Clg6611e (Dcec II) Service Manual 202007000-En

202007000
CLG6611E
ROLLER
SERVICE MANUAL
Applicable Type and Model: CLG6611E
Diesel Engine Model: 4BTAA3.9-C125

July 17, 2020 Table of Contents
CLG6611E
Table of Contents
General Information...........................................................................................................1-1
Power System ...................................................................................................................2-1
Powertrain System ............................................................................................................3-1
Hydraulic System...............................................................................................................4-1
Structural Component........................................................................................................5-1
Electrical System and A/C System ....................................................................................6-1
Cab and Covering Parts ....................................................................................................7-1
Appendix............................................................................................................................8-1
Table of Contents July 17, 2020
CLG6611E
1-1
July 17, 2020 General Information
CLG6611E
General Information
How to Use the Manual .....................................................................................................1-3
Important Safety Content...................................................................................................1-4
Cable Code Identification ..................................................................................................1-5
Coating Materials...............................................................................................................1-7
Weight Table .....................................................................................................................1-8
Unit Conversion Table .......................................................................................................1-9
Standard Torque Table....................................................................................................1-10
Usage Specification of Oil Product ..................................................................................1-14
Vehicle Technical Specification .......................................................................................1-16
1-2
General Information July 17, 2020
CLG6611E
1-3
July 17, 2020 How to Use the Manual
CLG6611E
How to Use the Manual ● Fault Diagnosis of DCEC Cummins Engine
Suggestions on How to Use and Read this

This Manual, which identifies and recommends Manual
the basic tools needed for certain service work,
is prepared for experienced technicians. This Manual starts with the "Failure
Phenomenon" to provide you with solutions for
This is the safety alert symbol identifier. troubleshooting. Please follow the diagram to
When you see such symbol on your machine troubleshoot.
or in this Manual, you should follow the
instructions in the safety information and be Instructions to Users
alert to the possibility of personal injury.
● Since the machine is affected differently by
The technical manual is divided into region or process, it is important to determine
maintenance and testing sections, where the which machine is applicable and which
maintenance section tells you how to repair the working devices are available.
components, and the testing section helps to
quickly identify most common faults. ● Some of the accessories and optional parts
in the Manual may not be transported to
Information is grouped for various components relevant regions, please consult your the
that require the maintenance instructions. Each distributors of Liugong in the region if
group begins with a summary list of all applicable required.
basic tools, service tools, other materials
required to perform the service work, service tool ● The materials and technical specifications in
kits specifications, wear tolerances and torque the Manual vary with changes in the product,
values. and all information, charts and specifications
in the Manual are the latest product
The technical manual is a rough guide for information available at the time of
specific machines, which contains as much publication. The Company shall reserve the
important information as possible needed for right to make any changes without notice.
fault diagnosis, analysis, testing and For the latest technical information, please
maintenance. consult the distributors of Liugong in the
Basic maintenance information is available from region or Service Department of LiuGong
other sources, including basic theory of Road Machinery Marketing Company.
operation, basic principle of troubleshooting, ● For the replacement of environment-friendly
general maintenance, basic fault types and their key parts and components when maintaining
causes. an engine, please use the OEM parts and
components of the same type and the same
Other Reference Manuals
specifications. Otherwise, LiuGong accepts
Basic information about the structure, operation no legal liability for any consequence
and maintenance of the machine can be referred resulting from the use of unapproved parts.
to in the following manuals which are sent to
users in the form of accompanying accessories.
● Parts drawings
● Operation and maintenance manual
● Parts Manual of DCEC Cummins Engine
● Service Manual of DCEC Cummins Diesel
Engine
1-4
Important Safety Content July 17, 2020
CLG6611E
Important Safety Content
Most accidents related to the operation, maintenance and repair of products are mostly caused by
negligence of basic safety rules or protective measures. If you can notice the potential accident hidden
danger before accidents occur, you can avoid accidents. Personnel concerned must be familiar with
potential accident hidden danger and have certain skills to use tools to troubleshoot after necessary
training.
Improper operation, lubrication, maintenance and repair are all dangerous and can cause death in
serious cases.
No operation, lubrication, maintenance, or repair on the machine is allowed until you read and
understand the contents of operation, lubrication, maintenance, and repair.
Safety precautions and warnings are listed in this Manual and on the products. Ignoring these warnings
could lead to death of the personnel concerned.
The dangers are marked with "safety alert symbols" and followed by "signal terms" such as "Danger",
"Warning" and "Caution".
The identifier of the safety warning "Warning" is as follows:

The meaning of this safety alert symbol is as follows: Caution! Watch out! For your safety! The
contents of the danger are explained in words or pictures under the warning board. Operations
that may cause damage to the machine are marked with "Caution" or " Warning" labels on the
machine and in this Manual.
It is impossible for Liugong to predict every hazardous operating environment. Therefore, the warnings
in this Manual and on the product cannot cover all the bases. If you use a certain tool, procedure,
operating method or operating technology that is not specially recommended by Liugong, you should
pay attention to whether you or others are safe. You should be sure that the operation, lubrication,
maintenance and repair procedures you choose do not damage or make the machine unsafe.
The instructions, numerical values and illustrations in this Manual are prepared based on the latest
information available at the time. The continuous improvement in the design of this machine will cause
changes in details, which may not be reflected in this Manual. Please contact Liugong or Liugong
distributor for the latest information about the machine or for any questions about the information in this
Manual.
California Recommendation Article 65
California believes that the diesel engine emissions and some compositions thereof can cause cancer,
birth defects or other reproductive damage.
Since battery posts, battery electrodes and related accessories contain lead and lead compounds, wash
your hands after touching them.
1-5
July 17, 2020 Cable Code Identification
CLG6611E
Cable Code Identification
The wire in circuit diagram is marked by combination of wire number, color abbreviation code and wire
gauge for maintenance. For example:
108 RD 50.0 It represents a wire with a red color, a wire number of 108 and a
wire diameter of 50.0 mm2
Wire gauge (Note: if the wire gauge is not marked, it is 0.85mm2)
Color abbreviation code
Wire Number
P26M00007
Wire Number
The wire number refers to a numeric code that identifies the wire by using three Arabic numerals
according to certain rules.
Wire Type
The types of wires used in construction machinery are generally AEX, AV, AVS, AVSS, and QVR. The
applicable ambient temperature ranges for various wires are shown in the Table below.
S/N Wire Type Wire Name Description Heat Resistance

Resistant to 70 °C (158 °F),
Low voltage wire for highway
1 QVR copper conductor PVC ≤70°C(158°F)
vehicles
insulated wire
The thickness of insulation
Thin-wall insulated low-voltage
2 AVSS layer is ≤80°C(176°F)
wire for vehicles
0.30~0.40mm{0.012~0.016 In}
Thin-wall insulated low-voltage
3 AVS layer is ≤80°C(176°F)
wire for vehicles
0.70mm{0.020~0.028In}
Insulated low-voltage wire for
4 AV layer is ≤80°C(176°F)
vehicles
0.60~2.0mm{0.024~0.079In}
Heat-resistant low-voltage wire Heat-resistant cross-linked
5 AEX ≤110°C(230°F)
for vehicles polyethylene wire
Color abbreviation code
Color English Abbreviation Color English Abbreviation

Black BLACK BK Blue BLUE BU
Grey GREY GY Green GREEN GN
Red RED RD Yellow YELLOW YL
1-6
Cable Code Identification July 17, 2020
CLG6611E
Color English Abbreviation Color English Abbreviation

Brown BROWN BR Pink PINK PK
Violet VIOLET VT Orange ORANGE OR
White WHITE WH Light blue LIGHTBLUE LTBU
Red/Green RED/GREEN RD/GN Yellow/Blue YELLOW/BLUE YL/BU
Note: The code consisting of 2 colors represents dual-color wire For example: "RD/GN" represents red-green wire.
Wire Specifications
The allowable current and voltage drop of AV wire are similar to those of of AVS, AVSS, and QVR, and
can be implemented with reference to the Table below.
Ambient
30°C (86°F) 40°C (104°F) 50°C (122°F) 60°C (140°F) 70°C (158°F)
temperature
Allowable
current/ voltage A mV/m A mV/m A mV/m A mV/m A mV/m
drop
0.85 18 463 16 412 14 360 11 283 8 206
1.25 23 407 21 372 18 319 14 248 10 177
2 31 338 28 305 24 262 20 218 14 153
3 42 291 38 263 33 228 27 187 19 132
5 57 248 51 222 44 192 36 157 25 109
8 74 213 66 190 57 164 47 135 33 95
Nominal
sectional 15 103 176 92 157 30 137 65 111 46 79
area 20 135 148 121 133 105 116 85 94 60 66
(mm2)
30 188 121 168 108 146 94 119 77 84 54
40 210 112 188 110 163 87 133 71 94 50
50 246 103 220 92 190 60 155 65 110 46
60 272 97 243 87 211 75 172 62 121 43
85 335 90 300 80 260 70 212 57 150 40
100 399 83 356 74 309 65 252 53 178 37
Circuit Type and Color Abbreviation Code
For general correspondence rules between circuit type and wire color, see the Table below.
Circuit type Color abbreviation code

Power wire OR, RD
Signal wire WH
Earth wire BK, GY
Communication wire RD/GN, YU/BU
1-7
July 17, 2020 Coating Materials
CLG6611E
Coating Materials
Item Specification Main features and uses

Anaerobic thread locking Features: Anaerobic, quick air drying
1277
sealant Uses: For parts that are not often disassembled
Thread locking sealant 1243 For detachable parts, usually speed sensor
Features: Rust protection for a long time
Long-term anti-rust agent LONG#2 light yellow Uses: For main pump mounting surface, sensor, hydraulic joint,
etc.
Molybdenum disulfide lithium-
2# For lubrication of cross axle, steering hinge, joint bearing, etc.
based grease
Features: Strong cleaning ability
Efficient cleaning agent 1755
Uses: For pump and motor
Features: Endothermic vaporization
Refrigerant R134a
Uses: For fluorine filling of air conditioner, etc.
Features: High temperature resistance, self-lubricating property,
medium resistance, used for sealing oil, gas, steam, water and
Anaerobic pipe thread sealant 1567
other medium pipeline tapers/taper threads
Uses: For water temperature sensor and oil pressure sensor
Cleaning agent for
HD-10 Used for cleaning oil pipe connectors, etc.
electromechanical equipment
Polyurethane sealant 1924 For water prevention of start motor and assembly clearance
RAL No. of paint
Liugong yellow RAL1006 Liugong gray RAL7021

90 90
1-8
Weight Table July 17, 2020
CLG6611E
Weight Table
The following table shows the reference value of the weight of each component. When using the lifting
equipment, please refer to the Table below to select the lifting appliance.
Weight (Kg) Weight (Ib)

Component
CLG6611E CLG6611E
Hood component assembly 90 200
Cab component assembly (including seat, instrument
400 1282
panel, etc.)
Engine assembly (excluding coolant and oil) 500 1105
Hydraulic twin pump 65 144
Water oil radiator assembly (excluding hydraulic oil
60 132
and coolant)
Drive axle assembly 715 1577
Tire assembly (including balance weight fluid) 460 1014
Fuel tank assembly (including hydraulic oil tank,
320 706
excluding hydraulic oil and fuel)
Hydraulic oil tank (excluding hydraulic oil) 280 617
Vibrating Motor 20 44
Propelling motor (Vibrating drum) 25 55
Propelling motor (Drive axle) 40 88
Steel gear reducer 145 320
Vibrating drum assembly (including reducer, propelling
4700 10364
motor, vibrating motor, etc.)
Vibration chamber assembly 354 781
Eccentric block component (vibration bearing) 110 243
Vibration chamber housing 180 397
Vibration chamber cover 85 187
Driver board 140 309
Front beam assembly 350 673
Front frame assembly 2068 4556
Steering hinge 79 174
1-9
July 17, 2020 Unit Conversion Table
CLG6611E
Unit Conversion Table
The Manual uses ISO International System of Units, and ISO international units are converted into
British units as shown in following figure:
Parameter Metric unit Imperial unit Multiple

mm In 0.03937
Length
mm ft 0.003281
L USgal 0.2642
Capacity L USqt 1.057
m3 Yd3 1.308
Weight kg lb 2.205
N kgf 0.10197
Intensity
N lbf 0.2248
Nm kgf-m 0.10197
Torque
Nm lbf-ft 0.7375
MPa kgf/cm3 10.197
Pressure
MPa psi 145.0
kW PS 1.360
Power
kW HP 1.341
Temperature °C °F °C×1.8+32
km/h mph 0.6214
Speed
min-1 rpm 1.0
L/min USgpm 0.2642
Flow
mL/rev cc/rev 1.0
1-10
Standard Torque Table July 17, 2020
CLG6611E
Standard Torque Table
Unless otherwise specified, the bolts used on this machine shall be tightened with the torque
requirements in the Table below.
Wrench Torque
NO. Description Bolt Specification
Size N.m lbft
Fixed bolt for shock absorber at front
1 M12×50-8.8-Zn.D 18 90±10 66±8
end of engine
Fixed bolt for shock absorber at rear end
2 M14×35-8.8-Zn.D 21 145±15 107±11
of engine
Fixed bolt for support at front end of
3 M18×55-8.8-Zn.D 27 310±35 229±23
engine
Fixed bolt for support at rear end of
4 M24×55-8.8-Zn.D 36 760±90 561±56
engine
5 Fixed bolt for diesel tank M24×60-8.8-Zn.D 36 760±90 561±56
6 Fixed bolt for hydraulic oil tank M10*30 16 52±6 38±4
Fixed bolt for rear cover of articulated
7 M24×120-10.9-Zn.D 36 1020±90 752±75
frame
Fixed bolt for upper and lower end caps
8 M12×12-45H-Zn.D 18 90±10 66±7
of articulated frame
9 Fixed mounting bolt for drive axle M24×2×245-10.9-Zn.D 36 1020±90 752±75
10 Fixed mounting bolt for rim M20 30 800±70 590±59
Fixed bolt for mounting and connecting
11 M24×110-8.8-Zn.D 36 760±90 561±56
plate of vibrating drum assembly
Fixed mounting bolt for shock absorber
12 M12×45-8.8-Zn.D 18 90±10 66±7
of vibrating drum
Fixed mounting bolt for vibration
13 M16×60-8.8-Zn.D 24 225±25 166±17
chamber
Fixed mounting bolt for vibration
14 M12×45-8.8-Zn.D 18 90±10 66±7
chamber cover
Fixed mounting bolt for front beam of
15 M24×75-8.8-Zn.D 36 760±90 561±56
front frame
Mounting bolt for intermediate shaft
16 M12×80-8.8-Zn.D 16 90±10 66±7
coupling of vibrating drum
17 Bolt for cab mounting base M20×140-8.8-Zn.D 30 430±50 317±32
Connecting bolt for coupling mounting
18 M10×1×35-8.8-Zn.D 16 47±2 35±2
flange and diesel engine flywheel
Set screw for coupling bushing and
19 M16×1.5×18-12.9 120±6 89±4
pump shaft
Connecting bolt for pump connecting
20 flange and flywheel casing of diesel M10×30-8.8-Zn.D 16 57±3 42±2
engine
1-11
July 17, 2020 Standard Torque Table
CLG6611E
Tightening torque of sealed hose connector of 24° cone with O-ring
Internal diameter
Tightening torque
Series Thread size of hose
mm N.m lbft
M12×1.5 5 16±1 11.8±0.7
M14×1.5 6.3 16±1 11.8±0.7
M16×1.5 8 26±2 19.2±1.5
M18×1.5 10 37±2 27.3±1.5
M22×1.5 12.5 47±2 34.7±1.5
Light type
M26×1.5 16 89±4 65.6±3.0
M30/2 19 116±5 85.6±3.7
M36/2 25 137±6 101±4.4
M45/2 31.5 226±11 166.7±8.1
M52/2 38 347±16 255.9±11.8
M14X1.5 5 26±2 19.2±1.5
M16X1.5 6.3 42±2 31.0±1.5
M18X1.5 6.3 53±2 39.1±1.5
M20X1.5 8 63±3 46.5±2.2
M22X1.5 10 79±4 58.3±3.0
Heavy type
M24X1.5 12.5 84±4 62.0±3.0
M30X2 16 126±6 92.9±4.4
M36X2 19 179±8 132.0±5.9
M42X2 25 263±12 194.0±8.9
M52X2 31.5 368±17 271.4±12.5
1-12
Standard Torque Table July 17, 2020
CLG6611E
Tightening torque of bolt of flange-type sealed hose connector
Performance Tightening torque

Series Bolt
level of bolt N.m kgf.m
M8 25.2±1.2 2.57±0.12
M10 52.5±2.5 5.35±0.25
8.8
M12 96.6±4.6 9.85±0.47
M16 220±10 22.5±1.07
M8 33.6±1.6 3.42±0.16
Light type
M10 73.5±3.5 7.5±0.35
M12 136±6 12.8±0.6
10.9
M16 310±15 31.6±1.5
M8 25.2±1.2 2.57±0.12
M10 52.5±2.5 5.35±0.25
M12 96.6±4.6 9.85±0.47
M16 8.8 220±10 22.5±1.07
M20 420±20 42.8±2.0
M8 33.6±1.6 3.42±0.16
Heavy type
M10 73.5±3.5 7.5±0.35
M12 10.9 136±6 12.8±0.6
M16 310±15 31.6±1.5
M20 577±27 58.9±2.8
Tightening torque of thread angle type sealed hose connector
Connector
Carbon steel, alloy steel Aluminum product
material
Tightening torque Tightening torque
Thread size
N.m kgf.m N.m kgf.m
G1/8 8.75±1.25 0.90±0.12 / /
G1/4 36±2 3.67±0.2 29.3±2.2 3.0±0.2
G3/8 73.5±4.5 7.5±0,46 49±3 5.0±0.3
G1/2 110±10 11.2±1.0 55±5 5.6±0.5
G3/4 165±15 16.8±1.5 74±4 7.5±0.4
G1 225±25 23.0±2.55 / /
G1-1/4 275±25 28.0±2.55 / /
G1-1/2 285±15 29.1±1.5 / /
1-13
July 17, 2020 Standard Torque Table
CLG6611E
Tightening torque of connector
Tightening torque
Thread size
N.m kgf.m
M12 24±2 2.4±0.2
M14 30±2 3.1±0.2
M16 30±2 3.1±0.2
M18 30±2 3.1±0.2
1-14
Usage Specification of Oil Product July 17, 2020
CLG6611E
Usage Specification of Oil Product
Oil change interval and approximate refill capacity
Oil change interval Approximate refill

Type Part
(Operating hour) capacity (L)
Engine oil Engine 400 11
Hydraulic oil Hydraulic oil tank 2000 110
Wheel rim of drive axle 1000 5×2
Main drive of drive axle 1000 8
Gear oil
Reducer 1000 1.9
Vibration chamber 500 2.3×2
Diesel oil Fuel tank 200
Coolant Water Radiator 2000 28
Technical Specification of Oil
When replenishing and replacing all kinds of oils for this machine, choose oils with specifications and
varieties specified in the table below to ensure the normal operation of the machine.
Oil type Ambient temperature Oil specification Position

-35~10 °C 0W-20 (API CH-4)
-35~30 °C 0W-30 (API CH-4)
-35~40 °C 0W-40 (API CH-4)
-30~30 °C 5W-30 (API CH-4)
Diesel engine oil Engine
-30~50 °C 5W-40 (API CH-4)
-20~40 °C 10W-30 (API CH-4)
-20~50 °C 10W-40 (API CH-4)
-10~50 °C 15W-40 (API CH-4) ★
≥8 °C 5#
≥4 °C 0# ★
≥-5 °C -10#
diesel oil Engine
≥-14 °C -20#
≥-29 °C -35#
≥-44 °C -50#
HM46 anti-wear hydraulic
-5~45 °C
oil ★
HV32 cryogenic hydraulic Working hydraulic system,
Hydraulic oil -15~35 °C
oil steering hydraulic system
HS32 cryogenic hydraulic
-18~35 °C
oil
1-15
July 17, 2020 Usage Specification of Oil Product
CLG6611E
Oil type Ambient temperature Oil specification Position

-40~50 °C Caltex SAE75W-90
Vibration chamber
-25~50 °C Caltex SAE80W-90
Gear oil -40~50 °C SAE75W-90
-20~50 °C SAE80W-90 Drive axle or reducer
-15~50 °C SAE85W-90 ★
Vibrating wheel walking
Molybdenum disulfide
Lubricating oil -20~40 °C bearing, steering hinge,
lithium base grease 2# ★
steering cylinder pin, etc.
Ethylene glycol-37 °
≥-30 °C
LiuGong HEC-II-35
Antifreeze Water tank
Ethylene glycol-45 °
≥-40 °C
LiuGong HEC-II-45
Air booster pump and clutch
Brake fluid DOT3 or DOT4
booster pump
Refrigerant R134a Air Conditioner
Note: Those marked with ★ are commonly used grades.
1. The oils marked with ★ are those added in the machine when it leaves the factory.
2. Oils of the same specification and different brands cannot be mixed in use. If, for some reason,
another brand of oil must be used, please clean the system first.
3. If the machine is used in low-temperature and high-cold areas for a long time, the hydraulic oil
should be HV32 low-temperature anti-wear hydraulic oil.
4. All kinds of lubricating oils should be replaced on time. Even if the oil is clean, it may
deteriorate if it has been kept for a long time.
5. The choice of fuel should be determined according to the local minimum temperature when the
machine is in use.
6. The oil must be selected according to both oil grade and oil viscosity grade. Only the oil that
meets the requirements for both oil grade and oil viscosity grade can be used on the engine.
7. The content provided in this manual is based on the current situation of the machine at the
time of compiling this manual. Any product is in the process of continuous improvement, and
this machine is no exception.
1-16
Vehicle Technical Specification July 17, 2020
CLG6611E
Vehicle Technical Specification
Applications
Fully Hydraulic Single Drum Vibratory Roller CLG6611E is a heavy self-propelled vibratory roller, which
is mainly suitable for the compaction of large area fill in foundation and sub-foundation layers of various
materials. It is ideal compaction equipment for the construction of high-grade highways, high-speed
railways, ports, dams and industrial construction sites.
This machine belongs to common construction machinery which is not suitable for flammable, explosive,
high dust or toxic gas environments.
Requirements of Operating Environments
1. Altitude: ≤3000m
2. Ambient temperature: -40°C~50°C (The cold starting Aid device is not available)
This Roller cannot be used in environments with tumbling or falling objects.
The preventive measures on operation, maintenance and safe operation rules given in this
Manual are only applicable to this machine for its intended use. If this machine is beyond the
scope of use specified in this Manual, LiuGong Machinery Co., Ltd. shall not assume any safety
responsibility, and the safety responsibility in such operations shall be borne by the user. The
operations prohibited in this Manual are allowed in no case.
1-17
July 17, 2020 Vehicle Technical Specification
CLG6611E
Main Component Diagrams
5
4
6
10
8
9
P26M00027
1. Front frame 5. Diesel engine 9. Ladder

2. Vibrating drum 6. Hood 10. Instrument desk
3. Cab 7. Rear frame
4. Rearview mirror 8. Rear axle
1-18
CLG6611E
Main Technical Parameters
All rated operating capabilities of the machine are based on the requirements of national standards. If
the operating environment conditions of the machine are different from the above reference conditions,
the operator should take these conditions into consideration.
Outline Dimension
P26M00028
1-19
CLG6611E
Vehicle Parameter
Item Unit CLG6611E

Operating Mass kg 11350
Mass on vibrating drum kg 6350
Mass load parameter
Mass on drive axle kg 5000
Front Drum Static Linear Load N/cm 298
L: Length mm 6000
W: Width mm 2280
H: Height mm 3180
C: Drum width mm 2130
Dimension parameters A: Drum diameter mm 1555
S: Drum shell thickness mm 30
B: Axle base mm 2980
0: Turning angle ° 35
R: Min. outer turning radius mm ≤ 6500
Compaction Vibration Frequency Hz 30/33

mechanism Nominal Amplitude mm 2.0/1.1
parameters Centrifugal Force kN 300/190
Component Parameter
Item Unit CLG6611E

Manufacturer DCEC Cummins
Model 4BTAA3.9-C125
Emission Regulation Tire II
Rated Power kW 93
Rated Rotation Speed r/min 2200
Engine system Theoretical Fuel Consumption g/kW.h 227
Max. Torque N.m 480
Number of Cylinders 4
Displacement L 3.9
Aspiration Turbocharger
Cooling Type Water Cooling
1-20
CLG6611E
Item Unit CLG6611E

Manufacturer Fengyi
Rear Axle
Model PS50.60B
Manufacturer Henan Fengshen
Tyre Specification 23.1-26-12PR
Transmission System Tyre Pressure kPa 200-220
F1/R1 km/h 6
F2/R2 km/h 10.5
Travel Speed
F3 km/h \
F4 km/h \
Variable displacement piston
Type
pump
Propelling Pump Max. Displacement ml/rev 75
Max. working pressure bar 450
Theoretical torque N.m/bar 1.19
Type
motor
Drum Propelling Max. Displacement ml/rev 55
Motor
Travel Hydraulic Variable displacement motor
Type
System with cambered axle
Drum Propelling Max. Displacement ml/rev 80
Motor
Planetary reducer with parking
Type
brake
Reducer
Ratio 41.1
Max. Output Torque N.m 18000
Pressure Filter for
μm 10
Hydraulic filter Suction
Return Filter μm 10
Type
pump
Vibrating Pump Max. Displacement ml/rev 46
Vibrating Hydraulic Theoretical torque Nm/bar 0.73
System Constant displacement piston
Type
motor
Vibrating Motor Max. Displacement ml/rev 44
1-21
CLG6611E
Item Unit CLG6611E

Type Gear pump
Steering Pump
Displacement ml/rev 25
Steering Hydraulic Displacement ml/rev 500
Steering gear
System Max. working pressure bar 120
Bore mm 100
Steering Cylinder
Piston rod radius mm 45
Type hydraulic neutral
Service brake
Rated brake toque np
Type Normally engaged wet brake
Brake System Parking brake Rated brake toque Nm 23485Nm(front)+32500Nm(axle)
Release pressure bar 10+17
Emergency
Type cut off releasing oil
brake
Type direct driven
Start Motor
Rated power KW 6
Battery Specification V/Ah 24/200
Electrical System
Type include alternator fan
Alternator Voltage V 28
Current A 70
A/C System
Notes:
1. In the continuous updating and improvement of Liugong products, we reserve the right to change the design
parameters without informing the users.
2. These parameters are theoretical values, with tolerance limits thereof being given by Liugong standard during the test.
1-22
CLG6611E
2-1
July 17, 2020 Power System
CLG6611E
Power System
Basic Information...............................................................................................................2-3
Safety .....................................................................................................................................................2-3
Overview -- System Components and Locations ...................................................................................2-5
System Technical Parameters ...............................................................................................................2-7
List of General Tools and Fixtures .........................................................................................................2-8
Structure and Function ......................................................................................................2-9

Diesel Engine .........................................................................................................................................2-9
Overview ............................................................................................................................................2-9
Diesel Engine ...................................................................................................................................2-10
Fuel System .........................................................................................................................................2-11
Fuel tank Assembly..........................................................................................................................2-11
Fuel Line ..........................................................................................................................................2-12
Cooling System ....................................................................................................................................2-14
Overview ..........................................................................................................................................2-14
Intake and Exhaust System .................................................................................................................2-19
Intake and Exhaust Assembly..........................................................................................................2-19
Air Cleaner .......................................................................................................................................2-21
Turbocharger....................................................................................................................................2-24
Test and Adjustment........................................................................................................2-26

Adjustment of Valve Clearance............................................................................................................2-26
Measurement of Crankcase Blow-by ...................................................................................................2-28
Removal and Installation .................................................................................................2-35

Diesel Engine Maintenance Table .......................................................................................................2-35
Removal and Installation of Diesel Engine ..........................................................................................2-37
Removal of Diesel Engine Assembly ...............................................................................................2-37
Installation of Diesel Engine Assembly ............................................................................................2-42
Removal and Installation of Intake System ..........................................................................................2-44
Removal of Intake System ...............................................................................................................2-44
Installation of Intake System ............................................................................................................2-45
Removal and Installation of Exhaust System.......................................................................................2-46
Removal of Exhaust System ...........................................................................................................2-46
Installation of Exhaust System .........................................................................................................2-47
2-2
Power System July 17, 2020
CLG6611E
Removal and Installation of Cooling System........................................................................................2-48

Removal of Cooling System.............................................................................................................2-48
Installation of Cooling System..........................................................................................................2-51
Removal and Installation of Radiator ...................................................................................................2-52
Removal of Radiator ........................................................................................................................2-52
Installation of Radiator .....................................................................................................................2-54
Removal and Installation of Diesel Engine Fan ...................................................................................2-55
Removal of Diesel Engine Fan.........................................................................................................2-55
Installation of Diesel Engine Fan......................................................................................................2-55
Removal and Installation of Coupling ..................................................................................................2-56
Removal of Coupling........................................................................................................................2-56
Installation of Coupling.....................................................................................................................2-57
Fault Diagnosis and Troubleshooting ..............................................................................2-59

Common Fault Diagnosis of Diesel Engine..........................................................................................2-59
2-3
July 17, 2020 Basic Information
CLG6611E Safety
Basic Information
Safety
Compressed Air
Compressed air may cause personal injury.

When using the compressed air for cleaning,
wear the mask, protective suits and safety
shoes. The maximum pressure of the
compressed air for cleaning should be lower than P26P00027
0.2 MPa.
Prevent Burns
Safe Disposal of Waste Fluid
After the machine has been running for a period
● Improper disposal of waste engine oil, diesel of time, some parts will heat up and should be
and urea is harmful to environment and repaired or inspected after these parts have
ecosystem. Disposal shall conform with the cooled down.
local laws and regulations.
● The liquid spilled from the machine during
inspection, maintenance, testing, adjustment
and repair must be kept in a container. A
suitable container for liquid collection shall be
prepared in advance before opening any fluid
chamber or disassembling the parts
containing fluid. Use a suitable container P26P00028
when draining the fluid.
● Do not use food or beverage containers
because the fluid in such containers may be
drunk by others by mistake.
P26P00026
2-4
Basic Information July 17, 2020
Safety CLG6611E
Coolant ● Put oily wipes or other combustible materials

in a protected container and place it in a safe
● At working temperature, the engine coolant is place.
at high temperature and has pressure. The
● Do not weld or flame cut pipes containing
radiator and all the lines connected to the
flammable liquids. Before welding or cutting,
radiator contain hot water or vapor, which can
flammable liquids should be cleaned up.
cause serious burns.
● Flammable materials such as fuel, lubricant
● When checking coolant level, the engine
or other debris accumulated on the machine
shall be shut down and the filler cap shall be
should be cleaned up.
cooled below 50°C. Loosen the filler cap of
the cooling system slowly to release
Diethyl Ether
pressure.
● Coolant contains alkali which may cause ● Do not start the machine by use of ether.
injury, so please prevent it from touching the ● Any attempt to start the engine with diethyl
skin, eyes and mouth. ether may result in serious damage to the
engine or casualties.
P26P00031
P26P00029
Fire & Explosion Prevention
● The mixtures of all fuels, most lubricants and

some coolants are flammable substances.
● Fuel leakage onto the hot surfaces or
electrical components may cause fire.
● Do not smoke while refueling or in refueling
areas and in places where combustible
materials are stored.
P26P00030
● Store fuel and lubricants in containers

marked with the corresponding marks.
2-5
CLG6611E Overview -- System Components and Locations
Overview -- System Components and Locations
The function of the power system is to convert chemical energy of fuel into mechanical energy for the
machine. The powertrain includes: diesel engine mounting assembly, intake and exhaust system
assembly, heat dissipation system assembly, and fuel system assembly.
Modular Structure Diagram of Power System
Fuel System
Heat-Removal
Power System
System
Intake and
Exhaust System
Installation of
Diesel Engine
P26P00104
Location of Power System on Vehicle
3
2
P26P00032
1. Fuel System 2. Intake and Exhaust 3. Installation of Diesel 4. Cooling System

System Engine
2-6
Overview -- System Components and Locations CLG6611E
Power System Components
3
4
5
2
1 6
P26P00033
1. Manual accelerator 3. Air Prefilter 5. Diesel Engine 7. Oil water separator

2. Radiator 4. Air Cleaner 6. Silencer 8. Fuel tank
2-7
CLG6611E System Technical Parameters
System Technical Parameters
Model DCEC Cummins, 4BTAA3.9-C125

Type In-line four cylinder, four-stroke, water cooling
Emission Regulation China stage II, EU Stage II, Tire2
★Rated Power 93kW/2200r/min(125BHP/2200rpm)
Diesel Engine
★Max. no-load speed 2460r/min
★Min. no-load speed 900rpm
Oil Level 9-11L
Rotation direction Anticlockwise (viewed from flywheel casing)
Fan Diameter 639mm, 9 blades, induced
Cooling System Opening temperature: 82°C
Thermostat
Full opening temperature: 93°C
Oil System Oil Filter Full flow, replaceable (rotary filter)
Preheating System Preheating Method Grille heating
Core type Plate-fin
Water Radiator 800mmX404mmX140mm
Core size (height Xwidth Xthickness)
(31.4961InX15.9055InX5.5118In)
Core type Plate-fin
Air-air intercooler 450mmX400mmX90mm
(17.7165InX15.7480InX3.5433In)
Core type Plate-fin
Hydraulic Oil Radiator 800mmX226mmX140mm
(31.4961InX8.8976InX5.5118In)
Note: The data marked with ? is based on the diesel engine with fuel system, the water pump and intake
resistance of 250 mm water height (atmospheric pressure of 2.449kPa), exhaust resistance of 50 mm
mercury height (atmospheric pressure of 7kPa) excluding generators, fans, optional configuration and
transmission components.
2-8
List of General Tools and Fixtures CLG6611E
List of General Tools and Fixtures

Name Specification
Open-end wrench 5#, 7#, 8#, 10#, 11#, 12#, 13#,16#, 18#, 19#, 20#, 22#, 24#, 30#
Ratchet wrench, socket Ratchet wrench, 10#, 11#, 12#, 13#, 16#, 18#, 19#, 20#, 22#, 24#, 30# socket
Torque wrench 120±6N.m(12±0.6kgf.m),1020±6N.m(102±0.6kgf.m)
Crane Above 2t (4410Ib)
Wire rope with hook Bearing 840 Kg(1852.2 Kg) or more
Steel ruler Steel ruler
Straight screwdriver
Cross screwdriver T25
Lifting lug
Plastic sealing film
Waste oil barrel
Note:
Precautions for removal and installation are as follows:

1. Removal and installation must be carried out when the engine is cool.
2. Measuring equipment and tools such as torque wrenches are required to have inspection certificate
issued by metrological service.
3. Due to the large number of other related components on the complete machine involved in the
removal and installation of the components, the removed components (especially the standard
components) should be properly placed to avoid problems such as mis-installation, neglected
installation and parts loss during reassembly.
4. If other parts on the vehicle need to be removed and installed during removal and installation of
various components, use tools with reference to the list of tools for removal and installation of other
parts, and do not list them again in the list of tools for these components.
5. The removal and installation of open-end wrench, that of blower gun and socket and that of ratchet
wrench and socket, all of which can achieve the desired effect, can be optional.
2-9
July 17, 2020 Structure and Function
CLG6611E Diesel Engine
Structure and Function
Diesel Engine
Overview
Components and Locations
The diesel engine installation assembly mainly consists of hydraulic pump mounting flange, coupling,
diesel engine, diesel engine front support, diesel engine front shock absorber, diesel engine rear
support, and diesel engine rear shock absorber.
4 8
2
1
7 9
P26P00652
1. Hydraulic Pump Mounting Flange 4. Hand Throttle 7. Oil Drain Pipe

2. Coupling 5. Front Support 8. Rear Support
3. Diesel Engine 6. Front Shock Absorber 9. Rear Shock Absorber
2-10
Structure and Function July 17, 2020
Diesel Engine CLG6611E
How It Works
The function of the diesel engine installation assembly is to enable the diesel engine to be installed
effectively.
The working principle of the diesel engine assembly is that the diesel engine is fixed to the vehicle
through a diesel engine mount consisting of a mounting base and shock absorbers, so that through the
vibration isolation function of the shock absorber, the diesel engine can work in a better environment
while the transmission of vibration of the diesel engine to the vehicle can be reduced, thereby improving
the riding comfort. Generally speaking, there are the following requirements for the diesel engine
installation assembly.
1. It can bear dynamic and static loads under all working conditions, and enable the displacement of the
engine assembly in all directions to be within an acceptable range without interference with other
parts on the chassis. At the same time, there will be no damage to parts before the overhaul of the
diesel engine.
2. It can sufficiently prevent the transmission of the vibration generated by the diesel engine to the
frame and the cab to reduce the vibration noise.
3. It can sufficiently isolate the vibration transmitted to the diesel engine through the diesel engine
mount due to uneven road surface to reduce the vibration noise.
4. It can ensure that the bending moment of the connecting surface between the diesel engine block
and the flywheel casing does not exceed the allowable value from the diesel engine manufacturer.
5. Visually check the diesel engine mount (including diesel engine mounting base, shock absorbers,
etc.) on a regular basis. Tighten the bolts if they are loose. Replace the diesel engine mounting base
if it is cracked. Replace the shock absorber if it is cracked, damaged or corroded.
Diesel Engine
Technical Parameters
Model/Weight (wet weight) DCEC Cummins 4BTAA3.9-C125

Weight (Wet) 453Kg
Number of Cylinders 4
Bore 102mm
Stroke 120mm
Displacement 3.9L
Induction system Inter-cooling
Rated Power 93kW
Max. no-load speed 2460r/min
Min. no-load speed 900r/min
Oil pressure alarm limit 69kPa
Intake manifold alarm temperature 91°C
Exhaust temperature 580±25°C
2-11
CLG6611E Fuel System
Fuel System
It consists of a fuel tank assembly and diesel lines.
Fuel tank Assembly
Technical Parameters
Available Volume 200L/52.841USgal
Introduction to Component Structure and Principle
The fuel tank assembly mainly consists of a fuel tank, an oil inlet, a return port, an oil filler and a cleaning
port.
3
2 4
6
1
P26P00035
1. Cleaning port 3. Fuel level sensor 5. Oil inlet

2. Fuel tank 4. Oil filler 6. Fuel return port
2-12
Fuel System CLG6611E
Fuel Line
The fuel lines mainly consist of fuel return pipe, fuel inlet pipe, and fuel-water separator.
1
4
P26P00653
1. Fuel inlet pipe I 3. Fuel inlet pipe II

2. Oil water separator 4. Oil return pipe
2-13
CLG6611E Fuel System
Schematic Diagram and Working Principle
P26P00654
The function of the fuel line is to provide clean and sufficient fuel to the diesel engine to ensure the
normal operation of the diesel engine. Its working principle is as shown in the figure above. when the
diesel engine is working, the fuel delivery pump sucks fuel from the fuel tank, removes water from the
fuel through the oil-water separator, removes impurities from the fuel through the fuel filter, and then
sends the fuel to the fuel injection pump. In the fuel injection pump, the fuel is supplied to the fuel injector
after being pressurized and metered and finally injected into the combustion chamber through the fuel
injector. The return fuel at the top of the fuel injector returns to the fuel inlet of the fuel injection pump,
and the excess fuel supplied by the fuel delivery pump returns to the fuel tank.
2-14
Cooling System CLG6611E
Cooling System
Overview
The cooling system consists of radiators and lines connected thereto.
2
3 6
P26P00038
1. Diesel engine intake pipe 3. Diesel engine vent pipe 5. Water inlet pipe of diesel 7. Water supply pipe
2. Intercooler intake pipe 4. Diesel engine outlet pipe engine 8. Radiator assembly
6. Radiator drain pipe
2-15
CLG6611E Cooling System
Schematic Diagram and Working Principle
The cooling system consists of radiators and corresponding lines connected thereto, wherein the
radiator consists of a water radiator, an air-air intercooling radiator and a hydraulic oil radiator. Its
function is to disperse the heat generated by each component (or system) during operation into the air
along with the cooling air to ensure the normal operation of each component within a suitable
temperature range.
Radiator Structure
P26P00039
1. Auxiliary Radiator 2. Hydraulic Oil Radiator 3. Water Radiator 4. Air-Air Intercooling Radiator
Hydraulic Oil Radiator
The function of the hydraulic oil radiator is mainly to dissipate heat generated by the hydraulic oil when
the hydraulic system is working. Excessive temperature of the hydraulic oil temperature will result in the
following adverse effects: decreased viscosity of the hydraulic oil, increased leakage and decreased
volumetric efficiency of the hydraulic oil; decreased oil film strength, decreased lubricating property and
increased friction force, causing the system to heat up and form a vicious cycle; accelerated oxidation of
oil, changes in property and reduced service life of oil; heating and deformation of hydraulic components
causing clearance changes and even "jamming" of kinematic pairs with different coefficients of thermal
expansion.
2-16
Water Radiator
The diesel engine cooling system is mainly consists of radiator (water tank), water pump, fan,
thermostat, oil cooler, inlet and outlet pipes and other parts.
5 4
1
P26P00040
1. Water supply line 3. Water line of engine block 5. Water line to cylinder block
2. Water pump 4. Water line of engine block
P26P00041
1. Water line between engine block and cylinder block 2. Water line returned to radiator
2-17
CLG6611E Cooling System
3 1 5
6
P26P00042
1. Water line of cylinder block 3. Thermostat not open 5. Thermostat open

2. Thermostat 4. Water line returned to engine block 6. Water line returned to radiator
The cooling system of this engine adopts a direct driven fan for cooling by suction. The working principle
of the system is as follows: the water outlet at the lower portion of the water radiator is connected to the
water inlet of the diesel engine through a water pipe, and the water pump pumps the coolant into the
water channel of the cylinder block. the coolant first passes through the water jacket inside the cylinder
block to cool the cylinder, then flows upward to cool the cylinder head, and then gathers at the
thermostat through the water outlet manifold. When the coolant temperature is lower than 82°C (180°F),
the thermostat is closed and all coolant is bypassed to the inlet of the water pump. At this moment,
coolant only circulates between the cylinder block and the cylinder head, which can warm the vehicle
quickly. When the coolant temperature reaches 82 °C (180°F), the thermostat starts to open, some
coolant flows to the water inlet at the upper portion of the radiator to enter the radiator and is cooled by
the cooling fan. When the coolant temperature is above 95°C (203°F), the thermostat is fully opened, the
bypass hole is closed, and all coolant is cooled by the radiator. At this time, the coolant flow direction is
as shown in the figure.
P26P00105
2-18
Air-Air Intercooling Radiator
The hot air compressed by the air-air Intercooling turbocharger is cooled sufficiently before entering the
cylinder for combustion in order to increase the volumetric efficiency of diesel engine, promote
combustion and reduce nitrogen oxide emissions.
P26P00043
2-19
CLG6611E Intake and Exhaust System
Intake and Exhaust System
Structure Diagram of Intake and Exhaust System of Diesel Engine
P26P00044
1. Air Cleaner 3. Silencer 5. Intake pipe

2. Exhaust Tail Pipe 4. Bellow 6. Air Prefilter
Intake and Exhaust Assembly
The function of the intake and exhaust assembly is to
1. Supply the diesel engine with clean and dry air with proper temperature for combustion to minimize
diesel engine wear and maintain optimal diesel engine performance.
2. Ensure the best performance of the diesel engine while safely transporting all exhaust gases away
from the diesel engine and quietly discharging them to the atmosphere.
3. Provide clean and dry air to the air compressor of the diesel engine to brake the vehicle.
2-20
Intake and Exhaust System CLG6611E
The working principle of the intake and exhaust assembly is as follows:
Intake air is from the air prefilter which is provided with rotating blades, so that the large dust in the intake
air can be exhausted from the bottom of the prefilter cap. The intake air reaches the air cleaner and
removes small dust and moisture through the filter element, namely it becomes clean and dry air and is
conveyed to the turbocharger, which is driven by the exhaust of the diesel engine to pressurize the
intake air, increase the air inflow and ensure the full combustion of the fuel. The air coming out of the
turbocharger passes through the air-air intercooler of the cooling system and the electric heater of the
diesel engine itself to obtain a proper temperature and then enters the diesel engine cylinder block for
combustion. The exhaust gas generated after combustion reaches the turbocharger through the exhaust
manifold, drives the turbocharger to pressurize the intake air, and then is exhausted to the silencer to
reduce exhaust noise. The exhaust air passes through the silencer and then is exhausted to the
atmosphere through the tail pipe.
Intake and Exhaust Path Diagram of Diesel Engine
P26P00045
2-21
Air Cleaner
Component Structure and Principle
The air cleaner consists of a housing, a main filter element, a safety filter element and an end cover.
P26P00046 P26P00047
1. Main filter element 2. Safety filter element
The air cleaner adopts two stage filtration of the main element and the safety element to ensure that the
air entering the diesel engine is clean and dry.
Main element: it has a filtering capability and can remove more than 99.9 % of dust in the air.
Safety element: it provides additional protection during maintenance operation or when the main
element is damaged or the seal is not good.
The air cleaner clog warning of this model is electronic induction type. When the filter is working for a
period of time and more dust is adsorbed on the filter element, the gas pressure passing through the
filter will become lower. When the intake resistance of the air cleaner exceeds 6.3 KPa (0.06 kgf/cm3 ),
the air cleaner clog warning sensor installed between the air cleaner and the turbocharger sends a signal
to the air cleaner clog indicator on the instrument panel. When the indicator is on, the air cleaner should
be maintained.
2-22
Main Element of Air Cleaner - Cleaning/Replacement
If the instrument panel is equipped with an air cleaner clog warning indicator of engine, when the
indicator is on, the air cleaner of engine should be maintained at this time.
Figure Operation Steps

1. Shut down the engine and open the hood.
2. Remove the outer cover of air cleaner.
P26P00048
3. Rotate along the direction of the housing to take out

the main element.
P26P00049
4. Check the main element.

a) If the folds and gaskets are damaged, the main
element should be replaced.
b) If the main filter element is not damaged, the
main element should be cleaned.
5. Clean the inner wall of the air cleaner housing.
P26P00050
2-23

6. Clean the main element and blow back the main
element from inside to outside with compressed air
(with pressure not more than 300 kPa/3.1kgf/cm3).
Warning:Do not purge the main
element from outside to inside with
compressed air. Do not clean the main
element with oil and water!
Caution:Do not knock when cleaning

P26P00051 the main element, otherwise the engine will
be damaged.
7. After cleaning the main element, use electric light to
check if there are small holes or particles on the
main element, if so, replace the main element with a
new one.
P26P00052
8. Install the clean main element into the air cleaner

housing to ensure that the main element is evenly
sealed with the housing and installed in place.
9. Clean and install the cover of the air cleaner to
ensure that the gasket of the air cleaner is in uniform
contact with the air cleaner housing.
Caution: The main filter element must
be replaced with a new one after 4-5 times
of cleaning and maintenance. Removal and
installation of safety filter element are
prohibited during cleaning and
maintenance of the main filter element.
10.Close the engine hood.
The replacement steps of the safety element are the same as those of the main element. The difference
is that do not use the safety element after cleaning, but it is only allowed to be replaced. When replacing
the safety element, the main element should be replaced at the same time.
2-24
Turbocharger
The turbocharger is mainly used to increase the pressure of the intake air and increase the air inflow
(intake air density), thus increasing the power of the diesel engine and improving the economy.
Installation Location and Diagram of Turbocharger
P26P00655
Turbocharger - Maintenance
As a precision machine operating at high speed, the turbocharger shall not be disassembled without
permission. If severe wear or damage is found during the inspection, the corresponding parts must be
adjusted, repaired or replaced. If the turbocharger is damaged or improperly adjusted, it cannot fully
perform its function, i.e., it cannot deliver enough air to the diesel engine. In case of fault occurrence, it
should be sent to Cummins Maintenance Center for repair.
2-25
Proper Operation:
1. Prior to establishing the lubricating oil pressure of the diesel engine, the engine must operate at idle
speed.
2. Before shutting down the diesel engine, its temperature and speed should be gradually reduced from
the maximum values (within about 5 minutes).
3. The turbocharger shall be pre-lubricated. After changing lubricating oil or carrying out any
maintenance (including discharge lubricating oil), the turbocharger should be pre-lubricated and the
crankshaft should be turned manually for several times prior to the startup of the diesel engine. After
the startup, the diesel engine should operate at idle speed for a while prior to achieving high-speed
operation, so as to establish the pressure for overall lubricating oil circulation.
4. The starting of the diesel engine at low temperature must be conducted with cautions. The super-low
ambient temperature or out-of-service for a long time could affect building-up of the normal pressure
and flow rate of lubricating oil of the engine. Under such condition, the started engine must operate at
ide speed for several minutes before entering the normal operation state.
5. Avoid making the diesel engine idle for a long time. In addition, after the lubricating oil is replaced,
the oil filter is cleaned up or the diesel engine is shut down for a long time (about more than one
week), the inlet connector of the turbocharger must be unscrewed, and then clean lubricating oil will
be injected so that the turbocharger lubricating system is filled with lubricating oil.
6. For other turbocharger maintenance information, please refer to the diesel engine operation and
maintenance manual attached to the engine.
2-26
Test and Adjustment July 17, 2020
Adjustment of Valve Clearance CLG6611E
Test and Adjustment
Adjustment of Valve Clearance

Preparation steps
Warning: Explosive gas may escape from

the battery. Be sure to keep the engine room
well ventilated before repairing the battery to
avoid personal injury. The battery negative (-)
cable shall be firstly removed and finally
connected to avoid an electric arc.
P26P00054
Adjustment
Caution: Engine coolant temperature

should be lower than 60°C [140 °F].
Use jigger tool (part number 3824591) or equivalent. Turn
the crankshaft and align the top dead center marks on the
gear housing cover and the fuel pump gear.
P26P00055
2-27
July 17, 2020 Test and Adjustment
CLG6611E Adjustment of Valve Clearance

When the crankshaft is turned to bring the first cylinder
piston to the end of the compression stroke (TDC), the
valve clearance check of the following rocker arms can be
performed: 1I, 1E, 2I, and 3E.
Lift the end of the rocker arm upward, and at the same time
insert a clearance gauge between the jumper press plate
and the ball head and socket of the rocking lever to
measure the clearance. If the clearance measurement
exceeds the technical specification, loosen the lock nut
and adjust the clearance to the nominal technical
specification.
Clearance reset technical specifications
mm in
Intake 0.254 Nominal 0.010
Exhaust 0.508 Nominal 0.020
Note: Only when the clearance is measured
and found to exceed the technical
specification, or when the engine maintenance
P26P00056 causes the rocker arm to be removed and/or
the adjusting screw is loose, the clearance
needs to be reset at the interval specified in the
corresponding maintenance regulations.
Tighten the lock nut and measure again.
Torque value: 24 N.m [212 in-lb]
Use jigger tool (part number 3824591) or equivalent. Turn

the crankshaft 360 degrees and measure the clearance
between rocker arms 2E, 3l, 4E, 4l. The clearance should
be reset in case of exceeding the technical specification.
P26P00057
2-28
Measurement of Crankcase Blow-by CLG6611E
Measurement of Crankcase Blow-by

Note: Some schematic diagrams in these steps
do not reflect the actual engine configuration.
However, the steps are the same.
Excessive crankcase blow-by can indicate failure of the
engine or related parts of the engine, thus allowing
combustion gases or air to leak into the crankcase. As a
result, the pressure generated is higher than the normal
crankcase pressure, thus increasing the blow-by level.
This step describes how to measure crankcase blow-by
and how to identify the faulty components.
The general purposes to measure blow-by are to:
● Check the running-in of the engine after refitting

● For open crankcase ventilation system, excess oil spills
over the crankcase breather pipe (also commonly
referred to as oil out)
Carry out fault diagnosis and troubleshooting
● Carry out fault diagnosis and troubleshooting on oil

P26P00058 inlet and intake system; Carry out fault diagnosis and
troubleshooting on the excessive crankcase pressure
for engines equipped with crankcase pressure sensor;
Carry out fault diagnosis and troubleshooting on
possible internal breakdown of the engine, such as
worn piston ring, valve rod seal or conduit,
turbocharger and air compressor.
This step provides General Guidance for measuring blow-
by related to the above situation.
2-29
CLG6611E Measurement of Crankcase Blow-by

It's worth noting that such two terms as "blow-by" and "oil
out (engine oil spills over from breather pipe)" can be often
used interchangeably.
Excess engine oil will spill over the breather pipe when the
blow-by is measured, so the engine oil level will also
directly affect the measurement result of blow-by. In
addition, the engine oil accumulated on the metering hole
of service tool for blow-by measurement will also affect the
measurement result of blow-by. It reduces the size of
metering hole, so the measurement result often is higher
than actual blow-by measured value. If so, some of the
following measures must be taken:
● Find different measuring positions on the engine to
measure the blow-by (such as engine oil filler, engine
oil filler cap and discharge position of unused
turbocharger).
● Clean residual engine oil on the breather and make the
breather completely dry before the blow-by is
measured.
● Determine whether some factors will make the
breather full of engine oil, e.g.:
P26P00059
1) Incorrect engine oil level
2) Vehicle operation (excess tilt and excessive left-right
rotation of engine)
3) Internal components of the engine cause the oil to
deflect to the ventilator cavity (piston cooling nozzle,
auxiliary oil drain pipe, etc. )
● Determine whether the engine under repair has
another breather option.
2-30

The tools used for blow-by measurement are generally
similar in structure. The size of metering hole is the main
distinction. Different sizes of metering hole is to more
accurately measure the blow-by, and to meet various needs
of engine arrangement and rated power. This is because
that the engine blow-by depends on air inflow.
For example:
If the blow-by is measured on two engines with same
arrangement and size, but their horsepower and rated
rotation speed are different, the measured maximum blow-
by values will also be different.
The engine with high rated horsepower and high rated
rotation speed also has relatively large air inflow, so the
blow-by value will be higher. That is, if the blow-by tool with
smaller metering orifice is used for measuring the engine
with high horsepower and high rated speed, the measured
value will exceed the limit of pressure measuring tool.
Blow-by Tool Part No. Size of Metering Orifice

3822566 7.67 mm(0.302 in)
P26P00060 When the crankcase blow-by pressure is measured,

connect water pressure gauge (Part Number ST1111-3) or
equivalent device, pressure gauge or sensor to blow-by
measurement service tool.
Note: Water pressure gauge (Part Number
ST1111-3) or equivalent device can measure
water column of 944 mm [36 in] at most.
The Table below shows the relationship between the measured pressure and the flow rate of orifice with
diameter of 7.67-mm [0.302-in].
Blow-by conversion table for orifice with diameter of 7.67-mm [0.302-in] and blow-by
mm H2O [in H2O] L [cfm] / Min
25.4 [1] 50 [1.766]
50.8 [2] 84 [2.966]
76.2 [3] 103 [3.637]
101.6 [4] 119 [4.202]
127 [5] 133 [4.697]
152.4 [6] 145 [5.121]
177.8 [7] 155 [5.474]
203.2 [8] 164 [5.792]
228.6 [9] 172 [6.074]
254 [10] 180 [6.357]
279.4 [11] 187 [6.604]
304.8 [12] 193 [6.816]
2-31
Blow-by conversion table for orifice with diameter of 7.67-mm [0.302-in] and blow-by
mm H2O [in H2O] L [cfm] / Min
330.2 [13] 200 [7.063]
355.6 [14] 206 [7.275]
381 [15] 211 [7.451]
406.4 [16] 217 [7.663]
431.8 [17] 222 [7.840]
457.2 [18] 226 [7.981]
482.6 [19] 229 [8.087]
508 [20] 235 [8.299]
533.4 [21] 239 [8.440]
558.8 [22] 242 [8.546]
584.2 [23] 246 [8.687]
609.6 [24] 248 [8.758]

Note: If it is suspected that the internal
breakdown of the engine leads to excessive
blow-by, other steps can be taken to verify this.
Consider to measure the blow-by only when
confirming the running-in or other symptoms
of the engine after overhaul. The symptoms
include:
● Excessive engine oil out (engine oil leakage from the
crankcase breather pipe)
● Too high crankcase pressure ( for engines equipped
with crankcase pressure sensors)
● Low power
● Consumption of engine oil
P26P00058
● Exhaust smoking
There is no need to measure the blow-by in case of no
other symptoms.
2-32
If it is suspected that the internal breakdown of the engine

leads to excessive blow-by,
other steps can be taken to verify this. These steps include:
● Confirm the maintenance practices of the engine
● Cut the oil filter to check whether it has debris.
● Take the engine oil sample to check for contamination.
P26P00061
Initial Check

Note: The location and type of crankcase
breather vary depending on the engine
configuration (front or rear gear train) and/or
engine application.
Before measuring the blow-by pressure, check whether the
crankcase breather pipe is blocked. If the fault diagnosis is
conducted on the problem of excessive breather pipe oil,
remove the breather components to clean and clear away
all the accumulated engine oil before the blow-by
measurement is made.
P26P00062
Check the engine oil level, and correctly calibrate the

engine oil dipstick if necessary. If the oil level is too high,
the blow-by pressure will exceed the normal level and/or
excess oil will be brought out.
P26P00063
2-33
Measurement
Select proper blow-by measurement and maintenance tool

for engine to be repaired.
Blow-by Tool Part No. Size of Metering Orifice

3822566 7.67mm[0.302in]
P26P00064
When the crankcase blow-by pressure is measured,

connect water pressure gauge (Part Number ST1111-3),
pressure gauge or sensor to blow-by measurement service
tool.
Note: The location and type of crankcase
breather pipe vary depending on the engine
configuration and/or specific application.
Install suitable blow-by maintenance tool:
For a typical open crankcase breather/ventilation system,
connect a suitable blow-by maintenance tool to the end of
the crankcase breather pipe. Connect water pressure
gauge or pressure gauge or sensor to blow-by
maintenance tool.
For engines with closed crankcase ventilation system
(without crankcase ventilation filter), disconnect the
breather pipe and plug the intake manifold or turbocharger
compressor housing port. Connect proper blow-by
maintenance tool to one end of crankcase breather pipe.
P26P00065 Connect water pressure gauge or pressure gauge or
sensor to blow-by maintenance tool.
For engines equipped with external fuel moisture
condensation breather cores ( CM871, CM876, CM2250,
CM2150, and engines equipped with Enviroguard filters),
connect the corresponding blow-by maintenance tool to the
crankcase breather pipe on the intake side of the fuel
moisture condensation breather housing.
2-34

Note: Excess engine oil will spill over the
breather pipe when measuring the blow-by, so
the oil level will also directly affect the
measurement result of blow-by.
Run the engine under rated rotation speed and full load
conditions until a stable reading is obtained.
Note: When the engine reaches peak power

and rated rotation speed in blow-by
measurement, the value will reach a "peak"
initially.
Wait until the blow-by measured value is stable before
reading.
Note: For engine running-in, if the blow-by

increases sharply or the blow-by exceeds the
maximum allowable limit in any running-in
period, return to the previous step to continue
P26P00066
running-in. If the blow-by fails to reach the
acceptable level, stop running-in and
determine causes.
Record the blow-by measured value under steady state.
If the blow-by is within the technical specifications, remove
the engine blow-by maintenance tool and water pressure
gauge or pressure gauge.
2-35
July 17, 2020 Removal and Installation
Removal and Installation
Diesel Engine Maintenance Table
Every 12 Every 2
First Every 3 Every 4 Every 6
Routine months or years or
Maintenance Maintenance months or months or months or
Maintenance every every
80~100h every 250h every 400 h every 500h
1000h 2000h
Check the periphery of diesel
● ● ● ● ● ●
engine
Check fuel tank ● ● ● ● ● ●
Check the primary fuel filter
● ● ● ● ● ●
service indicator
Check the oil level ● ● ● ● ● ●
Check the coolant level ● ● ● ● ● ●
Check the electrolyte level ● ● ● ● ● ●
Check the drive belt* ● ● ● ● ● ●
Check the cooling fan ● ● ● ● ● ●
Check the leak location ● ● ● ● ● ●
Check the tightening conditions
● ● ● ● ● ●
of accessories
Check the intake system ● ● ● ●
Check the intake intercooler and
● ● ● ●
its lines
Check the air cleaner ● ● ● ●
Replace the oil and oil filter ● ● ● ●
Replace diesel filter (including
● ● ●
oil-water separator) **
Replace the coolant filter (if
● ● ● ●
used)
Check the fuel system bleeding ● ● ●
Check the oil-gas separator ● ● ●
Check the concentration of
● ● ●
antifreeze solution
Check and adjust the valve
● ●
clearance
Check the coolant (DCA4
● ● ●
concentration (if used))
Check the adhesive tape
● ●
tension wheel ***
Check the fan shaft bearing ● ●
Check the degree of tension of
● ●
adhesive tape
Check the turbocharger ●
Check the shock absorber ●
Check the air compressor ●
Replace coolant and clean air
●
conditioning system
2-36
Removal and Installation July 17, 2020
Every 12 Every 2
First Every 3 Every 4 Every 6
Routine months or years or
Maintenance Maintenance months or months or months or
Maintenance every every
80~100h every 250h every 400 h every 500h
1000h 2000h
* The belt must be replaced in a timely manner when there are cracks or other defects affecting use on its surface.
** Check the filter replacement time on the diesel filter and replace the diesel filter according to the required replacement time. When the
fuel contains more impurities, the replacement time of fuel preliminary filter should be shortened appropriately.
*** When the tension wheel belt is stuck and cannot rotate flexibly, it needs to be replaced.
Note 1: Maintenance intervals are specified in this Table on an hourly or monthly basis, whichever comes first.
Note 2: The first maintenance content shall be subject to the product quality warranty manual.
2-37
CLG6611E Removal and Installation of Diesel Engine
Removal and Installation of Diesel Engine
Removal of Diesel Engine Assembly
Tools Required
Tools Part description Specification Quantity
A Manila rope Φ20mm 1
B Wrench 5#, 8#, 10#, 12#, 16#, 5
C Hook 2
D Cross screwdriver T25 1
General Torque Specification

Thread size Standard torque (N·m)/ (kgf·m)
M5
M8 33±3Nm 3.4±0.3kgf·m
M10 72±6Nm 7.3±0.6kgf·m
M12 82±20Nm 8.3±2kgf·m
M16 206±52Nm 20.6±5kgf·m
Cleaning is very important. Thoroughly clean the outer surface of the components before
removal. This will prevent dirt from entering the interior of the mechanism.
Stick identification labels on all the pipes, hoses, lines and steel tubes for easier installation.
Plug all the pipes, hoses and steel tubes. This will prevent fluid loss and prevent dirts from
entering the system.
During the inspection, maintenance, test and adjustment of the machine, the fluid must be
collected in a suitable container before removing any hydraulic oil lines or disassembling any
components containing fluid, and should be disposed in accordance with local laws and
regulations.
Hydraulic oil pressure and hot oil can cause casualties.

After the engine has stopped, there may still be hydraulic oil with pressure remaining in the
hydraulic system. Please release the remaining pressure before repairing the hydraulic system.
There is water vapor and hot water in the water radiator, so in maintenance, the water
temperature will drop below 10 before opening the radiator cap, otherwise, serious casualties will
be caused.
Make sure that all the working devices have been lowered down and the hydraulic oil has cooled
before removing any components or pipes. The oil filter cover can only be removed when the
engine has stopped and the filter cover is cool enough to be touched by bare hands.
2-38
Removal and Installation of Diesel Engine CLG6611E
Removal steps:

1. Park the vehicle on a flat ground, lock the steering frame
lock, turn off the negative switch, and hang a warning
sign " Do not operate".
P26P00067
P26P00068
2. First remove the rain shield (1), then remove the side
1 plate (2) and the hood (3), refer to "Hood Removal and
Installation" in this chapter for details.
3
P26P00069
3. Open the coolant outlet (1) in the heat dissipation

system, and collect the coolant with a container.
1
P26P00070
2-39

4. Open the oil drain outlet (1) beside the hydraulic oil tank
at the left side of frame, and collect the oil with a
container.
P26P00071
5. Remove the connecting pipe (1), air cleaner (2) and air
cleaner support (3), and seal each port with plastic
sealing film as required. Refer to " Removal and
1 Installation of Intake System" in this chapter for details.
2
3
P26P00072
6. Remove bellows (1), silencer (2) and mounting support

(3), and seal each port with plastic sealing film as
1
2 required. Refer to " Removal and Installation of Exhaust
System"in this chapter for details.
Note: Removal shall be carried out after the
exhaust system is cooled to avoid scalding.
P26P00073
7. Remove the electrical connectors and lines on the

engine. Refer to " Removal and Installation of Electrical
System"in this chapter for details.
2-40

8. Remove the A/C compressor, air conditioning pipe and
heater pipe on the engine and seal each port with plastic
sealing film as required. Refer to " Removal and
Installation of Air Conditioner"in this chapter for details.
9. Remove the fuel pipe connector and oil inlet screw
connected to the diesel engine fuel pump (1). Remove
the oil inlet screw and gasket, and seal them with plastic
bags. Seal the fuel pipe connector with a sealing film.
Fix the fuel lines properly to prevent fuel leakage from
the fuel tank.
1
P26P00074
10.Remove the intercooler pipe (1), feed water pipe (2),

1 vent pipe (3), intercooler pipe (4), water supply pipe (5)
2 and drain pipe (6) connecting the diesel engine to the
8
radiator, wrap the connector with plastic sealing bag,
3 and remove radiator protective net (7) and loosen bolts
(8). Refer to"Removal and Installation of Radiator" in this
chapter for details.
4
7
6
P26P0075
11.Remove the connecting pipe from the hydraulic pump

and collect overflowing hydraulic oil with a container.
Refer to "Removal and installation of hydraulic pump" in
this chapter for details.
2-41

12.Lift the main pump (1)with a lifting appliance, remove
2 the flange mounting bolts (2) and then move the main
pump and flange outward together to separate the
coupling bushing from the engine flywheel. (The total
1
weight of the main pump is about 150 kg)
P26P00076
13.Remove the oil pan drain line (1)
1
P26P00657
14.Remove the mounting bolts (1) of the four shock

absorbers of the diesel engine mount
1
P26P00658
15.After checking the components surrounding the diesel
engine and confirming that there is no influence. Lift the
1 lifting lug (1) of the diesel engine with a hook and hold
both sides of the diesel engine so as to ensure that the
diesel engine is slowly and smoothly lifted out of the
vehicle without collision with other components of the
vehicle and then placed in a safe place. (The total
weight of diesel engine, support and other components
is about500 kg).
P26P00079
2-42
Installation of Diesel Engine Assembly
The diesel engine is installed in the opposite order of removal. Attention shall be paid to the followings.

1. Installation of Coupling
a. First install the coupling hub (1) to the flywheel of the
diesel engine.
b. Install the bushing (2) on the pump shaft and lock it.
c. Install the hydraulic pump on the hydraulic pump
mounting flange.
d. Lift the pump with a lifting appliance and engage the
bushing (2) with the hub (1) and slowly insert it.
Finally, install the pump connecting flange on the
flywheel casing with bolts. Refer to "Removal and
Installation of Coupling" in this chapter for details.
1
P26P00080
2
P26P00081
2. When installing the damper on the frame, pay attention

to the upper damper (1) and the lower damper (3), with
the frame (2) being sandwiched between them.
1
P26P00082
2-43

3. When lifting the diesel engine onto the frame, control the
front and rear and left and right positions to ensure that
the bolt (1) can easily enter the mounting hole without
being extruded and inclined.
P26P00078
4. Clean the intake line properly before assembly.

5. Refill antifreeze solution with approx. 20L.
6. Refill oil with approx. 21L.
7. Run the engine at idle speed for a few minutes to see if
there is any leakage in the lines, and then fill up with the
antifreeze solution.
2-44
Removal and Installation of Intake System CLG6611E
Removal and Installation of Intake System
Tools Required
A Open-end wrench 4#, 10# 2
B Plastic sealing film Several
Removal of Intake System

1. Remove the clamps (1), (3) and (6) on the connecting
1 pipe, remove the rubber sleeve (7), reducer pipe (2) and
7 intake pipe (5), and plug the air inlet of the compressor
2
with plastic film.
3
4
P26P00083
2. Loosen the bolt (1) on the air cleaner clamp, and then
1 remove the air cleaner (2); refer to the "Intake and
2 Exhaust System" above for cleaning and replacing the
air cleaner element.
P26P00084
2-45
CLG6611E Removal and Installation of Intake System

3. Remove the connecting bolt (1) and take the air cleaner
2 support (2) down.
P26P00659
Installation of Intake System
Installation is in reverse order from removal

1. The tightening torque of the bolts refers to the general tightening torque.
2. Clean the dust from the lines before installation.
3. The dust discharge valve of the air cleaner faces vertically downward.
2-46
Removal and Installation of Exhaust System CLG6611E
Removal and Installation of Exhaust System
Tools Required
Removal of Exhaust System
Removal shall be carried out after the exhaust system is cooled to avoid scalding.

1. Loosen the clamp (1), remove the bellows (2), and seal
2 1 the exhaust outlet of the diesel engine with plastic film.
1
P26P00086
2. Loosen the four groups of bolts (2) and remove the

1 silencer (1).
P26P00087
2-47
CLG6611E Removal and Installation of Exhaust System

3. Loosen the bolt (2) and remove the silencer support (1).
1
P26P00088
Installation of Exhaust System
Installation is in reverse order from removal; the tightening torque of the bolts refers to the general
tightening torque.
2-48
Removal and Installation of Cooling System CLG6611E
Removal and Installation of Cooling System
Tools Required
C Manila rope Φ20mm 1
D Hook 2
Removal of Cooling System
Before removal, it is necessary to wait for the antifreeze solution to drop down to normal
temperature, and then put the antifreeze solution into a designated container. If the antifreeze
solution needs to be discarded, it should be disposed according to local laws.

1. Loosen clamps (1), (3) and (5) and remove water supply
pipe (2) and drain pipe (4). Note that the remaining
antifreeze solution in the lower lines should be collected
by a container. Each nozzle is sealed with plastic film.
4 5
P26P00089
2-49
CLG6611E Removal and Installation of Cooling System

2. Loosen the clamps (1), (3), (6), (7) and the U-bolt (2)
3 2 1 and remove the intercooler pipes (4), (5) and the rubber
4 hoses connected thereto. Each nozzle is sealed with
plastic film.
5
6
7
P26P00090
3. Loosen clamps (2), (3) and (6) and remove drain pipe
3 (1), vent pipe (4) and feed water pipe (5). Note that the
2 remaining antifreeze solution in the lower lines should
be collected by a container. Each nozzle is sealed with
1 plastic film.
4
6
P26P00091
4. Loosen the bolts (1), (2), (6) and (7) and remove the
2 3
4 5 support (3), the baffle (4), and the support (5). Note:
Sponge bars are arranged around the baffle and need to
6 be replaced in case of being damaged after removal.
P26P00092
2-50
Removal and Installation of Cooling System CLG6611E

5. Remove the hydraulic line connected to the hydraulic oil
radiator pipe orifice (1). The hydraulic oil is collected by
an oil collecting basin. Each nozzle is sealed with a
sealing bag.
1
1
P26P00093
6. Remove the drain line (1). Note that the remaining

antifreeze solution in the lower lines should be collected
by a container. Each nozzle is sealed with plastic film.
P26P00094
7. Lift the radiator (1) with a lifting appliance, remove the

bolts and nuts, and remove the shock absorber (2).
Then slowly lift the radiator (1) down to avoid collision
1
P26P00095
2-51
CLG6611E Removal and Installation of Cooling System

8. Put away the shock absorber (1) at the lower portion of
the shock absorber and use it during installation
1
P26P00096
Installation of Cooling System
The cooling system is installed in the opposite order of removal. Attention shall be paid to the followings.

1. Clean the radiator lines before installation.
2. Install the diesel engine, refer to "Installation of Diesel
1 Engine System” for details, and adjust the left and right
bending plates (1) so that the clearance between the
radiator cowl and the diesel engine fan is not less than
10 mm.
P26P00097
2-52
Removal and Installation of Radiator CLG6611E
Removal and Installation of Radiator
Tools Required
D Hook 2
Removal of Radiator
Please seal each nozzle with plastic film before removal.

1. Remove the mounting bolts from the cowl (1) and the
3 protective net (2), and remove the cowl (1), the
protective net (2), the windshield (3), and the windshield
(4).
1
P26P00098
2-53
CLG6611E Removal and Installation of Radiator

2. Loosen the connecting bolts between the intercooler (1)
and radiator bottom frame (2) and remove the
1 intercooler (1).
P26P00099
3. Loosen the connecting bolts between the auxiliary

radiator (1) and the top frame (2) and remove the
auxiliary radiator (1).
P26P00100
2-54
Removal and Installation of Radiator CLG6611E

4. Loosen the bolts of the radiator top frame (1) and the
radiator bottom frame (2) and remove the radiator top
frame (1).
P26P00101
5. Loosen the connecting bolts of the water radiator core

(1), the hydraulic oil radiator core (2) and the radiator
frame (3), and then lift out the water radiator core (1) and
the hydraulic oil radiator core (2).
P26P00102
Installation of Radiator
The installation order is reverse to the removal order.

1. A sealing sponge should be attached between the two radiator cores, between the radiator core and
the frame, and between the cowl and the frame.
2. Rubber gaskets are required between the top frame and the radiator core, and between the bottom
frame and the radiator core.
3. All mounting bolts should be selected according to their original length, and long bolts are not
allowed to be selected to avoid interference with the radiator core, causing damage to the core.
2-55
CLG6611E Removal and Installation of Diesel Engine Fan
Removal and Installation of Diesel Engine Fan
Tools Required
A Open-end wrench 10# 2
Removal of Diesel Engine Fan

1. Remove the fastening screws (1) of the fan and then
remove the fan (2).
P26P00103
Installation of Diesel Engine Fan
1. Clean the residual adhesive and grease on the bolt with cleaning agent, apply new thread locker, and
tighten the bolt. See "General Torque Specification" for tightening torque.
2. Note that the fan shall not be installed in opposite direction.
2-56
Removal and Installation of Coupling CLG6611E
Removal and Installation of Coupling
Tools Required
B Allen wrench 8# 1
D Hook 2
Removal of Coupling

1. Remove the hydraulic oil line connected to the hydraulic
pump (1), then lift the hydraulic pump with a traveling
2 crane, remove the connecting flange of the pump and
the connecting bolt (2) of the diesel engine, and then
horizontally disengage the pump from the diesel engine
1 outward.
P26P00076
2. Loosen the two fastening screws (1) on the shaft sleeve

and remove the shaft sleeve (2).
1
2
P26P00081
2-57
CLG6611E Removal and Installation of Coupling

3. Remove the bolts (1) of the coupling hub and remove
the coupling coupling hub (2).
1
2
P26P00080
Installation of Coupling

1. First, install the coupling hub (1) onto the flywheel of
diesel engine with bolts (2) with a tightening torque of
49N. Apply thread locker.
1
2
P26P00080
2-58
Removal and Installation of Coupling CLG6611E

2. Sleeve the shaft sleeve (1) onto the pump shaft of the
hydraulic pump, and adjust the distance so that the
distance between the end face of the pump shaft and
that of the shaft sleeve is 7.4 mm. Then tighten the set
screws (2) with a tightening torque of 70 N.m.
1
2
P26P00081
3. Then turn to make the coupling rotate to the
corresponding position in order to engage the shaft
2 sleeve. Then lift the hydraulic pump (1) with the traveling
crane to engage the shaft sleeve into the coupling hub.
Align the pump connecting flanges, and then tighten
1 them with bolts (2) with a tightening torque of 49 N.m.
P26P00076
2-59
July 17, 2020 Fault Diagnosis and Troubleshooting
CLG6611E Common Fault Diagnosis of Diesel Engine
Fault Diagnosis and Troubleshooting
Common Fault Diagnosis of Diesel Engine
The common fault analysis of diesel engine is shown in the Table below, and the fault should be
searched from top to bottom and from easy to difficult according to the order in the Table.
Fault
Part Possible Cause Troubleshooting Method
Symptom
Low battery power Charge.
Check whether the wiring is correct and
The connector of the starting circuit falls off
reliable, and remove dust and oil stains
or is in poor contact.
from the contact surface.
Repair or replace the electric brush, clean
Poor contact between starter motor carbon
the surface of the commutator with
Starting difficulty brush and commutator.
abrasive paper for wood and blow off dust.
or failure of
Too little diesel oil in the fuel tank or poor
diesel engine Add new oil that meets the requirements.
quality of the oil.
Fuel line or filter is blocked. Clean the oil inlet line and filter.
Check the leak location and take exhaust
Air in the fuel system.
measures.
Refer to the Diesel Engine Manual for
Other faults of diesel engine.
details.
Low temperature or poor fuel quality. Select qualified diesel according to season.
Smoke Engine overload. Eliminate overload.
produced when
Engine Blocked air cleaner and impeded intake. Clean the air filter.
the diesel
series engine is Too late oil injection. Adjust the injection advance angle.
working Other causes, such as oil pump, oil nozzle, Check and adjust according to Diesel
valve, piston ring wear. Engine Manual.
The diesel Impeded oil inlet and intake. Check and clean it.
engine is The throttle cannot be pulled to the end. Check the throttle lever system and adjust.
powerless in
work and cannot
reach the rated Failure of diesel engine itself. Perform the overhaul.
rotation speed
The oil level in the crankcase is too low or
Use a sufficient amount of qualified oil.
the brand of oil used is wrong.
Thermostat failure. Replace thermostat.
High water and Insufficient cooling water or poor
Add water and check the lines.
oil temperature circulation.
of diesel engine The fan belt is loose, the rotation speed is Adjust the tension of belt or replace the
reduced, and the air volume is reduced. belt.
The thermometer or temperature sensor
Replace
may fail.
2-60
Fault Diagnosis and Troubleshooting July 17, 2020
Common Fault Diagnosis of Diesel Engine CLG6611E
Fault
Part Possible Cause Troubleshooting Method
Symptom
Use the oil tank filled with good fuel to start
Fuel contamination
the diesel engine for verification.
Exhaust air from the fuel system and check
There is air in the fuel system.
leaks in the oil suction parts.
Fuel leakage from high pressure fuel pipe Check/replace return relief valve.
Use the temporary fuel tank filled with good
Fuel return relief valve failure fuel to drive for verification and clean the
fuel tank.
Fuel delivery pump failure Check/update fuel delivery pump.
Clean the coarse strainer and strainer
Stalling of the Fuel supply is blocked roughly, check the resistance of the fuel
diesel engine line, and replace the fuel filter.
Check push rod and spring and adjust
Incorrect adjustment of valve clearance
valve.
Engine Fuel injector blocked or failed Replace the fuel injector.
series
Incorrect fuel injection timing. Check/adjust fuel injection timing.
Check the compression pressure and find
Low.compression pressure of one or more
out the causes (such as piston ring,
cylinders.
cylinder head gasket or valve).
Check and correct gear transmission
Incorrect timing of camshaft
system timing
Camshaft.and push rod are damaged Check and replace the damaged parts.
Crankcase ventilator and breather pipe Check whether the ventilator and breather
blocked pipe are blocked or not
Excessive air Check the air sealing device of the
leakage from Air leakage at the seal of the turbocharger
turbocharger
crankcase of
diesel engine Valve guide pipes of the cylinder head incur
Replace the cylinder head.
excessive abrasion
Piston ring is damaged or worn Check the piston ring and cylinder sleeve.
3-1
July 17, 2020 Powertrain System
CLG6611E
Powertrain System
Safety .....................................................................................................................................................3-3
System components and locations ........................................................................................................3-4
Technical Parameters of the System .....................................................................................................3-5
Description of Principle of Drive Axles ...................................................................................................3-5
Removal and Installation ...................................................................................................3-6

Removal and Installation of Drive Axle ..................................................................................................3-6
Installation of Drive Axle.....................................................................................................................3-6
Oil Filling Method of Drive Axle ..........................................................................................................3-6
Correct Use of Brake..........................................................................................................................3-7
Removal and Installation of Tire ............................................................................................................3-7
Removal of tire ...................................................................................................................................3-8
Installation of Tires and Filling of Internal Liquid ................................................................................3-9
Troubleshooting...............................................................................................................3-11
Cause Analysis and Troubleshooting Method of Common Faults of Drive Axle..................................3-11
3-2
Powertrain System July 17, 2020
CLG6611E
3-3
CLG6611E Safety
Basic Information
Safety This word denotes potential danger. Failure

to observe the instructions could result in
Many accidents related to operation, injuries of a minor to moderate degree.
maintenance and repair are caused by failure to It is also used in this manual to indicate safety
observe basic safety rules and safety information relating to unsafe operations which
precautions. These accidents are usually may cause personal injuries. "Danger"
avoidable if potential hazards can be fully represents the most dangerous of conditions.
observed. Operating personnel must pay The "Danger" or "Warning" safety sign is set at a
attention to potential hazards, and must acquire specific dangerous place. General notice
corresponding skills through necessary training information is included under the safety signal
to operate, maintain and repair the machine in a "Caution.”
safe and correct manner.
In addition, some other "cautions" are also listed
● Improper operation, maintenance and repair in this Manual. Please observe these cautions;
of the machine may cause hazards and otherwise, your machine will suffer from great
personal injury and even death. damage. The company does not list all possible
● Before operation, maintenance and repair of hazards (including potential ones). Warning
the machine, operating personnel must read information listed in this Manual and on the
and understand relevant safety precautions product does not cover all hazardous matters. If
and notes. you use tools, operation steps, operation
methods or operation techniques other than
● In the process of operation, maintenance and those specifically recommended by Liugong, you
repair of the machine, please strictly observe must ensure the safety of yourself and others
safety warning information listed in this and ensure no harm to the machine.
Manual and on the machine; otherwise,
major casualty accidents may occur. This Manual is prepared based on the current
situation of the machine at the time of
The safety warning information in this Manual is preparation. Any product is in the process of
marked with the following symbols: continuous improvement and the machine is no
exception. Modifications will affect the operation,
maintenance and repair of the machine. For this
reason, before operation, maintenance and
This word denotes potential danger. Failure repair of the machine, please contact Liugong's
to observe the instructions could result in dealer for the latest and most comprehensive
death or serious injuries. service information.
This word denotes an impending danger.

Failure to observe the instructions could
result in death or serious injuries.
3-4
System components and locations CLG6611E
System components and locations
P26T00197
The basic structure of drive axle is mainly composed of axle housing, main driver, reducer, axle shaft,
wheel reducer, and dry multi-disc brake. The drive axles are located between two tires of roller.
3-5
CLG6611E Technical Parameters of the System
Technical Parameters of the System
Total drive ratio I=59.78 Maximum output torque M=50 (KN.m)

Brake torque M system = 17.5 (KN.m) Axle load W1=190(KN)
Total length of single axle A=2100(mm) Tread B=1726(mm)
Center-to-center distance of
Weight of single axle Q1=715(Kg) G=817.5(mm)
connecting holes
Description of Principle of Drive Axles
The operating principle of the drive axle is as shown in the figure below: Drive torque is input to the main
drive, the direction of power is changed through the driving bevel gear and driven bevel gear which are
vertically installed with each other, speed is reduced and the transmitted torque is increased. Then, the
power is transmitted to the wheel hub through the differential and axle shaft, and the motion and torque
are transmitted to the two drive wheels after further deceleration by the wheel hub reduction mechanism.
Operating principle diagram
P26T00198
The wheel reducer is a planetary reducer mechanism, which is mainly composed of planet carrier,
internal gear, planet gear, and sun gear (sun gear is integrated with axle shaft and called gear axle
shaft). The internal gear is fixed on the wheel supporting shaft through splines, and the planet carrier is
integrated with the hub.
The main drive structure consists of a pair of spiral bevel gears and a differential. The differential is a
differential planetary gear drive body consisting of two conical straight-toothed axle shaft gears, four
conical straight-toothed planetary gears, left and right differential cases and spider.
The disc brake is mainly composed of inner and outer pliers, brake discs, pistons, and friction plates.
The brake discs are fixed on the hub, and each pair of pliers is equipped with 4 pistons.
3-6
Removal and Installation of Drive Axle CLG6611E
Removal and Installation of Drive Axle
Installation of Drive Axle
The driving spiral bevel gear is of the right-handed rotation, and the driven spiral bevel gear is of the left-
handed rotation.
The rim nut is M22×1.5 and right-handed rotation, with a tightening torque of 580 N.m. Before tightening
one group of rim nuts, apply the 242 Loctitelok glues symmetrically and evenly. In normal use, frequently
check whether the nuts are loose or not. Timely tighten the nuts if loose. The nut ball end shall be fit with
the rim ball socket. The nut ball end shall tightly contact the socket and shall be firmly connected to the
socket.
Oil Filling Method of Drive Axle
First, loosen the oil level hole bolt on the drive axle housing , and make the oil filling hole at the left and
right wheel hubs at the same level with the oil level hole. Add lubricating oil to the left, right and middle
positions at the same time until the oil level hole overflows, as shown in the figure below. (Note: GL-
485W/90 gear oil for heavy-duty vehicle is generally used, with the standard code of GB12895-92 and
the oil quantity of 13 L).
1 2 3 4 5 6 7
P26T00199
1. Oil level hole 4. Oil level hole 7. Oil level hole

2. Oil filler 5. Vent hole
3. Oil level hole (oil filler) 6. Oil filler
3-7
CLG6611E Removal and Installation of Tire
Correct Use of Brake
Brake working pressure is 10MPa. Before running the base machine, please adjust the foot brake to
ensure braking flexibility and reliability. During commissioning, first tighten the deflating valve and
continuously depress the foot brake with force until it is very laborious to depress the brake forward. At
this moment, depress the foot brake with force and loosen the deflating valve (No.4) for deflation until
there are air bubbles, and then tighten the deflating valve and loosen the foot brake. Repeat the above
steps till no bubbles are seen. Each pair of brakes shall be operated according to the above
requirements. (719 or 7100 motor vehicle brake fluid shall be adopted for brake oil, with the standard
code of GB10830-89).
If a friction plate is worn and the rivet head is exposed, or when the friction plate is worn and its bottom
plate will contact the brake disc, the guide pin on the brake caliper must be removed to replace the
friction plate.
Removal and Installation of Tire
P26T00200
Regular inspection shall be carried out for the tire pressure and the fastening of rim nut.
A pressure gauge shall be used to test tire pressure, so as to ensure consistent tire pressure. If the tires
are filled with liquid, the inflation valve shall be set at the position of 12 o'clock during inspection.
Inspection shall be carried out to confirm whether the rim nuts are tightened. For a new machine or
replaced tires, the inspection shall cover all nuts of the tires on both sides.
Refer to the technical specification sheet for recommended pressure and tightening torque.
Tire specification 23.1-26-12PR
Tire pressure 200-220 kPa
This section mainly covers the removal and installation of tire, as well as precautions for installation.
The machine shall be parked on an open and flat ground and its front wheels shall be protected against
sliding with cleats, while its rear wheels shall be backed to the height that the tires can rotate freely.
3-8
Removal and Installation of Tire CLG6611E
Removal of tire
Figure Operation steps

1. Orderly loosen and remove the rim nuts with a 36 socket
wrench and a jackhammer, and keep two diagonal nuts
to prevent the tire from shaking during lifting.
P26T00011
2. Lift the tires with lifting cable and special tools (the lifting
cable shall be just tight). Gently shake and take out the
tires from both sides (remove the tires with mechanical
jack if the rim is rusted after long-time operation). Put the
tires on a safe and open ground.
P26T00012
The disassembling of tires and replacement of inner tubes both belong to special work. No detailed
descriptions will be given to them.
3-9
CLG6611E Removal and Installation of Tire
Installation of Tires and Filling of Internal Liquid

1. Lift up the rim and then take down the elastic lock ring
and the retaining ring. In this process, operating
personnel shall stand at the position opposite to the pop-
up direction of the lock ring, to ensure personal safety.
Place the rim on an installation platform with the side
having a larger diameter facing down.
P26T00013
2. Coat the protective pad and the outer surface of rim with
talcum powder. It is required that talcum powder should
be coated along the circumference until there is no
obvious omission visible to naked eyes.
P26T00014
Assembling
Lift the tire (with the valve facing up) into the rim and align
the valve with the valve hole passing through the rim. It is
required that the valve should not interfere with the rim wall
after installation. First, sleeve the retaining ring on the rim
and knock it tightly with an iron rod. It is required that the
lock ring groove should be exposed completely. Knock the
elastic lock ring into the lock ring groove with an iron rod,
with knock points and sequence as shown in the figure. It
is required that the elastic lock ring should be completely
clamped in the lock ring groove.
P26T00015
3-10
Removal and Installation of Tire CLG6611E
Exhaust the air

Remove the deflating valve cap, and remove the valve
core with special tool. Put the tire without valve core aside
for about 20 min. Exhaust the gas left in the inner tube.
P26T00016
Filling of Calcium Chloride Solution and Inflation (No

Solution for 6611E)
Filling of calcium chloride solution: Install the adapter on
the deflating valve, connect the calcium chloride hose to
the adapter, open the valve and begin to fill the calcium
chloride solution, observe the reading of liquid level, and
close the valve when the specified liquid level is reached.
Inflation: Install the valve core and then the inflation device.
Begin to inflate. Observe the reading of pressure gauge.
Stop inflating when the specified pressure is reached.
Record the reading of pressure gauge (as shown in the
figure) and properly install the deflating valve cap.
1. Gas pressure: 200 kPa
P26T00017
3-11
July 17, 2020 Troubleshooting
CLG6611E Cause Analysis and Troubleshooting Method of Common Faults of Drive Axle
Troubleshooting
Cause Analysis and Troubleshooting Method of Common Faults of Drive

Axle
S/N Features of fault Causes Troubleshooting

Disassemble the parts for
maintenance or replace the parts
Friction of parts
Abnormal sound during with new ones.
- Poor gear engagement
operation Make an adjustment after
Poor lubrication
reassembling.
Improve the lubrication.
Burnout and aging of oil seal Replace the oil seal
Loose bolts Tighten the bolts
II Oil leakage
Poor lubrication Improve the lubrication.
Too high oil level Drain oil to the specified level.
Poor lubrication Improve the lubrication.
Too high temperature of
III Improper assembling of gear and Make an adjustment according to
axle housing
bearing drawing requirements.
Clean the inner cavity and piston
Jamming of brake caliper piston
IV Locking of brake of brake caliper.
Problem with brake oil return line
Check the brake oil return line.
3-12
Troubleshooting July 17, 2020
Cause Analysis and Troubleshooting Method of Common Faults of Drive Axle CLG6611E
4-1
July 17, 2020 Hydraulic System
CLG6611E
Hydraulic System
Safety .....................................................................................................................................................4-5
Compressed Air .................................................................................................................................4-5
High-pressure Solution.......................................................................................................................4-5
Safe Disposal of Waste Fluid .............................................................................................................4-5
Preventing Extrusion or Cut Off .........................................................................................................4-6
Oil.......................................................................................................................................................4-6
Line, Pipe and Hose...........................................................................................................................4-6
Precautions for Accessories...............................................................................................................4-7
System Components and Locations ......................................................................................................4-8
Overview ............................................................................................................................................4-8
List of Major Hydraulic Components ..................................................................................................4-9
System Technical Parameters .............................................................................................................4-10
List of General Hydraulic Tools and Fixtures ......................................................................................4-11
Special Tools and Fixtures for Hydraulic Maintenance .......................................................................4-11
Structure and Function ....................................................................................................4-15

Travel Hydraulic System ......................................................................................................................4-15
Overview ..........................................................................................................................................4-15
Propelling Pump...............................................................................................................................4-17
Rear Axle Motor ...............................................................................................................................4-31
Drum Motor ......................................................................................................................................4-38
Reducer............................................................................................................................................4-42
Oil Return Filter ................................................................................................................................4-45
Vibrating Hydraulic System ..................................................................................................................4-46
Overview ..........................................................................................................................................4-46
Vibrating Pump.................................................................................................................................4-48
Vibrating Motor.................................................................................................................................4-59
Pressure Filter for Suction................................................................................................................4-63
Steering Hydraulic System...................................................................................................................4-64
Overview ..........................................................................................................................................4-64
Steering Pump .................................................................................................................................4-67
Steering Gear...................................................................................................................................4-68
Steering Cylinder..............................................................................................................................4-69
4-2
Hydraulic System July 17, 2020
CLG6611E
Test and Adjustment........................................................................................................4-70

Test ......................................................................................................................................................4-70
Pressure of Propelling Pump ...........................................................................................................4-70
Pressure of Vibrating Pump .............................................................................................................4-72
Steering Pressure ............................................................................................................................4-74
Adjustment ...........................................................................................................................................4-76
Overview ..........................................................................................................................................4-76
Adjustment of Charge Pressure Relief Valve of Propelling Pump ...................................................4-77
Adjustment of Pressure Limiting Valve ............................................................................................4-77
Enabling Bypass Function................................................................................................................4-79
Adjustment of Charge Pressure Relief Valve of Vibrating Pump .....................................................4-80
Adjustment of One-Way/Relief (SCR) Valve of Vibrating Pump ......................................................4-81
Adjustment of Vibration Frequency ..................................................................................................4-83

Overview ..............................................................................................................................................4-85
Removal and Installation of Hydraulic Oil Tank ...................................................................................4-85
Removal of Hydraulic Oil Tank.........................................................................................................4-85
Installation of Hydraulic Oil Tank......................................................................................................4-86
Removal and Installation of Twin Pump...............................................................................................4-87
Removal of Twin Pump ....................................................................................................................4-87
Installation of Twin Pump .................................................................................................................4-87
Removal and Installation of Suction Filter of Vibrating Pump ..............................................................4-88
Removal of Suction Filter of Vibrating Pump ...................................................................................4-88
Installation of Suction Filter of Vibrating Pump ................................................................................4-88
Removal and Installation of Return Filter .............................................................................................4-89
Removal and Installation of Rear Axle Motor.......................................................................................4-89
Removal of Rear Axle Motor ............................................................................................................4-89
Installation of Rear Axle Motor .........................................................................................................4-89
Removal and Installation of Steering Cylinder .....................................................................................4-90
Removal of Steering Cylinder ..........................................................................................................4-90
Installation of Steering Cylinder .......................................................................................................4-91
Removal and Installation of Steering Gear ..........................................................................................4-92
Removal of Steering Gear................................................................................................................4-92
Installation of Steering Gear.............................................................................................................4-92
Removal and Installation of Vibrating Motor ........................................................................................4-93
4-3
July 17, 2020 Hydraulic System
CLG6611E
Removal of Vibrating Motor..............................................................................................................4-93

Installation of Vibrating Motor...........................................................................................................4-93
Removal and Installation of Drum Motor..............................................................................................4-94
Removal of Drum Motor ...................................................................................................................4-94
Installation of Drum Motor ................................................................................................................4-94
Fault Diagnosis and Elimination ......................................................................................4-95

Vehicle cannot travel........................................................................................................................4-95
Vehicle has no high speed gear.......................................................................................................4-95
Vehicle has no steering or hard steering..........................................................................................4-96
No vibration (large vibration or small vibration)................................................................................4-96
Insufficient vibration frequency.........................................................................................................4-97
Noise and vibration ..........................................................................................................................4-97
4-4
Hydraulic System July 17, 2020
CLG6611E
4-5
CLG6611E Safety
Basic Information Even if the pressured liquid is leaked as small as

a pin hole, it may penetrate the muscles and lead
to personal injury and death. If being shot by the
Safety ejected high-pressure oil, please contact a
doctor for treatment immediately.
Compressed Air
Compressed air may cause personal injury.

When using the compressed air for cleaning,
wear the mask, protective suits and safety
shoes. Do not point the compressed air at
yourself or anyone else. The compressed air
may penetrate the skin and lead to severe injury
or even death. The max. pressure of the P26H00040
compressed air for cleaning should be lower than
0.2Mpa\29psi.
Safe Disposal of Waste Fluid
High-pressure Solution
Improper disposal of waste fluid will endanger
Be careful of burns from high-pressure oil. When environment and ecology. Please observe local
overhauling or replacing the pipes of hydraulic laws and regulations when disposing the waste
system, check whether the pressure of system liquid. The liquid spilled from the machine during
had been released. Hydraulic oil splashed under inspection, maintenance, testing, adjustment and
pressure can cause serious skin damage. repair must be kept in a container. A suitable
container for liquid collection shall be prepared in
Be careful during removal of the hydraulic lines
advance before opening any fluid chamber or
or connectors. When the oil is ejected, the
disassembling the parts containing fluid. Use a
released high pressure oil may lead to the
suitable container when draining the fluid. Do not
sweeping movement of the hoses.
use food or beverage containers because the
Please wear safety glasses and leather gloves fluid in such containers may be drunk by others
when checking for leaks. Do not use bare hands by mistake.
to check the leakage but plate or paper plate.
P26H00039
37
P19M00041
4-6
Safety CLG6611E
Preventing Extrusion or Cut Off Oil
Do not place your hands, arms, or any other Hot oil and components will cause personnel
parts of your body between movable parts. For injury, and do not let the hot oil and components
example, between working device and cylinder, touch skin.
and between machine and working device.
At working temperature, the hydraulic oil tank is
Properly support the equipment when working
hot and pressurized. When opening oil filler cap
under the working device. Do not support the
of hydraulic oil tank, shut off the engine and cool
working device by the hydraulic cylinder. If the
the filler cap down until it can be opened by bare
control mechanism moves or the hydraulic line
hands. Slowly remove the tank cover to release
leaks, the working device will fall off. If it is
the pressure of hydraulic oil tank so as to prevent
necessary to remove the shield during
from being scalded by hot oil. Release the
maintenance, the shield must be installed after
system pressure before removing all pipes,
maintenance.
connectors or related parts.
Line, Pipe and Hose
Do not bend or hammer the high pressure lines,

and do not install hard pipes or hoses that are
abnormally bent or damaged on the machine.
Repair any loose or damaged fuel and lubricating
oil lines, pipes and hoses of the hydraulic system
in a timely manner. Leakage may cause fire.
Please contact with the designated distributor of
Liugong Machinery Co., Ltd. for repair or
replacement.
P26H00042
If following problems are found, replacement
Since the rotating engine blades are dangerous shall be made.
to cut fingers, keep a safe distance or shut down ● Damage or leakage of connector.
the engine during maintenance.
● The outer layer of hose is worn or cracked,
Make sure there is no sundries in the blades of and reinforced steel wires are exposed.
the engine fan. The fan blades will throw out or
cut off the tools and sundries that fall into or are ● Partial bulge of hose.
pushed into the fan blades. Unless otherwise ● The hose is obviously twisted or flattened.
specified, no adjustment can be made while the
machine is running or the engine is running. Do ● The hose reinforcement steel has embedded
not leave the machine unattended if the to the outer layer.
maintenance procedure must be carried out ● Misplacement of the end connectors.
while the machine is running. Arrange one
person to sit on the operator's seat and prepare Make sure that all clamps, guards and heat
to shut down the engine at any time. Do not use shields are properly installed to prevent vibration
twisted or worn wire ropes. Wear gloves during or overheating due to friction with other parts.
use and handling. When pressing out the When removing the connecting pipe of the A/C
bayonet lock firmly, make sure there is no one compressor, no open flame, otherwise toxic gas
around. Wear safety goggles to avoid eye injury. will be produced to cause poisoning.
When striking an object with a hammer, make
sure that the flying debris will not hurt others.
4-7
CLG6611E Safety
Precautions for Accessories
Installation and commissioning must be carried

out by qualified personnel. Operators should be
trained to operate and maintain in strict
accordance with the operating instructions of the
accessories.
When installing and using the spare accessories,
please read related instructions, manuals and
information related to accessories in the manual.
Improper installation of accessories or options
will not only lead to safety problems, but also
adversely affect the operation of the machine
and the service life of the equipment.
Do not use the accessories unauthorized by
LiuGong. The use of unauthorized accessories
may cause safety problems, which are not
conducive to the normal operation of the
machine and affect the service life.
Do not make any adjustments to the accessories
without permissions; otherwise the responsible
person shall take the responsibility for all
consequences.
LiuGong Machinery Co., Ltd. is not responsible
for any damages, accidents or machine
damages caused by the use of unauthorized
accessories.
4-8
System Components and Locations CLG6611E
System Components and Locations
Overview
The hydraulic system of roller mainly consists of three functional modules: travel hydraulic system,
vibrating hydraulic system and steering hydraulic system, wherein the travel hydraulic system and the
vibrating hydraulic system are typical closed hydraulic systems. The main function of the hydraulic
system is to supply pressure oil through the twin pump and realize variable speed regulation of the pump
through the tandem pump control module, thus realizing the traveling and braking of the front and rear
wheels of the vehicle and the vibration of the steel drum. The function of the steering hydraulic system is
to supply pressure oil to the steering pump, control the flow rate and direction of pressure oil through the
steering gear, and realize the steering operation of the vehicle through the steering cylinder.
See appendix for its hydraulic schematic diagram.
Overall Layout of Hydraulic System
P26H00043
1. Vibrating Hydraulic System 2. Travel Hydraulic System 3. Steering Hydraulic System

4-9
CLG6611E System Components and Locations
Functional Block Diagram of Hydraulic System

Steel Steel wheel
drive line motor
Rear axle
Rear axle line motor Rear axle
Oil suction Twin

Fuel tank pump Brake line
filter
Vibration
Vibration line motor
Steering Steering Steering

pump gear cylinder
Oil return Radiator

filter P26H00044
List of Major Hydraulic Components
S/N Liugong No. Name Code Manufacturer

90R075M81BC60P3C7D03GBA424224
1 11W0065 Twin Pump Danfoss
MPV046C-BBBSBBAAGABHHDBAHHCNNN
H1-B-080-A-E2-AA-N-B-TB-DN-
2 11C1255 Rear Axle Motor Danfoss
JN-N-A-10-NN-032-Z-00-NNN
3 11C0035 Drum Motor 90K055NC0N8N0S1W00NNN0000E6 Danfoss
4 41C1028 Reducer CTU2150.1/CF-AP/41.1/A.D(90K055-S1) BREVINI
5 53W0029 Oil Return Filter AMF30E230/2EFD1 Pingfei
6 53W0028 Oil Suction Filter AMF30E130/2ECD1 Pingfei
7 11W0055 Vibrating Motor MMF044D-A-F-H-A-B-NNN Danfoss
8 11W0064 Steering Pump CBT-F419.2-ALΦ9 Changyuan
9 10W0004 Steering Cylinder
10 12W0006 Steering Gear BZZ500/FKA12.5-16
The hydraulic system of this model mainly consists of twin pump (propelling pump + vibrating pump),
vibrating motor, steel wheel propelling motor and reducer, rear axle propelling motor, steering pump,
steering gear, steering cylinder, filter, line connector, etc.
The double pump is installed on the connecting plate of the engine flywheel housing, and the pump input
shaft is connected with the engine flywheel through a coupling. The vibration motor is installed on the
vibration chamber mounting base. The output shaft of the motor is connected with the spline sleeve of
the vibration exciter to transmit torque. The steel wheel traveling motor and the reducer are installed
together. The output end of the reducer is connected with the steel wheel driving plate. The installation
end of the reducer is connected with the front frame side plate. The rear axle traveling motor is installed
on the drive axle to transmit torque to the drive axle.
4-10
System Technical Parameters CLG6611E
System Technical Parameters
Hydraulic
System Parameter Unit Remarks
Component
Type —— Variable axial piston pump
Propelling Max. Displacement ml/rev 75

Pump
Max. working bar 420
Type —— Variable displacement motor with
Drum
Propelling Max. Displacement ml/rev 80
Motor (Rear Max. working bar 420
axle)
Travel Hydraulic
System Type —— Variable displacement motor with
Drum Max. Displacement ml/rev 55
Propelling
Motor (Drum) Max. working bar 420
Type —— Planetary reducer with parking brake
Reducer Ratio —— 41.1
Max. Output Torque N.m 18000
Pressure Filter for μm 10
Filter
Return Filter μm 10
Type —— Variable axial piston pump
Max. Displacement ml/rev 46
Vibrating Pump
Vibrating
Max. pressure bar 345
Hydraulic System
Type —— Constant axial piston motor
Vibrating Motor Max. Displacement ml/rev 44
Type —— Gear pump
Steering Pump
Displacement ml/rev 19.2
Steering Hydraulic Displacement ml/rev 500

Steering gear
System Max. working bar 180
Steering Bore mm 100

Cylinder Piston rod radius s mm 45
4-11
CLG6611E List of General Hydraulic Tools and Fixtures
List of General Hydraulic Tools and Fixtures
Name Specifications (Qty.)

Open-end wrench 8#, 13#, 15#, 17#, 19#, 21#, 22#, 24#, 27#, 30#, 32#, 36#, 41#, 44#, 46#
Straight screwdriver
Cross screwdriver
Pliers
20~100N•m\14.75~73.75lbf•bt, 90~300N•m\66.38~221.25lbf•bt,
Torque wrench
160~680N•m\118~501.5lbf•bt
Allen wrench One set for metric system and one set for imperial system
Lifting equipment 2t
Lifting appliance 2t
Note: The removed standard parts should be placed with corresponding materials together
to avoid confusion.
Special Tools and Fixtures for Hydraulic Maintenance
Tool
S/N Liugong No. Figure Application
description
1 SP130702 Crowbar For assembling O-ring of piston
For assembling dust ring of cylinder

2 SP129313 Rubber hammer
head
For compressing dust ring of

3 SP130917 Dust ring fixture
cylinder head
4-12
Special Tools and Fixtures for Hydraulic Maintenance CLG6611E
Tool
description
4 SP130915 Pilot sleeve For assembling O-ring of piston rod
For assembling the cylinder head

5 SP130700 Pilot sleeve
assembly to the piston rod
For aligning flange bolt holes with

6 SP129308 Setting tool
cylinder head through holes
For aligning flange bolt holes with

7 SP130698 Alignment pin
cylinder head through holes
8 SP133205 Blower gun For pretightening bolts
9 SP129309 Sleeve For tightening bolts

4-13
CLG6611E Special Tools and Fixtures for Hydraulic Maintenance
Tool
description
10 SP130929 Wire cutter For cylinder head retainer ring
Press fitting
For press-fitting the friction ring to
11 SP130702 fixture for friction
the piston
ring
Compressing
12 SP129313 fixture for friction For compressing friction ring
ring
For assembling the cylinder head

13 SP130917 Pilot sleeve
assembly to the piston rod
14 SP130915 Pilot sleeve For assembling O-ring of piston rod
Press-fitting For assembling the bushing on the

15 SP130700
fixture for liner cylinder block
4-14
Special Tools and Fixtures for Hydraulic Maintenance CLG6611E
Tool
description
For supporting the cylinder block

Cylinder block
16 SP129308 and compressing the bushing to the
support
cylinder block
For detecting the size of the bushing

17 SP130698 Bushing detection
fitted to the cylinder block
18 SP133205 Blower gun For tightening nylon lock nut
For pressing the piston rod into the

19 SP129309 Copper rod
cylinder block
For pretightening the cylinder head

20 SP130929 Crescent wrench
assembly
For locking the cylinder head

21 SP129306 Sleeve
assembly
4-15
CLG6611E Travel Hydraulic System
Travel Hydraulic System
Overview
The propelling pump is driven by the engine flywheel, and realizes the variable displacement of the
pump by controlling the change of the wobble plate swing angle of the propelling pump through the
operating handle, so that the displacement of the pump continuously changes between the positive
maximum value and the negative maximum value, thereby making the change of the output flow of the
pump (or the input flow of the motor) realize the rotation speed change (i.e., the vehicle speed) of the
motor, and the switching of the pressure oil output at the high and low pressure ports of the pump
enables the motor to rotate forward and backward to realize the forward and backward movement of the
vehicle.
The hydraulic service brake is to stop the vehicle from the running state by positioning the wobble plate
on the pump in the neutral position when the handle is in the neutral position, and the pump has no flow
output, while the motor also overcomes the inertia load of the driving wheel (the output brake torque
under the pump operating condition of the motor).
The emergency braking and the parking braking are realized by controlling the brake solenoid valve of
travel pump. When the solenoid valve is powered on, part of pressure oil from the charge pump enters
the rear axle and reducer brake chambers, and open the brake to release the braking. During braking,
the solenoid valve is powered off and reverses its direction, the pressure oil of the brake is pressure
relieved by connecting with the oil tank, and the brake is mechanically locked to implement braking.
There are large and small displacement settings on the front and rear traveling motors. The combination
of the four displacements makes the whole machine have four gears.
4-16
Travel Hydraulic System CLG6611E
Components and Layout

Layout Diagram of Travel Hydraulic System
7
6
5
3 4
1 2
P26H00045
1. Reducer 4. Rear Axle 6. Propelling Pump

2. Drum Propelling Motor 5. Return Valve Block 7. Oil Return Filter
3. Drum Propelling Motor
Hydraulic Schematic Diagram
P26H00046
4-17
Propelling Pump
Working Principle
Mechanical energy input by the engine is transmitted to the cylinder block for high-speed rotation
through the piston pump input shaft, which is supported by bearings at the front and rear portions and is
connected to the cylinder block through splines. A lip-type shaft seal is arranged at the front of the shaft
which extends out of the pump case to prevent oil leakage. The cylinder block is provided with 9
reciprocating plungers each connected to a brass sliding shoe through a spherical hinge, and a fixed
clearance type return pressure plate enables the sliding shoe to contact with a variable wobble plate.
When the sliding shoe rotates around the spindle on the angled wobble plate, the plunger is pushed to
reciprocate in the cylinder block. The oil distribution disc is connected to the oil on the low pressure side
and the high pressure side of the cylinder block. The movement of the plunger in the cylinder block
completes the suction and discharge of oil and transfers the hydraulic energy to the system. A small
portion of the hydraulic oil flows out of three friction pairs as the cylinder block/oil distribution disc, sliding
shoe/variable wobble plate, plunger/cylinder block, playing a role of lubrication and cooling. The oil drain
port of the housing returns this portion of the oil to the oil tank.
The swash plate angle control determines the displacement of the pump, i.e., the hydraulic oil flow rate
of the pump input system. The servo control piston pushes the swash plate variable. The machine
operator adjusts the pressure on both sides of the servo control piston through the pump control
mechanism, thus realizing the pump displacement setting.
Internal Section View of Propelling Pump
P26H00047
1. Bushing 7. Swash plate guide 13. Displacement control module

2. Cylinder block group 8. Input shaft 14. Piston shoe
3. Oil distribution disc 9. Shaft seal 15. Plunger
4. Rear sliding bearing 10. Roller bearing 16. Servo connecting rod
5. Slippage pump 11. Swash plate bearing 17. Servo piston
6. Swash plate 12. Feedback connecting rod 18. Sliding block
4-18
Schematic Diagram of Propelling Pump
P26H00048
Key Parts
2 3
P26H00049
1. Manual Displacement Controller 2. Multifunction Valve 3. Integrated Pressure Oil Filter

4-19
Manual Displacement Controller
Control Principle: The manual displacement control converts the manual mechanical input signal
(flexible shaft control) into a hydraulic control signal, and propels the servo piston to move through the
hydraulic control signal, thus driving the wobble plate inclination angle change to adjust the pump
displacement stepless change between the positive maximum displacement and the negative maximum
displacement.
Since the mechanical wobble plate feedback link reacts upon the main spool of the displacement control
module, the control of the position of the main spool is simultaneously affected by the manual input
signal and the wobble plate position feedback signal, thus realizing closed loop control of displacement.
The proportional control of pump wobble plate angle (pump displacement) can be realized by changing
the input signal of the displacement control module. The control module is internally designed with a
mechanical input priority mechanism. Ensure that the control module is protected from damage when
the speed of movement of the mechanical input mechanism is higher than that of the wobble plate.
Advantage: —After the engine stops running, the pump will automatically return to the neutral position.
—When the input signal of the external handle fails or the charge pressure is insufficient, the pump will
automatically return to the neutral position.
Schematic Diagram of Manual Displacement Control
P26H00050
Internal Section View of Manual Displacement Control
P26H00051
4-20
Size Diagram of Manual Displacement Control Handle
P26H00052
Multifunction Valve
The multifunction valve is a replaceable threaded cartridge valve, which integrates the functions of a
single oil supplementary valve, a high-pressure relief valve, a pressure limiting valve and a bypass valve
of the system, and these functions play separate roles respectively. Two multifunction valves are
integrated on the propelling pump to realize pressure control on both sides.
Overpressure Protection Function: When the pressure of the travel hydraulic system reaches the
pressure limit (39 MPa), the pressure limiting valve opens rapidly to propel the wobble plate to move
toward the neutral position so as to reduce the displacement of the pump to reach the effect of limiting
the system pressure. For applications where there is a transient load (over 42 MPa), the high pressure
relief valve functions to achieve system overpressure protection. The pressure limiting valve is
equivalent to the pilot relief valve of the high pressure relief valve, which functions after the system
pressure exceeds the pressure limit level.
The pressure limiting valve, which cooperates with the high pressure relief valve, avoids the problem of
overheating of hydraulic oil caused by overflow heat to the greatest extent. The high pressure relief
valve, which functions after the pressure limiting valve is opened, plays a role of pressure peak
elimination under some severe working conditions. Because the high pressure relief valve is only
opened for a short time under the condition that the pressure peak occurs instantaneously in the system,
thus minimizing overflow heating. The response time of the high pressure relief valve is 20 ms, which is
independent of the pressure limiting valve.
Pressure Limiting Function: When the pressure of the travel hydraulic system reaches the pressure
limiti(39 MPa), the pressure limiting valve (A) opens, and the pressure signal reaches the low pressure
side of the servo cylinder through the oil duct (B) and the damping hole on the control valve spool. The
servo pressure relief valve (C) limits the servo pressure to a suitable range. At this time, the output signal
of the pressure limiting valve and the control signal from the displacement control module act on both
sides of the servo piston at the same time, thus weakening the control signal from the control module.
The displacement of the propelling pump is reduced under the action of the swash plate resetting force,
thus keeping the system pressure at the set point. In this system, the setting pressure of the high
pressure relief valve is 30 bar higher than that of the pressure limiting valve.
Bypass Function: When the main shaft of the propelling pump cannot rotate or is not suitable for rotation,
the bypass function is enabled to realize the circulation flow of hydraulic oil when the propelling pump
and the engine are not working.
4-21
Example: The vehicle needs to move to the maintenance service area or move to a flat bed trailer
without starting the engine after the vehicle fails.
Usage: The bypass nuts on the two multifunction valves are turned counterclockwise three times to
enable the multifunction valve bypass function.
When the bypass function is enabled, the vehicle speed should be less than 20 % of the
maximum speed and the duration should not exceed 3 minutes. The bypass valve is only suitable
for short-distance low-speed dragging of the vehicle without starting the engine. Be sure to
remember that the bypass valve is not a trailer valve.
Hydraulic Schematic Diagram of Multifunction Valve
P26H00053
4-22
Operation Schematic Diagram of Multifunction Valve
P26H00054
Integrated Pressure Oil Filter
In order to prevent premature wear of the components, it is necessary to ensure that the hydraulic oil
entering the system loop is clean. The travel system adopts an integrated pressure oil filter (the filter is
installed on the rear end cap of the pump), i.e. the filter is installed at the outlet of the slippage pump and
in the front of the oil supplementary relief valve, so that the supplementary oil flow will pass through the
filter completely.
Advantages: —The vacuum degree of the pump suction port during cold start can be reduced, and the
oil can be filtered just before entering the loop and the control system.
—It is easy to install, repair and replace.
4-23
Operation Schematic Diagram of Integrated Pressure Oil Filter
P26H00055
Technical parameters and related requirements of propelling pump
Parameter Unit Value Note/Description

Max. Displacement cc 75
Direction of rotation Right/clockwise rotation (as viewed from the input shaft end)
Input speed
Min. speed rpm 500
Rated rotation speed of engine is 2200
Rated Rotation Speed rpm 3600
rpm
Max. speed rpm 3950
System pressure
Max. Working Pressure Bar 420 Relief valve setting
Max. pressure of loop on the low
Bar 45
pressure side The normal pressure on the low
Min. pressure of loop on the low pressure side is the charge pressure
Bar 10
pressure side
Slippage pump
Oil suction pressure of slippage 0.7 bar (Vacuum The pressure for cold start is not less
Bar
pump degree) than 0.2 bar
Setting pressure of oil
Bar 24 Up to 34 bar and down to 18 bar
supplementary relief valve
Displacement of slippage pump cc 17
4-24

Case pressure
Continuous Bar 3
Max. (pressure for cold start) Bar 5
Oil requirements for hydraulic oil (fill 46# antiwear hydraulic oil when delivery)
Viscosity
Min. cst 7
Fill 46# antiwear hydraulic oil when
Continuous cst 12-80
delivery
Max. cst 1600
Temperature
Min. °C -40
The working oil temperature is
Continuous °C 104
controlled below 85°C
Max. °C 115
Note: Filtration requires cleanliness of 22/18/13 or higher, 1SO4406

4-25
Installation locations and parameters of oil ports of propelling pump

Location and Parameter Diagram of Oil Ports of Propelling Pump
P26H00056
4-26
Installation Diagram of Propelling Pump
P26H00057
Location Diagram of Main Oil Ports of Propelling Pump
1 4
6
2
8
3
P26H00058 P26H00059
1. System pressure test port M3 4. System pressure B test port M2 7. High pressure oil port A
2. High pressure oil port B 5. System pressure A test port M1 8. Case oil drain port L2
3. Case oil drain port L1 6. Oil suction port S of slippage pump
Size and parameter setting of main oil ports
Pressure Thread and flange
S/N Description Code Note
measurements dimensions
1 High pressure port A A 420Bar SAE1 Max. pressure setting
2 High pressure port B B 420Bar SAE1 Max. pressure setting
High pressure A test
3 M1/MA 420Bar 9/16-18UNF-2B Max. pressure setting
port
High pressure B test
4 M2/MB 420Bar 9/16-18UNF-2B Max. pressure setting
port
Pressure at cold start
5 Case leakage hole L1/L2 ≤3bar 1-1/16-12UNF-2B
moment 5 bar
4-27

Charge pressure test
6 M3 24bar 9/16-18UNF-2B
port
Slightly lower than the
7 Servo chamber test port M4 ≤24bar 9/16-18UNF-2B
charge pressure
Slightly lower than the
8 Servo chamber test port M5 ≤24bar 9/16-18UNF-2B
charge pressure
Oil supplementary and
9 S -0.7bar 1-5/16-12UNF-2B Vacuum degree
suction port
A) Introduction to simple maintenance of propelling pump

The maintenance here mainly focuses on the replacement guidance of the seal repair kit and the
replacement of simple external components. The overall overhaul requires professional maintenance.
Instructions before overhaul: Clean the surface of the pump before removing the propelling pump, and
disassemble the vibrating pump behind the propelling pump into a single pump. Before removing the
hydraulic line, make necessary marks on the removed oil lines and seal them. All openings need to be
plugged to prevent contaminants from entering the system.
Contamination will cause damage to internal components and the failure arisen therefrom is not
covered by the warranty. When removing or installing the system line, necessary measures shall
be taken to ensure the cleanliness of the system.
Replacement of shaft and shaft seal
Replacement of the shaft and shaft seal does not require disassembling the entire pump or thoroughly
cleaning the pump and the working area. Disconnect the pump from the hydraulic line to which it is
connected, remove the pump, and thoroughly clean it before starting maintenance. Mark all connectors
for subsequent assembly.
4-28

1. Place the pump horizontally with the shaft facing
upwards. When the shaft is pulled out, the pump body
will move or vibrate, causing the cylinder block to
deviate from its original position, and making it difficult to
install the subsequent shaft;
2. Remove the three fastening bolts as shown in figure
(L70), the bearing pressure plate as shown in figure
(L60) and the oil seal installation rack as shown in figure
(L30) with an Allen wrench of 6 mm;
3. After removing the fastening bolts, the spring force shaft
assembly on the inner shaft may push the oil seal
installation rack out of its installing hole by about 5 mm
[1/4 inch]. If the shaft seal installation rack does not
automatically pop out, use a rubber hammer to slightly
knock the shaft end while prying it away from the
installing hole;
4. Remove the O-ring (L50) from the shaft seal installation
rack and discard it;
5. Extrude the lip shaft seal (L40) out of the oil seal
installation rack with a press;
6. Remove the shaft (L100) and roller bearing assembly
(L10) from the pump, and the bearing assembly can be
reused;
7. Use the circlip pliers to remove the snap spring (L20)
which is used to position the roller bearing assembly.
Remove the roller bearing assembly.
8. Check whether the shaft seal installation rack, new lip
seal and O-ring are in good condition and free from
scratches;
9. Check whether the shaft and bearing are free from rust,
abrasion and contamination; rotate the bearing by hand
to feel whether the bearing is working well and replace it
if necessary;
10.Press the new lip seal (L40) into the oil seal installation
rack (L30) with a press and carefully install it to avoid
damage to the shaft seal;
11.Install the bearing assembly on the new shaft and
ensure that the snap spring is installed in place;
12.Install an assembly bushing on the shaft end or wrap a
spline or flat spline shaft end with plastic film to prevent
the lip shaft seal from being damaged during installation;
P26H00060 13.Lubricate the new O-ring (L50) with clean petroleum-
based grease and install it on the shaft seal installation
rack;
14.Install the shaft seal installation rack and oil seal in place
by passing through the shaft end;
15.Install the fastening bolt with a torque of 16N•m[12lbf•ft].
4-29
Replacement of Multifunction Valve

1. Remove the multifunction valve (as shown in P2A1 and
P2B1) with an outer hex wrench (1-1/4inch);
2. Remove and discard O-rings as shown in (P13 and
P06);
3. Remove the seat of the bypass valve as shown in (P03)
with a 1-1/16 wrench to release the spring pressure. In
order not to change the multifunction valve pressure set
value, do not remove the adjusting bolt (P01) and
locking thread (P04) from the bypass valve seat (P03);
P26H00061
4. Remove and discard O-ring (P02);
P26H00062
5. Press-fit the valve seat part through the neck, fasten the
cartridge valve to the vise and pry the valve seat (P12)
off with a suitable tool, take necessary measures to
prevent the internal components from being scattered
and lost, and do not damage the parts during
disassembly;
6. Remove internal components (P07, P08, P17, P16, P15,
P14, P09, and P11);
7. Clean and inspect all disassembled parts;
8. Lubricate and install parts (P07, P08, P17, P16, P15,
P14, P09, P11, and P12);
9. Place the cartridge valve on the vise and press the valve
seat (P12) into the vise;
10.Lubricate and install new O-rings (P02, P06, P13);
11.Install bypass valve seat (P03) and integral pressure
limiting valve (P01) and apply torque to 40N•m[30lbf•ft];
12.Install the cartridge valve and tighten with a torque of
89N•m[66lbf•ft].
4-30
Replacement of Charge Pressure Relief Valve

1. Remove the relief valve plug, mark the approximate
location between the plug (K10), locking nut (K90) and
the housing so as to maintain the setting pressure of the
original oil supplementary valve during reassembly. Only
after loosening the lock nut, the threaded adjustable oil
supplementary relief valve be removed; loosen the
screw plug of the oil supplementary relief valve with a
large screwdriver or a 1/2 inch outer hex wrench,
remove and discard the O-ring (K50);
2. Remove spring (K70) and relief valve spool (K80);
3. Check the valve spool (K80) and the valve seat holes on
the rear end cap for damage or external substances. Do
not replace gaskets or internal components when
checking the gasket adjustment type oil supplementary
relief valve;
4. Install the valve spool (K80) and spring (K70), install the
plug and lock nut, align the marks made during
disassembly,
P26H00063
4-31
Replacement of Integrated Pressure Oil Filter

1. Remove the steel filter tank (N40) from the filter
installation head (N10);
2. Loosen the lock nut (N20) with a wrench (1-5/8inch);
3. Unscrew the filter installation head counterclockwise
from the housing, remove and discard the O-ring (N15);
4. Remove the hydraulic oil line (N25) in the filter installing
hole of the rear end cap;
5. Check the sealing surface of the filter installation head
and lock nut. If scratch or damage is found on the
component, replace the damaged component;
6. Insert the hydraulic line (N25) into the installing hole of
the rear end cap; after replacing the new O-ring (N15),
install the filter installation head in place. Do not install
the hydraulic line vigorously.
7. After clockwise screwing the filter installation head
thread for 6-7 turns, position the installation head in the
required direction;
P26H00064 8. Tighten the lock nut (N20) to the torque shown in the
Table below on the premise of keeping the direction of
the filter installation head unchanged;
9. Install a new steel filter tank (N40).
Rear Axle Motor
Working Principle
The rear axle motor rotating assembly is of cambered axle arrangement, which can provide high starting
torque and high rotation speed output of the motor. The copper bushing on each plunger ball head is
pressed into that drive shaft to complete the conversion of hydraulic energy and mechanical energy
through the force transmission of the plunger. The pressure compensation spherical plunge ring is
always in contact with the plunger hole of the cylinder block, thus ensuring high volumetric efficiency and
low friction force of the motor. The synchronous shaft ensures that the motor rotating assembly is
synchronized with the rotation speed of the output shaft.
4-32
The hydraulic energy output by the propelling pump is converted into torque of the motor and then
transmitted to the rear axle to drive the rear wheel to run, and the two-point variable displacement motor
can realize switching of large and small displacements and high and low speeds.
P26H00065
1. Electronically controlled double-position 4. Axial bearing 7. Minimum displacement limiter

2. Differential servo piston 5. Tapered roller bearing 8. Loop flushing relief valve
3. Fan-shaped oil distribution disc 6. Speed ring 9. Loop flushing shuttle valve
P26H00066
4-33
Key Parts
P26H00067
1. Electronically controlled double-position 2. Flushing shuttle valve 3. Flushing relief valve
Electronically controlled double-position
The electronically controlled double-position control module contains a switching electromagnet, which
acts directly on a two-position three-way spool. The pressure on the high pressure side of the system
selected by the internal shuttle valve is led to the servo piston chamber to realize displacement
switching.
When the solenoid valve (24V) is de-energized, the motor works at the maximum displacement. When
the solenoid valve is energized, it drives the control valve spool to reverse, thus leading the pressure oil
on the high pressure side of the system to the large chamber side of the servo piston, and switching the
motor to the minimum displacement. After the solenoid valve is de-energized, the motor swash plate
swings back to the maximum displacement.
4-34
P26H00068
Dimension mm[in]
DIN140B4HL Standard ISO3019/2
AM 205.0[8.07]
EE 126.0[4.96]
EF 147.0[5.79]
EG 112.0[4.41]
EH 183.0[7.21]
Parameter table of electronically controlled double-position solenoid valve coil
Description Parameter
Rated voltage 24V
Min. supply voltage 21.1Vdc
Max. supply voltage 29.0Vdc
Nominal coil resistance @20°C[70°F] 34.5Ω
Recommended input current 500mA
IP Grade (IEC60529) IP67
IP Grade (IEC60529) with mating electrical
IP69K
connectors
4-35
Loop flushing shuttle valve
The loop flushing shuttle valve is located at the front end of the loop flushing relief valve to separate the
high and low pressure sides of the loop. The pressure on both sides in the loop acts on both ends of the
spool of the flushing shuttle valve at the same time. When the pressure difference between the two sides
of the spool exceeds 6.5 bar, the spool reverses and leads the pressure oil on the low pressure side in
the system loop to the loop flushing relief valve.
Loop flushing relief valve
The loop flushing relief valve replaces the oil from the low pressure side of the system to realize the
cooling of the oil in the working loop and replace the contaminants in the circulating loop. The flushing
relief valve spool is a spool with damping holes, with the opening pressure of 16 bar [232 psi].
P26H00069 P26H00070 P26H00071
Technical parameters and related requirements of rear axle motor

Electronically
Max. voltage of 29V, Min. voltage of 21.1V, and effective
Control mode controlled double-
nominal coil resistance of 34.5 Ω (20°C)
position 24V
Output speed
Rated (at Max. Displacement) rpm 3200
Max. (at Max. Displacement) rpm 5300
System pressure
The relief valve of the propelling pump is
Max. working pressure of system Bar 420
set to 420 bar
Max. working pressure of Maximum peak working pressure of
Bar 450
components motor 480 bar
Displacement
Small displacement when energizing,
Min. displacement setting cc 16 and large displacement when de-
energizing
4-36

Case pressure
Continuous Bar 3
Viscosity
Min. cst 7
delivery
Max. cst 1600
Temperature
Min. °C -40
The working oil temperature is controlled
Continuous °C 104
below 85°C
Max. °C 115
Installation locations and parameters of oil ports of rear axle motor
P26H00072 P26H00073
1. Case oil drain port L1 4. System pressure test port MB 7. Working port B
2. Loop flushing valve 5. System pressure test port MA 8. Case oil drain port L2
3. Servo pressure test port M5 6. Working port A
4-37

3 High pressure A test port M1/MA 420Bar 1-1/16-12UNF-2B Max. pressure setting
4 High pressure B test port M2/MB 420Bar 1-1/16-12UNF-2B Max. pressure setting
5 Case leakage hole L1/L2 ≤3bar 7/8-14UNF-2B
moment 5 bar
6 Servo pressure test port M4/M5 9/16-18UNF-2B
Introduction to simple maintenance of rear axle motor
Replacement of shaft and shaft seal

1. Thoroughly clean the outer surface of the motor before
disassembly;
2. Remove the shaft seal pressure plate snap ring (l80)
from the motor housing with suitable snap ring pliers;
3. Carefully remove the shaft seal pressure plate (L75)
from the motor housing and do not damage the shaft
seal installing hole or main shaft on the housing;
4. Remove the O-ring (L50C) from the housing installing
hole;
5. Before discarding the O-ring (L50C), please check
whether the size of the new O-ring for replacement is
appropriate;
6. Carefully remove the shaft seal (L40) from the shaft seal
pressure plate;
7. Before discarding the old shaft seal (L40), confirm
whether the replacement of the new shaft seal meets the
requirements;
8. Check whether the shaft seal pressure plate (L75) and
the housing installing hole are intact or not;
9. Check whether there is wear in the contact area
between the main shaft and the shaft seal;
10.Face the groove of new shaft seal (L40) inward;
11.Press the new shaft seal (L40) into the shaft seal
pressure plate (L75);
P26H00074 12.Grease the new O-ring (L50) and place it into the
grooved surface of the housing installing hole;
13.After installing a protective cover on the main shaft,
press the shaft seal pressure plate (L75) into the
installing hole on the housing until the snap ring installing
groove on the inner wall of the housing installing hole is
exposed;
14.Install the snap ring (L80) into the motor housing
installing hole with suitable snap ring pliers;
15.Remove the mounting protective cover from the shaft.
4-38
Drum Motor
Working Principle
The plunger/piston shoes are laid out horizontally for the drum motor. The swash plate is of the fixed
type. The vibration motor will convert the hydraulic energy into the mechanical energy and make the
steel wheels to vibrate. It is mainly composed of housing, output shaft, distribution plate, swash plate,
cylinder body and plunger assembly, and flush valve.
The steel wheel motor is an axial plunger closed motor, which converts hydraulic energy into mechanical
energy, outputs torque, and drives the steel wheel to move. During braking, the two-point variable
displacement motor can realize the switchover between large and small displacements and that between
high and low speeds through the hydraulic neutral self-locking braking.
The quantitative bidirectional motor with a steel wheel motor displacement of 55 cc/rew is of a plug-in
mounting flange.
P26H00547
4-39
P26H00548
Key Components
P26H00549
1. Purge valve
4-40
Purge valve
To meet the requirements of oil cooling and cleanliness, some oil needs to be drained from the main
circuit, and such drainage can be achieved by flushing the circuit. The circuit flush valve can be used to
drain both heat and pollutants from the main circuit at a certain speed.
The flush overflow valve on the flush valve of the integrated circuit is a pressure overflow valve of which
the valve element is equipped with damping hole. The flushing discharge depends on the size of oil
makeup overflow valve and damping hole.
P26H00550 P26H00551
Technical parameters and related requirements of drum motor

Electronically
controlled Max. voltage of 29V, Min. voltage of 21.1V, and effective nominal
Control mode
double-position coil resistance of 34.5 Ω (20°C)
24V
Output speed
Rated (at Max. Displacement) rpm 3900
System pressure
The relief valve of the propelling pump
Max. working pressure of system Bar 420
is set to 420 bar
Max. working pressure of Maximum peak working pressure of
Bar 450
components motor 480 bar
Displacement
Small displacement when energizing,
Min. displacement setting cc 12 and large displacement when de-
energizing
Case pressure
Continuous Bar 3
4-41

Viscosity
Min. cst 7
delivery
Max. cst 1600
Temperature
Min. °C -40
Continuous °C 104
Max. °C 115
Installation locations and parameters of oil ports of drum motor

Location Diagram of Main Oil Ports of Drum Motor
1 2 3 4 5 6
P26H00552 P26H00553
1. Pressure testing port M1 3. Housing return oil port L1 5. Oil port A

2. Pressure testing port M2 4. Oil port B 6. Housing return oil port L2

3 High pressure A test port M1/MA 420Bar 9/16″× 18UNF-2A Max. pressure setting
4 High pressure B test port M2/MB 420Bar 9/16″× 18UNF-2A Max. pressure setting
5 Case leakage hole L1/L2 ≤3bar 7/8″× 14UNF-2A
moment 5 bar
4-42
Reducer
Working Principle
The propelling motor is driven by the hydraulic pump to run at high speed, and the output rotation speed
is reduced by the reducer to drive the steel wheel to run.
The travel hydraulic system has a braking function, and the operating handle is pushed and pulled
forward or backward to move the vehicle. When the operating handle returns to the neutral position and
the hydraulic oil quantity decreases, the vehicle enables braking. The reducer and the drive axle are
respectively equipped with a multi-disc brake. as slight leakage in the hydraulic oil line is hard to avoid,
when the operating handle returns to the neutral position, the multi-disc brake will be closed to realize
parking brake to prevent the phenomenon of "sliding slope" of the vehicle on the slope. The parking
brake is controlled by a 3/2 way solenoid valve. When the vehicle is running, the solenoid valve is
powered off, the multi-disc brake is released, and hydraulic oil is drained back to the drain line from the
brake housing. Run the engine, release the brake button, energize the brake solenoid valve, and apply
hydraulic oil to the brake piston. Under the action of the hydraulic oil pressure and the spring force of the
brake spring - release the brake.
Main Performance Features
1. Equipped with three-stage reduction gear;

2. Equipped with multi-disc parking brake, and directly assembled with hydraulic motor;
3. Bearing structure made of steel or high strength ductile iron;
4. Due to the large number of tapered roller bearings, it has higher radial and axial bearing capacity;
5. Through careful selection of materials and application of heat treatment, the shape of gear teeth can
be designed to produce strong torque;
6. The gearbox is lubricated together with the brake but separately from the motor.
3D Schematic Diagram of Reducer
P26H00077
4-43
Technical parameters
Max. output Maximum Oil Min. brake release

Ratio Brake oil port
torque rotation speed capacity pressure
18000N.m 3500rpm 41.1 3L M12X1.5 10bar
P26H00078
Manually release brake of steel wheel reducer
Loosen the brake adjusting screws at the rear end of the steel wheel reducer evenly until the steel wheel
can rotate freely.
P26H00079
4-44
Fault and maintenance of reducer
The operator is responsible for routine maintenance and completes the following operations:
1. Replace the oil after the reducer is operated for 100 hours for the first time (including intermittent
operation).
2. Check whether there is any metal scrap in the reducer.
3. It is best to change the oil when the oil temperature has not cooled down, because it is more
beneficial to draining the oil in the tank.
4. Clean the inside of the reducer with the cleaning solution recommended by the lubricant
manufacturer.
5. Please change the oil every 2,000 to 2,500 hours or at least once a year.
6. Do not mix different types of oil for use.
7. Check the oil level regularly (once a month). If the oil level drops, please make up the oil level.
8. When the dynamic brake pedal does not work or fails: please adjust the brake shoe for drum brake
and please replace the brake pad for disc brake.
9. The lubricating oil of the reducer also lubricates the multi-disc reverse brake. Therefore, when the
reducer changes the oil, the lubricating oil of the brake is also changed.
Fault Cause Solution

Check the connection between motor and
Improper installation of motor
reducer
There is input but no output
Internal fault Contact Liugong Service Department
Brake locked Check hydraulic loop
Too high oil level Reduce the oil level
The oil overflows from the Brake or motor oil seal damaged Contact Liugong Service Department
air vent during operation Incorrect installation location of vent
Check location of oil plug
plug
Vent plug blocked Unchoke vent plug
Oil leakage from seal
Seal ring damaged Contact Liugong Service Department
Abnormal noise Internal fault Contact Liugong Service Department
Improper installation of reducer Check the connection part
Abnormal vibration
Bad rigidity of the coupling Increase the rigidity of the coupling
Unventilated Intensify ventilation
Reducer overheated
Too high thermal power Install oil circulation cooling system additionally
4-45
Oil Return Filter
Working Principle
entering the system loop is clean. A return filter is installed on the return line of the main hydraulic
system of this machine.
Parameter
Bypass valve opening pressure: 0.20MPa

Working pressure: ≤1MPa
Filtering fineness: 10μm
P26H00080
4-46
Vibrating Hydraulic System CLG6611E
Vibrating Hydraulic System
Overview
The vibrating pump outputs high-pressure oil to drive the hydraulic motor to rotate, the hydraulic motor
drives the exciter to rotate, the vibrating pump is controlled by an electrically controlled three positions,
and the solenoid valve of the control module is switched so that the pump has three working positions,
namely, zero displacement, positive maximum displacement and reverse maximum displacement, the
motor can rotate forward and backward, and large and small amplitudes are realized through the
vibrating drum exciter. Two working frequencies and amplitudes are thus used for compacting different
soils.
P26H00555 P26H00556
The vibrating hydraulic system is a closed hydraulic system just like the travel hydraulic system.
1. Viewed from the left side of the whole machine, the vibration exciter runs clockwise, the steel ball
coincides with the eccentric block, and the roller vibrates greatly.
2. Viewed from the left side of the whole machine, the vibration exciter runs counterclockwise, the steel
ball is separated from the eccentric block, and the roller vibrates slightly.
Schematic Diagram of Vibrating Hydraulic System
P26H00082
4-47
CLG6611E Vibrating Hydraulic System
Component and Location
1
P26H00083
1. Vibrating Motor 3. Vibrating Pump

2. Return Valve Block 4. Oil absorption filter

P26H00084
4-48
Vibrating Pump
Working Principle
The vibration pump converts the input energy into hydraulic energy, and the input shaft transmits the
turning force to the cylinder block. Bearings for supporting the input shaft are provided at the front and
rear of the vibrating pump, the input shaft is connected to the cylinder block through splines, and the part
at the front of the shaft extending out of the pump housing is provided with a lip shaft seal to prevent oil
drainage. The cylinder block is provided with seven reciprocating plungers each connected to a brass
sliding shoe through a spherical hinge. The return spring and the charge pressure make the sliding shoe
in contact with the variable swash plate. When the sliding shoe rotates around the spindle on the angled
wobble plate, the plunger is pushed to reciprocate in the cylinder block. The oil distribution disc is
connected to the oil on the low and high pressure sides of the cylinder block. The movement of the
plunger in the cylinder block completes the suction and discharge of oil and transfers the hydraulic
energy to the system. A small portion of the hydraulic oil flows out of three friction pairs as the cylinder
block/oil distribution disc, sliding shoe/variable wobble plate, plunger/cylinder block, playing a role of
lubrication and cooling. The case oil drain port returns this portion of the hydraulic oil to the oil tank, and
the slippage oil pump provides flow and keeps the system loop in a low pressure state. The swash plate
angle controls the flow of hydraulic oil of the pump into the system, and the servo piston controls the
swash plate angle. The machine operator adjusts the pressure on both sides of the servo control piston
through the pump control mechanism, thus realizing the pump displacement setting.
Structural Diagram of Vibrating Pump
1 2
3
5 P26H00085
1. Oil supplementary one-way/high-pressure relief valve 3. Input shaft 5. Control

2. Oil supplementary relief valve 4. Auxiliary flange
4-49
1 4
2
3
5 6 P26H00086
1. Cylinder block 3. Slippage pump 5. Plunger

2. Oil distribution disc 4. Variable swash plate 6. Ball bearing
Hydraulic Schematic Diagram of Vibrating Pump
P26H00087
4-50
Key Parts
P26H00088
1. Electronically Controlled Three Positions 2. High Pressure Relief Valve 3. Displacement Limiter
Electronically Controlled Three Positions
The three-position electric control FNR (forward - neutral - reverse) is a two-stage control. A three-
position four-way solenoid valve is used to control the pump displacement to switch from zero to the
maximum displacement in the forward or reverse direction. When the electromagnet is energized, the
charge pressure oil communicates with the corresponding end of the servo cylinder. The servo piston
switches the pump to the maximum displacement under the servo pressure.
The time required for the pump output flow to change from zero to maximum (acceleration) or from
maximum to zero (deceleration) depends on the size of the damping holes in the servo control oil line,
the servo oil supply line, and the oil drain line.
Damping hole diameter/ Average response time for Average response time for
mm acceleration/s deceleration/s
0.9 1.3 0.9
4-51
High Pressure Relief Valve
The high pressure relief valve and the oil supplementary check valve are a combination valve, and the
high pressure relief valve is an energy consumption (heating) pressure control valve which limits the
system pressure to be higher than the set value. The oil supplementary check valve supplements oil to
the low pressure side of the working loop. High pressure relief valves, which are set when delivery and
cannot be adjusted, are arranged on both sides of the vibrating hydraulic system loop.
When the system pressure exceeds the factory set value of the valve, the pressure oil on the high-
pressure side will flow out of the high-pressure oil line and enter the oil supplementary passage, and
then enter the loop on the low-pressure side through the oil supplementary check valve. The high
pressure relief valve is a differential pressure valve, which is the relative pressure of the high pressure
side relative to the oil supplementation (low pressure side).
The high pressure relief valve is used to realize intermittent overpressure protection of the
system and cannot be used as a pressure setting valve for continuous pressure control.
Prolonged overflow may lead to overheating of the system oil. Excessive flow through the relief
valve may cause the pressure grade of the system to exceed the nominal set value of the relief
valve, thus damaging the system components.
Displacement Limiter
The displacement limiter is designed to prevent the vibration frequency of the vibrating drum from falling
after the working time of the hydraulic pump is too long. The vibration frequency of the vehicle has been
set up when delivery. Please do not adjust the displacement of the vibrating pump without special
circumstances, or do not adjust the vibration frequency to a value other than that required by the design
value, causing unnecessary failures.
The vibrating pump can be equipped with non-adjustable mechanical displacement (stroke) limiters on
both sides of the servo piston, which can limit the maximum displacement of the pump to a certain
percentage of the maximum displacement of the pump itself. These displacement limiters are internal
fixed physical limiters and cannot be adjusted externally. The pump displacement is symmetrically
limited on both sides of the pump.
Turn the adjusting bolt one turn to change the displacement setting to about 4.4 cm3/rev [0.27in3/rev].
The pump reaches the maximum displacement when the adjusting bolt is completely screwed out of the
servo end cap.
Carefully adjust the displacement limiter to avoid sudden changes in output flow and rotation
speed. Always torque the lock nut again after each adjustment to prevent non-artificial changes
in the output displacement set value and external leakage.
4-52
1
2 3
P26H00089
1. Adjusting bolt at neutral position 3. Adjustable displacement limit adjusting bolt

2. Fixed displacement limiter
Technical parameters and related requirements of vibrating pump
Parameter Unit Value Note

Direction of rotation Right/clockwise rotation (as viewed from the input shaft end)
Input speed
Min. speed rpm 500
Rated Rotation Speed rpm 4000 Rated rotation speed of engine is 2200 rpm
Max. speed rpm 4100
System pressure
Max. Working Pressure Bar 300 Relief valve setting
Max. pressure of loop on the
Bar ——
low pressure side
Min. pressure of loop on the
Bar ——
low pressure side
Slippage pump
Oil suction pressure of
Bar 0.7 (Vacuum degree)
slippage pump
Setting pressure of oil
Bar 19.5
supplementary relief valve
Displacement of slippage
cc 13.9
pump
Case pressure
Continuous Bar 1.7
Max. (pressure for cold start) Bar 5.2
4-53
Parameter Unit Value Note

Viscosity
Min. cst 7
Continuous cst 12-60 Fill 46# antiwear hydraulic oil when delivery
Max. cst 1600
Temperature
Min. °C -40
The working oil temperature is controlled
Continuous °C 82
below 85°C
Max. °C 104
Installation locations and parameters of oil ports of vibrating pump

Location Diagram of Main Oil Ports of Drum Motor
2
7
4
8
5
6
P26H00090 P26H00091
1. System pressure test 3. System pressure test 5. High pressure oil port A 7. Case oil drain port L2
port MA port MB 6. Case oil drain port L1 8. Oil supplementary port S
2. Charge pressure test 4. High pressure oil port B
port
4-54

1 High pressure port A A 300Bar 1-5/16-12 Max. pressure setting
2 High pressure port B B 300Bar 1-5/16-12 Max. pressure setting
3 M1/MA 300Bar 9/16-18 Max. pressure setting
port
4 M2/MB 300Bar 9/16-18 Max. pressure setting
port
5 Case leakage hole L1/L2 ≤3bar 1-1/16-12
moment 5.2 bar
Charge pressure test
6 M3 24bar 9/16-18
port
Servo chamber test Slightly lower than the
7 M4 ≤24bar 9/16-18
port charge pressure
Servo chamber test Slightly lower than the
8 M5 ≤24bar 9/16-18
port charge pressure
Oil supplementary
9 S -0.7bar 1-5/16-12 Vacuum degree
and suction port
Introduction to simple maintenance of vibrating pump
The maintenance here mainly focuses on the replacement guidance of the seal repair kit and the
replacement of simple external components. The overall overhaul requires professional maintenance.
Instructions before overhaul: Clean the surface of the pump before removing the propelling pump, and
disassemble the vibrating pump behind the propelling pump into a single pump. Before removing the
hydraulic line, make necessary marks on the removed oil lines and seal them. All openings need to be
plugged to prevent contaminants from entering the system.
Contamination will cause damage to internal components and the failure arisen therefrom is not
covered by the warranty. When removing or installing the system line, necessary measures shall
be taken to ensure the cleanliness of the system.
4-55
Replacement of Slippage Pump

1. Use a 9/16 inch hex wrench to remove the screw (1506)
and end cap (1505), remove and discard the seal ring
(1504);
2. Use a 9/16 inch hex wrench to remove the screw (1502),
and remove the auxiliary mounting flange (1503);
3. Remove and discard the O-ring (141) and the clamp ring
(142);
4. Remove cycloidal rotor cover plate (155) and cycloidal
rotor pump (603);
5. Remove alignment pin (604) and key (605);
6. Check the cycloidal rotor (603) and the cycloidal rotor
cover plate (155) for wear, scratches or spots. If the
above problems are found, replace all damaged parts.
Check the damage of the alignment pin (604) and the
key (605). If necessary, replace the parts. When
disassembling the slippage pump, replace the O-ring
(141), clamp ring (142) and seal ring (1504);
7. Install key (605), lubricate and install the cycloidal rotor
assembly (603);
8. Install alignment pin (604) and cycloidal rotor cover plate
(155);
9. Lubricate and install new O-ring (141) and load ring
(142),and install auxiliary flange (1503);
10.Use a 9/16 inch hex wrench to install the screw (1502)
P26H00092 with an installation torque of 43N•m[32lboft];
11.Lubricate and press the seal ring (1504) onto the
auxiliary flange (1503);
12.Install the end cap (1505), use a 9/16 inch hex wrench
to install the screw (1506) with an installation torque of
77 N•m [57lbfoft•ft].
4-56
Replacement of Shaft Seal, Roller Bearing and Shaft
Replacement of the shaft assembly does not require disassembling the front cover plate of the pump, but
the slippage pump must be removed first.
Do not damage the housing cavity, shaft or bearing when removing the shaft and shaft seal. Do
not rotate or move the pump after removing the shaft to prevent the position change of the
internal components. After the position change of the internal components, the pump must be
completely disassembled before the main shaft can be replaced.

1. Use a snap ring pliers to remove the snap ring (132)
from the pump end cap, remove and discard the lip seal
(301), remove the second snap ring (132);
2. Remove the shaft assembly from the pump end cap;
3. Remove the snap ring (133) with the snap ring pliers and
extrude the bearing (131) out of the shaft;
4. Check whether the shaft and bearing are worn,
scratched or corroded. If the above problems are found,
replace the shaft and bearing, rotate the bearing to feel
whether it is working well, and if the bearing cannot
rotate freely, replace the bearing;
5. Install the snap ring (133) with snap ring pliers, lubricate
and install the bearing (131) on the shaft; install the
second snap ring (133).
6. Install the shaft and bearing assembly on the front end
cap and rotate the shaft to align the spline keys in the
cylinder block; Ensure that the bearing is installed to a
sufficient depth, leaving a snap ring groove;
7. Install the snap ring (132) with the snap ring pliers;
8. Use the installation shaft sleeve to sleeve the splines on
the shaft, protect the lip shaft seal during installation,
lubricate and press the new lip seal (301) into the pump
end cap;
9. Install the second snap ring (132), and remove the
installation shaft sleeve.
P26H00093
4-57
Replacement of Displacement Limiter
Replace the displacement limiter (911) only if necessary. Before disassembly, mark the locations of the
displacement limiter and the neutral adjusting screw, which can save the time of re-installation.

1. Remove the snap ring (928) and sleeve (929), maintain
the location of the neutral adjusting screw with a 1/4 inch
hex wrench, and remove the hex nut (115) with a 9/16
inch hex wrench;
2. Maintain the location of the displacement limiter (911)
with a straight screwdriver and remove the fixed nut
(927) with a 9/16 inch hex wrench;
3. Remove the five bolts (921) from the servo controller
cover plate (902) with a 3/8 inch hex wrench;
4. Remove the servo controller cover plate (902) from the
neutral adjusting screw, remove and discard the washer
(936);
5. Unscrew and remove the displacement limiter (911) from
the servo controller cover plate (902);
6. Check whether all parts are damaged, check the
assembly surface of the end cap (902) of the servo
controller and the housing of the pump, pay attention to
whether they are scratched, grooved or otherwise
damaged, check whether the screw threads of the screw
and nut are damaged, and replace all damaged parts;
7. Screw the displacement limiter (911) in the servo
controller cover plate (902), install a new washer (936),
and install the servo controller cover plate (902) onto the
neutral adjusting screw;
8. Install five bolts (921) with a 3/8 inch hex wrench with an
installation torque of 15 N•m [11 lbf•ft];
9. Adjust the displacement limiter to the original marked
P26H00094 location before removal, maintain the location of the
displacement limiter with a straight screwdriver, and
tighten the sealing nut (92) to the displacement limiter
(911) with a 9/16 inch hex wrench with an installation
torque of 12 N•m [9 lbf•ft];
10.Tighten the neutral adjusting screw to the location
marked during removal, maintain the location of the
neutral adjusting screw with a 1/4 inch hex wrench,
tighten the lock nut (115) with a 9/16 inch hex wrench
with an installation torque of 37 N•m [27lbfoft•ft], and
install the sleeve (929) and snap ring (928).
4-58
Replacement of Charge Pressure Relief Valve
If the charge pressure relief valve is damaged or suspected of failure, it can be replaced.

1. Remove the charge pressure relief valve plug (102) with
a 1inch hex wrench, remove and discard the O-ring
(103);
2. Remove washer (101), spring (104) and charge
pressure relief valve (105);
3. Check whether the sealing surface of the pump and that
of the relief valve ( 105 ) are intact and free of scratches,
and replace the relief valve (105) if it is damaged.
4. Install charge pressure relief valve, spring and washer;
5. Lubricate and install the O-ring on the plug and install
the plug with a 1 inch hex wrench with an installation
torque of 108 N•m[80 lbf•ft];
6. Operate the pump within the full control range to ensure
that the machine is working properly.
P26H00095
Replacement of Electrical Displacement Control

1. Remove the screws (1203 and 1204) or (1224) with a 3/
16 inch Allen wrench. If it is a three-position control,
remove the screws ( 1226 ) with a 4mm Allen wrench;
2. Remove the controller housing (1201) or valve block
(1225) and remove and discard O-rings (1220 and 304)
or (1227, 1228, and 1223A);
3. Check the control valve core for scratches, grooves or
other damages. If the valve core is damaged or
suspected of failure, replace the entire valve spool and
check the damage to the valve sleeve cavity;
4. Lubricate and install the O-rings (1220 and 304) onto the
control valve body (1201). For three-position control,
lubricate and install the O-rings (1227 and 1228) onto
the valve block (1225); install the O-ring (1229) ) to the
control valve body (1223), install the control valve body
(1201) or valve block (1225) to the pump housing, align
the sleeve groove and the feedback pin on the swash
plate;
5. If the pump is three-position controlled, install the screw
P26H00096 ( 1226 ) with a 4mm Allen wrench with an installation
torque of 14 N•m[10 lbf•ft]. When installing the three-
position controlled valve body (1223), tighten the screws
(1203 and 1204) or (1224) with a 3/16 inch Allen wrench
with an installation torque of 14 N•m [10 lbf•ft].
4-59
Vibrating Motor
Working Principle
The vibrating motor uses axial plungers/sliding shoes arranged in parallel, and the swash plate is fixed.
The vibrating motor converts hydraulic energy into mechanical energy to provide vibration for the steel
wheel, which mainly consists of housing, output shaft, port plate, swash plate, cylinder block and plunger
assembly, flushing valve and other parts.
1
2
3
4 5
P26H00097
1. Cylinder block 3. Output shaft 5. Lip type shaft seal

2. Plunger 4. Bearing
P26H00098
4-60
location Parameters of Key Components and Oil Ports
1 2 4 5
6 8
7
P26H00099
1. System pressure test port MB 5. High pressure oil port B

2. System pressure test port MA 6. Case oil drain port L2
3. Loop flushing relief valve 7. Case oil drain port L1
4. High pressure oil port A 8. Loop flushing shuttle valve
Flushing Valve
When a part of the oil needs to be drained from the main loop in order to meet the requirements of oil
cooling and cleanliness, it can be realized through loop flushing. The loop flushing valve can remove
heat and contaminants from the main loop at a certain rate.
The flushing relief valve on the integrated loop flushing valve is a pressure relief valve with a valve spool
and a damping hole. The flushing flow rate is related to the size of the oil supplementary relief valve and
the damping hole.
P26H00100
4-61
2
1
P26H00101
1. Flushing relief valve with damping hole 2. Flushing shuttle valve
Size and parameter setting of main oil ports:

1 High pressure port A A 300Bar 1-1/16-12 Max. pressure setting
2 High pressure port B B 300Bar 1-1/16-12 Max. pressure setting
3 M1/MA 300Bar 7/16-20 Max. pressure setting
port
4 M2/MB 300Bar 7/16-20 Max. pressure setting
port
5 Case leakage hole L1/L2 ≤3bar 7/8-14
moment 5 bar
Servo pressure test
6 M4/M5 7/16-20
port
4-62
Technical parameters and related requirements of vibrating motor

Displacement cc 44
Allowable max. rotation speed
Continuous (at Max. Displacement) rpm 3300
Continuous (at Min. Displacement) rpm ——
Max. (at Min. Displacement) rpm ——
System pressure
Max. pressure of the vibrating pump
Continuous Bar 300
is 300bar
Max. pressure of the vibrating pump
Max. Bar 345
is 3345bar
Flow level
Rated (at Max. Displacement, rated
l/min 145
rotation speed)
Max. (at Max. Displacement, Max. rotation
l/min 180
speed)
Case pressure
Continuous Bar 1.7
Max. (pressure for cold start) Bar 5.2
Viscosity
Min. cst 7
delivery
Max. cst 1600
Temperature
Min. °C -40
Continuous °C 82
Max. °C 104
Note: Filtration requires cleanliness of 22/18/13 or higher (1SO4406)

4-63
Pressure Filter for Suction

Working Principle
entering the system loop is clean. The vibrating hydraulic system selects the oil suction filter, and the oil
suction filter is installed in the system between the fuel tank and the supplementary suction port.
Working principle
P26H00102
Parameter
1. Bypass valve opening pressure: 0.025MPa; 2. Working pressure: ≤ 1MPa; 3. Filter fineness: 10
microns.
P26H00103
4-64
Steering Hydraulic System CLG6611E
Steering Hydraulic System
Overview
The engine PTO outputs power to the steering pump, which outputs pressure oil to the oil inlet p of the
steering gear. When the steering wheel does not rotate, the ports P and T of the steering gear are
communicated and the pressure oil is unloaded in the neutral position. When the steering wheel rotates,
the steering shaft drives the valve spool and sleeve of the steering gear to rotate relatively, the port P is
communicated with the port L or R, and at the same time, the driven metering motor controls the flow
rate of pressure oil entering the oil cylinder so as to realize the control of hydraulic left-right turning and
turning speed.
The steering gear mainly consists of a main safety valve, an inlet one-way valve, a rotary valve, a
metering motor and a buffer oil supplementary valve, wherein the steering gear is internally integrated
with the main safety valve to carry out pressure protection on the main loop system, and the inlet one-
way valve prevents the pressure of the load from back-flushing the pressure of the steering pump. The
rotary valve controls the commutation of oil, and the metering motor carries out the flow distribution of
the steering gear for the second time. The buffer oil supplementary valve is used to protect the impact of
the external load on the oil cylinder.
Components and Layout
2 3
P26H00104
1. Steering Pump 2. Steering Cylinder 3. Steering gear

4-65
CLG6611E Steering Hydraulic System
P26H00105
When not turning, the ports L and R are cut off, the ports P and T are connected, and the oil from the
steering pump is directly returned to the oil tank.
P26H00106
4-66
When turning, the ports P and R are connected, the ports T and L are connected, hydraulic oil is injected
into the cylinder through the rotor of the steering gear, and the cylinder swing frame realizes the steering
function of the vehicle.
P26H00107
When turning, the ports P and L are connected, the ports T and R are connected, hydraulic oil is injected
into the cylinder through the rotor of the steering gear, and the cylinder swing frame realizes the steering
function of the vehicle.
4-67
Steering Pump
Working Principle
The engine drives the steering pump to rotate so that the gear pump outputs high pressure oil, which
changes the oil port entering the steering cylinder through the commutation of the commutator, thus
propelling the steering cylinder to move telescopically to drive the steering of the vehicle.
P26H00108
1. Spring retainer ring for hole 6. Sealing element 11. Pump body
2. Reinforced seal 7. Shaft sleeve 12. Rear cover
3. Front cover 8. Self-lubricating bearing 13. Washer
4. Cylindrical pin 9. Drive gear 14. Screw
5. Seal ring 10. Driven gear
Technical Parameters of Steering Pump
Pressure rating 20MPa

Oil inlet size M33
Oil outlet size M27
Displacement 19.2cc
Rated 20MPa
Pressure
Max. 25MPa
Rated 2500r/min
Rotation Speed
Min. 600r/min
4-68
Steering Gear
Working Principle
The steering gear controls the direction and speed of oil flow entering the steering cylinder by controlling
the rotation direction and speed of the steering wheel, and determines that the oil entering the steering
cylinder is proportional to the rotation angle of the steering wheel through its own metering mechanism,
thus realizing accurate control of the steering action of the vehicle.
The driver can control the steering force with less control force through the steering gear, and the
steering gear is safe and reliable in performance, light and flexible in control.
P26H00109
1. Valve body 5. Oil inlet 9. Stator and rotor pair 13. Return spring
2. Oil return 6. Spacer 10. One-way valve 14. Bearing
3. Left turn 7. Stop block 11. Driver 15. Spool
4. Right turn 8. Rear cover 12. Valve sleeve 16. Universal driving shaft
Features
1. It eliminates mechanical linkage device and provides reliable and lightweight structure;
2. It is flexible and light to operate;
3. When the engine is shut down, emergency manpower steering can be realized;
4. Continuous stepless control rotation can be carried out with very small torque.
4-69
P26H00110 P26H00111
Parameter
No response to cartridge opening, long stop cross block connection, no tapping of oil port, flange
connecting thread: m10x1.5; The Fk combined valve block of the steering gear comprises an inlet one-
way valve, a two-way overload valve and a P port safety valve, and the oil port: 4 XM 20x11.5 plane seal.
Max. inlet pressure (MPa) 16
Max. continuous back pressure (MPa) 2.5
Over load pressure (MPa) 18
Steering torque (Nm) <5.0
Displacement (cc) 500
Steering Cylinder
Working Principle
The steering cylinder is an actuating element, wherein the piston rod lug is installed on the articulated
support lug, and the cylinder lug is installed on the frame support lug, so that the left and right steering is
realized through telescopic movement of the oil cylinder.
Parameters
Min. installation
Bore Bolt diameter Stroke Nominal pressure Port size
distance
100mm 45mm 254mm 530mm 18MPa M22X1.5
4-70
Test CLG6611E
Test and Adjustment
Test
Pressure of Propelling Pump
Test points of propelling pump
P26H00112
P26H00113
1. Reverse pressure test point 2. Forward pressure test point 3. Charge pressure test point
Tools required
Two pressure gauges (range 0-60 MPa and 0-6 MPa), three open end wrenches (sizes 19, 18 and 17),
one Allen key (size 7), and three pressure taps (30W0005).
4-71
CLG6611E Test
Schematic diagram of tools required for propelling pump pressure test
P26H00114
Machine status and parking space
1. A flat parking space;

2. Keep the hydraulic oil temperature at 50 ± 5°C.
Test Steps
1. The propelling pump has corresponding forward, reverse and charge pressure test ports, as shown
in the above figure;
2. Shut down the engine and release the residual pressure in the oil tank;
3. Remove and store the plugs on the corresponding pressure test points (forward, reverse and charge
pressures) on the propelling pump, and install the corresponding pressure taps and pressure gauges
with corresponding measuring ranges;
4. Start the engine and make sure there is no obvious oil leakage at the pressure gauge connection;
5. Propel frontward and backward and start measuring..
Installation diagram of pressure tap and pressure gauge of propelling pump
P26H00116
4-72
Test CLG6611E
Installation diagram of charge pressure test for propelling pump
P26H00117
Pressure of Vibrating Pump
Test points of propelling pump
1 2 3
P26H00118
1. Small vibration pressure test point 2. Charge pressure test point 3. Large vibration pressure test point
4-73
CLG6611E Test
Tools required
Two pressure gauges (range 0-60 MPa and 0-6 MPa), three open end wrenches (sizes 19, 18 and 17),
one Allen key (size 7), and three pressure taps (30W0005).
P26H00114

Test Steps
1. The vibrating pump has corresponding large vibration, small vibration and charge pressure test
ports, as shown in the above figure;
3. Remove and store the plugs on the corresponding pressure test points (large vibration, small
vibration and charge pressures) on the vibrating pump, and install the corresponding pressure taps
and pressure gauges with corresponding measuring ranges;
5. Start large vibration and small vibration, abd start measuring.
Installation diagram of large vibration pressure tap and pressure gauge of vibrating pump
P26H00119
4-74
Test CLG6611E
Installation diagram of small vibration pressure tap and pressure gauge of vibrating pump
P26H00120
Steering Pressure
Test Points of Steering Pump
The steering pump comes with a pressure tap.
Tools required
One pressure gauge (range 0-60 MPa), three open end wrenches (sizes 19, 18 and 17), one Allen key
(size 7), and the steering pump of this model comes with a pressure tap.
P26H00147 P26H00148

4-75
CLG6611E Test
Test Steps
1. When the steering hydraulic system of this model leaves the factory, a pressure tap is installed at the
oil drain of the steering pump as shown above.
3. Remove the dust cap of the pressure tap and connect the pressure gauge;
5. Travel in the rotation direction, and start measuring;
6. Repeat the test pressure 3 times for mean and the pressure should not exceed 160 bar.
4-76
Adjustment CLG6611E
Adjustment
Overview
Before operating the pump, thoroughly clean the outer surface of the pump. Contamination will damage
the internal parts of the pump, and the maintenance of faults caused by the contamination is not covered
by the warranty. When disassembling and reinstalling the system line, handle it carefully to ensure the
cleanliness of the system.
1. Shut down the engine and thoroughly clean the outer surface of the pump;
2. If the pump needs to be removed, label each oil line connected to the pump; After disassembling the
hydraulic lines on the pump, all oil ports should be closed with clean plugs to prevent dust or dirt from
entering the pump body;
3. Ensure the working environment is clean and free of contaminants;
4. Check whether the system has been contaminated;
5. Visually inspect the hydraulic fluid for system contaminants, whether the hydraulic oil is discolored,
and whether there is foam, sludge or metal particles in the oil;
6. If there is any sign of contamination of the hydraulic oil, replace all filters, drain the hydraulic oil from
the system, flush the pipeline, and then fill the new filtered hydraulic oil;
7. All hydraulic lines need to be flushed before changing oil.
4-77
CLG6611E Adjustment
Adjustment of Charge Pressure Relief Valve of Propelling Pump

1. Install a pressure gauge with a measuring range of 50
bar [1000 psi] on the charge pressure port (M3) of pump.
Install a pressure gauge with a measuring range of 10
bar [100 psi] to measure the case pressure (install a tee
on port L1 or L2, or use a servo pressure tap M4 or M5).
When measuring the makeup pressure, the pump works
at the neutral position (zero displacement).
2. The allowable charge pressure range for this propelling
pump is 18.1-21.7 bar, and the pressure value referred
here is the relative pressure value relative to the case
pressure. Prerequisite: Rotation speed 1500 revolutions
per minute (RPM), tank temperature: 50°C [120°F].
Higher pump input speed (resulting in higher charge
flow) allow the measured pressure value to exceed the
set allowable range.
3. The oil supplementary relief valve of the propelling pump
is an externally threaded adjustable pressure propelling
valve. After loosening the lock nut (k10), the adjusting
bolt (k90) is rotated by a screwdriver or a 1/2 inch open
end wrench to reset the charge pressure.
4. Rotating the adjusting bolt clockwise will increase the
P26H00121 setting of charge pressure and rotating it
counterclockwise will reduce the setting of charge
pressure(roughly adjusting rule: 3.9 bar/revolution), and
the installation torque of the lock nut is 52 N•m.
5. After setting the appropriate pressure value of the oil
supplementary relief valve, remove the pressure gauge
and install the plugs.
Adjustment of Pressure Limiting Valve
When adjusting the pressure limiting valve, the setting of the high pressure relief valve will be affected
synchronously, and the set value of the high pressure relief valve will be automatically changed to that of
the pressure limiting valve + 30 bar.
When adjusting the multifunction valve, necessary safety measures should be taken to ensure
that the motor output shaft remains stationary throughout the adjustment process. The motor
output shaft can be locked from rotation by braking the vehicle or rigidly fixing the working
device.
4-78
Adjustment CLG6611E
P26H00122
1. Install a pressure gauge with a range of 1000 bar on the high pressure test ports (M1 and M2) and
install a pressure gauge with a range of 50 bar on the charge pressure test port (M3);
2. Start the engine at the normal working speed;
3. Loosen the lock nut;
4. Insert an Allen wrench into the hole of the pressure adjusting bolt;
5. The adjustment value of the pressure limiting valve of the propelling pump is the factory set value of
the pressure limiting valve of the pump, which is the relative pressure value relative to the charge
pressure, i.e., the set value of the pressure limiting valve is the relative pressure value between the
high and low pressure sides in the system loop. Trigger or shift the pump control input signal so that
the pressure on the high pressure side of the closed loop rises to the pressure limiting valve setting.
The set pressure of the pressure limiting valve here is that the system pressure stops rising and is
stable at a given pressure level (the pressure gauge pointer is basically stable);
4-79
CLG6611E Adjustment
6. After the pump returns to the neutral position (zero flow output), use an outer hex wrench to turn the
pressure setting bolt to readjust the pressure limiting valve. Rotating the pressure adjusting bolt
clockwise will increase the set value of the pressure limiting valve and decrease its set value by
rotating counterclockwise. Fully rotate the pressure setting bolt one turn, and the pressure limiting
valve changes the pressure as shown in the Table below:
Wrench size and installation torque for Adjusting bolt Approximately change the pressure set value
lock nut Outer hexagon spanner for each turn of the adjusting bolt
19mm20N•m 5mm 90bar
7. Verify the set value of the pressure limiting valve. Enable or move the pump control input so that the
pump can establish pressure on the high pressure side of the loop to the new set value of the
pressure limiting valve. Read the value through the pressure gauge on the high pressure side, and
then return the pump to the neutral position, and the pressure on the high pressure side of the
system loop should be able to reduce to the set value of the charge pressure;
8. On the premise of ensuring that the pressure adjusting bolt is stationary, tighten the pressure
adjusting bolt lock nut, and the installation torque is as shown in the Table above;
9. Shut down the engine, remove the pressure gauge and install the plug at the pressure test port.
Follow the above steps to adjust the pressure limiting valve setting on another multifunction valve. At
this time, it is necessary to shift or trigger the control input signal in the opposite direction so that the
high voltage is established on the other side of the closed loop.
Enabling Bypass Function
The multifunction valve has a bypass valve function at the same time. when the bypass valve function is
enabled, the engine must be shut down while opening the two bypass valves to enable the machine
bypass function.
Rotating the cylinder block without charge flow lubrication can easily cause damage to the pump
and motor components. The bypass valve is designed to move the machine or vehicle at a very
short distance and at a very slow speed. Remember that the bypass valve is not a special trailer
valve.
1. Unscrew the bypass valve trigger nut 3 turns. The wrench sizes are shown in the below Table.
Specification displacement Wrench Size
075cc 1-1/16inch
The number of unscrewing turns should not exceed 3-1/2 turns. Excessive unscrewing turns will
lead to leakage outside the pump.
4-80
Adjustment CLG6611E
P26H00123
2. For the manual displacement control pump, pull the manual displacement control handle to the
maximum adjustment position in the forward direction before dragging the vehicle or motor output
shaft to rotate. Keep the control handle in this position during the whole bypass valve operation,
otherwise it will cause the pump shaft to drive the engine to rotate;
3. Close the bypass valve and tighten the trigger nut of the bypass valve. The installation torques are
shown in the Table below.
Specification displacement Torque
075cc 41N•m
Adjustment of Charge Pressure Relief Valve of Vibrating Pump
1. Install a pressure gauge with a measuring range of 50 bar on the charge pressure port M3 of pump,
and install a pressure gauge with a range of 10 bar at L1 or L2 to measure the case pressure. When
measuring the charge pressure, make the pump work at the neutral position (zero displacement);
2. Shut down the system to adjust the charge pressure;
3. Remove the charge pressure relief valve plug (102) with a 1 inch hex wrench, install or remove the
relief valve gasket (101), install the gasket to increase the charge pressure, and remove the gasket
to reduce the charge pressure;
4. Lubricate and install new O-ring (103);
5. Reinstall the plug with a 1inch hex wrench with an installation torque of 108 N•m;
6. Locate the pump in the neutral position to determine the set value of the charge pressure, and the
charge pressure is related to the case pressure. The charge pressure (M3) minus the case pressure
(L1/L2) is the actual set value. Repeat steps 1-5 if necessary;
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CLG6611E Adjustment
7. Remove the pressure gauges (M3, L1/L2) and reinstall the plugs; install the plug M3 with a 11/16
inch hex wrench with an installation torque of 37 N•m and install the plug with a 9/16 inch hex wrench
with an installation torque of 115 N•m.
P26H00124
Adjustment of One-Way/Relief (SCR) Valve of Vibrating Pump
The one-way valve combined SCR valve of the system is a high pressure relief valve, no matter whether
the SCR valve is replaced or opened, make the pump work within the maximum range to ensure the
normal operation of the machine. The SCR valve is set before delivery and cannot be adjusted. The
pressure code is marked on the valve body. If you are worried about SCR valve failure, replace the valve
and test the working condition of the pump.
1. Shut down the engine;
2. Remove relief valve plug (166) with a 1-1/4 inch hex wrench;
3. Remove the spring (165) and relief valve (1103) from the pump case;
4. Insert a new relief valve and spring into the pump case;
5. Lubricate and install new O-ring (106);
6. Install relief valve plug with a 1-1/4 inch hex wrench with an installation torque of 176 N•m.
4-82
Adjustment CLG6611E
P26H00125
4-83
CLG6611E Adjustment
Adjustment of Vibration Frequency
The vibration frequency is adjusted by a displacement limiter. The displacement limiter is designed to
prevent the vibration frequency of the vibrating drum from falling after the working time of the hydraulic
pump is too long. The vibration frequency of the vehicle has been set up when delivery. Please do not
adjust the displacement of the vibrating pump without special circumstances, or do not adjust the
vibration frequency to a value other than that required by the design value, causing unnecessary
failures.
The two sides of the servo cylinder are respectively provided with displacement limiters, and the
displacement limiter on each side is set with different values.
1 P26H00126 2 P26H00127
1. Large vibration frequency adjustment 2. Small vibration frequency adjustment
Large vibration Small vibration

Frequency (HZ) 33 30
Amplitude (mm) 1.1 2.0
P26H00128
4-84
Adjustment CLG6611E
1. Remove the snap ring (928) and the outer sleeve (929);
2. Fasten the displacement limiter with a straight screwdriver and loosen the lock nut (927) with a 9/16
hex wrench;
3. Rotate the displacement limiter (911) to adjust the maximum displacement limit. Rotating the
adjusting screw clockwise reduces the maximum displacement of the pump, while rotating the
adjusting screw counterclockwise increases the maximum displacement of the pump. The
displacement is reduced or increased by 4 cm3 per revolution.
4. After setting the maximum displacement, maintain the location of the displacement limiter with a
straight screwdriver, and tighten the lock nut with a 9/16 hex wrench with a tightening torque of 12
N•m. If you need to adjust the maximum displacement in the other direction, repeat the above steps.
Adjustment Diagram of Vibration Frequency
P26H00129
4-85
CLG6611E Overview
Overview
Before removing the hydraulic line, park the roller on a flat parking area, shut down the engine, release
the residual pressure in the hydraulic system, press the air cleaner valve, and release the internal
pressure of the hydraulic oil tank. Before removing the line connector or hose, it is necessary to mark it
so as to prevent it from reinstalling to the wrong position. Clean the vicinity of the assembly oil port as
necessary, and the oil receiving tray is required to receive oil. When the line, connector or hose is in a
disassembled state, use a plug or cover to shield it so as to prevent pollution sources from entering the
system.
Removal and Installation of Hydraulic Oil Tank
Removal of Hydraulic Oil Tank

1. Locate the oil drain plug (2) at the bottom of the
hydraulic oil tank (1) of the rear frame and wipe around
of the oil drain plug;
2. Place a clean oil basin at the lower part of the oil drain
plug (2) for collecting hydraulic oil, and unscrew the oil
drain plug (2);
2
1
P26H00131
3. Mark each oil port and corresponding oil line on the side
of the hydraulic oil tank (1), remove the oil line, and
3 shield each exposed oil port;
Oil port (3) for oil suction of vibrating pump;
4 Oil port (4) for oil return of system;
Oil port (5) for oil return of brake valve;
Oil port (6) for oil suction of propelling pump;
Oil port (7) for oil suction of steering pump.
5
6
7
P26H00132
4-86
Removal and Installation of Hydraulic Oil Tank CLG6611E

4. After the hydraulic oil in the hydraulic oil tank (1) is
drained, use a lifting rope to lift the lifting eye (8) of the
8 hydraulic oil tank (1);
5. Unscrew the 7 fastening bolts (M24X60-8.8) (9) on the
upper portion of the hydraulic oil tank (1);
6. Slowly lift the hydraulic oil tank (1) away. Pay attention to
the smooth lifting process and do not damage other
parts of the vehicle.
9
P26H00133
Installation of Hydraulic Oil Tank
1. Check the oil tank for impurities, if any, clean it before assembly;
2. Install the corresponding connector on the hydraulic oil tank, lift the hydraulic oil tank by the traveling
crane, and place it at the corresponding position of the rear frame;
3. Position through four fastening bolt fixing holes, and then tighten the four fastening bolts;
4. Finally, install the six oil lines at the corresponding oil ports according to the removal method, and
tighten the torque according to the torque comparison table.
4-87
CLG6611E Removal and Installation of Twin Pump
Removal and Installation of Twin Pump

Removal of Twin Pump

1. Place a clean oil basin at the lower part of the twin pump
(2) for collecting hydraulic oil;
1 2. Mark each oil port and corresponding oil line on the twin
pump (2);
3. Remove the hose assemblies of the twin pump port and
2 the pressure plate of the twin pump port to shield the
exposed oil ports;
P26H00134
4. Unscrew the twin pump mounting bolt (M14X35-10.9);

5. Lift the twin pump stably by a lifting appliance, and
unscrew the fastening bolt (M14X35-10.9) of the
propelling pump and the engine flywheel connecting
plate (1) slowly;
6. Slowly lift the twin pump (2) away. Pay attention to the
smooth lifting process and do not damage other parts of
the vehicle.
P26H00135
Installation of Twin Pump
1. Check the pump for any defects such as damage or rust corrosion, and install the required transition
joint at the corresponding position of the pump after passing the inspection;
2. Lift the pump to the installation position, so that the spline shaft of the twin pump is butted with the
shaft sleeve of the coupling, and is fixed by four fastening bolts;
3. Connect each hose with its corresponding connector and tighten the torque according to the torque
comparison table.
4. The assembled double pump must be filled with oil before the vehicle starts to avoid dry friction
damage of sliding shoes after starting.
4-88
Removal and Installation of Suction Filter of Vibrating Pump CLG6611E
Removal and Installation of Suction Filter of Vibrating Pump
Removal of Suction Filter of Vibrating Pump

1. Place a clean oil basin at the lower part of the suction
1 filter (3) for collecting hydraulic oil;
2. Mark the oil inlet and outlet pipes of the suction filter (3)
to prevent errors during the next installation;
2 3. Remove the two hose assemblies at port of the suction
filter (3) to shield the exposed oil ports;
3 4. Loosen the fixing bolt on the filter bracket and keep it
well;
5. Remove the suction filter (3) with a professional tool.
P26H00136
Installation of Suction Filter of Vibrating Pump
1. Check oil lines, connectors and filter ports for any impurities or contaminants, if any, clean them
before assembly;
2. Install the corresponding transition joint at the inlet and outlet end of the suction filter;
3. Install the filter on the filter bracket through fixed bolts;
4. Tighten the the inlet and outlet pipes by torque according to the joint tightening torque table.
4-89
CLG6611E Removal and Installation of Return Filter
Removal and Installation of Return Filter
Removal and installation procedures of return filter refer to removal procedures of suction filter of
vibrating pump.
Removal and Installation of Rear Axle Motor
Removal of Rear Axle Motor

1. Place a clean oil basin at the lower part of the rear axle
motor (2) for collecting hydraulic oil;
2. Mark each oil port and corresponding oil line on the rear
axle motor (2);
3. Remove the hose assemblies and the pressure plate of
the rear axle motor (2) port to shield the exposed oil
ports;
4. Unscrew the rear axle motor (2) mounting bolts
(M12X45-10.9);
1
2
P26H00137
5. Lift the rear axle motor (2) stably by a lifting appliance,
and unscrew the fastening bolt (M12X45-10.9) of the
rear axle motor (2) and the rear axle (1) slowly;
6. Slowly lift the rear axle motor (2) away. Pay attention to
P26H00138
Installation of Rear Axle Motor
1. Check the motor for any defects such as damage or rust corrosion, and install the required transition
joint at the corresponding position of the pump after passing the inspection;
2. Lift the motor to the installation location, so that the spline shaft of the rear axle motor is butted with
the shaft sleeve of the rear axle, and is fixed by four fastening bolts;
3. Connect each hose with its corresponding connector and tighten them with the torque according to
the torque comparison table.
4-90
Removal and Installation of Steering Cylinder CLG6611E
Removal and Installation of Steering Cylinder
Removal of Steering Cylinder
Park the machine on a horizontal hard ground → press the parking brake button→ shut down →
fix the front and rear frames with bumpers.
Take the left steering cylinder as an example, the removal steps of the right steering cylinder are the
same.

1. Place a clean oil basin at the lower part of the steering
2 3 cylinder (3) for collecting hydraulic oil from removing the
1
4 oil line;
2. Mark each oil port and corresponding oil line on the
steering cylinder (3);
3. Remove the hose assemblies at the ports of the steering
cylinder (3), shield the exposed oil ports, and if
necessary, remove the grease pipe (2);
4. Take pin (6) out of pin shaft (5) with a professional tool;
P26H00139
5. Tap lightly on the lower end of the pin shaft (5) with a
5 copper rod, and take it out of the oil cylinder base (1)
5 after the pin shaft (5) is loosened;
6 6. The bearing (7) cannot be removed if it is damaged. Tap
7 6 lightly on it with a copper rod and special fixture and
taken it out if it is damaged;
7 7. Slowly lift the steering cylinder (3) away. Pay attention to
P26H00140
4-91
CLG6611E Removal and Installation of Steering Cylinder
Installation of Steering Cylinder
1. Lightly tap the bearing into the oil cylinder base and the steering hinge base with a copper rod and
special fixture;
2. Lift the steering cylinder to the installation location with a suitable lifting appliance, adjust the location
of the cylinder support lug, and align it with the installation seat;
3. Install the steering cylinder pin shaft from top to bottom, then insert the pin into the pin shaft hole,
force a section of pin apart with the hands to position;
4. Install the corresponding hydraulic oil line at the corresponding oil port of the steering cylinder and
tighten it according to the standard torque.
4-92
Removal and Installation of Steering Gear CLG6611E
Removal and Installation of Steering Gear
Removal of Steering Gear

1. Mark the hoses installed on the steering gear as "T_oil
return pipe of steering gear", "P_oil inlet pipe of steering
T gear", "L_left steering pipe" and "R_right steering pipe".
L The marks shall be clear and firm without any falling-off;
2. Remove hoses at ports T, P, L and R on the steering
gear, and seal all oil ports;
R
P
P26H00141
3. Remove connectors installed on the steering gear and
seal oil ports on the steering gear;
4. Remove the fixing bolts of the steering gear on the
steering column in the cab, to take out the steering gear.
P26H00142
Installation of Steering Gear
1. Align the four installing holes of the steering gear with the four holes of the steering gear assembly at
the bottom of the cab. The four oil ports face the rear of the whole vehicle and are fixed with M10X20
flange bolts;
2. Install T\P\R\L port connectors of the steering gear, and tighten them according to standard torque;
3. Match the four hose assemblies with the corresponding oil ports and tighten them according to the
standard torque;
4. Fill the hydraulic oil, start the machine to run at idle speed for 5min, turn slowly for at least 10 times,
and remove the air in the lines;
5. Check whether the hydraulic oil level is qualified. If it is unqualified, please add hydraulic oil to the
specified level.
4-93
CLG6611E Removal and Installation of Vibrating Motor
Removal and Installation of Vibrating Motor
Removal of Vibrating Motor

1. Place a clean oil basin at the lower part of the vibrating
motor to collect the hydraulic oil overflowing from the
hose during removal;
2. Mark the corresponding hoses and oil ports to prevent
confusion during the next installation;
3. Remove the corresponding hose assembly with
professional tools to shield the exposed oil ports;
P26H00143
4. Lift the motor with a lifting appliance and remove the two
mounting bolts fixing the motor;
5. Stably lift the motor away from the vehicle. It is not
allowed to touch any other parts of the vehicle during the
lifting process;
6. Pay attention to keep the O-ring.
P26H00144
Installation of Vibrating Motor
1. Clean the O-ring and place it at the installation location of the vibrating motor stop. If the O-ring is
damaged, a new O-ring needs to be used;
2. Stably lift the vibration motor with a lifting appliance, align the motor spline shaft with the installation
seat, slowly shake and insert the motor spline shaft into the installation seat, align the motor installing
hole with the threaded installing hole on the installation seat, fix the motor spline shaft with the
mounting bolt, and tighten the motor spline shaft;
3. Clean the connectors of each hose assembly, remove contaminants, correspond to the
corresponding oil ports, and tighten them according to the standard torque.
4-94
Removal and Installation of Drum Motor CLG6611E
Removal and Installation of Drum Motor
Removal of Drum Motor

1. Place a clean oil basin at the lower part of the drum
motor to collect the hydraulic oil overflowing from the
hose during removal;
2. Mark the corresponding hoses and oil ports to prevent
confusion during the next installation;
3. Remove the corresponding hose assembly with
professional tools to shield the exposed oil ports;
P26H00557
4. Lift the motor with a lifting appliance and remove the two
mounting bolts fixing the motor;
5. Stably lift the motor away from the vehicle. It is not
allowed to touch any other parts of the vehicle during the
lifting process.
P26H00558
Installation of Drum Motor
1. Clean each port of the drum motor to remove contaminants;

2. Lift the drum motor with a special lifting appliance, pay attention to stability, align the spline shaft of
the drum motor with the internal spline of the reducer, shake and insert it;
3. Align the installing hole of the drum motor with that on the reducer and tighten it with bolts;
4. Clean all the line connectors, correspond to the marked oil port when removing, and tighten
according to the standard torque.
4-95
July 17, 2020 Fault Diagnosis and Elimination
CLG6611E Removal and Installation of Drum Motor
Fault Diagnosis and Elimination
Common hydraulic system faults and their diagnosis and elimination.
Vehicle cannot travel
Fault cause Analysis and elimination Solution

The quantity of hydraulic oil is insufficient to
Hydraulic oil tank Refill hydraulic oil
meet the system requirements
Check whether the brake button is pressed or Keep the brake button in the
damaged energized state
Repair or replace brake solenoid
Brake solenoid valve failure
The brake is still working valve
Repair or replace the propelling
Test whether the charge pressure is too low
pump and motor
Brake is jammed (less likely) Replace brake
Check whether the flexible shaft is jammed or
Replace or adjust the flexible shaft
No output from pump control broken
module Check the control module for faults
Replace the control module
Or the damping hole is blocked
The cylinder block assembly and port plate are
Replace or repair the propelling
worn, and the case pressure (high) and system
pump
Leakage from propelling pump pressure (low) can be tested
The high pressure relief valve is stuck, the spring Repair or replace the high pressure
is broken, or the stop valve is not locked relief valve
Test and observe motor case pressure (high)
Internal leakage from propelling and discharge flow (large), cylinder block
Replace or repair the motor
motor assembly, port plate, flush valve and other parts
damaged
Vehicle has no high speed gear

Check the motor solenoid valve coil for electrical
Gear switch is damaged Replace the coil
output
Motor solenoid valve is Check whether the solenoid valve is stuck;
Clean or replace
damaged or jammed Check the valve cartridge hole for impurities
Small displacement of motor Check the state of the locking bolt Re-adjust the adjusting bolts
4-96
Fault Diagnosis and Elimination July 17, 2020
Vehicle has no steering or hard steering

Check the condition of oil cylinder and
Mechanically jammed Adjust and repair
articulated frame
The bearing or spline at the engine power take-
Repair or replace
Pump power take-off port off port is damaged
failure Pump shaft broken (check pressure and flow
Repair or replace
output)
Steering pump failure or
Test pump pressure and output flow Repair or replace
leakage
Internal leakage of steering Test system pressure (cylinder keeps down
Repair or replace
cylinder pressure)
Test pressure to judge steering gear relief valve
Repair or replace
Steering gear is damaged Or the buffer valve is damaged
Large leakage in steering gear Repair or replace
No vibration (large vibration or small vibration)

Check the switch status of each electrical
Vibration switches and buttons Eliminate and replace
appliance
Check the pump control valve coil for damage Replace coil or line plug-in
The spool of the pump control solenoid valve is
Clean or replace
stuck or damaged
Pump control module
Control module is damaged
Or damping hole is blocked (measure servo Clean or replace
pressure)
The relief valve is stuck, damaged or the stop Repair or replace the high
valve is not locked pressure relief valve
The cylinder block assembly and distribution
Replace or repair the cylinder
Vibrating pump failure or plate are worn, and the system pressure (low)
block and port plate assembly
leakage and the case pressure (high) can be tested
Check the charge pressure and flow rate, and
Replace or repair the slippage
check whether the slippage pump and relief
pump assembly
valve are damaged
Vibrating motor failure and discharge flow (large), large internal Replace or repair the motor
leakage caused by internal components wear
4-97
July 17, 2020 Fault Diagnosis and Elimination
CLG6611E Removal and Installation of Drum Motor
Insufficient vibration frequency

The engine operates at rated
Engine Whether the engine operates at the rated speed
speed
Reset and adjust displacement
Pump displacement limiter The pump displacement limiter is loose
limit
Test the charge pressure and confirm that the Replace the slippage pump and oil
charge pressure of system is low supplementary relief valve
High pressure relief valve is jammed Replace the high pressure relief
Or leak (test main system pressure) valve
Leakage from vibrating pump
Check the charge pressure and the case
pressure of the pump, and observe the leakage
Replace or repair
from the pump case (component wear and
internal leakage)
Internal leakage from vibrating
and discharge flow (large), large internal Replace or repair the motor
motor
leakage caused by internal components wear
Noise and vibration

Check the oil level, insufficient suction leads to
The oil level of oil tank is low Refill hydraulic oil
air suction
Air leakage and suction of Check the oil suction pipe for air leakage and
Replace or tighten
system suction
Coupling Coupling connection is loose or damaged Repair or replace
Pipeline vibration caused by Improper fixing of oil lines, pipeline vibration
Optimize lines
pressure shock caused by shock
4-98
Fault Diagnosis and Elimination July 17, 2020
5-1
July 17, 2020 Structural Component
CLG6611E
Structural Component
Overview of Vibrating Drum Assembly...............................................................................................5-3
Working Principle of Vibrating Drum ..................................................................................................5-3
Overview of Frame Assembly ............................................................................................................5-5
Oil Tank..............................................................................................................................................5-7
Articulated Assembly..........................................................................................................................5-9

Removal and Installation of Vibrating Drum.........................................................................................5-11
Removal of Vibrating Drum Assembly .............................................................................................5-11
Installation of Vibrating Drum Assembly ..........................................................................................5-14
Replacement of Vibrating Motor, Coupling Sleeve and Oil Seal..........................................................5-16
Replacement of Vibrating Motor and Coupling Sleeve ....................................................................5-16
Replacement of Bearing End Cover Oil Seal ...................................................................................5-16
Oil Leakage from Travel Bearing Oil Seal and Replacement of Damaged Travel Bearing..............5-17
Replacement of Shock Absorber, Travel Motor, Reducer & Travel End Drive Board..........................5-20
Replacement of Shock Absorber at Vibrating Motor End.................................................................5-20
Replacement of Shock Absorber at Travel End ...............................................................................5-20
Replacement of Drive Board ............................................................................................................5-21
Removal of Drive Motor and Reducer..............................................................................................5-21
Removal of Vibration Chamber and Intermediate Shaft.......................................................................5-22
Removal of Vibration Chamber and Intermediate Shaft at Vibrating Motor End (on the right side).5-22
Removal of Vibration Chamber and Replacement of Eccentric Shaft and Vibrating Bearing ..........5-24
Replacement of Vibration Chamber Seal Oil Seal ...........................................................................5-25
Installation of Vibration Chamber Housing and Drum in Place ........................................................5-25
Assembly of Vibrating Drum Assembly ................................................................................................5-27
Removal and Installation of Articulated Assembly ...............................................................................5-28
Removal of Articulated Assembly ....................................................................................................5-28
Replacement of Knuckle Bearing for Articulated Assembly .............................................................5-29
Installation of Articulated Assembly .................................................................................................5-30
Troubleshooting...............................................................................................................5-32
Common fault analysis and troubleshooting methods of vibrating drum..............................................5-32
5-2
Structural Component July 17, 2020
CLG6611E
5-3
CLG6611E
Overview of Vibrating Drum Assembly
The vibrating drum of this machine is of a detachable independent excitation structure.
3 4 5 6 7 8
P26S00048
1. Left connecting plate 4. Idler wheel 7. Bearing block

2. Shock absorber 5. Intermediate shaft 8. Right connecting plate
3. Left vibration chamber 6. Right vibration chamber
Working Principle of Vibrating Drum
The left and right vibration chambers (3) and (6) of the vibrating drum are of independent structure and
are fixed on the vibration wheel radial plate by bolts. The left vibration chamber (3) is connected to the
front frame through three shock absorbers (2) and a left connecting plate (1). The shock absorbers (2)
on the left and right sides are adjusted through adjusting shims on the left and right sides so that they are
in a compressed state after the assembly is completed. Generally, the compression amount of the shock
absorbers is controlled within 2 mm. Since the left and right vibration chambers are of relatively
independent excitation structures, they are connected and run synchronously through the intermediate
shaft (5) to realize the power transmission. The intermediate shaft is provided with a coupling for
adjusting the coaxial deviation between the left and right vibration chambers. In addition, the radiator of
the intermediate shaft can accelerate the circulation of air in the drum cavity so as to achieve the heat
dissipation effect.
5-4
CLG6611E
The vibration chamber housing (1) and the vibration chamber cover (4) are connected through bolts to
form a closed cavity, the eccentric shaft (5) is supported in the vibration chamber cavity through the
vibration bearing (2), and the original power generated by the eccentric shaft rotation and the power
generated by the eccentric shaft rotation are respectively input and output through splines at the end of
the eccentric shaft (5). The vibration chamber cavity is filled with lubricating oil. The oil is filled and
drained through the screw plug (3), and the screw plug (3) is also used to check the oil level. The
eccentric shaft is provided with a fixed eccentric block and filling steel balls.
Left vibration chamber Right vibration chamber
3 4
2 5
1
P26S00049 P26S00050
The working principles of the left and right vibration chambers are the same, the basic structure is the
same, and the right vibration chamber is provided with one more spline shaft (1) than the left vibration
chamber. When the hydraulic system works, the vibrating pump inputs the hydraulic oil from the
hydraulic oil tank to the vibrating motor (when the roller is equipped with gear pump, the hydraulic oil is
input to the motor through the multiple directional control valve). The vibrating motor is connected to the
coupling shaft sleeve to drive the left and right eccentric shafts to rotate synchronously. At the same
time, the eccentric blocks on the left and right eccentric shafts generate centrifugal force when rotating,
thus causing the vibrating drum of the roller to generate exciting force (i.e., vibration force). The forward
and reverse rotation of the vibration motor is realized by controlling the directional valve, so that the
phase angle of the movable steel ball and the fixed eccentric block changes to generate two kinds of
exciting force and amplitude. When the fixed eccentric block and the movable steel ball are in the same
phase, the eccentric distances generated are superposed, which are called large vibration, as shown in
figure (a). When the fixed eccentric block and the movable steel ball are out of phase (the phase
difference is 180 degrees), the eccentric distances generated are superposed and reduced, which are
called small vibration, as shown in figure (b).
Figure A Figure B
P26S00051
5-5
CLG6611E
Overview of Frame Assembly
The frame of the single drum roller consists of a front frame, a rear frame, a articulated part, a diesel
tank, etc. The front frame and the rear frame are of a relatively complex box-shaped structure, and are
formed by welding plates and components. The front and rear frames are connected into a whole
through an articulated structure. Under the action of the articulated structure, the front and rear frames
can rotate 35 degrees left and right in the horizontal plane (i.e. the so-called turning angle) and swing 10
degrees in the vertical plane, thus ensuring the driving performance of the roller and the compaction
effect of the road surface.
The articulated part not only plays a role in connecting the front and rear frames, but also has the
function of rotating and swinging the front and rear frames around it. Therefore, regular adjustment is
required after long-term operation. Replacement of knuckle bearing (7 #) and steering hinge (14 #) is
required after wear occurs.
Front Frame Assembly
1
1
23
20
17
16
15 22
14
11
12
13
23
9
10
9
2 21
10
9 10
5
4 18
3 10
6
7 9
8 11
12
13
19
14
15
16 P26S00052
1. Front frame 9. Knuckle bearing 17.Off cup

2. Steering hinge 10.V-ring 18.Oil cup
3. Adjusting shim 11.Adjusting washer 19.Bolt
4. Adjusting shim 12.Adjusting washer 20.Left fender
5. Adjusting pad 13.Adjusting shim 21.Right fender
6. Cap 14.Cap 22.Scraping fender assembly
7. Washer 15.Washer 23.Bolt
8. Bolt 16.Bolt
5-6
CLG6611E
Rear Frame Assembly
The rear frame assembly is mainly composed of diesel tank assembly (4), hydraulic oil tank assembly
(21), and ladder (6). The diesel tank assembly is installed on the rear side of rear frame (1) via bolt.
17 20
18
16
13 21
12
23
4 13
3
2
7
9
7
7 16
8
17
8
14
19
15
22
10
1 14
22
11
5
22
6
22
22
P26S00053
1. Rear frame 9. Plug pin 17.Bolt

2. Oil cup 10.Connecting rod 18.Fuel tank
3. Mounting plate 11.Plate 1 19.Mounting plate
4. Bolt 12.Grease pipe 20.Mounting plate
5. Bolt 13.Grease pipe connector 21.Hydraulic oil tank
6. Ladder 14.Bottom seal plate 22.Bolt
7. Cotter pin 15.Bottom seal plate 23.Bolt
8. Pin 16.Washer
5-7
CLG6611E
Oil Tank
For the replacement of the hydraulic oil tank (diesel tank), it is generally recommended to weld the
hydraulic oil tank (diesel tank) due to welding quality problems resulting in welding or oil leakage. In case
of serious damage or welding failure, it is recommended to replace the hydraulic oil tank or diesel tank
assembly.
Fuel tank
2
3
4
7
8
P26S00054
1. Fuel tank 4. Bolt 7. O-ring

2. Oil tank cover 5. O-ring 8. Oil plug
3. O-ring 6. Cover plate
5-8
CLG6611E
Hydraulic oil tank
6
2
3
5
4
12
8
9 1
10
7 11
P26S00055
1. Hydraulic oil tank 5. Cover plate 9. Cover plate

2. Screw plug 6. Bolt 10.O-ring
3. Washer 7. Bolt 11.Oil plug
4. Air filter 8. O-ring 12.Liquid level meter
5-9
CLG6611E
Articulated Assembly
In the articulated steering roller, the articulated structure is a very important component, which not only
plays a role in connecting the front and rear frames, but also has the function of rotating and swinging
the front and rear frames around it.
Articulated Structure Diagram
16
17 14
7 16
7
16 8
9
18 10
11
15
13
12
16
18
7
1
2
3
4
5
6 P26S00056
S/N Item Quantity Specification

1 Adjusting shim 2
2 Adjusting shim 4
3 Adjusting shim 4
4 Cap 2
5 Washer 12 16
6 Bolt 12 M16x55-8.8-Zn.D
Angular contact knuckle
7 4 GAC85S/K
bearing
8 Adjusting pad 8
9 Adjusting shim 8
5-10
CLG6611E
S/N Item Quantity Specification

10 Adjusting shim 8
11 Cap 1
12 Bolt 10 M24x120-10.9-Zn.D
13 Washer 10 24
14 Steering hinge 1
15 Bolt 3 M12x25-8.8-Zn.D
16 V-ring 4
17 Oil cup 3 45M10x1
18 Oil cup 3 M10x1
The working conditions of the articulated part of the roller are worse than those of other parts. The load
acting on the articulated pin varies greatly and the impact load is large. Therefore, frequent maintenance
and repair are required.
1. The roller is realizes turning and swinging by the relative rotation of the inner and outer rings of the
knuckle bearing. Therefore, it is necessary to maintain the lubrication of the bearing so as to prevent
the bearing from generating dry friction and damaging the bearing. Lubricating oil can be regularly
filled according to the requirements of the instruction manual.
2. When the roller is working, the vibration is relatively large, and the bolts used to compress the
knuckle bearings will be loose. Therefore, it is necessary to check frequently to prevent the bolts from
becoming loose.
5-11
CLG6611E Removal and Installation of Vibrating Drum
Removal and Installation of Vibrating Drum
Preparation of tools
● Lifting equipment: The total weight of the steel wheel is about 5t, requiring larger than 10t slings and
lifting hooks, 20t jack and support parts.
● A set of 12-41 open-end wrenches and a set of 12-36 spline end wrenches, a pneumatic wrench (air
impact wrench) can be equipped;
● Each10P hammer, pliers, inside spring pliers, screwdriver, etc.
Material particulars during removal
● Clean the exterior of the drum before removal, and focus on cleaning the exterior of the hydraulic
components to prevent foreign matters from contaminating the hydraulic components!
● Place the container to receive lubricating oil, protect the disassembled hydraulic line and prevent oil
leakage!
● Prepare wedged slip pads for drums and rear tires to prevent personal injury caused by slippage
during startup!
● Collect and sort out the disassembled parts!
Removal of Vibrating Drum Assembly

1. Use a lifting appliance to lift the drum (1) (or jack to lift it)
with a clearance of 20 cm from the ground;
2. Support both sides of the frame (2) with supports and
the locations of the supports shall not interfere with the
drum;
1 2 P26S00057
5-12
Removal and Installation of Vibrating Drum CLG6611E

3. Remove the oil pipe fenders (1) on both sides of the
1 2 drum;
4. Loosen the oil pipe clamp rubber fixing plates (2) on
both sides respectively;
2
P26S00058
5. Unscrew the right vibrating motor (1) with a wrench to

connect the oil pipe connectors, and do a good job in the
binding protection of the oil pipe connectors;
1
P26S00059
6. Unscrew the left propelling motor (1) with a wrench to
connect the oil pipe connectors (2), and do a good job in
the binding protection of the oil pipe connectors;
2 1 P26S00060
7. Use a lifting appliance to lift the drum (1) until the lifting
1 appliance is tight so that the connecting bolts can be
removed;
P26S00058
5-13

8. Loosen the M24*150 connecting bolts on both sides of
the drum side plate (1) with a wrench, totaling 16 bolts;
1
P26S00061
9. Support the plate (1) and the front frame side plate (2)
with a mechanical jack so that the adjusting shim (3) can
be taken out;
10.Remove the adjusting shim (3) and then remove the
jack;
Caution: Falling objects during removal

2 3 1 cause personal injury!
P26S00062
11.Remove the drum (1) from the front frame (2) by a lifting
appliance;
1
P26S00063
5-14
Removal and Installation of Vibrating Drum CLG6611E
Installation of Vibrating Drum Assembly

1. Lift the drum (1) to be installed by a lifting appliance into
the frame of the front frame (2);
1
P26S00063
2. Align the mounting holes on the connecting plate (1) and
1 the front frame side plate (2), install M24*150 bolts, and
pre-tighten the locking nuts;
2
P26S00064
3. Place the jack (5) between the plate (1) and the side
plate (2) to compress the damping block (3), wherein the
compression amount of the damping block is 1-2 mm;
4. Install the adjusting shim (4) to ensure that the
1 compression amounts on the left and right sides are
consistent;
3
5
2
P26S00065
5-15

5. After the adjusting shim has been installed;
6. Tighten the connecting bolts of the left and right side
plates in the order of (1) to (8) with a wrench with
tightening torque of 760±100N.m;
7. After the bolts are tightened, lower the spreader.
P26S00066
5-16
Replacement of Vibrating Motor, Coupling Sleeve and Oil Seal CLG6611E
Replacement of Vibrating Motor, Coupling Sleeve and Oil Seal
The oil leakage outside the vibrating drum of the single drum roller is concentrated in the oil leakage
caused by the damage of the oil seal of the coupling sleeve at the end of the vibrating motor. When the
roller is used for a long time, the coupling sleeve and the spline shaft of the vibration motor are worn out,
resulting in vibrating failure. This section mainly introduces the replacement of the vibrating motor, the
spline coupling sleeve and the bearing end cover oil seal.
Replacement of Vibrating Motor and Coupling Sleeve

1. Unscrew the fixing bolts and washers of the vibrating
motor (1);
2. Remove the motor (1) together with the coupling sleeve
(3) from the drum;
3. Check the spline wear of the coupling sleeve (3) and the
vibrating motor (1). If the wear is serious, replace the O-
ring (2) at the same time.
1
2
P26S00067
Replacement of Bearing End Cover Oil Seal

1. Unscrew the fixing bolt M12 and washer of the vibrating
4 motor support (1) with a wrench and remove the
vibrating motor support (1);
3
2. Unscrew the bolt M12 and washer of the travel bearing
2 end cover (4) with a wrench and remove the end cover;
1 3. Check the oil seal (3) of the end cover (4) for damage
and replace it if there is wear;
4. Remove the snap spring (2) with the circlip pliers;
5. Remove the damaged oil seal (3) and check whether the
end cover (4) is damaged or cracked. If it needs to be
replaced, replace the O-ring at the same time. If normal,
install a new oil seal ( 3 ) after cleaning;
6. Tap with a hammer and install the oil seal (3);
7. Install the snap spring (2) after the oil seal is seated.
P26S00068
5-17
CLG6611E Replacement of Vibrating Motor, Coupling Sleeve and Oil Seal
Oil Leakage from Travel Bearing Oil Seal and Replacement of Damaged Travel
Bearing
Oil leakage from the travel bearing oil seal is one of the main causes of oil leakage from outside of
vibrating drum. In addition, if the travel bearing is not lubricated properly after long-term use, the travel
bearing will be damaged. This section mainly introduces the parts replacement and installation process
of these two parts. Replacement of these two components requires removing the drum assembly from
the front frame, refer to the removing process above.

1. After removing the vibrating motor support (1) and the
travel bearing end cover (2), turn the connecting plate
3 (3) and lift the connecting plate with a sling until the sling
is tight;
2
1
P26S00069
2. Use an iron plate (2) as a support between the
1 connecting plates (1), and place a mechanical jack in the
middle;
3. Two persons cooperate, one holds the connecting plate
(1) and the other holds the jack (3), and the connecting
plate is released from the vibration chamber;
P26S00070
5-18
Replacement of Vibrating Motor, Coupling Sleeve and Oil Seal CLG6611E

4. Check the bearing (1) on the right vibration chamber (2);
Take out the damaged bearing from the vibration
2
chamber cover with special tools or by oxygen welding
and heating;
P26S00071
5. Take out the bearing outer ring (2) from the bearing
3 2 1 block (1) with a tool;
6. Take out the damaged oil seal (3) from the travel bearing
block (1);
7. Clean the bearing block (1);
8. After removal, install the new bearing outer ring (2) with
a hammer, and then install the oil seal (3).
P26S00072
9. Install a new bearing (2) outside the vibration chamber
cover (1);
2
Caution: Do a good job in marking and
1 distinguishing the inner and outer rings of
double-row tapered roller bearings during
installation, and do not mix them.
10.Apply grease (3# general purpose lithium lubricating
grease) to the bearing (2);
P26S00073
5-19
CLG6611E Replacement of Vibrating Motor, Coupling Sleeve and Oil Seal

11.Lift the connecting plate (1) to a proper position of the
2 vibrating drum, and push the connecting plate into the
bearing block installation location on the vibration
3 chamber cover (2);
4 1
12.Adjust the bearing (3) to install it in place. Apply grease
(3# general purpose lithium lubricating grease) to the
bearing;
13.Install the bearing end cover (4) and replace the O-ring.
5 Requirement for tightening torque of bolt M12: 90N.m;
14.Install the vibrating motor support (5) and replace the O-
ring; the requirement for tightening torque of bolt M12:
90N.m;
15.Apply Tonsan 1242 thread locker to the bolt.
P26S00074
5-20
Replacement of Shock Absorber, Travel Motor, Reducer & Travel End Drive Board CLG6611E
Replacement of Shock Absorber, Travel Motor, Reducer & Travel End

Drive Board
Replacement of Shock Absorber at Vibrating Motor End
Regularly check whether the drum shock absorber is loose or damaged, tighten all bolts and nuts, and
replace the shock absorber that is damaged or has obvious cracks; if the lock nuts are loose, they must
be replaced.
If more than 25 % of shock absorbers on the same side have cracks of 10-15 mm depth, replace
all shock absorbers on that side.

1. After the connecting plate (1) at the end of the vibrating
3 motor is removed from the vibrating wheel, place it
somewhere safe and loosen the fixing bolt of the shock
absorber (2);
2. Remove the support plate (3) and remove the fixed bolts
of the shock absorber (2) on the connecting plate (1)
again;
3. After the replacement is completed, repeat the above
steps to complete the installation of the shock absorber.
The tightening torque of shock absorber bolt M12 is
1 2 P26S00075
90N.m.
Replacement of Shock Absorber at Travel End
In order to ensure the safety during the disassembly of the drive board, it is recommended to replace the
reducer, drive board and drive board shock absorber and erect the vibrating drum.

1. Lift the outer edge of the drum on the side of the
vibrating drum propelling motor with a sling, slowly lift
and erect the drum;
P26S00076
5-21
CLG6611E Replacement of Shock Absorber, Travel Motor, Reducer & Travel End Drive Board

2. Remove the fastening bolts of the drive board (1)
successively;
3. Lift the drive board (1) used for installing the reducer
slowly with a lifting appliance and place it in a safe
position;
4. Loosen the fixed bolts of the shock absorber (2) installed
2 on the drum. Replace shock absorber,tightening torque
1 of the bolt M12 is 90N.m, apply Tonsan 1242 thread
locker to the bolt.
P26S00077
Replacement of Drive Board

1. Turn over the drive board (1) with a crane;
2. Loosen the mounting bolts of the reducer (2)
2
1 successively;
3. Lift the drive board (1) with a lifting appliance and
replace with a new drive board;
4. Repeat the above steps to install the drive board fixed
bolt M16 with a tightening torque of 380N.m.
P26S00078
Removal of Drive Motor and Reducer

1. Turn over the connecting plate (1);
2 1 2. Loosen and remove the fastening bolts of the propelling
motor (2);
3. If the propelling motor is damaged, replace it with a new
3 one;
4. Remove the fixed bolts of the reducer (3) successively,
and if the reducer is damaged, replace it with a new one.
P26S00079
5-22
Removal of Vibration Chamber and Intermediate Shaft CLG6611E
Removal of Vibration Chamber and Intermediate Shaft
The left and right vibration chambers of the vibrating drum consist of a vibratory housing, a vibration
cover, an eccentric shaft, a vibrating bearing, etc. The structures of the left and right vibration chambers
are basically the same. The only difference is that there is one more spline shaft in the right vibration
chamber. This section mainly introduces the removal of vibration chamber and the replacement process
of eccentric shaft, vibrating bearing, vibration chamber seal and intermediate shaft.
Removal of Vibration Chamber and Intermediate Shaft at Vibrating Motor End (on the
right side)
Removal of the vibration chamber requires removal of the drum assembly from the pressure roller frame
as well as removal of the connecting plate and the drive part. Refer to the previous section for detailed
procedures.

1. Remove the fastening bolts of the vibration chamber (1)
with a wrench one by one;
2. Take out the vibration chamber from the drum with a
special tool;
1 3. In the maintenance process that lacks special tools, the
vibration chamber can be removed separately. For the
specific overhaul process, see the subsequent removal
of the vibration chamber.
P26S00080
4. Check the intermediate shaft (1) for damage after
removing the vibration chamber. If damaged, remove the
intermediate shaft for maintenance and replacement.
P26S00081
5-23
CLG6611E Removal of Vibration Chamber and Intermediate Shaft

1. Coupling
2. Spline shaft II
4 3. Fan
6 1
6 4. Spline shaft I
3 5. Bolt
6. Lock nut
7. Bolt
8. Washer
7 9. Nut
3 5. Disassemble and assemble the intermediate shaft
8 9
5 according to the exploded view of the intermediate shaft;
9 8 6. Attention during assembly: apply an appropriate amount
2
7 of molybdenum disulfide grease to the spline shaft
sleeves at both ends of the intermediate shaft so that the
P26S00082 concave surface of the intermediate shaft fan faces
inward.
7. Align and install the spline shaft sleeve mounting groove
(1) on the intermediate shaft with the welding spot (2) on
the spline shaft of the vibration chamber.
2
P26S00083
5-24
Removal of Vibration Chamber and Replacement of Eccentric Shaft and Vibrating

Bearing

1. Loosen the fixed bolts of the vibration chamber cover (1)
1 successively;
2. Place the vibration chamber on the worktable during
disassembly;
3. Resist M16 × 60 bolts on three disassembly process
holes on the vibration chamber cover (1) against the
2 vibration chamber cover to loosen it;
4. Lift the vibration chamber cover (1) out of the vibration
chamber with a sling and place it in a safe position;
5. Replace the O-ring seal (2) of the vibration chamber
3 cover;
6. Check whether the vibrating bearing (3) and eccentric
shaft (4) of the components in the vibration chamber are
4 damaged, and replace them if damaged;
P26S00084
7. There are three M12 process bolt holes (3) on the
3 1 opposite sides of the vibration chamber cover (2) and
the vibration chamber housing (1), and the vibration
bearing is evenly ejected from the vibration chamber
cover and the vibration chamber by M12 bolts for
replacement;
2
P26S00085
8. Install the set bolt on the vibration chamber cover (1),
1 first wind three turns of Teflon tape, and apply the
Tonsan 1242 thread locker;
9. When installing the tightening bolts, tighten them with a
wrench and turns around for one revolution when in
contact with the bearings;
P26S00086
5-25
CLG6611E Removal of Vibration Chamber and Intermediate Shaft

10.Common bearing damage is the abrasion of the inner
1 ring of the vibrating bearing (1). use a hammer to knock
(or heat up by oxygen welding) to remove the inner ring
of the bearing, and pay attention to the damage to the
eccentric shaft during oxygen welding.
P26S00087
Replacement of Vibration Chamber Seal Oil Seal
Oil leakage inside the vibrating drum is generally caused by damage to the oil seal of the vibration
chamber housing. the high temperature of the vibration chamber easily leads to aging damage of the oil
seal and oil leakage.

1. Remove the vibration chamber oil seal cover plate (1);
1 2. Remove the damaged oil seal (2) for replacement;
3. Install a new oil seal;
4. Install the vibration chamber oil seal cover plate (1) and
tighten it by bolt M8 with a tightening torque of 26N.m.
2
P26S00088
Installation of Vibration Chamber Housing and Drum in Place

1. Install the inner ring of the bearing (1) to the neck of the
1 eccentric shaft after being heated (it can be installed by
heating lubricating oil outside);
P26S00089
5-26

2. After the inner cavity of the vibration chamber (1) is
1 cleaned, install the eccentric shaft (2);
2
P26S00090
3. Apply an appropriate amount of 3# general purpose
1 lithium lubricating grease to the O-ring (1) and sleeve it
in the sealing groove of the vibration chamber cover (2);
P26S00091
4. Cover the vibration chamber cover (1) on the housing (2)

1 on which the eccentric block assembly has been
3 installed, and align to the holes;
5. Install the bolts and washers, apply the Tonsan 1242
thread locker, and tighten the bolts diagonally. Bolt M16
tightening torque is 225 N.m.
2
P26S00092
The assembly of the left vibration chamber is completed according to this assembly process.
5-27
CLG6611E Assembly of Vibrating Drum Assembly
Assembly of Vibrating Drum Assembly

1. Install the left vibration chamber (1) in place on an
2 upright drum;
2. Refer to the above installation instructions for installation
of shock absorber (2).
1
P26S00093
3. Lift the drive board (1) for installing the reducer and the
drive motor in place, and complete the installation of the
drive board (1);
P26S00094
4. After completion of the assembly of the left vibrating
drum component, lift to lay the drum (1) flat with a
special lifting appliance;
2 5. Complete the installation of the intermediate shaft (2) in
place;
1
P26S00095
6. Complete the installation of the right vibration chamber
(1) with fixtures;
1 7. Insert the adjustment tool into the center hole of the
2 spline shaft of the vibration chamber (1) to adjust the
clearance to ensure that the clearance is 1-2 mm. After
the eccentric shaft is rotated by external force, the on-
site maintenance and inspection will be considered to
meet the assembly requirements when it can run to self-
stop in a free state.
8. Open the oil plug (2) and fill the vibration chamber with
about 2.3L SAE80W-90 gear oil.
Refer to the above to complete the installation of travel
P26S00096 bearing and connecting plate, and complete the installation
of vibrating drum assembly.
5-28
Removal and Installation of Articulated Assembly CLG6611E
Removal and Installation of Articulated Assembly
Removal of Articulated Assembly
When removing the articulated assembly, first remove the vibrating drum assembly, steering cylinder,
drum motor oil pipe, cab and other components. Please refer to the previous sections for detailed
procedures.

1. Place a safe and firm cushion on the articulated part of
1 2 the rear frame (2) to keep the vehicle in a horizontal
state;
2. Lift the front frame (1) with a crane and adjust it up and
down so that the articulated part is in an unstressed
state;
P26S00097
3. Remove 10 mounting bolts M24×120 of the gland (1);
4. Take out the adjusting pads of the gland (1), record the
number of pads used on left and right sides, and place
the adjusting pads separately;
P26S00098
5. Slowly move the front frame (1) outward until it is
1 disengaged from articulated part (2);
6. Place the front frame (1) on a level ground;
2
P26S00099
5-29
CLG6611E Removal and Installation of Articulated Assembly

7. Remove 12 mounting bolts M16×55 of the upper and
3 lower glands (2) of the articulated assembly;
8. Take out the adjusting pads of the upper and lower
glands (2), record the number of pads used on upper
and lower sides, and place the adjusting pads
separately;
2 9. Take out the articulated assembly (1) from the rear
frame (3) with tools such as traveling crane and sling.
1
P26S00100
Replacement of Knuckle Bearing for Articulated Assembly
The articulated steering problem is usually caused by wear of knuckle bearings.

1. Take out the damaged knuckle bearing from the
1 articulated part (3) with special tools or by oxygen
welding and heating;
2. Remove sealing ring (2) and replace it if it is damaged.
3. After removal, install a new knuckle bearing (1) with a
hammer;
2
P26S00101
5-30
Removal and Installation of Articulated Assembly CLG6611E
Installation of Articulated Assembly

1. Install the articulated assembly (1) assembled with the
knuckle bearing into the rear frame (2) with tools such as
2 traveling crane and sling.
P26S00102
2. Place the gaskets (2) marked in the removal process at
1 the upper and lower parts of the articulated part;
3. Assemble the upper and lower glands (1), install 12 bolts
M16×55 with a torque of 225±35N.m;
1
P26S00103
5-31
CLG6611E Removal and Installation of Articulated Assembly

4. Install the front frame (1) into the rear frame (2) with
tools such as traveling crane and sling
1 P26S00104
P26S00105
5. Place the gaskets (2) marked in the removal process at
2 the left and right parts of the articulated part;
6. Assemble the gland (1), install 10 bolts M24×120 with a
torque of 1020±100N.m;
1
P26S00106
5-32
Troubleshooting July 17, 2020
Common fault analysis and troubleshooting methods of vibrating drum CLG6611E
Troubleshooting
Common fault analysis and troubleshooting methods of vibrating drum
Fault
S/N Cause Analysis Troubleshooting method
Phenomenon
Check the oil level according to the instructions
Cooling lubricating oil is too little
and fill enough oil.
Heating of vibrating
1 Cooling lubricating oil is too Check the oil level according to the instructions
bearings
much and drain the oil.
Bearing clearance is too small Adjust to proper clearance.
Lubricating oil of vibrating drum Check the oil level according to the instructions
is too much and drain the oil.
The setting value of pressure
Vibration frequency valve of vibration hydraulic Check and make adjustments.
2
is too small system is too low.
The oil pump or motor is worn
and the internal leakage is too Check and replace or repair
severe.
Wear of spline sleeve on
Check and replace.
The vibrating wheel vibration shaft
3
does not work. Check the system flow and pressure. Find the
Hydraulic system doesn't work
cause, and adjust or replace
The failure of shaft end seal of
vibration motor causes the Check whether the motor seal is reliable, and
increase in lubricating oil of adjust or replace it when necessary.
vibration shaft bearing.
4 Oil leakage
The failure of vibration shaft seal
causes the decrease in
Replacement of seal elements
lubricating oil of vibration shaft
bearing.
The rubber bears tension. Add gaskets to eliminate the tension.
It is subject to torsion during Perform reinstallation to eliminate the torsional
installation. stress.
Cracking of damping When the crack depth of the damping block
5
element rubber exceeds 15-25 mm, the damping block must be
Rubber aging replaced. If more than 25% of the damping blocks
on the same side have cracks, all damping blocks
shall be replaced immediately.
6-1
July 17, 2020 Electrical System and A/C System
CLG6611E
Electrical System and A/C System

Instruction to Service Manual.............................................................................................................6-3
Welding Precautions ..........................................................................................................................6-4
Introduction to Schematic Symbols of the Electrical Components.....................................................6-5
Structure and Function ....................................................................................................6-10

Power System ......................................................................................................................................6-10
Introduction to Function....................................................................................................................6-10
Analysis of Electrical Schematic Diagram........................................................................................6-11
Electric Lock.....................................................................................................................................6-12
Fuse .................................................................................................................................................6-14
Negative Switch ...............................................................................................................................6-17
Battery..............................................................................................................................................6-18
Power Contactor ..............................................................................................................................6-21
Starting System....................................................................................................................................6-23
Schematic Diagram of Starting System ...........................................................................................6-23
Starting Contactor ............................................................................................................................6-25
Relay ................................................................................................................................................6-27
Start Motor and Generator ...............................................................................................................6-29
Monitoring System ...............................................................................................................................6-32
Engine Coolant Temperature Indicator ............................................................................................6-32
Oil Pressure Alarm ...........................................................................................................................6-32
Fuel Level Indicator..........................................................................................................................6-33
Revolution Indicator .........................................................................................................................6-34
Parking Brake and Brake Low-voltage Circuit..................................................................................6-35
Air Cleaner Blocking Alarm Circuit (Optional) ..................................................................................6-35
Hydraulic Filter Blocking Alarm Circuit (Optional) ............................................................................6-36
Charge Indicator Circuit of Generator ..............................................................................................6-36
Voltage Indicator Circuit ...................................................................................................................6-37
Grille Heating Circuit (Optional) .......................................................................................................6-37
Instrument ........................................................................................................................................6-39
Sound-Light Alarm System ..................................................................................................................6-41
Electric Horn Circuit .........................................................................................................................6-41
Backup Alarm Circuit........................................................................................................................6-42
6-2
Electrical System and A/C System July 17, 2020
CLG6611E
Lighting System ...................................................................................................................................6-44

Vibration System ..................................................................................................................................6-49
Principle of Vibrating Circuit .............................................................................................................6-49
Vibrating Relay.................................................................................................................................6-49
Travel System ......................................................................................................................................6-52
6-3
CLG6611E
Basic Information
Instruction to Service Manual
The Manual is written by introducing the main functions of the electrical system into modules, so that the
maintenance personnel can quickly find relevant sections corresponding to faults at any time during
maintenance operations. Besides, the professional descriptions are compiled to be accessible in the
Manual, nonetheless, the maintenance personnel are also required to have certain professional
knowledge to understand the Service Manual.
In different modules, the Manual starts with introducing the functions of the modules, and then introduces
the main components of the functions, including the principles, functions and electrical appliance
diagrams of main components. After that, operation of module function and the fault diagnosis and test
of module are introduced.
The schematic symbols of components represent the representing methods of components on the
schematic diagram. The schematic symbols of most components represent the actual schematic
diagram of the components, whereas, the exceptions are specified when introducing the components.
This will be helpful to identify the fault phenomenon of the component.
The fault detection methods of components are also included in the component instruction of the
Manual. Such methods are only for the components, whereby, the faults are detected through removing
the components from the vehicle. It is unfeasible to detect the faults in accordance with the above-
mentioned methods if the components are installed on the vehicle. At this time, the judgment can be
made in accordance with the fault detection methods described behind the system, or the components
can be removed if necessary to judge the condition of components based on the component
troubleshooting method.
The fault diagnosis and test of the module introduced in the Manual does not cover all the faults, so that
please be diligent in thinking and focus on the accumulation of experience during the troubleshooting.
When introducing the principle of electrical appliance system, the Manual adopts colored fill lines to
describe the flow direction of current in the schematic diagram of electrical appliance, in order to better
describe the principle of electrical appliance. Full consideration to the relationship between the overall
and the individual (system and component) when judging the fault phenomenon will contribute to the
rapid, accurate and facilitated troubleshooting.
On condition that digital multimeter is used to detect faults, the inherent measuring errors might result in
a value slightly differing from that described in the Manual. For instance, when selecting the digital
multimeter with a range of 200 Ω, the values described in the Manual are comparable by shorting out the
red and black probes to measure the lead resistance and subtracting such lead resistance from the
measured resistance of other circuits.
6-4
CLG6611E
Welding Precautions
Be sure to comply with the correct welding procedures, so as to safeguard the electrical components and
bearings against potential damages. When welding on a loader or diesel engine equipped with electrical
appliance components, please follow the operating steps below:
1. Park the machine on a flat ground.
2. Turn the electric lock to "OFF" position, and shut down the diesel engine.
3. Enable the parking brake.
4. Turn off the negative switch of battery and disconnect the battery from the frame.
5. Clamp the parts to be welded with the ground cable of the welder tightly. The closer the grounding
location is to the welding location, the better. Check that the circuits from ground cable to welding
components do not flow through any of the below components:
● Bearing
● Hydraulic oil cylinder
● Internal circuits of the controller or other electronic components. This is done to reduce possible
damage to the following components:
● Bearing
● Hydraulic components
● Electronic component
● Other components available on the machine
6. The inflammables should be kept away from the welding site, and each cable should be protected
from splashing sparks and slag caused by welding, resulting in fire and unnecessary loss and
damage.
7. Perform the normal welding safety operation procedures for welding.
During welding, the grounding point of welder on the frame must be as close as possible to the
welding point, and the grounding point of the welder must ensure a reliable large-area grounding.
Do not use the grounding point of any electrical component on the machine as that of the welder!
To weld near the grounding point of the electrical components, the welding operation can be
carried out only when the grounding point of the electrical component must be disconnected and
the welding circuit of the welder does not pass through the electric appliance. Otherwise, it will
cause damage to the electrical components, and even lead to a fire!
To avoid possible losses, for the machine equipped with electronic control components, such as
electric interlocking control box, instrument and engine ECM, it is necessary to ensure that the
welding circuit is disconnected from the circuit of the above electronic control components
before welding, while the connectors closest to such control components shall be unplugged to
switch the circuit off.
6-5
CLG6611E
Introduction to Schematic Symbols of the Electrical Components
Graphic symbols of two-position hand-

Graphic symbols of control switch
operated switch
Graphic Graphic
S/N Item Description S/N Item Description
symbol symbol
Pressure Normally Emergency

1 1 Hold
switch open stop switch
Pressure Normally Button

2 2 Instant-on
switch close switch
3 Knob switch Hold
4 Knob switch Instant-on
Wire and connector

S/N Item Graphic symbol Description
1 Connecting point For wire intersections
Used as the wiring terminal of

2 Terminal
components
All are represented by no-bold

3 Wire and cable
solid lines
Male contact of
4 "Contact pin" of connector
connector
Female contact of
5 "Jack" of connector
connector
"Contact pin and jack" of

6 Contact of connector
connector
6-6
CLG6611E
Semiconductor device
1 Diode General symbol of diode
2 Light-emitting diode
Power supplies and motors

1 Ground General symbol of ground
The longer line represents

2 Battery positive pole and the shorter one
represents negative pole
The terminals varies according to

3 Generator
the actual situation of generator
4 Start motor
Including series excited motor,

5 DC motor shunt excited motor and
permanent magnet DC motor
6-7
CLG6611E
Lights and signal devices

General symbol of light and

1 Light and signal light
signal light
2 Rotating warning light
3 Electric horn
For alarm buzzer and back-up

4 Buzzer
buzzer
5 Loudspeaker
6 Flasher relay
Electromagnet
1 Switch electromagnet
Proportion
2
electromagnet
Double-coil power and

3 fuel cut-off type shutoff
solenoid valve
6-8
CLG6611E
Example of graphical symbols for multi-position hand-operated switch

Key-operated, four-position.
1 JK412 electric lock Position "1" for instant-on,
position 2 for instant-on
JK991-009 rocker
2 Instant-on
switch
JK991-157 rocker
3 Hold
switch
JK991-052 rocker
4 Hold
switch
JK991-107 rocker
5 Hold
switch
JK991-092 rocker
6 Hold
switch
6-9
CLG6611E
Sensors, relays, etc.

The sensor housing is grounded.

Temperature sensor, pressure
Variable resistance sensor and fuel level sensor with
1
type sensor non-linear resistance variation
can be represented by this
symbol
2 General-purpose relay A set of normally open contacts
3 Limit switch
4 Resistor General symbol of resistor
This symbol can represent "grill

5 Heating element
heater" of generator
6-10
Power System CLG6611E
Power System
Introduction to Function
The power system of this model supplies the power to the electric appliances of the vehicle. The diesel
engine is separately powered by the battery before it is started, and is jointly powered by the battery and
the generator after it is started.
Under normal working conditions, the normal power supply can be realized to turn on the electric lock
and start the diesel engine.
After switching on the negative switch and turning the electric lock to the I position, the electrical
components that can work normally are wall lights, rotating warning lights, parking lights, horns, radio
receivers, etc.
Except for the air conditioning function module and compressor module, other electrical components can
be used normally.
P26E00061
6-11
CLG6611E Power System
Analysis of Electrical Schematic Diagram
1. The schematic circuit diagram after the negative switch is switched on is as shown in the figure
below. The fuse of the non-overcurrent lock bus is powered on. The red part indicates the power-on
part and the direction of arrow indicates the current direction. Such representations are the same as
those in the following sections.
P26E00062
2. After the electric lock is turned to the ON position, the contact of the power relay is closed at this
time, and the fuse of the overcurrent lock bus is powered on.
P26E00063
6-12
Electric Lock
P26E00496 P26E00497
P26E00066 P26E00067
Description of pin definition:
Pins B1, B2, S, G2. M and G1;

Pin G1 is generally used for preheating system; pin G2 is generally not used; pins B1 and B2 are power
supply, pin M is used for ignition (control power relay coil), and pin S is used for starting.
Description of positions of electric lock
"OFF" - A position for inserting and removing the electric lock key. In this position, the power supply for
electrical appliances on the vehicle is cut off. Except for some electrical appliances such as wall lights
that are not controlled by the electric lock, these electrical appliances are controlled by the negative
switch of the power supply.
"ON" - The first position to which the electric lock key is clockwise turned after being inserted. The "ON"
position is used for switching on the power of the electrical appliances of the vehicle, and such power
comes from the battery.
"START" - The second position to which the electric lock key is clockwise turned after being inserted.
This position is used for starting the diesel engine, but can not be self-maintained. After the hand is
released, the electric lock key will automatically return to the "ON" position.
6-13
Precautions
After the diesel engine is started, the key of the electric lock should be released immediately to return the
right position. Otherwise, it will lead to serious electrical fault.
After an unsuccessful start, the electric lock needs to be turned off for the second and third starts. That
is, the key of the electric lock is first turned to the "OFF" position, then turned to the "ON" position, and
finally turned to "START" position, such operation completes a starting cycle.
If the starting time exceeds 15S and the diesel engine fails to start successfully, the electric lock should
be turned off for the second and third starts. Do not start more than three times in succession. Do not
start for more than 15S each time, which will cause the battery to lose power due to continuous high
power output.
If the engine fails to start successfully for three times in succession, the electric lock should be turned off
at this time, and the second start will be carried out after 30 minutes. Check the battery and the starting
circuit if necessary to determine if there is a fault affecting the start.
Most of the difficult starting situations occur in cold winter when starting outdoors. The ambient
temperature in these areas may be lower than -18 °C. If possible, the start can be carried out by
changing place to indoor or by auxiliary heating to improve the start.
Removal and installation of electric lock
If other components on the vehicle need to be removed and installed, use tools with reference to the list
of tools for removal and installation of other components, and do not list them again in this section.
Fault detection steps of electric lock
1. Unplug all the connectors on the pins of the electric lock so that the electric lock is disconnected from
the vehicle circuit.
2. Adjust the digital multimeter to the on/off range.
3. Turn the electric lock to the "OFF" position and measure two of the six pins of the electric lock with
the two probes of the digital multimeter. At this time, the indicated values of any other combinations
shall be no signal except that the indicated values of pins [B1, B2] mean the on light is on. The
indicated values of pins [B1, B2] should show an on state at any position, and the description will not
be repeated below.
4. Turn the electric lock to the "ON" position, as described in step 3, measure two of the six pins of the
electric lock with the two probes of the digital multimeter, where the pins [B1], [B2] and [M] are in on
state, and the indicated values of other pins all display no signal.
5. Turn the electric lock to the "START" position. Since the "START" position cannot be self-maintained,
it may require the help of a third party to keep it in the "START" position. As described in step 3,
measure two of the six pins of the electric lock with the two probes of the digital multimeter, where the
indicated values the pin [G1] and other pins all display no signal, and the indicated values of other
pins are in on state.
6-14
6. Turn the electric lock anticlockwise to the P position, as described in step 3, measure two of the six
pins of the electric lock with the two probes of the digital multimeter, where the pins [B1], [B2] and
[G1] are in on state, and the indicated values of other pins all display no signal.
The "on state" indicates that the measured resistance between the two pins is zero and the "no
signal" indicates that the measured resistance between the two pins is infinite.
B1 B2 S G2 M G1
OFF ● ●
ON ● ● ●
START ● ● ● ● ●
P ● ● ●
Fuse
Fuse mainly plays a part in short-circuit protection and over-current protection in circuits. Various series
of plug-in fuses and bolt fuses are used in the power system of this model. The plug-in fuses are
available in sizes 30A, 20A, 10A, 7.5A and 5A for each branch circuit. The bolt fuses are available in size
60A for main circuit.
Location Diagram of Bolt Fuses on Vehicle
P26E00068
6-15
Location Diagram of Plug-in Fuses on Vehicle
P26E00069
The color of the plug-in fuse is related to its size. the Table below lists the sizes and colors of the plug-in
fuses used in this machine and the Liugong part numbers for reference only.
Liugong Part Number Size Color

5A Yellowish brown
7.5A Dark brown
10A Red
20A Yellow
30A Green
6-16
The function definition list of the plug-in fuse is as follows
P26E00070
F1 Electric lock F6 Turn signal light F11 Instrument

F2 Spare F7 Vibration F12 Headlamp (Rear)
F3 Instrument reset F8 Traveling F13 Rotating alarm light
F4 Fuel cut valve F9 Preheating F14 Density meter
F5 Headlight F10 Horn F15 Armrest box switch
Precautions
The available sizes of various fuses are calculated in the process of circuit design, so when the fuse is
blown, it must be replaced with a fuse of the same series and size. Do not replace it with the fuse of
different sizes.
When the fuse is blown and replaced with a new one, but the new fuse is still blown, at this time, be sure
to check the circuit under the control of the fuse and replace the fuse only after the fault is removed.
6-17
Fault detection method of fuse
Unplug the plug-in fuse from the fuse holder and judge whether the internal fuse is blown or not by visual
inspection. It can also be detected by a method for judging whether the bolt fuse is blown or not.
The steps for judging whether the bolt fuse is blown or not are as follows:
Adjust the digital multimeter to the 200Ω range in Ω position.
Connect the probes of the digital multimeter to the two terminals on the fuse respectively.
The indicated value of the digital multimeter is "1", indicating that the fuse has been blown and needs to
be replaced. The indicated value of the digital multimeter is "0", indicating that the fuse is in good
condition and can continue to be used.
Negative Switch
The negative switch controls the connection between the negative pole of the battery and the frame of
the vehicle. When the negative switch is in the "OFF" position, the negative pole of the power supply of
the vehicle is cut off. Even if the electric lock is turned on, the electrical appliances of the vehicle do not
work. When the negative switch is in the "ON" (on) position, the negative pole of the power supply of the
vehicle is turned on. At this time, the connection between the electric appliance and the power supply of
the vehicle is controlled by the electric lock, and the diesel engine can be started.
P26E00072 P26E00071
Precautions
1. The negative switch must be turned off after each operation or end of the trip, otherwise it will cause
serious consequences of electric leakage.
2. Do not turn off the negative switch while the machine is running. Such wrong operation will cause
very serious damage to the electrical system of the vehicle.
3. Turn off the electric lock before turning off the negative switch when shutting down.
4. Turn on the negative switch before turning on the electric lock.
5. The negative switch must be turned off when connecting the battery cable or fastening the battery
cable stub or removing the battery cable.
6. The negative switch must be turned off when welding the vehicle.
6-18
Battery
The vehicle uses two batteries connected in series to obtain + 24V power supply, with a rated capacity is
120 Ah and low-temperature starting current of 850 CCA.
As a reversible DC power supply, the battery is connected in parallel to the generator to jointly supply
power to the electrical equipment of the vehicle. The battery can supply a large starting current to the
start motor in a short period of time to drive the diesel engine to start. The battery is also equivalent to a
very large capacitor, which can absorb any over-voltage in the circuit at any time, thus protecting the
electrical appliances of the vehicle.
P26E00072
State judgment of battery
Visually check the built-in hydrometer of the battery cover in well-lighted condition to judge the state of
charge of battery or take appropriate measures in accordance with the color displayed in the hydrometer,
namely:
Color of hydrometer Green Black Transparent
State or measure OK Charge Replace
6-19
Battery charging
For the batteries of which the hydrometer is black, recharging procedure is required.
For the batteries of which the hydrometer shows a transparent and bright color, there might be bubbles
in the hydrometer. Whereupon, remove all the battery connecting cables and shake the battery gently
after it is fully cooled. The battery shall be scrapped, provided that the above-mentioned color remains.
1. Switch the negative switch to "OFF" state. Turn the electric lock to the "OFF" position and remove the
key.
2. Remove the battery from the machine. Disconnect the battery negative cable and positive cable
successively before removing the battery.
3. Wipe the battery terminal and battery surface with a clean cloth to remove the oxide scale from the
surface.
4. Connect the positive (+) charging chuck of the charger to the positive (+) terminal of the battery, and
then connect the negative (-) charging chuck of the charger to the negative (-) terminal of the battery
at room temperature. Confirm that the battery terminals are clean, and the charging circuit is in good
connection.
5. Charge the battery with a charger at constant voltage of 16.0V (no more than 16.2V at most) until the
hydrometer shows green color, which indicates that the battery is fully charged.
6. If there is no condition to charge at constant voltage, the battery can be charged by constant current,
and is charged by constant charging current of 12 A until the hydrometer shows green color, which
indicates that the battery is fully charged.
Corresponding relation between the recharging time and battery voltage is as follows:
Battery voltage 12.45~12.55V 12.45~12.35V 12.35~12.20V 12.20~12.05V
Recharging time 2 hours 3 hours 4 hours 5 hours
Battery voltage 12.05~11.95V 11.95~11.80V 11.80~11.65V 11.65~11.50V
Recharging time 6 hours 7 hours 8 hours 9 hours
Battery voltage 11.50~11.30V 11.30~1100V Below 11.00V
Recharging time 10 hours 12 hours 14 hours
7. For the battery suffering severe power loss, it may not be recharged at the beginning of recharging.
As battery charge proceeds, the charging current of battery can return to normal state gradually. It
may take about 14 hours to complete the charging process.
8. If the battery temperature gets too high (exceeding approximately 45°C) during the charging process,
stop charging the battery until the battery is cooled to room temperature, then recharge it by halving
the charging current.
9. Check the state of hydrometer once every hour during battery charging. The green battery
hydrometer indicates that the battery is fully charged and should stop charging at this time.
10. Apply the terminals with Vaseline after the charging is completed, to prevent galvanic corrosion.
6-20
Precautions for battery charging
1. Do not charge two batteries which are connected in series.

2. Keep the environment ventilated during charging, and charge the batteries at normal temperature.
3. If acid is sprayed from the battery vent during charging, the charging shall be stopped immediately.
4. Charge the battery in well-ventilated area, and pay attention to the electrical safety.
5. Any battery with acid leakage or a broken case should rather be scrapped than recharged.
6. Any battery with a broken terminal should rather be scrapped than recharged.
7. Any battery that is inflated or bulged due to over-discharge or overcharge should rather be scrapped
than recharged.
8. If the hydrometer remains black after being charged for a period of time, check whether the charging
cable is well connected, the joint point is clean or the charging voltage reaches 16V.
Fault detection steps of battery
The vehicle is in the braking state, and the shift control lever is in the neutral position. The hydrometer
built in the battery cover is green in color. Doing the test in this step requires the help of a partner.
1. Switch the negative switch to "OFF" position.
2. Adjust the digital multimeter to the 200Ω range in voltage position.
3. Connect the red probe of the digital multimeter to the positive terminal of one battery and connect the
black probe to the negative terminal of the other battery. Be careful not to connect them to their
connecting cable terminals. The indicated value of the digital multimeter is between "24" and "32"V.
4. Keep the two probes of the digital multimeter in place. Switch the negative switch to "ON" position.
Turn on the electric lock and start the diesel engine.
5. At the moment when the starting motor starts to run, the indicated value of the digital multimeter is
between "20" and "24"V. After the diesel engine starts smoothly, the indicated value will return to the
indicated value described in step 3.
The battery that can complete the above steps and start the diesel engine smoothly is an intact battery. If
the battery fails to complete above steps, the detection is continued according to the following methods.
1. Remove all cables connecting the batteries, so that the two batteries will be completely
disconnected.
2. Adjust the digital multimeter to the 50V range in voltage position.
3. Connect the red probe of the digital multimeter to the positive terminal of one battery and connect the
black probe to its negative terminal. The indicated value of the digital multimeter is approximately
"12" to "16"V.
4. The other battery should be detected by the method as described in the step 3. The indicated value
is the same as that introduced in the step 3. Charge or replace the battery that cannot complete the
detection steps.
6-21
Power Contactor
This machine uses a contactor with a rated load current of 60A for power supply control. There is only
one set of operating contacts which are normally open contacts. When +24V voltage is applied to the
contactor coil, the generated electromagnetic attraction drives the internal armature to overcome the
acting force of spring so as to close the operating contact - normally open contact. After the operating
contact is closed, the external circuit with rated load current of 60A can be switched on. After the applied
voltage of +24V at the coil end of the contactor is disconnected, the contactor will return to its original
state.
The power contactor is located inside the interlocking control box in the cab.
P26E00073
P26E00074
6-22
Precautions
The rated load current of the power relay is 60A, and the maximum instantaneous current cannot exceed
200A. Improper use will reduce the service life of the contactor and cause serious damage.
Fault detection steps of power contactor
1. Adjust the digital multimeter to the 2kΩ range in Ω position.

2. Connect the two probes of the digital multimeter to the pin terminals 85 and 86 of the contactor
respectively, where the indicated value of the multimeter should be approximately "310Ω±10%".
3. Connect the two probes of the digital multimeter to the pin terminals 30 and 87 of the contactor
respectively, where the indicated value of the multimeter should be "L infinite".
4. Apply power supply of +24V to the pin terminals 85 and 86 of the contactor, connect the two probes
of the digital multimeter to the pin terminals 30 and 87 of the contactor respectively, where the
indicated value of the multimeter should be a few tenths (in on state).
After the above steps are completed, the indicated value of the multimeter is the same as that described
in the steps, which can basically judge that the contactor is in good condition.
6-23
CLG6611E Starting System
Starting System
Schematic Diagram of Starting System
P26E00075
Analysis of electrical schematic diagram
1. Turn on the negative switch and turn the electric lock to the ON position. Please refer to the power
system for the analysis of schematic diagram in this section;
6-24
Starting System CLG6611E
2. After the control lever is turned to the neutral position:
P26E00076
6-25
3. After the electric lock is turned to the STATR position;
P26E00077
4. After the vehicle is started, the electric lock will automatically return to the ON position from the
STATR position after being released. The D+ terminal of the generator will output high level signals,
the 700# wire will be powered on, and the vehicle will start timing.
Starting Contactor
This machine uses a starting contactor with a rated load current of 100A for starting the diesel engine.
There is only one set of operating contacts which are normally open contacts. When +24V voltage is
applied to the contactor coil, the generated electromagnetic attraction drives the internal armature to
overcome the acting force of spring so as to close the operating contact - normally open contact. After
the operating contact is closed, the external circuit with rated load current of 100A can be switched on.
After the applied voltage of +24V at the coil end of the contactor is disconnected, the contactor will return
to its original state.
6-26
The starting contactor is located inside the interlocking control box in the cab.
P26E00073
P26E00078
6-27
Precautions
Fault detection steps of power contactor

1. Adjust the digital multimeter to the 200Ω range in Ω position.
2. Connect the two probes of the digital multimeter to the terminals of the plug-in connector of the
contactor respectively, where the indicated value of the multimeter should be approximately "96Ω".
3. Connect the two probes of the digital multimeter to the two king bolts (the operating contact terminals
of contactor) of the contactor respectively, where the indicated value of the multimeter should be "1".
4. Apply power supply of +24V to the plug-in connector (coil terminal) of the contactor, connect the two
probes of the digital multimeter to the two king bolts of the contactor respectively, where the indicated
value of the multimeter should be "0".
in the steps, which can basically judge that the contactor is in good condition. The above detection steps
are not suitable for cases where the operating contact (normally open contact) is seriously worn.
Relay
The Micro relay has a rated load current of 10A/20A, and two sets of operating contacts. The load
current of the normally open contact is 20A, and that of the normally closed contact is 10A. When +24V
voltage is applied to the relay coil, the generated electromagnetic attraction drives the operating contact
- normally open contact to be closed. After the operating contact is closed, the external circuit with rated
load current of 20A can be switched on. After the applied voltage of +24V at the coil end of the relay is
disconnected, the relay will return to its original state.
Micro relays are all concentrated on the interlocking control box of electrical appliances.
P26E00079
Fault detection steps of relay

2. Connect the red probe of the digital multimeter to the terminal "1" of the relay and connect its black
probe to the terminal "2", where the indicated value of the multimeter should be approximately "320".
3. Connect one probe of the digital multimeter to the terminal "5" of the relay and connect the other
probe to the terminal "3", where the indicated value of the multimeter should be "1". Shift the probe
from the terminal "5" to the terminal "4", where the indicated value of the multimeter should be "0".
6-28
4. Apply the positive pole of external power of +24V to the terminal "1" of the relay and its negative pole
to the terminal "2", connect one probe of the digital multimeter to the terminal "5" of the relay and
connect the other probe to the terminal "3", where the indicated value of the multimeter should be
"0". Shift the probe from the terminal "5" to the terminal "4", where the indicated value of the
multimeter should be "1".
"0" indicates that the measured resistance between the two pins is zero and "1" indicates that the
measured resistance between the two pins is infinite.
in the steps, which can basically judge that the relay is in good condition. The above detection steps are
not suitable for cases where the operating contacts (normally open contact and normally closed contact)
are seriously worn.
The socket relays are all concentrated on the electric interlocking control box. The location diagram and
function definition diagram are shown below. The following sections do not repeat the description of the
location and function definition of socket relay.
P26E00073
K1 Power supply K5 Flasher

K2 Starting control K6 Preheating
K3 Starting K7 Vibration
K4 Engine off K8 Headlight
K9 Headlamp (Rear)
6-29
Fault detection steps of relay
1. Unplug the relay from the relay socket.

3. Connect the red probe of the digital multimeter to the terminal "86" of the relay and connect its black
probe to the terminal "85", where the indicated value of the multimeter should be approximately
"300".
5. Connect one probe of the digital multimeter to the terminal "30" of the relay and connect the other
probe to the terminal "87", where the indicated value of the multimeter should be "1".
6. Apply the positive pole of external power of +24V to the terminal "86" of the relay and its negative
pole to the terminal "85", connect one probe of the digital multimeter to the terminal "30" of the relay
and connect the other probe to the terminal "87", where the indicated value of the multimeter should
be "0".
in the steps, which can basically judge that the relay is in good condition.
"0" indicates that the measured resistance between the two pins is zero and "1" indicates that the
measured resistance between the two pins is infinite.
The above detection steps are not suitable for cases where the operating contact is seriously worn.
Start Motor and Generator
P26E00081
6-30
Start motor
The parameter configured for the start motor of this machine is 24V/6KW. The DC motor inside the start
motor can convert the electric energy of the battery into mechanical energy, and then the internal
transmission gear drives the flywheel of the engine, thus realizing the starting of the engine.
P26E00082 P26E00083
Generator
The generator is the main power supply equipment of the vehicle, which converts the energy from the
diesel engine into electric energy that can be used by electrical appliances. The electrical parameter is
28V/70A, with a built-in electronic regulator. The generator and the battery are connected in parallel to
form a power system of the vehicle. Before the diesel engine is started, the battery supplies power to the
electric appliances of the vehicle. After the diesel engine is started, the generator mainly supplies power
to the electric appliances while charging the battery. When the energy supplied by the generator cannot
meet the needs of the electric appliances of the vehicle, the generator and the battery supply power
together.
This machine uses three wiring ports of the generator, namely:
1. B+ (BatteryPositive); 2. D+ (one of the pins in the 4-pin connector); 3. E (GND).
P26E00084 P26E00085
6-31
Precautions
Do not allow the generator of this machine to supply power separately to the electrical equipment on the
machine when it is disconnected from the battery.
When the diesel engine is running, the metal tools or other metal conductors are not allowed to be close
to the "B+" (BatteryPositive) terminal of the generator and the generator casing, in order to avoid short
circuit accidents. A short-circuit fault on the generator will cause serious consequences.
Fault detection steps of generator
Different from the fault detection methods of other components as introduced, the fault detection of
generator must be completed on the vehicle without removing the generator for separate detection.
The following detection steps are not suitable for cases where the battery is fully charged and the
terminal voltage reaches 25V or higher.
1. Adjust the digital multimeter to the 200V range in voltage position.
2. Turn on the negative switch of the machine, do not start the diesel engine, connect the red probe of
the digital multimeter to the terminal " B+" of the generator, connect its black probe to the generator
casing, and record the indicated value of the digital multimeter. Normal value ranges from "24" to
"28"V.
3. Start the diesel engine, where the measurement method is the same as that described in step 2, and
record the indicated value of the digital multimeter again. This value should be larger than that
measured in step 2, indicating that the generator is generating electricity normally.
The above detection steps must be carried out under the condition of no-load of the vehicle (no-load
refers to turning on the electric lock without turning on all power switches or using electric appliances on
the machine). If there is no change in the indicated value of the digital multimeter after the detection in
steps 2 and 3, turn off the electric lock and detect the generator according to the following steps.
1. Check the generator drive belt according to the method described in the instruction manual. The belt
should be readjusted if it is too loose.
2. Check whether the wiring terminals of the generator are secure and tighten the wiring terminals on
the generator with a wrench.
If the above methods still cannot solve the problem, please contact maintenance service outlets of
LiuGong and Cummins.
6-32
Monitoring System CLG6611E
Monitoring System
Engine Coolant Temperature Indicator
P26E00086
This machine adopts Cummins two-stage engine, wherein the engine coolant temperature signal is
collected by the external coolant temperature sensor and sent to the instrument through 701# wire; after
reading the coolant temperature data, the instrument microcontroller calculates and processes the data
to finally drive the engine coolant temperature meter to indicate the coolant temperature.
Oil Pressure Alarm
P26E00087
This machine adopts Cummins two-stage engine, wherein the engine oil pressure signal is collected and
processed by the external oil pressure switch. When the engine oil pressure is lower than the specified
value, the engine is disconnected from the oil pressure switch and send an alarm signal to the
instrument, and the instrument microcontroller will drive the oil pressure alarm indicator to be on after
reading the oil pressure alarm signal.
6-33
CLG6611E Monitoring System
Precautions
When replacing the pressure switch, the electric lock must be turned off and the machine must be cooled
sufficiently before replacement.
Fault detection of the pressure switch
1. Unplug the connector connected to the oil pressure switch in the wiring harness of the rear frame;
2. Remove the pressure switch from the vehicle;
3. The operating value of the pressure switch is determined by the pressure test bench. the contact
type of the pressure switch is normally closed NC and the operating value is 0.088 MPa.
Fuel Level Indicator
It is configured to monitor the fuel capacity of the diesel tank.
P26E00088
Fuel level sensor
The sensor adopts a float to move up and down with the fuel level in the fuel tank. The float affects the
resistance of the resistor through the sensor. After the circuit is connected, the characteristic that the
resistance varies with the fuel level is changed into the characteristic that the voltage varies with the fuel
level. The changed voltage signal enters the microcontroller of the instrument cluster and is calculated
and processed by the microcontroller. The output signal drives the stepping motor type fuel level gauge
to indicate the fuel level.
Precautions
When replacing the fuel level sensor, the electric lock must be turned off and the machine must be
cooled sufficiently before replacement. When replacing, be careful not to let foreign objects fall into the
diesel tank.
Fault detection steps of fuel level sensor
1. Separate the wiring harness of the fuel level sensor from that of the vehicle;
2. Remove the fuel level sensor from the fuel tank;
3. Adjust the digital multimeter to the 2kΩ range in Ω position.
6-34
4. Connect the red probe to the terminal at 1# hole of the sensor connector and connect the black
probe to the terminal at 2# hole;.
5. Measure the resistance of the fuel level sensor when the float is in different positions;
P26E00089
Level of float 13 12 11 10 9 8 7
Liquid level 33±3 67±3 102±3 136±3 170±3 205±3 239±4
Resistance 3±2OΩ 14.2±2Ω 25.4±2Ω 36.6±2Ω 47.8±2Ω 59±1Ω 72.8±2Ω
Level of float 6 5 4 3 2 1 0
Liquid level 274±3 308±3 343±3 377±3 411±3 446±3 470±4
Resistance 89.2±2Ω 105.6±2Ω 122±2Ω 138.4±2Ω 155.7±2Ω 174±1Ω 183±2Ω
1. The technical performance of the sensor shall conform to JB/T7696.2-95.

2. Print PDM number: 30B0384.
Revolution Indicator
It is configured to monitor the rotation speed of the vehicle. The output speed sensor is installed on the
transmission housing and is used for detecting the rotation speed of the transmission output gear. The
speed sensor outputs a sinusoidal voltage signal proportional to the rotation speed. The signal is sent to
the instrument microcontroller by connecting the frame wiring harness for calculation and processing,
and finally the rotation speed is displayed on the LCD screen.
P26E00090
6-35
Parking Brake and Brake Low-voltage Circuit
P26E00091
Parking brake feedback switch
It is configured to monitor the braking and non-braking states of the vehicle.

When the brake switch is pressed, the brake solenoid valve is de-energized and the brake is
enabled. At the same time, the brake indicator on the instrument is turned on and the brake
indicator is on.
Air Cleaner Blocking Alarm Circuit (Optional)
When the intake resistance of the air cleaner exceeds the alarm value, the air cleaner blocking alarm
light is on. The air cleaner blocking alarm switch is normally open type.
P26E00092
6-36
Hydraulic Filter Blocking Alarm Circuit (Optional)
When the resistance of the hydraulic oil line exceeds the alarm value, the hydraulic filter blocking alarm
light is on. The hydraulic filter blocking alarm switch is normally open type.
P26E00093
Charge Indicator Circuit of Generator
It is configured to monitor whether the generator is in a state of supplying power to the external circuit
after the vehicle is started. The indicator light is off, indicating that the generator is in a state of supplying
power outward.
P26E00094
6-37
Voltage Indicator Circuit
The voltage signal of the vehicle system is directly output to the instrument by two batteries connected in
series. After acquisition of the voltage signal, the instrument reads the voltage signal data of the vehicle
system through the controller and calculates and processes the data to finally drive the voltage indicator
light to indicate the voltage.
The voltage indicator light is red and is configured to monitor the system voltage of the vehicle. it is on
when the power supply voltage of the vehicle is lower than the output voltage of the generator and off
when the power supply voltage of the whole vehicle is higher than the output voltage.
P26E00095
Grille Heating Circuit (Optional)
When the ambient temperature drops to 0 °C to -15 °C and the grille heating function is required to assist
the engine to start, the electric lock terminal controls the grille heating signal. The control signal enters
the grille heating contactor coil via 487# wire and then attracts the coil. The 489# wire is energized, the
normally open contact 103/488 of the grille heating contactor is closed, and the engine grille heater is
energized to work.
P26E00096
6-38
Grille heating relay
P26E00097
The contact circuit of grille heating contactor has a rated load current of 200A and has only one set of
operating contacts, which are normally open contacts. When +24V voltage is applied to the contactor
coil, the generated electromagnetic attraction drives the internal armature to overcome the acting force
of spring so as to close the operating contact - normally open contact. After the operating contact is
closed, the external circuit with rated load current of 200A can be switched on. After the applied voltage
of +24V at the coil end of the contactor is disconnected, the contactor will return to its original state.
Fault detection steps of contactor

2. Connect the two probes of the digital multimeter to the terminals of the plug-in connector of the
contactor respectively, where the indicated value of the multimeter should be approximately "40Ω".
3. Connect the two probes of the digital multimeter to the two king bolts (the operating contact terminals
of contactor) of the contactor respectively, where the indicated value of the multimeter should be "1".
4. Apply power supply of +24V to the plug-in connector (coil terminal) of the contactor, connect the two
probes of the digital multimeter to the two king bolts of the contactor respectively, where the indicated
value of the multimeter should be "0".
in the steps, which can basically judge that the contactor is in good condition. The above detection steps
are not suitable for cases where the operating contact (normally open contact) is seriously worn.
6-39
Instrument
P26E00498
The instrument provided for the machine is an electronic combination instrument which has two
indication areas.
Liquid crystal display area
Column 1 - coolant temperature

Column 2 - fuel level
Column 3 - voltage indicator
Column 4 - engine speed
Column 5 - working hour meter
Indicator area
Input signal Input signal level

Alarm light Requireme
Item Flash or not level in normal in alarm or on Icon
and Color nts
state state
Charging Suspended or
LED Light, red Flicker free 0V (grounded)
indication connected to 24V
Oil pressure Incapable of

LED Light, red Flicker free Cummins; driven by (SPN100);
indication silencing
Air cleaner
blocking LED Light, red Flicker free Suspended 0V (grounded)
indication
6-40
Input signal Input signal level

Alarm light Requireme
Item Flash or not level in normal in alarm or on Icon
and Color nts
state state
LED Light,
Neutral indicator Flicker free Suspended 24V
green
Hydraulic oil filter

blockage LED light, red Flicker free Suspended 0V (grounded)
indication light
Pre-heating LED light,

Flicker free Suspended 24V
indicator yellow
Small amplitude LED Light,

indicator green
Large amplitude LED Light,

indicator green
LED Light,
Headlight Flicker free Suspended 24V
green
LED Light,
Rear floodlight Flicker free Suspended 24V
green
Parking brake
LED Light, red Flicker free Suspended 0V
light
The engine
Engine coolant
coolant Incapable of
temperature LED Light, red Flicker free
temperature is silencing
alarm light
higher than 105°C
Silencing
LED Light, red Flicker free Suspended 0V
indication light
6-41
CLG6611E Sound-Light Alarm System
Sound-Light Alarm System
Electric Horn Circuit
This machine is equipped with an electric horn button located at the rocker combination switch on the
steering column, and the horn is located under the cab.
P26E00099
Electric horn
P26E00100
This machine is equipped with a high frequency horn.
Electrical parameters:
1. Rated voltage 24V;

2. Working current 2.0A;
3. Basic frequency 420±30Hz;
4. Sound pressure level 105dB-118dB (A)
Fault detection steps of electric horn
1. Connect the positive pole of 24V DC power supply to the terminal at 1# hole of the electric horn and
connect its negative pole to the terminal at 2# hole;
2. Turn on the DC power supply;
3. The electric horn sounds an alarm with a sound level in the range of 105dB-118dB(A).
6-42
Sound-Light Alarm System CLG6611E
Backup Alarm Circuit
P26E00101
Backup alarm
P26E00102
The backup alarm is a buzzer that intermittently sounds, which functions when the operator carries out
the backup operation and works simultaneously with the backup light.
6-43
CLG6611E Sound-Light Alarm System
Electrical parameters of backup alarm
Rated voltage 24Vv

Continuous working voltage 12-36V
<150mS 160V spike pulse
Instantaneous working voltage
<150mS 110V sawtooth pulse
Storage temperature -40°C to +75°C
Working temperature -40°C to +85°C
Relative humidity (30~90)%RH
Impact strength 10g at 0.03 to 0.08Hz
Vibration strength 5g at 10 to 1000Hz
Atmospheric pressure protection 86 to 106KPa
Detection steps of backup alarm
1. Connect the positive pole of 24V DC power supply to the terminal at 1# hole of the backup alarm and
connect its negative pole to the terminal at 2# hole;
2. Turn on the DC power supply;
3. The backup alarm sounds an alarm with a sound level of 112dB.
6-44
Lighting System CLG6611E
Lighting System
The backup light is configured to illuminate the area behind the vehicle when the vehicle is reversing.
This machine is equipped with a backup alarm. When reversing, the backup light and the backup alarm
work at the same time. The brake light is used to warn the vehicle behind that the machine is braking.
The turn signal light indicates the driving direction of the vehicle to be changed and the potential danger
signal (when used as a parking light).
Headlights and rear floodlights are configured to provide lighting for driving or operation of the vehicle.
The working light is mainly configured to provide lighting for operation of the vehicle.
Lighting circuit
P26E00105
6-45
CLG6611E Lighting System
Headlight and rear floodlight switches
P26E00106
6-46
Working light switch
P26E00107
6-47
CLG6611E Lighting System
Turn signal switch
P26E00108
6-48
Parking light switch
P26E00109
6-49
CLG6611E Vibration System
Vibration System
Principle of Vibrating Circuit
P26E00114
Vibrating Relay
The intelligent power relay ETR10 (electronic time relay) is a remote controlled solid state time relay that
integrates two functions:
● Solid state relay with time function (delay, pulse, flicker)
● Electronic over-current protection
6-50
Vibration System CLG6611E
Technical Specification (25°C)
Working voltage LINE+

System voltage UB 12/24VDC
Voltage range 9...32VDC
Quiescent current
OFF 150μA
consumption1)2)
Load circuit LOAD
Load output MOSFET, High Potential Switching (HSS)
Load type Resistive, sensitive and capacitive
Short circuit protection, overload protection
Protection function
Thermal protection
Rated current3) in 1...30A
70A (IN up to 10A) L/R=2ms
Short-circuit current IK max.
250A (IN from 15A) L/R=2ms
Freewheel diode Built-in
Voltage drop UON max in mV(at IN in A)
In 1 2 3 5 7.5 10 15 20 25 30
UON 50 55 60 80 90 110 70 90 120 140
Control input IN+
Control voltage ON 8.5...32VDC
Control current1) OFF 0...5VDC
Rising edge 1...10mA(8.5...32VDC)
Status output (optional) <5ms
Schematic Diagram
P26E00115
6-51
CLG6611E Vibration System
Pin definition
4 pins
LINE 30 2
LOAD 88a 8
GND 31 6
IN 86 4 P26E00116
7 pins
LINE 30 2
LOAD 88a 8
GND 31 6
IN 86 4
S1 S1 1
P26E00117
S2 S2 3
S3 S3 5
Trigger signal S1
Over-current signal S2
Pin definitions conform to ISO7588
Pins 15, 30, 87 and S3 --Plug-in Pin 6.3 × 0.8
Pins S1 and S2 --Plug-in Pin 2.8 × 0.8
The nomenclature of pin conforms to DIN72552
Vibration fault elimination
1. If there is no large vibration or small vibration at the same time, please check F7 vibration fuse first;
2. If there is a large vibration but no small vibration, or if there is a small vibration but no large vibration,
the first step is to check whether the socket indicator of the vibrating valve is on normally to eliminate
the valve block fault, then measure the time relay fault by a multimeter, and finally determine the fault
source by measuring the connectivity of the vibration knob switch with a multimeter.
6-52
Travel System CLG6611E
Travel System
P26E00118
Fault elimination for travel system
1. If the vehicle is unable to travel , please check the F8 travel fuse first;
2. If there is rear wheel drive but no forward wheel drive, or if there is forward wheel drive but no rear
wheel drive, the first step is to check whether the socket indicator of the solenoid driven valve is on
normally to eliminate the valve block fault, and then determine the fault source by measuring the
connectivity of the forward-rear wheel drive knob switch with a multimeter.
7-1
July 17, 2020 Cab and Covering Parts
CLG6611E
Cab and Covering Parts

Cab ........................................................................................................................................................7-3
Cab Assembly ....................................................................................................................................7-3
Hood Assembly ......................................................................................................................................7-4
Opening and Closing of Hood ................................................................................................................7-5
Opening of Hood ................................................................................................................................7-5
Closing of Hood..................................................................................................................................7-5
Removal and Installation ...................................................................................................7-6

Removal and Installation of Cab ............................................................................................................7-6
Removal and Installation of Hood Assembly........................................................................................7-10
Removal of Hood Assembly.............................................................................................................7-10
Installation of Hood Assembly..........................................................................................................7-11
7-2
Cab and Covering Parts July 17, 2020
CLG6611E
7-3
CLG6611E Cab
Cab
Cab Assembly
The cab system is mainly composed of cab, seat bracket, seat assembly, damper, and stop plate.
Among them: Hydraulic steering and electrical parts are assembled on the cab assembly.
8
7
19
22
20
2
6
9
16
11 10
12
14
19
4
20
15 21
19
10
16
13 17
12
14 P26C00194
1 Cab assembly 8 Guard plate 15 Bolt

2 Guard plate 9 Bolt 16 Bolt
3 Top cover 10 Washer 17 non-slip strip
4 Seat support 11 Shock absorber 19 Bolt
5 Seat assembly 12 Limit plate 20 Nut
6 Nut 13 Shock absorber 21 Rearview mirror
7 Bolt 14 Lock nut 22 Base
7-4
Hood Assembly CLG6611E
Hood Assembly
The hood is installed on the rear frame through two hinges. The hood is a front-hinged hood, and can
open at a maximum angle of approximately 50 degrees when lifted by a gas spring.
10 11
22 18
14
9 14 15
3 1
4
29
28
14
29
19
2
14
17
8
7 12 14
13 7
24 26 15 16
6 8 5
22
23
20
7
21
25 27 P26C00007
1. Hood 11. Rubber plate 21. Support

2. Reflective label 12. Pin shaft 22. Bolt
3. Reflective label 13. Lateral hood 23. Washer
4. Cable 14. Nut 24. Support
5. Gas spring 15. Bolt 25. Pin shaft
6. Hinge 16. Buffer head 26. Pin
7. Washer 17. Bending plate 27. Lateral hood
8. Bolt 18. Bending plate 28. Bending plate
9. Nut 19. Lock 29. Bolt
10. Pressure plate 20. Bolt
Precautions for removal and installation are as follows:
1. Special equipment operators are required to have corresponding operation qualification certificates.
2. Measuring equipment and tools are required to have inspection certificate issued by metrological
service.
3. Due to the large number of other related components on the vehicle involved in the removal and
installation of the components, the removed components (especially the standard components)
should be properly placed to avoid problems such as mis-installation, neglected installation and parts
loss during reassembly.
4. If other components on the vehicle need to be removed and installed during removal and installation
of various components, use tools with reference to the list of tools for removal and installation of
other components, and do not list them again in the list of tools for these components.
5. The removal and installation of open-end wrench, that of blower gun and socket and that of ratchet
wrench and socket, all of which can achieve the desired effect, can be optional.
7-5
CLG6611E Opening and Closing of Hood
Opening and Closing of Hood
Opening of Hood

1. Grasp the armrest at the rear of the hood by hand;
2. Press the switch button at the armrest;
P26C00008
3. Grasp the hood cable belt by hand and control the
opening speed of the hood until the hood is fully opened.
P26C00009
Closing of Hood

1. Grasp the hood cable belt by hand and slowly pull it
down to control the closing speed of the hood;
P26C00009
2. Grasp the armrest at the rear of the hood by hand, and
press it down gently to lock the hood.
P26C00008
7-6
Removal and Installation of Cab CLG6611E
Removal and Installation of Cab
Removal sequence for lifting cab
1. Removal of hydraulic steering gear components → removal of flexible control shaft components →
removal of electrical components → removal of flexible shaft components of engine throttle →
removal of cushion gasket → lifting
2. Steps for assembling cab to machine: assembly with reference to removal steps in reverse order.
Removal of cab

1. Remove 4 mounting bolts (M10×20) of hydraulic
steering gear (1);
1
P26C00195
2. Remove cotter pin (2) of the flexible control shaft;
P26C00012
7-7
CLG6611E Removal and Installation of Cab

3. Take out the hinge pin (3) of flexible control shaft.
P26C00013
4. Remove the fixing bolt of flexible control shaft with a

wrench;
5. Take out the flexible control shaft.
P26C00014
6. Remove the mounting bolt (4) between engine and

accelerator flexible shaft;
P26C00015
7-8
Removal and Installation of Cab CLG6611E

7. Remove the mounting bolt (5) between engine support
and accelerator flexible shaft;
8. Take out the engine accelerator flexible shaft.
P26C00016
9. Remove two mounting bolts (M20×130) (6) for front

damper of the cab;
10.Remove four mounting bolts (M20×140) (7) for rear
damper of the cab;
7 P26C00196
7-9
CLG6611E Removal and Installation of Cab

11.Lifting of the cab;
12.Perform lifting via 2 lift bolts behind the cab seat, and
place in a flat position;
P26C00197
7-10
Removal and Installation of Hood Assembly CLG6611E
Removal and Installation of Hood Assembly
Removal of Hood Assembly

1. Park the machine on the flat ground;
2. Remove the air prefilter (1);
1
3. Remove the left and right side covers (2), and install 16
bolts M8×20;
P26C00198
4. Assemble lifting rings and lifting tools at the lifting
threaded holes of the hood;
5. Lift with a traveling crane and tighten;
P26C00029
7-11
CLG6611E Removal and Installation of Hood Assembly

6. Remove the mounting pin shafts (2) of the left and right
gas springs (1);
P26C00199
7. Remove 6 mounting bolts M10×30 of the hood hinge (1);

8. Slowly lift the hood assembly with the traveling crane.
P26C00031
Installation of Hood Assembly

1. Lift the hood with the traveling crane to slowly approach
the installation location;
P26C00032
7-12

2. Install the left and right hinges (1) of the hood, and install
6 bolts M10×30 with a torque of 52±6N.m;
P26C00031
3. Slowly adjust the hood up and down, and install the pin
shaft (2) of the gas spring (1);
P26C00199
4. Install the air prefilter (1);

1 5. Install the left and right lateral hoods, and install 16 bolts
M8×20 with a torque of 26±4 N.m;
2
P26C00200
7-13
CLG6611E Removal and Installation of Hood Assembly
Installation of hood lock
The hood lock is installed in two parts, the locking part is installed at the rear of the hood, and the latch
part is installed on the rear frame.
11
10
9
9
10
11
8
7
5
6
P26C00033
1. Mounting plate 5. Column 9. Lock washer

2. Hood lock 6. Washer 10. Washer
3. Nut plate 7. Washer 11. Bolt
4. Latch support 8. Bolt
7-14
8-1
July 17, 2020 Appendix
CLG6611E
Appendix
Hydraulic Schematic Diagram ...........................................................................................8-3
Electrical Schematic Diagram............................................................................................8-4
8-2
Appendix July 17, 2020
CLG6611E
8-3
July 17, 2020 Hydraulic Schematic Diagram
CLG6611E

8-4
July 17, 2020 Electrical Schematic Diagram
CLG6611E
Electrical Schematic Diagram
50Y1427

Clg6611e (Dcec II) Service Manual 202007000-En

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Clg6611e (Dcec II) Service Manual 202007000-En

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202007000

Applicable Type and Model: CLG6611E

Diesel Engine Model: 4BTAA3.9-C125

How to Use the Manual ● Fault Diagnosis of DCEC Cummins Engine

Suggestions on How to Use and Read this

Important Safety Content

The identifier of the safety warning "Warning" is as follows:

California Recommendation Article 65

Cable Code Identification

Color abbreviation code

S/N Wire Type Wire Name Description Heat Resistance

Color abbreviation code

Color English Abbreviation Color English Abbreviation

Color English Abbreviation Color English Abbreviation

Circuit Type and Color Abbreviation Code

Circuit type Color abbreviation code

Item Specification Main features and uses

RAL No. of paint

Liugong yellow RAL1006 Liugong gray RAL7021

Weight (Kg) Weight (Ib)

Unit Conversion Table

Parameter Metric unit Imperial unit Multiple

Standard Torque Table

Tightening torque of sealed hose connector of 24° cone with O-ring

Tightening torque of bolt of flange-type sealed hose connector

Performance Tightening torque

Tightening torque of thread angle type sealed hose connector

Tightening torque of connector

Usage Specification of Oil Product

Oil change interval and approximate refill capacity

Oil change interval Approximate refill

Technical Specification of Oil

Oil type Ambient temperature Oil specification Position

Oil type Ambient temperature Oil specification Position

Vehicle Technical Specification

Requirements of Operating Environments

This Roller cannot be used in environments with tumbling or falling objects.

Main Component Diagrams

1. Front frame 5. Diesel engine 9. Ladder

Main Technical Parameters

Item Unit CLG6611E

Compaction Vibration Frequency Hz 30/33

Item Unit CLG6611E

Item Unit CLG6611E

Item Unit CLG6611E

Structure and Function ......................................................................................................2-9

Test and Adjustment........................................................................................................2-26

Removal and Installation .................................................................................................2-35

Removal and Installation of Cooling System........................................................................................2-48

Fault Diagnosis and Troubleshooting ..............................................................................2-59

Compressed air may cause personal injury.

Coolant ● Put oily wipes or other combustible materials

Fire & Explosion Prevention

● The mixtures of all fuels, most lubricants and

● Store fuel and lubricants in containers

Overview -- System Components and Locations

Modular Structure Diagram of Power System

Location of Power System on Vehicle

1. Fuel System 2. Intake and Exhaust 3. Installation of Diesel 4. Cooling System

Power System Components

1. Manual accelerator 3. Air Prefilter 5. Diesel Engine 7. Oil water separator

System Technical Parameters

Model DCEC Cummins, 4BTAA3.9-C125