777A Service Manual-201311

Service Manual
CLG766A/CLG777A
Backhoe Loader
Applicable type and model: CLG766A/777A

Contents
1. Overall Lubrication Part................................... 1-1
2. Hydraulic System............................................. 2-1
3. Steering System.............................................. 3-1
4. Brake System.................................................. 4-1
5. Electrical Use and Maintenance of A Series of
Backhoe Loaders................................................. 5-1
6. Air Conditioner System.................................... 6-1
7. Engine System................................................. 7-1
8. Power Train System......................................... 8-1
1. Overall Lubrication Part
General Information............................................................................1-3
Machine identification plate..............................................................................1-3
Serial plates .....................................................................................................1-3
Torque settings.................................................................................................1-5
Standard torque of connector nut.....................................................................1-6
Appendix: unit conversion table........................................................................1-9
Care and Safety................................................................................1-11
Safety notices.................................................................................................1-11
General safety................................................................................................1-11
Operating safety.............................................................................................1-12
Routine Service.................................................................................1-16
Lubricants - health and safety.........................................................................1-16
Overall lubrication third part - daily service.....................................................1-16
Engine lubrication...........................................................................................1-18
Service schedules...........................................................................................1-21
Loader arm safety strut...................................................................................1-27
Cleaning the machine.....................................................................................1-28
Lubrication of the complete machine..............................................................1-30
Tyre and rim....................................................................................................1-33
Brake..............................................................................................................1-34
Engine air filter................................................................................................1-35
Engine oil and filter.........................................................................................1-37
Engine cooling system....................................................................................1-38
Fuel system....................................................................................................1-40
Empty the sediment cup.................................................................................1-42
Synchronized shifting gearbox........................................................................1-43
Replace oil and oil filter...................................................................................1-44
Hydraulic system............................................................................................1-44
Front axle and rear axle..................................................................................1-47
Main Removal and Installation..........................................................1-51
Loader equipment...........................................................................................1-51
Backhoe Equipment..........................................................................1-64
Removal..........................................................................................................1-64
Frame system.................................................................................................1-71
Counterweight (optional for 777A ) ................................................................1-71
Swing seat......................................................................................................1-73
Sideway bracket and clamping cylinder (777A) .............................................1-78
1-2

Outrigger (766A) ............................................................................................1-81

Outrigger 777A................................................................................................1-83
Limit hook.......................................................................................................1-87
Cab and engine cover.....................................................................................1-88
Front cover......................................................................................................1-89
Cab.................................................................................................................1-91
Battery..........................................................................................................1-121
Instrument.....................................................................................................1-132
Radiator........................................................................................................1-138
Steering........................................................................................................1-149
1-3
General Information
Machine identification plate
General Information
Machine identification plate
You machine has an identification plate mount-
ed on the Loader tower. The serial numbers of
the machine and its major units stamped on the
plate.
The serial number of each major units is also
stamped on the unit itself. If a major unit is re-
placed by a new one, the serial number on the
identification plate will be wrong. Either stamp
the new number of the unit on the identification Fig. 1.3 ISO
plate, or simply stamp out the old number. This
will prevent the wrong unit number being quoted Serial plates
when replacement parts are ordered.
The machine and engine serial numbers can
help identify exactly the type of equipment you
have.
Fig. 1.4 Perkins Engine

Fig. 1.1 RUSSIA
Fig. 1.5 Weichai Engine

Fig. 1.2 UK. and R.O.W.
1-4
General Information
Serial plates
Fig. 1.6 Rear drive axle
Fig. 1.9 Mechanical shift gearbox
Fig. 1.7 Front drive axle
Fig. 1.8 Non- drive front axle
Fig. 1.10 Power shift gearbox

1-5
General Information
Torque settings
Torque settings
Use only where no torque settings is specified in the text. Values are for dry threads and may be within
three per cent of the figures stated. For lubricated the values should be REDUCED by one third.
Standard Thread Torque in Metric System
Standard Torque lb.ft (N•m)
Thread Size
Grade 8.8 strength Grade 10.9 strength
M6 7.7±1.1 (10.5±1.5)
M8 19±2.9 (26±4)
M10 38±5 (52±7) 53±4 (72±6)
M12 66±9 (90±12) 89±7 (120±10)
M14 107±15 (145±20) 144±11 (195±15)
M16 166±26 (225±35) 225±18 (305±25)
M18 229±33 (310±45) 306±26 (415±35)
M20 302±37 (410±50) 443±37 (600±50)
M22 443±59 (600±80) 590±52 (800±70)
M24 561±74 (760±100) 752±74 (1020±100)
M27 811±111 (1100±150) 1106±74 (1500±100)
M30 1106±148 (1500±200) 1364±11 (1850±150)
M33 1512±221 (2050±300) 2139±295 (2900±400)
M36 1955±258 (2650±350) 2286±184 (3100±250)
Bolt, nut and stud in grade 12.9

In general, the required torque for tightening grade 10.9 will meet the tightening requirements of grade
12.9.
Standard Thread Torque in British System
Thread size Standard Torque lb.ft (N•m)
1/4 9±3 (12±4)
5/16 18±5 (25±7)
3/8 33±5 (45±7)
7/16 52±11 (70±15)

1-6
General Information
Standard torque of connector nut
Thread size Standard Torque lb.ft (N•m)
1/2 74±11 (100±15)
9/16 110±15 (150±20)
5/8 148±18 (200±25)
3/4 266±37 (360±50)
7/8 420±59 (570±80)
1 645±74 (875±100)

Metric Thread
Thread Nut Torque (N•m)
M12X1.5 10-20
M14X1.5 20-35
M16X1.5 25-40
M18X1.5 30-45
M20X1.5 35-50
M22X1.5 40-70
M24X1.5 40-70
M26X1.5 60-100
M30X2.0 80-120
M36X2.0 100-150
M42X2.0 150-220
M45X2.0 180-250
M52X2.0 200-300
British Thread
G1/8"X28 11-12
G1/4"X19 25-28
1-7
General Information
G3/8"X19 41-48
G1/2"X4 72-82
G5/8"X14 96-110
G3/4"X14 124-137
G1"X11 151-165
G1.1/4"X11 192-206
G1.1/2"X11 261-275
G2"X11 343-357
JIC Thread in American System
Thread Nut torque (N•m)
7/16"X20 15-16
1/2"X20 19-21
9/16"X18 24-28
3/4"X16 49-53
7/8"X14 77-85
1.1/16"X12 107-119
1.3/16"X12 127-140
1.5/16"X12 147-154
1.5/8"X12 172-181
1.7/8"X12 215-226
2.1/2"X12 332-350
ORFS Thread in American System
9/16"X18 14-16
11/16"X16 27-27
13/16"X16 43-47
1-8
General Information
1"X14 60-68
1.3/16"X12 90-95
1.7/16"X12 125-135
1.11/16"X12 170-190
2"X12 200-225
1-9
General Information
Appendix: unit conversion table

Name Unit Conversion Unit Conversion Ratio
Length in mm 25.4
mm in 0.03937
ft m 0.3048
m ft 3.28084
Area in2 cm2 6.4516
cm2 in2 0.1550
Volume gal l 4.54609
l gal 0.219969
gal l 3.78541
l gal 0.264172
l dm3 1
Mass lb kg 0.453592
kg lb 2.204622
Torque lbf•in N•m 0.112985
N•m lbf•in 8.85075
Pressure 2 psi bar 0.06895
bar 2 psi 14.5038
2 psi MPa 0.006895
MPa 2 psi 145.038
MPa bar 10
bar MPa 0.1
Pa bar 10-5
bar Pa 105
Speed ft/s m/s 0.3048
m/s ft/s 3.28084

1-10
General Information
Flow gal/min l/min 4.54609
l/min gal/min 0.219969
gal/in l/min 3.78541
l/min gal/in 0.264172
Temperature °F °C 5/9* (°F-32)
°C °F °C*9/5+32
1-11
Care and Safety
Safety notices
Care and Safety Warning

Clothing
Safety notices You can be injured if you do not wear the proper
All construction and agricultural equipment can be clothing. Loose clothing can get caught in the ma-
hazardous. When a backhoe loader is correctly op- chinery. Wear protective clothing to suit the job.
erated and properly maintained, it is a safe machine Examples of protective clothing are: a hard hat,
to work with. But when it is carelessly operated or safety shoes, safety glasses, a well fitting overall,
poorly maintained it can become a danger to you ear-protectors and industrial gloves. Keep cuffs
(the operator) and others. fastened. Do not wear a necktie or scarf. Keep long
In this handbook and on the machine you will find hair restrained.
warning messages. Read and understand them. INT-1-3-6
They tell you of potential hazards and how to avoid
them. If you do not fully understand the warning Warning
messages, ask your employer or JOB distributor to Machine Modifications
explain them. This machine is manufactured in compliance with
But safety is not just a matter of responding to the legislative and other requirements. It should not be
warnings. All the time you are working on or with altered in any way which would affect or invalidate
the machine you must be thinking what hazards any of these requirements. For advice consult your
there might be and how to avoid them JOB Distributor.
Do not work with the machine until you are sure that Reference should also be made to Optional Attach-
you can control it. ments section where appropriate.
Do not start any job until you are sure that you and
those around you will be safe.
If you are unsure of anything, about the machine or Warning
the job, ask someone who knows. Do not assume Alcohol and Drugs
anything. It is extremely dangerous to operate machinery
Remember when under the influence of alcohol or drugs. Do
BE CAREFUL not consume alcoholic drinks or take drugs before
BE ALERT or whilst operating the machine or attachments. Be
aware of medicines which can cause drowsiness.
General safety INT-1-3-9
CAUTION
Warning
Passengers
Handbook Passengers in or on the machine can cause acci-
You and others can be injured if you operate or dents. The JCB Backhoe Loader is a one-man ma-
maintain the machine without first studying this chine. Do not
handbook. Read the safety instructions before INT-2-2-2
operating the machine. If you do not understand
anything, ask your employer or JCB distributor to
Warning
explain it. Keep this handbook clean and in good
condition. Do not operate the machine without a Raised Attachments
handbook in the cab, or if there is anything on the Raised attachments can fall and injure you. Do not
machine you do not understand. INT-1-3-2 walk or work under raised attachments unless they
are safely blocked.
INT-1-3-8
1-12
Care and Safety
Operating safety
CAUTION damage the machine, it can also be dangerous, Do

not operate the machine outside its limits. Do not
Regulations try to upgrade the machine performance with unap-
Obey all laws, work site and local regulations which proved modifications.
affect you and your machine. INT-2-t-4
INT-1-3-3
Warning
Warning
Controls
Care and Alertness You and others can be killed or injured if you oper-
ll the time you are working with or on the machine, ate the control levers from outside the cab. Operate
take care and stay alert. Always be careful. Always the control levers only when you are seated cor-
be alert for hazards. rectly in the cab.
INT-1-3-5 INT-2-1-3
Operating safety Warning

Road Wheel Alignment
Warning At the start of each working period, and at least
once a day, or if having difficulty in steering, check
Machine Condition and, if necessary, re-align the road wheels.
A defective machine can injure you or others. Do 2-1-1-10
not operate a machine which is defective or has
missing parts. Make sure the service procedures in
this handbook are completed before using the ma- Danger
chine. Sparks
INT-2-1-2 Explosions and fire can be caused by sparks from
the exhaust or the electrical system. Do not use the
Warning machine in closed areas where there is flammable
material, vapour or dust.
Lifting Equipment INT~2-2-10
You can be injured if you use faulty lifting equip-
ment. Make sure that lifting equipment is in good
condition Make sure that lifting tackle complies with Warning
all local regulations and is suitable for the job, Make Visibility
sure that lifting equipment is strong enough for the Accidents can be caused by working in poor vis-
job. ibility. Keep windows clean and use your lights to
INT-1-3 7 improve visibility. Do not operate the machine if you
cannot see properly.
Warning INT-2-1-11
Engine
The engine has exposed rotating parts. Do not Warning
open tile engine cover while the engine is running. Ramps and Trailers
Do not use the machine with the cover open. Water, mud, ice, grease and oil on ramps or trailers
INT-2-1-6/1 can cause serious accidents. Make sure ramps and
trailers are clean before driving onto them. Use ex-
Warning treme caution when driving onto ramps and trailers.
INT-2-2-6
Machine Limits
Operating the machine beyond its design limits can
1-13
Care and Safety
Operating safety
Warning
Safety Barriers Warning
Unguarded machines in public places can be dan- Metal Splinters
gerous. In public places, or where your visibility is You can be injured by flying metal splinters when
reduced, place barriers around the work area to driving metal pins in or out. Use a soft faced ham-
keep people away. mer or drift to remove and fit metal pins. Always
INT-2-2-8 wearsafety glasses.
INT-3-1-3
Warning
Parking Warning
An incorrectly parked machine can move without an Safety strut
operator. Follow the instructions in this handbook to Raised loader arms can drop suddenly and cause
park the machine correctly. serious injury. Before working under raised loader
INT-2-2-4 arms, fit the loader arm safety strut.
2-1 1-6
Warning
Hazardous Atmospheres Warning
This machine is designed for use in normal out door Communications
atmospheric conditions. It should not be used in an Bad communications can cause accidents. If two
enclosed area without adequate ventilation. Do not or more people are working on the machine, make
use the machine in a potentially explosive atmos- sure each is aware of what the others are doing.
phere, i.e. combustible vapours, gas or dust, with- Before starting the engine make sure the others are
out first consulting your JCB Distributor. clear of the danger areas; examples of danger ar-
INT-2-1-14 eas are: the rotating blades and belt on the engine,
the attachments and linkages, and anywhere be-
Warning neath or behind the machine. People can be killed
or injured if these precautions are not taken.
Should the machine start to roll over, you can be INT- 3-1-5
crushed if you try to leave the cab. If the machine
starts to roll over, DO NOT TRY TO JUMP FROM
THE CAB STAY IN THE CAB, WITH YOUR SEAT Warning
BELT FASTENED. Counterweights
INT-2-1-12 Your machine may be fitted with counterweights.
They are extremely heavy Do not attempt to remove
Service Safety them.
INT-3-2-5
Warning Warning
Modifications and Welding Fires
Non-approved modifications can cause injury and If your machine is equipped with a fire extinguisher,
damage. Parts of the machine are made from cast make sure it is checked regularly. Keep it in the
iron; welds on cast iron can weaken the structure operator’cap until you need to use it.
and break. Do not weld cast iron. Contact your JCB Do not use water to put out a machine fire, you
dealer before modifying the machine. could spread an oil fire or get a shock from an elec-
INT-3-1-2/1 trical fire. Use carbon dioxide, dry chemical or foam
extinguisher, Contact your nearest fire department
1-14
Care and Safety
Operating safety
as quickly as possible. Firefighters should use self- a JCB distributor as the sudden release of the hy-
contained breathing apparatus. draulic oil or gas may cause injury.
INT-3-2-7/1 7-1-1-4
Warning Warning
Battery Terminals Soft Ground
The machine is negatively earthed. Always connect A machine can sink into soft ground. Never work
the negative pole of the battery to earth. under a machine on soft ground.
When connecting the battery, connect the earth (-) INT 3-2-4
lead last
When disconnecting the battery, disconnect the Warning
earth (-) lead first.
INT-3-1-9 Jacking
A machine can roll off jacks and crush you unless
the wheels have been chocked. Always chock the
Warning wheels at the opposite end of the machine that is to
Repairs be jacked. Do not work underneath a machine sup-
Do not try to do repairs or any other type of service ported only by jacks. Always support a jacked-up
work you do not understand. Get a Service Manual machine on axle stands before working underneath
from your JCB distributor, or get the work done by a it.
specialist engineer. INT-3-2-8
INT-3-1-1
Warning
Warning Under no circumstances must the engine be run
Hydraulic Pressure with the gearbox in gear and only one driving wheel
Hydraulic fluid at system pressure can injure you. jacked clear of the ground, since the wheel on the
Before disconnecting or connecting hydraulic hos- ground will move the machine.
es, stop the engine and operate the controls to re- INT-3-1-16
lease pressure trapped in the hoses. Make sure the
engine cannot be started while the hoses are open. CAUTION
INT-3-1-11/1
Rams
The efficiency of the rams will be affected if they
Warning are not kept freeof solidified dirt. Clean dirt from
Hydraulic hoses around the rams, regularly. When leaving or parking
Damaged hoses can cause fatal accidents. Inspect the machine, close all rams if possible to reduce the
the hoses regularly for:Damaged end fittingsChafed risk of weather corrosion.
outer coversBallooned outer coversKinked or INT-3-2-10
crushed hosesEmbedded armouring in outer cov-
ersDisplaces end fittings. CAUTION
INT- 3-3-2
Arc Welding
Before carrying out arc welding on the machine,
Warning disconnect the battery and alternator to protect the
Accumulators circuits and components.
Tile accumulators contain hydraulic oil and gas at The battery must still be disconnected even if a bat-
high pressure. Prior to any work being carried out tery isolator is fitted.
on the braking system they must be discharged by Make sure that the welding earth return path is kept
1-15
Care and Safety
Operating safety
as short as possible. This prevents high currents or place yourself in dangerous positions to read the
being induced in the machine chassis or wiring har- decals.
nesses. INT-3-3-4
If the machine is equipped with amplifier drivers or
electronic control units (E. C. U. s) , then disconnect
them before welding. Failure to disconnect the am-
plifier drivers or E. C.U. s could result in irreparable
damage to the electronic components.
INT-3-1-15/1
Warning
Oil
Oil is toxic. If you swallow any oil, do not induce
vomiting, seek medical advice. Used engine oil con-
tains harmful contaminants which can cause skin
cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves
to prevent skin contact. Wash skin contaminated
with oil thoroughly in warm soapy water. Do not use
petrol, diesel fuel or paraffin to clean your skin.
INT-3-2-3
SAFETY DECALS
Keep all decals clean and readable. Replace lost or
damaged decals. The decals and their attachment
points are shown on the following page. Each decal
has a part number printed on it, use this number to
order a new decal from your JCB distributor.
INT-3-3-6
Warning
Decals
You can be injured if you do not obey the decal
safety instructions. Keep decals clean. Replace
unreadable or missing decals with new ones before
operating the machine. Make sure replacement
parts include warning decals where necessary.
INT-1-3-4
The illustration (s) show a typical machine model,
your machine may look different from the model
shown
Warning
If you need eye-glasses for reading, make sure you
wear them when reading the safety decals. Decals
are strategically placed around the machine to re-
mind you of possible hazards. Do not over-stretch
1-16
Routine Service
Lubricants - health and safety
Routine Service No special protective measure is applied to new

lubricant. However, be sure to be careful and
pay attention to your health.
Lubricants - health and safety
Used lubricant
Overall lubrication third part -
The used lubricant in the engine crankcase con-
daily service tains harmful substances.
Lubricants - insurance of health and To treat the used engine lubricant, follow the fol-
lowing requirements:
safety
1. Be sure to avoid prolonged, excessive or re-
It is very important for you to read and un- peated exposure to any used lubricant.
derstand the following contents and involved
information. Also, make sure your relevant col- 2. Prior to exposure to any oil, coat your hands
leagues have done so as well. with cream.
Health 3. To remove the engine oil on your skin, take

the following actions:
CLG lubricant does no harm to your body in nor-
a Wash your skin with soap and water im-
mal use. However, excessive or prolonged oil
mediately.
on your skin can cause degreasing of your skin,
resulting in skin dryness and irritation. b Clean your skin with a brush.
Low-viscosity lubricant is prone to the above- c Clean your skin with special cleaning so-
mentioned symptom. Therefore, be careful to lution.
treat the oil contaminated by fuel. d Don’t clean your skin with gasoline, die-
Whenever you are exposed to any oil product, sel or petroleum wax.
be sure to be careful and pay attention to your 4. Don’t be exposed to any oily duster cloth.
and your factory’s sanitation. For detailed pre-
vention measures, you are recommended to 5. Don’t put any duster cloth with oil into your
read the relevant publications of the local de- pocket.
partment of health. 6. Don’t re-use any cloth before washing it
Storage clean.
7. Discard any oily shoes.
Keep the lubricant away from children.
Do not store it in an open or unlabeled contain- Emergency treatment
er.
Eyes
Waste disposal If you get oil in your eyes, flush with clean water
Dispose of all waste oil in accordance with the for fifteen minutes. If the irritation persists, Call
relevant regulations. a physician immediately.
Collect or treat any used lubricant in accordance Swallowing
with the local regulations. Do not pour any en-
gine oil into any sewer or drainage ditch or onto Swallowing oil can cause serious vomiting. Call
ground directly. a physician immediately.
Treatment Skin
If you get oil on your skin badly, flush the skin
New lubricant with water and soap.
1-17
Routine Service
Overall lubrication third part - daily service
Overflow
Suck the spill oil completely with sand or ad-
sorbent granule materials. Wipe off the contami-
nated part, and then place the waste in a chemi-
cal waste tank.
Fire
To put out a fire, use carbon dioxide or dry pow-
der or foam. The firefighters should use the self-
contained breathing masks.
1-18
Routine Service
Engine lubrication
Engine lubrication
Engine oil selection
Liugong machine use SHELL Rimula R3 Multi 10W30 (CH-4) engine oil, and it can be applied in the cali-
brated environment.
See the following table: Normal Oil Viscosity Within the Specified Temperature Range
Instruction: do not add performance additive or other oil additive product to engine crankcase. The oil
drain intervals specified in the operation manual is measured under test method of Liugong lubrication.
Range chart of engine oil viscosity - temperature
Engine Oil Viscosity
EMA LRG-1 API CH-4 Ambient Temperature

Viscosity Grade Min. Max.
SAE OW20 -40°C (-40°F) 10 °C (50°F)
SAE OW30 -40 °C (-40°F) 30 °C (86°F)
SAE OW40 -40 °C (-40°F) 40 °C (104°F)
SAE 5W30 -30 °C (-22°F) 30 °C (86°F)
SAE 5W40 -30 °C (-22°F) 40 °C (104°F)
SAE 10W30 -20 °C (-4°F) 40 °C (104°F)
SAE 15W40 -10 °C (14°F) 50 °C (122°F)
Diesel fuel system

The machine uses 0# diesel under standard condition, and engine power may be decreased or specific
fuel consumption increased due to applying other fluids.
Be sure to fill the antifreezing solution by referring to the following proportion in cold areas:
Instruction: Please consult your local diesel dealer for the requirements of diesel operation in winter. If
diesel temperature is lower than the critical point, the oil will crystallized, and even deactivate the fuel filter,
then cause the engine power loss or failed to start.
The diesel that applied upon the complete machine shall be conformed to the following parameter require-
ments: “performance parameters of 0# diesel”
Diesel storage
If diesel needed to be stored for a certain period, you can put some water or irrelevant substances into the
diesel storage box.
Keep the diesel storage box opened widely, and make sure the cooling status of diesel. Drain the water
from the diesel storage box according to the required time cycle.
After daily work is over, diesel tank shall be refilled with diesel to prevent diesel in its tank from drying or
condensing.
1-19
Routine Service
Engine lubrication
Typical data for oil

0# Diesel
No. Item Specified Norms Typical Data
Oxidative stability, total undissolved
1 No more than 2.5 /
substance, mg/100ml
2 Sulfur content, % (m/m) No more than 0.035 0.0198
Carbon residue on residuum 10%, %
3 No more than 0.3 /
(m/m)
4 Ash content, % (m/m) No more than 0.01 /
5 Copper corrosion (50°C, 3h) , grade No more than 1 1
6 Water content, % (v/v) Trace None
7 Mechanical impurities None None

Lubricity Diameter of wear scar (60°C)
8 No more than 460 /
/ um
Palycyclic aromatic content d (mass
9 No more than 11 /
fraction) /%
10 Kinematic viscosity (20°C) , mm2 / s 3.0-8.0 /
11 Condensation point /
12 Condensation point, °C ≤4 -1
13 Flashing point (closed) , °C No less than 55 4
14 Cetane number Not less than 46 51

50% recovered
Distillation range No more than 300 286.0
temperature, °C
90% recovered
15 No more than 355 341.0
temperature, °C
95% recovered
No more than 365 352.0
temperature, °C
16 Density (20℃ ) ,kg/m3 810.0-850.0 8450.0
Fatty acid methyl ester (volume
17 No more than 0.5
fraction) /%
Note: typical values will change within the criteria at different periods.
1-20
Routine Service
Engine lubrication
CH-4 10W-30 Diesel Engine Oil

1 Appearance Transparent Transparent
2 Chroma/ No. Report 4
3 Kinematic viscosity (100℃ ) / (mm2 /s) 9.3~<12.5 10.59

High temperature and high shear
4 viscosity (150 ℃ , 106s-1) / (mPa? S) 2.9 3.084
not less than
Low temperature kinetic viscosity
5 (-25℃ ) 6569
(CCS) / ( mPa·s)
6 No more than 7000
Flow point/°C
7 -30 -35
No more than
Flashing point (opening) /°C
8 205 220
No less than
Water content (mass fraction) /%
9 Trace None
No more than
Evaporative loss (mass fraction) /%
10 No more than Noack method 20 9.86
(250℃ ,1h)
1-21
Routine Service
Service schedules
L-HM 46 Antiwear Hydraulic Oil

1 Appearance Transparent Transparent
2 Chroma, No. Report 1
3 Kinematic viscosity (40℃ ) , mm2/s 41.4~50.6 46.1
4 Viscosity index not less than 95 111
5 Pour point°C No more than -9 -27

Flashing point (opening) °C No less
6 180 238
than
7 Water content, % No more than Trace None
Copper corrosion (100, 3h) level No
8 1 1a
more than
Air release value (50℃ ) , min No
9 10 3
more than
Sealing applicable performance index,
10 10 3
No more than
Spumescence ml/ml
(froth tendency/ froth stability) 150/10 0/0
11 Front 24℃ No more than 150/10 0/0
93.5℃ No more than 150/10 0/0
Back 24℃ No more than
12 Resistance to emulsion (40-37-3) ,min 30 7'54"
Rust test in liquid phase (distilled
13 No rust Qualified
water)
14 Neutralization number, mgKOH/g Report 0.67
15 Density (20℃ ) ,kg/m3 Report 861.7

Service schedules
A poorly-maintained machine is dangerous to the operators and personnel around. To ensure safety and
efficiency of the machine, be sure to perform regular service and lubrication on the machine according to
the intervals specified in the table.
Warning
Service
Service can only be carried out by the qualified personnel. Before service, make sure that the machine is
safe. Be sure to park the machine on level ground. During service, if it is necessary to lift the loaderboom,
be sure to install the safety strut. For details, see the relevant contents.
1-22
Routine Service
Service schedules
In addition to routine service, during the operating time of the machine, be sure to maintain the machine
regularly according to the interval in the timer. Don’t continue to use the machine which has not been
maintained as required. If any problem detected during service, be sure to solve it immediately.
Equivalent time:
10 hr. = per day
50 hr.= per week
500 hr. = 6months
1,000 hr. = one year
2,000 hr. = two years
Cold check before starting
Service Points and 100 500 1000 2000
Job Content 10 Hours 50 Hours
Oil Level Hours Hours Hours Hours
Engine
Lubricant level Inspection O O
Lubricant and filter Replacement O O O O
Air filter external core Replacement O O
Air filter internal core Replacement O
Fuel filter Replacement O O O O
Fuel filter Drainage O

Coolant quality and
Inspection O O O O O
level
Drainage and
Fuel settler O O O O O
cleaning
Fan belt tension Inspection O O O O O
Valve clearance and
Inspection and
cleanliness of breath- O
adjustment
er (optional)
Degree of tightening
of engine mounting Inspection O O O O
bolts
Radiator Cleaning - O O O
Conditions of all hos-
Inspection - O O O O
es
Gearbox, Axle and 1000 2000
Job Content 10 hours 50 hours 100 hours 500 hours
Metering Pump hours hours
Gearbox oil level Inspection O O O O
1-23
Routine Service
Service schedules
Gearbox oil Replacement - O O
Gearbox filter Replacement - O O O O

Oil level in drive axle
Inspection O O
(including hub)
Oil in drive axle (in-
Replacement O O
cluding hub)
Oil in drive axle (lim-
Replacement O O O
ited slip differential)
Type pressure and
conditions
Front hub bearing Inspection - O O O O
Gearbox filter screen Cleaning O

Fastening and
Drive shaft O O
Lubrication
Movement/gasket of
Inspection - O O O O
steering axle
Shaft pin and link of
Replacement - O O O O
steering axle
Main shaft of front
Lubrication O O O O O O
axle
100 500 1,000 2,000
Hydraulic System Job Content 10 Hours 50 Hours
Hours Hours Hours Hours
Oil level Inspection O O O O O
Sampling and
Hydraulic oil O
replacement
Oil filter - Replacement O O O O
Cylinder, chromeplate
- Inspection O O O O
conditions
Hydraulic oil cooler Cleaning O O O
Hydraulic oil screen Cleaning O

Filler cap of hydraulic
oil tank (with filter ele- Replacement O
ment)
Drive shaft of hydrau- Commissioning
lic pump and Lubrication
100 500 1,000 2,000
Brake Job Content 10 Hours 50 Hours
Brake fluid level of
Inspection O O O O O O
braking system
Brake fluid of braking
Replacement O
system
1-24
Routine Service
Service schedules
Inspection and
Hand brake O O O O
adjustment
100 500 1,000 2,000
Electrical System Job Content 10 Hours 50 Hours
Battery electrolyte
Inspection O O O
level (if appropriate)
Wiring Inspection O O O O O
Battery connection
Inspection O O O O
terminals
100 500 1,000 2,000
Body and Cab Job Content 10 Hours 50 Hours
Inspect lubrica-
Shaft pin and sleeve O O O O O O
tion
Door and window
Lubrication O O O
hinge joints
All harnesses O O O
Cleaning / re-
Cab heater filter O O O
placing
Adjustment /
Telescopic bucket rod O O O O O
lubrication
Inspection and
Clight O O O O
adjustment
Doors - attachments
Inspection O O O O
and door locks
Adjustment of cab
Inspection O O O O
seat
Front fender Inspection O O
Liquid level of wind-
shield washer
Boom locking Inspection O O O O O O
Painting conditions Inspection O O O O
Outrigger Inspection O O O O O
Complete machine Inspection and
O O O O O O
conditions adjustment
Wear-resistant pad of
Lubrication O O O O O O
side way mechanism
Wear-resistant pad of
Inspection O
side way mechanism
100 500 1,000 2,000
Attachments Job Content 10 Hours 50 Hours
Four in one bucket Lubrication O O O O O O
1-25
Routine Service
Service schedules
Work implement Lubrication O O O O O O

Functional testing and
final inspection
100 500 1,000 2,000
Engine Job Content 10 Hours 50 Hours
Inspection and
Idling speed O O O O
adjustment
Idling speed Inspection O O O O
M a x i m u m n o - l o a d Inspection and
O O O O
speed adjustment
Smoke displacement Inspection O O O O
Safety of exhaust
system
Safety of air intake
Inspection O O O O
system
Throttle system and
Inspection O O O O
control circuit
Gearbox, Drive axle 100 500 1,000 2,000
Job Content 10 Hours 50 Hours
and Steering Hours Hours Hours Hours
Steering mode and
operation
2WD/4WD option Inspection O O O O
Tyre nut torque Inspection O O O O O O

Forward and revers-
ing gears and gear- Inspection O O O O
shift operation
Hydraulic speed con-
Inspection O O O O
trol
Steering loop pres-
Inspection O O O O
sure
Main pressure of
Inspection O O O
gearbox
Gearbox cut-off op-
Inspection O O O O
eration
Neutral engagement
pressure
Clutch engagement
Inspection O O O O
pressure
100 500 1,000 2,000
Hydraulic System Job Content 10 Hours 50 Hours
Inspect and ad-
MRV pressure O O O O
just
Service operation Inspection O O O O O
1-26
Routine Service
Service schedules
Anti-burst pressure
Inspection O O O O
valve of pipeline
Unloading valve pres- Inspection and
O O O O
sure adjustment
Auxiliary circuits and Inspection and
O O O O
pressure adjustment
100 500 1,000 2,000
Brake System Job Content 10 Hours 50 Hours
Foot brake operation Inspection O O O O O O
Hand brake operation Inspection O O O O O O
Servo Control Inspection O O O O

100 500 1,000 2,000
Electrical System Job Content 10 Hours 50 Hours
Start motor Inspection O O O O
Generator output Inspection O O O O

Electrical equipment
operation
100 500 1,000 2,000
Frame and Cab Job Content 10 Hours 50 Hours
Bucket teeth and side
Inspection O O O O
edges
Airtightness of doors
Inspection O O O O
and windows
Seat and safety belt Inspection O O O O
Note: only service during the first 100 hours should be carried out by the CLG dealer.
1. Note: check for leakage every 50 hours. If any, also check the oil level.
2. Note: to check the oil level of the hydraulic system, let the bucket and excavator grab be in the driving
position.
3. Note: the labeled service points can only be performed by the qualified specialized persons.
4. Note: if the operating conditions are bad, replace the engine oil and filter every 250 hours.
5. Note: check each system of the machine for overall leakage. Such as, hydraulic system, engine (cool-
ant, fuel and lubricant) , gearbox, brakes, drive axle, etc. If any leakage, find out the leakage source
and repair it. After repair, refill the system with the recommended oil. Meanwhile, repair the system as
required. If there is any information not detailed in this manual, please consult the CLG dealer.
6. Note: if operating in a dusty environment, be sure to repair it frequently.
7. Note: high-performance lubricant has been applied to the drive axle and the drive shaft before leaving
the factory. If the standard lubricant has been used during service, be sure to perform lubrication once
every 50 hours. For details, consult the CLG dealer.
8. Note: after service of gearbox, to eliminate the dirt produced during service, let the new oil run at the
1-27
Routine Service
Loader arm safety strut
operating temperature, and then replace it. If there is excessive dirt due to fault, let the new oil operate
for 100 hours, and then replace the oil and filter element.
9. Note: after repair, to eliminate the dirt produced during repair, let the new oil run at the operating tem-
perature, and then replace it. Moreover, after operating for 100 hours, replace the oil to remove the dirt
produced during running-in, especially, after installation of new brake linings.
Loader arm safety strut

Installation
Install the boom safety strut before working below the lifting arm.
Warning
Since the lifting arm can fall off suddenly, resulting in danger, be sure to install the safety strut before work-
ing below the boom.
1. Empty the bucket, and then lift the loader boom.
2. Shutdown the engine
Remove the start key.
Warning
If the loader control lever were operated suddenly, You would have life-threatening danger. Therefore,
don’t remove the safety strut until no person is on the machine.
3. Remove safety strut
a Unfasten the strap B.
b Remove the safety strut C from the cylinder piston rod.
4. Install safety strut
a Put the safety strut on the cylinder piston rod.
b Fix the safety strut with the strap B.
5. Lowering the safety strut on the cylinder
To prevent the loader boom from falling and jamming your fingers, be sure to be careful to control its fall
and let it fall onto the bracket as shown in the figure.
Start the engine, and then let the loader boom fall onto the safety strut. When the load on the loader boom
falls onto the safety strut completely, stop the boom from moving immediately.
Note: in the process of lowering the boom, be careful to operate the control lever. Be sure to move the
control lever slightly and lower the boom at a hyperslow speed.
1-28
Routine Service
Cleaning the machine
a Unfasten the strap B.

b Remove the safety strut C from the cylin-
der piston rod.
4. Set safety strut
Fix the safety strut with bolt A and put it on the
rack.
Cleaning the machine

Park the machine on solid and level ground.
Apply the hand brake and shift the gearbox into
the Neutral position. Lower the attachments
onto ground and let the engine misfire.
Fig. 3.1
Clean the machine with water and/or steam. Be
careful to clean the lower part of the machine.
No mud or impurity in the following areas is per-
mitted:
1. Hose port of the digging machine in the
frame.
2. Both rotary cylinders.
3. Both rotary beds on the chassis (mid-mount-
ed type) .
4. Slideway of sideway board (sideway type) .
5. Hose tray of sideway board and base cover
Fig. 3.2 (sideway type) .
Removal 6. Groove between rotary cylinder and sideway
1. Lift the loader boom up to its extreme posi- board casting (sideway type) .
tion. No dust on the engine or gearbox is permitted.
The purpose of this is to remove the load from Make sure that the radiator gap is not clogged.
the safety bracket.
2. Stop the engine
Remove the start key.
Warning
If the loader control lever were operated sud-
denly, You would have life-threatening danger.
Therefore, don’t remove the safety strut until no
person is on the machine.
3. Remove safety strut
1-29
Routine Service
Lubrication of the complete machine
Warning
No straw, wood chip or other combustible ma-
terial on the engine and in the wind channel is
allowed. Check the above-mentioned place regu-
larly or before working. Make ensure that there is
no dirt on the engine hood.
Don’t use any undiluted cleaning solution. To
avoid peeling paint, be sure to dilute the cleaning
solution based on the manufacturer’s recommen-
dations.
Water under pressure can damage the seal rings
and bearings. Therefore, don’t flush directly the
oil seal or knuckle bearing with high pressure wa-
ter during routine cleaning of the machine.
Note: Re-lubricate it after cleaning the machine.
Be sure to observe the local regulations on
waste disposal after cleaning the machine.
Some places where must be cleaned are shown
in the Fig. below.
Fig. 3.3
1-30
Routine Service

To make the machine work efficiently and prolong its service life, be sure to lubricate the machine regu-
larly.
Be sure to lubricate it after cleaning the machine.
Warning
Complete the following operations before Lubrication the machine nearby: Lower the attachments to their
lowest positions if necessary, remove the start key and turn off the electric lock to prevent the engine from
starting unexpectedly, and make sure that the hand brake has been set up.
Check all the wheels before working under the bottom of the machine.
Use the grease gun for lubrication. In general, press the grease gun twice. Stop filling when the grease
spills.
All lubrication points have been labeled in the following figure. Be careful to check each lubrication point.
Close the protective cover after lubrication.
Loader boom
Each lubrication point is shown in the Fig. below, and it is also on the other side of the machine accord-
ingly.
There is a total of 22 lubrication points.
Excavation side
22 lubrication points
Remark: the sequence of the lubrication points of the boom and the bucket rod is shown symbolically in
the Fig. below.
1-31
Routine Service
Fig. 3.4
Fig. 3.5
Front axle (4WD)
Fig. 3.6
Shaft
Front drive shaft
1-32
Routine Service
Fig. 3.7
Lubrication (continued)
Note: Lubrication point 5 is a remote one, which
is installed on one side of the machine chassis
(near the front left wheel) .
Rear drive axle

Fig. 3.9
Outrigger (for the mid-mounted
type)
There are 3 lubrication points for each outrigger,
totaling 6 lubrication points.
Fig. 3.8
Four in one bucket

There are 3 lubrication points on each end, tota-
ling 6 lubrication points. b
Fig. 3.10
Swing seat
1-33
Routine Service
Tyre and rim
area (around the tyres) .

The pressure of the nitrogen–inflated tyres is the
same as that of the air-inflated tyres. It is rec-
ommended to select the tyre inflation pressure
based on the machine operating conditions, and
consult your tyre supplier.
The tyre inflation pressure listed in the table
means the one at normal temperature.
Inflation
Front
Pressure Rear Wheel
Wheel
(kPa)
Standard 14-17.5
560 19.5L-24
tyre NHS
Large tyres 12.5/80-18 430 18.4-26
16.9-28
If the machine driving at freezing temperatures,
the original tyre pressure at 18-21℃ will change
greatly. Even if the tyre has been inflated to the
correct pressure at normal temperature, it will
Fig. 3.11
be under-inflated at freezing temperature. Low
Tyre and rim tyre pressure can shorten the tyre’s service life.
Information on tyre inflation

It is recommended to inflate the tyres with dry
nitrogen and adjust the tyre pressures. This is
applied to all the machines equipped with rub-
ber tyres. Since nitrogen is a type of inert gas, it
will not help to combust in the tyres.
Using nitrogen (N2) can not only reduce risk of
explosion but also help to prevent oxidation and
rubber ageing as well as corrosion of rim parts.
This is especially important to the tyres to be
used for more than four years.
Warning
It is necessary to train the operators to use the
inflatable equipment. Using improper tyre in-
flation technique can cause personal injury or
even death.
Don’t set the pressure of the tyre inflatable
Fig. 3.12
equipment to be 14 higher than that of the rec-
ommended tyre pressure. Inspection of rim nut torque
Keep all other person away from the dangerous Check the wheel nuts for tightness before daily
work.
1-34
Routine Service
Brake
The correct torque values are listed in the fol-

lowing table.
Front wheel ………350 N•m
Rear wheel ………500 N•m
Warning
Whatever the reason is, as long as you detect
one bolt is damaged, be sure to replace all other
bolts, because it is possible that all other bolts
have also been damaged.
For a new machine or removed wheel, check
the nut torque once every two hours until the
torque keeps stable.
Brake
Hand brake-- Inspection
Note: usually check the hand brake device per-
formance. Make sure that the machine can
be braked safely and it is provided with good
emergency brake performance. Fig. 3.13
Drive the machine forward by shifting into the
2nd gear position on level ground.
Pull up the hand brake lever slowly to allow the
parking ratchet to click. Make sure that the ma-
chine can be stopped after hearing the 4th click
or the 5th click.
Otherwise, press the brake pedal to stop the
machine.
Follow the following procedures to adjust the
hand brake, and then re-try to test it again. Fig. 3.14
Warning: when adjusting the hand brake, mov-
ing the machine can cause personal injury. Park the machine on level ground, and then
lay the outriggers down to prevent the machine
Adjustment of hand brake from moving.
1. Press the locking handle C,
Make sure that the hand brake lever is released.
2. Pull the control lever to its extreme position,
Hang the “DO NOT OPERATE” sign on the ma-
3. Check the hand brake, chine.
4. If the hand brake is failed, repeat the above- Locate the adjusting screw on the left end of the
mentioned steps. If the hand brake is still hand brake lever on the rear axle.
failed or the pin D has reached its maximum
Adjust the free travel of the pedal by adjusting
stroke, you have to adjust the brake lever on
the nut on the left end of the hand brake lever.
the rear drive axle.
Repeat the steps to check the hand brake.
1-35
Routine Service
Engine air filter
Note: No excessive tension of the steel cable

of the hand brake is permitted. Make sure there
are four clicks from the ratchet at least along the
free travel of the hand brake lever.
Inspect braking fluid level

Warning
Wrong parking can cause danger. Add the
oil to the brake oil cup regularly, and make
sure that the braking system is examined by Fig. 3.15
the specialized persons. Don’t operate the
machine until the fault has been eliminated. Engine air filter
1. Park the machine on solid level ground. Pull
up the hand brake and put the shifting con- Air filter element--Cleaning and
trol lever in the neutral position, and then lift replacing
and lock the loader boom. Lay the excavat-
ing gear down onto ground and shut off the Warning
engine. Clean or replace the air filter. It is recommended
2. Remove the oil cup cap A and check the oil to wear a dust mask or other breathing equip-
level. Label the lower and upper marks on ment.
one side of the oil cup. If necessary, add the Note: to prevent dust from entering into the en-
brake fluid following Step 3. gine, don’t clean or replace the air filter when
If the oil level is below the lower mark, have the engine operating.
the CLG dealer checked it. Don’t start the engine without air filter or if the
air filter damaged. Don’t any air filter with dam-
aged crease, gasket or seal. Dust entering into
Warning the engine can cause premature wear to the
Using unqualified brake fluid can cause damage engine, resulting in damage to the engine parts.
to the braking system. Please refer to the rel- The air filter element can prevent floating dust in
evant contents in the sections related to service. atmosphere from entering into the intake mani-
In addition, the brake fluid can do harm to your fold.
skin, be sure to wear gloves before working. When the air filter clog indicator piston reaches
3. If necessary, be careful to fill the qualified the red position, it is necessary to clean or re-
brake fluid up until to the proper fluid level. place the secondary filter element of the air fil-
ter.
4. Screw the oil cup cap and wipe off the over
spilled brake fluid. Park the machine and pull up the hand brake le-
ver, and then lift the loader boom and install the
boom safety strut in place. Shut off the engine
and remove the key.
1-36
Routine Service
Engine oil and filter
Flush the filter element from inside to outside
along the crease with the compressed air. The
air flow will blow off the dust on the crease.
Note: to avoid micropore or damage to the
crease, don’t let the air flow close the crease
very much.
Flush inside before washing out the loose sun-
dries from the outside of the filter element to in-
wards. If possible, it is recommended to suck up
the loose sundries from outside with a cleaner.
Fig. 3.16 Check the filter element for damage after com-
pletion of cleaning. The best way to check the
1. Outer cover 2. Primary filter element
filter element is to place a blue bulb inside the
3. Secondary filter 4. Air inlet
filter element in a dark room. If any ray of light
element
radiates in one direction, it indicates there is
Open engine cover. Remove the outer cover damage in the direction. Discard the damaged
and secondary filter element of the air filter. filter element properly and install the new one.
Make a mark on an obvious position on the fine
element with a pen or similar tool. You can use
this mark to record the number of times to re-
move the secondary filter element. Replace the
fine element once the secondary filter element
has been removed for three times. Don’t clean
the fine element.
Cleaning secondary filter element of

air filter
Caution: to avoid damage to the engine, don’t
strike the filter element or wash it with water
Fig. 3.17
After installation of filter element, reset the air fil-
when cleaning the filter element.
ter clog indicator. Click on the RESET button on
Clean the filter element with the compressed air the upper of the air filter clog indicator for three
with a pressure no more than 25 psi (0.2 mpa) times until you cannot see the yellow piston.
or a vacuum cleaner. Start the engine and let it operate for 3 minutes,
To avoid damage to the filter element, be careful and then let it idle at high speed for a period of
to clean it. time. Re-check the air filter clog indicator, and
make sure that the yellow piston is outside the
Don’t use any air filter with damaged crease, red zone.
gasket or seal.
Replacing air filter secondary filter ele-
Discard the used or damaged air filter element
ment
properly.
If necessary, clean the dust inside the filter
Warning housing, and then get new fine element ready.
Be sure to wear protective devices, such as Remove the old filter element and install the
gloves, goggles and dust mask when cleaning new one immediately. Discard the old filter ele-
the air filter element with compressed air. Adjust ment properly.
the air pressure to 25 psi (0.2 mpa) . Don’t let
the compressed air blow toward any part of your
body.
1-37
Routine Service
Engine oil and filter
Engine oil and filter use. Put the shifting control lever in the neu-
tral position, and then lay the loader boom
Inspection of engine oil level and the excavating gear down onto ground.
Shut off the engine and remove the start
1. Pull up the hand brake and put the shifting key.
control lever in the neutral position, and then
lay the loader boom and the excavating gear 3. Open drain plug.
down onto ground. Shut off the engine and 4. Drain out oil.
remove the start key.
CAUTION
2. Unscrew and remove the fill cap.
After removing the oil plug, the oil can spray out.
3. Check the oil level with the dipstick A. Make
The hot oil can scald you. To prevent the hot oil
sure that the oil level should be between the
from scalding you, be sure to stand on the side
lower and upper marks.
when removing the oil plug.
4. If necessary, unscrew and remove the side
a Place an appropriate container under the oil
cover, and pour the oil into the filler B. Make
plug.
sure to insert the oil dipstick and the filter
cap in place and tighten them. b Remove the oil plug and take out the O-ring.
Drain the oil and clean the oil plug. Re-install
Replace engine oil and filter the oil plug with new O-ring and tighten it to the
1. Park the machine on solid level ground. torque of 34 N•m.
Drain the oil when the engine is hot because
the dirt is floating at the moment.
Warning
To ensure it is safe to work under the bottom
of the machine, put the working devices on the
ground and pull up the hand brake. And then,
remove the start key and turn off the electric
lock.
Fig. 3.19
5. Replace filter
a Unscrew the strainer D. Be careful for it
is full of oil.
b Check the joint G for tightness.
c Clean the filter head F.
d Add clean oil to the new strainer. Leave
enough time to let the oil pass through
the filter element.
e Coat oil onto the seal ring E of the new
Fig. 3.18 filter. Screw the new strainer by hand.
2. Make sure that the hand brake is in effective
1-38
Routine Service
Engine cooling system
6. Pour oil into the engine through filler until

to the upper mark of the dipstick. For the
recommended oil grade, see the Chapter of
Service and Servicing. Wipe off the spilled
oil. Check for leakage and make sure the oil
fill cap is installed properly.
7. Don’t turn the start switch to start the en-
gine until the oil pressure light goes out. (To
prevent the engine from starting, turn off the
negative switch.)
8. Turn on the negative switch and start the en-
gine, and then check for leakage. Check the
oil level after the engine cools down.
Fig. 3.20
1. Pull up the hand brake and put the shifting
Engine cooling system lay the loader boom and the excavating gear
down onto ground. Shut off the engine and
Check coolant level remove the start key.
Warning 2. Open the radiator cover.
When the coolant is hot, the cooling system is 3. Be careful to unscrew the cover and release
under pressure. To check the coolant level or the pressure.
drain the coolant, be sure to let the engine cool
down.
1. Pull up the hand brake and put the shifting
lay the loader boom and the excavating gear
down onto ground. Shut off the engine and
2. Unscrew and remove the radiator cover.
3. The coolant level should be between the
“COOLING/MIN” and “HOT/MAX” marks.
If necessary, add pre-prepared water/anti-
freezing solution mixture.
Replace coolant
Warning
When the coolant is hot, the cooling system is
under pressure. To check the coolant level or
drain the coolant, be sure to let the engine cool
down.
1-39
Routine Service
Engine cooling system
CAUTION the radiator.
Keep your face away from the opening when re- 7. Bring the coolant level to reach the “COOL-
moving the plug. ING/MIN” position using the valid mixture of
soft-water and anti-freezing solution.
8. Start the engine and let it idle to circulate the
coolant. If necessary, add the coolant.
9. Close the filler cover and tighten it.
10. After the engine operating, when the coolant
rises to its working temperature and pres-
sure, stop the engine and check for leakage.
Note: make sure that the cab heater button is at
the “HOT” position. This can ensure that the
coolant circulates in the whole cooling sys-
tem.
Fig. 3.21 Engine cooling system

4. Unscrew the engine outlet switch and drain
the coolant. Adjustment of fan belt
5. Unscrew the radiator outlet switch and drain Warning
the coolant. Flush the cooling system with
fresh water. To prevent the engine from operating, discon-
nect the electric lock before adjusting the fan
belt.
up the hand brake and put the shifting con-
trol lever in the neutral position, and then lift
and lock the loader boom. Lay the excavat-
ing gear down onto ground and shut off the
engine.
2. Unscrew the bolts A, B, C and D.
3. Move the AC motor to leave a relaxation
value of 10mm at the X position.
4. Tighten bolts A,B, C, D.
Note: with the new fan belt, re-check the belt
tension after working for 20 hours.
Fig. 3.22
6. Close the drain valve after the coolant has
been drained from the engine cylinder and
1-40
Routine Service
Fuel system
Cetane number
It indicates the ignition performance. Low-
Cetane fuel oil can produce cold-start problems
and affect combustion.
Viscosity
It indicates the flow resistance. If the viscosity is
outside the limit range, the engine performance
will be affected.
Specific gravity
The fuel oil with low specific gravity can reduce
the engine output. The fuel oil with high specific
gravity can increase the engine power, but in-
creasing the gas displacement as well.
Fig. 3.23 Sulfur content
The diesel with high sulfur content will cause
wear to the engine. If the diesel with high sulfur
content has to be used, be sure to use the lu-
bricant with high alkalinity or replace the oil fre-
quently.
Low-sulfur fuel is used in the most regions
around the world. Such fuel contains less lu-
bricant additive. The fuel injection pump on the
engine is lubricated by the fuel, so prolonged
use of low-sulfur fuel can affect the fuel injection
pump. If the low- sulfur fuel has to be used, it is
recommended to use the additive recommend-
ed by the fuel oil supplier.
Distilled temperature
It represents the mixture of different hydrocar-
bons in the fuel. High-ratio light hydrocarbons
Fig. 3.24 can affect combustion characteristics.
Fuel standard
Fuel system For the adaptability of the fuel, please consult
the fuel supplier or the CLG dealer.
Fuel type
Low-temperature fuel
Using high-quality diesel can achieve a proper
power and performance. The recommended The winter fuel can be applied to the engine
diesel parameters are shown as follows: operating at low temperature (0 ℃ or 32 ℉ )
because such fuel has a lower viscosity and
Cetane value: 45 (mini.) restrain the formation of wax in the fuel at low
Viscosity: 3~8 mm2/s at 20℃ (68 ℉ ) temperature because the formation of wax in
the fuel can hinder the fuel to pass through the
Sulfur content: 0.5% (max.) fuel filter.
Distilted temperature: 90% at 355°C (671°F)
1-41
Routine Service
Fuel system
It is possible to increase the rate of flow. This Drain filter water

can reduce the wax in the fuel.
FAME (fatty acid methyl ester) fuel can be used up the hand brake and put the shifting con-
to replace the diesel. trol lever in the neutral position, and then lift
It is necessary to consult the CLG dealer on and lock the loader boom. Lay the excavat-
how to use the FAME fuel because improper ing gear down onto ground and shut off the
use of the FAME fuel can reduce the engine engine.
performance. 2. Unscrew and remove the plug B and drain
Gasoline the water in the filter element A.
Warning Replace filter element

Don’t use gasoline in the machine. Don’t mix the 1. Park the machine on solid level ground.
diesel with gasoline because the gasoline in the Pull up the hand brake and put the shifting
oil tank can float to the surface and form inflam- control lever in the neutral position. Lay the
mable gas. working devices down onto ground and shut
off the engine.
If you want to use non-standard fuel, do consult
the CLG dealer on the problems related to the 2. Unscrew the filter element A. Although the
adjustment of engine and interval of replace- filter element is tightened by hand, it is pos-
ment of lubricant. sible to need a strap wrench to unscrew it,
because it is full of fuel.
3. To help to bleed air, fill the new filter element
Warning with fuel before installation. Install and tight-
Since the diesel is inflammable, no open fire is en the new filter element by hand. Check for
permitted near the machine. Don’t smoke when leakage.
adding the diesel or working near the engine. 4. Bleed the air in the system.
Don’t fill the engine when the engine is run-
ning. Non-compliance with such regulations can Fuel system
cause a fire or personal injury or even death.
Fuel system
Refill the fuel tank
Warning
Before refilling, lower the lifting arm and shut off
the engine. Don’t operate the machine control
lever during refilling.
After end of daily work, add the diesel of the
correct brand to prevent the fuel from being con-
centrated.
A lock is mounted on the filler port on the fuel Fig. 3.25
tank. The lock can be unlocked only by the key.
Once you remove the key, you cannot unlock or
lock the fill cap.
1-42
Routine Service
Empty the sediment cup
Empty the sediment cup the engine.

2. Turn the start key to the IGN position.
1. Park the machine on solid level ground.
Pull up the hand brake and put the shifting
control lever in the neutral position. Lay the
working devices down onto ground and shut Warning
off the engine. Hot oil and engine parts can scald you. Be sure
2. Observe the cup A. If any sediment in the to let the engine cool down before starting work.
cup, follow Step 3 to Step 6. If any water but 3. Operate the manual fuel pump X slowly to
sediment in the cup, remove the Plug B to pump fuel for 2 minutes and then start the
drain water. Be sure to re-install the Plug B engine. After the engine operating smoothly
back in place. for a while, you can start enlarging the throt-
3. Support the Cup A and unscrew and remove tle or stop, and then re-check whether there
it. is any air in the fuel system. Check all posi-
tions, especially the oil seals and connecting
4. Clean the cup with clean fuel. components on the low-pressure side of the
5. Re-install the cup and make sure the gasket system.
is installed properly. Note: when the manual fuel pump X working, if
6. Bleed the air in the system. there is no fuel injection, it is that the diaphragm
is in the “maximum fuel-supply” position. In this
case, move the diaphragm and start the engine-
with the key, and then re-try the manual fuel
pump again.
Fig. 3.26
System exhaust
CAUTION
When there is air in the system, it will damage
the fuel injection pump. After service, bleed the
air in the system in accordance with the follow-
ing requirements.
1. Park the machine on solid level ground. Pull Fig. 3.27
up the hand brake and put the shifting con- Fuel secondary filter/oil-water
trol lever in the neutral position, and then lift
and lock the loader boom. Lower the exca- separator--drainage
vating gear down onto ground and shut off
1-43
Routine Service
Synchronized shifting gearbox
Warning Synchronized shifting gearbox

The fuel leaked or spilled on the hot surface or
electrical components can cause a fire. To avoid
Check oil level position
personal injury, shut off the engine when replac- 1. Pull up the hand brake and put the shifting
ing the fuel filter or separator element. If any control lever in the neutral position, and then
fuel leakage or spilling, clean it immediately. lay the working devices down. Shut off the
engine and remove the start key.
Note: The oil-water separator cannot be used as
a filter. The oil-water separator is used to sepa- 2. Open cover.
rate the fuel from the water. To avoid damage to
3. Add the recommended fluid to the gearbox
the engine, don’t start the engine if the liquid in
and bring it up to the highest level.
the oil-water separator exceeds half of its vol-
ume. 4. Start the engine and let it run at low speed
for no more than 5 minutes to allow the fil-
Note: the oil-water separator should be in the
ter, the oil pump, the torque converter, the
oil-absorbing state when the engine operates
torque converter oil radiator and the pipe-
normally. Therefore, to prevent air from enter-
lines to be filled with the gearbox fluid.
ing into the fuel system, make sure that oil drain
valve can be closed safely. 5. Let the engine misfire and remove the start
key. After 20 seconds later, re-check the
fluid level. If necessary, add the fluid to the
required level.
Fig. 3.28
1. Screw 1. Screw
3. Strainer 4. Bottom cover
5. Oil drain hole 6. Sensor connector Fig. 3.29
Put a proper container under the oil-water sepa-
rator.
Remove the oil drain plug to allow the liquid to
flow into the container.
When the liquid from the oil drain port becomes
clean fuel, close the oil drain port. Screw the oil
drain plug only by hand. Dispose of the waste
liquid properly.
1-44
Routine Service
Replace oil and oil filter
Replace oil and oil filter

Gearbox oil filter--Replace
Remove the two bolts and the cover, and then

remove the oil screen. Use the appropriate solu-
tion to clean the oil screen.
Fig. 3.30 Note: Please refer to the requirements for the

solution/detergent in the Safety Instructions.
1.Filter 2.Oil drain hole
Re-install the clean screen back in the gearbox.
3. Filter screen cover
Install the seal ring or gasket and the cover in
With the engine shutdown, unscrew the filter on place. Tighten cover bolt.
the top of the gearbox on the right side of the
machine. Discard the old filter properly. Gearbox oil--Refilling
Coat a layer of engine oil or lubricant onto the Add the specified grade gearbox oil into the fill-
O-ring on the top of the filter. Screw the filter un- er. When the engine shutdown, add oil into the
til it touches the seal ring. And then turn the filter filler to bring it to exceed the “MAX” mark a little.
for 3/4 turns. When starting the engine and let it idle, check
the oil level again and add oil into the filler to
Note: Don’t tighten the filter with any tool or ex-
bring it to the “MAX” mark.
cessively.
Note: If it is difficult to add oil into the gearbox,
Note: To ensure the service life of the gearbox,
it is possible that the vent hole on the top of the
only use a genuine filter of the CLG company to
gearbox housing is clogged. (Refer to the part
replace the filter.
of “Gearbox Venting Device--Cleaning”)
Gearbox oil--Replacement
Hydraulic system
Replace the gearbox oil when it is hot.
Check hydraulic fluid level
Prepare an appropriate container to store the
waste oil. Unscrew and remove the drain plug at
the bottom of the gearbox and drain the oil into
the container. Warning
When there is no oil flowing out any longer, wait Since high-pressure hydraulic oil can penetrate
for a few minutes to let the oil drop to the great- your skin, don’t use your finger to check the
est extent, and then clean and reinstall the drain hydraulic oil for leakage. Keep your face away
plug back in the gearbox. Tighten oil drain plug. from any potential leakage point. Be sure to use
a piece of paperboard to close any potential
Gearbox oil screen--Cleaning leakage point and check the paperboard for hy-
draulic oil mark. If any hydraulic oil sprays out
1-45
Routine Service
Hydraulic system
onto your skin, call a physician immediately. Insert the key D and turn it counterclockwise,
and then screw the cap B. If you feel a resist-
1. Park the machine on level ground and lay
ance, then screw it for 1/4 turns. Remove the
the loading bucket onto ground. If the ma-
key, and then the fill cap will reset automatically
chine is equipped with the telescopic bucket
so that it cannot be opened.
rod, be sure to retract it. Lift the boom and
retreat the bucket rod, and then the excava- Cap removal
tor bucket. Turn off the engine and remove
the start key. To open the cap, insert the key and turn it clock-
wise.
2. Observe the oil level in the glass A. The oil
level should be at the red mark (or above) .
CAUTION
If the liquid in the pipeline is turbid, it indicates
that there is water and air in the hydraulic sys-
tem. In this case, if you operate the machine,
the hydraulic pump will be seriously damaged.
Contact with the CLG dealer immediately.
3. If the oil level is below the red mark, if nec-
essary, unscrew the fill cap B of the hydrau-
lic oil tank to refill the recommended hydau-
lic oil.
Fig. 3.32
Hydraulic system
Replace filter element
Warning
Since high-pressure hydraulic oil can penetrate
your skin, don’t use your finger to check the
hydraulic oil for leakage. Keep your face away
from any potential leakage point. Be sure to use
Fig. 3.31 a piece of paperboard to close any potential
leakage point and check the paperboard for oil
Hydraulic oil tank cover mark. If any hydraulic oil sprays out onto your
skin, call a physician immediately.
The vent valve (and filter) of the hydraulic oil
tank is part of the fill cap B. Replace the oil fill 1. Park the machine on level ground and lay
cap (vent valve, filter) at the specified period. the loading bucket onto ground. If the machine
For details, see the service schedule. is equipped with a telescopic bucket rod, be
sure to retract it. Retreat the bucket rod and
The lock mounted on the oil fill cap can only be close the excavator bucket. Lower the boom to
unlocked by the door key. lay the excavator bucket onto ground and open
the outriggers to place them onto ground. Turn
Cap installation off the engine and remove the start key.
1-46
Routine Service
Hydraulic system
2. Remove the screws, cover, spring and gas- vator bucket onto ground, and then open the
ket from the top of the hydraulic oil tank. outriggers. Turn off the engine and remove
the start key, and then disconnect the bat-
Remove the filter with a wrench. Discard the
tery.
used filter element properly.
2. Remove the fill cap from the hydraulic oil
Install the new filter element in the housing. In-
tank.
stall the new filter element on a fine tube at the
bottom of the housing. Therefore, it is possible 3. Put a proper container under the hydraulic
to apply a larger force to install the filter element oil tank (see the Maintainability and Lubrica-
properly. tion in this chapter) . Remove the drain plug
and drain the hydraulic oil tank.
After installing the filter element in place, re-
install the spring, washer and cover. Tighten
setscrew.
Cover of suction
pipe strainer
Fig. 3.34
4 After draining the hydraulic oil, remove the
bolts of the cover of suction pipe strainer at
the bottom of the hydraulic oil tank.
Remove and discard the used suction pipe
strainer. Replace it with a new strainer.
Fig. 3.33
Install the strainer cover in place. Make sure the
1.Return oil filter element 2.Spring
seal ring/washer is full and complete. Tighten
3.Screw 4.Washer
captive bolt.
5.Cover 6.Oil drain plug
Replacement of oil-absorbing filter

Warning
To ensure that it is safe to work under the bot-
tom of the machine, lower the attachments onto
ground and pull up the hand brake. Turn off the
engine and remove the start key, and then dis-
connect the battery.
1. Park the machine on level ground. Tilt

the loading bucket forward and lay it onto
ground. Lower the boom and lay the exca-
1-47
Routine Service
Front axle and rear axle
Front axle and rear axle Warning

To ensure that it is safe to work under the bot-
Inspection of differential oil level tom of the machine, lower the working devices
onto ground and pull up the hand brake. Turn off
the engine and remove the start key, and then
Warning disconnect the battery.
To ensure that it is safe to work under the bot- The axle oil is used to lubricate the moving parts
tom of the machine, lower the working devices and to cool the brake discs, be sure to replace
onto ground and pull up the hand brake. Turn off it periodically in accordance with the service
the engine and remove the start key, and then schedule.
disconnect the battery.
1. Park the machine on level ground and pull
CAUTION up the hand brake. Shift the gearbox in its
neutral position and lower the working de-
To check the axle oil level, park the machine on
vices onto ground. Turn off the engine and
level ground. This can ensure that the oil level
will be displayed properly.
2. Put a proper container under the drain plug
1. Park the machine on level ground and pull
B. Remove the drain plug B and oil seal to
up the hand brake. Shift the gearbox in its
drain the oil into the container. Since the
neutral position and lower the working de-
drain plug is magnetic, be sure to wipe off it (
vices onto ground. Turn off the engine and
be careful to remove its adhering particles) .
Install the drain plug B and gasket.
2. Clean the area near the oil drain plug A, and
3. Park the machine on level ground. Check
then remove the drain plug and the sealing
the rear axle and repeat Step 2.
washer. The oil level should be level with the
bottom surface of the hole. If necessary, add
the recommended oil.
CAUTION
3. Clean and re-install the drain plug and
washer in place. When removing the drain plug, the oil will spray
out. Be sure to stand on the other side of the
drain plug.
Fig. 3.35 Fig. 3.36

Replace differential oil
1-48
Routine Service
Front axle and rear axle 1. Park the machine on level ground and al-
low the tyres to be off the ground. Turn the
Inspection of wheel oil level wheel to allow the oil level mark on the hub
and the oil plug C to be in the vertical posi-
Check the two wheel hubs separately. tion.
1. Park the machine on level ground. Make 2. a Put a proper container under the oil plug C.
sure the oil level mark is horizontal. How-
ever, an error of 5mm (0.2in) is permitted. b Remove the oil plug C to drain the oil.
2. Pull up the hand brake. Shift the gearbox in 3. a Let the oil level mark be in the horizontal
its neutral position, and lower the working position.
devices onto ground. Turn off the engine b Pour the recommended hub oil into the
and remove the start key. oil plug hole C until the oil is level with
3. Clean the area near the oil plug C, and then the bottom surface of the hole.
remove the oil plug. The oil level should be c Clean and re-install the drain plug C.
level with the bottom surface of the oil filler
hole. If necessary, add the recommended
oil. Clean and install the drain plug.
Fig. 3.38
Outriggers - Adjustment (Sideway
type)
Fig. 3.37 Wear-resistant pads
Replacement of wheel oil The wear-resistant pads are used as the sup-
The axle case oil is used to lubricate the moving port and guide rails of the outriggers.
parts and to cool the brake discs. It is important As shown in the figure, the upper wear-resistant
to replace the oil periodically in accordance with pads mounted on the top of the internal outrig-
the intervals specified in the service manual ger has three types of sizes in different colors,
because the brake wear can cause reduction of namely, 5mm (green) , 6mm (red) and 7mm
lubrication performance. (blue) . The lower wear-resistant pad consists
If necessary, consult the CLG dealer. of the shim B and the fixed pad C. When pad A
and pad C are worn to the minimum thickness
Replace the oil of the two hubs separately. of 0.5mm (0.02in) , be sure to replace them. To
1-49
Routine Service
replace the pad, remove the internal outrigger.

Please consult your CLG dealer.
Fig. 3.40
Fig. 3.39
Note: since pad C is designed to bear most load

when the outrigger operating, be sure to
check it for wear regularly.
In addition, be sure to replace the whole lower
wear-resistant pad (B and C) . Also, check the
upper wear-resistant pad regularly. If necessary,
replace it.
Adjustment of wear-resistant pads
Note: Adjust the wear-resistant pads based on Fig. 3.41
the service period properly. Since contact of the Add the adjusting washer D until tightness. And
external outrigger with the internal outrigger can then, loosen the bolt E.
produce scratch, this can reduce the service life
of the wear-resistant pads greatly.
Make sure that there is a clearance about 1mm
between the external and internal outriggers.
During adjustment, make sure the outriggers
are off the ground but they cannot be retreated
fully.
During adjustment, screw the bolt E, and screw
the wear-resistant pad B completely until it can
touch the internal outrigger.
Fig. 3.42
1-50
Routine Service
Fig. 3.43
After completion of adjustment, turn the bolt to
its original position and tighten the nut.
Fig. 3.44
1-51
Main Removal and Installation
Loader equipment
Main Removal and

Installation
Loader equipment
Tools list
Name Specification
16x18, round head
Wrench
wrench16,18
External snap spring
Snap spring pliers
pliers
Wind trigger MI-16
Socket 16,18
Nipper pliers Knock away the pin at the hinge joint between
the lifting arm and the bucket with the pin
Iron hammer/copper bar remover and a sledgehammer, and set the pin
aside. Don’t throw away the shim;
Pin remover
Removal
1. Pressure relief
Start the complete machine. Lift up the lifting
arm and turn over the bucket to allow the bucket
mouth to be down. Lower the lifting arm slowly
to allow the bucket to be put on the wood pre-
placed onto the ground. Let the engine misfire
and move the control lever for pressure-relief.
2. Removal of bucket
To remove and install the hydraulic pipelines,
refer to 5.4.8 Four-in-One Bucket Cylinder. Lift up the lifting arm to separate the bucket
Remove the captive bolts from the plate of the from the lifting arm.
pin at the hinge joint between the lifting arm and
the bucket with the 18# wrench (or pneumatic
tools +18# socket) , as shown in the figure, two
bolts on the right/left side, respectively;
1-52
Loader equipment
3. Removal of four-in-one bucket cylinder (If the

complete machine is equipped with the flat
bucket, this step will be omitted.)
Remove the captive bolts from the plate of
the pin on the four-in-one bucket with the 18#
wrench (or pneumatic tools +18# socket) , total- Remove the hose AS connected to the four-
ing four bolts. in-one bucket cylinder and wrap it with clean
plastic paper to prevent impurities from entering
into it.
Remove the bolts from the joint between the

piston rod end and the support lug with the 16#
wrench (or pneumatic tools +16# socket) , and
remove the T-shaped sleeve;
Remove the pin from the piston rod end. Lift
the cylinder with a sling. Remove the pin on the
other end of the cylinder, and then take out the
cylinder.
4. Remove lifting arm
To remove the hydraulic pipeline, refer to the
1-53
Loader equipment
hydraulic working system.

Remove the captive bolts from the plate of the
pin at the hinge joint between the lifting arm and
the lifting cylinder with the 18# wrench (or pneu-
matic tools +18# socket) , one bolt on the right/
left side, respectively;
Take out the pin and lay the cylinder down

slowly. Take out the pin of the other side in the
same manner.
Remove the snap spring from the hinge joint be-
tween the draw bar and the frame with the snap
spring pliers and take out the shim and the plug
(black plastic cover) ;
Hike the lifting arm about 1m with the travel-
ling crane, and withstand the lifting arm with the
tooling.
Remove the front hood by referring to 5.3.1

Method for Removal of Front hood.
Remove the four captive bolts (on the inside
of the frame) from the pressure plate of the pin
with the 16# wrench, and set the pressure plate
aside.
Hang the lifting arm cylinder with the sling and
pry out the fixed pin with the crowbar.
1-54
Loader equipment
Remove the captive bolts of the pin of the rear

draw bar on the other side in the same manner;
Remove the double nuts from the bolts at the Lift the lifting arm with the travelling crane.
hinge joint between the lifting arm and the frame Remove the two pins at the hinge joint between
with two 18# wrenches, and take out the bolts; the rear draw bar and the frame with the pin
remover and hammer, and set the pins aside.
Remove the captive bolts from the pin on the

inside of the frame with the 18# wrench.
1-55
Loader equipment
Pull out the bolts at the hinge joint between the

lifting arm and the frame using the pneumatic
impact wrench and the M20*65 bolts by
increasing steel sleeves stepwise, and set the
pins aside. Pull out the pins on the other side
just in the same manner.
Remove the snap spring from the mounting pin
of the rotating bucket cylinder with the snap
spring pliers, and take out the gaskets.
Lift the lifting arm to one side with the travelling

crane.
Knock out the pins, and remove the cylinder and

set it aside.
1-56
Loader equipment
Remove the snap spring from the pins at the

hinge joint between the front draw plate and the Remove the plate from the lifting arm just in the
two side plates and take out the shims. Knock same manner.
out the pins and remove the front draw plate.
1-57
Loader equipment
Remove the plate from the lifting arm just in the

Remove the snap spring from the pins at the same manner.
hinge joint between the front draw plate and the
two side plates and take out the shims. Knock
out the pins and remove the front draw plate;
1-58
Loader equipment
should be no more than one. Moreover, priority

should be given to use the adjustable thicker
pads.
Install the two sets of side plates fixing the front
draw bar in place in the same manner.
Installation
1. Install lifting arm
Align the mounting hole on the front draw bar to
Knock the copper bar slightly into the mounting
the hole of the fixing plate of the draw bar, and
hole with the pin. Install the two sets of side
knock the copper bar into the pin;
plates on the pins until the two side plates close
the lifting arm;
Add the shims to the outside of the side plates
to make sure that the snap springs can restrain
the horizontal movement of the side plates.
Add the shims to the outside of the fixing plate

of the front draw bar. Install the snap spring in
the pin snap spring groove with the snap spring
pliers. Make sure that the movement clearance
of the shims should be no more than 1.5mm
after installation;
Note: make sure that the clearance between the Lift the left and right cylinders of the rotating
shim and the snap spring should be no more bucket to the mounting positions with the trav-
than1.5mm after installation and the parts can elling crane (3t) . Let the pin pass through the
free rotate. The difference between the quanti- plate, the cushion cover, the shims--the quan-
ties of the shims on the two ends of the pins tity should be determined based on the actual
1-59
Loader equipment
conditions, the cylinder, the shims--the quantity

should be determined, the cushion and the
plate in turn. Add the shims outside the plates.
The shims should be added based on the ac-
tual conditions to make sure that the movement
clearance of the shims should be no more than
1.5mm. Install the snap spring in the pin snap
ring groove with the snap spring pliers. Install
the pin on the piston rod end in the same man-
ner.
2. Installation of lifting arm cylinder

Knock the pin into the mounting hole with the
copper bar. Adjust the position of the pin. Fix
the pin on the inside of the frame with the 16#
wrench.
Lift the lifting arm cylinder to the mounting posi- 3. Hoisting lifting arm
tion with the travelling crane. Let the assem- Lift the lifting arm to the frame position with the
bled pin pass through the cylinder end. Add the travelling crane. Adjust the positions of the lifting
shims if necessary. Install the snap spring in the arm and the frame to allow the mounting hole
pin snap spring groove with the snap spring pli- of the lifting arm to align to that on the frame.
ers. Make sure that the movement clearance of Adjust the left and right positions of the lifting
the shims should be no more than 1.5mm after arm to allow the distance from the inside of the
installation.
1-60
Loader equipment
lifting arm to the outer plate to be consistent. Knock the pin into the mounting hole of the
Based on the deviation conditions, determine frame with the copper bar. Turn the pin to allow
the quantity of the shims to be added. Knock the pressure plates to be aligned with the pin
the pin with the copper bar. Let the pin to pass groove. Fix the plates with the 16# wrench.
through the lifting arm, the shims and the frame;
Install the removed shims onto the pins. Mount

the rear draw bar on the pin and add the shims
to the other end. Install the snap spring in the
pin snap spring groove with the snap spring
pliers. After installation, make sure that the
movement clearance of the shims should be no
more than1.5mm, and then install the plug.
Install the sleeve on the pin. Let the bolt pass

through the sleeve and the hole in the pin from
the upper end. Use double nuts to tighten the
lower end of the sleeve with the 18# wrench (or
pneumatic tools +18# socket) .
Shim
4. Installation of rear draw bar
1-61
Loader equipment
Place the other end of the rear draw bar

between the side plates. Add the shims. Let the
pin pass through the plate, the shims, the rear
draw bar, the shims and the plate in turn with
the copper bar. After adding the shims to both
ends of the pin, install the snap spring in the pin
retaining groove with the snap spring pliers.
5. Lifting arm cylinder and lifting arm hinge joint

Lift the lifting arm cylinder with the travelling
crane to the mounting position of the lifting arm
and add the shims. Let the pin pass through
the lifting arm and cylinder with the copper bar.
Tighten the captive bolts of the plate with the
18# wrench;
1-62
Loader equipment
arm.
Determine the quantity of the shims and their

mounting positions in accordance with the
clearance at the mounting location between the
left/right lifting arm and the bucket body. Ensure
that the center plane of the lifting arm coincides
with the center plane of the bucket body. Knock
the hinge pin with the copper bar;
For the connection of pipelines, refer to 5.4.7

Two Types of Cylinders on Loading End;
6. Hoisting four-in-one bucket
Lift the four-in-one bucket with the travelling
crane;
Adjust the bucket position, if necessary, add the

shims. Knock the fixing pin between the front
draw bar and the bucket body with the copper
bar or hammer.
Adjust the position to allow the four-in-one buck-

et to align to the mounting position of the lifting
1-63
Backhoe Equipment
Loader equipment
Connect the hose AS with the cylinder by

referring to the connection mode of the pipelines
shown in the following figure.
Tighten the captive bolts of the plate with the

pneumatic impact wrench and the 18# socket.
1-64
Backhoe Equipment
Removal
Backhoe Equipment
Removal
1. Removal of bucket
Remove the captive bolts of the pins with two
18# wrenches (or the pneumatic impact wrench
and the 18# socket) , and take out the circular
sleeve.
2. Removal of bucket rod

Lift the bucket rod with the travelling crane to
separate the bucket rod from the bucket. Lay
the bucket rod onto the rack or stand.
Withstand the pin with a M20×100 bolt or other
columnar metal and knock the pin out with the
copper bar.
1-65
Backhoe Equipment
Removal
Remove the pin in the Fig. with the copper bar

(hammer) and bolt (or iron rod) . Lift the bucket
rod to one side with the travelling crane. Re-
move the retaining ring from the counterweight.
Remove the captive bolts of the pin plate with

the 18# wrench (or the pneumatic impact
wrench and the 18# socket) , and set it aside.
1-66
Backhoe Equipment
Removal
3. Removal of shims of telescopic bucket rod Unscrew the captive bolts of the pin of the tel-
Remove the bolts from the shims with the 18# escopic cylinder with the 19# socket;
wrench (or the pneumatic impact wrench and
the 18# socket) ;
Move the shims to one side with the Cross-

screwdriver and take out the shims; Knock out the pin with the copper bar;
Unscrew the adjustable bolts from the upper

and lower bucket rods with the 21# wrench (or
the pneumatic impact wrench and the 21# sock-
et) ; Separate the upper and lower bucket rod from
the lower one with the travelling crane, sling and
1-67
Backhoe Equipment
Removal
crowbar;
Let the pin pass through the hole and tighten the
captive bolts of the pin plate with the pneumatic
impact wrench.
4. Boom removal
Lift and hold the boom with the travelling crane.
Remove the bolts from the plate with the 18#
wrench. Withstand the pin with a M20×100 bolt
or other columnar metal. Knock out the pin with
the copper bar (or hammer) . To avoid injury
resulting from the pin falling off, be careful to 2. Installation of upper and lower bucket rods
knock the pin. Lift up the upper bucket rod with the travelling
crane;
Lift the boom to one side with the travelling

crane.
Installation Put the shims into the track;

1. Boom installation
Lift up the boom with the travelling crane to
align the mounting holes on the swing seat;
Move the travelling crane and install the upper

bucket rod in the groove of the lower one. Be
sure to make sure that the shims close the
1-68
Backhoe Equipment
Removal
inside of the track; holes;
Adjust the travelling crane to align the holes of

the upper and lower bucket rods. Add the shims
Tighten the captive bolts with the pneumatic im-
based on the left and right clearances. Let the
pact wrench and the 16# socket;
pin pass through the mounting holes;
4. Hoisting of bucket rods

Lift up the bucket rod with the travelling crane
to align the mounting holes of the boom. Add
Tighten the captive bolts of the plate with the the shims based on the actual conditions. Make
pneumatic impact wrench and the 18# socket; sure the swing range of the bucket rod should
be less than the thickness of one shim after in-
3. Installation of plates of bucket rods stallation. Let the pin pass through the mounting
Put the plate to the location shown in the figure. holes. Fix the pin plate with the bolts.
Adjust the positions of the shims in the track
with the Cross-screwdriver to align the mounting
1-69
Backhoe Equipment
Removal
Refer to “5.4.5 Installation Steps of Three Types

of Cylinders on Excavation Side”, install the cyl-
inder with the pin;
5. Installation of excavator bucket
Lift up the bucket rod and lay the position-limit
hook down. Lift the bucket to a safe place with
the travelling crane. Knock the pin into the mounting holes with the
hammer or copper bar.
Adjust the position of the bucket. Add the shims

based on the actual conditions. Make sure
that the movement clearance of the bucket
should be less than the thickness of one shim
after installation. Let the pin pass through the
mounting holes.
1-70
Backhoe Equipment
Removal
Install the columnar sleeve and bolts on the pin.

Fix the bolt with double nuts. Tighten the nuts
Lower the travelling crane slowly and remove with two 18# wrenches.
the sling. Hook the sling onto the bucket teeth.
Adjust the position of the bucket. Add the shims

based on the actual conditions. Make sure that
the movement clearance of the bucket should
be less than the thickness of one shim after
installation. Hinge it with the pin.
Lay the travelling crane down and remove the

sling to complete the installation of bucket.
1-71
Backhoe Equipment
Frame system
Frame system
Tools list
Name Specification
10×12,1
Wrench
6×18,18×21,19×22,36×41
Lifting tool Sling hook and sling
Nipper pliers
Wind trigger MI-17
Socket 16#, 18#, 24#, 36#
Copper bar
Remark: removed standard parts should be placed
with relevant material together to avoid mixing.
Counterweight (optional for

777A )
Removal
1. Removal of working devices for loading
Refer to 5.2.1 Working Devices for Loading and
remove the working devices on the front end.
2. Removal of radiating system and hood
Refer to 5.5.4 Radiating System and 5.3.1 Front
hood, and remove the radiator and the hood Remove the bolts from the additional counter-
and other. weight with the 18# wrench (or the pneumatic
impact wrench and the 18# socket) to separate
3. Removal of counterweight the additional counterweight (optional) from the
Install the sling ring onto the counterweight. counterweight.
Hang the two lifting hooks onto the travelling
crane to allow the travelling crane to hoist the
counterweight.
Unscrew and remove the bolts with the 36#
the 36# socket) , and place them in a safe
place.
1-72
Backhoe Equipment
Counterweight (optional for 777A )
Installation
1. Installation of additional counterweight and
counterweight
Lift up the counterweight with the travelling
crane to align the mounting holes of the counter-
weight to those of the additional counterweight.
Let the bolts pass through the mounting holes
from the lower end and pre-tighten the upper
end with the nuts. Tighten the bolts with the 18#
the 18# socket) .
2. Hoisting of counterweight
Lift the counterweight with the travelling crane to
the mounting position of the frame. Pre-tighten
the bolts for 3~5 threads by hand. Tighten the
bolts with the pneumatic impact wrench and the
36# socket.
1-73
Backhoe Equipment
Swing seat
Swing seat
Removal
1. Removal of working devices for excavation and
hydraulic pipelines
Refer to the removal procedures in 5.2.2
Working Devices for Excavation and 5.4.9
Swing Cylinders
2. Removal of hinged pin between swing cylinder
and swing seat
Remove the captive bolts from the pin with the
18# wrench (or the pneumatic impact wrench
and the 18# socket) . Remove the bolts from the
lower end of the pin with the 18# wrench and
take out the bolts to put them in a safe place.
3. Removal of pin hinging swing seat with lower
part of frame
Remove the captive bolts from the lower pin
plate with the 16# wrench (or the pneumatic im-
pact wrench and the 16# socket) .
Put a M24*100 bolt or other columnar metal on

the upper end of the pin. Knock the bolt with the
copper bar to knock the pin out. To avoid injury
resulting from the pin falling off, be careful to
knock the pin.
1-74
Backhoe Equipment
Swing seat
Lift and hold the swing seat with the travelling

crane and strain the sling only. Put a M24*100
bolt or other columnar metal on the upper end
of the pin. Knock the bolt with the copper bar to
knock the pin out. To avoid injury resulting from
the pin falling off, be careful to knock the pin.
Put a M24*100 bolt or other columnar metal on

the lower end of the pin with your left hand and
knock the bolt with the copper bar with your
right hand to knock out the pin. Place the pin in
a safe place. However, first of all, beat out the
pin to the lower end of the swing seat with the
copper bar.
4. Removal of pin hinging swing seat with frame

Remove the captive bolts from the upper pin
plate with the 18# wrench (or the pneumatic im-
1-75
Backhoe Equipment
Swing seat
Move the travelling crane and lift the swing seat Pry the swing cylinder with the crowbar and
to one side. move it to one side.
Installation
1. Installation of swing cylinder
Move the swing cylinder to the mounting
position of the frame to allow the mounting pin
5. Removal of swing cylinder
of the cylinder to enter into the mounting grove
Lock the lower bolts with the 36# wrench. Re-
of the sideway bracket.
move the captive bolts from the gland with the
pneumatic impact wrench and the 36# socket,
and remove the gland.
1-76
Backhoe Equipment
Swing seat
Knock the upper pin into the mounting hole with

the copper bar. And then, tighten the captive
bolts of the upper pin plate with the 18# wrench
Cover the gland on the mounting pin on the up- (or the pneumatic impact wrench and the 18#
per end of the swing cylinder. Lock the lower nut socket) .
with the 36# wrench. Tighten the bolts with the
pneumatic impact wrench and the 36# socket.
2. Installation of swing seat

Lift up the swing seat with the travelling crane.
Align the mounting hole of the swing seat to the
axis of the mounting hole of the sideway bracket
slowly.
1-77
Backhoe Equipment
Swing seat
Knock the pin into the lower hinge hole with

the copper bar. If necessary, add the shims.
Make sure that the clearance at the hinge
joint between the swing seat and the sideway
bracket should be less than the thickness of
one shim. Adjust the position of the hole of the
mounting pin with the wrench. Fix the pin with
the stop plate to prevent it from turning.
Connect the air source to push out the swing

cylinder piston rod to an appropriate length with
the compressed air. Align the cylinder mounting
hole to the axis of the mounting hole of the
swing seat. Fix the swing seat and the cylinder
with the pin.
1-78
Backhoe Equipment
Sideway bracket and clamping cylinder (777A)
Sideway bracket and clamping

cylinder (777A)
Removal
1. Removal of swing seat and swing cylinder
To remove the swing seat and swing cylinder,
refer to the procedures for removal in 5.1.2
Swing seat and 5.4.9 Swing Cylinder.
2. Removal of clamping cylinder
Remove the hose AS from the clamping cylinder
with the 21# wrench and store it in a safe place.
Rotate the pin. Let the bolt pass through the

holes of the swing seat and the pin. Tighten the
bolt with the 18# wrench (or the pneumatic im-
Strain the sideway bracket with the travelling

crane and sling. Unscrew the fixing nuts of the
clamping cylinder with the 54# wrench and re-
move the clamping cylinder.
3. Pipeline connection
Refer to 5.4.9 Swing Cylinder, connect the
pipelines.
1-79
Backhoe Equipment
Hoist the sideway bracket to one side with the

Installation
travelling crane. 1. Bolt installation
Put the baffle in the both sides of the chute. Let
the bolt pass through the hole of the baffle. In-
stall other bolts and baffles onto the frame in the
same manner.
Unscrew the bolts on both sides of the frame

and take out the bolts and baffle.
2. Hoisting of sideway bracket
Lift up the sideway bracket with the travelling
crane and move it to the mounting location.
Adjust the positions of the bolt and the baffle
to align the bolt to the mounting hole of the
sideway bracket. Move the sideway bracket to
let the bolt pass through the mounting hole of
the sideway bracket;
1-80
Backhoe Equipment
Move to both sides to take out the bolts and baf-

fles.
3. Installation of clamping cylinder
Install the clamping cylinder on the bolts and
pre-tighten the nuts by hand.
Adjust the angle of the joint of the clamping cyl-

inder and connect the hose AS.
1-81
Backhoe Equipment
Outrigger (766A)
Outrigger (766A)
Removal
1. Removal of hydraulic pipelines
Start the complete machine to open the outrig-
gers until the support frame off the ground for 2-3
cm. After misfiring and pressure-relief, refer to
the procedures of removal in 5.4.10 766A Out-
rigger Cylinder, and then remove the hose AS
and the outrigger cylinder.
2. Removal of captive bolts of pin plates
Remove the captive bolt from the pin of the out-
rigger with the 18# wrench (or the pneumatic
impact wrench and the 18# socket) and place it
properly.
Tighten the bolts with the 54# wrench or a large

monkey wrench to complete the installation.
1-82
Backhoe Equipment
Outrigger (766A)
Installation
1. Installation of outrigger
Lift up the outrigger with the travelling crane to
3. Removal of support frame (stand bar) align the outrigger mounting hole to the mount-
To remove the support frame, knock the pin out ing hole of the frame. Knock the pin into the
with the copper bar. mounting holes with the rubber hammer or cop-
per bar.
4. Remove outrigger
To remove the outrigger cylinder, refer to 5.4.10
766A Outrigger Cylinder 2. Installation of support frame (sole)
Move the support frame to the outrigger and put
Lift up the outrigger with the travelling crane to
the outrigger onto the mounting location of the
level the outrigger. Knock the pin out with the
support frame. Adjust the position of the support
copper bar or pry the pin out with the crowbar.
frame. Knock the pin with the rubber hammer.
Lift the outrigger with the travelling crane to one
side.
1-83
Backhoe Equipment
Outrigger 777A
3. Captive bolts of plates

Tighten the removed captive bolts of the plates
with the pneumatic impact wrench and the 18#
socket (or the18# wrench) ;
Outrigger 777A 2. Removal of hose

Removal Remove the connector with the 22# wrench.
Cover the hose end of the hose coupler to pre-
1. Removal of holder vent oil contamination from entering the pipe-
Remove the harness connector. Remove the line.
bolt with the 10# wrench. Remove the harness
connector and remove the holder.
1-84
Backhoe Equipment
Outrigger 777A
Knock out the pin with the copper bar;

4. Guide cylinder removal
Install the M16 bolt in the position shown in the
3. Removal of bracket Fig. and tighten it.
Remove the bolts from the fixing pin of the sup-
port with the pneumatic impact wrench and the
16# socket.
Withstand the shim with the bolt. Knock the

shim with the copper bar to remove it.
1-85
Backhoe Equipment
Outrigger 777A
Installation
1. Install the upper part of outrigger cylinder
Lift the cylinder to the mounting position with the
travelling crane and sling.
Install shim at both sides of pin shaft, and install

snap spring into mounting groove of pin shaft
with snap spring plier.
Put the backup rings into both sides of the

mounting hole on the upper end of the cylinder.
Knock the pin into the mounting hole with the
copper bar.
2. Install the lower part of outrigger cylinder

Knock the pin into the mounting hole with cop-
per bar. Fix the pin with the bolts and nuts.
Tighten the bolts and nuts with two 16# sockets
1-86
Backhoe Equipment
Outrigger 777A
to 52±7 N•m. it with the support. Give priority to use the thick
shims. Make sure that the clearance should be
less than the thickness of one thin shim.
Put the cover on the support. Fix the bolt with

the 10# wrench.
3. Installation of shims
Install the M16 bolt in the position shown in the
Fig. with the pneumatic impact wrench and the
24# socket, tighten it.
4. Installation of holder
Put the holder in the mounting position. Connect
the holder harness with the frame harness. And
Install the shim in the support shown in the then, fix the bolt and pads with the 10# wrench
figure. Beat out the shim with copper bar to level and tighten the bolt to 10.5±1.5 N•m.
1-87
Backhoe Equipment
Limit hook
Knock out the pin with the copper bar and the
M20×100 bolt (or iron bar) and remove the posi-
tion-limit hook.
Limit hook Installation

Put the position-limit hook in the mounting posi-
Removal tion and align the holes. Knock the pin into the
1. Remove snap spring holes with the copper bar.
Remove the snap springs on both sides with the Install the snap springs on both sides into the
snap spring pliers. groove with the snap spring pliers.
1-88
Backhoe Equipment
Cab and engine cover
Cab and engine cover

Cover
Removal
Preparations
Open the upper cover and support the lifting
arm. Fix the lifting arm with the safety strut.
1. Remove front cover door

Unscrew the four captive bolts from the front
hood door with the 16# wrench (or socket) and
remove the front hood door.
2. Remove horn
Cut off the fixing harness of the front horn. Un-
screw the captive bolts of the horn with two 13#
wrenches. Be careful to store the horn properly.
1-89
Backhoe Equipment
Front cover
Remove the four captive bolts of the front

hood on both sides of the front end with the
16# wrench. Take out the front hood along the
forward direction of the complete machine. Be
careful to store the front hood properly.
3. Remove relay
Pull out the front relay.
Front cover
Installation
1. Install front cover
Insert the lower end of the front hood in the fix-
ing position of the frame. Adjust the front hood.
Make sure it is bilaterally symmetric. Tighten the
four flat gaskets, spring gaskets and bolts on
Also, remove the support for fixing relay with the
both sides with the 16# wrench.
Cross-screwdriver. Be careful to store the relay
properly. Tighten torque 52±7 N•m
4. Remove front cover 2. Install relay

1-90
Backhoe Equipment
Front cover
Screw the relay support to the mounting position

with the Cross-screwdriver.
4. Install front cover door

Put the front hood door in the mounting position.
Insert the relay in place. Adjust the mounting position until the front hood
door will not interfere with the front hood or the
counterweight. Tighten the flat gaskets, spring
gaskets and bolts with the 16# wrench. Tighten
torque 52±7 N•m
3. Install horn
Screw the horn to the mounting position with
two 13# wrenches, and bind the harness to the
corresponding position. Tightening torque 26±4
N•m
1-91
Backhoe Equipment
Cab
Cab
Removal
1. Remove seat
Separate the seat from the seat base with the
two 13# wrenches.
Remove the two lock nuts from the handle knob

with two 25# wrenches, and unscrew the handle
knob.
Separate the seat base from the cab with the

16# wrench.
Remove the cover with the 8# wrench.
2. Removal of control lever on excavation side

Remove the upper end of the control handle
knob with the Cross-screwdriver.
1-92
Backhoe Equipment
Cab
and take out the cover and the dustproof hood. Take out the box.
Remove the bolts from the load control leather

cushion with the 8# wrench (or socket) and take
out the leather cushion.
Remove the bolts from the load control box with

the 8# wrench.
Remove the connecting bolts between the
control lever and the link with the 11# and 13#
wrenches and separate the control lever from
the link.
1-93
Backhoe Equipment
Cab
completely.
Pull out the connecting harness between the

control lever and the complete machine and
take out the control lever.
Remove the connecting bolts between the con-

trol lever base and the support with two 16#
wrench.
3. Remove shift lever
Remove the cover of the shift lever with the 8#
wrench or socket.
Separate the load control lever from the frame

1-94
Backhoe Equipment
Cab
Pull out the harness connector of the shift lever Take out the shift lever.
from the complete machine harness from the
machine bottom.
4. Remove excavation control

Remove the bolts from the excavation control
Remove the captive bolts connecting the shift cover with the 8# wrench or socket.
lever with the gearbox with the 18# wrench.
1-95
Backhoe Equipment
Cab
Remove the position-limit flexible shaft handle

with the 10# wrench.
Remove the lock nut of the knob with the 18#

wrench.
Remove the position-limit flexible shaft from the
excavation control box with the 22# wrench.
Screw off handle knob;
Remove the upper cap of the excavation control

knob with the cross-screwdriver.
Remove the lock nut from the outrigger control

1-96
Backhoe Equipment
Cab
lever with the 16# wrench.
Unscrew the outrigger control lever.
Remove the lock nuts from the 6 (six) links with

the 11# and 13# wrenches.
Remove the captive bolts from the excavation
control box with the 8# wrench and remove the
box, cover and the upper dustproof hood to-
gether.
1-97
Backhoe Equipment
Cab
Remove the bolts connecting the control lever Remove the bolts connecting the outrigger con-
and the support with the 18# wrench. trol lever and the support with the 18# wrench
and take down the outrigger control lever.
Pull out the harness connecting with the com-

plete machine and remove the excavation con- 5. Remove multi-way valve
trol lever. Remove the plug pin with the needle-nose pliers
and separate the multi-way valve link from and
the multi-way valve.
1-98
Backhoe Equipment
Cab
Remove the right nut connecting the hand brake

flexible shaft with the rear axle with the 18#
wrench. Separate the hand brake flexible shaft
from the rear axle.
7. Remove cable of accelerator

Remove the connecting nut between the throt-
tle cable flexible shaft and the engine throttle
with the 10# wrench. Remove the connecting
nut between the throttle cable flexible shaft and
the frame with two 13# wrenches. Separate the
throttle cable flexible shaft from the frame.
6. Remove the parking brake flexible shaft

Remove the left nut connecting the hand brake
flexible shaft with the rear axle with the 10#
wrench.
1-99
Backhoe Equipment
Cab
8. Remove fender
Remove the fenders on the left and right sides
with the 13# wrench. Each fender is equipped
with six bolts.
10. Remove A/C pipe

Unscrew the two caps on the compressor by
hand and connect them with the two connectors
of the machine to extract the Freon.
9. Remove plate
Remove the left and right plates with the 13#
wrench. Each plate is equipped with five bolts.
1-100
Backhoe Equipment
Cab
Start the machine to extract the Freon.
Remove the clight of the A/C tube of the evapo-

rator on the left side with the 13# wrench.
Remove the clight of the heater tube on the right
side of the cab with the 8# wrench or socket.
Remove the evaporator connector with the 19#

and 17# wrenches. Wrap the connectors of the
Remove the two A/C tubes on the right side of
hose and the evaporator with clean plastic bags
the cab with the 27# wrench.
and belts to prevent foreign matters from enter-
ing.
1-101
Backhoe Equipment
Cab
11. Remove the main fuse box and the harness Unscrew the earthing harness connecting with
connector at the bottom of the cab. the frame with the 13# wrench.
Cut off the belts used to bind the harness under
the machine.
Pull out the harness connector of the front work

light from the mounting hole of the shift lever.
1-102
Backhoe Equipment
Cab
Remove the plastic cap of the main fuse box on

the right side of the machine bottom. Unscrew
the terminal studs of the main fuse box with
the 14# wrench. Unscrew the fuse box with the
Cross-screwdriver.
Unplug the master socket of the outside wiring

harnesses.
Tear off the adhesive tape on the outer of the

master socket of the inside wiring harnesses.
1-103
Backhoe Equipment
Cab
Open the protective housing and unplug the on the left side of the cab.
master socket of the wiring harnesses.
Remove the wiper flow pipes at the bottom un-

der the front and rear of the cab separately.
Pull out the master light wiring harness socket

1-104
Backhoe Equipment
Cab
12. Removal of traveling brake hose and metering

pump hose
Remove the clight of the connecting hose be-
tween the assistor and the oil cup with the 8#
wrench.
Remove the clight of the assistor vacuum pipe

with the 8# wrench.
Remove the hose on the side of the metering

pump with the 19# wrench. Wrap the connec-
tors of the hose, assistor and metering pump
with the clean plastic bags and belts to prevent
foreign matters from entering.
Remove the four hoses from the metering pump

with the 24# wrench. Wrap the connectors of
the hoses, assistor and metering pump with the
clean plastic bags and belts to prevent foreign
matters from entering.
1-105
Backhoe Equipment
Cab
13. Lift the cab

Hold the cab in place with the travelling crane
and sling.
Remove the captive bolts connecting the frame

and the cab with the 24# wrench. Lift up the cab
with the travelling crane and sling.
1-106
Backhoe Equipment
Cab
Cab
Installation
1. Hoisting of cab
Lift the cab to the mounting position with the
travelling crane and sling.
Remove the shield on the assistor and the vac-

uum pipe. Connect the hose with the assistor
connector. Tighten the clight with the 8# wrench.
Be careful to prevent the clight from interfer-
ing with any other part. Screw the clight until it
touches the inside of the steel tube boss.
Align the four mounting holes at the bottom.

Tighten the connecting bolts between the frame
and the cab with 24# wrench. Tightening torque
225±35 N•m
Remove the shield on the front end of the me-

tering pump. Observe the hose connecting the
metering pump. Make sure that the hose O-ring
is in good condition. Connect the hose with the
metering pump’s connector. Be careful to avoid
2. Installation of travelling brake hose and meter- interfering with any other part. Tighten the four
ing pump hose hoses with the 24# wrench to 26±2 N•m.
Remove the shield on the assistor and the hose.
Connect the hose with the assistor connector.
Tighten the clight with the 8# wrench. Be care-
ful to prevent the clight from interfering with any
other part. Screw the clight until it touches the
inside of the steel tube boss.
1-107
Backhoe Equipment
Cab
in good condition. Connect the hose with the

metering pump’s connector. Be careful to avoid
interfering with any other part. Tighten the con-
nector with the 19# wrench. Tightening torque is
16±1N•m
3. Installation of main fuse box and wiring harness

connector at bottom of cab
Tighten the earthing wiring harness connecting
the frame with the 13# wrench to 26±4 N•m.
Insert the wiring harness connector of the front

work light from the mounting hole of the shift
lever.
Remove the shield on the side of the metering

pump. Observe the hose connecting the meter-
ing pump. Make sure that the hose O-ring is
1-108
Backhoe Equipment
Cab
Screw the fuse box with cross screwdriver, and

screw the wiring bolt on the main fuse box with Plug the master socket of the outside wiring
14# wrench, tightening torque 52±7 N•m, and harnesses.
then put the plastic cover on the main fuse box.
Plug the master socket of the inside wiring

harnesses.
1-109
Backhoe Equipment
Cab
Install the protective housing and then wind the Plug the main light wiring harness socket on the
outer of the master socket of wiring harness left side of the cab.
with electrical adhesive tapes.
Connect the wiper flow pipes at the bottom of

front and rear cab separately.
1-110
Backhoe Equipment
Cab
4. Removal and installation of A/C tube Remove the shield on the evaporator and the
Remove the shield on the evaporator and heat- air-conditioning tubes on the left side of the cab.
er pipe on the right side of the cab. Connect Observe the hose connected to the evaporator
the heater pipe with the evaporator connector. connector. Make sure the hose O-ring is in good
Screw the clight until it touches the inside of the condition. Connect the hose with the evaporator
steel tube boss. Tighten the clight with the 8# connector. Be careful to avoid interfering with
wrench or socket. any other part. Install the clight on the left evap-
orator air-conditioning tube with the 13# wrench.
Tightening toruqe is 26±4 N•m.
Remove the shield on the evaporator and the

air-conditioning tubes on the right side of the
cab. Observe the hose connected to the evapo- Connect the evaporator connector with the air-
rator connector. Make sure the hose O-ring is conditioning tube with the 19# and 17# wrench-
in good condition. Connect the hose with the es and tightening torque is 16±1 N•m.
evaporator connector. Be careful to avoid inter-
fering with any other part. Tighten the two air-
conditioning tubes with the 27# wrench to 37±2
N•m.
1-111
Backhoe Equipment
Cab
5. Install the plate

Install the left and right plates with the 13#
wrench. Each plate is equipped with five bolts
with a tightening torque of 26±4 N•m.
Unscrew the two caps on the compressor by

hand and connect them with the two connectors
of the machine to charge the Freon. Start the
machine to add the Freon.
6. Installation of fenders
Install the left and right fenders with the 13#
wrench. Each fender is equipped with six bolts
with a tightening torque of 26±4 N•m.
1-112
Backhoe Equipment
Cab
7. Installation of throttle cable 8. Install the parking brake flexible shaft

Tighten the connecting nut between the throttle Tighten the right connecting nut between the
cable flexible shaft and the engine throttle with hand brake flexible shaft and the rear axle with
10# wrench. The tightening torque is 15±2 N•m. the 18# wrench to 100±12 N•m.
Tighten the connecting nut between the throttle Tighten the left nut between the hand brake flex-
cable flexible shaft and the frame with two 13# ible shaft and the rear axle with the 10# wrench
wrenches to 32±4 N•m. to 15±2 N•m.
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Backhoe Equipment
Cab
9. Installation of multi-way valve 10. Installation of excavation control

Install the plug pin into the connecting hole of Tighten then connecting bolts between the out-
the link and the multi-way valve with the needle- rigger control lever and the support with the 18#
nose pliers and connect the link with the multi- wrench to 100±12 N•m.
way valve.
Install the excavation control lever and insert the

harness of the control lever connected to the
machine.
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Backhoe Equipment
Cab
Tighten the lock nuts to connect the six links

with the 11# and 13# wrenches to 26±4 N•m.
Tighten the connecting bolts between the con-

trol lever and the support with the18# wrench to
90±12 N•m.
Tighten the captive bolts between the excava-

tion control box and the cab with the 8# wrench
to 10.5±1.5 N•m.
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Backhoe Equipment
Cab
22# wrench to 160±20N•m.
Tighten the box, the cover and the upper dust-

proof hood with the 8# wrench to 10.5±1.5 N•m.
Install the position-limit flexible shaft knob, and
tighten its lock nut with the 10# wrench to 15±2
N•m.
Screw the excavation control lever knob.
Tighten the nuts on the position-limit flexible

shaft and the excavation control box with the
1-116
Backhoe Equipment
Cab
Screw the outrigger control lever knob.
Tighten the lock nut of the knob with the 18#

wrench to 100±12 N•m.
Tighten the lock nut of the outrigger control le-
ver with the 16# wrench to 60±5 N•m.
Install the upper cap of the knob with the cross-

screwdriver.
11. Install shift lever
Install the shift lever in the corresponding posi-
tion of the gearbox.
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Backhoe Equipment
Cab
Tighten the captive bolts with the 18# wrench to Install the dustproof hood on the shift lever.
90±12 N•m. Tighten the cover of the shift lever with the 8#
wrench or socket to 10.5±1.5 N•m.
Connect the harness connector of the shift

lever with the machine wiring harness from the
machine bottom.
12. Installation of control lever on load end

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Backhoe Equipment
Cab
Put the load control lever in the mounting posi-

tion of the frame.
Connect the wiring harness of the control lever

connected to the complete machine.
Put the control lever in the mounting position of

Tighten the connecting bolts between the con- the link of the loading valve. Tighten the con-
trol lever base and the support with two 16# necting bolts between the control lever and the
wrenches to 52±7 N•m. link with the 11# and 13# wrenches to 26±4 N•m.
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Backhoe Equipment
Cab
Put the leather cushion in the mounting position.

Tighten its bolts with the 8# wrench (or socket)
to 10.5±1.5 N•m.
Put the box in the mounting position of the cab.

Tighten the bolts of the load control box with the
8# wrench to 10.5±1.5 N•m.
Put the cover and the dustproof hood in the

mounting positions. Tighten the cover with the
8# wrench to 10.5±1.5 N•m.
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Backhoe Equipment
Cab
Tighten the upper end of the load control lever

knob with the cross-screwdriver.
13. Installation of seat

Tighten the connections between the seat base
and the cab with the 16# wrench to 52±7 N•m.
Screw the knob. Tighten the two lock nuts of the

knob with two 25# wrenches to 250±30 N•m.
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Backhoe Equipment
Battery
Tighten the connections between the seat and 2. Turn off the negative switch and make sure that
the seat base with two 13# wrenches to 26±4 it is in O (OFF) state.
N•m.
3. Removal of wiring harness between start motor

and battery
Push aside the jacket on the wiring harness
Battery between the start motor and the battery, and re-
move the wiring harness with the 10# wrench.
Removal
Remove the four captive bolts from the front
hood door with the 13# wrench and take out
the front hood door, and then place it in a safe
place.
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Backhoe Equipment
Battery
5. Remove negative switch

Remove the two bolts from the mounting board
of the negative switch with the 16# wrench. Re-
move the wiring harness between the start mo-
tor and the negative switch with the 17# wrench
and remove the negative switch, and then place
it properly.
4. Removal of wiring harness between negative

switch and battery
Push aside the jacket on the wiring harness be-
tween the negative switch and the battery, and
remove the wiring harness with the 10# wrench.
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Backhoe Equipment
Battery
6. Remove battery plate Installation

Remove the two bolts from the plate of the bat-
tery with the 17# wrench and take down the 1. Place the battery
plate. Install the battery in place. Make sure that the
battery is placed upright. No deflection of bat-
tery is permitted.
7. Replace the battery

Pick up the strap on the battery and move the
counterweight out of the used (or waste) battery, 2. Installation of plate of battery
and then install a new battery. Put the battery plate in the mounting position
and let the bolt pass through the bracket and
install the nut, and then tighten it with the 16#
wrench.
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Backhoe Equipment
Battery
3. Install negative switch 4. Installation of wiring harness between negative

Install the wiring harness between the start mo- switch and battery
tor and the negative switch on the downside of Remove the protection on the battery. Connect
the negative switch and put the nut on it and the wiring harness between the negative switch
tighten the nut with the 17# wrench. Put the and the battery to the negative battery terminal.
mounting board of the negative switch in the And then tighten it with the 10# wrench and put
corresponding position. Align the bolt to the hole the jacket properly.
of the frame and tighten it with the 16# wrench.
5. Installation of wiring harness between start

motor and battery
Remove the protection on the battery. Connect
the wiring harness between the start motor and
the battery to the positive battery terminal. And
then tighten it with the 10# wrench and put the
protection in place.
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Backhoe Equipment
Battery
6. Install front cover door

Put the front hood door in the mounting position.
Align the bolt to the mounting hole and tighten it
2. Remove left and right main lights

Remove the screws around the left and right
main lights (lighting lights) with the cross-
screwdriver.Take out the headlight. Remove
the setscrews of the snap spring with the cross-
Work light screwdriver and take out the bulb and its wiring
harness, and then pull out the bulb.
Removal
1. Removal of outrigger upside signal light
Remove the outer glass cover of the outrigger
upside signal light and rotate the bulb, and then
take out it.
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Backhoe Equipment
Battery
3. Remove front and rear work lights

Remove the screws around the work light with
the Cross-screwdriver and take out the work
light. Remove the snap spring inside and take
out the bulb and its wiring harness, and then
pull out the bulb.
Remove the screws around the left and right

main lights (steering lights) with the Cross-
screwdriver. Rotate the bulb and take it out.
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Backhoe Equipment
Battery
Remove the setscrews of the rear combination

signal light with the cross-screwdriver and take
out the signal light. Remove the screws around
the outer glass cover of the signal light with the
cross-screwdriver and rotate the bulb, and then
take out the bulb.
4. Remove rear combined signal light

Unplug the connector between the rear com-
bination signal light and the wiring harness.
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Backhoe Equipment
Battery
Installation
1. Install rotary signal light
Put the rotary signal light in the mounting posi-
tion at the top of the cab. Align to the mounting
hole at the top and install the screw. Tighten the
screw with the Cross-screwdriver and connect
the plug between the rotating signal light and
the wiring harness.
5. Remove rotary signal light

Unplug the connector between the rotating sig-
nal light and the wiring harness. Remove the
screws around the rotating signal light with the
Cross-screwdriver, and then take out the rotat-
ing signal light.
2. Install rear combined signal light

Rotate the bulb and snap in it in place. Tighten
the screws around the outer glass cover of the
signal light with the Cross-screwdriver. Install
the signal light in the corresponding position of
the cab. Tighten the captive bolts around the
signal light with the Cross-screwdriver, and then
connect the plug between the signal light and
the wiring harness.
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Backhoe Equipment
Battery
3. Install front and rear work lights

Put the bulb in the mounting position. Press
the snap spring to hold the bulb. Put the work
light in the mounting position of the cab. Tighten
the setscrews of the work light with the cross-
screwdriver.
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Backhoe Equipment
Battery
4. Install left and right main lights

Put the bulb in the mounting position. Press the
snap spring to hold the bulb. Tighten the set-
screws of the snap spring with the cross-screw-
driver. And then, put the front and rear main
lights (lighting lights) in the mounting position of
the cab. Tighten the setscrews of the main lights
Rotate the bulb and hold it and install it in place.

Tighten the screws around the left and right
main lights (steering lights) with the Cross-
1-131
Backhoe Equipment
Battery
screwdriver.
5. Installation of outrigger upside signal light

Rotate the bulb and hold it and install it in place.
And then install the outer glass cover of the
outrigger upside signal light.
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Backhoe Equipment
Instrument
Instrument
Removal
1. Remove switch
Remove the screws around the switch with the
cross-screwdriver. Disconnect the wiring har-
ness on the rear side of the switch and remove
the switch.
3. Remove cigarette lighter

Disconnect the wiring harness of the cigarette
lighter and rotate the cigarette lighter, and then
remove the cigarette lighter and put it in safe
place.
2. Remove side instrument

Remove the three setscrews of the dashboard
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Backhoe Equipment
Instrument
4. Remove instrument panel

Turn the (black) switch of the harness on the
rear side of the instrument panel rearward. Dis-
connect the wiring harness. Knock the instru-
ment panel down. Press the instrument panel
down by your hands to remove it and put it in a
safe place.
5. Remove the radio

Unplug the connector between the radio and the
wiring harness. Remove the radio antenna. Re-
move the setscrews of the radio with the cross-
screwdriver, and then remove the radio and put
it in a safe place.
1-134
Backhoe Equipment
Instrument
ing panel and the wiring harness. Remove the

radio with the cross-screwdriver before remov-
ing the setscrews of the air-conditioning panel.
And then, remove the air-conditioning panel and
place it properly.
Installation
1. Install A/C panel
Install the air-conditioning panel in the corre-
sponding position of the side instrument. Align
the mounting hole on the rear side and install
the screw. Tighten the screws with the Cross-
screwdriver, and then connect the wiring har-
ness connector with the air-conditioning panel.
6. Remove A/C panel

Unplug the connector between the air-condition-
1-135
Backhoe Equipment
Instrument
2. Install the radio

Install the radio in the corresponding position
of the side instrument. Align the mounting hole
on the rear side and install the screw. Tighten
the screws with the cross-screwdriver, and then
connect the wiring harness connector as well as
the antenna with the radio.
3. Install the instrument panel

Install the instrument panel in the corresponding
position of the side instrument. Press the
1-136
Backhoe Equipment
Instrument
instrument panel down by your hands until it has

been installed in place. And then, connect the
wiring harness connector with the instrument
panel.
5. Install side instrument

Install the side instrument in the correspond-
ing position of the instrument mask. Align the
mounting hole and install the screw. Tighten the
screws with the cross-screwdriver.
4. Install cigaret lighter
Install the cigarette lighter in the corresponding
position of the side instrument. Turn the
cigarette lighter until it has been installed in
place. And then, connect the wiring harness with
the cigarette lighter.
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Backhoe Equipment
Instrument
6. Install the switch

Insert the wiring harness on the rear side of the
switch in the corresponding interface. From left
to right, and from top to down, the combination
is shown in the figure, respectively. After com-
pletion of connection of wiring harness, install
the switch in the corresponding position of the
side instrument. Align the mounting hole and
install the screw. Tighten the screws with the
cross-screwdriver.
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Backhoe Equipment
Radiator
Radiator
Removal
1. Preparations
Open the upper hood door. Remove the up-
per end of the air spring on both sides with the
13# wrench. Hook the mounting hole of the air
spring with the lifting hook.
3. Remove top cover

Remove the captive bolts between the upper
hood and the hinged plate with two 13# wrench-
es. Lift the upper hood with the travelling crane,
and then place it properly. Be careful to protect
its surface paint.
2. Remove gas spring

Remove the captive bolt of the air spring on the
left side with the 12# wrench. Remove the cap-
tive bolt of the air spring on the right side with
the 13# wrench, and then place the air springs
properly.

Remove the four mounting bolts of the front
hood door with the 13# wrench. Remove the
front hood door and place it properly. Be careful
to protect its surface paint.
1-139
Backhoe Equipment
Radiator
5. Remove relay
Turn the negative switch to O position. Discon-
nect the relay inside the front hood. Remove the
wiring harness connected to the frame with the
Cross-screwdriver.
7. Remove front cover

Remove the four mounting bolts of the front
hood with the 16# wrench. Hold the upper sur-
face of the front hood by your hands and apply
a force backward, and then take down the front
6. Remove horn
hood and put it on level ground. Be careful to
Remove the horn fixed on the bracket with two
protect its surface paint.
13# wrenches, and cut off the nylon belt used to
connect the horn wiring harness with the frame
with the diagonal pliers.
1-140
Backhoe Equipment
Radiator
8. Removal of side plates

Remove the six mounting bolts of the side
plates on the left and right sides of the radiator
with 13# wrench, and take down the side plates
on the left and right sides and place them on
level ground. Be careful to protect their surface
paint.
10. Removal of air-conditioning tubes on condenser

Remove the upper and lower hoses connect-
ing the compressor with the condenser with the
10# wrench. After removal, wrap the hoses with
matters from entering. Also, cut off the fixing belt
of the air-conditioning hoses with the diagonal
9. Extraction of Freon
pliers.
Remove the plastic shield on the two connec-
tors of the compressor. Using the special Freon
charger, connect its connectors to those of the
compressor, as shown in the figure. Extract the
Freon in the machine pipelines back into the
Freon charger to avoid damage to person and
environment due to release of Freon during
follow-up removal.
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Backhoe Equipment
Radiator
11. Removal of left hydraulic pipeline of radiator 12. Removal of gearbox oil pipeline on right side of
Put a container right under the rear hose of radiator
the radiator. Remove the hose connecting the Remove the two hoses connecting the
radiator→oil return valve block on the upper of radiator→gearbox on the upper and lower of
the left side, as well as the hose connecting the the right side, respectively, with the 32# wrench.
radiator→hydraulic oil tank on the lower of the After removal, wrap the hoses with clean plastic
left side, respectively, with the 36# wrench. After bags and belts to prevent foreign matters from
removal, wrap the hoses with clean plastic bags entering.
ing.
1-142
Backhoe Equipment
Radiator
13. Removal of upper and lower water pipes and

filling water pipe of radiator
Put a clean container under the water drain port
of the radiator. Open the water drain valve to
let the antifreezing solution flow into the con-
tainer through the hoses. Once the antifreez-
ing solution has been drained up, remove the
upper and lower water pipes connecting the
engine→radiator as well as the filling water pipe
with the Cross-screwdriver or 8# socket wrench.
14. Removal of radiator supports

Remove the ten bolts of the left and right sup-
porting seats of the radiator with the 18# socket
1-143
Backhoe Equipment
Radiator
wrench.
Installation
15. Removal of radiator-fan wind shield 1. Install radiator
Remove the five captive bolts from the radia- Lift the radiator to the mounting position of the
tor wind shield with two 13# wrenches and take frame with the travelling crane, sling and sling
down the wind shield. Be careful not to scratch rings (with a nominal thread diameter of M14) .
any fan blade. During installation, lower the radiator slowly. Let
the diesel engine fan blades pass through the
rear protective cover and then lower the radiator
and put the radiator in place.
16. Remove radiator

Install two sling rings in the two holes on the top
of the radiator (with a nominal thread diameter
of M14) and screw the sling rings in place. Lift 2. Install radiator bracket
up the radiator at the positions of the sling rings Install the brackets on both sides of the radiator.
with the travelling crane and sling. Be careful to Adjust the position of the radiator. Make sure
tilt the radiator during lifting. When lifting up the that 2/3 of the radiator fan blades enters the
radiator, be sure to prevent the protective cover wind shield and there is a clearance of 7-13 mm
from touching any fan blade. Lift the radiator between the periphery of the fan blades and
away for repair or replacement. the wind shield. After completion of adjustment,
install the bolts into the mounting holes and
tighten them with the 18# socket wrench.
1-144
Backhoe Equipment
Radiator
The clearance between the fan blade and the 4. Re-installation of radiator upper and lower water
shield is between 7-13 mm. pipes and filling-water pipe
Remove the hoses and the protection on the
connectors of the radiator. Replace the O-rings
in the connectors. Connect the upper and lower
water pipes to the upper and lower interfaces of
the radiator. Connect the filling-water pipe to the
filling-water interface of the radiator. Tighten the
setscrews of the clamps with the Cross-screw-
driver or the 8# socket wrench.
3. Installation of wind shield of radiator fan

Let the wind shield pass through the fan blades
from top to bottom. After aligning the holes of
the radiator protection shield, install the con-
necting bolts and nuts. Tighten the mounting
bolts with two 13# wrenches.
1-145
Backhoe Equipment
Radiator
5. Re-installation of gearbox oil pipeline on right 6. Re-installation of hydraulic oil pipeline on left
side of radiator side of radiator
Remove the hoses and the protection on the Remove the hoses and the protection on the
connectors of the radiator. Replace the O-rings connectors of the radiator. Replace the O-rings
in the connectors.Connect the two hoses to in the connectors. Connect the two hoses to
the corresponding connectors of the radiator, the corresponding connectors of the radiator,
respectively, and tighten them with the 32# respectively, and tighten them with the 36#
wrench. wrench.
1-146
Backhoe Equipment
Radiator
8. Install side panel

Put the side plates in the mounting positions
on both sides of the frame. After aligning the
mounting holes of the frame, install the connect-
ing bolts and nuts. Adjust the positions of the
side plates from side to side to make sure there
is no clearance between the side plates and the
frame. Be careful to adjust to make sure there is
no clearance between the side plates. And then,
tighten the mounting bolts with the 13# wrench.
7. Re-installation of air-conditioning pipelines of

condenser
Remove the protection on the hoses. Connect
the upper hose to the upper connector of the
condenser. Connect the lower hose to the lower
connector of the condenser.And then, tighten
the captive bolts with the 10# wrench.
9. Install the cover

Put the cover in the mounting position in the
middle of the frame. After aligning the mount-
ing holes of the frame, install the connecting
bolts and nuts. Adjust the position of the front
hood from side to side to make sure the differ-
ence between the distances which both sides
of the cover exceed the counterweight should
1-147
Backhoe Equipment
Radiator
be<2mm. And then, tighten the mounting bolts

12. Install cover door

Put the front hood door in the mounting position
accordingly. After aligning the four bolt holes of
10. Install horn
the front hood, install the bolts. And then, tighten
Put the horn in the mounting position accord-
the bolts with the 13# wrench.
ingly. After aligning the mounting holes of the
frame, install the connecting bolts and nuts.
Tighten the mounting bolts with the 13# wrench.
And then, fix the horn harness onto the frame
with the belt.
13. Install upper cover

Let the sling pass through the handle of the
upper hood. Lift the upper hood to the proper
mounting position with the travelling crane. After
aligning the holes of the hinged plates, install
11. Install relay
the bolts and nuts. Adjust the upper hood to
Put the relay wiring harness in the mounting
make sure that the distances of the lower edges
position accordingly. After aligning the mounting
of its both sides from the side plates should be
holes of the frame, install the screws. Tighten
equal and should be < 5 mm. Tighten the bolts
the screws with the Cross-screwdriver. And
then, insert the relay into the wiring harness in-
terface.

1-148
Backhoe Equipment
Radiator
14. Install air spring

Let the bolt on the side of the air spring con-
nected to the upper hood enter into the hole of
the bracket. Install the nut and then tighten the
bolt with the wrench. (For the left air spring bolt,
use the 12# wrench and for the right air spring,
use the 13# wrench.)
15. Adding antifreezing solution and hydraulic gear-

box oil, and charging Freon
Unscrew the cap on the upper of the radiator
to add antifreezing solution. Fill 16L KH anti-
freezing solution and screw the cap. Unscrew
the plug of the filler tube of the gearbox and
the fill 16L 8# hydraulic gearbox oil (10W-30
CH-4) , and then re-install the rubber plug and
tighten it. Fill the machine with the refrigerant
2.1kg (R134a) using the Freon charger until the
prompt appears (press any button to exit) .
1-149
Backhoe Equipment
Steering
Steering
Removal
1. Remove upper switches of glass fiber reinforced
plastic
Press the switch from inside to outside, and
disconnect the wiring harness connected to
the switch. Remove the four switches in this
manner.
2. Remove steering cover

Remove the bolts around the glass fiber rein-
forced plastic with the 8# wrench and take out
the cover of the steering upward.
3. Remove front instrument

Pull out the horn button on the steering wheel.
1-150
Backhoe Equipment
Steering
4. Remove front instrument

Remove the screws on the upper cover of the
Remove the fixing nuts of the steering wheel
steering with the Cross-screwdriver.
with the 22# socket, extension rod and ratchet
wrench or special wrench.
Press the front instrument out with your hands

Knock down the steering wheel with your hands downward.
upward.
1-151
Backhoe Equipment
Steering
Disconnect the wiring harness connected

to the front instrument and remove the front
instrument.
Installation
1. Install steering
Put the steering in the mounting position. Align
5. Remove sliencer the mounting holes and install the bolts. And
Refer to “5.5.3 Removal of Silencer”, remove then, tighten the bolts with the 16# wrench.
the silencer from the machine and place it prop-
erly to remove metering pump.
6. Remove metering pump
Remove the four connecting bolts between the
metering pump and the steering wheel with the
16# wrench. Remove the metering pump and
place it properly.
2. Install metering pump

Put the steering in the mounting position. Align
the mounting holes of the metering pump and
install the bolts, and then tighten the bolts with
the 16# wrench.
7. Remove steering
Remove the four connecting bolts between
the metering pump and the cab with the 16#
wrench, and take out the metering pump and
place it properly.
1-152
Backhoe Equipment
Steering
3. Install silencer Tighten the setscrews on the upper cover of the

Refer to “5.5.3 Installation of Silencer”, install metering pump with the cross-screwdriver.
the silencer in the corresponding position of the
engine.
4. Install front instrument
Connect wiring harness with front instrument.
5. Install steering wheel

Put the steering wheel in the mounting position
of the metering pump. Tighten the fixing nuts of
the steering wheel with the 22# socket, exten-
sion rod and ratchet wrench or special wrench.
Press the front instrument with your hands to
install it onto the top cover of the steering.
1-153
Backhoe Equipment
Steering
Install the horn button on the steering wheel.
7. Install steering cover switches

6. Install steering cover Connect the wiring harness with the switch and
Put the metering pump cover in the mounting install the switch in place with your hands.
position from top to bottom. Align the mounting
holes of the cab and adjust the metering pump
cover to allow the left/right clearance between
the steering and its cover to be consistent. And
then install the bolts and tighten the bolts with
the 8# wrench.
2. Hydraulic System
Technical Data ......................................................................................3
Hydraulic pumps fixed flow..................................................................................3
Safety valve pressures........................................................................................4
Excavator valve - fixed flow ................................................................................9
Auxiliary valve - fixed Flow ...............................................................................12
Fixed Flow Double Pump Neutral Circuit Descriptions .......................14
Circuit schematics . ..........................................................................................14
Fixed flow double pump.....................................................................................15
766A/777A circuit descriptions . ........................................................................17
Fault Finding .......................................................................................19
Hydraulic system...............................................................................................19
Hydraulic contamination....................................................................................23
Hydraulic Service Tools and Test ........................................................25
Hydraulic service tools.......................................................................................25
Flow and pressure test......................................................................................26
Loader valve - pressure test..............................................................................28
Quick release couplings - connecting & disconnecting......................................29
Removal of Hydraulic System Parts.....................................................31
Removal of priority valve...................................................................................31
Installation of priority valve................................................................................35
Removal of loading valve...................................................................................38
Installation of loading valve................................................................................47
Remove double pump........................................................................................56
Installation of double pump................................................................................59
Remove backhoe valve.....................................................................................62
Installation of backhoe valve..............................................................................75
Removal of boom cylinder.................................................................................89
Installation of boom oil cylinder..........................................................................92
Remove bucket arm oil cylinder.........................................................................94
Installation of bucket arm oil cylinder.................................................................96
Removal of bucket cylinder................................................................................98
Installation of bucket cylinder...........................................................................101
Removal of four in one bucket cylinder............................................................104
Installation of four in one bucket cylinder.........................................................106
Removal of lifting arm cylinder.........................................................................107
Installation of lifting arm cylinder......................................................................109
Removal of bucket tilt cylinder......................................................................... 111
2-2

Installation of bucket cylinder........................................................................... 113

Removal of 777A outrigger cylinder................................................................. 115
Installation of 777A outrigger cylinder.............................................................. 118
Removal of 766A frog legs cylinder.................................................................121
Installation of 766A frog legs cylinder..............................................................123
Removal of angling cylinder.............................................................................126
Installation of angling cylinder..........................................................................128
Removal of telescoping cylinder......................................................................130
Installation of telescoping cylinder...................................................................132
2-3
Technical Data
Hydraulic pumps fixed flow
Technical Data
Hydraulic pumps fixed flow
Table 1: Pumps Fixed Flow
Model/Referenc Double pump/P257
Rotation (viewed on end of driveshaft) Anti-clockwise
Mounting Classis (driveshaft driven)
Theoretical displacement: cc/rev
Pump section 1 (mounting flange end) 40
Pump section 2 25
Flow at 2200 rev/min and system pressure (90% min displacement) Liters/min
Pump section 1 (mounting flange end) 79.2
Pump section 2 49.5
Maximum speed @ pressure P1 2400 rev/min
Minimum speed @ pressure P1 800 rev/min
Approximate Weight 24kg
Pumps Fixed Flow
Model/Reference Double pump/JHP2040/2025
Rotation (viewed on end of driveshaft) Anti-clockwise
Mounting Classis (driveshaft driven)
Theoretical displacement: cc/rev
Pump section 1 (mounting flange end) 40
Pump section 2 25
Flow at 2200 rev/min and system pressure (90% min displacement) Liters/min
Pump section 1 (mounting flange end) 79.2
Pump section 2 49.5
Maximum speed @ pressure P1 2400 rev/min
Minimum speed @ pressure P1 800 rev/min
Approximate Weight 24kg
2-4
Technical Data
Safety valve pressures
2.Part description
Fig. 1.1
Loader valve - fixed flow
MPa
Main Safety valve (M.R.V.) Unloader Valve 23.5-24.5
Auxiliary Safety valves (A.R.V.) 20.2 -21.2
Component Key:
1 Arms lift service
2 bucket service
3 Auxiliary (optional)
4 Pump section 1 - inlet
5 Pump section 2 - inlet
6 Pressure test port
7 Unloader Installation
8 Unloader solenoid
9 Auxiliary safety valve
10 Tank port
11 High pressure carry-over (HPCO) port
12 Service ports
13 Load hold check valve assemblies
14 Data plate
2-5
Technical Data
Fig. 1.2 Fig. 1.3
Fig. 1.4
2-6
Technical Data
EXPLODED VIEW FOR PARTS ASSEMBLED ON 6600-C41 CONTROL VALVE

BILL OF MATERIAL FOR PARTS ASSEMBLED ON 6600-C41 CONTROL VALVE
ITEM No. DESCRIPTION Qty REMARKS
1 Housing-Valve 1
2 Spool 1
3 Spool 1
4 Spool 1
5 Spool End Group 1 Torque to 7 ± 1 Ft. Lbs. (9.5 ± 1.0 N•m) .
6 Detent Group- Magnetic 1 Torque to 7 ± 1 Ft. Lbs. (9.5 ± 1.0 N•m) .
7 Spool End Assy.- Detent 1 Torque to 7 ± 1 Ft. Lbs. (9.5 ± 1.0 N•m) .
8 Seal Plate Group 2 Torque to 7 ± 1 Ft. Lbs. (9.5 ± 1.0 N•m) .
9 Seal Plate Group 1 Torque to 7 ± 1 Ft. Lbs. (9.5 ± 1.0 N•m) .
10 Plug Assy.-SAE, Special 1 Torque to 60 ± 6 Ft. Lbs. (81 ± 8 N•m) .
11 Spool-Unloader 1
12 Spring 1
13 Plug Assy.- Adapter 1 Torque to 60 ± 6 Ft. Lbs. (81 ± 8 N•m) .
14 Spring 1
15 Poppet-C.V. 1
2-7
Technical Data
BILL OF MATERIAL FOR PARTS ASSEMBLED ON 6600-C41 CONTROL VALVE (Continued)
ITEM No. DESCRIPTION Qty REMARKS

16 Poppet-C.V. 3
17 Spring 3
Torque to 90 ± 9 Ft. Lbs. (122 ± 12 N•m)
18 Plug Assy.-C.V. 3
.
19 Body-Solenoid 1 Torque to 20 Ft. Lbs (27 N•m) .
20 Coil-Solenoid 1
21 Nut-Special 1 Torque to 5 Ft. Lbs. (6.8 N•m)
22 Plug-Avseal 1
Torque to 33 ± 3.5 Ft. Lbs. (44.7 ± 4.7
23 Safety valve Assy.** 1
N•m)
24 Safety valve Assy.** 1 Torque to 48 ± 5 Ft. Lbs. (65 ± 6.8 N•m) .
25 Safety valve Assy.** 1 Torque to 48 ± 5 Ft. Lbs. (65 ± 6.8 N•m) .

Torque to 25 ± 2.5 Ft. Lbs. (34 ± 3.4 N•m)
26 Unloader Pilot Assy.** 1
.
2-8
Technical Data
Fig. 1.5
Port P
Port PT
Port P1
Port T
Auxiliary
joints
Boom joints
Buckt tilt
Loader valve connector
joints
description
Fig. 1.6
2-9
Technical Data
Excavator valve - fixed flow
Loading valve connector description

Loader
Bucket Ram Head Side 17.4 -18.4
Bucket Ram Rod side 31.2-32.2
Weight 25kg -3 spool

Component Key:
1 Bucket
2 Dipper
3 Stabiliser
4 Stabiliser
5 Boom
6 Slew
8 Tank port
9 High pressure carry-over (HPCO) port
10 Service ports
11 Load hold check valve assemblies
12 Make-up check valve installation
13 Inlet port
14 Hydraclamp solenoid
Fig. 1.7
Boom Ram Head Side 25.2 – 25.8
Boom Ram Rod Side 34.2 – 34.8
Bucket Ram Head Side 31.4 – 32.0
Bucket Ram Rod Side 25.2 – 25.8
Dipper Ram Head Side 25.2 – 25.8
2-10
Technical Data
Dipper Ram Rod Side 25.2 – 25.8

Slew Left and Right 26.6 – 27.2
Weight 46 kg
Fig. 1.8
Fig. 1.9
2-11
Technical Data
ITEM No. DESCRIPTION Qty. REMARKS

1 Housing-Valve 1
2 Spool 6
3 Spool End Group 6 Torque to 7 ± 1 Ft. Lbs. (9.5 ± 1.0 N•m)
4 Seal Plate Group 6 Torque to 7 ± 1 Ft. Lbs. (9.5 ± 1.0 N•m)
5 Check Valve Assy. 6 Torque to 60 ± 6 Ft. Lbs. (122 ± 12 N•m)
6 Clamp Valve Assy. 1 Torque to 33 ± 3.5 Ft. Lbs. 45 ± 5 N•m)
7 Plug Assy.-SAE 1 Torque to 90 ± 9 Ft. Lbs. (122 ± 12.2 N•m)
8 Spring 1
9 Poppet-C.V. 1
Torque to Body 20 Ft. Lbs. (27.1 N•m)

10 Solenoid Cartridge Valve 1
Torque to Nut 5 Ft. Lbs. (6.8 N•m)
11 Plug Assy.-SAE 1 Torque to 48 ± 5 Ft. Lbs. (65 ± 6.8 N•m)
12 Safety valve Assy.** 4 Torque to 48 ± 5 Ft. Lbs. (65 ± 6.8 N•m)
Torque to 18 ± 2 Ft. Lbs. (24.40 ± 2.71

16 Plug Assy.-SAE 2
N•m)
Torque to 105 ± 11 Ft. Lbs. (142.36 ±

17 Plug Assy.-SAE 1
14.91 N•m)
2-12
Technical Data
Auxiliary valve - fixed Flow
Port T
Outrigger oil
cylinder
Port T
Outrigger oil
cylinder
Port T
Bucket oil
cylinder
Bucket arm cylinder
Angling
Boom oil cylinder Grip cylinder
cylinder
Fig. 1.10
Backhoe valve connector description

Safety valve Pressures
Component Key:
1 Auxiliary Spool
2 inlet port
3 Outlet port
5 Service ‘A’ ports
6 Service ‘B’ ports
2-13
Technical Data
Fig. 1.11
MPa
Extendable stick Ram Head Side 17-19
Extendable stick Ram Rod Side 17-19
Hammer master 17-19
Port T
Port A
Port P
Fig. 1.12
Hydraulic hammer valve (Solenoid valve)
2-14
Fixed Flow Double Pump Neutral Circuit Descriptions
Circuit schematics

Circuit schematics
Fig. 2.1
2-15
Fixed flow double pump
Fixed flow double pump

Inlet return system assembly and circuit description:
Component Location
Component Key:
T Hydraulic Tank
P1 Hydraulic Pump (main section)
P2 Hydraulic Pump (secondary section)
1B Hose - High Pressure Carry Over
3 Loader Valve Block
4 Excavator Valve
5 Auxiliary Valve
6 Return Line Filter (inside hydraulic tank)
7 Steer Circuit Priority Valve
13 Return Line Check Valve
26 Hydraulic Oil Cooler
62 Hyclraclamp exhaust hose
Neutral Circuit Description
Fixed Flow Double Pump
Oil is drawn from the hydraulic tank T by the hydraulic pump. The pump has two sections P1 and P2
The hydraulic pump is mounted on the rear of the gearbox and is driven by the engine via a driveshaft
Oil from the larger section P1 flows direct to the loader valve 3.
Oil from pump section P2 flows to steering priority valve 7 and in neutral circuit flows through the priority
valve to join the flow from P1 at the loader valve.
From the loader valve neutral gallery oil flows via a high pressure carry-over line 1B to the excavator valve
4
Some of the exhaust oil flows directly back to the tank through an in tank filter 6 and some of the exhaust
oil returns to tank via the hydraulic oil cooler 26.
To help prevent excavator dipper ram and loader lift ram cavitation, there is a check valve 13 fitted to the
return line. The check valve raises approximately 5 bar of pressure in the line which improves the opera-
tion of the respective anti-cavitation valves
On sideshift machines only hydraclamp exhaust hose 62 is fitted. The hose connects the hydraclamp
spool directly into the exhaust circuit.
This prevents the clamps from ‘locking-up’ when the sideshifting operation is required
2-16
Circuit schematics
Loader valve Radiator

return oil
Excavator valve oil

return
return oil
tank
Buster hammer
return oil or other
valve return oil Priority valve return oin and pressure
joints G1/4
Return valve block connector description

Fig. 2.2
2-17
766A/777A circuit descriptions

Circuit Schematics - Fixed Flow
766A
Fig. 2.3
2-18
Circuit Schematics - Fixed Flow

777A Fig. 2.4
2-19
Fault Finding
Hydraulic system
Fault Finding
Hydraulic system
Fixed Flow
Introduction
1. Lack of power in all hydraulic functions
2. All hydraulic rams slow to operate
3. One hydraulic service fails to operate or is slow to operate
4. A spool is sticking
5. Leaking Oil Seal
6. Ram creep
7. Hydraulic oil becomes too hot
The purpose of this section is to help you trace hydraulic faults to a faulty unit (valve actuator ram etc) .
Once you have traced the faulty unit refer to the appropriate removal inspecting and test instructions given
elsewhere in the hydraulics section
Fault Probable Cause Action

Lack of power in all hydraulic func- Insufficient hydraulic fluid Check for leaks and top up as re-
tion quired
Hydraulic leaks in system Check hoses ,replace as required
Engine performance Check engine performance ,see

gearbox section for stall speed test
procedures
Main safety valve setting incorrect Check and adjust as required
Low pump flow Check pump flow ,if required serv-

ice or replace pump
Hydraulic tank breather Clean or replace the breather
Tank filter by pass valve Check condition or hydraulic filter
Unloader valve pressure setting Check pressure setting of the un-

too high loader valve
2-20
Fault Finding
Hydraulic system

All hydraulic rams slow to operate Neutral circuit or low pressure Check pipe lines and replace as
lines leaking, damaged, trapped or required
kinked
Low pump flow Check pump flow, if required serv-

ice or replace pump
Priority valve operating Check if the priority valve is stick-

ing, rectify as required
Main safety valve setting incorrect Check and adjust as required
Unloader valve Check if unloader valve is sticking
Tank filter by pass valve Check condition of hydraulic filter
Hydraulic tank breather Clean or replace the breather

One hydraulic service fails to oper- Associated service pipe lines, leak- Check hoses replace as required
ate or is slow to operate ing damaged, trapped or kinked
Associated ram leaking Complete ram leakage check re-

place seals as required
Auxiliary safety valve (ARV) setting Check and adjust as required

incorrect
Associated valve block section Check for leaks, rectify as required.

leaking or not operating Also, see fault 6 Leaking Oil Seal
Check valve malfunctioning Test check valve, rectify as re-

quired
Piston rod is bent Replace piston rod, check pressure

setting of MRV and ARV. Check
that associated pivot pins are ad-
equately greased
2-21
Fault Finding
Hydraulic system

The engine tends to stall when hy- M.R.V setting incorrect Check and adjust as required
draulics are under load.
Poor engine performance Check engine performance see
gearbox section for stall speed test
procedures
Unloader valve pressure setting Check pressure setting of the un-

too high loader valve

A spool is sticking Oil temperature abnormally high Check for correct fluid. Check oil
cooler and grille for blockage
The hydraulic fluid is dirty Clean the tank strainer. If strainer

badly clogged, drain and flush hy-
draulic system Fill with clean hy-
draulic fluid
The service pipe connection is over Check tightening torque

tightened
The valve housing was twisted dur- Loosen retaining bolts and tighten
ing installation. to correct torque figures
Pressure too high Check system pressure
A control linkage is bent Disconnect the linkage. Repair the

linkage if possible, or fit a new one
A spool is bent Remove the control valve. Renew

spool as necessary
A return spring is broken Renew as necessary
A return spring or cap is out of Remove the cap, check that the
alignment spring is in the correct position. Re-
fit cap and torque tighten bolts
Temperature distribution within Warm the entire system up before

control valve not uniform using service
2-22
Fault Finding
Hydraulic system

Leaking Oil Seal Paint or dirt on the seal face Remove the seal and clean
The back pressure in the valve cir- Check circuit pressures adjust if
cuit is excessively high possible. Otherwise investigate
thoroughly
Spool damaged Remove. Inspect all parts. Reno-

vate or renew as necessary
The seal is not secured Clean the seal and tighten the re-
taining bolts to the correct torque
The seal is cut or damaged Fit a new seal

Ram creep Associated ram or pipe lines from Check and rectify as required
ram leaking
Check valve malfunctioning Test check valve, rectify as re-

quired
Associated valve section spools Rectify, check for contamination

leaking
Associated ARV leaking Rectify, check for contamination

Hydraulic oil becomes too hot Oil cooler obstructed Remove debris from cooler fins
Restriction in neutral circuit lines Check hoses, replace as neces-

sary
Hydraulic filter clogged and by Check hydraulic filter

pass valve not working
2-23
Fault Finding
Hydraulic contamination
Hydraulic fluid quality
Construction machinery uses a large volume of fluid in the hydraulic system for power gearbox equipment
lubrication rust prevention and sealing
According to a survey conducted by a pump manufacturer seventy per cent of the causes of problems in
hydraulic equipment were attributable to inadequate service of the quality of the hydraulic fluid
Therefore it is obvious that control of the quality of the hydraulic fluid helps prevent hydraulic equipment
problems and greatly improves safety and reliability. Furthermore from an economic angle it extends the
life of the hydraulic fluid if quality
Effects of contamination
Once inside the system, hydraulic circuit contaminants greatly effect the performance and life of hydraulic
equipment. For example contaminants in a hydraulic pump develop internal wear to cause internal leak-
age and hence lower discharges. Wear particles generated will circulate with the hydraulic fluid to cause
further deterioration in the performance of this and other equipment
Contaminants also enter principal sliding sections of the equipment causing temporary malfunction scuff-
ing sticking and leakage and can lead to major problems
The main contaminants can be classified as follows:
1. Solid Particles - sand fibres metallic particles welding scale sealing materials and wear particles etc
2. liquid - usually water and incompatible oils and greases
3. Gases - Air, sulphur dioxide etc. which can create corrosive compounds if dissolved in the fluid
These contaminants can appear during manufacture assembly and operation
Cleaning Operation
The purpose of cleaning oil is to remove contaminants of all types and sludge by filtering hydraulic fluid
through a cleaning unit, as illustrated or similar.
Procedure
Connect the cleaning unit in place of the hydraulic filter and run the system for sufficient time to pump all
the hydraulic fluid through the unit. Disconnect the cleaning unit and reconnect the filter. Top up the sys-
tem with clean hydraulic fluid as required.
Contaminant standards
Dirt that damages your system is in many cases too small to be seen with the eye. The particle size is
measured in microns.
1 micron = 0.001mm (0.0000394 in)
Listed below are a few typical comparisons:
Red Blood Cell = 8 microns (0.008 mm 0.000315 in)
Human Hair = 70 microns (0.07 mm 0.00275 in)
Grain of Salt = 100 microns (0.1 mm 0.00394 in)
Smallest particle visible to the naked eye is 40 microns (0.00157) approximately.
2-24
Fault Finding
Standards will often be quoted to ISO for which literature can be obtained
Filters
The filter assembly fitted to all product ranges is designed to filter all the contamination that is generated
through use to the required level of cleanliness. The filter must be serviced to the requirements of the ma-
chineService Schedules
To ensure optimum performance and reliability it is important that the machines hydraulic system is serv-
iced periodically in accordance with the manufacturers requirements.
2-25
Hydraulic Service Tools and Test
Hydraulic service tools

Hydraulic service tools
Fig. 4.1 Fig. 4.2 Fig. 4.3 Fig. 4.4
Fig. 4.5 Fig. 4.6 Fig. 4.7
Fig. 4.1 Tee, used for pressure test

Fig. 4.2 Pressure joint
Fig. 4.3 Pressure gage
Fig. 4.4 Pressure pipeline
Fig. 4.5 Transition joint
Fig. 4.6 Flow sensor
Fig. 4.7 Precise flow and pressure multifunction tester
2-26
Flow and pressure test

Fixed Flow Pumps
Before removing the pump it is necessary to determine the source of any problem by measuring the out-
put flow at system pressure from both of the pump outlet ports
To check flow it is necessary to fit flow meter into the output line of each pump section in turn. If available
load valve should also be installed (see Note 1) . Make sure the flow meter is installed with its arrow point-
ing away from the pump and , if applicable , located between the pump and the load valve
Note 1: If no load valve is available, ignore the references to the load valve in Fitting/Removing a Flow
Meter and Load Valve below. An alternative method of determining flow is included in the Check Flow pro-
cedures following.
Fitting/removing a flow meter and load valve

Before fitting/removing a flow meter and load valve , switch off the machine and operate the loader/exca-
vator controls a few times to vent system pressure
Warning
Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hose, stop
the engine and operate the controls to release pressure trapped in the hoses. Make sure the engine cannot
be started while the hoses are open.
Warning
Take care when disconnecting hydraulic hoses and fitting as the oil will be HOT
Fitting
a Pump section 1 - Pipeline A is connected with tee and attached with pressure joint which could connect
with pressure gauge, if flowmeter needs to be connected, please remove pipeline A, and connect flowm-
eter and sensor.
b Pump section 2 - Pipeline B is in pressure test and needs to be connected with pressure joint; if flowmeter
needs to be connected, please remove pipeline B, connect flowmeter and sensor.
Removing
Removing is the reverse of fitting
Checking flow
Check the setting of the Main Safety valve as described in Loader Valve, Pressure Testing. Adjust if nec-
essary.
1. a Using a load valve- fit a flow meter and load valve, as described in Fitting, to each pump outlet in turn.
Fit a 0-400 bar pressure gauge to the load valve pressure test connector
2. b If no load valve is available - fit a flow meter , as described in Fitting , to each pump output in turn.
3. Start the engine and bring the hydraulic up to working temperature 50℃ Set the engine speed to 2200rpm.
4. a Using a load valve- adjust the load valve so that the pressure gauge reading is just below the MRV SET-
2-27
TING
b If no load valve is available- raise or lower the loader arms until the rams are fully open or closed . Con-
tinue to operate the raise/lower control so that system pressure builds up .Watch the flow meter and note
its reading at the moment the MRV operates.
5. The flow reading should be as listed in Technical Data.
Fig. 4.8
Hammer and extended arm valve pressure test
Make sure that the hydraulic oil is at working temperature,50℃
Lower the backhoe bucket and loader shovel to rest on the ground; stop the engine; operate the control
levers to vent residual hydraulic pressure
1. Connect a 0 - 400 bar) pressure gauge to pressure test connector Y on the loader valve
2. With the engine running at 1500 revs/min
3. Open corresponding hydraulic hammer circuit or telescopic bucket rod circuit, to create pressure in rel-
evant circuit; take back auxiliary coupling hammer or telescopic bucket rod, increase auxiliary coupling
load or stretched out bucket rod to the end in pressout way.
4. Take the readings of pressure tester at pump outlet B, please refer to hydraulic technical parameters for
correct reference valve.
2-28
Loader valve - pressure test

Unloader Valve
Make sure that the hydraulic oil is at working temperature 50℃
Lower the backhoe bucket and loader shovel to rest on the ground; stop the engine; operate the control
levers to vent residual hydraulic pressure
Make sure that the correct unloader valve pressure can be obtained
If the machine has a front-mounted hammer, ensure that the hammer control valve lever is in the “off”
position, otherwise the hammer safety valve will operate and prevent unloader valve pressure from being
reached.
1. Connect a 0-400bar pressure gauge to pressure test connector Y
2. With the engine running at 1500 revs/min, slowly operate arms raise or lower
Note 1: The arms raise or lower service is specified because it has no auxiliary safety valve (ARV) . Se-
lecting this service ensures that the pressure vents through the MRV and not an ARV.
3. When the service reaches full travel, return the lever to the neutral position. Select the service again, very
slowly, the pressure gauge will rise until a step/kick is seen in the rate of change in the pressure increase.
This is the start of unloader operation. Keep selecting the service until a sudden sharp increase in pres-
sure is observed with a change of engine sound , this point is the unloader setting and should be as speci-
fied in Technical Date
4. If the pressure is incorrect, slacken locknut and adjust cap E. Turn it clockwise to increase pressure and
anti-clockwise to decrease the pressure. When the pressure in correct ,tighten the locknut and check the
pressure again. Adjust as required.
If the correct pressure cannot be achieved, add or subtract shims as required, refer to Loader Valve- Fixed
Flow, Removal and Installation- Unloader valve
Fig. 4.9
2-29
Quick release couplings - connecting & disconnecting
Connect to metering Connect oto loader

pump valve
LS feedback port
Connect to return oil

valve
Connect to steering
pump
Pressure joints 9/16UNF
Steering priority valve Fig. 4.10

Auxiliary Relief Valves And Main Relief Vlave- Using Hand Pump
NOTE: The item belongs to profession category, and it must be tested by professional with professional
tool. Don’t suggest that users or deals test on their own.

Quick release couplings
Flat face quick release couplings allow the operator to remove and install attachments swiftly and efficient-
ly Generally your machine pipe work will have female couplings fitted and the optional attachment hoses
will have male couplings fitted
The quick release couplings should be trouble free and relatively easy to connect and disconnect provided
they are kept clean and used correctly. The recommendations listed below should always apply when us-
ing flat face quick release couplings
Finally please read the correct fitting and releasing procedures before installing or removing any optional
attachment fitted with quick release couplings
Quick release couplings - Do’s & Don’ts

2-30
Do wipe the two faces of the coupling and make service hose line must be vented. This is usually
sure they are clean before connecting achieved by switching off the engine and then
operating the attachment control lever several
Do make sure the outside sleeve is pulled back
times. Make sure the hose service line has been
when disconnecting
vented before connecting or removing hoses -
Do connect and disconnect a new coupling two refer to the appropriate attachment information
or three times to work the PTFE seals - some- in this section
times a new coupling will stick if the seals have
not been worked Connecting quick release couplings
Do use a spanner on the hexagon flats of the 1. Remove any residual hydraulic pressure
coupling when fitting adaptors trapped in the service line hose
Do use a rubber or hide hammer to disconnect 2. Wipe the two faces of the male and female cou-
a coupling if it sticks- sticking may occur if there plings and make sure they are clean
is dirt present in the coupling 3. Make sure that ball in the female coupling is lo-
cated in one of its slots
Don’t attempt to re-connect a damaged half
4. Fit the male coupling into the female coupling;
coupling - this will destroy the seals and neces-
To e sure that the coupling is not accidentally re-
sitate replacing both half couplings.
leased rotate sleeve half a turn and make sure
Don’t leave the coupling where it may be run that the locking ball does not align with the slot
over by machine or otherwise crushed- this will Disconnecting Quick Release Couplings
distort the coupling sleeve and prevent correct
Remove any residual hydraulic pressure
connection and disconnection
trapped in the service line hose
Don’t clamp on the smooth diameter of the
Align the slot with ball
coupling when fitting adaptors - always use the
hexagon Pull back sleeve to release the coupling.
Don’t try to turn the sleeve when the coupling
has been disconnected- the locking ball will
wedge underneath the sleeve and destroy the
coupling
Don’t damage the faces of the coupling - this
can prevent connection and disconnection, or
damage seals and cause leakage,
Don’t try to remove the coupling - they are non
serviceable parts, IF a coupling is damaged it
should be replaced with a new one.
Warning
Hydraulic fluid at pressure can injure you. Make
the machine safe before connecting or discon-
necting quick release couplings; stop the engine
and then operate the attachment control a few
times to vent residual hydraulic pressure in the
attachment hoses
Before connecting or removing any hydraulic
hose residual hydraulic pressure trapped in the
2-31
Removal of Hydraulic System Parts
Removal of priority valve
Pack up the connector of hose and steering pri-

ority valve with clean plastic bag and tie to pre-
vent foreign matters dropping in.
Fig. 4.11
Removal of Hydraulic
System Parts
Preparation work
Place oil container under the bottom of vehicle
to prevent hydraulic oil polluting ground.
2. Remove lower hose of steering priority valve

Remove lower hose of steering priority valve
with 30# wrench.
1. Remove right hose of steering priority valve up-

per end
Remove right hose of steering priority valve up-
per end with 30# wrench.
2-32
Pack up the connector of hose and steering pri- Pack up the connector of hose and steering pri-
ority valve with clean plastic bag and tie to pre- ority valve with clean plastic bag and tie to pre-
vent foreign matters dropping in. vent foreign matters dropping in.
3. Remove upper hose of steering priority valve 4. Remove lower hose of steering priority valve
right end right end
Remove upper hose of steering priority valve Remove lower hose of steering priority valve
right end with 19# wrench. right end with 19# wrench.
2-33
Pack up the connector of hose and steering pri- Pack up the connector of hose and steering pri-
ority valve with clean plastic bag and tie to pre- ority valve with clean plastic bag and tie to pre-
vent foreign matters dropping in. vent foreign matters dropping in.
5. Remove left hose of steering priority valve up- 6. Remove steering priority valve
per end Support steering priority valve by hands, re-
Remove left hose of steering priority valve up- move two blots and spring washer which con-
per end with 24# wrench. nect steering priority valve with frame with 13#
wrench, and take down steering priority valve.
2-34
2-35
Installation of priority valve

Preparation work
Connect hose with left connector of steering

priority valve upper end; do not mix it with other
parts, and tighten it with 24# wrench. Tightening
torque is 37±2 N•m
1. Installation of steering priority valve

Place steering priority valve to position of install-
ing, connect steering priority valve and frame
by washer and bolt with 13# wrench. Tightening
torque is 26±4N•m
3. Install lower hose of steering priority valve right

end
Remove lower shield of steering priority valve
right end, observe the hose connected with it to
ensure O-Ring of hose intact,
2. Install left hose of steering priority valve upper

end
Remove left shield of steering priority valve up-
per end, observe the hose connected with it to
2-36
Connect hose with lower connector of steering Connect hose with upper connector of steering
priority valve right end; do not mix it with other priority valve right end; do not mix it with other
parts, and tighten it with 19# wrench. Tightening parts, and tighten it with 19# wrench. Tightening
torque is 16±1N•m torque is 16±1N•m.
4. Install upper hose of steering priority valve right 5. Install lower hose of steering priority valve
end Remove shield of steering priority valve lower
Remove upper shield of steering priority valve end, observe the hose connected with it to en-
right end, observe the hose connected with it to sure O-Ring of hose intact,
2-37
Connect hose with lower connector of steering Connect hose with upper connector of steering
priority valve; do not mix it with other parts, and priority valve right end; do not mix it with other
tighten it with 30# wrench. Tightening torque is parts, and tighten it with 30# wrench. Tightening
63±3N•m. torque is 63±3N•m.
6. Install right hose of steering priority valve upper

end
Remove right shield of steering priority valve
upper end, observe the hose connected with it
to ensure O-Ring of hose intact,
2-38
Removal of loading valve

Preparation work
1. Remove A/C pipe and water pipe fixed clamp

Remove four clamps used to fix A/C hose and
water pipe by wind trigger with13# sleeve and
rod, move A/C hose to other side to make load-
ing valve fully exposed.
2. Remove upper harness connector of loading

valve
Pull out the harness connected left side and
2-39
bottom of loading valve, put connector beside to

prevent it being polluted by hydraulic oil.
Pack up the connector of hose and loading

valve with clean plastic bag and tie to prevent
foreign matters dropping in.
3. Remove left end hose of loading valve 4. Remove the first hose from the left at lower side
Remove left end hose of loading valve with 30# of loading valve front end.
wrench. Remove the first hose from the left at lower side
of loading valve front end by 30# wrench.
2-40
5. Remove the third hose from the left at upper

side of loading valve front end.
Remove the third hose from the left at upper
side of loading valve front end with 30# wrench.

2-41


6. Remove the second hose from the left at upper foreign matters dropping in.
Remove the second hose from the left at upper
2-42
7. Remove the first hose from the left at upper side

of loading valve front end.
Remove the first hose from the left at upper side
of loading valve front end with 30# wrench.

8. Remove the fourth hose from the left at lower

Remove the fourth hose from the left at upper
2-43
9. Remove the third hose from the left at lower

Remove the third hose from the left at upper

2-44


10. Remove the second hose from the left at lower foreign matters dropping in.
Remove the second hose from the left at upper
2-45
11. Remove front hose of loading valve right end 12. Remove rear hose of loading valve right end
Remove front hose of loading valve right end Remove rear hose of loading valve right end
with 36# wrench. with 36# wrench.
Pack up the connector of hose and loading Pack up the connector of hose and loading
valve with clean plastic bag and tie to prevent valve with clean plastic bag and tie to prevent
foreign matters dropping in. foreign matters dropping in.
2-46
13. Remove loading valve

Lift and hold loading valve with crane and sling,
Remove 3 bolts of loading valve installing plate

with 18# wrench (please recycle the 3 shock
absorber cushions and shims) , lift out loading
valve with crane.
2-47
Installation of loading valve

Preparation work
2. Install rear hose of loading valve right end

Remove rear shield of loading valve right end,
observe the hose connected with it to ensure O-
Ring of hose intact,
1. Install loading valve

Lift loading valve to mounting position of frame
with crane and sling.
Connect hose with rear connector of steering

priority valve right end; do not mix it with other
Place bolt, spring washer, shock absorber cush-

ion and shim in order used for installation to
installing plate, tighten three bolts on loading
valve installing plate with 18# wrench. Tighten-
ing torque is 90±12N•m
2-48
3. Install front hose of loading valve right end 4. Install the second hose from the left at lower
Remove front shield of loading valve right end, side of loading valve front end.
observe the hose connected with it to ensure O- Remove shield of the second hose from the left
Ring of hose intact, at lower side of loading valve front end, observe
the hose connected with it to ensure O-Ring of
hose intact,
Connect hose with front connector of steering

priority valve right end; do not mix it with other
2-49
Connect hose with front connector of loading

valve right end; do not mix it with other parts,
and tighten it with 30# wrench. Tightening

5. Remove the third hose from the left at lower
Remove shield of the third hose from the left at
lower side of loading valve front end, observe
hose intact.
2-50

Remove shield of the fourth hose from the left
at lower side of loading valve front end, observe
hose intact.
7. Install the first hose from the left at upper side of

loading valve front end.
Remove shield of the first hose from the left at
upper side of loading valve front end, observe
hose intact,
2-51
8. Install the second hose from the left at lower

Remove shield of the second hose from the left
at lower side of loading valve front end, observe
hose intact.

2-52


9. Install the third hose from the left at lower side torque is 63±3 N•m
Remove shield of the third hose from the left at
upper side of loading valve front end, observe
hose intact,
2-53
10. Remove the first hose from the left at lower side
lower side of loading valve front end, observe
hose intact.
11. Install left end hose of loading valve

Remove hose shield of loading valve left end,
Ring of hose intact,
2-54

13. Install A/C pipe and pipe fixed clamp

Place four clamps used to fix A/C hose and pipe
to mounting position, install them with wind trig-
12. Install upper harness connector of loading valve ger,13# sleeve and rod, and ensure the hose is
Connect harness used to connect left side and not twisted and deformed. Tightening torque is
bottom of loading valve with loading valve sock- 26±4 N•m
et.
2-55
Remove double pump
2-56
Remove double pump
Remove double pump

Preparation work
2. Remove A/C hose

Remove A/C hose with 17# and 19# wrench,
(Refer to removal of cab for removal of A/C pipe
and water pipe from cab) ,
1. Remove fixed plate of clamp

Remove fixed plate used to fix A/C hose and
water pipe clamp by wind trigger with 13#
sleeve and rod (or 13# wrench) .
Pack up hose connector with clean plastic bag

and tie to prevent foreign matters falling into,
and put A/C hose and water pipe aside to make
couple pump fully exposed.
2-57
Remove double pump
3. Remove oil suction rubber pipe of double pump 4. Remove front hose of double pump
Remove clamp on oil suction rubber pipe with Remove front hose of double pump with 36#
cross screwdriver, wrench
Pull out oil suction rubber pipe, and pack up the Pack up the connector of hose and double
connector of hose and double pump with clean pump with clean plastic bag and tie to prevent
plastic bag and tie to prevent foreign matters foreign matters dropping in.
dropping in.
2-58
Remove double pump
5. Remove rear hose of double pump 6. Remove double pump

Remove rear hose of double pump with 30# Lift and hold double pump with crane and sling,
wrench
Remove 2 bolts used to connect double pump

Pack up the connector of hose and double and gearbox box with 24# wrench, pull double
pump with clean plastic bag and tie to prevent pump outwards along vertical direction of gear-
foreign matters dropping in. box junction surface, to prevent deformation and
bend of spline; pack up the connector of hose
and double pump with clean plastic bag and tie
to prevent foreign matters dropping in, and lift
out double pump with crane.
2-59
Installation of double pump

Preparation work
1. Install double pump

Apply hydraulic oil on O-rings and put it along
the groove of double pump, lift double pump to
mounting position of gearbox box with crane
and sling.
Embed double pump into gearbox box along di-

rection of spline, install two flat gaskets, spring
washer and blot used to connect double pump
and gearbox box with 24# wrench. Tightening
2-60
2. Install rear hose of double pump 3. Install front hose of double pump
Remove hose shield of loading valve rear end, Remove hose shield of double pump front end,
observe the hose connected with it to ensure O- observe the hose connected with it to ensure O-
Ring of hose intact. Ring of hose intact.
Connect hose with rear connector of double Connect hose with front connector of double
pump; do not mix it with other parts, and tighten pump; do not mix it with other parts, and tighten
it with 30# wrench. Tightening torque is 63±3 it with 36# wrench. Tightening torque is 84±4
N•m . N•m .
2-61
4. Install oil suction rubber pipe of double pump 5. Install A/C hose
Remove oil suction rubber pipe of double pump Remove A/C hose shield, observe the hose
and shield of double pump connector. connected with it to ensure O-Ring of hose in-
tact, and connect A/C hose with 17# and 19#
wrench. Tightening torque is 16±1 N•m
Connect hose with front connector of double

pump with double wire clamp; do not mix it with
other parts, and tighten it with cross screwdriver. 6. Install fixed plate of clamp
Fix double wire clamp behind boss of connector. Install fixed plate used to fix A/C hose and water
pipe clamp to corresponding steel pipe by wind
trigger with 13# sleeve and rod (or 13# wrench)
, and keep fixed plate and steel pipe in vertical
without deflection. Tightening torque is 26±4
N•m
2-62
Remove backhoe valve

Preparation work
1. Remove the first hose from the left at upper side

of backhoe valve front end.
Remove the first hose from the left at upper side
of backhoe valve front end with 41# wrench.
2-63
Pack up the connector of hose and backhoe

3. Remove the second steel pipe from the left at

upper side of backhoe valve front end.
2. Remove steel pipe clamp of backhoe valve Remove the second steel pipe from the left at
Remove steel pipe clamp at both sides of back- upper side of backhoe valve front end with 30#
hoe valve with two 16# wrenches. wrench.
2-64
4. Remove the third steel pipe from the left at up-

per side of backhoe valve front end.
Remove the third steel pipe from the left at up-
per side of backhoe valve front end with 30#
wrench.
Pack up the connector of steel pipe and back-

hoe valve with clean plastic bag and tie to pre-

2-65
5. Remove the fourth hose from the left at upper Pack up the connector of hose and backhoe
side of backhoe valve front end. valve with clean plastic bag and tie to prevent
Remove the fourth hose from the left at up- foreign matters dropping in.
wrench.
6. Remove the fifth hose from the left at upper side

Remove the fifth hose from the left at upper side
2-66
7. Remove the sixth steel pipe from the left at up-

per side of backhoe valve front end.
Remove the sixth steel pipe from the left at up-
wrench.

2-67


8. Remove the seventh steel pipe from the left at
upper side of backhoe valve front end.
Remove the seventh steel pipe from the left at
upper side of backhoe valve front end with 24#
wrench.
2-68
9. Remove the second steel pipe from the left at

lower side of backhoe valve front end.
Remove the second steel pipe from the left at
lower side of backhoe valve front end with 30#
wrench.
10. Remove the third steel pipe from the left at low-
er side of backhoe valve front end.
Remove the third steel pipe from the left at
wrench.

2-69


side of backhoe valve front end.
Remove the fourth hose from the left at lower
side of backhoe valve front end with 21#
wrench.
2-70
12. Remove the fifth hose from the left at lower side
Remove the fifth hose from the left at lower side
13. Remove the sixth steel pipe from the left at low-
er side of backhoe valve front end.
Remove the sixth steel pipe from the left at
wrench.

2-71


14. Remove the seventh steel pipe from the left at
lower side of backhoe valve front end.
Remove the seventh steel pipe from the left at
wrench.
2-72
15. Remove harness connector of backhoe valve

right end
Pull out harness connector of backhoe valve
right end, to prevent it being polluted by hydrau-
lic oil.

16. Remove the eighth hose from the left at upper

Remove the eighth hose from the left at up-
wrench.
17. Remove right hose of backhoe valve

Remove right hose of backhoe valve with 36#
wrench.
2-73
18. Remove right hose of backhoe valve lower end

Remove right hose of backhoe valve lower end
with 21# wrench.

2-74

19. Remove left hose of backhoe valve lower end

Remove left hose of backhoe valve lower end
with 36# wrench
20. Remove backhoe valve
Hold bracket of backhoe valve upper end with
crane and sling.
Remove 5 bolts of backhoe valve installing plate

with 16# wrench, and lift backhoe valve.
2-75
Installation of backhoe valve

Preparation work
1. Install backhoe valve

Hold bracket of backhoe valve upper end with
crane and sling.
Place bolt, spring washer, and flat gasket in

order used for installation to 5 holes of back-
hoe valve installing plate, and tighten 5 bolts of
backhoe valve installing plate with 16# wrench.
Tightening torque is 52±7 N•m
2-76
Connect hose with rear connector of backhoe

valve; do not mix it with other parts, and tighten
it with 36# wrench. Tightening torque is 84±4
N•m.
2. Install left hose of backhoe valve lower end

Remove left hose shield of backhoe valve lower
end, observe the hose connected with it to en-
sure O-Ring of hose intact.
3. Install right hose of backhoe valve lower end

Remove right hose shield of backhoe valve
lower end, observe the hose connected with it
to ensure O-Ring of hose intact.
2-77
4. Install right hose of backhoe valve

Remove hose shield of loading valve right end,
Ring of hose intact.

N•m.
2-78

N•m

N•m
backhoe valve front end.
upper side of backhoe valve front end, observe
hose intact.
2-79
6. Install harness connector of backhoe valve right

end
Connect harness connector of backhoe valve
right end

7. Install the No. 7 steel pipe from the left at lower N•m.
Remove shield of the seventh hose from the left
at lower side of backhoe valve front end, ob-
serve the steel pipe connected with it to ensure
O-Ring of hose intact.
2-80
8. Install the No. 6 steel pipe from the left at lower Connect hose with rear connector of backhoe
side of backhoe valve front end. valve; do not mix it with other parts, and tighten
Remove shield of sixth steel pipe from the left at it with 30# wrench. Tightening torque is 63±3
lower side of backhoe valve front end, observe N•m.
the steel pipe connected with it to ensure O-Ring
of hose intact.
9. Install the No. 5 hose from the left at lower side

Remove shield of the fifth hose from the left at
lower side of backhoe valve front end, observe
hose connected with it to ensure O-Ring of hose
intact.
2-81
10. Install the No. 4 hose from the left at lower side
Remove shield of the fourth hose from the left at
hose connected with it to ensure O-Ring of hose
intact.

N•m.
2-82

N•m.

N•m.
11. Install the No. 3 steel pipe from the left at lower
Remove shield of third steel pipe from the left at
of hose intact.
2-83
12. Install the No. 2 steel pipe from the left at lower Connect hose with rear connector of backhoe
side of backhoe valve front end. valve; do not mix it with other parts, and tighten
Remove shield of second steel pipe from the it with 30# wrench. Tightening torque is 63±3
left at lower side of backhoe valve front end, ob- N•m.
13. Install the No. 7 steel pipe from the left at upper
Remove shield of seventh steel pipe from the
left at upper side of backhoe valve front end, ob-
2-84
Remove shield of sixth steel pipe from the left at
of hose intact.

N•m.
2-85

N•m.

N•m.
15. Install the fifth hose from the left at upper side of
backhoe valve front end.
Remove shield of the fifth hose from the left at
hose intact.
2-86
16. Install the fourth hose from the left at upper side Connect hose with rear connector of backhoe
of backhoe valve front end. valve; do not mix it with other parts, and tighten
Remove shield of fourth hose from the left at it with 21# wrench. Tightening torque is 26±2
upper side of backhoe valve front end, observe N•m.
hose intact.
Remove shield of third steel pipe from the left at
of hose intact.
2-87
Remove shield of second steel pipe from the left
at upper side of backhoe valve front end, ob-

N•m.
2-88
Connect hose with rear connector of backhoe Tighten steel pipe clamp at both sides of back-
valve; do not mix it with other parts, and tighten hoe valve with two 16# wrenches. Tightening
it with 30# wrench. Tightening torque is 63±3 torque is 52±7 N•m.
N•m.
19. Install steel pipe clamp of backhoe valve backhoe valve front end.
Place clamps at both sides to mounting position Remove shield of the first hose from the left at
hose intact.
2-89
Removal of boom cylinder

Preparation work
1. Remove the boom cylinder grease nozzle

Remove nut of fixed hose with 24# wrench, and
remove baffle of boom bottom with 10# wrench.

N•m.
2. Remove the boom oil cylinder pin shaft

Lift and hold boom oil cylinder with crane and
sling.
2-90
Remove lug bolt used to fix boom oil cylinder

front pin shaft with 19# wrench, and knock out
pin shaft with copper bar.
3. Remove the boom oil cylinder oil pipe

Release pressure of boom oil cylinder, and re-
move hose connected with oil cylinder with 30#
Start complete machine, return boom oil cylin-
wrench.
der jogger to its position, and turn off complete
machine; remove plug bolt used to fix boom oil
cylinder rear pin shaft with 19# wrench, recycle
shim and knock out pin shaft with copper bar.
2-91
Pack up the connector of hose and oil cylinder

with clean plastic bag and tie to prevent foreign
matters dropping in. Lift up oil cylinder with
crane sling.
2-92
Installation of boom oil cylinder

Preparation work
Connect hose with connector of cylinder; do not

mix it with other parts, and tighten it with 30#
wrench. Tightening torque is 63±3 N•m.
1. Install the boom oil cylinder oil pipe

Lift boom oil cylinder to mounting position with
crane and sling, remove shield of oil cylinder
and hose, observe the hose connected with it to
2. Install the boom oil cylinder pin shaft

2-93
Align with rear installing hole of boom oil cylin-

der to swing seat installing hole with crane and
sling, place shim at both sides of installing hole,
knock out pin shaft with copper bar, and ensure
total clearance between both sides is 1±0.5 mm.
3. Install the boom cylinder grease nozzle

Connect hose with baffle with 24# wrench and
tighten. Align hole of installing plate to boom
bottom installing hole, and tighten it with 10#
wrench. Tightening torque is 10.5±1.5 N•m.
Tighten bolt, spring washer and flat gasket used
to fix pin shaft with 19# wrench; start complete
machine, stretch oil cylinder jogger out, align
front installing hole of oil cylinder to boom in-
stalling hole, knock pin shaft into installing hole
with copper bar, and tighten bolt, spring washer
and flat gasket used to fix pin shaft with 19#
wrench. Take down sling of crane, and move
crane. Tightening torque is 90±12 N•m.
2-94
Remove bucket arm oil cylinder

Preparation work
1. Remove oil pipe of bucket arm oil cylinder

Release pressure of bucket arm oil cylinder, and
remove hose connected with oil cylinder with
30# wrench,
2. Remove pin shaft of bucket arm oil cylinder

Lift and hold bucket arm oil cylinder with crane
and sling.

matters dropping in.
2-95
Remove lug bolt used to fix pin shaft at the front

and rear end of bucket arm oil cylinder with 19#
wrench,
Recycle shim. Lift up oil cylinder with crane sling.
Knock pin shaft out with copper bar,

2-96
Installation of bucket arm oil cylinder
Installation of bucket arm oil

cylinder
Preparation work
1. Install pin shaft of bucket arm oil cylinder

Lift bucket arm oil cylinder to mounting position with
crane and sling, align front and rear installing
hole of oil cylinder with installing hole of boom
bucket arm.
Place shim at both sides of installing holes, in-

stall pin shaft with copper bar, and ensure total
clearance at both sides of oil cylinder is 1±0.5
mm.
2-97
Installation of bucket arm oil cylinder
2. Install oil pipe of bucket arm cylinder

Tighten lug bolt, spring washer and flat gasket Remove oil cylinder and hose shield, observe
used to fix pin shaft at the front and rear end of the hose connected with it to ensure O-Ring of
bucket arm oil cylinder with 19# wrench, Tight- hose intact,
ening torque is 90±12 N•m
2-98
Removal of bucket cylinder

wrench. Tightening torque is 63±3 N•m Preparation work
1. Remove oil pipe of bucket cylinder

Release pressure of bucket cylinder, and re-
move hose connected with cylinder with 30#
wrench.
2-99
2. Remove pin shaft of bucket cylinder

Lift and hold bucket arm oil cylinder with crane
and sling.

Remove bolt used to fix pin shaft at the front
end of bucket arm cylinder with two 19# wrench-
es,
Take down snap ring,

2-100
Knock pin shaft out with copper bar, Remove lug bolt used to fix pin shaft at the rear
end of bucket arm cylinder with 19# wrench,
Recycle shim.
Knock pin shaft out with copper bar,
2-101
Installation of bucket cylinder
Lift up oil cylinder with crane sling. Installation of bucket cylinder

Preparation work
1. Install pin shaft of bucket cylinder

Lift bucket arm oil cylinder to mounting position
with crane and sling, align front and rear install-
ing hole of oil cylinder with installing hole of
boom bucket arm,
Place shim at both sides of installing holes, and

ensure total clearance at both sides of oil cylin-
der is 1±0.5 mm.
2-102
Install pin shaft with copper bar. Install pin shaft with copper bar.
Tighten baffle, bolt and nut used to fix pin shaft

Tighten baffle, bolt and nut used to fix pin shaft
at the front end of bucket arm cylinder with two
at the rear end of bucket arm oil cylinder with
19# wrenches, Tightening torque is 90±12 N•m.
19# wrench, Tightening torque is 90±12 N•m.
2-103
Removal of four in one bucket cylinder
2. Install oil pipe of bucket arm cylinder

Remove oil cylinder and hose shield, observe
hose intact.

wrench. Tightening torque is 63±3 N•m.
2-104
Removal of four in one bucket cylinder
Removal of four in one bucket

cylinder
Preparation work
1. Remove four in one bucket cylinder hose

Release pressure of four in one bucket cylinder,
and remove two hoses connected cylinder in or-
der with 24# wrench. 2. Remove pin shaft of four in one bucket cylinder
Remove lug bolt used to fix pin shaft at the
rear end of four in one bucket cylinder with 18#
wrench.

Knock pin shaft out.
2-105
Installation of four in one bucket cylinder
Remove bolt and nut used to fix pin shaft at the

front end of four in one bucket cylinder with 16#
wrench.
Remove snap ring, and knock pin shaft out with

copper bar.
2-106
Installation of four in one bucket cylinder
Installation of four in one

bucket cylinder
Preparation work
1. Install pin shaft of four in one bucket cylinder

Align front and rear installing hole of cylinder
to installing hole of of four in one bucket, and
install pin shaft out with copper bar. Tighten lug
bolt, spring washer and flat gasket used to fix
pin shaft at the rear end of four in one bucket
cylinder with 18# wrench. Tightening torque is
90±12N•m
2. Install oil pipe of four in one bucket cylinder
hose intact,
Tighten snap ring, bolt and nut used to fix pin

shaft at the front end of four in one bucket cyl-
inder with 16# wrench. Tightening torque is
52±7N•m
2-107
Removal of lifting arm cylinder

Preparation work
1. Remove hose of lifting arm cylinder

Release pressure of lifting arm cylinder, and
remove two hoses connected cylinder with 27#
wrench,
mix it with other parts, and tighten it with 24 #
wrench. Tightening torque is 84±4N•m

2-108
2. Remove pin shaft of lifting arm cylinder Recycle shim, knock out pin shaft out;
Lift and hold lifting arm cylinder with crane and
sling.
Remove circlip and shim used to fix pin shaft at

the rear end of lifting arm cylinder with circlip pli-
ers, recycle shim, and pull out lifting arm.
Remove lug bolt used to fix pin shaft at the front
end of lifting arm cylinder with 18# wrench,
2-109
Installation of lifting arm cylinder
Installation of lifting arm

cylinder
Preparation work
1. Install pin shaft of lifting arm cylinder

Lift lifting arm cylinder to mounting position with
crane and sling, embed rear end of lifting arm
cylinder into lifting arm rear end pin shaft, align
installing hole at the front end of lifting arm cyl-
inder to corresponding installing hole of lifting
arm,
Put into shim at both sides, ensure the total

clearance is 1±0.5 mm, and knock in pin shaft
with copper bar.
2-110
Removal of bucket tilt cylinder
2. Install oil pipe of lifting arm cylinder

hose intact,
Tighten lug bolt used to fix pin shaft at the front

end of lifting arm cylinder with 18# wrench; in-
stall circlip and shim used to fix pin shaft at the
rear end of lifting arm cylinder with circlip pliers.
Tightening torque is 90±12 N•m
wrench. Tightening torque is 37±2 N•m
2-111

Preparation work
2. Remove pin shaft of bucket tilt cylinder

Lift and hold lifting arm cylinder with crane and
sling, remove circlip and shim used to fix pin
shaft at the rear end of lifting arm cylinder with
circlip pliers.
1. Remove hose of bucket tilt cylinder

Release pressure of bucket tilt cylinder, and
remove two hoses connected with cylinder with
27# wrench,

2-112
Knock pin shaft out with copper bar, recycle

shim and lift up lifting arm.
2-113

Preparation work
Make pin shaft go forward by copper bar
1. Install pin shaft of bucket tilt cylinder

Lift bucket tilt cylinder to mounting position
with crane and sling, align rear installing hole
of bucket tilt cylinder to corresponding install-
ing hole of lifting arm, place shim between both
sides to adjust clearance, and ensure total
clearance between both sides is 1mm±0.5mm.
Assemble circlip with circlip pliers.

2-114
Removal of 777A outrigger cylinder

wrench. Tightening torque is 37±2N•m
2. Install oil pipe of bucket tilt cylinder

hose intact,
2-115
Removal of 777A outrigger

cylinder
Preparation work
Disconnect connector used to connect light

holder with frame harness.
1. Removal of light holder

Remove 3 bolts used to fix light holder with 10#
wrench, and take out light holder,
2. Remove hose
Remove two hoses connected with cylinder with
22# wrench,
2-116
Pack up the connector of hose and oil cylinder Remove pin shaft by copper bar
4. Remove upper end pin shaft

Lift and hold cylinder with crane and sling.
3. Remove lower end pin shaft
Remove bolt and nut used to fix pin shaft at the
lower end of cylinder with two 16# socket.
2-117
Installation of 777A outrigger cylinder
Remove circlip used to fix upper pin shaft with Lift up cylinder with crane sling.
circlip pliers.
Recycle shim, knock out pin shaft with copper

bar,
Take out snap ring in the middle,

2-118
Installation of 777A outrigger

cylinder
Preparation work
Knock pin shaft into installing hole with copper

bar.
1. Install upper end pin shaft

Lift up cylinder to mounting position with crane
and sling.
Install shim at both sides of pin shaft, and install

snap ring into installing groove of pin shaft with
circlip plier.
Put snap ring into both sides of installing hole at

cylinder upper end,
2-119
2. Install lower end pin shaft

Knock copper bar into installing hole with pin
shaft.
Connect hose with cylinder connector, and

please do not mix with other parts; tighten two
hoses connected with cylinder with 22# wrench,
and tightening torque is 16±1 N•m.
Fix pin shaft with nut and bolt, tighten bolt and
nut with two 16# sleeves, and tightening torque
is 52±7 N•m.
4. Install light holder

Place light holder to mounting position.
3. Install hose
hose intact.
2-120
Connect harness of light holder with harness of

frame, fix bolt and shim with 10# wrench, and
tightening torque is 10.5±1.5 N•m.
2-121
Removal of 766A frog legs cylinder
Removal of 766A frog legs

cylinder
Preparation work

1. Remove guard plate of hydraulic lock

Remove bolt on hydraulic lock guard plate with
13# wrench and sleeve, and take down guard
plate.
2. Remove cylinder upper hose and hydraulic lock

Remove three hoses connected with cylinder
with 27# wrench.
2-122
Removal of 766A frog legs cylinder
3. Remove cylinder pin shaft

Lift and hold cylinder with crane and sling.
Remove hydraulic lock with 27# wrench, note

installing direction of hydraulic lock.
Remove bolts of two pin shafts in vertical direc-
tion with 18# wrench or sleeve.

2-123
Installation of 766A frog legs cylinder
Installation of 766A frog legs

cylinder
Preparation work
Knock out two pin shafts with copper bar, and

lift up cylinder with crane and sling.
1. Install pin shaft of cylinder

Lift up cylinder to mounting position with crane
and sling.
Knock two pin shafts into installing hole with

copper bar.
2-124
2. Install cylinder upper hose and hydraulic lock

Remove hydraulic lock and cylinder connector
shield, observe the hose connected with it, en-
sure hose O-ring intact; connect hydraulic lock
with cylinder, keep direction of hydraulic lock
same after removal; tighten three hoses con-
nected with cylinder with 27# wrench, and tight-
ening torque is 37±2 N•m.
Tighten bolts and shims of two pin shafts in ver-

tical direction with 18# wrench or sleeve, and
tightening torque is 90±12 N•m. Remove crane
and sling
Remove cylinder and hose shield, observe the

hose connected with it, ensure hose O-ring in-
tact; connect hose with cylinder, do not mix it
with other parts; tighten three hoses connected
with cylinder with 27# wrench, and tightening
torque is 37±2 N•m.
2-125
3. Install guard plate of hydraulic lock

Place guard plate to mounting position, tighten
bolt and nut of hydraulic lock guard plate with
13# wrench and sleeve, and tightening torque is
26±4 N•m.
2-126
Removal of angling cylinder

Preparation work
Take out cover plate.
1. Remove cover plate

Remove six bolts of guard plate with two 30#
wrenches.
2. Remove cylinder front end pin shaft

Remove bolts used to fix pin shaft at front end
of cylinder with two18# wrenches or sleeves.
Recycle shim at bottom of guard plate.

2-127
Knock out pin shaft from up to down with copper

bar,

Retract cylinder to proper position.
Take out cylinder.

3. Remove hose
Remove hose connected with cylinder with 22#
and 24# wrench respectively.
2-128
Installation of angling cylinder

Preparation work
Connect hose with cylinder connector, and

please do not mix it with other parts; tighten
hose connected with 22# and 24# wrench re-
spectively, and tightening torque is 90±12 N•m.
1. Install hose
Place cylinder to mounting position
2. Install cylinder front end pin shaft

Draw out front end of cylinder, align it to install-
ing hole of swing seat; knock in pin shaft from
up to down with copper bar; tighten bolts used
Remove oil cylinder and hose shield, observe to fix pin shaft at the front end of cylinder with
the hose connected with it to ensure O-Ring of two 18# wrenches or sleeves, and tightening
hose intact. torque is 26±2 N•m.
2-129
3. Install cover plate

Place cover plate to mounting position, and
place shim at the bottom.
Tighten six bolts of cover plate with two 30#

wrenches, and tightening torque is 430±50 N•m.
2-130
Removal of telescoping cylinder
Removal of telescoping
cylinder
1. Remove adjusting bolt
Screw off eight bolts used to fix nylon bar with
12# socket, and do not remove;
2. Remove pin shaft of telescoping cylinder

Screw off bolt used to fix pin shaft of telescoping
cylinder with 19# socket.
Screw off lock nut of adjusting bolt at both sides

of bucket arm with 22# wrench, and do not re-
move.
Knock pin shaft out by copper bar
And screw off adjusting bolt.

2-131
Removal of telescoping cylinder
Recycle adjusting shim;
Knock off the copper bar with a pin.

Stretch upper bucket arm outward with crane,
sling and crossbar.
3. Remove telescoping cylinder

Pull out cylinder from back.
Remove circlip used to fix pin shaft at front end
of cylinder with circlip pliers.
2-132
Installation of telescoping cylinder
Lift up cylinder with crane and sling. Installation of telescoping

cylinder
1. Install telescoping cylinder
Lift telescoping cylinder to corresponding posi-
tion of upper bucket arm with crane and sling.
Push telescoping cylinder into upper bucket

arm,align installing hole at front end of cylinder
to installing hole of upper bucket arm, and align
installing hole at rear end of cylinder to installing
hole of lower bucket arm.
2. Install pin shaft of telescoping cylinder

Knock front and rear pin shaft into installing hole
respectively with copper bar,
2-133
Put shim into both sides of front pin shaft re-

spectively, and tighten pin shaft with circlip pli-
ers.
Tighten captive bolt of rear pin shaft with19#

wrench, and tightening torque is 90±12 N•m.
Put in shim at the same time of installing rear
pin shaft, and require the clearance between
two ends of cylinder installing holes is 1±0.5
mm,
2-134
3. Install adjusting bolt

Tighten eight bolts used to fix nylon bar with 12#
socket, and tightening torque is 26±4N•m;
Tighten bolts of adjusting bolts at both sides of

bucket arm with 22# wrench, and ensure upper
bucket arm is in the middle.
And tighten lock nut. Tightening torque of nut is

160±20 N•m.
3. Steering System
Service Tools..........................................................................................2
System Type .........................................................................................3
Basic System Operation.........................................................................5
Steering system schematics................................................................................5
Basic system operation........................................................................................6
Fault Finding Contents...........................................................................7
Failure modes......................................................................................................7
Steering system - pressure test...........................................................................7
Hydraulic Steer Unit - Disassmbly and Replacement............................9
3-2
Service Tools

Service Tools
Fig. 1.1
1
Technical Data
3-3
System Type

System Type
LIUGONG Backhoe loader is 2 Wheel Steer
Machines
STEER UNIT – view 1
Model
- Volumetric Displacement
- Safety valve
- Check Valve
- Shock Valve
- Safety valve Operating Pressure (at 1500
revs/min)
- Shock Valve Operating Pressure
Model
- Volumetric Displacement
The view of the steer unit schematic Fig. 2.2
- Safety valve
- Check Valve The parameter of the steer unit
- Shock Valve Model:BZZ-160
- Safety valve Operating Pressure (at 1500 Serial numbers:530-7174

revs/min) Signal load sensing,displacement:160ml/r
- Stand by Pressure Maximum inlet pressure:17.2Mpa
Maximum continuous pressure 2.1Mpa
Maximum system temperature:93℃ ,
Maximum temperature difference:28℃
Steer torque:1.7-2.8N•m
Recommend pollution lever:ISO18/13
Shock valve operation pressure:200bar
PRIORITY VALVE – view 2
- Stand by Pressure
The view of the steer unit Fig. 2.1

3-4
Service Tools

The view of the priority valve Fig. 2.3
The view of the priority valve schematic Fig. 2.4

The parameter of the steer unit
Model:VLE-150
Serial numbers:882-2902-072
Flow:150L/min
Dynamic signal,control pressure:8.6bar
Safety valve setting pressure:17.2Mpa
P,EF interface:M27×2
CF interface:M22×1.5
LS,Tinterface:M12×1.5
Safety valve operation pressure:172bar
3-5
Basic System Operation
Steering system schematics

Steering system schematics
Component Key:
1 Front axle (steer oil cylinder) CF To the unit
2 Oil tank EF To the main hydraulic circuit
3 Pump C Pressure Test Point
P1 Pump, Main Section D Steer unit safety valve
PP Pump, Secondary Section E Shock valve
4 Priority valve S Suction Line
5 Steer unit
Fig. 3.1
3-6
Basic system operation

Hydraulic operation
The main components of the steering system are the front Axle (steering oil cylinder) 1,oil tank 2,pump
3,priority valve 4,steer unit 5,and some hoses.
When the steering wheel is not turned, flow from the hydraulic pump P2 is now distributed to the main hy-
draulic circuit via the priority valve 4
When the steering wheel is turned,Oil from the hydraulic pump P2 is then distributed via the priority valve
to the steer unit 5, which then directs the oil to the front power track rod ram of the front axle 1,untill the
required steering lock is achieved.
When the steering lock is held, flow from the hydraulic pump P2 is now distributed to the main hydraulic
circuit via the priority valve 4.
Maximum steering system pressure is controlled by a safety valve D, located in the priority valve 4,it’s
working pressure is 17.2Mpa.
Fig. 3.2
3-7
Fault Finding Contents
Failure modes

Failure modes
1. When the steering wheel turned.the machine will not turn.
2. Steering wheel very hard to turn.
3. Steering wheel turns on its own.
The following contents is to help you trace hydraulic faults to a faulty unit (for example:the valve,
pump,hoses, ram etc) . Once you have traced the faulty unit, according to the corresponding directions in-
specting and test instructions given elsewhere in the next.
1. Before you begin fault finding, read the Safety informationat the beginning of this manual.
2. Make sure that the hydraulic fluid is at correct working temperature (50℃ ) .
3. What ever the fault, check the condition of the hydraulic fluid. Drain and replace if necessary. Make any
relevant electrical checks before moving on to the hydraulics.
4. Be sure to remove ALL contamination and if possible identify its origin. It may be part of a component from
elsewhere in the circuit. Replace any seals such as ‘O’ rings before re-assembling hydraulic components
Fig. 4.1
Steering system - pressure test
Warning
Before you check the pressure,remember you
have to proceed the following steps:
1. Park the machine on level ground,and engage the parking brake

2. set the gearbox to neutral.
3. Lower the attachments to the ground.
3-8
4. Stop the engine and remove the starter key.

5. Turn the steering wheel to the left and to the
right several times to vent system pressure.
6. To cut off the power of the battery, to prevent
the engine being started while you are beneath
the machine.
7. Chock all four wheels to prevent unexpected
move of the machine.
And then
8. Connect a 0-400 bar (0-6000 Ibf/in9 pressure
gauge to test adaptor c (see the pic)
Fig. 4.2
9. Run the engine at 1500 revs/rain and turn the

steering to full lock. Check the gauge reading
which should equal the safety valve pressure,
refer to Technical Data.
Note: The steering wheel must be held on
full lock while the gauge reading is being
checked.
3-9
Hydraulic Steer Unit - Disassmbly and Replacement
Hydraulic Steer Unit

- Disassmbly and
Replacement
Warning
1. Park the machine on level ground,and engage
the parking brake
6. Make sure the engine cannot be started while
the hoses are open.so,To cut off the power of
the battery, to prevent the engine being started
while you are beneath the machine.
7. Chock all four wheels to prevent unexpected Fig. 5.1
move of the machine. 9. inside the cab, Get an assistant to hold the
steering unit, loosen and remove 4 bolts Lift the
steering column off the spline ,and then lift the
DANGER steering unit from the machine. as shown as the
following picture.
Hydraulic Pressure
Hydraulic fluid at system pressure can injure
you. Before disconnecting or connecting hy-
draulic hoses, stop the engine and operate the
controls to release pressure trapped in the hos-
es.
Next is the detailed steps
Some of the following pictures may not show
exactly your steering unit ,but the indicated op-
erations are correct anyway.
Disassmbly:
8. Disconnect and cap all hydraulic hoses from the
steering unit as shown at following picture. La-
bel the hoses to ensure correct refitting.
Fig. 5.2
3-10
Replacement
Warning
The jets of hydraulic fluid at high pressure can
penetrate the skin. Do not use your fingers to
check for hydraulic fluid leaks. Wear your classes
to protect your eyes.Do not put your face close
to suspected leaks. Hold a piece of cardboard
close to suspected leaks and then inspect the
Fig. 5.3 cardboard for signs of hydraulic fluid. If hydraulic
fluid penetrates your skin, get medical help im-
mediately.
10. Replacement is a reversal of the disassmbly se-
quence.
11. Make sure that the hoses are correctly installed.
12. If a new steering unit has been fitted then the
system safety valve must be tested for correct
pressure setting. Refer to Service Procedures,
Steering System - Pressure Test
Fig. 5.4
3-11
Fig. 5.5 Fig. 5.6
S212750 Priority Valve

Disassmbly and replacement
1. Park the machine on level ground,and engage the parking
brake
5. Turn the steering wheel to the left and to the right several times
to vent system pressure.
6. Make sure the engine cannot be started while the hoses are
open.so,To cut off the power of the battery, to prevent the en-
gine being started while you are beneath the machine.
7. Chock all four wheels to prevent unexpected move of the ma-
chine.
3-12
Fig. 5.7
DANGER
Hydraulic Pressure
Hydraulic fluid at system pressure can injure
you. Before disconnecting or connecting hy-
draulic hoses, stop the engine and operate the
controls to release pressure trapped in the hos-
es.
exactly your steering unit ,but the indicated op-
erations are correct anyway.
8. Disconnect and cap all hydraulic hoses from the
steering unit as shown at following picture. La-
bel the hoses to ensure correct refitting.
After disassembly the hoses and connectors
Fig. 5.9
Note:the priority valve is not serviceable be-

yond the removal of foreign matter,the faulty
unit must be replaced.
Fig. 5.8
3-13
Fig. 5.11
Warning
the parking brake
Fig. 5.10 3. Lower the attachments to the ground.
Removal 5. Turn the steering wheel to the left and to the
Press out the item 14,and take care not to dam- 6. To cut off the power of the battery, to prevent
age the bores of the valve. the engine being started while you are beneath
Installation the machine.
Make sure the item 14 faces toward ls connec- move of the machine.
tor Next is the detailed steps
Clean all parts Some of the following pictures may not show
Lubricate all parts with hydraulic fluid ,replace exactly your axle,but the indicated operations
the O ring. are correct anyway.
Link Arms-Disassmbly and replacement Disassmbly:
This section is for removal and replacement of Steering track rod assy
the steering track rod (which is in the steering
cylinder)
3-14
Fig. 5.12
Fig. 5.14
Fig. 5.15
Fig. 5.13 Assmbly (replacement) :
3-15
Fig. 5.16 Fig. 5.18
Fig. 5.17
Link Arms-Disassmbly and replacement Fig. 5.19
3-16
Fig. 5.20 Fig. 5.22

Torque Settings:
NUT 1:220N.M
BOLT 6:120N.M
NUT 9.250NM
THE BALL JOINTS 5 AND 8:300N.M
Toe-in/steering angle
After disassembly and assembly (replacement)
the track rod,you need to adjust “toe-in/steering
angle”,this is very important for the axle and the
machine !!
exactly your axle,but the indicated operations
are correct anyway.
Fig. 5.21 Disassmbly:
Link Arms-Disassmbly and replacement
3-17
Fig. 5.23
Fig. 5.25
Fig. 5.24
Toe-in/steering angle
Fig. 5.26
3-18
Fig. 5.27 Fig. 5.29

Steering angle adjustment
Fig. 5.30
Fig. 5.28
Fig. 5.31
4. Brake System
Service Tools.......................................................................................4-2
Hydraulic Service Brake System.........................................................4-3
System type .....................................................................................................4-3
Basic system operation.....................................................................................4-6
Brake system schematics.................................................................................4-6
Hydraulic operation...........................................................................................4-7
Driving braking-disassmbly and replacement...................................................4-8
The assistor disassembly inspection and assembly.......................................4-11
Compensation pressure balance valve...........................................................4-13
FAULT.............................................................................................................4-14
Pressure test...................................................................................................4-15
Vacuum Service Brake System.........................................................4-16
System type ...................................................................................................4-16
Brake system schematics...............................................................................4-17
Hydraulic operation.........................................................................................4-18
Driving braking................................................................................................4-19
Disassmbly and replacement..........................................................................4-19
Pressure test...................................................................................................4-24
FAULT.............................................................................................................4-27
Parking Braking (Moist-Brake) .........................................................4-29
The structure...................................................................................................4-29
The braking principle......................................................................................4-30
Disassembly and replacement........................................................................4-31
FAULT.............................................................................................................4-34
Parking Braking (Caliper Disc) .........................................................4-35
Structure.........................................................................................................4-35
The braking principle......................................................................................4-36
Disassmbly and replacement..........................................................................4-36
FAULT.............................................................................................................4-38
4-3
Service Tools

Service Tools
Fig. 1.1
1. Technical Data
4-4
Hydraulic Service Brake System
System type

System type
BRAKE ASSISTOR
The view of the brake assistor
Fig. 2.1
4-5
System type
Fig. 2.2
4-6
System type
Fig. 2.3
4-7

Brake system schematics
Component Kwwey:
1. Gearbox (the gearbox pump effort the hydralic oil)
2. Rear axle
3. Hoses (connect the rear axle and assistor)
4. Hoses (assistor oil back to the gearbox)
5. Hoses (gearbox to assisitor)
6. Assisitor
7. Right pedal
8. Left pedal
A: Cowwnnector (connect the hoses 5)
B: Connector (connect the hoses 4)
C: Connector (connect the hoses 3)
Fig. 2.4
4-8
Hydraulic operation
Hydraulic operation
Some of the following pictures may not show exactly your braking system ,but the form is the same.
The main wcomponents of the driving braking system are the
Gearbox 1; rear axle (bwrake clutch connectors) 2; hoses 3,4,5; assistor 6;and the pedals 7,8.
When step the pedals 7,8,the brake oil from the gearbox 1 will go to the clutch which are in the rear axle
2,realize the brake.
When step the pedals 7,8,the booster oil from the gearbox pump push the pistons which in the assistor 6,the
pressure can help the handlers feel easily.
When release the pedals 7,8,the pistons will go back because of the springs in the assistor 1.
The system can realize the one sides brake if you step the pedal 7 or 8.see the section”compensation
pressure balance valve”
Fig. 2.5
4-9
Hydraulic operation
Driving braking-disassmbly and

replacement
Warning
Before you disassmble,remember you have to
proceed the following steps:
the parking brake
Fig. 2.7
8. Disconnect all hydraulic hoses ,steel tubes and
connectors from the assistor as shown at follow-
ing picture. Label the hoses to ensure correct
refitting.
Danger
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before disconnecting or connecting hydraulic
hoses, stop the engine and operate the controls
to release pressure trapped in the hoses.
Removal:
7. Opening the engine cover,confirm the position

of the assistor assy.
Fig. 2.8
9. Disconnect the springs
(the internal of the cab) Fig. 2.6

4-10
Hydraulic operation
12. Take down the cotter pin,and unpin the cylindri-

cal pin,so the pedal assy Can take down from
the system
Fig. 2.9
10. Disconnect the cotter pins and cylindrical pins
Fig. 2.12
The pedal assy
Driving braking -Removal and replacement

Fig. 2.10
11. Disconnect the nuts,get off the forks.
Fig. 2.13
Fig. 2.11
4-11
Hydraulic operation
13. Take down the nut,and draw out the assistor

from the Direction of the engine
The assy of the assistor

Fig. 2.14
The assemble process is the reversible

Fig. 2.15
Warning
The optional plate is choose one-side or both-
sides braking,
Before you launch the engine,make sure theOp-
tional plate is in the potision that you want.And
make sure the plate is not damaged.
4-12
The assistor disassembly inspection and assembly

4-13
4-14
Compensation pressure balance valve
Compensation pressure balance valve
Fig. 2.18
4-15
FAULT
Fig. 2.19
FAULT
This section tell you how to determine the fault,and corresponding action.
Note:The braking part surface maybe in high temperature to touch,so inspect or disassembly be care-
fully.
4-16
Pressure test
Fig. 2.20
Pressure test
Same as the “vacuum service braking pressure test”
See the corresponding section.
4-17
Vacuum Service Brake System
System type

System type
vacuum pump
The parameter of the vacuum pump Fig. 3.2
The view of the vacuum service cylinder Fig. 3.3

The parameter of vacuum service cylinder:
The distance of move:32mm
Booster ratio:3:1
The diameter of cylinder:32mm
Working temperature:-40℃ -100℃
The view of the vacuum pump Fig. 3.1

4-18
Brake system schematics
Brake system schematics 8. Balance valve

9. Vacuum pump
Component Key: 10. One-way valve (in the service cylinder)
A: hoses connect the oil cup and service cylinders
1. Store braking oil cup
B: hoses connect the cylinder-balance valve-brak-
2. Right vacuum service cylinder
ing cylinder (in the rear axle)
3. Right pedal
C: hoses connect the vacuum pump and service
4. Left pedal
cylinder
5. Left vacuum service cylinder
6. Left braking clutch (in the rear axle)
7. Right braking clutch (in the rear axle)
Fig. 3.4
4-19
Hydraulic operation
Hydraulic operation
Some of the following pictures may not show exactly your braking system ,but the form is the same.
The main components of the driving braking system are the Braking oil cup 1; service cylinders 2,5; brak-
ing pedals 3,4; braking clutch (in the rear axle) 6,7; the balance valve8; the vacuum pump and related
hoses and steel tubes.
When step the pedals 3,4,the brake oil from the cup 1 will go to the clutch 6,7 which are in the rear
axle,realize the brake.
because the vacuum pump extract vacuo from the service cylinder,the negative pressure will make the
handlers feel easily when step the pedals 3,4,
When release the pedals 3,4,the pistons will go back because of the springs in the service cylinder..
The system can realize the one sides brake if you step the pedal 3 or 4.see the section "braking pressure
balance valve"
Fig. 3.5
4-20
Driving braking
Driving braking
Pedals and service cylinder
Warning
Before disassmbling,remember you have to pro-
ceed the following steps:
the parking brake
2. Set the gearbox to neutral.
4. Stop the engine and remove the starter key. Internal of the cab Fig. 3.7
5. Make sure the engine cannot be started while 8. The connection of the service cylinder
the hoses are open.so,to cut off the power of
Danger
Hydraulic Pressure
Removal:
7. Opening the engine cover,confirm the position
of the assistor assy.
Fig. 3.8
9. Disconnect all hydraulic lathedog and hoses ,use
wrench to disconnect two steel tubes and con-
nectors from the service cylinder as shown at
following picture. Label the hoses to ensure cor-
rect refitting.
Fig. 3.6
4-21
Driving braking
Fig. 3.11
12. Take down the cotter pin,and unpin the cylindri-
cal pin, so the pedal assy Can take down from
the system
Fig. 3.9
10. Disconnect the springs ,cotter pins and cylindri-
cal pins
Pedals and service cylinder Fig. 3.10

11. Disconnect the nuts,take down the forks.
Fig. 3.12 The pedal assy

4-22
Driving braking
13. Take down the nut,and draw out the assistor

from the Direction of the engine Warning
The optional plate is choose one-side or both-
sides braking,
Before you launch the engine,make sure theOp-
tional plate is in the potision that you want. And
make sure the plate is not damaged.
Fig. 3.13
Pedals and service cylinder
Magnetic valve Fig. 3.15
Warning
The assy of the service cylinder Fig. 3.14
The assemble process is the reversible have to proceed the following steps:
the parking brake
4-23
Driving braking

Danger
Hydraulic Pressure
Magnetic valve
8. Take down the hoses as the view
Fig. 3.17
10. Takedown the valve
Fig. 3.16
9. Next view is the assy of the magnetic valve,
Takedown the screws as the view shown
Fig. 3.18
4-24
Driving braking
11. Takedown the two screws as shown
Fig. 1.19
Fig. 3.21
This is the valve block Fig. 3.20

Braking pressure balance valve
If the handle step the both-sides pedals,the sig-
nal will transmit to the balance valve througn the
sensor which in the bottom of the braking ped- Fig. 3.22
als to two clutchs ,pressure will balance through
Pressure test
the balance valve.
We don’t obligate special test connector in the
braking system,so the user need assemble the
connector by
Himself.we will provide the corresponding di-
mensions.
Warning
if you need to intrance the bottom of the
machine,Before you disassemble the hoses ,re-
member you have to proceed the following steps:
4-25
Pressure test
1. Support the machine with legs and load-

ing attachment reach the height as you
need,remember you need to turn over the load-
er completely as shown.
2. Use the leg safety struts,and put them in the leg
cylinder rod as next view shown.
If your machine is CLG766A:
Take down the safety strut which in the left of
the machine,
Fig. 3.25
Put it here!
Fig. 3.23
Put it into the leg, and make sure the safety
strut is fit firm.
Fig. 3.26
4. Stop the engine and remove the starter key. To
cut off the power of the battery, to prevent the
engine being started while you are beneath the
machine.
Fig. 3.24
exactly your braking system ,but the form is the
Pressure test same.
5. You can replace the connectors “tee joints” and
If your machine is CLG777A
takedown the hoses B in the rear axle as shown
Take the special safety strut to assemble the
leg,see the view as shown,and make sure the
safety strut is fit firm.
The safety strut
4-26
Pressure test
Fig. 3.27 Fig. 3.29

6. And then you can assemble the new connectors Pressure test
to replace the tee joints for pressure test.the 7. connection the pressure gages
hoses B can cancel ,the connection form and
dimensions are as follows:
Fig. 3.30
8. after connection the pressure gage,you need to
Tee joins: Fig. 3.28 exclude the air in the braking air.
The connection of hose A and B NOTE:You need exclude the air in the sys-
tem after takedown or replace the connectors
or hoses,or the braking system with no effect.
9. you need three man to exclude the air.
One refuel the braking oil;one step the pedal in
the cab;one adjust the plug in the bottom of the
machine.
10. Step the pedals with all one’s strength for three-
five times,and keep the position to the end,the
one who is bottom the machine unscrew the two
plugs as shown,some oil will outflow.
4-27
Pressure test
Fig. 3.31
11. And then screw down the plugs,the one in the
cab loosen the pedals, continue to step the ped-
als with all one’s strength for three-five times
again,and keep the position to the end,the one
who is bottom the machine unscrew the two
plugs again,repeat four-ten times.the man who
is refuel the oil must make sure the cup is full,to
avoid air ingress the system
12. And then you can test the pressure.the pressure
is about 40 bar.
4-28
FAULT
FAULT
Note:The braking part surface maybe in high temperature to touch,so inspect or disassembly be care-
fully.
4-29
FAULT
Fig. 3.32
4-30
Parking Braking (Moist-Brake)
The structure

The structure
The view of the structure (hide the hand-rod cover)
If your rear axle is “moist-braking”
Fig. 4.1
Fig. 4.2
4-31
The braking principle

The view of the clutch of the rear axle.
Fig. 4.3
4-32
Disassembly and replacement
Disasseble the clutch ,The friction plates Disassembly and replacement

Parking braking pull rod
Position of the rod
Fig. 4.4
The cam in the shaft
Fig. 4.6
Warning
1. Park the machine on level ground
Fig. 4.5 while you are beneath the machine.
The handle pull the parking braking pull rod in 6. Chock all four wheels to prevent unexpected
the cab,the flexible shaft pull the braking tie rod move of the machine.
shaft rotate,the cams in the shaft will Extrusion Next is the detailed steps
the friction plates,realize the parking braking. Removal:
1. Our pull rod has the cover,unscrew the
NOTE:The driving braking and parking brak- screws,takedown the plate,and then takedown
ing use the same Clutch assy! the cover
4-33
Disassembly and replacement
Fig. 4.9
4. The assemble process is the reversible
N OTE:When you release the braking
rod,push the button at the same time as
Fig. 4.7 shown in left view.
2. Unscrew the bolts in the box,and then takedown
the box as shown Parking braking-Removal and replacement
Parking braking pull rod (in the axle) and bends
Position of the pull rods and bends (in the bot-
tom of the machine)
Fig. 4.8
3. Unscrew the four bolts and washers,the braking
pulling rod is down.
Fig. 4.10
4-34
FAULT
8. Disassmble the cotter pins and cylindrical pins.

Warning And you can takedown the bends
move of the machine. Fig. 4.12
Next is the detailed steps 9. The assemble process is the reversible
Dissmbly: 10. The flexible shaft drawing as shown
7. Unscrew the washers and bolts,and then you
can takedown the flexible shaft assy from the
cab.
Fig. 4.13
Fig. 4.11
4-35
FAULT
FAULT
This section tell you how to determine the fault,and corresponding action.FAULT
4-36
Parking Braking (Caliper Disc)
Structure

Structure
The view of the structure
If your rear axle is “caliper disc brake”
Fig. 5.1
Fig. 5.2
4-37

When driver pull the braking rod in the cab,the
plier assy will clamp the disc through the
flexible,the input shaft Cannot rotate,and the
tyres of the rear axle.The whole machine will
braking in the ground.
Fig. 5.4
8. Unscrew the bolts in the box,and then takedown
the box as shown
Pisition of the rod Fig. 5.3
Warning
4. Stop the engine and remove the starter key. Fig. 5.5
5. Make sure the engine cannot be started while 9. Unscrew the four bolts and washers,the braking
the hoses are open.so,To cut off the power of pulling rod is down.
Removal:
7. Our pull rod has the cover,unscrew the
screws,takedown the plate,and then takedown
the cover
4-38

Dissmbly:
7. Unscrew the washers ,nuts ,and the pins,then
you can takedown the flexible shaft assy from
the cab.
Fig. 5.6
N OTE:When you release the braking
rod,push the button at the same time as
shown in left view.
The flexible and disc
Position of the flexible and caliper disc (in the
bottom of the machine)
Fig. 5.8
9. The flexible shaft drawing as shown
Fig. 5.9
Fig. 5.7
Warning
4-39
FAULT
FAULT
5. Electrical Use and Maintenance of
A Series of Backhoe Loaders
Introduction.........................................................................................5-4
I. Basics Introduction of the Electrical System Layout........................5-5
1.1. Description of the cab wiring AS position...................................................5-5
1.2. Description of steering gear box wiring AS position...................................5-6
1.3. Basic description of dome light circuit AS position.....................................5-7
1.4. Description of the frame wiring AS position...............................................5-8
II. How to Use Machine.......................................................................5-9
2.1. Allowing the starting conditions (synchronization shift)..............................5-9
2.2 Start-up conditions (automatic shift).........................................................5-10
2.3. Foot brake power cut (synchronization shift) ..........................................5-11
2.4 2WD/4WD functions (synchronous shift)..................................................5-12
III. Description and Troubleshooting of the Electrical System...........5-13
3.1 General information .................................................................................5-13
3.1.1 Electrical graphical representation: .................................................5-13
3.1.2 Multimeter.........................................................................................5-13
3.1.3 Relay.................................................................................................5-16
3.1.4 Repair method of commonly used components in the electrical system.5-17
3.2 Alternator..................................................................................................5-20
3.3 Starter motor.............................................................................................5-22
3.4 Instruments and connector pin definitions (mechanical engine Weichai/Perkins)
5-24
3.5 Definitions of electrical centralized control box and connector pin...........5-26
3.6 Definitions of the front alarm unit and the connector pin..........................5-29
3.7 Combination switch (synchronous shift)...................................................5-30
3.8 Combination switch (automatic shift) .......................................................5-31
3.9 Gearbox controller (automatic shift)..........................................................5-32
3.10 Engine ECU (three phase electronic control engine)..............................5-37
3.11 Starting and running fault .......................................................................5-39
3.11.1 Battery.............................................................................................5-39
3.11.2 Disconnect switch...........................................................................5-41
5-2

3.11.3 Fuel lift pump (Perkins)...................................................................5-42

3.11.4 Oil cut-off valve...............................................................................5-43
3.11.5 Ignition switch (electric lock)...........................................................5-45
3.11.6 IGN start signal...............................................................................5-47
3.11.7 Forward and backward/backward alarm (synchronization shift).....5-49
3.11.8 Outrigger alarm (optional)...............................................................5-51
3.11.9 2WD/4WD shift (synchronous shift)................................................5-52
3.11.10 Shift handle unloading (synchronization shift)..............................5-53
3.11.11 Load/unload excavation handle....................................................5-54
3.11.12 Differential lock (synchronous shift)..............................................5-55
3.12 Display and alarm malfunction................................................................5-57
3.12.1 Engine oil pressure warning (mechanical engine)..........................5-57
3.12.2 Engine water temperature display alarm (mechanical engine).......5-58
3.12.3 Gearbox oil temperature warning (synchronous shift)....................5-59
3.12.4 Gearbox oil pressure warning (synchronous shift).........................5-60
3.12.5 Speed signal (mechanical engine)..................................................5-61
3.12.6 Air filter clogging alarm...................................................................5-62
3.12.7 Fuel sensor.....................................................................................5-63
3.13 Lighting fault...........................................................................................5-65
3.13.1 Brake light.......................................................................................5-65
3.13.2 Turn signal light...............................................................................5-67
3.13.3 Clearance light................................................................................5-69
3.13.4 Main light switch.............................................................................5-70
3.13.5 Front/rear work light........................................................................5-72
3.13.6 Hazard signal light..........................................................................5-74
3.13.7 Dome light.......................................................................................5-75
3.13.8 Rotating beacon (optional)..............................................................5-76
3.14 Work system fault...................................................................................5-78
3.14.1 Level the bucket..............................................................................5-78
3.14.2 Unloading........................................................................................5-79
3.14.3 Hydraulic hammer switch................................................................5-80
3.14.4 Clamping valve switch (777A)........................................................5-82
3.14.5 Fan (optional convertible)...............................................................5-83
3.14.6 Radio..............................................................................................5-84
3.14.7 Front wiper/ washer........................................................................5-86
3.14.8 Rear wiper/washer..........................................................................5-88
5-3

3.14.9 Front horn (synchronization shift)...................................................5-90

3.14.10 Rear horn......................................................................................5-92
3.14.11 Cigarette lighter.............................................................................5-93
5-4
Introduction

Introduction
This document is the maintenance and repair guideline of a three-phase electrical system of the backhoe
loader. It presents each electrical function schematic diagram in the form of functional modules, and de-
scribes every function’s realization principle, common faults and repair, maintenance methods.
Three-phase backhoe loader is divided into five electrical systems according to the engine manufacturer,
leg form and gearbox.
22E1192 777A Weichai + synchronous shift 50E0659
22E1197 766A Perkins + synchronous shift 50E0659
22E1198 777A Perkins + synchronous shift 50E0659
22E1199 766A Weichai + synchronous shift 50E0659
22E1276 Perkins + automatic shift 50E0753
22E1414 Perkins electronic control three phase + automatic shift 50E0935
22E1502 Perkins electronic control three phase + synchronous shift 50E2058

In the electrical system layout, the entire electrical system is divided into three large sections: frame
wiring, cab wiring, steering gear box wiring. But implementation of most electrical functions are carried
throughout these three sections, so in this document, introduction is made in accordance with the electrical
functions. In this paper, the electrical functions will be divided into 4 sections to introduce, namely starting
and running, alarms and display, lighting, work systems according to the different functional properties.
Important electrical components are disassembled in details, such as a battery, alternator, electrical
centralized control box etc.
Electrical system is rated at 12V, using Weichai/Perkins engines. Its main characteristics are as follows:
| Adopt Perkins three-phase electronically controlled engines, cut off the power, cut the oil, flameout,
electronic control throttle.
| All lights and solenoid valves are powered up through relays.
| Reverse alarm is installed.
| It is optional to install rotating warning lights, outrigger alarm function, bucket flat features, power off func-
tion.
| With a neutral start, 2WD/4WD lock function.
| Daily marked line is used for all wires, that is AVSS line with line mark.
This part is composed on the basis of relevant electrical system principle diagram and electrical working
principle during production. Please be subject to the delivery attached documentation from Liugong deal-
ers when purchasing machine if modifications of product are various according to different types of ma-
chine.
Maintenance personnel must master general knowledge of maintenance electrician and be familiar with
electrical system and working principle of Liugong skid steer loader before fault diagnosis and mainte-
nance.
1.1. Description of the cab wiring AS position
1. Unload switch of load handle 2. Hand brake switch 3. Fuse box 4. Rear horn switch 5. Unload switch of backhoe handle 6. Pedal switch of hydraulic hammer 7. Shift unload switch
8. A/C control panel 9. Combination instrument 10. Radio 11. Cigarette lighter 12. Sideway clamping switch 13. Hydraulic hammer 14. Rear window cleaning switch 15. Rear window
wiper switch 16. interflow switch 17. Switch of rotating light 18. Switch of differential lock 19. Rear working light swtich 20. Front working light switch 21. Electrical lock 22. Power
supply relay 23. Connect wiring harness of work light 24. Buzzer 25. Buzzer 26. Rear wiper controller 27. Main light 28. Power cut 29. Hazard lamp 30. 2WD/4WD
I. Basics Introduction of the Electrical System Layout
1.1. Description of the cab wiring AS position
5-5
5-6
1.2. Description of steering gear box wiring AS position
1. R10-neutral start relay 2. Front wiper motor 3. Front wiper 4. R11-brake balance relay 5. R9 ---Combination diode relay 6. Front
1.2. Description of steering gear box wiring AS position
alarm unit 7. Combination switch 8. R8---Combination diode relay 9. R7---Combination diode relay 10. R6---Combination diode
relay 11. R4---flash relay 12. R3---foot brake relay 13. Right foot brake switch 14. R2---horn brake light relay 15.
R1---forward/backward relay 16. Left foot brake switch 17. R5---2WD/4WD relay
1. Right floodlight 2. Left floodlight 3. Front
work light 4. Audio 5. Rotating beacon 6.
Dome light 7. Front work light 8. Audio 9.
Left rear combination beacon 10. Rear
work light 11. Rear work light 12. Right
rear combination beacon
1.3. Basic description of dome light circuit AS position
1.3. Basic description of dome light circuit AS position
5-7
5-8
1.4. Description of the frame wiring AS position
1.4. Description of the frame wiring AS position
????????????????????????????????????????????????????????????????
5-9
II. How to Use Machine
2.1. Allowing the starting conditions (synchronization shift)

2.1. Allowing the starting conditions (synchronization shift)
F/N/R handle is in neutral position
One of the conditions holds

Hand brake is in braking mode
System is in neutral Foot brake is in braking mode
position
Press button on the shift handle
Mainly for protecting wrong

operation after starting
Set one of starting condition (-)
Electrical lock is Alternator Cut off the power supply from electrical lock to start relay
in start position
Set another one of starting condition (+)

5-10
2.2 Start-up conditions (automatic shift)
2.2 Start-up conditions (automatic shift)
F/N/R handle is in neutral

position
One of the conditions holds

System is in neutral
position
Hand brake is in braking
mode
Mainly for protecting wrong

operation after starting
Set one of starting

conditions (-)
Cut off the power supply from electrical

Electrical lock is in If alternator generating lock to start relay
start position electricity
Set another one of starting condition (+)

5-11
2.3. Foot brake power cut (synchronization shift)
2.3. Foot brake power cut (synchronization shift)
Brake balance valve is

Step brake pedal on one side Brake light is
electrified, allows side brake, do
on
not cut off the power
Left and right Power supply of brake

Power cut-off Step brake pedals Brake light is brake lights are balance valve is cut off.
switch is turned on both sides on
turned off Cut off the power
off
Brake balance valve is

electrified, do not cut off
Foot brake power the power
cut-off fails
5-12
2.4 2WD/4WD functions (synchronous shift)
2.4 2WD/4WD functions (synchronous shift)

Two side
brake
4WD indicator is on
2WD/4WD switch
is turned off Power of
2WD/4WD relay 4WD mode
2WD/4WD valve
is turned off
is cut off
4th gear
4WD indicator
2WD/4WD relay
isn’t on
is turned off
2WD/ 4WD valve is

electrified
2WD mode
5-13
III. Description and Troubleshooting of the Electrical System
3.1 General information
III. Description and Troubleshooting of the Electrical

System
3.1.1 Electrical graphical representation:
The following symbols and practices have been used in the electrical wiring described in this guide:
Diode Switch 4th gear sensor
Temp alarm
Fuse Fuel level sensor
switch
Cigarette lighter Pressure switch Rev sensor
LED Buzzer Fuel lifting pump
Button switch Flash relay Connector
Alternator Electrical lock Audio
Choke electric
Bulb Electric fan
magnet
Disconnect
Motor Solenoid valve
switch
Switch Horn Backward alarm
Switch
Cable identification: for example: 602GN1.5 602: Wire NO. GN: Color 1.5: AWG (mm2), AWG unlabeled is
0.85mm2. Power line, No.1 of the line is in red (RED), earthing cable; No. 2 of the line is in gray (GY), the
remaining cables are in white (WH).
3.1.2 Multimeter
Electrical system test of the excavator loader requires use of a multimeterto carry out five tests. This sec-
tion provides the user with a common guideline on multimetercorrect measurement techniques. This sec-
tion provides pictures, so that it is relatively easy for users to compare required reading information, which
have been collected.
5-14
Resistance test
Digital automatic range multimeter and manual range

multimeter
Before using the equipment, make sure that 2 probes

connect to correct interface for test; black probes
connect to COM interface, red probes connect to
voltage, resistence and diode test interface. Select Ω position on automatic range multimeter,
Continuity test select 200 Ω position on manual range multimeter.
Use probe to test resistance according to the
method in manual, compare actual measurement
result with the value listed in manual. Correct value
should be zero or minimum, which indicates that
the circuit is in good situation.
Before run a continuity test, cut off the power supply

of tested units to insure safety. However, only 12 V
voltage can be used to electrify the coils of relay to
test the condition of relay units controled switch.
5-15
Resistance 20KΩ AC voltage
Max. resistance is shown in picture below Select AC voltage. Select AC voltage on automatic
range multimeter, select AC voltage 200V on
manual range multimeter. If select AC voltage letter
V and AC, they will show on the screen.
DC voltage
Select Ω position on automatic range multimeter,

select 20KΩ manual range multimeter. Test
resistance with probe according to the method in
manual. Compare actual measurement result with
the value listed in manual.
Test of diode
Select DC voltage. Select DC voltage on automatic
range multimeter. Select DC voltage 200V on
manual range multimeter. If select DC voltage letter
V and DC, they will show on the screen.
Select diode symbol. When testing diode, if connect

the two probes to both ends of diode, a high value
will appear, vice versa. Compare actual
measurement with the value listed in manual. If the
difference is very big, replace the diode.
5-16
3.1.3 Relay
Relay usage: control action, which uses very small current to control very large current. Moreover, the re-
lay can also use DC to control AC, or AC to control DC.
Switchover function: the logical function can be achieved through the combination of relays (relationship of
and, or,no). But inferior to plc etc.
A controller with a microprocessor is easy to use; it is more used for relatively simple logic.
Generally, the larger the volume of relay is, the stronger its capacity of loading current is.
Basic structure chart:
Relay of diode Relay Relay
Working principle:
The function of diode relay is to ensure single-way conduction and offer protection to prevent backflow of
current. The forward cunduction.
1. Reverse cut-off follow current. If the backward current is too large, the diode relay will be easily to be
breakdown and caused failure. Multimetercan be used to check whether it is good or bad, (diode gear) red
probe connects inlet wire of the diode, and the black probe connects with the diode, which is breakover.
Conversely, if the diode won’t conduct, it means the diode is normal without breakdown. If the backward
direction of it is also conductive, it means the diode has failed and please replace it.
2. Figure 2 shows the working principle of the relay, when two terminals of the electromagnetic relay coil are
applied with a certain voltage or current, the magnetic flux generated by the coil is through the magnetic
circuit, which are composed by the iron core, the yoke, the armature, the magnetic circuit working air
gap. Under the magnetic field action, the armature is attracted to the core pole face, thereby promoting
contacts constant-off contacts to disconnect, constant-oned contact to be closed; when the both ends
voltage or current of the coil is less than a certain value, the mechanic reaction force is greater than the
electromagnetic suction, the armature is back to the initial state, normal-open contacts are open, constant-
off contacts are connected.
Constant-off
stationary contact
Armature
Movable contact
Constant-on
stationary contact
Movable
contact spring
Coils
Yoke iron
Iron core
Figure 2 Construre diagram of relay
Attentions during Installation:

1. The installation position of magnetic sensitive elements should be far away from the relay.
2. Do not install the electromagnetic relay onto the mounting plate made of ferromagnetic material;
5-17
3. Install several time delay relays at the same time with a gap of more than 5.08 mm to avoid damages to
semiconductor in the relay caused by high heat due to intensive installation.
4. Pull-on direction of the contacts does not parallel with the driving direction of the machine, so as to avoid
machine movement may cause the relay malfunction.
5. The relay generally should not be installed upside down (except sealed waterproof ones).
3.1.4 Repair method of commonly used components in the electrical system

I. Objective
1. Control operational steps of wire repairing.
2. Control measures to test the automotive switch, fuse, relay etc intermediate components.
3. Master disassembly and inspection of the truck connector.
II. Instruments and Tools
Truck harness, switch, fuse, relay, connector, welding tool, multimeterand so on.
III. Contents
1. Wire maintenance
Most manufacturers recommend that all wires should be repaired by welding. When repair the wires, it is
important to use the correct operations as the circuit diagram shown.
(1). Remove 12.7 mm (1/ 2 in.) of insulation from each wire, which needs to be repaired and spliced.
(2). Prepare heat tubing with adhesive lining to be placed on the wire side. Ensure the tube long enough to
cover and seal the entire repair area.
3. Switch test
Turn the switch to the appropriate location; use a multimeterresistance gear to detect the corresponding
resistance between the terminals, and the contact resistance can not be out of range.
Fuse testing point
保险测试点
4. Fuse inspection
Observation method can be used to check, the resistance gear of a multimetercan also be used to
measure whether the fuse is blown out.
5. Relay test
(1). Open circuit test
The method uses a multimeterto measure resistance, taking a relay as an example which is shown in the
following figure, it uses the multimeter R X 100 Ω gear to check: if
Pin ① - Pin ② , connected
Pin ③ - Pin ④ , connected
Pin ③ - Pin ⑤ , resistance ∞.
It Is normal, or else it has problems.
5-18
(2). Power-on detection

Apply 12ν voltage between the feet ① and ② , then: feet ③ and ④ are not connected, feet ③ and ⑤ are
through, this state is as normal.
3. Removal, installation and test of the connector
Removal:
(1). Disconnect the battery or disconnect switches.
(2). Disconnect the connector from its paired half/component.
(3). Press the locking tabs on the yellow connectors to release the terminals.
(4). Use the special tool to crimp terminals and remove the wires from the connector.
(5). Repair or replace the terminals.
Special tool Locking tab
Connector
Connector
Installation:
(1). Reset the lock tabs.
(2). Plug the removed wire into the original jack of the repair plug.
(3). Repeat to plug each wire into the connector, and ensure that all wires are plugged into the correct
jacks. To the Identification of another connector pinout, pls see the relevant circuit.
(4). When re-assembly connectors, the locking tabs must be placed in the locked position, so as to prevent
the terminal prolapse.
(5). Connect the connector to its paired half/component.
(6). Connect the battery and test all affected systems.
Inspection
When checking the line voltage or conduction condition, it is not necessary to disengage the connectors,
only use two probes of the multimeterto plug into cable holes of the connector end to check.
Precautions for maintenance
Before maintenance, please do understand and keep safety and warning information & precautions in
mind in case of personal injuries or damages to electrical elements and its relevant equipments. Please
obey the following precautions strictly during the maintenance of electrical system.
| Read and understand the Manual for Testing Equipments to use the testing equipments correctly.
| Complete machine power should be cut off before maintenance; and then disconnect wires and
connectors. If not, harness will be damaged and the fuse will be blown; even fire will be caused because
of short circuit of wires.
| Please identify colors and functions of different wires correctly: the colors and wire gauge should be
5-19
correspond to the three-digit figures of wire labels in the principle diagram. Please distinguish colors and
wire gauges correctly for easy maintenance.
| Please connect the connectors correctly: letter codes of connectors should be correspond to colors of
wire during connection. Otherwise, damages to connectors will be caused and even harness will be burnt
down.
| Pull out the connector, grasp the connector main wires, do not pull it hardly. Make sure the fitting and good
contact of lock buckles when connecting the connectors.
| Make sure the connectors are dry and protective measure should be taken to meet the requirements of
damp proof and water proof.
| Understand the schematic circuit diagram which indicates mutual relationships and functions of each
elements and devices of the electrical system. This will be helpful to make a quick and correct judge of
fault and save maintenance time. Don’t remove the machine to a large extent blindly.
| Understand “ground” means correctly: battery (-) is the “ground”, engineering machinery generally use
negative earth, namely connect the battery’s negative pole to the whole body (including the frame, cab and
other metallic conductors connected together). Therefore, when the battery (-) connects the whole body
tightly and reliably, the whole body is the “ground.” (Note: surface of the measuring earth position can be
coated with butter, it should be appropriate to avoid the bad ground; paint, oil, dust etc are not allowed.).
| Bundled with the harness correctly: 1, Avoid bend the harness off; 2, It should stay away from moving
parts and prevent breakage and wear; 3. Avoid friction with sharp metal edges; 4. Try to be far away from
oil and water; 5, Make the best to be away from hot parts (such as the engine block).
| Bind and replace the harness immediately once find wear of them; and fix the wiringharness on the place
where there is no wear.
| Correctly replace the fuse: when replace the fuse, you must use one in the same specification, it does
not allow use of copper wire for emergency treatment. Chip type fuse and flat plate type fuse used in this
product should meet relevant regulations of QC/T 420 Fuses for Auto. Therefore, please use the authentic
parts from Liugong when replacing fuses during maintenance.
5-20
3.2 Alternator
3.2 Alternator
1. Functions of alternator
(1). The alternator is the diesel kit with built-in electronic regulator, its operating voltage is 14V.
(2). After starting the engine, the whole machine is powered, such as power for A/C, lighting, relay, all
kinds of electromagnet.
(3). Use with the starting battery in parallel, so as to achieve charging the battery.
(4). Provide part of the control and monitoring signals, such as: signal to measure the engine speed used
on the W-side, measure power generating used on the D-side.
2. Structure of alternator
Currently, alternator has many types but their basic structures are the same that is, they are all composed
of three-phase alternator and silicon rectifier. Three-phase synchronous alternator generates three-phase
AC, which output through Silicon output rectifier, its structure is shown as Fig.
1- Carbon brush spring cover; 5- Fan; 9- Component plate;

2- Carbon brush; 6- Front cover 10-Diode;
3- Carbon brush holder; 7- Armature set 11- Rear cover
4- Belt Pulley; 8- Field rotor;
3. Connection of alternator
B+ of alternator connects to the positive pole of battery, and D+ to charging indicator to excite the alternator.
5-21
3.3 Starter motor
4. Simple check of alternator faults

The first step, check whether there are disconnection, wrong connection and short circuit on the outer
wires connection positions of the alternator; moreover, use a voltinstrument to measure whether the B +
has the battery voltage.
The second step, turn the ignition switch to the “ON” position, but do not start the engine, use a
voltinstrument to measure whether D + point has voltage, and observe the charging indicator.
The third step, start the engine, and use a voltinstrument to measure voltage of the engine B + point, it
should reach the following values:
12V system with voltage of 13V or more, while add and subtract the throttle, there is little change in the
voltage (0.1 ~ 0.2V).
The fourth step, open part of the load, such as lights 12V system with voltage more than 13V while add
and subtract the throttle, there is moderate change in the voltage (0.2 ~ 0.4V).
To the third step, if the alternator has no voltage output, the following methods can be taken to check. For
D +point yielding excitation, a 2.5mm2 wire can be led from the battery positive; after starting the engine,
use the other end to click D + point (within 1S) instantaneously, and then use voltinstrument to measure
point B + whether there is the voltage output:
| If so, start checking from the third step to the fifth step, and judge whether the machine charging indicator
line occurs open circuit (generally it means indicator is damaged, instrument panel lever fittings loose,
circuit is broken). If there is no voltage output, it means the alternator has no electricity failure.
5. Precautions for alternator operation
|. Prohibit strictly supplying power to electric equipments when alternator is separated from the battery;
prohibit strictly disconnecting the disconnect switch when the engine is running.
|. Prohibit checking the alternator for electricity generation with the method of generating sparkle through
instant short circuit of negative and positive poles. To avoid burning down the silicon diode and damaging
electronic voltage regulator.
|. Prohibit any metal conductor closing to the positive wiring terminal of alternator randomly. Please shut the
electronic lock when checking the two wiring terminals for fastening and stability.
5-22
3.3 Starter motor
3.3 Starter motor

1. Structure of starter motor
Starter motor is the matched component of diesel engine. It is mainly composed of electromagnetic switch,
DC motor, fork and drive gear.
1. Electromagnet 5. To motor coils 9. Connect to control wire

2. Iron core 6. Contact 1 and contact 2 10. Holding coils
3. Fork 7. Connect to battery (+)
4. Movable disc 8. Push and pull coils
1. Precautions of starter operation
1. After starting the engine, the starter motor should be stopped immediately, otherwise it will cause
damage to the drive gear, DC motor burn, flame electromagnet damaged, and will seriously affect the
battery capacity and life.
2. Prohibits any metal conductor close to contacts and S terminals at random! Make sure the fuel pipe
across the starter motor nearby and other metal objects can’t touch or have friction with contacts and
terminal S after violent and vibrative running of the machine for a long time. Otherwise, fire will be
caused.
3. Please always check the wiring between contacts and S terminals are tight and reliable. Do disconnect
the disconnect switch before the check. Otherwise, short circuit sparkles might generate to damage
the wrench and wiring terminal.
3. FAQs of the starter motor
5-23
Turn off power locks, the engine does not stall
Fault features Possible causes and treatment methods
Contacts of the power relay sinter, replace the power relay.

After turn off the power lock, machine electrical
load still has power (for example, when control
The power lock is damaged, replace it
lighting switch, lights are lit; steering the wiper
switch, wiper works, etc.). Alternator is damaged, and the generating voltage is much
higher than 15V.
5-24
3.4 Instruments and connector pin definitions (mechanical engine

Weichai/Perkins)
Parameters
1. Rated voltage: 12VDC. Working voltage range: 9-16 V.
2. Working temperature: -40℃ -85℃ .
3. Storage temperature: -40$C ----
When the speed exceeds 300 rpm or instruments begin to detect the motor starts charging and oil
pressure light is off, the timer will start working.
The output of the combination instrument is pin 14, and should drive an external bulb or relay, the other
end should be earthed. Maximum output current of the instrument is 200mA. The combination instrument
will have output only its power is turned on and meet at least one of the following six conditions.
- The engine is running and low engine oil pressure warning light is lit.
- Engine is in running condition and charging indicator is ON.
- Gearbox oil temperature warning light goes on.
- Gearbox oil pressure warning light goes on.
- High-temperature cooling water warning light goes on.
- Hydraulic oil temperature high warning light goes on.
- Low brake pressure warning light is lit.
Other cases, the instrument is not output.
5-25
The instrument can be compatible three engines, for different engine speed ratio corresponding to different
selection and a temperature sensor of the curve. Through two different pins combination options are as
follows:
PIN 22 OPEN 22 PIN 22 GROUND 22

PIN 23 OPEN 23 vacant WeiChai engine Cummins engine
PIN 23 GROUND 23 Perkins engine YITUO engine

5-26
3.5 Definitions of electrical centralized control box and connector pin
3.5 Definitions of electrical centralized control box and connector

pin
Parameters
1. The electrical centralized control box are provided by the manufacturers as a whole, the specific details
are used for the guidance test and purchasing aftersales spare parts.
2. Rated voltage of all electrical appliance: 12 V

Generally, our automotive electrical components provides power to the electrical devices after through
fuses in the fuse box, mainly to protect the wires, when the wire is overheating, the fuse is burn-out
before the wire sends out smoke, so as to protect the machine lines. Except cigarette lighter, dome light,
emergency stop lights and the controller, the other machine electrical components are powered through
the electric lock control.
Fuse parameters: 5A-Orange; 7.5A-Brown; 10A-Red; 15A-Blue; 20A-Yellow; 30A-Green
There is a small light next to the fuse, when the fuse is burned out, a small light next to the fuse will be lit,
usually red lights. If the fuse is burned out, replace fuse piece in the same specification.
5-27
1 Holder 2 Rear work light relay 3 Charging relay 4 4th gear relay 5 Rear work light relay 6 Front work light
relay 7 Front work light relay 8 Hydraulic hammer relay 9 Start protection relay 10 Start relay 11 Interflow re-
lay 12 Manual brake neutral relay 13 Rear horn relay 14 Horn 15 Rear wiper 16 Brake 17 Clearance 18 Turn
signal light 19 Forward/backward valve 20 Instrument 21 Front wiper 22 Front floodlight 23 A/C 24 Solenoid
valve 25 Hydraulic hammer 26 Rear work light 27 Shift control 28 Fuel lift pump 29 Rotating light 30 Front
work light 31 Oil cut-off valve 32 Preheating plug chock control 33 Power control 34 Emergency stop light 35
Cigarette lighter
Operation
The electrical centralized control box collects all fuses and most relays of the system except the primary
fuse. When the disconnect switch is closed, the power supply line 107 supplies electricity. If the electric
lock gear is in the ON position, the power supply lines 107, 108 and 109 supply electricity. Specific use will
be described in detail in the following sections for specific functions.
5-28
Wiring diagram
5-29
3.6 Definitions of the front alarm unit and the connector pin
Troubleshooting 1. Low engine oil pressure

2. Charging indicator light goes on
1. The electrical centralized control box consists of 3. High shift oil temperature
a circuit board, relay and fuse. 4. Low shifting oil pressure
2. If there are no quality problems when leave the 5. High cooling water temperature
factory, the circuit boards are generally not dam-
aged; Troubleshooting
3. The fuse end has fault indicators, if a fuse has
1. Check the earthing wire is good.
failures, its corresponding indicator is lit, and the
2. Check the suspected fault indicator correspond-
fuse needs to be replaced;
ing pins on the connector, whether there is volt-
4. If it is judged to be the electrical centralized con-
age input. If so, LED inside the alarm unit may
trol box fault, the corresponding relays should
be damaged. If not, initially ruled out that the
be checked according to the circuit diagram of
alarm unit may be failed. Check according to
the function.
this function testing method.
3.6 Definitions of the front
alarm unit and the connector
pin
Parameters
Working ambient temperature (℃ ): -30 ~ 65
Wiring method: DJ7021-2-21
Rated voltage: DC12V
Display method: LED indicator
1. beam 2. differential lock 3. main light alarm 4.

Clearance 5. 4WD 6. Right steering 7. Middle-posi-
tion 8. fourth gear indicator 9. left steering
After starting the engine, if the side of the instru-
ment has the following alarm signal, the first warn-
ing light goes on
5-30
3.7 Combination switch (synchronous shift)
3.7 Combination switch (synchronous shift)

Operation
The combination switch is made up of left and right handles.
(1). Left handle button is for the front horn; left handle intermediate position is the neutral position, push
forward means going ahead, the back dial is backward.
(2). Right handle pushing forward is the left turn signal light, rear dial is the right turn signal light;
(3). Press the right handle end, and the front washing switch;
(4). The right handle knob is the front wiper switch, 0 gear is closed, rotation forward I gear is the reset
gear, the backward rotation J gear is the slow gear, backward rotation I gear is the fast gear.
Front horn Front washer Overtake
High beam
Low beam
Forward Left steering Output terminal
light Power
supply
Mediate
Output Output Forward
Power terminal terminal Backward
Power Power supply Earthing control
supply supply
Right
Output
Backward steering
J: wiper reset O:stop terminal
I: slow gear II:fast gear light High and low Steering

Front wiper
washer control
beam control control
(5). Right handle has three positions (upper, middle and lower) in the vertical direction, upper gear from
self-resetting gear is back to the mid-gear. When the main light switch is turned off, the middle and
lower gears are invalid, the upper gear is overtaking light, and the high beam light is lit. When the main
light switch is closed, the mid-gear is the low beam, the lower gear is high beam, the upper gear is
overtaking light, high and low beam lights both are lit.
Troubleshooting
Combination switch in the electrical system control multiple functions in later chapters for a single function
of the failure analysis.
5-31
3.8 Combination switch (automatic shift)
3.8 Combination switch (automatic shift)

Operation
The combination switch is made up of left and right handles.
(1). Press the end face of the left handle to force unloading; the middle of the left handle is in the middle
position, pushing forward is moving forward, the rear dial is backward.
(2). The knob of the left handle is the shift selector switch;
(3). Right handle pushing forward is the left turn signal light, rear dial is the right turn signal light;
(4). Button on the right handle is for washing/front horn;
(5). The right handle knob is the front wiper switch, 0 gear is closed, rotation forward I gear is the reset
gear, the backward rotation J gear is the slow gear, backward rotation I gear is the fast gear.
(6). Right handle has three positions (upper, middle and lower) in the vertical direction, the upper gear
from self-resetting gear is back to the mid-gear. When the main light switch is turned off, the middle
and lower gears are invalid, the upper gear is overtaking light, and the high beam light is lit. When the
main light switch is closed, the mid-gear is the low beam, the lower gear is high beam, the upper gear
is overtaking light, high and low beam lights both are lit.
Front washer/
Forced unload
front horn
Overtake
Low beam
High beam
Forward Left steering
light
Output Power Output Output
Output Output Output Output Power
Mediate supply Power Earth supply
supply
High and low Front wiper Shift Forward

Steering washer control Backward
Backward Right steering beam control control
control
Control
Selection of gear JJ: wiper reset O: stop light
I:slow gear II: fast gear
Troubleshooting
Combination switch in the electrical system control multiple functions in later chapters for a single function
of the failure analysis.
5-32
3.9 Gearbox controller (automatic shift)

Parameters
1. Rated voltage: 12 V.
2. Rated load: 180 A.
3. Working temperature: -30℃ -80℃ .
Operation
This section briefly describes how to achieve established functions of the electronic controller:
1. Reading the input signal from the machine
2. Have the gearbox to work correctly
3. Read and send data through the CAN bus (optional) and the serial line (optional).
4. Protect gearbox gearbox from harm gearbox management (Gearbox management)
The controller is used for signal gearbox management shown as follows:
(1). By adjusting the pressure on the clutch to drive the proportional solenoid, so as to provide forward and
backward functions.
(2). By adjusting the pressure on the clutch to drive the proportional solenoid, so as to provide the first and
second gear function.
(3). By appropriate adjustment of the pressure on the clutch to drive the proportional solenoid and the dig-
ital control valve, in order to provide the third and fourth gear function.
(4). Understand the operator’s intention: start machine, shift, and so on.
(5). Realize automatic shift function in case of need.
(6). Calculate the machine speed and the output of the drive shaft by the frequency signals measured by
the speed sensor.
Forward/backward management
Pins 18 and 46 are directly connected to the gear control handle, forward and backward signals are de-
tected by these two pins. If when the engine starts, the gear control handle is not placed in the neutral
position, then hanging any gear is invalid for the consideration of safety. When the gear control handle is
placed back in the neutral place, and then put to the forward or reverse gear, the gear engagement will be
effective.
The gear control handle is put in the F position, the machine is in forward condition; put in the R position,
the machine will be in reversing condition.
Gear control handle position FWD(18) RVS(46)

Forward gear ON (12V) OFF (0V)
Neutral gear OFF (0V) OFF (0V)
Reverse gear OFF (0V) ON (12V)
Undefined ON (12V) ON (12V)

5-33
Shift selector position logic

1st: manual mode, 1st gear meshing (if the speed is same as that of 1st gear)
2nd: manual mode, 2nd gear meshing (if the speed is same as that of 2nd gear)
3rd: manual mode, 3rd gear meshing (if the speed is same as that of 3rd gear)
4th: auto mode.
Shifter position Order 1 (19) Order 2 (47)

1st gear ON(12V) OFF(0V)
2nd gear OFF(0V) OFF(0V)
3rd gear OFF(0V) ON(12V)
4th gear ON(12V) ON(12V)

Gear control signal command 1 and gear control signal 2, use the position of the gear control handle to
detect the electric signal, the logic relationship is as follows:
Manual mode: when the operator selects 1st, 2nd and 3rd gear, the system works in manual mode, and
meshes corresponding gears. Before completing the shift, the system will detect the current speed is
suitable shift: If the current speed is greater than a set value (see the Fig. “Maximum Speed”). Therefore,
only until the speed is consistent with the setting value, shift operation can be performed (see downshift
speed protection).
Auto mode: automatic mode will be effective when in the 4th gear; manual selection of 4th gear can not be
achieved. Generally, when the machine is stationary, the 2nd gear is engaged.
Downshift speed protection

In order to shift to the lower gear to protect the gearbox when the machine is in high speed, the downshift
speed protection parameters are as follows:
from to kmph
2nd gear 3rd gear 7.6

5-34
from to kmph
3rd gear 4th gear 17
4th gear 3rd gear 12.7
3rd gear 2nd gear 6.2
Higher gears inhibition

In some cases, ECU setting 3rd and 4th is invalid.
Gears Maximum speed (kmph)

3rd gear 26.5
2nd gear 10.2
1st gear 8.3
(1). When move backwards, the automatic mode 4th gear is invalid.
(2). When using the crab-shaped steering, the 3rd and 4th gears are invalid.
(3). When using the round steering, the 4th gear is invalid.
Kickdown
Forced low button operation is as follows:
(1). Continuous shift from the 2nd into the 1st gear; and then shift from the 1st into the 2nd gear.
(2). When hanging the 2nd gear, the machine speed can be less than 8.5kph.
(3). Without considering gear control handle’s position (forward, backward, or neutral)
(4). The shift (to the 1st, 2nd, 3rd or automatic gear), the forced downshift is invalid.
(5). In the automatic gear, if the 1st gear is engaged, when the speed is faster than 5.5kph, the forced
downshift is to be canceled.
(6). When forced downshift switch handle is pulled up, a toggle switch is switched from turn-off to close.
(7). Whether to activate the speed limit is programmed to control.
Declutch
(1). When power cut-off switch is activated, the gearbox of the main clutch is disconnected.
(2). When the power cut-off switch is in a non-active state, adjust the clutch according to the handle opera-
tion command, and then adjust the power output.
(3). When the toggle switch is turned off, the power cut-off switch is active.
Hydraulic differential lock
(1). Power supply output is connected to the valve through a switch.
(2). 1st or 2nd gear meshing output the enable signal (+12 V).
Four wheel drive
(1). When the 4 WD valve is in the de-energized state, the 4 WD is activated.
(2). When the operator closes the switch, or depress the brakes (brakes on both sides) when in the 3rd or
4th gear, when the gearbox is in 4 WD state. This is a safety protection.
5-35
Wiring diagram
Troubleshooting
Fault: problems in the circuit or wiring caused by poor contact, insulation damage, earthing, or short.
When the sensor is damaged or bad contact, it will generate a fault.
| Warning: when working in an abnormal gearbox conditions, that is, gearbox oil temperature is too high,
wrong operation, and so on.
| When a fault or a warning is generated, in order to protect the safety of the operator, this event will be
processed by the controller, but will allow the machine to travel as much as possible (lame home mode). If
a failure occurred Is very dangerous, in order to protect the gearbox, the controller will cut off all the power
output (in the neutral position).
5-36
Troubleshooting methods:
Neutral position: All controller outputs are cut off and the machine and gearbox can not be driven
Lame home mode 1: You can select forward and back, but can not adjust; allow only 1st gear
Lame home mode 2: you can select forward and back, but can not adjust; allow only 2nd gear
Error/fault code is a numeric code (called DTC, Diagnostic Trouble Code), the code is composed of two
digits (in addition to 2, no error): The first number is shown as a long pulse, the second number is a short
pulse. That is, if you see four long and two short flashes, then this error code is 42, the current highest
priority code will continue to flash.
Handling method
1. Gearbox function is failure, check the fuse; check contacts of the gearbox controller connector are good;
2. Gearbox of a functional failure or working conditions do not meet the operational logic, the display switches
from a fault at the fault code read by the action items in the fault code table to determine the failure mode,
according to the failure mode, determine the point of failure in the wiring diagrams to troubleshoot.
5-37
3.10 Engine ECU (three phase electronic control engine)

Parameters:
1. Electronic control engine adopts its matched electronic control hand and feet throttle;
2. Sensors for oil pressure, coolant temperature and speed signal are provided together with the engine, the
read data is input to the combination instrument from the CAN bus.
Injector of electric control unit
ECM electrpnic controller

Diagnostic
connector
High pressure fuel pump
64 pin connector
Coolant temp
sensor
Oil pressure Exhaust door controller

sensor
Intake pressure
sensor
Cam shaft
speed/timing Intake temp
sensor sensor
Crank shaft/
timing sensor Common rail fuel
pressure sensor
5-38
Wiring diagram
Troubleshooting
1. Check the engine ECU power supply and earth are valid;
2. Check the CAN communication lines from ECU to the combination instrument and shielded wire are valid;
3. Read the fault code on the combination instrument to determine the failure mode;
4. Refer to circuit diagram according to the fault mode, determine whether it is the external line fault or
engine electrical control system failure;
5. After confirm it is the engine electrical system failure, contact the Perkins service personnel.
5-39
3.11 Starting and running fault

3.11.1 Battery
Parameters
20 hours rate capacity (Ah): 100; (It indicates total capacity obtained from the battery, the value is the re-
leased electricity, in A/H unit at 20 hours, below 27℃ .)
Low temperature start current (CCA): 750; (It indicates starting power which the battery can supply the en-
gine in the low temperature; i.e. the value is what the battery is discharged at -18℃ for 30s, A number that
can be released when the battery terminal voltage is 7.2V.);
RC: 180; (It indicates at night or in bad weather, when the charging system is fail, the battery can provide
machine load to work for the minimum time. The value is the time to reach the terminal voltage 10.5V
when discharging in 25A current at 27℃ , in min unit);
Terminal voltage: 12 V;
End column shape: conical.
Safety operation
Sequence of connecting battery wiring: first connect the positive terminal of battery, then connect the neg-
ative terminal.
Sequence of disconnecting battery wiring: first disconnect the negative terminal of battery, then disconnect
the positive terminal.
When the battery positive and negative electrode poles at both ends are accidentally shorted by metal
conductors (such as: metal tools, metal wires, metal parts, etc.), namely the battery occurs external short
circuit, it will cause the arc to melt poles, and cause the molten lead alloy to splash, generate a lot of heat
in the severe condition and cause burning.
Drop or overcharge the battery, it will cause the housing rupture, sulfuric acid may be an outflow from the
rupture or spill.
During the battery charging and testing process, a mixture of oxygen and hydrogen is discharged from
the discharge hole. If the concentration of hydrogen in the environment is more than 4%, it will explode if
encountered fire, sparks or heat.
5-40
Fault judgment of battery

Visual inspection of hydroinstrument condition
If one density instrument installed into the battery is designed on the battery, the density instrument top
has a color point in the top of the battery, in the event that there are unexplained battery failure or starting
problems, visual test the hydroinstrument condition, you may know that the battery current state of charge
and measures to be taken. (Note: Due to hydroinstrument can only reflect the state of a single cell,
sometimes it needs comprehensive judgments combining with the open circuit voltage)
Color Green Black Bright color (white)

Charging status Charge larger than 65% Charge smaller than 65% Electrolyte level is too low
Charge the battery, then do The battery should be
Measure Load test
the load test replaced
Inspection items Cause Handling method Remarks

Above 12.5 V, hydroin-
Normal Load test
strument is green
Between 11-12.4 V, hy-
Undercharge Charging
droinstrument is black
1.Overdischarge (hydrom-
Voltage Charging
eters are black)
2.Short circuit (most hy-
About 10.5 V or less Replacement
drometers are green)
3.Open circuit (most hy-
Replacement
droinstrument are green)
Green zone Normal -
Yellow zone Undercharge Charging

Load test
Undercharge Charging
Red zone Short circuit or open cir-
Replacement
cuit
Maintenance
If terminal is contaminated, wash it with hot water and coated with an appropriate amount of Vaseline (or
butter).
Electrolyte is acidic, avoid clothes and skin being stained, do not splash it into human’s eye. If the event
occurs, wash with water and immediately seek medical attention.
Check the connecting cable of battery post terminal frequently and do keep the cable connector contacting
with the terminal tightly.
The negative wiring of battery should be disconnected if the machine is stored for 15 days or above.
5-41
3.11.2 Disconnect switch

Parameters
Stud thread size: M10
Current continued through the contacts≤ 200A momentary (5S) current: 1200A
Operation
Battery disconnect switch is operated via a switch handle. This switch handle can be turned to the
following two locations.
O - disconnect switch is in the OFF state, the machine electrical system is cut off.
I - disconnect switch is in the ON state, the machine electrical system is powered on.
Note: before using the engine start switch device, you must turn the disconnect switch handle clockwise to
the ON state.
Negative battery switches and their settings
On position Off position

5-42
Wiring diagram
Dome lamp
Troubleshooting
1. When the battery disconnect switch is in the ON position, the starter or the ignition switch should work
properly.
2. If all circuits are not energized, the primary fuse has no fault, check 12V DC voltage of two terminals of the
battery negative poles.
3. If the output terminal is 0V when the switch is turned on and off, then the switch is faulty and should be
replaced.
4. If the disconnect switch input terminal of the battery has no 12V DC voltage, and then check the battery
connections.
5. If the battery connections are good, check the battery voltage. Failed battery voltage measured is less
than 12 V, the battery should be replaced or repaired.
3.11.3 Fuel lift pump (Perkins)

Position
Fuel lift pump is built with the Perkins engine.
Operation
When the electric lock is in ON position, the fuel lift pump power is turned on, begins to work, there is a
slight vibration sound during work.
5-43
Troubleshooting
1. When the electric lock is in ON position, the fuel lift pump is not working, or a fuel lift pump stops working
when the machine is running, causing the machine to be stalled due to lack of fuel, first rule out the fuse
failures.
2. Detect the 2nd pin of the connector C20 is good.
3. Detect 1 pin of fuel lift pump connector C20 is in 12V voltage, if not, it may be open circuit, poor contact
and other problems in the wiring. If so, it may be the fuel lift pump failure.
3.11.4 Oil cut-off valve

Operation
In the existing models, there are two types of oil cut-off valve.
1. Weichai. Switch the electric lock to the ON gear, turn-off electromagnet holds coils to be energized. When
ignition, push and pull coil to get power, and then push the electromagnet to the pull gear; after normally
starting, the electric lock is back to the 0N gear, push and pull coil to cut off power, the electromagnet
maintains in the suction gear location. If the electric lock is closed, maintain the coil to be cut-off powered,
the solenoid is back to its original position.
2. Perkins. If the electric lock is switched to the ON gear, turn off solenoid maintains coil energized until the
electric lock is off.
5-44
Wiring diagram
Troubleshooting
Weichai
1. Electric lock ignition, if flameout solenoid does not pull, detecting whether C17 pin B has 12V voltage, if
no, check the flameout relay is energized. If you do not pull, it is judged that the mediate relay does not
pull, so 320 is not grounded, may not satisfy the starting conditions; if the pull, then check 320 on the line
for open circuit.
2. Electric ignition lock, if the flameout solenoid can be pulled and pushed, but can not hold, test C17 pin A
to detect whether it has voltage of 12V. If not, check the cut-off valve maintaining fuse, and detect whether
there is disconnection in the circuit 301 after excluding safety fault.
3. When the electric lock ignites, if A and B of C17 are normal, C is earthed effectively, and then check
flameout solenoid mounting angle and rod length is reasonable.
Perkins
1. When the electric lock is in the ON gear, detect the 1st pin of C19 has 12V voltage, if not, check the cut-off
oil valve maintaining fuse, detect whether there is disconnection present in the circuit 301 after excluding
the fuse fault. If so, test whether earthing of the 2nd pin is valid. If the voltage and earthing both are
normal, it might be cut-off oil valve failure.
5-45
3.11.5 Ignition switch (electric lock)

Parameters
Operation
1. Insert the ignition switch key and turn to the OFF position. In this gear, the machine’s electrical equipment
is only dome light, the hazard warning lights and cigarette lighter can be used, other electrical equipment
have no power.
2. 1st gear is vacant.
3. Turn the starter switch key clockwise to the II gear position, the switch will remain in this gear after let it go, the
following electrical equipment is energized and working normally.
4. Turn the starter switch key clockwise to the III gear position, the switch will spring back II gear position
under the spring pressure after let it go. In the III gear location, the following electrical equipment is
energized besides electrical equipment energized in the II gear location.
5-46
Wiring diagram
Troubleshooting
Measure the conduction condition between the terminals in all positions of the starter switch with a
multimeter(for more information see chapter test with a multimeter), and record the conduction test. Compare
recorded values with expected ones, which are shown as below. The pained black portion in the table
indicates that the terminals are conductive.
If the following situations occur, replace the starter switch:
1. The obtained parameters by measuring the start switch do not match exactly those in the above table.
2. Reset function of the starter switch spring is fail.
3. Start switch key may be inserted or removed in any position, not only in the OFF position.
Check the starter switch connection
5-47
3.11.6 IGN start signal

Operation
1. Meet the starting conditions (cut off the power of the foot brake and hand brake, the handle neutral
position, shift handle unloading)
2. The alternator does not work before starting, the charging relay is pulled in, and the starter protection relay
does not pull in. When the electric lock is turned to the ignition gear, the power supply is connected with
the electric lock by fuses. The starter protective relay contacts supply power to the relay coil, the starter
relays are pulled together, the starter motor S terminal is energized, the starter motor begins to work.
3. When the electric lock is in ON gear, the flameout solenoid keep coil being energized, until the electric
lock is turned off. When the electric lock is switched to the ignition gear, the sliding end of the flameout
solenoid is energized, the plunger is pushed to the suction position, pulled by the holding coil.
4. After the alternator starts working, the charging relay is cut off. The starting protection relay is pulled,
starter relay is disconnected, and the starter motor stops to work, play a protective effect. The Electric lock
is back from the ignition position to the ON gear, when back to the ignition gear, the starting relay can’t be
pulled because of the starting protective relay is pulled, and the starter motor will not work.
5-48
Wiring diagram
Troubleshooting
1. Check whether voltage meets the starting conditions (< 12.5V);
2. The machine does not start, check whether it meets the starting conditions, if met, check whether the
neutral starter relay is pulled, starter relay coil is earthed through the neutral starter relay; if not, eliminate
faults in the wiring.
5-49
3. When starting, check the starter relay is pulled, if not pull, check the wire (from the power supply to the
fuse by the electric lock to the start protective relay contacts in the fuse box) is faulty;
4. Check the charge relay is pulled, the starter protective relay coil is grounded not passing the charging
relay contacts. If the charging relay is pulled, then check the alternator D + terminal is normal;
5. During the ignition, if starter relay of the starter motor is pulled, it can not be started, check the flameout
solenoid (Weichai)/cut-off valve (Perkins) is faulty.
3.11.7 Forward and backward/backward alarm (synchronization shift)

Parameters
Voltage range: DC12V-33V
Current: ≤0.5A
Polarity: positive and negative polarity protection
Sound level: when in DC24V, the maximum sound is 110 ± 10dB (A)
Interval: 0.9Sec
Quota of work: continuous operating frequency 1K ± 2% K
Operation
1. After starting the machine, determine besides the forward and backward handles are in the neutral
position, the other starting conditions are not met, the power supply is via fuse box fuse 6, provide power
to the front alarm unit neutral indicator light by the handle.
2. In the electric lock in the ON gear, push forward the left handle of the combination switch to the forward
gear, the power is supplied to the forward/backward relay coils via the fuse box fuse 6 and through the
handle switch, the forward/backward relays are pulled, the power is supplied to the forward valve through
relay contacts.
3. If the electric lock in the ON position, push backward the left handle of the combination switch to the
reverse gear, the power is supplied to the forward/backward relay coils via the fuse 6 in the fuse box and
through the handle switch, then forward/backward relay sucks close thus to supply power to forward valve
and back-up alarm through relay contacts.
5-50
Wiring diagram
Troubleshooting
1. If the machine is started, unable to move forward and backward, check the fuse; moreover check whether
the neutral relay is pulled. If pulled, check whether the following switches are closed: the hand brake
switch, shift handle unloading switch, foot brake switch, outrigger alarm switch. Check the forward/
backward relay connector terminals for poor contact. Check the voltage between the fuse box to the relay
wiring, and determine whether there is an open failure.
2. If the machine is started, unable to move forward or backward, examine the handle and the forward /back
relay, and then use the multimeterto determine points of failure according to the gear condition and circuit
diagrams.
3. If the above are all have no problems, check the solenoid valve connectors are faulty. After exclusion of
all faults and in the openness of the electric lock, switch the forward and backward gears, forward and
backward valves have actions, then check the hydraulic system.
5-51
3.11.8 Outrigger alarm (optional)

Parameters
Brake light switch assembly is a mechanical constant-off switch, in the normal state, the extension rod is in
the extended state, and the switch is in the closed mode. After the extension rod is compressed 3 ~ 5mm,
the switch is in the off mode, the disconnected mode extension rod stroke has 3 ~ 5mm.
1. plate 2. brake switch
Operation
1. After passing No.3 fuse in the fuse box, the power supply is supplied to the neutral starting relay coils of
the steering machine, after passing contacts of hand brake neutral relay R22 and outrigger alarm switch.
2. After the machine starts and exclusion of other starting conditions, if the left and right outriggers are not
closed, then the outrigger alarm switch is in the closed state, the neutral starter relay coil is energized, and
the neutral starter relay is closed, earthing of the forward/backward relay coil is disconnected, the crane
can not move forward and backward. The buzzer alarms until the outriggers recover in place, forward/
backward limits and alarm is released.
5-52
Wiring diagram
Troubleshooting
1. If the outrigger alarm function fails, check the fuse box on the No.12 fuse; use a multimeterdetection
function to detect on-off between the two terminals, and judge whether the brake light switch is failure; use
a multimeterto check whether there are fails in the wiring according to the circuit diagram.
2. If the outrigger alarm persists, check the installation status of the outrigger alarm switch, whether it can not
be compressed to disconnect.
3.11.9 2WD/4WD shift (synchronous shift)

Operation
1. Only 2WD function, do not install 2WD/4WD switch, 2WD/4WD relay, 120OR and 313a are shorted,
2WD/4WD valve has been energized, keeping 2WD.
2. There is 2WD/4WD function, 120OR and 313a are cut off, 2WD/4WD switch in the closed position,
2WD/4WD is power off, 4 WD mode.
3. Bilateral brakes, forced 4 WD;
4. When drive in the 4th gear, forced 2WD; in 4th gear, unilateral brake is the same with bilateral brakes,
brake is override, 4 WD mode.
5-53
Wiring diagram
Troubleshooting
Prop up the machine, if the 2WD/4WD mode does not match the operation, refer to circuit diagrams, and
check wiring corresponding to failure.
3.11.10 Shift handle unloading (synchronization shift)

Parameters
Handle switch: self-reset switch
Operation
1. One of the machine starting conditions, press and hold the shift handle unloading switch, the machine can
be started. After the machine starts, then release the switch.
2. When the machine is running, press the shift handle unloading switch, it can cut off the forward and
backward driving force.
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Wiring diagram
Troubleshooting
1. If it can not serve as starting conditions, check the switch mechanical structure is normal; use a
multimeterto check whether there is open circuit fault in the wiring reference circuit diagram check.
2. If the machine is started and excluding other issues, it still can not move forward/backward, check switch
is malfunctioning and can not be reset.
3.11.11 Load/unload excavation handle

Parameters
Handle switch: self-reset switch
Operation
1. During loading/excavating work, press the unloading button on the loading/excavating handle, the conflu-
ence relay is pulled, power is supplied to the unloading solenoid valve coil via confluence relay contacts,
so that unloading solenoid valve is pulled to reduce flow.
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Wiring diagram
Troubleshooting
1. During the loading and excavation operation, press the button but cannot unload, check the fuse failure;
2. Check whether mechanical structure of the switch is normal;
3. Press the switch, use a multimeterto test whether there is 12V on the terminals of the confluence relay
coil, if so, the relay is not energized, the relay may be faulty;
4. Use a multimeterto check whether there is disconnection fault in the wiring according to circuit diagrams.
3.11.12 Differential lock (synchronous shift)

Operation
1. Close the differential lock switch, power is supplied to the differential lock alarm indicator of the differential
lock valve and front alarm unit, via the fuse 14 to the 4th gear relay contacts then to differential lock switch.
2. When drive and the gear is in 4th gear, the 4th gear relay will be closed, power supply of the differential
lock switch is cut off, differential lock function is invalid.
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3.12 Display and alarm malfunction
Wiring diagram
Troubleshooting
1. Differential lock switch is invalid after being closed, check the fuse;
2. Check the 4th relay is pulled, if yes, check partial wiring of the 4th sensor.
3. Use a multimeterto check whether there is disconnection fault in the wiring according to circuit diagrams.
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3.12.1 Engine oil pressure warning (mechanical engine)
Position
Parameters
Switch type Pressure set value Remarks

Perkins Constant-off switch 0.88bar Engine self-contained
Weichai Constant-off switch 0.88bar Purchasing
Operation
When the electric lock is switched to ON gear, the instruments are powered. When the engine oil pressure
is too low, oil pressure switch is closed, the instrument pin 5 is earthing, and the alarm indicator is lit. If
the engine is running, the pin 14 outputs signals, the buzzer gives alarm, and the front alarm unit alarm
indicator lights.
Wiring diagram
Troubleshooting
The Jumper connect the oil pressure switch signal terminal and the ground, the instrument oil pressure
warning light is lit, oil pressure alarm switch may be faulty; if the light is still not lit, check whether pin 5 of
the instrument is earthed, it may be instrument failure if earthing, wiring fault if not earthed.
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3.12.2 Engine water temperature display alarm (mechanical engine)

Parameters
When connecting engines from Weichai, Cummins and YTO, parameters of the engine water temperature
sensor are as follows:
Temp (℃ ) Resistance Tolerance

40 596.5 Ω ±11.5Ω
60 267Ω ±4 Ω
80 127.5 Ω ±1.5 Ω
100 65.5 Ω ±0.5 Ω
105 58 Ω ±1 Ω
120 37.5 Ω ±0.5 Ω
When connecting to Perkins engine, water temp sensor parameters are as follows:
Temp (℃ ) Resistance Tolerance

40 500Ω ±11.5Ω
60 170Ω ±4 Ω
80 77Ω ±1.5 Ω
100 39Ω ±0.5 Ω
105 33 Ω ±1 Ω
120 23.4Ω ±0.5 Ω
Operation
When the electric lock is switched to ON gear, the instrument is powered; the water temperature gauge
reads the current temperature reading. When the water temperature exceeds 105 degrees, the indicator
begins to alarm, pin 14 outputs signals, and the buzzer gives alarm, the alarm indicator of the front alarm
unit is lit.
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Wiring diagram
Troubleshooting
1. If the combination instrument water temperature reading is not normal, check whether there is open or
short circuit faults; check wiring between No.22 and 23 pins of the combination instrument and the harness
is correct.
2. If the wiring is troubleshooting, check whether the coolant temperature sensor and switches are faulty.
Provide heat, determine whether the relationship between resistance and water temperature conforms to
requirements of the factory according to the above table.
3.12.3 Gearbox oil temperature warning (synchronous shift)

Parameters
Operation
When the electric lock is switched to ON gear, the instrument is powered, when the gearbox oil tempera-
ture exceeds the set temperature, gearbox oil temperature alarm switch is closed, the instrument gearbox
oil temperature alarm indicator is lit, and pin 14 outputs signal, the buzzer sends out alarm, alarm indicator
of the front alarm unit is lit.
Troubleshooting
1. If the gearbox oil temperature alarm of the combination instrument is abnormal, alarm or not alarm
continuously, check for open or short circuit fault;
2. If the wiring is troubleshooting, check the gear oil temperature alarm switch is faulty. Provide heat, test the
connection of No.3 and 2 pins of the C39 by the multi instrument under the condition that temperatures is
higher than the specified ones, and judge whether the gearbox oil temperature alarm switch is faulty.
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3.12.4 Gearbox oil pressure warning (synchronous shift)

Operation
When the electric lock is switched to ON gear, the instrument is powered, when the gearbox oil pressure
exceeds the set pressure, gearbox oil temperature alarm switch is closed. If the starting conditions are
not satisfied, the neutral starter relay does not pull, making the No.1 pin of the combination instrument to
ground, gearbox oil temperature warning indicator is lit. No.14 pin of the combination instrument outputs
alarm signals to the buzzer. When the machine is running and the alternator begins to generate electricity,
the earthing terminal of the buzzer is effective and starts alarming;
Constant-off switch 9Bar Synchronous shift
Constant-on switch 9.5Bar Self-automatic gearbox box
Troubleshooting
1. The jumper shorts the gearbox oil pressure alarm switch to meet starting conditions; if alarm, check
whether the neutral starter relay is energized; if starting conditions is not satisfied and not alarm, check the
wiring for open circuit fault;
2. If the first step is excluded, it may be gearbox oil pressure alarm switch failure. Use simple hydraulic test
stand, and set the pressure to the set value, use a multimeter test two terminals of the pressure switch. If
it reaches the set value, constant-on switch is closed, constant-off switch is disconnected, then it indicates
that pressure switch is intact. On the contrary, the pressure switch is damaged;
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3.12.5 Speed signal (mechanical engine)

Parameters
Because different engine speed sensors mounting holes have different specifications, different engines
are configured with different speed sensors; flywheel teeth are different, signals input from the speed
sensor to the instrument are different, wiring is different.
To Weichai engine, No. 1p and 2c of the instrument harness are not connected; to Perkins engine, No. 1p
of the instrument harness is grounded; to Cummins engine, No. 2c of the instrument harness is earthed.
Weichai: Voltage: 12V; operating temperature: -30℃ ~ 120℃ ; resistance between two terminals: 1150 ±
100Ω; installation size: M18 × 1.5-6g.
Perkins: 12V; operating temperature: -30℃ ~ 120℃ ; resistance between the two terminals: 1150 ± 100Ω;
Installation size: M16 × 1.5-6g.
Operation
When install, the sensor end face should be perpendicular to the top surface of the flywheel, its distance is
1 ~ 1.5mm;
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Troubleshooting
1. If the tachometer reading is not normal, use a multimeter to test the resistance between the two terminals
of the speed sensor. If the resistance value is tested to be 1150 ± 100Ω, then the tachometer sensor is
intact; if the resistance vale is infinite, then the speed sensor is damaged;
2. Well as speed sensor, tachometer normal, but speed is not displayed, it can be tightened to the limit speed
sensor position, passed on a ~ 1.5 pitch before testing;
3. If the first two steps have no problems, then the wiring is faulty, which should be excluded.
3.12.6 Air filter clogging alarm

Operation
1. If the air filter is faulty, air filter switch is closed, the combination instrument alarms.
Troubleshooting
1. If the air filter is clogged, the combination instrument does not alarm, check the air filter blockage switch is
closed;
2. If the air filter switch works properly, check the wiring is faulty.
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3.12.7 Fuel sensor

Parameters
Fuel level Basic resistance Basic tolerance

0 190.2 ±5
1/2 88.6 ±3
1 43 ±2
Operation
Slide rheostat pushes the float of the sensor to move through changes of fuel level in the fuel tank, there-
by change the resistance value of the sensor. Detect the oil level changes by measuring changes of the
resistance value.
Troubleshooting
1. Fuel gauge has been in full range, check the fuel sensor wiring terminals are shorted to the ground;
2. Fuel gauge has been in full range, check the fuel sensor wiring terminals are opened to the ground;
3. Check the fuel sensors if the wiring has no fault:
(1). Check whether the float is able to changed according to the oil level;
(2). If the float has no problem, then manually move the float, test resistance value of the sensor to see
whether the changes confirm to the above table;
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3.13 Lighting fault
floater
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3.13 Lighting fault
3.13 Lighting fault

3.13.1 Brake light
Position
Hand brake light switch is located below the handbrake, foot brake switch is located on steering column.
Brake lights are located at the rear and outriggers of the driving top and in red.
Parameters
Brake light switch assembly is a mechanical constant-off switch, in the normal state, the extension rod is in
the extended state, and the switch is in the closed mode. After the extension rod is compressed 3 ~ 5mm,
the switch is in the off mode, the disconnected mode expansion rod stroke has 3 ~ 5mm.
Operation
1. When the electric lock is in ON gear, the forward/backward handle is not in the neutral position, the hand
brake neutral relay does not pull; when the handbrake is pulled, the hand brake switch is turned on, the
hand brake indicator on the combination instrument is lit, brake light is lit. When forward/backward handle
is in the neutral position, the hand brake neutral relay is pulled, power is disconnected, the hand brake
lights are invalid;
2. When the electric lock is in ON gear, depress the left/right brake, foot brake switch is turned on, the power
supplies the brake light relay coil via the foot brake switch, and the brake light relay is pulled, power is
supplied to the brake light via the relay contacts of the brake light, brake light is lit;
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3.13 Lighting fault
Wiring diagram
Troubleshooting
1. Hand brake light switch fault
1. Inspect fuses; checking whether fuses have 12V voltage, if no, check the main power wiring and
electric locks;
2. If the electric lock is in ON position, forward/backward handle is not in the neutral position, pull the
hand brake, the brake light is not lit, check whether the hand brake pulls the mediate relay in place; if
energized, check the combination handle forward/backward gear is faulty; if without pull, then go on
the next step;
3. Check whether the brake lights relay is pulled, if not pull, check the coil terminal voltage and the
earthing are valid. If effective, check whether the relay is faulty; on the contrary, check the hand brake
switch and diode relay R6 are faulty, wiring from the hand brake neutral relay contact terminal to the
relay coil circuit is faulty. If the brake light relay is pulled, proceed to the next step;
4. Check the voltage at the fault brake light and earthing are valid, if valid, check that the bulb is
damaged; if invalid, then check whether the wiring is fault.
2. Foot brake light switch fault
1. Inspect fuses; checking whether fuses have 12V voltage, if no, check the main power wiring and
electric locks;
2. Electric lock is in ON position, depress the left/right brake, and check whether the brake light relays
are energized. If it does not pull, check the coil terminal voltage and the earthing are valid. If effective,
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3.13 Lighting fault
then check whether the relay is faulty; if invalid, check the left and right foot brake switch and diode
relay R7 are faulty. The wiring from the fuse 3 via the foot brake light switch, diode relay R7 to the
brake light coil contacts is faulty; if the brake light relay is pulled, proceed to the next step;
3. Check the voltage at the fault brake light and ground are valid, if valid, check that the bulb is damaged;
if invalid, check the wiring from the No. 3 fuse via brake light coil contacts to the brake light is faulty;
3.13.2 Turn signal light

Position
Turn signal light is located on the right handle of the combination switch. Turn signal lights are located at
the driving top rear, outriggers, front main lights, and in amber.
Operation
If the electric lock is in ON position, the hazard signal light switch is in 0 gear. After passing the fuse 5,
power is supplied to the turn signal light switch of the combination switch, after through the hazard signal
light switch to connect with the flash relay, and changed into a pulse signal by the flash relay.
Push the right handle of the combination switch, connect the left turn signal light, the left turn signal light is
lit; if dial backwards, connect the right turn signal light, and the right turn signal light is lit.
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3.13 Lighting fault
Wiring diagram
Troubleshooting
1. Check fuse;
2. Hazard signal light switch is in the 0 gear, open the turn signal light switch, the left and right turn signal
lights are off; check whether the fuse has 12V voltage; if no, check the main power wires and electric
locks;
3. Check the combination open steering switch meets the factory requirements. Check fault turn signal light
power and earthing are valid, check whether the bulb is damaged if effective;
4. Check the hazard signal light switch meets the factory requirements;
5. Check whether flash relay 12V input voltage, if not, check the fuse to flash relay input line; if it has an
input, no output, check the flasher relay is faulty.
6. Check the combination open steering switch meets the factory requirements. Check the combination
switch to turn signal lights lines.
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3.13 Lighting fault
3.13.3 Clearance light

Position
Clearance lights switch realized by the main light switch, main light switch is located on the steering
gearbox housing.
Operation
The main light switch to 1 gear, the power is supplied to the front combination light clearance lights,
rear combination light clearance light (777A outriggers), rear combination light clearance lights (cab roof
777A/766A), license plate light, the former alarm unit clearance light indicators, combination instrument
backlight, switch backlight through the fuse.
Wiring diagram
Hydraulic hammer sw Front work light sw Rotating signal light sw
Rear wiper switch

High- and low-voltage unloading sw Rear work light sw
Clamp sw (backhoe side) Rear wiper switch

Differential sw
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3.13 Lighting fault
Troubleshooting
1. Check fuse;
2. Check whether the fuse at 12V voltage, no, check the main power lines and electric lock;
3. Outline clearance lights and backlight are off, check the main light switch connector pin 2 if there is 12V
voltage, if not, then check the fuse to the main light switch circuit; if so, check the main light switch meets
the requirements of the factory;
4. Check whether there is fault lights 12V voltage, whether earthing is valid; checking fault light to the main
light switch between line is faulty.
3.13.4 Main light switch

Position
The main light switch is located on the direction of machine housing.
Operation
1. 1st gear is the main light switch backlighting and clearance lights, 2nd gear combination switch provide
power to light switch.
2. The main light switch is turned off or 1st gear. Combination switch light switch 0 gear, 1st gear is not valid,
playing to 2nd gear, high beam light. 2nd are self-resetting gear from reset to 1st gear.
3. The main light switch is in the 2nd. Combination switch light switch 0 gear, high beam light is on; 1 gear
low beam light is on; 2nd gear, high and low beam light illuminate simultaneously.
4. Combination switch light switch 2nd gear as ultra lights while driving use, when overtaking, hit consecutive
three under the high beam light.
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3.13 Lighting fault
Wiring diagram
Troubleshooting
1. Check fuse;
2. The main light switch 0/1st gear combination switch light switch 2nd gear, high beam light does not
light, check whether the fuse at 12V voltage, no, check the main power lines and electric locks; Check
combination switch light switch meets factory requirements; checking high beam light power and earthing
is valid, if valid, check the bulb is damaged; exclude component failure, check whether the fault line.
3. The main light switch 2nd gear, combination switch light switch to 0/1st/2nd gear, the corresponding light
is not lit, check whether the fuse has 12V voltage, if no, check the main power lines and electric locks;
Check combination switch light switch meets the requirements of the factory; checking power and ground
fault lights are valid, if valid, check the bulb is damaged; exclude component failure, check whether the
fault line.
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3.13 Lighting fault
3.13.5 Front/rear work light

Position
On top of the cab, before and after each 4.
Parameters
(outside) (12V/35W)
(inside) (12V/55W)
Quantity: backhoe loaders has 8 work lights, 4 in front, 4 in the rear, 2 is a group inside and outside.
Operation
In backhoe loaders, only after the engine is started, work lights before they can work. This control relay
controlled by the charger negative control, the engine does not start, the charging relay is closed, control
end earthing work light relay is cut off, at this time, work lights do not work; engine is started, the charging
relay is off, work lights relay control terminal is earthed connection at this time, work lights by the work light
switch control tasks. Work light switch has two gears: frong and rear. 1st gear outside work lights front and
rear, 2nd gear, both inside and outside lights go on.
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3.13 Lighting fault
Wiring diagram
Oil cut-off valve(hold)
Troubleshooting
1. Check fuse 13 and 17;
2. If the machine is started, all work lights are off, check the charge relay is disconnected, work light relay
control terminal is earthed. If the charging relay remains closed, check the alternator is faulty, check the
charging relay and alternator D + connection is faulty;
3. Check whether there is trouble work lights 12V voltage, whether earthing is good. If so, then check
whether the fault work lights; if not, check whether the light switch meets factory requirements;
4. Excluding electrical component failure, refer to the schematic diagram to check if there’s fault line.
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3.13 Lighting fault
3.13.6 Hazard signal light

Operation
Disconnect switch is closed, the fuse 21 is energized, hazard signal ights switch is closed, the power
supply through the fuse 21, turn flash relay, provides power supply to turn signal lights, left and right turn
signal lights are on.
Wiring diagram
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3.13 Lighting fault
Troubleshooting
1. Disconnect switch is closed, check the fuse is failure, check whether the fuse at 12V voltage, if not, to
exclude the fault between disconnect switch the fuse box;
2. Use a multimeterto check the hazard signal light switch off the situation meets the requirements of the
factory;
3. Check the turn signal light at the power supply has voltage of 12V, earthing is valid; exclusion, check
whether the turn signal light is faulty;
4. Excluding electrical component failure, the reference circuit diagram checking line fault.
3.13.7 Dome light

Position
On the cab roof.
Operation
According to national standards, dome lights without electric lock, take power directly from the battery.
After turn off disconnect switch, toggle button on the dome ligth to the closed position, dome light goes on.
Troubleshooting
1. Check fuse;
2. Check whether there is 12V voltage in dome light connector 2 pin and 1st pin earthing is valid; if are intact,
check whether the dome light bulb has failure; whether dome light switch structure is invalid;
3. Refer to wiring diagram using a multimeter check whether there is a fault line.
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3.13 Lighting fault
Dome lamp
3.13.8 Rotating beacon (optional)

Position
Rotating beacon is located right in front of the cab at the top, rotating beacon switch is located on the
instrument panel measured. Rotating beacon with the rotary beacon switch is optional.
Parameters
Working voltage: 10.8V ~13.8V
Working conditions: -20℃ ~ 60℃
Operation
Electric lock is ON, Fuse 16 is energized, closed rotating beacon switch to the ON position. Rotating
beacon switch and rotating beacon switch are connected to indicator, powered.
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3.13 Lighting fault
Wiring diagram
Rotating beacon SW
Troubleshooting
1. Check fuse;
2. Rotating beacon is closed, check rotating beacon whether the connector 2 pin 12V voltage, and 1 pin
earthing is valid; if they are intact, check the rotating beacon is faulty;
3. Use a multimeter to check rotary beacon switch off the situation meets the requirements of the factory;
4. Refer to wiring diagram using a multimeter check whether there is a fault line.
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3.14 Work system fault

3.14.1 Level the bucket
Parameters
Bucket flat limit switch: constant-off switch
Operation
When loading end is working, close fight, it will load the operating handle to play to the limit position, power
is supplied by the fuse 14 flat by the bucket flat limit switch to provide power to the bucket lock valve, lock
the operating handle will be loaded until the bucket is reset, bucket flat limit switch is disconnected, loader
buckets unlock the lock valve, loading the operating handle back into position.
1. Approach switch 2. Guide rod
Troubleshooting
1. Check the fuse, the bucket flat limit switch performance, line;
2. If the first step in checking intact, loader buckets lock valve tremble not reset state power ground are valid,
then check out the bucket lock valve failure.
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3.14.2 Unloading
Operation
In 777A/766A electrical systems, loading handle unloading switch, backhoe handle unloading switch, high
and low pressure unloading switch, hydraulic hammer switch can play unloading functions.
Loading handle unloading/backhoe handle unloading: loading handle unloads/backhoe handle unloading
is closed, the confluence relay pulls, power is supplied by the fuse 11 by merging the relay contacts to
unloading solenoid valve power supply.
High and low pressure unloading switch: loading handle unloading/backhoe handle unloading is not
closed, the confluence relay does not pull, power is supplied by the fuse 11 through high and low pressure
unloading switch and confluence relay contacts to the unloading solenoid valve.
Hydraulic hammer switch: hydraulic hammer switch is closed, the power is given by the fuse 11 unloading
solenoid valve.
Wiring diagram
5-80
Troubleshooting
1. Check fuse
2. Loading/backhoe handle unloading switch fails, press the loading handle unloading switch, check
hydraulic hammer relay power and earthing is valid; if effective, inspect hydraulic hammer solenoid valve
failure; if invalid, check the power supply to the fuse 12 via relay contacts to hydraulic hammer solenoid
circuit failure.
3. High and low pressure unloading switch fails, press high and low pressure switches.
4. Hydraulic hammer switch fails, press hydraulic hammer switch.
3.14.3 Hydraulic hammer switch

Position
Hydraulic hammer switch is in the side of the instrument cover, hydraulic hammer pedal on the floor of the
cab excavation side.
Operation
After starting the machine, press the hydraulic hammer switch, hydraulic hammer relay pulls, unloading
valve is energized, the power supply 12 through fuse through contacts to hydraulic hammer valve powered
by hydraulic hammer pedal control valve earthing. When hydraulic hammer pedal switch is depressed, the
switch is closed, the solenoid valve hydraulic hammer earthing, hydraulic hammer begins to work.
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Wiring diagram
Troubleshooting
1. Check fuse 11# and 12#;
2. Electric lock is ON gear, close hydraulic hammer switch, check whether the unloading valve connector has
12V voltage. If not, check the line; when unloading valve power and earthing are valid, unloading valve
does not work, unloading valve may be faulty.
3. Electric lock is ON gear, close hydraulic hammer switch, check the hydraulic hammer switch connectors
C69 6,1,2,5 whether there is 12V voltage, if there is voltage 6,1,2,5 not, check the hydraulic hammer
switch meets the requirements of the factory; if 6 there is no voltage, check the fuse to the hydraulic
hammer switch circuit;
4. Electric lock is ON gear, close hydraulic hammer switch, press hydraulic hammer pedal switch, hydraulic
hammer relay does’nt pull, check the hydraulic hammer relay coil power and earthing is valid; if invalid,
check the line; if valid, check whether the hydraulic hammer relay has failure;
5. Electric lock is ON gear, close hydraulic hammer switch, press hydraulic hammer pedal switch, hydraulic
hammer relay pulls, check the hydraulic hammer relay power and earthing is valid; if valid, check if
hydraulic hammer solenoid valve failure; if invalid, check if the power supply to the fuse 12 through
hydraulic hammer relay contacts to the solenoid valve circuit of hydraulic hammer has failure.
If no electrical fault, when the machine operating, there’s clamping failure, it may be a hydraulic system
failure.
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3.14.4 Clamping valve switch (777A)

Position
Clamping valve switch is located on measuring instruments cover.
Operation
When machine is operating, adjust the excavation side excavation arm position, press the clamping valve
switch, clamping valve is energized, the clamping excavation end support under the action of the clamping
cylinder grips.
Troubleshooting
1. Check fuse 11#;
2. Electric lock is ON gear, clamping switch is closed, check the power of clamping valve end and earthign is
valid; if valid, then check whether the clamping is faulty;
3. Check the clamping switch meets the requirements of the factory;
4. Electrical components are no failures, check the fuse 11 to clamping valve is faulty;
If no electrical fault, when the machine operating, the clamping failure, may be a hydraulic system failure.
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3.14.5 Fan (optional convertible)

Position
Located in the right side of the cab roof
Operation
Electric lock ON position, toggle switch on the fan, fan works.
Troubleshooting
1. Check fuse 10;
2. Electric lock is ON gear, check whether there is 12V voltage in fan power supply terminal; if no, check the
fuse 10 to fan lines;
3. If the fan power supply and earthing are effective, fan may have failure.
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3.14.6 Radio
Position
Radio is located in side of the instrument hood, roof antenna is located right behind the cab.
Parameters
Working voltage: 10-13.6 V
Working temperature: -20~70℃
Max. output power: 10W+10W
Configuration: two horns, a USB port, an antenna. Hosting control panel designed as a closed structure to
ensure waterproof and dustproof.
Operation
Operating instructions, see the radio operation manual. Only when the starter switch is not in the OFF
position when you can use the radio.
Troubleshooting
1. Check fuse
2. Electric lock is in the OFF gear, check if the voltage of pin 2 of the connectors C87 is 12V, no, check the
fuse box to the radio circuit;
3. Electric lock is in the ON gear, check if the voltage of pin 1 of the connectors C87 is 12V, no, check the
fuse box to the radio circuit;
4. If the measurement to determine the power supply and earthing are no problem, presumably radio or horn
failure.
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Power Control
Combination instrument panel

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3.14.7 Front wiper/ washer

Position
Front wiper is located on the front window glass, the front wiper motor is in the front steering gear box
hood. Front wiper, washing switch are in combination switch on the right handle.
Operation
Control:
1. There are 2 gears on wiper:
II gear rotates from the combination handle to II gear, wipers work intermittently, intermittent time is longer;
II gear rotates from the combination handle to II gear, wipers work intermittently, intermittent time is
shorter;
2. Press washer switch, nozzle plays water, wiper continuous scraping action.
Motor wiring diagram
Front wiper, angle 105°
Control loading
Wiper motor: socket (DJ7061-6, 3-11), piece (DJ611-6.38)

(+) red (-) black
Low speed (green) Reset (white)

High speed (blue)
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Wiring diagram
Troubleshooting
The first step: wiper motor is generally low level control, when the dysfunction occurs when the wiper
motor comes with the red wire to the power B +, black wire to the power B-, another control lines detect
the function corresponding to each of the wires according to electrical schematic diagram (B-);
The second step; currently wiper does not work, but after testing the power input, check the wiper brush
mounting position is reasonable, swing around scope and tightness of mounting bolts can cause the wiper
does not function to work; checking wiper motor drive institutions intact, whether to complete the driving
function.
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3.14.8 Rear wiper/washer

Position
Rear wiper switch is in the side of the instrument panel, the rear wiper controller is located in side
instrument hood, installed on the air evaporator. Rear wiper is installed on the rear window.
Operation
Cab rear wiper switch control rear wiper controller. Rear wiper controller provides power supply by the
fuse 8 and continued supply.
1. When the wiper switch is not energized, the wiper motor is always energized for reversing wiper to its
stop position. Divided into two gear wiper with wiper switch control: I gear, click the switch, wiper work
intermittently, intermittent time is 5s. II gear, and then click the switch, wiper continuous work;
2. Press washer switch, nozzle plays water, wiper continuous scraping action.
Rear
Rear wiper, angle 95° wiper motor
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Wiring diagram
Rear wiper switch
Rear wiper switch
Motor low speed control
Intermittence 5s control
Washer control
Washer motor anode
Door control (Active-high)
Rear window switch
Motor inverse control
Motor sequence control
Motor forward
Motor reverse
Motor reset cathode

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Troubleshooting
1. Open the electric lock and the switch is turned on, turn off the rear window, and then use a multimeter to
measure the voltage of the following terminals of the rear wiper controller C91.
When the wiper is in the stop position, measure terminal 12 and it should be 12 V;
When the wiper position in the 1st gear, measure terminals 6 and 4, there should be 12 V;
When the wiper position in 2nd gear, measure terminals 6 and 14, there should be 12 V.
When washing switch is closed, the measurement terminals 6, 3 and 1 should be 12 V.
2. If the above measurement all have corresponding voltage, and the wiper does not work, replace the wiper
motor.
3.14.9 Front horn (synchronization shift)

Position
Front horns are located above the battery, inside the front cover door. Front horn switch is located on the
right handle end face of the combination switch.
1. Power supply 2. Earth terminal 3. button
Parameters
Voltage: 12 V;
Current: 4A;
Using temperature: -40℃ ~+85℃
Operation
Press the load-side combination switch located in the cab at the top of the right handle horn button, horn
will sound.
5-91
Annex1 (continued)
Wiring diagram
Compressor soleniod clutch
Hron
Troubleshooting
1. Check the fuse No.1,9 is normal, if broken, replace it;
2. Press the front horn switch, use a multimeterto check horn voltage and earthing is valid; if valid, then
check whether the horn has fault; no voltage, the next step;
3. Press the horn switch, use a multimeter to check the conduction through the horn switch case. If you do
not turn, check the combination switch. If there is continuity, check the horn relay is energized, if not pull,
check the fuse 9 through front horn switch to the coil circuit is faulty;
4. Check the fuse 1 has failure between horn relay contacts and horn lines.
5-92
3.14.10 Rear horn

Position
Rear horn is located in the rear part of frame. Rear horn switch is located on the excavation side control
lever.
Parameters
Voltage: 12 V;
Current: 4 A;
Using temperature: -40℃ ~+85℃
Operation
Press the horn button on the left lever top of the cab excavation end, horn will sound.
Troubleshooting
1. Check the fuse No. 1 is normal, if broken, replace;
2. When pressing the rear horn switch, use a multimeter to check horn voltage and earthing is valid; if valid,
then check whether the horn fault; if no voltage, the next step;
3. Press the horn switch, use a multimeter to check the conduction through the horn switch. If there is no
conduction, replace switch. If turned on, check if rear horn relay pulls; if it doesn’t pull, check the relay coil
earthing to the rear horn switch to coil line;
4. Check the fuse 1 has failure between rear horn relay contacts and horn lines.
5-93
Hron
3.14.11 Cigarette lighter

Position
Cigarette lighter is located on the side instrument panel AS.
Parameters
Power: 12V/108W; current ≤ 9A
Ambient temperature: -45℃ ~85℃
Operation
Press the cigarette lighter button until it locks into the socket in a few seconds after the lock release button
will automatically pop up, remove the cigarette lighter.
Note: The other side coils of the cigarette lighter has been heated, hot coil can cause severe burns.
5-94
Troubleshooting
1. Remove from the cigarette lighter button from socket.
2. Use a multimeter to measure the conduction situation between the socket inner wall and machine chassis
(earthing).
3. Measure DC voltage through the insulating ends of the socket center and the inner wall, if working
properly, the voltage should be +12V.
4. If there is no +12V voltage in the cigarette lighter, check the fuse 22; If the fuse has no problems, it is
conferred to be harness failure.
5. If the measurement makes sure the power supply and earthing are correct, the fault lies in the cigarette
lighter button, which should be replaced timely.
Annex1
Code Shape Terminal Usage Remarks
DJ7013-7.8-20C A
DJ7022-7.8-20 C
DJ7013-9.5-20 D
DJ7141-6.3-20 E
5-95
Annex1 (continued)
DJ7121-6.3-20 G
DJ7081-6.3-20 H
DJ7068-6.3-20 J
DJ7083-6.3-20 K
DJ7171-3-21 X1
DJ7201-2-10 C1
DJ7081B-6.3-10 C2
DJ70411-6.3-20 C4
DJ7023-6.3-20 C7/C99/C9
5-96
Annex1 (continued)
Frame
192900-0425 C11/C50
harness
Cab/Steering
192900-0437 C50/C11 gear box
harness
DJ70116-6.3-20 C12
C14/C15/C30/C31/
DJ7021-1.5-10
C32/C33
Manual brake switch/

C18/C28/C46/C47/
DJ7021-1.5-20
C100/C38/C43/C29/
C65
5-97
Annex1 (continued)
7701996003 C17
DJ7041-1.5-20 C23/C22
DJ7051-3-10 C24/C26
C45/C44/C42/C41/
DT06-02S
C40/WD/CR/CF/4G
DJ7031-1.5-20 C53/C39
DJ7131-3-10 C51 Cab harness

Annex1 (continued)
Work light
DJ7131-3-20 C51
harness
DJ7041-6.3-10 C52
Work light
DJ7031-6.3-20 C53
harness
DJ7031-6.3-11 C53 Cab harness
DJ7022-6.3-20 C66
C76/78/80/82/72
DJ7031-2.8-20
/70/74/84/86
5-99
Annex1 (continued)
C69/85/83/71/81/79/
DJ7086-6.3-20
77/75/C5/C6/C98/C8
DJ7041-6.3-20 I/C95/C52/C63/C64
DJ7072-3-10 C87
09706-16120-21 C91
DJ7051-1.5-10 C92
5-100
Annex1 (continued)
DJ70116-6.3-10 C94
Frame har-
121583-0000 C97
ness
121583-0008 C97 Cab harness

6. A/C System
A/C System Fault Diagnosis and HFC-134a System Detection..........6-2
Precautions.......................................................................................................6-2
Operation..........................................................................................................6-4
System service.................................................................................................6-8
Service of fan and compressor electromagnetic clutch ...................................6-9
Cab temperature detection.............................................................................6-10
Observation and detection of leakage............................................................6-11
Detection of core of the evaporator / heater...................................................6-11
Evaporator / heater core.................................................................................6-11
Pressure detection..........................................................................................6-12
Pressure - Temp Table....................................................................................6-13
Troubleshooting Table.....................................................................................6-13
Connections for recollecting and refilling of A/C system.................................6-14
Service of A/C System......................................................................6-22
Instruction.......................................................................................................6-22
Special tools...................................................................................................6-22
Recycle of refrigerant in A/C system...............................................................6-22
Vacuuming and charging the A/C system with refrigerant..............................6-23
Removal and Installation of A/C Components...................................6-25
Removal and installation of compressor.........................................................6-25
Disassembly of evaporator.............................................................................6-27
Removal and installation of the condenser and the refrigerant receiver.........6-29
6-2
A/C System Fault Diagnosis and HFC-134a System Detection
Precautions
A/C System Fault Diagnosis and HFC-134a System

Detection
Precautions
Only technical personnel, who have been professionally trained or certified by related institutions, will be
allowed to provide services and repairs for the A/C system of engineering vehicles. When service the A/C
system of the machine, be sure to reserve the refrigerant in the system for reuse after repair.
Currently refrigerant HFC-R134a, which is used in the A/C system, is quite stable chemically, and does not
contain any CFC group with damage effect to atmospheric ozone layer.
In order to protect yourself, you must follow a few items when working in an environment with HFC-134a:
1. When working near the A/C system, you must wear goggles. Because if liquid refrigerant splashed into the
eyes, it can cause serious injury. When the refrigerant is splashed into or around your eyes, you should
immediately follow these steps:
A. Rinse eyes with water for about 15 min.
B. Immediately go to hospital.
2. If liquid refrigerant drops on the skin, it can cause skin frostbite. Therefore, when maintaining the A/C sys-
tem, you should open the A/C equipment carefully and slowly. If the refrigerant accidentally stained on the
skin, it is not necessary to see a doctor.
3. The container holding refrigerant must be placed upright, as well as avoid heat and sunlight. Refrigerant
temperature rise will lead to increased pressure within the container.
4. When you need for welding or steam cleaning near the A/C system, you must first recycling A/C system
refrigerant.
5. During a test of refrigerant and before recycling refrigerant, first check the temperature and pressure of the
A/C system.
6. When the refrigerant contacts with flame, they will react to produce a toxic gas.
7. Experimental results show that mixture of compressed HFC-134a and the air will generate a flammable
gas. Therefore, it is not allowed to compress air or smoke when detecting the system leakage.
8. Before removing any component of the A/C system, you should recycle refrigerants.
6-3
Precautions
Figure1.1 Refrigerant Recollecting, Reuse and Refilling Apparatus (SPX 347112K)

6-4
Operation
Operation
A/C system refrigerant circuit consists of five main components : a compressor, a condenser, a refrigerant
receiver, an expansion valve and an evaporator. These components are connected by pipelines to form a
closed system. The refrigerant used in the A/C system is HFC-134a.
The refrigerant at the inlet of the compressor is gaseous in low pressure, and turns into high pressure gas
after compressed by the compressor, then flows into the condenser. After the refrigerant flows through the
condenser, most heat will be dissipated. Therefore, the refrigerant will be condensed into high pressure
liquid.
The liquid refrigerant in high pressure then flows into the refrigerant receiver after through the condenser.
there is absorbent material Inside the refrigerant receiver, which can absorb water in the A/C system, in
order to prevent corrosion caused by water to the inside of the A/C system components.
Cooling air
Wet and warm air
Low temperature
low pressure gas
High tempera-
ture high pres-
sure gas
Low tempera-
ture high pres-
sure gas
Transparent Hot air
glass
Air from cooling fan
1. Compressor 2. Condenser 3. Reservoir 4. Expansion valve 5. Evaporator
Fig. 1.2
The refrigerant flows to the expansion valve in high pressure liquid after passing through the refrigerant re-
ceiver. Expansion valve will release pressure of the refrigerant to drop its pressure, and then flow into the
evaporator core. The evaporator controls the expansion valve to release a suitable amount of refrigerant
according to its own thermal load.
When the refrigerant flows through the evaporator core, it will absorb heat around the evaporator core and
in the air to flow through the evaporator fins. The refrigerant will evaporate into low pressure gas under the
combined effect of heat rise and pressure drop, and cool down temperature of the air passing through the
6-5
Operation
evaporator fins. Therefore, the cool air will flow from the evaporator into the cab, and make the operator
feel comfort.
Electrical components of the A/C system include a control panel, temperature sensors, fan motors, fan re-
sistors, compressor electromagnetic clutches and pressure switches etc.
Troubleshooting
First, observe the state of the machine carefully, check as the following and correct if necessary:
1. View previous service records of the machine.
2. Check whether the compressor belt is tensioned.
3. Check whether fins, fan blades, condensers, filters or evaporators have been clogged.
4. Check whether the A/C lines have been excessively bent or knotted.
5. Check whether there are leaks on the components, which have a large accumulation of oil or oily dust.
6. Check whether the air ducts are intact, and seals are in right place.
7. Check whether the condensate drain lines and valves are blocked.
6-6
Operation
Fault: no refrigeration
For mechanical structure, please refer to page 6-8

Does compressor run? No Service of compressor mechanical structure;
For electrical equipment, please refer to page 6-9
Service of fan and compressor electromagnetic clutch.
Yes
Fault inside the system;

please refer to page 6-12
Pressure detection.
6-7
Operation
Fault: insufficient refrigeration Fault: intermittent refrigeration
Heater Mechanical structure

Confirm the heater control is closed, and also heater Please refer to 6-8 Service of compressor mechanical
water vlave is closed, no coolant flowing through structure
heater core
Seal Electrical parts

Confrim the seal parts are installed correctly Please refer to page 6-9 Service of fan and
compressor electromagnetic clutch - service of fan
motor, fan switch and compressor electromagnetic
clutch
Mechanical structure System inside fault

Please refer to page 6-8 Service of compressor Please refer to page 6-12 Pressure detection
mechanical structure, and refer to page 6-12 Service
of evaporator heater core Fault: system has abnormal sound
Electrical parts Please refer to 6-8 Service of compressor mechanical

Please refer to page 6-9 Service of fan and structure and fan motor
compressor electromagnetic clutch
Refrigerant Electrical parts

Please refer to page 6-10 Temperature detection Please refer to page 6-9 Service of fan and
compressor electromagnetic clutch
System inside fault System inside fault

Please refer to page 6-12 Pressure detection Please refer to page 6-12 Pressure detection
6-8
Operation
System service
Service of compressor mechanical structure
1. Belt is badly broken - replace with a new one
Compressor and belt
cause worn belt will lead to belt slipping
1. Loose support bolt - tighten the bolt to the

specific torque
Compressor mounting support
2. Broken or damaged support - replace with a new
one
1. If the compressor itself fails, it will lead to belt

slipping at compressor pulley. The compressor
should be serviced or replaced right now.
2. Check and confirm that clearance between
Compressor electromagnetic compressor electromagnetic clutch and pulley is
clutch
between 0.41-0.79 mm.
3. Clockwise rotate the compressor with a wrench
slowly, the compressor can run smoothly without
too much force.
1. Collinearity between compressor pulley and

drive belt must be 1.6 mm. The collinearity can
Colinear pulley and belt be measured by using a straight edge. And the
collinearity can be rectified through adjusting the
compressor mounting support if it is incorrect.
6-9
Operation
Service of fan and compressor electromagnetic clutch

Caution: check the voltage of compressor
connectors when in an energized state. If no
current passing, the voltage will drop.
Compressor
electromagnetic clutch 1. If no current passing through electromagnetic
clutch and excessive voltage drop at the earthing
points of electromagnetic clutch is detected, please
refer to Section three and replace the compressor.
1. Please refer to Section three and check if the

Pressure sw
pressure switch is closed.
A/C system fuse 1. Check if A/C system fuse is blown.
1. Check the switch function. The switch should

have 4 shifts: Close, Low-speed, Mid-speed, High-
speed.
Blower speed sw
2. Check wiring connectors for looseness and har-
ness for wear. If any, please repair.
3. Check the speed resistor.
1. Check if blower motor harness is correct, if not,

please repair or replace.
Blower motor
2. Check motor earthing cable and confirm that it
was well contacted with support.
1. Keep the key sw is power-on and tune the temp

sw to the max. refrigeration position. The compres-
sor electromagnetic clutch will act.
Caution: blower must be in work state as the
power supply of temp control sw is controlled by
Temp control sw
blower sw.
2. Close the blower sw. Cut off the temp controller
wiring. Use ohms range to test the continuty of
temp sw ends. When in max. refrigeration position,
replace the temp sw if it is not conducted.
6-10
Operation
Cab temperature detection

1. In order to experience the A/C effect efficiently, please
confirm that the air outlet and air return outlet are fully open.
Air inlet and outlet
The defrosting air outlet must be closed.
2. Check the blower which must be operating.
Caution: the line may be hot, and please pay attention when
feeling the line temperature. Approach slowly with fingers and
touch the line several times shortly, and the touching duration
can be longer than that of last time.
Temperature of line
1. Feel the line temperature. Generally, the temperature of high-
pressure line is higher than that of low-pressure line.
2. If the temperatures of both are the same, it indicates that
refrigerant is insufficient or the compressor does not work.
1. Put the thermometer at the air duct port, turn on the cooling
system for about 5min to keep the temperature stable. Refer to
Page 12 for details.
2. If the system is working at the maximum effect, the
temperature of air duct port must be lower than 25℃ (72 ℉ ).
Temperature of air duct Caution: the ambient temperature must be between 27℃ and
43℃ (80 ℉ and 110 ℉ ).
3. If the temperature is higher than 25 ℃ (72 ℉ ), it indicates
that refrigerant is insufficient, clogging occurs in some position,
the compressor does not work normally or line sealing is poor.
1. Stop the engine, keep the machine energized, turn on

the blower, and adjust the temperature control switch to the
maximum.
2. Remove the temp sensor from the evaporator. Refer to Part
III.
3. Put the end of temp sensor into ice water mixture.
Detection of temp sensor
4. After the sensor tube into the ice water mixture is cooled
down, temperature control switch will cut off the current of
compressor, and the compressor will stop. Detect the current at
the terminal of control switch as introduced before. If the current
is not cut off, it is necessary to replace the control switch.
6-11
Operation
Observation and detection of leakage

1. Confirm that all pipes are firmly connected and
Connect the compressor sealed.
pipes 2. Check all pipes for bend or damage, and replace
them if any.
1. Close the engine.

Warning: toxic gas may be generated when
refrigerant contacts with open fire. DO NOT
breathing in the toxic gas.
2. Test all the connectors with electronic leak tester.
Refer to the method from instrument manufacture
Leak detection for use.
Caution: clockwise rotate the electromagnetic
clutch when testing the compressor tightness.
Caution: remove the tie on the expansion valve to
test tightness carefully.
3. Repair all leaks, and refill freon into the system,
refer to Section two for specific operations.
1. Confirm that no sundries blocked on the

condenser outer surface, and well sealed. And
Condenser
confirm that condenser runs normally when the
temp sw is open.
Detection of core of the evaporator / heater.
Confirm that heater water valve is closed already.
Evaporator / heater core

1. Please refer to Section three for the removal and
installation of evaporator / heater core
2. Check the fins of evaporator / heater core. and
straighten all bend or broken fins.
3. Test the liquidty of evaporator / heater core. If the
core is dry, clear it with compressed air, brush, or
vacuum cleaner. If the core is wet or covered with
Evaporator / heater core
mud, clean it using a water hose without pressure.
Make sure water is able to smoothly pass through
the evaporator / heater core. DO NOT use steam.
Warning: if the sytem is filled with freon already,
DO NOT use steam to clean any A/C parts. The
steam heat will improve the refrigerant pressure
and may lead to system explosion then.
6-12
Operation
1. Please refer to Section three for the removal and

installation of evaporator / heater core.
Tightness of evaporator /
2. Confirm the evaporator / heater core are well
heater core
sealed, and the wind from blower only pass through
the evaporator / heater core, not pass around.
Filter paper 1. Confirm the filter paper is clean and not blocked.
Pressure detection
Multifuctional measuring device
NOTE : this measuring device can not optimize the system accurately, which has already charged with
HFC-134a. Therefore, this device is better used to measure whether the system is charged with insuffi-
cient or excessive refrigerant, and then recycle refrigerant of the system, recharge HFC-134a to the speci-
fied amount of refrigerant.
Multifunctional measuring device is the most important tool for service services of the A/C system. As a
troubleshooting tool for refrigerant charging, system diagnostics and operational effect, it can be used to
measure the system pressure. Multi-functional measuring device can simultaneously read high and low
pressure values, so that diagnosis can be made by contrasting high and low pressure.
Low pressure measuring instrument - it has dual functions. Generally the low pressure measuring instru-
ment is used to test exhaust effect of the measuring system. Degree of vacuum can indicate a system fail-
ure, therefore an instrument is important which can measure pressure and degree of vacuum.
Generally after the system operates 10-15 min, the Low pressure gage must show a pressure value of 10
to 35 psi (0.7-2.4 bar).
High pressure measuring instrument - it is generally used for measuring pressure on the high pressure
side, its minimum range is from 0 to 400 psi (0-27.6 bar).
Generally, in normal system operation, pressure on the high pressure side is from 120 to 310 psi (8.3-21.4
bar). Refer to P13 for pressures- Thermometer
Connection for pressure detection
The multifunctional measuring device is connected to the A/C system as shown in the drawing. Ensure
that both valves are closed during the connection.
6-13
Operation
Pressure - Temp Table

Ambient Temp Normal Low-pressure Normal High-pressure Min. Temp at Air Port
℉ (℃ ) Value psi (bar) Value psi (bar) ℉ (℃ )
80 (27) 9-12 (0.62-0.83) 145-165 (10-11.53) 55 (14)
90 (32) 11-15 (0.76-1.04) 190-210 (13.10-14.48) 61 (18)
95 (35) 16-18 (1.10-1.24) 210-230 (14.48-15.86) 63 (20)
100 (38) 17-19 (1.17-1.31) 235-255 (16.2-17.58) 66 (22)
105 (41) 20-21 (1.38-1.45) 260-280 (17.93-19.31) 68 (23)
110 (43) 22-24 (1.93-2.14) 290-310 (20-21.37) 72 (25)
This Pressure - Temp Table is based on the following conditions:
Note : it will cause the air duct temperature to increases if the air humidity is too high, and pressure on the
low pressure side rises. Therefore, adjust data appropriately in the table according to different geographi-
cal environment.
1.The engine operates at the speed of 1,500 rpm without any load. Fan speed and temperature are both
controlled at maximum setting. A/C switch is turned on, and all the vents are open.
2.Install well and close all fences and doors.
3.Install and clean filters in the cab.
4.Close the heater valve of the engine.
5.Measure after starting 15 min.
Troubleshooting Table
Low pressure High pressure
Faults Reference page
measurement measurement
No refrigeration Very low Very low 14
No refrigeration High High 15
Insufficient refrigeration Same as high-pressure end Normal 17
Insufficient refrigeration Low Low 17
Insufficient refrigeration High Low 19
Insufficient refrigeration High High 19
Intermittent refrigeration Normal Normal 20
Abnormal system noise. Same as high-pressure end High 21

6-14
Operation
Connections for recollecting and refilling of A/C system

1. Clear stains and moisture on the outer surface of the compressor and conduits, and remove the cap of the
charging port.
WARNING: If the system is charged with freon, do not clean any A/C system component with steam. Be-
cause heat of the steam will cause pressure of the refrigerant to rise, which may cause the system to ex-
plode.
2. Use the red terminal to connect the high pressure charging port of the A/C conduits.
3. Use the blue terminal to connect the low pressure charging port of the A/C conduits.
WARNING:When there is liquid refrigerant in operation, be sure to wear protective glasses. Because if liq-
uid refrigerant splashes in the eyes, it may cause blindness.
4. Confirm the valve of the multifunctional measuring device is in the closed state.
5. Start the engine and let it run at a maximum speed of 1,500 rpm. Open the cab door, and switch the cool-
ing function of the A/C system to the maximum, let the fan run at the fast speed for 15 min. Observe the
measured pressure value and compare it with the table in page 13.
Defect: no refrigeration
Low pressure gauge High pressure gauge
very low very low
Refer to P13 for Pressure-Temp Table

The symptoms of insufficient freon or no freon
1. Test the system for leaks, refer to Page 6-9. And refer to part 9003,
A. Air from evaporator
fill more refrigerant.
is hot
2. Refer to part 9003, recycle the remaining refrigerant in the system.
B. Compressor doesn't
3. If any leaks found, repair them refer to the repair steps provided.
run, or the cycle
4. Check the compressor lubricating oil level - maybe insufficient now.
frequently shut down
5. Exhaust the air and moisture from the system. Refer to part 9004 to
after starting. (the green
replace the refrigerant receiver.
indicator of A/C system
6. Refer to part 9003, refill new refrigerant into the system.
in cab goes on)
7. Keep detection to check for other faults.
6-15
Operation
High High

Features of the system containing large amount of air:
1. Recycle the remaining refrigerant from the system. Refer to Section two.
2. Replace the refrigerant receiver.
Air from evaporator
Y 3. Exhaust the air and moisture from the system. Refer to Section three to
is hot
replace the refrigerant receiver.
4. Refer to Section two to refill new refrigerant into the system.
Features of condenser fault

1. Check the belts of compressor and engine fan for looseness or damage.
2. Check if the condenser is clean and not blocked, and fins are not bend.
3. Check if excessive refrigerant in the system. Recycle and refill
refrigerant until the pressure gauge shows normal value. Refer to Section
A. Liquid refrigerant two.
pipes are very hot 4. Remove the condenser and check if it is blocked or the heat dissipation
Y
(between evaporator is getting worse.
and condenser) A. Refer to Section two to recycle the refrigerant.
B. Blow the oil stains away from the condenser by compressed air.
C. Replace the refrigerant receiver.
D. Refer to Section two to vacuum and refill the refrigerant.
5. Keep detection to check for other faults.
Features of expansion valve fault
A. Air from evaporator is hot.
B. Too much condensed water on the
low-pressure pipes of compressor. Replace the expansion valve refer to Section three
C. Too much condensed water at the
evaporator outlet.
6-16
Operation
Refrigerant contamination
Refer to table below, test the stable saturation pressure of refrigerant under a certain
temperature to check if it is contaminated.
A. Measure its pressure with instrument recovery unit.
B. Measure the temperature of refrigerant receiver. If the refrigerant has been
Refrigerant
recycled to the tank for a while, then measure the ambient temp instead. Value in the
contamination
table stands for the boiling point.
C. The lower limit pressure of refrigerant contaminated is given in the table.
Caution: do not use refrigerant contaminated or the mixture. Please deal with the
refrigerant contaminated on the basis of the local laws and regulations.
HFC-134a stable saturation pressure - temperature gauge

Temperature ℉ (℃ ) Pressure psi (bar)
50 (10) 45 (3.1)
55 (13) 51 (3.5)
60 (16) 57 (3.9)
65 (18) 64 (4.4)
70 (21) 71 (4.9)
75 (24) 78 (5.4)
80 (27) 88 (6.1)
85 (29) 95 (6.6)
90 (32) 104 (7.2)
95 (35) 114 (7.9)
100 (38) 124 (8.6)
102 (39) 129 (8.9)
104 (40) 133 (9.2)
106 (41) 138 (9.5)
108 (42) 142 (9.8)

6-17
Operation
Temperature ℉ (℃ ) Pressure psi (bar)

110 (43) 147 (10.1)
112 (44) 152 (10.5)
114 (46) 157 (10.8)
116 (47) 162 (11.2)
118 (48) 167 (11.5)
120 (49) 172 (11.9)
Fault: insufficient refrigeration

Same
as the high- Normal
pressure
end

Features of the system containing air
1. Check the system for leaks. Refer to Page 6-9. Check the
A. The low-pressure pipes is a tightness of compressor carefully to avoid air in system.
little hot for hand 2. Drain refrigerant from the sytem, refer to Section two.
B. Air exhausted from the 3. If any leaks, repair them.
evaporator is not cool enough 4. Replace the refrigerant receiver.
5. Check lubricating oil level in the compressor.
Low Low

6-18
Operation
Features of insufficient refrigerant

1. Leak test - test for refrigerant leaks.
Caution: in normal condition, about 0.5 lounce (14.7-29.5 g)
refrigerant leaks from system each quarter.
A. If any leaks found, go on the Step 2.
B. If no leaks found, turn to Step 6.
Air exhausted from evaporator
2. Drain refrigerant from the sytem, refer to Section two.
is not cold enough
3. Repair the leaks.
4. Check lubricating oil level in the compressor.
5. Refer to Section three to vacuum or replace the refrigerant
receiver.
6. Refill new refrigerant into the system. Refer to Section two.
Features of blockage at the high pressure side

A. Air exhausted from the evaporator is
not cool enough 1. Remove the blocked refrigerant in the receiver or
B. There is condensed water or frost on liquid refrigerant pipe.
the receiver 2. Remove and replace the blocked parts.
C. There is condensed water or frost on 3. Refer to Section two to vacuum.
the liquid refrigerant pipe to receiver 4. Refer to Section two to refill new refrigerant into
Caution: frosting will extend from block the system.
points.
Features of expansion valve not working

1. The condensed water or frost at the outlet of
expansion valve indicates the expansion valve is
A. Air exhausted from the evaporator is not
blocked. Refer to Section two.
cold enough
2. Warm (not hot) expansion valve inlet end
B. There is condensed water or frost at the
indicates the expansion valve is not fully opened. If
outlet of expansion valve
the expansion is sticky and blocked, only a little or
C. The expansion valve inlet end is warm.
no refrigerant will pass through the expansion valve.
Refer to Section three refer to expansion valve.
6-19
Operation
High Low

Features of the compressor turning but not pumping refrigerant
1. Refer to Section two to drain refrigerant from the system.
2. Refer to Section three to remove compressor from the machine.
3. Replace the compressor because of leaks inside the compressor.
A. Proper refrigerant is filled
4. Replace the compressor.
into the sytem
5. Replace the receiver if any conditions below occur:
B. Air exhausted from the
A. System was opened before.
evaporator is cool
B. The receiver has been used for over two years. Replace it refer to
Section three.
6. Refer to Section two to refill refrigerant into the system.
Expansion valve stuck after opening
The expansion valve is 1. Refer to Section three for repalcement of expansion

stuck after opening valve.
High High

6-20
Operation
Features of the condenser not working:

1. Check the belts of compressor and fan for looseness or damage
2. Check if the condenser is clean or blocked, and fins are not bend.
3. Check if excessive refrigerant in the system.
A. Drain refrigerant from the system until the pressure is lower than
normal value. Refer to Section two.
A. Liquid refrigerant
B. Fill refrigerant until the pressure is the same as normal level.
pipe is very hot
Refer to Section two.
B. Air exhausted from
C. Go on Step 4 if still any faults.
evaporator is hot
4. Remove the condenser and check if it is blocked by oil or the heat
dissipation is getting worse.
A. Recycle the refrigerant. Refer to Section two.
B. Blow alway oil stains from the condenser with compressed air.
C. Replace the receiver.
Features of the system containing air:

1. Drain refrigerant from the system. Refer to Section two.
Air from the 2. Replace the receiver.
evaporator is hot 3. Vacuum the system. Refer to Section two.
4. Refill new refrigerant into the system. Refer to Section two.
Fault: intermittent refrigeration
Normal Normal

Features of too much moisture in the system
1. Drain refrigerant from the system. If excessive water flows
into the small hole, the condenser will be blocked when it's
frozen. Refer to Section two.
2. Replace the receiver. The absorbent material in the receiver
Intermittent refrigeraion, it's
may be saturated. Refer to Section three.
normal during refrigeration
3. Vacuum to eliminate moisture in the system. Refer to Section
two.
Caution: it generally takes 2 or 3 hours to drain the large amout
of water in the system.
Fault: system has abnormal noise

6-21
Operation

Same
as the high- High
pressure
end

Features of excessive refrigerant in the system
1. Drain refrigerant from the system until the pressure is
A. Air from the evaporator is cool
lower than normal level. Refer to Section two.
B. the compressor has abnormal
2. Fill new refrigerant until the pressure back to normal level.
sound
Refer to Section two.
Table of conduit connection Torque
Hose
3/8inch 1/2inch 5/8inch
dimension
Thread size M16-1.5 M22 3/4-18 or 3/4-16 7/8-18 or 7/8-14 M24
Copper &
aluminum 15-25 Nm 20-25 Nm 24-30 Nm 30-37 Nm 30-34 Nm
couplings
Note: when tightening air ducts or duct parts, give a hard tightening action with the given torque value in
the table.
Note: when tighten connection devices of the compressor, condenser and evaporator, you must be very
careful, because these components are easily deformed and distorted.
6-22
Service of A/C System
Instruction
Service of A/C System 2. Turn on the main power switch, and empty the
oil recovery tank on the right side of the device.
Instruction
Refrigerant quantity in A/C system: 1.0 kg
Lubricant re-
Special tools covery tank
3. Press the recycle switch.
4. If more than 150Ib (68 kg) refrigerant has been

recollected since last replacing dry filter, the in-
strument will display: filtered weight is xxx Ib (xx
kg). Press the start button.
5. Connect the high and low pressure conduits

to the A/C system, and open the connection
valves.
6. Rotate both the low and high pressure valves to

the Recover / Vacuum location, and then press
the Start button to continue.
Figure2.1 Refrigerant Recollecting, Reuse and

Refilling Apparatus - (SPX 347112K) Recycle
Recycle of refrigerant in A/C system

Stop
The recycled refrigerant will pass through the oil Start
separator and the filter dryer in turn, and finally
into the refrigerant tank. When the dried refrig- Valve sw
erant flows through the humidity indicator, it will
turn green.
Fig. 2.2
If possible, it is better to run the A/C system for 7. If the system pressure is below 25 psi (1.72
about 10 min before recycling the refrigerant. bar), the instrument will display : the system
Then shut down the system to start recycling pressure is low until the pressure rises or press
the refrigerant. the Start button. You can press the button to
1. Connect the power cord of multifunction devices exit.
to the 220 V power supply. 8. If there is refrigerant in the low pressure conduit
6-23
Service of A/C System
Instruction
of the device, the instrument will start cleaning

program and display: being cleaned. If you want
to skip or stop cleaning program, you can press Start
the Start button again.
9. When the amount of the system recollection Stop

reaches 13in.Hg. (0.44 bar), the vacuum com-
pressor will automatically shut down.
10. Next, the instrument will automatically recover Valve sw

lubricant, and the instrument will show: lubricant
is being recycled. Oil recovery needs 90s or so.
11. After completion of the recovery of lubricant, F. The system is opened as long as up to 5
check the lubricant recovery tank, and write min when replacing the compressor.
down amount of the lubricant recovered from 13. Place valves of the multifunctional device in
the system. The system needs to be charged the closed state, and connect the high and low
with more lubricant after being vacuumed. pressure conduits to the A/C system, then open
12. To confirm whether the refrigerant is completely the connection valves.
recollected, wait for 5 minutes and observe 14. Connect the main power of the multifunction de-
whether the pressure of the multifunction instru- vice to 220V power supply, and then turn on the
ment will rise higher than 0 in.Hg. (0 bar) after main power switch.
the recollection. If the pressure is picked up, you
need to press the start button again to repeat 15. Press the vacuum button, and then press the
the recovery process until the system pressure start button.
can be maintained for 2 min, then press the stop
button to exit the recovery.
Start
Vacuuming and charging the A/C
system with refrigerant
Stop
Note: before vacuuming and extracting mois-
ture, replace the refrigerant receiver if one or
more of the following conditions are satisfied.
Valve sw
A. The system has been opened for several
times.
B. The refrigerant receiver has been used for Fig. 2.3

two or more years. 16. Press the start button again to confirm vacuum-
C. Remove the compressor, and the desiccant ing for 15 minutes, or change time to vacuum by
material has turned into small particles ( numeric buttons, and then press the Start button
golden or brown particles). once more.
D. The system has large amount of leaking. ( 17. When the set time is up, the vacuuming will au-
the conduit is broken). tomatically stop. Press the stop button to exit
the process. Press the start switch to resume
E. The system contains too much air or mois- continue vacuuming, or exit by pressing the stop
ture. button. Now it is ready to charge the system
with refrigerant.
6-24
Removal and Installation of A/C Components
Instruction
18. Press the Charge button.
Start Fill
Stop
Valve sw
Fig. 2.4
19. Rotate the low pressure valve to the Closed
position, and the high pressure valve to the Oil
Inject / Charge position. Press the start button.
20. Enter the amount of refrigerant 0.85 kg required

to charge by numeric buttons, and then press
the Start button again.
21. The instrument will show after filling: charge has

completed, the amount of filling is x.xx lb (kg).
22. Close high and low pressure valves, and re-

move the filling conduits.
Note: when the remaining refrigerant in the re-

frigerant storage tank is less than 3 lbs (1.36
kg), it can’t charge the system with refrigerant,
the refrigerant storage tank should be supplied
with refrigerant at this time.
6-25
Removal and installation of compressor

Fig. 3.1
1. Condenser 2. Refrigerant receiver 3.Closable outlet 4.New fan motor as
5.High capacity evaporator 6.Low capacity evaporator 7. Air duct 8. Compressor
Removal of Compressor ( Wei Chai Type)

1. Shut down the machine power supply
2. Refer to Section two to recollect refrigerant in

the system.
3. Disconnect compressor power plug.
4. Remove the air ducts connected with the com-

pressor and plug the inlet and outlet of the com-
pressor and air duct ports, be sure to protect the
o-rings of the duct.
5. Remove compressor control board.
6. Unscrew compressor fixing nut.

Fig. 3.2
7. Rotate compressor outward, take out compres- 8. Unscrew compressor fixing bolt, take out com-
sor belt. pressor.
Installation of compressor
9. The installation sequences of the compressor
is opposite to the disassembly, for tightening
6-26
torque of each conduct coupler refer to the table 8. The installation sequences of the compressor is
of conduct coupler connecting torque opposite to the removal, for tightening torque of
each conduct coupler refer to the table of con-
10. Refer to Section two to refill refrigerant to A/C duct coupler connecting torque
system after the accomplishment of the com-
pressor assembling.
Removal of compressor (Perkins type)

1. Shutdown the machine power supply
2. Refer to Section two to recollect refrigerant in

the system.
3. Disconnect compressor power plug.
4. Remove the air ducts connected with the com-

pressor and plug the inlet and outlet of the com-
pressor and air duct ports, be sure to protect the
o-rings of the duct.
5. Remove each fixing nut of compressor control

rod in turn and remove the control rod ( as the
arrow shows in the figure)
Fig. 3.4
9. Refer to Section two to refill refrigerant to A/C
system after the accomplishment of the com-
pressor installation.
Fig. 3.3
6. Remove compressor fixing bolt ( the circled bolt
in the Fig.), remove compressor belt and re-
move the compressor as.
7. Remove the four bolts fixing the compressor, re-

move the compressor.
Installation of compressor
6-27
Disassembly of evaporator
View of the inner structure of the evaporator
High cpacity evaporator: Fig. 3.5
Low capacity evaporator: Fig. 3.6
1. Expansion valve 2. Heating core 3. Refrigeration core 4. Sealing sponge
5. Evaporator motor 6. Thermal detector 7. Fan speed control re- 8. Evaporator case
( temperature sensor) sistance
6-28
Removal of Evaporator water pipe port of the evaporator, remove away

the water pipe connected with the evaporator,
let the refrigerant flow into the container.
8. Wait until the refrigerant completely drains, re-

move away the wiper controller on the evapora-
tor.
9. Remove the four bolting fixing the evaporator,

remove the high capacity evaporator.
Fig. 3.7
1. Park the vehicle in a relatively flat ground.
2. Shut down the machine power supply
3. Refer to Section two to recollect system refriger-

ant and close warm air water valve.
4. Remove away all the elements on the right-side

instrument cover. (as it circle in the figure).
5. Remove right-side instrument cover, remove the

plugs connected with evaporator.
Fig. 3.9
10. Remove left-side instrument cover, remove the
plugs connected with evaporator.
11. Remove the air ducts connected with the evapo-

rator and plug the inlet and outlet of the evapo-
rator and air duct ports, be sure the o-rings of
Fig. 3.8 the duct are well protected.
6. Remove the air ducts connected with the evapo-
rator and plug the inlet and outlet of the evapo- 12. Remove the air duct connected with the evapo-
rator and air duct ports, be sure the o-rings of rator.
the duct are well protected. 13 .Remove the bolt fixing the evaporator, remove
7. Prepare a 30 L container and place it under the the low capacity evaporator.
6-29
Installation of Evaporator frigerant receiver pressure switch.
14. The installation sequences of the high and low

capacity evaporators are opposite to the remov-
al, for tightening torque of each conduct coupler
refer to the table of conduct coupler connecting
torque
15. After the completion of the evaporator installa-

tion, refill refrigerant to the system according to
Section two.
Removal and installation of the

condenser and the refrigerant
receiver
Fig. 3.11
Removal of the condenser and the 7. Remove the air ducts connected with the reser-
refrigerant receiver voir and plug the inlet and outlet of the evapora-
tor and air duct ports, be sure the o-rings of the
1. Park the vehicle in a relatively flat ground. ducts are well protected.
2. Turn off the machine power supply 8. Remove the two bolts fixing the reservoir as,
take out the reservoir as.
9. Loosen the bolt fixing the refrigerant receiver,

take out the reservoir as from the duct clamp.
Installation of condenser and refrigerant receiv-
er
10. The installation sequences of the condenser
and the reservoir are opposite to the removal,
for tightening torque of each conduct coupler
refer to the table of conduct coupler connecting
torque
11. After the completion of the condenser and re-

frigerant receiver installation, refill refrigerant to
Fig. 3.10 the system according to Section two.
3. Refer to Section two to recollect system refriger-
ant.
4. Open the machine cover door, remove the air

ducts connected with the condenser and plug
the inlet and outlet of the evaporator and air
duct ports immediately, be sure the o-rings of
the duct are well protected.
5. Remove the four condenser fixing bolts, take

out the condenser.
6. Remove the electric plug connected with the re-

7. Engine System
Removal and Installation of Engine Attachments and Filter...................2
Air filter removal...................................................................................................2
Remove and installation of muffler......................................................................5
Removal and installation of diesel engine body...................................................9
Engine Service.....................................................................................24
Refer to engine original manual (optional).........................................................24
Refer to the original manual of Perkins engine (optional)..................................24
7-2
Removal and Installation of Engine Attachments and Filter
Air filter removal
Removal and Installation

of Engine Attachments and
Filter
Air filter removal
Air filter
Removal
1. Remove switch wire harness of air filter
Push aside the protective sleeve of the back-up
alarm switch on the air filter and disconnect the
harness.
2. Remove the connecting pipeline between air fil- 3. Remove the connecting pipeline between air fil-
ter and its cap ter and diesel engine
Remove the fixing bolt from the clamp of the Remove the two fixing bolts from the connect-
connecting pipeline between air filter and its cap ing pipeline between the air filter and the diesel
with the 13# wrench and take down the air filter engine with the 8# wrench and take down the
pipeline, and then place it properly. pipeline, and then place it properly.
7-3
Air filter removal
4. Remove air filter and bracket asembly Installation

Remove the four fixing nuts from the support-
ing seat of the air filter with the 18# wrench and 1. Install air filter bracket
take down the air filter and fixed supporting seat Align the fixing plate of the air filter to the holes
as, and then place it properly. of the air filter and install the three bolts, and
then tighten the bolts with 16# wrench.
5. Remove air filter bracket

Remove the three bolts from the supporting seat 2. Install air filter and bracket as
of the air filter with the 16# wrench and take Put the supporting seat of the air filter in the
down the air filter, and then place it properly. mounting position and let it pass through the
four studs on the engine, and then install the
nuts on the studs and tighten the nuts with the
18# wrench.
7-4
Air filter removal
3. Install air filter to diesel engine connection pipe-

line
Put the connecting pipeline between the air
filter and the engine in the mounting position.
Connect one end to the circular hole of the air
filter and the other end to the circular hole of the
engine. Install the annular clamps on both ends
of the pipeline and tighten the bolts with the 8#
wrench.
5. Install air filter switch wire harness

Connect the harness to the back-up alarm
switch of the air filter and put the protective
sleeve in place.
4. Install air filter to air filter cap connection pipe-

line
Put the connecting pipeline between the air filter
and its cap in the mounting position. Connect
one end to the circular hole of the air filter and
the other end to the circular hole of the air filter
cap. Install the annular clamps on both ends of
the pipeline and tighten the bolts with the 13#
wrench.
7-5
Remove and installation of muffler
Remove and installation of

muffler
Muffler
Removal
1. Remove sleeve on muffler
Unscrew the spring on the protective sleeve and
remove the protective sleeve, and then place it
properly.
4. Remove exhaust pipe

a Remove the four fixing bolts of the exhaust
pipe with the 13# wrench.
b Remove the four fixing bolts of the exhaust
pipe and the braided tube with the# 13 and#
16 wrenches.
c Remove the mounting plate to fix the ex-
haust pipe with the# 13 wrench, and then
take out the exhaust pipe from the upward
side and place it on the ground properly.
2. Remove muffler clamp

Remove the fastening hoop from the muffler
3. Remove U-shaped fastener of muffler pipeline

Remove the two fixing bolts on the down side of
the U-shaped fastener with the 13# wrench and
take down the U-shaped fastener.
7-6
6. Remove muffler piping

Remove the four connecting bolts between the
muffler and the pipeline with the 16# wrench.
Take down the muffler and place it properly.
5. Remove muffler and pipeline as

Remove the four bolts from the muffler pipeline
and the bellows joint with two 13# wrenches.
Take down the muffler and pipeline as and place
it properly.
Installation
1. Install muffler piping
Put the muffler pipeline in the mounting posi-
tion. Align the holes of the muffler and install the
bolts, and then tighten the bolts with the 16#
wrench.
7-7
2. Install muffler and pipeline as

Put the muffler and pipeline as in the mounting
position. Align the holes of the muffler pipeline
and the bellows and install the bolts, and then
tighten the bolts with the 13# wrench.
3. Install exhaust pipe

Put the mounting plate of the exhaust pipe in
the mounting position. Align the holes of the
frame and install the bolts, and tighten the bolts
with the 13# wrench. Put the exhaust pipe onto
the braided tube. Align the holes of the braided
tube and install the bolts and nuts, and then
tighten the nuts with the 13# and 16# wrenches.
Finally, fix the exhaust pipe onto the mounting
plate with the U-shaped hoop and tighten the
bolts. No deflection or shaking of exhaust pipe
is permitted. 4. Install U-fastner to muffler pipeline
Put the U-shaped fastener of the muffler in the
mounting position. Let it pass through the brack-
7-8
et of the engine and install the nuts on it, and

then tighten the nuts with two 13# wrenches.
5. Install muffler clamp

Put the annular fastening hoop in the mounting
position on the muffler and tighten the bolts of
the fastening hoop with the 13# wrench.
6. Install sleeve on muffler

Install the protective sleeve on the muffler and
connect the spring.
7-9
Removal and installation of diesel engine body
Removal and installation of

diesel engine body
Diesel engine
Removal
1. Park the complete machine
Park the machine on level ground. Pull up the
parking brake to its extreme position and turn
the negative switch to the power-off position.
2. Remove radiator
Refer to 5.5.1, remove the radiator as and other
components, and place them properly.
3. Remove cooling cotton and rear cover 4. Remove air filter
Tear off the heat-sinking asbestos. Remove the Refer to 5.5.2, remove the air filter and place it
four bolts on the rear cover board with the 13# properly.
wrench. Take down the rear cover board and 5. Remove sliencer
place it properly. Refer to 5.5.3, remove the muffler and place it
properly.
6. Remove rear cover
Remove the four fixing bolts of the rear hood
with the 16# box spanner, and take down the
rear hood and put it on level ground. Be careful
to protect its surface paint.
7. Lift the cab

Refer to 5.3.2, remove the cab as and other
components and place them properly.
8. Remove the connecting hose between loading
valve and steel tube inside frame
Refer to 5.4.2, remove the hose between the
loading valve and the connecting end of the
7-10
steel tube inside the frame with the appropri- matters from entering.
ate wrench. After removal, wrap the hoses with
matters from entering.
9. Install vehicle frame inside steel pipe and hose
Remove the six small clamps for fixing the air-
conditioning pipeline with the 13# wrench and
move the air-conditioning pipeline away.
Remove the six large clamps for fixing the steel

tube with the 16# wrench and move the steel
tube away.
Remove the four hoses on the outside of the

hydraulic loading pipeline with the 27# wrench.
After removal, wrap the hoses with clean plastic
bags and belts to prevent foreign matters from
entering.
10. Remove oil cup

Remove the oil cup on the left inside of the
frame with the 13# wrench. Take down the oil
cup and place it properly.
Remove the hose on the side close to the frame

in the hydraulic loading pipeline with the 30#
wrench. After removal, wrap the hoses with
7-11
11. Remove rear gearbox shaft 12. Remove front gearbox shaft
Remove the connecting bolts between the rear Remove the connecting bolts between the front
drive shaft and the gearbox as well as between drive shaft and the gearbox with the 6# inch
the rear drive shaft and the rear axle, respec- hex wrench. Take down the connecting spline
tively, with the 6# inch hex wrench. Remove the between the front drive shaft and the front axle
rear drive shaft and place it properly. and place it properly.
7-12
13. Remove diesel engine wiring harness Disconnect the harness of the 4th gear sensor.
Disconnect the harness of the gearbox oil tem-
perature sensor.
Disconnect the harness of the forward and

back-up gears.
Disconnect the harness of the 2WD/4WD selec-
tor switch.
7-13
Push aside the protective sleeve of the gearbox Push aside the protective sleeve of the connect-
oil temperature sensor cable and remove the ing cable between the frame and the magnetic
harness. packageon the start motor. Remove the fixing
bolts of the harness connector with the 16#
wrench and take down the harness.
Push aside the protective sleeve of the con-

necting cable between the frame and the start
motor. Remove the fixing bolts of the harness Push aside the protective sleeve of the connect-
connector with the 19# wrench and take down ing cable between the frame and the starting
the harness. relay on the start motor. Remove the fixing bolts
of the harness connector with the 7# wrench
and take down the harness.
7-14
Push aside the protective sleeve of the oil pres-

sure sensor cable and disconnect the harness
of the oil pressure switch.
Disconnect the harness between the speed sen-

sor on the left side of the engine and the frame.
Push aside the protective sleeve of the cable
on the alternator. Remove the fixing bolts of the
harness connector with the 7# wrench and 10#
wrench, respectively, and take down the har-
ness.
Disconnect the harness between the frame and

the misfire electromagnet.
7-15
Disconnect the connecting harness between the Cut off a series of belts used for connecting the
water temperature sensor and the frame. engine and frame harness with the diagonal pli-
ers.
Disconnect the connecting harness between the

compressor and the frame. 14. Removal of pumps
Refer to 5.4.3, remove the pump and place it
properly.
15. Removal of fixing bolts of engine and gearbox
as
Remove the four fixing bolts from the engine
and gearbox as with the 30# socket, extension
rod and ratchet wrench (or special wrench) ,
and take down the bolts and shock pads.
7-16
16. Install diesel engine gearbox as hoisting ring As shown in the figure, remove one bracket on
As shown in the figure, remove one bracket on the rear side of the engine with the 18# wrench.
the right side of the engine with the 18# wrench. After removing the bracket, screw the eye ring
After removing the bracket, screw the eye ring firmly in the bracket position as well.
firmly in the bracket position.
7-17
Installation
1. Install engine and gearbox as
Hook the eye rings on the engine with the lifting
hook. Lift the engine and gearbox as slowly with
the traveling crane above the frame and move
it toward the rear of the frame. Align the mount-
ing holes of the diesel engine and the frame and
insert the bolts and shock pads, and tighten the
bolts. Measure the tightening torque with the
fixed torque wrench (200-680N•m) . Make sure
that the tightening torque should be 610 N•m.
During lifting and installation, be careful to pre-
vent the engine and gearbox as from crashing
both sides of the frame or the crossbeam.
17. Hoist diesel engine gearbox as
Hook the two eye rings on the engine with the
lifting hook. Lift the engine and gearbox as
slowly with the travelling crane until it is slightly
higher than the frame. Shift out the engine and
gearbox as slowly from the front of the frame,
and then lift it to the special tooling and place it
properly. During lifting and installation, be care-
ful to prevent the engine and gearbox as from
crashing both sides of the frame or the cross-
beam.
2. Install pump
Refer to 5.4.3 Pump Installation, install the
pump in the gearbox.
3. Connect wire harness
Connect the connector on the compressor with
the corresponding connector of the frame har-
ness.
7-18
Connect the water temperature sensor harness Connect the speed sensor harness with the
to the water temperature sensor and put the connection of the speed sensor.
protective sleeve in place.
Install the alternator harness in the correspond-

Connect the misfire electromagnet harness with ing connector of the alternator with the 7#
the connection of the misfire electromagnet. wrench and10# wrench, respectively, and then
tighten the nuts and put the protective sleeve in
place.
7-19
Connect the gearbox oil pressure sensor har- Install the harness of the magnetic package on
ness to the sensor and cover the harness con- the start motor in the corresponding connector
nector well. of the magnetic package with the 16# wrench,
and then tighten the nuts and put the protective
sleeve in place.
Install the starting relay harness on the start mo-

tor in the corresponding connector of the start-
ing relay with the 7# wrench, and then tighten Install the start motor harness in the corre-
the nuts and put the protective sleeve in place. sponding connector of the start motor with the
19# wrench, and then tighten the nuts and put
the protective sleeve in place.
7-20
Connect the gearbox oil pressure sensor har- Connect the 4th gear sensor harness with the
ness with the corresponding connector of the oil corresponding interface.
pressure sensor.
Connect the 2WD/4WD harness with the corre-

Connect the forward and back-up gear harness sponding interface.
with the corresponding interface.
7-21
Connect the gearbox oil temperature sensor

harness with the corresponding interface.
5. Install rear drive shaft

Install the end (with a larger diameter) of the
4. Install front axle gearbox shaft
rear drive shaft in the rear axle, and install the
Insert the spline end of the front drive shaft
other end in the gearbox. Tighten the connecting
into the front axle, and install the other end in
bolts to 26±4N•m with the 6# inch hex wrench.
the gearbox. Tighten the connecting bolts to
26±4N•m with the 6# inch hex wrench.
7-22
7. Install vehicle frame inside steel pipe and hose

Remove the protection from the steel tube. Put
the steel tube in the mounting position. Clamp
the steel tube with the large clamps and align
the mounting holes, and then install the bolts.
Tighten the bolts with the 16# wrench. No de-
flection of the steel tube trend is permitted.
6. Install oil cup

Align the mounting holes of the oil cup fixing
plate and the frame and install the bolts, and
then tighten the bolts with the 13# wrench.
Remove the protection from the hoses and the

steel tubes. Connect the hose with the inner-
most steel tube of the frame. Tighten the con-
nection with the 30# wrench. No twist or interfer-
ence of any hose is permitted.
7-23
8. Install loading valve and vehicle frame inside

steel pipe connecting hose
Remove the protection from the hose. Refer to
Remove the protection from the hoses and the 5.4.2 Removal and Installation of Loading Valve
steel tubes. Connect the hoses with the four Hose, connect the hose of the loading valve
outside steel tubes of the frame. Tighten the with the connecting end of the inner steel tube
connections with the 27# wrench. No twist or in- of the frame and tighten it with the appropriate
terference of any hose is permitted. wrench. No twist or interference of any hose is
permitted.
9. Install cab
Refer to 5.3.2, lift and install the cab as and
other components in the machine and connect
various connections and pipelines well.
10. Install rear cover
Put the rear hood in the mounting position of
the frame. Align the holes of the frame and in-
stall the bolts and nuts. Adjust the position of
the rear hood from side to side to make sure the
difference between the distances which both
sides of the rear hood exceed the frame should
be<2mm. And then, tighten the four mounting
bolts of the rear hood with the 16# box spanner.
Put the air-conditioning pipeline in the mounting

position. Clamp the hoses with the small clamps
and align the mounting holes and install the
bolts. And then, tighten the bolts with the 13#
wrench. No twist or interference of any hose is
permitted.
7-24
Engine Service
Refer to engine original manual (optional)
11. Install muffler

Refer to 5.5.3, install the muffler as and other
components in the corresponding positions of
the front end of the engine.
12. Install air filter
Refer to 5.5.2, install the air filter as and other
components in the corresponding positions of
the front end of the engine.
13. Install rear cover panel and cooling cotton
Put the rear cover board in the mounting posi-
tion. Align the holes of the frame and install the
bolts. Tighten the four bolts on the rear cover
board with the 13# wrench. After completion
of installation of the rear cover board, stick the
heat-sinking asbestos in the position shown in
the figure. 14. Install radiator
Refer to 5.5.1, install the radiator as and other
components in place, and connect various steel
tubes and hoses well and smooth the hoses. No
twist or interference of any hose is permitted.
Engine Service
Refer to engine original manual
(optional)
Refer to the original manual of
Perkins engine (optional)
8. Power Train System
Front and Rear Axles.............................................................................2
Removal and installation of front and rear axles..................................................2
Service of front drive axle (refer to the original manual of CARRARO front drive axle)
Service of rear drive axle (refer to the original manual of CARRARO rear drive axle)
Service of front non-drive axle (refer to the original manual of CARRARO front non-drive axle)
Gearbox & Torque Converter As..........................................................10
Removal and installation of Gearbox & torque converter as.............................10
Removal and Installation of Tyre and Tyre rim.....................................14
8-2
Front and Rear Axles
Removal and installation of front and rear axles

front and rear axles
Front and rear axles
Removal (front axle)
1. Remove the front tyre
Refer to 5.6.3 Removal of Front Tires in Tires
and Rims, remove the front tires and place them
properly.
2. Remove front gearbox shaft
Remove the connecting bolts between the front 3. Remove front axle steering hose
drive shaft and the gearbox with the 6# inch Remove the two hoses on the front axle to the
hex wrench. Take down the connecting spline metering pump with the 24# wrench. After re-
between the front drive shaft and the front axle moval, wrap the hoses with clean plastic bags
and place it properly. and belts to prevent foreign matters from enter-
ing.
4. Removal of grease pipeline connector of front

axle
Remove the connector on the front axle end of
the grease pipeline (between the front axle and
the frame) with the 17# wrench. After removal,
wrap the grease pipeline with clean plastic bags
ing.
8-3
5. Remove battery 8. Remove front axle pin

Refer to 5.7.1 Removal of Battery of Electrical Lift and hold the front axle with travelling crane
System, remove the battery and place it prop- and sling. Let the M20X220 bolt (about 220mm
erly. long) pass through the cylinder jacket and screw
it in the threaded hole of the pin. Tighten the
6. Remove counterweight retaining ring
bolt with the pneumatic impact wrench (with a
Remove the circular retaining ring on the coun-
30# socket) continuously to drag out the pin of
terweight with the 13# wrench.
the front axle. Lift the front axle away for repair
or replacement.
7. Remove the bolt on axis pin

Remove the bolts from the axis pin of the front
axle with two 16# wrenches.
8-4
Installation (front axle)

1. Install front axle pin
Hold on to both ends of the front axle with the
sling. Lift the front axle to the mounting position
with the travelling crane. Align the pin hole and
let the pin pass through the hole. Add the pads
to adjust the clearance.After the pin entering
into the hole, adjust the positions of the holes of
the pin and the frame, and then install the bolts.
Tighten the double nuts with two 16# wrenches.
Make sure that the front axle is provided with a
displacement of 2-5mm after completion of in-
stallation of the mounting bolts.
2. Install counterweight retaining ring

Put the retaining ring of the counterweight in the
mounting position. Align the threaded holes of
the counterweight and install the bolts. And then
tighten the bolts with the 13# wrench.
8-5
3. Install battery
Refer to 5.7.3 Installation of Battery of Electrical
System, install the battery in place.
4. Installation of grease pipeline connector of front
axle
Remove the protection from the grease pipeline
connector. Screw the connector in the threaded
hole of the pin of the front axle, and then tighten
it with the 16# wrench.
6. Install front axle gearbox shaft

Let the spline of the front drive shaft enter into
the front axle end. Put the other end of the front
drive shaft in the mounting position of the gear-
box. Tighten the four fastening bolts with the 6#
inch hex wrench to 26±4N•m.
5. Install front axle steering hose

Remove the protection from the hose. Install the
hose onto the connector of the front axle with
the 24# wrench. After completion of tightening,
adjust the position of the connector with two 22#
wrenches. Make sure that the connector will not
interfere with the engine base.
8-6
Removal (rear axle)

1. Remove rear tyre
Refer to 5.6.3 Removal of Rear Tires of Tires
and Rims, remove the rear tires and place them
properly.
2. Remove rear gearbox shaft
Remove the connecting bolts between the rear
drive shaft and the gearbox as well as between
the rear drive shaft and the rear axle, respec-
tively, with the 6# inch hex wrench.Remove the
rear axle and place it properly.
7. Install front axle tyre

Refer to 5.6.3 Installation of Front Tires of Tires
and Rims, install the tires onto the front axle.
3. Removal of pipeline between assistor and rear

axle
Remove the hose connecting the assistor with
the rear axle with the 17# wrench. After removal,
wrap the hose with clean plastic bags and belts
to prevent foreign matters from entering.
8-7
4. Removal of pipeline between brake balance

valve and rear axle
Remove the hose connecting the brake balance
valve with the rear axle with the 17# wrench.
After removal, wrap the hose with clean plastic
bags and belts to prevent foreign matters from
entering.
6. Remove rear axle fixing bolt

Lift and hold both ends of the rear axle with the
travelling crane and sling. Remove the fasten-
ing bolts from the rear axle with the 30# socket,
extension rod and ratchet wrench (or special
wrench) . Remove the rear axle and place it
properly.
5. Removal of brake flexible shaft on side of rear
axle
Remove the fastening bolts on the right end of
the parking brake flexible shaft on the rear axle
with the 10# wrench. Remove the fastening
bolts on its left end with two 18# wrenches.
8-8
Installation ( rear axle)

1. Install rear axle fixing bolt
Lift and hold both ends of the rear axle with the
traveling crane and sling. Lift the rear axle to
the mounting position. Let the bolt pass through
the hole of the frame and the groove of the rear
axle. Compress the rear axle with the pressure
plates and then screw in the nut. Tighten the
bolt to 400-480N•m with the 30# socket, exten-
sion rod and ratchet wrench (or special wrench)
.
2. Install hand brake flexible shaft

Let the parking brake flexible shaft pass through
the two eye plates on the rear axle and put it in
the mounting position. Install the bolt and strain
the flexible shaft. Tighten the fastening bolt on
the right end of the flexible shaft with the 10#
8-9
wrench. And then, tighten the fastening bolt on

the left end of the flexible shaft with two 18#
wrenches.
4. Install booster to rear axle end piping

Remove the protection from the hose. Screw
the hose onto the rear axle with the 17# wrench.
5. Install rear drive shaft

Put the larger end of the rear drive shaft in
3. Install braking balance valve to rear axle piping
the mounting position of the rear axle. Tighten
Remove the protection from the hose. Screw
the four connecting bolts with the 6# inch hex
the hose onto the rear axle with the 17# wrench.
wrench. And then, put the other end of the
rear drive shaft in the mounting position of the
gearbox. Tighten the four connecting bolts to
26±4N•m with the 6# inch hex wrench.
8-10
Gearbox & Torque Converter As
Removal and installation of Gearbox & torque converter as
Gearbox & Torque

Converter As
Gearbox & torque converter as
Gearbox & torque converter as
Removal
1. Refer to 5.5.2 Diesel Engine, lift the gearbox as
2. Preparations for diesel engine and gearbox re-
moval
Install the two eye rings (with a nominal thread
diameter of M14) into the two holes on both
sides of the gearbox. Screw the eye rings in
place and hook the eye rings with the lifting
hook. Start the travelling crane and strain the
lifting hook to apply a slight force to the gear-
box.
6. Install the rear tyre

Refer to 5.6.3 Installation of Rear Tires of Tires
and Rims, install the rear tires onto the rear
axle.
3. Remove diesel engine and gearbox inside con-
nection bolts
Push aside the protective sleeve of the circular
hole on the down side of the start motor. Turn
the diesel engine fan blades to a proper position
until you can see the bolt in the hole as viewed
from the outside to inside.
8-11
Remove the bolt inside the hole with the 16#

socket, extension rod and ratchet wrench or
special wrench.And then, turn the fan blades
continuously until you have removed the re-
maining bolts. There are four bolts in total.
4. Removal of connecting bolts outside diesel en-

gine and gearbox
Remove the connecting bolts outside the diesel
engine and gearbox with the 16# wrench. Lift
the gearbox away and place it properly.
8-12
Installation
1. Install diesel engine and gearbox inside connec-
tion bolts
Install the two eye rings (with a nominal thread
diameter of M14) into the two holes on both
sides of the gearbox. Screw the eye rings in
place and hook the eye rings with the lifting
hook.Lift the gearbox to the mounting position
with the travelling crane. Align the mounting
holes of the gearbox and the engine and install
the bolts, and then tighten the bolts with the 16#
wrench.
2. Install diesel engine, gearbox inside connection

bolt
Turn the engine fan blades to a proper position
8-13
until the upper hole of the engine is in alignment

with the threaded hole inside the gearbox. Coat
the bolt with the 1277adhesive and install the
bolt. Tighten the bolt with the 16# socket, exten-
sion rod and ratchet wrench or special wrench.
And then, turn the fan blades continuously until
you have removed the remaining bolts. There
are four bolts in total.Finally, remove the eye
rings and lifting hook.
3. Installation of engine and gearbox as

Refer to 5.5.2 Lifting and Installation of Engine
and Gearbox As, install the engine and gearbox
as onto the machine.
8-14
Removal and Installation of Tyre and Tyre rim
Removal and Installation of 3. Remove tyre

Lift and hold the tire with the travelling crane
Tyre and Tyre rim and sling and unscrew the remaining nuts. Lift
the tire away and put it on level ground for re-
Tyre and tyre rim pair.
Removal (front tyre)

1. Park the machine and hold up the bucket and
outriggers.
Park the machine on level ground. Start the en-
gine and operate the handle of the control lever
on the loading end and lower the bucket until
the front end of the machine has been held up
and the front tires has been off the ground.
Installation (front tyre)

1. Install the front tyre
and sling. Lift the tire to the front axle to align
the mounting holes of the wheel rim to the
wheel rim bolts on the axle, and then install the
tire onto the axle.
2. Removal of wheel rim nuts
Unscrew the nuts with the 27# socket, extension
rod and ratchet wrench or special wrench and
remove some wheel rim nuts.
2. Installation of wheel rim nuts

Install the wheel rim nuts and tighten them
wrench or special wrench. Be sure to tighten the
nuts alternatively to 265N~355N•m.
8-15
Removal (rear tyre)

1. Park the machine and hold up the bucket and
outriggers.
Park the machine on level ground. Start the
engine and operate the outrigger handle on the
excavation side and raise the outriggers until
the rear end of the machine has been held up
and the rear tires has been off the ground.
3. Lay down the complete machine

Start the machine and operate the handle of the
control lever on the loading end and lower the
bucket until the front tires have been laid down
onto the ground steadily.
2. Remove fender
Remove the fixing bolts of the fenders with the
13# wrench and take down the fenders, and
then put the fenders properly.
3. Removal of wheel rim nuts

Unscrew the nuts with the 32# socket, extension
rod and ratchet wrench or special wrench and
remove some wheel rim nuts.
8-16
Installation (rear tyre)

1. Install the rear tyre
and sling. Lift the tire to the rear axle to align the
mounting holes of the wheel rim to the wheel
rim bolts on the axle, and then install the tire
onto the axle.
4. Remove tyre
and sling and unscrew the remaining nuts. Lift
the tire away and put it on level ground for re-
pair.
2. Installation of wheel rim nuts

Install the wheel rim nuts and tighten them
wrench or special wrench. Be sure to tighten the
nuts alternatively to 450N~550N•m.
3. Installation of fenders
Put the fender in the mounting position. After
aligning the mounting holes, install the bolts and
tighten the bolts with 13# wrench.
8-17
4. Lay down the complete machine

Start the machine and operate the handle of the
outrigger control lever and retract the outriggers
until the rear tires have been laid down onto the
ground steadily.

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Service Manual

Applicable type and model: CLG766A/777A

Outrigger (766A) ............................................................................................1-81

Fig. 1.4 Perkins Engine

Fig. 1.5 Weichai Engine

Fig. 1.6 Rear drive axle

Fig. 1.9 Mechanical shift gearbox

Fig. 1.7 Front drive axle

Fig. 1.8 Non- drive front axle

Fig. 1.10 Power shift gearbox

M10 38±5 (52±7) 53±4 (72±6)

M12 66±9 (90±12) 89±7 (120±10)

M14 107±15 (145±20) 144±11 (195±15)

M16 166±26 (225±35) 225±18 (305±25)

M18 229±33 (310±45) 306±26 (415±35)

M20 302±37 (410±50) 443±37 (600±50)

M22 443±59 (600±80) 590±52 (800±70)

M24 561±74 (760±100) 752±74 (1020±100)

M27 811±111 (1100±150) 1106±74 (1500±100)

M30 1106±148 (1500±200) 1364±11 (1850±150)

M33 1512±221 (2050±300) 2139±295 (2900±400)

M36 1955±258 (2650±350) 2286±184 (3100±250)

Bolt, nut and stud in grade 12.9

1/4 9±3 (12±4)

5/16 18±5 (25±7)

3/8 33±5 (45±7)

7/16 52±11 (70±15)

Thread size Standard Torque lb.ft (N•m)

1/2 74±11 (100±15)

9/16 110±15 (150±20)

5/8 148±18 (200±25)

3/4 266±37 (360±50)

7/8 420±59 (570±80)

Standard torque of connector nut

Thread Nut Torque (N•m)

Thread Nut torque (N•m)

Appendix: unit conversion table

Area in2 cm2 6.4516

cm2 in2 0.1550

Volume gal l 4.54609

Torque lbf•in N•m 0.112985

N•m lbf•in 8.85075

Pressure 2 psi bar 0.06895

bar 2 psi 14.5038

2 psi MPa 0.006895

MPa 2 psi 145.038

bar MPa 0.1

Speed ft/s m/s 0.3048

m/s ft/s 3.28084

Flow gal/min l/min 4.54609

l/min gal/min 0.219969

gal/in l/min 3.78541

l/min gal/in 0.264172

Temperature °F °C 5/9* (°F-32)

Care and Safety Warning

CAUTION damage the machine, it can also be dangerous, Do

Operating safety Warning

Routine Service No special protective measure is applied to new

Health 3. To remove the engine oil on your skin, take