SDLG1

Service Manual of Wheel Loader
CONTENTS
0 SAFETY &
ENVIRONMENT .......................................................................
.. 0-1
01
PREFACE ...........................................................................
................................ 0-1
02
SAFETY ............................................................................
................................. 0-1
021 Safety
tips ..............................................................................
.................... 0-2
022 Safety regulations during repair and
maintenance ................................... 0-4
023 Service
position ..........................................................................
............... 0-5
024 Safety of hoisting and
support .................................................................. 0-6
025 Other safety
precautions .......................................................................
.... 0-7
03
ENVIRONMENT .......................................................................
......................... 0-17
031 Waste
treatment .........................................................................
.............. 0-17
032 Working in polluted
environments.......................................................... 0-19
033Decontamination after
accidents .............................................................. 0-20

0-1
0 Safety &environment
01 Preface
This manual is a part of the whole Service Manual of
Wheel Loader. Please carefully read it.
Warning: Be sure to read the part about safety
in this manual before operations.
Safety is related to everyone
Always abide by the instructions in the Operation and
Maintenance Manual attached to the machine.
SDLG designs and manufactures safe and efficient
machines. However, if the operators using the
Company�s machines fail to carefully read the safety
operation instructions or fail to follow the rules
thereof, or use the tools not supposed to be used for
the operations of the project, all our previous efforts
will be wasted.
To keep the machine�s functions safe and efficient, the
appropriate spare parts (authentic products
manufactured by Shandong Lingong Construction
Machinery Co., Ltd. (SDLG)) specially designed for
this machine should always be used. If the spare parts
that are not authentic products manufactured by
Shandong Lingong Construction Machinery Co., Ltd.
are used, the Company (Shandong Lingong
Construction Machinery Co., Ltd.) shall not be
responsible for the damaged machines arising
therefrom or make any warranty compensations.
When the workers have safety awareness and the
machines are properly maintained, the safety and
efficiency can be ensured and benefits can be brought
in.
In the event of noncompliance with the safety
operation instructions and paying no attention to the
precautions of the manual, the operator himself should
ensure that his operation methods are safe and reliable.
Otherwise, there will be a risk of accidents.
02 Safety
Shandong Lingong Construction Machinery Co., Ltd.
will only be liable for the following situations:
correctly using and maintaining the machine according
to the instructions in the Service Manual of Wheel
Loader and Operation and Maintenance Manual.
- Specified maintenance and checking are carried
out within the specified time intervals.
- Abide by the instructions in the manual on the
lubrication of machines.
0-2
- No safe sealing elements are opened by the
unauthorized person.
All the maintenance and repair are conducted in the
manner as specified by the Company (SDLG)
Only the original authentic parts, accessories or
additional devices that conform to the requirements of
the Company (SDLG) are used.
021 Safety tips
In the process of assembling and disassembling, the
wrong operation methods will cause damaged parts,
reduced service life and deteriorated use performance.
Meanwhile, there are unsafe factors. Therefore, please
carefully read the relevant contents of the manual
during the assembling and disassembling of the parts.
1. The parameters, graphics and relevant contents, etc.
are applicable to products with standard configuration
in the manual. As for the deformed products, please
consult the Company or refer to relevant information.
2. In the repair workshop, places should be set up for
assembling and disassembling and for the exclusive or
special use by the disassembled parts. Put the
corresponding tools and parts in the appropriate
places. In the meantime, ensure the tidiness of the
operation area and that the operation area has no
greasy dirt or contaminants. Smoke in the specified
smoking place. No smoking during the operations.
Corresponding fire extinguishing apparatus should be
equipped.
3. The welding operations should be carried out by the
well-trained personnel experienced in welding. Before
welding, turn off the start switch of engine, remove the
battery cable and ensure the safety of various kinds of
pipelines, sealing elements and cables. During the
operation, welding gloves, baffle, goggles, operation
helmet and other uniforms suitable for welding
operations should be used.
4. Before removing the parts of the loader, the
contaminants on its outer surface must be cleaned up,
so as to avoid the contaminated parts during the
disassembling.
5. In the process of operations, wear safety shoes and
safety helmets. Wear the uniform that conforms to the
requirements and do up the buttons. To strike the parts
with copper bar, wear goggles.
6. When the removed parts are cleaned up, gasoline,
kerosene and water-base grease cleanser can be used.
7. During the use of traveling crane or other hoisting
equipment, first check whether relevant hoisting
appliances are damaged. The hoisting equipment with
0-3
a sufficient hoisting capacity must be used. During the
hoisting operation, slowly hoist according to the
designated hoisting position so as to avoid collision
between parts. Do not work under the hoisted parts.
8. When the operation is to be conducted by two or
more people, the operation procedures should be
agreed to be mutually complied with before the
operation, so as to avoid the occurrence of accidents
due to inconsistent pace.
9. Be sure to properly keep all the serviceable tools
and get familiar with their application methods.
10. During the alignment of two holes, do not insert
the finger or other parts of the body into the holes. As
for the parts to be directly assembled by hands, be sure
to note whether the position held by the hand is at risk
of being squeezed.
11. The removed parts must be detected. The parts
whose operational performance has been affected must
be replaced with new ones.
12. After each part is assembled, there should be any
interference.
13. In the process of assembling oil seals and seal
rings, if they pass through key grooves, screw holes
and steps, relevant protective measures should be
taken, so as to avoid damaged oil seals and seal rings.
14. During the assembling of the parts, the tools used
must match the threaded fasteners, so as to avoid
damaged the threaded fasteners.
15. To tighten the joint body and the screw plug, such
tightening tools as pneumatic wrench should not be
used. Be sure to tighten the said parts with hand to
some extent and then fasten them with torque wrench
of corresponding specifications, so as to reach
corresponding torque value.
16. As it is impossible to foresee all the potential
dangers, the instructions on safety in the manual and
on the machine cannot include all the safety
preventive measures. In the event of carrying out the
steps and operations not recommended in the manual,
be sure that others and you are safe and the machine
will not be damaged. In the event of uncertainty on the
safety of some operations, please consult with the
Company or the dealers.
17. The parts of rack or rope ladder to be pressed by
foot or held by hand should be free from mud or
greasy dirt. To get on and get off the vehicle, handrail
and rope ladder should be used. Never jump up and
down. If the handrail and rope ladder cannot be used,
the steps provided at the safe foot hold can be used
instead.
0-4
Fig. 0-1 Reading Operation and
Maintenance Manual before operations
18. To disassemble the screw plugs with hydraulic
pressure, slowly loosen the screw plug so as to prevent
oil liquid from splashing; to remove the pipelines with
pressure, the pressure of the pipelines should be
eliminated first.
19. After the engine just shut down, the temperature of
the oil or water in the pipeline is quite high. During
the disassembling of pipelines with oil or water,
relevant work should be carried out after the
temperature reduces.
20. To disassemble the oil way, be sure to prevent the
overflow of fuel and hydraulic oil. If the fuel and
hydraulic oil are accidentally dropped on the surface
of the parts in the process of disassembling, they
should be wiped immediately, so as to avoid the
occurrence of potential safety hazards in the process of
disassembling.
21. All the various hydraulic pipelines, air pipes and
corresponding pipe joints removed must be properly
provided with measures to prevent contamination. For
example, various kinds of hydraulic pipeline joints
removed must be properly wrapped with clean plastic
bags or other feasible preventive measures can also be
adopted.
22. To fasten each bolt connecting part, as for the parts
fastened with many bolts, it is best to mark on the
fastened bolts so as to looseness.
022 Regulations for safety during the
repair and maintenance
Note: See the Operation and Maintenance
Manual attached to the vehicle for the safety
precautions on the operations and maintenance.
0-5
023 Service position
1. Place the machine on the horizontal and hard
surface as shown below:
Fig. 0-2 Service position
1. Place the attachments horizontally on the ground.
2. Turn off the engine and remove the ignition key.
3. Relieve the pressure in the pressurized pipelines and oil tank, so as to release
the high pressure
and prevent the accidents.
Warning: If the pressure is not reduced before the hydraulic system opens, the
hydraulic oil will be ejected under high pressure and it might cause severe
personal injuries and
accidents.
4. Connect the yellowish-black warning flags (in the U.S.A., red warning flags
might be used) to
the steering wheel.
5. The frame locking lever has been connected.
6. Keep the vehicle in the parking brake state and have the vehicle wedged up.
7. Turn off the isolating switch of the battery.
8. Cool down the machine.
Warning: If you must operate before the machine is cooled down, please be
especially
careful with the hot liquid and machinery parts, so as to avoid being burnt.
0-6
Fig. 0-4
Fig. 0-5
2. When maintenance is to be conducted under the
boom, it should be always supported with bracket
before operations. The bracket must be placed on the
solid and flat surface.
Warning: Note the correct position of the
support under the lifting arm! If the support is placed
near the front too much, it will be overridden when the
fixator of the auxiliary tools bends forward.
024 Safety of hoisting and support
Hoisting
1. If it is hard to remove the parts from the machine,
the following checking must be done: check whether
all the fixed bolts of the components to be removed
have been removed.
Check whether there are other components that
prevent the components to be removed from being
removed.
2. Steel rope (can be substituted by ropes with equal
carrying capacity)
1) The steel ropes must be hoisted between the
hooks.
If they are hoisted at the end of the hook, the steel
might be off the hook during the hoisting, thus causing
severe accidents. The strength of the middle part of the
hook is maximal as shown in Fig. 0-4.
2) Do not use only one steel rope. Two or more steel
ropes should be used to be wound around the
load.
Note: Using only one steel rope might cause the
load to revolve, the steel rope to be loosened or the
load to slide from the original winding and bundling
position during the hoisting, thus leading to dangerous
accidents.
3) When the heavy load is hoisted, the hoisting
angle of the steel rope and the hook should not be
excessively large.
When the load is hoisted with two or more steel ropes,
the force borne by each steel rope will increase with
the increase in the hoisting angle. As shown in Fig.
0-5, when two steel ropes (the maximum vertical
hoisting weight of each steel rope is 1,000kg) are used
to hoist loads, the total weight to be hoisted is
2,000kg. When the hoisting angle is up to 120�, the
loading weight can only be up to 1,000kg. On the
other hand, when the load of 2,000kg is hoisted with
Load capacity
Load capacity
0-7
two steel ropes with the 150� hoisting angle, the force
to be borne will be up to 4,000kg.
Support
Place the machine at the service position and always
use jack and support equipment with sufficient
carrying capacity.
Be sure to provide support for front and rear axles in a
safe manner before carrying out other work.
Warning: When the machine is supported by
jack, do not enter the machine or walk under the
machine.
To replace the wheels and brake, always operate one
axle at a time.
Methods applicable to front axle
Elevate the machine through the working device of the
machine and use special tooling as the support.
Methods recommended for rear axle
After the machine is jacked up by the jack, support the
balance weight with special tooling and place wood
blocks between the axle and frame to prevent the rear
axle from swinging.
Note: Before lowering the machine, do not
forget to remove the wood blocks.
The machine must use the tooling and jack with
sufficient supporting capacity.
When two wheels are lifted, it is easier to rotate the
wheels so as to put the wheel nuts in place.
025 Other safety precautions
Electrical system
� Check whether the cable is scratched and ensure
that the cable will not be so damaged, which is
especially important for the cable without fuse.
For instance, the cables between the following
components:
- Battery
- Battery - starting motor
- Alternator - starting motor
- Preheating coil of the cable to the engine.
� If the cable without fuse is disconnected, ensure
that the cable has been connected and the
connection way can greatly reduce the risk of
scratched cable. The cable without fuse cannot
get close to the engine oil or the fuel hose.
0-8
Fig. 0-6 Do not stand beside the tires
during the inflation
� To install any optional equipment, be sure to
confirm that all the cables are connected by one
fuse and ensure that both the wiring and fixing
way can prevent the cables from being scratched.
Fuel oil, hydraulic pressure and brake system
� Check and confirm that the fuel, hydraulic
pressure and brake hose are not scratched.
Welding and grinding
In the process of any electric welding, the fire
extinguisher must be readily available.
� Welding and grinding can only be carried out on
the cleaned parts of the machine, except for those
parts with inflammable liquid, such as oil tank
and hydraulic pipe. If those parts with
inflammable liquid are to be welded and ground,
please be particularly careful.
� If the surface with paint is required to be welded,
the paint must be removed first. Welding the
surface with paint will not only produce harmful
gas, but also cause poor welding, and even result
in faults and eventually lead to the accidents.
� Utilize personal protective equipment. If
conditions permit, the toxic gas produced in the
welding and grinding can be removed with the
exhaustion fan.
Precautions for tires
Warning: To inflate the tires installed on the
split rim, it might cause explosion, thus leading to
severe damage.
Inflation
� To inflate the tire installed on the split rim, do not
stand beside on one side of the tire. During the
inflation, you may stand outside the dangerous
area by using the air nozzle that can be
automatically locked and one hose that is long
enough.
� Confirm that no one is standing in the dangerous
area during the inflation of the tire.
� Check the tire pressure when the machine is
under no load.
� The spare tire should only be inflated to keep the
rim components in place.
� To inflate the tires, one box and one rope or chain
should be used to fix the loosened wheels. Before
dismantling the box, check whether the tire is
0-9
Fig. 0-7 Corrosive sulfuric acid
correctly installed on the rim.
� After inflating the tire, do not adjust the side ring
and clamping ring.
� If the pressure of the tires installed on the vehicle
is less than 80% of the normal pressure, and the
rims or tires are suspected to have been damaged,
the tires should be removed for inflation at this
time.
Installation of tire and rim
� Only the well-trained technicians can treat the
tires.
� To remove the tires from the rims, first deflate
the tires.
� If the tires and the rims do not match, such tires
cannot be installed on such rims.
� Never assemble the rim components of different
dimensions. Never use damaged or inoperative
components.
� If you use the repaired wheel parts, you should be
very careful. The inoperative or wrong welding,
heating or welding might damage component
strength.
� Before installing the locking rings, be sure to
confirm that the locking rings in the rims have no
dirt or dust.
� To install tires on the rims, the lubricant
recommended by the tire manufacturers should
be used.
Repairing tire and rim
� Do not cut, weld or heat the wheel components.
� Be careful to use wheel bead breaker and
hydraulic jack. To remove the foreign matters
from the tires, be sure to stand outside the
dangerous area. Loosening the wheel bead
breaker is very dangerous, which might result in
sever personal injuries and lead to death.
Safety during the operation of battery
Warning: Danger! Severe corrosion.
The battery has sulfuric acid and it is highly corrosive
to human body and machinery parts.
In all the work involving the vehicle battery, the
mixture of such explosive gas and the corrosive
sulfuric acid is very dangerous.
Therefore, during the operations of battery, please
0-10
Fig. 0-8 Wear goggles and gloves at risk of
contacting refrigerator
carefully read and abide by the following regulations.
During the operation of the battery, please abide by
these instructions:
� The battery will release explosive gases. Do not
smoke near the battery.
� At the time of disassembling the battery, first
disconnect the ground wire. During the installation of
battery, connect the ground wire at last.
� Never excessively tilt one battery, as the
electrolyte of battery may flow out.
� Do not install the battery discharging massively
and the full charged battery in series, as such act is in
danger of explosion.
� Do not let metals (such as tools, ring and watch)
contact the battery terminal, as it is at risk of fire and
personal injuries.
� When working near the battery, cover the top of
the battery with one piece of cloth or other
nonconductors.
� Always install the caps for battery terminal.
� As the battery has substances harmful to health
and environment, the battery must be discarded
according to relevant local/national regulations.
Battery charging
Explosion hazard
When the battery is charging, the explosive hydroxide
mixture will form. The short circuit, open fire or spark
near the battery will result in explosion. Before the
disconnection of charging clamp, please first turn off
the charging current. When the battery is in an
enclosed space, please keep it well ventilated.
Warning: Danger! Sever corrosion.
Corrosive sulfuric acid
The battery electrolyte includes corrosive sulfuric
acid. After the electrolyte is splashed on the exposed
skin, the electrolyte should be immediately washed.
Wash the affected parts with soapy water and plenty of
water. If the electrolyte is splashed into the eye or any
sensitive part of the body, they should be washed with
plenty of water and checked by doctors.
Starting with power battery
Note: Check whether the booster battery pack or
any other power supplies have the same voltages with
the machine�s battery pack.
Warning: If one fully charged battery is
connected to one battery running out of power, the
0-11
battery will explode due to current surges, thus
causing personal injuries.
During the starting with the power battery, please
abide by these steps:
1. Open the engine hood.
2. Open the battery cover.
3. Turn off the battery switch.
4. Do not disconnect the battery cable of the
machine.
5. Remove the end cap from the battery terminal.
6. Connect the anode cable from the booster battery
or other power supplies to the positive terminal of
the battery pack.
7. Connect the cathode cable from the booster
battery to the engine cylinder.
8. Turn on the battery switch.
9. Start the engine with the ignition switch in the
cab.
10. If the alternator is charging, remove the jump
start cable from the earth point and the negative
terminal of booster battery. Then remove the
jump start cable between the positive terminals.
Note: If the alternator is not charged, turn off
the machine with switch and check the cause.
11. Recover the machine.
Safety in the process of disposing of engine oil and
fuel
Warning: Danger! Burning. Use protective
gloves.
� When replacing the hydraulic oil, engine oil and
transmission oil: remember that the oil liquid is
very hot, as it may cause burns.
� Engine oil, transmission oil, hydraulic oil and
diesel can corrode the mucosa, such as eye, throat
and skin. Therefore, be sure to keep those
sensitive body parts away from engine oil.
� When discharging the engine oil or fuel, be sure
to take measures to avoid unnecessary splashing.
The places where the oil liquid cannot be
collected with containers, the suction pump
should be used or a hose should be connected as
the safety measures. Arbitrary release of engine
0-12
oil and fuel not only is harmful to the
environment, but also might lead to fire.
� The wasted oil liquid should be disposed of by
the authorized company.
� Keep fire hazards in mind!
Safety during the operation of air-conditioner
refrigerant
Overview
When it is required to turn on the air conditioning
system, the maintenance and the further work should
be carried out by professionals. Get familiar with and
abide by the administrative provisions of your country.
Refrigerant R134a is used for air condition unit.
The label will mark out the type of refrigerant and the
filling quantity.
Note: R134a will increase the greenhouse
effect; therefore, do not release R134a on purpose.
Personal protection facilities
At risk of skin contacting the refrigerant, please use:
Tighten goggles and protective gloves and protect
other naked skins (in danger of frostbite).
Danger
Warning: These odorless and tasteless gases
will hurt the lungs even under the low concentration.
In the event of incorrect treatment, refrigerant R134a
will cause severe personal injuries and environmental
hazards. Therefore, be very careful when operating the
air condition unit! In order to avoid the harm to the
personnel contacting the refrigerant, please observe
the following rules:
Warning: Danger! Frostbite. Use protective
gloves.
� The liquid refrigerant will cause frostbites.
� Gaseous refrigerant of low concentration has
certain effects, especially on the nervous
system.
� Gaseous refrigerant of high concentration has
anesthetic effects.
� The air condition unit is of high voltage and the
refrigerant will unintentionally leak. Do not
disconnect the hose or remove the filler plug on
the compressor.
If you have doubt about the leakage, you should
0-13
contact one maintenance station and have
professionals eliminate the faults and repair.
� The refrigerant gas is heavier than the air and
sink to the ground. Therefore, ensure that any
escaped gas has been spilled out before you carry
out low-position operations.
Smoking, welding or other open fires are prohibited in
the working places with operations of refrigerant. The
refrigerant gas will burn and form one kind of toxic
gas. It is very dangerous to inhale such gas. The gas
formed under high concentration after heating the
refrigerant will emit one kind of pungent odor.
The symptoms might occur after the exposure to the
gas for several hours (might be as long as 24 hours).
Actions taken during the accidents
Inhalation
In the event of doubt about escaped gas, please leave
immediately and move the affected personnel to the
place with fresh air. The vapor of a small amount of
refrigerant R134a will have certain impact, especially
on the nervous system. When the amount is large,
there will be anesthetic effects. In the severe cases,
immediately seek for medical aid.
Skin exposure
In the event of frostbites, wash with warm water. If a
large amount of liquid refrigerants contact the
unprotected skin, the damaged area should be kept
warm with warm water or warm cloth. If the
symptoms continue, immediately seek for medical aid.
Splashing into eyes
Wash with warm water until the stimulation
disappears. Otherwise, immediately seek for medical
aid.
Safety during the operations of energy accumulator
Only professional servicemen are allowed for
operations.
Warning: If the pressure is not reduced before
the system opens, the engine oil will be ejected under
high pressure and it might cause severe personal
injuries.
The pressure of the system should be first relieved
before the energy accumulator is removed from the
machine.
Some energy accumulators will still have pressure
even if removed from the machine, namely the
so-called precharge pressure. Therefore, be very
careful when treating and carrying out operations on
0-14
Fig. 0-9
the energy accumulator.
Before taking any measures for the energy
accumulator, the precharge pressure must be reduced
to the atmospheric pressure.
Do not expose the energy accumulator to the high
temperatures. Do not handle it roughly.
Warning: The discarded energy accumulator
without perforation might still have high pressure. Be
extremely careful during the disposal.
The pressure of the discarded energy accumulator
should be relieved before being crushed so as to avoid
explosion.
Safety issues of the hydraulic system
The hydraulic system in the loader runs at a very high
pressure. To avoid severe personal injuries,
maintaining the hydraulic system in a correct manner
is very important, namely all the personnel contacting
the machine should be very careful and pay close
attention to any defects.
Please abide by the following regulations in order to
avoid accidents.
Overview
� The relief valve should not be adjusted to the
pressure level higher than that recommended by
the manufacturer.
� The expanded hydraulic hose (at the junction for
instance) indicates that it is about to break and
requires the replacement of hose as soon as
possible! Pay attention to the leakage of hydraulic
hose and junctions. Have the hose repaired before
the parts are broken!
� The energy accumulator should be punched
before disposal in case of explosion.
Warning: If the pressure is not reduced before
the system opens, the engine oil will be ejected under
high pressure and it might cause severe personal
injuries.
Pressure relief
After the engine shuts down, the system will have
accumulated pressure left. Prior to loosening or
opening the hose connections of the hydraulic system
or the brake system, the remaining pressure in the
system must be released.
In the case where the engine shuts down, release the
pressure used to lower the energy accumulator of the
lifting arm by moving the lifting lever back and forth
0-15
for several times.
� All the booster tanks/containers should be
carefully opened so as to release the remaining
pressure.
� Only when the pressure of the system is
completely relieved can the joints and
connections of the leaking pipe be checked to see
whether they are fastened.
Warning: The hydraulic hose under high
pressure might cause severe damages. The ejected and
splashed liquid on the naked skin will be very
penetrating.
� In the process of checking leakage, use steel
plates or hard board. Do not check it with hands.
Checking after experiencing fires or high heat
� As one preventive measure, the sealing ring
(O-ring or axle/shaft seal) should be always
regarded as being made of fluorous rubber and
please refer to the part of fluorous rubber.
Warning: Clean up the machine burnt by fire
and avoid splashed water! Therefore, do not use
high-pressure cleaning.
� When the burnt the elements or components
might contact the melt polymer, do not directly
contact them with hands. First wash them with a
large amount of whitewash (a kind of aqua calcis
or suspension liquid).
� Use protective gloves made of thicker rubber and
wear goggles so as to protect your eyes.
� If your skin might contact the burnt fluorous
rubber, please seek for medical aid. The skin
should be treated with hydrofluoric acid burn
cream or similar medicine. The symptoms might
occur a few hours later after directly contacting
the burnt fluorous rubber.
� Discard the protective gloves, cloth and other
objects that might directly contact the burnt
fluorous rubber.
� During the operations, keep well ventilated.
� When the eyes are subjected to irritation,
immediately wash them with running water for at
least 15min. Then seek for medical treatment.
Harm of paint, plastic or rubber to the health
0-16
Work on the paint finish
Do not directly weld or cut the paint surface. All the
paints will be decomposed and produce a large amount
of different substances after being heated. Repeated
exposure to such environment will be very harmful to
health.
The following safety measures must be adopted:
� Polish at least 10cm paint finish around the
welding point or cutting point with abrasive paper
(please use respirator mask).
If the paint finish cannot be polished with sand paper,
it should be removed in other methods, for example,
paint remover.
Note: If the paint finish is to be removed with
the paint remover, you should use an exhaust fan and
properly wear the mask with respirator and the
protective gloves.
� The paint finish of the grinding machine with
high-speed millstone will also be heated; therefore, it
can only be used when equipped with the exhaust fan.
Meanwhile, be sure to wear a mask or other tools for
respiratory protection.
Rubber and plastic
Warning: When the rubber and plastic are
being heated, they will emit substances harmful to
health and environment.
The following safety rules must be observed:
� If no heat insulation measures are taken, no
welding or cutting with the flame projector near
the polyester materials (plastic or rubber) should
be allowed.
� Do not burn the polymeric materials at the time
of scraping them.
� The machine after suffering from fire or high heat
should be carefully treated.
� Always use gloves, goggles and masks, or other
respiratory protection equipment.
Fluorous rubber
Warning: The heated fluorous rubber will
generate fluorine and hydrogen. The inhalation of such
gases will corrode the respiratory tract.
Some sealing elements designed to withstand high
0-17
temperature (i.e. sealing elements in the engine,
transmission, axle, brake, hydraulic motor and
hydraulic pump) are made of fluorous rubber. After
being heated to high temperature, they will generate
hydrogen fluoride and hydrofluoric acid.
Fluoric acid is strongly acidic and corrosive. The
fluoric acid on the skin cannot be washed away and it
will result in severe burns and corrosive injuries. It
will require a long time to get recovered. As a general
principle, the injured issues must be removed with
surgery.
The fluoric acid will remain on the machine
components for a long time (up to a few years) after
the fires.
Note:
Symptoms might occur a few hours later after
contacting the hydrofluoric acid.
In the event of swell, rubedo or burn and suspecting
that such symptoms are caused by the contact with
fluorous rubber subjected to high temperature, seek for
medical advice immediately.
If one machine or one component is subjected to fires
or other intense heat, it should be only treated by the
specially-trained servicemen.
As to operations on all the machines after the fires,
strong rubber gloves and effective protective glasses
should be used.
Warning: The burning of paint parts and
plastic/rubber parts is harmful to the health.
Decontamination
In the event of doubt about the highly heated parts
made of fluorous rubber, thoroughly wash the parts
with plenty of whitewash (a kind of solvent of calcium
hydroxide or suspension liquid). After the
decontamination, wash the gloves in the whitewash
and then have them discarded.
03 Environment
031 Waste treatment
The following steps should be followed in the process
of disposing of rubbish and wastes:
Reuse
It is the best from the perspective of environmental
protection.
Material recycling
Material recycling is a good means of environmental
0-18
protection during the use of new products.
Energy recovery
To burn the inflammable materials as the fuel at the
time of failing to recycle materials is a good treatment
method.
Destruction
This method can be used for hazardous wastes. The
destruction must be carried out at special places.
Deposition
As the worst method from the viewpoint of
environmental protection, the destruction should be
avoided as much as possible.
Storage
It is a temporary measure. Treatment should be
conducted after appropriate recycling technologies are
developed.
Treatment of environmental protection
Always select the most appropriate method for the
environmental protection. If possible, use biochemical
oil for instance.
Always abide by the national and local environmental
regulations.
All the wastes should be handed over to the waste
treatment company authorized by the authorities for
disposal.
Engine oil and liquid
The engine oil or liquid that cannot be reused, for
example, cooling liquid, should be collected by the
airtight container and left with the destruction
department for treatment.
Filter
The engine oil and fuel filter should be drained and
put into the airtight container and then handed over to
the destruction department for treatment.
Refrigerant R134a
Refrigerant R134a including the substances that affect
the greenhouse effects should not be released into the
atmosphere. It should be recycled.
Battery
The battery contains substances harmful to the
environment and corrosive sulfuric acid. It should be
handed over to the recycling department.
Chemicals
Chemicals, paint, glue and cleanser, etc. should be left
with the recycling department for treatment or
destruction.
0-19
Rubber and plastic
Rubber materials and plastic components should not
be burnt. They should be handed over to the recycling
department.
The tires should be treated according to the special
regulations.
Electronic elements
The electrical appliance and electronic wastes, such as
circuit board and bulb, should be handed over to the
recycling department.
Liquid harmful to the environment
Note that whether fuel, engine oil and other liquids are
leaked from the machine.
Take appropriate measures to immediately seal the
leakage and try to eliminate the contamination of the
polluted places.
Engine oil and fuel
In the process of emptying/discharging engine oil/fuel,
be sure to take appropriate measures to prevent
unnecessary splashing. Please use pump or hose at the
places unable to use discharging containers.
Air conditioning equipment
Refrigerant R134a including the substances that affect
the greenhouse effects should not be released into the
atmosphere.
The servicemen treating the refrigerant must get
familiar with the relevant legal regulations of the
country concerned and the international rules.
It is recommended that all the servicemen targeted at
the maintenance of air conditioning should be trained
first. Many countries require these servicemen to carry
out such work with the certificates issued by the
authorities.
032 Work in the pollution environment
When the machine is operating in the polluted
environments or the places harmful to the health,
special equipment should be equipped for operations
in such environments.
After the operations in the polluted environments with
asbestos or other toxic dust, the used cab and engine
air filter must be placed in the airtight plastic bag and
handed over to the destruction department for
treatment.
Decontamination
Carry out decontamination as soon as possible, as
some substances will spread to the environment very
quickly.
Decontamination after leakage/splashing
0-20
Collect the leaked engine oil or fuel with appropriate
absorbing materials, such as absorbent pad.
Be sure to prevent the leaked engine oil/fuel from
being discharged into the sewer with the
rainwater/flood.
The polluted soil and materials on the ground must be
removed and collected in the appropriate containers.
The collected soil and absorbing materials should be
left with the destruction department for treatment.
033 Decontamination after the accidents
If possible, the leakage on the machine should be
sealed.
Isolate the places with leakage with drainage barriers.
Increase absorbing materials, such as absorbing or
sawdust.
Prevent the leaked liquid from being discharged into
the sewer with the rainwater/flood.
Collect the absorbing materials and soil floating layer
and place them into the airtight containers and
transported to the destruction department.
Decontamination after the fire
First put out the fire.
Dispose according to the decontamination measures
after the accidents.
Note: Pay close attention to the toxicity of some
substances after being caught on fire.
1-1
Contents
1.
General ...........................................................................
....................................... 1-1
11 Precautions before
service ...........................................................................
....... 1-1
12
Specification .....................................................................
.................................... 1-3
121 Specification and
torque ............................................................................
.... 1-3
122 Unit
conversion ........................................................................
....................... 1-5
13
Mark ..............................................................................
....................................... 1-7
14 Service
criterion .........................................................................
.......................... 1-7
141 Visual inspection or touching
determination ............................................... 1-7
142 Determination of measurement
method ....................................................... 1-8

1-1
1. General
11 Precautions before service
Park the loader at the service location.
Hang up warning sign.
In case of service, put the warning sign near the start
button so as to prevent people from starting the
engine.
Accessory preparation
Carry out the service and replacement with repairable
part specified by our company.
Oil preparation
Select oil specified in this manual based on
environment temperature.
Use specified oil.
Keep the oil tank clean and use the specified oil.
Keep the loader clean.
Keep the loader clean, especially the oil injection
parts including oil cup and oil filler so as to prevent
the entrance of impurities.
Pay attention to high-temperature oil and
high-temperature coolant
When the engine stops, it is dangerous to discharge
the high-temperature oil and the coolant or take down
the oil filter. The above operation can only be carried
out after the engine cools down completely. The
proper temperature of oil to be discharged is within
20~40?. If lower than this temperature, the oil can
only be discharged after being heated to this
temperature.
Check oil and oil filter
After replacing oil or oil filter, check the discharged
oil and the replaced oil filter. Contact the service
personnel if finding a large number of metal particles
or other impurities.
Fuel coarse filter
Do not take down the fuel coarse filter when filling
the fuel.
Replacement of oil
Replace the oil at clean place so as to ensure the oil
not polluted when replaced.
1-2
Welding guidance
� Turn off the engine start switch and remove the
battery cable.
� The distance between the welding area and the
earthing cable should be above 1 m.
� Avoid implementing the welding near the seal
ring and the bearing.
� Do not weld the pipeline or tank with oil fluid.
Fire prevention
Clean parts with non-flammable detergent or
ordinary diesel and keep away from spark or
firework.
Sealing element
To replace O-shape ring or sealing gasket, clean the
sealing surface firstly and then install the new
O-shape ring or the sealing gasket into the accurate
position.
Check frame
After shoveling and transporting aggregated rocks for
a long time, check whether the frame is damaged and
whether connecting bolts and nuts of components are
loosened and damaged.
Precautions for cleaning the loader
� The engine should be cleaned after cooling
down completely.
� Do not spray water to the electrical apparatus
element.
Check in rain and snow environments
After the operation in rain and snow environments,
clean the loader immediately and apply lubricating
oil and rust-preventative oil at more components.
Dusty environment
Pay attention to following points when the loader
operates in dusty environment:
� Usually check and clean the air filter to avoid
the blocking.
� Usually clean the radiator to avoid the blocking.
� Usually clean and replace the fuel filter.
� Clean the electric installation, especially the
start motor and the generator, to prevent the
accumulated dust from affecting the radiation.
Refer to the Operation and Maintenance Instructions
1-3
of Diesel Engine attached with the loader for detailed
replacement and maintenance of air filter.
12 Specification
121 Specification and torque
Table 1 Tightening torque of commercial bolt
Strength
grade of
bolt
Yield
strength
N/ mm2
Nominal diameter of bolt mm
6 8 10 12 14
Tightening torque N�m
8.8 640 9~12 22~30 45~59 78~104 124~165
10.9 900 13~16 30~36 65~78 110~130 180~210
12.9 1080 16~21 38~51 75~100 131~175 209~278
Strength
grade of
bolt
Yield
strength
N/ mm2
16 18 20 22 24
8.8 640 193~257 264~354 376~502 521~683 651~868
10.9 900 280~330 380~450 540~650 740~880 940~1120
12.9 1080 326~434 448~597 635~847 864~1152 1098~1464
Strength
grade of
bolt
Yield
strength
N/ mm2
27 30 33 36 39
10.9 900 1400~1650 1700~2000 2473~3298 2800~3350 4111~5481
12.9 1080 1606~2142 2181~2908 2968~3958 3812~5082 4933~6577
Table 1-2 Tightening torque table of bolts used to connect cast iron or aluminum
Bolt grade and torque
Bolt specification
8.8 10.9
Torque(N�m) Torque(N�m)
Cast iron Aluminum Cast iron Aluminum
M8 20~25 15~20 28~33 15~20
M10 45~50 25~30 55~60 25~30
M12 70~80 50~55 100~105 50~55
M14 110~125 80~90 150~165 80~90
M16 160~180 120~140 220~240 120~140
M18 205~230 165~180 295~320 165~180
1-4
Table 1-3 Tightening torque of joint body
Joint with copper seal gasket or seal taper thread Joint with O-shape seal ring
Joint specification Tightening torque N�m Joint specification
Tightening torque
N�m
M14, G1/4 34�5 M12�1.5 35�3.5
M18, G3/8 73�10 M14�1.5 45�4.5
M20, G1/2 93�10 M16�1.5 55�5.5
M24 142�20 M18�1.5 70�7.0
M27, G3/4 205�30 M20�1.5 80�8.0
M33, G1 421�49 M22�1.5 110�10
M42 872�98 M27�2.0 170�17
M30 320�40 M33�2.0 310�31
Table 1-4 Tightening torque of 24� taper seal
Tightening torque of 24�taper seal pipe joint nut
Specification Tightening torque (N�m)
M12�1.5 20�5
M14�1.5 30�5
M16�1.5 35�5
M18�1.5 45�5
M20�1.5 50�5
M22�1.5 65�10
M24�1.5 70�10
M26�1.5 85�10
M30�2 115�15
M36�2 145�15
M42�2 210�20
Table 1-5 Tightening torque of hinged bolt
Thread specification Tightening torque (N�m)
M10�1 25~35
M12�1.5 60~75
M14�1.5 80~100
M16�1.5 105~115
M18�1.5 20~130
1-5
M22�1.5 140~155
M24�1.5 160~180
M27�2 190~230
M33�2 270~320
Table 1-6 Length
Unit Centimeter Meter Kilometer Inch Foot Yard Mile
Centimeter 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006
Meter 100 1 0.001 39.37 3.2808 1.0936 0.00062
Kilometer 100000 1000 1 39370.7 3280.8 1093.6 0.62137
Inch 2.54 0.0254 0.000025 1 0.08333 0.02777 0.000015
Foot 30.48 0.3048 0.000304 12 1 0.3333 0.000189
Yard 91.44 0.9144 0.000914 36 3 1 0.000568
Mile 160930 1609.3 1.6093 63360 5280 1760 1
1 millimeter=0.1 centimeter 1 micrometer=0.001 millimeter
Table 1-7 Area
Unit cm2 m2 km2 Acre ft2 yd2 in2
cm2 1 0.0001 - 0.000001 0.001076 0.000012 0.155000
m2 10000 1 0.000001 0.01 10.764 1.1958 -
km2 - 1000000 1 10000 1076400 1195800 -
Acre 0.01 100 0.0001 1 1076.4 119.58 -
ft2 - 0.092903 - 0.000929 1 0.1111 144.000
yd2 - 0.83613 - 0.008361 9 1 1296.00
in2 6.4516 0.000645 - - 0.006943 0.000771 1
1 hectare=100 acre 1 mile2=259 hectare=2.59 km2
Table 1-8 capacity/volume
Unit cm3 m3 dm3 in3 ft3 yd3
Milliliter 1 0.000001 0.001 0.061024 0.000035 0.000001
Liter 1000000 1 1000 61024 35.315 1.30796
L 1000 0.001 1 61.024 0.035315 0.001308
in3 16.387 0.000016 0.01638 1 0.000578 0.000021
ft3 28316.8 0.028317 28.317 1728 1 0.03704
122 Unit conversion
1-6
yd3 764529.8 0.76453 764.53 46656 27 1
1 gallon(American system)=3785.41 cm3=231 in3=0.83267 gallon(British system)
Table 1-9 Weight
Unit g kg mt Ounce Ib.(pound)
g 1 0.001 0.000001 0.03527 0.0022
kg 1000 1 0.001 35.273 2.20459
mt 1000000 1000 1 35273 2204.59
ounce 28.3495 0.02835 0.000028 1 0.0625
Ib (pound) 453.592 0.45359 0.000454 16 1
1 t(metric system)=1.1023 t(American system)=0.9842 t(British system)
Table 1-10 Pressure
Unit kip/cm2 Bar Pa=N/m2 Kpa Lbf/in2 Lbf/ft2
kip/cm2 1 0.98067 98066.5 98.0665 14.2233 2048.16
Bar 1.01972 1 100000 0.001 0.00015 0.02086
Pa=N/m2 0.00001 0.001 1 0.001 0.00015 0.02086
Kpa 0.01020 0.01 1000 1 0.14504 20.886
Lbf/in2 0.07032 0.0689 6894.76 6.89476 1 144
Lbf/ft2 0.00047 0.00047 47.88028 0.04788 0.00694 1
kg/cm2=735.56 dry measure (mmHg) =0.96784 barometric pressure
Table 1-11 Unit description
Unit Abbreviation
Newton meter N�m
Kilopound meter kpm
Kilopascal kPa
Megapascal MPa
Kilowatt kW
Kilojoule kj
Thermal unit in British system Btu
Calorie ca
1-7
13 Mark
To emphasize the importance of safety and quality,
make following marks.
Table 1-12
Mark Item Remark
Safety
During the operation, pay special attention to safety.
When carrying out the operation, pay special attention to
safety because internal pressure exists.
Note
During the operation, pay special attention to technical
requirements and ensure the operation quality in conformity
with standards.
Weight
Weight or assembling method of component or device. Pay
attention to selecting load lifting device and the posture
during the operation.
Tightening
torque
During the assembly, pay special attention to the tightening
torque of components
Coating The position needs to be coated with adhesive and grease.
Oil and
water
Fill certain amount of oil, water and fuel.
Discharge
The place where oil or water is discharged and the discharge
amount
14 Service criterion
141 Visual inspection or touching
determination
1. Parts with severe bump, crack, breakage and loss
of function should not be used any more.
2. Oil seal, scraper seal, O-shape ring and seal
gasket disassembled due to leakage, poor
reliability and short life time for reuse should not
be used continuously.
3. Bolt, nut, washer, plug screw and pipe joint with
serious corrosion, un-tightened and damaged
thread, excessive wear and slipping should not be
used continuously.
4. Locking steel wire used to connect bolt should
not be used continuously after being
1-8
disassembled.
5. Bearing not turned flexibly by hand, with cracked
components, worn raceway and damaged ball
should not be used continuously.
6. Gear or spline with crack, sheeting, damage and
excessive wear in teeth should not be used
continuously.
7. Shell with crack and crack, wear, oval and
sheeting in shell bearing mounting hole and shell
thread not tightened normally should not be used
continuously.
8. Bearing seat and oil seal seat with crack, wear,
oval, damage and sheeting in fitting surface/seam
allowance should not be used continuously.
9. Pin with serious wear, damage and crack should
not be used continuously.
10. Implement the primary determination by visual
inspection and smelling. The hydraulic oil should
be replaced if following conditions appear during
use and inspection: milk white, acid smell, yellow
or muddy oil.
142 Determination of measurement
method
Visual inspection or touching cannot be used for
determination, the measurement determination can be
adopted.
Table 1-13
Type of part Inspection item
Criteria Measure for
out of
tolerance
Dimension
(tolerance)
Allowable limit
Bearing
Internal diameter
tolerance
About 0~-0.02 +0.02
Replacement
External diameter
tolerance
About 0~-0.02 -0.04
Gear
Wear in gear
thickness
About 0~0.10
12% of reference circle
gear thickness
(usually within 1.2~1.4)
Replacement
Ordinary
components
External diameter
for ordinary
matching
Tolerance is
marked as T
Recommendation: less
than lower limit 0.3T
Replacement
Internal diameter for
ordinary matching
Tolerance is
marked as T
Recommendation: larger
than upper limit 0.3T
Multiple unit
Fit clearance
between valve
>0.02 Replacement
1-9
valve element and valve
opening
Steering gear
Fit clearance
between valve
element and valve
sleeve
>0.02 Replacement
Stator and rotator >0.08 Replacement
Single
stabilizer
valve
Fit clearance
between valve
element and valve
body
>0.02 Replacement
Priority valve
Fit clearance
between valve
element and valve
body
>0.02 Replacement
?????????
?
Table of Contents
2 Engine
System ............................................................................
................................................... 2-1
21 Key parameters of engine
maintenance .......................................................................
................... 2-1
22 Detection range and use steps of engine detection
tools ................................................................. 2-2
221 WP6G125E332 series engine
detection .........................................................................
....... 2-2
222 YC6J125-T300 series engine
detection .........................................................................
....... 2-3
23 Engine failure diagnosis
codes .............................................................................
............................. 2-5
231 WP6G125E332 series engine failure diagnosis
codes ......................................................... 2-5
232 YC6J125-T300 series engine failure diagnosis
codes .................................................................. 2-19
26 Engine failure diagnosis
code ..............................................................................
........................... 2-44
?????????
2-1
2 Engine System
21 Key parameters of engine
maintenance
Engine model
Engine rated
speed
Engine
idle speed
Air inlet
valve
clearance
Air exhaust
valve clearance
Engine oil
pressure (rated
speed)
WP6G125E332 2200r/min 750�30 0.2 mm 0.3 mm 0.3-0.6MPa
YC6J125-T300 2200r/min 750�30 0.4�0.05mm 0.45�0.05mm 0.3-0.6MPa
Table 1 Key parameters of engine
This table is for reference only, specific complete engine is subject to parameters
on engine
nameplate!
?????????
2-2
Figure 1 Position of detection port of
three-stage Weichai engine
Figure 2 Special detection tools for
Weichai three-stage engine
22 Detection range and use steps of
engine detection tools
221 WP6G125E332 series engine detection
Detection by the use of detector
Weichai WP6G125E332 engine equipped in three-stage
machine models adopts electronically controlled
high-pressure common-rail technology, and has
characteristics of high injection pressure and accurate
control. The engine can be detected by the use of special
detection tools for Weichai, to be more convenient and
accurate!
Part name No. Figure
DiagSmar 612600900287
?????????
2-3
Figure 3 Yuchai engine detection port
WP6G125E332 engine detection steps
1) Place the loader on the maintenance location, put
the bucket on the ground, and shut down the engine.
2) Dismantle cover of storage box on the right side of
the cab, and connect diagnostic tool to failure diagnosis
port, and connect the other side of the diagnostic tool to
a computer.
3) Turn start key, switch on power of the overall
machine, and take a test.
4) See diagnosis instructions for specific diagnosis
methods and failure codes.
(Failure codes occurring during the detection will be
specified in the next chapter)
222 YC6J125-T300 series engine detection
When the engine encounters abnormity or failure, we
need to detect various sensors of the engine, so as to
distinguish engine failure.
Detection by the use of special diagnostic unit
Controller (ECU) of Yuchai YC6J non-road state III
series electronic control diesel engine has failure
self-diagnosis function. In case of detecting a failure, it
will generate corresponding failure code information,
and store it in ECU memory. In aftermarket, failure code
information in ECU memory is generally read via
special diagnostic unit or on-board failure indicator
lamp (flash code).
?????????
2-4
Figure 4 Special diagnostic unit for
Yuchai
YC6J125-T300 three-stage series engine detection
steps
1) Place the overall vehicle on the maintenance
location, put the bucket on the ground, shut down the
engine, and press the parking brake button.
2) Dismantle cover of storage box on the right side of
the cab, and connect wiring harness of diagnostic unit to
failure diagnosis port of the engine.
3) See instructions of diagnostic unit for specific
diagnosis methods.
(Failure codes occurring during the detection will be
specified in the next chapter)
Part name No. Figure
HED-ST4.1.2
6430001350
?????????
2-5
23 Engine failure diagnosis codes
231 WP6G125E332 series engine failure
diagnosis codes
Code DFC name Fault description
DTC
for
J1939
SPN
DTC
for
J1939
FMI
010 DFC_APP1SRCMax
Voltage of accelerator pedal 1
exceeds maximum threshold
91 3
011 DFC_APP1SRCMin
Voltage of accelerator pedal 1 less
than minimum threshold
91 4
012 DFC_APP12Plaus
Incredible double signal
relationship between accelerator
pedal 1 and accelerator pedal 2
520252 2
013 DFC_APP2SRCMax
Voltage of accelerator pedal 2
29 3
014 DFC_APP2SRCMin
Voltage of accelerator pedal 2 less
29 4
015 DFC_APP21Plaus
Incredible 1/2 signal relationship
between accelerator pedal 2 and
accelerator pedal 1
1 0
019 DFC_AccPedBrkPlaus
Incredible accelerator and braking
signal
91 7
020 DFC_AirHtStickOn Air intake heater stuck-open fault 2898 7
021 DFC_ArHt1SCBat Air intake heater short-to-power 2898 3
022 DFC_ArHt1SCGnd Air intake heater short-to-ground 2898 4
023 DFC_ArHt1OpenLoad Air intake heater in open load 2898 5
024 DFC_BPSCDSRCMax
Voltage of air intake heater
102 3
025 DFC_BPSCDSRCMin
Voltage of air intake heater less
102 4
026 DFC_BPSCDNPL
Incredible air intake pressure
sensor signal
1 0
027 DFC_BattCDSRCMax
Original value of battery voltage
168 3
028 DFC_BattCDSRCMin
Original value of battery voltage
less than minimum threshold
168 4
029 DFC_BrkCDSig Braking signal error 597 19
?????????
2-6
030 DFC_BrkCDNpl Incredible braking signal 597 2
031 DFC_CSLpCDSCBat
Cold start indicator lamp
short-to-power
626 3
032 DFC_CSLpCDSCGnd
Cold start indicator lamp
short-to-ground
626 4
033 DFC_CSLpCDNoLoad
Cold start indicator lamp in open
load
626 5
034 DFC_CTSCDSRCMax
Voltage of coolant temperature
sensor exceeds maximum
threshold
110 3
035 DFC_CTSCDSRCMin
Voltage of coolant temperature
sensor less than minimum
threshold
110 4
036 DFC_CTSCDNpl
Incredible coolant temperature
and engine oil temperature signal
110 2
037 DFC_ClgAbsTst
Coolant temperature has not
reached minimum within certain
period of time
110 17
038 DFC_Clg_DynTst
Increasing amplitude of coolant
temperature has not reached
minimum within certain period of
time
110 18
039 DFC_ConvCDNpl Incredible clutch state signal? 598 2
040 DFC_TECUSRCMax
Voltage of ECU temperature
threshold
1136 3
041 DFC_TECUSRCMin
Voltage of ECU temperature
threshold
1136 4
042 DFC_ECBtCDPlausLock
Start beneath vehicle/stop button
gets stuck
520203 5
043 DFC_EngMBackUpLimp
Only camshaft signal, enter limp
home state
4203 13
044 DFC_EngMCaSPer Camshaft cycle error 4201 2
045 DFC_EngMCaSSyn Camshaft synchronization error 4201 11
046 DFC_EngMCaS1NoSig Camshaft signal missing 4201 12
047 DFC_EngMCaSSynCrS
Camshaft and crankshaft
synchronization error
4201 13
048 DFC_EngMCrS1NoSig Crankshaft signal missing 4203 12
049 DFC_EngMCrSToothNr Crankshaft tooth number error 4203 4
050 DFC_EngMCrSSyn Crankshaft synchronization error 4203 3
?????????
2-7
051 DFC_EngMCrSToothPer Crankshaft tooth cycle error 4203 2
052 DFC_EngMOfsCaSCrSSRCMax
Crankshaft and camshaft signal
deviation exceeds threshold
4201 14
053 DFC_EngPrtOvrSpd Engine over speed 1769 11
054 DFC_EngSpdSCBat
Engine speed signal
short-to-power
1623 3
055 DFC_EngSpdSCGnd
Engine speed signal
short-to-ground
1623 4
056 DFC_EngSpdOpenLoad Engine speed signal in open load 1623 5
057 DFC_ExFlCDSCBat
Exhaust brake butterfly valve
short-to-power
520208 3
058 DFC_ExFlCDSCGnd
Exhaust brake butterfly valve
short-to-ground
520208 4
059 DFC_ExFlCDOpenLoad
Exhaust brake butterfly valve in
open load
520208 5
062 DFC_FanCD1SCBat
Fan actuator (PWM wave)
short-to-power
4815 9
063 DFC_FanCD1SCGnd
Fan actuator (PWM wave)
short-to-ground
4815 10
064 DFC_FanCD1OpenLoad
Fan actuator (PWM wave) in
open load
4815 7
065 DFC_FanCD2SCBat
Fan actuator (digital signal)
short-to-power
4815 3
066 DFC_FanCD2SCGnd
Fan actuator (digital signal)
short-to-ground
4815 4
067 DFC_FanCD2OpenLoad
Fan actuator (digital signal) in
open load
4815 5
068 DFC_FanCDSpMax
Cooling fan speed exceeds
maximum threshold
1639 3
069 DFC_FanCDSpMin
Cooling fan speed less than
minimum threshold
1639 4
079 DFC_FlSysWtDet
Water-in-oil sensor detects water
in oil
520264 11
080 DFC_InjVlvCyl1ERR Oil atomizer error of cylinder 1 1413 11
081 DFC_InjVlvCyl1SCB
Oil atomizer of cylinder 1
short-to-power
1413 3
082 DFC_InjVlvCyl1SCG
short-to-ground
1413 7
?????????
2-8
short-to-power
1414 3
short-to-ground
1414 7
short-to-power
1415 3
short-to-ground
1415 7
short-to-power
1416 3
short-to-ground
1416 7
short-to-power
1417 3
short-to-ground
1417 7
short-to-power
1418 3
short-to-ground
1418 7
098 DFC_FrmMngETC1TO ETC1 message receiving delay 522022 19
099 DFC_FrmMngETC1DLC ETC1 message data length error 522022 14
100 DFC_FrmMngRxCCVSTO RxCCVS message receiving delay 522030 19
101 DFC_FrmMngRxCCVSDLC
RxCCVS message data length
error
522030 14
102 DFC_FrmMngDEC1TO DEC1 message receiving delay 522062 19
103 DFC_FrmMngETC7TO ETC7 message receiving delay 522063 19
104 DFC_FrmMngAppMaxErr
Bus receiving throttle signal
overruns
522064 19
105 DFC_FrmMngRemAppMaxErr
Bus receiving remote throttle
signal overruns
522065 19
106 DFC_FrmMngTSC1PEDLC
CAN-TOTSC1PE data volume
error
522039 14
107 DFC_FrmMngTSC1PETO
CAN-TOTSC1PE communication
error
522039 19
?????????
2-9
108 DFC_FrmMngTSC1TEDLC
CAN-TOTSC1TE data volume
error
522040 14
109 DFC_FrmMngTSC1TETO CAN-TOTSC1TE timeout error 522040 19
110 DFC_FrmMngTSC1TRDLC
CAN-TOTSC1TR data volume
error
522041 14
111 DFC_FrmMngTSC1TRTO CAN-TOTSC1TR timeout error 522041 19
112 DFC_FrmMngTSC1VEDLC
CAN-TOTSC1VE data volume
error
522042 14
113 DFC_FrmMngTSC1VETO CAN-TOTSC1VE timeout error 522042 19
114 DFC_FrmMngTSC1VRDLC
CAN-TOTSC1VR data volume
error
522043 14
115 DFC_FrmMngTSC1VRTO CAN-TOTSC1VR timeout error 522043 19
116 DFC_FrmMngTimeDateDLC
CAN-TOTimeDate data volume
error
522034 14
117 DFC_FrmMngTimeDateTO CAN-TOTimeDate timeout error 522034 19
118 DFC_GearbxIncMax Too long gear lifting interval 520221 2
119 DFC_Gen1FlSysWtSCBat
(Water-in-oil indicator lamp)
indicator lamp 1 power
short-circuit
624 3
120 DFC_Gen1FlSysWtSCGnd
indicator lamp 1 short-to-ground
624 4
121 DFC_Gen1FlSysWtOpenLoad
indicator lamp 1 in open load
624 12
122 DFC_HWEMonEEPROMRdErr EEPROM reading error 2802 14
123 DFC_HWEMonEEPROMWrtErr EEPROM writing error 2802 12
124 DFC_IATSCDSRCMax
Voltage of air intake temperature
threshold
105 3
125 DFC_IATSCDSRCMin
Voltage of air intake temperature
threshold
105 4
126 DFC_stFuelFoul Fuel filter replacement 520289 11
127 DFC_FrmMngEBC1TO
CAN receiving frame EBC1
timeout error
522013 19
128 DFC_FrmMngEBC1DLC
CAN receiving frame EBC1 data
length error
522013 14
129 DFC_stAirFltFoul Air filter replacement 107 7
130 DFC_stOil Engine oil replacement 99 11
131 DFC_InjVlvCyl1ALSSCBat
Low end of oil atomizer1
short-to-power
1413 16
?????????
2-10
132 DFC_InjVlvCyl1ALSSCGnd
Low end of oil atomizer 1
short-to-ground
1413 18
133 DFC_InjVlvCyl1AHSSCBat
High end of oil atomizer1
short-to-power
1413 15
134 DFC_InjVlvCyl1AHSSCGnd
short-to-ground
1413 17
135 DFC_InjVlvCyl1SCL
short-to-low end
1413 4
136 DFC_stOilFlt Oil filter replacement 99 7
137 DFC_InjVlvCyl1BNoLoad Atomizer1 in open load 1413 5
short-to-power
1414 16
short-to-ground
1414 18
short-to-power
1414 15
High end of oil atomizer 2
short-to-ground
1414 17
short-to-low end
1414 4
short-to-power
1415 16
short-to-ground
1415 18
short-to-power
1415 15
short-to-ground
1415 17
short-to-low end
1415 4
short-to-power
1416 16
short-to-ground
1416 18
short-to-power
1416 15
short-to-ground
1416 17
?????????
2-11
short-to-low end
1416 4
short-to-power
1417 16
short-to-ground
1417 18
short-to-power
1417 15
short-to-ground
1417 17
short-to-low end
1417 4
161 DFC_InjNDiafactor
Fault rate of orifice abrasion
within 0-20%
520210 13
162 DFC_InjVlvCyl5BNoLoad Atomizer 5 in open load 1417 5
short-to-power
1418 16
short-to-ground
1418 18
short-to-power
1418 15
short-to-ground
1418 17
short-to-low end
1418 4
168 DFC_InjNDia
exceeds 20%
520210 14
169 DFC_InjVlvCyl6BNoLoad Atomizer 6 in open load 1418 5
171 DFC_InjIniAsicErr
INJ driver IC initialization version
error
507 9
172 DFC_InjIniEnaErr
INJ driver IC initialization error
after power-on
507 10
173 DFC_InjPwrDrvDis
INJ driver IC repeated power-on
error
507 11
175 DFC_MFLvCrCtlMode
Unreliable cruise signal (void
switch combination)
596 2
179 DFC_MSSCDSRCMax
Voltage of polymorphic switch
exceeds maximum
976 3
180 DFC_MSSCDSRCMin
Voltage of polymorphic switch
exceeds minimum
976 4
?????????
2-12
181 DFC_MSSCDNpl
Incredible polymorphic switch
signal
976 19
182 DFC_NetMngCANAOff CAN communication error 522000 12
183 DFC_OLSCDSRCMax
Voltage of engine oil level sensor
exceeds maximum
98 3
184 DFC_OLSCDSRCMin
Voltage of engine oil level sensor
less than minimum
98 4
185 DFC_OLSCDNpl
Unreliable engine oil level sensor
signal
98 2
186 DFC_OPSCDSRCMax
Voltage of engine oil pressure
100 16
187 DFC_OPSCDSRCMin
Voltage of engine oil pressure
100 18
188 DFC_OPSCDNpl
Too high oil pressure or unreliable
oil temperature signal
100 15
189 DFC_OPSCDLow Too low oil pressure 100 17
190 DFC_OTSCDSRCMax
Voltage of engine oil temperature
threshold
175 3
191 DFC_OTSCDSRCMin
Voltage of engine oil temperature
threshold
175 4
192 DFC_OTSCDSRCNPL
Incredible engine oil temperature
and coolant temperature signal
1 0
193 DFC_OTSCD1Npl
Incredible engine oil temperature
sensor signal
175 15
194 DFC_SSpMon1SRCMax
Voltage of sensor power supply 1
3509 3
195 DFC_SSpMon1SRCMin
3509 4
3510 3
3510 4
3511 3
3511 4
200 DFC_T50CDTimeOut T50 turn-on timeout 520253 11
201 DFC_VSSCD1Max
Vehicle speed 1 exceeds
maximum threshold
84 0
?????????
2-13
202 DFC_VSSCD1Npl
Incredible vehicle speed 1,
fuel-injection quantity and engine
speed
84 2
203 DFC_VSSCD3Max
Pulse width of vehicle speed 3
signal exceeds maximum
threshold
1624 3
204 DFC_VSSCD3Min
Pulse width of vehicle speed 3
signal less than minimum
threshold
1624 4
205 DFC_VSSCD3Sig
Averaging period of vehicle speed
signal less than threshold
1624 8
206 DFC_WrnSCBat Alarm light short-to-power 520250 3
207 DFC_WrnSCGnd Alarm light short-to-ground 520250 4
208 DFC_WrnOpenLoad Alarm light in open load 520250 5
209 DFC_ECRVlvSCBat
In-cylinder exhaust brake valve
short-to-ground
571 3
210 DFC_ECRVlvSCGnd
In-cylinder exhaust brake valve
short-to-power
571 4
211 DFC_ECRVlvOpenLoad
In-cylinder exhaust brake valve in
open load
571 5
212 DFC_HpTst High voltage test error 520223 20
213 DFC_MeUnCDNoLoad Fuel gauge in open load 1442 7
214 DFC_MeUnCDSCBat Fuel gauge short-to-power 1442 9
215 DFC_MeUnCDSCGnd Fuel gauge short-to-ground 1442 10
216 DFC_PRVOpn
Common-rail decompression
valve opened
520241 14
217 DFC_PRVTiOpnMax
Opening time of pressure limiting
valve exceeds maximum
520241 0
218 DFC_PRVMonPresShck
Common-rail decompression
valve not opened during pressure
fluctuation
523470 21
219 DFC_PRVMonwearNumMax
Opening times of common-rail
decompression valve exceeds
maximum times specified in
technical requirements
520241 11
220 DFC_RailCDSRCMax
Voltage of rail pressure sensor
157 3
221 DFC_RailCDSRCMin
157 4
222 DFC_RailCDOfsTstSRCMax
exceeds maximum deviation
157 15
?????????
2-14
223 DFC_RailCDOfsTstSRCMin
less than minimum deviation
157 17
224 DFC_RailMeUn0OfsMax
Rail pressure deviation exceeds
maximum threshold
520243 16
225 DFC_RailMeUn1OfsMaxQHi
maximum threshold and
fuel-injection quantity overruns
520243 0
226 DFC_RailMeUn2OfsMinQLo
Rail pressure deviation less than
minimum threshold and
fuel-injection quantity less than
threshold
520243 1
227 DFC_RailMeUn3PkLo
Peak value of rail pressure less
520243 20
228 DFC_RailMeUn4PkHi
Peak value of rail pressure
520243 21
229 DFC_RailMeUn6Rmp Rail pressure decreases too fast 520243 18
230 DFC_RailMeUn7MeUnSetPlaus
Incredible setting of fuel capacity
metering unit in overspeed mode
520243 23
231 DFC_RailMeUn8LowIdlMeUnMontr
Monitor error of fuel capacity
metering unit at low idle speed
520243 24
232 DFC_RailMeUn10MeUnQHi
Fuel capacity in fuel gauge
exceeds threshold
520243 7
233 DFC_RailMeUn12OfsMaxMeUnQHi
threshold and fuel capacity in fuel
gauge exceeds threshold
520243 5
234 DFC_StrtCDLSSCBat
Low end of cranking motor relay
short-to-power
1675 3
235 DFC_StrtCDLSSCGnd
short-to-ground
1675 4
236 DFC_StrtCDNoLoad
in open load
1675 5
237 DFC_CTSCDOvrTemp
Water temperature sensor operates
smoothly but water temperature
exceeds threshold
110 15
238 DFC_Brk1SwtCrCtlRls
Cruise control inhibition error
before stepping on brake pedal
597 7
239 DFC_Brk1SwtCrCtllmp
Identification error of cruise
control requirement keeps trouble
light on
597 11
240 DFC_RmtApp1SRCMax
Output voltage of remote
accelerator pedal 1 exceeds
maximum
520277 3
?????????
2-15
241 DFC_RmtApp1SRCMin
accelerator pedal 1 less than
minimum
520277 4
242 DFC_RmtApp2SRCMax
accelerator pedal 2 exceeds
maximum
520278 3
243 DFC_RmtApp2SRCMin
accelerator pedal 2 less than
minimum
520278 4
244 DFC_WtLvSRClMax
Original voltage of water-in-oil
threshold
520264 3
245 DFC_WtLvSRClMin
Original voltage of water-in-oil
threshold
520264 4
246 DFC_CoVehPrfmLimAct
OBD torque limiting activation
error
520198 11
247 DFC_FrmMngEBC2DLC Data length error 522015 14
248 DFC_FrmMngEBC2TO Time-out error 522015 19
249 DFC_MisFireCyl1 Cylinder 1 catches fire 1323 3
261 DFC_MisFireTot
Total number of cylinders on fire
overruns
1322 3
262 DFC_STGPRSLCKMOD1
Lock vehicle and execute vehicle
lock mode 1
522014 1
263 DFC_STGPRSLCKMOD2
Lock vehicle and execute vehicle
lock mode 2
522014 2
264 DFC_InjDiaQOC
exceeds 20% for 20 consecutive
times
520210 16
?????????
2-16
265 DFC_InjDiaQOCfactor
ranges from 5% to 20% for
consecutive500ms
520210 15
271 DFC_ComEngSpdUnAvail Unavailable engine speed signal 190 2
272 DFC_ComCTSCDUnAvail
Unavailable water temperature
signal
1 0
329 DFC_FrmMngTSC1DRDLC
CAN receiving frame TSC1DR
data volume error
522038 14
330 DFC_FrmMngTSC1DRTO
CAN receiving frame TSC1DR
timeout error
522038 19
331 DFC_FrmMngTSC1ARDLC
CAN receiving frame TSC1AR
data volume error
522036 14
332 DFC_FrmMngTSC1ARTO
CAN receiving frame TSC1AR
data timeout error
522036 19
333 DFC_FrmMngTSC1DEDLC
CAN receiving frame TTSC1DE
data volume error
522037 14
334 DFC_FrmMngTSC1DETO
CAN receiving frame TSC1DE
timeout error
522037 19
335 DFC_FrmMngTSC1AEDLC
CAN receiving frame TSC1AE
data volume error
522035 14
336 DFC_FrmMngTSC1AETO
CAN receiving frame TSC1AE
timeout error
522035 19
337 DFC_FrmMngEngTemp2DLC
CAN receiving frame EngTemp2
data volume error
522020 14
338 DFC_FrmMngEngTemp2TO
CAN receiving frame EngTemp2
timeout error
522020 19
339 DFC_FrmMngETC2DLC
CAN receiving frame ETC2 data
volume error
522023 14
340 DFC_FrmMngETC2TO
CAN receiving frame ETC2
timeout error
522023 19
341 DFC_FrmMngERC1DRDLC
CAN receiving frame ERC1DR
data volume error
522021 14
342 DFC_FrmMngERC1DRTO
CAN receiving frame ERC1DR
timeout error
522021 19
343 DFC_FrmMngAT1OGC2DLC
CAN receiving frame AT1OGC2
data volume error
522011 14
344 DFC_FrmMngAT1OGC2TO
timeout error
522011 19
345 DFC_FrmMngAT1OGC1DLC
data volume error
522010 14
?????????
2-17
346 DFC_FrmMngAT1OGC1TO
timeout error
522010 19
347 DFC_FrmMngAT1IGC2DLC
CAN receiving frame AT1IGC2
data volume error
522008 14
348 DFC_FrmMngAT1IGC2TO
timeout error
522008 19
349 DFC_FrmMngAT1IGC1DLC
data volume error
522007 14
350 DFC_FrmMngAT1IGC1TO
timeout error
522007 19
351 DFC_FrmMngAT1IG1DLC
CAN receiving frame AT1IG1
data volume error
522006 14
352 DFC_FrmMngAT1IG1TO
CAN receiving frame AT1IG1
timeout error
522006 19
353 DFC_FrmMngAT1OG1DLC
CAN receiving frame AT1OG1
data volume error
522009 14
354 DFC_FrmMngDM1DCUDLC
CAN receiving frame DM1DCU
data volume error
522012 14
355 DFC_FrmMngDM1DCUTO
CAN receiving frame DM1DCU
data volume error
522012 19
356 DFC_FrmMngDM19DLC
CAN receiving frame DM19 data
volume error
522060 14
357 DFC_FrmMngDM19TO
CAN receiving frame DM19
timeout error
522060 19
358 DFC_FrmMngETC7DLC
CAN receiving frame ETC7 data
volume error
522063 14
359 DFC_FrmMngDEC1DLC
CAN receiving frame DEC1 data
volume error
522062 14
360 DFC_FrmMngAMCONDLC
CAN receiving frame AMCON
data volume error
522050 14
361 DFC_FrmMngAMCONTO
CAN receiving frame AMCON
timeout error
522050 19
362 DFC_FrmMngHRVDDLC
CAN receiving frame HRVD data
volume error
522051 14
363 DFC_FrmMngHRVDTO
CAN receiving frame HRVD
timeout error
522051 19
364 DFC_FrmMngDashDsplDLC
CAN receiving frame DashDspl
data volume error
522052 14
365 DFC_FrmMngDashDsplTO
CAN receiving frame DashDspl
timeout error
522052 19
?????????
2-18
366 DFC_FrmMngEGF1DLC
CAN receiving frame EGF1 data
volume error
522053 14
367 DFC_FrmMngEGF1TO
CAN receiving frame EGF1
timeout error
522053 19
368 DFC_FrmMngDM13DLC
CAN receiving frame DM13 data
volume error
522054 14
369 DFC_FrmMngDM13TO
CAN receiving frame DM13
timeout error
522054 19
370 DFC_FrmMngTRF1DLC
CAN receiving frame TRF1 data
volume error
520217 14
371 DFC_FrmMngTRF1TO
CAN receiving frame TRF1
timeout error
520217 19
372 DFC_FrmMngCM1DLC
CAN receiving frame CM1 data
volume error
522056 14
373 DFC_FrmMngCM1TO
CAN receiving frame CM1
timeout error
522056 19
424 DFC_PIntkVUsPlsHi
Upstream intake pressure signal
exceeds maximum
102 0
425 DFC_PIntkVUsPlsLo
Upstream intake pressure signal
less than minimum
102 1
478 DFC_RmtAPP12Plaus
Incredible double relationship of
remote accelerator
520253 2
479 DFC_RmtAccPedBrkPlaus
Credibility verification of remote
accelerator and brake
520277 7
480 DFC_ComGPSKeyErr Key message fault 520218 14
481 DFC_ComGPSMsgTo Key message timeout 520218 19
?????????
2-19
232 YC6J125-T300 series engine failure diagnosis
codes
Failure name
Flash
code of
failure
Failure
path
Failure
code
SPN FMI
Intake flow sensor power failure - too high or too
low
11 708 P0100 132 11
Intake flow sensor signal compensation failure - it
exceeds upper limit
12 2 P1000 1694 15
Intake flow sensor signal compensation failure -
irrational
13 3 P1001 1694 17
compensation exceeds the limit at the time of
loading
14 4 P2074 1694 16
compensation exceeds the limit at the time of
idling
15 5 P2073 1694 18
Intake flow sensor signal drift failure - it exceeds
upper limit
21 6 P0101 1694 0
Intake flow sensor signal drift failure - it exceeds
lower limit
22 7 P010B 1694 1
Intake flow sensor signal failure - there is no
signal
23 8 P0104 132 2
Intake flow sensor signal failure - cycle exceeds
upper limit
24 9 P0103 132 3
Intake flow sensor signal failure - cycle exceeds
lower limit
25 10 P0102 132 4
Air conditioning compressor (type 1) control
circuit failure - open circuit
177 11 P0640 1351 5
circuit failure - excess temperature
711 12 P0641 1351 6
circuit failure - open circuit
149 13 P0642 1352 5
circuit failure - excess temperature
159 14 P0643 1352 6
circuit failure - short circuit to power supply
169 15 P0646 1352 3
circuit failure - short circuit to ground
219 16 P0644 1352 4
circuit failure - short circuit to power supply
712 17 P0647 1351 3
?????????
2-20
circuit failure - short circuit to ground
713 18 P0645 1351 4
Air conditioning request switch signal failure -
connection timeout; CAN reception timeout
229 19 U0164 985 19
Air conditioning request switch signal failure - it
is irrational; CAN reception timeout
239 20 U0165 985 19
Exhaust gas recirculation control deviation
over-limit failure - it exceeds upper limit of EOM
714 21 P1007 1241 15
over-limit failure - it exceeds lower limit of EOM
715 22 P1008 1241 17
over-limit failure - it exceeds upper limit
716 23 P0402 1241 0
over-limit failure - it exceeds lower limit
717 24 P0401 1241 1
Exhaust gas recirculation / normal mode switch
failure - timeout
721 25 P1009 1241 11
Intake preheating drive circuit test failure - it
exceeds upper limit at the time of activation
249 26 P100A 729 16
exceeds lower limit at the time of activation
259 27 P100B 729 18
exceeds upper limit at the time of exit
269 28 P100C 729 15
exceeds lower limit at the time of exit
279 29 P100D 729 17
Intake preheating drive circuit failure - normally
open
516 30 P0540 729 7
Temperature sensor rationality failure -
irrationality 1
289 31 P100E 171 2
irrationality 2
291 32 P100F 176 2
irrationality 3
292 33 P1010 177 2
irrationality 4
293 34 P1011 178 2
irrationality 5
294 35 P1012 179 2
undetermined failure
295 36 P1013 171 11
CY141 control relay output voltage 0 failure -
short circuit to power supply
31 37 P0659 1485 3
32 38 P2671 1486 3
short circuit to ground
34 40 P0658 1485 4
?????????
2-21
35 41 P2670 1486 4
Battery voltage failure - too high 722 43 P0563 444 16
Battery voltage failure - too low 723 44 P0562 444 18
Battery voltage detection circuit failure - short
circuit to power supply
42 45 P1014 444 3
Battery voltage detection circuit failure -
short-circuit to ground
43 46 P1015 444 4
Brake switch failure - in the process of cruise
control
724 47 P0568 597 11
Brake switch failure - before activation of cruise
control
725 48 P0572 597 12
Brake signal failure - signal of main and auxiliary
brakes is irrational
726 49 P0504 597 2
Brake switch failure - single side brake failure 727 50 P0501 597 14
Brake signal reception failure - CAN reception
timeout
296 51 U0418 597 19
CAN node A failure - Passive 71 52 U0029 639 14
CAN node B failure - Passive 72 53 U0038 1231 14
CAN node C failure - Passive 73 54 U0047 1235 14
CAN node D failure - Passive 74 55 U0056 1668 14
CAN node A failure - Busoff 75 56 U0028 639 12
CAN node B failure - Busoff 76 57 U0037 1231 12
CAN node C failure - Busoff 81 58 U0046 1235 12
CAN node D failure - Busoff 82 59 U0055 1668 12
Cooling water temperature rationality failure -
absolutely irrational
44 60 P0115 110 17
Cooling water temperature rationality failure -
dynamically irrational
45 61 P0116 110 18
Cooling water temperature signal reception
failure - CAN
297 62 U013C 110 19
Cooling water temperature sensor circuit failure -
short circuit to power supply or open circuit
51 63 P0118 110 3
Cooling water temperature sensor circuit failure -
52 64 P0117 110 4
Cooling water temperature rationality failure - it
is irrational with the second temperature
53 65 P011A 110 2
Clutch signal rationality failure - it is irrational
with gear signal
731 66 P0704 598 2
Clutch signal reception failure - CAN reception
timeout
732 67 U0114 598 19
Torque limit function activation - pressure boost
protection
54 68 P1019 518 14
?????????
2-22
Torque limit function activation - engine
protection
55 69 P101A 519 14
Torque limit function activation - injection
system
111 70 P101B 520 14
Torque limit function activation - restricted
information
112 71 P101C 521 11
Torque limit function activation - negative torque 113 72 P101D 522 14
Torque limit function activation - particulate filter 114 73 P101E 523 14
Torque limit function activation - performance
limit
115 74 P101F 524 14
Torque limit function activation - smoke limit 121 75 P1020 525 14
Communication failure - air conditioning request
switch signal received is wrong
941 747 U1101 2000 14
Communication failure � reception of air
conditioning request switch signal is overtime
942 748 U1102 2000 19
Communication failure - sending of ACK is
overtime
83 76 U2100 2001 19
Communication failure - sending of AmbCon is
overtime
84 77 U2101 2002 19
Communication failure - upstream NOX
information received is wrong
85 78 U0113 2003 14
Communication failure - reception of upstream
NOX signal is overtime
86 79 U0114 2003 19
NOX signal sent by PNG is overtime
87 80 U0115 2004 19
216 81 U0116 2005 19
Communication failure - downstream NOX
information received is wrong
217 82 U0117 2006 14
Communication failure - reception of downstream
NOX signal is overtime
218 83 U0118 2006 19
226 84 U0119 2007 19
227 85 U011A 2008 19
NOX signal requested by DM19 is overtime
228 86 U011B 2009 14
NOX signal requested by DM19 is overtime -
BAM
181 87 U1103 2010 19
182 88 U1104 2011 11
PCK
183 89 U1105 2012 31
?????????
2-23
184 90 U011C 2013 14
BAM
185 91 U1106 2014 19
186 92 U1107 2015 11
PCK
187 93 U1108 2016 31
Communication failure - reception of DM1 sent
by DCU is overtime - BAM
236 94 U011D 2017 11
by DCU is overtime - PCK
237 95 U011E 2018 31
Communication failure - received information
processing timeout 1
238 96 P1400 2019 0
246 97 P1401 2020 1
247 98 P1402 2021 2
248 99 P1403 2022 3
256 100 P1404 2023 4
by DCU is overtime
257 101 P1405 2024 19
Communication failure - EBC1 information
received is wrong
258 102 U1109 2025 14
Communication failure - reception of EBC1 is
overtime
261 103 U110A 2025 19
Communication failure - EBC2 information
received is wrong
951 801 U0129 2115 14
Communication failure - reception of EBC2 is
overtime
952 802 U012A 2116 19
Communication failure - sending of EEC1 is
overtime
262 104 U2102 2026 19
overtime
263 105 U2103 2027 19
overtime
264 106 U2104 2028 19
Communication failure - sending of EFL_P1 is
overtime
265 107 U2105 2029 19
Communication - external shutdown request,
from EBC1
266 108 U110B 2030 19
?????????
2-24
Communication failure - sending of EngTemp is
overtime
267 109 U2106 2031 19
Communication failure - sending of ERC1 is
overtime
268 110 U2107 2032 19
Communication failure - ETC1 information
received is wrong
271 111 U110C 2033 14
Communication failure - reception of ETC1 is
overtime
272 112 U110D 2033 19
Communication error - ETC2 information
received is wrong
273 113 U110E 2034 14
Communication failure - reception of ETC2 is
overtime
274 114 U110F 2034 19
Communication failure - sending of FD is
overtime
943 749 U2108 2035 19
Communication failure - sending of FlEco is
overtime
275 115 U2109 2036 19
Communication failure - sending of IC1 is
overtime
276 116 U210A 2037 19
Communication failure - sending of LFC
information is overtime
277 117 U210B 2038 19
Communication failure - reception of NOX
information is overtime - SAE
278 118 U011F 2039 19
281 119 U0120 2040 19
282 120 U0121 2041 14
283 121 U0122 2042 14
284 122 U0123 2043 15
285 123 U0124 2044 15
286 124 U0125 2045 16
287 125 U0126 2046 16
288 126 U0127 2047 17
316 127 U0128 2048 17
317 128 U0129 2049 18
318 129 U012A 2050 18
?????????
2-25
326 130 U012B 2051 0
327 131 U012C 2052 0
328 132 U012D 2053 1
336 133 U012E 2054 1
337 134 U012F 2055 2
338 135 U0130 2056 2
Communication failure - reception of O2
346 136 U0131 2057 3
Communication failure - reception of O2NOX
347 137 U0132 2058 3
Communication failure - sending of PROSCR1
953 781 U110E 2117 19
Communication failure - sending of PROSCR2
954 782 U110F 2118 19
Communication failure - sending of ERC
information is overtime - BAM
348 138 U210C 2059 19
Communication failure - sending of ERC
information is overtime - PAC
356 139 U210D 2060 14
Communication failure - CCVS information
received is wrong
357 140 U1110 2061 14
Communication failure - reception of CCVS
358 141 U1111 2061 19
361 142 U0133 2062 4
362 143 U0134 2063 4
363 144 U0135 2064 5
364 145 U0136 2065 5
Communication failure - reception of sensor
voltage signal is overtime - SAE
365 146 U0137 2066 6
voltage signal is overtime - SAE
366 147 U0138 2067 6
temperature signal is overtime - SAE
367 148 U0139 2068 7
temperature signal is overtime - SAE
368 149 U013A 2069 7
?????????
2-26
Communication failure - sending of ShutDwn is
overtime
369 150 U210E 2070 19
Communication failure - tachometer information
received is wrong
371 151 U1112 2071 14
Communication failure - reception of tachometer
372 152 U1113 2071 19
Communication failure - sending of Adblue tank
373 153 U013B 2072 19
Communication failure - TimeDate information
received is wrong
374 154 U1114 2073 14
Communication failure - reception of TimeDate
is overtime
375 155 U1115 2073 19
Communication failure - reception of TSC1_AE
is overtime (activated)
376 156 U1116 2074 8
is overtime (not activated)
377 157 U1117 2075 10
Communication failure - reception of TSC1_AR
378 158 U1118 2076 8
381 159 U1119 2077 10
Communication failure - reception of TSC1_DE
382 160 U111A 2078 8
383 161 U111B 2079 10
Communication failure - reception of TSC1_DR
384 162 U111C 2080 8
385 163 U111D 2081 10
Communication failure - reception of TSC1_PE
386 164 U111E 2082 8
387 165 U111F 2083 10
Communication failure - reception of TSC1_TE
388 166 U1120 2084 8
416 167 U1121 2085 10
Communication failure - reception of TSC1_TR
417 168 U1122 2086 8
418 169 U1123 2087 10
Communication failure - reception of TSC1_VE
426 170 U1124 2088 8
427 171 U1125 2089 10
?????????
2-27
Communication failure - reception of TSC1_VR
428 172 U1126 2090 8
436 173 U1127 2091 10
Communication failure - TSC1_AE information
received is wrong
437 174 U1128 2092 14
is overtime
438 175 U1129 2092 19
Communication failure - TSC1_AR information
received is wrong
446 176 U112A 2093 14
is overtime
447 177 U112B 2093 19
Communication failure - TSC1_DE information
received is wrong
448 178 U112C 2094 14
is overtime
456 179 U112D 2094 19
Communication failure - TSC1_DR information
received is wrong
457 180 U112E 2095 14
is overtime
458 181 U112F 2095 19
Communication failure - TSC1_PE information
received is wrong
461 182 U1130 2096 14
is overtime
462 183 U1131 2096 19
Communication failure - TSC1_TE information
received is wrong
463 184 U1132 2097 14
is overtime
464 185 U1133 2097 19
Communication failure - TSC1_TR information
received is wrong
465 186 U1134 2098 14
is overtime
466 187 U1135 2098 19
Communication failure - TSC1_VE information
received is wrong
467 188 U1136 2099 14
is overtime
468 189 U1137 2099 19
Communication failure - TSC1_VR information
received is wrong
471 190 U1138 2100 14
is overtime
472 191 U1139 2100 19
Communication failure - sending of CCVS is
overtime
473 192 U210F 2101 19
Communication failure - sending of PGNRQG1b
is overtime
474 193 U2110 2102 19
?????????
2-28
Communication failure - sending of PGNRQ is
overtime
475 194 U2111 2103 19
Communication failure - sending of UAA1 is
overtime
476 195 U2112 2104 19
overtime
477 196 U2113 2105 19
overtime
478 197 U2114 2106 19
overtime
481 198 U2115 2107 19
overtime
482 199 U2116 2108 19
overtime
483 200 U2117 2109 19
overtime
484 201 U2118 2110 19
overtime
485 202 U2119 2111 19
Communication failure - sending of VD is
overtime
486 203 U211A 2112 19
Communication failure - sending of VEP1 is
overtime
487 204 U211B 2113 19
Communication failure - sending of WFI is
overtime
488 205 U211C 2114 19
Engine torque limit - post-processing failure 122 206 P1021 526 14
Cruise button rationality failure - it is irrational 733 207 P0546 596 2
ECU internal hardware communication failure -
CY146SPI communication
123 208 P0608 1231 19
ECU internal hardware communication failure -
CY320SPI communication
124 209 P0607 1232 19
Actuator protection function execution - battery
voltage is too high
734 210 P1022 445 3
Actuator protection function execution - battery
voltage is too low
735 211 P1023 445 4
Brake rationality failure - idling brake switch and
service brake switch are irrational
736 212 P1024 571 2
Shutdown button circuit failure - normally open 737 213 P2535 970 2
Start button circuit failure - normally open 741 214 P2534 1656 5
In-cylinder brake control circuit failure - open
circuit
742 215 P3402 1072 5
In-cylinder brake control circuit failure - excess
temperature
298 216 P3401 1072 6
In-cylinder brake control circuit failure - short
743 217 P3404 1072 3
?????????
2-29
In-cylinder brake control circuit failure - short
circuit to ground
744 218 P3403 1072 4
ECU internal hardware failure - erasing
EEPROM
125 219 P062F 1560 11
ECU internal hardware failure - reading
EEPROM
131 220 P062A 1562 14
ECU internal hardware failure - writing
EEPROM
132 221 P0602 1561 12
EGR control failure - opening is limited 133 222 P2413 27 6
EGR valve body dislocation detection - voltage is
out of range at the time of full closing
134 223 P1025 27 17
EGR valve body dislocation detection - voltage is
out of range at the time of full opening
135 224 P1026 27 15
EGR valve body dislocation detection - voltage
difference is out of range
141 225 P1027 27 2
EGR control failure - deviation between the
actual value and the target is too large in cold
start
142 226 P1028 27 12
EGR control failure - positive deviation between
the actual value and the target is too large
143 227 P1029 27 18
EGR control failure - negative deviation between
the actual value and the target is too large
144 228 P102A 27 16
EGR valve blocking failure - large opening 145 229 P102B 27 1
EGR valve blocking failure - small opening 151 230 P102C 27 0
EGR valve body dislocation detection - the
difference from the voltage at the first time is too
large at the time of full closing
152 231 P102D 27 10
difference from the voltage at the first time is too
large at the time of full opening
153 232 P102E 27 10
EGR valve drive circuit failure - open circuit 154 233 P0404 27 5
EGR valve drive circuit failure - excess
temperature
155 234 P0403 27 6
EGR opening detection failure � the voltage is
larger than the one at the time of full opening or
full closing
211 235 P102F 27 16
EGR opening detection failure - the voltage is
smaller than the one at the time of full opening or
full closing
212 236 P1030 27 18
EGR valve drive circuit failure - short circuit to
power supply
213 237 P0490 27 3
EGR valve drive circuit failure - short circuit to
ground
214 238 P0489 27 4
?????????
2-30
difference from the voltage last time is too large
at the time of full closing
215 239 P1031 27 10
difference from the voltage last time is too large
at the time of full opening
221 240 P1032 27 10
EGR opening sensor circuit failure - short circuit
to power supply
222 241 P0406 27 3
EGR opening sensor circuit failure - short circuit
to ground
223 242 P0405 27 4
EGR opening sensor circuit failure - virtual
connection
224 243 P0409 27 2
High engine speed failure - it exceeds ICO limit 225 244 P1033 1109 11
Engine speed control failure - excessive speed 231 245 P0219 890 11
Engine speed control failure - too low 232 246 P1034 890 7
Open circuit of engine speed output circuit - open
circuit
299 247 P0723 890 5
Open circuit of engine speed output circuit -
excess temperature
319 248 P0722 890 6
Open circuit of engine speed output circuit - short
329 249 P0720 890 3
Open circuit of engine speed output circuit - short
circuit to ground
339 250 P0721 890 4
Environmental pressure signal reception failure -
CAN reception is overtime
349 251 U1300 108 19
Environmental pressure sensor circuit failure -
233 252 P2229 108 3
Environmental pressure sensor circuit failure -
234 253 P2228 108 4
Environmental temperature rationality failure - it
is irrational with TAFS
235 254 P1035 172 2
Environmental temperature sensor circuit failure -
241 255 P0073 172 3
Environmental temperature sensor circuit failure -
242 256 P0072 172 4
Camshaft signal failure - signal error 243 257 P0341 637 2
Camshaft signal failure - no signal 244 258 P0340 637 12
Phase failure - signal deviation between
crankshaft and camshaft is too large
245 259 P0016 637 14
Crankshaft signal failure - signal error 251 260 P0336 636 2
Crankshaft signal failure - no signal 252 261 P0335 636 12
Exhaust brake control circuit failure - open circuit 745 262 P0476 1074 5
Exhaust brake control circuit failure - excess
temperature
359 263 P0475 1074 6
?????????
2-31
Exhaust brake control circuit failure - short circuit
to power supply
746 264 P0478 1074 3
Exhaust brake control circuit failure - short circuit
to ground
747 265 P0477 1074 4
Exhaust brake test failure - test value is high
when signal is low
179 266 P0479 1074 2
Exhaust brake test failure - test value is low when
signal is high
379 267 P0479 1074 19
Digital fan 1 control circuit failure - open circuit 751 269 P0480 977 5
Digital fan 2 control circuit failure - open circuit 752 270 P0481 978 5
Digital fan 1 control circuit failure - excess
temperature
753 271 P0484 977 6
Digital fan 2 control circuit failure - excess
temperature
754 272 P0485 978 6
Digital fan 1 control circuit failure - short circuit
to power supply
755 273 P0692 977 3
to power supply
756 274 P0694 978 3
to ground
757 275 P0691 977 4
to ground
761 276 P0693 978 4
PWM fan control circuit failure - open circuit 389 277 P0482 979 5
PWM fan control circuit failure - excess
temperature
391 278 P0486 979 6
PWM fan control circuit failure - short circuit to
power supply
392 279 P0696 979 3
PWM fan control circuit failure - short circuit to
ground
393 280 P0695 979 4
Fan speed signal failure - counter overflow 762 281 P0483 1639 8
Fan speed failure - too high 763 282 P0495 1639 3
Fan speed failure - too low 764 283 P0494 1639 4
FBC over-limit correction failure - cylinder 1 394 284 P0263 651 16
Oil filter blocking sensor (analog) circuit failure -
419 290 P103A 95 3
Oil filter blocking sensor (analog) circuit failure -
429 291 P103B 95 4
Oil filter blocking failure - blocking 439 292 P1018 95 7
?????????
2-32
Oil filter blocking rationality failure - blocking at
the time of electrification without running
449 293 P1017 95 14
Fuel heating control circuit failure - open circuit 459 294 P2029 854 5
Fuel heating control circuit failure - excess
temperature
469 295 P2029 854 6
Fuel heating control circuit failure - short circuit
to power supply
479 296 P2030 854 3
Fuel heating control circuit failure - short circuit
to ground
489 297 P2030 854 4
Fuel oil water sensor (analog) circuit failure -
491 298 P2267 97 3
Fuel oil water sensor (analog) circuit failure -
492 299 P2266 97 4
Fuel oil water failure 765 300 P2269 97 11
Fuel level failure - too low 493 301 P103E 96 1
Fuel temperature sensor circuit failure - short
254 302 P0183 174 3
Fuel temperature sensor circuit failure - short
circuit to ground
255 303 P0182 174 4
Fuel temperature rationality failure - the second
temperature is irrational
311 304 P0181 174 2
Neutral switch signal reception failure - CAN
reception is overtime
494 305 U1301 59 19
Preheating light control circuit failure - open
circuit
766 306 P0382 1677 5
Preheating light control circuit failure - excess
temperature
495 307 P0381 1677 6
Preheating light control circuit failure - short
767 308 P0384 1677 3
Preheating light control circuit failure - short
circuit to ground
771 309 P0383 1677 4
Preheating control circuit failure - open circuit 772 310 P2605 729 5
Preheating control circuit failure - excess
temperature
496 311 P2606 729 6
Preheating control circuit failure - short circuit to
power supply
773 312 P2608 729 3
Preheating control circuit failure - short circuit to
ground
312 313 P2607 729 4
Oil injection control failure - number of injection
times is too much (electric loading)
313 314 P103F 164 11
times is too much (fuel control balance)
314 315 P1040 165 8
times is too much (system requirement)
315 316 P1041 166 8
?????????
2-33
times is too much (running time)
321 317 P1042 167 8
Oil injection control failure - start test 322 318 P1043 168 11
Oil injection control failure - rail pressure is too
low
323 319 P0087 164 1
Over-limit oil injection correction failure - oil
atomizer 1
497 320 P020A 651 14
atomizer 2
498 321 P020E 652 14
atomizer 3
499 322 P020C 653 14
atomizer 4
519 323 P020F 654 14
atomizer 5
529 324 P020B 655 14
atomizer 6
539 325 P020D 656 14
Oil atomizer common port 1 circuit failure - short
circuit
324 326 P062D 633 3
Oil atomizer common port 2 circuit failure - short
circuit
325 327 P062E 634 3
Oil atomizer control chip failure - CY33x 331 328 P062B 635 11
Oil atomizer 1 drive circuit failure - open circuit 332 329 P0201 651 5
Oil atomizer 1 drive circuit failure - reservation 549 335 P1044 651 11
Oil atomizer 1 drive circuit failure - short circuit 343 341 P0262 651 3
Oil atomizer 1 drive circuit failure - short circuit
of high and low ends
354 347 P0261 651 4
355 348 P0273 655 4
?????????
2-34
411 349 P0267 653 4
412 350 P0276 656 4
413 351 P0264 652 4
414 352 P0270 654 4
Oil atomizer circuit failure - BANK0
short-circuits to ground
415 353 P104A 633 14
Oil atomizer circuit failure - BANK1
421 354 P104B 634 14
Oil atomizer circuit failure -BANK0 ground
detection is overtime
944 750 P1581 633 11
Oil atomizer circuit failure -BANK1 ground
detection is overtime
945 751 P1582 634 11
PTO switch circuit failure - short circuit to power
supply
517 355 P251C 976 3
Fuel metering valve drive circuit failure - virtual
connection of low end
422 356 P0255 1442 2
Fuel metering valve drive circuit failure - open
circuit of low end circuit
423 357 P0251 1442 5
Fuel metering valve drive circuit failure - excess
temperature
424 358 P0252 1442 6
Fuel metering valve drive circuit failure �high
end short-circuits to power supply
425 359 P0007 1442 15
Fuel metering valve drive circuit failure - high
end short-circuits to ground
431 360 P0006 1442 17
Fuel metering valve drive circuit failure - low end
short-circuits to power supply
432 361 P0254 1442 16
Fuel metering valve drive circuit failure - low end
433 362 P0253 1442 18
Fuel metering valve current sensor short-circuits
to power supply
434 363 P025D 1442 3
Fuel metering valve current sensor short-circuits
to ground
435 364 P025C 1442 4
MIL light control circuit failure - open circuit 774 365 P0650 1213 5
MIL light control circuit failure - excess
temperature
775 366 P104C 1213 6
MIL light control circuit failure - short circuit to
power supply
776 367 P104D 1213 3
MIL light control circuit failure - short circuit to
ground
777 368 P104E 1213 4
PTO switch circuit failure - short circuit to
ground
18 369 P251B 976 4
?????????
2-35
ECU internal hardware failure - AD conversion
voltage is too low
441 370 P060B 2629 12
ECU internal hardware failure - AD conversion
voltage exceeds the limit
442 371 P104F 2630 12
ECU internal hardware failure - AD correction
factor exceeds the limit
443 372 P1050 2631 12
ECU internal hardware failure - FC and MM
rationality failure (communication)
444 373 P063A 2632 12
ECU internal hardware failure - SPI
communication outage (communication)
445 374 P063B 2633 12
ECU internal hardware failure - ROM 451 375 P0605 2634 12
ECU internal hardware failure - SOP (no
response to monitoring)
452 376 P0604 2635 12
ECU internal hardware failure - SOP
(NOTCHECK; torque reduction)
453 377 P0601 2636 12
ECU internal hardware failure - SOP (failure
monitoring response time setting failure)
454 378 P060A 2637 12
ECU internal hardware failure - SOP (SPI failure) 455 379 P063C 2638 12
ECU internal hardware failure - SOP (ABELINE
overvoltage)
511 380 P0606 2639 12
ECU internal hardware failure - SOP
(WDALINE)
512 381 P0603 2640 12
ECU internal hardware failure - SOP (failure after
system response)
513 382 P063D 2641 12
ECU internal hardware failure - SOP (failure at
the time of function test)
514 383 P060C 2642 12
ECU internal hardware failure - SOP (detection is
overtime)
515 384 P0613 2643 12
ECU internal hardware failure - SOP (ABELINE
overvoltage)
521 385 P0614 2644 12
Relevant failures of torque limit activation -
circuit 1 and circuit 2 of accelerator are irrational
522 386 P060D 1254 11
1-stage and 2-stage calculated revolving speeds
are irrational
523 387 P061C 1255 11
electrification time of main injection and pilot
injection is irrational
524 388 P0612 1256 11
electrification angle at the time of starting is
irrational
525 389 P0611 1257 11
undetermined
531 390 P1051 1258 11
undetermined
532 391 P1052 1259 11
?????????
2-36
undetermined
533 392 P1053 1260 11
undetermined
534 393 P1054 1261 11
electrification time of oil atomizer is too long at
the time of OVERRUN
535 394 P0618 1108 16
electrification time of oil atomizer is too long at
the time of overheating protection
541 395 P1055 1108 15
undetermined
542 396 P1056 1262 11
Relevant failures of torque limit activation
-1-stage and 2-stage rail pressure monitoring
543 397 P1057 1263 11
Relevant failures of torque limit activation
�circuit 1 and circuit 2 of remote accelerator are
irrational
544 398 P1058 1264 11
undetermined
545 399 P1059 1265 11
Relevant failures of torque limit activation - rail
pressure is limited
551 400 P105A 1266 14
intake is limited
552 401 P105B 1267 14
torque and fuel capacity
553 402 P105C 1268 14
undetermined
554 403 P105D 1269 11
undetermined
555 404 P105E 1270 11
Main relay circuit failure - it is shut down early 16 405 P068A 818 7
Main relay circuit failure - it cannot be shut down 26 406 P068B 818 12
PTO switch circuit failure - irrational 567 426 P253E 976 11
Nox over-limit failure 1 - clearable 696 448 P1080 2173 20
OBD relevant failure 2 - not clearable 697 449 P1081 2174 21
OBD over-limit failure 2 - clearable 759 456 P1088 2173 21
OBD over-limit failure 3 - clearable 769 457 P1089 2173 22
Nox over-limit failure 4 - clearable 779 458 P108A 2173 23
Nox over-limit failure 5 - clearable 789 459 P108B 2173 24
?????????
2-37
Nox over-limit failure 6 - clearable 799 460 P108C 2173 25
Nox over-limit failure 7 - clearable 819 461 P108D 2173 26
Nox over-limit failure 8 - clearable 829 462 P108E 2173 27
OBD relevant failure 1 - not clearable 839 463 P108F 2174 20
ECU internal failure - communication failure
(WDA activation)
36 464 P1090 629 11
ECU internal failure - voltage is too low (ABE
activation)
46 465 P1091 629 4
ECU internal failure - voltage is too high (ABE
activation)
56 466 P1092 629 3
ECU internal failure - undetermined (ABE/WDA
activation)
61 467 P1093 629 14
Engine oil level sensor circuit failure - short
849 468 P250D 98 3
Engine oil level sensor circuit failure - short
circuit to ground
859 469 P250C 98 4
Engine oil level rationality failure � voltage does
not change
869 470 P250B 98 2
Engine oil level - too high 879 471 P252F 98 0
Engine oil level - too low 889 472 P250F 98 1
Engine oil warning light control circuit failure -
open circuit
891 473 P1094 835 5
excess temperature
892 474 P1095 835 6
893 475 P1096 835 3
894 476 P1097 835 4
Engine oil pressure (digital sensor) signal
rationality failure - there is no signal at the time
of running
895 477 P1098 100 1
Engine oil pressure (digital sensor) signal
rationality failure - there is signal at the time of
shutdown
896 478 P1099 100 2
Engine oil pressure failure - high (temperature
and speed)
62 479 P0521 100 15
Engine oil pressure failure - low ( speed) 63 480 P0524 100 17
Engine oil pressure signal reception failure -
CAN reception is overtime
897 481 U1302 100 19
Engine oil pressure sensor circuit failure - short
64 482 P0523 100 16
Engine oil pressure sensor circuit failure - short
circuit to ground
65 483 P0522 100 18
Engine oil temperature failure - high 66 484 P0196 175 15
?????????
2-38
Engine oil temperature signal reception failure
-CAN reception is overtime
898 485 U1303 175 19
Engine oil temperature sensor circuit failure -
116 486 P0198 175 3
Engine oil temperature sensor circuit failure -
126 487 P0197 175 4
Engine oil temperature rationality failure - it is
irrational with the second temperature
136 488 P109A 175 2
Boost pressure control deviation failure - too
large
146 489 P2263 1127 0
Boost pressure control deviation failure - too
small
156 490 P2263 1127 1
Torque and fuel capacity calibration rationality
failure - curve line is not monotonous
161 491 P109B 512 13
Boost pressure and environmental pressure
rationality failure - the difference is too large
162 492 P0236 102 0
Boost pressure and environmental pressure
rationality failure - the difference is too small
163 493 P0240 102 1
Boost pressure sensor circuit failure - short circuit
to power supply
164 494 P0238 102 3
Boost pressure sensor circuit failure - short circuit
to ground
165 495 P0237 102 4
Particulate filter - blocking failure 568 496 P2202 81 0
Particulate filter - RMV failure 571 497 P2203 81 1
Particulate filter - physical signal is ultrahigh 572 498 P109E 81 15
Particulate filter - physical signal is ultralow 573 499 P109F 81 17
Particulate filter - signal is irrational 574 500 P2453 81 2
Particulate filter - CAN signal reception timeout
failure
575 501 U3110 81 19
Particulate filter - signal voltage value exceeds
upper limit
576 502 P2455 81 3
Particulate filter - signal voltage value exceeds
lower limit
577 503 P2454 81 4
Forced opening of pressure release valve - there
are too many opening times
166 504 P10A0 1349 11
Forced opening of pressure release valve - rail
pressure is built
611 505 P10A1 1349 20
Forced opening of pressure release valve -
opening test
612 506 P10A2 1349 21
Forced opening of pressure release valve - opened 613 507 P10A3 1349 14
Forced opening of pressure release valve - fuel
capacity is unbalanced
614 508 P10A4 1349 22
blocked
615 509 P10A5 1349 2
?????????
2-39
opening time is too long
616 510 P10A6 1349 0
ECU internal hardware failure - R2S2
communication outage
621 511 P0635 629 19
Rail pressure closed-loop control mode failure 0 -
the actual one is smaller than the target (large
metering valve flow)
622 512 P10A7 679 1
Rail pressure closed-loop control mode failure 10
- metering valve flow is unbalanced
623 513 P10A8 679 7
the actual one is larger than the target (metering
valve 0 flow)
624 514 P10A9 679 0
- the actual one is larger than the target by two
levels (metering valve 0 flow)
625 515 P10B0 679 3
rail pressure is too small
626 516 P10B1 679 5
rail pressure is too large by one level
631 517 P10B2 679 15
- rail pressure is too large by two levels
632 518 P10B3 679 16
metering valve flow is too large (at the time of
OVERRUN)
633 519 P10B4 679 12
metering valve flow is too large (at the time of
idling)
634 520 P10B5 679 17
Rail pressure sensor circuit failure- virtual
connection
635 521 P0194 679 2
Rail pressure signal drift failure - too large 636 522 P0190 157 15
Rail pressure signal drift failure - too small 641 523 P0191 157 17
Rail pressure control failure - LIMPHOME rail
pressure is too high
642 524 P0088 677 0
Rail pressure control failure - LIMPHOME fuel
capacity is large (PRV is not started)
643 525 P10B8 677 11
Rail pressure control failure - LIMPHOME oil
temperature is high
644 526 P10B9 677 14
Rail pressure sensor circuit failure - short circuit
to power supply
645 527 P0193 157 3
Rail pressure sensor circuit failure - short circuit
to ground
646 528 P0192 157 4
Anti-theft signal error - signal is high 946 752 P0648 2029 12
PTO switch signal reception failure - CAN
reception timeout
899 573 U0104 976 19
?????????
2-40
Accelerator circuit 1 circuit failure - short circuit
to power supply
652 581 P0123 91 3
to power supply
653 582 P0223 29 3
Remote accelerator circuit 1 circuit failure - short
654 583 P1563 92 3
655 584 P1566 30 3
to ground
656 585 P0122 91 4
to ground
661 586 P0222 29 4
circuit to ground
662 587 P1564 92 4
circuit to ground
663 588 P1567 30 4
Reference supply 1 voltage failure - it is out of
range
664 591 P0654 1079 2
range
665 592 P0653 1080 2
range
666 593 P0699 1081 2
12V power supply monitoring circuit failure -
17 594 P0631 1542 3
12V power supply monitoring circuit failure -
27 595 P0632 1542 4
Internal 12V power supply monitoring circuit
failure - short circuit to power supply
37 596 P0633 1543 3
Internal 12V power supply monitoring circuit
failure - short circuit to ground
47 597 P0634 1543 4
Shutdown time calculation failure - timing of
timer is inaccurate
913 598 P2610 590 11
Shutdown light control circuit failure - open
circuit
914 599 P1105 623 5
Shutdown light control circuit failure - excess
temperature
915 600 P1106 623 6
Shutdown light control circuit failure - short
916 601 P1107 623 3
Shutdown light control circuit failure - short
circuit to ground
917 602 P1108 623 4
Start relay control circuit failure - open circuit 28 603 P0817 1675 5
Start relay control circuit failure - excess
temperature
918 604 P0615 1675 6
Start relay control circuit failure - short circuit to
power supply
38 605 P0617 1675 3
?????????
2-41
Start relay control circuit failure - short circuit to
ground
48 606 P0616 1675 4
Failure light control circuit failure - open circuit 58 607 P161B 623 5
Failure light control circuit failure - excess
temperature
68 608 P161C 623 6
Failure light control circuit failure - short circuit
to power supply
78 609 P1619 623 3
Failure light control circuit failure - short circuit
to ground
88 610 P161A 623 4
Reset monitoring - relevant software reset failure
0
57 611 P110D 152 12
1
67 612 P110E 153 12
2
77 613 P110F 154 12
Accelerator signal rationality failure - circuit 1
and circuit 2 are irrational
117 614 P2135 91 2
Accelerator signal rationality failure - circuit 1
and idle switch are irrational
127 615 P1111 91 20
Remote accelerator signal rationality failure -
circuit 1 and circuit 2 are irrational
137 616 P1565 974 2
Start request switch circuit failure - normally
open
118 617 P2530 1041 11
AFS temperature sensor signal failure - duty ratio
exceeds upper limit
147 618 P0113 172 0
AFS temperature sensor signal failure - duty ratio
exceeds lower limit
157 619 P0112 172 1
AFS temperature sensor signal failure - cycle
exceeds upper limit
167 620 P0111 172 15
AFS temperature sensor signal failure - cycle
exceeds lower limit
171 621 P0110 172 17
Intake temperature signal reception failure - CAN
reception timeout
919 622 U1304 105 19
Intake air temperature sensor circuit failure -
172 623 P0098 105 3
173 624 P0097 105 4
Intake temperature rationality failure � it is
irrational with the second temperature
174 625 P1113 105 2
ECU temperature sensor circuit failure - short
175 626 P0669 1136 3
ECU temperature sensor circuit failure - short
circuit to ground
176 627 P0668 1136 4
Throttle valve control failure - opening is limited 921 628 P2100 51 6
?????????
2-42
Throttle valve body dislocation detection -
voltage is out of range at the time of full closing
922 629 P2109 51 17
voltage is out of range at the time of full opening
923 630 P2110 51 15
voltage difference is out of range
924 631 P2113 51 2
Throttle valve control failure - deviation between
the actual value and the target is too large in cold
start
925 632 P2114 51 12
Throttle valve control failure - positive deviation
between the actual value and the target is too
large
926 633 P2115 51 18
Throttle valve control failure - negative deviation
between the actual value and the target is too
large
927 634 P2116 51 16
Throttle valve blocking failure - large opening 928 635 P2112 51 1
Throttle valve blocking failure - small opening 929 636 P2111 51 0
Throttle valve body dislocation detection - the
difference from the voltage detected at the first
time is too large at the time of full closing
931 637 P2108 51 10
difference from the voltage detected at the first
time is too large at the time of full opening
932 638 P2108 51 10
Throttle valve control circuit failure - open circuit 933 639 P2100 51 5
Throttle valve control circuit failure - excess
temperature
934 640 P2101 51 6
Throttle valve body dislocation detection - it is
larger than the maximum voltage at the time of
full opening or full closing
935 641 P2101 51 16
Throttle valve body dislocation detection - it is
smaller than the maximum voltage at the time of
full opening or full closing
936 642 P2101 51 18
Throttle valve control circuit failure - short circuit
to power supply
937 643 P2103 51 3
Throttle valve control circuit failure - short circuit
to ground
938 644 P2102 51 4
difference from the voltage detected last time is
too large at the time of full closing
189 645 P2108 51 10
difference from the voltage detected last time is
too large at the time of full opening
791 646 P2108 51 10
Throttle valve opening sensor circuit failure -
792 647 P2622 51 3
?????????
2-43
Throttle valve opening sensor circuit failure -
793 648 P2621 51 4
Throttle valve control circuit failure - virtual
connection
794 649 P2620 51 2
128 650 P009A 1636 3
138 651 P0099 1636 4
Turbocharger control circuit failure - open circuit 148 652 P0045 1188 5
Turbocharger speed failure - ultrahigh 158 653 P0049 103 0
Turbocharger control circuit failure - excess
temperature
795 654 P0046 1188 6
Turbocharger control circuit failure - short circuit
to power supply
168 655 P0048 1188 3
Turbocharger control circuit failure - short circuit
to ground
178 656 P0047 1188 4
Vehicle speed signal reception failure - CAN
reception timeout
188 734 U1305 84 19
Vehicle speed signal failure - vehicle speed is
excessive speed
811 735 P0297 84 0
Vehicle speed sensor circuit failure - open circuit 812 736 P2162 84 14
Vehicle speed signal - failure of engine
speed-torque rationality
813 737 P2159 84 2
Vehicle speed sensor circuit failure - short circuit
to power supply
814 738 P0503 84 3
Vehicle speed sensor circuit failure - short circuit
to ground
815 739 P0502 84 4
Vehicle speed signal failure - cycle is too long 816 740 P2158 1624 3
Vehicle speed signal failure - cycle is too short 817 741 P2160 1624 4
Vehicle speed signal failure - time of high voltage
level is short
818 742 P2161 1624 8
Warning light control circuit failure - open circuit 821 743 P1631 624 5
Warning light control circuit failure - excess
temperature
798 744 P1632 624 6
Warning light control circuit failure - short circuit
to power supply
822 745 P162F 624 3
Warning light control circuit failure - short circuit
to ground
823 746 P1630 624 4
Table 3 Yuchai three-stage engine failure codes
?????????
2-44
26 Engine failure diagnosis code
Failure type
Failure
classification
Failure causes Solution
Engine fails to
be started
Starting
system
factors
Low battery power
Check battery power carefully, charge or
replace it
Starting motor
damage
Repair or replace starting motor
Fuel system
factors
Air in oil-way
system
Dredge oil-way (blow with high pressure
air), fasten all joints and drain oil-way
Oil-way system
blockage
Dredge oil-way (blow with high pressure
air), fasten all joints and drain oil-way
Too dirty diesel
filter element
Replace filter element
Severe
piston/delivery
valve wear
Repair oil injection pump professionally
Low-pressure oil
transfer pump
damage
Replace oil transfer pump
Adjustment
factors
Oil injection
advance angle
misalignment
Adjust oil injection advance angle
Air valve clearance
change
Check and adjust air valve clearance
Few starting oil
mass
Check oil injection pump professionally
Engine
underpower
Diesel filter
blockage or inlet
connector strainer
blockage of oil
transfer pump
Clean or replace it
Oil atomizer
underpressure or
poor atomization
Overhaul oil atomizer or replace nipple
matching parts
Excess precise
nipple matching
parts wear
Adjust fuel delivery or overhaul piston
matching parts
Air in fuel system Exhaust air in fuel system
Incorrect oil
injection advance
angle
Adjust as specified
Uneven fuel Adjust fuel delivery in all cylinders
?????????
2-45
delivery in all
cylinders
Air filter blockage Clean or replace filter element
Abnormal
exhaust
Blue smoke
in diesel
exhaust
Too high
lubricating oil level
in engine oil pan
Discharge redundant lubricating oil to keep
oil level within specified scale of oil level
gauge
Untight oil
atomizer needle
valve or burns out
at open position and
diesel oil enters oil
pan
Clean and adjust oil atomizer or replace
needle valve matching parts
Piston bushing seal
ring damage of oil
injection pump
(P-type pump), or
poor sealing of
piston bushing and
pump body, fuel
flows into oil pan
along lubricating
oil passage
Replace seal ring
Air valve and oil
seal damage or
excess clearance
between air valve
and duct, engine oil
drawn into the
combustion
chamber during
intake stroke
Replace defective air valves, ducts and oil
seals (all oil seals subject to disassembly
must be replaced. Duct may not be replaced
if clearance meets the requirements after
replacing a new air valve)
Seal ring damage of
turbocharger,
lubricating oil
enters combustion
chamber along air
flue for combustion
Repair or replace it
White smoke
in diesel
exhaust
Water in fuel
system
Clean tank and filter, use qualified diesel oil
Cylinder valve
wear
Replace worn components
Poor oil injection
atomization at
nipple, diesel oil
mist drops in
combustion
chamber without
Adjust oil atomizer and oil supply advance
angle
?????????
2-46
combustion
Black smoke
in diesel
exhaust
Too high exhaust
back pressure or
exhaust duct
blockage
Reduce bends of exhaust pipe and remove
dust on silencer
Oil injection delay Adjust oil injection advance angle
Oil atomizer in
poor operating or
oil atomizer
damage
Disassemble it for cleaning and checking
Poor diesel oil or
incorrect marks
Replace diesel oil
Severe cylinder
liner and piston
group wear
Replace worn components
Lubricating
oil
overpressure
or
underpressure
Engine oil
overpressure
Abnormal engine
oil pressure display
unit
Replace display unit
Too high oil
viscosity
Select engine oil of certain mark, take
preheating measures when starting engine in
winter.
Too small clearance
of pressure
lubrication point or
fine oil filter
blockage
Adjust clearance of pressure lubrication
point, clean or replace oil filter
Improper pressure
limiting valve
adjustment
Readjust spring force of pressure limiting
valve to restore engine oil pressure to
specified value
Too low oil
pressure
Oil pump wear or
sealing gasket
damage
Repair oil pump and replace sealing gasket
Reduced oil mass
charged by oil
pump
Check oil mass, charge oil and clean oil
pump suction filter
Excess oil leakage
Check if lubrication circuit is broken, check
and adjust fit clearance of bearings at
crankshaft and camshaft
Oil filter or cooler
blockage
Check and clean oil filter and cooler
Too low oil
viscosity
Select oil of certain mark as required
Improper pressure
limiting valve
Clean pressure limiting valve, adjust or
replace spring
?????????
2-47
adjustment
Too low engine oil
pressure display
Check and adjust engine oil pressure sensor
and engine oil pressure gauge
High
lubricating oil
consumption
Improper oil
viscosity
Select proper lubricating oil
Excess negative
pressure in
combustion
chamber and oil
flows upward into it
Check causes of excess negative pressure,
adjust
speed and operating
mode change
Test indicates that oil consumption increases
significantly with the increase of speed, run
the engine as specified
High coolant
temperature
Improper coolant or
water shortage
Select proper coolant and add to proper level
Water radiator
blockage
Set heat sink back to normal position with
stalloy carefully, keep it flat and straight and
then clean it with compressed air or water
gun
Water-thermometer
or beacon
indication error
Measure temperature at water temperature
sensor by using surface thermometer,
observe if indicated value of
water-thermometer complies with actual
temperature
Too low fan speed,
blade deforms or
fitted reversely
Too loose fan adhesive tape may lead to
slipping, too low fan speed and poor
efficiency of air supply. Adjust too loose
adhesive tape. Replace it in case of rubber
layer aging and damage or fibrous layer
fracture. Replace deformed fan blades
Cooling water
pump failure
Replace water pump
Thermostat failure Replace thermostat
Cylinder head
gasket damage
Replace cylinder head gasket
Diesel overloaded
operation
Reduce engine load
Table 5 Common engine failure diagnosis
3 Elec
31. Ove
311
312
313
32 Elem
321
322
323
324
325
326
327
328
329
321
311
312
321
321
321
32 Elec
321
332
trical and in
erview of ele
1. Specificatio
2 Description
3 Special inst
ments of elec
1 I-ECU of In
2 Engine con
3 Engine con
4 Polymorph
5 Electronic a
6 Battery .....
7Generator .
8 Starter ......
9 Starting sw
10Fuel level s
1Power switc
2 Pressure sw
13 Torque co
14Engine wa
15 Wiper and
ctrical circui
1 Compariso
2 Wiring diag
nformation sy
ectrical syste
on of electric
n of electrica
tructions on
ctrical system
nstrument p
ntrol unit EC
ntrol unit EC
hic fuel-savin
accelerator p
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or .................
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overall unit .
Manual of W
1
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9
4
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8
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5
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Fig. 3-1
Service Manual of W
2
3 Ele
infor
31. Ove
311. Spe
The voltag
machine lo
312 Desc
The Servic
theories, f
system and
This sectio
troublesho
electrical s
The electr
electronic
battery, sw
electrical
control sys
state and
functions.
All re
conducted
general spe
313 Spe
of the el
Special ins
overview
Never
approval
machine fu
to the mach
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mean serio
following
methods m
electrical s
section and
Befor
Wheel Loa
ectric
rmati
erview of
ecification
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oader is 24v
cription o
ce Manual o
functions an
d elements c
on also con
oting and
system.
ical system
componen
witch, solen
system als
stem, which
control th
epairs about
strictly ac
ecification.
cial instr
ectrical s
structions o
r change the
from SDL
unction and
hine.
ating the el
ous injury a
instruction
must be obs
system. Ref
d service ma
e starting
ader
cal
on sy
f electric
n of elect
lectrical sys
v.
of electri
of the electr
nd paramet
contained in
ntains descr
maintenan
m is compos
nts and ot
noid valve,
so includes
h is used to
he machine
t the electr
ccording to
ructions
system
n repair of
e electrical
LG. Chang
cause risks
lectric syst
and damage
ns and des
erved caref
fer to instru
anual at the
the electric
ystem
cal system
trical Sys
stem of the
ical syste
rical system
ters of the
n the machin
criptions on
nce method
sed of elec
ther parts,
fuse and r
s a compu
monitor th
e to achiev
rical system
o provision
on main
f the electric
system wit
ges may a
s of injury o
tem careles
e to the mac
scriptions o
fully in ope
ructions in
e same time.
cal system,
and
m
m
stem
e complete
em
m describes
electrical
ne.
n function,
ds of the
ctrical and
such as
relay. The
uter-based
e machine
ve related
m must be
ns of the
tenance
c system -
thout prior
affect the
or damage
ssly might
chine. The
on related
erating the
the safety
.
, watches,
Service Manual of W
3
rings, brac
removed fr
Don't
start the m
machine t
another m
machine s
machine w
Never test
short circu
permanent
Special in
system-bat
The c
when charg
so-called h
battery. Sh
battery ma
The chargi
loosening t
Keep good
a confined
Electrolyte
acid. Elect
immediate
electrolyte
parts of th
contact a d
If a f
exhausted
It may ca
contains su
Never
The main
disconnect
The anode
installing
mechanism
Note! Inc
control as
shutdown.
Fully char
Wheel Loa
celets and
rom the bod
connect to
machine. S
to get out
machine is u
should not
which is boo
whether th
uit. It may
ly.
nstructions
ttery
over of the
ging the bat
hydrogen g
hort circuit,
y cause pow
ing current
the charging
d ventilation
space.
e of the ba
trolyte spla
ly with so
comes int
he body, ri
doctor for he
fully charg
battery, the
ause person
ulfur acid.
r charge a fr
current or
ted in the en
of the batte
or remov
m of the elec
correct ope
ssembly su
rged battery
ader
other met
dy.
o the startin
Such opera
of contro
used to bo
come int
sted.
hey carryin
damage e
on repair
battery box
ttery rapidly
gas will be
, open flam
werful explo
should be
g clip.
n, especially
attery conta
shed on sk
oap and p
to the eyes
inse with p
elp immedia
ged battery
e battery wi
nnel injury
rozen battery
battery ca
ngine is ope
ery must be
ving eleme
ctrical syste
eration will
uch as EC
y must be u
tal objects
ng motor d
ation will
ol and mov
oost the sta
to contact
ng current b
electrical co
r of the
x should be
y. When cha
e accumulat
me or spark
osion.
disconnect
y charging b
ains corros
kin should b
plenty of
s or other v
plenty of w
ately.
is connec
ill burst due
because th
ry. Explosio
able should
erated.
e disconnec
ents or c
em.
l cause d
CU and th
used when
must be
directly to
cause the
ve. When
arting, the
with the
by making
omponents
electrical
e removed
arging, the
ted in the
k near the
ted before
batteries in
ive sulfur
be washed
water. If
vulnerable
water and
cted to an
e to surge.
he battery
on hazard!
never be
cted before
connecting
amage of
hus cause
check the
Service Manual of W
4
electrical s
charge it fu
The polar
battery wh
When char
the same c
This is bec
a certain am
the aging d
Special ins
generator
Before an
check whe
loose or r
according
before any
Check the
be adjusted
Note! Mak
and guaran
the cable.
generator
simultaneo
Note! Neve
is operated
voltage reg
Note! Nev
chassis. It
damage the
Special ins
electrical e
The bus m
bus is dam
Note: The
including a
protected f
be repaired
might be re
Electronic
be damage
the tools o
to comply
performing
component
To meet
Wheel Loa
system. If t
ully or repla
conductor
en the batte
rging batter
apacity and
cause the cu
mount of el
degree of th
structions on
ny testing o
ether the b
rusted. Any
to the ab
electrical te
belt of the
d/repaired p
ke sure to co
ntee that th
Loose cab
and the
ously.
er disconne
d. It will
gulator simu
er connect t
may dama
e voltage re
structions on
elements
must be repl
maged.
e two wire
are in pairs
from electri
d by trained
eplaced.
equipment
ed by elect
or the huma
y with the
g operatio
ts.
the nee
ader
the battery
ace it with a
mist be di
ery is charge
ies in series
d service life
urrent amou
lectricity to
e battery.
n repair of t
on the alte
battery and
y error wh
bove check
esting.
generator. I
properly bef
onnect the c
ere is no c
le connecti
voltage
ct the gener
damage th
ultaneously.
the anode o
age the gen
egulator.
n repair of t
laced if any
es included
s and hover
ical interfer
d personnel
is very sen
tromagnetic
n body. The
e following
ns concer
eds of t
is not fully
new one.
isconnected
ed.
s, batteries
e (equal qua
unt required
a battery d
the electrica
ernator or
d wire are
hich might
k must be
If necessary
fore troubles
cable in a s
corrosion an
ion may da
regulator
rator when
he generato
.
of the gener
nerator and
the electrica
y contact o
d in each
ring. They
rence. Wires
l. Or the w
nsitive and i
c field or s
erefore, it i
g instructio
rning to
the electr
y charged,
d from the
must have
ality).
d to charge
depends on
al system -
regulator,
insulated,
be found
corrected
y, it should
shooting.
ecure way
nd dust on
amage the
damage
the engine
r and the
rator to the
may even
al system -
n the data
data bus
should be
s can only
whole wire
is likely to
tatic from
is required
ons when
electronic
omagnetic
Service Manual of W
5
compatibil
following i
When a c
power, the
disconnect
damaged in
Before mai
tool come
connected
Never touc
Avoid touc
the electri
touched, o
grasped ca
Make sure
when repla
Never rep
non-spirale
Special ins
system
When wel
must be di
out from th
When cond
required to
electrical c
When wash
the nozzle
particularly
cleaning ag
Auxiliary
When
starting, th
with the m
Auxiliary s
The follo
connecting
1. Ignitio
the of
2. The
startin
Wheel Loa
lity (EMC),
instructions
ertain elect
e connectio
ted. The
n case of di
intenance o
into contac
to the frame
ch the plug p
ching the c
cal system
only the one
n be touche
e the groun
acing the co
place spira
ed wires in p
structions o
ding the m
sconnected
he control a
duct washin
o operate ve
components
hing the veh
should not
y important
gent.
starting
n another m
he machine
machine whic
starting with
wing item
g:
on switches
ff position.
machine s
ng.
ader
it is require
:
tronic elem
on to the u
electronic
sconnection
of the electri
ct with a m
e to dischar
pin on the e
circuit boar
. If the cir
e with whic
ed.
nding wire
ontrol unit.
aled wires
pair.
on maintena
machine, the
AND THE
ssembly.
ng the mach
ry carefully
from being
hicle with h
aim to elec
t when usin
machine is
e should no
ch is booste
h starting ca
ms should
s on both m
should not
ed to compl
ment is supp
unit should
element m
n.
ical system
metal mecha
rge static of
electronic un
rd when m
rcuit board
ch the edge
is connec
in pair w
ance of the
e wire of th
E plug must
hine by spra
y to prevent
g damaged.
high pressur
ctronic elem
ng hot wat
s used to
ot come int
ed.
able
be checke
machines sh
t be move
ly with the
plied with
never be
might be
, make the
anical part
f the tool.
nit.
maintaining
d must be
e could be
ted safely
wire with
e electrical
he battery
t be pulled
aying, it is
t cable and
re sprayer,
ments. It is
er and oil
boost the
to contact
ed before
ould be in
ed during
Fig. 3-2 B
Fig.3-3 C
Fig. 3-4 R
Belt inspecti
Connection o
Removal of
ion
of starting c
starting cab
Service M
circuit
ble
Manual of W
6
3. Both
voltag
4. Speci
maxim
5. Check
oxidat
6. The
conne
condit
7. The m
other.
Positive an
contact wi
used. Dang
The startin
method bel
1. Conne
batter
started
2. Conne
cathod
startin
3. Conne
the ca
startin
4. Conne
earth
started
Auxiliary s
Check whe
and correct
1. Start
machi
2. Start
the en
3. Wait f
The startin
method bel
1. Remo
the fr
startin
2. Remo
from
Wheel Loa
machines
ge.
fication of
mum rated c
k whether
tion and oth
battery c
ectors are
tion.
machine do
nd negative
ith each ot
ger of perso
ng cable sh
low (as sho
ect the first
ry on the m
d (1).
ect the oth
de (2) of
ng engine.
ect one end
athode (3)
ng machine.
ect the oth
point (4) of
d. Check wh
starting:
ether startin
tly.
the engin
ine.
the engine
ngine can't b
for about tw
ng cable sho
low (as sho
ove the cabl
rame on th
ng.
ove the othe
the cathode
ader
should hav
starting ca
current gene
they starti
her problem
able shou
connected
oes not hav
connector
ther when
nnel injury.
hould be co
wn in figure
t cable (A)
machine w
er end of t
the batter
d of another
of the batt
.
her end of
f the frame
hether the c
ng cables ar
ne on the
on the mac
be started w
wo seconds,
ould be remo
wn in figure
le (B) from
he machine
er end of th
e of the bat
ve the sam
able should
erated by th
ing cable f
ms.
uld be in
should be
ve contact
should not
boosting c
.
onnected th
re 3-3):
) to the ano
which is go
the cable (
ry on the
r starting ca
tery on the
the cable (
of the mac
contact is pr
re connecte
e auxiliary
chine to be
within 30 sec
and then tr
oved accord
re 3-4):
the earth p
started by
the starting
ttery on the
me system
d bear the
he battery.
for crack,
ntact. All
e in good
with each
come into
cables are
hrough the
ode of the
oing to be
A) to the
auxiliary
able (B) to
e auxiliary
B) to the
chine to be
roper.
d securely
y starting
started. If
conds.
ry again.
ding to the
oint (1) of
y auxiliary
cable (B)
e auxiliary
Service Manual of W
7
machi
3. Remo
of the
4. Remo
from
machi
Wheel Loa
ine.
ove the start
e battery on
ove the othe
the cathod
ine started b
ader
ting cable (A
the auxiliar
er end of th
de (4) of
by auxiliary
A) from the
ry machine.
he starting
the batter
y starting.
e anode (3)
cable (A)
ry on the
Fig. 3-5 Instrument panel (T3)
Service Manual of W
8
32 Elem
321 I-
(equippe
I-ECU rec
switch of t
panel. It he
the machin
Panel displ
Self-check
power, the
return to z
Meanwhile
1.5s, the
model of t
after powe
Description
when the
display is r
stores eve
flashing w
It stops f
30n/min.
LCD of wo
Normal m
The first ro
The second
00000.0 h
countdown
hour timin
working.
Fault mod
The first ro
significant
total faults
The secon
significant
The third
alternative
is displaye
not flash w
Wheel Loa
ments of
-ECU o
ed with T
eives inform
he machine
elps operato
ne.
lay of startking
process
meter need
zero and fi
e, after all
LED of s
the panel. T
r disconnec
n of the wor
engine spe
refreshed ev
ery minute.
hen the eng
flashing wh
orking proc
mode: Displa
ow shows th
d row displ
and 99
n icon flash
ng is disp
de: Displaye
ow shows:
figures, 1
respectivel
nd row sho
figures).
d row sho
ly at a chan
ed reversely
when the hou
ader
electrica
of Inst
T3 engine
mation com
e and display
or to learn t
up process
s: After bei
dle points to
inally point
indicator la
elf-checkin
The meter n
ction.
rking hour m
eed is 350n
very six min
. The hour
gine speed i
hen the sp
ess:
ayed on the
he driving sp
ays time an
9999.9 h.
hes at frequ
played in
ed on the LC
FMI: 12 1/
/1 shows t
ly, the pream
ws: SPN:
ows: Warn
nge frequenc
y). The hou
urmeter is d
al system
trument
e)
ming from s
ay it on the i
the working
ing connec
o the maxim
ts to the ri
amps are k
ng shows n
needle retur
meter: It sta
n/min or la
nutes. But t
rglass sym
is 350n/min
peed is sm
e LCD in tw
peed.
nd maximum
The funn
uency of 2
the midd
CD in three
/1 (FMI is o
the current
mble-less is
123456 (SP
ning and
cy of 2s (th
useglass sym
displayed.
m
panel
sensor and
instrument
g status of
cted to the
mum, then
ght place.
ept on for
name and
rns to zero
arts timing
arger. The
the storage
mbol starts
n or larger,
maller than
wo rows
m range in
nel-shaped
2.5 S. The
dle during
e rows
one or two
fault and
0).
PN is 2-6
hourmeter
he warning
mbol does
Fig. 3-6 No
Functions a
A. Instrum
Function
Engine
tachometer
Working h
meter:
Engine coo
thermomet
Brake pres
gauge
Oil
thermomet
torque
converter
Fuel level
gauge
Speedomet
Language
switch
Alarms:
Function
Low oil
pressure al
Low brake
pressure al
ormal mode
and require
ments:
Spec
r
Ran
our Ran
time
stora
oling
ter
Ran
ssure Ran
ter of
Ran
Ran
Red
ter
Ran
in th
the d
the d
with
20km
The
the c
and
Spe
larm
Ind
the
e
larm
The
whe
grou
e of panel L
ments of in
cific require
nge: 0-3000,
nge: 99999.9
e display is
age stores e
nge: 40-120
nge: 0 -1 MP
nge: 40-140
nge: 0-1/8-1
d zone: 0-1/8
nge: 999.9, l
he normal m
display spee
driving spee
h 8% of corr
m/h should
switch is tr
connection
Chinese is
ecific requir
icating acco
CAN agree
e alarm sym
en the press
unded.
Service M
LCD display
nstrument pa
ements
, red zone: 2
9; when eng
refreshed ev
every minut
?, range of
Pa, red zone
?, red zone
/4-3/8-1/2-5
located in th
mode, unit: k
ed is greater
ed below 20
rection. The
be added w
riggered by
lasts 2 seco
supported.
rements
ording to in
ement.
mbol flashes
sure is 0.4 M
Manual of W
9
y Fig. 3
anel:
2500-3000;
gine speed=
very six mi
te.
f red zone:
e: 0-0.4 MP
e: 120-140?
5/8-3/4-7/8-
he middle o
km/h. In ord
r than the a
0 km/h shou
e speed high
with 6% of c
inching. It
onds. Switch
formation tr
and the buz
MPa or less,
Wheel Loa
3-7Fault mo
unit: n/min
=350n/min, t
nutes. But t
103-120?;
Pa, 0.9-1 MP
?.
-1;
f the first li
der to ensur
ctual speed
uld be added
her than
correction.
is valid wh
h of English
ransferred i
zzer alarms
, or signal is
ader
ode of panel
Signa
n. CAN
the
the
CAN
Pa. Senso
Senso
Senso
ne
re
,
d
Senso
en
h
Groun
Color
in Red
(steadily
on)
s Red
l LCD displ
al Rem
N
Sel
inst
N
or
or
or
or
unding
Sign
ly CAN
com
Sens
grou
lay
mark
f-timing of
trument
nal
N
mmunication
sor or
unding
n
Low
transmissio
pressure al
Charging
indicator a
Oil-water
separation
alarm
Coarse fue
filter alarm
Low fuel o
level alarm
Engine fau
alarm
Engine fau
alarm
Low coola
level alarm
Air filter
blocking al
High coola
temperatur
alarm
High hydra
oil tempera
alarm
Rear hood
opening ala
on oil
larm
1. B
whe
disc
2. A
swi
that
flas
disc
alarm
Com
the
stea
than
use
the
D+
gen
inst
exc
Ind
the
el
m
Ind
the
oil
m
If th
flas
ult The
alar
from
ult Non
ant
m
Ind
the
larm
Ind
the
ant
re Wh
the
aulic
ature The
tem
arm
The
rear
Before starti
ether the sw
connected.
After starting
itch is conne
t the signatu
shes and the
connected, t
mpare volta
generator, t
adily on if v
n that of the
d for power
indicator la
is higher th
nerator is us
trument is e
itation resis
icating acco
CAN agree
icating acco
CAN agree
he fuel leve
shes.
e alarm sym
rms when th
m the CAN
ne
icating acco
CAN agree
icating acco
CAN agree
hen the wate
alarm symb
e alarm sym
mperature is
e symbol of
r hood of th
Service M
ing, the alar
witch is conn
g, if the pre
ected (delay
ure is true),
e buzzer alar
the symbol
age of termin
the charging
voltage of te
e battery and
r generation
amp is off w
han that of t
ed for powe
equipped wi
stance.
ording to in
ement.
ording to in
ement.
l is 1/8 or le
mbol is stead
here is fault
agreement.
ording to in
ement.
ording to in
ement.
er temperatu
bol flashes a
mbol is stead
higher than
f the panel is
he engine is
Manual of W
10
rm symbol i
nected nor
essure is low
y 10 second
the alarm s
rms; if the s
is off;
nal D+ and
g indicator l
erminal D+
d the genera
n or works a
when voltag
the battery a
er generatio
ith a built-in
formation tr
formation tr
ess, the alar
dily on and t
t informatio
.
formation tr
formation tr
ure is 105?
and the buz
dily on when
n the set valu
s steadily on
opened.
Wheel Loa
is kept off
w and the
ds to confirm
ymbol
switch
battery of
lamp is
is lower
ator is not
abnormally;
e of termina
and the
on. The
n 5w 200 O
ransferred i
ransferred i
rm symbol
the buzzer
n transferre
ransferred i
ransferred i
? or higher,
zzer alarms.
n the oil
ue.
n when the
ader
m
Red
al
Red
(steadily
on)
in Yellow
(steadily
on)
in Yellow
(steadily
on)
Red
ed
Yellow
(steadily
on)
Red
(flashin
in Red
(steadily
on)
in Yellow
(steadily
on)
Red
Red
Yellow
Grou
sens
ly
Rigi
ly CAN
com
ly
CAN
com
or gr
Sens
ly CAN
com
ng)
CAN
com
ly
CAN
com
or gr
ly
CAN
com
or gr
CAN
com
Sens
Grou
unding or
sor
id wire
N
mmunication
N
mmunication
rounding
sor
N
mmunication
N
mmunication
N
mmunication
rounding
N
mmunication
rounding
N
mmunication
sor
unding
n
n
n
n
n
n
n
Transmissi
oil filter al
Central ala
lamp
Indicators:
Function
Power cutindication
Preheating
indication
Right steer
indication
Right-hand
turning
instruction
High beam
indication
Differentia
indicator
Mute indic
Unlock of
lock
Hand braki
indicator
Independen
cooling
indication
ion
arm
Wh
con
valu
on.
arm It is
eng
han
sym
Sp
-off Th
po
g Th
pr
ring Th
lam
d
n
Th
lam
m Th
hig
al lock Th
ke
co
cator
Th
mu
is
safety
Th
bu
co
sta
ing
W
the
en
ha
W
the
ala
wh
n/m
nt
Th
hen the key i
ntent of tran
ue of the sw
s the same a
gine speed is
nd brake is n
mbol flashes
pecific requi
he indicating
ower of the t
he indicating
eheater of th
he indicator
mp or the le
he indicator
mp or the ri
he indicating
gh beam of
he indicating
ey is turned
onnected.
he indicator
ute switch i
stopped.
he indicator
uzzer alarms
onnected and
ate.
When the inst
e indicator s
ngine speed
and brake is
When the inst
e indicator s
arms and th
hen then en
min and the
he indicator
Service M
is turned to
smission oi
witch, the ala
as SDLG - 1
s larger than
not released
s and the bu
irements
g symbol is
transmissio
g symbol is
he engine w
lamp flashe
eft steering
lamp flashe
ight steering
g symbol is
f the front co
g symbol is
to ON and t
lamp is ste
s connected
lamp is ste
s when the l
d the workin
trument is c
symbol is st
is 1000 n/m
not release
trument is c
symbol is st
he central ala
gine speed
e hand brake
symbol is s
Manual of W
11
ON, if the
il is higher t
arm symbol
1. Meanwhi
n 1000 n/mi
d, the centra
uzzer alarms
s steadily on
on is cut off.
s steadily on
works.
es when the
switch is on
es when the
g switch is o
s steadily on
ombination
s steadily on
the switch i
eadily on wh
d and the so
eadily on an
local switch
ng device is
connected to
teadily on w
min or less a
ed.
connected to
teadily on, t
arm symbol
is larger tha
e is not rele
steadily on.
Wheel Loa
water
than the set
l is steadily
ile, if the
in and the
al alarm
s.
n when the
.
n when the
e alarm
n.
e alarm
on.
n when the
lamp is on.
n when the
is
hen the
ound alarm
nd the
h is
s in a free
o power,
when the
and the
o power,
the buzzer
l flashes
an 1000
eased.
ader
Yellow
Red
(flashin
Color
Red
Yellow
Green
Green
Blue
Yellow
Yellow
Red
Red
Yellow
Grou
ng) CAN
wire
Signal
Power
supply
Power
supply
Power
supply
Power
supply
Power
supply
Groundin
Groundin
Power
supply
Groundin
Groundin
unding
N or rigid
e signal
Remark
ng
ng
ng
ng
k
Shaft cooli
indication
Quick chan
indication
Pressure
stabilizing
system
Other:
Function
Instrument
backlight
Power inpu
Buzzer
Connector
Software
Pin functio
Fig. 3-8 Pi
A Pin func
Pin
No. F
1 C
2 C
ing Th
nge
Th
bu
co
ch
Th
pr
Sp
t T
co
ut Dd
r
C
20
V
on
n of instrum
ction
Function
CANH
CANL
he indicator
he indicator
uzzer alarms
onnected and
hange state.
he indicator
essure stabi
pecific requ
he backligh
onnected to
DC 5 v / 24 v
riving: 200
Clearance bu
0pin: molex
Version num
ment panel
Pin
No.
11
12
Service M
symbol is s
lamp is ste
s when the q
d the attach
lamp is ste
ilizing is wi
uirements
ht of instrum
power.
DC power
mA.
uzzer, 1.0 - 1
x 00392812
ber of softw
Funct
Left s
Right
Manual of W
12
steadily on.
eadily on an
quick chang
hment is in a
eadily on wh
itched on.
ment is on w
r output inte
1.2 Hz, 85 d
03; 22pin: m
ware: VEr 1
tion
steering lam
t steering la
Wheel Loa
nd the
ge switch is
quick
hen the
when the bac
erface with
decibels.
molex 0039
.0
Pin
No
.
mp 6
amp 7
ader
Yellow
Red
Green
cklight swit
load capaci
9281223?
Function
Signal of
thermome
r
Null
Power
supply
Power
supply
Power
supply
tch is
ity of
Pin
No
.
f
ete 16
17
Remark
Function
TACH 3
Common
3 D
4 Ci
n
5 S
B Pin func
Pin
No. Fu
1 C
2 C
3 Pr
sy
4 Pa
5 Sa
6 Tr
pr
Differential
Charge
ndication
Speed pulse
ction
unction
CAN2H
CAN2L
ressure
ystem
arking brak
afety lock
ransmission
ressure
lock 13
14
15
stabilizing
ken
oil
Service M
Trans
filter
TACH
TACH
Pin
No.
7
8
9
10
11
12
Manual of W
13
smission
H1
H 2
Function
Power shut
High beam
indication
Unlock of q
change
Language s
Coolant lev
Reverse sig
Internal wi
Figure sh
instrument
and some
instrument
Wheel Loa
oil 8
9
10
toff
m
quick
switch
vel
gnal input
iring diagram
hows the i
t panel of c
warning
t controller.
ader
Signal
fuel meter
Brake
pressure
gauge/lam
Analog
ground
Pi
n
No
.
Func
13 Preh
indic
14 Air f
bloc
15 Inde
nt co
16
Axle
temp
e
17 5 v o
18 Rear
open
m of panel
internal wir
combined t
lamps are
of
r 18
mp
19
20
ction
Pi
n
No
.
heating
cation 19
filter
cking- 20
epende
ooling 21
e oil
peratur 22
output
r hood
ning
ring diagra
type. The i
e controlled
power
Switching
power
supply
Hydraulic
oil
temperatur
e
Grounding
o
Functio
n
9
Coarse
fuel
filter
0
Revers
e signal
24V
output
1 Mute
2 Back
lighting
am of the
instrument
d by the
l
g
Fig. 3-9Int
Fig. 3-10W
Tachom
eter
O
temp
e g
Barome
tre
Steerin
ternal wiring
Wiring diagr
Oil
peratur
gauge
Hour meter
LCD
Water
thermomet
er
Instrument contro
Differential lock
Air temperature
sensor
Oil level sensor
Air pressure sensor
Steering switch:
ng switch:
Filter switch
Air temperature
sensor
g diagram o
ram of pane
Fuel
gauge:
ol circuit
Differe
e
Speed selection
wire
Ch
Vehic
Transm
Fuel
Brak
Left s
Righ
Transm
Comm
Switc
Hydr
Service M
of panel
l
ential lock indicator
harge indicator
le speed signal input
mission oil temperature
indicator
level gauge indicator
ke pressure indicator
steering indicator
ht steering indicator
mission oil filter indicator
mon power
ch power
raulic oil temperature
indicator
Manual of W
14
Wheel Loa
Language switch
Pressure stabilizing
indica
Parking b
Safety lock unloc
Transmission oil pr
Power cut-off
High beam in
Quick change unl
Coolant level
Low brake
Preheating
Air filter indicator
Independent cooling i
Axle oil temperature
5 v output
Rear hood opening
Coarse fuel filter in
Mute indicato
Backlit light o
ader
Air filter switch
g system opening
ator
brake
ck indicator
ressure indicator
indicator
ndicator
lock indicator
indicator
pressure
indicator
indicator
indicator
indicator
ndicator
r
on
P
P
Pressure stabilizing s
Parking switch
Unlock switch
Pressur
Cut off switch
High beam
switch
Selector switch
Liquid level
switch
Preheating grill
P
Cooling ECU
Temperature
switch
Travel switch
Coarse filter
switch
Mute switch
Light switch
Back
lighti
ng
circui
t
ystem switch
re sensor
Quick
change
switch
Pressure
switch
Terminal
type
Normal
value
l Powe
24-
er cord G
-28V
Service M
Ground lead
0V
Manual of W
15
Detection m
Connection
composed
CAN bus.
the panel m
The harnes
detect the h
d Connec
the sign
Accord
the wo
sta
322 Eng
with We
Engine con
the engine
engine se
communica
Main techn
Working te
Storage tem
Rated volta
Working v
voltage: 36
ECU is - 20
The ECU i
for reverse
anode and
Protection
E - ECU
connected
is connecte
Wheel Loa
method of p
n harness
of power co
If there is
might be det
ss should be
harness term
ction to
nal line
ding to
orking
ate
gine cont
eichai T3
ntrol unit is
e. It is used
ensor, cont
ate with the
nical parame
emperature:
mperature: -
age: 28.5V
voltage ran
6 v (5 minu
0?).
is equipped
e power con
cathode are
grade: IP6K
U has two
to harness o
ed to the eng
ader
panel
of the
ord, ground
a fault in t
tected to jud
e disconnec
minal.
The resista
and CAN
trol unit
engine)
an electric
d to receiv
trol the e
e other parts
eter:
-40~85?
40~105?
ge: 9 - 32
utes, when s
d with a bui
nnection. Th
e connected
K9K
connector
of the mach
gine.
panel is
d lead, signa
the panel, h
dge the poin
cted form th
CAN bus
ance betwee
N L is abou
ECU (e
control me
ve message
engine run
s of the mac
2v, limiting
surface tem
ilt-in protec
he fuse will
reversely.
rs, connec
hine, and co
generally
al line and
harness of
nt of fault.
he panel to
en CAN H
ut 120O
equipped
echanism of
s from the
nning and
chine.
g operating
mperature of
ction circuit
be fused if
ctor X1 is
onnector X2
d
f
e
d
g
f
t
f
s
2
Figure 3-1
Meanings o
Pin No.
X1-01
X1-02
X1-03
X1-04
X1-05
X1-06
X1-07
X1-08
X1-09
X1-10
X1-12
X1-13
X1-19
X1-20
X1-22
X1-23
X1-24
X1-25
X1-27
1Diagram o
of pins of c
Ab
WI
PW
PW
PW
PW
PW
PW
I_A
I_A
I_A
I_A
I_S
I_A
O_
O_
O_
O_
V_
G_
G_
of engine co
onnector X
bbreviation o
ISE15
WR_V_VBR
WR_G_GND
WR_V_VBR
WR_G_GND
WR_V_VBR
WR_G_GND
A_APP1
A_APP2
A_RMTAPP
A_RMTAPP
S_WFS
A_TL
_F_ENGN
_S_EBR
_S_STRT
_S_WFLP
_V_5VAPP1
_R_APP1
_R_APP2
Service M
ontrol unit (W
1
of
R
D
R
D
R
D
P1
P2
1
Manual of W
16
Weichai) an
Descripti
Power an
Power ca
Power an
Power ca
Power an
Power ca
Signal of
Signal of
Input sign
Input sign
Signal of
Signal of
Output of
Relay of
Starter re
Water in f
Power sup
accelerato
Accelerat
ground
Accelerat
ground
Engin
Wheel Loa
nd connecto
on
node
thode
node
thode
node
thode
f accelerator
f accelerator
nal of doubl
nal of doubl
f water in fu
f polymorph
f engine spe
exhaust bra
lay
fuel indicat
pply of acce
or pedal 1
tor pedal an
tor pedal 2 a
ne V
ader
ors
r pedal 1
r pedal 2
le accelerato
le accelerato
el sensor
hic switch
eed
ake
or lamp
elerator ped
nd double ac
and double
Vehicle
or pedal 1
or pedal 2
dal and doub
ccelerator p
accelerator
ble
edal 1
pedal 2
X1-28
X1-31
X1-32
X1-33
X1-34
X1-35
X1-37
X1-38
X1-39
X1-40
X1-42
X1-43
X1-44
X1-45
X1-46
X1-47
X1-51
X1-52
X1-53
X1-54
X1-55
X1-57
X1-58
X1-59
X1-60
X1-61
X1-62
X1-63
X1-64
X1-65
X1-66
X1-67
X1-68
V_
G_
I_F
G_
O_
O_
O_
O_
O_
B_
B_
S_G
B_
B_
I_S
I_S
I_S
I_S
I_S
I_S
I_S
I_S
I_S
I_S
I_S
I_S
I_S
I_S
I_S
I_S
I_S
_V_5VAPP2
_R_TL
F_VSS
_R_VSS
_S_DIA
_S_IMPH
_S_AC
_S_OBD OB
_S_CSLP
_D_CANH0
_D_CANL0
GND
_D_CANH1
_D_CANL1
S_CRCNEG
S_ACSW
S_CONV
S_GNSW
S_BRKPS
S_ENGSA
S_T50
S_T15
S_DIAREQ
S_BRKMN
S_BRKRED
S_CRCOFF
S_CRCRES
S_EBR
S_STP
S_RMTEN
S_CRCPOS
Service M
2
BD
0
G
D
F
S
S
Manual of W
17
Accelerat
Power sup
Multimod
water in f
Signal of
Vehicle sp
Fault diag
Intake he
Air condi
Indicator
Cold start
Commun
Commun
CAN w
Commun
Commun
Constant
Cruise -
Air condi
Clutch sw
Neutral sw
Hand bra
Off vehic
T50 start
T15 switc
Diagnosis
Main brak
Second b
Cruise of
Cruise res
Exhaust b
Off vehic
Double ac
Cruise +
Wheel Loa
tor pedal 2 a
pply
de switch
fuel sensor
f vehicle spe
peed sensor
gnosis lamp
ating relay
itioning com
lamp
t indicator l
nication CAN
nication CAN
wire shieldin
nication CAN
nication CAN
speed switc
itioning dem
witch
witch
ke switch
cle start swit
switch
ch
s request sw
ke switch
rake switch
ff
sume
brake switch
cle stop swit
ccelerator p
ader
and double
ground
eed sensor
r ground
p
mpressor rel
lamp
N0 high
N0 low
ng
N1 high
N1 low
ch
mand switch
tch of engin
witch
h
h
tch of engin
pedal reques
accelerator
lay
h
ne
ne
st switch
pedal 2
Poly
sw
Fig. 3-12 s
Accelerator ped
Accelerator pedal
Remote pedal1
Remote pedal2
ymorphic
witch
schematic di
dal 1
l2
Vehicle speed
O
iagram for p
Power supply-
Power supply-
Power supply-
Signal line of accelerator pedal 1
Signal line of accelerator pedal2
Ground wire
Ground wire
Ground wire
Signal line
Signal line
Ground electrode
Signal line of remote pedal 1
Signal line of remote pedal 2
Output of engine speed
Signal line
Ground wire
Ground wire
Ground wire
Ground wire
Ground wire
Power supply 5V
Power supply 5V
Power supply 5V
Signal line
Pressure signal line
Temperature signal line
Temperature signal line
Positive end
Positive end
Negative end
Shield
Negative end
Shield
Power supply 5V
Service M
pins of ECU
Manual of W
18
U (Weichai)
Power supply+
Power supply+
Power supply+
Cruise +
Cruise -
Cruise off
Cruise resume
Main brake
Second brake
Hand brake
Exhaust brake switch
Clutch
Gear neutral
Diagnosis request
Constant engine speed
Starter relay
Air conditioning compressor
Intake heating
Cold start lamp
Water in fuel lamp
OBD lamp
Diagnosis lamp/flash code lamp
Exhaust brake
Signal line
Ground wire
AC request
Engine start
Engine stop
Remote accelerator selector
switch
24v output
24v output
24v output
24v output
PWM output
Negative end driving PWM
Wheel Loa
)
Water in fuel
Maximum bearable
Maximum bearable
Cooling fan (PWM)
Electromagnetic fan relay
ader
The four la
connected
instrum
T15
current 3A
current 4A
Flow measurement unit
Ignition sequence 1 5 3
amps may not be
d in case of CAN
ment control
5 Load 2
T15 Load 1
3 6 2 4
Fig. 3-13E-ECU
Service Manual of W
19
323 Eng
with YU
Engine con
of the engi
engine se
communic
Wheel Loa
gine cont
UCHAI T
ntrol unit is
ine. It is us
ensor, cont
ate with the
ader
trol unit
T3 engine)
s an electri
ed to receiv
trol the e
e other parts
ECU (eq
e)
ic control m
ve message
engine run
s of the mac
quipped
mechanism
s from the
nning and
chine.
Service Manual of W
20
Wheel Loader
DPSCJ_ED
_V1.0
K-XX=??
??-
??+
????
?????
K ?
??CAN
??CAN
?????
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????
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?????
?????
?????
????
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DC17BASIC
?
?ON ?
? ?ST
N H
N L
?
????
????
????
???
?
?
?
?
???+
???-
???
???
??
?(LED
?
?
???
?
(?)(V1
??
??
????
??
??
C_T30_??
TART ?
?
?
?
D)
0)
?
Service M
????
Manual of W
21
?DPS
wiri
K-X
Pow
Pow
Igni
Star
K w
Com
Com
Diag
Com
Eng
Eng
Pow
Cold
Mai
Pres
Aux
Pres
Diag
Clut
Neu
Dep
Crui
Crui
Crui
Crui
Preh
Wat
Wat
Aux
Rem
Air
Pow
Mul
Mul
Elec
mult
Vehi
Vehi
Vehi
Pow
Wheel Loa
SCJ_EDC17
ng harness
XX=overall
wer supply +
wer supply -
tion switch
rt control sw
wire
mmunication
mmunication
gnosis calib
mmunication
ine failure i
ine failure i
wer output
d start prehe
n brake swi
ss on brake
xiliary brake
ss on brake
gnosis reque
tch switch
utral position
press clutch
ise control a
ise control a
ise control s
ise control e
heating cont
er alarm ind
er overflow
xiliary start
mote acceler
conditionin
wer output (g
ltifunctional
ltifunctional
ctrical
tifunctional
icle speed s
icle speed s
icle speed s
wer output
ader
7BASIC_T3
diagram_V
vehicle end
connecting
witch connec
n CAN H
n CAN L
bration inter
n interface w
indicator lam
indicator lam
eating indic
itch
for connect
e switch
for disconn
est switch
n switch
for disconn
adjustment
adjustment
stop switch
enabling sw
trol relay
dicator lamp
w alarm indic
switch
rator enablin
ng request sw
ground) (V1
l switch gro
l switch sign
resistance
l switch
ensor signa
ensor
ensor circui
30_overall
V1.0
d
g ON gear
cting STAR
rface
with other c
mp power s
mp circuit
cator lamp
tion
nection
nection
switch +
switch -
witch
p (LED)
cator lamp
ng switch
witch
10)
ound wire
nal
proper
al
uit
vehicle
RT gear
controllers
supply
rties of
e
f
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????
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??1 ??
??1 ??
??1 ??
??2 ??
??2 ??
?????
??2 ??
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??2#
1 ??
2 ??
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Service Manual of W
22
Fuel
Star
Pow
Fan
Fan
Acc
Acc
Acc
Acc
Acc
Mai
Acc
Rem
Rem
Rem
Eng
Wheel Loa
l preheating
rt control rel
wer output
control rela
control rela
elerator 1 c
elerator 1 si
elerator 1 p
elerator 2 si
elerator 2 p
n accelerato
elerator 2 c
mote acceler
mote acceler
mote acceler
ine speed o
ader
g relay
lay
ay 1#
ay 2#
ircuit
ignal
ower supply
ignal
ower supply
or pedal
ircuit
rator 1 signa
rator 2 signa
rator pedal
utput pulse
ly
ly
al
al
signal
Fig. 3-14
diagram
switch
4 Connect
of polym tors and s
morphic fu
Full load
Half load
No- load
Service M
schematic
uel-saving
Manual of W
23
324 Poly
The engin
load and no
controls t
according t
The resist
whether th
Wheel Loa
ymorphic
e has three
o load. The
the engine
to different
tance value
e switch is
ader
c fuel-sav
e working m
polymorph
e to sele
working co
e might be
damaged.
ving swit
mode: full
hic fuel-sav
ect differen
onditions to
e detected
ch
load, half
ing switch
nt output
save fuel.
to judge
Fig. 3-15
electronic
5 Pins and
c accelerator
d output fe
r pedal
Service M
atures of
Manual of W
24
325 Elec
The engin
accelerator
to limit th
when abn
accelerator
As shown
pedal is co
as APS1 a
voltage of A
Electrical c
Working v
Rated curre
Allowable
ground of A
Allowable
power supp
Relation of
Synchrono
SY=( APS
Wheel Loa
ctronic ac
ne throttle
r pedal. Th
he maximu
normal out
r is detected
n in the fig
omposed of
and APS2
APS1 is abo
characteristi
oltage (ACC
ent (APS1,
duration o
APS1 and 2
duration o
ply of APS1
f APS1 and
ous deviation
1 /2)-APS
ader
ccelerato
is controll
e protection
um engine
tput signal
d.
gure, the e
power cord
signal outp
out 2 times
ics
C1, ACC2)
APS2) : �1
of instantan
2: 20Min ma
of instantan
1 and 2: 20M
APS2 outpu
n between A
S2=�0.07V
or pedal
led by an
n function
speed at
l of the
electronic a
d, ground le
put lines. T
of APS2.
: �5.5V
0mA
neous short
ax
neous short
Min max
put voltage:
APS1 and A
V
electronic
is applied
1000r/min
electronic
accelerator
ead as well
The output
circuit to
circuit to
APS2 (SY)
Figure 3-
Common f
Fault
Short circu
Open circu
Capacity re
Overcharg
16 Battery
faults of ba
uit
uit
educing
e
attery
P
B
m
F
se
R
Service M
Phenomenon
Battery vol
multiples of
Fault of char
elf-discharg
Reducing of
Manual of W
25
326 Batt
Maintenan
loader.
Main param
Rated volta
Rated capa
Reserve ca
Low tempe
Open circu
battery: 12
n
ltage drop
2.
rging and di
ge
f electrolyte
Wheel Loa
tery
nce-free lea
meters:
age: 12V
acity of 20h
apacity: 230
erature start
uit voltage
2.5 V to 12.9
ps by inte
ischarging
level
ader
d-acid batt
: 120A.h
0min
ting current
: Open cir
9 V
Mea
egral Repl
Repl
Repl
Repl
teries are a
: 850A
rcuit voltag
asure
lace
lace
lace
lace
adopted to
ge of new
Figure 3-
Figure 3-
17weichai
18 yuchai A
Alternator
Alternator
Service Manual of W
26
327Gene
Alternator
battery an
generators
generator h
Wheel Loa
erator
is a mech
d the mach
for accord
has three ter
ader
hanism to s
hine. There
ding to dif
rminals: B+
supply pow
e are three
fferent eng
+, D+ and W
wer to the
e types of
gines. The
W.
Generator
Equipped
Weichai
engine
Equipped
yuchai T3
Methods an
1. Check
voltag
probe
voltag
voltag
prope
readin
2. If the
2.1 Firstly,
2.2 Close
correctly, s
2.3 Check
2.4 If the p
manufactur
specificatio
Sp
with
T3
28
with
engine
28
nd measure
k with 200V
ge of the ge
e to the gro
ge of the ba
ge of the g
erly, the rea
ng.
generator d
, check whe
the electri
securely and
whether the
problem sti
rer.
on:
pecification
8V-55A
8V-70A
es for judgin
V DC volt
nerator (con
und). Reco
attery. It is u
generator ag
ading should
does not gen
ether the tran
ic lock. Ch
d reliably.
e generator
ll can't be s
Service M
n Function
of
terminal
Charging
Charging
ng whether p
age of a m
nnecting the
rd reading
usually less
gain. Recor
d about 28V
nerate powe
nsmission b
heck wheth
is grounded
solved, plea
Manual of W
27
n
B
Functio
of
termina
g Charge
indicat
g Charge
indicat
power gene
multimeter.
e red probe
of the mul
than 26V).
rd reading
V). The sec
er:
belt of the g
er the wiri
d reliably.
ase replace
Wheel Loa
on
al D
Func
e
ting
e
ting
eration of th
Unlock the
to D+ of th
timeter (the
. Start the m
of the mu
cond readin
generator is
ing operato
the generat
ader
ction of term
he generator
e electric lo
he generator
e reading is
machine and
ultimeter (it
ng should b
too loose.
or of the g
tor or conta
minal W
r is proper:
ock. Measu
r; connectin
s actually th
d measure t
t the gener
be higher th
generator is
act professio
ure terminal
ng the black
he terminal
the terminal
rator works
han the first
connected
onals of the
l
k
l
l
s
t
d
e
Fig. 3-19
Diagnosis
The starter
The starter
starting rel
if the start
reasons are
poor conta
Insufficien
Although t
cannot be
power is d
caused by
spring forc
caused by t
The starter
The starter
reasons are
Idling of th
The starter
the one-wa
drive gear,
may remov
Too large s
Possible r
electromag
friction or
sweeping o
Starter
and remova
r refuses to w
r refuses to
lay or the st
ter still refu
e fault in the
act or open c
nt power of
the starter c
started sm
decreased. P
oxidation a
ce, local sh
tightness of
r can't be sto
r cannot sto
e fault of the
he starter
r runs but th
ay clutch, d
, gear break
ve the fault.
starting nois
reasons for
gnetic switc
howling so
of motor cau
al of commo
work
o work whe
tarting switc
uses to work
e solenoid c
circuit in the
starter
can drive th
oothly. It m
Possible reas
and corrosio
ort circuit o
f engine ass
opped
op working
e power sta
he cranksha
disorder or
king or exce
se
r rhythmic
ch, damage o
ound might
used by roto
Service M
on fault of s
n it is conn
ch is discon
k after trou
coil of starte
e brush, com
he cranksha
means that
sons are fee
on, burning
of motor ar
sembly and
when the p
arting switch
aft of the en
clamping
essive wear
c crash in
of starting r
t because da
or out-of-ro
Manual of W
28
328 Star
The starter
mechanica
and finally
equipped
according
controls ar
starter
nected to po
nnected, or t
ubleshooting
er electrom
mmutator, a
aft of the e
the loading
ed of battery
of commuta
rmature and
low environ
power and th
h or starting
ngine refus
of the rotar
ring of gear
starting a
relay, feed o
amage of b
ound, burnin
Wheel Loa
rter
r transfer el
al power to
y rotate the
with thre
to differen
re also differ
ower and sw
there is an o
g, there is a
agnetic swi
armature, m
engine, the
g capacity
y, looseness
ator, excess
d field wind
nment temp
he starting
g relay or bo
es to rotate
ry mechani
rs, loss of sh
are open
of battery, p
bearing, ben
ng of comm
ader
lectric energ
drive the fl
e crankshaft
ee modes
nt engines s
rent.
witched on
open circuit
fault insid
tch, burning
magnetic fiel
speed is to
is reduced
s of battery
sive wearing
ding, excess
perature.
switch are d
onding of th
. Possible r
ism, insuffi
hift rail, etc
circuit of
poor contact
nding of arm
mutator, poor
gy of the b
lywheel of t
ft of the en
of starte
so that the
n. It might b
in the conn
de the starte
g of the eng
ld of the mo
oo low that
and the ac
terminal, p
g of brush,
sive starting
disconnecte
he engine sw
reasons are
icient extru
c. Replacing
holding c
t of pole, et
mature shaf
r contact of
attery into
the engine
ngine. it is
er motors
eir starting
because the
necting wire
er; Possible
gine switch,
otor.
the engine
ctual output
poor contact
insufficient
g resistance
ed. Possible
witch.
slipping of
usion of the
g the clutch
coil in the
tc. Constant
ft, chamber
f brush, etc.
e
e;
e
,
e
t
t
t
e
e
f
e
h
e
t
r
Fig. 3-20S
Location
Termin
Starting swi
Startin
nal
itch
g switch
Service Manual of W
29
329 St
As show
gears of
B/BR/R
connecte
learnt in
Detectio
Methods
damaged
Remove
the digi
should b
conducti
Commo
1. The st
switched
Fault
phenom
No r
after st
Start
being
connec
power
Interrup
starting
Wheel Loa
tarting sw
wn in figure,
f ON/HEAT
R1 / R2 / C/A
ed at ON. S
n the same w
on method:
s for judgin
d. Disconn
e the electri
ital multim
be repaired
ing.
n faults of s
tarting swit
d on
menon C
response
arting
Oo
after
cted to
Ccs
pted
g P
ader
witch
, the starting
T/ON/OFF a
ACC. Termi
ituations of
way.
ng whether
ect the wir
ic lock from
meter at 200
or replace
starting swit
ch does not
Cause:
Out of tou
of contacts
Contact
cannot
separated
Poor contact
g switch ha
and six term
inal B/BR/A
f other gears
r the electr
re and elec
m the vehic
0O of resi
ed in case o
tch :
t response e
Measu
uch Repla
be Repla
t Repla
s four
minals of
ACC are
s might be
ric lock is
ctric lock.
cle. Check
istance. It
of fault in
even if it is
ures
ce
ce
ce
1 - sens
Fig. 3 -21
or float 2
1 Fuel level
1
2
- floater
sensor
Service Manual of W
30
3210F
The fuel
float 1 a
sensor fl
Floater 2
1 With t
down flo
the float
correspo
connect
example
to R30 i
displays
Compar
resistanc
Oil lev
9
27
49
74
87
10
Detectio
? Sho
of
bon
the
sho
con
circ
rep
is a
pro
? Res
sen
of
mu
tab
Wheel Loa
Fuel level
l level senso
and floater 2
float.
moves up
he change o
oat with cha
ter is in a ce
onding reed
correspond
e, if switch K
s connected
s a reading.
ison table
ce value
vel (H)
95
74
95
47
75
002 E
on method:
ort circuit m
the fuel le
nded, the in
sensor is
ow the min
nnection be
cuit. Any
placed. Othe
fault in th
operly.
sistance me
nsor plug an
200 O. O
ultimeter an
le above.
ader
sensor
or is mainly
2. There is a
and down a
of liquid lev
ange of the
ertain positio
switch will
ding resistan
K30 is conn
d to power. T
for liqui
Gear
Full tank]
6/8
4/8
2/8
1/8
Empty tank
:
method: Re
vel sensor.
strument w
suspended,
nimum read
etween the
damaged
erwise, che
e instrumen
easurement
nd use multi
Observe rea
d compare
y composed
reed switc
along the se
vel, move up
liquid level
on, switch o
l be turned o
nce bank. Fo
nected, resis
The fuel ga
id level,
Resista
6.2�
19.2
32.
55.6
80.4
k 109
emove the
If the sen
will show ful
, the instru
ding to refle
instrumen
sensor s
eck the circ
nt if the circ
method: Re
timeter at a
ading chang
with the d
of sensor
h in the
ensor float
p and
l. When
of
on to
or
stance R1
auge
gear and
ance (O)
�0.6
2�0.8
.2�1
6�1.4
4�1.6
9.7�2
sense line
nse line is
ll range. If
ument will
ect proper
nt and the
hould be
cuit. There
cuit works
emove the
resistance
ge of the
data in the
Fig. 3-22P
1
Fig. 3-23
1. Revers
2.Transmi
Power switc
ing switch
ission press
ch
2
sure switch
Service Manual of W
31
3211Pow
The pow
battery v
The pow
rear fram
to the ca
The wor
75?. T
90%.
Fault de
two term
meter.
3212 Pr
The pre
oil press
disconne
specific
below:
Transmi
used to d
transmis
the trans
Main pa
1. The
2. The
to 0
3. Rat
Reverse
variable
displaye
pressure
Main pa
1. The
2. The
to 0
3. Rat
Wheel Loa
wer switch
wer switch d
voltage wh
wer switch i
me. The ba
athode (24V
rking envir
The relative
etection met
minals of th
ressure swit
ssure switc
sure of the
ects the sw
value. it
ission press
detect press
ssion alarm
smission is t
arameters:
e switch con
e contact is
0.95�0.05M
ted voltage:
switch 3
speed con
ed on the p
e.
arameters:
e switch con
e contact is
0.7�0.05MP
ted voltage:
ader
disconnects
en the mac
is located on
attery disco
V) of the bat
onment tem
e humidity
thod: Check
e power sw
tch
h mainly ch
machine sy
witch when
mainly hav
sure switch
sure of the tr
lamp is on
too low.
ntact is usua
closed whe
MPa.
DC24V; ra
10-LGK1
ntrol valve,
anel accord
ntact is usua
opened wh
Pa .
DC24V; ra
s the machin
chine is not
n the right s
onnector is
ttery.
mperature is
is not gre
k on-off sit
witch with a
hecks air p
ystem. It co
the pressur
ve pressure
YK215B1
transmission
when the p
ally closed.
en the press
ated power:
is installe
, the revers
ding to cha
ally opened
hen the pres
ated power:
ne and the
t operated.
side of the
connected
s - 40? -
eater than
tuations of
resistance
pressure or
onnects or
re exceeds
e switches
is mainly
n. The low
pressure of
sure drops
45W.
d on the
se gear is
ange of oil
d.
ssure rises
45W.
Fig. 3-24
Fig. 3-25
Brake lamp
Parking bra
p switch
ake switch
Service Manual of W
32
Brake la
brake va
brake la
lamp cir
Main pa
1. The
2. The
to 0
3. Rated
Parking
Main pa
1. The
2. The
rise
3. Rated
Emergen
pressure
when th
The swit
Main pa
1. The
2. The
to 0
3. Rat
Brake pr
engine)
brake pr
of the pa
Detectin
shell of
Wheel Loa
amp switch
alve. When
mp switch i
rcuit and the
arameters:
e switch con
e contact is
0.13�0.015M
d voltage: D
brake switc
arameters:
e switch con
e contact is
es to 0.4�0.0
d voltage: D
ncy brake
e inside the
he pressure
tch is conne
arameters:
e switch con
e contact is
0.3~0.4Mpa
ted voltage:
ressure sens
is installed
ressure and
anel. The se
ng the resis
f the sensor
ader
YK209KL
n the brake
is turned on
e brake lamp
ntact is usua
s closed wh
MPa.
C24V; rate
ch HFF-375
ntact is usua
disconnect
025Mpa.
C24V; rate
switch LY
gas tank. It
is lower th
ected to line
ntact is usua
s closed wh
a.
DC24V; ra
sor YG901C
d on the ga
show it on
ensor is conn
stance betw
r can judge
LA is install
pedal is ste
n to connect
mp will be on
ally opened
hen the pres
ed power: 45
57002 (YK2
ally closed.
ted when th
ed power: 45
- 3720002
t forces park
han the saf
e 54.
ally opened
hen the pres
ated power:
C3 (equippe
as tank to
n the brake
nnected to lin
ween termin
e whether t
led on the
epped, the
t the brake
n.
d.
ssure rises
5W.
210B)
he pressure
5W.
2 tests the
king brake
fety value.
d.
ssure rises
45W.
ed with T3
detect the
barometer
ne 18.
nal G and
the sensor
Fig. 3-26
brake pre
Fig. 3-27
Pressure
Referenc
Allowab
6 Emergen
ssure senso
Temperatur
e (Mpa)
ce resistanc
ble error (O)
ncy brake
r
re sensor
0
e (O) 20
) �1.5
Service M
switch and
0.4
59
5 �3
Manual of W
33
d works p
below:
3213 T
sensor
Torque
equipped
resistanc
is used
oil in the
Changes
are show
Tempe
Resista
Tempe
Resista
Method
Short cir
torque c
line is b
If the se
show th
connecti
Any d
Otherwi
instrume
Measure
a multim
screw o
Observe
3214E
Engine w
engine
tempera
0.5
70
Wheel Loa
properly. Sp
Torque co
r
converter
d with WD
ce decrease
to detect th
e torque con
s of tempe
wn in the fol
rature (?)
ance (O)
rature (?)
ance (O)
of fault dia
rcuit metho
converter oil
bonded, the
ense line is
he minimu
ion between
damaged s
ise, check th
ent if the cir
ement meth
meter. Conn
on the sens
e the resistan
Engine wa
water temp
is the sam
ture sensor.
0.7
87
ader
pecific para
onverter
oil tem
DG1371 tem
s with the r
he temperat
nverter.
erature and
llowing tabl
40
351 2
100 1
40.4 2
agnosis:
od: Remove
l temperatur
instrument
suspended
um reading
n the instru
sensor sho
he circuit. T
rcuit works
hod: measur
nect the red
sor and bo
nce changes
ater temp
erature sens
me with t
0.8
92.5
ameters are
oil temp
mperature s
mperature se
rise of temp
ature of the
electrical
le
50 60
226 153
115 120
26.4 23
e the sense l
ure sensor. If
will show
d, the instru
g to refle
ument and t
ould be
There is a f
properly.
re the resist
d probe to
ond the bla
s with temp
perature
sor equippe
torque con
0.9
100.5
shown as
perature
sensor is
ensor. The
perature. It
hydraulic
resistance
80
76
0 140
13.6
line of the
f the sense
full range.
ument will
ct proper
the circuit.
replaced.
fault in the
tance with
the small
ack probe.
perature.
sensor
ed with T2
nverter oil
1
107
�5
Fig. 3-28
external w
Figure 3-2
handle
Red Yello
8 Interior p
wiring diagr
29 Solenoid
Fr
Red
(positive)
ow Black
principle d
ram of wipe
d valves ins
Red
Black
White
Blue
White (slow)
White
Blue
Service M
diagram and
er
ide the pilo
Black
Manual of W
34
d
ot
3215 W
Figure 3
and exte
of extern
Line
No.
0
24
25
26
37
If the wi
1. Che
2. Che
is p
3. Che
4. If t
wip
mo
3216P
There ar
valve an
handle.
valves is
Wheel Loa
Wiper an
3-29 shows
erior wiring
nal wiring a
Functio
Ground
Reset li
Low sp
wiper
High sp
wiper
Power c
iper refuses
eck whether
eck whethe
proper.
eck whether
the circuit w
per might b
otor.
Pilot hand
re floating
nd boom s
Internal re
s 100O.
ader
d wiper m
the interio
g diagram is
are shown in
n
ding
ne of front w
peed wiring
peed wiring
cord of fron
to work:
r the fuse F
r voltage of
r the switch
works prope
be damaged
dle soleno
solenoid va
solenoid va
esistance va
motor
or schemati
s the wiper
n the table b
wiper
g of front
g of front
nt wiper
F9 is fused.
f each funct
h works prop
erly, the mo
d. Pease re
oid valve
alve, bucke
alve inside
alue of the
c diagram
r. Function
below:
Color
Black
White
White
White
Red
tional wire
perly.
otor of the
eplace the
es
et solenoid
the pilot
e solenoid
32 Elect
321 Com
Compariso
different fr
Lin
e
no.
Lin
(co
0 B
01 B
02 B
03 B
04 B
05 B
06 B
07 B
0a
0b
0c
0d
0e
1 R
2
2A R
2B
2C Blu
2D R
trical cir
mparison
on table for
rom the actu
e color
lorful) (m
ro
Black
Black
Black
Black
Black
Black
Black
Black
Red
Red
ue/Red
Red
rcuit of m
n table for
r line numb
ual situation
Line
color
monoch
omatic)
W
d
Black
Black
Black
Black
Black
Black
Black
Black
Black
Black
Black
Black
Black
Black
Black
Black
Red
Red
Red
Red
Red
Red
Service M
machine
r line No
ber and fun
n)
Wire
diamet
er
5 Gr
1.25 Gr
0.85
Gr
2
0.85
Gr
1.25
2
1.25
2 Gr
5
0.85 Gr
0.85
Gr
1.25
1.25
Gr
3
Gr
Gr
0.85 Gr
hyd
3 Wi
5 Ter
5 En
5 En
2 EC
2 Pow
Manual of W
35
e
o. and fun
nctions of th
round cable
round wire o
round wire o
round wire
round wire o
round wire o
round wire o
round wire o
round wire o
round wire o
round wire o
draulic oil t
ire from rel
rminal wire
ngine chargi
ngine chargi
CU power co
wer cord of
Wheel Loa
nctions of
he machine
Name
of power su
of inductive
of resistiv
of frame
of switch
of controller
of air condit
of engine
of instrumen
of emergenc
temperature
ay to stator
e on fuse bo
ing line
ing line
ord of engin
f shutdown
ader
f the mac
e (for refere
pply
e load
e load
r
tioner
nt
cy steering
e sensor
motor
ox
ne
relay
chine
ence only, i
Re
Ground
relay
Light
Single
tempera
control
Warm w
it might be
emark
d wire of
ature
harness
wind
e
2e Blu
2F R
3 Ligh
4 Brow
5 Blu
6 Wh
7 Gre
n
8 Yel
o
9 Blue
10 Bro
e
11 Bro
12 Yell
e
13 Wh
l
14 Wh
15 Wh
16
17 Purp
18 Purp
19 Yel
a
20 Purp
21 Red
ue/Red
Red
ht pink
wn/Bla
ck W
ue/Blac
k W
hite/Pur
ple W
een/Ora
nge W
low/Br
own W
e/Yello
w W
own/Gr
een W
own/Bl
ue W
low/Gr
een W
hite/Yel
low W
ite/Bro
wn W
ite/Gre
en W
ple/Bla
ck W
ple/Gre
en W
low/Bl
ack W
ple/Wh
ite W
d/Yello
w
Red
Red
Red
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
Red
Red
Red
Service M
1.25 Pow
0.85 Pow
2 Pow
1.25 Hig
1.25 Lo
0.85 Co
lam
0.85 Co
0.85 Co
0.85 Co
1.25 Hig
1.25 Lo
0.85 Co
0.85 Co
sw
0.85 Sig
wa
0.85 Co
of
0.85 Sig
pre
0.85 Sig
0.85 Sig
0.85 Sig
1.25
Co
wit
R
P
Manual of W
36
wer cord of
wer cord of
wer cord of
gh beam wi
ow beam wir
onnecting w
mp
onnecting w
onnecting w
onnecting w
gh beam wi
ow beam wir
onnecting w
onnecting w
witch
gnal line of
ater-thermom
onnecting w
torque conv
gnal line of
essure
gnal line of
gnal line of
gnal line of
ommon pow
th power sw
Reserved pow
withou
Power cord o
Wheel Loa
f ECU ignit
f battery rel
f vehicle har
ire of rear h
re of rear he
wire of right
wire of left st
wire of brake
wire of rever
ire of front h
re of front h
wire of horn
wire of hand
engine
meter
wire of oil th
verter
transmissio
brake barom
fuel gauge
charging
wer cord (20
witch)
wer cord (2
ut power sw
of electric l
fuse)
ader
ion switch
ay
rness
headlamp
eadlamp
steering
teering lamp
e switch
se signal
headlamp
headlamp
button
brake
ermometer
on oil
meter
-way fuse,
0-way fuse,
witch)
ock (8-way
p
,
y
21a
21B
21C
22 Yel
h
22a Blu
22b Whi
22c Ye
23 Pu
24 Yel
24a Yel
25 Brol
25a Brol
26 Gre
26a Gre
27
28 Wh
29 Gre
30
Gre
30A
31 Wh
32 Gre
33 Purpl
34 Bro
h
low/W
hite W
ue/Red W
ite/Red W
ellow
urple W
low/Bl
ue W
low/Bl
ue W
own/Ye
llow W
own/Ye
llow W
een/Bla
ck W
een/Bla
ck W
hite/Blu
e W
een/Wh
ite W
een/Bro
wn
W
W
hite/Bla
ck W
ey/Blac
k W
ple/Yel
low W
own/W
hite W
Red
Red
Red
White
White
White
Red
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
Service M
0.85
Pow
pow
Pow
fus
Pow
(20
0.85 Wi
rel
0.85 Co
pro
0.85 Co
1.25 Co
wir
0.85 Co
0.85 Re
0.85 Re
1.25 Lo
1.25 Lo
1.25 Hig
1.25 Hig
0.85 Co
2 Pu
shu
1.25 Co
0.85 Co
bac
0.85 Co
pre
0.85 Co
ala
0.85 Ou
1.25 Sig
Manual of W
37
wer cord of
wer switch)
wer cord of
se, with pow
wer cord of
0-way fuse,
ire from ele
ay
onnecting w
otection swi
onnecting w
onnecting w
re
ontrol line o
eset line of w
eset line of r
ow speed wi
ow speed wi
gh speed w
gh speed w
onnecting w
ull in windin
utdown
onnecting w
onnecting w
cklight
onnecting w
essure alarm
onnecting w
arm lamp
utgoing line
gnal of head
Wheel Loa
f flasher (20
)
f roof lamp
wer switch)
f roof alarm
with power
ectric lock to
wire of startin
itch
wire of starte
wire of start p
f sprinkler m
wiper
rear wiper
ire of wiper
ire of rear w
ire of wiper
ire of rear w
wire of batter
ng of electri
wire of width
wire of rocke
wire of engin
m lamp
wire of brake
of flash sig
dlamp
ader
00-way, with
(20-way
m lamp
r switch)
o starter
ng
er
protection
motor
wiper
r
wiper
ry relay coil
city
h lamp
er switch
ne oil
e pressure
gnal
th
l
35
35A Red
35B
36
R
36A
36B
36C
36D
37
Oran
37A
37B
37C
37D
37E
37F
38
38A Whi
38B
38C
39 Blac
40
Red
40A
40B
40C
40D Pu
41
Bro
41A
d/Black
Red
nge/Re
d
ite/Red
ck/Red
d/Black
urple
own/Re
d
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Service M
1.25 Co
1.25 Co
sup
0.85 Ba
3
Co
Air
1.25 Fan
1.25 Fan
fus
1.25 Fla
1.25
Co
Pow
Pow
Pow
sw
Pow
Pow
Pow
(8-
1.25
Co
(21
Pow
(21
Pow
fus
Re
1.25 Pow
0.85
Co
Pow
Pow
Pow
0.85 Ou
1.25
Co
P
Pow
fus
Manual of W
38
onnecting w
onnecting w
pply
acklight pow
onnecting w
r conditione
n power sup
n heater pow
se)
asher power
onnecting w
wer cord of
wer cord of
wer cord of
witch
wer cord of
wer cord of
wer cord of
-way fuse)
onnecting w
1-way, pow
Power cord
withou
wer cord re
1-way fuse,
wer cord of
se, with pow
eserve powe
wer supply
onnecting w
wer cord of
wer cord of
wer cord of
utgoing line
onnecting w
Power cord
with
wer cord of
se, without p
Wheel Loa
wire of fuse b
wire of headl
wer supply c
wire of fuse b
er power su
pply (20-wa
wer supply
r supply (8-
wire of fuse b
f wiper
f wiper rock
f sprinkling
f radio (8-w
f roof lamp
f roof alarm
wire of fuse b
wer switch)
d of flasher
ut power sw
eserved for c
with power
f safety lock
wer switch)
er supply int
of headlam
wire of fuse b
f horn
f brake
f reversing
of horn rel
wire of fuse b
of radio(21
power swit
f roof lamp
power switc
ader
box
lamp power
cord
box
pply
ay fuse)
(20-way
way fuse)
box
ker switch
can rocker
way fuse)
(8-way fuse
m lamp
box
(21-way,
witch)
cold start
r switch)
k (21-way
terface
mp
box
ay
box
-way fuse,
tch)
(20-way
ch)
r
e)
41B
41C
42
L
42A pin
42B
43 Red
E44 G
44 Red
45
45A Gre
45B
46 Red
47 Red
48 Red
49 Gre
50 Wh
51
52 Brow
53 Gre
54 Bro
e
55 Bro
56
R
56A
56a R
56b R
Light
nk/Red
d/Brow
n W
Green W
d/Brow
n
en/Red
d/Green
d/Grey
d/Blue
ey/Yell
ow W
ite/Gre
y W
wn/Bla
ck W
een/Blu
e W
own/Gr
een W
own/Bl
ue W
Red
Red
Red
Red
Red
Red
Red
Red
White
White
Red
Red
Red
Red
Red
Red
Red
Red
White
White
White
White
White
White
Red
Red
Red
Red
Service M
Pow
(20
Pow
wit
1.25 Pow
loc
0.85 Pow
val
0.85 Pow
0.85 Pow
0.85 Sig
1.25 Pow
1.25
Co
Pow
Ro
fus
Pow
fus
1.25 Pow
1.25 Pow
0.85 Pow
box
0.85 Sig
0.85 Sig
0.85 Co
wo
1.25 Co
0.85 Wi
bra
0.85 Wi
han
5 Pow
2 Co
5 Po
5 Wi
Manual of W
39
wer cord of
0-way fuse,
wer cord of
thout power
wer cord of
cation)
wer cord of
lve location
wer interfac
wer cord of
gnal line of
wer cord of
onnecting w
wer supply
ocker switch
se)
wer supply
se)
wer cord of
wer cord of
wer cord of
x
gnal line of
gnal line of
onnecting w
ork indicato
onnecting w
ire from em
ake switch
ire from bra
nd brake sw
wer cord of
onnecting w
sitive wire
ire from rel
Wheel Loa
f roof alarm
without po
f radio (20-w
r switch)
f pilot valve
f pilot valve
n)
ce of proxim
f stopwatch
preheat ind
f combinatio
wire of fuse b
of rear hea
h of fan heat
of electric
f brake solen
f rear hood d
f transmissio
high beam
low beam
wire of comp
r lamp
wire of fan h
mergency bra
ake solenoid
witch
f machine
wire of fuse b
of battery
ay to electri
ader
m lamp
wer switch)
way fuse,
e (fuse
e (pilot
mity switch
dicator
on switch
box
dlamp
ter (8-way
fan (8-way
noid valve
downlight
on control
puter box
eater
ake to hand
d valve to
box
ic pump
)
d
56c R
56d R
57 W
57a Br
58 A
59 Ligh
60 Ye
E61 R
61 Blu
62 Bro
h
E63 B
63 Brol
64 Gre
65 Gre
66 W
67 R
67a R
68 Ye
69 W
70 W
71 Gre
l
72 Blu
73 Wh
n
74 Blu
75 Gre
76 Red
77 R
78 Red
Red
Red
White W
rown W
Ash W
ht pink W
ellow W
Red W
ue/Blac
k W
own/W
hite W
Blue W
own/Ye
llow W
een/Bla
ck W
een/Blu
e W
White W
Red W
Red W
ellow W
White W
White W
een/Yel
low W
ue/Gree
n W
ite/Ora
nge W
ue/Oran
ge W
een/Wh
ite W
d/Green
Red
d/Grey
Red
Red
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
Red
Red
Red
Service M
5 Wi
5 Po
0.85 Sig
0.85 Co
bac
0.85 Sig
0.85 Sig
0.85 Wi
int
0.85 Sig
0.85 Co
lam
0.85 Wi
sol
0.85 Sig
0.85 Wi
sol
0.85 Co
(bo
0.85 Co
(bu
0.85 Sig
3 Co
4 Co
0.85 Sig
0.85 Sig
0.85 Sig
1.25 Co
0.85 Co
0.85 Co
me
0.85 Co
0.85 Sig
0.85 Pow
1.25 Pow
0.85 Pow
Manual of W
40
ire from fus
sitive wire
gnal line of
onnecting w
cklight
gnal line of
gnal line of
ire from ele
terlock relay
gnal line of
onnecting w
mp
ire from int
lenoid valve
gnal line of
ire from int
lenoid valve
onnecting w
oom)
onnecting w
ucket)
gnal line of
onnecting w
onnecting w
gnal line of
gnal line of
gnal line of
onnecting w
onnecting w
onnecting w
eter:
onnecting w
gnal line of
wer supply
wer cord of
wer cord of
Wheel Loa
se to relay
of battery
power shut
wire of powe
reversing
start interlo
ectric lock to
y
preheater re
wire of prehe
ermediate r
e (boom)
fault indica
ermediate r
e (bucket)
wire of proxi
wire of proxi
water level
wire of heate
wire of heate
oil cut-off v
oil cut-off v
variable pu
wire of rear i
wire of roof a
wire of work
wire of headl
rear illumin
of defroste
f spare elect
f coarse filte
ader
toff
er shutoff
ock
o start
elay
eat indicator
elay to
ator
elay to
imity switch
imity switch
alarm
er
er
valve relay
valve relay
ump
lluminator
alarm lamp
ing hour
lamp
nator
r
trical outlet
er
r
h
h
79 Blu
80 Red
81 Ligh
gree
82 R
82a Gre
83 W
84 W
85 Gre
86 L
pink
87 B
88 W
89 G
90 Red
91 Wh
92 Gre
93 R
94 R
95 Ye
96 L
gree
97 Blu
98 Blac
99 Yell
100 Bla
101 Bla
102 Bla
ue/Whit
e W
d/Blue
ht
en W
Red W
een/Wh
ite W
White W
White W
en/Red W
Light
k/Black W
Blue W
White W
Green W
d/Orang
e W
hite/Bla
ck W
een/Wh
ite W
Red W
Red W
ellow W
Light
en/Red W
ue/Gree
n W
ck/Red W
low/Re
d W
ck/Bro
wn W
ck/Gre
en W
ack/Blu
e W
White
Red
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
Service M
0.85 Sig
0.85 Pow
0.85 Sig
0.85 Sig
0.85 Sig
0.85 Sig
blo
0.85 Sig
0.85 Co
0.85 Co
0.85 Co
buz
0.85 Sig
0.85 Co
tem
0.85 Pow
1.25 Co
con
1.25 Wi
5 Pow
5 Pow
1.25 Co
sol
0.85 Sig
1.25 Sig
0.85 Sig
0.85 Sig
0.85 Wi
lam
0.85 Sig
0.85 Wi
com
Manual of W
41
gnal line of
wer supply
gnal line of
gnal line of
gnal line of
gnal line of
ocking
gnal line of
onnecting w
onnecting w
onnecting w
zzer
gnal line of
onnecting w
mperature se
wer cord of
onnecting w
ntroller
ire from ele
wer cord of
wer cord of
onnecting w
lenoid valve
gnal line of
gnal line of
gnal line of
gnal line of
ire from wa
mp to compu
gnal line of
ire from ala
mputer box
Wheel Loa
rear headla
of instrume
vehicle spe
coarse filte
coarse filte
transmissio
temperature
wire of quick
wire of quick
wire of quick
water level
wire of prehe
ensor
f quick chan
wire of prehe
ectric lock to
f preheater
f preheater
wire of safety
e
emergency
defrost
alarm
mute
aiting to star
uter box
tachometer
arm indicato
ader
amp
ent lamp
eed
r alarm
r alarm
on oil filter
e switch
k change
k change
k change
switch
eating water
nge button
eating
o preheater
y lock
steering
rt indicator
r
or lamp to
r
103 Bla
n
104 Red
105 Red
106 Gre
107
L
pink
108 L
pink
109 Br
110 G
111 B
112 Blac
113 Gre
l
114 R
115 Gre
116
L
gree
117 L
gree
118
119
120
L
gree
121 Gre
122 Gre
123
124
ck/Ora
nge W
d/White W
d/Yello
w W
y/Whit
e W
Light
k/Gree
n
W
Light
k/Black W
rown W
Green W
Blue W
ck/Yell
ow W
een/Yel
low W
Red W
een/Gre
y W
Light
en/Blac
k
W
Light
en/Blue W
W
W
Light
en/Whi
te
W
ey/Red
ey/Red W
W
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
Red
White
White
Service M
0.85 Wi
com
0.85 Pow
int
0.85 OE
1.25 193
1.25 193
1.25 193
1.25 Co
pos
1.25 Co
pos
1.25 Co
pos
0.85 Co
0.85 Co
5 Pow
0.85 Co
0.85 Co
sw
0.85 Co
sw
0.85 Sig
0.85 Sig
ind
0.85 Co
rel
1.25 Pow
1.25 Co
rel
0.85 Sig
Manual of W
42
ire from par
mputer box
wer cord of
terface
EM power c
39 data cab
39 data cab
39 data cab
onnecting w
sition senso
onnecting w
sition senso
onnecting w
sition senso
onnecting w
onnecting w
wer cord
onnecting w
onnecting w
witch
onnecting w
witch
gnal line of
gnal line of
dicator lamp
onnecting w
ay
wer cord of
onnecting w
ay
gnal line of
Wheel Loa
rking indica
f fault diagn
cord
le
le
le
wire of accel
or
wire of accel
or
wire of accel
or
wire of idling
wire of idling
wire of diagn
wire of diagn
wire of diagn
differential
differential
p
wire of intake
f electric loc
wire of intake
language sw
ader
ator lamp to
nosis
erator
erator
erator
g switch
g switch
nosis switch
nosis paging
nosis paging
l lock
l lock
e heating
ck
e heating
witch
o
h
g
g
125 Br
126 A
127
128
129
130 B
131
132 L
gree
133 Red
134 L
gree
140 Pu
141 Br
142 Bro
143 G
144 W
145 A
146 Pu
147 Ye
148 B
150 Ye
152 Yel
153 L
g
155 Yell
156 Ligh
rown W
Ash W
Blue W
Light
en/Red W
d/White
Light
en/Red W
urple W
rown W
own/Re
d W
Green W
White W
Ash W
urple W
ellow W
Blue W
ellow W
low/Bl
ue
Light
green W
low/Re
d
ht pink
White
White
White
White
Red
White
White
White
White
White
White
White
White
White
White
White
Red
White
Red
Red
Service M
0.85 Co
0.85 Co
pre
0.85 Co
M1
0.85 Co
coo
1.25 Pow
sys
0.85 Co
tem
0.85 Co
M2
0.85 Po
con
0.85 Pow
0.85 Po
tem
0.85 Wi
coo
0.85 Wi
coo
1.25 Co
coo
0.85 Po
to c
0.85 Ne
tem
0.85 Co
M3
1.25 Pow
1.25 Pow
0.85 Pow
1.25 Pow
Manual of W
43
onnecting w
onnecting w
essure
onnecting w
1
onnecting w
oling switch
wer cord of
stem
onnecting w
mperature an
onnecting w
2
sitive signa
ntroller
wer cord of
sitive signa
mperature se
ire from con
oling valve
ire from con
oling valve
onnecting w
oling rocker
sitive signa
controller
egative sign
mperature se
onnecting w
3
wer cord of
wer cord of
wer cord of
wer cord of
Wheel Loa
wire of speed
wire of transm
wire of solen
wire of indep
h
f independe
wire of transm
nd pressure
wire of solen
al line of int
f pilot transi
al line from
ensor and co
ntroller to in
block
ntroller to in
block
wire of indep
r switch to c
al line from
al line from
ensor and co
wire of solen
f gas meter
f horn
f reversing r
f safety lock
ader
d sensor
mission oil
noid valve
pendent
nt cooling
mission oil
noid valve
ercooler and
ition
water
ontroller
ndependent
ndependent
pendent
controller
intercooler
m water
ontroller
noid valve
rearview
k
d
t
t
157 Ye
158 Br
159 G
160 G
161 Ye
162 Yell
e
163
164
165
166
170 Br
Ht+
Ht-
C_
H
C_L
C_
G
MS
+
MS-
/E
MS/
S
179
180 W
183 W
ellow W
rown W
Green W
Green W
ellow
low/Gr
een
W
W
W
W
rown W
W
W
W
W
W
W
W
W
White W
White W
White
White
White
White
Red
Red
White
White
White
White
White
White
White
White
0
White
White
White
White
White
White
White
Service M
0.85 Ala
0.85 Co
ind
0.85 Co
ind
0.85 Co
M4
1.25 Pow
1.25 Re
0.85 Sig
pre
0.85 Sig
pre
0.85 Sig
tem
0.85 Sig
0.85 Co
M5
0.85 Sig
rel
0.85 Gr
hea
0.75*2
CA
com
the
CA
com
the
Sh
com
the
0.85 EC
sw
0.85 Lig
con
0.85 Sta
0.85 Co
M6
0.85 Co
sw
Manual of W
44
arm signal o
onnecting w
dicator lamp
onnecting w
dicator lamp
onnecting w
4
wer cord of
eserved pow
gnal line of
essure signa
gnal line of
essure signa
gnal line of
mperature\
gnal line of
onnecting w
5
gnal line of
ay
round electr
ating relay
AN H signal
mmunicatio
e machine
AN L signal
mmunicatio
e machine
hield of CAN
mmunicatio
e machine
CU power su
witch
ght load wo
ndition/fuel
andard work
onnecting w
6
onnecting w
witch
Wheel Loa
of oil-water
wire of engin
p
wire of air fil
p
wire of solen
f panel
wer cord
oil outlet pr
al valve
oil inlet pre
al valve
hydraulic o
emergency
wire of solen
ECU intake
rode of ECU
l line for
on between
l line for
on between
N line for
on between
upply/fuel-s
orking
l-saving gro
king conditi
wire of solen
wire of front
ader
r separation
ne fault
lter alarm
noid valve
ressure of
essure of
oil
invalid
noid valve
e heating
U intake
ECU and
ECU and
ECU and
saving
ounding
ion
noid valve
axle coolin
n
ng
184 W
185 W
186
187
188
189
210 Brol
220 Bro
240 Gre
l
270 Wh
l
280 Blue
290 Gre
310 Purpl
320 Gre
321 B
322 Or
323 Gre
324 Gre
325 Gre
326 Gre
327 Gre
328 Red
White W
White W
W
W
W
W
own/Ye
llow W
own/Re
d W
een/Yel
low W
hite/Yel
low W
e/Yello
w W
en/Red W
ple/Yel
low W
ey/Yell
ow W
Black W
range W
ey/Bro
wn W
ey/Gree
n W
ey/Blue W
ey/Red W
y/Whit
e W
d/Pink W
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
White
Service M
0.85 Co
sw
0.85 Co
sol
0.85 Sig
con
0.85 Sig
con
0.85 Sig
con
0.85 Sig
con
0.85 KD
0.85 Pow
0.85 Ou
0.85 Ou
0.85 Ou
0.85 Pow
0.85 Ou
0.85 Ou
0.85 Gr
0.85 Co
abs
0.85 Co
ele
0.85 Co
abs
0.85 Co
filt
1.25 Pow
rel
0.85 Co
sta
0.85 Co
sta
Manual of W
45
onnecting w
witch
onnecting w
lenoid valve
gnal line for
ntroller soft
gnal line for
ntroller soft
gnal line for
ntroller soft
gnal line for
ntroller soft
D output lin
wer output
utput line of
utput line of
utput line of
wer cord
utput line of
utput line of
round lead o
onnecting w
sorption filt
onnecting w
ement senso
onnecting w
sorption filt
onnecting w
ter sensor
wer supply
ay
onnecting w
arting
onnecting w
arting
Wheel Loa
wire of front
wire of axle c
e
r partition o
tware
r partition o
tware
r partition o
tware
r partition o
tware
ne
line
f forward ge
f speed
f speed
f speed sens
f speed sens
of time-dela
wire of vibra
ter element
wire of oil re
or
wire of steeri
ter element
wire of transm
wiring of ti
wire of oscill
wire of oscill
ader
axle coolin
cooling
of emergenc
of emergenc
of emergenc
of emergenc
ear
sor
sor
ay relay
tion oil
sensor
turn filter
ing oil
sensor
mission
ime-delay
lation
lation
ng
cy
cy
cy
cy
329 Blu
330 Gre
l
E7
E8
E22
E24
E25
E27
E28
Note: acco
battery and
of battery,
be red. The
ue/Gree
n W
een/Yel
low W
W
W
W
W
W
W
W
ording to the
d total fuse,
charging li
e ground ele
White
White
White
White
White
White
White
White
White
e requireme
, alternator
ine, electric
ectrode shou
Service M
0.85 Co
vib
0.85 Co
vib
0.75 Sig
pos
0.75 Sig
pos
0.75 Sig
0.75 Pow
pos
0.75 Gr
pos
0.75 Pow
pos
0.75 Gr
pos
ents of the s
and motor
wire of the
uld be black
Manual of W
46
onnecting w
bration valv
onnecting w
bration valv
gnal input o
sition senso
gnal input o
sition senso
gnal line of
wer supply
sition senso
round electr
sition senso
wer supply
sition senso
round electr
sition senso
standard GB
should be r
e vehicle, ou
k. All other
Wheel Loa
wire of low f
ve
wire of high
ve
of accelerato
or 1
of accelerato
or 2
starter relay
of accelera
or 1
rode of acce
or 1
of accelera
or 2
rode of acce
or 2
B/T22353-2
red. On this
utgoing line
wires shou
ader
frequency
frequency
or pedal
or pedal
y
ator pedal
elerator peda
ator pedal
elerator peda
008, wire o
basis, wire
e for power
uld be white
al
al
or cable con
e connecting
r supply of
e.
nnecting the
g the anode
fuse should
e
e
d
332 Wiri
?
ing diagr
CN11
0
????
1
3
2
4
0
42
64
65
???
ram of th
?
-B ????
CN13
153
0
153
0
Service M
e overall
3-32 Wiring
0 0
10 6
11 30
11
10
30
7
0 0
600
150
200
200
150 350 300 150
4
5
6
4
5
6
3-B
Manual of W
47
l unit
g of the fron
200
200
700
200
???
???
CN12-A
3
2
1
3
2
1
?????
?????
1
6
CN14-B
Wheel Loa
nt frame(T
CN10-
CN
3
7
1
14
2 3 4 5 6
7 10 11 30 42
ader
3)
-B ??????
12-A ?????
153 0
1 2
153 0
1 2
2 1
6 5 4
10 9 8
4 13 12 11
7 8 9 10 11
64 65 85 86 87
???
???
CN10-B
????
?????
1
3
2
4
0
85
86
87
12 13 14
153
?????
???
CN10-B ?
CN11-B ?
???
??
???
??
???
???
???
CN12-A ?
???
?????
????
???
????
?
????
Service Manual of W
48
Righ
Con
CN1
CN1
Jack
Wire
Jack
Wire
Hole
Wire
Con
Inter
wiri
Con
Left
Wheel Loa
ht front com
nnecting hor
10-B quick
11-B proxim
k No.
e No.
k No.
e No.
e site No.
e serial No.
nnecting fram
rface betwe
ng harness
nnecting hor
t front comb
ader
mbination lig
rn
change dev
mity switch
me
een CN12-A
rn
bination ligh
ght
vice interfac
and instru
ht
ce
ument panel
0
19
3 1
18 0c
0
54 CN26-B
?????
??????
56a
13
0
?????? ???????
????????
1 2 3
????????
0
???
??
1 2
9
3
56 4
EA24
E37
61
Service M
0c
46
55
CN15-B
2
2f
??
55
?????
46
30 7
Manual of W
49
????
B
A
CN19-B
???
1 2
40
???
??
1 2
9
???
CN63-B
2
2f
???
??
1
0
CN63-B
0 9 8
Wheel Loa
??
56 0
3 2 1
7 6 5 4
10 9 8
14 13 12 11
3 2 1
7 6 5 4
10 9 8
14 13 12 11
ader
0c
Ht+ Ht- 61
CN1-A CN3-A CN4-A CN2-A
??17 0
??? 1 2
2a
CN3-A
??4
??? 1 2 3 5
6
4
2 3 4 5
??
??? 1 6 7 8 9 10 11 12 13 14
6 7 8 9 10 11 12 13 14
7 8 30 40
13 15 17 18
46
19 20 54 55
2
15
CN18-B
CN24-B
????????
????????
2b
???????
????
0 9 8
30 6
???
CN1-A
20
?????
??
???
??
???
???
??
?????
?????
?????
???
??
?????
?????
???
??
???
??
?????
???
??
?????
????
???
???
??
???
?????
?????
???
??
Figure 3-3
???
???
?
??
?
???
???
?
3 L936 rear frame wiri
Service M
ing harness
Manual of W
50
Inter
Wire
Hole
Wire
Hole
Hole
Wire
Brak
Park
Eme
Hole
Wire
Brak
Brak
Hole
Wire
Hole
Wire
Rev
Hole
Wire
Torq
Con
Righ
Hole
Wire
Left
Con
Con
Hole
Wire
(equipped w
Wheel Loa
rface with i
e No.
e site No.
e No.
e site No.
e site No.
e No.
ke solenoid
king brake i
ergency brak
e site No.
e No.
ke solenoid
ke pressure
e site No.
e No.
e site No.
e No.
ersing switc
e site No.
e No.
que convert
nnecting gen
ht taillight
e site No.
e No.
t taillight
nnecting pre
nnecting batt
e site No.
e No.
with T3 eng
ader
nstrument p
valve
ndicator sw
ke switch
valve
sensor
ch interface
er oil tempe
nerator
heating rela
tery anode
gine in Chin
panel wiring
witch
e
erature sens
ay coil
na)
g harness
sor
Figure 3-34 L936 rear
0
19
3 1
0c
0
54
CN26-B
18 0
1 2
??
???
?????
??????
56a
r frame wiri
13
??????
????????
CN39-B
1 2 3
??????
????????
0
???
??
1 2
9
3
56 4
Ht+
Ht-
61
Service M
ing harness
0
0c
46
55
CN15-B
??
55
?????
46
50
a
b
30 7
Manual of W
51
(equipped w
B
A
C D
CN19-B
???
1 2
???
40
???
??
1 2
9
0 9 8
Wheel Loa
with T3 eng
??????
56 0
3 2 1
7 6 5 4
10 9 8
14 13 12 11
3 2 1
7 6 5 4
10 9 8
14 13 12 11
ader
gine in Braz
0c
Ht+ Ht- 61
C
B A
????
??17 0
?? ? 1 2
59
60
?????
0
A
B
C
2a
CN3-A
??4
??? 1 2 3 5
6
4
2 3 4 5
??
??? 1 6 7 8 9 10 11 12 13 14
6 7 8 9 10 11 12 13 14
7 8 30
13 15 17 18
40
19 20 54 55
406 59 60
zil)
15
CN18-B
CN24-B
????????
????????
2b
???????
0 9 8
30 6
???
CN1-A
20
????2b
?????
??
???
??
???
?????
?????
??
???
?????
?????
??
???
???
??
????
??
???
?????
??
???
?????
???
?????
?????
???
??
???
????
???
???
?
???
?
?
?
Service Manual of W
52
Inter
Wire
Hole
Wire
Hole
Park
Eme
Wire
Hole
Brak
Low
Wire
Hole
Pin N
Wire
Prox
Wire
Hole
Rev
Wire
Hole
Oil l
Left
Con
Con
Hole
Wire
Righ
Con
Wheel Loa
rface with i
e No.
e site No.
e No.
e site No.
king brake i
ergency brak
e No.
e site No.
ke solenoid
w pressure w
e No.
e site No.
No.
e No.
ximity switc
e No.
e site No.
ersing switc
e No.
e site No.
level sensor
t taillight
nnecting pre
nnecting batt
e site No.
e No.
ht taillight
nnecting gen
ader
nstrument p
ndicator sw
ke switch
valve
warning swit
ch
ch interface
r
heating rela
tery anode
nerator
panel wiring
witch
tch of brake
e
ay
g harness
e
CN18-B
20
????2b
0 9 8
???
0c
15
??17 0
??? 1 2
CN24-B
????????
????????
2b 2a
???????30 6
CN3-A
CN1-A
??4
??? 1 2 3 5
6
4 6 7 8 9 10 11 12 13 14
7 8 9 30 40 2
Fig
Ht+ Ht- 61
56 0
3 2 1
7 6 5 4
10 9 8
3 2 1
7 6 5 4
10 9 8
2 3 4 5
??
??? 1 6 7 8 9 10 11 12 13 14
13 15 17 18 19 20 54 55
Service M
gure 3-35L93
B
A
C D
CN63-B
2
2f
???
??
1
0
CN63-B
350
14 13 12 11
14 13 12 11
Manual of W
53
38 Wiring of
0c
�8
CN19-B
2
??
2f
???
??
1 2
55
?????
40
???
0 9 8
30 7
Wheel Loa
f the rear fra
13
0
????????
40
55
1 2 3
CN15-B
1 2
a
b
ader
ame
0
19
3 1
0c
0
54
??????
CN39-B
CN26-B
??????
18 0
1 2
??
???
????????
0
???
??
9
3
4
56a
56
Ht+
Ht-
61
?????
???
????
?????
?????
?????
??
???
??
???
?????
?????
???
??
?????
??
???
??
???
???
??
?????
?????
?????
??
???
?????
?????
???
??
???
???
?
?
???
?
???
Service Manual of W
54
Righ
Con
Torq
Tran
Inter
Wire
Hole
Wire
Hole
Park
Eme
Hole
Wire
Brak
Fuse
Hole
Wire
Left
Hole
Wire
Con
Oil l
Low
Wire
Hole
Eme
Park
Wheel Loa
ht taillight
nnecting gen
que convert
nsmission p
rface with i
e No.
e site No.
e No.
e site No.
king brake i
ergency brak
e site No.
e No.
ke solenoid
e
e site No.
e No.
t taillight
e site No.
e No.
nnecting pre
level sensor
w pressure w
e No.
e site No.
ergency brak
king brake i
ader
nerator
er oil tempe
ressure swit
nstrument p
ndicator sw
ke switch
valve
heating rela
r
warning swit
ke switch
ndicator sw
erature sens
tch
panel wiring
witch
ay
tch of brake
witch
sor
g harness
e
Figure 3-3
?????
??
???
???? 0
56
2
11 12 13 14
1 2 3
8 9 10
4 5 6 7
11 12 13 14
1 2 3
8 9 10
4 5 6 7
CN1-B CN3-B
CN2-B CN4-B
????????
A
B
0c
Ht+ Ht- 61
?? 4
??? 1 2 3 5
6
4
2 3 4 5
??
??? 1 6 7 8 9 10 11 12 13 14
6 7 8 9 10 11 12 13 14
7 8 40
CN3-B
30
13 15 17 18
46
19 20 54 55
22
5 L936 Inst
?
???
???
44
1 2 3 4 5 6 7 8 9 10 11 12 13 14
6 7 10 11 30 42 64 65 85 86 87 153
CN1-B
trument pan
4
5
35
49
10
12
74
34
39
50
11
6
7
8
9
10
11
12
13
14
4
5
6
7
8
9
10
11
12
37
80
28
33
121
0
21
13
14
4
5
6
7
8
9
10
11
12
13
14
77
65
63
64
62
46
CN29-B ????
38
42
2
???
??
1 2
40 8
11 12 13 14
1 2 3
8 9 10
4 5 6 7
????????
CN10-A,CN11-A,CN22-A
????????
CN12-B
Service M
nel wiring h
50
2
3
?????
1
4
2
3
?????
1
41
40
153
2
3
?????
1
71
79
79
56 36
CN22-A
????
CN9-B
3
2
4
????????
1
5
9
10
11
12
6
7
13
14
??
11 12 13 14
1 2 3
8 9 10
4 5 6 7
CN9-B
71
45
21
36
34
0
72
8
41
????????
CN10-A CN11-A CN7-A CN8-B
23
0
14 13 12 11
10 9 8
7 6 5 4
3 2 1
14 13 12 11
10 9 8
7 6 5 4
3 2 1
14 13 12 11
10 9 8
7 6 5 4
3 2 1
Manual of W
55
harness (equ
Cha
Mut
Back
Quic
50
50
????
7
6
33
CN23-B
12
6
CN31-21
80
17
20
18
0c
?????
CN5-B
CN6-B
????
E F H
25 24 37
0 26
4
5
6
0
28
7
8
56
9
10 22
11
12 Ht+
Ht-
Wheel Loa
uipped with
nge-over bu
te
klight
ck change b
???? 12
50
50 CN30-B
CN31 B
1
11 2
12
18
7
10
11
?????
4
8
15
19
9
6
0c
1
2
5
?????
4
6
13
17
8 49
22 30
21 99
12
CN6-CN5 28
121 22
??? ??
1 21
2 46
3 0
4
5 C_H
C_L
7
8 232R
232T
?????
??????
CN96-B
?GPS
CN96-B
???
1
2
??
C_L
C_H
CN90-B
3 C_G
20
13 61
C_H
C_L
ader
T3 Weichai
utton wiring
button
50
50
4 6
3 2 1
5
CN76-B
3
5 25
37
1
7
2 26
37
24
30
- 0
+
6
4
8
???
????
25
24
???
????
0
37
23
23
30
37
1
5
2
6
+
-
26
???
???????
???
30
0
+
-
6 2
5
1
79
79
45
45
????
74
39
39
74
30
0
1
5
2
6
+
-
?????
??????
?????
36
53
36
53
30
0
1
5
2
-
+
6
0
30
51
51
36
36
1
5
2
6
+
-
4
3
5
7 6
8
9
10 CN6 B CN5-B
0
42
63
42 42
62
???
?? 0 46
???
??
1 2
0 44
55
54
??????
??????
??????
CN83-A
CN84-A
i engine in C
g
50 50
50
50
50
50
2 1
3 4
?????
???
85
86
1 2
1 21
2 232T
3 232R
4 0
????
???? ????
????
?? ????
50 50
90
90
CN20-B
0
77
50
???
??
1 2
38 0
???
??
1 2
77 0
China)
CN66-B
????
2
6
1
5
-
0 +
30
99
0
99
0
??
???
???
???
7
2
4
30
49
35
1
35
3
8 30
30
0 +
???
-
50
???
30
0
30
35
30
35
6
2
5
1
-
+
???
???
72
0
30
21
21
72
5
2
6
1
+
-
2
6
???
5
1
+
-
30
0
33
7
6
33
????????
51
53
0
36
?GPS ?? ??
??? ??
62
42
87
86
85
87
90 86 90 85
63
42
42
0
??????
CN21-B
CN97-B
CN97-B
1
??
???2
36 0
0 ?????
?????
?????
?????
????
???
???
????
???
??
???
??
?????
????
????
?????
????
?????
????
????
???
??
?????
?????
???
???
?????
??
???
??
???
??
???
????
?????
???
???
?????
????
?????
???
???
?????
???
??
?
?
?
???
???
???
???
???
??
Service Manual of W
56
Inter
Inter
Con
Fron
Back
Back
Fron
Jack
Wire
Jack
Wire
Con
Horn
Con
Con
Stee
Inter
Con
Brak
Hole
Wire
Inter
Inter
Hole
Wire
Inter
Wire
Hole
Wire
Hole
Wire
Hole
Brak
Inter
Back
Back
Fron
Rear
Fan
Back
Back
Fan
Hole
Wire
Wheel Loa
rface with p
rface with p
nnecting han
nt window w
klight
klight
nt sprinkler
k No.
e No.
k No.
e No.
nnecting star
n button
nnecting inst
nnecting win
ering switch
rface with c
nnecting spr
ke switch
e site No.
e No.
rface with f
rface with f
e site No.
e serial No.
rface with r
e No.
e site No.
e No.
e site No.
e No.
e site No.
ke switch
rface with c
klight
klight
nt work ligh
r work light
heater swit
klight
klight
heater door
e site No.
e No.
ader
pilot valve
pilot valve
nd brake sw
wiper
rt switch
trument pan
ndow wiper
h
cab wiring h
inkler
front frame w
front frame w
rear frame w
cab wiring h
ht of cab
t
ch
r
witch
nel
r motor
harness
wiring harn
wiring harn
wiring harne
harness
ness
ness
ess
Figure 3-3
???
??
?????
????
???? 0
56 11 12 13 14
1 2 3
8 9 10
4 5 6 7
11 12 13 14
1 2 3
8 9 10
4 5 6 7
CN1-B CN3-B
CN2-B CN4-B
????????
A
B
Ht+ Ht- 61
2 3 4 5
??
??? 1 6 7 8 9 10 11 12 13 14
13 15 17
18
19 20 54 55
6 L936 Inst
???
???
???CN28-B
????(?)
11 12 13 14
8 9 10
1 2 3 4 5 6 7 8 9 10 11 12 13 14
6 7 10 11 30 42 64 65 85 86 87 153
??
???1 2
40 8
????????
0c
H
??4
??? 1 2 3 5
6
4
6 7 8 9 10 11 12 13 14
7 8 40
CN3-B
30
CN1-B
46
59 60
trument pan
35
49
10
12
8
11
9
10
11
12
13
14
8
9
10
11
12
121
0
21
13
14
8
9
10
11
12
13
14
63
46
CN29-B
38
42
44
60
59
22
????(?)
???
??
1 2
40 8
1 2 3
4 5 6 7
????????
CN12-B
Service M
nel wiring h
50
2
3
4
5
?????
1
4
74
34
39
50
6
7
2
3
4
5
?????
1
6
7
41
37
80
28
33
40
153
2
3
4
5
?????
1
6
7
71
77
79
65
64
62
79
CN22-A
21
80
17
20
18
0c
1
11
2
12
33
35
CN6-B
CN9-B
11 12 13 14
1 2 3
8 9 10
4 5 6 7
CN9-B
3 45
2
4
????????
1
5
8
9
10
11
12
6
7
13
14
??
0
0
21
30
36
37
34
41
45
39
71
74
79
CN9-B
????????
CN10-A,CN11-A,CN22-A
CN10-A CN11-A CN7-CN8-Manual of W
57
harness (equ
Jack
Wire
Inter
Con
Horn
50
50
DJ221-4BHB
????
56 36
18
7
6
10
11
12
?????
4
8
15
19
9
6
0c
1
2
5
?????
4
6
13
17
8 49
22 30
21 99
12
50
4
3
5
7 6
8
9
10
49
50
30
7
6
35
CN5-B
C 6
CN7-B
????
CN7 A CN8 B
E F H
????
14 13 12 11
10 9 8
7 6 5 4
3 2 1
14 13 12 11
10 9 8
7 6 5 4
3 2 1
14 13 12 11
10 9 8
7 6 5 4
3 2 1
20
13 61
6
28
7
8
56
9
10 22
11
12 Ht+
Ht-
C_H
C_L
Wheel Loa
uipped with
k No.
e No.
rface with f
nnecting inst
n button
12
50
50 CN30-B
CN31-B
?????
?????
??
CN90-B
???? ????
CN6-B CN5-B
28
121 60
?????
??????
CN90-B
???
4
1
2
5
??
0
C_L
C_H
3 C_G
ader
T3 Weichai
front frame w
trument pan
50
50
4 6
3 2 1
5
CN76-B
??????
36
53
36
53
30
0
1
5
2
-
+
6
0
30
51
51
36
36
1
5
2
6
+
-
6
2
5
1
30
99
99
0
0
0
???
+
-
???
90
90
0
5 42
7
1
-
+ ?
?
?
0
5
7
1
-
+
76
76a
76a
0
42
63
42 42
62
???
??
1 2
0 46
???
??
1 2
0 44
55
54
??????
??????
??????
CN83-A
CN84-A
CN90 i engine in B
wiring harn
nel
50 50
50
50
50
50
2 1
3 4
????
?????
???
85
86
42
62
63 42
42
0 42
90
90
CN21-B
CN20-B
0
77
50
???
??
1 2
38 0
???
??
1 2
77 0
Brazil)
ness
CN66-B
?????
???
51
0
53
0
36
??
+
-
1
5
26
33
7
33
30
0
???
???
6
62
90 86 90 85
63
42
42
0
??????
1
??
???2
36 0
????
????
?????
????
?????
???
?????
??
???
?????
?????
?????
????
????
???
??
???
????
?????
?????
?????
?????
????
???
???
(?)
???
?
?
?
?
Service Manual of W
58
Brak
Com
Inter
Brak
Inter
Ciga
Rese
Air
Fan
Con
Fan
Fan
Quic
Volt
Back
Mut
War
Quic
Con
Con
Inter
Quic
Quic
War
Wheel Loa
ke switch
mbined swit
rface with c
ke switch (r
rface with r
arette lighte
erved powe
conditionin
heater
nnecting eng
heater door
heater swit
ck change p
tage stabiliz
klight
te
rning light
ck change b
nnecting star
nnecting han
rface with p
ck change b
ck change b
rning light
ader
ch
cab wiring h
right)
rear frame w
er
r interface
g
gine wiring
r
ch
power suppl
zing module
button
rt switch
nd brake sw
pilot valve
button wirin
button
harness
wiring harne
harness
ly
e
witch
ng
ess
Figure 3-3
???
??
?????
?ECU ?
?????
???
CN66-B
????
26
1
5
-
0 +
30
99
0
99
0
??
???
?????
???
51
0
53
0
36
??
87
86
85
87
90 86 90 85
63
42
42
0
??????
1
??
???2
36 0
6 L938 Inst
?
85
86
50 50
50
50
50
50
2 1
3 4
?????
?62
42
????
???? ????
????
?? ????
90
90
CN21-B
CN20-B
0
50
???
??
1 2
38 0
???
??
1 2
77 0
trument pan
0
42
63
42 42
62
???
??
1 2
0 46
???
??
1 2
0 48
6
50
50
4 6
3 2 1
5
CN76-B
??????
36
53
36
53
30
0
1
5
2
-
+
6
0
30
51
51
36
36
1
5
2
6
+
-
??
???
???
+
-
1
5
2
33
7
33
30
0
6
???
90
90
0
5 42
7
1
-
+
??????
CN83-A
55
54
??????
??????
??????
CN84-A
77
???
??
CN90-B
Service M
nel wiring h
CN6-B CN5-B
28
121 22
50
50 CN30-B
CN31-B
??????????????
18
?????
4
8
15
19
9
6
1
2
5
?????
4
6
13
17
8 49
21 99
12 57 59 58
????
7 57
?????
?ECU??
25 24 37
0 26
4
1
2
5
6
0
28
C_L
C_H
7
8
56
3 C_G
9
10 22
11 Ht-
20
13 61
C_H
C_L
CN90-B
Manual of W
59
harness
Jack
Wire
Rese
Con
Fan
Fan
CN5-B
CN7-B
50 50
50
???? 12
7
6
10
11
12
21
80
17
20
18
0c
0c
22 30
?????
0
48
0
48
4
3
5
7 6
8
9
10 49
50
30
7
6
35
????
????
????
12 Ht+
Wheel Loa
k No.
e No.
erved powe
nnecting EC
heater door
heater
CN6-B
CN9-B
11 12 13 14
1 2 3
8 9 10
4 5 6 7
CN9-B
3
2
4
?????
1
5
0
0
21
30
34
CN9-B
???
8
9
10
11
12
??
41
45
39
71
74
50
?????
1
?????
1 153
?????
79 1 79
56 36
CN22-A
CN23-A
CN23-A
1
11 2
12
33
35
????????
CN10-A CN11-A CN7-A CN8-B
14 13 12 11
10 9 8
7 6 5 4
3 2 1
14 13 12 11
10 9 8
7 6 5 4
3 2 1
14 13 12 11
10 9 8
7 6 5 4
3 2 1
2 1
4 3
ader
r interface
U wiring ha
r
b a
???
??
1 2
40 8
45
????????
6
7
36
37
13
14
79
??
???a b
57 8
2
3
4
5
35
49
10
12
4
74
34
39
50
11
6
7
8
9
10
11
12
2
3
4
5
6
7
8
9
10
11
12
41
37
80
28
33
121
40
0
21
2
3
4
5
6
7
8
9
10
11
12
71
77
65
63
64
62
46
CN29-B ????(?)
????
2
3
?????
1
57
13
58
4 9
59
22
60
23
0
arness
11 12 13 14
1 2 3
8 9 10
4 5 6 7
1 2 3 4 5 6 7 8 9 10 11 12 13 14
6 7 10 11 30 42 64 65 85 86 87 153
??
???1 2
40 57
13
14
13
14
13
14
???
???
38
42
48
????(?)
CN28-B
2 a
????????
CN12-B
CN1-B
11 12 13 14
1 2 3
8 9 10
4 5 6 7
11 12 13 14
1 2 3
8 9 10
4 5 6 7
CN1-B CN3-B
CN2-B CN4-B ????????0 56
A
B
0c
Ht+ Ht- 61
??4
??? 1 2 3 5
6
4
2 3 4 5
??
??? 1 6 7 8 9 10 11 12 13 14
6 7 8 9 10 11 12 13 14
7 8 40
CN3-B
30
13 15 17
CN1 18 19 20 54 55
9 2
??
???
???
?????
?????
????
??
???
?????
????
?????
?????
?????
????
????
????
?????
????
?????
????
?????
????
???
?????
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Service Manual of W
60
Air
Ciga
Back
Fan
Fan
Quic
Mut
War
Con
Quic
Quic
Con
Inter
Con
Horn
Fron
Con
Con
Con
Com
Inter
Brak
Hole
Inter
Brak
Inter
Wheel Loa
conditionin
arette lighte
klight
heater door
heater swit
ck change p
te
rning light
nnecting star
ck change b
ck change b
nnecting han
rface with p
nnecting inst
n button
nt window w
nnecting win
nnecting spr
nnecting star
mbined swit
rface with c
ke switch (r
e site No.
rface with r
ke switch (l
rface with f
ader
g
er
r
ch
power suppl
rt switch
button
button wirin
nd brake sw
pilot valve
trument pan
wiper
ndow wiper
inkler
rt switch
ch
cab wiring h
right)
rear frame w
eft)
front frame w
ly
ng
witch
nel
r motor
harness
wiring harne
wiring harn
ess
ness

I
Contents
4 Overview of transmission
system ................................................................. 4-1
41 A30X and BX50 transmission
system .......................................................... 4-1
411 Basic parameters of transmission and torque converter system ............... 4-
1
412 Detection and adjustment of transmission and torque converter system . 4-1
413 Common faults and troubleshooting method of planetary transmission .. 4-2
42 VRT200 transmission system ....................................... 4-??!??????
421 Basic parameters of transmission and torque converter system4-??!??
????
422 Detection and adjustment of transmission and torque converter system4-?
?!??????
423 Common faults and troubleshooting method of VRT200 transmission4- ?
?!??????
43 Maintenance of transmission and torque converter system4-??!??????
431 Precautions for disassembling and assembling transmission4-??!???
???
432 Disassembly and assembly flow chart of transmission4-??!??????
44 Transmission shaft
system ..........................................................................
4-22
441 Precautions for maintaining transmission
shaft ...................................... 4-22
45 Drive axle
system ............................................................................
............. 4-22
451 Fault diagnosis and troubleshooting of drive
axle .................................. 4-22

1
4 Overview of transmission system
41 A30X and BX50 transmission system
411 Basic parameters of transmission and torque converter system
Table 4-1 Basic parameters of transmission
Item Parameter
Torque
converter
Type
Single-stage four �element double-turbine
hydraulic torque converter
Inlet oil pressure of torque
converter (MPa)
0.5~0.6
Outlet oil pressure of torque
converter (MPa)
0.21~0.26
Transmission
Type Planetary power shift
Transmission gear Two forward and one reverse
Transmission working pressure
(MPa)
1.1~1.5
412 Detection and adjustment of transmission and torque converter system
Fig. 4-1 Pressure detection tool
1 2
Fig. 4-2
1 Reverse pressure switch
1. Detection of transmission pressure
Tool:
Test connector of transmission pressure: 6410006225
Test hose SMS20/M1/4-3000A: 4030000368
Pressure gauge CPG063-00025-01-S-B04: 6430000943
a) Place the loader at the service location, put down
the bucket on the ground and implement the
parking brake. Shut down the engine and operate
the control lever 3-5 times and then release residual
pressure. (Oil temperature: 45~55?)
b) Disassemble the maintenance cover of the loader.
c) Disconnect the transmission pressure switch
connector.
d) Disassemble the pressure switch on the
transmission control valve as shown in the figure
and install the transmission test connector at the
disassembly location.
e) Connect one end of test pipe to the test connector
of transmission pressure and the other end to the
pressure gauge (range: 0~6MPa).
2
2 Alarm switch of transmission
pressure
f) Start the engine, step on the brake, shift all gears
and observe the table pressure value of oil pressure
gauge which is the current transmission pressure of
tested loader. Determine whether the oil supply
system is normal based on conditions.
g) After the test, repeat a) pressure discharging step
and then install transmission control lever pressure
sensor (switch) and pressure sensor connector and
then wipe out the transmission oil leaked outside.
Note:
? Pressure gauge pipe, instruments on both ends and pressure detection port should
be connected
reliably so as to prevent the oil leakage from affecting measurement value during
the test.
? During the test, the engine speed should increase gradually. Do not accelerate
the engine
suddenly so as to avoid damaging the pressure gauge due to impact.
? The pressure gauge is the precise measuring instrument, so it should be detected
regularly (half
a year or a year).
? Avoid impact and collision during the use and wipe it out and place it in the
special storage
location in the tool kit after use.
2. Adjustment of transmission pressure
Adjustment of transmission pressure: remove plug screws on both ends of pressure
regulating valve
and take down energy storage piston, pressure adjusting spring and pressure
regulating valve
element. Adjust the transmission pressure by replacing pressure adjusting spring or
increasing and
reducing gasket on the spring seat of pressure regulating valve element. The
increase of spring
length or gasket will make the pressure rise; the decrease of spring length or
gasket will lower the
pressure.
Note: Detect the pressure at the neutral gear after adjusting pressure so as to
prevent
excessive pressure from damaging oil cylinder.
1
Fig. 4-3
1 Installation location of adjusting gasket
413 Common faults and troubleshooting method of planetary transmission
1. What are causes that the transmission oil level lowers, the junction of torque
converter and
engine has oil leakage and sometimes the engine oil level rises?
Diagnosis:
If the rotary oil seal between the torque converter idler pulley seat and the
transfer gear is damaged,
3
the torque converter oil will leak into four enclosed active wheels and torque
converter shell along
the damaged part. Due to larger leakage, the oil-returning inclined holes in the
torque converter
shell cannot be discharged immediately, so some oil will be thrown away by the
active wheel
rotating at high speed, which will cause the oil leakage on the junction between
the torque converter
and the engine. When the crankshaft oil seal of the engine loses efficacy, the
hydraulic oil will enter
the engine to make the engine oil rise and lower the transmission oil.
2. What is the cause that the level of transmission oil pan automatically rises?
Diagnosis:
This is caused by the damaged oil seal of steering pump or working pump input
shaft. The oil in the
hydraulic system flows into the transmission oil pan through the torque converter
gearbox to make
the oil level rise. Replace new oil seal based on damage conditions.
3. What is the cause that the torque converter has higher oil temperature?
Diagnosis: If the engine operates normally, the torque converter can only work with
the oil
temperature over 65?. The optimum oil temperature is 85�95?. When exceeding 120?,
the oil
temperature of torque converter will be regarded to be excessive. Faults are caused
by:
(1) Lower level of transmission oil pan or blocked filter screen reduces the oil
supply in the oil-way,
makes it difficult for hydraulic pump to absorb oil and generates cavity and
erosion in the system
pipeline, which will the oil heating. When the transmission oil pan level is
higher, the increased
stirring of moving parts in the transmission shell will also make the oil
temperature rise. Check the
oil level and increase or decrease (replace) the oil to implement the
troubleshooting.
(2) The transmission pressure is smaller. When the transmission pressure is less
than 0.88Mpa, the
relative sliding friction of transmission friction plates at all gears will
generate heat. Thinner friction
plates and faulted return spring will cause the clutch slide frequently to make the
oil temperature
rise. Carry out the retrieval processing respectively.
(3) The oil cooler of torque converter cannot work normally (the radiator is
blocked and oil sludge
between radiating fins is excessive). Check the cooler and clean the dust
completely. When
necessary, clean and maintain the interior of cooler and timely adjust the
operation load and shut
down for cooling. Carry out the operation after the oil temperature recovers to the
normal state.
(4) The large overrunning clutch of transmission is broken. The sliding friction
among inner ring
cam, large outer ring gear and 24 pin rollers generates heat.
(5) Continuous operation time of torque converter is too long. The poor-quality and
deterioration of
oil will also cause the higher oil temperature of torque converter. Respectively
eliminate these
causes.
4. What is the cause that the machine cannot start after the gear shift?
Diagnosis:
(1) The transmission oil level is not in conformity with requirements.
(2) The gear is not engaged. Re-adjust the transmission control lever.
(3) The parking brake is not released.
(4) The transmission pump is worn seriously. After the machine is set aside for a
long time or the
transmission pump is removed, the oil in the pipeline will return to the tank. So
the transmission
cannot pump out oil.
(5) Lower pressure in the transmission system and infirm connection between
shifting friction plate
and clutch will also cause the machine unable to drive.
4
5. What are causes that the loader has insufficient driving force (no power for
operation)? How to
eliminate?
Diagnosis: The insufficient driving force of machine means that the machine cannot
overcome large
load. If the engine power is normal, following causes may be possible:
(1) If the pressure in the transmission system is lower, the machine with large
load will slide. Check
the transmission pump and the transmission valve based on method to inspect low
pressure.
(2) The transmission pressure is normal but the operation is still lack of power
and oil overflows
from the motor. This is usually caused by the damaged rotary oil seal of the torque
converter or the
damaged O-shape seal ring between cover wheel and pump impeller. Disassemble and
inspect the
torque converter and at the same time check the wear in circular groove of idler
pulley and inner
hole of transfer gear and then carry out replacement and maintenance as
appropriate.
(3) The transmission pressure is normal, operation is lack of power, oil
temperature is high and the
bottom of oil has aluminum skimmings. This is caused by damage in pump impeller,
idler pulley or
Grade I, II turbine. Disassemble the torque converter for inspection.
(4) The transmission pressure is normal and the machine can drive but lack power.
This is mainly
caused by damaged overrunning clutch. If three compressing springs of overrunning
clutch lose
efficacy, the isolating ring breaks off, pin roller surface of inner ring cam or
outer ring cam is worn
seriously, disassemble and replace parts or large overrunning clutch assembly.
(5) The transmission pressure can reach the normal condition, but the meter hand
swings and loses
stability, the transmission pump has abnormal noise, the operation lacks power or
works normally
at the beginning but still lacks power after a while. This is usually caused after
the transmission
pump is replaced or the assembly of transmission and torque converter is serviced.
The cause is that
the transmission low-pressure pipeline is not sealed tightly and the entered large
amount of gas
makes the torque converter unable to provide sufficient oil. Check whether the
joint paper washer of
transmission pump is flat and tight, whether the junction between the oil suction
pipe and the pump
has gas leakage and whether the oil suction pipe is aging and has gas leakage.
(6) The transmission pressure is normal, the operation can be done at the first but
lacks power after
a while. The vehicle cannot drive with accelerator stepped hard and can drive after
the accelerator is
released or stopping a while. Firstly clean the transmission oil pan, because this
fault is caused by
the dirt blocking the filter screen which causes the oil unable to be sucked up.
The aging oil suction
pipe of transmission pump delaminates the inlayer and causes the suction become
difficult.
6. What are causes that the transmission oil pan has lots of aluminum skimmings or
metal filings
and the oil temperature rises?
Diagnosis:
(1) The numerous aluminum skimmings in the oil indicate that there exists abrasion
between active
wheels of torque converter. By this time, the transmission efficiency lowers and
the working oil
radiates.
(2) The numerous copper scales in the oil indicate that there exists dry friction
or sliding between
active friction plate and driven friction plate. Check whether the level of
hydraulic oil and the
transmission pressure are normal. If the above condition is normal, it may be
caused by improper
assembly of active friction plate and driven friction plate or deformation.
(3) The numerous iron scraps in the oil indicate that the overrunning clutch
slides. By this time, the
loader operates from high speed and light duty to low speed and heavy duty. The
sound of metal
friction exists in the transmission and the operation lacks power. The pin roller
of the overrunning
clutch gets stuck at the wedge-caulking position. In this circumstance, the
operation has power at
5
gear I but the speed cannot increase at gear II. Disassemble and check the
overrunning clutch.
(4) The oil pan with metal fragments indicates that the bearing in the assembly of
transmission and
torque converter is damaged.
7. What is cause that transmission pressure at all gears is low?
Diagnosis: The optimum transmission pressure at all gears is 1.1�1.5MPa. The
pressure lower than
0.88MPa cannot be used for the following reasons:
(1) The transmission oil level is lower or the oil inlet of transmission pump is
not connected firmly,
which may cause the air enter the hydraulic pump and lead to serious cavitation.
After the gear shift
lever is changed to the new gear, the machine delays to change speed and lacks
power for operation.
Respectively check the connection between oil level and pipes.
(2) The transmission pump is worn seriously, the inner leakage is excessive or the
pump speed is
lower, which all make the volume efficiency lower. Firstly check the connection
part of pump and
then check the transmission pump.
(3) The setting pressure of pressure valve on the transmission control valve is
lower or the pressure
spring loses efficacy (losing elasticity or broken). Re-adjust the pressure or
replace the spring.
(4) The stuck pistons of transmission control valve or energy accumulator cannot
contract the
pressure spring. Eliminate the fault by cleaning control valve.
(5) Main oil way has leakage or the oil filter is blocked. Check and clean the oil
way.
(6) The gasket on the junction surface between the transmission valve and the
transmission is
damaged. High pressure and low pressure at all gears are connected, so the pressure
cannot rise.
Check the sealing gasket.
(7) The pressure loses efficacy and does not real pressure value of transmission at
all gears. Check
the pressure gauge.
8. What is the cause that the pressure at gear I and reverse gear cannot rise and
the pressure at gear
II is normal?
Diagnosis:
Generally, do not check the transmission pump or the transmission valve and just
inspect the
transmission. Firstly check whether the connecting bolt between the central cover
and the
transmission body is broken; then check and measure whether the axial clearance
between central
cover and hydraulic cylinder at gear I is controlled within 0.3~0.4 mm.
9. What is the cause that the pressure at gear I cannot rise and the pressure at
gear II and reverse
gear is normal?
Diagnosis:
(1) Check whether the oil seal of piston at gear I is damaged.
(2) Check whether the piston at gear I has sand hole.
10. What is the cause that the pressure at reverse gear cannot rise and the
pressure at gear I and gear
II is normal?
Diagnosis:
Firstly check whether the reverse position of transmission has crack, which may be
caused by
higher system pressure.
6
11. What is the cause that the pressure at gear II cannot rise and the pressure at
gear I and reverse
gear is normal?
Diagnosis:
(1) Whether the rotary oil seal at the matching part between the center of rear
transmission end
cover and hydraulic cylinder at gear II is damaged or lacks assembly.
(2) Whether the O-shape ring of oil outlet of oil way at gear II at the junction
between transmission
and the rear end cover is damaged.
(3) Check whether 3 piston guide pins in the hydraulic cylinder at gear II falls
off.
12. Why does the transmission have �chaotic� gears? How to resolve it?
Diagnosis:
(1) Two locking balls in the valve rod and the valve body of transmission valve do
not align the slot.
(2) Spring of two locking balls loses efficacy.
(3) The deviation is caused by the lengthened control lever.
13. Why does the brake occur suddenly when the gear II is changed to gear I or the
gear I is
changed to gear II?
Diagnosis:
The loader operates for a long time, so the control lever becomes inaccurate due to
being stretched.
During the gear shifting, the pressure oil enters gear I and gear II at the same
time, so gear I and
gear II generates interference phenomenon and causes sudden braking.
14. What are phenomena reflected by faults of transmission overrunning clutch?
Diagnosis:
(1) In case of low speed and heavy duty, sudden cause will occur;
(2) The vehicle drives normally at gear II and lacks power for operation suddenly;
(3) The transmission generates abnormal noise suddenly and the vehicle speed
decreases suddenly;
(4) In case of starting or gear shifting, the machine reacts slowly;
(5) Speed at gear II and gear I has no difference and the vehicle speed cannot
rise.
15. What is the cause that the transmission pressure at all gears is normal, but
the loader cannot
drive?
Diagnosis:
(1) The axle shaft breaks off.
(2) The hand braking locks.
(3) The brake caliper and the axle lock.
(4) The clearance between the central cover and the oil cylinder at gear I and the
clearance between
the end cover and the cylinder at gear II are too small. The bearing is pressed
tightly and gears of all
shifts cannot drive normally.
16. What is the transmission pressure at all gears? What danger will be caused if
the pressure is
higher or lower?
The transmission pressure should be controlled with 1.1-1.5 Mpa. The higher
pressure will cause
7
the transmission cylinder break at the reverse gear; and the lower pressure will
cause the friction
plates at all gears slide and the loader drive slowly. The higher or lower pressure
will rise the oil
temperature of torque converter dramatically.
17. What is the cause that the loader sometimes does not drive, namely driving in
the condition that
the engine temperature in conformity with the environment temperature but not
driving in the
condition that the engine temperature higher than the environment temperature?
Diagnosis:
(1) Check the oil limit valve next to the transmission and fill new oil if finding
the lack of oil.
(2) If the oil mass is normal. Check the transmission pressure gauge. If the
pressure gauge point
swings vigorously, it means that the oil supply is insufficient. Check whether the
oil inlet is
blocked, the rubber pipe gets blister due to aging inlayer, the torque converter
filter is blocked and
the oil filter element is cleaned in turn.
(3) The working oil has poor cleanliness and the dirt sucked surrounding the filter
screen gradually
blocks the filter screen and the dirt will disperse when the vehicle parks.
(4) The transmission pump is burnt out. In case of engine temperature in conformity
with
environment temperature, the oil is dense and the inner leakage is small, which can
meet
requirements at all gears. However, in case of engine temperature higher than
environment
temperature, the oil is thin and the inner leakage is large, so the oil supply
cannot meet requirements
at all gears and the vehicle cannot drive.
(5) Check the transmission oil pan and observe whether there is metal block and
aluminum
shimming on the filter screen. If any, it means that torque converter and the
transmission have
damaged parts inside and should be inspected after disassembly. Damaged parts
should be replaced.
18. What is the cause that the loader can only moves forward but cannot move
backward?
Diagnosis:
(1) Check whether the pressure indicated on the transmission pressure gauge is
normal. If the
pressure lowers at the reverse gear, it means that oil leakage is too much at the
reverse, which
causes the vehicle unable to drive at reverse gear. Disassemble and inspect the
transmission, replace
the piston ring at reverse gear, check the wear in friction plate and replace the
friction plate with
serious wear.
(2) If the pressure at reverse gear does not lower, it means that the forward gear
gets stuck, which
causes the friction plate slide at the reverse gear and the vehicle unable to drive
at the reverse gear.
Disassemble and inspect the transmission. Check whether the isolating ring on
annular gear at gear I
is broken, because the broken plate will get the friction plate stuck at gear I and
then make the
friction plate at reverse gear lose efficacy, which will lead to the condition that
the vehicle can only
move forward but cannot move back.
19. What is the cause that the transmission pressure is normal, but the vehicle at
gear I and reverse
gear cannot drive and can only drive normally at gear II?
Diagnosis:
The cause of this fault is directly shifting gear instead of stepping pedal, so the
terminal pad at gear
I and reverse gear in the transmission will twist off or the connecting bolt breaks
off, which causes
the power unable to be transferred. Therefore, the vehicle at gear I and reverse
gear cannot drive.
The gear II is connected to the internal spline of sun gear directly and the power
can be transferred,
so the vehicle at gear II can drive.
8
20. Why does the machine �nod� in case of the gear shift?
Diagnosis:
(1) The control valve element of gear shift does not move to the specified place,
so oil way is not
cut off immediately and the gear shift of machine delays. Check and clean the
control valve and
replace new valve when necessary.
(2) The shift piston twists and deforms and cannot return to the location
completely. Check and
replace the piston.
(3) The shifting oil pressure of machine is higher and adjust the shifting oil
pressure again.
(4) The system oil has serious inner leakage, so the piston cannot return to the
location completely
after the oil pressure at this gear is released. Check and eliminate the inner
leakage of oil.
(5) When the machine cannot reach the shifting speed, shift the gear again.
21. The vehicle with the gear engaged before being refueled drives slowly but
cannot drive after
being refueled.
Diagnosis:
(1) The filter pipe of torque converter or the oil suction pipe of transmission
pump is aging, so the
inside is peeling. Non-refueling belongs to natural state and the pipe is slightly
blocked. However,
the oil will be sucked up to block the pipe in case of the refueling.
(2) The foreign matters falling into the pipe will be sucked up to block the pipe
in case of the
refueling.
22. In case of the engine temperature higher than the environment temperature, the
vehicle cannot
dive with heavy duty.
Diagnosis:
(1) The pin roller of overrunning clutch wears out, slides in case of the engine
temperature higher
than the environment temperature and cannot fit in and the gears of inner and outer
rings cannot
rotate in the same direction at the same time.
(2) The pump pulley of torque converter has tiny crack or sand hole. In case of the
engine
temperature higher than the environment temperature, the oil leakage of torque
converter will cause
the driving force insufficient.
23. The transmission pressure is normal after the machine is started, but the
pressure at all gears
increases dramatically after the acceleration and exceeds the normal pressure.
Diagnosis:
The blocked main oil inlet of converter (near the overflow valve) causes the
converter oil unable to
flow into the torque converter after supplying all gears. When the torque converter
was delivered to
the factory, the main oil way had a white plastic plug. If the plug is not taken
down in case of the
assembly, the above condition may occur.
24. In severe cold area, if the drive forgets to make water-proof preparations, the
oil cooler of
torque converter will be frozen. After replacing damaged part and anti-freezing
solution, when the
driver starts the machine on the second day, the transmission pump will have
abnormal noise and
have no transmission pressure.
Diagnosis:
After the oil cooler of the torque converter is frozen, the water will flow into
the transmission with
9
oil. After be placed for the whole night, the water will precipitate to the
transmission oil pan (the
water specific gravity is larger than the torque converter oil) and will be frozen
with the oil suction
pipe of transmission pump. Therefore, the oil cannot be sucked up when the machine
is started.
10
42 YD13 transmission system
421 Basic parameters of transmission and torque converter system
Table 4-3 Basic parameters of YD13 transmission
Item Parameter
Torque
converter
Type
Single-stage three-element single-turbine
hydraulic torque converter
Inlet oil pressure of torque
converter (MPa)
0.85
Outlet oil pressure of torque
converter (MPa)
0.5
Transmission
Type Fixed shaft power shift
Transmission gear Four forward and three reverse
Transmission working pressure
(MPa)
1.3~1.7
422 Detection and adjustment of transmission and torque converter system
1. Detection of transmission pressure and gear pressure
Tool:
Test connector of transmission pressure: 6410006224
Test hose SMS20/M1/4-3000A: 4030000368
Pressure gauge CPG063-00025-01-S-B04: 6430000943
a) Disassemble the maintenance cover of the machine.
b) Break the transmission pressure switch connector.
c) Disassemble the pressure sensor (switch) and the
pressure sensor connector on the transmission control
lever as shown in the figure and then install the
transmission test connector on the disassembly location.
Specification of mounting hole: M10�1
d) Connect one end of test pipe to the transmission
pressure test connector and the other end to the pressure
gauge (range 0~6MPa)
Note:
? Pressure gauge pipe, instruments on both ends and
pressure detection port should be connected reliably
so as to prevent the oil leakage from affecting
measurement value during the test.
11
1
2 3 4 5 6 7
1 Detection port of transmission
pressure
2 Detection port of clutch at gear II
3 Detection port of clutch at gear I
4 Detection port of clutch at gear III
5 Detection port of clutch at gear IV
6 Detection port of clutch at reverse
gear
7 Detection port of clutch at forward
gear
? During the test, the engine speed should increase
gradually. Do not accelerate the engine suddenly so
as to avoid damaging the pressure gauge due to
impact.
e) Start the engine, step on the brake and shift gears to
observe the stable pressure value in the oil pressure
gauge which is the current transmission pressure of
measured loader. Determine whether the oil supply
system is normal based on conditions.
f) After the test, repeat a) pressure discharging step
and then install transmission control lever pressure
sensor (switch) and pressure sensor connector and
then wipe out the transmission oil leaked outside.
2. Outlet oil pressure detection of torque converter
a) Disconnect the oil temperature sensor connector of
torque converter.
b) Disassemble the oil temperature sensor on the outlet
of transmission torque converter as shown in the
figure and install the transmission test joint at the
disassembly location.
Specification of mounting hole: M14�1.5
12
Table 4-4 Definition and logics of
YD13 transmission gear selector
output lead
Fig. 4-10 Solenoid valve
3. Detection of gear selector
Tool: Multimeter
a) When the finished vehicle is powered on, as shown
in the left figure, remove the interior panel under the
steering wheel in the cab, dismantle the fixing bolt on
the gear selector and disassemble the gear selector.
Note: Separately detect the power supply of gear
selector cannot determine the good or the bad. The
detection can only be completed when the special
detection equipment or the computer control box is
connected to form the network loop.
b) Switch the multimeter to the gear measuring DC
voltage. The red probe connects the wire in the color
indicating different functions and the black probe
connects the black harness.
Note: the working voltage of this gear selector is
5 VDC. Do not need to provide power supply for the
gear selector separately after the connection with
computer control box forms a network.
c) Check the voltage displayed on the multimeter to
determine the function of gear selector.
4. Detection of solenoid valve
a) Disconnect the power supply of finished vehicle,
screw off the connector of transmission control valve,
open the side cover, release the solenoid valve connector
and then connect the red end V/O of multimeter to one
end of solenoid valve and the other end to another
terminal to measure the resistance value. The resistance
value should be within 60-70O. The resistance value not
within the range means that the solenoid valve has fault
and needs to be replaced.
Note: During the detection, consider the effect of
environment temperature on resistance value. When the
resistance value actually measured has little difference
from the specified resistance, the solenoid valve can still
operate normally.
Control valve
Function
Gear
Green Blue Yellow White Purple Brown Red Black
13
Table 4-5 Logic diagram of solenoid
valve and clutch
Gear IV Solenoid valve Clutch
The solenoid valve is on; The brake switch cuts off anode circuit.
14
423 Common faults and troubleshooting methods of YD13 transmission
Table 4-6 Common faults of fixed shaft transmission
No. Fault feature Main cause Fault check and troubleshooting
1
The engine cannot
start.
1. The starting circuit (like
power supply, electric lock,
start relay, start motor etc.)
of main engine breaks down.
2. The handle is not engaged
at neutral gear.
3. The fuse on the main
engine leading to the control
circuit is burned out.
4. The handle plug has poor
contact or the handle breaks
down.
5. The electronic control box
plug has poor contact or the
electronic control box breaks
down.
1. Check the circuit of main engine and
refer to the instructions of starting
circuit of main engine.
2. The handle should be engaged at
neutral gear.
3. Replace the fuse.
4. Arrange the plug or check whether
the handle circuit is powered on
normally.
5. Arrange the plug or treat it as the
electronic control box fault.
2
Low pressure at
all gears
1. Oil pressure gauge breaks
down.
2. The tightening torque of
transmission control valve
bolt is insufficient.
3. The spring of main
pressure valve breaks off.
4. The transmission pump is
worn.
5. The scraps enter into the
transmission control valve or
valve clutch.
1. Replace the oil pressure gauge.
2. M8 tightening torque of control
valve bolt is 20 Nm.
3. Replace the spring.
4. Replace the transmission pump.
5. Replace the filter and clean the
control valve.
3
Oil pressure at
forward gear 1, 2,
3 is low but at
other gears is
normal.
1. Internal discharge of
clutch at forward gear
1. After the engine shuts down, block
the oil-way leading to KV clutch and
then start the engine and engage gear 1,
2, 3 so as to make the transmission
pressure increase to the normal value. It
means that the clutch at this gear has
internal discharge and the transmission
needs to be repaired.
15
4
Oil pressure at
reverse gear 1, 2,
3 is low but at
other gears is
normal.
clutch at reverse gear
the oil-way leading to KR clutch and
then start the engine and engage gear 1,
2, 3 so as to make the transmission
pressure increase to the normal value. It
means that the clutch at this gear has
internal discharge and the transmission
needs to be repaired.
5
Oil pressure at
forward and
reverse gear 1 is
low but at other
gears is normal.
clutch at gear 1.
the oil-way leading to K1 clutch and
then start the engine and engage
forward and reverse gear 1 so as to
make the transmission pressure
increase to the normal value. It means
that the clutch at this gear has internal
discharge and the transmission needs to
be repaired.
6
Short shifting time
for all gears
1. O-shape ring on the
throttle plug screw breaks
down.
2. The tightening torque of
bolt on pressure control
valve is not within the
specified range.
1. Replace O-shape ring.
2. M8 tightening torque of control
valve bolt is 20 Nm.
7
Long shifting time
for all gears
1. The throttle plug screw is
blocked.
2. The pressure control valve
gets stuck.
1. Wash and clear the screw.
2. Wash and check the valve.
16
8
High oil
temperature of
torque converter
1. Oil temperature sensor
breaks down.
2. Oil temperature gauge
breaks down.
3. The oil level is
insufficient.
4. Oil radiator of torque
converter has gas.
5. Oil-way from torque
converter to radiator is not
smooth.
6. The radiation capacity of
radiator is not enough.
7. The counter-balance valve
of torque converter gets
stuck.
1. Replace part.
2. Replace part.
3. Check the oil level and refuel
according to correct method.
4. Exhaust the gas from the upper gas
vent on the radiator (for machine with
gas vent)
5. Check whether the oil pipe from the
radiator to the transmission and the
radiator are blocked.
6. Check whether the radiation capacity
is enough including inspecting the
looseness of engine fan belt and dirt on
the radiator surface.
7. Pay attention to checking the hose
joint from transmission to radiator. If
the joint stretches into the transmission
deeply, it will stand up to the
counter-balance valve element, get the
valve stuck and cause the oil-way
blocked.
9
The vehicle
cannot drive at
any gear.
1. The oil level is not
enough.
2. The elastic plate
connecting the engine and
the torque converter breaks
or the power connection
from torque converter to
transmission input gear has
fault (rarely occurring).
3. Circuit of finished vehicle
breaks down.
4. Transmission pressure is
too low.
5. The solenoid valve breaks
down.
6. The shifting handle breaks
down.
7. The electronic control box
breaks down.
1. Check the oil level and refuel
according to correct methods.
2. Replace the elastic plate or
corresponding damaged parts.
3. Check whether the power supply
voltage is normal, whether the cable is
worn and whether the cable plug is
loosened.
4. Implement the operation based on
above mentioned troubleshooting
method.
5. The solenoid valve is 65+5 O. If the
resistance value is 0 or ?, it means
that the solenoid valve breaks down
and needs to be replaced.
6. Check and replace the handle based
on handle fault check method.
7. Check the box based on
troubleshooting method of electronic
control box or with PR68 detector.
10
Vehicle cannot
drive at gear I and
II.
1. Emergency brake pressure
or parking brake pressure
switch breaks down.
2. Solenoid valve loses
efficacy (M4).
1. If breaking the connection between
emergency brake pressure switch or
parking brake pressure switch and the
circuit recovers the gear I and II of
vehicle, it means that this switch needs
to be replaced.
2. Replace the solenoid.
17
11
When gear III and
IV are engaged,
the vehicle drives
at gear II.
1. Speed sensor breaks
down.
1. The measured resistance of speed
sensor is 1,020�100 O. If the resistance
is 0 or ?, it means that the speed
sensor breaks down and needs to be
replaced.
12
Vehicle does not
have forward gear
1, 2 and 3.
1. The clutch at forward gear
has internal discharge.
2. Circuit contact inside the
shifting handle is burnt out
and the circuit has poor
contact.
3. The solenoid valve loses
efficacy (M3).
4. The transmission control
valve gets stuck.
1. Treat this fault as the above
mentioned internal discharge fault in
clutch.
2. Arrange the handle wire or replace
the handle.
3. The resistance value of the solenoid
valve is 100�10 O. If the resistance is 0
or ?, it means that the solenoid breaks
down and needs to be replaced.
4. Clean the transmission control valve.
13
Vehicle does not
have reverse gear.
clutch at reverse gear.
2. Circuit contact inside the
shifting handle is burnt out
and the circuit is not
powered on.
efficacy (M1).
4. The valve gets stuck.
1. Treat this fault as the above
mentioned internal discharge fault in
clutch.
2. Arrange the handle wire or replace
the handle.
3. The resistance value of the solenoid
valve is 65�5 O. If the resistance is 0 or
?, it means that the solenoid breaks
down and needs to be replaced.
4. Clean the transmission control valve.
14
The gear is
sporadic.
1. The voltage provided to
the electric control system is
not stable.
2. The power supply circuit
provided to the electric
control system has poor
contact.
3. The shifting handle cannot
operate stably or the
connection plug has poor
contact.
4. The oil level of the
transmission is not enough.
5. Solenoid valve or
electronic control box cannot
operate stably or the
connection plug has poor
contact.
1. Check the power supply system of
finished vehicle.
2. Check the circuit based on main
engine circuit.
3. Arrange or replace the shifting
handle connection plug.
4. Refuel according to correct method.
5. Arrange the connection plug.
6. Clean the valve.
18
15
Abnormal noise in
transmission
1. The connecting bolt fixing
the engine transmission is
loosened.
2. The oil level of the
transmission is not enough.
3. Transmission shaft
connecting the transmission
breaks down.
4. The elastic plate
connecting the engine and
the torque converter breaks.
5. Mechanical fault inside
the transmission.
1. Check and fix the bolt.
2. Refuel to the normal oil level.
3. Check the transmission shaft.
4. Replace the elastic plate.
5. Remove the transmission shaft and
check whether there is any abnormal
noise after the removal. If any, check
whether the transmission has
mechanical fault.
16
The vehicle
reverses at neutral
gear, cannot drive
at forward gear 1,
2, 3 and drive
normally at
reverse gear.
1. The clutch at reverse gear
is sintered.
efficacy (M1).
4. The handle breaks down.
the oil-way of KR clutch and then start
the engine. If the vehicle can drive at
reverse gear, it means that the clutch at
reverse gear is sintered and needs
mechanical maintenance.
2. Clean the valve.
3. Replace the solenoid valve.
4. Replace the handle.
17
The vehicle moves
forward at neutral
gear but cannot
drive at reverse
gear; The vehicle
can drive normally
at forward gear 1,
2, 3.
1. The clutch at forward gear
is sintered.
efficacy (M3).
the oil-way of KV clutch and then start
gear 1, 2, 3, it means that the clutch at
forward gear is sintered and needs
mechanical maintenance.
2. Clean the valve.
18
The vehicle only
has forward and
reverse gear 1 and
cannot drive at
other gears.
1. The K1 clutch is sintered.
efficacy.
the oil-way of K1 clutch and then start
forward and reverse gear 1, it means
that the clutch at gear 1 is sintered and
needs mechanical maintenance.
2. Clean the valve.
19
43 Maintenance of transmission and torque converter system
431 Precautions for disassembling and assembling transmission
Note:
? The machine must be placed at the maintenance position.
? The transmission can only be disassembled after cooling down.
? Contain the transmission with clean container to avoid the spraying of oil.
? During the disassembly, all pipe joints should be bound up and protected so as to
prevent sundries
from entering the pipeline.
? The transmission should be hoisted steadily and vertically so as to prevent the
slipping of torque
converter.
432 Disassembly and assembly flow chart of transmission
Note: The flow chart is just the cue for maintenance, disassembly and assembly. The
specific
operation flow should be carried out based on specific model and configuration.
1. Disassembly of transmission
20
1. Maintenance
position
2. Disassemble
engine cover
Refer to 8 Cab and covering part system
3. Disassemble rack
and cab
4. Disassemble side
plates on both sides
of the machine
5. Disassemble the
hydraulic oil tank
Refer to 9 Working hydraulic system
6. Disconnect the oil
outlet hose of pump
Transmission
7. Disconnect the
radiating oil inlet pipe
and oil return pipe
8. Disconnect the
connecting harness.
Line of transmission control
valve
9. Disassemble the
intermediate
transmission shaft
Pressure sensor
10. Disassemble the
rear transmission
shaft
Oil temperature sensor of torque
converter
11. Discharge the
transmission oil.
12. Disassemble the
oil filling pipe.
13. Disconnect the
brake cylinder.
14. Disconnect the
connection with
engine.
15. Disconnect the
connection with the
frame.
16. Straighten the
pipeline and carry out
the hoist.
21
2. Assembly of transmission
1. Hoist transmission and
make preparation
2. Connect the engine
3. Connect the frame
4. Connect the oil outlet
rubber pipe of pump
5. Install the oil filling pipe
6. Connect the brake
cylinder
7. Install the transmission
shaft.
Line of transmission
control valve
8. Connect radiating oil
inlet pipe and oiler turn
pipe
Assembly of
transmission
Pressure sensor
9. Connect harness and
sensor
Oil temperature sensor of
torque converter
10. Install the hydraulic oil
tank
11. Hoist the cab
12. Hoist the engine cover
13. Install the side plate.
14. Connect the rack.
15. Fill the transmission
oil.
16. Check transmission
functions.
22
44 Transmission shaft system
441 Precautions for maintaining transmission shaft
Note: when delivered, the transmission shaft has been provided with dynamic balance
and
arrow mark. Do not damage the balance during disassembly, wash or repair, or else
carry out the
dynamic balance again.
45 Drive axle system
Note: refer to 024 Hoist and support safety for precautions of drive axle and see
Service
Manual of Drive Axle for drive axle maintenance.
451 Fault diagnosis and troubleshooting of drive axle
1. Abnormal noise in drive axle
a) Phenomenon and danger
The abnormal noise in wheel drive axle has multiple phenomena: Some noise sounds
continuously
or intermittently; other noise sounds when the speed changes or the vehicle drives
normally; some
noise sounds uphill or downhill; others sound depressive or clear.
The abnormal noise in drive axle reflects the abnormal technical state between
drive axle parts.
Therefore, find out the cause and eliminate the abnormal noise immediately, or else
it may cause
larger fault and even accident.
b) Cause and elimination of abnormal noise in drive axle
The abnormal noise in drive axle is usually caused by the collision between parts
in rear axle
(including wheel reducer).
Different parts can cause noise with different strength and properties in different
states, therefore,
judge the source of abnormal noise and find out the cause based on condition and
part where the
noise is generated.
? The noise generated from loosened connection and damage between parts mostly
belongs to
abnormal friction and collision between parts, so it sounds clear.
? The noise generated from abnormal matching of bearing and abnormal engagement of
gears.
? The abnormal engagement of gear means that the engagement clearance is too small
or too
large, the engagement part is not correct and the engagement area is insufficient.
By this time,
continuous and clear sound will be generated and will increase as the increasing
speed. The
abnormal matching of bearing means that the bearing clearance is too large or too
small. When
the clearance is excessive, continuous sound will be generated and will increase as
the
increasing speed.
? When the rear axle packet generates sound, except checking whether the parts have
looseness,
firstly check whether the engagement region of main transmission bevel gear is
correct.
2. Heat in drive axle
Heat in the drive axle means that after operating for a while, the temperature of
drive axle exceeds
the allowable range of normal temperature rise and when inspecting the drive axle
by hand, it feels
hot. The heat is mainly generated in the drive axle packet (excluding main
transmission and
differential mechanism) and wheel reducer. The heat in the drive axle is also the
reflection of
23
abnormal technical state of drive axle parts, abnormal matching or abnormal
lubrication. So
eliminate the heat immediately so as to avoid damaging relevant parts.
b) Cause and troubleshooting of heat in the drive axle
? Cause of heat in the drive axle: excessive heat; the heat cannot be radiated
immediately.
? The heat source of wheel drive axle is mainly the friction heat which is caused
by smaller
matching clearance between moving parts. Matching parts of drive axle are divided
into
bearing and gear. Therefore, the root cause of heat in the drive axle is the
smaller matching
clearance between bearings or engagement clearance between gears.
? The main reason why the heat in the drive axle cannot be radiated is that the
drive axle (and
the wheel reducer) lacks oil or has poor-quality oil. Lack of oil or poor-quality
oil not only
makes the friction heat generated by the drive axle not radiated immediately but
also makes the
moving parts in the dry friction condition and increases the friction heat.
? For the heat in the drive axle, the cause of heat can be determined based on the
heating part. If
the bearing is overheating, it means that the heat is caused by the bearing. If the
overall drive
axle shell is heating, it may be caused by abnormal engagement of gear or lack of
oil.
Therefore, fill standard lubricating oil immediately.
3. Oil leakage in the drive axle
The oil leakage of drive axle mainly occurs at the drive axle packet and wheel
reducer through the
sealing point and the junction.
b) Cause and troubleshooting of oil leakage in the drive axle
? Oil leakage is mainly caused by the damage in sealing elements and sealing
gasket. The former
is the oil leakage caused by damage of final transmission oil and the latter is the
oil leakage on
junction of rear drive shell and wheel reducer.
? Check whether the oil seal is aging, cracked and damaged. Do not pull out the oil
seal
vigorously so as to avoid the plastic deformation; try to immerse the oil seal into
the fluid with
the temperature similar to the working temperature and then carry out the
installation by
special tool.
L
Contents
5 Brake
system ............................................................................
............................................................. 1
51 Service brake
system ............................................................................
...................................................... 3
511 Composition of service brake
system ............................................................................
.................... 3
512 Maintenance of foot brake
valve .............................................................................
.......................... 3
513Assembling and disassembling of
booster ...........................................................................
............... 6
514Air
tank ..............................................................................
................................................................... 9
515 oil-water
separator .........................................................................
....................................................11
516 Brake
caliper ...........................................................................
.......................................................... 14
517 Exhaustion method of brake
system ............................................................................
................... 15
52 Parking brake
system ............................................................................
................................................... 16
521 Introduction of parking brake
system ............................................................................
................ 16
522 Replacement of parking brake
chamber ...........................................................................
............. 16
523 parking brake solenoid
valve .............................................................................
.............................. 17
53 Common faults of brake
system ............................................................................
.................................. 18

5-1
5 Brake system
The brake system of the loader includes service brake system and parking brake
system. The
Manual mainly introduces the dual-circuit dry brake. As the working principle of
the single-circuit
brake is the same with that of the dual-circuit brake, it will not be repeated
here.
Fig. 5-1 Layout of Service Brake System
1. Foot brake valve; 2. Booster; 3. Air tank; 4. Rear axle brake tube; 5. Front
axle brake tube; 6.
Oil-water separator
Fig. 5-2 Schematic Diagram of Service Brake
1. Booster; 2. Power stop valve; 3. Foot brake valve; 4. Air tank; 5. Oil-water
separator; 6. Air
compressor
To power slot of
variable speed pilot
valve
To air compressor
5-2
Fig. 5-3 Layout of Parking Brake System
1. Parking brake chamber; 2. Parking brake solenoid valve; 3. Air tank
Fig. 5-4 Schematic Diagram of Parking Brake
1. Parking brake chamber; 2. Parking brake solenoid valve; 3.Air tank
5-3
Fig. 5-5 Connection Dimension of
Foot Brake Valve
Opening A: to air tank interface
M22�1.5
Openings B&D: to booster interface
M22�1.5
Opening C: interface of brake tail
lamp switch NPT1/8
51 Service brake system
511 Composition of service brake system
The air-over-oil caliper disc dry brake is mainly
composed of air compressor, dryer (equipped), booster,
brake caliper, foot brake valve, air tank and pipelines,
etc.
512 Maintenance of foot brake valve
Main technical parameters
Rated working air pressure: 784kpa;
Operating temperature range: -30?~+80?;
Sealing requirements: off working state =10kpa,
working state =20kpa.
Disassembling of foot brake valve assembly
1. Place the machine at the maintenance position.
2. Turn on the drain valve of the air tank to unload the
brake system.
3. Disconnect the connectors of the stop lamp switch
of the brake valve.
4. Disconnect the brake valve to the booster and air
pipe of air tank.
5. Disconnect the brake valve to the air pipe of
variable speed pilot valve.
6. Disconnect the intake pipe of brake valve.
7. Disassemble the four bolts connected to the foot
brake valve assembly and the cab and remove the
foot brake valve.
Assembling of foot brake valve assembly
1. Place the foot brake valve assembly in the cab and
fasten the four bolts of foot brake valve connected
to the cab.
2. After applying an appropriate amount of sealant
545 on the elbow connection, T-junction and stop
lamp switch and then fasten them to the brake
valve. The bent end of the elbow connection is
towards the back downwards, basically with a 45�
angle to the horizontal plane.
5-4
Fig. 5-6 Brake performance test
Note:
1) Wipe clean the foreign matters of the threads.
2) Apply an appropriate amount of sealant on the ends
of the straight joint and stop lamp switch. When
doing so, start to apply sealant on the second
buckle at the end of the external thread and fill the
third to fifth buckles of the thread with glue
solutions.
3) After the completion of assembling, there should
be one complete circle of glue line at the edge of
the external thread and the threaded hole. During
the assembling, the glue should be timely applied.
The threads should be manually fastened. The
setting time should be at least over 30min after the
assembling.
AT545 sealant
T-junction/elbow connection: 60�10Nm
Air pipe: 57�7.5Nm
3. Connect the foot brake valve to the booster hose
and the intake hose.
4. Connect the harness of the stop lamp switch.
5. The disassembling steps of different vehicles
equipped with dual-foot brake valve are the same
with those equipped with the one-foot brake valve.
Carry out the disassembling by reference
accordingly.
Common fault diagnosis and troubleshooting of foot
brake valve
The working performance of the foot brake valve will
directly affect the braking effects and the safety of the
loader during the driving. Generally, it is not allowed to
arbitrarily disassemble the foot brake valve. However,
the common faults in the foot brake valve should be
mastered so as to quickly solve the problems.
1. Detection of the brake performance of foot brake
valve
? In the event of any doubt about the performance of
the air brake valve, there is no need to remove the
air brake valve. When inflating the air inlet with
about 800kPa air pressure, immerse the air outlet of
the valve into the water.
? If there is no bubble coming out of the water, it
indicates that the non-brake performance of the air
5-5
Fig. 5-7 Balance spring
1. Balance spring assembly
Fig. 5-8
1. Piston return spring
2. Piston
brake valve is normal;
? When there is bubble coming out of the water, in
indicates that the brake valve leaks air in the
non-brake state;
2. Balance assembly
The balance spring that becomes less resilient is likely
to slow down or deactivate the brake.
3. Piston and return spring
The piston return spring that becomes less resilient or is
broken will result in excessive brake; if the stuck piston
assembly fails to effectively push down the intake valve
core to open the air inlet, it will cause the reduction of
braking torque.
4. Intake valve assembly
When the rubber valve aperture on the top of the intake
valve is damaged or has sundries, part of the air will
leak from the intake valve. The valve return spring that
becomes less resilient, rusted or broken will lead to poor
sealing;
The poor sealing caused by worn O-ring will result in
air leakage from the air outlet during the brake, thus
causing slow brake. During the maintenance, paper pad
or copper sheet can be added in the groove installed
with seal rings to enhance the sealing. When the seal
5-6
Fig. 5-9 Intake Valve Assembly
1.Rubber valve aperture
2. Valve return spring
3. O-ring
4. O-ring
Fig. 5-10 Detection of booster
pressure
rings are severely damaged, become less elastic or
broken, they should be replaced by new ones.
513Assembling and disassembling of
booster
Detection of booster pressure
1. There is doubt about the performance of the
booster, remove the fittings of the oil outlet of the
booster and install one hydraulic pressure indicator
(0-25MPa, accuracy: not less than level 0.4) at the oil
outlet. Press the air brake valve pedal and observe the
pressure values of the barometer and the hydraulic
pressure indicator of the oil outlet:
? when the ratio of the pressure values of hydraulic
pressure indicator and barometer reaches 90% of
the supercharge ratio, it indicates that the
performance of the booster is normal; when such
ratio is less than 90% of the supercharge ratio, it
indicates that the performance of the booster
attenuates;
? When the hydraulic pressure indicator has no
pressure value, it indicates that the piston is stuck;
? When the pressure values of the hydraulic pressure
indicator and barometer synchronously reduce, it
indicates that air chamber leaks air;
? When the pressure value of the barometer does not
decrease, while the pressure value of the hydraulic
pressure indicator reduces, it indicates that the
hydraulic chamber of the booster leaks oil.
Note: The pressure measuring openings vary with
different boosters. The actual object shall prevail.
Disassembling of booster assembly
1. Place the vehicle at the service position.
2. Remove the pressure of the air tank.
3. Disconnect the booster to the front and rear axle
brake hoses and collect the discharged brake fluid with a
clean container.
5-7
Fig. 5-11 Assembling of Piston Ring
Cup
1. Push rod piston assembly
2. Air piston ring cup
Fig. 5-12 Assembling of Push Rod
Piston Assembly
1. Push rod piston assembly
Fig. 5-13 Assembling of Connection
Cover
1. Connection cover assembly
4. Disconnect the intake hose and steel pipe of the
booster.
5. Disassemble the fixed bolts of the booster and
remove the booster.
Note: The booster should be assembled according
to the reverse steps of those as mentioned above.
Disassembling of booster
1. During the disassembling and the reassembling,
please note not to damage each finished surface
and rubber parts of the products. In the event of
damaged rubber parts, replace them with new parts
and ensure that the assembling environment and
the components are clean.
2. Assemble air piston ring cup and push rod piston
assembly and then set the seal ring in the piston
groove with the tools. Note the installation
direction. The installation method is similar to that
of the belt. Be sure not to damage the seal ring and
the piston.
Note: Please use blunt wrench during the
installation and do not damage the seal ring.
5-8
Fig. 5-14 Assembling of Cylinder
Assembly and Connection Cover
Assembly
1. Cylinder assembly
2. Connection cover assembly
Fig. 5-15 Assembling of Piston
Assembly
1. Hydraulic piston
2. Cup
Fig. 5-16 Assembling of Piston
Assembly
3. After applying one layer of #2 lithium-based grease
on the inner wall of the cylinder and on the surface
of the seal ring, be sure to place the push rod piston
assembly in the cylinder assembly.
Note: The rubber parts of the air chamber should
not contact such oil liquid as brake fluid; otherwise, it
will cause corroded rubber.
4. Assemble the scraper seal, liner and Y-ring to the
connection cover and assemble them into the
connection cover assembly.
installation. Do not damage the scraper seal, liner and
Y-ring.
5. Connect the cylinder assembly and the connection
cover assembly and fasten them with bolts, nuts
and washers.
5-9
Fig. 5-17 Assembling of Hydraulic
Cylinder
1. Assembling of hydraulic cylinder
Fig. 5-18 Air tank
1. A- Air inlet
2. B- Tire inflation inlet
3. C-Air outlet
4. D- Preformed opening
5. E- Interface of brake pressure
switch
6. F- Interface of air pressure sensor
7. G- Drain valve
6. Assemble the cup and the hydraulic piston into
hydraulic piston assembly.
installation. Do not damage the cup.
7. After the air enters the air chamber, push out the air
piston. Assemble the push rod seat assembly and
the hydraulic piston assembly with the retainer
ring.
8. Assemble the hydraulic cylinder and the
connection cover with the bolts and spring washers.
9. The inner structures of the booster of different
models and manufacturers will vary slightly. The
actual object shall prevail.
10. The booster should be disassembled according to
the reverse steps of those as mentioned above.
514Air tank
Function
The air tank installed on the left side of the middle part
of the loader, mainly used to:
(1) Store compressed air to provide brake air source
for the brake system;
(2) When the air compressor is not working, ensure the
brake air for certain times;
(3) Install carriers for safety valve, brake pressures
switch and drain valve;
(4) When the driver presses the foot brake pedal, the
compressed air enters the brake or the braking
chamber through the control valve to achieve
service brake;
Note: The appearances and structures of air tanks
of different models vary. This introduction shall be only
for reference.
Compositions
Brake pressure switch
Provide pressure values for the barometer to enable the
driver to correctly determine the brake state according to
the readings of the barometer and determine whether the
A B
C
D
E
F
G
5-10
performance of the air channel is good.
Emergency brake switch
When the air tank pressure is excessively low or the
brake system leaks air, the emergency brake switch
functions to interrupt the power transmission and
control the parking brake solenoid valve to achieve the
parking brake.
Safety valve
When the safety control valve of the oil-water separator
combination valve fails, it protects the safety of the
brake system. The set pressure is 0.85-0.9Mpa. When
the pressures is excessively high, switch on the safety
valve to exhaust air.
Inflation valve
The inflation valve is used to inflate the tire.
Use and maintenance of air tank
Harm of accumulated water in the air tank
When the water is accumulated to certain extent, if it is
not discharged timely, the water, rust and impurities will
enter the foot brake valve and the inner part of the
booster along the pipelines during the braking, thus
causing contaminated foot brake valve and inner part of
the booster and resulting in such faults in reduced
lubricity, rust, worn sealing elements and stuck piston,
etc.
Note: The accumulated water in air tank is the
main reason to cause fault in brake elements. Users
should discharge the water regularly according to the
requirements of the operation and maintenance manual
during the use!
Disassembling of air tank assembly
3. Disassemble the bolts of the air tank hood and
remove the hood.
4. Disconnect the air tank to the brake valve hose.
5. Remove the emergency brake switch and the
pressure switch.
6. Disconnect the air inlet and parking brake air pipe
of air tank.
7. Disassemble the fixed bolts of air tank and remove
the air tank?
5-11
Figure 5-19 Oil-water separator
Assembling of air tank assembly
8. Fasten the air tank assembly to the frame.
9. Connect the intake pipe and parking brake air pipe
of air tank, and
Intake pipe: 80�10N�m
Parking brake air pip: 40-50N�m
10. Install the emergency brake switch, pressure switch
and air tank to the brake valve hose.
Emergency brake switch: 30�5N�m
Pressure switch: 35�5N�m
Connection: 80�10N�m
Hose: 57�7.5N�m
11. Install air tank hood.
Note: The volume and the tire inflation inlets of
different air tanks might be different. The actual object
shall prevail.
515 oil-water separator
Usage
A combination valve for oil-water separator is a
combination valve consisting of an oil-water separator
and an air pressure regulator. It provides the functions
below:
(1) Automatically regulate the operating pressure of the
brake system air source, ensuring the safety of the
loader brake system;
(2) Separate such impurities as oil and water in the
compressed air, and automatically drain such impurities
through the unloading mechanism;
(3) Inflate the pneumatic tyre when its win nut has been
removed.
5-12
Figure 5-20
1. Adjusting spring 2. Control
piston
3. Tympan 4. Regulating
valve
5. Valve seat 6 Return spring
7. Oil collector 8. Plug screw
9. Filter element assembly 10.
Check valve
11. Spring 12. Relief valve assembly
Composition
The air pressure regulator of a combination valve for
oil-water separator mainly consists of control piston,
regulating valve, adjusting spring, and tympan.
The gas-liquid drain valve mainly consists of air bleed
piston assembly, oil collector, and valve seat;
1
2
3
4
5
6
7 8
9
10
11
12
5-13
Figure 5-21
1. Air pressure adjusting screw
2. Relief valve assembly
3. Wing nut
Figure 5-22
1. Bleed valve 2. Return spring
of air bleed piston
3. Air breather 4. Tympan
5. Pressure adjusting spring 6.
Orifice
Usage notes
Such key parts as air pressure adjusting screws and relief valve
assemblies have been adjusted by the manufacturer when
delivered from the factory. For these parts, change without
permission which may endanger the whole brake system and
then driving safety is usually prohibited. In case an adjustment is
really required, be sure to adjust first the relief valve assembly
and then the air pressure adjusting screws, so that the pressure of
the adjusted system will not rise too much. Then, screw off the
wing nut (as shown in the figure) and connect the inflation pipe.
The filtered compressed air can be used to inflate the pneumatic
tyre.
Common faults
1) When the seal ring of the bleed valve below the
exhaust piston is damaged or stuck by sundries, the
valve may fail to be closed tightly and air leakage may
be caused;
2) When the return spring of air bleed piston fails or the
air bleed piston is stuck, the valve may fail to be closed
tightly and air leakage may be caused;
3) When the air hole (towards atmosphere) of the upper
shell is blocked, the air bleed piston may fail to return
effectively. Then, the valve may fail to be closed tightly
and air leakage may be caused;
4) After the tympan cracks, the pressure may drop and
the compressed air may leak from the air breather of the
upper cover;
5) When the pressure adjusting spring has a smaller elastic force
due to long-time work, the system pressure will drop, too;
1
2
3
4
5
6
1 2
3
5-14
Fig. 5-20
6) When the orifice from cavity C to cavity D is blocked and at
the same time the pressure adjusting spring and the piston
assembly are stuck, the air pressure regulator may lose some of
its functions. When the air pressure exceeds 0.784Mpa, the
compressed air will act on the relief valve and jack it open, and
discharge air into the relief valve.
516 Brake caliper
Replacement
Check whether the groove in the middle of the friction
plate is ground flush. If so, it indicates that the friction
plate is severely worn and it should be replaced. (If the
braking force is inadequate, check the worn conditions
of the friction plates and have them replaced timely).
The caliper disc type brake caliper is an integral
structure. Such structure has good strength and rigidity.
Friction plate that can slide along the guiding shaft is
installed between the brake disc and the piston;
The brake caliper is an integral structure. The brake
caliper should be removed as a whole for the
maintenance after having the friction plate replaced.
Disassembling of brake caliper
1. Disassemble the fixed cotter pins of the connection
pin shaft of the friction plate; remove the
connection pin shaft and the brake friction plate.
D
D
C
5-15
Fig. 5-21
Fig. 5-22
2. Dismantle the connection bolts and the washers of
the inner and outer calipers. Separate the inner and
outer calipers and remove the O-rings between
them.
3. Disassemble the collar and dust cover of the inner
caliper and disassemble the piston and rectangular
seals. The assembling should be conducted
according to the reverse steps of disassembling.
517 Exhaustion method of brake system
1. Place the machine at the service position.
2. Fill the oil cup of booster with the brake fluid.
3. Loosen the air vent screws of the booster. After an
entire stream of liquid flows out, tighten the
bleeder screws.
4. Start the engine. After the air pressure rises to the
specified value, press the brake valve pedal for
several times to enable the brake pipelines and the
brake caliper to be filled with brake fluid. When
the brake pedal is pressed, loosen the air vent
screws of the brake caliper to discharge the air and
quickly fasten the bleeder screws. Repeat the
operations till no bubble comes out of the brake
caliper and an entire stream of brake fluid flows
out. Stop the exhaust and tighten the bleeder
screws.
5. During the air bleeding, brake fluid should be
continually filled in the brake oil cup, so as to
prevent the air from entering again.
5-16
6. After the air is discharged completely, add the
brake fluid in the oil cup to over two thirds and
screw the oil cup cap.
52 Parking brake system
521 Introduction of parking brake system
Parking brake mainly consists of: parking brake
chamber, solenoid valve, bracket and parking brake
switch, etc.
522 Replacement of parking brake
chamber
Disassembling of parking brake chamber
2. Place the key at the �ON� position and screw the
parking brake button.
Note: This act aims at relieving the parking
brake to enable the air chamber to be released, so as to
disconnect from the parking brake.
3. Disconnect the air chamber from the parking brake.
Note: After disconnecting the air chamber from
the parking brake, press the parking brake button and
place the key at the �OFF� position.
5. Remove the air pressure signal lamp switch.
6. Disconnect the intake pipe of the parking brake
chamber and remove the tee pieces.
7. Dismantle the fixed nut of the air chamber and
remove the air chamber.
Assembling of parking brake chamber
1. Place the air chamber on the fixed bracket and
fasten it with fixed nuts.
2. Install the tee pieces and the air pressure signal
lamp switch.
3. Connect the intake pipe of the air chamber.
4. Start and idle run the machine. After the air
pressure reaches the requirements and remains
stable, shut down the engine and place the key at
the �ON� position. Screw the parking brake switch.
5-17
Fig. 5-23parking brake solenoid valve
Note: This act aims at relieving the parking brake
to enable the air chamber to be released, so as to
facilitate the connection between the air chamber and
the parking brake.
5. Connect the air chamber to the parking brake with
the pin shaft.
Note: To connect the air chamber and the parking
brake, the engine must be shut down.
523 parking brake solenoid valve
Specifications
Rated air pressure: 0.784Mpa
Resistance: 26.3O
Operating mode: Power-off brake
Method to determine whether there is a failure: Use a
multimeter to measure the resistance of the solenoid
valve. If the resistance is about 26.3O, it indicates that
the internal coil of the solenoid valve is normal.
When the internal valve element of the brake solenoid valve
operates, you will hear a sound. If no sound is heard, it indicates
the valve element is stuck.
5-18
53 Common faults of brake system
1. Fault: braking drag of loader
1) Definition of braking drag: when the brake is
relieved, the brake caliper cannot be separated,
which causes the brake caliper in the non-brake
state to still transmit part of the braking torque.
2) Judgment:
? If the air enters the brake system and the pipeline is
mixed with air, during the brake, the braking effect lags
behind as the volume of the compressed air becomes
smaller. After the brake is released, the volume of the
compressed air in the pipeline increases, causing the
stagnation due to the incomplete backflow of the brake
fluid.
? The brake caliper is in fault. The rectangular oil seal
is damaged. The brake caliper cannot return smoothly or
the inner piston is rusted.
? The foot brake valve is in fault. The movement of
the inner piston suffers from clamping stagnation.
? The booster is in fault. The booster chamber piston
of the booster is abnormally worn and its return is
subjected to clamping stagnation.
2. Fault: �no brake� suddenly
Judgment:
�No brake� suddenly occurs when the pressure in the air
tank and the trapped fuel in the oil cup of the booster are
within the specified range, check the following reasons:
? The chamber ring cup of the booster suddenly
spreads rims or is damaged and the compressed air
jumps into the low-pressure chamber through the
sealing elements;
? The master cylinder cup of the booster suddenly
spreads rims or is damaged and the brake fluid of the
high-pressure chamber jumps into the low-pressure
chamber;
? The piston assembly of the air brake valve suddenly
get stuck and the intake valve cannot be effectively
pushed down to open the air inlet;
3. Fault: The loader is off the track during the
braking.
Judgment:
The direct reason for the off tracking is the unequal
braking torques of wheels on left and right sides.
5-19
When the brake caliper on one side of the wheel is
�locked� and it is hard to be released in the process of
running, usually, it is because the rectangular seal rings
in the brake caliper that play the role of returning are
damaged. After pressing the foot brake pedal, the brake
caliper on one side brakes; while on the other side, the
brake fluid cannot enter the brake caliper due to the
inner leakage, blocked oil way or rusted brake caliper,
thus causing off tracking resulting from unequal braking
torques.
4. Fault: The loader slides during the parking brake.
Judgment:
The fractional resistance between the brake disc and the
brake pad is small.
? The greasy dirt between the brake disc and the brake
pad reduces the friction coefficient. In such case, clean
up the greasy dirt between the brake disc and the brake
pad with gasoline.
? The flexible operating shaft is not properly adjusted.
Readjust the pin shaft moving stroke of the control
handle. The direct contact area of the brake pad and the
brake disc is small.
6 Stee
61 Ove
611 Lo
62 Pres
62
62
63 Prep
64 Intr
64
64
64
64
65 Stee
66 Fau
66
66
ering system
erview of stee
ocation of ste
ssure test an
21 Pressure m
22 Pressure a
paration bef
roduction to
41 Steering p
42 Priority va
43 Steering o
44 Steering g
ering system
ult diagnosis
61 Diagnosis
62 Example o
S
m ....................
ering system
eering system
nd adjustmen
measuremen
adjustment o
fore steering
main elemen
pump ............
alve ..............
oil cylinder ...
gear ...............
exhaust ......
and eliminat
of main faul
of typical fau
Service Ma
C
.....................
m ...................
m parts .........
nt of steering
t of steering
of steering hy
system main
nts ................
.....................
.....................
.....................
.....................
.....................
tion of steeri
lts ................
ult eliminatio
anual of Wh
I
Conte
....................
....................
....................
g system.......
hydraulic sy
ydraulic syst
ntenance .....
....................
....................
....................
....................
....................
....................
ing system ..
....................
on ................
heel Loade
ents
.....................
.....................
.....................
.....................
ystem ...........
tem ...............
.....................
.....................
.....................
.....................
.....................
.....................
.....................
.....................
.....................
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er
.....................
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.................. 1
.................. 1
.................. 3
.................. 4
.................. 4
.................. 5
.................. 6
.................. 7
.................. 7
.................. 8
................ 10
................ 10
................ 12
................ 13
................ 13
................ 22
0
0
2
2
(Dom
????
???
?????
????
???
mestic reso
P ?
S
urces)
Service Manual of Wh
1
6 St
61 Ov
L936/L
of pilot
is as fo
to con
system
as for o
Stee
Stee
Con
Con
Prio
heel Loade
teering sy
verview o
L938 loader
t control, an
ollows (stee
figuration).
of domestic
overseas res
ering cylind
ering unit
nnecting oil
nnecting mu
ority valve
er
ystem
of steerin
working hy
nd correspo
ering pump
Working
c resources
ources.
(Ove
er
return filter
ltiple unit v
ng system
ydraulic sys
onding steer
is differen
pressure o
is 14MPa,
erseas resou
r
valve P port
m
stem is type
ring system
t according
of steering
and 12MPa
rces)
em
g
ga
???
??????P1 ?
S
Figure
Service Ma
(mecha
e 6-1 Schem
anual of Wh
2
Gea
Con
anical)China
matic figure
heel Loade
r pump
nnecting pre
a market
of steering
er
ssure select
system
tor valve
1 Steering gea
4
S
ar 2 Steering
1
Service Ma
g pump 3 Pr
3
anual of Wh
3
611 L
Fig. 6-3 Lo
riority valv
steering
steering
hydraul
pipeline
(only f
object).
compac
flexible
paveme
device.
heel Loade
Location o
ocation of st
e 4 Steering
g system
g pump,
lic steering
e. See the a
for diagram
. This system
ct structure,
e and labor
ent impact a
2
er
of steerin
teering syste
g cylinder 5
consists
priority
g gear, stee
above figur
m reference
m possesses
high sensit
r-saving op
and no need
5
ng system
tem parts
Hydraulic
of compo
valve, lo
ering oil cy
re for speci
and subjec
s advantage
tivity, good
peration, ab
d of setting
m parts
oil tank
nents like
oad-sensing
ylinder and
fic location
ct to actual
es including
d reliability,
sorption of
lubrication
eg
d
nlg
,
fn
Fig. 6-5 40
Fig. 6-6
Fig. 6-
030000370 p
412000294
-740300003
S
pressure ga
45 pressure m
368 piezome
Service Ma
uge
measuring j
etric hose
anual of Wh
4
62 Pr
steeri
621 P
hydra
Measur
Pressur
range
measur
(403000
Pressur
Pressur
steering
Pr
1. Low
up
sto
2. Shu
10
the
hyd
3. Scr
4. Ins
out
joint
5. Tig
me
6. Co
tub
7. Sta
lim
the
the
val
cur
sys
heel Loade
ressure
ing syste
Pressure
aulic syst
rement of oi
re measurem
of 40M
ement joint
00368).
re measuring
re measurin
gear.
essure meas
wer the wo
the hand b
ne to wedge
ut down the
times and
en release
draulic oil in
rew off the p
stall the pr
tlet steel
ghten the p
easuring join
nnect the p
be.
art the engi
miting positi
e limiting po
e maximum
lue on the
rrent workin
stem of mea
er
test and
em
measure
tem
il temperatu
ment tool:
Mpa (403
t (41200029
g standard:
g location:
suring proce
orking devic
brake and
e the tire.
e engine, op
the steerin
the residu
n the pipe.
plug screw
ressure me
tube of ste
piezometer
nt.
pressure gau
ine, turn th
on. When th
osition, incr
m. Observe
oil pressur
ng pressure
asured loade
d adjust
ement of
ure: 45~55?
pressure g
30000370),
945), piezo
14Mpa.
On oil outlet
ess:
ce on the g
adopt woo
perate the co
ng wheel 5
dual pressu
on the cylin
easuring jo
eering gear
tube to th
uge to the
he front fra
the front fra
rease the ac
e the stabl
re gauge w
e of steering
er.
ment of
steering
?.
gauge with
pressure
ometer tube
t steel tube of
ground, pull
od block or
ontrol lever
times and
ure of the
nder joint.
oint On oil
r.
he pressure
piezometer
ame to the
ame reaches
celerator to
le pressure
which is the
g hydraulic
f
g
hee
f
l
r
r
d
e
l
e
r
eso
eec
Fig. 6-
Fig. 6-9 Lo
1
Fig. 6-10 L
1 Safety va
1
-8 Pressure
ocation of p
Location of
alve
S
measuring
priority valv
safety valv
Service Ma
location
ve
e
anual of Wh
5
622 P
hydra
After m
is foun
value, a
this ste
pressur
The pri
frame a
The saf
the side
the oil r
1. Re
scr
2. To
scr
scr
Re
cyc
and
me
heel Loade
Pressure
aulic syst
measuring o
nd to be hi
adjust the s
eering syst
re of safety
iority valve
as shown in
fety valve o
e of oil retu
return pipe
lease the lo
rew as show
increase t
rew clockw
rew anticlo
ference val
cle is 2Mpa
d specific
easurement)
er
adjustm
tem
oil pressure,
gher or low
system pres
em is dec
y valve abo
is installed
the figure.
of the priori
urn pipe and
of priority v
cking nut a
wn in the figu
the pressur
ise and the
ockwise to
lue: the re
. (This valu
c operatio
ment of
, if the mea
wer than th
ssure. The
cided by th
ove the prio
d at the left
ity valve is
d can be adj
valve is rem
and rotate th
gure.
re, turn the
en rotate th
lower the
egulating v
ue is only fo
on is s
steering
asured data
he standard
pressure of
he opening
ority valve.
side of rear
installed at
djusted after
moved.
he adjusting
e adjusting
he adjusting
e pressure.
ariable per
or reference
subject to
g
adfg
.
r
t
r
g
gg
.
reo
Fig. 6-11 A
1 Adjusting
Fig. 6-12 D
Fig. 6
1 Stee
Fig. 6
1 Loc
Adjusting sc
g screw
Direction of
1
6-13
ering wheel
1
6-14
cking lever o
S
crew
f increasing
of frame
Service Ma
pressure
anual of Wh
6
63 Pr
maint
1. Pre
Park th
ground
clockw
oil pres
2. Co
pre
fram
3. Fix
4. Pre
heel Loade
reparatio
tenance
essure disch
he complete
and then t
ise and anti
ssure in the
nnect the
event the re
mes from d
x the loader
epare proper
er
on before
harging
machine at
urn the stee
iclockwise a
steering sys
locking le
elative rotat
damaging op
tire by woo
r oil receivi
e steering
the flat an
ering whee
and then di
stem.
ever of the
ation of fron
perators.
od wedge bl
ing containe
g system
nd spacious
el 5-6 times
scharge the
e frame to
nt and rear
lock.
er.
m
s
s
e
or
Fig. 6-15 CBGj3100/10
S
010-XF steer
Service Ma
ring pump
anual of Wh
7
64 In
641 S
ste
pump i
transmi
energy
energy
pressur
L936, in
engine,
in case
CBGj31
L936, C
overseas
Table
CBGj31
C
Di
Theo
heel Loade
troducti
teering p
eering pum
s connected
ission and
input by t
of oil and
re and flow
n case of be
CBGj3100/1
e of being
00A steering
CBGj2063A s
s L938, CBGj
6-1
00/1010-XF
Name
Connection
irection of t
oretical disp
Rated spe
Rated press
er
ion to ma
pump
mp is gear
d to the tor
will con
the transmi
d then inp
w to the sys
eing configur
010-XF dupl
configured
g pump is a
steering pum
j2063 steering
Technical
steering pum
type
urning
lacement
eed
sure
ain elem
pump. Th
rque extract
nvert the
ission to th
put them in
stem. ?As
ured with We
lex pump is
d with Yuc
adopted; as
mp is adopted
ng pump is ad
parame
ump
Para
Rectangu
Left-han
10
22
2
ments
he steering
tion port of
mechanical
he pressure
n forms of
for domestic
eichai Deutz
adopted, and
chai engine,
for overseas
d, and as for
dopted.
eters of
ameter
ular spline
nd turning
0/10
200
20
g
f
l
e
f
c
z
d
,
s
r
f
Fig. 6-16C
Fig. 6-19 E
1 T port 2
1 2
BGj3100A/2
External vie
Safety valv
3
S
2063/2063Ast
ew of priorit
e 3 LS port
4 5 6
Service Ma
teering pum
ty valve VLH
4 EF port 5
anual of Wh
8
Table
CBGj31
C
Di
Nom
mp
642 P
This st
VLE-15
differen
load pr
change
differen
orifice
supplie
steering
displace
P port o
of steer
steering
multipl
connect
connect
connect
H-240S-14
P port 6 C
heel Loade
6-2
00A/2063/20
Name
Connection
irection of t
minal displa
Rated spe
Rated pres
Priority v
teering sys
0) priority
ntial stress
ressure and
, the priori
ntial pressu
in the steer
d to the ste
g wheel
ement.
of priority v
ring pump,
g unit, EF
e unit valv
ts with tran
ts with LS
ts with hydr
CF port
er
Technical
063A steerin
type
turning
acement
eed
sure
alve
stem adopts
valve. Th
component
d the oil su
ity valve c
ure on both
ing gear an
ering gear e
speed
valve connec
CF port co
port conn
e (EF port
nsmission o
port of ste
raulic oil tan
param
ng pump
Para
Rectangu
Left-han
100/
22
2
s VLH-240S
he priority
t. No matte
upply in the
can still m
th ends of
nd then ensu
equal to the
and steer
cts with oil
onnects wit
nects with
of oversea
oil radiator
eering unit
nk.
meter of
ameter
ular spline
nd turning
/63/63
200
20
S-14(CHINA
valve is a
er how the
e oil pump
maintain the
f adjustable
ure the flow
e product of
ring gear
outlet hose
th P port of
P port of
as resources
r), LS port
and T port
f
A
e
p
e
e
wfr
e
f
f
st
t
1 2 3
Fig. 6-19 E
1 T port 2 P
Fig. 6-20 P
4 5
External vie
port 3 saf
Priority valv
S
6
ew of priorit
fety valve 4
ve diagram
Service Ma
ty valve VLE
EF port 5 L
anual of Wh
9
E-150
LS port 6 CF
Table 6
(Eton)
Nom
Sa
p
Cont
heel Loade
F port
6-5 Technica
Name
minal flow
afety valve
pressure
trol pressure
Signal
er
al parameter
e
S
r of priority
Paramete
240/150
14/12
6.9
Static state s
y valve
er
0
signal
1 Pi
S
Fig. 6
iston rod
Fig.
1 LS po
Service Ma
6-21 Structu
2 Cylinder
6-22 Extern
ort 2 L po
anual of Wh
10
643 Ste
The ste
energy
reciproc
cylinde
contrac
function
consists
piston a
ure chart of
r head 3
644 Ste
This m
load se
gear of
diagram
nal view of
ort 3 T p
heel Loade
eering oil cy
eering oil c
of liquid
cating rectil
er is fixed
ction of oil
n of vehicle
s of cylinde
and seal kit
f steering cy
Cylinder bo
eering gear
machine ado
ensing flow
f which the a
m is as show
BZZ6-630As
port 4 R p
er
ylinder
cylinder can
to the m
linear move
on the fra
l cylinder
e. The steeri
er body, pist
of oil cylin
linder
ody 4 Pi
r
pts BZZ6-63
amplificati
appearance
wn below.
steering gea
port 5 P
n convert th
mechanical
ement. The
ame by piv
achieves th
ing oil cylin
ton rod, cyl
nder.
iston
30A static
tion hydrau
and interio
ar
port
he pressure
energy in
steering oil
vot and the
he steering
nder mainly
linder head,
state signal
lic steering
r schematic
enle
g
y
,
l
g
c
Fig. 6-23
P port of s
cylinder re
with LS po
3 Steering g
teering unit
espectively,
ort of priorit
S
gear diagram
t connects w
oil liquid o
ty valve pre
Service Ma
m
with CF por
of T port ret
eferentially,
anual of Wh
11
Main te
Equ
Max
Maxim
Ove
Am
rt of priority
turns to oil
and steerin
heel Loade
echnical par
Model
Connection
ivalent disp
ximum inlet
mum contin
pressur
erload valve
Steering to
mplification
y valve, L a
tank upon
ng unit splin
er
ameters of s
Table 6-7
n type
lacement
t pressure
nuous back
e
pressure
rque
n factor
and R ports
oil return f
ne connects
steering gea
BZZ
British inv
630/5
17.
1.0
20
1.7-
s connect w
filter. LS po
with steerin
ar
6-630A
volute spline
500ml/r
2MPa
0MPa
0MPa
2.8Nm
1.6
with steering
ort connects
ng post.
e
g
s
Fig. 6-
1 Fillin
1
-24
ng filter elem
S
ment
Service Manual of Wh
12
65 St
After
priority
pipe in
steering
1.
1.
2.
3.
4.
5.
heel Loade
eering sy
replacing
y valve, ste
n the steerin
g system ba
Park the
position a
hydraulic
Start the e
several m
any hydrau
After the
system is
wheel slig
keeping th
the end.
Keep the e
steering w
with full
times so a
When nec
the oil re
make the
complete
cylinder.
hydraulic
exhaust.
After the
working
and then c
cap.
Stop the
whether t
leakage.
er
ystem ex
steering p
eering cylin
ng circuit, e
sed on follo
loader at t
and then ope
oil tank.
ngine and m
minutes. Pay
ulic function
hydraulic
circulated f
ghtly several
he steering
engine idling
wheel to mak
travel stretc
as to exhaust
cessary, rem
eturn pipe o
hydraulic
the full
Pay attentio
system stor
exhaust, se
device at
check the oi
engine and
the hydrau
xhaust
pump, stee
nder and hy
exhaust the
owing meth
the right m
en the filler
make the eng
attention to
n during thi
oil in the
fully, turn t
l times. Pay
cylinder n
ng and carefu
ke the steeri
ch forth an
t the air in t
move the oil i
of steering
oil overflow
exhaust of
on to not m
ore pressure
et the mach
the standar
il and tighte
d check an
ulic pipelin
ering gear,
ydraulic oil
e gas in the
hods:
maintenance
r cap of the
gine idle for
o not using
s process.
e hydraulic
the steering
attention to
ot move to
ully turn the
ing cylinder
nd back 3-5
the pipeline.
inlet pipe or
cylinder to
w so as to
f hydraulic
making the
during the
ine and the
rd position
en the filler
nd confirm
ne has any
,
le
e
e
rg
cg
o
o
e
r
.
ro
oc
e
e
enr
my
Table 6-8 F
N
o.
1
The
valv
bloc
stee
2
The
turn
The
rese
3
LS p
twis
long
bloc
4
The
dam
torq
5
The
stee
stee
inte
axia
stee
asse
Fault cause
Fault c
e damaged o
ve in the ste
cks the entr
ering gear.
e steering ge
ns to the one
e stuck steel
et.
pipe of prio
sts together
g. The damp
cked or has
e steering co
maged and th
que is exces
e joint part b
ering colum
ering gear h
erference an
al or radial f
ering gear af
embly.
S
of heavy st
cause
one-way
eering gear
ance of
ear stalls an
e-way valve
l ball canno
ority valve
or is too
ping hole is
oil leakage
olumn is
he rotating
ssive.
between
mn and
as
nd produces
force to the
fter
Service Ma
eering
Ref
nd
e.
t
s
e.
anual of Wh
13
66 Fa
of ste
661 Dia
ference diag
heel Loade
ault dia
eering sy
agnosis of m
gram of faul
er
agnosis a
ystem
main faults
lt location
and elim
s
R
This st
does no
one-wa
mination
Remark
teering gear
ot have the
ay valve.
n
r
Table 6-9 F
No.
6
7
8
9
10
Fault cause
Fa
The pres
valve and
valve is l
valve elem
the dam
blocked.
element of
stuck or
main sprin
The press
valve in co
of steering
The oil
blocked.
The pump
or damage
efficiency,
cannot
requiremen
The block
whole s
pipeline w
throttle and
S
of heavy st
ault cause
sure of p
d the ov
low or the
ment is stu
mping hol
The main
f priority v
the elastic
ng is smaller
sure of ov
ombination
g gear is low
return fil
is worn se
ed. The volu
, pressure o
meet
nts.
ked location
steering
will cause s
d heavy stee
Service Ma
eering (con
priority
verflow
e main
uck or
le is
valve
valve is
city of
r.
verload
valves
w.
lter is
riously
umetric
or flow
system
n in the
system
serious
ering.
anual of Wh
14
ntinued)
Referenc
heel Loade
ce diagram o
er
of fault locaation
Remark
Table 6-10
No.
1
2
3
4
5
0 Fault cause
Fa
Check wh
cylinder i
The oil cy
leakage.
Two tires
pressure d
One side o
overload v
two-way o
supplemen
leakage.
The oil ha
S
e of vehicle
ault cause
hether the oi
s loosened.
ylinder has
have larger
difference.
of two-way
valve or
oil
ntary valve
as air.
Service Ma
e deviation
R
il
r
y
has
anual of Wh
15
Reference d
heel Loade
diagram of f
er
fault location Remark
Table 6-11
No.
1
2
3
4
5
6
Fault cause
Fau
The system
The pin of
loosened.
Thermal sh
The main v
of priority
The oil cyl
leakage.
The low ef
pump caus
pressure.
S
e of inaccur
ult cause
m has air.
f oil cylinde
hock.
valve eleme
valve is stu
linder has
fficiency of
ses unstable
Service Ma
rate steering
Ref
r is
ent
uck.
fe
anual of Wh
16
g
ference diag
heel Loade
gram of fau
er
lt location Remark
Table 6-12
No.
1
2
3
2 Fault cause
Fau
The nuts o
column an
wheel fall
The joint b
steering co
and the ste
valve elem
The level o
lower.
S
e of that the
ult cause
on the steerin
nd steering
off.
between the
olumn spind
eering gear
ment fall off
of oil tank i
Service Ma
e steering w
Ref
ng
e
dle
f.
s
anual of Wh
17
wheel has no
ference diag
heel Loade
o pressure or
gram of fau
er
r the tumble
lt location
er does not
Rem
move
mark
Table 6-13
No.
1
2
Table 6-14
No.
1
2
3
4
Fault cause
Fau
Two-way o
or two-way
supplemen
serious lea
The oil cyl
has serious
4 Fault cause
Fau
The nut on
wheel is lo
The joint b
steering co
steering ge
seriously o
The oil has
Two-way o
and two-w
supplemen
have leaka
S
e of that the
ult cause
overload va
y oil
ntary valve h
akage.
linder piston
s leakage.
e of idle stro
ult cause
n the steerin
oosened.
between the
olumn and t
ear is worn
or damaged.
s air.
overload va
way oil
ntary valve
age.
Service Ma
e tumbler do
Ref
alve
has
n
oke in the s
Ref
ng
e
he
.
alve
anual of Wh
18
oes not mov
ference diag
steering whe
ference diag
heel Loade
ve or moves
gram of fau
eel
gram of fau
er
s slowly
lt location
lt location
Rem
Rem
mark
mark
5
6
Table 6-15
No.
1
2
Oil cylinde
The conne
the oil cyli
steering lin
wear clear
damaged.
Fault cause
Fau
The steerin
the steerin
connected
unsmoothl
Larger oil
back-press
poor return
S
er has leaka
ection betwe
inder and th
nkage has la
ance or is
e of abnorm
ult cause
ng column a
g gear are
tightly or
ly.
return
sure can cau
n.
Service Ma
age.
een
he
arge
mal return or
Ref
and
use
anual of Wh
19
r driven turn
ference diag
heel Loade
ning
gram of fau
er
lt location Remark
3
4
Table 6-16
No.
1
2
The large c
particles en
between th
element an
sleeve can
non-return
The spring
steering ge
or has sma
6 Fault cause
Fau
The assem
wrong. Du
overhaul a
the spline t
correspond
pulling slo
to the inter
cavity of r
cavity.
Connect th
or L port a
steering m
steering ge
automatica
S
contaminati
ntering
he valve
nd the valve
cause
n.
g strip of
ear is damag
aller elastici
e of steering
ult cause
mbly relation
uring the
and re-assem
tooth
ding to the p
ot correspon
rnal spline t
otor tooth
he oil inlet t
and then the
motor in the
ear can rotat
ally.
Service Ma
ion
e
ged
ity.
g wheel vib
Ref
n is
mbly,
pin
nds
tooth
to R
e
te
anual of Wh
20
brating or ro
ference diag
heel Loade
otating autom
gram of fau
er
matically
lt location Remark
Table 6-17
Fault
phenom
At the sta
short-time
inflexible
steering.
The steeri
cylinder c
The tumb
the steerin
wheel hav
opposite
directions
The steeri
wheel
rebound
7 Other fault
menon
arting,
e
e
N
tim
el
te
sy
ing
crawls. T
bler and
ng
ve
s.
Rc
o
ing
ds.
Ts
t
S
ts
Fault
Not working
me, the stee
lements hav
emperature
ystem oil.
The system h
R and L port
onnected.
The one-way
teering gear
Service Ma
t cause
for a long
ering gear
ve larger
difference w
has air.
ts are invers
y valve in th
r is damaged
anual of Wh
21
R
with
sely
he
d.
heel Loade
Reference di
loca
er
iagram of fa
ation
fault Remark
662
Faul
2 Example of
lt 1: Heavy steer
Make
the
judgmen
t based
on fault
phenome
non
The oil
hydrauli
irregula
The stee
steering
Whether
heavy dur
f typical faul
ring
cylinder crawls and the
ic oil has foam and
ar noise.
ering is heavy and the
g cylinder has no power.
the direction is
ring the quick turn.
lt eliminatio
Yes
Yes
Yes
No
No
Check whether the
steering column is
flexible.
Whether the level of h
oil is lower.
Service M
n
Yes
No
No
Whether the system
pressure is in
conformity with
requirements.
hydraulic
Manual of Whe
22
Yes
No
Check whether the
feedback oil pipe is
smooth.
Whether the oil suction
pipe is blocked.
el Loader
Yes
No
Adjust system pressure and
check whether the pressure
changes.
Yes
No
The system
manual st
valve lose
overload has
oil cylinder h
The pip
The spring
breaks off or
stuck.
The syste
The level o
The pipel
The steerin
Cause
m has air, the
teering one-way
s efficacy, FK
s leakage and the
has inner leakage.
eline is blocked.
of priority valve
r the valve element is
em pressure is low.
of hydraulic oil is
low
line is blocked.
ng pump is worn.
Exhau
check
wheth
replac
and
cylind
Clean,
Adju
Fill t
Measure
ust the air in the system,
k the oil inlet pipe, check
her the steel ball is stuck,
ce KF combination valve
check whether the oil
der has inner leakage.
Clean or replace.
repair or replace.
ust the system pressure to the
specified value.
the oil to the specified
range.
Clean or replace.
Repair or replace.
Faul
Faul
lt 2: The steering
lt 3: The steering
After the stee
position and
continuously,
and have no fe
The steering
position and
g has no ending
g cylinder canno
ering cylinder tur
d turn the steer
the steering whee
eeling of ending po
g cylinder cannot
d the steering is hea
point
ot turn to the lim
rns to the limiting
ring wheel hard
el can turn slightly
oint.
turn to the limitin
avy.
Service M
miting position.
g
d
y
ng
Manual of Whe
23
Cause
The press
valve is lo
Caus
The p
valve
el Loader
sure of overload
ow
se
pressure of safet
e is low.
Countermea
Properly
pressure of
ty Properly
pressure
valve.
Counte
asures
increase the
overload valve
increase the
of safety
ermeasures
e

I
Contents
7 Frame, tire and working
device ......................................................................... 7-
1
71 Overview of frame and working
device ...................................................... 7-1
711 Overview of
frame .............................................................................
....... 7-1
712 Overview of working
device..................................................................... 7-1
72 Disassembly and assembly of balance
weight ............................................. 7-2
721 Disassembly of balance
weight ................................................................ 7-2
722 Assembly of balance
weight ..................................................................... 7-2
73 Disassembly of frame
joint ...........................................................................
7-2
731 Disassembly of frame
joint ....................................................................... 7-2
732 Replacement of
bearing ...........................................................................
. 7-3
733 Joint of lower
frame .............................................................................
..... 7-3
734 Joint of upper
frame .............................................................................
..... 7-4
735 Connection between front and rear
frames ............................................... 7-4
736 Joint of upper
frame .............................................................................
..... 7-4
737 Joint of lower
frame .............................................................................
..... 7-4
74 Disassembly and assembly of front and rear
wheels .................................. 7-5
741 Disassembly of rear
wheel ........................................................................ 7-5
742 Assembly of rear
wheel .............................................................................
7-5
743 Disassembly of front
wheel ...................................................................... 7-6
744 Assembly of front
wheel ...........................................................................
7-6
75 Disassembly and assembly of working
device ............................................ 7-6
751 Disassembly of connecting
bar ................................................................. 7-6
752 Assembly of connecting
bar ...................................................................... 7-7
753 Disassembly of rocker
arm ....................................................................... 7-7
754 Assembly of rocker
arm ............................................................................ 7-
9
755 Disassembly of
boom ..............................................................................
.. 7-9
756 Assembly of
boom ..............................................................................
.... 7-10
757 Adjustment requirements of clearance between typical parts ................ 7-
10

1
Fig. 7-1
1 Bucket 2 Connecting rod
3 Rocker arm 4 Boom
5 Boom cylinder 6 Rotating bucket
cylinder
7 Frame, tire and
working device
71 Overview of frame and working
device
711 Overview of frame
This machine adopts the articulated frame.
The front frame mainly bears the working device and
the front drive axle.
Pivots on rear frame are used to fix parts like engine,
assembly of transmission and torque converter, rear
drive axel, cab and oil tank.
712 Overview of working device
The working device adopts Z-shape inversion six-bar
mechanism with features including big digging force,
high efficiency and large discharge height and discharge
distance.
The Z-shape inversion six-bar mechanism consists of
boom cylinder, boom, rotating bucket cylinder, rocker
arm, connecting rod and bucket. (see Fig. 7-1)
2
72 Disassembly and assembly of
balance weight
721 Disassembly of balance weight
1. Connect both sides and center of the balance
weight by the hoisting rope.
2. Disassemble four fixing bolts of balance weight.
Note: Keep the hoisting rope vertical and
tensioned so as to prevent the swinging balance weight
from injuring people after the bolt is removed.
3. Lower the balance weight, remove it from the
machine and then take it out.
722 Assembly of balance weight
1. Connect both sides and center of the balance
weight by the hoisting rope and make the upper
surface of balance weight and the upper surface of
rear frame parallel.
2. Fix the balance weight to the machine with 4 bolts.
3. Remove the hoisting rope.
73 Disassembly of frame joint
731 Disassembly of frame joint
1. Park the vehicle at the service position.
2. Disconnect the transmission shaft and remove it
from the machine.
3. Disassemble the fastening pivot bolt on the front
pin of steering cylinder, remove the union nut,
lubricating pipe, card board bolt and card board
and pinch the pivot out.
4. Disconnect the hose from the multiple unit valve
and block all connectors. Ensure that pin
connection between front and rear frames and
connection in other forms are disconnected.
5. Place two single-jacks at the back of rear frame.
Note: The back of rear frame is heavier.
6. Remove the floor mate and the front floor from the
cab.
7. Remove the cotter pin and the slotted nut.
8. Place support frames at the front of rear frame and
the back of front frame.
9. Knock the hinged pivot out by copper bar and
3
place the pin in the freezer or similar equipment.
Note: Knock the pivot out slowly and do not strike
it hard so as to avoid damaging the pivot.
Fig. 7-2 Joint of upper and lower
frames
1 Bush 2 Upper bearing cap
3 Adjusting gasket 4 Bearing
5 Bearing 6 Lower bearing cap
10. Remove the fixing bolt, union nut and lubricating
pipe on upper and lower pins and then knock the
pivot out by copper bar. Place the pin in the freezer
or similar equipment.
732 Replacement of bearing
11. Place a jack respectively on both sides of machine.
Push the front frame to move forward horizontally till
the frame is separated to contact the bearing position.
733 Joint of lower frame
12. Mark the position of bearing cap. Remove upper
and lower bearing caps, bush and adjusting gasket
of upper and lower caps. (see Fig. 7-2)
13. Remove the seal ring and clean the bearing cap to
ensure the mark not cleaned.
14. Remove two rolling bearings and spacer sleeve by
setting tools.
15. Clean the hinged hole, smear appropriate
lubricating oil and replace new bearing and space
sleeve. During the assembly, narrow sides of outer
rings of two bearings are opposite and the spacer
sleeve is placed at the center. Press the bearing and
the spacer sleeve into the hinged hole.
Note: The rolling bearing should be assembled
after being frozen for 4 hours.
16. Install upper and lower bearing caps with 4
cross-placed bolts. Pre-tighten the bolts to ensure
that there is no clearance between the lower end
face of lower bearing and the upper end face of
lower cap. Then remove upper and lower bearing
caps.
Note: This step is only used to adjust the
clearance between the lower cap and the bearing and is
not the formal assembly.
17. Adjust the axial displacement of inner ring to
0.1~0.2 mm.
18. Install upper and lower bearing caps and tighten
them diagonally based on assembly and tightening
order of bolts.
4
1 2
Fig. 7-3
1 Upper bearing cap
2 Bush
90�20Nm
Note: In the assembly, place the bearing caps
based on marks made before removal.
19. Install new seal ring, smear hydraulic oil on the
bush and press it into the upper bearing cap. (See
Fig. 7-3)
734 Joint of upper frame
20. Remove upper and lower bearing caps.
21. Take out the joint bearing by setting tool.
22. Clean bearing cap.
23. Clean the hinged hole, smear proper lubricating oil
and replace new bearing.
24. Install upper and lower bearing caps and tighten
them diagonally based on assembly and tightening
order.
90�20Nm
735 Connection between front and rear
frames
25. Install two chain blocks. Ensure that the support
frame under the front frame can move back.
26. Pull the front frame back by the chain block.
27. Align two frames carefully. Ensure that the bush
inside the bearing cap does not contact the rear
frame and avoid damaging the seal ring.
736 Joint of upper frame
28. Align the location of upper pin. Lubricate the
locations of upper hinge pin and bearing by
hydraulic oil.
29. Press the hinge pin in.
30. Install and tighten the fixing bolt of pivot and
connect the lubricating pipe.
90�20Nm
737 Joint of lower frame
31. Align the hinge hole of front and rear locations at
the lower hinge pin.
32. Lubricate the lower hinge pin and bearing with
hydraulic oil.
5
Fig. 7-4
1 Special support device
33. Press the hinge pin in and make the upper
protruded block on the pivot stuck in the neck.
34. Tighten the slotted nut, insert the cotter pin and
bend one edge.
35. Remove chain block, jack, support frame and the
stopper at the wheel.
36. Install the transmission shaft.
37. Connect the hydraulic pipe.
38. Install the front pin of steering cylinder.
39. Lubricate the parts (pin and upper/lower bearing)
needing lubrication.
40. Check the hydraulic oil level and fill the hydraulic
oil to the standard level when necessary.
41. Start the engine to check whether there is oil
leakage.
74 Disassembly and assembly of front
and rear wheels
741 Disassembly of rear wheel
1. Park the vehicle on the flat and solid ground.
2. Place the stopper at the front wheel to prevent the
vehicle from moving.
3. Place the jack under the balance weight. Lift the
machine and place the special support device under
the balance weight and then remove the jack.
4. Release the wheel nut.
Note: Before the wheel is fixed, do not remove
the wheel nut.
5. Remove wheel nut and wheel.
742 Assembly of rear wheel
1. Clean the contact surface between rim and hub.
Keep the thread on the hub cleaned and free from
damage.
2. Install the wheel by forklift tool. Assemble 4 wheel
nuts alternately by diagonal method and then
tighten these nuts in turn.
Note: Tighten the nuts clockwise. Tighten it
slightly each time to avoid inclination of wheel.
6
Remove the wheel forklift tool.
Install and tighten rest wheel nuts.
310�45Nm
1. Install the jack, lift machine and remove special
supporting device.
2. Lower the machine and remove the jack.
3. Check whether the function is normal.
743 Disassembly of front wheel
1. Park the vehicle on the flat and solid ground.
2. Place stopper at the rear wheel to prevent the
vehicle from moving.
3. Lift the machine with special lifting equipment to
make the front wheel off the ground.
4. Release but not remove the wheel nut.
5. Install the wheel forklift tool and fix the wheel.
6. Remove the wheel nut and the wheel.
744 Assembly of front wheel
1. Clean the contact surface between rim and hub.
Keep the thread on the hub cleaned and free from
damage.
2. Install the wheel by forklift tool.
Assemble 4 wheel nuts alternately by diagonal method
and then tighten these nuts in turn.
Note: Tighten the nuts clockwise. Tighten it
slightly each time to avoid inclination of wheel.
Remove the wheel forklift tool.
Install and tighten rest wheel nuts.
310�45Nm
3. Lower the machine and remove special tooling.
4. Check whether the function is normal.
75 Disassembly and assembly of
working device
751 Disassembly of connecting bar
1. Start the vehicle, drive the vehicle to the flat,
7
spacious and solid ground and then park the
vehicle. Place the bucket on the ground and put
down all control levers in the central position.
Press the parking brake button, shut down the
engine and fit the loader tire with wooden wedge
block.
2. Hoist the removal end of connecting bar with
travelling crane so as to prevent the falling
connecting bar from injuring people or damaging
ground when the pivot is taken down.
3. Remove the fixing bolt of pivot and knock it out
with copper bar. Disassemble the connecting pivot
between connecting bar and quick coupling device.
4. Place the connecting bar on the ground and release
the hoisting rope to lift the other end of connecting
bar.
5. Remove the fixing bolts connecting the connecting
bar and the rocker arm to the pivot.
6. Knock it out with copper bar, remove the pivot and
hoist the connecting bar.
752 Assembly of connecting bar
1. Clean dirt in holes on both ends of connecting bar
and fill proper lubricating oil into each hole.
2. Install the hoisting rope to the one end of
connecting bar to lift the connecting bar.
3. Place an O-shape dust ring respectively at two
surfaces of junction between connecting bar and
rocker arm. Connect the connecting bar to the
rocker arm with pivot.
4. Tighten the fixing bolt of pivot on the rocker arm.
5. Place an O-shape dust ring respectively at two
surfaces of junction between connecting bar and
rocker arm.
6. Adjust the connecting bar and control the rotating
bucket cylinder to align the connecting bar to the
axle hole of quick coupling device.
7. Connect the quick coupling device with the
connecting bar with pivot and tighten the fixing
bolt of pivot on the quick coupling device.
8. Inject proper lubricating oil to the joint of pivot
through the grease nipple on the pivot end face.
753 Disassembly of rocker arm
8
Fig. 7-5
1 Hoisting rope
Fig. 7-6
1 Hoisting rope
1. Lift the rotating bucket cylinder with the hoisting
rope which should have certain pre-tightening force
to prevent the rotating bucket cylinder from falling
off when the pivot is taken down.
2. Remove the fixing bolt connecting the rotating
bucket cylinder and the rocker arm to the pivot and
knock out the pivot with copper bar. (See Fig. 7-5)
3. Lift the rotating bucket cylinder from the ground.
(See Fig. 7-6)
4. Lift the rocker arm by hoisting rope.
5. Remove the fixing bolt of pivot between the
connecting bar and the rocker arm, knock out the
pivot with copper bar and take down the O-shape
dust ring.
6. Remove the fixing bolt of pivot between the rocker
arm and the boom and knock out the pivot with
copper bar.
7. Lift the rocker arm and place it on the prepared
rubber blanket.
9
754 Assembly of rocker arm
1. Clean the central hole and smear proper lubricating
oil.
2. Install frozen axle sleeve in the pin hole and make
the distance from the axle sleeve to both end faces
of hole equal.
3. Install O-shape dust ring on the outer end of axle
sleeve.
4. Lift the rocker arm by the hoisting rope.
5. Clean the pin hole on the connecting bar and smear
proper lubricating oil.
6. Install frozen axle sleeve in the pin hole and make
the distance from the axle sleeve to both end faces
of hole equal.
7. Install O-shape dust ring on the outer end of axle
sleeve.
8. Connect the connecting bar and the rocker arm
with pivot and tighten the fixing bolt of pivot.
9. Align the central pin hole on the rocker arm to the
pin hole on the boom. Connect the rocker arm and
the boom with pivot. Tighten the fixing bolt of
pivot.
10. Keep the rocker arm stable and remove the hoisting
rope inside the pivot hole of rocker arm.
11. Lift the front end of rotating bucket cylinder with
hoisting rope and take down the support block
under the rotating bucket cylinder.
12. Start the vehicle and control the handle to adjust
the stroke of piston rod of rotating bucket cylinder
and at the same time adjust the hoisting height of
rotating bucket cylinder to align the pin hole on the
piston rod to the pivot hole on the rocker arm.
13. Connect the rotating bucket cylinder and the rocker
arm with pivot and place gasket on the joint surface
to ensure the installation clearance within 0.5~1.5
mm.
14. Tighten the fixing bolt of pivot of rocker arm.
15. Inject proper grease into the pivot joint through the
grease nipple of pivot end face.
755 Disassembly of boom
1. Remove the rocker arm (refer to the disassembly of
rocker arm).
2. Remove the quick coupling device (refer to the
10
Fig. 7-7
disassembly of quick coupling device).
3. Start the vehicle, lift the boom to the horizontal
position and place special support frame under the
boom.
4. Lift the boom with the hoisting rope which should
be tensioned properly.
5. Remove the fixing bolt of boom cylinder and boom
connecting pivot. Knock out and take down the
pivot.
6. Remove the fixing bolt of front frame and boom
connecting pivot and knock out and take down the
pivot.
7. Lower the boom.
756 Assembly of boom
1. Clean the internal surface of boom pin hole and
smear proper grease.
2. Press two frozen axle sleeves into the hinge hole of
boom and front frame and place an O-shape dust
ring respectively on both ends of axle sleeves.
3. Lift the boom to the frame slowly and align the
axle hole of boom to the corresponding axle hole of
front frame.
4. Connect the front frame and the boom with pivot
and tighten the fixing bolt of pivot on the front
frame. Adjust the clearance between boom and
front frame end face within 0.5~1.5 mm by adding
gaskets.
5. Start the vehicle, control the handle to adjust the
stroke of boom cylinder and coordinate the hoisting
height of boom to align the axle hole of boom
cylinder to the axle hole of boom.
6. Connect the front frame and the boom by pivot and
tighten the fixing bolt of pivot on the front frame.
757 Adjustment requirements of clearance
between typical parts
The clearance between following typical part should be
adjusted to conform to requirements in Table 7-1 by
LGB303 washer. See Fig. 7-7 for specific location.
11
No. Description of typical part
Adjustment requirements (mm)
Sleeve (unilateral
clearance)
Joint bearing (unilateral
clearance)
1 Joint between boom and bucket 0.5~1.5 \
2 Joint between rocker arm and boom 0.5~1.5 \
3
Joint between boom and boom
cylinder
0.5~1.5 1~2
4
Joint between rotating bucket
cylinder and front frame
0.5~1.5 1~2
5 Joint between boom and front frame 0.5~1.5 \
Table 7-1 Adjustment requirements of clearance at typical part

?

Contents
8 Cab & air conditioner
system ............................................................................
...... 1
81 General cab disassembly and installation
steps ....................................................... 1
82 Air conditioner system
description .......................................................................
... 2
821 Working principle and layout of air conditioner
system .................................. 2
822 Air conditioner control
principle ...................................................................... 5
823 Considerations of installing and using air
conditioner ..................................... 8
83Routine check of air conditioner
system ................................................................... 9
84 Maintenance instruction of air conditioner
system ................................................ 11
841 Basic
process ...........................................................................
....................... 11
842 system drains
refrigerant .......................................................................
......... 11
843 dissemble pipeline or pressure
switch ............................................................ 11
844 refrigerant
oil ...............................................................................
................... 12
845 Refrigerant charging
method ..........................................................................
14
85 Common fault diagnosis and troubleshooting of air conditioner
system .............. 16
The system fails in
refrigeration .....................................................................
....... 17
System refrigerating capacity
shortage ................................................................. 18
The refrigeration system works discontinuously
automatically. .......................... 19
Common fault diagnosis and
troubleshooting ....................................................... 20
Common troubleshooting flow diagram of the air conditioner system ................
23
8-1
8 Cab & air conditioner system
81 General cab disassembly and installation steps
Lift cab
Disassemble foot brake valve pipeline
Disassemble steering gear pipeline
Disconnect cable accelerator
(two-stage)
Disconnect flexible shaft of
transmission (mechanical control)
Disconnect cab harness
Disassemble cab
Disconnect flexible shaft of multiway
valve (mechanical control)
Disconnect flexible shaft of parking
brake
Disconnect water pipe of fan heater
Disconnect fuel level sensor
Disassemble fixing bolts of cab
Life cab
Assembly steps are basically opposite to disassembly steps, pay attention to
hoisting safety.
8-2
82 Air conditioner system description
821 Working principle and layout of air conditioner system
1.1 Heating system
Heating system of loader air conditioner consists of engine, heater valve, heater
pipe, evaporator,
connector, etc.
Use circulating coolant of the engine as the heat source, circulating coolant
enters heater core of air
conditioner system from the engine and then returns to radiator after circulating
in the heater core.
The fan exchanges heat by blowing air to the heater, hot air blows off from the air
port and
circulates continuously to supply heat for the cab.
Fig.8-1 Heating principle
Engine circulating water
Back to engine
Cab return air-cold air
Enter cab-hot air
Heater core
Evaporator
Engine
Heater valve
Heater pipe
8-3
1.2 Refrigeration system
The refrigeration system of the loader circulates in the system by using
refrigerant, turns into
gaseous state from liquid state when passing through evaporator and absorbs plenty
of latent heat in
cab, then it releases the heat in condenser through compressor and blows off the
heat to outside air
through the fan to reduce interior temperature of the cab. It can be divided into
five processes:
1. Compression process: compress low temperature and low pressure gas refrigerant
flowing
through the evaporator into high temperature and high pressure gas refrigerant and
covey it to the
condenser.
2. Condensation process: cool the high temperature and high pressure gas
refrigerant off to
produce intermediate temperate and high pressure gas refrigerant and convey it to a
drying bottle.
3. Drying process: filter intermediate temperate and high pressure gas refrigerant
to remove
impurities and water in it, convey it to a throttle valve and store a fraction of
refrigerant.
4. Expansion process: transform the filtered intermediate temperate and high
pressure gas
refrigerant into low pressure vaporous liquid/gaseous state mixture by taking
advantage of throttling
principle, then convey it to the evaporator.
5. Evaporation process: low pressure vaporous liquid/gaseous state mixture flows
into the
evaporator, absorbs surrounding heat and vaporizes for the purpose of
refrigeration, then draws in
from low pressure intake tube of the compressor to proceed to next cycle and so
forth.
Fig.8-2 Refrigeration principle
Compressor
belt
Compr
essor
Evaporator
Temperature
controller panel
Condenser
Fluid reservoir
Expansion
valve
8-4
1.3 Air conditioner system arrangement
There are two types of system layout in accordance with manufacturers of air
conditioner parts:
Fig.8-3 Layout of Xinxiang Yuxin air conditioner
Fig.8-4 Layout of Hangzhou Aolan air conditioner
8-5
822 Air conditioner control principle
2.1 Fan control principle
Air volume switch:
Power air volume switch is a three-grade rotary switch, cut off control supply at
�0�, switch on
�control supply� at other positions, air volume of the fan corresponds to low, mid-
and high ranges.
Fig.8-5 Air volume switch
Fan high range
Fig.8-6 Schematic diagram of high range
Fan mid-range
Main vehicle power positive
Main vehicle power negative
Fuse
Power line
Air conditioner
controller
Fan high range
Fan mid-range
Fan low range
Sensor positive
Sensor ground
Refrigeration output
Fresh air control output
Refrigeration indicator
lamp input(+)
Green/bla
ck
Brown
Yellow
Green
Fan high range
control line
Wh
ite
White
Purple
Red/black
Grey
Black Black
Fresh air servo
motor
Relay coil
control
Purple
Black
Purple
Black
Blue
High/low pressure switch
of air conditioner
Refrigeration control relay
Compressor
electromagnetic
clutch
Conden
ser
motor
Fan high range control line
Control line of fan mid-range
Control line of fan low range
Speed control resistance
Evaporative motor
Speed
control
resistance
Diode
Defrost
sensor
Red Red
Black
Black
GND ground
8-6
Fig.8-7 Schematic diagram of mid-range
Fan low range
Fig.8-8 Schematic diagram of low range
2.2 Working principle of air conditioner system
Rotate the temperature control switch to a certain position, refrigeration
indicator lamp is on,
Fuse
Power line
Air conditioner
controller
Fan high range
Fan mid-range
Fan low range
Sensor positive
Sensor ground
lamp input(+)
Green/bla
ck
Brown
Yellow
Green
Fan high range
control line
Wh
ite
White
Purple
Red/black
Grey
Black Black
Fresh air servo
motor
Relay coil
control
Purple
Black
Purple
Black
Blue
of air conditioner
Compressor
electromagnetic
clutch
Conden
ser
motor
Evaporative motor
Speed
control
resistance
Diode
Defrost
sensor
Red Red
Black
Black
GND ground
Fuse
Power line
Air conditioner
controller
Fan high range
Fan mid-range
Fan low range
Sensor positive
Sensor ground
lamp input(+)
Green/bla
ck
Brown
Yellow
Green
Fan high range
control line
Wh
ite
White
Purple
Red/black
Grey
Black Black
Fresh air servo
motor
Relay coil
control
Purple
Black
Purple
Black
Blue
of air conditioner
Compressor
electromagnetic
clutch
Conden
ser
motor
Evaporative motor
Speed
control
resistance
Diode
Defrost
sensor
Red Red
Black
Black
GND ground
8-7
indicating start of refrigeration. The temperature sensor detects cab temperature,
the indicator lamp
is off and the compressor stops working when the temperature falls to required
temperature,
temperature in the cab at present is set temperature. When indoor temperature
exceeds this
temperature, the indicator lamp is on, the compressor starts automatically and the
system starts
refrigeration; when indoor temperature is lower than this temperature, the
indicator lamp is off and
the system stops working;
Fig.8-9 Temperature control switch
Fig.8-10 Schematic diagram of air conditioning
2.3 Fresh air control principle
Change-over switch of fresh air:
controls operation of fresh air actuator as well as internal and external
circulating intake. Air inlet of
fresh air and recirculating air is controlled by throttle motor at unit ventilator.
Its control panel is on
the right panel inside the cab.
Fuse
Power line
Air conditioner
controller
Fan high range
Fan mid-range
Fan low range
Sensor positive
Sensor ground
lamp input(+)
Green/bla
ck
Brown
Yellow
Green
Fan high range
control line
Wh
ite
White
Purple
Red/black
Grey
Black Black
Fresh air servo
motor
Relay coil
control
Purple
Black
Purple
Black
Blue
of air conditioner
Compressor
electromagnetic
clutch
Conden
ser
motor
Evaporative motor
Speed
control
resistance
Diode
Defrost
sensor
Red
Red
Black
Black
GND ground
8-8
Fig.8-11 Change-over switch of fresh air
Fig.8-12 Route diagram of fresh air
Fig.8-13 Schematic diagram of fresh air
823 Considerations of installing and using air conditioner
1. To extend service life of air conditioner system, we recommend you to run the
air conditioner 1-2
time (s) for 15-20 minutes monthly when it is not used and run it in winter while
using warm air.
: fresh air
: recirculating air
Fuse
Power line
Air conditioner
controller
Fan high range
Fan mid-range
Fan low range
Sensor positive
Sensor ground
lamp input(+)
Green/bla
ck
Brown
Yellow
Green
Fan high range
control line
Wh
ite
White
Purple
Red/black
Grey
Black Black
Fresh air servo
motor
Relay coil
control
Purple
Black
Purple
Black
Blue
of air conditioner
Compressor
electromagnetic
clutch
Conden
ser
motor
Evaporative motor
Speed
control
resistance
Diode
Defrost
sensor
Red Red
Black
Black
GND ground
8-9
2. Correct steps of starting air conditioner system: turn off air volume switch of
evaporator fan and
adjust refrigeration knob to 0 position before starting the engine; first turn on
air volume switch of
evaporator fan and then adjust refrigeration knob after starting the engine.
3. Models with air conditioner filter element shall be cleaned on a regular basis
according to
operating condition. Clean the filter element when the air volume reduces
significantly. Filter
element replacement is recommended when the air volume still reduces significantly
after cleaning
filter element.
4. To guarantee refrigeration performance of air conditioner, clean condenser core
on a regular basis
to keep the condenser clean and give full play to its heat dissipation performance.
5. Refrigerant charging shall be completed by professionals in accordance with
specified process.
6. LG918 and higher level SDLG loaders provide reserved installation interface of
air conditioner
and supporting optional air conditioner modules for users.
7. Reserved power interface must be used when installing the air conditioner
system, do not alter
original circuit without authorization.
8. Do not remove sealing elements mounted at pipeline joints of the new reservoir
before
connecting pipeline to protect service life of the air conditioner system from
being affected by dryer
failure.
9. Try not to dissemble pipeline and discharge refrigerant when repairing parts of
the air conditioner
system. Repairable parts are not recommended to be replaced. The assembly is not
recommended to
be replaced if secondary parts can be replaced. Parts maintenance and replacement
should be
operated in strict accordance with technological requirements, otherwise secondary
failures may be
caused.
83 Routine check of air conditioner system
Main check methods:
??Check if temperature in each part is normal by touching.
??Check leaking parts and surface conditions through visual inspection.
??Judge system operating condition from sight glass.
??Check electrical apparatus elements by disconnecting and connecting circuit.
??Check abnormal sound and smell by hearing and smelling.
Check item Check content
Check time
Daily Semi-annually Annually
Pipeline Poor fixation with gap v v
8-10
assembly
Junction looseness, nut and bolt
looseness
v v
Connecting bolt
Junction looseness, nut and bolt
looseness and detachment
v v
Driving belt
Looseness and bending v v
Degradation: wear, scar, crack v v
Noise, smell or abnormal heating v
Condenser
assembly
Fins lodging v
Impurities blockage (rubbish, dust,
worm grass, etc.)
v v v
Air volume
switch of air
conditioner
Starting check, air volume, switch
control
v v
Switch function v v
Refrigerant
leakage
Leakage at pipeline joints v v
Internal leakage of components and
parts (compressor, condenser,
evaporator, receiver-dryer)
v
Refrigerant
quantity
Check refrigerant quantity (observe
sight window)
v v
Noise
Compressor (including unloaded) v
Condenser fan, evaporator fan v
Reservoir
temperature
Temperature difference indicates
blockage in the dryer
v
8-11
difference
84 Maintenance instruction of air
conditioner system
841 Basic process
Discharge refrigerant ?replace parts, charge
refrigerant oil?vacuumize?charge refrigerant
?commission and operate
Vacuum pump connecting end, refrigerant
charging end, refrigerant discharge end
Fig.8-14
842 system drains refrigerant
1. Make sure knob switch of the pressure gauge is
switched off.
2. Connect the pressure gauge to refrigerant
charging point. Connect red pipeline joints of the
pressure gauge to high pressure end (H) and blue to
low pressure end (L).
3. Discharge refrigerant: rotate knobs on high and
low pressure sides of the pressure gauge to discharge
the refrigerant in gas state by yellow pipeline of the
pressure gauge.
Note: do not discharge the refrigerant in
liquid state. Wear gloves to prevent hand
frostbite during operation.
843 dissemble pipeline or pressure switch
4. Make sure there is no refrigerant in the system
before dissembling pipeline or pressure switch,
discharge it if any by using a pressure gauge.
5. Keep the whole process of parts replacement
shall be clean and free from pollution to avoid
system pollution if pipeline or pressure switch shall
be dissembled to replace parts.
Blue Red
Low
pressure
end (L)
High
pressure
end (H)
8-12
Special O ring made from hydrogenated
nitrile rubbers (H-NBR)
Fig.8-16
6. When connecting pipeline joints or pressure
switch due to parts replacement, check if the O ring
is intact, replace it with a new one in case of any
damage.
Note: please use special O ring made from
hydrogenated nitrile rubbers (H-NBR) designed
for R134a system.
Evaporator Condenser
Fig.8-17
7. Connect pipeline as directed by arrows when
replacing the reservoir.
Connect inlet end of refrigerant to pipeline on the
condenser end and outlet to pipeline on the
evaporator end.
Note: arrow in the left figure indicates flow
direction of refrigerant.
Fluid reservoir
Pipeline
844 refrigerant oil
8. Charge refrigerant oil to the system when
replacing the evaporator, condenser, reservoir and
pipeline.
Note: refrigerant oil shall be PAG100 model
and do not use other models of refrigerant oil.
Replaced components
Refrigerant oil charge
(ml)
Evaporator 30
Condenser 70
Reservoir 30
8-13
Condenser
Fig.8-18
Autoclaved pipe 30
Pressure cooling pipe,
cold storage pipe and
steam storage pipe
10
Fig.8-19
9. Replace compressor
10. Discharge refrigerant oil in a faulty compressor
and measure refrigerant oil mass.
(Discharge 100ml of refrigerant oil)
Fig.8-20
11. Discharge refrigerant oil in new compressor,
recharge refrigerant oil with mass equivalent to that
in the faulty compressor.
8-14
Fig.8-21
12. Recharge 10ml of refrigerant oil to the new
compressor (100+10=110ml).
Connecting pipe of vacuum pump
Fig.8-22 Pressure gauge
845 Refrigerant charging method
Note: refrigerant charging method for air
conditioner system without refrigerant is as
follows.
1. Vacuumize the system
a) Connect the pressure gauge to refrigerant
charging point. Connect red joints of the pressure
gauge to high pressure end (H) and blue to low
pressure end (L). At present knob switch of the
pressure gauge is switched off.
b) Connect yellow pipeline of the pressure gauge to
vacuum pump.
c) Switch on the vacuum pump and then turn on
knob switch of the pressure gauge to vacuumize it on
high and low pressure sides simultaneously for 25 to
30 minutes.
d) Maintain pressure. Maintain pressure for 5-10
minutes to check if pressure changes. Check leaking
point in case of obvious change. Otherwise continue
vacuumizing.
Note: first turn off the knob switch of
pressure gauge and then the vacuum pump when
maintaining pressure.
e) Vacuumize it again. The start the vacuum pump
Blue Red
Low
pressure
end (L)
High
pressure
end (H)
8-15
and turn on the pressure gauge knob. Vacuumize it
on high and low pressure sides simultaneously again
for 15 to 20 minutes. In case of high ambient
humidity (rainy days), extend vacuumizing by 20-30
minutes.
f) Maintain pressure again. Turn off the knob
switch of pressure gauge and then the vacuum pump
to maintain pressure for 5 minutes.
Note: failing to vacuumize it within required
time may produce residual moisture in the system
and further cause such system failures as
reservoir failure and evaporator ice blockage.
2. Charge refrigerant to the system
a) After vacuumizing, dissemble yellow pipeline of
the pressure gauge from the vacuum pump and
connect it to refrigerant tank.
Note: the refrigerant shall be R134a model,
any other models of refrigerant are forbidden.
Unqualified refrigerant may cause deadly damage to
the system.
Recommended brand: Xi�an Jincool.
Fig.8-24
Connect refrigerant charging
exhaust button
Fig.8-25
b) Turn on exhaust knob of the yellow pipeline to
inject some refrigerant and exhaust air in the yellow
pipeline.
c) Turn on the knob switch on high and low
pressure ends of the pressure gauge to cause the
refrigerant to be drawn in by the air conditioner
system under effect of negative pressure.
Blue
Red
8-16
Close button of high pressure end
Fig.8-26
d) When the pressure gauge shows no change in
pressure display, turn off knob switch on high
pressure end.
e) Start the engine and air conditioner system to
adjust air volume switch and refrigeration knob to
the maximum. Note to see if the compressor clutch
works and the condensate fan runs properly.
Open button of low pressure end
Fig.8-27
f) Turn on knob switch on low pressure end of the
pressure gauge to cause the refrigerant to be drawn
in by the air conditioner system from the low
pressure end.
g) After charging the first tank, turn off knob
switch of the pressure gauge and replace the
refrigerant tank, continue charging refrigerant from
the low pressure end. Repeat b operation each time
when replacing the tank with a new one.
h) Observe flow of the refrigerant through sight
glass during charging, stop charging when many
foams reduce to several (clearly countable).
Note: do not charge refrigerant from high
pressure end after starting the engine.
3. Operation debugging.
Start and run the air conditioner system to keep the
system free from leakage and runs properly.
85 Common fault diagnosis and troubleshooting of air conditioner
system
Note to find out causes of malfunction in accordance with abnormal running
phenomenon of the air
conditioner when checking and repairing failures of the air conditioner system,
then take measures
to repair the system. Common failures present in air conditioner system are usually
system
refrigeration failure, system refrigerating capacity shortage and discontinuous
system working.
Blue Red
Blue Red
8-17
The system fails in refrigeration
The diesel engine works in idle state after starting the engine. Adjust change-over
switch to
refrigeration position, temperature control switch to maximum refrigeration
position and fan switch
to H (high speed) position, cold air shall blow off from air outlet after the air
conditioner system
runs steadily for 2min, otherwise check following items
??Check if circuit fuse of the air conditioner is subject to fusing, the circuit is
subject to short
circuit and all connector clips are in good contact, whether the evaporator fan and
compressor
clutch work, temperature switch is turned on and the relay pulls in.
??High/low pressure switch fault on fluid reservoir; working range of the switch,
high pressure up
to 2.65MPa and low pressure up to 0.20MPa. High pressure switch acts in case of too
high
pressure in the system; or low pressure switch acts when there is no refrigerant in
the system.
Cut off the clutch to judge whether the high/low pressure switch fails or not. Cut
out the
high/low pressure switch if necessary. When the clutch pulls in and system starts
working,
replace the faulty high/low pressure switch.
The high/low pressure switch shall not be subject to short circuit to work during
check,
otherwise it may damage the whole system
??Drive belt of the compressor is too loose. It shall drop by 14-20mm under 110N of
pressure.
First tighten and turn the nut when adjusting the belt until appropriate belt
tension is achieved.
Considerations of using and maintaining compressor
1. Air intakes and exhaust ports of the compressor must be mounted upward with
allowable
deflecting angle <45�
2. System connecting hose shall be fixed securely and do not contact with hot parts
so as to avoid
damage to the hose.
??There is no refrigerant in the refrigerating system. In case of serious
refrigerant leakage, detect
it by using integrated high and low pressure gauge. High and low pressure display
is very low
and no cold air blows off even if the compressor works.
At a temperature of 32-37� and the compressor rotates at a revolving speed of 1800-
2000r/min,
normal pressure of the system is as follows
Pressure of high pressure gauge amounts to 1.27-1.52MPa
Pressure of low pressure gauge amounts to 0.12-0.15MPa
Find out leaking point of the refrigeration system by using a refrigerant air
leakage detector and
treat it correspondingly, then vacuumize the refrigeration system and charge
refrigerant.
??The refrigeration system is blocked by dirt, the refrigerant can not flow and
refrigerate any
more. Low pressure of the integrated high and low pressure gauge presents vacuum
indication
while high pressure presents higher indication. Such situation is usually present
in the fluid
reservoir or expansion valve. Deal with it by replacing fluid reservoir or
expansion valve.
??Compressor of the system is damaged and fails to discharge high temperature and
high pressure
8-18
refrigerant, the integrated high and low pressure gauge indicates almost equal high
and low
pressure. Deal with it by replacing the compressor or dissembling it for repairing.
Following items shall be noted when overhauling the refrigeration system
1. Wear protective glasses or face shield as far as possible during overhaul. Wear
gloves to
prevent refrigerant from spilling on the skin and causing skin frostbite.
2. First switch off the diesel engine, then connect the integrated high and low
pressure gauge to
the compressor for detection.
3. Do not touch hot and moving parts of the diesel engine
4. Ensure that system joints and inner chamber are clean when replacing components
for the
system. Paint seal ring of the joints with a layer of refrigerator oil before
pipeline mounting.
Use a torque wrench when tightening pipeline joints. Tightening torque is as shown
in the table
below. Supplement refrigerator oil when replacing parts and components for the
system.
System refrigerating capacity shortage
??Condensation effect is poor, oil stain, dirt and debris on the condenser may
prevent the
condenser from radiating heat outwards. Detect it by using the integrated high and
low pressure
gauge. The detection shows very high indicated value of high and low pressure,
clean the
condenser and clear debris. Note not to damage fins of the condenser while cleaning
the
condenser.
??Evaporating fan of the evaporator blows off low air volume and brings few cold
air. It seems
that the cold air is insufficient mainly because impediments inside the air duct
have blocked the
air inlet and outlet.
??In case of refrigerant shortage in the refrigeration system, detect it by using
the integrated high
and low pressure gauge. The detection shows that the indicated values of high and
low pressure
are lower. Bubbles roll can be observed from the reservoir sight glass, charge
sufficient
refrigerant.
??Evaporation temperature increases since excess refrigerant has been charged,
discharge some
refrigerant.
??If the refrigeration system is mixed with air, detect it by using the integrated
high and low
pressure gauge. The detection shows that the indicated values of high and low
pressure as well
as the condenser temperature are higher, radiating effect is poor. Hence discharge
the
refrigerant, vacuumize it and recharge it.
??Warm water solenoid valve is damaged and should be turned off when not
electrified, the water
pipe is relatively warm and outlet pipe is under normal temperature by touching.
After the
warm water solenoid valve is damaged, touch the inlet pipe and outlet pipe and find
that both
are hot. Poor refrigeration effect will be made while refrigeration and heating
elements of the
evaporator work simultaneously. The warm water solenoid valve must be replaced.
8-19
The refrigeration system works discontinuously automatically.
??The refrigeration system works discontinuously automatically because the system
is mixed with
moisture, few moisture freezes and blocks the expansion valve, causing the system
to stop
working and recover working after the ice melts. The moisture freezes at the
expansion valve
after refrigeration and so forth, causing the system to work discontinuously
automatically.
Troubleshooting: discharge the refrigerant, replace the fluid reservoir, vacuumize
the
refrigeration system in dry environment for a relatively long period, vacuumize it
for 30min
and maintain pressure for 30min, then vacuumize it for 30min again and finally
charge
refrigerant.
??Circuit contact is poor. The power is connected and disconnected now and then,
check the
circuit carefully.
Considerations of overhauling air conditioner system
1. Do not close all air outlets when the air conditioner system works so that the
system can
exhaust air.
2. Do not put cotton yarn, waste paper, plastic film and other debris which may
easily block the
air inlet in the cab. Serious blockage and poor ventilation may lead to electrical
faults of the
system and even cause fire.
3. Discharge the refrigerant from the low pressure side and keep the workplace in
good ventilation
conditions to protect personnel from suffocation accidents.
4. Liquid inlet and outlet of the fluid reservoir shall be connected properly,
otherwise the system
may fail in refrigeration.
8-20
Common fault diagnosis and troubleshooting
S/N Fault phenomenon Failure causes Troubleshooting
1 Fan does not rotate
Poor connector clip
contact
Blowing rate switch,
relay and cold hot
switch damage
Fuse break or battery
undervoltage
Repair or replace it
2 Fan runs properly
Obstacles on suction
side, rib plate of
evaporator and
condenser blocked by
dust
Clear
3
Compressor does not run or runs with
difficulty
Compressor clutch does
not pull in as a results of
circuit disconnection
and poor contact
Loose stretching device
of the compressor belt
falls off and the belt is
too loose
Coils of the compressor
clutch is broken and
faulty
High/low pressure
switch of the fluid
reservoir works, there is
excess or few
refrigerant
Repair
Repair
Replace pull-in coil
Discharge or charge
refrigerant
4 Refrigerant supply
Refrigerant leakage
Insufficient refrigerant
charge
Eliminate air leakage,
supply refrigerant
8-21
5
Measure spot high pressure and low
pressure according to readings of
high/low pressure gauge
At a temperature of 32-37� and the compressor
rotates at a revolving speed of 1800-2000r/min,
normal pressure of the system is as follows
Pressure of high pressure gauge amounts to
1.27-1.52MPa
Pressure of low pressure gauge amounts to
0.12-0.15MPa
Higher low
pressure
Frost on low pressure
pipe surface
Excess expansion valve
opening
Poor thermal bulb
contact of expansion
valve
Excess refrigerant in
system
Replace expansion
valve
Install thermal bulb
properly
Discharge part of
refrigerant
Lower low
pressure
Displayed value on
low pressure gauge
lower than normal
value
Pipeline joint looseness
due to vibration leads to
leakage and refrigerant
shortage
Find out leak points
by using leak
detector, tighten the
loose parts carefully
as charge refrigerant
as specified
The low pressure
gauge indicates
negative pressure
sometimes
Low pressure rubber
hose is blocked or
expansion valve blocked
by ice
Evacuate the system,
replace fluid reservoir
and recharge
refrigerant
Evaporator freeze
Temperature controller
failure
Replace temperature
controller
Inlet side of the
expansion valve is
cool and covered by
frost
Expansion valve
blockage
Clean or replace
expansion valve
Outlet side of the
expansion valve is not
cool, the low pressure
gauge indicates
negative pressure
sometimes
Air leakage at
temperature sensitive
pipe and thermal bulb of
the expansion valve
Replace expansion
valve
8-22
6
Higher high
pressure
Air conditioner
system
Air in air conditioner
system
Evacuate and
vacuumize the
system again,
maintain pressure and
charge refrigerant
Excess refrigerant
charge
Excess refrigerant
charge
Discharge a given
mass of refrigerant to
keep appropriate
mass of refrigerant in
the system
Poor condensation
effect of condenser
Poor condensation
effect of condenser
Clean condenser and
clear debris
Check and replace
broken condensate
fan
Lower high
pressure
Pipeline
Pipeline joint looseness
due to vibration leads to
leakage and refrigerant
shortage
Find out leak points
by using leak
detector, tighten the
loose parts carefully
as charge refrigerant
as specified
Low pressure
indicates negative
pressure state
sometimes
Low pressure pipeline is
blocked and damaged
Clean or replace
pipeline
Not hot compressor
and high pressure
pipeline
Compressor failure Replace compressor
7 Poor refrigeration effect Block valve damage Replace block valve
8-23
Common troubleshooting flow diagram of the air conditioner system
Abnormal refrigeration
system
Check air outlet of the evaporator
Low or none air volume at air outlet
Check fan motor of the evaporator Check compressor rotation
In accordance with
the table
First check item
In accordance
with the table
Second check
item
Normal blowing rate at air outlet
Fan motor does not rotate Compressor Fan motor rotates, few blowing rate rotates
normally
Compressor does not rotate or rotates
abnormally
Check refrigerant charge
In accordance with
the table
Third check item
Normal or excess refrigerant
charge
Refrigerant shortage
In accordance
with the table
Fifth check item
Abnormal system pressure
In accordance with
the table
Forth check item
Check system pressure
In accordance
with the table
Sixth check item
Normal system pressure
9 W
91 Ove
92 Mea
92
92
92
92
92
92
93
94 Intr
94
94
94
94
94
95 Fau
96
96
96
96
96
96
Working hydr
erview of wo
asurement an
21 Measurem
22 Overload
23 Primary p
24 Secondary
25 Settlemen
26 Pressure a
3 Precautions
roduction to
41 Hydraulic
42 Working p
43 Multiway v
44 Pilot contr
45 Pressure s
ult diagnosis
61 Bucket fal
62 Boom sett
63 Slow lift o
64 Inability o
65 Blow buck
66 Inability b
S
raulic system
rking hydra
nd adjustme
ment of system
pressure me
pressure mea
y pressure m
t detection o
adjustment o
s for repairin
hydraulic co
c oil tank ......
pump ...........
valve ............
rol valve ......
selector valve
and troubles
lling .............
tlement .........
of the boom ..
of boom lift ..
ket movemen
bucket move
Service Ma
Co
m ...................
ulic system .
ent of workin
m working p
easurement o
asuring of pil
measuring of
of cylinder ...
of safety valv
ng the hydra
omponents ...
.....................
.....................
.....................
.....................
e ...................
shooting of h
.....................
.....................
.....................
.....................
nt .................
ment ...........
anual of Wh
I
onten
.....................
.....................
ng hydraulic
pressure ......
of rotating bu
lot control ..
pilot control
....................
ve .................
aulic system
.....................
....................
....................
....................
....................
....................
hydraulic sys
....................
....................
....................
....................
....................
....................
heel Loade
nts
.....................
.....................
system ........
.....................
ucket cavity
.....................
l ....................
.....................
.....................
.....................
.....................
.....................
.....................
.....................
.....................
.....................
stem .............
.....................
.....................
.....................
.....................
.....................
.....................
r
.....................
.....................
.....................
.....................
....................
.....................
.....................
.....................
.....................
.....................
.....................
.....................
.....................
.....................
.....................
.....................
.....................
.....................
.....................
.....................
.....................
.....................
.....................
.....................
.....................
.....................
....................
....................
....................
....................
....................
....................
....................
.....................
....................
....................
....................
....................
....................
.....................
....................
....................
....................
....................
....................
....................
.................. 1
.................. 1
.................. 4
.................. 4
.................. 6
.................. 7
.................. 8
.................. 9
................ 10
.................11
................ 12
................ 12
................ 12
................ 13
................ 17
................ 19
................ 20
................ 20
................ 22
................ 23
................ 26
................ 27
................ 27
0
2
2
2
7
9
0
0
2
6
7
7
????
LIFTING CYL
????
TILT CYLIN
F
?9-1 L936
T
A2
B2
A1
B1
INDER
NDER
????
ILTER INSERT
6Hydraulic s
120bar
schematic d
180bar
Service Ma
diagram (me
4
P
160bar
anual of W
1
9 W
syst
91 O
system
Workin
mechan
Workin
schema
echanical)C
Wheel Loade
Worki
tem
Overview
m
ng hydraulic
nical contro
ng pressure
atic diagram
China marke
???
STEERING
er
ing
w of wor
c system ha
ol type an
e of the sy
m is as follow
t
T
L
PR
G UNIT
140b
hydr
rking hy
as two type
nd pilot co
ystem is 1
ws:
Ls CF
P
T Ls P
???
RIORITY VALVE
bar
???
GEAR PUMP
raulic
ydraulic
es including
ontrol type.
16Mpa. Its
EF
R
????
STEERING CYLIN
c
c
g
.
s
NDER
?9-2 L936
????
LIFTING CYLINDER
6Hydraulic s
????
STEERING CYLINDER
????
B2
K
????
2B
2A
2C
schematic d
L R
TILT CYLINDER
????
????
B1
??
2b
1B
1A
Service Ma
diagram (pil
???
180bar 120bar
????
1b
anual of W
2
lot) China m
???
???
???
CONTROL VALVE
PILOT VAVLE
T P
160bar
P T
Wheel Loade
market
T Ls P
Ls CF EF
STEERING UNIT
FILTER
er
P
T
???
140bar
P1
P3
T
????? PRIORITY VALVE
???
PRESSURE SELECTOR VALVE
GEAR PUMP
????
FILTER INSERT
????
?9-3 L936
????
B2
K
????
LIFTING CYLINDER
2C 6
L938 Hydra
????
2b
TILT CYLINDER
????
????
STEERING CYLINDER
2B
2A
1B
1A
aulic schem
B1
180bar 120bar
????
1b
L R
Service Ma
matic diagram
????
B3
????
3b
???
PILOT VALVE
P T
anual of W
3
m (pilot)
T P
160bar
???
??? FILTER ???
STEERING Wheel Loade
except Chin
CONTROL VALVE
CYLINDER
??
T Ls P
UNIT
er
na market
P3
T
???
HYDRAULIC LOCK
Ls CF EF
T
120bar
P1
?????
PRESSURE SELECTOR VALVE
???
SOLENOID VALVE ??? P
PRIORITY VALVE
???
GEAR PUMP
????
??? FILTER INSERT
GEAR PUMP
???? FILTER INSERT
Fig. 9-3 40
Fig. 9-4 41
030000370 p
120002945 p
pressure ga
pressure me
Service Ma
uge
easuring joi
anual of W
4
92 M
work
921 M
pressu
Measur
Pressur
(403000
piezom
Pressur
Pressur
the oil i
Pressur
1. Pla
the
wi
2. M
wh
res
hy
me
3. Re
the
4. In
pre
5. Ti
me
int
6. Co
me
7. Sta
the
the
the
ma
pre
wh
wo
loa
No
control
lifting
measur
Wheel Loade
Measurem
king hydr
Measurem
ure
rement of oi
re measurin
00370), pr
metric tube (4
re measuring
re measuring
inlet of the m
re measuring
ace the wor
e button of
ith wood or
anipulate th
heel for 1
spectively t
ydraulic oil
easuring.
emove the p
e oil inlet of
stall the p
essure port
ghten piez
easuring joi
onnect the
easuring ho
art the engin
e rotating b
e bucket is
e limit pos
aximum (
essure gaug
hich is the
orking devi
ader.
ote: To con
handle of
or fall
ements.
er
ment and
raulic sy
ment of
il temperatu
ng tool: 40
essure con
4030000368
g standard:
g position: p
multi-way v
g process:
rking device
f parking b
stone. Turn
he control h
10 times
to release re
pipe. Prep
pressure me
f the multi-w
pressure me
of the multi
zometric tu
int.
pressure g
se.
ne and plac
bucket in the
placed in p
ition, gradu
2200/rpm).
ge to obtai
current wo
ce hydrauli
nfirm measu
f the boom
ing posit
d adjust
ystem
system
ure: 45 - 55
0Mpa press
nnector (41
8).
16 Mpa
plug screw
valve.
e on the gro
brake. Wed
n off the eng
handle and t
and about
esidual pres
pare tools f
easuring plu
way valve.
easuring jo
ti-way valve
ube on th
gauge to th
ce the contro
he close pos
position and
ually accele
. Observe
in the stabl
orking pres
ic system o
urement ac
m might be
tions for
tment of
working
?.
sure gauge
20002945),
location on
ound. Press
dge the tire
gine.
the steering
t 5 times
ssure in the
for pressure
ug screw on
oint to the
e.
he pressure
he pressure
ol handle of
sition. After
d moved to
erate to the
e the oil
le pressure,
sure of the
f the tested
ccuracy, the
moved to
repeated
f
g
e
,
n
s
e
g
s
e
e
n
e
e
e
f
r
o
e
l
,
e
d
e
o
d
Fig. 9-5 40
Fig. 9-6 M
030000368 p
Measurement
pressure me
t location of
Service Ma
easuring ho
f system pre
anual of W
5
se
essure Fig.
Wheel Loader
Fig. 9-7 Measurement position of
Service Ma
f overload v
anual of W
6
922 O
rotati
Note:
applica
prohibi
machin
Measur
Pressur
(403000
piezom
Measur
Pressur
Pressur
steel pip
Pressur
1. Pla
the
wi
2. M
wh
res
hy
me
3. Re
on
4. In
pre
5. Ti
me
6. Sta
po
M
bu
po
the
the
the
cy
aft
Note:
confirm
valve pressu
Wheel Loade
Overload
ing bucke
This press
ble to fau
ted to adj
ne.
rement of oi
re measurin
00370), pr
metric tub
rement of sy
re measuring
re measurin
pe of the ro
re measuring
ace the wor
e button of
ith wood or
anipulate th
heel for 1
spectively t
ydraulic oil
easuring.
emove the p
n the steel pi
stall the p
essure port
ghten piez
easuring joi
art the engi
osition. Run
anipulate th
ucket to the
osition. Ope
e boom. Th
e pressure g
e overload
ylinder cavit
ter the buck
The measu
mation.
ure
er
pressure
et cavity
ure measur
ult diagno
ust the ov
il temperatu
ng tool: 40
essure con
e (40300
ystem worki
g standard:
ng position
tating buck
g process:
rking device
f parking b
stone. Turn
he control h
10 times
to release re
pipe. Prep
plug screw
ipe of the ro
pressure me
of the multi
zometric tu
int.
ine. Lift the
n the diesel
he control h
maximum.
erate the co
he current m
gauge is the
d valve of
ty. (The ma
ket reaches t
urement mi
e measur
uring metho
osis. Servic
verload val
ure: 45 - 55
0Mpa press
nnector (41
000368).
king pressur
18 Mpa.
n: Plug scr
ket cavity
e on the gro
brake. Wed
n off the eng
handle and t
and about
esidual pres
pare tools f
of pressure
otating buck
easuring jo
ti-way valve
ube on th
e boom to
l engine at
handle of t
. Return to
ontrol hand
maximum p
e overload
f the rotati
aximum str
the limit po
might be re
ement of
od is only
cemen are
lve on the
?.
sure gauge
20002945),
See 921
e
rew on the
ound. Press
dge the tire
gine.
the steering
t 5 times
ssure in the
for pressure
e measuring
ket cavity.
oint to the
e.
he pressure
the highest
idle speed.
the rotating
the neutral
le to lower
pressure of
pressure of
ing bucket
ess appears
sition)
epeated for
f
y
e
e
e
,
e
s
e
g
s
e
e
g
e
e
t
.
g
l
r
f
f
t
s
r
Fig. 9-8 64
Fig. 9-9 T-j
Fig. 9-10 4
410003106 p
junction an
4030000368
pressure ga
nd test joint
8 pressure m
Service Ma
uge
measuring h
anual of W
7
923 P
pilot c
Note: T
control
Measur
Pressur
(641000
T-juncti
(403000
Pressur
Pressur
Measur
1. Pla
the
bra
ha
tim
oil
2. Re
the
In
T-j
3. Co
an
4. Sta
lim
the
5. Th
lim
gu
6. Af
Re
7 W
hose
Wheel Loade
Primary
control
This operati
only.
rement of oi
re measurin
03106), pr
ion (41200
00368).
re measuring
re measuring
rement proc
ace the loa
e bucket on
ake. Shut
andle of th
mes to relea
l pipe.
emove the i
e T-junctio
stall the t
junction.
onnect one
nd the other
art the engi
mit position
e pressure g
he control h
mit position
uarantee acc
fter test, rep
emove the T
Wipe hydraul
er
pressur
on is applic
il temperatu
ng tool: 6
essure con
001100) an
g standard:
g position: O
cess:
ader in the
n the ground
down the
e working
ase residual
nlet pipe of
on on the
est joint a
end of the
end to the p
ine. Move t
n. Gradually
gauge for a s
handle mig
n to repeat
curacy of tes
peat step 1
T-junction an
lic oil leakin
re measu
cable to mo
ure: 45 - 55
6Mpa press
nnector (41
nd piezom
3.5 Mpa.
Oil inlet of
service loc
nd. Pull up t
engine. O
device han
stress in th
f the pilot f
location o
and oil pi
e test hoes t
pressure gau
the pilot ha
y accelerate
stable press
ght be move
t the measu
st data.
of pressure
and install th
ng in the rem
uring of
odel of pilot
?.
sure gauge
20001751),
metric tube
pilot filter.
cation. Lay
the parking
Operate the
ndle 3 - 5
he hydraulic
filter. Install
of removal.
ipe on the
to the joint
uge.
andle to the
to observe
sure value.
ed to other
urement to
e releasing.
he oil pipe.
moval.
f
t
e
,
e
y
g
e
c
l
.
e
t
e
e
r
o
.
Fig. 9-11 P
Fig. 9-12 6
Fig. 9-13 T
Primary pres
6410003106
T-junction a
ssure measu
6 pressure g
and test joint
Service Ma
uring positio
gauge
t
anual of W
8
on of pilot c
924 S
pilot c
Note: T
control
Measur
Pressur
(641000
T-juncti
(403000
Pressur
Pressur
multi-w
Pressur
1. Pla
the
bra
ha
to
pip
2. Re
9-
rem
on
3. Co
joi
4. Sta
mo
gra
Ob
sta
Wheel Loade
control
Secondar
control
This operati
only.
rement of oi
re measurin
03106), pr
ion (41900
00368).
re measuring
re measurin
way valve.
re measuring
ace the loa
e bucket on
ake. Shut
andle of the
release res
pe.
emove the p
15. Install t
moval. Insta
n the T-junct
onnect one
int and the o
art the engin
ove the buc
adually a
bserver the
able pressu
er
y pressu
on is applic
il temperatu
ng tool: 6
essure con
000208) an
g standard:
ng position
g process:
ader in the
n the ground
down the
working de
sidual stres
pilot oil pip
the T-juncti
all the test j
tion.
end of the
other end to
ne. Manipu
ket to the li
accelerate
oil pressur
ure value,
ure meas
cable to mo
ure: 45 - 55
6Mpa press
nnector (41
and piezom
2.5 Mpa.
n: Pilot pip
service loc
nd. Pull up t
engine. O
evice handl
ss in the hy
pe as shown
ion on the
joint and pi
e test hoes
o the pressu
ulate the pilo
imit position
to the
re gauge to
which is
suring of
odel of pilot
?.
sure gauge
20001854),
metric tube
pe joint of
cation. Lay
the parking
Operate the
le 3-5 times
ydraulic oil
n in Figure
location of
ilot oil pipe
to the test
re gauge.
ot handle to
n. And then
maximum.
o obtain the
the pilot
f
t
e
,
e
f
y
g
e
s
l
e
f
e
t
o
n
.
e
t
Fig. 9-14 4
Fig. 9-15 P
4030000368
Pilot pressur
8 pressure m
re measurem
Service Ma
measuring h
ment point o
anual of W
9
pre
loa
Measur
it.
hose
5. Th
lif
gu
6. Af
Re
the
of back join
925 S
Measur
Pressur
Measur
Cylinde
Lift cyl
Measur
cylinde
Measur
1. Lo
rev
cy
po
ne
2. M
an
rec
tot
Wheel Loade
essure at th
ader.
rement meth
he control h
ft position
uarantee acc
fter test, rep
emove the T
e oil pipe. W
nt
ettlemen
rement of oi
re measuring
rement stand
er of rotatin
linder =50m
ring positio
er
rement proc
oad the buck
verse it b
ylinder to
osition. Mo
eutral positio
easure the e
nd bucket
cord the d
tal test dura
er
e back joint
hods of oth
handle migh
to repeat
curacy of tes
peat step 1
T-junction a
Wipe hydrau
nt detectio
il temperatu
g tool: Time
dard:
ng bucket =2
mm/h.
on: Boom
cess:
ket to the ra
backward.
lift the bu
ove the mu
on and turn
extension le
cylinder ev
ata in corr
ation is 3h.
nt position o
her joints ar
ht be move
the measu
st data.
of pressure
and install a
ulic oil leak
on of cyli
ure: 50 � 3?
er and mete
20mm/h;
cylinder
ated workin
Operate
ucket to t
ulti-way va
off the eng
ength of boo
very 15 m
responding
of the tested
e similar to
ed to boom
urement to
e releasing.
and remove
ked.
inder
?.
er ruler.
or bucket
ng mass and
the boom
the highest
alve to the
gine.
om cylinder
minutes and
table. The
d
o
m
o
.
e
t
d
m
t
e
r
d
e
Fig. 9-16 P
Fig. 9-17 M
1 Locknut
3 Protectio
Fig. 9-18 P
Position of m
Main safety
2 Pressur
on cover
Position of s
main safety
1 2
valve
re regulatin
safety valve
Service Ma
valve
3
g screw
e of pilot pu
anual of W
10
926
valve
If any
measur
pressur
main sa
the wo
pressur
decides
Now it
safety p
exampl
Adjustm
1. Re
at
scr
2. Lo
3. Ro
so
wh
pre
an
an
adj
scr
4. Pe
pre
int
sea
Adjustm
similar
values
The ad
screw b
Note: T
The spe
pressur
ump
Wheel Loade
Pressure
y pressur
ement of t
re of the saf
afety valve
orking pre
re of the s
s the prima
is to introd
pressure w
le.
ment proces
emove the l
the end su
rew .
oosen lockn
otate the p
cket head
hen the sc
essure decr
nticlockwise
nd fasten
djustment am
rew by a cir
enetrate a fi
essure regu
to the prote
aling.
ment of the
to the ab
of adjustm
djustment am
by a circle is
The adjustm
ecific adjust
re value.
er
e adjust
re abnorm
the hydraul
fety valve. T
on the mu
ssure of t
safety valve
ary pressur
duce how to
ith the mai
ss:
lead sealing
urface of th
nut with a w
ressure reg
wrench. Th
crew is rot
reases when
e. Adjust to
locknut. R
mount for
rcle is 4Mpa
ne steel wir
ulating screw
ection cove
safety valv
bove descr
ent are diff
mount for
s 1Mpa.
ment vales a
tment shoul
tment o
mity after
lic system,
The set pres
ulti-way val
the system
e on the p
re of the p
adjust the s
ain safety v
g and prote
he pressure
wrench.
gulating scr
The pressure
tated clock
n the screw
o the prop
Reference v
rotating th
a.
re into the
w 3 and the
er. Seal it w
ve on the pi
ription. But
fferent to so
rotating th
are for refe
ld be subjec
f safety
r pressure
adjust the
ssure of the
lve decides
m. The set
pilot pump
pilot pump.
set value of
valve as an
ction cover
e regulating
rew with a
e increases
kwise. The
w is rotated
er pressure
value: The
e adjusting
hole on the
en penetrate
with a lead
lot pump is
t reference
ome extent.
e adjusting
erence only.
ct to the set
y
e
e
e
s
t
p
.
f
n
r
g
s
e
d
e
e
g
e
e
d
s
e
.
g
.
t
Fig. 9-19 Pressure relief of the sy
Service Ma
ystem
anual of W
11
93 P
hydra
1. Av
or
str
2 Th
an
In
wi
3. Pa
4. It
tem
dis
5. In
eq
fat
flu
cir
flu
sp
6 In
of
ac
Ex
lea
7 Pr
ac
the
(1)
an
hig
(2) Pu
ba
dis
(3) Af
ha
gra
Pla
co
the
Wheel Loade
Precautio
aulic syst
void adding
preparing t
rong wind o
he hydraulic
nd maintaine
addition, i
ith special t
ay attention
is suggeste
mperature
scharged th
disassem
quipment or
tlute and u
ushing oil
rcumstances
ushing oil;
ecified hyd
the process
f hydraulic
cording to t
xcessive or
akage of hy
ressure of
cording to
e hydraulic
Start the e
nd wide gr
ghest positi
sh the con
ackward sl
scharge oil
fter the buc
andle forwa
adually to d
ace the bu
ontrol handl
e oil pressur
er
ons for
tem
g hydraulic
the machin
or much dus
c device sh
ed in a spec
its performa
est devices.
to openings
ed to replac
is hot. U
oroughly in
mbly, asse
r oil replace
sed oil in t
l. Rinse
s: Rinse
rinse the
raulic oil.
s of disman
system, it
the torque r
insufficien
draulic oil.
the system
steps belo
system:
engine. Driv
round. Mov
on. Retrove
ntrol handl
owly. Ante
in the bucke
cket is mov
ard slowly
discharge oi
ucket on th
e all aroun
re in the sys
repairi
oil or repl
ne in rains o
st.
hould be di
cial dust-free
ance should
.
s of the seal
ce the oil w
Used oil
n oil replace
embly of
ement, rinse
the hydraul
twice i
the first
e second
ntling and m
is required
required in t
nt torque m
m should b
ow before m
ve the vehic
ve the bo
ert the buck
le of the p
tevert the
et cylinder.
ved in plac
to lower
il in the boo
he ground.
nd 5-6 times
stem.
ing the
lacing filter
or places of
sassembled
e workshop
d be tested
l.
when the oil
should be
ement.
hydraulic
e pollutant,
lic oil with
n normal
time with
time with
maintenance
d to fasten
the manual.
might cause
be released
maintaining
cle to a flat
om to the
et.
pilot valve
bucket to
e, push the
the boom
om cylinder
Move the
s to release
e
r
f
d
p.
d
l
e
c
,
h
l
h
h
e
n
.
e
d
g
t
e
e
o
e
m
r.
e
e
Fig. 9-20 H
Figure 9-2
Figure 9-24
Hydraulic oi
3 L936 wor
4 L938 wor
il tank
rking pump
rking pump
Service Manual of W
12
94
comp
941 H
It is u
system.
to rem
guarant
942 W
L936/L
first on
and the
Table 9
Co
Rot
Nomi
R
Wo
Safet
Table 9
Co
Rot
Nomi
R
Wo
Workin
in Chin
steering
Wheel Loade
Introdu
ponents
Hydraulic
used to sup
. An oil retu
ove impuri
tee cleanline
Working p
L938 worki
ne supplies
e second one
9-1 L936 wo
Name
onnection m
tation direc
inal displac
Range of spe
orking press
ty valve pre
9-2 L938 wo
Name
onnection m
tation direc
inal displac
Range of spe
orking press
ng pump an
na belong
g system for
er
uction
c oil tank
pply oil to
urn filter tan
ities in the
ess of hydra
pump
ing pump i
oil to work
e supplies o
orking pump
mode
tion
ement
eed
sure
essure
orking pump
mode
tion
ement
eed
sure
nd steering
to the sam
r details.
to hy
k
the whole
nk is set in
e hydraulic
aulic oil.
is duplex p
king hydrau
oil to pilot sy
mp parameter
Parame
Rectangula
Laevorot
100/1
600-2500
20Mp
3.5 M
mp parameter
Parame
Rectangula
Laevorot
100/1
600-2500
20Mp
pump of L
me pump.
ydraulic
e hydraulic
the oil tank
system to
pump. The
ulic system,
ystem.
rs
eter
ar spline
tatory
10
0r/min
pa
Mpa
rs
eter
ar spline
tatory
10
0r/min
pa
L936 loader
Please see
c
c
k
o
e
,
r
e
Figure 9-
Figure
-25 DFS-25
9-27 D32-1
-16 multiwa
16 multiway
Service Ma
ay valve
y valve
anual of W
13
943 M
Multiw
mechan
control
Mechan
movem
realizin
multiw
through
control
pilot co
In the n
D32AFigure
Figur
Wheel Loade
Multiway val
way valve o
nical contr
multiway
nical cont
ment of valv
ng make-br
way valve r
h piloting o
multiway
ontrol multiw
non-Chinese
16.
9-26 DFS-2
re 9-28 D32
er
lve
of the loade
rol multiw
valve acco
trol multiw
ve rod throu
reak of oil
realizes mo
oil liquid.
valve mod
way valve m
e region, mu
25-16 multiw
2-16 multiw
er can be d
way valve
ording to co
way valve
ugh flexible
l liquid; pi
ovement of
In China,
del is DFSmodel
is D3
ultiway valv
way valve p
way valve pr
divided into
and pilot
ontrol type.
e controls
e shaft, thus
ilot control
f valve rod
mechanical
-25-16, and
32-16.
ve model is
principle
rinciple
o
t
.
s
s
l
d
l
d
s
Figure 9-29 D32A-16 multi
Service Ma
iway valve
anual of W
14
Precaut
valve
Take an
to avoid
To prev
hydraul
machin
The ins
Installa
prevent
The wo
oil and
19/16 o
Multi-v
working
Wheel Loade
Figure 9-3
tions for ins
nd place ge
d collision.
vent foreig
lic oil port
ne is assemb
stallation p
ation bolts
t the valve b
orking oil s
d system sh
of ISO4406
valve and pi
g oil port co
er
30 D32A-16
stallation an
ently in han
gn matters,
shall not b
bled.
plate and br
should be
body from d
hould be cl
hould not
or grade 11
ilot valve sh
orrectly.
6 multiway
nd using of
ndling and
plastic plu
be removed
racket shou
fastened un
deformation
lean. The c
be lower
1 of NAS16
should be co
valve
f multi-way
installation
ug of each
d before the
uld be flat.
niformly to
n
leanness of
than grade
38.
onnected to
y
n
h
e
.
o
f
e
o
Table 9-2 F
S/N
1
Au
du
fal
ro
bu
2
Ro
bu
inc
or
su
the
ve
3
In
or
the
lif
4
Ex
se
of
Fault and tro
Fault
utomatic
ump and
lling of
tating
ucket
Ce
pv
El
b
otating
ucket
capable
r fails to
upport
e
ehicle
Ce
pv
El
b
ncapable
r slow
e boom
fting
Cs
e
Es
p
Lp
xcessive
ttlement
f boom
El
b
Ei
o
oubleshooti
Caus
Clamping o
element of h
pressure ove
valve
Excessive in
leakage of r
bucket cylin
Clamping o
element of l
pressure ove
valve
Excessive in
leakage of r
bucket cylin
Clamping o
safety valve
element
Excessive lo
safety valve
pressure
Lose efficie
pump
Excessive in
leakage of b
bucket cylin
Excessive le
in neutral po
of the valve
Service Ma
ing of multi
se
f valve
high
erload
Ur
o
nterior
rotating
nder
R
md
f valve
low
erload
Ur
o
nterior
rotating
nder
R
md
f the
e Ur
ow
e Ar
ency of M
nterior
boom
nder
R
md
eakage
osition
e body
Rv
anual of W
15
Fault an
i-way valve
Solut
Unpick and
replace high
overload val
Refer to the
manufacture
details.
Unpick and
replace low
overload val
Refer to the
manufacture
details.
Unpick and
replace relie
Adjust posit
relief valve
Maintain oil
Refer to the
manufacture
details.
Replace the
valve
Wheel Loade
nd troublesh
e
tion
wash or
h pressure
lve
cylinder
er for
wash or
pressure
lve
cylinder
er for
wash or
ef valve
tion of
l pump
cylinder
er for
entire
er
hooting of m
Refere
multi-way v
ence map of
location
valve:
f fault
5
Ex
oil
lea
xternal
l
akage
O
Ra
O-rings dam
Relevant fas
are loose
Service Ma
maged Rc
steners Tf
anual of W
16
Replace
correspondin
Tighten corr
fasteners
Wheel Loade
ng O-rings
responding
er
Figure 9-3
Figure 9-3
1 Pilot cont
3 Schematic
trol valve
c diagram o
Service Ma
of pilot cont
anual of W
17
944 P
Pilot c
pilot c
installe
Throug
personn
or slide
valve,
the veh
Figure
valve
trol valve
Wheel Loade
Pilot cont
control hyd
control valv
ed on the rig
gh controlli
nel can cont
e valve of
thus realizi
hicle.
9-32 Oil po
er
rol valve
draulic syste
ve. The p
ght side of d
ing the pil
trol action o
rotating bu
ing control
orts at the b
et
em is equ
pilot contro
driver�s seat
lot control
of slide valv
ucket in the
of working
bottom of p
ipped with
ol valve is
t in the cab.
lever, the
ve of boom
e multiway
g device of
pilot control
h
s
.
e
m
y
f
l
Table 9-4 T
S/N
1 Pi
2 Mu
n
3 Fl
fau
4 Le
Troubleshoo
Fault
lot valve fa
Magnet po
nreliable
loating fu
ult
eakage
oting of pilo
ault
Jam
mo
De
spr
Ins
pre
Un
osition
Po
Lo
Du
ele
ins
Ele
unction Cla
Spr
0-r
Oil
Service Ma
ot control va
mmed va
ovement fau
eformation
ring
sufficient
essure
niversal join
or contact o
w power su
ust cover da
ectromagnet
sufficient su
ectromagnet
amping of th
ring deform
ring damage
l leakage of
anual of W
18
Tr
alve
Cause
alve elem
ult
of pressu
control
nt inflexible
of circuit
upply voltag
amaged. Du
t resul
uction.
t damaged
the valve ele
med
ed
f dynamic s
Wheel Loade
roubleshooti
ment or
ure relief
flow or
e
ge
ust entering
lts in
ement
eal
er
ing of pilot
Re
Check the
clean the
hole.
Replace th
Check w
system wo
Add greas
Check and
Replace th
Remove
surface o
electroma
amount
hydraulic
dust cove
Replace th
Clean par
Replace th
Replace th
Replace
dynamic s
control valv
emoval met
e cleanness
valve core
the spring
whether the
works norma
se for joints
nd maintain
the battery
dirt on th
of pure iron
agnet. App
of anti-ru
c oil and r
er.
the electrom
rts
the spring
the sealing e
component
sealing cov
ve
thod
s of the oil,
e and valve
oil supply
ally.
s
the circuit
he junction
n plate and
ly a small
ust oil or
replace the
magnet
element
ts of the
er
,
e
y
n
d
l
r
e
e
Fig. 9-26 A
Fig. 9-27 S
valve
Appearance
Section of p
of pressure
pressure sele
Service Ma
e selector va
ector valve
anual of W
19
945 P
The pre
oil-way
elemen
role is
the pilo
the grou
The mo
Its nom
the relie
alve
Fig. 9
Wheel Loade
Pressure s
essure selec
y. It is mainl
t, spring, e
to provide
ot valve and
und even if
odel of the
minal pressu
ef port is 4�
9-28 Schem
er
selector v
ctor valve i
ly compose
etc. The pr
control oil
d guarantee
the diesel e
pressure se
ure is 20Mpa
�0.2MPa.
matic diagra
valve
is installed
ed of valve b
ressure sele
of certain
e to place th
engine has f
elector valve
a. The exit
am of pressu
in the pilot
body, valve
ector valve
pressure to
he boom on
flameout.
e is SF8-D.
pressure of
ure selector
t
e
e
o
n
.
f
r
R
bu
Fig. 9-29 S
Rotating
ucket valve
Schematic d
Filter valv
Rotat
slide
multidiagram
of r
ve
ing buck
valve
-way valve
Service Ma
rotating buc
ket
of
anual of W
20
95
troub
961 B
Fault
antever
pilot va
Fault a
state an
the neu
the buc
cavity.
automa
cavity
opening
Fault ca
1. Pip
pip
mu
ins
2 Oi
rot
the
co
3. M
?
?
?
?
cket joint
Fault de
Wheel Loade
Fault
bleshooti
Bucket fal
phenomeno
rts (falling)
alve is in the
analysis: wh
nd the contr
utral position
cket cylinde
At this
atically as lo
pressure h
g.
auses:
peline faul
pe fittings, j
ulti-valve
stallation.
il cylinder f
tating buck
e rotating
ompared wit
ulti-way va
The rever
bucket fa
so that th
bucket cy
multi-way
opening.
The over
valve for
bucket cy
The oil s
cavity of
oil.
Valve el
reversing
the fit clea
hole is mu
As a resu
of the rota
etection and
er
dia
ing of hy
lling
on: the b
when the
e neutral po
hen the bu
rol handle o
n, dead load
er suffer pr
point, th
ong as the p
has leakag
t: There is
joints of cy
and jun
fault: Beside
ket cylinder
bucket
th the return
alve or pilot
rsing slid
ils to return
he small c
ylinder is co
y valve, larg
rload press
the large
linder on th
upplementa
the rotating
ement or
valve is ex
arance of va
uch higher
lt, pressure
ating bucket
d troublesho
agnosis
ydraulic
bucket au
control han
osition.
ucket is in
of the pilot
d of the bu
ressure from
he bucket
pressure oi
ge against
s apparent
ylinder large
nction su
es inner lea
r, the smal
cylinder a
n opening.
valve fault
valve of th
rn the neutr
cavity of th
onnected to
ge cavity an
sure of the
cavity of t
he multi-way
ary valve o
g bucket cyl
valve ho
xcessively w
alve elemen
than the de
oil in the l
t cylinder le
ooting
and
system
utomatically
ndle of the
the closed
valve is in
cket causes
m the large
anteverts
l in the big
the return
leakage in
e cavity and
urface of
akage of the
ll cavity of
also leaks
:
he rotating
ral position
he rotating
o Port P of
nd returning
e overload
the rotating
y valve.
of the large
linder leaks
ole of the
worn so that
nt and valve
esign value.
large cavity
eaks.
d
y
e
d
n
s
e
s
g
n
n
d
f
e
f
s
g
n
g
f
g
d
g
e
s
e
t
e
.
y
Service Manual of W
21
1. Ch
ma
to
wh
joi
cy
jun
2. Ju
ex
po
Af
clo
bo
va
fal
tha
rot
po
Di
va
ste
3 Ju
the
to
to
dis
rot
hy
op
ret
po
cy
the
lea
rep
ha
jud
4. Ju
su
40
me
rot
Op
the
on
the
pre
the
dis
or
Wheel Loade
heck the p
achine and
return the b
hether there
ints from th
ylinder to
nction surfa
udge whethe
xternal leaka
osition by o
fter the bu
ose the eng
oth ends of
alve rotating
ll, it might
at the slide
tating buck
osition and
ismount, ch
alve. Or oth
eps for judg
udge whethe
e handle of
the lowest
the max
sconnect th
tating buck
ydraulic oil
perate the
trovert the
ort of the la
ylinder leaks
e rotating
akage. It is
pair or rep
as no leaka
dgment.
udge wheth
upplementar
0mpa pres
easuring po
tating buck
perate the h
e bucket in
n the accele
e pilot. Obs
essure gaug
e lifting p
smount, che
oil supplem
er
pipeline fo
raise the bo
bucket to th
e is appare
he large cav
the multiace
of instal
er the pilot
age, raise th
operating th
cket is rais
gine and re
the slide v
g bucket join
be the pil
e valve of
ket fails t
d thus cau
heck and cle
herwise, co
gment.
er the oil cy
the pilot va
position an
imum. Clo
e hose for t
ket and l
tank. Then,
handle of
bucket. Ob
arge cavity
s hydraulic
bucket c
required to
lace the cy
age, contin
her the ove
y valve is
sure gaug
ort of the
ket cylinde
handle of th
n the most f
erator and
serve wheth
ge reaches th
process of
eck and cle
mentary val
or leakage:
oom to a cer
he maximum
ent leakage
vity of rota
-way valve
llation, etc.
valve has
he boom to
he pilot va
sed to the
emove pilo
valve of the
nt The buck
lot valve w
f the multito
return t
auses buck
ean or repla
ontinue the
ylinder leak
alve to lowe
nd retrovert
ose the e
the small ca
lead it ba
, start the m
f the pilot
bserve whet
of the rota
oil constan
cylinder h
o dismount,
ylinder. If o
nue the nex
erload valv
damaged:
ge to the
large cav
er. Start the
he pilot val
forward po
operate the
her the rea
he design v
f the boom
ean the ove
lve of the l
Start the
rtain height
m. Observe
e on pipes,
ting bucket
e and the
fault: If no
the highest
lve handle.
maximum,
ot pipes on
e multi-way
ket does not
which cause
-way valve
the neutral
ket falling.
ace the pilot
e following
ks: Operate
er the boom
t the bucket
engine and
avity of the
ack to the
machine and
t valve to
ther the oil
ting bucket
ntly. If yes,
has serious
, check and
oil cylinder
xt step for
ve and oil
Connect a
e pressure
vity of the
e machine.
ve to make
sition. Step
e handle of
ding of the
value during
m. If not,
rload valve
large cavity
e
t
e
,
t
e
o
t
.
,
n
y
t
e
e
l
.
t
g
e
m
t
d
e
e
d
o
l
t
,
s
d
r
r
l
e
e
.
e
p
f
e
g
,
e
y
Fig. 9-30 S
Connec
Boom
cylinder
Schematic d
cted by pressu
diagram of b
ure selector v
Service Ma
boom joint
valve
anual of W
22
of
5. Ch
mu
sit
low
Re
mu
va
or
ex
va
tha
in
cy
962 Bo
Fault p
pilot v
lowers
standar
Fault an
any he
corresp
cavity o
lowers
the big
the retu
Fault ca
1. Pip
pip
mu
ins
2. Oi
bo
als
3. M
?
?
Wheel Loade
f the rotating
heck whet
ulti-way va
tuations are
wer the boo
emove the
ulti-way va
alve holes ca
valve ho
xcessively w
alve elemen
an the desig
the large
ylinder leaks
om settlem
henomenon
alve is in
automatica
rd of the cyl
nalysis: wh
eight, dea
ponding oil
of the boom
automatica
cavity pres
urn opening
ause:
peline faul
pe fittings, j
ulti-valve
stallation.
il cylinder f
oom cylinde
so leaks com
ulti-way va
The boom
multi-way
position s
boom cyl
large cavi
Valve el
reversing
er
g bucket cyl
ther the
alve is dam
excluded,
om and the
rotating bu
alve and che
arefully for
ole of the
worn so tha
nt and valve
gn value. A
cavity of
s.
ment
n: when the
the neutra
ally and ex
inder.
hen the boom
d load of
pressure be
m cylinder. A
ally as long
ssure has le
.
t: There is
joints of cy
and jun
fault: Beside
er, the sma
mpared with
alve or pilot
m reversin
y valve fail
so that the
inder is con
ty and retur
ement or
valve is ex
linder.
slide valv
maged: If
stop the m
bucket to t
ucket slid v
eck the val
fitness. Val
e reversing
at the fit c
e hole is m
As a result, p
f the rotat
e control ha
al position,
xceeds the
m is lifted
f the boo
e reserved i
At this poin
as the pre
eakage com
s apparent
ylinder large
nction su
es inner lea
all cavity of
h the return
valve fault
ng valve r
ls to return
e small cav
nnected to
rning openin
valve ho
xcessively w
ve of the
the above
machine and
the bottom.
valve of the
lve rod and
lve element
g valve is
learance of
much higher
pressure oil
ing bucket
andle of the
the boom
settlement
and kept at
om makes
in the large
nt, the boom
ssure oil in
mpared with
leakage in
e cavity and
urface of
akage of the
f the boom
opening.
:
rod of the
the neutral
vity of the
pump port,
ng.
ole of the
worn so that
e
e
d
.
e
d
t
s
f
r
l
t
e
m
t
t
s
e
m
n
h
n
d
f
e
m
e
l
e
,
e
t
Service Manual of W
23
Fault de
1. Ch
ma
po
Ob
pip
cy
jun
2. Ju
ex
po
Af
clo
bo
va
set
tha
bo
po
Di
va
ste
3 Ju
bo
op
cy
tan
of
of
hy
cy
dis
cy
is
4. Ju
bu
of
an
963 S
Fault p
valve a
time re
the hig
lifting t
Wheel Loade
the fit clea
hole is mu
As a resu
of the boo
etection and
heck the p
achine and
osition to re
bserve whe
pes, joints
ylinder to
nction surfa
udge whethe
xternal leaka
osition by o
fter the bu
ose the eng
oth ends of
alve boom s
ttle, it migh
at the slide
oom slide v
osition and
ismount, ch
alve. Or oth
eps for judg
udge whethe
oom to the
pen the hose
ylinder to le
nk. Start the
f the pilot va
f the small c
ydraulic oil
ylinder has
smount, ch
ylinder. If oi
required for
udge fault of
ucket to the
f the multind
the valve
low lift o
phenomenon
at the rated
equired to l
ghest positi
time.
er
arance of va
uch higher
lt, pressure
om cylinder
d troublesho
pipeline fo
raise the
eturn the bu
ther there i
from the l
the multiace
of instal
er the pilot
age, raise th
operating th
cket is rais
ine and dis
the slide v
slide valve.
ht be the pil
e valve of
valve fails
thus caus
heck and cle
herwise, co
gment.
er the oil cy
maximum.
e of the sma
ead it back
e machine a
alve. Observ
cavity of th
l constantly
inner leaka
heck and r
il cylinder h
r analyze fu
f multi-way
bottom. Re
way valve.
hole carefu
of the boo
n: operate th
speed of t
ift the boom
ion is long
alve elemen
than the de
oil in the l
r leaks.
ooting
or leakage:
boom to t
ucket to the
is apparent
large cavity
-way valve
llation, etc.
valve has
he boom to
he pilot va
sed to the
sconnect pil
valve of the
If the boom
lot valve wh
f the multito
return
ses boom
ean or repla
ontinue the
ylinder leaks
Close the
mall cavity o
k to the hy
and operate
ve whether
he boom cyl
y. If yes,
kage. It is r
repair or r
has no inner
urther.
y: Lower the
emove boom
Check the
ully for fitne
om
the handle o
the diesel e
m from the
ger than th
nt and valve
esign value.
large cavity
Start the
the highest
maximum.
leakage on
y of boom
e and the
fault: If no
the highest
lve handle.
maximum,
lot pipes on
e multi-way
m does not
hich causes
-way valve
the neutral
settlement.
ace the pilot
e following
s: Raise the
engine and
of the boom
ydraulic oil
e the handle
the oil port
linder leaks
the boom
required to
replace the
r leakage, it
e boom and
m valve rod
e valve rod
ess.
of the pilot
engine. The
e bottom to
he standard
e
.
y
e
t
.
n
m
e
o
t
.
,
n
y
t
s
e
l
.
t
g
e
d
m
l
e
t
s
m
o
e
t
d
d
d
t
e
o
d
Service Manual of W
24
Fault a
the hyd
lifting o
pump to
Fa
?
?
?
?
?
?
?
?
?
Fault de
1. Ch
lif
an
ca
su
2. Ch
co
hy
Wheel Loade
analysis: ac
draulic pow
of the boom
o the hydrau
ault cause:
Joints, pi
opening t
cylinder a
severe lea
The hydra
of air bub
deteriorati
viscosity.
The sucti
rubber of
and thus
blocked. A
suction ca
the workin
The work
which cau
The boo
leakage.
Main sa
multi-way
There is s
oil inlet p
multi-way
Reversing
boom is
clearance
is much h
result, pr
cavity of t
The openi
is insuffic
etection and
heck for out
ft the boom
nd valves fro
avity of the
urfaces have
heck the oi
onduct bas
ydraulic oil
er
cording to
er compone
m is: the flo
ulic oil cylin
pes and va
to the large
and other ju
akage.
aulic oil co
bbles or app
ion and los
ion filter i
f the fuel s
causes the
As a result,
auses insuff
ng pump.
k pump has
uses insuffic
m cylinde
afety valv
y valve is to
severe inner
passage and
y valve body
g valve or h
excessively
of valve el
higher than t
essure oil
the boom cy
ing degree
cient.
d troublesho
ter leakage:
m. Observe
om the pum
boom cylin
severe leak
il: In case
sic inspec
level in the
the charac
ent, the cau
ow delivere
nder is insu
alves from
e cavity of
unction sur
ontains a lar
pears black,
ses the cor
is blocked
sucking pip
fuel sucki
severe insu
fficient outp
s severe inn
cient output
er has sev
ve pressure
oo low.
er leakage b
d return pas
y.
hole of the
y worn so
lement and
the design
leaks from
ylinder.
of the mult
ooting
Start the m
whether jo
mp opening
nder and oth
kage.
of no out
ctions: wh
e oil tank is
cteristics of
use for slow
ed from the
ufficient.
the pump
f the boom
rfaces have
rge amount
gets severe
rresponding
or interior
pe falls out
ng pipe be
ufficient oil
put flow of
ner leakage
t flow.
vere inner
e of the
between the
ssage of the
e multi-way
that the fit
valve hole
value. As a
m the large
ti-valve rod
machine and
oints, pipes
to the large
her junction
er leakage,
hether the
s above the
f
w
e
p
m
e
t
e
g
r
t
e
l
f
e
r
e
e
e
y
t
e
e
d
d
s
e
n
,
e
e
Service Manual of W
25
low
co
bla
3. Ch
ma
ab
to
req
the
it
pu
su
4. Ch
the
pil
mi
the
sh
wo
ca
5. Te
ga
the
an
pre
ob
rea
fol
de
6. Te
ma
to
ret
en
ca
the
an
low
of
hy
cy
dis
cy
7. Ch
ch
ma
irr
ele
8. Ch
Wheel Loade
west level
ontains larg
ack.
heck sound
achine to ju
bnormal. Op
the hydra
quired to p
ere is any sq
means that
ump is woe
uction filter
heck the wo
e working p
lot valve to
inutes. Clos
e working p
ell is very
orking pum
auses insuffi
est pressure
auge to the
e multi-way
nd operate t
ess the h
bserve the p
ach the d
llowing ins
esign pressu
est the oil cy
achine. Ope
lower the
trovert the b
ngine and d
avity of the b
e hydraulic
nd operate t
wer the boo
f the large c
ydraulic oil
ylinder has
smount, ch
ylinder.
heck the m
heck and cl
ain safety v
reparable iss
ement, hole
heck the m
er
l; whether
ge amount
d: It is r
udge wheth
perate the p
aulic system
pay attenti
queal in the
t the oil su
efully inade
and hose.
orking pump
pump has n
o make the
se the engin
pump with
hot. It cou
p has sever
icient outpu
e: Connect
pressure m
y valve Po
the handle
hydraulic
pressure gau
design pre
spections if
ure.
ylinder for i
erate the ha
boom to th
bucket to th
disconnect t
boom cylin
oil tank. T
the handle
om. Observ
cavity of the
l constantly
serious leak
heck and r
main safety
lean the ma
alve should
sues such as
, etc.
multi-way v
r the hyd
of bubble
required to
her the hydr
pilot valve t
m. Meanw
ion to judg
e working p
uction of th
equate. Che
mp for inner
no squeal,
pump load
ne. Touch t
hand caref
uld be judg
re inner leak
ut flow.
t a 40MP
measuring
ort P. Start
of the pilo
system. M
uge. Its read
essure. Co
f it fails to
inner leakag
andle of the
he lowest p
he maximum
the hose fo
nder and lea
Then, start th
of the pilo
ve whether
e boom cyl
y. If yes,
kage. It is
repair or r
y valve: d
main safety
d be replace
s deformati
valve: If t
draulic oil
es or turns
o start the
raulic oil is
to add load
while, it is
ge whether
ump. If yes
he working
eck the oil
leakage: If
operate the
ded for 1-2
the shell of
fully. It the
ged that the
kage, which
Pa pressure
opening of
the engine
ot valve to
Meanwhile,
ding should
onduct the
o reach the
ge: Start the
pilot valve
osition and
m. Close the
or the large
ad it back to
he machine
ot valve to
the oil port
linder leaks
the boom
required to
replace the
isassemble,
valve. The
d in case of
ion of valve
the system
l
s
e
s
d
s
r
s,
g
l
f
e
f
e
e
h
e
f
e
o
,
d
e
e
e
e
d
e
e
o
e
o
t
s
m
o
e
,
e
f
e
m
Service Manual of W
26
pre
aft
dis
the
va
va
9. If
the
the
the
Operate
bucket
the slid
valve b
attentio
of the v
free.
Exchan
bucket
machin
whethe
check a
valve.
964 In
Fault p
valve t
speed o
boom.
Fault an
the boo
large ca
Fault ca
The ov
the mul
The wo
disables
design p
The boo
There i
passage
body. I
reach th
Fault de
As for t
required
Wheel Loade
essure still
ter the abo
sassemble a
e multi-way
alve rod, va
alve hole for
the pressur
e design va
e boom stil
e inspection
e the pilot v
to the lowe
de valve end
boom. Mo
on to observ
valve rod is
nge the pilo
valve rod a
ne and ope
r the boom
and clean th
nability o
phenomenon
o lift the b
of the diese
nalysis: the
om lift is th
avity of the
ause:
verload pres
lti-way valv
orking pump
s the system
pressure.
om cylinder
is severe in
e and return
It disables
he design pr
etection and
troubleshoo
d to focus t
er
fails to reac
ove attempt
and check t
y valve. C
lve hole as
r fitness car
e of the hyd
alue and the
ll exists, it
ns and troub
valve to low
st position.
d without sp
ve the va
ve whether t
s proper and
ot pipes co
and the boo
erate the p
lift is norm
he boom va
of boom l
n: operate th
boom with
el engine, b
most direc
he excessiv
boom cylin
ssure of the
ve is too low
p has sever
m to form
r has severe
ner leakage
n passage o
the system
ressure.
d troublesho
oting of inab
the above fo
ach the desig
ts. It is su
the boom v
Check the v
well as val
refully.
draulic syst
e slow lifti
is required
bleshooting
wer the boo
Open the e
pring of the
alve rod ax
the moveme
d whether th
ontrolling t
om valve ro
pilot valve
mal. If yes, d
alve block
lift
the handle o
full load a
but it fails
ct cause for
ve low pres
nder.
e main safe
w.
re inner leak
pressure o
e inner leaka
e between t
of the multi
m to form p
ooting
bility of boo
four points a
gn pressure
uggested to
valve rod of
valve body,
lve rod and
tem reaches
ng issue of
to conduct
below:
om and the
nd cover of
e multi-way
xially. Pay
ent distance
he return is
the rotating
od. Start the
e. Observe
disassemble
of the pilot
of the pilot
at the rated
to lift the
inability of
ssure in the
ty valve of
kage which
r reach the
age.
the oil inlet
i-way valve
pressure or
om lift, it is
and refer to
e
o
f
,
d
s
f
t
e
f
y
y
e
s
g
e
e
e,
t
t
d
e
f
e
f
h
e
t
e
r
s
o
Service Manual of W
27
the fau
boom li
965 B
Analyz
966 In
Analyz
lift.
Wheel Loade
ult detectio
ift".
Blow buck
e and solve
nability b
e and solv
er
on of troub
ket move
referring to
bucket m
e referring
bleshooting
ement
o slow boom
movement
to inabilit
g of "slow
m lift.
t
ty of boom
w
m

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Service Manual of Wheel Loader

Service Manual of Wheel Loader

Service Manual of Wheel Loader

Service Manual of Wheel Loader

Service Manual of Wheel Loader

Service Manual of Wheel Loader

Service Manual of Wheel Loader

Service Manual of Wheel Loader

Service Manual of Wheel Loader

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