal
open the display function
show function name and parameter

set function parameter

switch running mode and show

SET mode
parameter set
to the next lubrication cycle
straightly during short circuit
DK interval time
fault reset
 387
Electrical System
Lubrication system

Lubrication system adjustment and setting:

Step Button Display Remark

1 Press SET longer than 2s.

000 display is flashing(code 000 is the
setting by the factory)

2 Press SET shortly (confirm code).

Automatic display of the first parameter
”tPA” pause in timer operation. The
“pause” LED is flashing.
3 Press SET shortly.
Pause time 1h (setting by factory).

4 Set new value. Example:6.8h=6 h 48

min.

5 Press SET shortly, confirm new value.

Display of the next parameter “tCO”
pump operation time in timer operation.
The “contact” LED is flashing.
6 Press SET shortly.
Pump operation time 12 min.(setting by
factory)

7 Set new value. Example: 3min.

8 Press SET shortly, confirm new value.

9 Press SET longer than 2s.

Alterations will be written into the
memory and the display will go off.
388
Electrical System
Lubrication system

Pump unit 78A0034 Safety valve

KFGS1-5+924 piston pump device has 3

lubrication outlet, where can install 3 sets pump
units separately, connecting each pump unit and
the progressive feeder to form separately the
lubrication line.
This machine just needs to install 1 set pump unit
for the whole machine lubrication requirement.
15C0019 (KFG1.U1) pump unit lubrication
feeding quantity is 2.5ml//min.
Pump unit

Progressive feeder

The progressive feeder will divide the grease

from the pump device into several parts.
This machine has 3 sets progressive feeders, the
Safety valve tab in the system principle drawing is VPKM-8
VPKM-10,VPKM-3.
A pressure safety valve fitted to the pump
element is to safeguard the entire lubrication Central lubrication principle drawing (the sample
system against damages that caused by is CLG856III with 8-bar front frame)
excessive system pressure.
SEE THE DRAWING, i i=1,2,3
The preset opening pressure of this valve is IS A POSITIONS OF LUBRICATE POINTS

300bar±20bar.
When system pressure exceeds 300 bar due to
the progressive feeder or lubrication point
blockage, the valve opens and discharges
lubricant.

ELECTRIC PISTON SAFETY

PUMP PUMP PUMP
 389
Electrical System
Lubrication system

Each set progressive feeder consists of the first Oil drain sequence of the progressive feeder is:
section, the end section and the feeder section, the farthest outlet away from the inlet drains oil
the first section and the end section has one firstly, and the nearest outlet away form the inlet
each, the feeder section is not less than 3. This drains oil lastly. The second feeder section can't
machine will define the progressive feeder as drain oil if the first section blocks.
VPKM-8, 8 feeder sections; VPKM-10, 10 feeder
sections; VPKM-3, 3 feeder sections according
to the middle section's quantity of the
progressive feeder.
Progressive feeder with 3 feeder sections

Each feeder section has the different type for NOTICE: The different type feeder sections
distinguishing; the different type feeder section have the same figurations, keep the feeder
has the different parameter. section type consistency if replace the feed
section separately, otherwise the lubrication
These types are marked on the feeder sections
system can not work separately.
and the central lubrication principle drawing, eg:
"2S","2T","0.5S" etc. The first number shows oil
drain capacity of each outlet and each cycle in
type label. The second English letter shows each
section outlet quantity, "T" means 2 outlets,
"S"means 1 outlet.
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Electrical System
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Tube accessory and connector Manual lubrication switch and principle drawing
symbol
Straight male connector and elbow male
connector

One terminal of the straight male connector

00A0569 (or elbow male connector 01A0255) is
connected to the control valve outlet of the
progressive feeder, and one terminal is The manual lubrication switch is the special
connected to oil tube. pendant switch, which has 2 characteristics, one
Tube connection is it is an instanting switch, it can't be hold at ON
position, another is it has lock buckle and locked
at OFF position. The switch with lock buckle is
designed for preventing incorrect operation.

Manual lubrication switch fault test steps:

The manual lubrication switch is installed on 4-

(1) High-pressure hose 31A0124 joint switch group of the panel.
(2) Sleeve 00A0568 1. Disassemble the left panel from the
(3) Straight tube connector 00A0570
(4) Elboe tube connector 01A0256
instrument. Push the 4-joint pendant switch
from the switch groove, don't damage the
Manual lubrication switch fixing buckle of integration switch groove
when take out. Remove 8 white cores
The manual lubrication swich is the pendant receptacle from the rear of manual lubrication
switch with closedown device, the lock buckle is switch, and expose the copper on the back of
locked at OFF position, turn the lock buckle and the switch.
press the pendant switch to start a new 2. Adjust the digital multimeter to function (200
lubrication cycle when need manual lubrication. Ω ).
The manual lubrication switch can't hold
automatically, release the switch it will return the 3. Hold the manual lubrication switch at OFF
NEUTRAL position and lock at OFF position. position, use the digital multimeter probe
(See the operation & maintenance manual for either positive or negative to measure the
details) copper on the back of the pendant switch
[1,5], the digital multimeter reading is 1.
4. Unlock the manual lubrication switch and
hold at ON position (need another person),
use the digital multimeter probe either
positive or negative to measure the copper
on the back of the pendant switch [1,5], the
digital multimeter reading is 0.
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5. Release it after measuring, the switch resets. The auto-lubrication system which is chosen by
Liugong for users doesn't assemble with cycle
The pendant switch is normal if it can complete
switch or pressure switch, and the feeder section
above test, otherwise the pendant switch may be
configuration can't assemble with cycle switch or
damaged.
pressure switch, but the lubrication system fault
indicator runs through the cycle switch and
Lubrication system running indicator pressure switch. The instrument system of
Liugong machine has been designed with the
The lubrication system running indicator is lubrication system fault indicator as the machine
located on the instrument system, it is actually spare indicator or convenient for users' re-
the pump running indicator. The lubrication installation. The lubrication system fault indicator
system indicator lightens when the piston pump can not use in the machine when leaving the
runs. The lubrication system indicator goes out factory as special instruction.
when the piston pump stops running.
Lubrication system fault indicator
Lubrication system running indicator

Lubrication system fault indicator

VOGEL lubrication system fault indicator defines

as system jam alert indicator.
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Electrical System
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Function Operation

The auto-lubrication system has auto-lubrication

function of the whole lubrication points.
VOGEL centralized lubrication device configuration

1, Pump 2, High pressure hose 3, Main feeder 4, secondary feeder 5, Lubrication point
6, Pump unit 7, Wire package 8, Safety valve

12-A Auto-lubrication Function Operation The machine turns off the start switch or
lubrication pump motor is turned off during stop
The auto-lubrication function doesn't need the machine time or lubrication cycle, this cycle will
operator's special operation, the controller inside be terminated, time will be stored. Operation will
the piston pump controls the auto-lubrication proceed from the last stored time when turn on
function ON/OFF. It works once the machine the start switch again.
powers on.
The following components are needed for
The first lubrication cycle starts automatically realizing this function:
after turning on the start switch first time, the
● Fuse
lubrication pump motor starts, the lubrication
system works. The lubrication pump motor turns ● Instrument system (lubrication fault and work
off automatically after the lubrication cycle time indication)
reaches the preestablished value-12min, stop ● VOGEL centralized lubrication device (with
machine time starts, next lubrication cycle starts
controller inside the piston pump, pump unit,
after stop machine time reaches the
progressive feeder, lubricant, straight male
preestablished intervals time-1h. All subsequent
connector, elbow male connector etc).
lubrication operations will proceed according to
the preestablished time program.
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Electrical System
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Main components Main components (tfhe sample is CLG856III with

8-bar front frame manual shift control)

12-B Manual Lubrication System Operation (1) Manual lubrication switch

Use the manual lubrication button to start a 12-C Filling the Lubricant
lubrication cycle if consider that it's necessary to
carry out a manual lubrication or service Observe the lubricant quantity in the transparent
operation requirement during auto-lubrication set reservoir of piston pump. The system will work
ting stop cycle. abnormally if not filling the lubricant in time and
The work time of manual lubrication cycle is the thereby let air enter into the lubrication line when
same with auto-lubrication function setting cycle the lubricant level is less than "min" sign.
when start a manual lubrication. When the lubricant level is low, please fill the
The auto-lubrication setting stop cycle resets lubricant by the following methods.
automatically after start the manual lubrication
cycle, the auto-lubrication stop time starts timing Fill grease with common grease gun
newly after finished manual lubrication cycle.
Fill the lubricant with the common grease gun
The following components are needed for through the conical head nipple on the pump.
realizing this function:
Conical head grease nipple on the pump
● Fuse
● Manual lubrication switch
● Instrument system (lubrication fault and work
indication)
● VOGEL centralized lubrication device (with
controller inside the piston pump, pump unit,
progressive feeder, lubricant, straight male
connector, elbow male connector etc).
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Electrical System
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(1) Conical head grease nipple Fill grease with manual pump
(2) Closure plug

Fill grease with manual pump

Assemble the filler connector 995-000-705

(VOGEL goods number, need to order) instead
of the conical head grease nipple; install the
matching connector 995-001-500 (VOGEL
goods number, need to order) on the outlet of
filling pump. Fill grease with the manual pump.
The manual filling pump exhaust quantity is 12-D System Empty Operation
40ml/jounery, there are following types (VOGEL
goods number, need to order) for choice. The system needs empty operation after
replacing or service system parts in order to
Handcart type with 25Kg oil canister, 169-000- avoid that air exists in the system and influences
042 the normal running of the system.
Handcart type with 50Kg oil canister, 169-000-
054 System empty operation steps:
No handcart with 25Kg oil canister, 169-000-342
1. Disassemble the safety valve of connection
Fill grease with manual pump pump of piston pump, hold the line
connecting with safety, turn on the start
switch, press the manual lubrication button
once to start the piston pump. Observe the
grease until there isn't air bubble in the
grease discharged from the pump unit. Turn
off the start switch, the piston pump stops
working, connect the safety valve newly.
2. Disassemble the main line of main feeder
inlet, turn on the start switch, press the
manual lubrication button once to start the
Fill grease with small type manual pump piston pump (don't need to press the manual
lubrication button if the piston pump still runs
Disassemble M20X1.5 plug, screw the filler after turn on the start switch), observe the
connector 169-000-170 (VOGEL goods number, removed main line until there isn't air in the
need to order), remove the protective cap small grease, turn off the start switch, connect the
type manual filler pump 169-000-171 (VOGEL main line to main feeder newly.
goods number, need to order) when filling oil.
3. Remove the branch line of main feeder
Small type manual filler pump' capacity is outlet, turn on the start switch, press the
(450~550ml). manual lubrication button once to start the
piston pump (don't need to press the manual
lubrication button if the piston pump still runs
after turn on the start switch), observe the
removed branch line until there isn't air in the
grease, turn off the start switch, connect the
branch line newly.
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Electrical System
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4. Empty the oil intake of the secondary feeder, No.154 wire from 10A fuse passes XA2→XK7
oil outlet of the secondary feeder and every receptacle and provides +24V power to the
lubrication point according to above method. lubrication system, grounding after passes
No.221 wire behind XK7 receptacle. The
5. Assemble all lines after empty each
electrical controller inside the lubrication system
component and lines, starts the piston pump,
passing XK7→No.411 wire exports the running
observe each lubrication point by eye until
indication signal of lubrication system to
overflowing the grease which shows the
instrument system as indication, indicating the
system works normally.
instrument system by XK7→No. 305 wire output
The above steps are the empty operation of the the lubrication system fault indication signal.
whole system, it is not necessary to empty and
+24V voltage from 10A fuse reaches the manual
check each system node according to above
lubrication switch by No.154 wire, No.154 wire
operation if know clearly the position of
connects No.470 wire when press the manual
replacement components or service point or air
lubrication switch, +24V voltage exports the
bubble influence position, only empty the front/
manual lubrication indicating singal through
rear service nodes.
No.470 wire→XK7→the controller inside the
lubrication system.
Troubleshooting

System work principle general

The exterior lines of lubrication system shown as

below, the exterior lines are simple.
Lubrication system principle drawing
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Electrical System
Lubrication system

12-A-F1 Fault test when the piston pump Conclusion:

doesn't work
If it has melted, please replace 10A fuse, and
Fault phenomenon definition: turn to step 3.
If it doesn't melt, please check the lines between
The rotary cam mechanism of piston pump can't
10A fuse and round receptacle of piston pump in
run after the preestablished lubrication stop time
lubrication system, check XA2, XK7 receptacles
finished or the operator presses the manual
and grounding wire have fault or not.
lubrication button.
Step 3. The fuse melts or not after
Fault test steps:
replacement
Step 1. Test the round receptacle of the
a.Don't turn off the electronic control box, turn on
piston pump. (Doesn't draw in illustration 12-
the start switch newly, and hear the sound
18)
carefully in the 10A fuse of centralized lubrication
system. Turn off the start switch after turn on it
a.Adjust the digital multimeter to voltage function
for 5 mins, pull out 10A fuse of centralized
(50V).
lubrication system, observe it has melted or not
b.Pull out the round receptacle of piston pump. by eye.
Notice the draw and insert method, is there any
screw thread? Conclusion:
c.Turn on the sart switch, use the digital
multimeter red probe to contact No.2 core of If it keeps melting, there is short circuit fault in
receptacle according to the core sign of the the line or the piston pump, please eliminate the
round receptacle, the black probe contacts with short circuit falut.
No.1 core. If it doesn't keep melting, the fault has been
eliminated.
Test result:
Step 4. Press and hold the manual lubrication
The digital multimeter reading is between 24V button, check whether there is +24V voltage
and 31V. in pin1 and pin3 (doesn't draw in illustration
12-18) of round receptacle of piston pump or
Conclusion: not.

If the result does OK, please turn to step 4. a.Adjust the digital multimeter to voltage function
If the result doesn't OK, please turn to step 2. (50V)
b.Pull out the round receptacle of piston pump.
Step 2. Test 10A fuse of centralized Notice the draw and insert method, is there any
lubrication system has melted or not. screw thread?
c.Turn on the start switch, press the manual
a.Turn off the start switch, open the electronic
lubrication button and hold at ON position (need
controller, find the 10A fuse of centralized
another person).
lubrication system, pull it out, and observe its
melting condition by eye. d.Use the digital multimeter red probe to contact
No.3 core of receptacle according to the core
sign of the round receptacle, the black probe
contacts with No.1 core.
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Electrical System
Lubrication system

Test result: Conclusion:

The digital multimeter reading is between 24V If the result does OK, please check the line fault
and 31V. between the manual lubrication button and the
piston pump.
Conclusion:
If the result doesn't OK, please turn to step 7.
If the result does OK, please turn to step 5.
Step 7. Test whether there is +24V voltage in
If the result doesn't OK, please turn to step 6. No.154 wire and No.204 wire of manual
lubrication button.
Step 5. Plug the receptacle newly.
a.Adjust the digital multimeter to voltage function
a.Plug the round receptacle of piston pump (50V).
newly. b.Press the manual lubrication button and hold it
b.Draw and plug XK7 receptacle once. at ON position (need another person), use the
c.Turn on the start switch, press the manual digital multimeter red probe to contact No.154
lubrication button, and judge the piston pump wire, the black probe contacts with No.204 wire
running condition. (or metallic component in the cab).

Conclusion:

If the result does OK, the fault has been

eliminated.
If the result doesn't OK, please relpace the piston
pump.

Step 6. Test whether there is +24V voltage in

No.407 wire and No.204 wire of manual
lubrication button.

a.Adjust the digital multimeter to voltage function

(50V).
b.Disassemble the left panel of the instrument,
and take out the 4-joint switch from the switch
groove.
c.Press the manual lubrication button and hold it
at ON position (need another person), use the
digital multimeter red probe to contact No.407
wire, the black probe contacts with No.204 wire
(or metallic component in the cab).

Test result:

The digital multimeter reading is between 24V

and 31V.
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Electrical System
Lubrication system

Test result:

The digital multimeter reading is between 24V

and 31V.

Conclusion:

If the result does OK, please replace the manual

lubrication switch.
If the result doesn't OK, please check the line
fault of No.154 wire from 10A fuse of central
lubrication system to manual lubrication switch.
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Electrical System
Lubrication system

12-A-F1 Fault flow chart when the piston pump can't work
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Electrical System
Lubrication system

12-A-F2 Safety valve oil drain fault test

(available for CLG856III with 6-bar front
frame)

Fault phenomenon definition:

Drain grease from the safety valve after starting

the piston pump, which shows the lubrication
system has fault resulting in system
pressure≥300 bar, the safety valve opens and
drains oil automatically.

Fault test steps:

Check the grease qualiity firstly, most of non-

lubrication point block faults are caused by oil
quality. The grease dirty, rigid, cold weather or
parking machine for a long time will change the
grease quality, and lead to extortionate system
pressure. The piston pump will idle and can't
drain oil if the grease quality is too rigid.
Analyze the safety valve fault of draining oil
according to occurrence probability after
eliminating the grease quality question. Firstly,
check the lubrication point block condition;
secondly, check progressive feeder block
condition; finally, check the line block condition.
Illustration 12-20 Lubrication system principle
drawing (available for CLG856III with 6-bar front
frame)
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Electrical System
Lubrication system

Lubricaiton point position 1 (available for CLG856III with 6-bar front frame)
402
Electrical System
Lubrication system

Lubrication point postion 2 (available for CLG856III with 6-bar front frame)

The whole lubrication system can not lubricate Disassemble the line connecting this lubrication
once one lubrication point or fault point is point which doubt blocking, clean the oil outlet of
blocked, but piston pump still runs, the safty the safety valve, start the piston pump (by
valve drains oil. pressing the manual lubrication button), observe
the safety valve condition, the removed oil lines
One lubrication point blocks resulting in the
for grease overflow or not. The oil lines have no
safety valve oil drain fault, sometimes, some
problem, this lubrication point has been blocked
lubrication points block also resulting in the fault,
if the safety valve doesn't drain oil and the
so just need your patience when eliminate fault.
grease overflows in the removed oil lines.
Observe the overflow grease from bearing of
It has to spend some time to judge and settle the
lubrication point or mobile parts if the machine is
problem if doesn't know what causes the system
new, which shows the lubrication point is fluent; it
jam, and waster some greases and use
is difficult to judge the lubrication point fluence by
eliminating method to analyse the system fault
aspect if the machine is old or the lubrication
step by step.
point is not easy to observe. The lubrication point
will be blocked due to the mobile parts over-worn
or dirty entering. The worn will be appeared and
give off the sound if the lubricant can't enter in
some lubrication point.
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Electrical System
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Step 1. Test whether there is grease (2) The line connected to the main feeder intake
overflows from the outlet of the main feeder has grease overflow when the safety valve
or not? doesn't drain oil.

a.Turn off the start switch, and disassemble the Conclusion:

two outlet lines of the main feeder.
The previous line or part of the main feeder block
b.Wipe up the outlet of the safety valve, turn on
if the observing result is the same to the first
the start switch.
condition. Please turn to step 3.
c.Press the manual lubrication button, start the
piston pump (this step can be omitted if the The main feeder blocks if the observing result is
piston pump is running after starting the start the same to the second condition. Disassemble
switch). the main feeder to clean, check or replace,
assemble it after eliminating the fault, empty the
Test result: main feeder firstly after assemble it, then install
the intake and outlet of the main feeder valve
(1) Two outlets of main feeder overflow grease if after empty.
the safety valve doesn't drain oil.
Step 3. Judge the safety valve blocks or not.
(2) Two outlets of main feeder don't overflow
grease if the safety valve drains oil. a.Turn off the start switch, and disassemble the
outlet oil line of the safety valve.
Conclusion:
b.Wipe up the outlet of the safety valve, turn on
The line is fluent from the safety valve to main the start switch.
feeder if the observing result is the same to the c.Press the manual lubrication button, start the
first condition. Please turn to step 4. piston pump (this step can be omitted if the
piston pump is running after starting the start
The system blocks if the observing result is the
same to the second condition. Please turn to switch).
step 2.
Test result:
Step 2. Test whether there is grease
Observe the safety valve drains oil or not.
overflows from the intake of the main feeder
or not?
Conclusion:
a.Turn off the start switch, and disassemble the
If it drains oil, please clean, check or replace the
intake of the main feeder.
safety valve, install it after eliminating the fault.
b.Wipe up the outlet of the safety valve, turn on Empty the safety valve firstly after assemble it,
the start switch. and then install the removed line after emptying.
c.Press the manual lubrication button, start the If it doesn't drain oil, please clean the lines when
piston pump (this step can be omitted if the the lines between the safety valve and the main
piston pump is running after starting the start feeder are blocked, empty the lines firstly after
switch). assemble it, and then install the removed lines
after emptying.
Test result:

(1) The line connected to the main feeder intake

doesn't have grease overflow when the
safety valve drains oil.
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Electrical System
Lubrication system

Step 4. Judge VPKM-8 II level feeder line or Step 6. Use elimination method to inspect
the lubrication point blocks or not. block point on VPKM-8 II level feeder line or
the lubrication point.
a.Turn off the start switch, connect one of
disassembled two lines in step1 to main feeder. a.Turn off the start switch, Mark number on
b.Clean the safety valve outlet, turn on the start VPKM-8 II level feeder oil outlet line according to
switch. lubrication system principle drawing. Then
remove all connecting lines of oil outlet.
c.Press the manual lubrication button, start the
piston pump (this step can be omitted if the b.Clean the safety valve oil outlet, turn on the
piston pump is running after starting the start start switch. Press the manual lubrication button,
switch) . start the piston pump (not need to press the
manual lubrication button if the piston pump is
Test result: running after starting the start switch). Observe
the safety valve drains oil or not, grease
Observe the safety valve drains oil or not. overflows from VPKM-8 feeder outlet if the safety
valve doesn't drain oil, please turn to step d.
Conclusion: c.Turn off the start switch if the safety valve
drains oil. Disassemble the oil intake of VPKM-8
If it drains oil, VPKM-8 II level feeder line or the II feeder, clean the safety valve oil drain outlet,
lubrication point blocks, please turn to step 6. turn on the start switch and start the piston
pump, observe oil intake overflows grease or not,
If it doesn't drain oil, please turn to step 5.
the safety valve drain oil. The VPKM-8 has inner
block and clean or replace if the safety valve
Step 5. Judge VPKM-5 II level feeder line or
doesn't drain oil and the oil intake overflows
the lubrication point blocks or not.
grease. The block doesn't appear frequently due
to inner diameter of line is usuall bigger than the
a.Turn off the start switch, connect the other one
safety valve or grease line inside feeder.
of disassembled two lines in step1 to main
feeder. d.Turn off the start switch, connect lines of 22, 23
lubrication points to oil outlet of VPKM-8 II level
b.Clean the safety valve outlet, turn on the start
feeder. Clean the safety valve oil outlet, turn on
switch.
the start switch and start piston pump, observe
c.Press the manual lubrication button, start the the safety valve drains oil or not. Please turn to
piston pump (this step can be omitted if the step e if the safety valve drains oil. If the safety
piston pump is running after starting the start valve doesn't drain oil, please turn to step f.
switch) .

Test result:

Observe the safety valve drains oil or not.

Conclusion:

If it drains oil, VPKM-5 II level feeder line or the

lubrication point blocks, please turn to step 7.
If it doesn't drain oil, the system is good, no
block, and can work normally.
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Electrical System
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e.If the safety valve drains oil, the block may be Test result:
on 22, 23 lubrication points or lines, perhaps one
point block or two points all block, confirm it in The blocked lubrication point or line can be found
this step. The detais as follows: turn off the start after inspecting all lubrication points.
switch, remove the line connecting 22 lubrication
point, clean the oil outlet, then turn on the start Conclusion:
switch, start the piston pump and observe the
safety valve drains oil or not; if the safety valve Clean and service the blocked lubrication point
drains oil, the block point is on 23 lubrication or line, replace it if necessary.
point or connection line. If the safety valve
doesn't drain oil, the block point is on 22 Step 7. Use the elimination method to inspect
lubrication point or the connection line, not on 23 block point of VPKM-5 II level feeder line or
lubrication point. If the block is on 23 lubrication the lubrication point
point, also need to confirm 22 lubrication point
for block. Turn off the start switch, remove line of a.Turn off the start switch, Mark number on
23 lubrication point and assemble 22 lubrication VPKM-5 II level feeder oil outlet line according to
point, clean the safety valve oil outlet, turn on the lubrication system principle drawing. Then
start switch, start the piston pump, observe the remove all connecting lines of oil outlet.
safety valve drains oil or not, if the safety valve b.Clean the safety valve oil outlet, turn on the
doesn't drain oil, 22 lubrication point doesn't start switch. Press the manual lubrication button,
block, vice visa. start the piston pump (not need to press the
f.Repeat step d, and step e, connect lines of 20 manual lubrication button if the piston pump is
lubrication point, 14 lubrication point and 21 running after starting the start switch). Observe
lubrication point, 17 lubrication point and 18 the safety valve drains oil or not, grease
lubrication point, 15 and 16 lubrication points, 13 overflows from VPKM-5 feeder outlet if doesn't
lubrication point, 11 and 12 lubrication point, 9 drain, please turn to step d.
and 10 lubrication point step by step, connect oil c.Turn off the start switch if the safety valve
outlet line of one distributary piece per time, for drains oil. Disassemble the oil intake of VPKM-5
example, 05S just connects 20 lubrication point, II feeder, clean the safety valve oil outlet, turn on
this step is just as one point, 1T distributary piece the start switch and start the piston pump,
connects 14 and 20 lubrication points, ,this step observe oil intake overflows grease or not, the
has two lubrication points. safety valve oil drain. The VPKM-5 has inner
g.Judge the line or lubrication pont for block after block and clean or replace if the safety valve
finding the block lubrication point line. For doesn't drain oil and the oil intake overflows
example, find 23 lubrication point block after grease. The block doesn't appear frequently due
passing through above checks, turn off the start to inner diameter of line is usuall bigger than the
switch, disassemble the rear swing lubrication safety valve or grease line inside feeder.
point line where 23 lubrication point has reached, d.Turn off the start switch, connect lines of 7, 8
clean the safety valve oil outlet, turn on the start lubrication points to oil outlet of VPKM-5 II level
switch, start the piston pump, observe overflow feeder. Clean the safety valve oil outlet, turn on
grease of disassemble line of 23 lubrication the start switch and start piston pump, observe
point, the safety valve drains oil, the block point the safety valve drains oil or not. Please turn to
is inside 23 lubrication point if the line overflows step e if the safety valve drains oil. If the safety
grease and the safety valve doesn't drain,. 23 valve doesn't drain oil, please turn to step f.
lubrication point blocks if the safety valve drains
and line doesn't overflow grease.
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Electrical System
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e.If the safety valve drains oil, the block may be Conclusion:
on 7, 8 lubrication points or lines, perhaps one
point block or two points all block, confirm it in Clean and service the blocked lubrication point
this step. The detais as follows: turn off the start or line, replace it if necessary.
switch, remove the line connecting 7 lubrication
point, clean the oil outlet, then turn on the start
switch, start the piston pump and observe the
safety valve drains oil or not; if the safety valve
drains oil, the block point is on 8 lubrication point
or connection line. If the safety valve doesn't
drain oil, the block point is on 7 lubrication point
or the connection line, not on 8 lubrication point.
If the block is on 8 lubrication point, also need to
confirm 7 lubrication point for block. Turn off the
start switch, remove line of 8 lubrication point
and assemble 7 lubrication point, clean the
safety valve oil outlet, turn on the start switch,
start the piston pump, observe the safety valve
drains oil or not, if the safety valve doesn't drain,
7 lubrication point doesn't block, vice visa.
f.Repeat step d, step e, connect lines of 4 and 6
lubrication points, 3 and 5 lubrication points, 2
lubrication point, 1 lubrication point step by step,
connect oil outlet line of one distributary piece
per time, for example, 3S just connects one
lubrication point, this step is just as one point, 1T
distributary piece connects two lubrication points,
this step has two lubrication points.
g.Judge the line or lubrication pont for block after
finding the block lubrication point line. For
example, find 8 lubrication point block after
passing through above checks, turn off the start
switch, disassemble the rear swing lubrication
point line where 8 lubrication point has reached,
clean the safety valve oil outlet, turn on the start
switch, start the piston pump, observe overflow
grease of disassemble line of 8 lubrication point,
the safety valve drain, the block point is inside 8
lubrication point if the line overflows grease and
the safety valve doesn't drain,. 8 lubrication point
blocks if the safety valve drains and line doesn't
overflow grease.

Test result:

The blocked lubrication point or line can be found

after inspecting all lubrication points.
 407
Electrical System
Lubrication system

12-A-F3 Safety valve oil drain fault test flow chart (suitable for CLG856III with 6-bar front frame)

12-A-F3 Safety valve oil drain fault test starting the piston pump which shows the
(suitable for CLG856III with 8-bar front frame) lubrication system has block and makes the
system pressure higher than 300 bar, the safety
Fault phenomenon definition: valve drains oil automatically.

The lubricant drains from the safety valve after

408
Electrical System
Lubrication system

Fault test steps: Analyze the safety valve fault of draining oil
according to occurrence probability after
Check the grease qualiity firstly, most of non- eliminating the grease quality question. Firstly,
lubrication point block faults are caused by oil check the lubrication point block condition;
quality. The grease dirty, rigid, cold weather or secondly, check progressive feeder block
parking machine for a long time will change the condition; finally, check the line block condition.
grease quality, and lead to extortionate system
pressure. The piston pump will idle and can't
drain oil if the grease quality is too rigid.
Lubrication system assembly principle drawing (suitable for CLG856III with 8-bar front frame)
 409
Electrical System
Lubrication system

Lubrication point position 1 (suitable for CLG856III with 8-bar front frame)
410
Electrical System
Lubrication system

Lubrication point position 2 (suitable for CLG856III with 8-bar front frame)
 411
Electrical System
Lubrication system

The whole lubrication system can not lubricate Test result:

once one lubrication point or fault point is
blocked, the piston pump still runs, the safety (1) Two oil outlets of main feeder overflow oil if
valve drains oil the safety valve doesn't drain oil.
One lubrication point blocks resulting in the (2) Two oil outlets of main feeder don't overflow
safety valve oil drain fault, sometimes, some grease if the main safety valve drains oil.
lubrication points block also resulting in the fault,
so just need your patience when eliminate fault. Conclusion:
Sometimes, you can see grease overflow from
The line is fluent from the safety valve to main
bearing of lubrication point or the active parts if
feeder if the result is the same to the first
the machine is new, which shows this lubrication
condition. Please turn to step 4.
point is not block, it is difficult to judge whether it
is block or not from exterior if the machine is old The system blocks, check the blocked point if the
or the lubrication point is difficult to observe. The result is the same to the second condition.
lubrication point will be blocked if the active parts Please turn to step 2.
worn out or dirty in. Some lubrication points will
sound if the lubricant can't enter in some Step 2. Test whether there is grease
lubrication point. overflows from the intake of the main feeder
or not.
Disassemble the lines, clean the safety valve oil
outlet and start the piston pump (realize for
a.Turn off the start switch, and disassemble the
pressing the manual lubrication button) if doubt
oil inlet of the main feeder.
somewhere lubrication point blocks, observe the
safety valve for drain, disassemble line for b.Clean the safety valve oil outlet, turn on the
overflow grease. The line has no problem if the start switch.
safety valve doesn't drain oil and the c.Press the manual lubrication button , start the
disassemble line overflows grease, this piston (this step can be omitted if the piston
lubrication point blocks. pump is still running after turning on the start
It has to spend some time in judging and settling switch)
the problem and wasting some grease if doesn't
know what causes the system jam, use the Test result:
eliminating method to analyze the system fault
step by step. (1) The line connected to the oil inlet of main
feeder doesn't overflow grease when the
Step 1. Test whether there is grease safety valve drains oil.
overflows from the oil outlet of the main (2) The line connected to the oil inlet of main
feeder or not. feeder overflows grease when the safety
valve doesn't drain oil.
a.Turn off the start switch, and disassemble the
two outlet lines of the main feeder. Conclusion:
b.Clean the safety valve oil outlet, turn on the
start switch. The previous line or part of the main feeder block
if the observing result is the same to the first
c.Press the manual lubrication button, start the
condition. Please turn to step 3.
piston pump (this step can be omitted if the
piston pump is still running after turning on the
start switch)
412
Electrical System
Lubrication system

The main feeder blocks if the result is the same Test result:
to the second condition.-Disassemble the main
feeder to clean or replace, assemble it again Observe the safety valve drains oil or not.
after eliminating fault. Drain out the main feeder
firstly after assemble it, and then assemble the Conclusion:
oil outlet and intake of the main feeder after drain
out. If it drains oil, VPKM-8 II level feeder line or the
lubrication point blocks, please turn to step 6.
Step 3. Judge the safety valve blocks or not.
If it doesn't drain oil, please turn to step 5.
a.Turn off the start switch, and disassemble the
Step 5. Judge VPKM-10 II level feeder line or
outlet oil line of the safety valve. the lubrication point blocks or not.
b.Clean the oil outlet of the safety valve, turn on
the start switch. a.Turn off the start switch, connect the other one
c.Press the manual lubrication button, start the of disassembled two lines in step1 to main
piston pump (this step can be omitted if the feeder.
piston pump is still running after turning on the b.Clean the safety valve outlet, turn on the start
start switch) switch.
c.Press the manual lubrication button, start the
Test result:
piston pump (this step can be omitted if the
piston pump is running after starting the start
Observe the safety valve drains oil or not.
switch) .
Conclusion:
Test result:
If it drains oil, please clean or replace the safety
Observe the safety valve drains oil or not.
valve, assemble it after eliminating fault. Drain
out the safety valve firstly after assemble it, fixing
Conclusion:
the line after draining out the safety valve.
If it doesn't drain oil, please clean the line when If it drains oil, VPKM-10 II level feeder line or the
there is block in line from the safety valve to the lubrication point blocks, please turn to step 7.
main feeder, drain out the line firstly after
If it doesn't drain oil, the system is good, no
assembly, fixing the line again after draining out
block, and can work normally.
the safety valve.
Step 6. Use elimination method to inspect
Step 4. Judge VPKM-8 II level feeder line or
block point on VPKM-8 II level feeder line or
the lubrication point blocks or not.
the lubrication point.
a.Turn off the start switch, connect one of
a.Turn off the start switch, Mark number on
disassembled two lines in step1 to main feeder.
VPKM-8 II level feeder oil outlet line according to
b.Clean the safety valve outlet, turn on the start lubrication system principle drawing. Then
switch. remove all connecting lines of oil outlet.
c.Press the manual lubrication button, start the
piston pump (this step can be omitted if the
piston pump is running after starting the start
switch) .
 413
Electrical System
Lubrication system

b.Clean the safety valve oil outlet, turn on the f.Repeat step d, step e, connect lines of 30 and
start switch. Press the manual lubrication button, 31 lubrication points, 29 lubrication point, 27 and
start the piston pump (not need to press the 28 lubrication points, 25 and 26 lubrication
manual lubrication button if the piston pump is points, 23 and 24 lubrication points, 21 and 22
running after starting the start switch). Observe lubrication points, 19 and 20 lubrication points
the safety valve drains or not, grease overflows step by step, connect oil outlet line of one
from VPKM-8 feeder outlet if the safety valve distributary piece per time, for example, 05S just
doesn't drain oil, please turn to step d. connects 29 lubrication point, this step is just as
c.Turn off the start switch if the safety valve one point, 2T distributary piece connects two
drains oil. Disassemble the oil intake of VPKM-8 lubrication points, this step has two lubrication
II feeder, clean the safety valve oil outlet, turn on points.
the start switch and start the piston pump, g.Judge the line or lubrication pont for block after
observe oil intake overflows grease or not, the finding the block lubrication point line. For
safety valve drain oil. The VPKM-8 has inner example, find 33 lubrication point block after
block and clean or replace if the safety valve passing through above checks, turn off the start
doesn't drain oil and the oil intake overflows switch, disassemble the rear swing lubrication
grease. The block doesn't appear frequently due point line where 33 lubrication point has reached,
to inner diameter of line is usuall bigger than the clean the safety valve oil outlet, turn on the start
safety valve or grease line inside feeder. switch, start the piston pump, observe overflow
d.Turn off the start switch, connect lines of 22, 23 grease of disassemble line of 33 lubrication
lubrication points to oil outlet of VPKM-8 II level point, the safety valve drain, the block point is
feeder. Clean the safety valve oil outlet, turn on inside 33 lubrication point if the line overflows
the start switch and start piston pump, observe grease and the safety valve doesn't drain,. 33
the safety valve drains oil or not. Please turn to lubrication point blocks if the safety valve drains
step e if the safety valve drains oil. If the safety and line doesn't overflow grease.
valve doesn't drain oil, please turn to step f.
Test result:
e.If the safety valve drains oil, the block may be
on 32, 33 lubrication points or lines, perhaps one The block lubrication point or line can be found
point block or two points all block, confirm it in after inspecting all lubrication points.
this step. The detais as follows: turn off the start
switch, remove the line connecting 32 lubrication Conclusion:
point, clean the oil outlet, then turn on the start
switch, start the piston pump and observe the Clean and service the blocked lubrication point
safety valve drains oil or not; if the safety valve or line, replace it if necessary.
drains oil, the block point is on 33 lubrication
point or connection line. If the safety valve Step 7. Use the elimination method to check
doesn't drain oil, the block point is on 32 the block point of VPKM-10 II level feeder line
lubrication point or the connection line, not on 33 or the lubrication point.
lubrication point. If the block is on 33 lubrication
point, also need to confirm 32 lubrication point a.Turn off the start switch, Mark number on
for block. Turn off the start switch, remove line of VPKM-10 II level feeder oil outlet line according
33 lubrication point and assemble 32 lubrication to lubrication system principle drawing. Then
point, clean the safety valve oil outlet, turn on the remove all connecting lines of oil outlet.
start switch, start the piston pump, observe the
safety valve drains oil or not, if the safety valve
doesn't drain, 32 lubrication point doesn't block,
vice visa.
414
Electrical System
Lubrication system

b.Clean the safety valve oil outlet, turn on the f.Repeat step d, step e, connect lines of 15 and
start switch. Press the manual lubrication button, 16 lubrication points, 13 and 14 lubrication
start the piston pump (not need to press the points, 11 and 12 lubrication points, 9 and 10
manual lubrication button if the piston pump is lubrication points, 7 and 8 lubrication points, 5
running after starting the start switch). Observe and 6 lubrication points, 3 and 4 lubrication
the safety valve drains oil or not, grease points, 2 lubrication point, 1 lubrication point step
overflows from VPKM-10 feeder outlet if the by step, connect oil outlet line of one distributary
safety valve doesn't drain oil, please turn to step piece per time, for example, 2S just connects
d. one lubrication point, this step is just as one
c.Turn off the start switch if the safety valve point, 1T distributary piece connects two
drains oil. Disassemble the oil intake of VPKM- lubrication points, this step has two lubrication
10 II feeder, clean the safety valve oil outlet, turn points.
on the start switch and start the piston pump, g.Judge the line or lubrication pont for block after
observe oil intake overflows grease or not, the finding the block lubrication point line. For
safety valve drain oil. The VPKM-10 has inner example, find 18 lubrication point block after
block and clean or replace if the safety valve passing through above checks, turn off the start
doesn't drain oil and the oil intake overflows switch, disassemble the rear swing lubrication
grease. The block doesn't appear frequently due point line where 18 lubrication point has reached,
to inner diameter of line is usuall bigger than the clean the safety valve oil outlet, turn on the start
safety valve or grease line inside feeder. switch, start the piston pump, observe overflow
d.Turn off the start switch, connect lines of 17, 18 grease of disassemble line of 18 lubrication
lubrication points to oil outlet of VPKM-10 II level point, the safety valve drain, the block point is
feeder. Clean the safety valve oil outlet, turn on inside 18 lubrication point if the line overflows
the start switch and start piston pump, observe grease and the safety valve doesn't drain,. 18
the safety valve drains oil or not. Please turn to lubrication point blocks if the safety valve drains
step e if the safety valve drains oil. If the safety and line doesn't overflow grease.
valve doesn't drain oil, please turn to step f.
Test result:
e.If the safety valve drains oil, the block may be
on 17, 18 lubrication points or lines, perhaps one The blocked lubrication point or line can be found
point block or two points all block, confirm it in after inspecting all lubrication points.
this step. The detais as follows: turn off the start
switch, remove the line connecting 17 lubrication Conclusion:
point, clean the oil outlet, then turn on the start
switch, start the piston pump and observe the Clean and service the blocked lubrication point
safety valve drains oil or not; if the safety valve or line, replace it if necessary.
drains oil, the block point is on 18 lubrication
point or connection line. If the safety valve
doesn't drain oil, the block point is on 17
lubrication point or the connection line, not on 18
lubrication point. If the block is on 18 lubrication
point, also need to confirm 17 lubrication point
for block. Turn off the start switch, remove line of
18 lubrication point and assemble 17 lubrication
point, clean the safety valve oil outlet, turn on the
start switch, start the piston pump, observe the
safety valve drains oil or not, if the safety valve
doesn't drain, 17 lubrication point doesn't block,
vice visa.
 415
Electrical System
Lubrication system

12-A-F3 Safety valve oil drain test flow chart (suitable for CLG856III with 8-bar front frame)

12-A-F4 Other faults test The faults of lubrication point or lubrication line
can be checked out by eye. So please foster the
The most faults of the lubrication system are due habit to observe the lubrication point or line by
to lubrication line damages except for above eye after driving or operating the machine, in
faults. The lubricant will overflow from damaged order to find the faults as soon as possible.
point, can't reach the lubrication point, some may
block after the lubrication point or line damage.
416
Electrical System
Lubrication system

12-B-F Fault test when the manual lubrication Step 2. Test whether there is +24V voltage in
function can't start the piston pump. No.470 wire of the manual lubrication switch.

Fault phenomenon definition: a.Insert red probe of the digital multimeter to the
corresponding copper piece of No.470 wire of
There is no problem of the lubrication system No.8 core on the back of the manual lubrication
normal lubrication periodic running, but the switch, black probe contacts with the machine
piston pump can't be started even if pressing the metal housing.
manual lubrication button.
b.Press the manual lubrication switch and hold it.
The manual lubrication switch is installed on 4- c.Release the manual lubrication switch after
joint switch combination of the panel. Turn on the measurement.
start switch, observe the piston pump of the
lubrication system for running, if running, wait for Test result:
finishing one lubrication period, the stop running
period is coming, inspect according to the The digital multimeter reading is between 24V
following steps. and 31V.
Step 1. Test whether there is +24V grounding Conclusion:
voltage in No.154 wire of the manual
lubrication switch. If the result does OK, please turn to step 3.

a.Turn off the start switch, and disassemble the If the result doesn't OK, the manual lubrication
left panel from the instrument. Push 4-joint switch is damaged, please replace it.
pendant switch out from the socket groove, don't
damage the buckle of the integration switch Step 3. Test whether there is +24V voltage in
when take it out. No.470 wire and No.211 wire of XK7
receptacle (need another person).
b.Adjust the digital multimeter to 50V range of
voltage function. a.Turn off the start switch, pull out XK7
c.Turn on the start switch, insert red probe of the receptacle under the steering column of the cab,
digital multimeter into the corresponding copper measuring direction is from the cab harness
piece of No.154 wire of No.8 core receptacle on connecting XK7 receptacle.
the back of the manual lubrication switch, black b.Use red probe of the digital multimeter to
probe contacts with the machine metal housing. connect the corresponding No.2 core of No.470
line, and use black probe to connect the
Test result:
corresponding No.5 core of No.221 line.
The digital multimeter reading is between 24V Test result:
and 31V.
The digital multimeter reading is between 24V
Conclusion: and 31V.
If the result does OK, please turn to step 2.
If the result doesn't OK, the line from 10A fuse to
No.154 wire of the manual lubrication switch has
fault. Pull & insert XJ1 receptacle newly, pull
No.154 wire of XJ1 receptacle two terminals by
hand, judge the connecting condition between
the inner piece and lead.
 417
Electrical System
Lubrication system

Conclusion:

If the result does OK, pull No.470 wire of XK7

receptacle connecting with main controller of
lubrication system slightly, judge the connecting
condition between the inner piece and lead. The
lines from XK7 receptacle to main controller has
fault or the main controller has fault.
If the result doesn't OK, check the line from the
manual lubrication switch to XK7 receptacle
carefully, eliminate the fault.
12-B-F Fault test flow chart when the manual
lubrication function can't start the piston pump
418
Electrical System
Horn and lighter

Horn and lighter Horn relay

Introduction

Turn on the start switch, and press the horn

button can make the horn work.
Turn on the start switch, press the button in the
middle of the lighter, the lighter resistance wire is
heated enough, the button will spring out
automatically and can light the cigar. The lighter
plug also can be used to 24V (10A) power supply
output.

Main Components 37B0230 Lighter

38B0075 Horn

Horn button of the combination switch

 419
Electrical System
Horn and lighter

Horn principle 2. Press te lighter button, use the resistance

function of digital multimeter to measure the
resistance between No. 11 pin (No. 140 wire)
and No. 3 pin (No.237 wire) of XJ 7
receptacle, the lighter has been damaged if
the resistance is infinity, please replace it.
3. Check the receptacle contact condition and
wiring harness condition according to the
lighter principle if the lighter and its fuses
haven't damaged.

Lighter principle

Fault check steps of the Lighter

1. Check the lighter fuse has melted or not,

replace the fuse if it has melted.
420
Electrical System
Horn and lighter

Horn fault test flow char

 421
Electrical System
RIDE CONTROL SYSTEM

RIDE CONTROL SYSTEM

Function General Information

Start the ride control system to decrease bumpy

range for improving the driving comfortable
under the bad driving road.

Main Component

34B0340 Ride control switch

Start and close the ride control system.

34B0340 ride control switch
The ride control system fault test steps:
Ride control system can't work normally
1-A check 5A fuse of ride control system for
melting?
Yes: replace the fuse
No: to 1-B
1-B switch off the start switch, pull out the ride
control switch receptacle, press the switch, use
the resistance function of multimeter to measure
No.1 pin and No.5 pin of switch for connecting?
Yes: to 1-C
Ride control solenoid No: replace the ride control switch
1-C pull out XQ5 receptacle, use the resistance
The details see the hydraulic section.
function of multimeter to measure the resistance
Ride control solenoid between two pins of XQ5 receptacle for open
circuit or short circuit?
Yes: ride control solenoid winding is damage,
replace the solenoid
No: to 1-D
1-D start the start switch, pull out XQ5
receptacle, press the ride control switch, use the
DC voltage function of multimeter to measure
voltage between No.475 wire and No.219 wire
for 24?31V?
Yes: check the hydraulic system
No: to 1-E
422
Electrical System
Electrical Lift System

1-E check the receptacle for loosening and Main Components

harness for damage according to ride control
system principle
Lift Mechanism

Electrical Lift System Lift Mechanism outline and principle drawing

symbol
Introduction

The electrical lift system is used for tilting

operation of the rear hood on the machine, the
rear hood tilting function is used normally in the
machine maintenance and service.
For safety consideration, never permit person
stand inside the tilting radius when tilt the rear
hood. The rear hood of the machine isn't steel Lift motor technique parameter:
configuration; therefore, it can't be used as the
support point when climbing the machine. Load Distance Screw Motor rated
capacity length type power
The rear hood has reached the lift limit position
or the lift has exceeded the load capacity of the 6000N 200mm Trapezia 250W
lift motor when tilt the rear hood and hear sound thread
like KA, KA, KA, please stop lifting at this time.
The lift mechanism uses DC electromotor as
Observe the rear hood reaches the lift limit
power, through the reducer and helix lift/lower
position or not, if it doesn't, please observe
system as beeline output, there are the overload
whether the rear hood distorts or the center of
clutch and manual mechanism inside the
gravity diverges. If such problems still exist after
reducer.
adjustment, please replace the rear hood
assembly. The grease nipple of the lift mechanism needs to
fill up lubrication periodically 3# lithium grease
The tilting operation is not controlled by the start
(common region), fill up 2# lithium grease at cold
switch. The rear hood works as long as connect
region or winter (temperature is at 0°C) to make
the disconnect switch and operate the lift switch.
sure the normal lubrication of the inner gear
mechanism.
The lubrication points of VOGEL lubrication
system using in the machine don't contain the
lubrication points of the lift mechanism, which
needs to fill manually in addition.
Adjust and lubricate the lift mechanism
completely during assembly. It doesn't need
lubrication in service life (3000 times circulation),
but need to fill the lubrication at two hinges of the
lift mechanism every 30 days and check each
bolt condition periodically. Tighten them if they
have loosened. Replace the lift mechanism or
send it back to the manufacturer to change the
inner clutch if find the lift motor can't work
normally.
 423
Electrical System
Electrical Lift System

The lift mechanism has the special tool, which

can be used to turn the little gear mechanism
manually in order to finish the lifting when the
electrical lift operation fails.

Lift mechanism motor fault test steps:

1. Disassemble the connection wiring harness

of the lift mechanism motor.
2. Adjust the multimeter to Ω function (200 Ω ).
3. Use the probe of the digital multimeter to
contact two copper pieces of the lift
mechanism motor receptacle, pay attention
not to contact with each other.
4. The digital multimeter reading is about 10.
The motor is damaged if the reading is not at
this range.

Notice: When install and use the lift

mechanism, please keep the pivots of two
hinges in the same line and plumb with the
fixing holes of two pivots. Two hinges don't
have blocked phenomenon after installation.

When install and use the lift mechanism, two

hinges need to fill up the lubrication.
424
Electrical System
Electrical Lift System

Hood lift controller

Hood lift controller outline and principle drawing symbol

VIEW A
RED (+) WHITE (MOTOR-)

BLACK (-) GREEN (MOTOR+)

BLUE (UP SIGNAL)

YELLOW (DOWN SIGNAL)

The hood lift controller is the special controller of Breaker and principle drawing symbol
the lift mechanism which is used to control the
positive and negative journey (lift or lower). The
lift controller is composed by relays.

Breaker

A 40A auto-return breaker is used in this

machine for controlling the hood lift mechanism.
The breaker will be off and then return according
to the current state when the lift system is
electrified.
 425
Electrical System
Electrical Lift System

When there is overcurrent, the auto-return Fuse fault test method

breaker will disconnect firstly and then return
automatically after several seconds. The breaker Pull out the piece fuse from the fuse base, and
will disconnect automatically again after return if observe the inner fuse condition by eye, or test it
the circuit has fault. Therefore, need to eliminate by the digital multimeter.
the fault before use the hood lift system.
Fuse fault test steps:
Breaker fault test steps:
1. Adjust the digital multimeter to Ω function
1. Disassemble the connection wiring harness (200 Ω )
of the breake.
2. Use the probe of the digital multimeter to
2. Adjust the digital multimeter to Ω function connect two terminals of the fuse.
(200 Ω ) 3. The digital multimeter reading is 1, the fuse
3. Use two probes of the digital multimeter to has melted, please replace it; the digital
contact two plugs of the breaker separately; multimeter reading is 0, the fuse doesn't melt.
the reading on the multimeter is 0. The
breaker is damaged if the reading is 1. Lift switch
4. The multimeter reading is 0, the breaker
disconnects and returns frequently after Lift switch outline and principle drawing symbol
installed back to the machine, which is
damaged after eliminating other faults.

Single circuit fuse

Single circuit fuse base and inner breaker

The lift switch is a three-position instant switch.

Pull the lift switch upwards when tilting the rear
hood, the hood tilts; the lift switch returns to
NEUTRAL position when stop pulling the switch,
the rear hood stops tilting. Pull the lift switch
downwards, the rear hood tilts back, the lift
switch returns to NEUTRAL position when stop
HHR pulling the switch, the rear hood stops tilting
back.
NOTICE: The usage specifications of various
fuses are obtained by calculating at the Lift switch fault test steps
circuit design process, so use the same
series and specification fuses to replace 1. Open the lift control box, and pull out the
when the fuse melts. It's forbidden to replace receptacle of the lift switch.
with the different specification fuses. 2. Adjust the digital multimeter to Ω function
(200 Ω ).
Check the line controlled by the fuse when
the new fuse melts again, eliminate the fault
firstly and replace with a new one.
426
Electrical System
Electrical Lift System

3. Use the digital multimeter probes to connect Lift mechanism and lift control box
the middle receptacle and another receptacle
of the lift switch separately, move and hold
the lift switch along another receptacle
connected to the probe. The digital
multimeter reading is 0.
4. Release the lift switch, it resets automatically,
hold the probe connecting with the middle
receptacle of the lift switch, another probe
connects to another receptacle of the lift
switch, move and hold the lift switch along
reverse direction of step 3. The digital
multimeter reading is 0.
5. The lift switch which can complete these test
steps successfully is good. Otherwise it is
damaged.

Function Operation

16-A Wheel loader rear hood lift function

When perform maintenance, service, check and

lubrication to the machine, open the control box
cover located on the rear right side of the
machine and find the lift control box, tilt the rear
hood or tilt back according to the nameplate on
the lift control box.

Illustration of the above pictures in sequence

Lift control box

Lift mechanism
Rear hood illustration
The following components are needed for
realizing rear hood lifting function:
● Disconnect switch
● Lift mechanism
● Lift controller
● 40A breaker
 427
Electrical System
Electrical Lift System

● 5A fuse Lifting principle drawing

● Lift switch

Troubleshooting

Lift work principle

The battery +24V voltage is divided into two

ways from XG8 receptacle passing No.104 wire
after close the disconnect switch, one way is
passing 40A breaker No.492 wire→lift controller,
another way is passing XZ2 receptacle→5A
fuse→No.493 wire→the lift switch.
The lift switch connects No.493 wire and the blue
signal wire inside the lift controller when open the
rear hood. +24V voltage is input into the lift
controller by the blue signal wire and order the lift
controller to carry out the motor positive rotating
dictate. The relay inside the lift controller exports
+24V voltage signal to the lift motor by XI1
receptacle (490+, 490-), the lift motor carries out
the positive rotating, the rear hood tilts.
The lift switch switches on No.493 wire and the 16-A-F Lift mechanism can't work
yellow signal wire inside the lift controller when
close the rear hood. +24V voltage is input into Fault phenomenon definition
the lift controller by the yellow signal wire and
order the lift controller to carry out the motor The lift mechanism doesn't carry out tilting or
reversal rotating dictate. The relay inside the lift tilting back when pull the lift switch up or down.
controller exports +24V reversal voltage signal to Or the lift mechanism stops suddenly and can't
the lift motor by XI1 receptacle (490+, 490-), the work when tilting or tilting back.
lift motor carries out the reversal rotating, the
rear hood tilts back. Fault test steps:

Step 1. 40A breaker disconnects or not due to

overcurrent?

a.Turn on the disconnect switch, open the lift

control box cover. The lift switch is located on the
cover. Block a wedge under the cover after open
the cover, and don't let the terminal contact the
ground.
b.Operate the lift switch newly after 5s, and
observe the lift mechanism lifts or not. If 40A
breaker disconnects due to overcurrent, it will
close again automatically after 5s.
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Conclusion: b.Adjust the digital multimeter to voltage function

(50V).
The lift mechanism runs normally after 5s, which
c.Use the red probe of the digital multimeter to
shows 40A breaker just disconnects temporarily
contact No.104 wire of 40A breaker, the black
due to overcurrent, renews normal condition
probe contacts with the grounding terminal near
after closes newly.
the lift control box (need to open the rubber
The lift mechanism can't run after 5s, please turn lagging).
to step 2.
Test result:
Step 2. Test whether there is +24V voltage in
No.492 wire and No.255 wire of XG9 The digital multimeter reading is between 24V
receptacle. and 31V.

a.Adjust the digital multimeter to voltage function Conclusion:

(50V).
If the result does OK, 40A breaker is damaged,
b.Turn No.492 wire of 40A breaker slightly by
please replace it. Turn off the disconnect switch
hand, judge the wire connecting condition;
when replace the beaker.
please tighten it by the spanner if it has
loosened. If the result doesn't OK, please check the
connecting condition of No.104 wire of battery
c.Pull each lead of XG9 receptacle slightly by
terminal, and check whether there is open circuit
hand, judge the lead and inner copper receptacle
or damages in the line from the battery to the lift
have separated or not. Use the special tool to
control box.
tighten it if there is separate phenomenon.
d.Pull out XG9 receptacle, use the red probe of Step 4. Test 5A fuse has melted or not?
the digital multimeter to contact No.492 wire
corresponding receptacle of XG9 receptacle a.Open the single circuit fuse box, observe 5A
(wiring harness terminal), the black probe fuse has melted or not.
contacts with No.255 wire corresponding
receptacle of XG9 receptacle, pay attention not Conclusion:
to contact these two probes with each other.
If it has melted, please turn to step 5.
Test result:
If it doesn't melt, please turn to step 6.
The digital multimeter reading is between 24V
and 31V. Step 5. Replace with new 5A fuse.

Conclusion: a.Turn off the disconnect switch, replace 5A fuse.

b.Turn on the disconnect switch newly, operate
If the result does OK, please turn to step 4. the lift switch, observe the fuse has melted or
If the result doesn't OK, please turn to step 3. not.

Step 3. Test whether there is +24V grounding

voltage in No.104 wire of 40A breaker.

a.Turn No.104 wire of 40A breaker slightly by

hand, judge the connecting condition; please
tighten it by the spanner if it has loosened.
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Conclusion: If the result doesn't OK, if only one actual test

result of step c and step d accords with academic
If it keeps melting, please check the line between test result, which means the lift switch is
No.493 wire and lift controller carefully if there is damaged, please replace it. If both actual test
short circuit fault in the line. Turn off the results don't accord with academic test result,
disconnect switch when check, cut each circuit please turn to step7.
node, measure the grounding voltage of No.493
wire, the grounding voltage of the lift switch and Step 7. Test whether the lift switch input has
the grounding voltage of the lift controller by the +24V voltage.
digital multimeter. There is short circuit fault if the
reading is 0, please eliminate the falut. a.Adjust the digital multimeter to voltage function
(50V).
Step 6. Test whether the lift switch output has
b.Use the red probe to connect the receptacle on
+24V voltage.
the back of the lift switch, the black probe
connects to the ground near the lift control box.
a.Adjust the digital multimeter to voltage function Observe the digital mulimeter reading.
(50V).
b.Turn each terminal of the lift switch slightly by Test result:
hand, judge the connecting condition, please
tighten it if it has loosened. The digital multimeter reading is between 24V
and 31V.
c.Use the red probe to contact the receptacle
loacated on the back of the lift switch, the black
Conclusion:
probe contacts with the grounding point of the lift
control box. Pull the lift switch upwards and hold
If the result does OK, the lift switch is damaged,
it, observe the digital multimeter reading (need
please replace it.
another person), then release it, the lift switch
will return to NEUTRAL position. If the result doesn't OK, please turn to step 8.
d.Use the red probe of the digital mulimeter to
contact the receptacle located on the back of the Step 8. Test whether there is +24V voltage in
lift switch, hold the black probe, pull the lift switch No.104 wire of XZ2 receptacle.
downwards and hold it, observe the digital
multimeter reading (need another person), then a.Pull each lead of XZ2 receptacle slightly by
release it, the lift switch will return to NEUTRAL hand, judge the connecting condition between
position. the lead and inner receptacle, and use the
special tool to tighten it if it has loosened.
Test result: b.Pull out the XZ2 receptacle, adjust the digital
multimeter to voltage function (50V).
The digital multimeter reading is between 24V
c.Use the red probe of the digital multimeter to
and 31V.
connect No.104 wire corresponding receptacle of
XZ 2 receptacle (40A breaker terminal), the black
Conclusion:
probe connects to the ground near the lift control
box.
If the result does OK, please turn to step 9.
Test result:

The digital multimeter reading is between 24V

and 31V.
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Conclustion: Step 10. Test the resistance of XI1 receptacle

(lift mechanism terminal).
If the result does OK, please check whether the
line has loosened or open circuit from No.104 a.Adjust the digital multimeter to resistance
wire to 5A fuse to No.493 wire receptacle on the function (200 Ω ).
back of the lift switch.
b.Use two probes of the digital multimeter to
If the result doesn't OK, please check the connect two copper receptacles of XI1
connecting condition of No.104 wire of battery receptacle (lift mechanism terminal) separately.
terminal, and check whether the line between the
battery and the lift control box has open circuit or Test result:
damage phenomenon.
The ditital multimeter reading is about 10Ω.
Step 9. Test No.491 wire and No.490 wire at
XI1 receptacle (lift controller terminal) are Conclusion:
normal or not.
If the result does OK, the lift force exceeds the
a.Turn and pull each lead of XI1 receptacle by load capacity of the lift mechanism motor,
hand, judge the connecting condition between thereby start the lift mechanism motor overload
each lead and inner receptacle, use the special protection device. At this time, please check the
tool to tighten it if it has loosened. center of the hood gravity diverges or not due to
the rear hood distortion, replace the rear hood
b.Pull out XI1 receptacle, adjust the digital
assembly if it has diverged.
multimeter to voltage function (50V). Use the red
probe and black probe to connect No.491 wire If the result doesn't OK, the lift mechanism motor
and No.490 wire corresponding receptacle of XI1 is damaged.
receptacle (lift controller terminal) separately, pay
attention not to contact these two probes with 16-B-F Open or close the rear hood without
each other. using the lift switch,
c.Pull the lift switch upward and hold it, observe
When it is necessary to open or close the rear
the digital multimeter reading (need another
hood but the lift mechanism doesn't work, please
person).
use a spanner to turn the screw in order to drive
d.Release it, pull the lift switch downward and the inner pinion mechanism to finish the
hold it, observe the digital multimeter reading. operation. The location of screw sees the
Then release it and let it reset after observing. following illustration. This operation is just used
under the condition that the gear mechanism
Test result: doesn't have fault in the lift mechanism.

The digital multimeter reading is between 24V

and 31V in step b and it is between -24V and -
31V in step c. That is step b and step c have the
same test values, but one of the voltages is
positive, the other is negative.

Conclusion:

If the result does OK, please turn to step 10.

If the result doesn't OK, the lift controller is
damaged.
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Screw location
432
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Others

Others

Appendix 1: CLG856III Wheel Loader Pressure Switch Paremeter Table

Contact Action value Action value

Pressure switch Thread Delay
Part No. original (the metric (the British
name connection characteristic
state system) system)
Parking brake clutch
30B0138 NC+NO 7Mpa 1015.2psi M12 X 1.5 Yes
cut-off switch
Parking brake low
30B0139 NC 11.5Mpa 1668psi M12 X 1.5 Yes
pressure alert swtich
Transmission oil
30B0132 NC 1.5Mpa 217.5psi M10X1T Yes
pressure alert swtich
Engine oil pressure
30B0131 NC 0.069Mpa 10psi 1/8"NPT Yes
alert switch
Secondary steering
30B0291 NO 0.6 Mpa 87.02 psi 1/8"NPT Yes
pressure switch
Steering system low
30B0292 NC 0.6 Mpa 87.02 psi 1/8"NPT Yes
pressure alert switch
Brake light switch 30B0181 NO 0.5Mpa 72.5psi M12 X 1.5 Yes
Service brake clutch
30B0177 NO 1.5Mpa 217.5psi M12 X 1.5 Yes
cut-off switch
Service brake low
30B0182 NC 10MPa 1450.4psi M12 X 1.5 Yes
pressure alert switch

Appendix 2: CLG856III Wheel Loader Pendant Switch Parameter Table

34B0350 Pendant Combination Switch

Lock Special
No. Name Instruction Reset Illustration Color
buckle instruction
0 Lock
Manual lubrication
1 Green
switch I 1---5 Yes

0
Rear window defroster
2 Green
switch I 1---5

0 5---7
3 Rear wiper switch I 3---5 Green
II 1---3
0
4 Alert indicator switch Red
I 1---5

5 Cover
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0
6 Rear window washer Green
I 1---5 Yes

34B0482 Pendant Combination Switch

Lock Special
No. Name Instruction Reset Illustration Color
buckle instruction
0 Lock
Quick coupler unlock
1 Red
switch I 1---5

0
2 Ride control switch Blue
I 1---5

3 Cover
0
4 I 1---5 Yellow
Lock
2---6

Pendant Combination Switch

Lock Special
No. Name Instruction Reset Illustration Color
buckle instruction
0 Lock
Diagnostic ON/OFF
1 Green
switch I 1---5 DIAG
I 1---3 Yes
Idle/diag (diagnostic) ID L E
2 0 D IA G Green
inc /dec switch
II 3---7 Yes
0
3 Rear floodlight switch Blue
I 1---5

0 5---7 is
auxiliary
4 Hazard flasher switch I 1---3 Red contact, the
2---4 rated current
5---7 is 2A
0
5 Work light switch Green
I 1---5

0
I 2--- 6
Position light & 2---8
6 Green
floodlight switch II 1---3
2--- 6
2---8
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0
Secondary steering
7 Yellow
switch I 1---5 Yes

0
8 Buzzer mute switch Green
I 1---5

Appendix 3: CLG856III Wheel Loader Main Electronic A/C Components Installation

Positions

Position
Component Name Part No. Remark
code
1 Dome light 32B0066
Work light, rear
2 Work light 32B0140
floodlight
3 Nameplage light 32B0154
4 Rotating Beacon 32B0080
5 Rear right position light GP 32B0138
6 Front right combination light 32B0136
7 Rear left position light GP 32B0139
8 Front left combination light 32B0137
9 Backup alarm 38B0042
10 Shift control lever 46C0253 ZF fittings (Semiauto)
EST117 ZF fittings
11 Control unit 37B0428
(Semiauto)
12 Speed sensor 30B0032 ZF fittings (Currency)
40A fuse 34B0348
Knob switch 34B0126
13 Lift control box
Single circuit fuse 37B0352
Lift control box 31B0075
14 Battery 37B0108
15 Disconnect switch 34B0297
16 Rear wiper assembly 46C0641
17 Front wiper assembly 46C1017
18 Double motor kettle 46C1455
19 Torque converter oil temperature sensor 30B0100
AMG fuse 37B0299
AMG fuse receptalce 37B0298
Electronic control
20 Single circuit fuse 37B0352
box assembly
Relay 31B0042
Control relay 31B0059
21 Water level sensor 30B0319
22 Water temperature sensor 30B0065
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23 Parking brake clutch cut-off switch 30B0138

24 Parking brake low pressure alert switch 30B0139
25 Transmission oil pressure alert switch 30B0132
26 Engine oil pressure alert switch 30B0131
27 Secondary steering pressure switch 30B0291
28 Steering system low pressure alert swtich 30B0292
29 Oil level sensor 30B0279
9-pin J1939/1587
36B0527
30 Diagnostic interface diagnostic interface
Guard 36B0528
31 Lighter 37B0230
32 Pendant combination switch 34B0482
33 Ice box 46C1202
34 Lighter receptacle 37B0290
35 DC-DC switcher 37B0268
Brake solenoid 34B0032
36 Parking brake button Auxiliary contact
34B0082
block
Relay 31B0095
Relay 31B0113
Fuse piece 37B0359
Electronic centralized Fuse piece 37B0360
37
control box Fuse piece 37B0361
Fuse piece 37B0362
Fuse piece 37B0363
Flasher relay 31B0099
38 Accelerator assembly 23C0075
39 Voltage/service meter 35B0118
40 Pendant combination switch 34B0350
41 Horn 38B0075
42 Radio assembly 46C1399
43 Antenna 37B0243
44 Speaker 38B0047
45 Tank receiver 47C0758
46 Control panel 46C1525
47 Condensator assembly 46C1000
48 Water intake 46C0486
49 Filter 46C1672
50 Compressor 46C0752
51 Evaporator assembly 46C1726
52 Bucket switch 34B0142
53 Boom switch 34B0141
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54 Boom magnet 34C0023

55 Bucket tilting magnet 34C0026
56 Brake light switch 30B0181 Brake valve fittings
57 Service brake low pressure alert switch 30B0182 Brake valve fittings
58 Parking brake valve Brake valve fittings
59 Service brake clutch fut-off switch 30B0177 Brake valve fittings
60 Shift control lever ZF fittings (auto)
61 Display 30B0330 ZF fittings (auto)
62 Speed sensor 30B0255 ZF fittings (auto)
63 Shift control lever 46C0382 ZF fittings (auto)
64 Control unit 37B0306 EST-25
65 Start motor Engine fittings
66 Alternator Engine fittings
67 Pilot valve electromagnetism winding Pilot valve fittings
68 Secondary steering motor 11C0255
69 Diesel Engine ECM Diesel engine fittings
70 Ride control solenoid 12C0681
71 Steering wheel and switch assembly 46C1458
72 Panel assembly 46C1519
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Appendix 3: CL856III Wheel Loader Main Electronic A/C Components Installation

Positions (6-bar)
438
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Others

Appendix 3: CLG856III Wheel Loader Main Electronic A/C Components Installation

Positions (8-bar)
 439
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Appendix 4: CLG856III Wheel Loader Main Receptacles Installation Positions

Position code Receptaclemark Remark

1 XD1,XD2 Front left work light
2 XD3,XD4 Front right work light
3 XD5 Rear left floodlight
4 XD6 Rear right floodlight
5 XD7 Radio
6 XD8 Dome light
7 XD9 Right speaker
8 XE1 Left speaker
9 XE2 Cab harness and top cover harness interface
10 XE3,XE4 Top cover harness and overhead light harness interface
11 XK5,XK6 Overhead light harness and cab harness interface
12 XJ1 Left panel assembly interface
13 XJ2 Front wiper
14 XJ3 Voltage/service meter
15 XE7 Quick coupler solenoid
16 XJ4 A/C control unit
17 XJ6 9-pin data diagnostic interface
18 XJ7 Side plate assembly interface
19 XJ8 Rear wiper
20 XJ9 Defroser device
21 XK1 Boom float winding
22 XK2 Boom lift kickout winding
23 XK3 Bucket positioner winding
24 XK0 KD key(additional) (semi-auto)
25 XK4 Parking brake button
26 XK7 Centralized lubrication system interface
27 XK8 Counterweight system
28 XK9 Counterweight system
29 XQ2,XQ1 Front right combination light
30 XQ8 Horn
31 XQ3 Boom lift kickout switch
32 XQ4 Bucket positioner switch
33 XQ5 Ride control soleniod
34 XQ6,XQ7 Front left combination light
35 XQ8 Front frame harness and cab harness interface
36 XL3,XL4 Throttle assemble
37 XL5 Parking brake solenoid
38 XA1,XA2,XA3,XA4,XA5 Electronic centralized control box and cab harness interface
440
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Position code Receptaclemark Remark

39 XL1 Seat
40 XL2 +12V 8A DC-DC
41 XH1,XH2,XH3,XH4 Rear frame harness and cab harness interface
42 X5 ZF harness and cab harness interface
43 XY1,XY2 Steering column assembly and cab harness interface
44 XY3,XY4 Steering column assembly and rear frame harness interface
45 XH5,XH7 Electronic engine and rear frame harness interface
46 XZ1 Electronic control box 30A fuse interface
47 XH9 Engine interface
48 XG8,XZ2,XG9 Lift control box interface
49 XI1 Lift motor interface
50 XH8 Diesel engine coolant level switch
51 XG1 Oil level sensor
52 XG3,XG4 Double motor kettle
53 XG5 Condenser blower motor
54 XG6 Compressor clutch
55 XG7 A/C pressure protection switch
56 XI2,XI3 Rear right position GP
57 XI4 Backup alarm
58 XI5 Nameplate light
59 XI6,XI7 Rear left position GP
 441
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Appendix 4: CLG856III Wheel Loader Main Receptacles Installation Positions (6-bar)

442
Electrical System
Others

Appendix 4: CLG856III Wheel Loader Main Receptacles Installation Positions (8-bar)

 443
Electrical System
Others

Appendix 5: 50E0136-1 001 Electronic System Principle Drawing (available for semi-
auto CLG856III Wheel Loader)
444
Electrical System
Others

Appendix 6: 50E0137-1 001 Electronic System Principle Drawing (available for full-
auto CLG856III Wheel Loader)
 445
Electrical System
Others

Appendix 7: 50E0137-2 001 Electronic System Principle Drawing (available for fully-
auto CLG856III Wheel Loader)

50E0136-2 001 Electronic System Principle Drawing (available for semi-auto CLG856
III Wheel Loader)