L936L938英文 PDF

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 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.
0-1
- 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
0-2
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.
0-3
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
Fig. 0-1 Reading Operation and Manual attached to the vehicle for the safety
Maintenance Manual before operations precautions on the operations and maintenance.
0-4
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.
0-5
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
Fig. 0-4 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.
Load capacity
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
Fig. 0-5 Load capacity 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
0-6
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.
0-7
• 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
Fig. 0-6 Do not stand beside the tires in faults and eventually lead to the accidents.
during the inflation
• 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
0-8
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
Fig. 0-7 Corrosive sulfuric acid

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
0-9
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
Fig. 0-8 Wear goggles and gloves at risk of the machine’s battery pack.
contacting refrigerator
Warning: If one fully charged battery is
connected to one battery running out of power, the
0-10
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
0-11
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
0-12
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
0-13
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
Fig. 0-9 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
0-14
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
0-15
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
0-16
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
0-17
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.
0-18
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
0-19
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.
0-20
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.
1-1
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
1-2
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 Yield Nominal diameter of bolt mm

grade of strength 6 8 10 12 14
bolt N/ mm2 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

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

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 8.8 10.9
Torque(N·m) Torque(N·m)
Bolt specification 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
1-3
Table 1-3 Tightening torque of joint body

Joint with copper seal gasket or seal taper thread Joint with O-shape seal ring
Tightening torque
Joint specification Tightening torque N·m Joint specification
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
1-4
M22×1.5 140~155
M24×1.5 160~180
M27×2 190~230
M33×2 270~320
122 Unit conversion

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
2
m 10000 1 0.000001 0.01 10.764 1.1958 -
2
km - 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
2
in 6.4516 0.000645 - - 0.006943 0.000771 1
2 2
1 hectare=100 acre 1 mile =259 hectare=2.59 km
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
3
ft 28316.8 0.028317 28.317 1728 1 0.03704
1-5
yd3 764529.8 0.76453 764.53 46656 27 1
3 3
1 gallon(American system)=3785.41 cm =231 in =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
2
Pa=N/m 0.00001 0.001 1 0.001 0.00015 0.02086
Kpa 0.01020 0.01 1000 1 0.14504 20.886
2
Lbf/in 0.07032 0.0689 6894.76 6.89476 1 144
2
Lbf/ft 0.00047 0.00047 47.88028 0.04788 0.00694 1
2
kg/cm =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
1-6
13 Mark
To emphasize the importance of safety and quality,
make following marks.
Table 1-12
Mark Item Remark
During the operation, pay special attention to safety.
Safety
When carrying out the operation, pay special attention to
safety because internal pressure exists.
During the operation, pay special attention to technical
Note requirements and ensure the operation quality in conformity
with standards.
Weight or assembling method of component or device. Pay
Weight attention to selecting load lifting device and the posture
during the operation.
Tightening During the assembly, pay special attention to the tightening
torque torque of components
Coating The position needs to be coated with adhesive and grease.
Oil and
Fill certain amount of oil, water and fuel.
water
The place where oil or water is discharged and the discharge

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
1-7
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
Criteria Measure for
Type of part Inspection item Dimension out of
Allowable limit tolerance
(tolerance)
Internal diameter
About 0~－0.02 +0.02
tolerance
Bearing Replacement
External diameter
About 0~－0.02 －0.04
tolerance
12% of reference circle
Wear in gear gear thickness
Gear About 0~0.10 Replacement
thickness
(usually within 1.2~1.4)
External diameter
Tolerance is Recommendation: less
for ordinary
Ordinary marked as T than lower limit 0.3T
matching Replacement
components
Internal diameter for Tolerance is Recommendation: larger
ordinary matching marked as T than upper limit 0.3T
Fit clearance >0.02 Replacement
Multiple unit
between valve
1-8
valve element and valve
opening
Fit clearance
between valve
>0.02 Replacement
Steering gear element and valve
sleeve
Stator and rotator >0.08 Replacement
Fit clearance
Single
between valve
stabilizer >0.02 Replacement
element and valve
valve
body
Fit clearance
between valve
Priority valve >0.02 Replacement
element and valve
body
1-9
轮式装载机维修手册
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
Ⅰ
2 Engine System
21 Key parameters of engine
maintenance
Air inlet Engine oil

Engine rated Engine Air exhaust
Engine model valve pressure (rated
speed idle speed valve clearance
clearance
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!
2-1
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!
Figure 1 Position of detection port of

three-stage Weichai engine
Part name No. Figure
DiagSmar 612600900287
Figure 2 Special detection tools for

Weichai three-stage engine
2-2
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).
Figure 3 Yuchai engine detection port
2-3
Part name No. Figure
HED-ST4.1.2
6430001350
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)
2-4
23 Engine failure diagnosis codes

231 WP6G125E332 series engine failure
diagnosis codes
DTC DTC
for for
Code DFC name Fault description
J1939 J1939
SPN FMI
Voltage of accelerator pedal 1
010 DFC_APP1SRCMax 91 3
exceeds maximum threshold
Voltage of accelerator pedal 1 less
011 DFC_APP1SRCMin 91 4
than minimum threshold
Incredible double signal
012 DFC_APP12Plaus relationship between accelerator 520252 2
pedal 1 and accelerator pedal 2
Voltage of accelerator pedal 2
013 DFC_APP2SRCMax 29 3
Voltage of accelerator pedal 2 less
014 DFC_APP2SRCMin 29 4
Incredible 1/2 signal relationship
015 DFC_APP21Plaus between accelerator pedal 2 and 1 0
accelerator pedal 1
Incredible accelerator and braking
019 DFC_AccPedBrkPlaus 91 7
signal
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
Voltage of air intake heater
024 DFC_BPSCDSRCMax 102 3
Voltage of air intake heater less
025 DFC_BPSCDSRCMin 102 4
Incredible air intake pressure
026 DFC_BPSCDNPL 1 0
sensor signal
Original value of battery voltage
027 DFC_BattCDSRCMax 168 3
Original value of battery voltage
028 DFC_BattCDSRCMin 168 4
less than minimum threshold
029 DFC_BrkCDSig Braking signal error 597 19
2-5
030 DFC_BrkCDNpl Incredible braking signal 597 2

Cold start indicator lamp
031 DFC_CSLpCDSCBat 626 3
short-to-power
Cold start indicator lamp
032 DFC_CSLpCDSCGnd 626 4
short-to-ground
Cold start indicator lamp in open
033 DFC_CSLpCDNoLoad 626 5
load
Voltage of coolant temperature
034 DFC_CTSCDSRCMax sensor exceeds maximum 110 3
threshold
Voltage of coolant temperature
035 DFC_CTSCDSRCMin sensor less than minimum 110 4
threshold
Incredible coolant temperature
036 DFC_CTSCDNpl 110 2
and engine oil temperature signal
Coolant temperature has not
037 DFC_ClgAbsTst reached minimum within certain 110 17
period of time
Increasing amplitude of coolant
temperature has not reached
038 DFC_Clg_DynTst 110 18
minimum within certain period of
time
039 DFC_ConvCDNpl Incredible clutch state signal? 598 2
Voltage of ECU temperature
040 DFC_TECUSRCMax sensor exceeds maximum 1136 3
threshold
Voltage of ECU temperature
041 DFC_TECUSRCMin sensor less than minimum 1136 4
threshold
Start beneath vehicle/stop button
042 DFC_ECBtCDPlausLock 520203 5
gets stuck
Only camshaft signal, enter limp
043 DFC_EngMBackUpLimp 4203 13
home state
044 DFC_EngMCaSPer Camshaft cycle error 4201 2
045 DFC_EngMCaSSyn Camshaft synchronization error 4201 11
046 DFC_EngMCaS1NoSig Camshaft signal missing 4201 12
Camshaft and crankshaft
047 DFC_EngMCaSSynCrS 4201 13
synchronization error
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
2-6
051 DFC_EngMCrSToothPer Crankshaft tooth cycle error 4203 2

Crankshaft and camshaft signal
052 DFC_EngMOfsCaSCrSSRCMax 4201 14
deviation exceeds threshold
053 DFC_EngPrtOvrSpd Engine over speed 1769 11
Engine speed signal
054 DFC_EngSpdSCBat 1623 3
short-to-power
Engine speed signal
055 DFC_EngSpdSCGnd 1623 4
short-to-ground
056 DFC_EngSpdOpenLoad Engine speed signal in open load 1623 5
Exhaust brake butterfly valve
057 DFC_ExFlCDSCBat 520208 3
short-to-power
Exhaust brake butterfly valve
058 DFC_ExFlCDSCGnd 520208 4
short-to-ground
Exhaust brake butterfly valve in
059 DFC_ExFlCDOpenLoad 520208 5
open load
Fan actuator (PWM wave)
062 DFC_FanCD1SCBat 4815 9
short-to-power
Fan actuator (PWM wave)
063 DFC_FanCD1SCGnd 4815 10
short-to-ground
Fan actuator (PWM wave) in
064 DFC_FanCD1OpenLoad 4815 7
open load
Fan actuator (digital signal)
065 DFC_FanCD2SCBat 4815 3
short-to-power
Fan actuator (digital signal)
066 DFC_FanCD2SCGnd 4815 4
short-to-ground
Fan actuator (digital signal) in
067 DFC_FanCD2OpenLoad 4815 5
open load
Cooling fan speed exceeds
068 DFC_FanCDSpMax 1639 3
maximum threshold
Cooling fan speed less than
069 DFC_FanCDSpMin 1639 4
minimum threshold
Water-in-oil sensor detects water
079 DFC_FlSysWtDet 520264 11
in oil
080 DFC_InjVlvCyl1ERR Oil atomizer error of cylinder 1 1413 11
Oil atomizer of cylinder 1
081 DFC_InjVlvCyl1SCB 1413 3
short-to-power
082 DFC_InjVlvCyl1SCG 1413 7
short-to-ground
2-7

short-to-power
short-to-ground
short-to-power
short-to-ground
short-to-power
short-to-ground
short-to-power
short-to-ground
short-to-power
short-to-ground
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
RxCCVS message data length
101 DFC_FrmMngRxCCVSDLC 522030 14
error
102 DFC_FrmMngDEC1TO DEC1 message receiving delay 522062 19
103 DFC_FrmMngETC7TO ETC7 message receiving delay 522063 19
Bus receiving throttle signal
104 DFC_FrmMngAppMaxErr 522064 19
overruns
Bus receiving remote throttle
105 DFC_FrmMngRemAppMaxErr 522065 19
signal overruns
CAN-TOTSC1PE data volume
106 DFC_FrmMngTSC1PEDLC 522039 14
error
CAN-TOTSC1PE communication
107 DFC_FrmMngTSC1PETO 522039 19
error
2-8
CAN-TOTSC1TE data volume

108 DFC_FrmMngTSC1TEDLC 522040 14
error
109 DFC_FrmMngTSC1TETO CAN-TOTSC1TE timeout error 522040 19
CAN-TOTSC1TR data volume
110 DFC_FrmMngTSC1TRDLC 522041 14
error
111 DFC_FrmMngTSC1TRTO CAN-TOTSC1TR timeout error 522041 19
CAN-TOTSC1VE data volume
112 DFC_FrmMngTSC1VEDLC 522042 14
error
113 DFC_FrmMngTSC1VETO CAN-TOTSC1VE timeout error 522042 19
CAN-TOTSC1VR data volume
114 DFC_FrmMngTSC1VRDLC 522043 14
error
115 DFC_FrmMngTSC1VRTO CAN-TOTSC1VR timeout error 522043 19
CAN-TOTimeDate data volume
116 DFC_FrmMngTimeDateDLC 522034 14
error
117 DFC_FrmMngTimeDateTO CAN-TOTimeDate timeout error 522034 19
118 DFC_GearbxIncMax Too long gear lifting interval 520221 2
(Water-in-oil indicator lamp)
119 DFC_Gen1FlSysWtSCBat indicator lamp 1 power 624 3
short-circuit
120 DFC_Gen1FlSysWtSCGnd 624 4
indicator lamp 1 short-to-ground
121 DFC_Gen1FlSysWtOpenLoad 624 12
indicator lamp 1 in open load
122 DFC_HWEMonEEPROMRdErr EEPROM reading error 2802 14
123 DFC_HWEMonEEPROMWrtErr EEPROM writing error 2802 12
Voltage of air intake temperature
124 DFC_IATSCDSRCMax sensor exceeds maximum 105 3
threshold
Voltage of air intake temperature
125 DFC_IATSCDSRCMin sensor less than minimum 105 4
threshold
126 DFC_stFuelFoul Fuel filter replacement 520289 11
CAN receiving frame EBC1
127 DFC_FrmMngEBC1TO 522013 19
timeout error
CAN receiving frame EBC1 data
128 DFC_FrmMngEBC1DLC 522013 14
length error
129 DFC_stAirFltFoul Air filter replacement 107 7
130 DFC_stOil Engine oil replacement 99 11
Low end of oil atomizer1
131 DFC_InjVlvCyl1ALSSCBat 1413 16
short-to-power
2-9
Low end of oil atomizer 1

132 DFC_InjVlvCyl1ALSSCGnd 1413 18
short-to-ground
High end of oil atomizer1
133 DFC_InjVlvCyl1AHSSCBat 1413 15
short-to-power
134 DFC_InjVlvCyl1AHSSCGnd 1413 17
short-to-ground
135 DFC_InjVlvCyl1SCL 1413 4
short-to-low end
136 DFC_stOilFlt Oil filter replacement 99 7
137 DFC_InjVlvCyl1BNoLoad Atomizer1 in open load 1413 5
short-to-power
short-to-ground
short-to-power
High end of oil atomizer 2
short-to-ground
short-to-low end
short-to-power
short-to-ground
short-to-power
short-to-ground
short-to-low end
short-to-power
short-to-ground
short-to-power
short-to-ground
2-10

short-to-low end
short-to-power
short-to-ground
short-to-power
short-to-ground
short-to-low end
Fault rate of orifice abrasion
161 DFC_InjNDiafactor 520210 13
within 0-20%
162 DFC_InjVlvCyl5BNoLoad Atomizer 5 in open load 1417 5
short-to-power
short-to-ground
short-to-power
short-to-ground
short-to-low end
168 DFC_InjNDia 520210 14
exceeds 20%
169 DFC_InjVlvCyl6BNoLoad Atomizer 6 in open load 1418 5
INJ driver IC initialization version
171 DFC_InjIniAsicErr 507 9
error
INJ driver IC initialization error
172 DFC_InjIniEnaErr 507 10
after power-on
INJ driver IC repeated power-on
173 DFC_InjPwrDrvDis 507 11
error
Unreliable cruise signal (void
175 DFC_MFLvCrCtlMode 596 2
switch combination)
Voltage of polymorphic switch
179 DFC_MSSCDSRCMax 976 3
exceeds maximum
Voltage of polymorphic switch
180 DFC_MSSCDSRCMin 976 4
exceeds minimum
2-11
Incredible polymorphic switch

181 DFC_MSSCDNpl 976 19
signal
182 DFC_NetMngCANAOff CAN communication error 522000 12
Voltage of engine oil level sensor
183 DFC_OLSCDSRCMax 98 3
exceeds maximum
Voltage of engine oil level sensor
184 DFC_OLSCDSRCMin 98 4
less than minimum
Unreliable engine oil level sensor
185 DFC_OLSCDNpl 98 2
signal
Voltage of engine oil pressure
186 DFC_OPSCDSRCMax 100 16
sensor exceeds maximum
Voltage of engine oil pressure
187 DFC_OPSCDSRCMin 100 18
sensor less than minimum
Too high oil pressure or unreliable
188 DFC_OPSCDNpl 100 15
oil temperature signal
189 DFC_OPSCDLow Too low oil pressure 100 17
Voltage of engine oil temperature
190 DFC_OTSCDSRCMax sensor exceeds maximum 175 3
threshold
Voltage of engine oil temperature
191 DFC_OTSCDSRCMin sensor less than minimum 175 4
threshold
Incredible engine oil temperature
192 DFC_OTSCDSRCNPL 1 0
and coolant temperature signal
Incredible engine oil temperature
193 DFC_OTSCD1Npl 175 15
sensor signal
Voltage of sensor power supply 1
194 DFC_SSpMon1SRCMax 3509 3
195 DFC_SSpMon1SRCMin 3509 4
200 DFC_T50CDTimeOut T50 turn-on timeout 520253 11
Vehicle speed 1 exceeds
201 DFC_VSSCD1Max 84 0
maximum threshold
2-12
Incredible vehicle speed 1,

202 DFC_VSSCD1Npl fuel-injection quantity and engine 84 2
speed
Pulse width of vehicle speed 3
203 DFC_VSSCD3Max signal exceeds maximum 1624 3
threshold
Pulse width of vehicle speed 3
204 DFC_VSSCD3Min signal less than minimum 1624 4
threshold
Averaging period of vehicle speed
205 DFC_VSSCD3Sig 1624 8
signal less than threshold
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
In-cylinder exhaust brake valve
209 DFC_ECRVlvSCBat 571 3
short-to-ground
In-cylinder exhaust brake valve
210 DFC_ECRVlvSCGnd 571 4
short-to-power
In-cylinder exhaust brake valve in
211 DFC_ECRVlvOpenLoad 571 5
open load
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
Common-rail decompression
216 DFC_PRVOpn 520241 14
valve opened
Opening time of pressure limiting
217 DFC_PRVTiOpnMax 520241 0
valve exceeds maximum
Common-rail decompression
218 DFC_PRVMonPresShck valve not opened during pressure 523470 21
fluctuation
Opening times of common-rail
decompression valve exceeds
219 DFC_PRVMonwearNumMax 520241 11
maximum times specified in
technical requirements
Voltage of rail pressure sensor
220 DFC_RailCDSRCMax 157 3
221 DFC_RailCDSRCMin 157 4
222 DFC_RailCDOfsTstSRCMax 157 15
exceeds maximum deviation
2-13

223 DFC_RailCDOfsTstSRCMin 157 17
less than minimum deviation
Rail pressure deviation exceeds
224 DFC_RailMeUn0OfsMax 520243 16
maximum threshold
225 DFC_RailMeUn1OfsMaxQHi maximum threshold and 520243 0
fuel-injection quantity overruns
Rail pressure deviation less than
minimum threshold and
226 DFC_RailMeUn2OfsMinQLo 520243 1
fuel-injection quantity less than
threshold
Peak value of rail pressure less
227 DFC_RailMeUn3PkLo 520243 20
Peak value of rail pressure
228 DFC_RailMeUn4PkHi 520243 21
229 DFC_RailMeUn6Rmp Rail pressure decreases too fast 520243 18
Incredible setting of fuel capacity
230 DFC_RailMeUn7MeUnSetPlaus 520243 23
metering unit in overspeed mode
Monitor error of fuel capacity
231 DFC_RailMeUn8LowIdlMeUnMontr 520243 24
metering unit at low idle speed
Fuel capacity in fuel gauge
232 DFC_RailMeUn10MeUnQHi 520243 7
exceeds threshold
233 DFC_RailMeUn12OfsMaxMeUnQHi threshold and fuel capacity in fuel 520243 5
gauge exceeds threshold
Low end of cranking motor relay
234 DFC_StrtCDLSSCBat 1675 3
short-to-power
235 DFC_StrtCDLSSCGnd 1675 4
short-to-ground
236 DFC_StrtCDNoLoad 1675 5
in open load
Water temperature sensor operates
237 DFC_CTSCDOvrTemp smoothly but water temperature 110 15
exceeds threshold
Cruise control inhibition error
238 DFC_Brk1SwtCrCtlRls 597 7
before stepping on brake pedal
Identification error of cruise
239 DFC_Brk1SwtCrCtllmp control requirement keeps trouble 597 11
light on
Output voltage of remote
240 DFC_RmtApp1SRCMax accelerator pedal 1 exceeds 520277 3
maximum
2-14

241 DFC_RmtApp1SRCMin accelerator pedal 1 less than 520277 4
minimum
242 DFC_RmtApp2SRCMax accelerator pedal 2 exceeds 520278 3
maximum
243 DFC_RmtApp2SRCMin accelerator pedal 2 less than 520278 4
minimum
Original voltage of water-in-oil
244 DFC_WtLvSRClMax sensor exceeds maximum 520264 3
threshold
Original voltage of water-in-oil
245 DFC_WtLvSRClMin sensor less than minimum 520264 4
threshold
OBD torque limiting activation
246 DFC_CoVehPrfmLimAct 520198 11
error
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
Total number of cylinders on fire
261 DFC_MisFireTot 1322 3
overruns
Lock vehicle and execute vehicle
262 DFC_STGPRSLCKMOD1 522014 1
lock mode 1
Lock vehicle and execute vehicle
263 DFC_STGPRSLCKMOD2 522014 2
lock mode 2
264 DFC_InjDiaQOC exceeds 20% for 20 consecutive 520210 16
times
2-15

265 DFC_InjDiaQOCfactor ranges from 5% to 20% for 520210 15
consecutive500ms
271 DFC_ComEngSpdUnAvail Unavailable engine speed signal 190 2
Unavailable water temperature
272 DFC_ComCTSCDUnAvail 1 0
signal
CAN receiving frame TSC1DR
329 DFC_FrmMngTSC1DRDLC 522038 14
data volume error
CAN receiving frame TSC1DR
330 DFC_FrmMngTSC1DRTO 522038 19
timeout error
CAN receiving frame TSC1AR
331 DFC_FrmMngTSC1ARDLC 522036 14
data volume error
CAN receiving frame TSC1AR
332 DFC_FrmMngTSC1ARTO 522036 19
data timeout error
CAN receiving frame TTSC1DE
333 DFC_FrmMngTSC1DEDLC 522037 14
data volume error
CAN receiving frame TSC1DE
334 DFC_FrmMngTSC1DETO 522037 19
timeout error
CAN receiving frame TSC1AE
335 DFC_FrmMngTSC1AEDLC 522035 14
data volume error
CAN receiving frame TSC1AE
336 DFC_FrmMngTSC1AETO 522035 19
timeout error
CAN receiving frame EngTemp2
337 DFC_FrmMngEngTemp2DLC 522020 14
data volume error
CAN receiving frame EngTemp2
338 DFC_FrmMngEngTemp2TO 522020 19
timeout error
CAN receiving frame ETC2 data
339 DFC_FrmMngETC2DLC 522023 14
volume error
CAN receiving frame ETC2
340 DFC_FrmMngETC2TO 522023 19
timeout error
CAN receiving frame ERC1DR
341 DFC_FrmMngERC1DRDLC 522021 14
data volume error
CAN receiving frame ERC1DR
342 DFC_FrmMngERC1DRTO 522021 19
timeout error
CAN receiving frame AT1OGC2
343 DFC_FrmMngAT1OGC2DLC 522011 14
data volume error
344 DFC_FrmMngAT1OGC2TO 522011 19
timeout error
345 DFC_FrmMngAT1OGC1DLC 522010 14
data volume error
2-16

346 DFC_FrmMngAT1OGC1TO 522010 19
timeout error
CAN receiving frame AT1IGC2
347 DFC_FrmMngAT1IGC2DLC 522008 14
data volume error
348 DFC_FrmMngAT1IGC2TO 522008 19
timeout error
349 DFC_FrmMngAT1IGC1DLC 522007 14
data volume error
350 DFC_FrmMngAT1IGC1TO 522007 19
timeout error
CAN receiving frame AT1IG1
351 DFC_FrmMngAT1IG1DLC 522006 14
data volume error
CAN receiving frame AT1IG1
352 DFC_FrmMngAT1IG1TO 522006 19
timeout error
CAN receiving frame AT1OG1
353 DFC_FrmMngAT1OG1DLC 522009 14
data volume error
CAN receiving frame DM1DCU
354 DFC_FrmMngDM1DCUDLC 522012 14
data volume error
CAN receiving frame DM1DCU
355 DFC_FrmMngDM1DCUTO 522012 19
data volume error
CAN receiving frame DM19 data
356 DFC_FrmMngDM19DLC 522060 14
volume error
CAN receiving frame DM19
357 DFC_FrmMngDM19TO 522060 19
timeout error
CAN receiving frame ETC7 data
358 DFC_FrmMngETC7DLC 522063 14
volume error
CAN receiving frame DEC1 data
359 DFC_FrmMngDEC1DLC 522062 14
volume error
CAN receiving frame AMCON
360 DFC_FrmMngAMCONDLC 522050 14
data volume error
CAN receiving frame AMCON
361 DFC_FrmMngAMCONTO 522050 19
timeout error
CAN receiving frame HRVD data
362 DFC_FrmMngHRVDDLC 522051 14
volume error
CAN receiving frame HRVD
363 DFC_FrmMngHRVDTO 522051 19
timeout error
CAN receiving frame DashDspl
364 DFC_FrmMngDashDsplDLC 522052 14
data volume error
CAN receiving frame DashDspl
365 DFC_FrmMngDashDsplTO 522052 19
timeout error
2-17
CAN receiving frame EGF1 data

366 DFC_FrmMngEGF1DLC 522053 14
volume error
CAN receiving frame EGF1
367 DFC_FrmMngEGF1TO 522053 19
timeout error
CAN receiving frame DM13 data
368 DFC_FrmMngDM13DLC 522054 14
volume error
CAN receiving frame DM13
369 DFC_FrmMngDM13TO 522054 19
timeout error
CAN receiving frame TRF1 data
370 DFC_FrmMngTRF1DLC 520217 14
volume error
CAN receiving frame TRF1
371 DFC_FrmMngTRF1TO 520217 19
timeout error
CAN receiving frame CM1 data
372 DFC_FrmMngCM1DLC 522056 14
volume error
CAN receiving frame CM1
373 DFC_FrmMngCM1TO 522056 19
timeout error
Upstream intake pressure signal
424 DFC_PIntkVUsPlsHi 102 0
exceeds maximum
Upstream intake pressure signal
425 DFC_PIntkVUsPlsLo 102 1
less than minimum
Incredible double relationship of
478 DFC_RmtAPP12Plaus 520253 2
remote accelerator
Credibility verification of remote
479 DFC_RmtAccPedBrkPlaus 520277 7
accelerator and brake
480 DFC_ComGPSKeyErr Key message fault 520218 14
481 DFC_ComGPSMsgTo Key message timeout 520218 19
2-18
232 YC6J125-T300 series engine failure diagnosis

codes
Flash
Failure Failure
Failure name code of SPN FMI
path code
failure
Intake flow sensor power failure - too high or too
11 708 P0100 132 11
low
Intake flow sensor signal compensation failure - it
12 2 P1000 1694 15
exceeds upper limit
Intake flow sensor signal compensation failure -
13 3 P1001 1694 17
irrational
compensation exceeds the limit at the time of 14 4 P2074 1694 16
loading
compensation exceeds the limit at the time of 15 5 P2073 1694 18
idling
Intake flow sensor signal drift failure - it exceeds
21 6 P0101 1694 0
upper limit
Intake flow sensor signal drift failure - it exceeds
22 7 P010B 1694 1
lower limit
Intake flow sensor signal failure - there is no
23 8 P0104 132 2
signal
Intake flow sensor signal failure - cycle exceeds
24 9 P0103 132 3
upper limit
Intake flow sensor signal failure - cycle exceeds
25 10 P0102 132 4
lower limit
Air conditioning compressor (type 1) control
177 11 P0640 1351 5
circuit failure - open circuit
711 12 P0641 1351 6
circuit failure - excess temperature
149 13 P0642 1352 5
circuit failure - open circuit
159 14 P0643 1352 6
circuit failure - excess temperature
169 15 P0646 1352 3
circuit failure - short circuit to power supply
219 16 P0644 1352 4
circuit failure - short circuit to ground
712 17 P0647 1351 3
circuit failure - short circuit to power supply
2-19

713 18 P0645 1351 4
circuit failure - short circuit to ground
Air conditioning request switch signal failure -
229 19 U0164 985 19
connection timeout; CAN reception timeout
Air conditioning request switch signal failure - it
239 20 U0165 985 19
is irrational; CAN reception timeout
Exhaust gas recirculation control deviation
714 21 P1007 1241 15
over-limit failure - it exceeds upper limit of EOM
715 22 P1008 1241 17
over-limit failure - it exceeds lower limit of EOM
716 23 P0402 1241 0
over-limit failure - it exceeds upper limit
717 24 P0401 1241 1
over-limit failure - it exceeds lower limit
Exhaust gas recirculation / normal mode switch
721 25 P1009 1241 11
failure - timeout
Intake preheating drive circuit test failure - it
249 26 P100A 729 16
exceeds upper limit at the time of activation
259 27 P100B 729 18
exceeds lower limit at the time of activation
269 28 P100C 729 15
exceeds upper limit at the time of exit
279 29 P100D 729 17
exceeds lower limit at the time of exit
Intake preheating drive circuit failure - normally
516 30 P0540 729 7
open
Temperature sensor rationality failure -
289 31 P100E 171 2
irrationality 1
291 32 P100F 176 2
irrationality 2
292 33 P1010 177 2
irrationality 3
293 34 P1011 178 2
irrationality 4
294 35 P1012 179 2
irrationality 5
295 36 P1013 171 11
undetermined failure
CY141 control relay output voltage 0 failure -
31 37 P0659 1485 3
short circuit to power supply
32 38 P2671 1486 3
34 40 P0658 1485 4
short circuit to ground
2-20

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
42 45 P1014 444 3
circuit to power supply
Battery voltage detection circuit failure -
43 46 P1015 444 4
short-circuit to ground
Brake switch failure - in the process of cruise
724 47 P0568 597 11
control
Brake switch failure - before activation of cruise
725 48 P0572 597 12
control
Brake signal failure - signal of main and auxiliary
726 49 P0504 597 2
brakes is irrational
Brake switch failure - single side brake failure 727 50 P0501 597 14
Brake signal reception failure - CAN reception
296 51 U0418 597 19
timeout
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 -
44 60 P0115 110 17
absolutely irrational
Cooling water temperature rationality failure -
45 61 P0116 110 18
dynamically irrational
Cooling water temperature signal reception
297 62 U013C 110 19
failure - CAN
Cooling water temperature sensor circuit failure -
51 63 P0118 110 3
short circuit to power supply or open circuit
Cooling water temperature sensor circuit failure -
52 64 P0117 110 4
Cooling water temperature rationality failure - it
53 65 P011A 110 2
is irrational with the second temperature
Clutch signal rationality failure - it is irrational
731 66 P0704 598 2
with gear signal
Clutch signal reception failure - CAN reception
732 67 U0114 598 19
timeout
Torque limit function activation - pressure boost
54 68 P1019 518 14
protection
2-21
Torque limit function activation - engine

55 69 P101A 519 14
protection
Torque limit function activation - injection
111 70 P101B 520 14
system
Torque limit function activation - restricted
112 71 P101C 521 11
information
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
115 74 P101F 524 14
limit
Torque limit function activation - smoke limit 121 75 P1020 525 14
Communication failure - air conditioning request
941 747 U1101 2000 14
switch signal received is wrong
Communication failure – reception of air
942 748 U1102 2000 19
conditioning request switch signal is overtime
Communication failure - sending of ACK is
83 76 U2100 2001 19
overtime
Communication failure - sending of AmbCon is
84 77 U2101 2002 19
overtime
Communication failure - upstream NOX
85 78 U0113 2003 14
information received is wrong
Communication failure - reception of upstream
86 79 U0114 2003 19
NOX signal is overtime
87 80 U0115 2004 19
NOX signal sent by PNG is overtime
216 81 U0116 2005 19
Communication failure - downstream NOX
217 82 U0117 2006 14
information received is wrong
Communication failure - reception of downstream
218 83 U0118 2006 19
NOX signal is overtime
226 84 U0119 2007 19
227 85 U011A 2008 19
228 86 U011B 2009 14
NOX signal requested by DM19 is overtime
NOX signal requested by DM19 is overtime - 181 87 U1103 2010 19
BAM
182 88 U1104 2011 11
PCK
2-22

184 90 U011C 2013 14
BAM
186 92 U1107 2015 11
PCK
Communication failure - reception of DM1 sent
236 94 U011D 2017 11
by DCU is overtime - BAM
237 95 U011E 2018 31
by DCU is overtime - PCK
Communication failure - received information
238 96 P1400 2019 0
processing timeout 1
246 97 P1401 2020 1
247 98 P1402 2021 2
248 99 P1403 2022 3
256 100 P1404 2023 4
257 101 P1405 2024 19
by DCU is overtime
Communication failure - EBC1 information
258 102 U1109 2025 14
received is wrong
Communication failure - reception of EBC1 is
261 103 U110A 2025 19
overtime
Communication failure - EBC2 information
951 801 U0129 2115 14
received is wrong
Communication failure - reception of EBC2 is
952 802 U012A 2116 19
overtime
Communication failure - sending of EEC1 is
262 104 U2102 2026 19
overtime
263 105 U2103 2027 19
overtime
264 106 U2104 2028 19
overtime
Communication failure - sending of EFL_P1 is
265 107 U2105 2029 19
overtime
Communication - external shutdown request,
266 108 U110B 2030 19
from EBC1
2-23
Communication failure - sending of EngTemp is

267 109 U2106 2031 19
overtime
Communication failure - sending of ERC1 is
268 110 U2107 2032 19
overtime
Communication failure - ETC1 information
271 111 U110C 2033 14
received is wrong
Communication failure - reception of ETC1 is
272 112 U110D 2033 19
overtime
Communication error - ETC2 information
273 113 U110E 2034 14
received is wrong
Communication failure - reception of ETC2 is
274 114 U110F 2034 19
overtime
Communication failure - sending of FD is
943 749 U2108 2035 19
overtime
Communication failure - sending of FlEco is
275 115 U2109 2036 19
overtime
Communication failure - sending of IC1 is
276 116 U210A 2037 19
overtime
Communication failure - sending of LFC
277 117 U210B 2038 19
information is overtime
Communication failure - reception of NOX
278 118 U011F 2039 19
information is overtime - SAE
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
2-24

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
348 138 U210C 2059 19
information is overtime - BAM
Communication failure - sending of ERC
356 139 U210D 2060 14
information is overtime - PAC
Communication failure - CCVS information
357 140 U1110 2061 14
received is wrong
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
365 146 U0137 2066 6
voltage signal is overtime - SAE
366 147 U0138 2067 6
voltage signal is overtime - SAE
367 148 U0139 2068 7
temperature signal is overtime - SAE
368 149 U013A 2069 7
temperature signal is overtime - SAE
2-25
Communication failure - sending of ShutDwn is

369 150 U210E 2070 19
overtime
Communication failure - tachometer information
371 151 U1112 2071 14
received is wrong
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
374 154 U1114 2073 14
received is wrong
Communication failure - reception of TimeDate
375 155 U1115 2073 19
is overtime
Communication failure - reception of TSC1_AE
376 156 U1116 2074 8
is overtime (activated)
377 157 U1117 2075 10
is overtime (not activated)
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
2-26
Communication failure - reception of TSC1_VR

428 172 U1126 2090 8
436 173 U1127 2091 10
Communication failure - TSC1_AE information
437 174 U1128 2092 14
received is wrong
438 175 U1129 2092 19
is overtime
Communication failure - TSC1_AR information
446 176 U112A 2093 14
received is wrong
447 177 U112B 2093 19
is overtime
Communication failure - TSC1_DE information
448 178 U112C 2094 14
received is wrong
456 179 U112D 2094 19
is overtime
Communication failure - TSC1_DR information
457 180 U112E 2095 14
received is wrong
458 181 U112F 2095 19
is overtime
Communication failure - TSC1_PE information
461 182 U1130 2096 14
received is wrong
462 183 U1131 2096 19
is overtime
Communication failure - TSC1_TE information
463 184 U1132 2097 14
received is wrong
464 185 U1133 2097 19
is overtime
Communication failure - TSC1_TR information
465 186 U1134 2098 14
received is wrong
466 187 U1135 2098 19
is overtime
Communication failure - TSC1_VE information
467 188 U1136 2099 14
received is wrong
468 189 U1137 2099 19
is overtime
Communication failure - TSC1_VR information
471 190 U1138 2100 14
received is wrong
472 191 U1139 2100 19
is overtime
Communication failure - sending of CCVS is
473 192 U210F 2101 19
overtime
Communication failure - sending of PGNRQG1b
474 193 U2110 2102 19
is overtime
2-27
Communication failure - sending of PGNRQ is

475 194 U2111 2103 19
overtime
Communication failure - sending of UAA1 is
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
overtime
Communication failure - sending of VD is
486 203 U211A 2112 19
overtime
Communication failure - sending of VEP1 is
487 204 U211B 2113 19
overtime
Communication failure - sending of WFI is
488 205 U211C 2114 19
overtime
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 -
123 208 P0608 1231 19
CY146SPI communication
ECU internal hardware communication failure -
124 209 P0607 1232 19
CY320SPI communication
Actuator protection function execution - battery
734 210 P1022 445 3
voltage is too high
Actuator protection function execution - battery
735 211 P1023 445 4
voltage is too low
Brake rationality failure - idling brake switch and
736 212 P1024 571 2
service brake switch are irrational
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
742 215 P3402 1072 5
circuit
In-cylinder brake control circuit failure - excess
298 216 P3401 1072 6
temperature
In-cylinder brake control circuit failure - short
743 217 P3404 1072 3
2-28
In-cylinder brake control circuit failure - short

744 218 P3403 1072 4
circuit to ground
ECU internal hardware failure - erasing
125 219 P062F 1560 11
EEPROM
ECU internal hardware failure - reading
131 220 P062A 1562 14
EEPROM
ECU internal hardware failure - writing
132 221 P0602 1561 12
EEPROM
EGR control failure - opening is limited 133 222 P2413 27 6
EGR valve body dislocation detection - voltage is
134 223 P1025 27 17
out of range at the time of full closing
EGR valve body dislocation detection - voltage is
135 224 P1026 27 15
out of range at the time of full opening
EGR valve body dislocation detection - voltage
141 225 P1027 27 2
difference is out of range
EGR control failure - deviation between the
actual value and the target is too large in cold 142 226 P1028 27 12
start
EGR control failure - positive deviation between
143 227 P1029 27 18
the actual value and the target is too large
EGR control failure - negative deviation between
144 228 P102A 27 16
the actual value and the target is too large
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 152 231 P102D 27 10
large at the time of full closing
difference from the voltage at the first time is too 153 232 P102E 27 10
large at the time of full opening
EGR valve drive circuit failure - open circuit 154 233 P0404 27 5
EGR valve drive circuit failure - excess
155 234 P0403 27 6
temperature
EGR opening detection failure – the voltage is
larger than the one at the time of full opening or 211 235 P102F 27 16
full closing
EGR opening detection failure - the voltage is
smaller than the one at the time of full opening or 212 236 P1030 27 18
full closing
EGR valve drive circuit failure - short circuit to
213 237 P0490 27 3
power supply
EGR valve drive circuit failure - short circuit to
214 238 P0489 27 4
ground
2-29

difference from the voltage last time is too large 215 239 P1031 27 10
at the time of full closing
difference from the voltage last time is too large 221 240 P1032 27 10
at the time of full opening
EGR opening sensor circuit failure - short circuit
222 241 P0406 27 3
to power supply
EGR opening sensor circuit failure - short circuit
223 242 P0405 27 4
to ground
EGR opening sensor circuit failure - virtual
224 243 P0409 27 2
connection
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
299 247 P0723 890 5
circuit
Open circuit of engine speed output circuit -
319 248 P0722 890 6
excess temperature
Open circuit of engine speed output circuit - short
329 249 P0720 890 3
Open circuit of engine speed output circuit - short
339 250 P0721 890 4
circuit to ground
Environmental pressure signal reception failure -
349 251 U1300 108 19
CAN reception is overtime
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
235 254 P1035 172 2
is irrational with TAFS
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
245 259 P0016 637 14
crankshaft and camshaft is too large
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
359 263 P0475 1074 6
temperature
2-30
Exhaust brake control circuit failure - short circuit

746 264 P0478 1074 3
to power supply
Exhaust brake control circuit failure - short circuit
747 265 P0477 1074 4
to ground
Exhaust brake test failure - test value is high
179 266 P0479 1074 2
when signal is low
Exhaust brake test failure - test value is low when
379 267 P0479 1074 19
signal is high
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
753 271 P0484 977 6
temperature
Digital fan 2 control circuit failure - excess
754 272 P0485 978 6
temperature
Digital fan 1 control circuit failure - short circuit
755 273 P0692 977 3
to power supply
756 274 P0694 978 3
to power supply
757 275 P0691 977 4
to ground
761 276 P0693 978 4
to ground
PWM fan control circuit failure - open circuit 389 277 P0482 979 5
PWM fan control circuit failure - excess
391 278 P0486 979 6
temperature
PWM fan control circuit failure - short circuit to
392 279 P0696 979 3
power supply
PWM fan control circuit failure - short circuit to
393 280 P0695 979 4
ground
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
2-31
Oil filter blocking rationality failure - blocking at

449 293 P1017 95 14
the time of electrification without running
Fuel heating control circuit failure - open circuit 459 294 P2029 854 5
Fuel heating control circuit failure - excess
469 295 P2029 854 6
temperature
Fuel heating control circuit failure - short circuit
479 296 P2030 854 3
to power supply
Fuel heating control circuit failure - short circuit
489 297 P2030 854 4
to ground
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
255 303 P0182 174 4
circuit to ground
Fuel temperature rationality failure - the second
311 304 P0181 174 2
temperature is irrational
Neutral switch signal reception failure - CAN
494 305 U1301 59 19
reception is overtime
Preheating light control circuit failure - open
766 306 P0382 1677 5
circuit
Preheating light control circuit failure - excess
495 307 P0381 1677 6
temperature
Preheating light control circuit failure - short
767 308 P0384 1677 3
Preheating light control circuit failure - short
771 309 P0383 1677 4
circuit to ground
Preheating control circuit failure - open circuit 772 310 P2605 729 5
Preheating control circuit failure - excess
496 311 P2606 729 6
temperature
Preheating control circuit failure - short circuit to
773 312 P2608 729 3
power supply
Preheating control circuit failure - short circuit to
312 313 P2607 729 4
ground
Oil injection control failure - number of injection
313 314 P103F 164 11
times is too much (electric loading)
314 315 P1040 165 8
times is too much (fuel control balance)
315 316 P1041 166 8
times is too much (system requirement)
2-32

321 317 P1042 167 8
times is too much (running time)
Oil injection control failure - start test 322 318 P1043 168 11
Oil injection control failure - rail pressure is too
323 319 P0087 164 1
low
Over-limit oil injection correction failure - oil
497 320 P020A 651 14
atomizer 1
498 321 P020E 652 14
atomizer 2
499 322 P020C 653 14
atomizer 3
519 323 P020F 654 14
atomizer 4
529 324 P020B 655 14
atomizer 5
539 325 P020D 656 14
atomizer 6
Oil atomizer common port 1 circuit failure - short
324 326 P062D 633 3
circuit
Oil atomizer common port 2 circuit failure - short
325 327 P062E 634 3
circuit
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
354 347 P0261 651 4
of high and low ends
355 348 P0273 655 4
2-33

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
415 353 P104A 633 14
short-circuits to ground
Oil atomizer circuit failure - BANK1
421 354 P104B 634 14
Oil atomizer circuit failure -BANK0 ground
944 750 P1581 633 11
detection is overtime
Oil atomizer circuit failure -BANK1 ground
945 751 P1582 634 11
detection is overtime
PTO switch circuit failure - short circuit to power
517 355 P251C 976 3
supply
Fuel metering valve drive circuit failure - virtual
422 356 P0255 1442 2
connection of low end
Fuel metering valve drive circuit failure - open
423 357 P0251 1442 5
circuit of low end circuit
Fuel metering valve drive circuit failure - excess
424 358 P0252 1442 6
temperature
Fuel metering valve drive circuit failure –high
425 359 P0007 1442 15
end short-circuits to power supply
Fuel metering valve drive circuit failure - high
431 360 P0006 1442 17
end short-circuits to ground
Fuel metering valve drive circuit failure - low end
432 361 P0254 1442 16
short-circuits to power supply
Fuel metering valve drive circuit failure - low end
433 362 P0253 1442 18
Fuel metering valve current sensor short-circuits
434 363 P025D 1442 3
to power supply
Fuel metering valve current sensor short-circuits
435 364 P025C 1442 4
to ground
MIL light control circuit failure - open circuit 774 365 P0650 1213 5
MIL light control circuit failure - excess
775 366 P104C 1213 6
temperature
MIL light control circuit failure - short circuit to
776 367 P104D 1213 3
power supply
MIL light control circuit failure - short circuit to
777 368 P104E 1213 4
ground
PTO switch circuit failure - short circuit to
18 369 P251B 976 4
ground
2-34
ECU internal hardware failure - AD conversion

441 370 P060B 2629 12
voltage is too low
ECU internal hardware failure - AD conversion
442 371 P104F 2630 12
voltage exceeds the limit
ECU internal hardware failure - AD correction
443 372 P1050 2631 12
factor exceeds the limit
ECU internal hardware failure - FC and MM
444 373 P063A 2632 12
rationality failure (communication)
ECU internal hardware failure - SPI
445 374 P063B 2633 12
communication outage (communication)
ECU internal hardware failure - ROM 451 375 P0605 2634 12
ECU internal hardware failure - SOP (no
452 376 P0604 2635 12
response to monitoring)
ECU internal hardware failure - SOP
453 377 P0601 2636 12
(NOTCHECK; torque reduction)
ECU internal hardware failure - SOP (failure
454 378 P060A 2637 12
monitoring response time setting failure)
ECU internal hardware failure - SOP (SPI failure) 455 379 P063C 2638 12
ECU internal hardware failure - SOP (ABELINE
511 380 P0606 2639 12
overvoltage)
ECU internal hardware failure - SOP
512 381 P0603 2640 12
(WDALINE)
ECU internal hardware failure - SOP (failure after
513 382 P063D 2641 12
system response)
ECU internal hardware failure - SOP (failure at
514 383 P060C 2642 12
the time of function test)
ECU internal hardware failure - SOP (detection is
515 384 P0613 2643 12
overtime)
ECU internal hardware failure - SOP (ABELINE
521 385 P0614 2644 12
overvoltage)
Relevant failures of torque limit activation -
522 386 P060D 1254 11
circuit 1 and circuit 2 of accelerator are irrational
1-stage and 2-stage calculated revolving speeds 523 387 P061C 1255 11
are irrational
electrification time of main injection and pilot 524 388 P0612 1256 11
injection is irrational
electrification angle at the time of starting is 525 389 P0611 1257 11
irrational
531 390 P1051 1258 11
undetermined
532 391 P1052 1259 11
undetermined
2-35

533 392 P1053 1260 11
undetermined
534 393 P1054 1261 11
undetermined
electrification time of oil atomizer is too long at 535 394 P0618 1108 16
the time of OVERRUN
electrification time of oil atomizer is too long at 541 395 P1055 1108 15
the time of overheating protection
542 396 P1056 1262 11
undetermined
Relevant failures of torque limit activation
543 397 P1057 1263 11
-1-stage and 2-stage rail pressure monitoring
Relevant failures of torque limit activation
–circuit 1 and circuit 2 of remote accelerator are 544 398 P1058 1264 11
irrational
545 399 P1059 1265 11
undetermined
Relevant failures of torque limit activation - rail
551 400 P105A 1266 14
pressure is limited
552 401 P105B 1267 14
intake is limited
553 402 P105C 1268 14
torque and fuel capacity
554 403 P105D 1269 11
undetermined
555 404 P105E 1270 11
undetermined
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
2-36
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
36 464 P1090 629 11
(WDA activation)
ECU internal failure - voltage is too low (ABE
46 465 P1091 629 4
activation)
ECU internal failure - voltage is too high (ABE
56 466 P1092 629 3
activation)
ECU internal failure - undetermined (ABE/WDA
61 467 P1093 629 14
activation)
Engine oil level sensor circuit failure - short
849 468 P250D 98 3
Engine oil level sensor circuit failure - short
859 469 P250C 98 4
circuit to ground
Engine oil level rationality failure – voltage does
869 470 P250B 98 2
not change
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 -
891 473 P1094 835 5
open circuit
892 474 P1095 835 6
excess temperature
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 895 477 P1098 100 1
of running
Engine oil pressure (digital sensor) signal
rationality failure - there is signal at the time of 896 478 P1099 100 2
shutdown
Engine oil pressure failure - high (temperature
62 479 P0521 100 15
and speed)
Engine oil pressure failure - low ( speed) 63 480 P0524 100 17
Engine oil pressure signal reception failure -
897 481 U1302 100 19
CAN reception is overtime
Engine oil pressure sensor circuit failure - short
64 482 P0523 100 16
Engine oil pressure sensor circuit failure - short
65 483 P0522 100 18
circuit to ground
Engine oil temperature failure - high 66 484 P0196 175 15
2-37
Engine oil temperature signal reception failure

898 485 U1303 175 19
-CAN reception is overtime
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
136 488 P109A 175 2
irrational with the second temperature
Boost pressure control deviation failure - too
146 489 P2263 1127 0
large
Boost pressure control deviation failure - too
156 490 P2263 1127 1
small
Torque and fuel capacity calibration rationality
161 491 P109B 512 13
failure - curve line is not monotonous
Boost pressure and environmental pressure
162 492 P0236 102 0
rationality failure - the difference is too large
Boost pressure and environmental pressure
163 493 P0240 102 1
rationality failure - the difference is too small
Boost pressure sensor circuit failure - short circuit
164 494 P0238 102 3
to power supply
Boost pressure sensor circuit failure - short circuit
165 495 P0237 102 4
to ground
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
575 501 U3110 81 19
failure
Particulate filter - signal voltage value exceeds
576 502 P2455 81 3
upper limit
Particulate filter - signal voltage value exceeds
577 503 P2454 81 4
lower limit
Forced opening of pressure release valve - there
166 504 P10A0 1349 11
are too many opening times
Forced opening of pressure release valve - rail
611 505 P10A1 1349 20
pressure is built
Forced opening of pressure release valve -
612 506 P10A2 1349 21
opening test
Forced opening of pressure release valve - opened 613 507 P10A3 1349 14
Forced opening of pressure release valve - fuel
614 508 P10A4 1349 22
capacity is unbalanced
615 509 P10A5 1349 2
blocked
2-38

616 510 P10A6 1349 0
opening time is too long
ECU internal hardware failure - R2S2
621 511 P0635 629 19
communication outage
Rail pressure closed-loop control mode failure 0 -
the actual one is smaller than the target (large 622 512 P10A7 679 1
metering valve flow)
Rail pressure closed-loop control mode failure 10
623 513 P10A8 679 7
- metering valve flow is unbalanced
the actual one is larger than the target (metering 624 514 P10A9 679 0
valve 0 flow)
- the actual one is larger than the target by two 625 515 P10B0 679 3
levels (metering valve 0 flow)
626 516 P10B1 679 5
rail pressure is too small
631 517 P10B2 679 15
rail pressure is too large by one level
632 518 P10B3 679 16
- rail pressure is too large by two levels
metering valve flow is too large (at the time of 633 519 P10B4 679 12
OVERRUN)
metering valve flow is too large (at the time of 634 520 P10B5 679 17
idling)
Rail pressure sensor circuit failure- virtual
635 521 P0194 679 2
connection
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
642 524 P0088 677 0
pressure is too high
Rail pressure control failure - LIMPHOME fuel
643 525 P10B8 677 11
capacity is large (PRV is not started)
Rail pressure control failure - LIMPHOME oil
644 526 P10B9 677 14
temperature is high
Rail pressure sensor circuit failure - short circuit
645 527 P0193 157 3
to power supply
Rail pressure sensor circuit failure - short circuit
646 528 P0192 157 4
to ground
Anti-theft signal error - signal is high 946 752 P0648 2029 12
PTO switch signal reception failure - CAN
899 573 U0104 976 19
reception timeout
2-39
Accelerator circuit 1 circuit failure - short circuit

652 581 P0123 91 3
to power supply
653 582 P0223 29 3
to power supply
Remote accelerator circuit 1 circuit failure - short
654 583 P1563 92 3
655 584 P1566 30 3
656 585 P0122 91 4
to ground
661 586 P0222 29 4
to ground
662 587 P1564 92 4
circuit to ground
663 588 P1567 30 4
circuit to ground
Reference supply 1 voltage failure - it is out of
664 591 P0654 1079 2
range
665 592 P0653 1080 2
range
666 593 P0699 1081 2
range
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
37 596 P0633 1543 3
failure - short circuit to power supply
Internal 12V power supply monitoring circuit
47 597 P0634 1543 4
failure - short circuit to ground
Shutdown time calculation failure - timing of
913 598 P2610 590 11
timer is inaccurate
Shutdown light control circuit failure - open
914 599 P1105 623 5
circuit
Shutdown light control circuit failure - excess
915 600 P1106 623 6
temperature
Shutdown light control circuit failure - short
916 601 P1107 623 3
Shutdown light control circuit failure - short
917 602 P1108 623 4
circuit to ground
Start relay control circuit failure - open circuit 28 603 P0817 1675 5
Start relay control circuit failure - excess
918 604 P0615 1675 6
temperature
Start relay control circuit failure - short circuit to
38 605 P0617 1675 3
power supply
2-40
Start relay control circuit failure - short circuit to

48 606 P0616 1675 4
ground
Failure light control circuit failure - open circuit 58 607 P161B 623 5
Failure light control circuit failure - excess
68 608 P161C 623 6
temperature
Failure light control circuit failure - short circuit
78 609 P1619 623 3
to power supply
Failure light control circuit failure - short circuit
88 610 P161A 623 4
to ground
Reset monitoring - relevant software reset failure
57 611 P110D 152 12
0
67 612 P110E 153 12
1
77 613 P110F 154 12
2
Accelerator signal rationality failure - circuit 1
117 614 P2135 91 2
and circuit 2 are irrational
Accelerator signal rationality failure - circuit 1
127 615 P1111 91 20
and idle switch are irrational
Remote accelerator signal rationality failure -
137 616 P1565 974 2
circuit 1 and circuit 2 are irrational
Start request switch circuit failure - normally
118 617 P2530 1041 11
open
AFS temperature sensor signal failure - duty ratio
147 618 P0113 172 0
exceeds upper limit
AFS temperature sensor signal failure - duty ratio
157 619 P0112 172 1
exceeds lower limit
AFS temperature sensor signal failure - cycle
167 620 P0111 172 15
exceeds upper limit
AFS temperature sensor signal failure - cycle
171 621 P0110 172 17
exceeds lower limit
Intake temperature signal reception failure - CAN
919 622 U1304 105 19
reception timeout
Intake air temperature sensor circuit failure -
172 623 P0098 105 3
173 624 P0097 105 4
Intake temperature rationality failure – it is
174 625 P1113 105 2
irrational with the second temperature
ECU temperature sensor circuit failure - short
175 626 P0669 1136 3
ECU temperature sensor circuit failure - short
176 627 P0668 1136 4
circuit to ground
Throttle valve control failure - opening is limited 921 628 P2100 51 6
2-41
Throttle valve body dislocation detection -

922 629 P2109 51 17
voltage is out of range at the time of full closing
923 630 P2110 51 15
voltage is out of range at the time of full opening
924 631 P2113 51 2
voltage difference is out of range
Throttle valve control failure - deviation between
the actual value and the target is too large in cold 925 632 P2114 51 12
start
Throttle valve control failure - positive deviation
between the actual value and the target is too 926 633 P2115 51 18
large
Throttle valve control failure - negative deviation
between the actual value and the target is too 927 634 P2116 51 16
large
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 931 637 P2108 51 10
time is too large at the time of full closing
difference from the voltage detected at the first 932 638 P2108 51 10
time is too large at the time of full opening
Throttle valve control circuit failure - open circuit 933 639 P2100 51 5
Throttle valve control circuit failure - excess
934 640 P2101 51 6
temperature
Throttle valve body dislocation detection - it is
larger than the maximum voltage at the time of 935 641 P2101 51 16
full opening or full closing
Throttle valve body dislocation detection - it is
smaller than the maximum voltage at the time of 936 642 P2101 51 18
full opening or full closing
Throttle valve control circuit failure - short circuit
937 643 P2103 51 3
to power supply
Throttle valve control circuit failure - short circuit
938 644 P2102 51 4
to ground
difference from the voltage detected last time is 189 645 P2108 51 10
too large at the time of full closing
difference from the voltage detected last time is 791 646 P2108 51 10
too large at the time of full opening
Throttle valve opening sensor circuit failure -
792 647 P2622 51 3
2-42
Throttle valve opening sensor circuit failure -

793 648 P2621 51 4
Throttle valve control circuit failure - virtual
794 649 P2620 51 2
connection
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
795 654 P0046 1188 6
temperature
Turbocharger control circuit failure - short circuit
168 655 P0048 1188 3
to power supply
Turbocharger control circuit failure - short circuit
178 656 P0047 1188 4
to ground
Vehicle speed signal reception failure - CAN
188 734 U1305 84 19
reception timeout
Vehicle speed signal failure - vehicle speed is
811 735 P0297 84 0
excessive speed
Vehicle speed sensor circuit failure - open circuit 812 736 P2162 84 14
Vehicle speed signal - failure of engine
813 737 P2159 84 2
speed-torque rationality
Vehicle speed sensor circuit failure - short circuit
814 738 P0503 84 3
to power supply
Vehicle speed sensor circuit failure - short circuit
815 739 P0502 84 4
to ground
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
818 742 P2161 1624 8
level is short
Warning light control circuit failure - open circuit 821 743 P1631 624 5
Warning light control circuit failure - excess
798 744 P1632 624 6
temperature
Warning light control circuit failure - short circuit
822 745 P162F 624 3
to power supply
Warning light control circuit failure - short circuit
823 746 P1630 624 4
to ground
Table 3 Yuchai three-stage engine failure codes
2-43
26 Engine failure diagnosis code

Failure
Failure type Failure causes Solution
classification
Check battery power carefully, charge or
Starting Low battery power
replace it
system
factors Starting motor
Repair or replace starting motor
damage
Air in oil-way Dredge oil-way (blow with high pressure
system air), fasten all joints and drain oil-way
Oil-way system Dredge oil-way (blow with high pressure
blockage air), fasten all joints and drain oil-way
Too dirty diesel
Replace filter element
Fuel system filter element
factors
Engine fails to Severe
be started piston/delivery Repair oil injection pump professionally
valve wear
Low-pressure oil
transfer pump Replace oil transfer pump
damage
Oil injection
advance angle Adjust oil injection advance angle
misalignment
Adjustment
Air valve clearance
factors Check and adjust air valve clearance
change
Few starting oil
Check oil injection pump professionally
mass
Diesel filter
blockage or inlet
connector strainer Clean or replace it
blockage of oil
transfer pump
Oil atomizer
Overhaul oil atomizer or replace nipple
underpressure or
matching parts
poor atomization
Engine
underpower Excess precise
Adjust fuel delivery or overhaul piston
nipple matching
matching parts
parts wear
Air in fuel system Exhaust air in fuel system
Incorrect oil
injection advance Adjust as specified
angle
Uneven fuel Adjust fuel delivery in all cylinders
2-44
delivery in all
cylinders
Air filter blockage Clean or replace filter element
Too high Discharge redundant lubricating oil to keep
lubricating oil level oil level within specified scale of oil level
in engine oil pan gauge
Untight oil
atomizer needle
valve or burns out Clean and adjust oil atomizer or replace
at open position and needle valve matching parts
diesel oil enters oil
pan
Piston bushing seal
ring damage of oil
injection pump
(P-type pump), or
poor sealing of
Replace seal ring
piston bushing and
pump body, fuel
Blue smoke
flows into oil pan
in diesel
along lubricating
exhaust
oil passage
Air valve and oil
seal damage or
Abnormal excess clearance Replace defective air valves, ducts and oil
exhaust between air valve seals (all oil seals subject to disassembly
and duct, engine oil must be replaced. Duct may not be replaced
drawn into the if clearance meets the requirements after
combustion replacing a new air valve)
chamber during
intake stroke
Seal ring damage of
turbocharger,
lubricating oil
Repair or replace it
enters combustion
chamber along air
flue for combustion
Water in fuel
Clean tank and filter, use qualified diesel oil
system
Cylinder valve
Replace worn components
White smoke wear
in diesel Poor oil injection
exhaust atomization at
nipple, diesel oil Adjust oil atomizer and oil supply advance
mist drops in angle
combustion
chamber without
2-45
combustion
Too high exhaust
back pressure or Reduce bends of exhaust pipe and remove
exhaust duct dust on silencer
blockage
Oil injection delay Adjust oil injection advance angle
Oil atomizer in
Black smoke
poor operating or
in diesel Disassemble it for cleaning and checking
oil atomizer
exhaust
damage
Poor diesel oil or
Replace diesel oil
incorrect marks
Severe cylinder
liner and piston Replace worn components
group wear
Abnormal engine
oil pressure display Replace display unit
unit
Select engine oil of certain mark, take
Too high oil
preheating measures when starting engine in
viscosity
winter.
Engine oil Too small clearance
overpressure of pressure
Adjust clearance of pressure lubrication
lubrication point or
point, clean or replace oil filter
fine oil filter
blockage
Improper pressure Readjust spring force of pressure limiting
limiting valve valve to restore engine oil pressure to
Lubricating adjustment specified value
oil
overpressure Oil pump wear or
or sealing gasket Repair oil pump and replace sealing gasket
underpressure damage
Reduced oil mass
Check oil mass, charge oil and clean oil
charged by oil
pump suction filter
pump
Check if lubrication circuit is broken, check
Too low oil Excess oil leakage and adjust fit clearance of bearings at
pressure crankshaft and camshaft
Oil filter or cooler
Check and clean oil filter and cooler
blockage
Too low oil
Select oil of certain mark as required
viscosity
Improper pressure Clean pressure limiting valve, adjust or
limiting valve replace spring
2-46
adjustment
Too low engine oil Check and adjust engine oil pressure sensor
pressure display and engine oil pressure gauge
Improper oil
Select proper lubricating oil
viscosity
Excess negative
pressure in
High Check causes of excess negative pressure,
combustion
lubricating oil adjust
chamber and oil
consumption
flows upward into it
Test indicates that oil consumption increases
speed and operating
significantly with the increase of speed, run
mode change
the engine as specified
Improper coolant or
Select proper coolant and add to proper level
water shortage
Set heat sink back to normal position with
Water radiator stalloy carefully, keep it flat and straight and
blockage then clean it with compressed air or water
gun
Measure temperature at water temperature
Water-thermometer sensor by using surface thermometer,
or beacon observe if indicated value of
indication error water-thermometer complies with actual
temperature
High coolant Too loose fan adhesive tape may lead to
temperature slipping, too low fan speed and poor
Too low fan speed,
efficiency of air supply. Adjust too loose
blade deforms or
adhesive tape. Replace it in case of rubber
fitted reversely
layer aging and damage or fibrous layer
fracture. Replace deformed fan blades
Cooling water
Replace water pump
pump failure
Thermostat failure Replace thermostat
Cylinder head
Replace cylinder head gasket
gasket damage
Diesel overloaded
Reduce engine load
operation
Table 5 Common engine failure diagnosis
2-47
Service M
Manual of Wheel
W Loa
ader
Coonten
nts
3 Electrical and in
nformation sy
ystem................................................................................................................. 2
2
31. Oveerview of eleectrical systeem....................................................................................................................... 2
2
3111. Specificatioon of electriccal System... .............................................................. ...................................... 2
2
3122 Description al system ...... .............................................................. ...................................... 2
n of electrica 2
m.................... ...................................... 2
3133 Special insttructions on maintenancee of the electtrical system 2
32 Elem
ments of elecctrical system
m ........................................................................................................................ 8
8
3211 I-ECU of In
nstrument panel (equipp
ped with T3 engine)
e .............................. ...................................... 8
8
3222 Engine con
ntrol unit ECU (equipped hai T3 enginee) .................. .................................... 15
d with Weich
3233 Engine con
ntrol unit ECU (equipped
d with YUCH ne) ............... .................................... 199
HAI T3 engin
3244 Polymorph ng switch ...... .............................................................. .................................... 23
hic fuel-savin
3255 Electronic accelerator
a pedal
p ............ .............................................................. .................................... 244
3266 Battery ............................................... .............................................................. .................................... 25
3277Generator ........................................... .............................................................. .................................... 266
3288 Starter ................................................ .............................................................. .................................... 288
witch .................................. .............................................................. .................................... 288
3299 Starting sw
32110Fuel level sensor
s ............................... .............................................................. .................................... 300
3111Power switcch ....................................... .............................................................. .................................... 31
witch .................................. .............................................................. .................................... 31
3122 Pressure sw
32113 Torque converter oil teemperature sensor ................................................... .................................... 33
32114Engine waater temperatture sensor .. .............................................................. .................................... 33
32115 Wiper and or ................. .............................................................. .................................... 344
d wiper moto
32 Elecctrical circuiit of machinee ....................................................................................................................... 355
3211 Comparison table for liine No. and ffunctions of the machinee .................... .................................... 35
3322 Wiring diaggram of the overall unit. .............................................................. .................................... 477
1
Service M anual of Wheel
W Loa
ader
3 Eleectriccal and
inforrmation syystem
m
31. Oveerview off electriccal system
m
311. Speecification
n of electtrical Sysstem
The voltag
ge for the electrical sysstem of thee complete
machine lo
oader is 24v
v.
312 Desccription of
o electriical systeem
The Servicce Manual of
o the electrrical system
m describes
theories, functions
f an
nd parametters of the electrical
system andd elements contained
c inn the machinne.
This sectioon also con
ntains descr
criptions on
n function,
troubleshooting and maintenannce method ds of the
electrical system.
s
The electrical system
m is compossed of elecctrical and
electronic componen nts and otther parts, such as
battery, sw
witch, solen
noid valve, fuse and relay.
r The
electrical system alsso includess a compu uter-based
control sysstem, which
h is used to monitor the machine
state and control th he machinee to achiev ve related
functions.
All reepairs aboutt the electrrical system

m must be
conducted strictly acccording too provision ns of the
general speecification.
313 Special instrructions on maintenance
of the electrical system
s
Special insstructions on repair off the electricc system -
overview
Neverr change thee electrical system witthout prior

approval from SDL LG. Changges may affect a the
machine fuunction and cause riskss of injury or
o damage
to the machhine.
Operaating the ellectric systtem carelesssly might

mean serio ous injury and
a damagee to the macchine. The
following instruction ns and desscriptions on o related
Fig. 3-1 methods must
m be observed careffully in opeerating the
electrical system.
s Reffer to instru
ructions in the safety
section andd service maanual at thee same time..
Before starting the electriccal system,, watches,

2
W Loa
ader
rings, braccelets and other mettal objects must be
removed frrom the boddy.
Don't connect too the startinng motor directly

d to
start the machine.
m Such
S operaation will cause the
machine tot get out of controol and mov ve. When
another machine
m is used
u to booost the staarting, the
machine should
s not come intto contact with the
machine which
w is boosted.
Never test whether thhey carryinng current by
b making
short circu
uit. It may damage eelectrical coomponents
permanently.
Special innstructions on repairr of the electrical
system-batttery
The cover of the battery boxx should bee removed

when chargging the batttery rapidlyy. When chaarging, the
so-called hydrogen
h gas
g will bee accumulatted in the
battery. Sh
hort circuit,, open flam
me or spark k near the
battery may cause powwerful exploosion.
The chargiing current should be disconnectted before
loosening the
t chargingg clip.
Keep goodd ventilation
n, especiallyy charging batteries
b in
a confined space.
Electrolytee of the baattery contaains corrosive sulfur
acid. Electtrolyte splashed on skkin should be
b washed
immediately with so oap and pplenty of water. If
electrolyte comes intto the eyess or other vulnerable
v
parts of thhe body, riinse with pplenty of water
w and
contact a doctor
d for heelp immediaately.
If a fully
f chargged battery is conneccted to an
exhausted battery, thee battery wiill burst duee to surge.
It may caause person nnel injury because th he battery
contains su
ulfur acid.
Neverr charge a frrozen battery

ry. Explosio
on hazard!
The main current or battery caable should never be
disconnectted in the en
ngine is opeerated.
The anode of the batteery must bee disconneccted before
installing or remov ving elemeents or connecting
c
mechanism m of the elecctrical systeem.
Note! Inccorrect opeeration willl cause damage of
control asssembly suuch as EC CU and th hus cause
shutdown.
Fully charrged battery
y must be uused when check the
3
W Loa
ader
electrical system.
s If the
t battery is not fully y charged,
charge it fu
ully or replaace it with a new one.
The polar conductor mist be diisconnected
d from the
battery when the batteery is chargeed.
When charrging batteries in seriess, batteries must have
the same capacity and
d service lifee (equal quaality).
This is beccause the cu
urrent amouunt required d to charge
a certain am
mount of ellectricity to a battery depends
d on
the aging degree
d of the battery.
Special insstructions on
n repair of tthe electricaal system -
generator
Before anny testing on o the alteernator or regulator,
check wheether the battery
b andd wire are insulated,
loose or rusted.
r Anyy error whhich might be found
according to the ab bove checkk must be corrected
before any electrical teesting.
Check the belt of the generator. IIf necessary
y, it should
be adjusted
d/repaired properly
p beffore troublesshooting.
Note! Makke sure to coonnect the ccable in a secure way
and guaranntee that there is no ccorrosion annd dust on
the cable. Loose cable connectiion may daamage the
generator and the voltage regulator damage
simultaneo
ously.
Note! Neveer disconnect the generrator when the engine
is operated
d. It will damage thhe generator and the
voltage reg
gulator simu
ultaneously..
Note! Never connect thet anode oof the generrator to the
chassis. It may damaage the gennerator and may even
damage thee voltage reegulator.
n repair of tthe electricaal system -
electrical elements
e
The bus must
m be repllaced if anyy contact on the data
bus is dam
maged.
Note: Thee two wirees includedd in each data bus
a in pairss and hoverring. They should be
including are
protected from
f electriical interferrence. Wiress can only
be repairedd by trained d personnell. Or the whole
w wire
might be reeplaced.
Electronic equipment is very sennsitive and is
i likely to
be damageed by electtromagneticc field or static from
the tools or
o the human body. Theerefore, it is
i required
to comply y with thee followingg instructio ons when
performingg operations concerrning to electronic
componentts.
To meet the neeeds of tthe electromagnetic
4
W Loa
ader
compatibillity (EMC), it is requireed to complly with the
following instructions
i :
When a certain electtronic elemment is suppplied with
power, thee connectioon to the uunit should never be
disconnectted. The electronic element mightm be
damaged inn case of disconnectionn.
Before maiintenance of
o the electriical system, make the
tool come into contacct with a m metal mechaanical part
connected to the framee to discharrge static off the tool.
Never toucch the plug pin
p on the eelectronic un
nit.
Avoid toucching the circuit
c boarrd when maintaining
m
the electrical system. If the cirrcuit board
d must be
touched, only
o the onee with whicch the edgee could be
grasped can be toucheed.
Make suree the groun nding wire is connected safely
when replaacing the co
ontrol unit.
Never rep place spiraaled wires in pair wire
w with
non-spiraleed wires in pair.
p
o maintenaance of thee electrical
system
When welding the machine,
m thee wire of th
he battery
must be disconnected AND THE E plug mustt be pulled
out from th
he control assembly.
When cond duct washin
ng the machhine by spraaying, it is
required too operate very carefullyy to preventt cable and
electrical components
c from beingg damaged.
When wash hing the veh
hicle with hhigh pressurre sprayer,
the nozzle should not aim to elecctronic elem
ments. It is
particularly
y importantt when usinng hot water and oil
cleaning aggent.
Auxiliary starting
Whenn another machine

m iss used to boost the
starting, th
he machinee should noot come intto contact
with the machine
m whicch is boosteed.
Auxiliary starting
s with
h starting caable
The following item
ms should be checkeed before
connecting
g:
1. Ignitio machines should be in
on switchess on both m
the offf position.
2. The machine should
s nott be moveed during
startin
ng.
5
Service M
Manual of Wheel
W Loa
ader
3. Both machines should havve the sam
me system
ge.
voltag
4. Specification of starting caable shouldd bear the
maxim
mum rated current
c geneerated by th
he battery.
5. Checkk whether they startiing cable for
f crack,
oxidattion and oth
her problem
ms.
6. The battery cable shouuld be in ntact. All
conneectors are connected should bee in good
condittion.
7. The machine
m do
oes not havve contact with each
other.
Positive an
nd negative connector should not come into
contact wiith each otther when boosting cables
c are
used. Dangger of personnel injury..
The startin
ng cable sh
hould be coonnected th
hrough the
method bellow (as shown in figure
re 3-3):
Fig. 3-2 B
Belt inspectiion
1. Conneect the firstt cable (A)) to the ano
ode of the
batterry on the machine
m w
which is go oing to be
startedd (1).
2. Conneect the other end of tthe cable (A)
( to the
cathodde (2) of the batterry on the auxiliary
startin
ng engine.
3. Conneect one endd of anotherr starting caable (B) to
the caathode (3) of the batttery on thee auxiliary
startin
ng machine..
4. Conneect the othher end of the cable (B) ( to the
earth point (4) off the frame of the macchine to be
started
d. Check wh hether the ccontact is prroper.
Auxiliary starting:
s
Fig.3-3 C
Connection of
o starting circuit
c Check wheether startin
ng cables arre connected securely
and correcttly.
1. Start the engin
ne on thee auxiliary
y starting
machiine.
2. Start the engine on the macchine to be started. If
the en
ngine can't be
b started w
within 30 secconds.
3. Wait for
f about tw
wo seconds, and then trry again.
The startin
ng cable sho
ould be remooved accord
ding to the
method bellow (as shown in figure
re 3-4):
1. Remo ove the cablle (B) from the earth point (1) of
the frrame on thhe machine started by y auxiliary
startin
ng.
Fig. 3-4 R
Removal of starting cab
ble 2. Remoove the otheer end of th
the starting cable (B)
from the cathodee of the batttery on thee auxiliary
6
W Loa
ader
machiine.
3. Remo ove the startting cable (A
A) from thee anode (3)
of thee battery on the auxiliarry machine.
4. Remoove the otheer end of thhe starting cable (A)
from the cathod de (4) of the batterry on the
machiine started by
b auxiliaryy starting.
7
W Loa
ader
32 Elem
ments of electricaal system
m
321 I--ECU of o Insttrument panel
(equippeed with T3
T enginee)
I-ECU receives inform mation com ming from sensor
s and
switch of the machinee and displayay it on the instrument
i
panel. It heelps operato
or to learn tthe workingg status of
the machinne.
Panel displlay of start-up process
king processs: After beiing conneccted to the
Self-check
power, the meter need dle points too the maxim
mum, then
return to zero
z and fiinally pointts to the right place.
Meanwhilee, after all indicator laamps are kept on for
1.5s, the LED of self-checkinng shows name n and
model of the
t panel. The
T meter nneedle returrns to zero
after power disconnecction.
Descriptionn of the worrking hour m
meter: It staarts timing
when the engine speeed is 350nn/min or laarger. The
display is refreshed
r ev
very six minnutes. But the
t storage
stores eveery minute.. The hourrglass sym mbol starts
flashing when the eng gine speed iis 350n/minn or larger,
It stops flashing
f whhen the sppeed is sm maller than
30n/min.
LCD of wo
orking process:
Fig. 3-5 Innstrument panel (T3)
Normal mode:
m Displaayed on thee LCD in tw
wo rows
The first ro
ow shows th
he driving sppeed.
The second
d row displays time annd maximumm range in
00000.0 h and 99 9999.9 h. The funn nel-shaped
countdownn icon flash
hes at frequuency of 2.5
2 S. The
hour timinng is dispplayed in the midd dle during
working.
de: Displayeed on the LC
Fault mod CD in threee rows
The first roow shows: FMI: 12 1//1 (FMI is one o or two
significant figures, 1/1 shows tthe current fault and
total faults respectivelly, the pream
mble-less is 0).
The secon nd row shows: SPN: 123456 (SP
PN is 2-6
significant figures).
The third d row sho ows: Warnning and hourmeter
alternatively at a chan
nge frequenccy of 2s (th
he warning
is displayeed reversely
y). The houuseglass symmbol does
not flash when
w the hou
urmeter is ddisplayed.
8
Service M
Manual of Wheel
W Loa
ader
Fig. 3-6 Noormal modee of panel LCD

L displayy Fig. 3-7Fault
3 mo
ode of panell LCD displlay
Functions aand requirements of in
nstrument paanel:
A. Instrum
ments:
Function Speccific requireements Signaal Rem
mark
Engine Rannge: 0-3000,, red zone: 22500-3000; unit: n/min
n. CAN
N
tachometerr
Working hour Rannge: 99999.9 9; when enggine speed≥ ≥350n/min, the
t Self-timing of
meter: timee display is refreshed evvery six minutes. But the
t insttrument
storaage stores every
e minutte.
Engine coooling Rannge: 40-120℃, range off red zone: 103-120℃; CAN
N
thermometter
Brake presssure Sensoor
Rannge: 0 -1 MP
Pa, red zonee: 0-0.4 MP
Pa, 0.9-1 MP
Pa.
gauge
Oil Rannge: 40-140℃, red zonee: 120-140℃
℃. Sensoor
thermometter of
torque
converter
Fuel level Rannge: 0-1/8-1/4-3/8-1/2-55/8-3/4-7/8--1; Sensoor
gauge Redd zone: 0-1/8
8
Rannge: 999.9, located
l in thhe middle of the first line Sensoor
in thhe normal mode,
m unit: kkm/h. In ordder to ensurre
the display
d speeed is greaterr than the actual speed,
Speedometter
the driving
d speeed below 200 km/h shou uld be added d
withh 8% of corrrection. Thee speed high her than
20km m/h should be added w with 6% of correction.
c
The switch is trriggered by inching. It is valid when unding
Groun
Language
the connection
c lasts 2 secoonds. Switch
h of English
h
switch
and Chinese is supported.
Alarms:
Function Speecific requirrements Color Sign
nal
Red
Low oil Indicating acco
ording to in formation trransferred in
i CANN
(steadily
ly
pressure allarm the CAN agreeement. com
mmunicationn
on)
Low brakee Thee alarm sym
mbol flashes and the buzzzer alarms
Senssor or
pressure allarm wheen the presssure is 0.4 M
MPa or less,, or signal iss Red
grou
unding
grouunded.
9
Service M
Manual of Wheel
W Loa
ader
Low 1. Before
B startiing, the alarrm symbol is i kept off
transmissioon oil wheether the sw witch is connnected nor
pressure allarm discconnected.
2. After
A startingg, if the preessure is low
w and the Grou unding or
Red
swiitch is conneected (delayy 10 second ds to confirm
m senssor
thatt the signatuure is true), the alarm symbol
flasshes and thee buzzer alarrms; if the switch
s
discconnected, thet symbol is off;
Charging Com mpare voltaage of terminnal D+ and battery of Rigiid wire
indicator aalarm the generator, the
t chargingg indicator lampl is
steaadily on if voltage
v of teerminal D+ is lower
thann that of thee battery andd the generaator is not
Red
used for powerr generationn or works abnormally;
a
(steadily
ly
the indicator laamp is off wwhen voltage of terminaal
on)
D+ is higher th han that of tthe battery and
a the
gennerator is used for poweer generatio on. The
insttrument is equipped
e wiith a built-in
n 5w 200 Ω
excitation resisstance.
Oil-water Indicating acco
i Yellow
CANN
separation the CAN agreeement. (steadily
ly
com
mmunicationn
alarm on)
Yellow CAN N
Coarse fueel Indicating acco
i
(steadily
ly com
mmunicationn
filter alarm
m the CAN agreeement.
on) or grrounding
Low fuel ooil If thhe fuel level is 1/8 or leess, the alarrm symbol Red Senssor
level alarm
m flasshes.
Thee alarm sym
mbol is steaddily on and the
t buzzer Yellow
Engine fauult CANN
alarrms when th
here is faultt information transferreed (steadily
ly
alarm com
mmunicationn
fromm the CAN agreement.. on)
Engine fauult Red CANN
Nonne
alarm (flashinng) com
mmunicationn
Red CAN N
Low coolaant Indicating acco
i
ly
(steadily com
mmunicationn
level alarm
m the CAN agreeement.
on) or grrounding
Yellow CAN N
Air filter Indicating acco
i
(steadily
ly com
mmunicationn
blocking allarm the CAN agreeement.
on) or grrounding
High coolaant
Whhen the wateer temperatuure is 105℃
℃ or higher, CANN
temperaturre Red
the alarm symbbol flashes aand the buzzzer alarms. com
mmunicationn
alarm
High hydraaulic
Thee alarm sym
mbol is steaddily on when n the oil
oil temperaature Red Senssor
tem
mperature is higher thann the set valu
ue.
alarm
Rear hood Thee symbol off the panel iss steadily on
n when the
Yellow Grou
unding
opening alaarm rearr hood of th
he engine is opened.
10
Service M
Manual of Wheel
W Loa
ader
Transmissiion Whhen the key isi turned to ON, if the water

oil filter alarm conntent of transmission oiil is higher than
t the set
Yellow Grou
unding
valuue of the sw
witch, the alaarm symboll is steadily
on.
Central alaarm It iss the same as
a SDLG - 11. Meanwhiile, if the Red
lamp enggine speed iss larger thann 1000 n/miin and the (flashinng) CAN N or rigid
hannd brake is not
n releasedd, the centraal alarm wiree signal
symmbol flashess and the buuzzer alarmss.
Indicators:
Function Sppecific requiirements Color Signal Remarkk
Power cut--off Thhe indicating
g symbol iss steadily on
n when the Power
Red
indication poower of the transmissio
t on is cut off.. supply
Preheatingg Thhe indicating
n when the Power
Yellow
indication preheater of th
he engine w
works. supply
Right steerring Thhe indicator lamp flashees when thee alarm Power
Green
indication lam
mp or the leeft steering switch is on
n. supply
Right-handd
Thhe indicator lamp flashees when thee alarm Power
turning Green
lam
mp or the riight steeringg switch is on.
o supply
instructionn
High beamm Thhe indicating
n when the Power
Blue
indication higgh beam off the front coombination lamp is on. supply
Thhe indicatingg symbol iss steadily on
n when the
Differentiaal lock
keey is turned to ON and tthe switch is
i Yellow Groundin
ng
indicator
coonnected.
Thhe indicator lamp is steeadily on wh
hen the
Mute indiccator muute switch is connectedd and the soound alarm Yellow Groundin
ng
is stopped.
Thhe indicator lamp is steeadily on an
nd the
Unlock of safety buuzzer alarmss when the llocal switch
h is Power
Red
lock coonnected andd the workinng device iss in a free supply
staate.
When the insttrument is cconnected to
W o power,
thee indicator symbol
s is stteadily on when
w the
enngine speed is 1000 n/m min or less and
a the
haand brake is not releaseed.
Hand brakiing
W
When the insttrument is cconnected too power, Red Groundin
ng
indicator
thee indicator symbol
s is stteadily on, the
t buzzer
alaarms and thhe central alaarm symboll flashes
whhen then engine speed is larger thaan 1000
n/mmin and thee hand brakee is not releeased.
Independennt
cooling Thhe indicator symbol is ssteadily on. Yellow Groundin
ng
indication
11
Service M
Manual of Wheel
W Loa
ader
Shaft cooliing Power

Thhe indicator symbol is ssteadily on. Yellow
indication supply
Thhe indicator lamp is steeadily on annd the
Quick channge buuzzer alarmss when the qquick chang ge switch is Power
Red
indication coonnected and d the attachhment is in a quick supply
chhange state.
Pressure
Thhe indicator lamp is steeadily on whhen the Power
stabilizing Green
pressure stabiilizing is wiitched on. supply
system
Other:
Function Sppecific requ
uirements Remark
Instrumentt The backlighht of instrum
ment is on when
w the baccklight swittch is
backlight coonnected to power.
Power inpuut DC 5 v / 24 v DC powerr output inteerface with load capaciity of
D
drriving: 200 mA.
Buzzer C
Clearance bu
uzzer, 1.0 - 11.2 Hz, 85 decibels.
d
Connector 200pin: molex
x 00392812 03; 22pin: molex
m 0039
9281223。
Software V
Version number of softw
ware: VEr 1.0
Pin functioon
Fig. 3-8 Pin of instrum

ment panel
A Pin funcction
Pin Pin
Pin Pin
F
Function Functtion No Function No Function
No. No.
. .
Signal off
1 C
CANH 11 Left ssteering lam
mp 6 thermomeete 16 TACH 3
r
2 C
CANL 12 Rightt steering laamp 7 Null 17 Common
12
Service M
Manual of Wheel
W Loa
ader
power
Switching
Transsmission oil Signal of
3 D
Differential lock 13 8 18 power
filter fuel meterr
supply
Hydraulic
Brake
C
Charge oil
4 14 TACH
H1 9 pressure 19
inndication temperatur
gauge/lammp
e
Analog
5 S
Speed pulse 15 TACH
H2 10 20 Grounding
ground
B Pin funcction
Pi Pi
Pin Pin n n Functio
Fuunction Function Funcction
No. No. No Noo n
. .
Coarse
Prehheating
1 C
CAN2H 7 Power shuttoff 13 19
9 fuel
indiccation
filter
Revers
High beamm Air ffilter e signall
2 C
CAN2L 8 14 20
0
indication bloccking- 24V
output
Prressure stabilizing Unlock of quick
q Indeepende
3 9 15 21
1 Mute
syystem change nt coooling
Axlee oil
Back
4 Paarking brakke- 10 Language switch
s 16 tempperatur 22
2
lightingg
e
5 Saafety lock 11 Coolant lev
vel 17 5 v ooutput
Trransmissionn oil Rearr hood
6 12 Reverse sig
gnal input 18
prressure openning
Internal wiiring diagram

m of panel
Figure sh hows the internal
i wirring diagraam of the
instrumentt panel of combined
c ttype. The instrument
i
and some warning lamps aree controlled d by the
instrumentt controller.
13
Service M
Manual of Wheel
W Loa
ader
Hour meter
Barome Tachom O
Oil Water Fuel
tempperatur LCD thermomet gauge:
tre eter e ggauge er
Back
lighti
ng
circui
t
Instrument controol circuit
Fig. 3-9Intternal wiringg diagram of

o panel
Pressure stabilizing system switch

Differential lock
Differe
ential lock indicator Pressure stabilizing
g system opening
indicaator
PParking switch
Ch
harge indicator Parking brake
b
Unlock switch
Air temperaturee Vehicle speed signal input Safety lock unloc
ck indicator
sensor
Transm
mission oil temperature Pressurre sensor
Transmission oil prressure indicator
indicator
Cut off switch
Power cut-off indicator
Oil level sensor
Fuel level gauge indicator High beam
High beam in
ndicator
switch
Quick
Brak
ke pressure indicator Quick change unllock indicator change
switch
Air pressure sensor Language switch Selector switch
Liquid level
Steering switch: Left steering
s indicator Coolant level indicator switch
Pressure
P
switch
Steerinng switch: Righ
ht steering indicator Low brake pressure
PPreheating grill
Transm
mission oil filter indicator Preheating indicator
Filter switch Air filter switch

Air filter indicator
Speed selection Cooling ECU

Independent cooling indicator
i
wire
Axle oil temperature indicator
Comm
mon power 5 v output Temperature
switch
Switc
ch power Rear hood opening indicator Travel switch
Air temperature Hydrraulic oil temperature Coarse filter

Coarse fuel filter in
ndicator
sensor indicator switch
Mute switch
Mute indicator
Backlit light on
o Light switch
Fig. 3-10W
Wiring diagrram of panel
14
Service M
Manual of Wheel
W Loa
ader
Detection method
m of panel
p
Connectionn harness of the panel is generally
composed of power co ord, groundd lead, signaal line and
CAN bus. If there is a fault in tthe panel, harness
h of
the panel might
m be dettected to juddge the poin
nt of fault.
The harnesss should bee disconneccted form th
he panel to
detect the harness
h term
minal.
Terminall Poweer cord Ground

G leadd Connecction to CAN bus
type the sign
nal line
Normal 24--28V 0V Accord ding to The resistaance betweeen CAN H
value the wo orking and CAN N L is abou
ut 120Ω
staate
322 Enggine conttrol unit ECU (eequipped

d
with Weeichai T3 engine)
Engine con ntrol unit is an electric control meechanism off
the enginee. It is used d to receivve messages from thee
engine seensor, conttrol the eengine run nning andd
communicaate with thee other partss of the macchine.
Main techn nical parameeter:
Working teemperature:-40~85℃
Storage temmperature: -40~105℃
-
Rated voltaage: 28.5V
Working voltage
v range: 9 - 322v, limiting g operatingg
voltage: 366 v (5 minu utes, when ssurface temmperature off
ECU is - 20 0℃).
The ECU is i equipped d with a buiilt-in protecction circuitt
for reversee power con nnection. Thhe fuse will be fused iff
anode and cathode aree connected reversely.
Protection grade: IP6K K9K
E - ECU U has two connectorrs, connecctor X1 iss
connected to harness of o the machhine, and co onnector X22
is connecteed to the enggine.
15
Service M
Manual of Wheel
W Loa
ader
Engin
ne Vehicle
V
Figure 3-11Diagram of
o engine co
ontrol unit (W
Weichai) an
nd connecto
ors
Meanings oof pins of connector X1
Pin No. Abbbreviation of
o Description
WIISE15
X1-01 PW
WR_V_VBR
R Power an
node
X1-02 PW
WR_G_GND
D Power cathode
X1-03 PW
WR_V_VBR
R Power an
node
X1-04 PW
WR_G_GND
D Power cathode
X1-05 PW
WR_V_VBR
R Power an
node
X1-06 PW
WR_G_GND
D Power cathode
X1-07 I_A
A_APP1 Signal off acceleratorr pedal 1
X1-08 I_A
A_APP2 Signal off acceleratorr pedal 2
X1-09 I_A
A_RMTAPP
P1 Input sign
nal of doublle acceleratoor pedal 1
X1-10 I_A
A_RMTAPP
P2 Input sign
nal of doublle acceleratoor pedal 2
X1-12 I_S
S_WFS Signal off water in fuel sensor
X1-13 I_A
A_TL Signal off polymorph
hic switch
X1-19 O__F_ENGN Output off engine speeed
X1-20 O__S_EBR Relay of exhaust braake
X1-22 O__S_STRT Starter relay
X1-23 O__S_WFLP Water in fuel
f indicator lamp
X1-24 V__V_5VAPP1
1 Power suppply of acceelerator peddal and doub
ble
accelerato
or pedal 1
X1-25 G__R_APP1 Accelerattor pedal an
nd double acccelerator pedal 1
ground
X1-27 G__R_APP2 Accelerattor pedal 2 and
a double accelerator pedal 2
ground
16
Service M
Manual of Wheel
W Loa
ader
X1-28 V__V_5VAPP2
2 Accelerattor pedal 2 and
a double accelerator pedal 2
Power sup pply
X1-31 G__R_TL Multimod
de switch
X1-32 water in fuel
f sensor ground
X1-33 I_F
F_VSS Signal off vehicle speeed sensor
X1-34 G__R_VSS Vehicle sp
peed sensorr ground
X1-35 O__S_DIA Fault diag
gnosis lamp
p
X1-37 O__S_IMPH Intake heating relay
X1-38 O__S_AC Air condiitioning com
mpressor rellay
X1-39 O__S_OBD OB
BD Indicator lamp
X1-40 O__S_CSLP Cold startt indicator lamp
l
X1-42 B__D_CANH0
0 Commun
nication CAN
N0 high
X1-43 B__D_CANL0 Commun
nication CAN
N0 low
X1-44 S_G
GND CAN wire
w shieldin
ng
X1-45 B__D_CANH1 Commun
nication CAN
N1 high
X1-46 B__D_CANL1 Commun
nication CAN
N1 low
X1-47 Constant speed switcch
X1-51 I_S
S_CRCNEG
G Cruise -
X1-52 I_S
S_ACSW Air condiitioning dem
mand switchh
X1-53 I_S
S_CONV Clutch sw
witch
X1-54 I_S
S_GNSW Neutral sw
witch
X1-55 I_S
S_BRKPS Hand brake switch
X1-57 I_S
S_ENGSA Off vehiccle start swittch of enginne
X1-58 I_S
S_T50 T50 start switch
X1-59 I_S
S_T15 T15 switcch
X1-60 I_S
S_DIAREQ Diagnosiss request sw
witch
X1-61 I_S
S_BRKMN Main brak
ke switch
X1-62 I_S
S_BRKRED
D Second brake switch
h
X1-63 I_S
S_CRCOFF
F Cruise offf
X1-64 I_S
S_CRCRES
S Cruise ressume
X1-65 I_S
S_EBR Exhaust brake
b switch
h
X1-66 I_S
S_STP Off vehiccle stop swittch of enginne
X1-67 I_S
S_RMTEN Double acccelerator pedal
p requesst switch
X1-68 I_S
S_CRCPOS
S Cruise +
17
Service M
Manual of Wheel
W Loa
ader
Power supply- Power supply+
Cruise +
Cruise -
Cruise off
Signal line of accelerator pedal 1

T15 Load 1
Accelerator peddal 1
Ground wire Cruise resume
Signal line of accelerator pedal2

Main brake
Ground wire
Accelerator pedall2
Second brake
Hand brake
Exhaust brake switch

T155 Load 2
Clutch
Signal line of remote pedal 1
Gear neutral
Remote pedal1
Diagnosis request
Constant engine speed

Signal line of remote pedal 2
Remote pedal2 Starter relay
Poly
ymorphic Signal line Air conditioning compressor
sw
witch
Ground electrode Intake heating
Signal line
OBD lamp
The four laamps may not be
Ground wire connectedd in case of CAN
Vehicle speed
instrumment control
Cold start lamp
O
Output of engine speed
Water in fuel lamp
Diagnosis lamp/flash code lamp
Exhaust brake
Signal line
Water in fuel
Ground wire
AC request
Engine start
Engine stop
Remote accelerator selector

switch
24v output Maximum bearable current 3A
24v output Maximum bearable current 4A
Power supply 5V
Signal line
Ground wire 24v output
Power supply 5V
PWM output
Cooling fan (PWM)
Pressure signal line
Temperature signal line

Ground wire Electromagnetic fan relay
Signal line
24v output
Ground wire
Negative end driving PWM Flow measurement unit
Power supply 5V
Ground wire
Power supply 5V
Temperature signal line

Ground wire Ignition sequence 1 5 33 6 2 4
Positive end
Negative end
Shield
Positive end
Negative end
Shield
Fig. 3-12 sschematic diiagram for pins

p of ECU
U (Weichai))
18
W Loa
ader
323 Eng
gine conttrol unit ECU (eq
quipped
with YU
UCHAI T3
T engine) e)
Engine con ntrol unit iss an electriic control mechanism
m
of the engiine. It is used to receivve messages from the
engine seensor, conttrol the eengine run nning and
communicate with thee other partss of the macchine.
E-ECU
Fig. 3-13E
19
W Loa
ader
20
Service M
Manual of Wheel
W Loa
ader
DPSCJ_ED
DC17BASIC
C_T30_整车线束原理图 DPSSCJ_EDC17 7BASIC_T330_overall vehiclee
_V1.0 wiring harness diagram_V V1.0
K-XX=整车车端 K-X
XX=overall vehicle endd
电源- Pow
wer supply +
电源+ Pow
wer supply -
占火开关接 ON 档 Ignition switch connectingg ON gear
起动控制开开关接 STTART 档 Starrt control sw
witch conneccting STAR RT gear
K线 K wire
w
通讯 CANNH Commmunication n CAN H
通讯 CANNL Commmunication n CAN L
诊断标定接接口 Diaggnosis calibbration interrface
与其它控制制器通信接接口 Commmunication n interface wwith other controllers
c
发动机故障障指示灯电电源 Engine failure indicator
i lammp power supply
s
发动机故障障指示灯回回路 Engine failure indicator
i lammp circuit
电源输出 Pow
wer output
冷起动预热热指示灯 Coldd start preheeating indiccator lamp
主刹车开关关 Main brake swiitch
踩下刹车接接通 Presss on brake for connecttion
副刹车开关关 Auxxiliary brakee switch
踩下刹车断断开 Presss on brake for disconnnection
诊断请求开开关 Diaggnosis requeest switch
离合器开关关 Cluttch switch
空档开关 Neuutral positionn switch
踩下离合断断开 Deppress clutch for disconnnection
巡航控制调调整开关+ Cruiise control adjustment
a switch +
巡航控制调调整开关- Cruiise control adjustment
a switch -
巡航控制停停止开关 Cruiise control stop
s switch
巡航控制使使能开关 Cruiise control enabling
e sw
witch
预热控制继继电器 Prehheating conttrol relay
水报警指示示灯（LED D） Water alarm ind dicator lampp (LED)
汕水报警开开关 Water overflow w alarm indiccator lamp
辅助起动开开关 Auxxiliary start switch
远程油门使使能开关 Remmote accelerrator enablinng switch
空调请求开开关 Air conditionin ng request sw witch
电源输出（地）（V10） Pow
wer output (g ground) (V110)
多功能开关关地线 Mulltifunctionall switch groound wire
多功能开关关信号 Mulltifunctionall switch signnal
多功能开关关各电阻特特性 Elecctrical resistance properrties off
multtifunctionall switch
车速传感器器信号 Vehiicle speed sensor signaal
车速传感器器 Vehiicle speed sensor
车速传感器器回路 Vehiicle speed sensor circui uit
电源输出 Pow
wer output
21
W Loa
ader
燃油预热继继电器 Fuell preheatingg relay
起动控制继继电器 Starrt control rellay
电源输出 Pow
wer output
风扇控制继继电器 1# Fan control relaay 1#
风扇控制继继电器 2# Fan control relaay 2#
油门 1 回路
路 Accelerator 1 circuit
油门 1 信号
号 Accelerator 1 siignal
油门 1 电源
源 Accelerator 1 power supply ly
油门 2 信号
号 Accelerator 2 siignal
油门 2 电源
源 Accelerator 2 power supply ly
主油门踏板板 Main accelerato or pedal
油门 2 回路
路 Accelerator 2 circuit
远程油门 1 信号 Remmote accelerrator 1 signaal
远程油门 2 信号 Remmote accelerrator 2 signaal
远程油门踏踏板 Remmote accelerrator pedal
发动机转速速输出脉冲冲信号 Engine speed output pulse signal
22
Service M
Manual of Wheel
W Loa
ader
324 Poly
ymorphicc fuel-savving switch
The engine has threee working m mode: full load, half
load and no
o load. The polymorphhic fuel-saving switch
controls the
t enginee to seleect differen nt output
according to
t different working coonditions to save fuel.
The resisttance valuee might bee detected to judge
whether the switch is damaged.
Full load
Half load
No- load
Fig. 3-144 Connecttors and schematic

s
diagram of polymmorphic fu uel-saving
switch
23
Service M
Manual of Wheel
W Loa
ader
325 Elecctronic accceleratoor pedal

The engin ne throttle is controllled by an electronic
acceleratorr pedal. The protectionn function is applied
to limit thhe maximu um engine speed at 1000r/min
when abn normal outtput signall of the electronic
acceleratorr is detected
d.
As shown n in the figgure, the eelectronic accelerator
a
pedal is co
omposed of power cordd, ground leead as well
as APS1 anda APS2 signal outpput lines. The T output
voltage of APS1
A is abo
out 2 times of APS2.
Electrical characteristi
c ics
Working voltage (ACC
C1, ACC2) : ±5.5V
Rated curreent (APS1, APS2) : ±1 0mA
Allowable duration of
o instantanneous short circuit to
ground of APS1
A and 2:
2 20Min maax
o instantanneous short circuit to
Allowable duration of
ply of APS1
power supp 1 and 2: 20M
Min max
Relation off APS1 and APS2 outpu
put voltage:
Synchrono
ous deviation
n between A
APS1 and APS2
A (SY)
SY=( APS1 /2)－APS
S2＝±0.07V
V
Fig. 3-155 Pins andd output features of

electronicc acceleratorr pedal
24
Service M
Manual of Wheel
W Loa
ader
326 Batttery
Maintenan
nce-free lead-acid battteries are adopted
a to
loader.
Main param
meters:
Rated voltaage: 12V
Rated capaacity of 20h: 120A.h
Reserve caapacity: 230
0min
Low tempeerature startting current : 850A
Open circu uit voltage: Open cirrcuit voltag
ge of new
battery: 12
2.5 V to 12.9
9V
Figure 3-16 Battery
Common ffaults of baattery

Fault Phenomenon
P n Meaasure
Short circuuit Battery
B volltage drop
ps by inteegral Repllace
multiples
m of 2.
Open circuuit Fault
F of charrging and diischarging Repllace
Capacity reeducing seelf-dischargge Repllace
Overcharge Reducing
R off electrolyte level Repllace
25
W Loa
ader
327Geneerator
Alternator is a mechhanism to ssupply pow wer to the
battery and the mach hine. Theree are threee types of
generators for accordding to diffferent eng
gines. The
generator has
h three terrminals: B+
+, D+ and W.
W
Figure 3-17weichai Alternator
Figure 3-18 yuchai Alternator

A
26
Service M
Manual of Wheel
W Loa
ader
Generator specificatioon:
Sppecification
n Functionn Functio
on Funcction of term
minal W
of of
terminal B terminaal D
Equipped with 288V-55A Chargingg Chargee
Weichai T3 indicatting
engine
Equipped with 288V-70A Chargingg Chargee
yuchai T3 engine indicatting
Methods annd measurees for judgin

ng whether ppower geneeration of th
he generatorr is proper:
1. Checkk with 200V V DC voltage of a m multimeter. Unlock thee electric loock. Measu ure terminall
voltagge of the generator (con nnecting thee red probe to D+ of thhe generatorr; connectin
ng the blackk
probee to the ground). Record reading of the multimeter (thee reading iss actually th he terminall
voltagge of the baattery. It is usually
u less than 26V).. Start the machine
m andd measure the
t terminall
voltagge of the generator
g ag
gain. Recorrd reading of the mu ultimeter (itt the generrator workss
propeerly, the reaading should d about 28V V). The seccond readin ng should bbe higher thhan the firstt
readinng.
2. If the generator does
d not gen
nerate poweer:
2.1 Firstly,, check wheether the tran
nsmission bbelt of the generator
g is too loose.
2.2 Close the electriic lock. Ch heck wheth er the wiriing operato
or of the ggenerator is connectedd
correctly, ssecurely andd reliably.
2.3 Check whether thee generator is groundedd reliably.
2.4 If the pproblem still can't be solved,
s pleaase replace the generattor or contaact professio
onals of thee
manufacturrer.
27
Service M
Manual of Wheel
W Loa
ader
328 Starrter
The starterr transfer ellectric energgy of the battery into
mechanicaal power to drive the fllywheel of the t engine
and finallyy rotate thee crankshaftft of the enngine. it is
equipped with threee modes of starteer motors
according to differen nt engines sso that theeir starting
controls arre also differrent.
Fig. 3-19 Starter
Diagnosis and removaal of commo

on fault of sstarter
The starterr refuses to work
w
The starterr refuses too work when it is connnected to po ower and sw witched onn. It might because
b thee
starting rellay or the sttarting switcch is disconnnected, or there
t is an open
o circuit in the connnecting wiree;
if the startter still refuuses to workk after trouubleshootingg, there is a fault insidde the starteer; Possiblee
reasons aree fault in thee solenoid coil
c of starteer electromagnetic switch, burningg of the eng gine switch,,
poor contaact or open circuit
c in thee brush, commmutator, armature,
a magnetic
m fielld of the mo
otor.
Insufficiennt power of starter
Although tthe starter can
c drive th he crankshaaft of the engine,
e the speed is tooo low that the enginee
cannot be started smoothly. It means
m that the loading g capacity is reduced and the acctual outputt
power is ddecreased. Possible
P reassons are feeed of battery
y, loosenesss of battery terminal, poor
p contactt
caused by oxidation and
a corrosio on, burning of commutaator, excesssive wearingg of brush, insufficientt
spring forcce, local short circuit of
o motor arrmature and d field windding, excesssive starting
g resistancee
caused by ttightness off engine asssembly and low environ nment temp perature.
The starterr can't be stoopped
The starterr cannot stoop working when the ppower and th he starting switch are ddisconnecteed. Possiblee
reasons aree fault of thee power staarting switchh or starting
g relay or bo
onding of thhe engine sw
witch.
Idling of thhe starter
The starterr runs but thhe crankshaaft of the enngine refuses to rotate. Possible rreasons are slipping off
the one-waay clutch, disorder
d or clamping of the rotarry mechaniism, insuffiicient extru usion of thee
drive gear,, gear breakking or exceessive wearring of gearrs, loss of sh
hift rail, etcc. Replacing
g the clutchh
may removve the fault.
Too large sstarting noisse
Possible rreasons forr rhythmicc crash in starting are a open circuit of holding coil c in thee
electromaggnetic switcch, damage of
o starting rrelay, feed of
o battery, poor
p contactt of pole, ettc. Constantt
friction or howling soound mightt because daamage of bearing,
b bennding of arm
mature shafft, chamberr
sweeping oof motor cauused by roto
or out-of-roound, burninng of comm
mutator, poorr contact off brush, etc.
28
W Loa
ader
329 Sttarting sw
witch
As show wn in figure,, the startingg switch has four
gears off ON/HEAT T/ON/OFF aand six term minals of
B/BR/R R1 / R2 / C/A
ACC. Termiinal B/BR/A ACC are
connecteed at ON. Situations off other gearss might be
learnt in
n the same way.
w
Detectio
on method:
Methodss for judginng whetherr the electrric lock is
damaged d. Disconnect the wirre and elecctric lock.
Removee the electriic lock from
m the vehiccle. Check
Starting switch the digiital multim
meter at 2000Ω of resiistance. It
Location
Terminnal should be
b repaired or replaceed in case of
o fault in
conductiing.
Common faults of starting
s swittch :
1. The sttarting switch does nott response even
e if it is
switchedd on
Fault
Cause:
C Measu
ures
phenommenon
No response
r Out
O of touuch
Replace
after starting of
o contacts
Start after
Contact
C
being
cannot
c be Replace
Fig. 3-20S
Starting swiitch conneccted to
separated
s
power
Interrup
pted
Poor
P contactt Replace
starting
g
29
W Loa
ader
3210F
Fuel level sensor
The fuell level senso
or is mainlyy composed of sensor
float 1 and
a floater 2.2 There is a reed switch in the
sensor float.
fl
1 Floater 2 moves up and down aalong the seensor float
1 With the change of o liquid levvel, move up p and
down flo oat with chaange of the liquid levell. When
the floatter is in a ceertain positioon, switch of
o
2 correspoonding reed switch willl be turned on o to
connect correspond ding resistannce bank. Fo or
examplee, if switch K30 K is connnected, resisstance R1
to R30 is connected d to power. T The fuel gaauge
displayss a reading.
Comparison table for liquiid level, gear and
resistancce value
Oil lev
vel (H) Gear Resistaance (Ω)
95
9 Full tank] 6.2±
±0.6
27
74 6/8 19.2
2±0.8
1- sensor float 2 - floater 49
95 4/8 32..2±1
Fig. 3 -211 Fuel level sensor 74
47 2/8 55.6
6±1.4
87
75 1/8 80.4
4±1.6
10
002 Empty
E tankk 109
9.7±2
Detectio
on method::
 Shoort circuit method:
m Reemove the sense line
of the fuel level sensor. If the sen nse line is
bonnded, the instrument wwill show fulll range. If
the sensor is suspended,, the instru ument will
shoow the min nimum readding to refleect proper
connnection beetween the instrumen nt and the
circcuit. Any damaged sensor should be
rep
placed. Otheerwise, cheeck the circcuit. There
is a fault in the instrumennt if the circcuit works
prooperly.
 Ressistance meeasurement method: Reemove the
sen nd use multitimeter at a resistance
nsor plug an
of 200 Ω. Observe
O reaading chang ge of the
muultimeter and compare with the data
d in the
table above.
30
W Loa
ader
3211Pow
wer switch
The pow wer switch disconnects
d s the machin ne and the
battery voltage
v when the macchine is nott operated.
The pow wer switch is
i located onn the right side
s of the
rear framme. The baattery discoonnector is connected
to the caathode (24V
V) of the batttery.
The worrking environment tem
mperature iss - 40℃ -
75℃. The
T relativee humidity is not greeater than
90%.
Fault deetection metthod: Checkk on-off sittuations of
two term
minals of the power swwitch with a resistance
meter.
Fig. 3-22P
Power switcch
3212 Prressure swittch

The pressure switch mainly chhecks air pressure
p or
oil presssure of the machine syystem. It co
onnects or
disconneects the swwitch when the pressurre exceeds
specific value. it mainly havve pressuree switches
below:
Transmiission presssure switch YK215B1 is mainly
used to detect
d presssure of the tr
transmission
n. The low
transmisssion alarm lamp is on when the pressure
p of
the transsmission is too
t low.
Main paarameters:
1. Thee switch con
ntact is usuaally closed.
2. Thee contact is closed wheen the presssure drops
to 0.95±0.05M
0 MPa.
3. Ratted voltage: DC24V; raated power: 45W.
Reverse switch 310-LGK1 is installed on the

1 2 variable speed conntrol valve,, the reversse gear is
Fig. 3-23 displayeed on the panel accordding to chaange of oil
pressuree.
1. Reversing switch
Main paarameters:
2.Transmiission presssure switch
1. Thee switch con
ntact is usuaally opened
d.
2. Thee contact is opened whhen the presssure rises
to 0.7±0.05MP
0 Pa .
31
W Loa
ader
Brake laamp switch YK209KL LA is installled on the
brake vaalve. When n the brake pedal is steepped, the
brake lamp switch is i turned onn to connectt the brake
lamp cirrcuit and thee brake lamp
mp will be on
n.
Main paarameters:
1. Thee switch con
d.
2. Thee contact iss closed whhen the presssure rises
to 0.13±0.015M
0 MPa.
d voltage: DC24V; rateed power: 45
3. Rated 5W.
Fig. 3-24 Brake lampp switch
Parking brake switcch HFF-37557002 (YK2

210B)
Main paarameters:
1. Thee switch con
ntact is usuaally closed.
2. Thee contact is disconnectted when th
he pressure
risees to 0.4±0.0
025Mpa.
3. Rated
d voltage: DC24V; rateed power: 45
5W.
Fig. 3-25 Parking braake switch
Emergen ncy brake switch LY - 3720002 2 tests the

pressuree inside the gas tank. Itt forces park
king brake
when thhe pressure is lower thhan the saffety value.
The swittch is conneected to linee 54.
Main paarameters:
1. Thee switch con
d.
2. Thee contact iss closed whhen the presssure rises
to 0.3~0.4Mpa
0 a.
Brake prressure senssor YG901C C3 (equippeed with T3

engine) is installed d on the gaas tank to detect the
brake prressure and show it onn the brake barometer
of the paanel. The seensor is conn
nnected to lin
ne 18.
Detectinng the resisstance betw
ween terminnal G and
shell off the sensorr can judgee whether the
t sensor
32
Service M
Manual of Wheel
W Loa
ader
Fig. 3-266 Emergenncy brake switch andd works properly.
p Sp
pecific paraameters are shown as
brake pressure sensor below:
Pressuree (Mpa) 0 0.4 0.5 0.7 0.8 0.9 1

Referencce resistance (Ω) 20 59 70 87 92.5 100.5 107
Allowabble error (Ω)) ±1.5
5 ±3 ±5
3213 Torque
T co
onverter oil temp
perature
sensorr
Torque converter oil tem mperature sensor
s is
equipped d with WD DG1371 temmperature seensor. The
resistancce decreases with the rrise of temp
perature. It
is used to detect th he temperat
ature of the hydraulic
oil in thee torque con
nverter.
Changess of tempeerature and electrical resistance
wn in the folllowing tablle
are show
Temperature (℃) 40 50 60 80
Resistaance (Ω) 351 2226 153 76
Temperature (℃) 100 1115 120
0 140
Resistaance (Ω) 40.4 226.4 23 13.6
Method of fault diaagnosis:
Fig. 3-27 Temperaturre sensor Short cirrcuit methood: Removee the sense linel of the
torque converter
c oill temperatur
ure sensor. Iff the sense
line is bonded,
b the instrument will show full range.
If the seense line is suspendedd, the instruument will
show th he minimu um readingg to reflect proper
connectiion between n the instruument and the
t circuit.
Any damaged
d sensor
s shoould be replaced.
Otherwiise, check th he circuit. T
There is a fault
f in the
instrumeent if the cirrcuit works properly.
Measureement meth hod: measurre the resisttance with
a multim
meter. Conn nect the redd probe to the small
screw on
o the senssor and boond the blaack probe.
Observee the resistan
nce changess with temp
perature.
3214E
Engine wa
ater temp
perature sensor
Engine water
w temperature senssor equippeed with T2
engine is the sam me with ttorque con nverter oil
temperature sensor.
33
Service M
Manual of Wheel
W Loa
ader
3215 Wiper
W and wiper m
motor
Figure 3-29
3 shows the interioor schematic diagram
and exteerior wiring
g diagram iss the wiperr. Function
of extern
nal wiring are
a shown inn the table below:
b
Red Yelloow
Black
Blue
Black
Line Function Color
White No.
Red White (slow)
(positive)
0 Ground
ding Black
24 Reset line of front w
wiper White
25 Low sppeed wiringg of front White
wiper
Fr
26 High sp
peed wiringg of front White
wiper
37 Power cord
c of fronnt wiper Red
Red
Black
White
Blue If the wiiper refuses to work:

1. Cheeck whetherr the fuse FF9 is fused.
2. Cheeck whether voltage off each functtional wire
is proper.
p
Fig. 3-288 Interior principle
p diagram
d andd
external w
wiring diagrram of wipeer 3. Cheeck whetherr the switchh works prop
perly.
4. If the
t circuit works
w propeerly, the mo
otor of the
wipper might be
b damagedd. Pease reeplace the
mootor.
3216P
Pilot hand
dle solenooid valvees
There arre floating solenoid vaalve, buckeet solenoid
valve an nd boom solenoid
s vaalve inside the pilot
handle. Internal reesistance vaalue of thee solenoid
valves iss 100Ω.
Figure 3-229 Solenoidd valves inside the piloot

handle
34
Service M
Manual of Wheel
W Loa
ader
32 Electtrical cirrcuit of machine

m e
321 Com
mparison
n table forr line Noo. and fun
nctions off the macchine
Comparisoon table forr line numb ber and funnctions of th
he machinee (for refereence only, it
i might bee
different frrom the actuual situation
n)
Line
Lin color Wire
W
Line color
e diamet
d Name Reemark
(colorful) (mmonoch
no. er
roomatic)
0 B
Black Black 5 Grround cable
01 B
Black Black 1.25 Grround wire of
o power supply
Groundd wire of
Black 0.85
02 B
Black Grround wire of
o inductivee load relay
Black 2
Black 0.85
Black 1.25 Light
03 B
Black Grround wire of resistive load Single
Black 2 temperaature
control harness
Black 1.25
04 B
Black Black 2 Grround wire of
o frame
Black 5
05 B
Black Black 0.85 Grround wire of
o switch
Black 0.85
06 B
o controllerr
Black 1.25
Black 1.25 Warm wind
w
07 B
o air condittioner
Black 3
0a Grround wire of
o engine
0b
0c Grround wire of
o instrumen
nt
0d
Grround wire ofo emergenccy steering
0e Black 0.85
hyddraulic oil temperature
t e sensor
1 R
Red Red 3 Wiire from relay to stator motor
2 Red 5 Terrminal wiree on fuse bo
ox
2A R
Red Red 5 Enngine chargiing line
2B Red 5 Enngine chargiing line
2C Bluue/Red Red 2 EC
CU power co
ord of engin
ne
2D R
Red Red 2 Pow
wer cord off shutdown relay
35
Service M
Manual of Wheel
W Loa
ader
2e Bluue/Red Red 1.25 Pow
wer cord off ECU ignition switch
2F R
Red Red 0.85 Pow
wer cord off battery relay
3 Lighht pink Red 2 Pow
wer cord off vehicle harrness
Brow
wn/Bla
4 W
White 1.25 Higgh beam wiire of rear headlamp
h
ck
Bluue/Blac
5 W
White 1.25 Loow beam wirre of rear heeadlamp
k
Whhite/Pur Coonnecting wire
w of right steering
6 W
White 0.85
ple lam
mp
Greeen/Ora
7 W
White 0.85 Coonnecting wire
w of left stteering lampp
nnge
Yellow/Br
8 W
w of brakee switch
oown
Bluee/Yello
9 W
w of reverse signal
w
Broown/Gr
10 W
White 1.25 Higgh beam wiire of front headlamp
h
eeen
Broown/Bl
11 W
White 1.25 Loow beam wirre of front headlamp
h
ue
Yelllow/Gr
12 W
w of horn button
eeen
Whhite/Yel Coonnecting wire
w of hand brake
13 W
White 0.85
llow sw
witch
White/Bro Siggnal line of engine
14 W
White 0.85
wn waater-thermom meter
White/Gre Coonnecting wire
w of oil thermometer
15 W
White 0.85
en of torque conv
verter
16
Purpple/Bla Siggnal line of transmissio
on oil
17 W
White 0.85
ck preessure
Purpple/Gre
18 W
White 0.85 Siggnal line of brake barom
meter
en
Yellow/Bl
19 W
White 0.85 Siggnal line of fuel gauge
aack
Purpple/Wh
20 W
White 0.85 Siggnal line of charging
ite
Coommon pow wer cord (20-way fuse,
Red
witth power sw
witch)
Redd/Yello R
Reserved pow
wer cord (20-way fuse,,
21 Red 1.25
w withou
ut power sw
witch)
P
Power cord of
o electric lock (8-wayy
Red
fuse)
36
Service M
Manual of Wheel
W Loa
ader
Pow
wer cord off flasher (20
00-way, with
th
21a Red
pow
wer switch))
Pow wer cord off roof lamp (20-way
21B Red 0.85
fusse, with pow
wer switch)
Powwer cord off roof alarm
m lamp
21C Red
(200-way fuse, with powerr switch)
Yellow/W Wiire from eleectric lock to
o starter
22 W
White 0.85
hhite rel ay
Coonnecting wire
w of startin
ng
22a Bluue/Red W
White 0.85
prootection swiitch
22b Whiite/Red W
w of starteer
Coonnecting wire
w of start protection
p
22c Yeellow Red 1.25
wirre
23 Puurple W
White 0.85 Coontrol line of sprinkler motor
m
Yellow/Bl
24 W
White 0.85 Reeset line of wiper
w
ue
Yellow/Bl
24a W
White 0.85 Reeset line of rear
r wiper
ue
Broown/Ye
25 W
White 1.25 Loow speed wiire of wiper
lllow
Broown/Ye
25a W
White 1.25 Loow speed wiire of rear wiper
w
lllow
Greeen/Bla
26 W
White 1.25 Higgh speed wire of wiperr
ck
Greeen/Bla
26a W
White 1.25 Higgh speed wire of rear wiper
w
ck
27
Whhite/Blu
28 W
w of batterry relay coill
e
Greeen/Wh Puull in windin
ng of electricity
29 W
White 2
ite shuutdown
30 W
w of width
h lamp
Greeen/Bro
wn Coonnecting wire
w of rockeer switch
30A W
White 0.85
baccklight
Whhite/Bla Coonnecting wire
w of engin
ne oil
31 W
White 0.85
ck preessure alarm
m lamp
Greey/Blac Coonnecting wire
w of brakee pressure
32 W
White 0.85
k alaarm lamp
Purpple/Yel
33 W
White 0.85 Ouutgoing line of flash sig
gnal
llow
Broown/W
34 W
White 1.25 Siggnal of head
dlamp
hhite
37
Service M
Manual of Wheel
W Loa
ader
35 Red 1.25 Coonnecting wire
w of fuse box
b
Coonnecting wire
w of headllamp powerr
35A Redd/Black Red 1.25
suppply
35B Red 0.85 Baacklight pow
wer supply cord
c
36 Red Coonnecting wire
w of fuse box
b
3
36A Red Airr conditioneer power supply
36B Red 1.25 Fann power sup
pply (20-waay fuse)
R
Red
Fann heater pow
wer supply (20-way
36C Red 1.25
fusse)
36D Red 1.25 Flaasher powerr supply (8-way fuse)
w of fuse box
b
37A Red Pow
wer cord off wiper
37B Red Pow
wer cord off wiper rock
ker switch
Pow
wer cord off sprinkling can rocker
37C Orannge/Re Red
1.25 sw
witch
d
37D Red Pow
wer cord off radio (8-w
way fuse)
37E Red Pow
wer cord off roof lamp (8-way fusee)
Pow wer cord off roof alarm
m lamp
37F Red
(8--way fuse)
Coonnecting wire
w of fuse box
b
Red
(211-way, pow
wer switch)
38
Power cord
d of flasher (21-way,
Red
withouut power swwitch)
Whiite/Red 1.25 Powwer cord reeserved for cold
c start
38A Red
(211-way fuse, with powerr switch)
Pow wer cord off safety lock
k (21-way
38B Red
fusse, with pow
wer switch)
38C Red Reeserve poweer supply intterface
39 Blacck/Red Red 1.25 Pow
wer supply of headlam
mp
w of fuse box
b
40A Red Pow
wer cord off horn
Redd/Black 0.85
40B Red Pow
wer cord off brake
40C Red Pow
wer cord off reversing
40D Puurple Red 0.85 Ouutgoing line of horn relay
Red Coonnecting wire
w of fuse box
b
41 P
Power cord of radio(21-way fuse,
Broown/Re Red
1.25 with power swittch)
d
Pow wer cord off roof lamp (20-way
41A Red
fusse, without power
p switcch)
38
Service M
Manual of Wheel
W Loa
ader
Powwer cord off roof alarm
m lamp
41B Red
(200-way fuse, without power switch))
Powwer cord off radio (20-w
way fuse,
41C Red
witthout powerr switch)
Pow wer cord off pilot valvee (fuse
42 Red 1.25
loccation)
L
Light
Powwer cord off pilot valvee (pilot
42A pinnk/Red Red 0.85
vallve location
n)
42B Red 0.85 Pow
wer interfacce of proxim
mity switch
Redd/Brow
43 W
White 0.85 Pow
wer cord off stopwatch
n
E44 G
Green W
White 0.85 Siggnal line of preheat ind
dicator
Redd/Brow
44 Red 1.25 Pow
wer cord off combinatio
on switch
n
Red Coonnecting wire
w of fuse box
b
45
Red Pow
wer supply of rear headlamp
Roocker switch
h of fan heatter (8-way
45A Green/Red Red 1.25
fusse)
Pow wer supply of electric fan (8-way
45B Red
fusse)
46 Redd/Green Red 1.25 Pow
wer cord off brake solen
noid valve
47 Redd/Grey Red 1.25 Pow
wer cord off rear hood downlight
d
Powwer cord off transmissio
on control
48 Redd/Blue Red 0.85
boxx
Greey/Yell
49 W
White 0.85 Siggnal line of high beam
ow
White/Gre
50 W
White 0.85 Siggnal line of low beam
y
51
Brow
wn/Bla Coonnecting wire
w of compputer box
52 W
White 0.85
ck woork indicator lamp
Greeen/Blu
53 W
w of fan heater
e
Broown/Gr Wiire from emmergency braake to handd
54 W
White 0.85
eeen braake switch
Broown/Bl Wiire from braake solenoid
d valve to
55 W
White 0.85
ue hannd brake sw
witch
56 Red 5 Pow
wer cord off machine
R
Red
56A Red 2 Coonnecting wire
w of fuse box
b
56a R
Red Red 5 Po sitive wire of battery
56b R
Red Red 5 Wiire from relay to electriic pump
39
Service M
Manual of Wheel
W Loa
ader
56c R
Red Red 5 Wiire from fusse to relay
56d R
Red Red 5 Po sitive wire of battery
57 W
White W
White 0.85 Siggnal line of power shuttoff
Coonnecting wire
w of poweer shutoff
57a Brrown W
White 0.85
baccklight
58 A
Ash W
White 0.85 Siggnal line of reversing
59 Lighht pink W
White 0.85 Siggnal line of start interlo
ock
Wiire from eleectric lock to
o start
60 Yeellow W
White 0.85
intterlock relay
y
E61 R
Red W
White 0.85 Siggnal line of preheater reelay
Bluue/Blac Coonnecting wire
w of preheeat indicatorr
61 W
White 0.85
k lam
mp
Broown/W Wiire from intermediate relay to
62 W
White 0.85
hhite sollenoid valvee (boom)
E63 B
Blue W
White 0.85 Siggnal line of fault indicaator
Broown/Ye Wiire from intermediate relay to
63 W
White 0.85
lllow sollenoid valvee (bucket)
Greeen/Bla Coonnecting wire
w of proxiimity switchh
64 W
White 0.85
ck (booom)
Greeen/Blu Coonnecting wire
w of proxiimity switchh
65 W
White 0.85
e (buucket)
66 W
White W
White 0.85 Siggnal line of water level alarm
67 R
Red W
White 3 Coonnecting wire
w of heateer
67a R
Red W
White 4 Coonnecting wire
w of heateer
68 Yeellow W
White 0.85 Siggnal line of oil cut-off valve
v relay
69 W
White W
White 0.85 Siggnal line of oil cut-off valve
v relay
70 W
White W
White 0.85 Siggnal line of variable pu
ump
Greeen/Yel
71 W
w of rear illuminator
llow
Bluue/Gree
72 W
w of roof alarm
a lamp
n
White/Ora Coonnecting wire
w of working hour
73 W
White 0.85
nnge meeter:
Bluue/Oran
74 W
w of headllamp
ge
Greeen/Wh
75 W
White 0.85 Siggnal line of rear illumin
nator
ite
76 Redd/Green Red 0.85 Pow
wer supply of defroster
77 R
Red Red 1.25 Pow
wer cord off spare electtrical outlet
78 Redd/Grey Red 0.85 Pow
wer cord off coarse filteer
40
Service M
Manual of Wheel
W Loa
ader
Bluue/Whit
79 W
White 0.85 Siggnal line of rear headlaamp
e
80 Redd/Blue Red 0.85 wer supply of instrumeent lamp
Pow
Lighht
81 W
White 0.85 Siggnal line of vehicle speeed
greeen
82 R
Red W
White 0.85 Siggnal line of coarse filter alarm
Greeen/Wh
82a W
White 0.85 Siggnal line of coarse filter alarm
ite
Siggnal line of transmissio
on oil filter
83 W
White W
White 0.85
bloocking
84 W
White W
White 0.85 Siggnal line of temperaturee switch
85 Green/Red W
w of quick
k change
L
Light
86 W
w of quick
k change
pinkk/Black
Coonnecting wire
w of quick
k change
87 B
Blue W
White 0.85
buzzzer
88 W
White W
White 0.85 Siggnal line of water level switch
Coonnecting wire
w of preheeating waterr
89 G
Green W
White 0.85
tem
mperature seensor
Redd/Orang
90 W
White 0.85 Pow
wer cord off quick chan
nge button
e
Whhite/Bla Coonnecting wire
w of preheeating
91 W
White 1.25
ck conntroller
Greeen/Wh
92 W
White 1.25 Wiire from eleectric lock to
o preheater
ite
93 R
Red W
White 5 Pow
wer cord off preheater
94 R
Red W
White 5 Pow
wer cord off preheater
Coonnecting wire
w of safety
y lock
95 Yeellow W
White 1.25
sollenoid valvee
L
Light
96 W
White 0.85 Siggnal line of emergency steering
greeen/Red
Bluue/Gree
97 W
White 1.25 Siggnal line of defrost
n
98 Blacck/Red W
White 0.85 Siggnal line of alarm
Yelllow/Re
99 W
White 0.85 Siggnal line of mute
d
Black/Bro Wiire from waaiting to starrt indicator
100 W
White 0.85
wn lam
mp to compu uter box
Black/Gre
101 W
White 0.85 Siggnal line of tachometerr
en
Blaack/Blu Wiire from alaarm indicato
or lamp to
102 W
White 0.85
e com
mputer box
41
Service M
Manual of Wheel
W Loa
ader
Black/Ora Wiire from parrking indicaator lamp too
103 W
White 0.85
nnge com
mputer box
Pow wer cord off fault diagn
nosis
104 Redd/White W
White 0.85
intterface
Redd/Yello
105 W
White 0.85 OE
EM power cord
c
w
Grey/Whit
106 W
White 1.25 19339 data cable
e
L
Light
107 pinkk/Gree W
n
L
Light
108 W
pinkk/Black
Coonnecting wire
w of accelerator
109 Brrown W
White 1.25
possition senso
or
Coonnecting wire
w of accelerator
110 G
Green W
White 1.25
possition senso
or
Coonnecting wire
w of accelerator
111 B
Blue W
White 1.25
possition senso
or
Blacck/Yell
112 W
w of idling
g switch
ow
Greeen/Yel
113 W
w of idling
g switch
llow
114 R
Red W
White 5 Pow
wer cord
Greeen/Gre
115 W
w of diagn
nosis switchh
y
L
Light
Coonnecting wire
w of diagn
nosis pagingg
116 greeen/Blac W
White 0.85
sw
witch
k
L
Light Coonnecting wire
w of diagn
nosis pagingg
117 W
White 0.85
greeen/Blue sw
witch
118 W
White 0.85 Siggnal line of differentiall lock
Siggnal line of differentiall lock
119 W
White 0.85
inddicator lampp
L
Light
Coonnecting wire
w of intakee heating
120 greeen/Whi W
White 0.85
rel ay
te
121 Greey/Red Red 1.25 Pow
wer cord off electric locck
Coonnecting wire
w of intakee heating
122 Greey/Red W
White 1.25
rel ay
123 W
White 0.85 Siggnal line of language sw
witch
124
42
Service M
Manual of Wheel
W Loa
ader
125 Brrown W
w of speed
d sensor
Coonnecting wire
w of transm
mission oil
126 A
Ash W
White 0.85
preessure
127
128
129
Coonnecting wire
w of solen
noid valve
130 B
Blue W
White 0.85
M11
131
L
w of indep
pendent
132 W
White 0.85
greeen/Red coooling switch
h
Powwer cord off independent cooling
133 Redd/White Red 1.25
sysstem
L
w of transm mission oil
134 W
White 0.85
greeen/Red tem
mperature an
nd pressure
Coonnecting wire
w of solen
noid valve
140 Puurple W
White 0.85
M22
Po sitive signaal line of intercooler andd
141 Brrown W
White 0.85
conntroller
Broown/Re
142 W
White 0.85 Pow
wer cord off pilot transiition
d
Po sitive signaal line from water
143 G
Green W
White 0.85
tem
mperature seensor and co ontroller
Wiire from conntroller to in
ndependentt
144 W
White W
White 0.85
coooling valve block
Wiire from conntroller to in
ndependentt
145 A
Ash W
White 0.85
coooling valve block
Coonnecting wire
w of indep pendent
146 Puurple W
White 1.25
coooling rockerr switch to controller
c
Po sitive signaal line from intercooler
147 Yeellow W
White 0.85
to ccontroller
Neegative signal line from
m water
148 B
Blue W
White 0.85
tem
mperature seensor and coontroller
Coonnecting wire
w of solen
noid valve
150 Yeellow W
White 0.85
M33
Yellow/Bl
152 Red 1.25 Pow
wer cord off gas meter
ue
L
Light
153 W
White 1.25 Pow
wer cord off horn
ggreen
Yelllow/Re
155 Red 0.85 Pow
wer cord off reversing rearview
r
d
156 Lighht pink Red 1.25 Pow
wer cord off safety lock
k
43
Service M
Manual of Wheel
W Loa
ader
157 Yeellow W
White 0.85 Alaarm signal of
o oil-waterr separationn
Coonnecting wire
w of engin
ne fault
158 Brrown W
White 0.85
inddicator lamp
p
Coonnecting wire
w of air fillter alarm
159 G
Green W
White 0.85
inddicator lamp
p
Coonnecting wire
w of solen
noid valve
160 G
Green W
White 0.85
M44
161 Yeellow Red 1.25 Pow
wer cord off panel
Yelllow/Gr
162 Red 1.25 Reeserved pow
wer cord
eeen
Siggnal line of oil outlet prressure of
163 W
White 0.85
preessure signaal valve
Siggnal line of oil inlet preessure of
164 W
White 0.85
preessure signaal valve
Siggnal line of hydraulic oil
o
165 W
White 0.85
tem
mperature\
166 W
White 0.85 Siggnal line of emergency invalid
Coonnecting wire
w of solen
noid valve
170 Brrown W
White 0.85
M55
Siggnal line of ECU intakee heating
Ht+ W
White 0.85
rel ay
Grround electrrode of ECU
U intake
Ht- W
White 0.85
heaating relay
CAAN H signall line for
C_
W
White commmunicatioon between ECU and
H
thee machine
0.75*2
0
CAAN L signall line for
C_L W
thee machine
Shhield of CAN
N line for
C_
W
G
thee machine
MS EC
CU power su
upply/fuel-ssaving
W
White 0.85
+ sw
witch
MS- Ligght load wo
orking
W
White 0.85
/E conndition/fuell-saving gro
ounding
MS/
W
White 0.85 Staandard work
king conditiion
S
179
Coonnecting wire
w of solen
noid valve
180 W
White W
White 0.85
M66
Coonnecting wire
w of front axle coolinng
183 W
White W
White 0.85
sw
witch
44
Service M
Manual of Wheel
W Loa
ader
Coonnecting wire
w of front axle coolinng
184 W
White W
White 0.85
sw
witch
Coonnecting wire
w of axle cooling
c
185 W
White W
White 0.85
sollenoid valvee
Siggnal line forr partition of
o emergenccy
186 W
White 0.85
conntroller softtware
o emergenccy
187 W
White 0.85
o emergenccy
188 W
White 0.85
o emergenccy
189 W
White 0.85
Broown/Ye
210 W
White 0.85
lllow KD
D output lin
ne
Broown/Re
220 W
White 0.85 Pow
wer output line
d
Greeen/Yel
240 W
White 0.85 Ouutput line off forward geear
llow
Whhite/Yel
270 W
White 0.85 Ouutput line off speed
llow
Bluee/Yello
280 W
White 0.85 Ouutput line off speed
w
290 Green/Red W
White 0.85 Pow
wer cord
Purpple/Yel
310 W
White 0.85 Ouutput line off speed senssor
llow
Greey/Yell
320 W
White 0.85 Ouutput line off speed senssor
ow
321 B
Black W
White 0.85 Grround lead of
o time-delaay relay
Coonnecting wire
w of vibration oil
322 Orrange W
White 0.85
abssorption filtter element sensor
Greey/Bro Coonnecting wire
w of oil return filter
323 W
White 0.85
wn eleement senso
or
Greey/Gree Coonnecting wire
w of steeriing oil
324 W
White 0.85
n abssorption filtter element sensor
Coonnecting wire
w of transm
mission
325 Greey/Blue W
White 0.85
filtter sensor
Pow wer supply wiring of tiime-delay
326 Greey/Red W
White 1.25
rel ay
Grey/Whit Coonnecting wire
w of oscilllation
327 W
White 0.85
e staarting
Coonnecting wire
w of oscilllation
328 Redd/Pink W
White 0.85
staarting
45
Service M
Manual of Wheel
W Loa
ader
Bluue/Gree Coonnecting wire
w of low frequency
f
329 W
White 0.85
n vibbration valv
ve
Greeen/Yel Coonnecting wire
w of high frequency
330 W
White 0.85
llow vibbration valv
ve
Siggnal input of
o accelerato
or pedal
E7 W
White 0.75
possition senso
or 1
Siggnal input of
o accelerato
or pedal
E8 W
White 0.75
possition senso
or 2
E22 W
White 0.75 Siggnal line of starter relay
y
Powwer supply of acceleraator pedal
E24 W
White 0.75
possition senso
or 1
Grround electrrode of acceelerator pedaal
E25 W
White 0.75
possition senso
or 1
Powwer supply of acceleraator pedal
E27 W
White 0.75
possition senso
or 2
Grround electrrode of acceelerator pedaal
E28 W
White 0.75
possition senso
or 2
Note: accoording to thee requiremeents of the sstandard GB B/T22353-2008, wire oor cable con nnecting thee
battery andd total fuse,, alternator and motor should be red.
r On this basis, wiree connecting g the anodee
of battery, charging liine, electric wire of thee vehicle, ouutgoing linee for powerr supply of fuse shouldd
be red. Thee ground eleectrode shou uld be blackk. All other wires shou
uld be whitee.
46
Service M
Manual of Wheel
W Loa
ader
332 Wiriing diagrram of the overalll unit

6 11 30 1 CN14-B
5 10 6 2 前右组合灯
4 0 0 3
接喇叭
150
200
0
153 0
153 1 2
300
CN10-B
CN10--B 快换装置接口
200 插孔号线号
1 0
2 85
3 86
4 87
600
CN12-A
插孔号
插线号 CN11-B 接近开关
1 0 孔位号 1 2 3 4 5 6 7 8 9 10 11 12 13 14
2
150
42
3 64 线序号 6 7 10 11 30 42 64 65 85 86 87 153
4 65
CN12-A 与仪表台线
线束的接口
200
3 2 1
200 700 7
1
10
6
9
5
8
4
0
接车架 144 13 12 11
350
200 接喇叭
0 153 0
153 1 2
150
前左组合灯
6 11 30 1
CN133-B 5 10 7 2
4 0 0 3
图 3-32 Wiring
g of the fron
nt frame（T3）
47
W Loa
ader
前右组合灯灯 Righht front com

mbination ligght
接喇叭 Connnecting horrn
CN10-B 快
快换装置接口 CN1 10-B quick change devvice interfacce
CN11-B 接
接近开关 CN1 11-B proximmity switch
插孔号 Jack
k No.
线号 Wiree No.
插孔号 Jack
k No.
线号 Wiree No.
孔位号 Holee site No.
线序号 Wiree serial No.
接车架 Connnecting framme
CN12-A 与
与仪表台线束的接口 Interrface betweeen CN12-A A and instru
ument panell
wiring harness
接喇叭 Connnecting horrn
前左组合灯
灯 Leftt front combbination lighht
48
20
接发电机
右尾灯
CN18-B 0 9 8
变速箱压力开关变矩器油温传感器
15 30 6
CN24-B
与仪表台线束接口
CN1-A
2b
线号 4 0c 6 7 8 30 40 46 2 孔位号 1 2
线号 17 0
孔位号 1 2 3 4 5 6 7 8 9 10 11 12 13 14
2a
CN3-A
线号 13 Ht+ 15 17 18 19 20 Ht- 61 54 55
ader
孔位号 1 2 3 4 5 6 7 8 9 10 11 12 13 14
CN1-A CN3-A CN4-A CN2-A
Loa
3 2 1 3 2 1
7 6 5 4 7 6 5 4
10 9 8 10 9 8 56 0
Manual of Wheel
14 13 12 11 14 13 12 11
W
倒车开关接口
倒车关接
B CN63-B 孔位号 1 2
A 线号 40 9
CN63-B
孔位号 1 2
49
线号 0 2f
左尾灯 CN19-B
Service M
孔位号 1 2 0 9 8
线号 46 55
制动电磁阀 2f 30 7
0c
55 2
46
CN15－B
0
1 2 3
13
停车制动指示开关
孔位号 1 2 3
61 56 线号 0 4 9
EA24
紧急制动开关制动气压传感器
E37 接预热继电器线圈
0 1
0 3 56a
54 18 CN26-B 0c 19
油位传感器
接蓄电池正极
Service M
Manual of Wheel
W Loa
ader
与仪表台线线束接口 Interrface with instrument ppanel wiring
g harness
线号 Wiree No.
线号 Wiree No.
线号 Wiree No.
制动电磁阀阀 Brakke solenoid valve
停车制动指指示开关 Park
king brake indicator sw witch
紧急制动开开关 Emeergency brak ke switch
线号 Wiree No.
制动气压传传感器 Brakke pressure sensor
线号 Wiree No.
线号 Wiree No.
倒车开关接接口 Reversing switcch interfacee
线号 Wiree No.
变矩器油温温传感器 Torqque converter oil tempeerature senssor
接发电机 Connnecting gen nerator
右尾灯 Righht taillight
线号 Wiree No.
左尾灯 Leftt taillight
接预热线电电器线圈 Connnecting preheating relaay coil
接蓄电池正正极 Connnecting batttery anode
线号 Wiree No.
Figure 3-33 L936 rearr frame wiriing harness (equipped with
w T3 eng gine in Chinna)
50
接发电机 2b
20
右尾灯
CN18-B 0 9 8
变速箱压力开关变矩器油温传感器
15 30 6
CN24-B
gine in Brazzil)
CN1-A
2b
线号 4 0c 6 7 8 30 40 40
46 59 60 孔位 1 2
孔位号
线号 17 0
孔位号 1 2 3 4 5 6 7 8 9 10 11 12 13 14
2a
CN3-A
接近开关
线号 13 Ht+ 15 17 18 19 20 Ht- 61 54 55
针脚号线号
孔位号 1 2 3 4 5 6 7 8 9 10 11 12 13 14 A 60 C
ader
B 0 B A
CN1-A CN3-A CN4-A CN2-A C 59
w T3 eng
3 2 1 3 2
Loa
1
7 6 5 4 7 6 5 4
10 9 8 10 9 8 56 0
Manual of Wheel
14 13 12 11 14 13 12 11
Figure 3-344 L936 rearr frame wiriing harness (equipped with

W
倒车开关接口
B C D 孔位号 1 2
A 线号 40 9
51
CN19-B
左尾灯
Service M
孔位号 1 2 0 9 8
线号 46 55
制动电磁阀 30 7
0c
a
55 b
46
50 CN15－B
0
1 2 3
13
停车制动指示开关孔位号 1 2 3
61 56 线号 0 4 9
Ht+
制动低压报警开关
紧急制动开关 CN39-B
Ht- 接预热继电器
0 1 56a
0 3
54 0c 19
孔位号 1 2 CN26-B
线号 18 0 油位传感器
接蓄电池正极
Service M
Manual of Wheel
W Loa
ader
与仪表台线线束接口 Interrface with instrument ppanel wiring g harness

线号 Wiree No.
线号 Wiree No.
线号 Wiree No.
制动低压报报警开关 Loww pressure warning
w swittch of brakee
线号 Wiree No.
针脚号 Pin No.
N
线号 Wiree No.
接近开关 Proxximity switcch
线号 Wiree No.
倒车开头接接口 Reversing switcch interfacee
线号 Wiree No.
油位传感器器 Oil level
l sensorr
接预热继电电器 Connnecting preheating relaay
接蓄电池正正极 Connnecting batttery anode
线号 Wiree No.
52
接发电机 2b
20
右尾灯
CN18-B 0 9 8
变速箱压力开关变矩器油温传感器 30 6
15
CN24-B
2b
CN1-A
线号 4 0c 6 7 8 9 30 40 2 孔位号 1 2
线号 17 0
孔位号 1 2 3 4 5 6 7 8 9 10 11 12 13 14
2a
CN3-A
线号 13 Ht+ 15 17 18 19 20 Ht- 61 54 55
孔位号 1 2 3 4 5 6 7 8 9 10 11 12 13 14
CN1-A CN3-A CN4-A CN2-A
3 2 1 3 2 1
7 6 5 4 7 6 5 4
10 9 8
Fig
10 9 8 56 0
14 13 12 11 14 13 12 11 CN63-B
CN63-B
孔位号 1 2
线号 0 2f
B C D
A
350
Service M
2f
保险
CN19-B
左尾灯
53
孔位号 1 2 0 9 8
线号 40 55
制动电磁阀 2 30 7
0c
Ø8
W
a
55 b
40
CN15－B
Manual of Wheel
0
1 2 3
13
Loa
停车制动指示开关孔位号 1 2 3
61 56 线号 0 4 9
ader
gure 3-35L9338 Wiring off the rear fraame

Ht+
制动低压报警开关
紧急制动开关 CN39-B 接预热继电器
Ht-
0 3 1 56a
0 CN26-B
54 孔位号 1 2 0c 19
线号 18 0
油位传感器
W Loa
ader
变矩器油温温传感器 Torqque converter oil tempeerature senssor
变速箱压力力开关 Trannsmission pressure swittch
与仪表台线线束接口 Interrface with instrument ppanel wiring g harness
线号 Wiree No.
线号 Wiree No.
线号 Wiree No.
保险 Fusee
线号 Wiree No.
线号 Wiree No.
接预热继电电器 Connnecting preheating relaay
油位传感器器 Oil level
l sensorr
制动低压报报警开关 Loww pressure warning
w swittch of brakee
线号 Wiree No.
停车制动指指示开头 Park
54
0 暖风机风门
快换按钮接线
51 36
静音警顶灯
0 90 86 90 85 背光灯前大灯警示灯开关 0 暖风机
42 53
85 背光灯背光灯
背光灯背光灯
63 87
uipped with T3 Weichaii engine in China)

背光灯孔位号 1 2
1
5
+
0 -
+
-
21 6
7 5
2
33 1
空调
1
0 +
-
1
0 +
-
4
3
7
2
8
2
5
42 接GPS键盘线号 36 0
30
21
33
72
72
30
6
0
35
35
30
30
49
30
30
35
30
30
50
35
86
0 +
-
1
0 5
99 2
0 6
30
99
87 CN66-B CN97-B
62
CN97-B
42
C
快换按钮孔位号线号 CN21-B
50 50 1 21
50 孔位号 1 2 预留电源口
3 4 2 232T 线号 38 0
0 42 50 50 85 90 3 232R
50
4 0 CN20-B
50 86 1 90
2
63 42 孔位号 1 2
50 线号 77 0
0
62 42 50 点烟器
77
与先导阀接口孔位号 1 2
g
wiring
4 5 6
42 42 42 线号 0 46
CN76-B CN83-A
63 62 0
3 2 1 55 CN84-A
50 孔位号 1 2
23
23
5 37
30
6 37
与先导阀接口
37
25
24
37
25
24
+ 30
26
26
51
51
- 0
- 0
30
36
36
- 0
1 39
74
30
30
74
2 39
5 45
6 45
79
79
53
53
36
6 36
30
+ 0
- 0
0
50 线号 0 44 7 6
1
54
Quicck change button

2
6
4
+
5
8
3
6
1
+
-
1
1
2
6
1
2
背光灯
+
+
-
5
utton
背光灯背光灯背光灯 8 5
接手制动开关背光灯
ader
背光灯
前刮雨器前喷水壶驾驶室前工作灯后工作灯暖风机开关暖风机风门
9 4
bu
CN5 B
CN5-B 10 3
b
CN6-BB
CN6
Loa
插孔号线号插孔号线号接发动机线束 11 2

1 C_H 4 13 CN96-B
nge-over
2 C_L 6 17 孔位号线号 12 1
4 20 8 49 接启动开关 1 21
Manual of Wheel
5 12 2 46
CN90-B
klight
6 15 13 61 3 0
8 50 121 22 CN30-B 接GPS
19 21 99 4 C_L 插孔号线号
9 18 22 30
CN96-B
50 5 C_H 1 C_H
W
10 0c
喇叭按钮 12 28
7 232T 2 C_L
11 7
Mutte
8 3 C_G
Back
232R
12 6 CN31-B
CN31 B 4 0
nel wiring hharness (equ

25 24 37
Cha
17 21 CN5-B 5
18 80 0 26 6 28
20 0c 7 56
8
55
50 接雨刮电机
9
接仪表盘 CN23-B 10 22
E F H 11 Ht-
7
50 33 转向开关 12 Ht+
6
Service M
CN6-B
3 2 1 3 2 1 3 2 1
CN9-B CN9-B 与驾驶室线束接口插孔号线号插孔号线号 7 6 5 4 7 6 5 4 7 6 5 4
1 36 8 10 9 8
56
10 9 8 10 9 8
1 2 3
2 34 9 14 13 12 11 14 13 12 11 14 13 12 11 36
50 4
8
5
9
6
10
7
3 21 10
4 0 11 71 CN7-A CN8-B
11 12 13 14
CN10-A CN11-A CN22-A
5 41 12 72
0 接喷水壶 6 13 插孔号线号插孔号线号插孔号线号
7 14 1 79 1 153 1 79
23 2 4 2 40 2 71
3 45 3 41 3
4 74 4 37 4 64
Figure 3-35 L936 Insttrument pan

CN29-B 刹车开关 5 34 77
5 80 5
6 39 6 28 6 62 CN10-A,CN11-A,CN22-A
7 50 7 33 7 65
孔位号 1 2 11
8 8 21 8 46
线号 40 8
35 63
与前车架线束接口 9
49
9 121 9
10 10 10
CN12-B 1 2 3 11 10 11 11
4 5 6 7
12 12 12 0 12
与前车架线束接口 8 9 10
11 12 13 14
13 13 2 13 42
14 14 44 14 38
孔位号 1 2 3 4 5 6 7 8 9 10 11 12 13 14
线序号 6 7 10 11 30 42 64 65 85 86 87 153
切换按钮接接线
CN1-B
A 线号 2 4 0c 6 7 8 22 30 40 46
快换按钮
B
孔位号 1 2 3 4 5 6 7 8 9 10 11 12 13 14
背光灯
CN3-B
线号 13 Ht+ 15 17 18 19 20 Ht- 61 54 55
静音
1 2 3 1 2 3
4 5 6 7 4 5 6 7
孔位号 1 2 3 4 5 6 7 8 9 10 11 12 13 14
CN1-B 8 9 10 CN3-B 8 9 10
11 12 13 14 11 12 13 14 CN2-B 0 CN4-B 56
与后车架线束接口
W Loa
ader
与先导阀接接口 Interrface with pilot
p valve
p valve
接手制动开开关 Connnecting han nd brake swwitch
前刮雨器 Fronnt window wiper
w
背光灯 Back klight
前喷水壶 Fronnt sprinkler
插孔号 Jack
k No.
线号 Wiree No.
插孔号 Jack
k No.
线号 Wiree No.
接启动开关关 Connnecting starrt switch
喇叭按钮 Horn n button
接仪表盘 Connnecting insttrument pannel
接雨刮电机机 Connnecting win ndow wiperr motor
转向开关 Steeering switch
h
与驾驶室线线束接口 Interrface with cab
c wiring hharness
接喷水壶 Connnecting sprinkler
刹车开关 Brakke switch
线号 Wiree No.
与前车架线线束接口 Interrface with front
f frame wwiring harn
ness
f frame wwiring harn
ness
线序号 Wiree serial No.
与后车架线线束接口 Interrface with rear
r frame w wiring harneess
线号 Wiree No.
线号 Wiree No.
线号 Wiree No.
c wiring hharness
驾驶室前工工作灯 Fronnt work lighht of cab
后工作灯 Rearr work lightt
暖风机开关关 Fan heater switch
暖风机风门门 Fan heater doorr
线号 Wiree No.
56
0 暖风机风门
快换按钮接线
51 36
0 90 86 90 85 0 暖风机
42 53
uipped with T3 Weichaii engine in Brazil)

警示灯
63 孔位号 1 2
42
背光灯
线号 36 0
空调
ness
30 +
0 -
33 15
72
33 6
CN66-B
6
62
wiring harn
42 快换按钮 CN21-B
50 50
3 4 线号 38 0
0 42 85 90
50
86 1 90 CN20-B
50 2
63 42 孔位号 1 2
50 线号 77 0
0
nnecting insttrument pannel

62 42 50
frame w
点烟器
77
与先导阀接口孔位号 1 2
4 5 6 线号 0 46
42 42 42 CN83-A
CN76-B
63 62 0 55 CN84-A
3 2 1 50 孔位号 1 2
51
51
30
1 36
36
30
53
53
36
6 36
- 0
30
0
99
线号 0 44
99
+ 0
50
1 0
与先导阀接口 54
Interrface with front

5
2
6
1
-
5
2
2
6
+
+
-
ader
5
76a
76a
背光灯
90
90
5 42
5 76
0
0
接手制动开关背光灯背光灯
+
-
1
-
+
背光灯背光灯
静音暖风机开关暖风机风门
CN90-BB
CN90
Loa
f
稳压模块快换电源
接发动机线束
50 121 60 CN30-B
n button
CN90-B
50 接启动开关
Manual of Wheel
插孔号线号
28
1 C_H
Wiree No.
k No.
CN31-B 2 C_L
3 C_G
W
CN6-B CN5-B
4 0
喇叭按钮 12 5
Horn
插孔号线号
Jack
插孔号线号 6 28
nel wiring hharness (equ
Con
1 C_H 4 13 DJ221-4BHB
7 56
2 C_L 6 17 8
4 20 8 49 CN5-B E F H
9
5 12 10 22
57
7 6
6 15 13 61 30
8 组合开关 11 Ht-
19 21 99 50 8 35 50 5
3 2 1 3 2 1 3 2 1 12 Ht+
9 18 22 30 接仪表盘 7 6 5 4 7 6 5 4
10 0c CN7-B 9 7 4
7 6 5 4
10 9 8
56
10 9 8 10 9 8
11 7 36
50 50 10 6 49 3
14 13 12 11 14 13 12 11 14 13 12 11
Service M
12 6
17 21 CCN6-B
6 11
33 2
CN7-AA
CN7 CN8-BB
CN8
CN10-A CN11-A CN22-A
18 80
20
12 35 1 CN9-B
0c
插孔号线号插孔号线号插孔号线号插孔号线号插孔号线号
CN9-B CN9-B 与驾驶室线束接口 1 0 8 39 1 79 1 153 1 79
1 2 3
2 0 9 41 2 4 2 40 2 71
50 4 5 6 7 3 21 10 45 3 45 3 41 3
8 9 10
4 30 11 71 4 74 4 37 4 64
11 12 13 14
5 34 12 74 5 34 5 80 5 77 CN10-A,CN11-A,CN22-A
6 36 13 79 6 39 6 28 6 62
7 37 14 7 50 7 33 7 65
8 11 8 21 8 46

9 35 9 121 9 63
10 49 10 10 59
CN29-B 刹车开关(右) 10
11 11 11 22
12 12 12 0 12 60
孔位号 1 2 13 13 13 42
线号 40 8
14 14 44 14 38
与前车架线束接口
CN12-B 1 2 3
4 5 6 7
与前车架线束接口 8 9 10
11 12 13 14
刹车开关（左）
线束接口
孔位号 1 2
孔位号 1 2 3 4 5 6 7 8 9 10 11 12 13 14 CN28-B 线号 40 8
CN1-B
线序号 6 7 10 11 30 42 64 65 85 86 87 153
线号 4 0c 6 7 8 30 40 46 59 60
孔位号 1 2 3 4 5 6 7 8 9 10 11 12 13 14
与前车架线
CN3-B
线号 13 HHt+ 15 17 18 19 20 Ht- 61 54 55
A
接仪表盘
喇叭按钮
B 孔位号 1 2 3 4 5 6 7 8 9 10 11 12 13 14
插孔号
线号
1 2 3 1 2 3
4 5 6 7 4 5 6 7
CN1-B 8 9 10 CN3-B 8 9 10
11 12 13 14 11 12 13 14 CN2-B 0 CN4-B 56
W Loa
ader
组合开关 Commbined switch
c wiring hharness
刹车开关（右） Brakke switch (rright)
点烟器 Cigaarette lighteer
预留电源口口 Reseerved power interface
空调 Air conditioning
暖风机 Fan heater
接发动机线线束 Connnecting eng gine wiring harness
快换电源 Quicck change power
p supplly
稳压模块 Volttage stabilizzing modulee
静音 Mutte
警示灯 Warrning light
快换按钮 Quicck change button
b
接手制动开开关 Connnecting han nd brake sw
witch
p valve
快换按钮接接线 Quicck change button
b wirinng
b
58
0 暖风机风门
快换按钮接线
51 36
静音
线号
0 90 86 90 85 0 暖风机
42 53
85
暖风机
插孔号
63 87 背光灯孔位号 1 2
线号 36 0
空调
42 CN66-B
1
86
0 6
0 +
0 5
30
99 2
99
87
接 ECU 线
62 快换按钮
暖风机风门
预留电源口
门
口
42 CN21-B
线束
50 50
3 4 线号 38 0
0 42 85 90
50
CN20-B
50 2
86 1 90
63 42 孔位号 1 2
50 线号 77 0
0
62 42 50 点烟器
77
200
与先导阀接口 4 5 6 孔位号 1 2
42 42 42 线号 0 46
CN76-B CN83-A
63 62 0
3 2 1 55
6
CN84-A
30
50
1
27
5 33
6 33
+
-
孔位号 1 2
51
51
30
36
0
30
53
36
53
与先导阀接口
线号 0 48
1 36
50
5
2
6
1
2
-
+
- 0
5
+
6 36
背光灯
0
54
90
90
5 42
1
7
-
+
CN90-B
接手制动开关背光灯背光灯背光灯
警示灯插孔号线号

前刮雨器暖风机开关暖风机风门 1 C_H
CN6-B CN5-B
快换电源 CN90-B 2 C_L
接启动开关 3 C_G
4 0
插孔号线号插孔号线号接ECU线束
50 121 22 CN30-B 5
1 C_H 4 13 6 28
2 C_L 6 17
50 7 56
4 20 7 57 8
5 8 49 28
9
6 15 12 37 CN31-B 57 59 58
25 24 10 22
8 19 13 61
9 18
11 Ht-
21 99 0 26
10 0c 22 30 喇叭按钮 12 12 Ht+
Service M
11 7
12 6 接雨刮电机
CN5-B 48 48
17 21 组合开关
18 80 7 6 0 0
30
nel wiring hharness

CN7-B
20 0c
59
50 8 35 50 5 组合开关
接仪表盘 9 4
7
50 50 10 6 3
49
Con
Jack
11 33 2
CN6-B
W
3 2 1 3 2 1 3 2 1
12 1 7 6 5 4
35 7 6 5 4 7 6 5 4
2 1
10 9 8 10 9 8 10 9 8
4 3 56
k No.
14 13 12 11 14 13 12 11 14 13 12 11 36
Wiree No.
CN9-B
CN9-B
Fan heater
CN9-B 与驾驶室线束接口
Manual of Wheel
插孔号线号插孔号线号 CN23-A

1 2 3 1 0 8 39 CN10-A CN11-A CN22-A CN7-A CN8-B
4 5 6 7
50 2 0 9 41
8 9 10
11 13 14
3 21 10 45
12
4 30 11 71 插孔号线号插孔号线号插孔号线号
1 79 1 153 1 79 CN23-A
Loa
Fan heater doorr

5 34 12 74
孔位号 a b 0 接喷水壶 6 36 13 79 2 4 2 40 2 71
线号 57 8 7 3 45 3 41 3 插孔号线号
37 14 1
b a 23 4 74 4 37 4 64 13
ader
5 34 5 80 5 77 2 57
CN29-B 6 39 6 28 6 62 3 58
刹车开关(右) 7 50 4
7 33 7 65 9
8 11 8 21 8 46
孔位号 1 2 9 35 9 121 9 63
线号 40 8 10 49 10 10 59
Reseerved power interface

与前车架线束接口 11 10 11 11 22
12 12 12 0 12 60
CN12-B 1 2 3
13 13 2 a 13 42
4 5 6 7
与前车架线束接口 8 9 10 14 14 48 14 38
11 12 13 14
刹车开关（左）
CN28-B 孔位号 1 2
nnecting ECU wiring haarness

孔位号 1 2 3 4 5 6 7 8 9 10 11 12 13 14
线号 40 57
线序号 6 7 10 11 30 42 64 65 85 86 87 153
CN1 B
CN1-B
线号 4 0c 6 7 8 9 30 40 2
A
B 孔位号 1 2 3 4 5 6 7 8 9 10 11 12 13 14
CN3-B
线号 13 Ht+ 15 17 18 19 20 Ht- 61 54 55
1 2 3 1 2 3
4 5 6 7 4 5 6 7 孔位号 1 2 3 4 5 6 7 8 9 10 11 12 13 14
CN1-B 8 9 10 8 9 10
CN3-B
11 12 13 14 11 12 13 14 CN2-B 0 CN4-B 56
W Loa
ader
空调 Air conditioning
点烟器 Cigaarette lighteer
背光灯 Backklight
快换电源 Quicck change power
p supplly
静音 Mutte
b
快换按钮接接线 Quicck change button
b wirinng
接手制动开开关 Connnecting han nd brake sw
witch
p valve
接仪表盘 Connnecting insttrument pannel
喇叭按钮 Hornn button
前刮雨器 Fronnt window wiper
w
接雨刮电机机 Connnecting win ndow wiperr motor
接喷水壶 Connnecting sprinkler
组合开关 Commbined switch
c wiring hharness
刹车开关（右） Brakke switch (rright)
刹车开关（左） Brakke switch (left)
f frame w wiring harn
ness
60
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-错误!未定义书签。
421 Basic parameters of transmission and torque converter system4-错误!未定
义书签。
422 Detection and adjustment of transmission and torque converter system4-错
误!未定义书签。
423 Common faults and troubleshooting method of VRT200 transmission4- 错
误!未定义书签。
43 Maintenance of transmission and torque converter system4-错误!未定义书签。
431 Precautions for disassembling and assembling transmission4-错误!未定义
书签。
432 Disassembly and assembly flow chart of transmission4-错误!未定义书签。
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
I
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
Single-stage four –element double-turbine
Type
hydraulic torque converter
Torque Inlet oil pressure of torque
0.5~0.6
converter converter (MPa)
Outlet oil pressure of torque
0.21~0.26
converter (MPa)
Type Planetary power shift
Transmission gear Two forward and one reverse
Transmission
Transmission working pressure
1.1~1.5
(MPa)
412 Detection and adjustment of transmission and torque converter system

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
Fig. 4-1 Pressure detection tool 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.
1 2
e) Connect one end of test pipe to the test connector
Fig. 4-2
of transmission pressure and the other end to the
1 Reverse pressure switch pressure gauge (range: 0~6MPa).
1
2 Alarm switch of transmission f) Start the engine, step on the brake, shift all gears
pressure 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,
2
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.
3
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
4
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.
5
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
6
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.
7
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
8
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.
9
42 YD13 transmission system

421 Basic parameters of transmission and torque converter system
Table 4-3 Basic parameters of YD13 transmission
Item Parameter
Single-stage three-element single-turbine
Type
hydraulic torque converter
Torque Inlet oil pressure of torque
0.85
converter converter (MPa)
Outlet oil pressure of torque
0.5
converter (MPa)
Type Fixed shaft power shift
Transmission gear Four forward and three reverse
Transmission
Transmission working pressure
1.3～1.7
(MPa)
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
Fig. 4-7 Pressure detection tool
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.
10
1  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.
234 5 6 7
Fig. 4-8 Pressure detection tool f) After the test, repeat a) pressure discharging step
and then install transmission control lever pressure
1 Detection port of transmission sensor (switch) and pressure sensor connector and
pressure then wipe out the transmission oil leaked outside.
2 Detection port of clutch at gear II
3 Detection port of clutch at gear I 2. Outlet oil pressure detection of torque converter
4 Detection port of clutch at gear III a) Disconnect the oil temperature sensor connector of
5 Detection port of clutch at gear IV torque converter.
6 Detection port of clutch at reverse b) Disassemble the oil temperature sensor on the outlet
gear of transmission torque converter as shown in the
figure and install the transmission test joint at the
7 Detection port of clutch at forward
disassembly location.
gear
Specification of mounting hole: M14×1.5
11
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.
Fig. 4-9 Pressure detection tool
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
Function Green
Gear
Blue Yellow White Purple Brown Red Black 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

Table 4-4 Definition and logics of a) Disconnect the power supply of finished vehicle,
YD13 transmission gear selector screw off the connector of transmission control valve,
output lead open the side cover, release the solenoid valve connector
and then connect the red end V/Ω of multimeter to one
end of solenoid valve and the other end to another
Control valve
terminal to measure the resistance value. The resistance
value should be within 60-70Ω. 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.
Fig. 4-10 Solenoid valve
12
Gear IV Solenoid valve Clutch
The solenoid valve is on; The brake switch cuts off anode circuit.
Table 4-5 Logic diagram of solenoid

valve and clutch
13
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 starting circuit (like 1. Check the circuit of main engine and
power supply, electric lock, refer to the instructions of starting
start relay, start motor etc.) circuit of main engine.
of main engine breaks down. 2. The handle should be engaged at
2. The handle is not engaged neutral gear.
at neutral gear. 3. Replace the fuse.
3. The fuse on the main 4. Arrange the plug or check whether
The engine cannot engine leading to the control the handle circuit is powered on
1
start. circuit is burned out. normally.
4. The handle plug has poor 5. Arrange the plug or treat it as the
contact or the handle breaks electronic control box fault.
down.
5. The electronic control box
plug has poor contact or the
electronic control box breaks
down.
1. Oil pressure gauge breaks 1. Replace the oil pressure gauge.
down. 2. M8 tightening torque of control
2. The tightening torque of valve bolt is 20 Nm.
transmission control valve 3. Replace the spring.
bolt is insufficient. 4. Replace the transmission pump.
Low pressure at 3. The spring of main 5. Replace the filter and clean the
2
all gears pressure valve breaks off. control valve.
4. The transmission pump is
worn.
5. The scraps enter into the
transmission control valve or
valve clutch.
1. After the engine shuts down, block
the oil-way leading to KV clutch and
Oil pressure at
then start the engine and engage gear 1,
forward gear 1, 2,
1. Internal discharge of 2, 3 so as to make the transmission
3 3 is low but at
clutch at forward gear pressure increase to the normal value. It
other gears is
means that the clutch at this gear has
normal.
internal discharge and the transmission
needs to be repaired.
14

the oil-way leading to KR clutch and
Oil pressure at
then start the engine and engage gear 1,
reverse gear 1, 2,
2, 3 so as to make the transmission
4 3 is low but at 1. Internal discharge of pressure increase to the normal value. It
other gears is clutch at reverse gear
means that the clutch at this gear has
normal.
internal discharge and the transmission
needs to be repaired.
the oil-way leading to K1 clutch and
Oil pressure at then start the engine and engage
forward and forward and reverse gear 1 so as to
1. Internal discharge of
5 reverse gear 1 is make the transmission pressure
clutch at gear 1.
low but at other increase to the normal value. It means
gears is normal. that the clutch at this gear has internal
discharge and the transmission needs to
be repaired.
1. O-shape ring on the 1. Replace O-shape ring.
throttle plug screw breaks 2. M8 tightening torque of control
down. valve bolt is 20 Nm.
Short shifting time
6 2. The tightening torque of
for all gears
bolt on pressure control
valve is not within the
specified range.
1. The throttle plug screw is
Long shifting time blocked. 1. Wash and clear the screw.
7
for all gears 2. The pressure control valve 2. Wash and check the valve.
gets stuck.
15
1. Replace part.
2. Replace part.
1. Oil temperature sensor 3. Check the oil level and refuel
breaks down. according to correct method.
2. Oil temperature gauge 4. Exhaust the gas from the upper gas
breaks down. vent on the radiator (for machine with
3. The oil level is gas vent)
insufficient. 5. Check whether the oil pipe from the
4. Oil radiator of torque radiator to the transmission and the
High oil radiator are blocked.
converter has gas.
8 temperature of 6. Check whether the radiation capacity
torque converter 5. Oil-way from torque
converter to radiator is not is enough including inspecting the
smooth. looseness of engine fan belt and dirt on
the radiator surface.
6. The radiation capacity of
radiator is not enough. 7. Pay attention to checking the hose
joint from transmission to radiator. If
7. The counter-balance valve
the joint stretches into the transmission
of torque converter gets
deeply, it will stand up to the
stuck.
counter-balance valve element, get the
valve stuck and cause the oil-way
blocked.
1. The oil level is not 1. Check the oil level and refuel
enough. according to correct methods.
2. The elastic plate 2. Replace the elastic plate or
connecting the engine and corresponding damaged parts.
the torque converter breaks 3. Check whether the power supply
or the power connection voltage is normal, whether the cable is
from torque converter to worn and whether the cable plug is
transmission input gear has loosened.
fault (rarely occurring). 4. Implement the operation based on
The vehicle 3. Circuit of finished vehicle
above mentioned troubleshooting
9 cannot drive at breaks down.
method.
any gear.
4. Transmission pressure is 5. The solenoid valve is 65+5 Ω. If the
too low. resistance value is 0 or ∝, it means
5. The solenoid valve breaks that the solenoid valve breaks down
down. and needs to be replaced.
6. The shifting handle breaks 6. Check and replace the handle based
down. on handle fault check method.
7. The electronic control box 7. Check the box based on
breaks down. troubleshooting method of electronic
control box or with PR68 detector.
1. If breaking the connection between
1. Emergency brake pressure emergency brake pressure switch or
Vehicle cannot or parking brake pressure parking brake pressure switch and the
10 drive at gear I and switch breaks down. circuit recovers the gear I and II of
II. 2. Solenoid valve loses vehicle, it means that this switch needs
efficacy (M4). to be replaced.
2. Replace the solenoid.
16
1. The measured resistance of speed

When gear III and sensor is 1,020±100 Ω. If the resistance
IV are engaged, 1. Speed sensor breaks
11 is 0 or ∝, it means that the speed
the vehicle drives down.
sensor breaks down and needs to be
at gear II.
replaced.
1. The clutch at forward gear 1. Treat this fault as the above
has internal discharge. mentioned internal discharge fault in
2. Circuit contact inside the clutch.
shifting handle is burnt out 2. Arrange the handle wire or replace
Vehicle does not and the circuit has poor the handle.
12 have forward gear contact.
3. The resistance value of the solenoid
1, 2 and 3.
3. The solenoid valve loses valve is 100±10 Ω. If the resistance is 0
efficacy (M3). or ∝, it means that the solenoid breaks
4. The transmission control down and needs to be replaced.
valve gets stuck. 4. Clean the transmission control valve.
1. Treat this fault as the above
1. Internal discharge of mentioned internal discharge fault in
clutch at reverse gear. clutch.
2. Circuit contact inside the 2. Arrange the handle wire or replace
shifting handle is burnt out
Vehicle does not and the circuit is not the handle.
13
have reverse gear. powered on. 3. The resistance value of the solenoid
valve is 65±5 Ω. If the resistance is 0 or
3. The solenoid valve loses
∝, it means that the solenoid breaks
efficacy (M1).
down and needs to be replaced.
4. The valve gets stuck.
4. Clean the transmission control valve.
1. The voltage provided to 1. Check the power supply system of
the electric control system is finished vehicle.
not stable. 2. Check the circuit based on main
2. The power supply circuit engine circuit.
provided to the electric 3. Arrange or replace the shifting
control system has poor handle connection plug.
contact. 4. Refuel according to correct method.
3. The shifting handle cannot 5. Arrange the connection plug.
operate stably or the
The gear is connection plug has poor 6. Clean the valve.
14
sporadic. 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.
6. The valve gets stuck.
17
1. The connecting bolt fixing

the engine transmission is
loosened. 1. Check and fix the bolt.
2. The oil level of the 2. Refuel to the normal oil level.
transmission is not enough. 3. Check the transmission shaft.
3. Transmission shaft 4. Replace the elastic plate.
Abnormal noise in
15 connecting the transmission 5. Remove the transmission shaft and
transmission
breaks down. check whether there is any abnormal
4. The elastic plate noise after the removal. If any, check
connecting the engine and whether the transmission has
the torque converter breaks. mechanical fault.
5. Mechanical fault inside
the transmission.
The vehicle 1. The clutch at reverse gear the oil-way of KR clutch and then start
reverses at neutral is sintered. the engine. If the vehicle can drive at
gear, cannot drive 2. The valve gets stuck. reverse gear, it means that the clutch at
16 at forward gear 1, reverse gear is sintered and needs
2, 3 and drive 3. The solenoid valve loses mechanical maintenance.
normally at efficacy (M1). 2. Clean the valve.
reverse gear. 4. The handle breaks down. 3. Replace the solenoid valve.
4. Replace the handle.
The vehicle moves the oil-way of KV clutch and then start
forward at neutral 1. The clutch at forward gear
the engine. If the vehicle can drive at
gear but cannot is sintered.
gear 1, 2, 3, it means that the clutch at
drive at reverse 2. The valve gets stuck. forward gear is sintered and needs
17
gear; The vehicle 3. The solenoid valve loses mechanical maintenance.
can drive normally efficacy (M3). 2. Clean the valve.
at forward gear 1, 4. The handle breaks down.
2, 3. 3. Replace the solenoid valve.
the oil-way of K1 clutch and then start
The vehicle only 1. The K1 clutch is sintered. the engine. If the vehicle can drive at
has forward and 2. The valve gets stuck. forward and reverse gear 1, it means
18 reverse gear 1 and 3. The solenoid valve loses that the clutch at gear 1 is sintered and
cannot drive at efficacy. needs mechanical maintenance.
other gears. 4. The handle breaks down. 2. Clean the valve.
3. Replace the solenoid valve.
18
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
19
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
Refer to 9 Working hydraulic system
hydraulic oil tank
6. Disconnect the oil
outlet hose of pump
7. Disconnect the
Transmission radiating oil inlet pipe
and oil return pipe
8. Disconnect the Line of transmission control
connecting harness. valve
9. Disassemble the
intermediate Pressure sensor
transmission shaft
10. Disassemble the
Oil temperature sensor of torque
rear transmission
converter
shaft
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.
20
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 8. Connect radiating oil

Assembly of
control valve inlet pipe and oiler turn
transmission
pipe
Pressure sensor 9. Connect harness and

sensor
Oil temperature sensor of 10. Install the hydraulic oil

torque converter 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.
21
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
22
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.
23
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
L
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.
To power slot of To air compressor

variable speed pilot
valve
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
5-1
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
5-2
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
Fig. 5-5 Connection Dimension of of the brake valve.
Foot Brake Valve
4. Disconnect the brake valve to the booster and air
Opening A: to air tank interface pipe of air tank.
M22×1.5
5. Disconnect the brake valve to the air pipe of
Openings B&D: to booster interface variable speed pilot valve.
M22×1.5
6. Disconnect the intake pipe of brake valve.
Opening C: interface of brake tail
lamp switch NPT1/8 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.
5-3
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.
Fig. 5-6 Brake performance test  If there is no bubble coming out of the water, it
indicates that the non-brake performance of the air
5-4
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.
Fig. 5-7 Balance spring

1. Balance spring assembly
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.
Fig. 5-8
1. Piston return spring
2. Piston
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
5-5
Fig. 5-9 Intake Valve Assembly rings are severely damaged, become less elastic or
broken, they should be replaced by new ones.
1.Rubber valve aperture
2. Valve return spring
3. O-ring
4. O-ring
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
Fig. 5-10 Detection of booster pressure indicator of the oil outlet:
pressure  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.
5-6
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.
Fig. 5-11 Assembling of Piston Ring

Cup
1. Push rod piston assembly
2. Air piston ring cup
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.
Fig. 5-12 Assembling of Push Rod

Piston Assembly
2. Assemble air piston ring cup and push rod piston
1. Push rod piston assembly 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.
Fig. 5-13 Assembling of Connection

Cover
1. Connection cover assembly
5-7
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.
Fig. 5-14 Assembling of Cylinder

Assembly and Connection Cover
Assembly
1. Cylinder assembly
2. Connection cover assembly
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.
Fig. 5-15 Assembling of Piston

Assembly
1. Hydraulic piston
2. Cup
5. Connect the cylinder assembly and the connection

cover assembly and fasten them with bolts, nuts
and washers.
Fig. 5-16 Assembling of Piston

Assembly
5-8
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
Fig. 5-17 Assembling of Hydraulic the hydraulic piston assembly with the retainer
Cylinder ring.
1. Assembling of hydraulic cylinder 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
A B 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;
C
D (2) When the air compressor is not working, ensure the
E brake air for certain times;
F (3) Install carriers for safety valve, brake pressures
switch and drain valve;
(4) When the driver presses the foot brake pedal, the
G compressed air enters the brake or the braking
chamber through the control valve to achieve
service brake;
Fig. 5-18 Air tank
1. A- Air inlet Note: The appearances and structures of air tanks
2. B- Tire inflation inlet of different models vary. This introduction shall be only
3. C-Air outlet for reference.
4. D- Preformed opening Compositions
5. E- Interface of brake pressure Brake pressure switch

switch Provide pressure values for the barometer to enable the
6. F- Interface of air pressure sensor driver to correctly determine the brake state according to
the readings of the barometer and determine whether the
7. G- Drain valve
5-9
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。
5-10
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.
Figure 5-19 Oil-water separator
5-11
Composition
1 The air pressure regulator of a combination valve for
12
2
oil-water separator mainly consists of control piston,
regulating valve, adjusting spring, and tympan.
3
11 The gas-liquid drain valve mainly consists of air bleed
4 piston assembly, oil collector, and valve seat;
10
5
6 9
7 8
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
5-12
1 2 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.
Figure 5-21
1. Air pressure adjusting screw
2. Relief valve assembly
3. Wing nut
5
4 Common faults
3 6
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;
2 3) When the air hole (towards atmosphere) of the upper
1 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
Figure 5-22 upper cover;
1. Bleed valve 2. Return spring 5) When the pressure adjusting spring has a smaller elastic force
of air bleed piston due to long-time work, the system pressure will drop, too;
3. Air breather 4. Tympan
5. Pressure adjusting spring 6.
Orifice
5-13
6) When the orifice from cavity C to cavity D is blocked and at

D 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.
Fig. 5-20
5-14
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.
Fig. 5-21
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.
Fig. 5-22
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.
5-15
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.
5-16
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: 26.3Ω
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 26.3Ω, 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.
Fig. 5-23parking brake solenoid valve
5-17
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:
① 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.
② The brake caliper is in fault. The rectangular oil seal
is damaged. The brake caliper cannot return smoothly or
the inner piston is rusted.
③ The foot brake valve is in fault. The movement of
the inner piston suffers from clamping stagnation.
④ 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:
① 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;
② 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;
③ 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.
5-18
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.
① 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.
② 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.
5-19
I
Service
S Maanual of Wh
heel Loadeer
C
Conteents
m ......................................... .............................................................. ...................................... 1
6 Steeering system
m ................... .............................................................. ...................................... 1
61 Oveerview of steeering system
m parts ......... .............................................................. ...................................... 3
611 Loocation of steeering system
62 Presssure test an nt of steeringg system................................................. ...................................... 4
nd adjustmen 4
6221 Pressure measuremen
m ystem ................................ ...................................... 4
t of steering hydraulic sy 4
6222 Pressure adjustment
a o steering hyydraulic systtem .................................... ...................................... 5
of
63 Prep ntenance ............................................... ...................................... 6
paration beffore steering system main 6
nts ................ .............................................................. ...................................... 7
64 Intrroduction to main elemen 7
6441 Steering pump
p ................................. .............................................................. ...................................... 7
7
6442 Priority vaalve ................................... .............................................................. ...................................... 8
8
o cylinder ........................ .............................................................. .................................... 100
6443 Steering oil
g .................................... .............................................................. .................................... 100
6444 Steering gear
65 Steeering system exhaust ........................... .............................................................. .................................... 122
ult diagnosis and eliminattion of steeriing system ............................................ .................................... 13
66 Fau
6661 Diagnosis of main faullts ................ .............................................................. .................................... 13
6662 Example of ult eliminatioon .......................................................... .................................... 222
o typical fau
I
Service
S Maanual of Wh
heel Loadeer
6 Stteering sy
ystem
61 Ov
verview of
o steerin
ng system
m
L936/L L938 loader working hyydraulic sysstem is typee
of pilott control, an
nd correspoonding steerring system
m
is as fo
ollows (steeering pump is different accordingg
to configuration). Working pressure of o steeringg
system of domesticc resources is 14MPa, and 12MPaa
as for overseas
o resources.
(Dom
mestic resources) (Oveerseas resources)
转向油缸 Steeering cylinder
转向器 Steeering unit
接回油滤芯芯 Connnecting oil return filterr
接多路阀 P 口 Connnecting multiple unit vvalve P port
优先阀 Prio
ority valve
1
Service
S Maanual of Wh
heel Loadeer
齿轮泵 Gear pump
接压力选择
择阀 P1 口 Con
nnecting pressure selecttor valve
(mechaanical)Chinaa market
Figuree 6-1 Schem

matic figure of steering system
2
Service
S Maanual of Wh
heel Loadeer
611 Location
L of
o steerin
ng system
m parts
5
4
2
Fig. 6-3 Lo
ocation of stteering syste
tem parts
1S
Steering geaar 2 Steering g cylinder 5 Hydraulic oil tank
g pump 3 Prriority valve 4 Steering
steeringg system consists of components likee
steeringg pump, priority valve, lo oad-sensingg
hydraullic steeringg gear, steeering oil cy
ylinder andd
pipelinee. See the above
a figurre for specific locationn
(only for
f diagram m reference and subjecct to actuall
object).. This system
m possessess advantagees includingg
compacct structure, high sensittivity, good
d reliability,,
flexiblee and laborr-saving opperation, absorption off
pavemeent impact anda no needd of setting lubricationn
device.
3
Service
S Maanual of Wh
heel Loadeer
62 Prressure test and

d adjustment off
steeriing systeem
621 Pressure
P measureement of steeringg
hydra
aulic systtem
℃.
Measurrement of oiil temperatuure: 45~55℃
Pressurre measurem
ment tool: pressure gauge
g withh
range of 40M Mpa (40330000370), pressuree
measurement jointt (41200029945), piezo
ometer tubee
(403000 00368).
Pressurre measuring
g standard: 14Mpa.
Pressurre measuring location: On oil outlett steel tube off
steering gear.
Fig. 6-5 40030000370 pressure
p gauge
Pressure meassuring proceess:
1. Lowwer the wo
orking devicce on the ground,
g pulll
up the hand brake
b and adopt woo
od block orr
stone to wedgee the tire.
2. Shu ut down thee engine, opperate the co
ontrol leverr
10 times and the steerinng wheel 5 times andd
theen release the residu dual pressu ure of thee
hyddraulic oil in
n the pipe.
3. Scrrew off the plug
p screw on the cylin
nder joint.
4. oint On oill
Insstall the prressure meeasuring jo
outtlet steel tube of steeering gearr.
Fig. 6-6 41200029445 pressure measuring
m jjoint
5. Tig
ghten the piezometer
p tube to th
he pressuree
meeasuring join
nt.
6. Connect the pressure
p gauuge to the piezometerr
tub
be.
7. Staart the engiine, turn thhe front fraame to thee
lim
miting position. When th the front fraame reachess
thee limiting po
osition, incrrease the accelerator too
thee maximum m. Observee the stablle pressuree
vallue on the oil pressurre gauge which
w is thee
currrent workinng pressuree of steering g hydraulicc
sysstem of meaasured loadeer.
Fig. 6--740300003368 piezomeetric hose
4
Service
S Maanual of Wh
heel Loadeer
Fig. 6--8 Pressure measuring location
622 Pressure
P adjustm
ment of steeringg
hydra
aulic systtem
After measuring
m oil
o pressure,, if the meaasured dataa
is foun
nd to be higher or low wer than th he standardd
value, adjust
a the system
s presssure. The pressure off
this steeering system is deccided by th he openingg
pressurre of safety
y valve aboove the prio ority valve..
The priiority valve is installedd at the left side of rearr
frame as
a shown in the figure.
Fig. 6-9 Loocation of priority
p valv
ve
The saffety valve ofo the prioriity valve is installed att
the sidee of oil retu
urn pipe andd can be adjdjusted afterr
the oil return
r pipe of priority vvalve is rem
moved.
1. Release the locking nut aand rotate th
he adjustingg
scrrew as show
wn in the figu
gure.
1
Fig. 6-10 L
Location of safety valve
1 Safety vaalve
2. To increase the
t pressurre, turn thee adjustingg
scrrew clockwise and theen rotate th he adjustingg
scrrew anticlo
ockwise to lower thee pressure..
Reference vallue: the reegulating variable perr
cyccle is 2Mpa. (This valuue is only fo
or referencee
andd specificc operatioon is subject s too
meeasurement)
5
Service
S Maanual of Wh
heel Loadeer
Fig. 6-11 A
Adjusting sccrew
1 Adjustingg screw
Fig. 6-12 D
Direction off increasing pressure
63 Prreparatio
on beforee steering
g system
m
mainttenance
1. Preessure disch
harging
Park thhe complete machine at the flat an
nd spaciouss
ground and then turn the steeering wheeel 5-6 timess
clockwise and antiiclockwise aand then discharge thee
oil presssure in the steering sysstem.
1
Fig. 66-13
1 Steeering wheel
2. Connect the locking leever of thee frame too
preevent the reelative rotat
ation of fron
nt and rearr
frammes from damaging
d opperators.
3. Fix
x the loader tire by woood wedge bllock.
4. Preepare properr oil receiviing containeer.
1
Fig. 66-14
1 Loccking lever of
o frame
6
Service
S Maanual of Wh
heel Loadeer
64 Introductiion to maain elem

ments
641 Steering pump
p
steeering pum
mp is gear pump. Th
he steeringg
pump is connected
d to the torrque extracttion port off
transmiission and will connvert the mechanicall
energy input by the

t transmiission to th
he pressuree
energy of oil and

d then inpput them in
n forms off
w to the sysstem. 。As for domesticc

pressurre and flow
L936, in
n case of beeing configur
ured with Weeichai Deutzz
engine, CBGj3100/1010-XF dupllex pump is adopted, andd
in casee of being configuredd with Yucchai engine,,
CBGj3100A steering
g pump is aadopted; as for overseass
L936, CBGj2063A
C steering
s pum
mp is adopted
d, and as forr
overseass L938, CBGjj2063 steering

ng pump is ad
dopted.
Table 6-1 Technical parameeters off

CBGj3100/1010-XF steering pum
ump
Name Paraameter
Connection
C type Rectangu
ular spline
Diirection of turning Left-han

nd turning
100/10
Theo
oretical displacement
22
200
Rated speeed
20
2
Rated presssure
Fig. 6-15 C
CBGj3100/10010-XF steerring pump
7
Service
S Maanual of Wh
heel Loadeer
Table 6-2 Technical param
meter off
063A steerin
CBGj3100A/2063/20 ng pump
Name Paraameter
Connection
C type Rectangu
ular spline
Diirection of turning
t Left-han
nd turning
100//63/63
Nom
minal displaacement
22
200
Rated speeed
20
2
Rated pressure
Fig. 6-16CBGj3100A/22063/2063Astteering pum

mp
642 Priority
P valve
This stteering sysstem adoptss VLH-240S S-14(CHINA A
VLE-150) priority valve. Th he priority valve is a
differen
ntial stress componentt. No matteer how thee
load prressure and d the oil suupply in thee oil pumpp
change, the prioriity valve ccan still maintain
m thee
ntial pressu
differen ure on both th ends off adjustablee
orifice in the steering gear annd then ensu
ure the flow
w
supplied to the steering gear eequal to thee product off
steering
g wheel speed and steerring gearr
displaceement.
P port of
o priority valve
v conneccts with oil outlet hosee
of steerring pump, CF port coonnects witth P port off
steering
g unit, EF port connnects with P port off
multiple unit valve (EF port of overseaas resourcess
connectts with trannsmission ooil radiatorr), LS portt
connectts with LS port of steeering unit and T portt
connectts with hydrraulic oil tannk.
1 2 3 4 5 6
Fig. 6-19 E
External vieew of prioritty valve VLH
H-240S-14
1 T port 2 Safety valve 3 LS port 4 EF port 5 P port 6 CF
C port
8
Service
S Maanual of Wh
heel Loadeer
1 2 3 4 5 6
Fig. 6-19 E
External vieew of prioritty valve VLEE-150
1 T port 2 P port 3 saffety valve 4 EF port 5 L
LS port 6 CF
F port
Table 6-5
6 Technicaal parameterr of priority
y valve
(Eton)
Name Parameteer
240/150
0
Nom
minal flow
14/12
Saafety valve
pressure
p
6.9
Conttrol pressuree
Signal SStatic state signal

s
Fig. 6-20 P
Priority valvve diagram
9
Service
S Maanual of Wh
heel Loadeer
643 Steeering oil cy
ylinder
The steeering oil cylinder
c cann convert th he pressuree
energy of liquid to the m mechanical energy inn
reciproccating rectillinear moveement. The steering oill
cylindeer is fixed on the fraame by piv vot and thee
contracction of oill cylinder achieves th he steeringg
functionn of vehiclee. The steeriing oil cylin
nder mainlyy
consistss of cylindeer body, pistton rod, cyllinder head,,
piston and
a seal kit of oil cylinnder.
Fig. 6-21
6 Structuure chart off steering cylinder
1 Piiston rod 2 Cylinderr head 3 Cylinder bo
ody 4 Piiston
644 Steeering gearr
This machine
m adopts BZZ6-6330A static state signall
load seensing flow amplificatition hydraulic steeringg
gear off which the appearance
a and interior schematicc
diagramm is as show
wn below.
Fig. 6-22 Externnal view of BZZ6-630Asteering

s geaar
1 LS po
ort 2 L poort 3 T port
p 4 R port
p 5 P port
10
Service
S Maanual of Wh
heel Loadeer
Main teechnical parameters of ssteering geaar
Table 6-77
Model BZZ6-630A
Connection
n type British inv
volute splinee
Equivalent displacement 630/5

500ml/r
Max
ximum inlett pressure 17.2MPa
Maxim
mum contin
nuous back 1.0
0MPa
pressure
Oveerload valve pressure 20

0MPa
Steering torque 1.7-2.8Nm
Am
mplification
n factor 1.6
Fig. 6-233 Steering gear

g diagram
m
P port of steering unitt connects with
w CF porrt of priority y valve, L and
a R portss connect with
w steeringg
cylinder reespectively, oil liquid of
o T port retturns to oil tank upon oil return ffilter. LS po
ort connectss
with LS poort of prioritty valve preeferentially, and steerin
ng unit splin
ne connects with steerin
ng post.
11
Service
S Maanual of Wh
heel Loadeer
65 Steering sy
ystem exxhaust
After replacing steering ppump, steeering gear,,
priority
y valve, steeering cylinnder and hy ydraulic oill
pipe inn the steerin
ng circuit, eexhaust thee gas in thee
steeringg system based on folloowing meth hods:
1. Park the loader at tthe right maintenance
m e
position and
a then opeen the fillerr cap of thee
hydraulic oil tank.
1. Start the engine and mmake the eng gine idle forr
several minutes.
m Pay attention to o not usingg
any hydrau ulic functionn during this process.
2. After the hydraulic oil in thee hydraulicc
system is circulated ffully, turn the
t steeringg
ghtly severall times. Pay attention too
wheel slig
keeping thhe steering cylinder not move too
the end.
3. Keep the engine
e idling
ng and carefuully turn thee
steering wheel
w to makke the steeriing cylinderr
with full travel stretcch forth annd back 3-55
times so as
a to exhaustt the air in the
t pipeline..
When neccessary, rem move the oil inlet
i pipe orr
1 the oil reeturn pipe oof steering cylinder too
Fig. 6--24 make the hydraulic oil overflow w so as too
1 Fillinng filter elem
ment complete the full exhaust off hydraulicc
cylinder. Pay attentioon to not making
m thee
hydraulic system stor ore pressure during thee
exhaust.
4. After the exhaust, seet the machine and thee
working device at the standarrd positionn
and then check
c the oiil and tighteen the fillerr
cap.
5. Stop the engine andd check an nd confirm
m
whether the
t hydrauulic pipelin
ne has anyy
leakage.
12
Service
S Maanual of Wh
heel Loadeer
66 Fa ault dia
agnosis aand elim
mination
n
of steeering sy
ystem
661 Dia
agnosis of main
m faultss
Table 6-8 F
Fault cause of heavy steering
N
Fault cause
c Refference diag
gram of faullt location Remark
R
o.
Thee damaged one-way

o
valvve in the steeering gear
1
bloccks the entrance of
steeering gear.
Thee steering geear stalls an

nd
This stteering gearr
turnns to the onee-way valvee.
2 does no ot have the
Thee stuck steell ball cannot
one-waay valve.
reseet.
LS ppipe of prioority valve

twissts together or is too
3
longg. The dampping hole iss
bloccked or has oil leakagee.
Thee steering coolumn is

4 dammaged and thhe rotating
torqque is excesssive.
Thee joint part between

b
steeering colummn and
steeering gear has
5 inteerference annd produces
axiaal or radial force
f to the
steeering gear affter
asseembly.
13
Service
S Maanual of Wh
heel Loadeer
Table 6-9 F
Fault cause of heavy steering (conntinued)
No. Faault cause Referencce diagram of

o fault locaation Remark
The pressure of priority

p
valve andd the ov verflow
valve is low
l or thee main
valve elemment is stu uck or
6 the dam mping holle is
blocked. The main valve
element off priority valve
v is
stuck or the elasticcity of
main sprinng is smallerr.
The presssure of ov verload

7 valve in coombination valves
of steeringg gear is low
w.
The oil return fillter is

8
blocked.
The pump is worn seriously

or damageed. The volu umetric
9 efficiency,, pressure or
o flow
cannot meet system
requiremennts.
The blockked location n in the

whole s
steering system
10
pipeline will
w cause serious
s
throttle andd heavy steeering.
14
Service
S Maanual of Wh
heel Loadeer
Table 6-100 Fault causee of vehiclee deviation
No. Faault cause R

Reference diagram
d of fault
f locatioon Remark
R
Check whhether the oiil

1
cylinder is loosened.
The oil cyylinder has

2
leakage.
Two tires have largerr

3
pressure difference.
d
One side of
o two-way y
overload valve
v or
4 two-way oil
o
supplemenntary valve has
leakage.
5 The oil haas air.
15
Service
S Maanual of Wh
heel Loadeer
Table 6-11 Fault causee of inaccurrate steeringg
No. Fauult cause Refference diag

gram of fault location Rem
mark
1 The system
m has air.
The pin off oil cylinder is

2
loosened.
3 Thermal shhock.
The main valve

v elemeent
4
of priority valve is stu
uck.
The oil cyllinder has

5
leakage.
The low effficiency off

6 pump causses unstablee
pressure.
16
Service
S Maanual of Wh
heel Loadeer
Table 6-122 Fault causee of that thee steering w
wheel has no
o pressure orr the tumbleer does not move

mark
The nuts on
o the steerin
ng
1 column annd steering
wheel fall off.
The joint between

b thee
steering coolumn spind dle
2
and the steeering gear
valve elem
ment fall offf.
The level of
o oil tank is
3
lower.
17
Service
S Maanual of Wh
heel Loadeer
Table 6-13 Fault causee of that thee tumbler dooes not mov
ve or movess slowly

mark
Two-way overload
o vaalve
or two-wayy oil
1
supplemenntary valve has
h
serious leaakage.
The oil cyllinder piston

n
2
has seriouss leakage.
Table 6-144 Fault causee of idle stro

oke in the ssteering wheeel

mark
The nut onn the steerin

ng
1
wheel is looosened.
The joint between

b thee
steering coolumn and the
2
steering geear is worn
seriously or
o damaged..
3 The oil hass air.
Two-way overload
o vaalve
and two-w
way oil
4
supplemenntary valve
have leakaage.
18
Service
S Maanual of Wh
heel Loadeer
5 Oil cylindeer has leakaage.
The conneection betweeen

the oil cyliinder and th
he
6 steering linnkage has laarge
wear clearance or is
damaged.
Table 6-15 Fault causee of abnorm

mal return orr driven turn
ning

mark
The steerinng column and

a
the steering gear are
1
connected tightly or
unsmoothlly.
Larger oil return

2 back-presssure can cau
use
poor returnn.
19
Service
S Maanual of Wh
heel Loadeer
The large contaminati

c ion
particles enntering
between thhe valve
3
element annd the valvee
sleeve can cause
non-returnn.
The springg strip of

4 steering geear is damag ged
or has smaaller elasticiity.
Table 6-166 Fault causee of steering

g wheel vibbrating or ro
otating autom
matically

mark
The assem mbly relation n is

wrong. Duuring the
overhaul and
a re-assem mbly,
the spline tooth
t
1 correspondding to the pin
p
pulling sloot corresponnds
to the interrnal spline tooth
t
cavity of rotor tooth
cavity.
Connect thhe oil inlet to

t R
or L port and
a then thee
2 steering motor
m in the
steering geear can rotatte
automaticaally.
20
Service
S Maanual of Wh
heel Loadeer
Table 6-177 Other faultts
Fault Reference
R diiagram of fa
fault
Faultt cause Remark
phenommenon locaation
Not working for a long

N
At the staarting,
timme, the steeering gear
short-timee
ellements hav ve larger
inflexiblee
teemperature difference w with
steering.
syystem oil.
The steeriing
T system has
The h air.
cylinder ccrawls.
The tumbbler and

the steerinng
R and L portts are inverssely
wheel havve
coonnected.
opposite
directionss.
The steeriing
The one-way
T y valve in thhe
wheel
stteering gearr is damagedd.
reboundds.
21
Service M
Manual of Wheel Loader
6622 Example off typical faullt elimination

Faullt 1: Heavy steerring
Cause Measure
Yes
The oil cylinder crawls and the
hydrauliic oil has foam and
irregulaar noise.
Exhau ust the air in the system,
The system m has air, the checkk the oil inlet pipe, check
manual stteering one-way whethher the steel ball is stuck,
Yes valve loses efficacy, FK
The steeering is heavy and the replacce KF combination valve
steeringg cylinder has no power. overload hass leakage and the and check whether the oil
oil cylinder has
h inner leakage. der has inner leakage.
cylind
Yes
Check whether the
steering column is
Make flexible.
the No No
judgmen Whether the system Check whether the Yes
t based pressure is in feedback oil pipe is The pipeline is blocked. Clean or replace.
on fault conformity with smooth.
phenome requirements.
No No
non The spring of priority valve Clean, repair or replace.
Whether the direction is Adjust system pressure and
check whether the pressure breaks off orr the valve element is
heavy durring the quick turn.
changes. stuck.
Yes
No The systeem pressure is low. Adju

ust the system pressure to the
specified value.
Yes
Whether the level of hhydraulic The level of
o hydraulic oil is Fill the
t oil to the specified
oil is lower. low range.
No
Yes The pipelline is blocked. Clean or replace.
Whether the oil suction
pipe is blocked.
No
The steerin
ng pump is worn. Repair or replace.
22
Service M
Manual of Wheel Loader
Faullt 2: The steeringg has no ending point
After the steeering cylinder turrns to the limitingg Countermeaasures

Cause
position andd turn the steerring wheel hardd
continuously, the steering wheeel can turn slightlyy The presssure of overload Properly increase thee
and have no feeeling of ending po
oint. valve is lo
ow pressure of overload valve
Faullt 3: The steeringg cylinder canno

ot turn to the lim
miting position.
Causse Counteermeasures
The steeringg cylinder cannot turn to the limitinng
position andd the steering is heaavy. The pressure
p of safetty Properly increase the
valvee is low. pressure of safety
valve.
23
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
I
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)
Fig. 7-1
1 Bucket 2 Connecting rod
3 Rocker arm 4 Boom
5 Boom cylinder 6 Rotating bucket
cylinder
1
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
2
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.
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.
Fig. 7-2 Joint of upper and lower
frames 16. Install upper and lower bearing caps with 4
cross-placed bolts. Pre-tighten the bolts to ensure
1 Bush 2 Upper bearing cap that there is no clearance between the lower end
3 Adjusting gasket 4 Bearing face of lower bearing and the upper end face of
lower cap. Then remove upper and lower bearing
5 Bearing 6 Lower bearing cap 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.
3
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.
1 2 24. Install upper and lower bearing caps and tighten
them diagonally based on assembly and tightening
Fig. 7-3
order.
1 Upper bearing cap
2 Bush 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.
4
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
Fig. 7-4 tighten these nuts in turn.
1 Special support device
Note: Tighten the nuts clockwise. Tighten it
slightly each time to avoid inclination of wheel.
5
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,
6
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
7
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)
Fig. 7-5
1 Hoisting rope
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.
Fig. 7-6 7. Lift the rocker arm and place it on the prepared
1 Hoisting rope rubber blanket.
8
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
9
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.
Fig. 7-7
10
Table 7-1 Adjustment requirements of clearance at typical part
Adjustment requirements (mm)

No. Description of typical part Sleeve (unilateral Joint bearing (unilateral
clearance) clearance)
1 Joint between boom and bucket 0.5~1.5 \
2 Joint between rocker arm and boom 0.5~1.5 \
Joint between boom and boom
3 0.5~1.5 1~2
cylinder
Joint between rotating bucket
4 0.5~1.5 1~2
cylinder and front frame
5 Joint between boom and front frame 0.5~1.5 \
11
Ⅰ
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 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
Disconnect flexible shaft of multiway
Disassemble cab
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.
8-1
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.
Evaporator
Heater valve
Heater pipe
Engine
Enter cab-hot air

Engine circulating water
Heater core
Back to engine
Cab return air-cold air
Fig.8-1 Heating principle
8-2
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.
Temperature Expansion
controller panel valve
Evaporator
Condenser
Compressor Compr
belt essor Fluid reservoir
Fig.8-2 Refrigeration principle
8-3
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
8-4
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
Fuse Red Red
Main vehicle power positive
Main vehicle power negative

Power line Fan high range control line
Control line of fan mid-range
Brown
Fan high range Control line of fan low range
Yellow
Fan mid-range
Green Relay coil
Fan low range control
Fan high range Wh Refrigeration control relay Speed control resistance
Sensor positive control line ite Defrost
White Evaporative motor sensor
Sensor ground
Air conditioner
controller Purple
Refrigeration output Diode
Red/black Black Speed
control
Green/bla resistance
ck Black
Fresh air control output Fresh air servo
motor
Refrigeration indicator Grey Purple

lamp input(+)
Black Black
Purple
Blue
High/low pressure switch
of air conditioner Conden
Compressor ser
electromagnetic motor
clutch
Black
Black
GND ground
Fig.8-6 Schematic diagram of high range

Fan mid-range
8-5
Fuse Red Red

Brown
Control line of fan low range
Fan high range
Yellow
Fan mid-range
Green Relay coil
Fan high range Wh Speed control resistance
control line ite
Refrigeration control relay
Sensor positive Defrost
Sensor ground
Air conditioner
controller Purple
control
Fresh air control output ck Black

Fresh air servo
motor

lamp input(+)
Black Black
Purple
Blue
Compressor ser
clutch
Black
Black
GND ground
Fig.8-7 Schematic diagram of mid-range

Fan low range
Fuse
Red Red

Brown
Fan high range
Yellow
Fan mid-range
Green Relay coil
control line ite
Refrigeration control relay
Sensor positive Defrost
Sensor ground
Air conditioner
controller Purple
control

Fresh air servo
motor

lamp input(+)
Black Black
Purple
Blue
Compressor ser
clutch
Black
Black
GND ground
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,
8-6
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

Fuse Red Red

Brown
Fan high range
Yellow
Fan mid-range
Green Relay coil
Fan high range Wh Refrigeration control relay Speed control resistance
Sensor positive control line ite Defrost
White
Evaporative motor sensor
Sensor ground
Air conditioner
Purple
controller Refrigeration output Diode

control

Fresh air servo
motor

lamp input(+)
Black Black
Purple
Blue
Compressor ser
clutch
Black
Black
GND ground
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.
8-7
Fig.8-11 Change-over switch of fresh air
: fresh air
: recirculating air
Fig.8-12 Route diagram of fresh air
Fuse
Red Red

Brown
Fan high range
Yellow
Fan mid-range
Green Relay coil
Sensor positive control line ite Refrigeration control relay
Defrost
Evaporative motor
White sensor
Sensor ground
Air conditioner
controller Purple
Speed
Red/black Black control
ck Black
Fresh air control output Fresh air servo
motor

lamp input(+)
Black Black
Purple
Blue
Compressor ser
clutch
Black
Black
GND ground
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.
8-8
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 time
Check item Check content
Daily Semi-annually Annually
Pipeline Poor fixation with gap √ √
8-9
assembly
Junction looseness, nut and bolt √ √
looseness
Junction looseness, nut and bolt √ √

Connecting bolt
looseness and detachment
Looseness and bending √ √
Driving belt Degradation: wear, scar, crack √ √
Noise, smell or abnormal heating √
Fins lodging √
Condenser
assembly Impurities blockage (rubbish, dust, √ √ √
worm grass, etc.)
Starting check, air volume, switch √ √

Air volume control
switch of air
conditioner
Switch function √ √
Leakage at pipeline joints √ √
Refrigerant
leakage Internal leakage of components and √
parts (compressor, condenser,
evaporator, receiver-dryer)
Refrigerant Check refrigerant quantity (observe √ √

quantity sight window)
Compressor (including unloaded) √

Noise
Condenser fan, evaporator fan √
Reservoir Temperature difference indicates √

temperature blockage in the dryer
8-10
difference
84 Maintenance instruction of air

conditioner system
841 Basic process

Discharge refrigerant replace parts, charge
refrigerant oilvacuumizecharge refrigerant
commission and operate
842 system drains refrigerant

Low High
pressure pressure 1. Make sure knob switch of the pressure gauge is
end (L) end (H) switched off.
2. Connect the pressure gauge to refrigerant
charging point. Connect red pipeline joints of the
Blue Red 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.
Vacuum pump connecting end, refrigerant Note: do not discharge the refrigerant in
charging end, refrigerant discharge end
liquid state. Wear gloves to prevent hand
Fig.8-14 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.
8-11
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.
Special O ring made from hydrogenated

nitrile rubbers (H-NBR)
Fig.8-16
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.
Evaporator Condenser
Fig.8-17
Fluid reservoir
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.
Pipeline
Refrigerant oil charge
Replaced components
(ml)
Evaporator 30
Condenser 70
Reservoir 30
8-12
Condenser
Autoclaved pipe 30
Pressure cooling pipe,

cold storage pipe and 10
steam storage pipe
Fig.8-18
9. Replace compressor
10. Discharge refrigerant oil in a faulty compressor
and measure refrigerant oil mass.
(Discharge 100ml of refrigerant oil)
Fig.8-19
11. Discharge refrigerant oil in new compressor,

recharge refrigerant oil with mass equivalent to that
in the faulty compressor.
Fig.8-20
8-13
12. Recharge 10ml of refrigerant oil to the new

compressor (100+10=110ml).
Fig.8-21
Low High
pressure pressure 845 Refrigerant charging method
end (L) end (H)
Note: refrigerant charging method for air

Blue Red
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
Connecting pipe of vacuum pump
pressure gauge is switched off.
Fig.8-22 Pressure gauge
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
8-14
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
b) Turn on exhaust knob of the yellow pipeline to

Red inject some refrigerant and exhaust air in the yellow
Blue 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.
Connect refrigerant charging

exhaust button
Fig.8-25
8-15
d) When the pressure gauge shows no change in

pressure display, turn off knob switch on high
pressure end.
Blue Red
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.
Close button of high pressure end

Fig.8-26
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
Blue Red
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.
Open button of low pressure end
h) Observe flow of the refrigerant through sight
Fig.8-27 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.
8-16
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
8-17
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.
8-18
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.
8-19
Common fault diagnosis and troubleshooting
S/N Fault phenomenon Failure causes Troubleshooting
Poor connector clip

contact
Blowing rate switch,
1 Fan does not rotate relay and cold hot Repair or replace it
switch damage
Fuse break or battery
undervoltage
Obstacles on suction
side, rib plate of
2 Fan runs properly evaporator and Clear
condenser blocked by
dust
Compressor clutch does

not pull in as a results of
circuit disconnection
and poor contact
Repair
Loose stretching device
of the compressor belt
falls off and the belt is
Repair
Compressor does not run or runs with too loose
3
difficulty Coils of the compressor
clutch is broken and Replace pull-in coil
faulty
Discharge or charge
High/low pressure refrigerant
switch of the fluid
reservoir works, there is
excess or few
refrigerant
Refrigerant leakage
Eliminate air leakage,
4 Refrigerant supply Insufficient refrigerant supply refrigerant
charge
8-20
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
Measure spot high pressure and low
pressure according to readings of Pressure of high pressure gauge amounts to
high/low pressure gauge 1.27-1.52MPa
Pressure of low pressure gauge amounts to
0.12-0.15MPa
Excess expansion valve

Replace expansion
opening
valve
Poor thermal bulb
Higher low Frost on low pressure Install thermal bulb
contact of expansion
pressure pipe surface properly
valve
Discharge part of
Excess refrigerant in
refrigerant
system
Find out leak points

Displayed value on Pipeline joint looseness by using leak
low pressure gauge due to vibration leads to detector, tighten the
lower than normal leakage and refrigerant loose parts carefully
5
value shortage as charge refrigerant
as specified
The low pressure Low pressure rubber Evacuate the system,

gauge indicates hose is blocked or replace fluid reservoir
negative pressure expansion valve blocked and recharge
sometimes by ice refrigerant
Lower low Temperature controller Replace temperature

Evaporator freeze
pressure failure controller
Inlet side of the

expansion valve is Expansion valve Clean or replace
cool and covered by blockage expansion valve
frost
Outlet side of the

expansion valve is not Air leakage at
cool, the low pressure temperature sensitive Replace expansion
gauge indicates pipe and thermal bulb of valve
negative pressure the expansion valve
sometimes
8-21
Evacuate and
vacuumize the
Air conditioner Air in air conditioner
system again,
system system
maintain pressure and
charge refrigerant
Discharge a given
mass of refrigerant to
Higher high Excess refrigerant Excess refrigerant
keep appropriate
pressure charge charge
mass of refrigerant in
the system
Clean condenser and

clear debris
Poor condensation Poor condensation
effect of condenser effect of condenser Check and replace
broken condensate
6 fan
Find out leak points

Pipeline joint looseness by using leak
due to vibration leads to detector, tighten the
Pipeline
leakage and refrigerant loose parts carefully
shortage as charge refrigerant
as specified
Lower high
Low pressure
pressure
indicates negative Low pressure pipeline is Clean or replace
pressure state blocked and damaged pipeline
sometimes
Not hot compressor

and high pressure Compressor failure Replace compressor
pipeline
7 Poor refrigeration effect Block valve damage Replace block valve
8-22
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 Normal blowing rate at air outlet
Check fan motor of the evaporator Check compressor rotation
Fan motor does not rotate Fan motor rotates, few blowing rate Compressor rotates normally Compressor does not rotate or rotates
abnormally
In accordance Check refrigerant charge

In accordance with In accordance with
the table with the table
Second check the table
First check item Third check item
item
Normal or excess refrigerant Refrigerant shortage

charge
In accordance with
Check system pressure the table
Forth check item
Abnormal system pressure Normal system pressure
In accordance In accordance
with the table with the table
Fifth check item Sixth check item
8-23
Service
S Maanual of Wh
heel Loader
Coonten
nts
9 W m ......................................................................................................................... 1
Working hydrraulic system
91 Oveerview of working hydraulic system ....................................................................................................... 1
92 Meaasurement an
nd adjustmeent of workin
ng hydraulic system .................................................................... 4
4
9221 Measurem
ment of system pressure ................................................ ...................................... 4
m working p 4
ucket cavity .................... ...................................... 6
9222 Overload pressure meeasurement oof rotating bu 6
9223 Primary pressure
p asuring of pillot control ............................................ ...................................... 7
mea 7
9224 Secondaryy pressure measuring
m of pilot controll ......................................... ...................................... 8
8
o cylinder ... .............................................................. ...................................... 9
9225 Settlement detection of 9
9226 Pressure adjustment
a o safety valvve ........................................................... .................................... 100
of
ng the hydraaulic system .......................................... .....................................11
933 Precautionss for repairin
94 Intrroduction to hydraulic co
omponents....................................................................................................... 122
9441 Hydraulicc oil tank ........................... .............................................................. .................................... 122
9442 Working pump
p ................................ .............................................................. .................................... 122
9443 Multiway valve
v ................................. .............................................................. .................................... 13
9444 Pilot contrrol valve ........................... .............................................................. .................................... 177
9445 Pressure selector
s valvee ................... .............................................................. .................................... 199
95 Fau
ult diagnosis and troublesshooting of h
hydraulic sysstem ....................................................................... 200
9661 Bucket fallling .................................. .............................................................. .................................... 200
9662 Boom setttlement .............................. .............................................................. .................................... 222
o the boom ....................... .............................................................. .................................... 23
9663 Slow lift of
o boom lift ....................... .............................................................. .................................... 266
9664 Inability of
9665 Blow buck nt ................. .............................................................. .................................... 277
ket movemen
9666 Inability bucket
b movement ........... .............................................................. .................................... 277
I
Service Maanual of Wheel
W Loadeer
9 Worki
W ing hydrraulicc
systtem
91 Overview
O w of worrking hy
ydraulicc
system
m
Workin
ng hydraulicc system haas two typees includingg
mechannical controol type annd pilot co
ontrol type..
Workin
ng pressuree of the syystem is 16Mpa.
1 Itss
schemaatic diagram
m is as follow
ws:
转向油缸
STEERING CYLINNDER
动臂油缸缸
LIFTING CYLINDER
L R
B2
A2 4
B1
A1
120bar 180bar
转斗油缸缸
TILT CYLINNDER
160bar 转向器器
STEERINGG UNIT
T P
T Ls P
Ls CF EF
140bbar
回油滤芯
FILTER INSERT 优先阀 P
PRRIORITY VALVE
齿轮泵
GEAR PUMP
图 9-1 L9366Hydraulic schematic

s diagram
d (meechanical)C
China market
1
动臂油缸
LIFTING CYLINDER
K 2C
A2
转向油缸
B2 STEERING CYLINDER
2a
2A
2B
转斗油缸 2b 1A L R
TILT CYLINDER 1B
A1
B1
d
1
1a
180bar 120bar 1b
图 9-2 L9366Hydraulic sschematic diagram

先导阀
160bar PILOT VAVLE
P T
2
T 多路阀 P
CONTROL VALVE
滤油器
W
m
转向器
FILTER
STEERING UNIT
T Ls P
(pillot) China market

Ls CF EF
Loadeer
T T
P3
140bar
压力选择阀 P1 优先阀 P
PRESSURE SELECTOR VALVE PRIORITY VALVE
齿轮泵
GEAR PUMP
回油滤芯
FILTER INSERT
动臂油缸
LIFTING CYLINDER
K 2C
A2
B2
2a
2A
2B
转斗油缸 2b 1A
TILT CYLINDER 1B
A1 转向油缸
STEERING CYLINDER
图 9-3 L9366 L938 Hydra

B1
1a
L R
180bar 120bar 1b
aulic schem
A3
先导阀
B3 PILOT VALVE
3a
P T
3b
matic diagram
3
160bar
m (pilot)
滤油器
T 多路阀 P FILTER 转向器
W
CONTROL VALVE STEERING UNIT

油缸
CYLINDER
T Ls P
except Chin
Loadeer
Ls CF EF
液压锁
T T
na market
HYDRAULIC LOCK
P3
120bar
电磁阀
SOLENOID VALVE 压力选择阀 P1 优先阀 P
PRESSURE SELECTOR VALVE PRIORITY VALVE
回油滤芯
齿轮泵 FILTER INSERT
GEAR PUMP 齿轮泵
回油滤芯 GEAR PUMP
FILTER INSERT
W Loadeer
92 Measurem
M ment and d adjusttment off
work
king hydrraulic syystem
921 Measurem
M ment of system workingg
pressu
ure
Measurrement of oiil temperatuure: 45 - 55℃.
Pressurre measurinng tool: 400Mpa presssure gaugee
(403000 00370), pressure connnector (4120002945),,
piezom 40300003688).
metric tube (4
Pressurre measuring
g standard: 16 Mpa
Pressurre measuring g position: pplug screw location onn
the oil inlet
i of the multi-way
m vvalve.
Fig. 9-3 40030000370 pressure
p gauge
Pressurre measuring
g process:
1. Plaace the worrking devicee on the gro
ound. Presss
thee button off parking bbrake. Wed dge the tiree
wiith wood or stone. Turnn off the eng
gine.
2. Manipulate th he control hhandle and the
t steeringg
whheel for 10 1 times and aboutt 5 timess
resspectively to
t release reesidual presssure in thee
hy
ydraulic oil pipe. Preppare tools for
f pressuree
meeasuring.
3. Reemove the pressure
p meeasuring plu
ug screw onn
thee oil inlet off the multi-w
way valve.
4. Install the pressure
p meeasuring jo oint to thee
preessure port of the multiti-way valvee.
5. Tighten piezzometric tuube on th
he pressuree
meeasuring joiint.
Fig. 9-4 41120002945 pressure
p meeasuring joiint
6. onnect the pressure ggauge to th
Co he pressuree
meeasuring hose.
7. Staart the engin
ne and placce the contro
ol handle off
thee rotating bucket
b in the
he close possition. Afterr
thee bucket is placed in pposition andd moved too
thee limit position, graduually acceleerate to thee
maaximum (2200/rpm).
( . Observee the oill
preessure gaug ge to obtaiin the stablle pressure,,
whhich is the current woorking pressure of thee
woorking device hydrauliic system of the testedd
loaader.
No
ote: To con
nfirm measuurement acccuracy, thee
control handle off the boom
m might be moved too
lifting or falling posittions for repeatedd
measurements.
4
W Loadeer
Fig. 9-5 40030000368 pressure
p meeasuring ho se
Fig. 9-6 M
Measurementt location off system preessure Fig.
5
W Loadeer
922 Overload
O pressuree measurement off
rotatiing buckeet cavity
Note: This pressure measururing metho od is onlyy
applicable to fauult diagnoosis. Serviccemen aree
prohibited to adjust the ovverload vallve on thee
machinne.
Pressurre measurin
ng tool: 400Mpa presssure gaugee
metric tube (40300000368). See 921
piezom
Measurrement of sy
ystem worki
king pressure
g standard: 18 Mpa.
Pressurre measuring
Pressurre measurin ng positionn: Plug scrrew on thee
steel pip
pe of the rotating buckket cavity
Pressurre measuring
g process:
1. Plaace the worrking devicee on the gro
ound. Presss
thee button off parking bbrake. Wed dge the tiree
wiith wood or stone. Turnn off the eng
gine.
2. Manipulate th he control hhandle and the
t steeringg
whheel for 10 1 times and aboutt 5 timess
resspectively to
t release reesidual presssure in thee
hy
ydraulic oil pipe. Preppare tools for
f pressuree
meeasuring.
3. Reemove the plug
p screw of pressuree measuringg
on
n the steel piipe of the rootating buck
ket cavity.
4. Install the pressure
p meeasuring jo oint to thee
preessure port of the multiti-way valvee.
5. Tighten piezzometric tuube on th
he pressuree
meeasuring joiint.
6. Staart the engiine. Lift thee boom to the highestt
po
osition. Run n the diesell engine at idle speed..
Manipulate th he control hhandle of the
t rotatingg
bu
ucket to the maximum.. Return to the neutrall
po
osition. Opeerate the coontrol handle to lowerr
thee boom. Th he current m maximum pressure
p off
thee pressure gauge
g is thee overload pressure off
thee overload d valve off the rotatiing buckett
cy
ylinder cavitty. (The maaximum stress appearss
aftter the buck
ket reaches tthe limit position)
Note: The measu
urement mi
might be reepeated forr
confirm
mation.
Fig. 9-7 M
Measurementt position off overload vvalve pressu
ure
6
W Loadeer
923 Primary
P pressurre measu
uring off
pilot control
c
Note: This
T operation is appliccable to mo
odel of pilott
control only.
T-junctiion (41200001100) annd piezom metric tubee
(403000 00368).
Pressurre measuring
g standard: 3.5 Mpa.
Pressurre measuring
g position: O
Oil inlet of pilot filter.
Fig. 9-8 64410003106 pressure
p gauge
Measurrement proccess:
1. Plaace the loaader in the service loccation. Layy
thee bucket onn the ground
nd. Pull up the
t parkingg
braake. Shut down the engine. Operate O thee
haandle of the working device han ndle 3 - 5
tim
mes to releaase residual stress in th
he hydraulicc
oill pipe.
2. Reemove the inlet pipe off the pilot filter.
f Installl
thee T-junctio
on on the location of o removal..
Install the test joint aand oil piipe on thee
T-jjunction.
3. Co
onnect one end of thee test hoes to t the jointt
an
nd the other end to the ppressure gau
uge.
Fig. 9-9 T-jjunction annd test joint
4. Staart the engiine. Move tthe pilot haandle to thee
lim
mit position
n. Graduallyy accelerate to observee
thee pressure gauge
g for a sstable presssure value.
5. Thhe control handle
h migght be moveed to otherr
lim
mit positionn to repeatt the measuurement too
guuarantee acccuracy of tesst data.
6. Affter test, rep
peat step 1 of pressuree releasing..
Reemove the T-junction
T an
and install th
he oil pipe.
7 Wipe
W hydraullic oil leakinng in the rem
moval.
m hhose
7
W Loadeer
Fig. 9-11 P
Primary presssure measu
uring positioon of pilot control
c
924 Secondar
S y pressu
ure meassuring off
pilot control
c
Note: This
T operation is appliccable to mo
odel of pilott
control only.
T-junctiion (41900000208) anand piezommetric tubee
(403000 00368).
Pressurre measuring
g standard: 2.5 Mpa.
Pressurre measurin
ng positionn: Pilot pip
pe joint off
multi-w
way valve.
Fig. 9-12 664100031066 pressure gauge
g
Pressurre measuring
g process:
1. Plaace the loaader in the service loccation. Layy
thee bucket onn the ground
nd. Pull up the
t parkingg
braake. Shut down the engine. Operate
O thee
haandle of the working deevice handlle 3-5 timess
to release ressidual stresss in the hy
ydraulic oill
pippe.
2. Reemove the pilot
p oil pippe as shown n in Figuree
9-15. Install the
t T-junctiion on the location off
rem
moval. Instaall the test jjoint and piilot oil pipee
on
n the T-juncttion.
3. Coonnect one end of thee test hoes to the testt
joiint and the other
o end too the pressure gauge.
Fig. 9-13 T
T-junction and
a test jointt
4. Staart the engin
ne. Manipuulate the piloot handle too
mo ove the bucket to the liimit position
n. And thenn
graadually accelerate
a to the maximum..
Ob bserver the oil pressurre gauge to o obtain thee
staable pressuure value, which is the pilott
8
W Loadeer
preessure at the back joint
nt position of
o the testedd
loaader.
Measurrement meth
hods of othher joints are similar too
it.

m hhose
5. Th he control handle
h mighht be moveed to boom
m
lifft position to repeat the measu urement too
guuarantee acccuracy of tesst data.
6. peat step 1 of pressuree releasing..
Affter test, rep
Reemove the T-junction
T aand install and
a removee
thee oil pipe. Wipe
W hydrauulic oil leak ked.
Fig. 9-15 P
Pilot pressurre measurem
ment point oof back join
nt
925 Settlemen
nt detectioon of cyliinder
Measurrement of oiil temperatuure: 50 ± 3℃
℃.
Pressurre measuring
g tool: Timeer and meteer ruler.
Measurrement stand
dard:
Cylindeer of rotatin
ng bucket ≤220mm/h;
Lift cyllinder ≤50m
mm/h.
Measurring positio
on: Boom cylinder or buckett
cylindeer
Measurrement proccess:
1. Looad the buck ket to the raated workin
ng mass andd
revverse it backward.
b Operate the boom m
cy
ylinder to lift the buucket to the t highestt
po
osition. Mo ove the muulti-way vaalve to thee
neeutral positio
on and turn off the enggine.
2. Measure the extension
e leength of boo
om cylinderr
nd bucket cylinder evvery 15 minutes
an m andd
reccord the data in corrresponding table. Thee
tottal test duraation is 3h.
9
W Loadeer
926 Pressuree adjusttment of safetyy

valve
If any y pressurre abnorm mity afterr pressuree
measurement of the t hydraullic system, adjust thee
pressurre of the saffety valve. T
The set presssure of thee
main saafety valve on the muulti-way vallve decidess
the wo orking pressure of tthe system m. The sett
pressurre of the safety
s valvee on the pilot
p pumpp
decidess the primaary pressurre of the pilot
p pump..
Now it is to introd
duce how to adjust the sets value off
safety pressure
p with the mai ain safety valve
v as ann
examplle.
Fig. 9-16 P
Position of main
m safety valve
Adjustm
ment processs:
1. Reemove the lead
l sealingg and protection coverr
at the end su
urface of thhe pressuree regulatingg
scrrew .
2. Lo
oosen lockn
nut with a w
wrench.
3. Rootate the pressure reggulating scrrew with a
socket head wrench. Th The pressuree increasess
whhen the sccrew is rottated clock kwise. Thee
preessure decrreases whenn the screw
w is rotatedd
an
nticlockwisee. Adjust too the proper pressuree
an
nd fasten locknut. R Reference value:
v Thee
adj
djustment am mount for rotating the adjustingg
scrrew by a cirrcle is 4Mpaa.
4. Peenetrate a fine steel wirre into the hole on thee
preessure regu
ulating screww 3 and theen penetratee
intto the proteection coveer. Seal it with
w a leadd
seaaling.
1 2 3
Fig. 9-17 M
Main safety valve
1 Locknut 2 Pressurre regulating screw
3 Protectioon cover
Adjustmment of the safety valvve on the pilot pump iss
similar to the ab bove descrription. Butt referencee
values of adjustment are difffferent to so
ome extent..
The addjustment am mount for rotating the adjustingg
screw by
b a circle iss 1Mpa.
Note: The
T adjustm ment vales aare for refeerence only..
The speecific adjusttment shoulld be subjecct to the sett
pressurre value.
Fig. 9-18 P
Position of safety
s valvee of pilot puump
10
W Loadeer
93 Precautio
P ons for repairiing thee
hydra
aulic systtem
1. Avvoid addingg hydraulic oil or repllacing filterr
or preparing the
t machinne in rains or
o places off
strrong wind or
o much dusst.
2 Thhe hydraulicc device shhould be disassembledd
an
nd maintaineed in a speccial dust-freee workshopp.
In addition, its
i performaance should d be testedd
wiith special test devices..
3. Paay attention to openingss of the seall.
4. It is suggesteed to replacce the oil when
w the oill
tem
mperature is hot. U Used oil should bee
disscharged thoroughly inn oil replaceement.
5. In disassem mbly, asseembly of hydraulicc
eq
quipment orr oil replaceement, rinsee pollutant,,
fattlute and used oil in tthe hydraullic oil withh
flu
ushing oill. Rinse twice in normall
cirrcumstancess: Rinse the first time withh
flu
ushing oil; rinse thee second time withh
specified hydraulic oil.
6 In the processs of dismanntling and maintenance
m e
off hydraulic system, it is requiredd to fastenn
according to the
t torque rrequired in the
t manual..
Exxcessive or insufficiennt torque might
m causee
leaakage of hydraulic oil.
7 Prressure of the systemm should be
b releasedd
according to steps beloow before maintaining
m g
thee hydraulic system:
(1) Start the engine.
e Drivve the vehiccle to a flatt
an
nd wide grround. Movve the boom to thee
hig
ghest position. Retroveert the bucket.
(2) Push the con ntrol handlle of the pilotp valvee
baackward slowly. Ante tevert the bucket too
disscharge oil in the buckeet cylinder.
(3) Affter the buccket is movved in place, push thee
haandle forwaard slowly to lower the boom m
graadually to discharge
d oiil in the boo
om cylinderr.
Plaace the bu ucket on thhe ground. Move thee
co
ontrol handle all arounnd 5-6 timess to releasee
thee oil pressurre in the sysstem.
Fig. 9-19 P
Pressure reliief of the sy
ystem
11
W Loadeer
94 Introdu uction to hy
ydraulicc
ponents
comp
941 Hydraulic
H c oil tank
k
It is used
u to sup
pply oil to the wholee hydraulicc
system.. An oil retu
urn filter tannk is set in the oil tankk
to remove impuriities in thee hydraulic system too
guaranttee cleanlineess of hydraaulic oil.
Fig. 9-20 H
Hydraulic oiil tank
942 Working
W pump
p
L936/L L938 workiing pump iis duplex pump. p Thee
first on
ne supplies oil to workking hydrau ulic system,,
and thee second onee supplies ooil to pilot sy
ystem.
Table 9-1
9 L936 wo orking pump
mp parameterrs
Name Parameeter
Coonnection mode
m Rectangulaar spline
Rottation direction Laevorottatory
Nomiinal displacement 100/110
Range
R of speeed 600-2500 0r/min
Figure 9-23 L936 worrking pump Woorking presssure 20Mp pa
Safetty valve preessure 3.5 Mpa
M
Table 9-2
9 L938 wo orking pump
mp parameterrs
Name Parameeter
Coonnection mode
m Rectangulaar spline
Rottation direction Laevorottatory
Nomiinal displacement 100/110
Range
R of speeed 600-2500 0r/min
Woorking presssure 20Mp pa
Figure 9-244 L938 worrking pump
Workin ng pump annd steering pump of L936
L loaderr
in Chin na belong to the sam me pump. Please seee
steering
g system forr details.
12
W Loadeer
943 Multiway
M vallve
Multiwway valve ofo the loadeer can be divided
d intoo
mechan nical contrrol multiw way valve and pilott
control multiway valve accoording to co ontrol type..
Mechan nical conttrol multiw way valvee controlss
movem ment of valvve rod throuugh flexiblee shaft, thuss
realizin
ng make-brreak of oill liquid; piilot controll
multiwway valve realizes
r moovement off valve rodd
throughh piloting oil
o liquid. In China, mechanicall
control multiway valve moddel is DFS--25-16, andd
pilot co
ontrol multiw
way valve mmodel is D3 32-16.
In the non-Chinese
n e region, muultiway valvve model iss
D32A-16.
Figure 9--25 DFS-25-16 multiwaay valve Figure 9-26 DFS-2

25-16 multiw
way valve principle
p
Figure 9-27 D32-116 multiway

y valve Figurre 9-28 D32
2-16 multiw
way valve prrinciple
13
W Loadeer
Figurre 9-29 D322A-16 multiiway valve Figure 9-3

30 D32A-166 multiway valve
Precauttions for insstallation annd using off multi-wayy

valve
Take annd place geently in hanndling and installationn
to avoid
d collision.
To prevvent foreiggn matters, plastic pluug of eachh
hydraullic oil port shall not bbe removed
d before thee
machin
ne is assemb bled.
The insstallation plate
p and brracket shou
uld be flat..
Installaation bolts should be fastened unniformly too
preventt the valve body
b from ddeformation
n
The woorking oil should be cllean. The cleanness off
oil and
d system sh hould not be lower than gradee
19/16 of
o ISO4406 or grade 111 of NAS1638.
Multi-v
valve and piilot valve sh
should be co
onnected too
workingg oil port co
orrectly.
14
W Loadeer
Fault an
nd troublesh
hooting of m
multi-way valve:
v
Table 9-2 F
Fault and trooubleshootiing of multii-way valvee
Refereence map off fault
S/N Fault Causse Soluttion location
Clamping of valve
C
UUnpick and wash or
e
element of high
h
Auutomatic rreplace high
h pressure
p
pressure oveerload
duump and ooverload vallve
v
valve
1 fallling of
rotating
buucket E
Excessive in
nterior RRefer to the cylinder
lleakage of rotating
r mmanufactureer for
b
bucket cylin
nder ddetails.
Clamping of valve
C
Rootating UUnpick and wash or
e
element of low
l
buucket rreplace low pressure
p
pressure oveerload
inccapable ooverload vallve
v
valve
2 orr fails to
suupport
thee
veehicle Excessive in
E nterior RRefer to the cylinder
l
leakage of rotating
r mmanufactureer for
b
bucket cylin
nder ddetails.
Clamping of the
C
UUnpick and wash or
s
safety valvee
rreplace relieef valve
e
element
Inncapable
orr slow Excessive lo
E ow
3 AAdjust posittion of
thee boom s
safety valvee
rrelief valve
liffting p
pressure
Lose efficieency of
L
M
Maintain oill pump
p
pump
Excessive in
E nterior RRefer to the cylinder
l
leakage of boom
b mmanufactureer for
Exxcessive b
bucket cylin
nder ddetails.
4 settlement
off boom Excessive leeakage
E
RReplace the entire
i neutral po
in osition
vvalve
o the valvee body
of
15
W Loadeer
RReplace
O
O-rings dam
maged
ccorrespondin
ng O-rings
Exxternal
5 oill
leaakage Relevant fassteners
R TTighten corrresponding
a loose
are ffasteners
16
W Loadeer
944 Pilot
P control valvee
Pilot control
c hyddraulic syste tem is equipped withh
pilot control
c valv
ve. The ppilot contro ol valve iss
installeed on the rig
ght side of ddriver’s seatt in the cab..
Throug gh controlliing the pillot control lever, thee
personn nel can conttrol action oof slide valvve of boom m
or slidee valve of rotating buucket in thee multiwayy
valve, thus realiziing control of working g device off
the vehhicle.
Figure 9-31 Pilot conttrol valve Figure 9-32 Oil po

orts at the bbottom of pilot
p controll
valve
Figure 9-33 Schematicc diagram of

o pilot conttrol valve
17
W Loadeer
Trroubleshootiing of pilot control valv
ve
Table 9-4 T
Troubleshoooting of pilo
ot control vaalve
S/N Fault Cause Reemoval metthod
Check thee cleannesss of the oil,,
Jam
mmed vaalve elem
ment or
clean the valve coree and valvee
moovement fauult
hole.
Deeformation of pressu
ure relief
1 Pilot valve faault Replace th
the spring
sprring
Inssufficient control flow or Check wwhether the oil supplyy
preessure system wo
works normaally.
Un
niversal joinnt inflexiblee Add greasse for jointss
Poor contact oof circuit Check and
nd maintain the circuit
Low power suupply voltag
ge Replace th
the battery
Remove dirt on th he junctionn
M
Magnet poosition Du surface oof pure iron
n plate andd
2 ust cover daamaged. Du ust entering
unnreliable electromaagnet. App ly a smalll
eleectromagnett resullts in
amount of anti-ru ust oil orr
inssufficient suuction.
hydraulicc oil and replace
r thee
dust coveer.
Eleectromagnett damaged Replace th
the electrom
magnet
Flloating fuunction Claamping of th
the valve eleement Clean parrts
3
fauult Sprring deform
med Replace th
the spring
0-rring damageed Replace th
the sealing element
e
4 Leeakage Replace componentts of thee
Oill leakage off dynamic seal
dynamic ssealing cover
18
W Loadeer
945 Pressure
P selector
s vvalve
The preessure selecctor valve iis installed in the pilott
oil-wayy. It is mainlly composeed of valve body,
b valvee
element, spring, etc.
e The prressure seleector valvee
role is to provide control oil of certain pressure too
the pilo
ot valve and d guaranteee to place th
he boom onn
the grouund even if the diesel eengine has flameout.
f
The mo odel of the pressure seelector valvee is SF8-D..
Its nom
minal pressu ure is 20Mpaa. The exit pressure off
the relieef port is 4±
±0.2MPa.
Fig. 9-26 A
Appearance of pressuree selector vaalve
Fig. 9-27 S
Section of pressure
p seleector valve Fig. 9-28
9 Schem
matic diagraam of pressu
ure selectorr
valve
19
W Loadeer
95 Fault diaagnosis and

d
bleshootiing of hyydraulic system
troub
961 Bucket
B fallling
Fault phenomeno on: the bbucket au utomaticallyy
anteverrts (falling) when the control han ndle of thee
pilot vaalve is in thee neutral poosition.
Fault analysis:
a whhen the buucket is in the closedd
state an
nd the contrrol handle oof the pilot valve is inn
the neu n, dead loadd of the bucket causess
utral position
the buccket cylindeer suffer prressure fromm the largee
cavity. At this point, thhe bucket antevertss
automaatically as loong as the ppressure oil in the bigg
cavity pressure has h leakagge against the returnn
openingg.
Fault caauses:
1. Pippeline fault: There iss apparent leakage inn
pip
pe fittings, joints
j of cyylinder largee cavity andd
muulti-valve and junnction su urface off
insstallation.
2 Oiil cylinder fault:
f Besidees inner leaakage of thee
rottating buckket cylinderr, the smalll cavity off
thee rotating bucket cylinder also a leakss
co
ompared witth the returnn opening.
3. Multi-way vaalve or pilot valve fault:
 The reverrsing slid valve of th he rotatingg
Filter valvve bucket fails to return
rn the neutrral positionn
so that thhe small ccavity of th he rotatingg
bucket cyylinder is coonnected too Port P off
multi-wayy valve, largge cavity an
nd returningg
opening.
Rotating
R
bu
ucket valve  The overrload presssure of thee overloadd
valve for the large cavity of the
t rotatingg
bucket cylinder on thhe multi-wayy valve.
Rotating buck
ket  The oil supplementaary valve of o the largee
slide valve of cavity of the rotatingg bucket cyllinder leakss
multi--way valve
oil.
 Valve element or valve ho ole of thee
reversing valve is exxcessively worn
w so thatt
the fit cleaarance of vaalve elemen
nt and valvee
hole is mu uch higher than the deesign value..
As a result, pressure oil in the large
l cavityy
of the rotaating buckett cylinder leeaks.
Fig. 9-29 S
Schematic diagram
d of rotating
r buccket joint
Fault deetection and
d troubleshoooting
20
W Loadeer
1. Chheck the pipeline
p foor leakage: Start thee
maachine and raise the booom to a cerrtain heightt
to return the bucket
b to thhe maximum m. Observee
whhether theree is appareent leakagee on pipes,,
joiints from th
he large cavvity of rotating buckett
cy
ylinder to the multi--way valvee and thee
jun
nction surfaace of installlation, etc.
2. Ju
udge whetheer the pilot valve has fault: If noo
ex
xternal leakaage, raise thhe boom to the highestt
po
osition by operating
o thhe pilot valve handle..
Affter the bucket is raissed to the maximum,,
cloose the eng gine and reemove pilo ot pipes onn
bo
oth ends of the slide vvalve of thee multi-wayy
vaalve rotating
g bucket joinnt The buckket does nott
falll, it might be the pillot valve which
w causee
thaat the slidee valve off the multi--way valvee
rottating buck ket fails tto return thet neutrall
po
osition and d thus cau auses buck ket falling..
Diismount, ch heck and cleean or replaace the pilott
vaalve. Or oth herwise, coontinue thee followingg
steeps for judg
gment.
3 Ju
udge whetheer the oil cyylinder leak ks: Operatee
thee handle of the pilot vaalve to loweer the boomm
to the lowest position annd retrovertt the buckett
to the maximum. Cloose the engine e andd
dissconnect the hose for tthe small caavity of thee
rottating buck ket and llead it baack to thee
hy
ydraulic oil tank. Then,, start the machine
m andd
op
perate the handle off the pilott valve too
rettrovert the bucket. Obbserve whetther the oill
po
ort of the laarge cavity of the rotating buckett
cy
ylinder leakss hydraulic oil constan ntly. If yes,,
thee rotating bucket ccylinder has h seriouss
leaakage. It is required too dismount,, check andd
reppair or replace the cyylinder. If oil
o cylinderr
haas no leakaage, continnue the nex xt step forr
juddgment.
4. Ju
udge wheth her the oveerload valv ve and oill
su
upplementary valve is damaged: Connect a
40
0mpa pressure gaugge to thee pressuree
meeasuring po ort of the large cav vity of thee
rottating buckket cylindeer. Start thee machine..
Opperate the handle
h of thhe pilot valve to makee
thee bucket in
n the most fforward position. Stepp
on
n the acceleerator and operate thee handle off
thee pilot. Obsserve whethher the reading of thee
preessure gaug
ge reaches thhe design value
v duringg
thee lifting process
p off the boom m. If not,,
dissmount, cheeck and cleean the overload valvee
or oil supplemmentary vallve of the large
l cavityy
21
W Loadeer
off the rotating
g bucket cyllinder.
5. Chheck whetther the slide valv ve of thee
mu ulti-way vaalve is dam maged: If the abovee
sittuations are excluded, stop the machine
m andd
lowwer the booom and the bucket to the t bottom..
Reemove the rotating buucket slid valve
v of thee
mu ulti-way vaalve and cheeck the vallve rod andd
vaalve holes caarefully for fitness. Vallve elementt
or valve ho ole of thee reversing g valve iss
ex
xcessively worn
w so thaat the fit clearance off
vaalve elemen nt and valvee hole is much
m higherr
thaan the desig
gn value. A As a result, pressure
p oill
in the large cavity off the rotating buckett
cy
ylinder leakss.
962 Boom settlem
ment
Fault phenomenon n: when thee control haandle of thee
pilot valve is in the neutraal position, the boom m
lowers automaticaally and exxceeds the settlementt
Conneccted by pressuure selector valve
v standarrd of the cylinder.
Fault annalysis: wh
hen the boom m is lifted and kept att
any heeight, dead load off the boo om makess
correspponding oil pressure bee reserved ini the largee
cavity of
o the boomm cylinder. A
At this poinnt, the boom
m
lowers automaticaally as long as the pressure oil inn
Boom the big cavity presssure has leeakage commpared withh
cylinder urn opening.
the retu
Fig. 9-30 S
Schematic diagram
d of boom
b joint
Fault caause:
1. Pippeline fault: There iss apparent leakage inn
pip
pe fittings, joints
j of cyylinder largee cavity andd
muulti-valve and junnction su urface off
insstallation.
2. Oiil cylinder fault:
f Besidees inner leaakage of thee
bo
oom cylindeer, the smaall cavity off the boom m
alsso leaks com
mpared withh the return opening.
3. Multi-way vaalve or pilot valve fault:
 The boom m reversinng valve rod r of thee
multi-wayy valve faills to return the neutrall
position so
s that thee small cav vity of thee
boom cylinder is connnected to pump port,,
large cavity and returrning openin
ng.
 Valve element or valve ho ole of thee
reversing valve is exxcessively worn
w so thatt
22
W Loadeer
the fit cleaarance of vaalve elemen
nt and valvee
hole is mu uch higher than the deesign value..
As a result, pressure oil in the large
l cavityy
of the booom cylinderr leaks.
d troubleshoooting
1. Chheck the pipeline
p foor leakage: Start thee
maachine and raise the boom to the t highestt
po
osition to reeturn the buucket to the maximum..
Obbserve whether there iis apparent leakage onn
pip
pes, joints from the llarge cavity y of boom
m
cy
ylinder to the multi--way valvee and thee
jun
nction surfaace of installlation, etc.
2. Ju
udge whetheer the pilot valve has fault: If noo
ex
xternal leakaage, raise thhe boom to the highestt
po
osition by operating
o thhe pilot valve handle..
Affter the bucket is raissed to the maximum,,
cloose the engine and dissconnect pillot pipes onn
oth ends of the slide vvalve of thee multi-wayy
bo
vaalve boom slide
s valve. If the boom m does nott
setttle, it migh
ht be the pillot valve whhich causess
thaat the slidee valve off the multi--way valvee
bo
oom slide valvev fails to return the neutrall
po
osition and thus causses boom settlement..
Diismount, ch heck and cleean or replaace the pilott
vaalve. Or oth herwise, coontinue thee followingg
steeps for judggment.
3 Ju
udge whetheer the oil cyylinder leakss: Raise thee
booom to the maximum. Close the engine andd
oppen the hosee of the smamall cavity of
o the boom m
cy
ylinder to leead it backk to the hy ydraulic oill
tannk. Start thee machine aand operatee the handlee
off the pilot vaalve. Observve whether the oil portt
off the small cavity
c of thhe boom cyllinder leakss
hyydraulic oill constantlyy. If yes, the boom m
cy
ylinder has inner leaka kage. It is required
r too
dissmount, ch heck and rrepair or replace
r thee
cy
ylinder. If oiil cylinder hhas no innerr leakage, itt
is required forr analyze fuurther.
4. udge fault off multi-wayy: Lower thee boom andd
Ju
bu
ucket to the bottom. Reemove boom m valve rodd
off the multi-way valve. Check thee valve rodd
nd the valve hole carefuully for fitneess.
an
963 Slow lift of
o the booom
Fault phenomenon
p n: operate ththe handle of
o the pilott
valve ata the rated speed of tthe diesel engine.
e Thee
time reequired to lift the boom m from thee bottom too
the hig ghest positiion is longger than th
he standardd
lifting time.
t
23
W Loadeer
Fault analysis:
a according to the characcteristics off
the hyddraulic power componeent, the cau use for slow
w
lifting of
o the boomm is: the floow delivereed from thee
pump to o the hydrau
ulic oil cylinnder is insu
ufficient.
Faault cause:
 Joints, pipes and vaalves from the pumpp
opening to t the largee cavity off the boom
m
cylinder and
a other juunction surrfaces havee
severe leaakage.
 The hydraaulic oil coontains a larrge amountt
of air bub
bbles or apppears black, gets severee
deterioratiion and losses the corrrespondingg
viscosity.
 The suctiion filter iis blocked or interiorr
rubber off the fuel ssucking pippe falls outt
and thus causes the fuel sucking pipe bee
blocked. As
A a result, severe insu
ufficient oill
suction caauses insuff
fficient outp
put flow off
the workinng pump.
 The workk pump hass severe inn ner leakagee
which cau
uses insufficcient outputt flow.
 The boom cylindeer has sev
vere innerr
leakage.
 Main saafety valvve pressuree of thee
multi-way
y valve is tooo low.
 There is severe
s inner
er leakage between
b thee
oil inlet passage
p andd return passsage of thee
multi-way y valve bodyy.
 Reversingg valve or hhole of thee multi-wayy
boom is excessivelyy worn so that the fitt
clearance of valve ellement and valve holee
is much higher
h than tthe design value. As a
result, pressure oil leaks from m the largee
cavity of the
t boom cyylinder.
 The openiing degree of the multti-valve rodd
is insufficcient.
d troubleshoooting
1. Ch heck for outter leakage: Start the machine
m andd
lifft the boom
m. Observe whether jo oints, pipess
annd valves fro
om the pum mp opening to the largee
caavity of the boom cylinnder and oth her junctionn
su
urfaces have severe leakkage.
2. heck the oiil: In case of no outer leakage,,
Ch
co
onduct bassic inspecctions: wh hether thee
hy
ydraulic oil level in thee oil tank iss above thee
24
W Loadeer
low
west levell; whetherr the hyddraulic oill
co
ontains larg
ge amount of bubblees or turnss
blaack.
3. Chheck sound d: It is rrequired to o start thee
maachine to ju udge whethher the hydrraulic oil iss
abbnormal. Op perate the ppilot valve to
t add loadd
to the hydraaulic system m. Meanw while, it iss
reqquired to pay
p attentiion to judgge whetherr
theere is any sq
queal in thee working pump. If yess,
it means thatt the oil suuction of th he workingg
puump is woeefully inadeequate. Cheeck the oill
su
uction filter and hose.
4. Chheck the wo orking pump mp for inner leakage: Iff
thee working pump
p has nno squeal, operate thee
pillot valve to
o make the pump load ded for 1-22
miinutes. Closse the enginne. Touch thet shell off
thee working pump
p with hand careffully. It thee
shell is very hot. It couuld be judg ged that thee
wo orking pump has severre inner leak kage, whichh
caauses insuffiicient outpuut flow.
5. Teest pressuree: Connectt a 40MP Pa pressuree
gaauge to the pressure m measuring opening off
thee multi-wayy valve Poort P. Start the enginee
an
nd operate thet handle of the pilo ot valve too
preess the hydraulic
h system. Meanwhile,
M ,
ob
bserve the pressure
p gauuge. Its readding shouldd
reaach the design
d preessure. Co onduct thee
folllowing insspections iff it fails to
o reach thee
deesign pressu
ure.
6. Teest the oil cy
ylinder for iinner leakag
ge: Start thee
maachine. Opeerate the haandle of the pilot valvee
to lower the boom to thhe lowest position andd
rettrovert the bucket
b to thhe maximum m. Close thee
en
ngine and disconnect
d tthe hose fo
or the largee
caavity of the boom
b cylinnder and leaad it back too
thee hydraulic oil tank. TThen, start thhe machinee
an
nd operate the t handle of the pilo ot valve too
lowwer the boo om. Observve whether the oil portt
off the large cavity
c of thee boom cyllinder leakss
hyydraulic oill constantlyy. If yes, the boom m
cy
ylinder has serious leakkage. It is required too
dissmount, ch heck and rrepair or replace
r thee
cy
ylinder.
7. Ch heck the main
m safetyy valve: disassemble,,
ch
heck and cllean the ma main safety valve. Thee
maain safety valve shouldd be replaced in case off
irrreparable isssues such ass deformatiion of valvee
eleement, hole, etc.
8. Ch
heck the multi-way
m vvalve: If the
t system
m
25
W Loadeer
preessure still fails to reac
ach the desig
gn pressuree
aftter the abo ove attemptts. It is suuggested too
dissassemble and
a check tthe boom valvev rod off
thee multi-way y valve. C Check the valve
v body,,
vaalve rod, valve hole as well as vallve rod andd
vaalve hole forr fitness carrefully.
9. If the pressure of the hyddraulic systtem reachess
thee design vaalue and thee slow lifting issue off
thee boom stilll exists, it is required to conductt
thee inspection
ns and troubbleshooting below:
Operatee the pilot valve
v to low
wer the boo om and thee
bucket to the lowest position. Open the end cover off
the slid
de valve end d without sppring of thee multi-wayy
valve boom.
b Move the vaalve rod ax xially. Payy
attentio
on to observ
ve whether tthe movemeent distancee
of the valve
v rod iss proper andd whether th he return iss
free.
Exchan nge the pilo
ot pipes coontrolling the
t rotatingg
bucket valve rod and
a the booom valve ro od. Start thee
machin ne and opeerate the ppilot valvee. Observee
whether the boom lift is norm
mal. If yes, disassemble
d e,
check and
a clean thhe boom vaalve block of the pilott
valve.
964 In
nability of
o boom llift
Fault phenomenon
p n: operate th
the handle ofo the pilott
valve to lift the boom
b with full load ata the ratedd
speed of
o the dieseel engine, bbut it fails to lift thee
boom.
Fault annalysis: the most direcct cause for inability off
the booom lift is thhe excessivve low presssure in thee
large caavity of the boom cylinnder.
Fault caause:
The ov
verload presssure of thee main safety valve off
the mullti-way valv
ve is too low
w.
The woorking pump p has severre inner leak
kage whichh
disabless the system
m to form pressure or reach thee
design pressure.
p
The boo
om cylinderr has severee inner leakaage.
There is
i severe inner leakagee between the
t oil inlett
passagee and return
n passage oof the multii-way valvee
body. It
I disables the systemm to form pressure
p orr
reach th
he design prressure.
d troubleshoooting
As for troubleshoo
t oting of inabbility of boo
om lift, it iss
required
d to focus the
t above fo four points and
a refer too
26
W Loadeer
the fau
ult detectio
on of troubbleshooting
g of "slow
w
boom liift".
965 Blow
B buck
ket moveement
Analyze and solve referring too slow boom
m lift.
966 In
nability bucket
b m
movementt
Analyze and solve referring to inabilitty of boom
m
lift.
27

L936L938英文 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

L936L938英文 PDF

Uploaded by

Copyright:

Available Formats

Service Manual of Wheel Loader

Warning: Be sure to read the part about safety

Fig. 0-2 Service position

Warning: Note the correct position of the

024 Safety of hoisting and support

Note: Using only one steel rope might cause the

When the load is hoisted with two or more steel ropes,

Warning: When the machine is supported by

Note: Before lowering the machine, do not

Warning: To inflate the tires installed on the

Fig. 0-7 Corrosive sulfuric acid

Warning: Danger! Sever corrosion.

Note: Check whether the booster battery pack or

Note: If the alternator is not charged, turn off

Warning: Danger! Burning. Use protective

Note: R134a will increase the greenhouse

Warning: These odorless and tasteless gases

Warning: Danger! Frostbite. Use protective

Warning: If the pressure is not reduced before

Warning: The discarded energy accumulator

Warning: If the pressure is not reduced before

Warning: The hydraulic hose under high

Warning: Clean up the machine burnt by fire

Note: If the paint finish is to be removed with

Warning: When the rubber and plastic are

Warning: Danger! Severe corrosion.

Warning: The burning of paint parts and

Warning: Danger! Severe corrosion.

Note: Pay close attention to the toxicity of some

Table 1 Tightening torque of commercial bolt

Strength Yield Nominal diameter of bolt mm

Strength Yield Nominal diameter of bolt mm

Strength Yield Nominal diameter of bolt mm

Table 1-3 Tightening torque of joint body

Table 1-4 Tightening torque of 24°taper seal

Table 1-5 Tightening torque of hinged bolt

122 Unit conversion

Table 1-7 Area

Table 1-8 capacity/volume

Table 1-9 Weight

Table 1-10 Pressure

Table 1-11 Unit description

The place where oil or water is discharged and the discharge

21 Key parameters of engine maintenance .......................................................................................... 2-1

221 WP6G125E332 series engine detection ................................................................................ 2-2

231 WP6G125E332 series engine failure diagnosis codes ......................................................... 2-5

26 Engine failure diagnosis code ......................................................................................................... 2-44

Air inlet Engine oil

YC6J125-T300 2200r/min 750±30 0.4±0.05mm 0.45±0.05mm 0.3-0.6MPa

Table 1 Key parameters of engine

22 Detection range and use steps of

Figure 1 Position of detection port of

Part name No. Figure

Figure 2 Special detection tools for

WP6G125E332 engine detection steps

222 YC6J125-T300 series engine detection

Figure 3 Yuchai engine detection port

Part name No. Figure

Figure 4 Special diagnostic unit for

YC6J125-T300 three-stage series engine detection

23 Engine failure diagnosis codes

030 DFC_BrkCDNpl Incredible braking signal 597 2

051 DFC_EngMCrSToothPer Crankshaft tooth cycle error 4203 2