3_DH24-B2装修手册-中译英-20220319-英译文

Installation and Maintenance Manual of DH24-B2 Full-hydraulic
Bulldozer
Contents
Contents
Safety .................................................................................................................................... 1
Safety Notice ................................................................................................................... 1
Safety Precautions .......................................................................................................... 1
Safety Principles ....................................................................................................... 1
General Hazard Information ..................................................................................... 1
Preventive Measures against Crush or Cut Injuries .................................................. 4
Preventive Measures against Scald .......................................................................... 5
Preventive Measures against Fire and Explosion ..................................................... 6
Precautions of Track ............................................................................................... 11
HP Fuel Pipelines ................................................................................................... 11
Precautions for Refitting ......................................................................................... 12
Safety Rules .................................................................................................................. 13
Before Starting of Engine ........................................................................................ 13
Starting the Engine ................................................................................................. 15
Before Operation .................................................................................................... 15
Operating the Machine ........................................................................................... 16
Driving on Slopes ................................................................................................... 18
Parking of Machine ................................................................................................. 19
Engine Stop ............................................................................................................ 19
Transportation ........................................................................................................ 19
Dragging ................................................................................................................. 20
Before Service ........................................................................................................ 20
During Service ........................................................................................................ 21
Foreword.............................................................................................................................. 25
Overview ....................................................................................................................... 25
Structure and Function .................................................................................................. 25
Test and Adjustment ...................................................................................................... 25
Disassembling and Assembling ..................................................................................... 25
Maintenance and Service Standards ............................................................................. 25
Fault Diagnosis ............................................................................................................. 25
How to Read this Installation and Maintenance Manual ................................................ 25
Lifting Instructions ......................................................................................................... 26
Shantui Construction Machinery Co., Ltd. I
Contents
Steel Wire Rope ............................................................................................................ 26
Standard Tightening Torque .......................................................................................... 28
Conversion Table........................................................................................................... 28
Use Methods .......................................................................................................... 28
Chapter 1 Overview.......................................................................................................... 35
1.1 General Information and Technical Specifications of Machines ........................ 35
1.1.1 General Information of Complete Machine ................................................ 35
1.1.2 Engine ........................................................................................................... 35
1.1.3 Drive System ................................................................................................. 36
1.1.4 Undercarriage System .............................................................................. 36
1.1.5 Work Tools ................................................................................................ 36
Chapter 2 Power System.................................................................................................. 39
2.1 Structure and Function Description of Power Components .............................. 39
2.1.1 Installation of Engine Accessories and Engine .......................................... 39
2.1.2 Engine Cooling System ............................................................................. 39
2.2 Removal and Installation of Power Components .............................................. 40
2.2.1 Engine....................................................................................................... 40
2.2.2 Removal and Installation of Cooling System ............................................. 44
2.2.3 Removal and Installation of Fuel System .................................................. 46
Chapter 3 Undercarriage System ..................................................................................... 49
3.1 Structure and Function..................................................................................... 49
3.1.1 Trolley Assembly ....................................................................................... 49
3.1.2 Tensioning Device ..................................................................................... 49
3.1.3 Front Idler ................................................................................................. 50
3.1.4 Track Roller ............................................................................................... 52
3.1.5 Carrier Roller ................................................................................................. 53
3.1.6 Track ......................................................................................................... 55
3.2 Disassembling and Assembling ....................................................................... 56
3.2.1 Test and Adjustment of Track Tension ....................................................... 56
3.2.2 Removal and Installation of Trolley Assembly............................................ 57
3.2.3 Removal and Installation of Front Idler Assembly ...................................... 60
3.2.4 Removal and Installation of Tensioning Assembly ..................................... 61
3.2.5 Removal and Installation of Track Roller Assembly ................................... 61
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Contents
3.2.7 Removal and Installation of Carrier Roller Assembly ................................. 62
3.2.9 Removal and Installation of Track Assembly ............................................. 63
Installation .............................................................................................................. 65
Chapter 4 Final Drive and Transfer Case ......................................................................... 67
4.1 Structure and Function..................................................................................... 67
4.1.1 Overview ................................................................................................... 67
4.1.2 Power Transfer Route ............................................................................... 69
4.2 Removal and Installation of the Final Drive Assembly ...................................... 69
4.2.1 Removal of the Final Drive Assembly ........................................................ 69
4.2.2 Disassembling of the Final Drive Assembly ............................................... 71
4.2.3 Assembling the Final Drive Assembly ....................................................... 74
4.3 Transfer Case .................................................................................................. 75
4.3.1 Overview ................................................................................................... 75
4.3.2 Disassembling and Assembling the Transfer Case ........................................ 77
4.3.3 Fault Diagnosis ......................................................................................... 92
Chapter 5 Work Tools ....................................................................................................... 93
5.1 Work Tools ....................................................................................................... 93
5.1.1 Overview ................................................................................................... 93
5.1.2 Semi-U Blade ............................................................................................ 93
5.2 Inspection Items, Judgment Criteria and Measures for Blade Maintenance ............. 94
5.2.1 Semi-U Blade ............................................................................................ 94
5.2.2 End Bit and Cutting Edge .......................................................................... 97
5.2.3 Removal and Installation of the Blade Assembly ....................................... 98
5.3 Structure, Functions and Maintenance Standards for the Ripper ................... 100
5.3.1 Overview ................................................................................................. 100
5.3.2 Inspection Items of the Ripper ................................................................. 103
5.4 Disassembling and Assembling Three-shank Ripper Assembly ..................... 105
5.4.1 Disassembling......................................................................................... 105
5.4.2 Assembling ............................................................................................. 106
Chapter 6 Hydraulic System ........................................................................................... 109
6.1 Hydraulic System of the Work Tools ............................................................... 110
6.1.1 Configuration of Hydraulic System of the Work Tools .............................. 110
6.1.2 Working Hydraulic System Principle ......................................................... 111
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Contents
6.1.3 Hydraulic Tank ........................................................................................ 115
6.1.4 Work Tool Cylinder .................................................................................. 116
6.2 Testing and Adjustment of the Working Hydraulic System .............................. 122
6.2.1 Visual Inspection and Maintenance ......................................................... 122
6.2.2 Testing and Adjustment of Pilot Pressure ..................................................... 125
6.2.3 Testing and Adjustment of the Working System Pressure ........................ 126
6.2.4 Settlement Testing of the Hydraulic Cylinder ........................................... 127
6.2.5 Leakage Test in the Hydraulic Cylinder ................................................... 128
6.3 Travel Hydraulic System ................................................................................ 129
6.3.1 Configuration of the Travel Hydraulic System .......................................... 129
6.3.2 Principle of the Hydraulic System ............................................................ 129
6.3.3 Structure and Principle of the Travel Pump ............................................. 131
6.3.4 Structure and Principle of the Travel Motor ............................................. 135
6.3.5 Structure and Principle of Oil Return Valve Block .................................... 138
6.3.6 Make-up Pump........................................................................................ 139
6.3.7 Principle of Make-up Filter....................................................................... 139
6.3.8 Centralized Pressure Measurement ........................................................ 139
6.3.9 Testing and Adjustment of Make-up Pressure .............................................. 140
6.3.10 Testing and Adjustment of Hydraulic Zero Point of the Travel Pump ........ 141
6.3.11 Testing and Adjustment of Braking Pressure ........................................... 141
6.4 Disassembling and Assembling Main Hydraulic Components of Working
Hydraulic System ........................................................................................................ 142
6.4.1 Removal and Installation of Implement Pump ......................................... 142
6.4.2 Removal and Installation of the Working Valve ........................................ 143
6.4.3 Removal and Installation of the Hydraulic Tank ....................................... 145
6.4.4 Removal and Installation of the Hydraulic Cylinder ................................. 147
6.5 Disassembling and Assembling Main Hydraulic Components of Travel Hydraulic
System 151
6.5.1 Removal and Installation of Travel Pump ................................................ 151
6.5.2 Removal and Installation of Two Travel Motors (Left Motor) .................... 154
6.5.3 Removal and Installation of the Make-up Pump ...................................... 156
6.5.4 Removal and Installation of Oil Return Valve Block ................................. 158
Chapter 7 Frame and Hood ............................................................................................ 161
7.1 Structure and Function................................................................................... 161
IV Shantui Construction Machinery Co., Ltd.
Contents
7.2 Removal and Installation of Main Frame ........................................................ 163
7.3 Removal and Installation of Hood .................................................................. 164
7.3.1 Removal and Installation of Front Grille................................................... 164
7.3.2 Removal and Installation of Front Hood .................................................. 165
7.3.3 Removal and Installation of Upper Hood ................................................. 166
7.3.4 Engine Side Shield and Its Removal and Installation............................... 167
7.3.5 Removal and Installation of Gantry ......................................................... 168
7.3.6 Removal and Installation of Rear Side Shield.......................................... 169
Chapter 8 Electrical system ............................................................................................ 171
8.1 Specifications of Fuses and Relays ............................................................... 171
8.2 Overview of Electrical Location Information ................................................... 173
8.3 Electrical Schematic Diagram ........................................................................ 179
8.3.1 Electrical System Schematic Diagram——SCH1 .................................... 179
8.4 Layouts of Components and Harnesses ........................................................ 196
8.5 Operation Guide of Diagsmart ....................................................................... 225
8.5.1. Software Startup ..................................................................................... 225
8.5.2. Software Configuration ............................................................................ 226
8.5.4. Description of Function ........................................................................... 229
8.6 Fault Diagnosis and Description .................................................................... 233
8.6.1 WISE40 Vehicle Controller Fault Information ............................................... 233
Chapter 9 Driving System............................................................................................... 243
9.1 Structure and Function................................................................................... 243
9.1.1 Cab Assembly ......................................................................................... 243
9.1.2 Travel Locking Lever ............................................................................... 244
9.1.3 Instrument Box Assembly ........................................................................ 245
9.2 Seat Assembly ............................................................................................... 245
9.2.1 Seat Structure ......................................................................................... 245
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Contents
9.2.2 Seat Testing and Adjustment ................................................................... 246
9.3 A/C System.................................................................................................... 249
9.3.1 A/C System Structure .............................................................................. 249
9.3.2 Principle for A/C System.......................................................................... 249
9.4 Removal and Maintenance: ........................................................................... 251
9.4.1 Removal and Installation of Cab Assembly and Instrument Box Assembly251
9.4.2 Removal and Installation of Seat Assembly ............................................. 251
9.4.3 Removal and Installation of A/C assembly .............................................. 252
9.5 Precautions.................................................................................................... 253
Chapter 10 Fault Diagnosis .............................................................................................. 255
10.1 Description of Safety Operations and Warnings ............................................. 255
10.1.1 During fault diagnosis, the equipment shall be kept in a safe state. ......... 255
10.1.2 Precautions for Operation of Electrical Components ............................... 257
10.1.3 Precautions for Operation of Hydraulic Components ............................... 267
10.2 Inspection Before Fault Diagnosis.................................................................. 269
10.2.1 Before Starting the Engine ...................................................................... 270
10.2.2 Start the Engine ...................................................................................... 272
9.2.3 Before Operation ......................................................................................... 272
10.2.4 Operation of the Machine ........................................................................... 273
10.2.5 Parking of Machine ................................................................................. 276
10.2.6 Engine Stop ............................................................................................ 276
10.2.7 Dragging ................................................................................................. 276
10.2.8 Troubleshooting Under the Machine ........................................................ 277
10.2.9 Keep the Machine Clean ......................................................................... 277
10.2.10 Use of Lighting ................................................................................. 277
10.2.11 Handle High Pressure Hoses .................................................................. 278
10.3 Vehicle Fault Diagnosis Description ............................................................... 278
10.3.1 Electrical Technical Specifications ........................................................... 278
10.3.2 Description of Fault Diagnosis Table ....................................................... 278
10.4 Mechanical and Hydraulic System Faults of Complete Vehicle ............................ 279
10.4.1 Work Tool Does Not Work ....................................................................... 279
10.4.2 Low Speed of All Work Tools ...................................................................... 279
10.4.3 Abnormal Noise Around the Implement Pump ............................................ 280
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Contents
10.4.4 System Oil Temperature High .................................................................... 280
10.4.5 Severe Malfunction of Hydraulic Cylinder................................................... 281
10.4.6 Hydraulic System Stalled ........................................................................ 281
10.4.7 Low Oil Replenishing Pressure ............................................................... 282
10.4.8 Traveling Without Any Movement ............................................................... 282
10.4.9 Single Crawler Belt Does Not Work ......................................................... 283
10.4.10 One-side One-way No Action ................................................................... 283
10.4.11 Low Speed or Low Power ....................................................................... 284
10.4.12 Non-adjustable Driving Speed .......................................................... 285
10.4.13 Large Vibration When the Complete Machine is Stopped or Started ........ 285
10.4.14 Serious Deviation of the Complete Machine ..................................... 285
10.4.15 Abnormal Noise from Travel Pump or Motor ..................................... 286
10.5 Transfer Case Fault ....................................................................................... 287
10.6 Common Faults of Engine ............................................................................. 287
10.6.1 Difficult Start or Start Fault of Engine (Smoking during Air Exhaust) ........ 287
10.6.2 Insufficient Power of Engine .................................................................... 288
10.6.3 High Black Smoke Emission of Engine.................................................... 289
10.6.4 High White Smoke Emission of Engine ................................................... 289
10.6.5 Low Engine Oil Pressure ......................................................................... 290
10.6.6 Starting Motor Does Not Work................................................................. 290
10.6.7 Powerless Motor ..................................................................................... 291
10.6.8 Electric Generator Fault .......................................................................... 291
10.6.9 Insufficient Charging of the Electric Generator ........................................ 291
10.7 Common Faults of Electrical System ............................................................. 292
10.7.1 Engine Start Fault ................................................................................... 292
10.7.2 Intake Preheater Does Not Work ............................................................. 292
10.7.3 Display Does Not Light Up When the Starter Switch is Turned ON ............ 293
10.7.4 Air Filter Blockage Alarm Lamp Flashes ..................................................... 293
10.7.5 Engine Oil Pressure Alarm Lamp Flashes ............................................... 293
10.7.6 Engine Coolant Temperature Alarm Lamp Flashes .................................... 294
10.7.7 Drive System Oil Temperature Alarm Lamp Flashes .................................. 294
10.7.8 Abnormal Fuel Level Indication .................................................................. 294
10.8 Common Faults of Driving System ................................................................. 295
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Contents
10.8.1 Cab Assembly ......................................................................................... 295
10.8.2 A/C System Assembly ............................................................................. 295
VIII Shantui Construction Machinery Co., Ltd.

Safety
Safety
Safety Notice
Proper maintenance is of great significance for working safety of the machine. The
maintenance and repair techniques recommended by Shantui Construction Machinery Co.,
Ltd. (“Shantui”) and described in this Manual are both effective and safe. Some of these
techniques require special tools designed by Shantui.
To avoid injuries to workers, safety precautions are marked with the symbol in this Manual.
The precautions with these symbols must be handled with care. Safety shall be guaranteed
first in case of danger or possible danger, with necessary measures being taken.
Safety Precautions
Safety Principles
Only those specially trained and permitted are allowed to be engaged in operation and service
of the machine. Those drunken or exhausted shall never operate the machine, which shall not
work with any fault or overload.
Safety rules, preventive measures and instructions shall be strictly followed during operation
and service of the machine.
It must be guaranteed that relevant personnel understand all gestures and signals while
working with other operators or those in charge of traffic guidance on the construction site.
In case of any abnormality during running of the machine, it shall be stopped immediately for
maintenance, until such abnormality is eliminated. Besides, all relevant provisions shall be
followed.
This machine can only be used at an altitude below 2,000 m, and the power will be lowered
with the increase in altitude. The parts and components will be damaged if working above the
specified altitude for a long term. Shantui Highland Bulldozers are recommended if working
above the specified altitude.
General Hazard Information
Safety Devices
• Guarantee that all shields and covers are at the correct position and repair the damaged
components.
• Properly use safety devices such as safety levers and seat belts.
• Prohibit removing any safety device, which shall be under a favorable working state.
• Improper use of safety devices may lead to severe personal injuries or death.
Service and Maintenance Precautions

• During service and maintenance of the machine, please place the warning label such as
“Do Not Operate” or other similar labels at the Start switch or the handle. These warning
labels can be acquired from Shantui dealers.
• During maintenance and commissioning of the machine with obstacles around, please
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Safety
guarantee sufficient space for running and commissioning of the machine.
• Pay attention to concealed HV cables and wires. Direct contact between the machine and
such cables and wires will lead to severe personal injuries or death.
Fig 0.1 Signboard
Working and Personal Protective Articles

• Do not wear loose clothes, jewelries or have long hairs on the ground that they may get
caught by operating levers and movable components, leading to severe casualties.
• Do not wear the clothes with oil stains, to prevent fire.
• Wear helmets, safety goggles, masks, gloves and safety shoes during operation and
service of the machine. If metal fillings and other fine particles may be touched during
working, wear goggles, hard helmets and heavy gloves. Check surroundings for any
person while knocking the pin via a hammer or cleaning the filter element of the air filter
with compressed air.
Fig 0.2 Signboard
Please wear the hearing protection devices to protect the hearing of the driver.
Precautions for Using Compressed Air and Water

• Compressed air or water will bring debris and hot water splashes, direct contact with
2 Shantui Construction Machinery Co., Ltd.

Safety
which will lead to personal injuries.
• Please wear protection suit, safety shoes, safety goggles, masks and gloves while
cleaning the machine with compressed air or water.
• The maximum pressure of compressed air shall be lowered to below 205 kPa (30 psi) in
case of no load at the nozzle of compressed air. The maximum pressure of the cleaning
water must be lower than 275 kPa (40 psi).
Precautions for Internal Pressure of Hydraulic System

• Considering pressure inside the hydraulic system, releasing internal pressure of the
system will lead to sudden movement of the machine or its accessories.
• One must handle with care while connecting hydraulic pipelines or equipment, and the
HP oil will lead to sudden movement of the hose.
• Releasing of HP oil will lead to oil splashes, which will lead to severe personal injuries or
death if penetrating human bodies.
Preventive Measures against Liquid Penetration

• Pressure can still remain inside the hydraulic pipelines for a long time even after the
machine stops working. If the pressure in the hydraulic pipelines is not released properly,
hydraulic oil or joints will fly out rapidly.
• Before complete releasing of internal pressure of the hydraulic system, do not move or
remove any hydraulic element, or otherwise personal injuries will be triggered. Please
abide by every step about releasing internal pressure of the hydraulic system in this
Manual.
Fig 0.3 Signboard
• The hydraulic oil leaked will penetrate body tissues under the effect of pressure, leading
to severe personal injuries even death. A pinhole-sized leakage will trigger severe
personal injuries. Please use a plank or a hardboard while checking leakage in the
hydraulic pipelines. Please receive treatment immediately if being hit by pressure oil.
Prevention of Inhalation Hazards

The smoke emitted from the machine may lead to diseases or death. Please guarantee well
ventilation if working in an enclosed environment.
Inhalation of asbestos dust shall be avoided while handling with the parts and components
containing asbestos products, or otherwise it will do harm to your health. The components
containing asbestos mainly include brake pads, brake hoops, clutch discs and some bushings.
The asbestos of these components is generally contained in resin or is sealed. The above will
not do harm to human bodies generally unless the asbestos dust is generated. The followings
Safety
shall be followed while handling with the materials containing asbestos fiber:
• Do not clear dirts with compressed air.
• Do not polish the materials containing asbestos.
• Clear dirts with water to prevent spreading of dust.
• Use a vacuum cleaner equipped with a high-efficiency air filter.
• Operate against the wind as far as possible.
• Wear a gas mask if there are no methods to control dust.
• Abide by the provisions in relevant laws and those related to environment management
while handling with asbestos products.
• Do not approach the area with asbestos dust in the air if without any protective measure.
Fig 0.4 Signboard
Proposal Disposal of Wastes
Fig 0.5 Signboard
• Improper treatment of fuel, hydraulic oil, filters and batteries will do harm to the
environment. Pouring of waste oil into rivers or onto the ground is not allowed.
• Since the A/C refrigerant will pollute the atmosphere, only some designated service
centers are allowed to dispose and recycle refrigerant according to the systems stipulated
by some government authorities.
• Local relevant laws and provisions shall be followed while disposing engine oil, fuel,
refrigerant, solvent, filters, batteries and other toxic/harmful substances.
Preventive Measures against Crush or Cut Injuries

• Please guarantee the stability of equipment supports before maintenance and service

Safety
below the machine. Do not support equipment with a hydraulic cylinder since the
equipment may fall due to leakage in hydraulic cylinder pipelines.
• Please guarantee that the cab is correctly fixed and supported during maintenance and
service below the cab.
• Commissioning of the machine started is not allowed at any moment unless otherwise
required.
• Starting of the engine without operating the electromagnetic coil terminal of the starter is
not allowed, or otherwise unpredictable movement will be triggered.
Fig 0.6 Signboard
• Relative movement among linkage devices of equipment will lead to change in the gap.
Please do not stand at the gap of such devices.
• Do not approach rotating and moving components.
• Install the shields removed after maintenance and service.
• The debris generated will splash while knocking some object with force. If such
knocking is inevitable, please ensure no harm to the person around.
• Do not approach rotating fans and belts, to prevent injuries. The bodies or tools touching
fan blades may be cut or fly out, so never touch a rotating part.
Fig 0.7 Signboard
Preventive Measures against Scald
Engine
• Do not touch any part of a working engine.
• The engine cooling water, engine oil and hydraulic oil are in a HT and HP state when the
machine just stops working. At this moment, oil/water drainage by taking down the cover
or replacement of the oil filter may lead to severe scald. Therefore, the operation
Safety
specifications must be followed when it cools down.
• To prevent splashing of hot water and hot oil, the engine must be turned off before taking
down the cover. Besides, the water and oil shall cool down, and then slowly unscrew the
cover, to release the internal HP gas.
Fig 0.8 Signboard
• (Once the water and oil cools down, get close to the surface of the radiator and the
working oil tank to check the ambient temperature with hands. Do not touch the radiator
and the working oil tank.)
Coolant
• High-temperature coolant and steam will lead to severe scald. Do not operate it before
the cooling system cools down.
• The coolant level can only be checked after the cooling system cools down once the
engine stops working. Slowly unscrew the cover to release the internal HP gas, and then
take it down.
Fig 0.9 Signboard
• Since the rust inhibitor added in the coolant contains alkaline substances, direct contact
will lead to burn. Please protect your skin and eyes.
Battery
• Direct contact with the electrolyte, an acidic material, will lead to burn. Please protect your
skin and eyes. It is recommended that the operator should wear protective gloves and
goggles during maintenance of the battery.
Preventive Measures against Fire and Explosion
Precautions for Using Fuel Substances

Safety
• All fuels, most lubricants and some coolant mixtures are flammable. To lower the
possibility of fire or explosion, SHANTUI suggests the user to follow the following
provisions:
• The machine shall always be checked in an overall manner to figure out the hidden
danger in fire. Do not operate the machine in case of hidden danger in fire, and ask
Shantui dealers for help timely.
• Please do not start the machine in case of fuel leakage, and the fuel leaked shall be
cleared and the parts and components triggering such leakage shall be repaired first. The
fuel leaked onto the machine and electronic elements may trigger a fire if starting the
machine directly, leading to personal injuries even death.
• Remove garbage such as leaves, dead branches, waste paper and waste materials
accumulated at the engine and other hot parts of the machine to avoid fire caused by
thermal combustion.
• Clear the fuel, hydraulic oil, debris etc. on the surface of the machine, and do not start the
machine beside flame.
• Do not weld on the oil tank and pipelines containing fuel or other flammable liquids
directly or cut with flame. Empty and clean up the oil tank and pipelines, to guarantee that
they are free from flammables during welding or cutting, to avoid unnecessary danger.
• The dust arising from maintenance of non-metallic engine hoods and baffles is flammable
or explosive. Therefore, maintenance of these components must be made in a
well-ventilated area without open fire. Meanwhile, personal protective articles shall be
provided.
• Check all circuit lines and hoses for abrasion and damage, and replace the damaged
ones. The circuit lines and hoses must have sufficient pipe clamps for fixing and
supporting, and enhance tightness at connections. Damaged protecting covers and
insulating materials may lead to fuel leakage, and result in a fire.
Fire Protection of Oils

• Fuel, engine oil and antifreeze are flammable and explosive, which may trigger a fire
easily.
• Keep the liquid away from flame.
Fig 0.10 Signboard
• The engine must be turned off during refueling and smoking is prohibited.

Safety
Fig 0.11 Signboard
• Refueling or injection of lubricating oil shall be made at a well-ventilated place.
Fig 0.12 Signboard
• Reliably tighten the covers of the fuel tank and the working oil tank.
• Save fuel and engine oil at the designated place and entry of unauthorized personnel is
prohibited.
• Save the damaged rag with oil stains and the flammables into a special container.
Precautions for Using Battery and Battery Cables
Fig 0.13 Signboard
To lower the possibility of fire or explosion, SHANTUI suggests the user to follow the following
provisions:
• Do not operate the machine if the battery cables or relevant components are damaged,
and ask Shantui dealers for help timely.
• The provisions in safety steps shall be followed if starting the engine with firing cables.
Please refer to detailed instructions on this maintenance and service manual. Improper
cable connection will trigger explosion even personal injuries.
• Please do not charge non-rechargeable batteries since it may lead to explosion.
• The flammable hydrogen in the battery will lead to explosion, and the area above the
battery shall be kept away from open fire and spark. Do not smoke around the space in
which a battery is installed.
• Measure the voltage of the battery via a voltmeter.
Safety
• Check the cables in visible areas per day, and check cables and cable clamps for
damage and timely replace the damaged ones.
• Replace the damaged cables and relevant components. Clear the sediments which may
lead to insulation failure and damage and abrasion of electronic elements, to guarantee
that all elements can be properly set.
• Contact of the exposed conductors on battery cables with the grounding cables will lead
to short circuit of the battery. The current of the short-circuited battery will generate heat,
causing a hidden danger in fire.
• Maintenance of the machine will be in a unsafe state if the exposed conductors on the
grounding cables between the battery and the cut-off switch are not grounded. The
grounding cables shall be repaired or replaced first before maintenance.
Battery
• The sulfuric acid contained in the battery electrolyte will burn skin and clothes rapidly if
touched carelessly. In this case, you shall wash with water immediately. The acid liquor in
the battery will lead to blind if touching eyes. At this moment, you shall wash your eyes
with substantial clear water and see a doctor as soon as possible.
Fig 0.14 Signboard
• If you accidentally drink acid liquor, you shall immediately drink a lot of water or milk, eggs
or vegetable oil, and see a doctor immediately
• Wear safety glasses or goggles while handling with the battery.
• A battery will give rise to hydrogen, which is explosive and may be ignited by spark or
flame.
Fig 0.15 Signboard
• Before handling with the battery, stop the engine and turn the ignition switch to OFF.

Safety
• Check the positive and negative poles during removal or installation.
• Reliably tighten the battery cover.
• Reliably tighten the electrode, and a loose electrode may trigger spark, leading to
explosion.
Fig 0.16 Signboard
Wire
• Perform routine inspection for wires, and replace before operating the machine in case of
any of the followings:
• Abrasion or damage;
• Cracking;
• Fading;
• Cracked insulating layers;
• Other forms of damage.
Contact between wires and debris and the hose containing flammable oil shall be avoided as
much as possible. To prevent abrasion and damage of the wires, please guarantee that the
wires have sufficient supports and pipe clamps.
Hydraulic Pipelines
Do not curve or knock HP hoses, and do not install the curved and damaged hoses. The
hydraulic oil leaked will penetrate body tissues under the effect of pressure, leading to severe
personal injuries even death. Please use a plank or a hardboard while checking leakage in the
hydraulic pipelines to prevent liquid penetration. Please receive treatment immediately if
being hit by pressure oil. Replace the hose with one of the followings:
• Damage or fuel leakage at joints;
• Worn or cut outer rubber layers;
• Exposed metal wires;
• Swollen or inflated outer rubber layers;
• Twisted flexible parts of the hose;
• Joint dislocation;
• Other forms of damage.
To prevent abrasion and damage of the hose, please guarantee that the hose has sufficient

Safety
supports and pipe clamps. In case of hidden danger in fire, please do not operate the machine,
and timely replace the damaged hose. As for the information concerning maintenance and
replacement of parts and components, please consult Shantui dealers.
Fire Extinguishers and First-aid Kits (Self-supplied)

• A fire extinguisher shall be provided, and the use methods shall be clearly known. It shall
be placed at the designated position, and shall not be removed if without permission. It
shall be used immediately in case of fire, to avoid property loss.
• A first-aid kit shall be provided inside the glove compartment.
• Escape as per the following methods in case of fire: Turn off the Start switch, to stop the
machine. Leave the machine with handrails and pedals.
• The phone number of the contact to be called in case of emergency must be known.
Fig 0.17 Signboard
Precautions of Track
• For the track tension adjustment system, the track is maintained in a tensioning state
through the HP grease or hydraulic oil.
• The HP grease and hydraulic oil leaked from the relief valve can penetrate human bodies,
leading to personal injuries or death. Do not observe the relief valve directly to judge on
leakage of the HP grease and hydraulic oil. The track or the track tension adjusting
cylinder can be observed directly to judge on whether the track is loose.
• The connections between the track pin and the axle sleeve will become extremely hot
after motion, so long-term contact with these components may lead to scald.
• Preventive Measures against Thunder and Lightning
• The operator shall remain inside the cab in case of intense thunder and lightning during
working, to prevent lightning stroke.
• The operator shall keep away from the machine immediately and go to a safe area in
case of intense thunder and lightning around the machine.
HP Fuel Pipelines

Safety
5
4
3
6
Fig 0.18 Signboard
(1): Fuel common rail; (2)~(6): HP fuel pipelines

HP fuel pipelines include the pipelines between HP fuel pumps and fuel common rails as well
as those between fuel common rails and the engine cylinder. These fuel pipelines are different
from other fuel system pipelines. The HP fuel pipelines are full of HP fuel, so the pressure is
higher than that of other types of fuel system. The HP fuel pipelines are specially formed and
reinforced, so do not step onto, curve or knock them.
Do not check the HP fuel pipelines when the engine is started as much as possible. Wait for
around one minute after the engine stops running, and service and maintenance of the HP
fuel pipelines are only allowed after pressure release. There is no need to loosen the HP fuel
pipelines just to clear the air inside the fuel system. Please refer to the safety steps on this
maintenance and service manual while checking HP fuel pipelines when the engine is running,
to avoid personal injuries due to penetration of HP liquid. The HP fuel pipelines shall be
checked before starting the machine per day.
• Check HP fuel pipelines for damage, deformation, cracks, cuts, folds and dents.
• Do not operate the engine in case of fuel leakage. Do not tighten the connections
excessively just to prevent fuel leakage. Tighten connections as per the tightening torque
specified.
• If fuel leakage still occurs when the fuel pipelines are tightened as per the correct torque,
replace such pipelines.
• Guarantee that the pipe clamps of all fuel pipelines are installed at a correct position. Do
not start the engine when the pipe clamps are damaged, lost or loose.
• Do not lean other components against HP fuel pipelines.
• Replace the loose and dislocated HP fuel pipelines. Please refer to “Fuel
Pipelines-Installation” in this removal and installation manual.
Precautions for Refitting
Unauthorized Refitting
Any refitting not recognized by Shantui may lead to danger. Please negotiate with Shantui
Safety
before refitting, and Shantui refuses to shoulder any liability for the injuries and damage
caused by any unauthorized refitting.
Precautions for Optional Parts

Installation and use of optional parts will undoubtedly affect the stability and reliability of the
machine, with potential risks in bringing danger to the operator and those around the machine.
The instructions of optional parts and relevant contents in this Manual shall be read first
during installation and use of optional parts.
Do not use the optional parts not permitted by Shantui or your dealer since this will trigger
safety concerns, and affect normal running and service life of the machine.
Shantui refuses to shoulder any liability for the injuries, accidents and mechanical faults due
to use of unauthorized optional parts.
Safety Rules
Before Starting of Engine
On-site Safety
• Check surroundings for abnormalities which may trigger danger before starting.
• Check the landform and soil texture and select the optimal working methods, and do not
work in the area susceptible to falling objects.
• When working on the highway, special personnel shall be assigned to direct traffic and set
up roadblocks to ensure the safety of traffic and pedestrians.
• If working at the place with buried facilities such as water pipes, gas pipelines, HV cables
etc., contact relevant departments first, to determine the position of pipelines, so as to
prevent damage to them during construction.
Fig 0.19 Signboard
• If working in water or passing through a sandbank, check ground mass, water depth and
flow velocity first, and do not work in a water area beyond the allowable water depth.
Fire Protection
• Remove garbage such as leaves, dead branches, waste paper and waste materials
thermal combustion.

Safety
• Check the fuel, lubricating oil and the hydraulic system for leakage, and repair any leak.
Clear all surplus oil, fuel or other flammable liquids.
• Guarantee that a reliable fire extinguisher is provided.
• Do not operate the machine around open fire.
Getting on/off
• Do not jump up and down while getting on/off the machine. Getting on/off of the machine
running is prohibited, or otherwise accidental injuries will be triggered.
• Face the machine while getting on/off the machine, and always maintain three-point
contact (feet and a single hand, or hands and a single foot) among the human body,
handrails and the ladder, to guarantee safety.
Fig 0.20 Signboard
• Do not grasp any control lever while getting on/off the machine.
• Check handrails and ladders while getting on/off the machine. Wipe any oil stains or
sludge found on the handrail or ladders immediately. Timely repair the damaged parts,
and tighten the loose bolts.
Inside the cab

• Store tools or spare parts inside the tool kit in the machine other than inside the cab in a
scattered manner, to avoid damage or breaking of the control lever or the switch.
• Keep the cab floor, the control lever, the pedal and handrails free from oils, grease, snow
or other dirts.
• Check seat belts, buckles and parts for damage or abrasion, and replace the damaged
components. Seat belts shall not be made of flexible materials, and must be replaced
after 3-year use regardless of the appearance.
• Do not bring inflammable, explosive or dangerous goods into the cab.
• No smoking inside the cab.
Precautions for Rearview Mirror, Windows and Lamps

• Wipe all windows and lamps clean to guarantee a clear field of view.
• Use acetaldehyde other than formaldehyde cleaning fluid since it will irritate eyes.
• Adjust the rearview mirrors on both sides, so that you can see clearly on the driver’s seat.

Safety
Replace the cracked ones immediately.
• Guarantee that the roof lamp works normally.
Starting the Engine

• Do not start the machine if the signboard of “Do Not Operate” is pasted at the Start switch
or the control handle.
• The waste gas emitted from a diesel engine includes some substances harmful to health.
Please start and operate the engine in a well-ventilated area. If the engine is started in an
enclosed area, please guarantee sufficient space for air circulation. The waste gas can be
discharged to the outside via exhaust pipelines in an enclosed area.
• Check and guarantee that the control lever is reliably at Neutral before starting or
operating the machine.
• The engine can only be started after taking seat.
• When starting the engine, after the key is turned to the starting position, the starting time
shall not exceed 20s, and the interval between two starts shall not be less than 2 minutes.
When starting the engine with the starting cable, follow the safety procedures. Improper
cable connection will result in explosion and even personal injury.
• Wear safety glasses or goggles when starting with the starting cable.
• Avoid contact of both machines if starting with the battery of other machines.
• Guarantee reliable bonding if bonding ground wires to the frame of the machine to be
started.
• Bond positive cables first if using starting cables, and remove negative ground wires first.
• Avoid contact between tools and the positive and negative poles simultaneously, which
will trigger spark and may lead to explosion. This is extremely dangerous, so handle with
care.
• When the battery is connected in parallel, the positive pole is connected to the positive
pole, and the negative pole is connected to the negative pole.
Fig 0.21 Signboard
Before Operation
• Prohibit approaching of irrelevant personnel towards the machine and working areas.
• Clear the obstacles on the path of the machine and pay attention to wires, ditches etc.
• Prohibit entry of any person in the cab except for the driver or lingering at other positions
of the machine, to prevent falling from the machine and influence on the field of view of
Safety
the driver.
Fig 0.22 Signboard
• For the machine installed with a reversing alarm bell and a buzzer, guarantee that the
alarm can work normally.
• Firmly buckle the seat belt during driving.
Buckle
seat belt
Fig 0.23 Signboard
Operating the Machine
Working Temperature Range

The applicable temperature range of a standard model: -40°C(-40℉)~50°C (122℉). Other
temperature ranges may be applicable to the machine of a special structure. For details on
the applicable temperature ranges for machines of different construction, consult the Shantui
dealers.
Precautions for Driving

• The blade shall be 40~50 cm above the ground when driving on a flat road.
• Slow down, turn stably and avoid sudden turning if driving on an uneven pavement.
• Do not use mobile phones during driving.
• If the engine or control lever is abnormal during driving, stop the vehicle immediately for
maintenance.
• Use work lights and roof lamps if working at a dark place and install the lighting devices
on the construction site.
• Stop working in case of poor field of view on a foggy, snowy and rainy day, and go back to
work after the weather is better.

Safety
Keeping away from HV Cables

Do not drive or operate the machine around cables. There is a risk of electric shock, which
may cause serious personal injury and property damage. If this is inevitable, follow the
following requirements:
• Before construction, inform the local electric power department to take necessary
measures, and the construction can be carried out only after obtaining their permission.
• Those operating close to HV cables may suffer from electric shock, leading to severe fire
and personal injuries. Therefore, certain safety distance (see the right table) must be
maintained between the machine and cables. The safe operation rules specified by local
electric power department shall be clearly known before operating the machine.
• Wear rubber shoes and gloves to prevent any possible emergency. A rubber pad shall be
placed on the driver's seat. Make sure the exposed parts of the body will not touch the
undercarriage.
• When the machine is too close to the cable, a signaler shall be assigned to give a
warning.
• Prohibit approaching of any person when the machine works around HV cables.
• If approaching or contact with cables is inevitable for the machine, to prevent electric
shock, the operator must stay inside the cab, until it is ensured that the power has been
cut off. Prohibit approaching of any person towards the machine.
Tab 0. 1
Cable voltage Safety distance
100V-200V >2m
6600V >2m
22000V >3m
66000V >4m
154000V >5m
187000V >6m
275000V >7m
500000V > 11 m
Precautions for Reversing

Follow the following steps before operating the machine or work tools:
• Whistle to warn people around.
• Make sure that there is no other person around the machine, especially behind the
vehicle.
• Assign a person to check if necessary, especially during reversing.
• Assign a person to direct traffic in a dangerous area or in case of poor field of view.

Safety
• No one is allowed to enter the path of the machine.
• The provisions above must be followed even if the machine is installed with a reversing
alarm bell and rearview mirrors.
Precautions for Construction on Soft Ground

• Do not work too close to cliffs, and deep ditches. If these positions collapse, you and your
machine will have the risk of falling or turnover, leading to death. The bearing capacity of
soil at these positions will be lowered after wind and rain.
• The soil around gullies is relatively loose, and may collapse due to the weight and
vibration of your machine.
Fig 0.24 Signboard
Driving on Slopes
Fig 0.25 Signboard
• When driving on steep hills, embankments or slopes, the vehicle may roll over or slip.
• The blade shall be close to ground while driving on hills, embankments or slopes, and be
about 20~30 cm above the ground. The blade shall be lowered to ground rapidly in case
of emergency, to help stop the machine or to prevent rollover.
• Do not turn on a slope or cross a slope, and do this kind of operation at a flat place. Put
the heavy end of the machine on the upper slope side while working on a slope.
• Rocks and wetlands will seriously affect the traction and stability of the machine. Uneven
rock surfaces may cause sliding at one end of the machine.
• Do not cross grasslands, leaves or wet steel plates, which may lead to slip of the machine.
A very low speed shall be maintained while driving along slope edges.
• Slow down while driving downslope.
• Lower the blade immediately if the engine stalls on a slope and use the parking brake.
• Prohibit downsloping under the effect of dead load or inertia.

Safety
Parking of Machine
• The machine shall be parked on a flat and hard ground as far as possible. If parking on a
slope is inevitable, the head shall face the downslope direction. If the gradient is large,
the blade shall be slightly shoveled to prevent the body from sliding down if necessary.
• Ensure the safety control lever and the parking brake are locked. Otherwise, the unlocked
control lever may be triggered, causing sudden action of the work tool, and resulting in
serious injury or damage.
• When leaving the machine, be sure to lower the work tool completely to the ground,
ensure the safety control lever is locked, turn the Start switch to the "OFF" position, shut
down the engine, and lock all devices with the key. Keep your keys with you.
Fig 0.26 Signboard
• If the machine is idle for a long term, the cut-off switch of the battery shall be turned to
“OFF” with the rear shield being locked, to prevent battery discharge due to short circuit,
damage to some elements and artificial reasons.
Engine Stop
• The engine is allowed to run for 5 min at a low speed before stop, so that hot positions on
the engine can cool down gradually.
Transportation
Loading and Unloading

• Considering potential danger in landing and unloading of the bulldozer, handle with care.
The engine shall run at a low speed in this process.
• Load and unload on a hard flat ground, and maintain certain safety distance from road
edges.
• Pave the wheels and sloping plates of the trailer with a cushion block before loading and
unloading.
• Use the sloping plate with a sufficient strength, and guarantee that it has a length and a
width large enough, to form a safe slope.
• Guarantee that sloping plates are firmly placed and fixed, and both plates shall be on the
Safety
same plane.
• Guarantee that the surface of sloping plates is clean without oil stains, ice or other loose
matters. Clear the dirts on the dulldozer track.
• Do not operate the steering control lever on the sloping plate. If necessary, retract the
sloping plate and correct direction, and then climb.
• Pave the track with a wood block after loading and stop the machine reliably.
Shipment
• The provisions concerning length, width and height of cargoes in various countries and
regions as well as all applicable laws shall be followed during shipment of the bulldozer.
• The length, width and height of cargoes shall be considered while determining the
shipment route, to prevent off-limit.
Dragging
• The ropes can only be used for dragging when the machine is started, or otherwise
hydraulic components of the machine will be damaged.
• The ropes of sufficient strength must be used while dragging this vehicle with other
machines.
• Do not drag the machine on a slope.
• Do not use curved or twisted pulling ropes.
• Do not cross or get close to the pulling rope.
• Do not let any person stand between the tractor and the pulled vehicle while bonding the
pulled machine.
• Make the axes of the tractor and the pulled part locate on the same axis, to guarantee
that it is at a correct position.
• The machine not started shall be moved by lifting.
Before Service
Engine Stop before Inspection and Service

• Park the machine on a hard and flat ground first before inspection and service, with the
engine being turned off and the key being pulled out, or otherwise death may occur due to
engine start or operation of the control lever by someone unknown during service or
lubrication.
• If service when the engine is running is required, such as cleaning the inside of the
radiator, the safety control lever must be locked by two persons, one of which shall sit at
the driver’s seat, so that the engine can be turned off instantly in need. However, the
operator must handle with care, to avoid injuries to the service personnel due to
mistakenly touch of the control lever.
• The service personnel must take special care, to avoid contact with movable components
or being caught by such components.

Safety
Suitable Tools
• Use high-quality reliable tools only. Use of damaged, low-quality, defective or temporary
tools may bring injuries to you.
Fig 0.27 Signboard
Regular Replacement of Critical Safety Components

• Regularly replace the following components easy to aging.
Fuel system: hoses.
Hydraulic system: output hose of pumps and the branch pipes in front of and behind oil
pumps.
• Regularly replace the elements above regardless of the appearance since they may age
with the time passing by.
• Replace those with any defect identified even before the period of replacement.
During Service
Personnel
Only the authorized personnel can be engaged in service and maintenance. Additional safety
measures shall be taken during grinding, welding and hammering.
Fittings
The parts removed from the machine shall be placed at a safe area, to avoid severe personal
injuries due to falling.
Fig 0.28 Signboard
Working below the Machine

• Before service of the machine or maintenance below it, the work tools shall be lowered to
ground or the lowest position.
• Prohibit working below a machine not reliably supported.

Safety
Fig 0.29 Signboard
Maintaining Machine Clean

• The machine shall be kept clean and tidy at any moment. The oils and grease spilled, the
tools scattered or the parts damaged may lead to personal injuries due to falling.
• Do not clean up the sensor, plugs or inside the cab with water or steam. Entry of water in
the electrical system may get the machine stuck or lead to sudden movement of it.
Fig 0.30 Signboard
Principles of Refueling and Engine Oil Injection

• Clear the fuel and engine oil leaked timely, to avoid slip.
• Tighten the oil filler cover.
• Do not wash components with fuel.
• Refuel at a well-ventilated place.
The model and type of the oil and water used for the locomotive depend on working
environment and temperature. Please refer to this “Operation and Maintenance Manual”.
• The antifreeze shall not be made with methyl alcohol or ethyl alcohol, to avoid engine
faults. As a flammable, the antifreeze shall be isolated from fire sources.
• Soft water or coolant shall serve as the cooling water other than tap water or sewage.
The cooling water shall not be added with any leak preventive.
• Various filters must be cleaned up or replaced as scheduled.
• Cooling water, fuel, lubricating oil and working oil shall always be checked and be
replenished as required, to guarantee normal use of the machine.
Use of Lighting
Explosion-proof lamps must be used while checking fuel, engine oil, coolant or battery

Safety
electrolyte, or otherwise explosion may occur.
Fig 0.31 Signboard
Precautions for Service of Battery

The negative pole of the battery shall be disconnected to cut off power supply while repairing
the electrical system or during electrowelding.
Fig 0.32 Signboard
Handle High Pressure Hoses

• Do not curve or knock HP hoses with hard objects, and do not use curved or cracked
hoses/rigid tubes, or otherwise there may be risks in burst.
• Repair loose or cracked oil pipes, and fire may be triggered in case of oil leakage.

Safety

Foreword
Foreword
Overview
This Manual is prepared to help maintenance personnel better understand this product, show
them correct methods of repair and judgment, so as to improve maintenance quality. The
contents in this Manual must be clearly known, to realize the optimal effect.
This Manual mainly includes the technical materials required to complete operations in the
maintenance workshop. To facilitate better understanding, this Manual is classified into the
followings based on components: engine auxiliary devices, undercarriage system,
transmission and control systems, work tools and control system, frame and balance beam
and electrical system. Each part is elaborated respectively as per structure and functions, test
and adjustment, disassembling and assembling, maintenance standards.
Structure and Function

The structure and functions of each component is elaborated. It can not only help understand
the component structure, but also can serve as the references of troubleshooting.
Moreover, the diagram of hydraulic oil pipelines, circuit diagram and maintenance and service
standards are covered.
Test and Adjustment

The inspection to be carried out before and after repair is elaborated as well as the
adjustment to be made after inspection and repair.
The fault diagnosis table in which “Problems” and “Cause” are involved in is also included.
Please notice the followings while judging based on the standard value table of tests,
adjustment or fault diagnosis:
• The values given in this table are those of the machine just shipped from the
manufacturer, and are for reference only. Such values are used as the reference values
judging the abrasion degree of the used machine and of repair.
• The reference value for fault judgment given in this table is the estimated value of the
machine shipped based on test results, and it can be used as references with the repair
conditions and use history of machines, to facilitate judgment in case of faults.
• These standard parameters cannot serve as the standards for handling claim.
Disassembling and Assembling

The procedures and precautions for removing, installing, disassembling and assembling each
component are mainly elaborated.
Maintenance and Service Standards

The criteria for checking disassembled components are given for some components.
Fault Diagnosis
Common troubleshooting and fault eliminating methods are given.
How to Read this Installation and Maintenance Manual

Foreword
Symbol
To improve the practicability of this Manual, important safety and quality parts are marked with
the following symbols:
Tab 0.2 Symbol Description
Symbol Item Notes
Safety
Caution
Weight
Tightening torque
Applying
Oil, water
Drainage
Lifting Instructions
Lifting
Heavy parts (more than 25 kg) must be lifted by a crane.
If parts and components cannot be lifted from the machine stably via a crane, the followings
shall be checked:
• Check all fastening bolts fixing this component onto relevant components to see whether
they are removed;
• Check for parts interfering with the parts to be removed.
Steel Wire Rope

• Use proper steel wire ropes as per the weight of lifting components by reference to the
table below:
Tab 0.3 Selection of Steel Wire Ropes
Steel wire ropes (standard Z-shaped or S-shaped ungalvanized twisted steel wire ropes)
Diameter Allowable load
mm kN t
10 9.8 1.0
11.5 13.7 1.4

Foreword
12.5 15.7 1.6
14 21.6 2.2
16 27.5 2.8
18 35.3 3.6
20 43.1 4.4
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0
The allowable load shall be calculated as per 1/6 or 1/7 of breaking strength of the steel wire
ropes used.
• Hang steel wire ropes in the middle of the hook.
Steel wire ropes may fall from the hook during lifting if the steel wire ropes are too close to the
hook edge, causing severe accidents. The maximum strength of the hook lies in the middle.
100% 88% 79% 71% 41%
Fig 0.33 Strength at Different Locations of Hook
1) Do not lift heavy objects with a single steel wire rope, and two or more steel wire ropes
should be wrapped on the heavy objects in a symmetric manner.
The lifted objects may move during lifting if heavy objects are lifted with a single rope,
loosening steel wire ropes, or leading to slip from the original wrapping position on the load,
causing accidents.
2) Do not lift heavy objects when a large hanging angle is formed between the steel wire
rope and the hook.
If heavy objects are lifted with two or above steel wire ropes, the bearing capacity of each
rope increases with the increase in hanging angle. The table below shows the variation of
allowable load at different angles when heavy objects are lifted with two steel wire ropes (the
allowable vertical lifting weight of each piece is 9.8 kN {1,000 kg}).
If two steel wire ropes are used for vertical lifting, the total lifting weight is 19.6 kN {2,000 kg}.
Such figure becomes 9.8 kN {1,000 kg} if an angle of 120° is formed for two steel wire ropes.
On the other hand, if 19.6 kN {2,000 kg} load is lifted at 150°, two steel wire ropes will bear a
force up to 39.2 kN {4,000 kg}.

Foreword
Steel wire ropes may fall from the hook during lifting if the steel wire ropes are too close to the
hook edge, causing severe accidents. The maximum strength of the hook lies in the middle.
Fig 0.34 Relationship Between Different Lifting Angles (°) and Load
Standard Tightening Torque

Table of Standard Tightening Torque (while using a torque wrench)
★ Metric nuts and bolts without special instructions shall be tightened to the torque given in
the table below.
Tab 0.4 Tightening Torque of Common Metric Nuts (Bolts)
Wrench Opening
Bolt Diameter Bolt (grade-10.9)
Width
mm mm Nm kgm
13.2±1.4 1.35±0.15
6 10
31 ±3 3.2 ±0.3
8 13
66 ±7 6.7 ±0.7
10 17
113 ±10 11.5 ±1
12 14 19 22
177 ±19 18 ±2
279±30 28.5±3
16 24
382 ±39 39 ±4
18 27
549 ±59 56 ±6
20 30
745 ±83 76 ±8.5
22 24 32 36
927 ±103 94.5 ±10.5
1320±140 135±15
27 41
1720 ±190 175 ±20
30 46
2210 ±240 225 ±25
33 50
2750 ±290 280 ±30
36 39 55 60
3290 ±340 335 ±35
Conversion Table
Use Methods
The Conversion Table in this Chapter may be used for simple numerical conversion. See the
Foreword
example below for detailed use methods of this table:
Example: Use this conversion table to convert millimeters into inches.
1. Converting 55 mm into inches
(1) Find out 50 in the left column and take this point as A
○, and draw a traverse line from A
○.
(2) Find out 5 in the top row and take this point as B
○, and draw a vertical line from B
○.
(3) Take the intersection point of both lines as C
○. C
○ is the value converting millimeters into
inches. Therefore, 55 mm = 2.165 in.
2. Converting 550 mm into inches
(1) There is no number 550 in this table, so it is divided by 10 (one decimal point shifted to
the left) to obtain 55 mm.
(2) Convert 55 mm into 2.165 in. as per the procedures above.
(3) Because the original value (550 mm) has been divided by 10, the 2.165 in. shall be
multiplied by 10 (one decimal point shifted to the right) to restore the original value. The
result is 550 mm = 21.65 in.
Tab 0.5 Conversion Table (1 mm=0.03937 in)
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Tab 0.6 Conversion Table (1 kg = 2.2046 lb)

0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 52.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.43 114.64 116.84 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Tab 0.7 Conversion Table (1 L = 0.2642 U.S.Gal)

Foreword
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.868 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.794 15.058 15.322 15.586
60 15.850 16.114 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Tab 0. 8 Conversion Table (1 L = 0.21997 U.K.Gal)

0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.739 3.959 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.218 11.438 11.658 11.878 12.098 12.318 12.538 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
Tab 0. 9 Conversion Table (1 kgm = 7.233 ft.lb)

0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.3 390.6 397.8 405.0 412.3 419.5 426.7
60 434.0 441.2 448.4 455.7 462.9 470.1 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.6 1048.8 1056.0 1063.3 1070.5 1077.7

Foreword
150 1085.0 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1229.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.2 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
Tab 0.10 kg/cm2–lb/in2(1kg/cm2 = 14.2233 lb/in2)

0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.3 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.0 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2133 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2390 2404
170 2418 2432 2446 2461 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2774 2788 2802 2816 2830
200 2845 2859 2873 2887 2902 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3342 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
Temperature Conversion Table

Fahrenheit-Celsius conversion: A simple way to convert a Fahrenheit number into a Celsius
number or vice versa is to look up the middle column or the boldface numbers in the table
below.
These figures are either in degrees Fahrenheit or Celsius.
If conversion from Fahrenheit to Celsius is required, the numbers in the middle column of the
following table can be considered as Fahrenheit degree, and corresponding Celsius degree
Foreword
can be read from the left column.
If conversion from Celsius to Fahrenheit is required, the numbers in the middle column of the
following table can be considered as Celsius degree, and corresponding Fahrenheit degree
can be read from the right column.
Tab 0.11 Conversion Table (°C to °F)
°C °F °C °F °C °F °C °F
-40.0 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8

-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0.0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.8 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 5 6.7 7.2 44 45 111.2 26.1 2 79 80 174.2 76.7 7 170 17 338.0
-12.2 10 0.0 113.0 6.7 176.0 9.4 5 347.0
Unit
In this Manual, measuring units are expressed in SI.
The conventional gravity system unit is expressed in { } as references.

Foreword
For example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}

Foreword

Chapter 1 Overview
Chapter 1 Overview
1.1 General Information and Technical Specifications of Machines
1.1.1 General Information of Complete Machine
Fig 1.1 Diagram of Main Frame Dimensions
Tab 1.1 Table of Main Frame Dimensions

S/N Model Value
1 Operating mass 23820 kg
2 Length of complete machine (including a ripper) 7428 mm
3 Grounding length 3050mm
4 Track center distance 2000mm
5 Height of complete machine 3310 mm
6 Width of complete machine (with a blade) 3840mm
7 Minimum ground clearance 450mm
1.1.2 Engine
Tab 1.2 Engine Information
Engine Model WD12
In-line, direct-injection, water-cooled, four-stroke,
Type
turbocharged & non-intercooled
Overall length (mm) 1404.6
Dimensions
Overall width (mm) 900

Chapter 1 Overview
Overall height (mm) 1844.5
Rated speed (rpm) 2100

Rated power (kW) 185
Maximum torque (N.m/rpm) 1200/1300-1400
Idle speed (rpm) 750
Minimum fuel consumption (g/kwh) 190.6
Charging generator 28V/80A
Starting mode Starting motor 24V 6kW
Lubricating oil capacity (L) 24L
Capacity of coolant (L) 24L
1.1.3 Drive System

Tab 1.3 Information of Transmission Parts
Transfer case One-stage spur transmission, elastic rubber column shock absorber
Travel pump Linde 135-displacement travel pump*2 (series)
Travel motor Linde 210-displacement travel motor *2 (parallel)
Final drive Three-stage deceleration, one-stage spur gear + two-stage planetary deceleration
1.1.4 Undercarriage System

Tab 1.4 Information of Undercarriage Parts
Type Pivoted connection
Number of carrier 2 per side

rollers
Number of track 7 per side (5 pieces on one side and 2 pieces on both sides)
rollers
Track type Single-tooth shoes, lubricating track
Track shoe width 560mm 610mm 660mm
Track tooth height 72mm
Chain track pitch 216mm
1.1.5 Work Tools

Tab 1.5 Dimensions of Blade
Blade structure Semi-U blade
Blade width (mm) 3496
Blade height (mm) 1512
Maximum lifting height (mm) 1247
Maximum digging depth (mm) 540

Chapter 1 Overview
Blade capacity (m³) 6.9
Tab 1.6 Dimensions of Ripper

Ripper structure Three-shank ripper
Lifting height (mm) 567
Lowering height (mm) 655
Weight (kg) 2646
Ripper width (mm) 1882
Ripper length (mm) 2246

Chapter 1 Overview

Chapter 2 Power System

2.1 Structure and Function Description of Power Components
2.1.1 Installation of Engine Accessories and Engine
The engine is arranged in front of the main frame, and its structure mainly includes: (1) engine
body, (2) shock absorber, (3) oil filter, (4) muffler, (5) exhaust pipes, (6) fuel filter, (7) air filter
and (8) pre-filter.
Fig. 2.1 Engine Mounting Base
2.1.2 Engine Cooling System

Tab2.1 Structure of Cooling System
S/N Description S/N Description S/N Description S/N Description
Auxiliary Vapor exhaust
1 Water radiator 2 Oil cooler 3 4
water tank pipe of radiator
Vapor exhaust Engine coolant Water Engine coolant
5 6 7 8
pipe of engine outlet pipe injection pipe inlet pipe
Fan protection
9 Fan belt 10 Fan 11 Fun pulley 12
frame
Basic principle of engine cooling system

Fig. 2.2 Structure of Cooling System
● The engine cooling system mainly includes a water radiator, an oil radiator, a fan etc.;
● The water radiator cools engine coolant, while the oil radiator cools the hydraulic oil;
2.2 Removal and Installation of Power Components

2.2.1 Engine
1) Disconnect the negative switch.
2) Discharge the coolant.
3) Remove the fixing pipe clamp of the connecting hose below the transitional air duct 4, to
disconnect the hose. Remove fixing bolts 1 and 4 of the transitional air duct, and remove the
pre-filter 3 and the transitional air duct 4 together. Remove the fixing bolt 2 of the exhaust tail
pipes and remove the assemblies of such pipes.

3) Remove the side shield 6. See the removal process of the hood for details.
5) Separate the pipe clamps at both ends of hoses 7, 8 and 9 and remove the hoses.
Remove the bolts 10 and 4 and remove the expansion tank 11.
6) Remove the upper shield. See the removal process of the hood for details.
7) Remove the engine coolant inlet and outlet pipes 12 and 14, loosen the fan belt tensioner
pulley, and remove the fan belt 13.

8) Remove the A/C and heater pipelines. See the removal process of the A/C for details.
9) Remove relevant engine harnesses and connectors. See the removal process of the
electrical part for details.
10) Remove the throttle lever 15.
11) Close the fuel inlet and return valves of the fuel system and separate the fuel inlet and
return pipelines.
12) Remove the gantry 18. See the removal process of the hood for details.
13) Remove the cab.

See the removal process of the cab for details.
14) Remove the floor flange plate beam 19.

15) Remove the hydraulic system pipelines.

See the removal process of the hydraulic part for details.
16) Remove the front mounting bolt 20 and the rear mounting bolt 21.
17) Remove the engine assembly.

Remove the engine 22, the transfer case 23 and the hydraulic pump 24 together.
The total weight is about 1,600 kg.
Note: While removing the engine, check whether all pipelines and wires are disconnected.
Installation:
● Install in the reverse order of removal.
Do not distort or affect each other while installing hoses.
Avoid entry of dirts, dust or water in the host while installing A/C hose.
● Refill coolant.
Fill the coolant to the specified level, start the engine to circulate the coolant in the system,
and then check the coolant again.
● Fill the A/C refrigerant.
Fill the A/C refrigerant into the A/C pipelines with a tool.
2.2.2 Removal and Installation of Cooling System

(1) Empty the coolant of the radiator and the hydraulic oil in the hydraulic oil cooler.
(2) Remove the radiator upper shield 1 and the side shield 2.
See the removal process of the engine hood for details.
(3) Disconnect the water radiator pipelines 3 and 8, and the expansion tank pipelines 4, 5
and 7 respectively,
Remove the expansion tank 6.
(4) Disconnect hydraulic oil radiator pipelines 9 and 10.

(5) Install the lifting lugs on both sides (M12 threaded holes) of the water radiator at the
installation point 11 (left and right) and lift them properly.
(6) Remove the mounting bolts 13 and 4 of the upper bracket of the water radiator, and
disconnect the upper mounting bracket.
(7) Remove the bolts 15 and 2 and remove the plate 16.
(8) Remove the fixing bolt 17 of the shock absorber at the bottom of the water radiator.

(9) Lift and remove the water radiator, the weight of which is 85 kg.
(10) Remove the 55 kg oil radiator in the same way as the water radiator.
Installation: Install in the reverse order of removal.
Refill the coolant: Fill the coolant to the specified level, start the engine to circulate the coolant
in the system, and then check the coolant again after parking.
2.2.3 Removal and Installation of Fuel System

(1) Remove the rear bolts 1 and 8 of the bulldozer and remove the rear cover 2.
(2) Remove the floor flange plate side shield. See the removal process of the floor flange
plate for details.
(3) Empty the hydraulic oil in the working oil tank and remove relevant pipelines. See the
removal process of the hydraulic system for details.
(4) Operate the rear valve 3 of the bulldozer to empty the fuel in the fuel tank, remove the
rear hose clamp of the valve, and release the hose.

(5) Close the fuel tank valve 4, remove the fuel inlet pipe joint in front of the fuel tank and
separate the fuel inlet pipelines.
(6) Close the valve 5 and separate the fuel return pipelines.
(7) Remove the bolt 6 and the cover plate 7.
(8) Disconnect the oil level gauge wire connector 8.

(9) Remove the mounting bolt 9 at the bottom of the fuel tank (6 on the left and right).
(10) Lift the fuel tank assembly, the weight of which is about 280 Kg (no-load) and 680 Kg
(full-load).
Installation: Install in the reverse order of removal.

Chapter 3 Undercarriage System

3.1 Structure and Function
3.1.1 Trolley Assembly
Fig 3.1 Structure of Trolley Assembly
1-Front idler 2-tensioning device 3-carrier roller 4-track roller guard 5-trolley frame 6-single-side track
roller 7-double-side track roller 8-sprocket 9-track
Tab 3. 1 Qty. and Distribution of Track Rollers

Flange form and
Item Qty.
arrangement
Track roller 7 S,D,S,S,S,D,S
3.1.2 Tensioning Device
Fig 3.2 Tensioning Device
1-seat 2-piston rod 3-lifting lug 4-base 5-tensioning spring 6-cylinder block 7-spring box 8-big nut
9-grease cup

Overview
The tensioning spring adjusts the tension of the track shoe by moving the piston rod ②
forward or backward. Releasing or adding grease via the grease cup ⑨can adjust the
pre-tightening force of the tensioning spring ⑤, which can also absorb the impact force
applied to the front idler.
Tab 3.2 Maintenance Standards of Tensioning Device
Unit: mm
Inspection
S/N Standard Measures
Items
Item Repair limits
Track frame Bending 7 (3,000 mm long)
1 Correct
deformation Torsion 3 (3,000 mm long)
Opening at front idler 5
Standard dimensions Repair limits
Installation Installation Free Installation
Tensioning Free length
2 length load length load Replace
spring
226KN 208.9KN
787 651 855
(23073kg) (21300kg)
Adjust the Tolerance
Standard Standard Clearance
clearance
dimensions Axle Hole clearance limit Replace the
3 between
bushing
cylinder and -0 ＋0.03 0-
80 1.0
bushing -0.45 0 0.48
3.1.3 Front Idler
Fig 3.3 Structure of Front Idler

Tab 3.3 Inspection and Maintenance Standards of Front Idler
Unit: mm
S/N Inspection Items Standard Measures
Outer diameter of bulged Standard dimensions Repair limits

1
part φ686 ―
Outer diameter of roller
2 φ650 φ625
path surface Repair or
3 Width of bulged part 105 115 replace
Width of roller path

4 49.5 44.5
surface
5 Total width 204 ----
Standard Tolerance Standard Clearance

Replace
Clearance between the dimensions Axle Hole clearance limit
6 the
shaft and the bushing
-0.250 +0.188 0.226- bushing
68 1.5
-0.350 -0.024 0.538
Standard clearance Clearance limit
7 Axial play
3 ------
Clearance between the
Adjust the
8 side guide plate and the 0.5-1
gaskets
bracket
Clearance between the
Adjust the
9 lower guide plate and the 1
gaskets
bracket
Clearance between the Conduct
10 upper wearing plate and 2.0 surfacing
the bracket or replace
Standard gasket
11 4.0
thickness
Standard gasket
12 8.0 Adjust
thickness
Standard gasket
13 6.0
thickness

3.1.4 Track Roller
Fig 3.4 Structure of Track Roller
Tab 3.4 Inspection and Maintenance Standards of Track Roller

Unit: mm
Diameter of roller Standard dimensions Repair limits

1
surface φ222 φ182
Outer diameter of
2 roller edge (outer φ257 ---
side) Repair or
Outer diameter of replace
roller edge (inner
3 φ249 ---
side, double-side
track roller)
4 Width of roller 55.6 ---

surface (single)
Width of roller
5 51.6 ---
surface (double)
Width of roller edge
6 21 ---
(single)
(outer side,
7 21 ---
double-side track
roller)
(inner side,
8 21 ---
double-side track
roller)
9 Total width 251.2 ---
Standard Tolerance
Clearance between Standard clearance
dimensions Axle Hole Replace the
10 the shaft and the
bushing
bushing -0.210 +0.13 0.270-
φ70
-0.260 +0.06 0.390
Standard Tolerance
Interference fit Standard interference
dimensions Axle Hole Replace the
11 between the bushing
bushing
and the track roller +0.094 0.013-
φ115 ±0.027
+0.040 0.121
Axial clearance of Standard clearance

12 Replace
shaft 0.200-0.425
13 Shoulder width 20 -----
3.1.5 Carrier Roller

6
5 2 1
3 4
Fig 3.5 Carrier Roller

Tab 3. 5 Inspection and Maintenance Standards of Carrier Roller
Unit: mm

Outer diameter of Standard dimensions Repair limits
1 roller edge (outer
side) φ217 -
Outer diameter of
2 roller edge (inner φ185 φ162 Repair or
side) replace
Width of roller
3 57 -
path surface
Width of roller
4 19 -
edge
Standard Tolerance
Clearance Standard clearance
dimensions Axle Hole
5 between the shaft
and the bracket 0 +0.30
φ58 0-0.50
-0.200 0.
Replace
Standard Tolerance Standard
Interference
dimensions Axle Hole interference
6 between the shaft
and the ring +0.035 -0.1
φ68 0.065-0.2
0 -0.2
Oil filling level 260ml(SAE85W-140)

3.1.6 Track
Fig 3.6 Structure of Track
Tab 3.6 Inspection and Maintenance Standards of Track

Unit: mm

1 Track link spacing
216 219.3
Repair or
Track shoe height replace
2 72 25
(single-gear)
3 Chain belt height 125 112
Bushing outer 67 (under heavy load) Steer or
4 71
diameter 65 (under light load) replace
Standard Tolerance
Interference between Standard interference
5 the bushing and the
Steer or
link +0.4 +0.12
71 0.23-0.4 replace
+0.35 0
Interference between +0.25 +0.1
6 47.32 0.12-0.25
the master pin and the +0.22 0

link
Interference between
+0.4 +0.1
7 the common pin and 47.32 0.25-0.4
+0.35 0
the link
8 Bushing extension 9
Adjust
9 Pin extension 3
Initial torque Fastening angle

Tightening torque of Tighten or
10 680±39Nm
track shoe bolts 120±10° replace
(69.4±4kgm)
3.2 Disassembling and Assembling

3.2.1 Test and Adjustment of Track Tension
Test
1. Drive the machine forward and stop it on a flat ground.
★ Stop the machine without using the brake.
2. Place the straight steel plate ① between the front idler and the front carrier roller, and
measure the clearance a between the bottom of the steel plate and the track shoe
grouser.
● Standard clearance a: 15-20 mm
Adjust
★ If the tension of the track shoe is abnormal, adjust as per the following requirements.
1. Remove the cover ②.

2
2. If the tension is too high:

Loosen the plug ③and drain some grease.
The plug may fly out under the HP effect of the internal grease, so it shall not be loosened
for above 1 circle.
3. If the tension is too small:
Pump grease in via the grease cup ④.
★ If the track has a poor tension, move the machine backward or forward slowly.
★ Repeat the above steps to check the tension again after adjustment.
3.2.2 Removal and Installation of Trolley Assembly

Removal
1. Remove the track assembly.
2. Jack up the undercarriage via a jack or a ripper, and then place the support ① below the
main frame, to make the rear part of the undercarriage above ground.
3. Place the hydraulic jack ② in the center of the balance beam, and lift the front part of the
undercarriage.
4. Hang the trolley assembly.

5. Remove the cover ①.

6. Remove the cover ②.
1
7. Use a lifting eye bolt ④to pull out the pin ③.

★ If the center of the balance beam hole and the trolley frame hole is not aligned, it is
difficult to remove the pin. Therefore, adjust the height of the trolley frame before removal.

8. Remove mounting bolts and the covers ⑤⑦from the trolley frame.
9. Remove the covers ⑨⑧.

10. Remove the seal and the gasket together. [*1]
11. Remove the trolley assembly.
★ The oil will flow out from the pivot box and is therefore received in a container.
Trolley assembly: 4,663 kg

Installation
★ Before installing the pin, adjust the height of the trolley frame to align the center of the
balance beam hole and the trolley frame hole.
★ Place the pin with the grease hole facing the outside of the machine.

★ Apply bushing sealant (LG-6) after removing grease from the sealed press fitting surface.
★ Do not install the seal when it is displaced in the twisted direction.
★ Do not install the trolley frame when the seal is displaced in the twisted direction.
● Refueling (Pivot Box)
Fill the oil to the specified level via the oil filler.
3.2.3 Removal and Installation of Front Idler Assembly

Removal
1. Remove the baffle ①and then the grease cup ②.

There is negative pressure inside the tensioning spring cylinder, so the fork arm will be
pulled back to inside the cylinder if the lubricator is not removed when the fork arm is
disconnected from the bracket of front idlers.
Do not stand in front of or behind the tensioning assembly to avoid danger.
2. Unscrew the bolts of the left and right side plate ③.

★ Remove the gaskets ⑧⑨, and check the quantity and thickness and save them at a safe
place.
3. Lift the front idler assembly and pull it out and then remove the mounting bolts of
the bracket ⑤ and the base ⑥.
4. Lift the front idler assembly ⑦.
Front idler: 308 kg
Installation
1. Install in the reverse order of removal.

★ The standard gasket thickness is shown in the figure below:
★ Adjust the gasket thickness so that the clearance A between the trolley frame and the
guide plate is 0.5-1.0 mm.
Threads of mounting bolts of guide plates: thread fastening agent (LS3)
3.2.4 Removal and Installation of Tensioning Assembly

Removal
1. Lift the front idler and the tensioning assembly ①
Front idler and tensioning assembly: 590 kg
2. Remove the bolt ②, and separate the front idler ③ from the tensioning device④.
Front idler: 308 kg
Tensioning assembly: 282 kg
Installation
Install in the reverse order of removal.
Do not disassemble the tension spring to avoid danger.
3.2.5 Removal and Installation of Track Roller Assembly
1. Remove the mounting bolt of the track roller guard ①.
2. Remove the mounting bolt ② of the track roller.

Start the engine and operate the bulldozer blade. The ripper jacks up the bulldozer to lift the
undercarriage off the ground. Place the jack or support on the ground to prop up the bulldozer.

After jacking the machine, install a cushion block on the top of the track shoe and lock the
work tool control lever and the braking lock lever.
3. Remove the track roller assembly ③. ※2

Track roller assembly: (S) 71.6 kg; (D) 79.5 kg
Fig. 3.7 Removal of Track Roller Assembly
Installation

Thread of the mounting bolt of the track roller guard:
Thread fastening agent (LS3)
Thread of the mounting bolt of the track roller guard:
Thread fastening agent (LS3)
Mounting bolt of the track roller:
662-828 Nm
The screw plug of the track roller is on the outside of the undercarriage during the installation.
3.2.7 Removal and Installation of Carrier Roller Assembly
1. Open the track frame cover, and loosen the grease cup ① to release the track
shoe tension.

Do not loosen the grease cup ① more than one turn. If the track shoe tension is not
released when the grease cup is loosened, move the machine back and forth.
2. Press the jack to lift the track shoe.
3. Remove bolt ②.
Pass the wire rope through the hole of the track link and fix it on the support bypassing the
carrier roller ③, then gradually loosen the wire rope and pull out the carrier roller ③ from the
bracket ④.
Carrier roller: 39 kg
Fig. 3.8 Removal of Carrier Roller
Installation

When installing the carrier roller on the bracket, leave a certain clearance as shown in the
figure.
Mounting bolt of the bracket: thread fastening agent (LS3)
Adjust the tension of the track assembly.
3.2.9 Removal and Installation of Track Assembly
It is quite dangerous to remove the track assembly in some cases.

To avoid danger, perform the following inspections before removing the track assembly.
Pre-inspections:
1. Loosen the grease cup at the tensioner cylinder, remove the grease, move the machine
forward and backward for a small distance, and check whether the track tension is
released. If the track tension is not released and the track assembly is still under tension,
there may be a fault inside the track frame (The tensioning spring cylinder is damaged or
the nut at the shaft end falls off).
Do not loosen the grease cup more than one turn.

2. Check if there is interference between the track frame and the guide plate as shown in the
figure. If there is any interference (when the elongation process of the track link spacing
reaches the limit), it is impossible to know any fault occurring inside the track frame.
※ Removal of Track Assembly (Normal)

The position of the master link.
Set the position of the master link, stop the machine, make the master link in the front and
about 500 mm from the ground, and place a cushion block (height: 300 mm) under the track.
1. Loosen the track.
Do not loosen the grease cup ① more than one turn.

If the track shoe tension is not released when the grease cup is loosened, move the machine
back and forth.
Remove track shoe ② of the master link.
Disconnect the master link ③. ※2
2. Lift the end of the master link, then move the machine slowly in the opposite direction and
spread the track assembly ④.
The length of the unfolding track: about 8.7m
Fig. 3.10 Removal of Track Assembly
※ Removal of Track Assembly (Fault in the Track Frame)

★ If a fault is found in the "inspection before removal of track assembly", follow the steps
below.
Remove the work tools assembly.
1. Loosen the grease cup ① and release the tension of the track assembly.
The tension spring cylinder is subjected to a considerable internal force. Do not loosen the
grease cup ① more than one turn. If the track shoe tension is not released when the grease
cup is loosened, move the machine back and forth until the track is completely released.
Drive forward slowly to allow the track shoe at the front idler end to contact the large cushion
block or wall (If there is another bulldozer with the same power, contact its blade). When the
tensioning spring is bent and the track shoe is bent, stop the machine and apply the brake.
Now set the master link between the front idler and the front carrier roller. For safety reasons,
install a lever block between the carrier roller bracket and the track link.
Extrude the master pin ② using hydraulic equipment or tooling.
Take special care to ensure safety when disconnecting the track.

2. Slowly move the machine backward, and unfold the track assembly.
Fig. 3.11 Removal of Track Assembly (In Case of Fault)
Installation
※ Install in the reverse order of removal.

1. Set dimension a to 25±5 mm when adjusting track shoe tension.
2. If the track shoe needs to be replaced, tighten the track shoe bolts in the order shown in
the figure below.
Track shoe bolt:

Initial torque: 1,100 ± 50 Nm
Fig. 3.12 Installation and Testing of the Track

Chapter 4 Final Drive and Transfer Case

4.1.1 Overview
Fig. 4.1 Final Drive
The final drive employs a deceleration system with a first-stage spur gear and a second-stage
planetary gear.
The final drive can be removed and installed as a separate component.
Lubrication method: splash lubrication that facilitates gear rotation.
The floating oil seal is installed in the rotating and sliding part of the sprocket to prevent the
entry of soil or sand and the leakage of lubricating oil.

Fig. 4.2 Structure of Final Drive
1. Sun gear 8 Driven gear

2. Planetary carrier 9. Connecting plate
3. Gear ring 10. Tooth block
4. Floating oil seal ring 11. Sprocket hub
5. Outer case 12. Planetary gear
6. First-stage pinion 13. Gear shaft
7. Housing

4.1.2 Power Transfer Route
Fig. 4.3 Power Transfer Route
Power is transferred from the travel motor to the first-stage pinion 6 and then to the sun gear 1
via the driven gear 8 that engages with the first-stage pinion. The sun gear 1 rotates so that
the power is transferred to the planetary gear 12 and eventually output through the planetary
carrier (sprocket).
4.2 Removal and Installation of the Final Drive Assembly

4.2.1 Removal of the Final Drive Assembly
1. Remove the track assembly
Refer to "Removal of Track Assembly" for details.
2. Jack up the undercarriage with a jack (50T), and then install the bracket at the front and
rear ends of the main frame (as shown in the figure).

Fig. 4.4 Final Drive Tooling
Note: The bracket shall be firmly installed in a proper position

3. Drain the oil in the final drive case
1) Turn the oil drain port on the planetary side to the lowest point (as shown in the figure).
2) Unscrew the oil drain ports on the planetary side and first-stage gear side, and drain the
lubricating oil in the planetary drive case and first-stage drive case.
3) The final drive oil volume of the single-flange standard type is about 37L, and that of the
single-flange wetland type is about 46L.
Oil drain port on Oil drain port on the

the planetary side first-stage gear side
Fig. 4.5 Final Drive Oil Drain Port
4. Drain the oil of the hydraulic tank

Refer to "Oil Drainage of the Hydraulic Tank "
5. Remove the travel motor pipeline and electrical components
Refer to "Removal of the Travel Motor Pipeline" for details
Refer to "Removal of Travel Motor Electrical Components"
6. Remove the mounting bolts of the final drive
1) Remove the mounting bolts of the final drive
Note: Reserve 2-3 mounting bolts at the top

2) Lift the final drive assembly with the hoisting tool and fix it
Note: The final drive assembly is about 1,152 kg
3) Remove the remaining mounting bolts of the final drive
4) Lift out the final drive assembly (including the travel motor)
Note: Do not bump the travel motor 16 when lifting
16
Fig. 4.6 Final Drive Hoisting
5) Remove the travel motor, and separate the travel motor from the final drive assembly
4.2.2 Disassembling of the Final Drive Assembly
※ Brake Assembly
1) Remove the mounting bolt 18 of the brake, and take out the brake assembly 19, brake
gear ring 20, friction disc 21, polished plate 22 and spline housing 23 in sequence.
18
20
23
22 21
19
Fig. 4.7 Removal of the Brake
1) Disassemble the brake assembly

Press the removal snap ring of the brake disc spring with the special tooling, take out the disc
spring and gland, loosen the tooling bolt, and take out the piston from the brake.
Note: Do not damage the O-ring and the Glyd ring when removing the piston.
Fig. 4. 8 Disassembling the Brake Assembly
※ Planetary Drive Assembly

1) Remove end cover 24, gasket, and sun gear shaft 1
2) Remove mounting bolt 25 of the planetary carrier
24
25
Fig. 4.9 Removal of Planetary Drive
3) Remove the planetary carrier assembly with a lifting eye

Disassemble the planetary carrier assembly:
Remove bolt 27 of the planetary carrier cover plate, remove the cover plate, remove the fixing
bolt of the planetary gear shaft, and remove the planetary gear shaft and planetary gear.
12
26
13
27
Fig. 4.10 Removal of Planetary Drive

4) Remove the gear ring and the fixed support
Remove the end cover 28. Remove the assembly of gear ring 3 and the fixed support 30 with
a lifting eye. Remove the fixed support 30 from the gear ring 3.
28
30
Fig. 4.11 Removal of the Gear Ring and the Fixed Support
5) Sprocket and hub assembly

 Install the lifting eye bolt, remove the sprocket and hub assembly with a jack, and the
bearing 31 will be exposed
 Remove the floating oil seal 4. Take care not to damage the sealing surface and keep it in
a safe and clean place
③ Remove the sprocket tooth block 10
31
10
Fig. 4.12 Removal of Sprocket and Hub
6) First-stage drive assembly

 Pull the outer case 5 out of the inner case 7 with the jack screw. Lift it out with the lifting
eye bolt. The bearings will now be exposed.
Fig. 4.13 Removal of First-stage Drive Assembly
 Gently knock the connecting plate 9 with a copper bar, and press the driven gear bearing
34 downward until the end face of the connecting plate fits the end face of the inner case.
Note: The driven gear bearing 34 must be pressed downward, otherwise the driven gear ring
cannot be removed.
 Remove bolt 32. Remove the driven gear ring 8 from the connecting plate with a lifting
eye, and take out the connecting plate 9.
 Remove the pinion assembly
Loosen the fixing bolt, and remove the pinion shaft 6 with a special tooling. Remove the
bearing from the pinion shaft.
8
6
9
34
32
Fig. 4.14 Removal of First-stage Drive Assembly
4.2.3 Assembling the Final Drive Assembly

1. Clean all components, and check for dirt and damage. Apply engine oil to the sliding
surfaces of all components before installation.
2. Assemble the final drive assembly in an order reverse to its removal
3. Precautions for assembling friction disc and polished plate
Apply lubricating oil on the surface when assembling the friction disc and polished plate. Align
the tooth removal part of friction disc with the oil drain port of the inner case (diameter: 18
mm)
4. Adjust the clearance of pinion shaft to be 0.225~0.3 mm
Measure dimension A and dimension B. Adjusting shim thickness: A+ (0.225+0.3) /2-B
Fig. 4.15 Dimensional Measurement
5. Check the sealing of the brake

After the brake is assembled, apply 2.5Mpa oil pressure from the brake oil port for 10min.
There shall be no oil seepage from the end face of the brake case and the contact surface

between the piston and the brake case
Note: During field operation, oil can be taken from the oil supplement system to ensure the
sealing of the brake.
Fig. 4.16 Check of Brake Sealing
4.3 Transfer Case

4.3.1 Overview
The transfer case is mainly composed of case (1), shock absorber, driving gear (11) and
pump drive gear (10). One of the two functions of the transfer case is to attenuate the
torsional vibration caused by fluctuation of engine torque and the impact torque caused by
heavy-load operation through the shock absorber. The other function is to distribute the power
transferred by the engine into the travel pump and lubricating pump respectively.
Power transfer route: engine flywheel → shock absorber outer case 8 → rubber block 2 →
shock absorber inner case 4 → driving gear 11 → pump drive gear 10.
S/N Description S/N Description
1 Case 2 Rubber block
3 Bearing pedestal 4 Shock absorber inner case

5 Spline shaft 6 Plate
7 Plate 8 Shock absorber outer case
9 Bearing pedestal 10 Gear
11 Gear 12 Screw plug
13 Refueling hard pipe 14 Breather plug
15 Left travel pump port 16 Right travel pump port
17 Implement pump port
S/N Inspection Items Judgment Criteria Measures
Standard Tolerance
1 Outer -0.008 Replace

Fit clearance Φ130 -----
diameter -0.033
of spline shaft
Inner +0.021
bearing Φ75 -----
diameter +0.002
Outer diameter of the Standard Repair limits
Tolerance Brush
contact surface of the dimensions
plating or
spline shaft skeleton oil 0
Φ75 Φ74.9 replacement
2 seal -0.074
Fit clearance between the
+0.054
skeleton oil seal and the Φ100 -------
0 Replace
hole
3 Standard Tolerance

-0.006
Φ120 -----
-0.028
Fit clearance of the pump
+0.021
drive gear shaft
Φ65 +0.002 -----
Standard Tolerance
4
Fit clearance of the pump -0.006
Φ120 -----
drive gear shaft -0.028
+0.021
Φ65 +0.002 -----
Backlash between the

5 gear and the pump drive 0.19-----0.49
gear
Tolerance Replace
Standard
6 Fit Outer -0.008

Φ125 -----
clearance of diameter -0.033
input gear Inner +0.021
Φ70 -----
shaft diameter +0.002
4.3.2 Disassembling and Assembling the Transfer Case

Removal of Transfer Case Assembly:
(1)
i. Remove the hydraulic pipeline;
ii. Lift out the engine and transfer case assembly;
iii. Remove the screw plug at the bottom of the transfer case and drain the oil;
iv. Remove left travel pump 1;
v. Remove left travel pump 2;
vi. Remove implement pump 3.

2
1
(2) Remove the connecting bolt and washer 4, and separate the transfer case assembly 5
from the engine;
(3) Remove the bolt and washer 6, and separate the shock absorber assembly 7 from the
engine;
Installation of Transfer Case Assembly

(1) Lift the shock absorber assembly 7, install the shock absorber housing and flywheel
connecting bolt and washer 6, and tighten the bolt

(2) Lift the transfer case assembly 5, install the connecting bolt and washer 4 between the
engine and the transfer case body, and tighten the bolt;
(3) Install right travel pump 1, left travel pump 2 and implement pump 3.
2
1
Disassembling and Assembling the Assembly

Disassembling the Transfer Case
(1) i. Remove the dipstick 14;
ii. Remove the breather plug assembly 13;
iii. Remove the U clamp and nut 9;

iv. Remove the bolt and washer 11, and remove the fixing plate 10;
v. Remove the bolt and washer 12, and remove the refueling hard pipe 8
13
8 14
10
11
12
(2) Remove the connecting bolt and washer 16, and take off the bearing pedestal assembly
15
15
15
16
16
(3) Place the bearing pedestal assembly 15 on the platform, remove the O-ring 17, and
remove the bearing outer ring 18 with the tooling
17 18

(4) Lift out gear assembly 19
19
19
(5) Place gear assembly 19 on the platform, and remove the bearing inner ring 20 from gear
21 with the tooling.
20
21
20
(6) Remove the bolt and washer 22, and lift out the bearing pedestal assembly 23
22
23

(7) Place the bearing pedestal assembly 23 on the platform, remove the O-ring 27, and
remove the bearing outer ring 24 and skeleton oil seal 25 from the bearing pedestal 26
with tooling
24 25
27
26
(8) Lift out the spline shaft assembly 28
28
(9) Place the spline shaft assembly 28 on the platform, remove the O-ring 29, and remove
the bearing inner ring 30 with tooling;

29
30
(10) Reverse the spline shaft assembly 28, remove the bolt and washer 32, separate the
spline shaft 33 from the gear 34, and remove the bearing inner ring 31 with the tooling
34
31
32
33
(11) Remove the retaining ring 35

35
(12) Remove the cotter pin 36, bolt and nut 37 and plate 38. Remove the bearing outer rings
46 and 47 from case 49 with the tooling. Remove the screw plug 48;
38 46
36 37
47
46 49 48
(13) Place the shock absorber assembly 7 on the platform;

i. Remove the bolts and washer 39;

39
ii. Remove the plate 40, shock absorber inner case 41, plug and safety valve 42, and rubber
block 43 from the shock absorber outer case 44 in sequence;
iii. Lift the shock absorber outer case 44, and separate it from the plate 45;
40
41
42
43
44
45
Assembling the Transfer Case

(1) Assemble the shock absorber:
I. Install the safety valve and plug 42 on the shock absorber inner case 41;

42
41
ii. Place the plate 45 on the platform;

iii. Apply sealant to the joint surface between the shock absorber outer case 44 and the plate
45, and apply grease to the inner surface of the outer case 44. Lift the outer case 44,
align the threaded hole with the plate 45, and then install them;
iv. Apply grease on the joint surface of the buffer of the shock absorber inner case 41, and
then install it on the plate 45;
v. Apply grease on the surface of rubber block 43 and assemble it; then fill 30%-50%
clearance between the inner and outer cases with grease;
43
41
vi. Install the plate 40, the bolt and washer 39, and tighten the bolt;

39
40
(2) Assemble the case:
38 46
36 37
47
46 49 48
35
i. Install the plate 38 on the case 49, then install the bolt 36, tighten the nut, and install the
cotter pin 37;
ii. Cool the bearing outer rings 46 and 47, and press-fit them into the mounting holes of the
case 49;
iii. Install plug screw 48;
iv. Install the retaining ring 35
(3) Assemble the spline shaft assembly 28:
i. Place the spline shaft 33 on the platform;
ii. Install gear 34 and align threaded holes;
iii. Install the bolt and washer 32 and tighten them;
iv. Heat the bearing out ring 31, and press-fit it on the spline shaft 33;

34
31
32
33
v. Heat the bearing out ring 30, and press-fit it on the spline shaft 33
vi. Install the O-ring 29
29
30
(4) Assemble the bearing pedestal assembly 23:

i. Place the bearing pedestal 26 on the platform;
ii. Cool the bearing outer ring 24, and press-fit it into the mounting hole of the bearing
pedestal 26;
iii. Install the O-ring 27 and the skeleton oil seal 25;

24 25
27
26
(5) Assemble the gear assembly 19:

i. Place gear 21 on the platform;
ii. Heat the inner ring 20, and press-fit it to the shaft diameter of gear 21;
20
21
20
(6) Assemble the bearing pedestal assembly 15:

i. Place the bearing pedestal 50 on the platform;
ii. Cool the bearing outer ring 18, and press-fit it into the mounting hole of the bearing
pedestal 50;
iii. Install the O-ring 17；

17 18
50
(7) Install the spline shaft assembly 28 on the case
28
(8) Lift the bearing pedestal assembly 23, install the bolt and washer 22, and tighten the bolt;
22
23
(9) Install the gear assembly 19

19
19
(10) Lift the bearing pedestal assembly 15, install the connecting bolt and washer 16, and
tighten the bolt;
15
15
16
16
(11) Install the O-ring 51 into the groove of the refueling hard pipe 8
51

(12) i. Install the refueling hard pipe 8, install the bolt and washer 12, and tighten the bolt;
ii. Install the fixing plate 10, the bolt and washer 11, and tighten the bolt;
iii. Install the U clamp and nut 9;
iv. Install the breather plug assembly 13;
v. Install the dipstick 14;
13
14
8
10
11
12
4.3.3 Fault Diagnosis

(1) Fault: Too high temperature of the oil inside the transfer case
Causes: i. Too much lubricating oil that is heated up due to stirring; the normal oil volume
of the transfer case is 10L;
(2) Fault: High temperature of the transfer case bearing
Causes: i. Low amount of lubricating oil in the case and insufficient lubrication at the
bearings;
ii. The lubricating oil channel inside the case is not smooth, and the oil trap does not collect
enough oil, resulting in insufficient lubricating oil;
iii. Unreasonable fit tolerance of bearing results in wear and heating of bearing;
(3) Fault: Abnormal sound inside the transfer case
Cause: Excessive backlash, and abnormal sound when the gear teeth are engaged;
Schedule: Lubricating Oil Grade and Volume
10

Chapter 5 Work Tools

5.1 Work Tools
5.1.1 Overview
The work tools mainly refer to the blade and ripper, which are used to complete various
operations of the bulldozer.
The semi-U blade is a box structure with good bending strength, compressive strength and
rigidity. The front end is hinged to the blade with a cross joint, and the rear end is connected
to the trunnion spherical hinge that is fixed on the track frame.
Under the action of the blade lift cylinder, the push arms and the blade swing with the
trunnion as the axis to realize the lift and drop of the blade. The tilt cylinder enables the
blade to tilt left, right, and pitch in a direction perpendicular to the ground.
After a period of use, the blade can be turned over 180°for further use
5.1.2 Semi-U Blade
Fig. 5.1 Blade Structure
1 Blade 2 Trunnion
3 Diagonal support 4 Bracket
5 Push arm 6 Support

7 Cutting edge 8 End bit
5.2 Inspection Items, Judgment Criteria and Measures for Blade

Maintenance
5.2.1 Semi-U Blade
1. Relieve pressure from the working valves and pipelines;

Fig. 5.2 Blade Inspection Positions
Tolerance
Standard Standard Clearance
Clearance between dimensions clearance limit
Axle Hole
1 the ball joint and
seat surface
0 +0.5
100 0.2-0.6 1
-0.1 +0.2
Replace
2 Clearance between 100 0 +0.5 0.2-0.6 1

ball joints on both -0.1 +0.2

sides of diagonal
support and the
seat surface
Clearance between
-0.5 +0.5
3 trunnion cover and 160 0.5- 1.5 5
-1.0 0
trunnion sphere
Clearance between
-0.2 +0.5
4 the push arm seat 120 0.5-1.2 5
-0.7 +0.3
and the blade seat
Clearance between
-0.3 +0.3
5 blade pin and 60 0.3-0.8 3 Replace
-0.5 0
bearing
Clearance between
the push arm seat -0.2 +0.5
6 120 0.5-1.2 5
and the connecting -0.7 +0.3
block
Clearance between
the push arm pin -0.3 +0.3
7 60 0.3-0.8 3
and the joint -0.5 0
Clearance between
the support pin and -0.3 +0.5
8 60 0.6-1.0 2
the push arm -0.5 +0.3
Clearance between
the support pin and -0.3 +0.5
9 60 0.5-1.0 2
the bracket -0.5 +0.2
Clearance between
the middle pin of the -0.3 +0.1
10 85 0.2-0.6 1
blade and -0.5 -0.1
the bracket
Clearance between
the middle pin of the -0.3 +0.3
11 85 0.3-0.8 3
blade and -0.5 0
the seat

Clearance between
the ball joint of the
0 +0.5
12 right diagonal 100 0.2-0.6 1
-0.1 +0.2
support and
the bracket
Clearance between
the ball joint of the
0 +0.5
13 left diagonal support 100 0.2-0.6 1
-0.1 +0.2
and
the bracket
Clearance between
-0.1 +0.087
14 arm cover and arm 120 0.1-0.287 Adjust it
-0.2 0
seat or
replace
Clearance between gaskets
-0.1 +0.087
15 arm cover and arm 120 0.1-0.287
-0.2 0
seat
5.2.2 End Bit and Cutting Edge
Fig. 5.3 End Bit and Cutting Edge

Basic Standard
S/N Inspection Items Service Limit Countermeasures
Dimensions clearance
1 Inside height of the end bit 254 — 213
2 Outside height of the end bit 292 — 211

Replace
3 End bit width 435 — 360
4 Cutting edge height 254 — 211
5 Tightening torque 460-620N.m Adjust

5.2.3 Removal and Installation of the Blade Assembly
Lower the work tool to flat ground, and firmly set the cushion blocks [1] under the left and right
push arms.
1. Remove the lift cylinder assembly cover (1).

★ Check the quantity and thickness of gaskets
2. Temporarily hang the lift cylinder assembly (2). Run the engine and fully retract the
cylinder.
3. Install the lift cylinder assembly (2) to the radiator cover using the seat (3).
★ Bind the plunger rod with wires to prevent it from coming out.
4. Disconnect the lift cylinder assembly from the other side of the blade.
Release the residual pressure in the cylinder of the work tool.

5. Remove the left and right covers (4).

6. Disconnect 2 diagonal hoses (5) from the right push arm.

★ Make distinguishing marks on the hoses and block them to prevent dirt from entering the
pipeline.
7. Remove left and right pivot covers (6).

8. Remove the blade assembly (7).
★ Run the engine and slowly reverse the machine to disconnect the blade assembly from
the pivot.
Installation
★ Adjust the clearance a of the fitting surface of the cover with a gasket to the following
values and check whether the pivot rotates smoothly.
• Standard clearance a: 0.2-0.5 mm
• Standard gasket thickness: 4 mm
★ After installing the blade, adjust the tilting distance of the blade.

★ Adjust the height b and width c of the two push arms using cushion blocks [1] to the
following values.
• Pivot height b: 460 mm
• Frame width c: 2772 mm
● Refill (the hydraulic tank)

Fill oil to the specified level with the grease cup. Run the engine to circulate oil in the
system. Check the oil level again.
● Bleed air
Bleed air from the work tool cylinder.
5.3 Structure, Functions and Maintenance Standards for the Ripper

5.3.1 Overview
Ripper
The bulldozer ripper is connected to the main frame by pins. It is connected to the cross beam
with pins at the connecting frame end. The cross beam is equipped with a ripper shank, to
which the tooth tip and holder are connected by pins. The ripper has a reinforcing tooth tip.
The lift cylinder of the ripper controls the ripper shank to move up and down (ripping depth),
and its bottom side is fixed on the ripper bracket with a pin, and the piston rod is connected to
the beam with a pin.
The tilt cylinder of the ripper controls the ripping angle of the ripper shank (tooth tip), and its
bottom side is fixed on the ripper bracket and its piston side is fixed on the beam with pins.
The pin puller cylinder can be operated to change the hole position of the mounting pin, thus
adjusting the ripping depth.

※ Schematic Diagram for Installation of the Ripper
 
 


⑧
⑨
Fig. 5.4 Ripper

S/N Description S/N Description S/N Description
1 Connecting rod (left) 2 Connecting rod (right) 3 Ripper cylinder (right)
4 Ripper cylinder (left) 5 Connecting frame 6 Cross beam
7 Ripper shank 8 Holder 9 Tooth tip

5.3.2 Inspection Items of the Ripper
Fig. 5.5 Ripper Inspection Positions

Inspection
S/N Judgment Criteria Measures
Items
1 Clearance Standard Tolerance Standard Clearance Replace

between the dimensions Axle Hole clearance limit
fixing pin of the
upper -0.030 +0.4
connecting rod 75 0.230-0.476 1.5
-0.076 +0.2
and the bushing
Clearance
between the
fixing pin of the -0.030 +0.4
2 75 0.230-0.476 1.5
connecting -0.076 +0.2
frame and the
bushing
Clearances of
the bushing to
the connecting -0.030 +0.4
3 75 0.230-0.476 1.5
frame and the -0.076 +0.2
fixing pin of the
cross beam
Standard
Outer diameter Tolerance Repair limits
dimensions
of the mounting
4
pin of the ripper Axle 60 ±0.3 —
shank Hole 62 ±0.3 —

5 Tooth tip wear
335 185
6 Guard wear 112 90

5.4 Disassembling and Assembling Three-shank Ripper Assembly
5.4.1 Disassembling
1. Park the machine on flat ground and lower the blade to the ground.
! Lock the brake firmly.
2. Hang the ripper shank (1), and remove the fixing pin shaft (2).
3. Lift the ripper completely and lower the ripper shank (1) for removal, and lift the ripper
shank away from the machine.
Ripper shank: 190 Kg

4. Place the bracket [1] under the cross beam.
2
[1]
5. Hang the connecting rod (4), remove the pins (3) (on the left and right sides), and lift the
left and right connecting rods (4) away from the machine.
Connecting rod: 85 Kg
6. Disconnect the four lift cylinder hoses (5), hang the lift cylinder, remove the pins (6) (on
the left and right sides), and
lift the lift cylinder (7) away from the machine.
Lift cylinder: 110 Kg

4 5
7
6
3
7. Place the bracket [2] under the connecting frame, remove the pins (8) (on the left and
right sides), and lift the cross beam (9) away from the machine.
Cross beam: 1,080 Kg

8. Remove the shafts (10) (on the left and right sides) and lift the connecting frame (11)
away from the machine.
Connecting frame: 345 Kg
9
10
8 11
[2]
5.4.2 Assembling
1. Hang the connecting frame (11) and place it in the installation position, then install the pin
shafts (10) on the left and right sides and fix them with bolts.
Connecting frame: 345 Kg

★ Place the bracket [1] under the connecting frame
2. Hang the cross beam (9) and place it in the installation position, then install the pin shafts
(8) on the left and right sides and fix them with bolts.
Cross beam: 1,080 Kg

★ Place the bracket [2] under the cross beam.
9
10
11 8
[2]
[1]
3. Hang the lift cylinder assembly (7) and place it in the installation position. Start the engine,
extend the piston rod and align it with the pin hole. Install the pin shaft (6) and fix it with
bolts. Connect the four lift cylinder hoses (5).
Lift cylinder assembly: 110 Kg

4. Hang the left and right connecting rods (4) and place them in the installation positions.
Install the upper pin shafts (3) (on the left and right sides) and fix them with bolts.
Connecting rod: 85 Kg

5 4
7
6
3
5. Place the machine on the ground and lower the blade to the ground.
! Lock the brake firmly.
6. Operate to lift the ripper slightly to remove the bracket [1].
7. Lift the ripper completely, and hang the ripper shank (1) with a hook. Slowly lift the ripper
shank (1), align the pin hole, and install the upper pin shaft (2).
Ripper shank: 190 Kg

2
[1]
8. Bleed air from the cylinder.

Refer to "Bleed air from hydraulic cylinder" in "Testing and Adjustment" for details.

Chapter 6 Hydraulic System

※ Overview
Table 6.1 Specification of Hydraulic System
Model DH24
System pressure MPa 42
Type L/min Swash plate type variable
Travel pump Flow (at an engine speed of displacement piston pump HPV135
1,900) 300
Travel
hydraulic Type Swash plate type variable
system Travel motor displacement piston motor
HMV280
Type
Make-up Gear pump 60
Flow (at an engine speed of L/min
pump 120
1,900)
Maximum pressure MPa 28
Type
Implement Gear pump
pump 203
1,900)
Pilot pump Type
Gear pump
18
1,900)
Type: hydraulic pilot control MPa 4-way valve, 4.1
For blade lifting: safety valve 29
Working
For blade tilting: safety valve
valve
For ripper lifting: safety valve
For ripper tilting: safety valve 29
Hydraulic Type Reciprocating
system of
Cylinder bore 100
the work
Outer diameter of 65
tools
piston rod 1320
Dimensions
Piston stroke 2028 708
of the blade mm
Maximum distance
lift cylinder
between pin shafts
Hydraulic Minimum distance
cylinder between pin shafts
Cylinder bore 160
Dimensions piston rod 130
of the blade Piston stroke mm 1198 1068
tilt cylinder Maximum distance
between pin shafts
Minimum distance
between pin shafts
Cylinder bore 130

piston rod 410
Ripper lift
Piston stroke 1328 918
cylinder mm
Maximum distance
dimensions
between pin shafts
Minimum distance
between pin shafts
Lift 2-4
Drop 1-3
Working
Blade Quick drop s 1-2
cycle time of
the Left tilt 1-3
hydraulic Right tilt 1-3
cylinder
Lift 1-3
Ripper s
Drop 1-3
6.1 Hydraulic System of the Work Tools

6.1.1 Configuration of Hydraulic System of the Work Tools
Fig. 6.1 Layout of the Working Hydraulic System
1 - implement pump 2 - working valve 3 - hydraulic tank 4 - quick drop valve 5 - oil cooler 6 - right lift
cylinder 7 - left lift cylinder 8 - tilt cylinder 9 - ripper cylinder

Fig. 6.2 Layout of Working Pilot Hydraulic System
1 - blade handle 2 - ripper handle 3 - working valve 4 - pilot valve block 5 - accumulator 6 - pilot filter
element
6.1.2 Working Hydraulic System Principle
Fig. 6.3 Working Hydraulic System Principle
1 - hydraulic tank 2 - two-way implement pump 3 - oil returning filter element 4 - pilot valve block 5 -
accumulator 6 - oil cooler 7 - working valve 8 - blade handle 9 - ripper handle 10 - tilt cylinder 11 - quick

drop valve 12 - right lift cylinder 13 - left lift cylinder 14 - ripper cylinder 15 - ball valve
Working Principle
The hydraulic system of the work tools is a quantitative hydraulic pilot control system,
consisting of the implement pump, working valve, handle, oil tank and cylinder.
The front pump of the two-way implement pump 2 is the implement pump, and the rear pump
is the pilot pump. The implement pump sucks oil from hydraulic tank 1 and supplies oil to the
working valve 7. Working valve 7 includes the blade lift control valve, the blade tilt control
valve, and the ripper control valve. When the operating handle is in the neutral position, the oil
will return to hydraulic tank 1 through port T of the working valve 7 and the oil return filter 3. If
the blade handle 8 is operated, the blade cylinder acts to lift, drop, hold, float the blade and tilt
it left or right. If the ripper handle 9 is operated, the ripper cylinder acts to lift or drop the ripper.
Each way of working valve 7 is equipped with an in-line check valve. The in-line check valve
prevents oil from flowing backward. If the engine shuts down suddenly when the blade is lifted,
the hydraulic pump stops supplying oil, and the in-line check valve locks the cylinder. The
blade can be maintained in the lifted position. The lifting way is equipped with a make-up
check valve to prevent cavitation in the hydraulic system. When the blade falls, the oil inlet
chamber of the cylinder will be vacuumized due to gravity. At this time, the make-up check
valve acts to allow oil to enter the cylinder from the oil tank, thus preventing cavitation.
The ripper way is equipped with an overload valve to prevent the ripper from overloading and
thus damaging the hydraulic components. When the oil pressure exceeds the set value of the
overload valve, the valve will overflow to unload.
In the pilot control hydraulic system, the pilot oil source is provided by the pilot pump of the
travel system. The oil is filtered by the pilot valve block and then sent to the pilot chamber of
the working valve through the ball valve 15, so as to control the movement of the main valve
core and enable the action of the blade and ripper.
The pilot valve block 4 integrates the check valve, filter element, sequence valve and
accumulator. When the whole machine cannot be started, the blade and ripper can be
dropped using the pressure oil stored in the accumulator.
The blade handle 8 is with a spider, and it can be controlled to lift, drop and tilt the blade;
The ripper handle 9 is with a slot-type shaft, and it can be controlled to lift and drop the ripper;
The ball valve 15 is used to lock the pilot oil source. When ball valve 15 is closed, the work
tools do not act no matter which handle is operated. Only when the ball valve 16 is connected
can each work tool acts;
If the load is too large during operation, the system pressure will temporarily exceed the set
pressure of 21 Mpa. At this time, the overflow valve inside the main valve is opened, and the
working oil returns to the oil tank through the overflow valve to protect the system.

Working valve
Table 6.1 Structural Description of the Working Valve

Symbol Description Symbol Description
P Oil inlet T Oil return port

Oil port of the tilt cylinder chamber with Oil port of the tilt cylinder chamber without
B1 A1
rod rod
Oil port of the lift cylinder chamber with Oil port of the lift cylinder chamber without
B2 A2
rod rod
Oil port of the ripper cylinder chamber Oil port of the ripper cylinder chamber
B3 A3
with rod without rod
1 System overflow valve 2 Lifting way make-up check valve
3 Ripper way safety valve 4 In-line check valve
The working valve is installed on the right fender of the machine using a bracket. According to
different work tools, the working valves can be of 2 pieces (with traction frame) or 3 pieces (for
the ripper). The valve core of the working way moves in the valve body, changes the on-off
relationship of different oil lines, and controls various actions of the blade and ripper
respectively. Both ends of the valve are equipped with centering springs. The centering spring
can provide a pre-tightening force to keep the reversing valve core in the neutral position.
The blade lifting way is equipped with a 6/4 valve. It controls the pilot handle to lift, drop,
neutralize and float the blade, and the other ways are equipped with 6/3 valves to lift, drop and
neutralize the ripper;
In the floating position, the two chambers of the blade lift cylinder communicate with the oil
inlet and oil return lines. The blade is free to stand on the ground and its height changes with
the terrain;

The maximum working pressure of the hydraulic system for overflow valve 1 is 21MPa. When
the oil pressure exceeds 21 MPa, the overflow valve 1 is opened for unloading to protect the
safety of the hydraulic system;
The in-line check valve 4 is used to prevent the oil from flowing backward. If the engine shuts
down suddenly when the blade is lifted, the hydraulic pump stops supplying oil. At this time,
the in-line check valve locks the hydraulic cylinder to keep the blade in the current position,
avoiding an accident due to a sudden drop from gravity;
When the ripper is working in a fixed position and the oil pressure in one chamber of the
cylinder increases suddenly due to a sudden load, the safety valve 3 opens to unload to
protect the hydraulic cylinder when its set pressure is reached.
The speed of the blade is accelerated by gravity when it is falling, which may cause
insufficient oil supply, forming a local vacuum in the oil inlet chamber of the cylinder and
resulting in cavitation. At this point, as the pressure of the oil inlet cavity decreases, the
make-up check valve 2 in the blade lifting way opens under the pressure difference, and
makes up oil to the oil inlet chamber of the cylinder from the oil tank, so as to avoid vacuum
and make the cylinder act smoothly.
Handles
Fig. 6.4 Working Handles
1 - blade lifting 2 - blade left tilting 3 - blade drop 4 - blade right tilting 5 - ripper lifting 6 - ripper drop
The hydraulic pilot oil is supplied by the pilot pump. The oil goes to the working handle or
ripper handle through the pilot valve block. When the work tool needs to be operated, the
handle shall be deflected to enable the pilot fluid to reach the pilot chamber of the main valve
core and push the main valve core into action. The output pressure of the pilot oil port is
proportional to the stroke of the handle and the stiffness of the working spring, and the
blade/ripper can act at the corresponding speed and direction. When the handle returns to the
neutral position, the handle oil inlet port is closed under the force of the reset spring, and the
working oil port and the oil return port are connected.

Pilot Valve Block
Fig. 6.5 Pilot Valve Block
1 - filter 2 - accumulator 3 - sequence valve 4 - pressure measuring connector P - to oil outlet pipe of
pilot pump P1-to oil inlet of handle T/T1 - to oil tank
The pilot valve block is located on the right fender and consists of a sequence valve, an
accumulator, a filter and a check valve. Filter 1 cleans the oil in the pilot circuit, accumulator 2
stabilizes the pressure and lowers the work tools to the ground in case of engine flameout due
to failure. Sequence valve 3 limits the pressure in the pilot circuit. Pressure measuring
connector 4 tests the pressure in the pilot circuit. Port P is connected to the oil outlet of the
pilot pump, port P1 is connected to the oil inlet of the handle, and port T1/T is connected to the
oil return tank.
When the working handle is operated after the startup, the oil in the pilot pump travels from
port P to the filter element for filtering. Part of the oil is then filled into the accumulator, and the
rest enters the pilot chamber of the working valve through the handle to drive the main valve
core to move. When the handle is in the neutral position, the oil of the pilot pump overflows to
the oil tank through the sequence valve. At this time, the oil in the spring chamber of the pilot
valve returns to the oil tank through port T1.
6.1.3 Hydraulic Tank

The hydraulic tank is located on the right fender of the machine and is used for the oil supply
of the hydraulic system of the work tools. The total capacity of the oil tank is 135l and the filling
amount is 95l.
The oil return filter element is placed inside the oil tank and integrated with a bypass valve.
When the pressure difference reaches 0.34 MPa, the bypass valve is opened, and the return
oil of the working system directly flows back to the oil tank without filtering, which will affect the
cleanliness of the hydraulic system.
Fig. 6.6 Hydraulic Tank

1 - breather 2 - level gauge 3 - oil drain valve 4 - oil suction port 5 - oil return port 6 - oil return filter
element and bypass valve
6.1.4 Work Tool Cylinder

Blade Lift Cylinder
Fig. 6.7 Lift Cylinder

Table 6.2 Inspection Standard for the Blade Lift Cylinder
Standard
S/N Inspection Items Standard Tolerance Clearance

Standard clearance
dimensions Axle Hole limit
Clearance -0.03 +0.145

between the
1 65 0.125-0.221
piston rod and the -0.076 +0.095
bushing
Clearance -0.2 +0.3
between the
2 85 0.2-0.6
piston rod head -0.3 0
and the pin shaft
between the
3 cylinder trunnion 75 0.145-0.213
bushing and the -0.210 0
bushing
Blade Tilt Cylinder
Fig. 6.8 Lift Cylinder

Standard
S/N Inspection Items Standard Tolerance Clearance

Standard clearance
dimensions Axle Hole limit

between the
1 80 0.130-0.241
piston rod and the -0.076 +0.100
bushing
Clearance 0 +0.5
between the
2 100 0.2-0.6
piston rod head -0.1 +0.2
and the pin shaft
Clearance -0.3 -0.145
between the inner
3 60 0.09-0.355
hole of cylinder -0.5 -0.210
tail bushing and

the pin shaft
Fig. 6.9 Ripper Cylinder

Standard
S/N Inspection Items Standard Tolerance Standard Clearance

dimensions Axle Hole clearance limit
Clearance between -0.030 +0.174

the inner hole of
1 piston rod head 75 0.07-0.25
bushing and the pin -0.076 -0.100
shaft
2 the piston rod and the 70 0.131-0.221
bushing -0.076 +0.095

the inner hole of
3 75 0.07-0.25
cylinder tail bushing -0.076 -0.100
and the pin shaft
Piston Valve of the Blade Lift Cylinder

The piston valve is installed on the piston of the blade lift cylinder. When the piston comes to
the end of the stroke, the piston valve releases the hydraulic oil delivered by the work tool
pump to reduce the oil pressure applied to the piston. The piston valve also releases hydraulic
oil before the piston reaches the bottom or top of the cylinder, so as to reduce the impact at
the end of the stroke and the impact pressure due to the impact.
Operation
When the piston valve is "closed"
The hydraulic oil from the work tool pump acts on piston (1) and piston valve (2). Piston valve
(2) is therefore pushed to the right to seal the tapered portion of the piston valve seat (3). As a
result, the oil pressure in the cylinder rises, causing piston (1) to move to the right.

Fig. 6.10 Piston Valve Closed
When the piston valve is "open"

Before the piston rod (1) reaches the end of the stroke, the end of the piston valve (2)
contacts the bottom of the cylinder, so that the piston valve (2) no longer moves, only the
piston (3) continues moving. At this time, the hydraulic oil on the top side of the cylinder, which
has been blocked by piston valve (2), is discharged
through piston valve seats (4) and (5), so the oil pressure in the cylinder no longer rises.
Fig. 6.11 Piston Valve Open
Quick Drop Valve
Fig. 6.12 Quick Drop Valve in the Lift Pipeline
1 - right lift cylinder 2 - quick drop valve 3 - to rod chamber of lifting cylinder 4 - to lift cylinder chamber

with rod 5 - left lift cylinder 6 - to oil port on the inner side of the body of working valve lifting way 7 - to
oil port on the outer side of the body of working valve lifting way
Fig. 6.13 Quick Drop Valve
1 - valve body 2 - check valve 3 - slide valve 4 - spring A - to cylinder chamber without rod B - to cylinder
chamber with rod
The quick drop valve is located on the side of the front engine hood and is installed in the
blade lift pipeline to increase the blade drop speed and prevent vacuum on the bottom side of
the cylinder, and to shorten the hysteresis at the beginning of work. The quick drop valve
consists of the valve body, check valve, slide valve, and spring.
Operation:
1) Blade rise

Fig. 6.14 Operation of Quick Drop Valve during Blade Rise
When the blade is in the rising position, the pump oil from the working valve enters the
cylinder chamber with rod from orifice 1. Part of the pump oil acts on the lower end of the slide
valve through orifice 2. Under the action of oil pressure and spring, the check valve closes the
channel of the cylinder chambers with rod and without rod, and the oil in the cylinder chamber
without rod returns to the oil tank through the quick drop valve.
1) Quick drop of blade
Fig. 6.15 Operation of Quick Drop Valve during Quick Drop of Blade
When there is no external load on the blade and the working valve opens wide to drop the
blade, the pumping oil from the working valve goes to the cylinder chamber without rod

through the oil channel of the quick drop valve, and the return oil from the cylinder chamber
with rod goes back to the oil tank through orifice 1 via the working valve. The self-weight of
the blade tends to drag the piston rod downward rapidly. Therefore, when the drop speed
reaches a certain value, the return oil in the rod chamber forms a pressure difference before
and after orifice 1. The check valve and slide valve resist the spring force to move downward,
thus opening the oil lines of the two chambers of the cylinder. The return oil of the rod
chamber is replenished to the bottom chamber, and the blade drops faster.
2) Slow drop of blade
When the blade drops slowly, the working valve opens little, the pressure difference generated
when the oil return from the cylinder chamber with rod passes through the orifice is not
enough to make the valve core move down. The two chambers of the cylinder are closed by
the valve core, the intake oil of the cylinder chamber without rod only comes from the pump,
and the blade drops normally.
6.2 Testing and Adjustment of the Working Hydraulic System

Note:
1) When testing and adjustment are performed, park the machine on flat ground, and use
safety pins and cushion blocks to prevent the machine from moving.
1) When working with other personnel, use the signals and keep irrelative personnel away
from the machine.
2) When checking the water level, wait until the water cools down. If the radiator cap is
removed while the water is still hot, the water may spray out and cause injury.
4) Release the system pressure before removing hydraulic pipes, joints, pressure tester and
elements. Do not use the hands or any other part of the body to check for leaks in pressure
pipelines. If you are cut by hydraulic oil, see a doctor immediately.
6.2.1 Visual Inspection and Maintenance

Complete all scheduled maintenance and inspection prior to testing and adjusting the system.
For intermediate testing/adjustment, observe the following:
1) Service items and repairs
Check the coolant level, fuel level and hydraulic tank level, and add oil if necessary.
Check the air filter for contamination, damage, proper installation and correct type.
Add fuel if necessary. Drain water and deposit from the radiator and the pre-separator.
Check the hydraulic filter and oil return filter element of the oil tank. In case of temperature
problems, check whether the oil cooler and fan are contaminated/damaged.
2) Mechanical components
Check the adjustment/wear of handle, controller, etc
Check the harness for damaged, scratched and defective plug connections.
Check for leaks, and check system function and hose routing.
Check the installation of components, such as the cylinder.

Table 6.5 Standard Values of Working Hydraulic System
Model DH24
Standard
Category Measuring items Measurement conditions Unit
value
Low idle 21±1.4
Left tilt
High idle 21±1.4
Blade
Low idle 21±1.4
Right tilt
Hydraulic oil temperature: High idle 21±1.4
Working
45-55 °C
Oil system Low idle 21±1.4
Lift Operate the handle to the
pressure pressure
corresponding position High idle 21±1.4
of the MPa
work Ripper Low idle 21±1.4
tools Drop High idle 21±1.4
High idle 21±1.4

Hydraulic oil temperature:
45-55 °C
Pilot pressure High idle 3.0
Work tool handle is in the
neutral position
Model DH24
Measurement conditions Standard

Category Measuring items Unit
value
Low idle 3-5
Lift
High idle 3-5
High idle 1-3

Lift/drop of Hydraulic oil temperature:
the blade within the operating range
Drop
No load on the blade Low idle 1-3
Blade on the ground and
lifted to maximum
Blade
speed Left Low idle 1-3
Work
tilt High idle S 1-3
tools
Low idle 1-3
Blade tilt Hydraulic oil temperature:

Right
within the operating range
tilt High idle 1-3
No load on the blade
Blade is between left and
right tilt
Ripper Ripper Low idle 1-3

Lift
speed lift/drop High idle 1-3

Hydraulic oil temperature: Drop Low idle 2-4
within the operating range
No load on the ripper
Ripper is between the High idle 2-4
ground and end of lifting
stroke
Hydraulic oil temperature: within Low idle 1-2
the operating range
Blade Time spent by the blade from the
highest lifted position until it starts High idle 1-2
Quick to support the vehicle

drop Hydraulic oil temperature: within Low idle 1-2
the operating range
Ripper Time spent by the ripper from the
highest lifted position until it starts High idle 1-2
to support the vehicle
Settlement
for blade 150
lift Hydraulic oil temperature: within the
operating range
Engine flameout
Raise the blade to the maximum height and
measure the reduction of the blade bottom
height h within 15 minutes
Settlement mm/min
Settlement
for blade Hydraulic oil temperature: within the 50
tilt operating range
Engine flameout
Tilt the blade to the maximum extent to jack
the track on either side, and then measure
the reduction in track shoe height h within 5
minutes
Settlement
of blade
50
supporting
the vehicle

Hydraulic oil temperature: within the
operating range
Engine flameout
Jack up the front of the machine with the
blade, and measure the reduction of the idler
center height h within 5 minutes
Settlement
for ripper Hydraulic oil temperature: within the 80
lift operating range
Engine flameout
Raise ripper to the highest position, and
measure the reduction of ripper height h in 15
minutes
Settlement
of ripper
supporting
the vehicle
Hydraulic oil temperature: within the
operating range 30
Engine flameout
Jack up the rear of the machine with the
ripper, and measure the reduction of the
height h of the final drive center within 5
minutes
Testing Tools
Mechanical or digital pressure A: Mechanical
Stress testing tools
tester pressure tester
Sensor range (bar) 0-60 0-600 B: Pressure
measuring wire
C: Digital
Pressure measuring wire 5m pressure tester
D: Sensor
6.2.2 Testing and Adjustment of Pilot Pressure

Specification
Hydraulic oil temperature 50-60℃ Testing position
Engine speed High idle 1900rpm
Pilot pressure 30Bar On the pilot valve block
Working system pressure 210bar Port P of the working valve

a. Install a 0 - 60 bar pressure tester or digital pressure tester at the centralized pressure
measuring port A, and increase the oil temperature to the specified range before testing;
b. Run the engine at high and low idle speeds, place the blade and ripper handles in the
neutral position, and start the testing;
c. If the pressure is not the specified design value, adjust the sequence valve 3 on the pilot
valve block
1) Loosen the nut and adjust the screw;
2) Rotate it clockwise to increase the pressure, rotate it counterclockwise to decrease the
pressure;
3) Tighten the nut after adjustment.
Remove the testing tools.
6.2.3 Testing and Adjustment of the Working System Pressure
1) Install a 0 - 60 bar pressure tester or digital pressure tester at the centralized pressure
measuring port B, and increase the oil temperature to the specified range before testing;
2) Run the engine at high idle speed, place the blade handle to the left or right tilt position,
and start the testing;
3) If the pressure is not the specified design value, adjust the overflow valve C on the

working valve;
4) Loosen the nut and adjust the screw;
5) Rotate it clockwise to increase the pressure, rotate it counterclockwise to decrease the
pressure;
6) Tighten the nut after adjustment.
Remove the testing tools.
6.2.4 Settlement Testing of the Hydraulic Cylinder

★ If hydraulic drift occurs in the blade or the ripper, follow the steps below to check if it is
due to the seal side of the cylinder or the control valve side.
1. Put the cylinder to be tested in the following positions and shut down the engine.
1) The blade lift cylinder supports the blade to jack up the front part of the body.
★ Do not extend the blade lift cylinder to the end of the stroke as it is equipped with a piston
valve.
2) The blade tilt cylinder retracts the tilt cylinder to the end of the stroke and supports the
blade to jack up the right side of the body.
3) The ripper lift cylinder supports the ripper to jack the rear of the body.
2. Extend the cylinder to be measured with the corresponding control lever and check its
movement.
• If the lowering speed increases, the cylinder seal is faulty.
• If the lowering speed does not change, the control valve is faulty.
★ If the pressure in the accumulator is lost, run the engine for about 10s to increase the
pressure in the accumulator.
[Reference]
When the cylinder seal causes hydraulic drift,
Reasons for increased lowering speed are:

1) If the machine is placed in the above position (pressure shall be held to the bottom), the
oil will leak from the bottom side to the top side. Because the volume of the piston rod at
the top is smaller than that at the bottom side, oil flows from the bottom side, and the
pressure on the top side increases.
2) As pressure at the top rises, it achieves balance at some point (depending on the amount
of leakage), and then the lowering speed is reduced.
3) If the oil line to the bottom side of the discharge oil line is opened by the above operation
of the handle (at this time the bottom side is closed by the check valve) and the oil on the
top side flows into the discharge oil line, the pressure is out of balance and the lowering
speed is increased.
6.2.5 Leakage Test in the Hydraulic Cylinder

Measure the internal leakage of work tool cylinder under the following conditions: hydraulic oil
temperature: 45-55 °C
★ Since the blade lift cylinder is equipped with a piston valve, its internal leakage cannot be
measured.
1. Extend the cylinder to be measured to the end of the stroke, and set the machine in the
measuring position.
1) The blade tilt cylinder extends the cylinder to be measured to the end of the stroke.
2) The ripper lift cylinder pulls out the handle pin and lowers the ripper to the ground.
3) Ripper tilt cylinder tilts the ripper forward to the end.
2. Disconnect the hose at the top of the cylinder and plug the oil port on the hose side
★ Remove the hose cover of the cylinder to be tested. Be careful not to disconnect the hose
at the bottom.
3. Start the engine and run it at 1,000 RPM:

• Blade tilt cylinder: Operate it to extend the cylinder to be measured.
• Ripper lift cylinder: Operate it to lift the ripper.
• Ripper tilt cylinder: Operate it to tilt the ripper forward.
4. After 30 seconds, measure the leakage in 1 minute: 5 ml/min
5. After measurement, install the removed parts in place.

6.3 Travel Hydraulic System
6.3.1 Configuration of the Travel Hydraulic System
Fig. 6.16 Layout of the Travel Hydraulic System
1 - left and right two-way travel pump 2 - make-up pump 3 - make-up filter 4 - oil return valve block 5 -
manifold 6- left and right travel motor 7 - radiator
6.3.2 Principle of the Hydraulic System

The travel hydraulic system adopts a closed variable system composed of the variable pump
and the variable motor, and independent left and right drive circuits composed of two pumps
and two motors.
The travel pump and travel motor are of the swash plate type variable displacement pistons.
The left and right travel pumps are single pumps, and the hydraulic power is transmitted from
each pump to the travel motor through high-pressure pipelines;
The control and adjustment of the travel hydraulic system is of electric proportional control.
The driving and steering of the machine, the straight driving, and spin turn are all subject to
stepless adjustment by moving the driving control handle. Stepless adjustment maximizes the
utilization of the engine power.
The hydraulic power transmitted to the travel motor is output as mechanical power through
the travel motor shaft to the final drive. The final drive drives the sprockets through a
deceleration system with the first-stage spur gear and the second-stage planetary gear to
make the tracks travel.

The pressure between the travel pump and the travel motor depends on the traveling
resistance, and the transmitted torque depends on the angle of the motor
Fig. 6.17 Layout of Travel Hydraulic Components
1 - left travel pump 2 - right travel pump 3 - makeup pump 4 - oil return valve block 5 - manifold 6 -
makeup filter 7 - left travel motor 8 - right travel motor
The left and right travel pumps are connected to the engine through the gear transfer case,
and the engine drives the travel pump to rotate through the transfer case. The left and right
travel pumps are connected to the left and right travel motors 7/8 through high-pressure
pipelines. The variable pump converts the torque provided by the engine into high-pressure oil
flow, and the high-pressure oil flow transfers energy to the left and right travel motors. The
motors convert hydraulic energy into mechanical energy to drive the sprockets, making the
tracks travel.
The make-up pump of the travel pump is a single pump. The make-up pump sucks oil from
the oil tank, and the respective oil outlets pass through filter 6 to the make-up systems of the
left/right closed travel systems, ensuring the cleanliness of oil in the closed system. Make-up
pump 3 also provides control oil for the brake system and the travel motor.
The oil return valve block 4 integrates an overflow valve and a solenoid valve to limit the
pressure of the make-up system and release the travel brake.
The flow and direction of the travel pump are adjusted through two proportional solenoid
valves. The travel motor is adjusted through one proportional solenoid valve. The speed of the
pump and motor can be adjusted in a stepless manner:
Low speed and large torque: travel pump: small angle and small flow travel motor; large
angle and large consumption
High speed and low torque: travel pump: large angle and large flow travel motor: small
angle and small consumption

6.3.3 Structure and Principle of the Travel Pump
Fig. 6.18 Travel Pump Oil Port
S/P: HP and LP working oil ports of the pump MS/MP: pressure measuring oil ports of
HP and LP oil ports
F: Make-up pressure oil port T: pump control oil drain port
L/U/: oil drain port of pump housing Z/Y: pressure measuring oil port of servo
pressure
MY/MZ: travel pump solenoid valve
Fig. 6.19 Schematic Diagram of the Travel Pump
1 - travel pump 2 - HP overflow valve 3 - makeup overflow valve 4 - variable piston 5 - variable
mechanism 6 - electric proportional reducing valve
The travel pump is a swash plate type close circuit axial piston variable displacement pump.

The displacement of the pump is controlled by the input current of the proportional
electromagnet to realize the stepless speed change of the system.
(1) Pressure
The maximum working pressure of the travel pump is 435 bar, the peak pressure is 450 bar,
and the continuous working pressure is 250 bar.
(2) Composition
The travel pump mainly includes: HP overflow valve 2, make-up overflow valve 3, variable
piston 4, variable mechanism 5 and electric proportional reducing valve 6.
(3) Makeup overflow valve and HP overflow valve
The pressure oil from the make-up pump enters port F of the pump after passing through the
make-up filter, and then reaches the make-up overflow valve (25 bar) and at the same time,
the HP overflow valve (435 bar). In the HP overflow valve, the pressure oil from the make-up
pump goes to the closed travel pump through the check valve, and the make-up pressure is
the make-up overflow pressure of 25 bar. The outlet of the travel pump is connected to the HP
overflow valve. If the outlet pressure of the pump exceeds the set pressure value of 435 bar of
the HP overflow valve, the overflow will be conducted through the HP overflow valve.
The HP/makeup overflow valve is integrated on the travel pump. Each travel pump is provided
with 2 HP/makeup overflow valves, which are composed of the valve core, valve body,
high-pressure spring, makeup spring, spring seat, and snap ring. The pressure setting value
of the valve cannot be adjusted. The valve shall be replaced as a whole if other pressures
need to be set.
Make-up valve function: Due to the makeup pressure, there is always pressure in the oil
channel "F". If the pressure in P/S is lower than that in oil channel "F", the pressure in
chamber "F" acts on the effective conical surface of the check valve due to pressure
difference, so as to overcome the force of the makeup spring 2, move the valve core upward,
open the oil channels "F" and P/S to balance the pressure to avoid cavitation.
Function of HP overflow valve: When the high pressure in the oil channel P/S acting on the
slide valve area D reaches the set value of spring 1, the slide valve moves against the spring
force to open the oil channel between P/S and "F", and release the pressure to channel "F".

(4) Variable mechanism
On the one hand, the pressure oil from the make-up pump supplements the travel pump,
which constitutes the make-up line; on the other hand, it goes to the servo valve and the
solenoid valve, which constitutes the servo (control) oil line. During operation, the controller
controls the solenoid valve according to the working condition, and controls the oil in the servo
oil line to reach the variable mechanism (regulating piston of the pump), and adjusts the swing
angle of the pump by controlling the amount of oil entering the two chambers of the piston,
that is, the displacement. The voltage of the electric proportional reducing valve is 24V, and
the pump displacement is directly proportional to the input current of the solenoid valve. When
the current is maximum, so is the displacement.
(5) Housing return oil
The leaked oil for cooling and lubrication flows back to the oil tank through the radiator from
ports L and U (hot oil) or directly (cold oil).
(6) Structure of the travel pump
2 - swash plate 6/7 - variable displacement piston 14 - electro-hydraulic control valve block 18 -
feedback rod 21 - shaft 22 - pilot piston 23 - variable cylinder 24 - valve plate 25 - holder 26 - fixing plate
27 - PTO port 28 - feedback rod 29 - locating pin (control device E1 centering) 40 - seal ring 42 - seal
ring 43 - oil pipe

3 - pilot piston 5 - pilot valve core 15 - spring 16 - proportional valve 18 - position feedback rod 30 -
housing 31 - spring seat 32 - adjusting plug 33 - lock plate 34 - adjusting stud for maximum
displacement 35 - nut (tightening torque 23n.m) 36 - lock plate 37 - hollow screw to adjust hydraulic
neutral position
Variable displacement process of the main

pump:
When the engine drives the main pump to
rotate and the input current of the proportional
solenoid valve is zero or less than the start
current, the pressure acting on pilot piston 3 is
less than the pre-pressure of the spring 15,
the pilot piston 3 has no displacement, and the
output flow of the main pump is zero.
When the input current of the solenoid valve is
increased and the pressure acting on pilot
piston 3 is greater than the force of spring 15
applied on pilot piston 3, pilot piston 3 starts to
move (the displacement is proportional to the
current). At the same time, the variable lever
drives the pilot valve core 5 to offset, so that
one of the variable displacement pistons 6/7 is
connected to the housing, and the other one is
connected to the control oil pressure to push
swash plate 2 to deflect, and the main pump starts to output flow. While the swash plate 2
deflects, its position feedback rod 18 drives the pilot valve core 5 to move in the opposite
direction. If the input current remains unchanged, the pilot valve core 5 will quickly return to
the neutral position, the variable displacement pistons 6 and 7 will simultaneously bear the oil

pressure in the control area again. Swash plate 2 will stop deflecting, and the main pump will
maintain the displacement corresponding to the input current.
The pre-pressure of springs 15 at both ends of the pilot piston 3 determines the start current
of the displacement and the start pressure of the main pump.
6.3.4 Structure and Principle of the Travel Motor
Fig. 6.20 Schematic Diagram of the Travel Motor
1 - pilot valve 2 - proportional electromagnet 3 - flushing valve 4 - flushing overflow valve A/B - pressure
oil port L/U/L1/L2 - oil drain port E - control oil port Ss - speed sensor Lmin: adjusting screw for
minimum displacement of motor Lmax: adjusting screw for maximum displacement of motor Ma/Mb -
pressure measuring port
The travel motor is a swash plate type axial piston variable displacement pump. The hydraulic
pump provides high-pressure oil for the high-pressure oil port A/B of the motor. The oil flows
through the swash plate and the variable cylinder and acts on the end face of the piston and
pushes the piston to realize the rotary movement of the motor. The left-hand rotation
(counterclockwise) or right-hand rotation (clockwise) depends on whether the high-pressure
oil inlet is A or B.
The travel motor is installed on the final drive brake housing through bolts in the main frame.
Solenoid valve 2 adjusts the displacement of the motor. The maximum displacement of the
motor at the initial position is the maximum displacement. The control oil at port E comes from
the make-up pump.
(1) Pressure
The maximum working pressure of the travel motor is 450 bar, the peak pressure is 500 bar,
and the continuous working pressure is 250 bar.
(2) Composition
The travel motor has a variable structure (regulating piston of the motor), a flushing overflow
valve, a flushing valve and a speed sensor.
(3) Electric proportional reversing valve
It is a 4/2 solenoid valve with a voltage of 24V. The control oil source is provided by the
make-up system through the motor E port. The motor displacement is inversely proportional
to the input current of the solenoid valve. When the current is the maximum, the displacement
is minimum; when the current is minimum, the displacement is maximum.
When the proportional solenoid valve 2 is not energized, the pilot valve core 1 does not act,
and the motor is at the maximum displacement.
When the proportional solenoid valve 2 is energized, the pilot valve core 1 opens, which
pushes the piston to move and changes the swash plate angle, thus changing the motor
displacement.
(4) Flushing system
The flushing system can sufficiently reduce the temperature in the closed system. The
low-pressure side of the motor is connected to overflow valve 4 through flushing valve 3. After
the flushing oil is cooled, it returns to the system to cool the whole closed circuit through the
make-up circuit (installed on the travel pump).
The flushing system can quantitatively supply flushing oil to the housing through overflow
valve 3. After flushing the housing, the flushing oil will be discharged out of the housing with
the oil drainage of the housing. The oil drainage of the housing will flow back to the oil tank
through L/U/L1/L2 via the brake oil return valve block and the radiator (hot oil) or directly (cold
oil).
Function of the flushing valve: As shown in the figure below, when the pressure at ports A and
B of the motor is equal (The travel pump is at zero displacement, and the pressure at ports A
and B of the main oil line is at make-up pressure), the two valve cores of flushing valve 4 are
in the neutral position under the action of spring force, and the flushing overflow valve 3 has
no flow

Fig. 6.21 Flushing System
When the system starts to work, as shown in the figure below, pressure is established on the
high-pressure side of the main oil line. If port A is HP and port B is LP, A1 and B1 are pushed
to the right. Part of the LP flow is pushed through the groove at B1 to open flushing overflow
valve 3, and enters the motor housing. Then it returns to the oil tank through the oil return pipe
of the housing. The flushing flow of this part is 10 L/min. The taper C of A1 limits the maximum
stroke of A1 while closing the flow channel from HP to flushing overflow valve 4.
 Variable displacement process of the motor:
When the proportional solenoid valve 10 is not energized, the pilot valve core 1 is in the upper
position under the action of the feedback spring 16. The oil of port E (from the make-up pump)
enters the oil chambers of pistons 13 and 14 through the oil channel, and returns to the oil
return tank through the housing. At this time, the motor is at the maximum displacement.
When the proportional solenoid valve 10 is energized, the current reaches the opening value
of the pilot valve core 1. Pilot valve core 1 overcomes the thrust of feedback spring 16 under
the action of the electromagnetic force and moves downwards, opening the channel from port
E to the oil chamber of piston 14. The pressure in the oil chamber of piston 14 gradually
increases until the swash plate 3 swings back. Under the action of feedback rod 15, the
electromagnetic force and feedback spring 16 establish a new force balance, so that pilot
valve core 1 is in a new balance position. The motor will maintain the displacement under the
current until the current changes.

Fig. 6.22 Motor Structure
1 - pilot valve core 2 - shaft 3 - swash plate 7 - piston 8 - cylinder barrel 9 - valve plate 10 - proportional
solenoid valve 13 - piston 14 - piston 15 - feedback rod 16 - feedback spring 17 - pilot valve housing 18
- oil pipe 19 - rear end cover 20 - speed sensor 21 - tonewheel
6.3.5 Structure and Principle of Oil Return Valve Block
1 - Brake Solenoid Valve

The oil return valve block is installed in the left side of the main frame, and the brake solenoid
valve is integrated into the valve.
Braking function: When solenoid valve 1 is powered on, the makeup pressure is transmitted
to the traveling brake piston chamber through the solenoid valve and overcomes the spring
force. The piston moves and releases the braking. When solenoid valve 1 is powered off, it
blocks the make-up pressure. No pressure oil enters the brake, the spring pre-pressure
compresses the friction plate, and the machine is in the braking state.
Oil return function for housings: The valve block is used for oil return of left and right travel
pumps and left and right travel motor housings. When the oil temperature is low, the oil does
not need to dissipate heat and is directly bypassed to the oil tank. When the oil temperature is
high, the returning oil from the housing is cooled by the electronic heat dissipation module and
then returns to the oil tank.

6.3.6 Make-up Pump
1 - Oil Outlet 2 - Oil Suction Port
The make-up pump is a gear pump, connected in series behind the right travel pump. 2 is the
oil suction port, and 1 is the oil outlet which is connected with the oil inlet of the make-up filter.
6.3.7 Principle of Make-up Filter
1 - alarm 2 - oil inlet (to make-up pump outlet) 3 - oil outlet (to port p of manifold)
The make-up oil filter is located on the left side of the machine. Port 2 is the oil inlet, which is
connected to the outlet of the make-up pump. Port 3 is the oil outlet, which is connected to
port P of the manifold. 1 is the filter with pressure alarm, the alarm pressure is 2.4 bar, and the
bypass pressure is 3.4 bar.
6.3.8 Centralized Pressure Measurement

The centralized pressure measurement is located on the left fender, designed with 5 pressure
measurement points for the travel system pressure and braking pressure, respectively.

Low idle speed High idle Low idle speed High idle speed
Description Description
(MPa) speed (MPa) (MPa) (MPa)
Ms1: Port Ms of Mp1: Port Mp of
2.3-46.5 2.3-46.5 2.3-46.5 2.3-46.5
left travel pump left travel pump
Ms2: Port Ms of Mp2: Port Mp of
2.3-46.5 2.3-46.5 2.3-46.5 2.3-46.5
right travel pump right travel pump
BR: Braking
2.3±0.3 2.6±0.3
pressure
6.3.9 Testing and Adjustment of Make-up Pressure

Specification
Hydraulic oil
50-60℃
temperature
Engine speed High idle
Make-up pressure
26±0.3
(bar)
a. Jack up the machine, and lower the work tools. The tracks on both sides can operate
freely;
b. Install a 0 - 60 bar pressure tester or digital pressure tester at port G of the manifold, and
increase the oil temperature to the specified range before testing;
c. With the working handle and traveling handle in the locked positions, run the engine at
high idle speed, start the test and record the value of G;
d. If the pressure is not the specified value, adjust the makeup overflow valve;
e. Loosen the corresponding nut with a 14 wrench, and screw the adjusting screw with an
Allen wrench. Rotate it clockwise to increase the pressure and counterclockwise to
decrease the pressure;
f. If the pressure cannot reach the design value, repair or replace the overflow valve;
g. Put down the traveling lock lever, move the traveling handle forward or backward, and
observe the pressure of G. When the handle is pushed forward or backward, the pressure
drops by about 2 bar. If the pressure is abnormal, check the pressure of the overflow
valves of the left and right travel motors;
h. Remove the testing tools.

6.3.10 Testing and Adjustment of Hydraulic Zero Point of the Travel Pump
Whether the hydraulic zero point is aligned is determined by the position of part 1 on the travel
pump. When the zero point is aligned, the dimension here shall be 14.75 mm.
When the travel pump is repaired or the hydraulic zero point of the travel pump is misaligned,
the hydraulic zero point shall be adjusted.
freely;
b. Install a 0 - 60 bar pressure tester or digital pressure tester at centralized pressure
measurement ports MS1 and MP1 or MS2 and MP2 (Use a pressure tester of 0 - 600 bar
if abnormal pressure is suspected), and increase the oil temperature to the specified
range before testing;
c. When the working handle and traveling handle are in the locked positions, run the engine
at a high idle speed. Observe whether the pressure values of the 2 pressure measuring
ports are equal to the make-up pressure, and the maximum difference is about ±1 bar;
d. If the pressure is abnormal, adjust the hydraulic zero point alignment;
e. Refer to position ①. Remove the paint film, loosen the screw, remove the base plate,
adjust part ① so that the distance is 14.75 mm, and then restore;
f. Test the pressures of MS1 and MP1 or MS2 and MP2 again.
6.3.11 Testing and Adjustment of Braking Pressure
Before the test, make sure that nothing is on the track to prevent personal injury due to
unexpected operation of the track.

freely;
b. Install a 0 - 60 bar pressure tester or digital pressure tester at the centralized pressure
measuring port BR
c. Start the engine and raise the oil temperature to 50-60 °C;
d. The brake solenoid valve is energized, and the traveling handle and the working handle
are in the neutral position. Observe the pressure value, which shall be consistent with the
makeup pressure;
e. If the pressure is abnormal, test whether the resistance of the solenoid valve is 28-36Ω. If
the resistance is abnormal, repair or replace the solenoid valve.
6.4 Disassembling and Assembling Main Hydraulic Components of

Working Hydraulic System
6.4.1 Removal and Installation of Implement Pump
Removal
Drop the work tools to the ground and shut down the engine. Release the residual pressure in
the hydraulic line.
Refer to "Testing and Adjustment" about the release of residual pressure in the hydraulic oil
line for details.
Then slowly loosen the filler cap to relieve the pressure in the hydraulic tank.
Disconnect the cable from the battery negative (-) terminal.
1. Drain the hydraulic tank.
Total volume of hydraulic tank: 135L
2. Remove the mounting bolts at the front of the cab, and then remove the cab according to
the instructions for "Cab Removal Operation".
Refer to "Cab Removal Operation" for details.
3. Remove hose clamp (1) and jointless hose (2).
4. Disconnect oil outlet hose (3) of the pilot pump and oil outlet hose (4) of the implement
pump.

6. Lift the two-way pump (5), remove the mounting bolt (6) and remove the two-way pump.
Two-way pump: 35 kg
7. Plug the oil port of the hose.
Installation
 Installation shall be in the reverse order of removal.
 Refill (the hydraulic tank)
Fill the oil to the specified level through the oil filler, and run the engine to circulate the oil
through the system. Check the oil level again.
6.4.2 Removal and Installation of the Working Valve

Removal
the hydraulic line.
line for details.
Total volume of hydraulic tank: 135L.
2. Remove the bolt (1), bolt (2) and right guard (3).
3. Disconnect 6 pilot hoses (4), (5), (6), (7) (8) and (9).
4. Disconnect 1 hose (10) and 7 hard pipes (11), (12), (13), (14), (15), (16), (17).
5. Hang the working valve (19), remove 3 bolts (18), and remove the working valve (19).
Working valve assembly: 86KG.

6. Plug the hose and oil port with the plug and the flange plate.
Installation
Refill (the hydraulic tank)
6.4.3 Removal and Installation of the Hydraulic Tank

Removal
the hydraulic line.
line for details.
Total volume of hydraulic tank: 135L.
2. Remove the guard (1) according to the instructions in "Removal and Installation of Shield"

4. Remove hose clamp (2) and jointless hose (3).
5. Disconnect oil return hoses (4), (5), (6), (7) and (8).
6. Disconnect oil suction pipe (9).

7. Plug the oil tank port with the plug and the block plate.
8. Remove bolt (11).

9. Hang the hydraulic tank (10) and take it off.
Hydraulic tank: 122 Kg
Installation
Refill (the hydraulic tank)
6.4.4 Removal and Installation of the Hydraulic Cylinder

1) Removal and Installation of the Blade Lift Cylinder
■ Removal of the Blade Lift Cylinder

The lift cylinders are arranged symmetrically on the left and right. Only the removal and
installation process of the right lift cylinder will be described.
1. Drop the work tools to the ground and shut down the engine. Release the residual
pressure in the hydraulic line.
2. Before removal, tie the lift cylinder lug with the lifting tool (sling) to prevent the cylinder
from falling off the machine during removal.
3. Remove the hose connecting the large and small chambers of the lift cylinder at (1) (2)
4. Take off bolt (3) and remove cover (4). At this time, the rod head of the lift cylinder can
move freely and separate from the pin shaft.
5. Take off the bolt and cover (6) at (5), and gently push the lift cylinder away from the yoke.
■ Installation of the Blade Lift Cylinder
1. Drop the work tools to the ground and shut down the engine.
2. Before installation, tie the lift cylinder lug with the lifting tool (sling) and place it inside the
yoke slowly. Install the cover (6) with bolt (5).
3. Install the hose connecting the large and small chambers of the lift cylinder at (1) (2).
4. Install the cover (4) on the pin shaft with bolt (3). (When connecting the rod head of the
cylinder with the work tool, the following operations can be performed if the cylinder
piston does not extend long enough, so as to ensure that the hoses of the large and small
chambers of the left and right cylinders can be connected: Start up the machine and
gently push the blade handle forward to extend the lift cylinder piston to the pin shaft
position of the rod head)
2) Removal and Installation of the Blade Tilt Cylinder
■ Removal of the Blade Tilt Cylinder

2. Before removal, tie the middle of the tilt cylinder with the lifting tool (sling) to prevent the
cylinder from falling off the machine during removal.
3. Remove tilt cylinder guard (1)
4. Remove hoses (2) and (3) connecting the large and small chambers of the tilt cylinder
4. Remove the bolt at (5) and lock washer at (6), and pull out pin shaft (4). At this time, the
rod head of the lift cylinder can move freely and separate from the pin shaft hole.

5. Remove the bolt at (7), and gently lift the sling to disengage the tilt cylinder from the
mounting base.
■ Installation of the Blade Tilt Cylinder
2. Before installation, tie the middle of the tilt cylinder barrel with the lifting tool (sling) and
place it slowly in the mounting base of the cylinder body. Install bolt (4), lock washer (6)
and bolt (5);
3. Install the hose connecting the large and small chambers of the tilt cylinder at (2) (3).
4. Install the bolt (7), and install the rod head on the work tool. (When connecting the rod
head of the cylinder with the work tool, the following operations can be performed if the
cylinder piston does not extend long enough, so as to ensure that the hoses of the large
and small chambers of the cylinder can be connected: Start up the machine and gently
push the blade handle leftward to extend the tilt cylinder piston to the installation position
of the rod head).
3) Removal and Installation of the Ripper Lift Cylinder
■ Removal of the Ripper Lift Cylinder

The ripper lift cylinders are arranged symmetrically on the left and right. Only the removal and
2. Before removal, tie the middle of the lift cylinder with the lifting tool (sling) to prevent the
3. Remove hoses (1) ~ (4) connecting the large and small chambers of the lift cylinder
4. Remove the pin shafts at (5) and (6), and gently lift the sling to separate the ripper lift
cylinder from the mounting base.
■ Installation of the Ripper Lift Cylinder
2. Before installation, tie the middle of the tilt cylinder barrel with a lifting tool (sling), and
place it slowly in the mounting base of the cylinder block. Align it with the pin shaft hole,
and insert pin shafts (5) and (6). (When connecting the rod head of the cylinder with the
work tool, the following operations can be performed if the cylinder piston does not extend
long enough, so as to ensure that the hoses of the large and small chambers of the left
and right cylinders can be connected: Start up the machine and gently push the ripper
handle leftward (rightward) to extend the tilt cylinder piston to the pin shaft position of the
rod head)
3. Install hoses (1) ~ (4) connecting the large and small chambers of the lift cylinder.
4) Removal and Installation of the Ripper Tilt Cylinder
■ Removal of the Ripper Tilt Cylinder

The ripper lift cylinders are arranged symmetrically on the left and right. Only the removal and
2. Before removal, tie the middle of the lift cylinder with the lifting tool (sling) to prevent the
3. Remove hoses (1) ~ (2) connecting the large and small chambers of the lift cylinder
4. Remove the pin shafts at (3) and (4), and gently lift the sling to separate the ripper lift
cylinder from the mounting base.
■ Installation of the Ripper Tilt Cylinder
2. Before installation, tie the middle of the tilt cylinder barrel with a lifting tool (sling), and
place it slowly in the mounting base of the cylinder block. Align it with the pin shaft hole,
and insert pin shafts (3) and (4). (When connecting the rod head of the cylinder with the
work tool, the following operations can be performed if the cylinder piston does not extend
long enough, so as to ensure that the hoses of the large and small chambers of the left
and right cylinders can be connected: Start up the machine and gently push the ripper
handle leftward (rightward) to extend the tilt cylinder piston to the pin shaft position of the
rod head)

3. Install hoses (1) ~ (2) connecting the large and small chambers of the lift cylinder.
6.5 Disassembling and Assembling Main Hydraulic Components of

Travel Hydraulic System
6.5.1 Removal and Installation of Travel Pump
Fig. 6.23 Removal and Installation of Relevant Components of the Two-way Travel Pump
Main pipeline between Two-way implement
1 2 Make-up pump 3
pump and motor pump
Oil return hose of the Make-up hose of
Oil return hose of the right
4 control mechanism of 5 6 the right travel
travel pump housing
the right travel pump pump
Oil return hose of the
Oil return hose of the Make-up hose of
7 8 control mechanism of the 9
left travel pump housing the left travel pump
left travel pump
Centralized pressure 12 Left travel pump
10 11 Transfer case
measuring hose
13 Right travel pump
Removal
the hydraulic line.
line for details.
2. Remove the cab, the engine guard assembly, engine accessories and pipelines
connecting the engine and the radiator, so as to lift the engine and transfer case pump
assembly as a whole. Refer to the removal and installation process of the cab, guard
assembly and engine for details.
3. Remove the main line (1) from the motor end that connects the travel pump to the travel
motor. The oil port and hose connector shall be protected.
4. Remove the pipeline connecting the make-up pump (2). Refer to the disassembly
process of make-up pump for details.
5. Remove the pipeline connecting the two-way implement pump (3). Refer to the
disassembly process of the implement pump for details.
6. Remove the hose connecting the travel pump, and protect each oil port with plastic bags.
The hoses to be removed include oil drain pipe (7) of the left travel pump housing, oil
drain pipe (5) of the right travel pump housing, oil return hose of the control mechanism of
the right travel pump (4), oil make-up hose of the right travel pump (6), oil return hose of
the control mechanism of the left travel pump (8), oil make-up hose of the left travel pump
(9) and centralized pressure measuring hose (10).
7. Remove the cooling pipeline of transfer case (12) and relevant brackets. Refer to the
removal process of the transfer case for details.
8. Unplug the 4 electrical plugs on the left and right travel pump solenoid valves, the oil
temperature sensor plug of the transfer case, etc. and relevant engine harnesses.
Disconnect all relevant connecting harnesses from the frame.
9. After confirming that the pump, transfer case and engine are not connected with other
components, use lifting equipment to lift the engine, transfer case (12), pump assembly
and main travel pipeline (1) as a whole. Refer to the engine disassembly and assembly
process for the specific lifting positions.
10. Lift the engine, transfer case and pump assembly as a whole and place them in safe
positions.

11. Remove the make-up pump (2) and the two-way implement pump (3) as a whole. Refer to
the disassembly and assembly process of make-up pump and the implement pump for
details. Protect the rear oil outlet of the right travel pump with a cover plate
12. Disconnect the traveling main pipeline hose (1) from the left travel pump (12) and the right
travel pump (13) and protect the hose joint from the pump oil port with a plastic plug or
cover plate.
13. Lift the left travel pump (12) or right travel pump (13) with the lifting equipment.
14. Remove the mounting bolts for the lifting of the travel pump, slowly pull out the travel
pump with lifting equipment and place it in a safe position.
15. Protect the transfer case mounting port with a cover plate.
■ Installation of the Travel Pump
1. Lift the left travel pump (12) or right travel pump (13) with lifting equipment, engage the
travel pump spline shaft with the transfer case spline sleeve, and then push the mounting
flange rabbet of the travel pump to fit with the transfer case groove.
2. Install the left travel pump (12) or right travel pump (13) on the corresponding mounting
flanges with mounting bolts, with tightening torque of 540 N*m respectively.
3. Install the main travel pipeline (1) at the port of the left travel pump (12) or the right travel
pump (13) as marked.
4. Install the two-way implement pump (3) and the make-up pump (2) at the rear flanges of
the transfer case and the right travel pump respectively. Refer to the disassembly and
assembly process of the implement pump (3) and the make-up pump (2) for details.
5. Install the engine, transfer case and pump assembly into the frame as a whole with lifting
equipment. Refer to the disassembly and assembly process of the engine for details.
6. Restore pipeline connections as marked.

7. Fill oil into the oil pump housing and the oil tank, and replace the travel system filter.
8. Install the cab and other related components.
9. Turn the battery negative switch to the ON position.
10. Carry out the initial startup process of the pump and the motor, bleed and calibrate the
travel hydraulic system.
6.5.2 Removal and Installation of Two Travel Motors (Left Motor)

Removal
the hydraulic line.
line for details.
1. Remove the cab. Refer to the specification of cab removal operation for details.
2. Mark pipelines (1) ~ (6) before removal to facilitate recovery.
3. Remove oil drain pipeline (2), main pipeline (3), brake pipeline (1) and (6) of the motor
housing, and motor control pipeline (4).
4. Plug all oil ports and pipelines with plugs or end covers to prevent pollution.
5. Remove the wire plug (5) from the speed sensor and motor solenoid valve.
Relevant Components of the Travel Motor


Main pipeline
Outlet hose of brake
1 2 Oil return hose of motor housing 3 between pump
solenoid valve
and motor
Motor displacement Harness connector of motor Connecting hose
4 5 6
control hose solenoid valve and speed sensor of brake
Mounting bolt of final Mounting bolt of
7 8 Left final drive 9
drive motor
10 Left motor
6. Detach the track. Refer to the disassembly and assembly process of the track for details.
7. Remove fixing bolt (7) between final drive (8) and the frame, and lift out the final drive
together with the motor.
Removal and Installation of the Final Drive

8. Lift the final drive to a safe position, and mark the motor oil port relative to the final drive
direction.
9. Remove mounting and fixing bolt (9) of left motor (10), lift the motor out, and place it in a
safe area. Protect the exposed brake from contamination.

Installation (Left Motor)
1. Place the brake end face horizontally, lift the motor and install it on the brake. Calibrate
the oil port relative to the final drive direction according to the mark. Install the fixing bolt
of the motor to a tightening torque of 540 N*m.
2. Lift the final drive so that the motor is close to horizontal. Refuel through the oil drain port
of the motor housing, fill it up and protect the oil port.
3. Install the final drive. Refer to the final drive installation for details.
4. Install hoses and connectors according to the markings made during removal.
5. Fill the oil tank to a level above the level gauge for the first time.
6. After replacing the motor with a new one, carry out the initial startup process of the pump
and the motor, and calibrate the motor.
Caution
• The motor pipeline must be consistent before and after removal.
• Bleed the closed system for the initial startup
• Refer to technical sample for oil types
• The maximum temperature of the motor housing shall not exceed 95 °C
• Allowable pressure of the housing: 1.5 bar (absolute pressure: 2.5 bar)
The removal and installation of the right motor shall be carried out with reference to that of the
left motor.
6.5.3 Removal and Installation of the Make-up Pump
Relevant Components of the Make-up Pump

Oil outlet hose of
1 Hose clamp 2 Jointless hose 3
make-up pump

Oil suction hard pipe of
4 5 Make-up pump 6 Bolt
make-up pump
Removal
the hydraulic line.
line for details.
1. Remove the cab. Refer to the specification of cab removal operation for details.
2. Remove the pipeline connecting the make-up pump, and make corresponding marks.
Protect all oil ports (including hose ports, connectors, oil inlet and outlet of the pump, etc.)
with plastic bags and plugs. Remove hoses including hose clamp (1), jointless hose (2),
oil suction hard pipe of the make-up pump (4) and oil outlet hose of the make-up pump
(3).
Removal and Installation of the Two-way Make-up Pump

4. Remove mounting bolt (6) of the make-up pump, and hang the make-up pump (5) with
lifting equipment. Slowly pull out the spline, lift out the make-up pump, and place it in a
safe area.
Installation
 Installation shall be in the reverse order of removal.
 Refill (the hydraulic tank)

6.5.4 Removal and Installation of Oil Return Valve Block
Removal and Installation of Components of the Oil Return Valve Block

Oil return hose of left
1 Oil return valve block 2 To brake hose 3
motor housing
Oil return hose of the
Oil return hose of right Oil return hose of the left
4 5 6 right travel pump
motor housing travel pump housing
housing
Oil return hose of the Oil return hose of the
Hose connecting
7 control mechanism of 8 control mechanism of the 9
manifold
the left travel pump right travel pump
Hose connecting oil inlet of 12 Hose connecting oil
10 Oil return hard pipe 11
oil cooler outlet of oil cooler
13 Brake solenoid valve 14 Bolt
Removal
the hydraulic line.
line for details.
2. Remove the cab. Refer to the cab removal procedure.
3. Mark the pipeline and electrical connectors for easy subsequent assembly.
4. Remove the pipe fittings (2) - (12) on the valve block, and plug all oil ports to prevent
contamination.
5. Remove the electrical connector of the brake solenoid valve (13) on the valve block.

6. Remove side fixing bolt (14) of valve block (1) and the bracket, and remove the valve
block.
Installation of Oil Return Valve Block
(1) Put the oil return valve block on the upper side of the bracket, and install fastening bolt
(14)
(2) Connect each hose and electrical connector based on the previous marks.
(3) Install the cab.
(4) Turn the battery negative switch to the ON position.
(5) Start the machine, check for oil leakage, and repair it if necessary.


Chapter 7 Frame and Hood

Fig 6.1 Main Frame
As shown in the figure, the main frame is the most critical structural part of the complete
machine and is used for fixing and installation of components, such as hood, radiator, engine,
balance beam, cab, fuel tank, hydraulic fuel tank, final transmission. The machining accuracy
of each installation position on the main frame determines the operating performance and
appearance coordination of the whole machine.

Fig 6.2 Hood

1 Gantry 2 Upper hood of engine
3 Front hood 4 Front grille

Side shield upper cover of Side shield lower cover
5 6
engine of engine
The bottom of the front hood and the front side of the main frame are installed on the main
frame through the pin shaft; the front grille is fixed on the front hood through bolts; the gantry
is installed on the main frame through bolts; the upper hood of engine is fixed on the front
hood and the gantry through bolts; the side shield upper cover of engine is fixed on the upper
hood and the side shield lower cover of engine through bolts; and the side shield lower cover
of engine is fixed on the main frame and flange plate through bolts. After removing the 4 bolts,
the front grille can be opened sideways to observe the operating conditions of the fan and
radiator inside. The engine side shield can be opened directly to facilitate the inspection and
replacement of the filter element.

7.2 Removal and Installation of Main Frame
Fig 6.3 Removal and Installation of Main Frame

S/N Description Qty. S/N Description Qty. S/N Description Qty.
Radiator 1 2 Washer Bolt 12*30 2

1 2 3
base plate
4 Plate 1 5 Washer 2 6 Bolt 12*30 2
Front bottom 1 8 Washer Bolt 12*30 6

7 6 9
guard plate
Middle 1 11 Washer Bolt 12*30 6
10 bottom guard 6 12
plate
Rear bottom 2 14 Washer Bolt 12*30 8
13 8 15
guard plate
Note: The bottom guard plate is heavy, and shall be removed with proper tools to avoid
crushing.
1. Remove the front bottom guard plate(7), middle bottom guard plate(10), and rear bottom
guard plate(13).
2. Clean the dust, soil and other sundries left on the bottom plate of the main frame.
3. Install the front bottom guard plate(7), middle bottom guard plate(10), and rear bottom
guard plate(13).
4. When observing the oil drain port, only remove the plate (4).
Specification:
Weight of front bottom guard plate: 24.7kg
Weight of middle bottom guard plate: 37.5kg
Weight of rear bottom guard plate: 14.3kg/piece
7.3 Removal and Installation of Hood

7.3.1 Removal and Installation of Front Grille
Fig 6.4 Removal and Installation of Front Grille

1 Front grille 1 2 Cover 4 3 Bolt 12*35 4
4 Washer 4
Note: The front grille is heavy, and shall be removed with proper tools to avoid injury.
1. Remove the cover (2), bolt (3), and washer (4), and the front grille (1) can be opened by
rotation;
2. Fix the front grille (1), mounting cover (2), bolt (3) and washer (4).
Specification:
Weight of front grille: 76.7kg

7.3.2 Removal and Installation of Front Hood
Fig 6.5 Removal and Installation of Front Upper Hood

Front upper
1 1 2 Bolt 12*50 4 3 Washer 4
hood
4 Shock pad 4
Note: The front hood is heavy, and shall be removed with proper tools to avoid injury. During
removal, keep the shock pad to prevent loss.
1. Remove the bolt (2), washer (3) and shock pad (4), and remove the front upper hood (1);
2. Install the front hood (1), and install the bolt (2), washer (3) and shock pad (4).
Specification:
Weight of front hood: 33.7 kg

7.3.3 Removal and Installation of Upper Hood
Fig. 6.6 Removal and Installation of Upper Hood of Engine

Upper hood
1 1 2 Bolt 16*50 2 3 Washer 2
of engine
4 Washer 2 5 Exhaust pipe 1 6 Bolt 12*30 4
7 Washer 4 8 Plate 2 9 Bolt 12*25 4
10 Washer 4 11 Plate 1 12 Plate 1
13 Pre-filter 1 14 Bolt 12*30 2 15 Washer 2
16 Plate 2 17 Bolt 12*30 6 18 Washer 6
Note: The upper hood is heavy, and shall be removed with proper tools to avoid injury. During
removal and installation, pay attention to protecting the transition channel under the pre-filter.
1. Remove the bolt (6) and washer (7), and take away the plate (8) and exhaust pipe (5).
Remove bolt (17), washer (18), and take away the plate (16), plate (11), plate (12) and
pre-filter (13). Remove bolt (9) and washer (10). Remove bolt (2), washer (3), washer (4),
bolt (14) and washer (15), and finally remove the upper hood (1) of engine.
2. Install the upper hood (1), and install the bolt (2), washer (3) and washer (4), bolt (14) and
washer (15). Install the exhaust pipe (5), plate (8), bolt (6) and washer (7). Install the bolt
(9) and washer (10). And install the pre-filter (13), plate (11), plate (12), (16), bolt (17) and
washer (18).
Specification:
Weight of upper hood: 79.7 kg

7.3.4 Engine Side Shield and Its Removal and Installation
Fig. 6.7 Engine Side Shield and Its Removal and Installation
Side shield
1 1 2 Washer 4 3 Bolt 12*30 4
upper cover
Side shield
4 1 5 Cover 3 6 Bolt 12*30 3
lower cover
7 Washer 3 8 Pin 1
Note: The engine side shield is heavy. To avoid injury, please remove the upper half before
the lower half with a proper tool.
1. Remove the bolt (3) and washer (2), remove the upper cover (1) of the engine side shield,
remove the cover (5), bolt (6) and washer (7), move the lower cover of the engine side
shield backward to disengage the pin shaft (8), and then remove the lower cover (4) of
side shield.
2. Connect the pin shaft (8) with the corresponding hole, install the side shield lower cover
(4), install the cover (5), bolt (6) and washer (7), install the side shield upper cover (1),
and install the bolt (3) and washer (2).
Specification:
Total weight of engine side shield: 129kg

7.3.5 Removal and Installation of Gantry
Fig 6. 8 Removal and Installation of Gantry

S/N Name Qty. S/N Description Qty. S/N Description Qty.
1 Gantry 1 2 Bolt 14*45 8 3 Washer 8
Note: The gantry is heavy, and shall be removed with proper tools to avoid injury.
1. Remove the bolt (2) and washer (3), and take down the gantry (1);
2. Install the gantry (1), and fix the washer (3) and the bolt (2).
Specification:
Weight of gantry: 44.5kg

7.3.6 Removal and Installation of Rear Side Shield
Fig 6.9 Removal and Installation of Rear Side Shield

Left rear
1 1 2 Washer 9 3 Bolt 12*35 9
hood
4 Bolt 12*30 2 5 Washer 2 6 Right rear hood 1
7 Bolt 12*35 4 8 Washer 4 9 Washer 2
10 Bolt 12*30 2
Note: The rear side shield is heavy, and shall be removed with proper tools to avoid injury.
1. Remove bolts (3), (4) and washers (2), (5), and take down the left rear hood (1). Remove
bolts (7), (10) and washers (8), (9), and take down the right rear hood (6).
2. Install the left rear hood (1), and fix the bolts (3), (4) and washers (2), (5). Install the right
rear hood (6) and fix the bolts (7), (10) and washers (8), (9).
Specification:
Weight of left rear hood: 62kg


Chapter 8 Electrical system

8.1 Specifications of Fuses and Relays
Fig. 8.1 Floor Rack Fuse Box

Fig. 8.2 Cab Fuse Box
Specifications of Fuses and Relays

Floor rack fuse box
F1——Horn relay
F2——Hydraulic oil filter clogging alarm
F3——Travel switch
F4——Empty
F5——WISE40 controller power-on
F6——Empty
F7——Empty
F8——air conditioner (A/C) panel
F9——Empty
F10 ——Cigar lighter
F11——USB backup power
F12——Empty
F13——Empty
F14——Reversing alarm bell relay
F15 ——Empty
F16——Starting switch
R1——Horn relay
R2——Reversing alarm bell relay
R4——Empty
Cab fuse box
F17——Main lamp switch
F18 ——Taillamp switch
F19 ——Headlamp switch
F20 ——Water spray switch
F21 ——Condenser fan relay
F22——Fan
F23——Interior lamp & radio
F24——Left wiper & right wiper
F25 ——Front wiper & rear wiper
8.2 Overview of Electrical Location Information

For example: W1/CN5——to oil replenishing pump pressure switch (SCH2, LAY1, W1)
● W1: wiring harness including the component
● CN5: component symbol
● To oil replenishing pump pressure switch: connection position of the component
● SCH2: electrical schematic diagram including the component
● LAY1: layout including the component
W1/CN2——to cab wiring harness W9/CN2 (SCH1, SCH4, SCH5, LAY2, W1)
W1/CN3——to inflation pump switch (SCH2, SCH3, LAY1, W1)
W1/CN4——to cab wiring harness W9/CN4 (SCH4, SCH5, SCH6, LAY2, W1)
W1/CN5——to oil replenishing pump pressure switch (SCH2, LAY1, W1)
W1/CN6——to controller 94-pin connector (SCH2, SCH3, LAY1, W1)
W1/CN7——to controller 61-pin connector (SCH2, SCH7, LAY1, W1)
W1/CN8——to travel handle (SCH2, LAY1, W1)
W1/CN9——to travel locking switch (SCH2, LAY1, W1)
W1/CN11——to floor rack fuse box (BLACK) (SCH2, SCH3, LAY1, W1)
W1/CN12——to floor rack fuse box (GREY) (SCH1, SCH2, LAY1, W1)
W1/CN13——to floor rack fuse box (BLUE) (SCH1, SCH2, SCH3, LAY1, W1)
W1/CN14——to floor rack fuse box (GREEN) (SCH1, SCH2, SCH3, SCH6, LAY1, W1)
W1/CN17——to instrument box wiring harness W10/CN17 (SCH1, SCH3, SCH6, SCH7,
LAY1, W1)
W1/CN18——to single-signal position sensor (SCH2, LAY1, W1)
SCH6, SCH7, LAY1, W1)
W1/CN23——to reversing alarm bell (SCH2, LAY1, W1)
W1/CN24——to oil level sensor (SCH3, LAY1, W1)
W1/CN26——to oil filter clogging alarm switch (SCH3, LAY1, W1)
W1/CN30——to solenoid valve wiring harness W2/CN30 (SCH2, LAY1, W1)
W1/CN31——to left/right water spray motor (SCH5, LAY2, W1)
W1/CN32——to front/rear water spray motor (SCH5, LAY2, W1)
W1/CN36——to USB backup power (SCH3, LAY2, W1)
W1/CN37——to cigar lighter (SCH3, LAY2, W1)
W1/CN39——download interface (SCH7, LAY1, W1)
W2/CN30——to floor rack wiring harness W1/CN30 (SCH2, LAY3, W2)
W2/CN60——to right reversing solenoid valve (SCH2, LAY3, W2)
W2/CN61——to left reversing solenoid valve (SCH2, LAY3, W2)
W2/CN62——to right forward solenoid valve (SCH2, LAY3, W2)
W2/CN63——to left forward solenoid valve (SCH2, LAY3, W2)
W2/CN65——to brake solenoid valve (SCH2, LAY3, W2)
W2/CN66——to left motor speed sensor (SCH2, LAY3, W2)
W2/CN67——to left motor solenoid valve (SCH2, LAY3, W2)
W2/CN68——to right motor speed sensor (SCH2, LAY3, W2)
W2/CN69——to right motor solenoid valve (SCH2, LAY3, W2)
W9/CN1——to left wiper motor (SCH5, LAY5, W9)
W9/CN2——to floor rack wiring harness W1/CN2 (SCH4, SCH5, LAY5, W9)
W9/CN3——cab fuse box (SCH4, SCH5, SCH6, LAY5, W9)
W9/CN4——to floor rack wiring harness W1/CN4 (SCH4, SCH5, SCH6, LAYY5, W9)
W9/CN5——to headlamp (left) (SCH4, LAY5, W9)
W9/CN6——to front wiper motor (SCH5, LAY5, W9)
W9/CN7——to interior lamp (SCH4, LAY5, W9)
W9/CN8——to right wiper motor (SCH5, LAY5, W9)
W9/CN9——to headlamp (right) (SCH4, LAY5, W9)
W9/CN10——to fan (SCH5, LAY5, W9)
W9/CN11——to condenser fan 1 (SCH6, LAY5, W9)
W9/CN14——to taillamp (left) (SCH4, LAY5, W9)
W9/CN15——to taillamp (right) (SCH4, LAY5, W9)
W9/CN16——to loudspeaker (right) (SCH4, LAY5, W9)
W9/CN17——to condenser fan relay (SCH6, LAY5, W9)

W9/CN18——to loudspeaker (left) (SCH4, LAY5, W9)
W9/CN20——to rear wiper motor (SCH5, LAY5, W9)
W9/CN21——to main lamp switch (SCH4, LAY5, W9)
W9/CN22——to headlamp switch (SCH4, LAY5, W9)
W9/CN23——to taillamp switch (SCH4, LAY5, W9)
W9/CN24——to front wiper switch (SCH5, LAY5, W9)
W9/CN25——to rear wiper switch (SCH5, LAY5, W9)
W9/CN26——to left wiper switch (SCH5, LAY5, W9)
W9/CN27——to right wiper switch (SCH5, LAY5, W9)
W9/CN28——to front/rear wiper water spray switch (SCH5, LAY5, W9)
W9/CN29——to left/right wiper water spray switch (SCH5, LAY5, W9)
W9/CN30——to radio (SCH4, LAY5, W9)
W10/CN10——to display (SCH1, SCH3, SCH7, LAY6, W10)
W10/CN11——to A/C panel (SCH6, LAY6, W10)
W10/CN15——to pedal controlling both throttle and brake (SCH2, LAY6, W10)
W10/CN16——to engine wiring harness W11/CN1(SCH1, SCH2, SCH4, SCH6, SCH7, LAY6,
W10)
W10/CN17——to floor rack wiring harness W1/CN17 (SCH1, SCH3, SCH6, SCH7, LAY6,
W10)
W10/CN19——to floor rack wiring harness W1/CN19 (SCH1, SCH2, SCH3, SCH4, SCH6,
SCH7, LAY6, W10)
W10/CN20——to engine wiring harness W11/CN2 (SCH1, SCH7, LAY6, W10)
SCH7, LAY7, W11)
W11/CN2——to instrument box wiring harness W10/CN20 (SCH1, SCH7, LAY7, W11)
W11/CN3——to starting relay coil (SCH1, LAY7, W11)
W11/CN8——to fan horn wiring harness W12/CN20 (SCH2, SCH4, LAY7, W11)
W11/CN9——to compressor (SCH6, LAY7, W11)
W11/CN10——to HV/LV switch (SCH6, LAY7, W11)
W12/CN20——to engine wiring harness W11/CN8 (SCH2, SCH4, LAY7, W12)
W12/CN30——to main lamp (left) (SCH4, LAY7, W12)
W12/CN31——to main lamp (right) (SCH4, LAY7, W12)
W1/CL1——floor rack wiring harness GND (SCH1, SCH2, SCH3, SCH5, SCH7, LAY1, W1)
W1/CL2——to battery relay coil + (SCH1, SCH3, LAY1, W1)

W1/CL3——to battery relay coil - (SCH1, LAY1, W1)
W1/CL4——to battery constant power terminal (SCH1, SCH3, LAY1, W1)
W1/CL5——to battery constant power terminal (SCH1, SCH2, SCH7, LAY1, W1)
W1/CL6——to battery non-constant power terminal (SCH1, SCH2, SCH3, SCH4, SCH5,
SCH6, LAY1, W1)
W1/CL7——to floor rack fuse box L1 (SCH1, LAY1, W1)
W1/CL8——to floor rack fuse box L2 (SCH1, LAY1, W1)
W1/CL9——to operating oil temperature sensor (SCH3, LAY1, W1)
W9/CL1——cab wiring harness GND (SCH4, SCH5, SCH6, LAY5, W9)
W10/CL1——to starting switch G2 (SCH1, LAY6, W10)
W10/CL2——to starting switch B2 (SCH1, SCH3, SCH7, LAY6, W10)
W10/CL3——to starting switch M (SCH1, SCH3, SCH7, LAY6, W10)
W10/CL4——instrument box wiring harness GND (SCH3, SCH6, SCH7, LAY6, W10)
W11/CL1——engine wiring harness GND (SCH1, LAY7, W11)
W11/CL2——to generator B (SCH1, LAY7, W11)
W11/CL3——to generator D+ (SCH1, LAY7, W11)
W11/CL4——to starting motor B (SCH1, LAY7, W11)
W12/CL5——fan horn wiring harness GND (SCH2, SCH4, LAY7, W12)
W12/CL6——horn - (SCH2, LAY7, W12)
W12/CL7——horn + (SCH2, LAY7, W12)
D1——oil level sensor (SCH3, LAY1, W1)
D2——reversing alarm bell (SCH2, LAY1, W1)
D3——hydraulic oil temperature sensor (SCH3, LAY1, W1)
D4——floor rack fuse box (SCH1, SCH2, SCH3, SCH6, LAY1, W1)
D5——travel handle (SCH2, LAY1, W1)
D6——travel locking switch (SCH3, LAY1, W1)
D8——hand throttle (SCH2, LAY1, W1)
D9——position sensor (double signal) (SCH2, LAY1, W1)
D10——WISE controller (SCH2, SCH3, SCH7, LAY1, W1)
D11——oil replenishing pump pressure switch (SCH2, LAY1, W1)
D12——travel switch
D13——battery relay (SCH1, LAY1, W1)
D14 ——USB backup power (SCH3, LAY2, W1)
D15——cigar lighter (SCH3, LAY2, W1)
D16——battery (SCH1, LAY4)
D17——negative switch (SCH1, LAY4)
D18——10-way rocker switch (SCH4,SCH5,LAY5,W9)
D19——interior lamp (SCH4, LAY5, W9)
D20——headlamp (right) (SCH4, LAY5, W9)
D21——headlamp (left) (SCH4, LAY5, W9)
D22——front wiper (SCH5, LAY5, W9)
D23——right wiper (SCH5, LAY5, W9)
D24 ——left wiper (SCH5, LAY5, W9)
D25——scrubber (SCH5, LAY5, W1)
D26——radio (SCH4, LAY5, W9)
D27——fan (SCH5, LAY5, W9)
D28——taillamp (left) (SCH4, LAY5, W9)
D29——rear wiper (SCH5, LAY5, W9)
D30——taillamp (right) (SCH4, LAY5, W9)
D31——display (SCH1, SCH3, SCH7, LAY6, W10)
D33——starting switch (SCH1, SCH3, SCH7, LAY6, W10)
D34 ——to main lamp (left) (SCH4, LAY7, W12)
D35 ——horn (SCH1, LAY7, W12)
D36 ——to main lamp (right) (SCH4, LAY7, W12)
W1——floor rack wiring harness (SCH1, SCH2, SCH3, SCH4, SCH5, SCH6, SCH7, LAY1,
LAYY2)
W2——solenoid valve wiring harness (SCH2, LAYY3)
W3——cable (battery+ to battery-) (SCH1, LAY4)
W4——cable (battery- to negative switch) (SCH1, LAY4)
W5——cable (negative switch GND) (SCH1, LAY4)
W6——cable (battery+ to battery relay) (SCH1, LAY4)
W7——cable (battery relay to starting motor) (SCH1, LAY4)
W8——cable (floor flange plate GND) (LAY4)
W9——cab wiring harness (SCH1, SCH4, SCH5, SCH6, LAY5, LAY2)
W10——instrument box wiring harness (SCH1, SCH2, SCH3, SCH4, SCH6, SCH7, LAY6)
W11——engine wiring harness (SCH1, SCH7, LAY6, W10)
W12——fan horn wiring harness (SCH6, LAY7, W11)
W13——cable (engine housing GND) (SCH2, LAY7, W12)
W14——cable (starting motor GND) (SCH2, LAY7, W12)
W15——cable (100A online fuse to starting motor B) (SCH2, LAY7, W12)
F1——horn relay power supply (SCH2, LAY1)
F2——oil filter clogging alarm (SCH3, LAY1)
F3——controller (SCH2, LAY1)
F4——Empty
F5——horn relay coil & travel locking switch (SCH2, SCH3, LAY1)
F6——Empty
F7——Empty
F8——A/C panel (SCH6, LAY1)
F9——Empty
F10——cigar lighter (SCH3, LAY1)
F11——USB backup power (SCH3, LAY1)
F12——Empty
F13——Empty
F14——reversing alarm bell relay (SCH2, LAY1)
F15——Empty
F16——starting switch (SCH1, SCH3, LAY1)
F17——main lamp switch (SCH4, LAY5)
F18——taillamp switch (SCH4, LAY5)
F19——headlamp switch (SCH4, LAY5)
F20——water spray switch (SCH5, LAY5)
F21——condenser fan relay (SCH6, LAY5)
F22——fan (SCH5, LAY5)
F23——interior lamp & radio (SCH23, LAY5)
F24——left wiper & right wiper (SCH5, LAY5)
F25——front wiper & rear wiper (SCH5, LAY5)
R1——horn relay (SCH2, LAY1)
R2——reversing alarm bell relay (SCH2, LAY1)
R4——safety relay (SCH1, LAY1)

8.3 Electrical Schematic Diagram
8.3.1 Electrical System Schematic Diagram——SCH1
W1/CN2——to cab wiring harness W9/CN2

W1/CN12——to floor rack fuse box (GREY)
W1/CN13——to floor rack fuse box (BLUE)
W1/CN14——to floor rack fuse box (GREEN)
W1/CN17——to instrument box wiring harness W10/CN17
W9/CN2——to floor rack wiring harness W1/CN2
W9/CN3——cab fuse box
W10/CN10——to display
W10/CN16——to engine wiring harness W11/CN1
W11/CN3——to starting relay coil
W1/CL1——floor rack wiring harness GND
W1/CL2——to battery relay coil +
W1/CL3——to battery relay coil-
W1/CL4——to battery constant power terminal
W1/CL6——to battery non-constant power terminal
W1/CL7——to floor rack fuse box L1
W10/CL1——to starting switch G2
W10/CL2——to starting switch B2
W10/CL3——to starting switch M
W11/CL1——engine wiring harness GND
D4——floor rack fuse box
D13——battery relay
D16——battery
D17——negative switch
D31——display
D33——starting switch

W1——floor rack wiring harness
W3——cable (battery+ to battery-)
W4——cable (battery- to negative switch)
W5——cable (negative switch GND)
W6——cable (battery+ to battery relay)
W7——cable (battery relay to starting motor)
W9——cab wiring harness
W10——instrument box wiring harness
W11——engine wiring harness
W15——cable (100A online fuse to starting motor B)

W1/CN3——to inflation pump switch

W1/CN5——to oil replenishing pump pressure switch

W1/CN6——to controller 94-pin connector
W1/CN8——to travel handle
W1/CN11——to floor rack fuse box (BLACK)
W1/CN18——single-signal position sensor
W1/CN23——to reversing alarm bell
W2/CN60——to right reversing solenoid valve
W2/CN61——to left reversing solenoid valve
W2/CN62——to right forward solenoid valve
W2/CN63——to left forward solenoid valve
W2/CN65——to brake solenoid valve
W2/CN66——to left motor speed sensor
W2/CN67——to left motor solenoid valve
W2/CN68——to right motor speed sensor
W2/CN69——to right motor solenoid valve
W10/CN15——to pedal controlling both throttle and brake
W11/CN8——to fan horn wiring harness W12/CN20
W12/CL5——fan horn wiring harness GND
W12/CL6——to horn-
W12/CL7——to horn+
D2——reversing alarm bell

D5——travel handle
D8——single-signal position sensor
D9——position sensor (double signal)
D10——WISE controller
D11——oil replenishing pump pressure switch
D35——horn
W2——solenoid valve wiring harness
W12——fan horn wiring harness


W1/CN24——oil level sensor
W1/CN26——to oil filter clogging alarm switch
W1/CN36——to USB backup power
W1/CN37——to cigar lighter
W1/CL2——to battery relay coil+
W1/CL9——to operating oil temperature sensor
W10/CL4——instrument box wiring harness GND
W11/CL4——to engine water temperature sensor
W11/C5——oil pressure sensor
D1——oil level sensor
D2——engine water temperature sensor
D3——hydraulic oil temperature sensor
D5——oil pressure sensor
D6——travel locking switch
D14——USB backup power
D15——cigar lighter
D31——display


W9/CN5——to headlamp (left)
W9/CN7——to interior lamp
W9/CN9——to headlamp (right)
W9/CN14——to taillamp (left)
W9/CN15——to taillamp (right)
W9/CN16——to loudspeaker (right)
W9/CN18——to loudspeaker (left)
W9/CN21——to main lamp switch
W9/CN22——to headlamp switch
W9/CN23——to taillamp switch
W9/CN30——to radio
W11/CN8——to fan horn wiring harness W12/CN20
W12/CN30——to main lamp (left)
W12/CN31——to main lamp (right)
W1/CL6 ——to battery non-constant power terminal
W9/CL1——cab wiring harness GND
D18——10-way rocker switch
D19——interior lamp
D20——headlamp (right)
D21——headlamp (left)
D26——radio
D28——taillamp (left)
D30——taillamp (right)

D34——main lamp (left)
D36——main lamp (right)


W1/CN31——to left/right water spray motor
W1/CN32——to front/rear water spray motor
W9/CN1——to left wiper motor
W9/CN6——to front wiper motor
W9/CN8——to right wiper motor
W9/CN10——to fan
W9/CN20——to rear wiper motor
W9/CN24——to front wiper switch
W9/CN25——to rear wiper switch
W9/CN26——to left wiper switch
W9/CN27——to right wiper switch
W9/CN28——to front/rear wiper water spray switch
W9/CN29——to left/right wiper water spray switch
W1/CL6 ——to battery non-constant power terminal
W9/CL1——cab wiring harness GND
D22——front wiper
D23——right wiper
D24——left wiper
D25——scrubber
D27——fan
D29——rear wiper


W10/CN11——to A/C panel
W11/CN9——to compressor
W11/CN10——to HV/LV switch
W9/CN11——to condenser fan 1
W9/CN17——to condenser fan relay
W9/CL1—— cab wiring harness GND

W1/CN7——To controller 61-pin connector

W1/CN39——download interface
W1/CL5 ——to battery constant power terminal
D31——display

8.4 Layouts of Components and Harnesses
Layout of Component and Harnesses——LAY1
Layout of Component and Harnesses——LAY2


W1/CN9——to travel locking switch

W1/CN24——to oil level sensor
W1/CN30——to solenoid valve wiring harness W2/CN30
W1/CN31——to left/right wiper water spray motor
W1/CN32——to front/rear wiper water spray motor
D3——operating oil temperature sensor

D14 ——USB backup power

Floor Rack Wiring Harness Diagram——W1


W1/CN9——to travel locking switch

W1/CN24——to oil level sensor
W1/CN30——to solenoid valve wiring harness W2/CN30
W1/CN31——to left/right wiper water spray motor
W1/CN32——to front/rear wiper water spray motor
D3——operating oil temperature sensor

D14 ——USB backup power

Layout of Component and Harness——LAY3


Solenoid Valve Wiring Harness Diagram——W2



W3——cable (battery+ to battery-)

W4——cable (battery- to negative switch)
W5——cable (negative switch GND)
W6——cable (battery+ to battery relay)
W7——cable (battery relay to starting motor)
W8——cable (floor flange plate GND)
D16——battery
D17——negative switch



W9/CN8——to right wiper motor
W9/CN10——to fan
W9/CN18——to loudspeaker (left)
W9/CL——cab wiring harness GND

D24——left wiper
D25——scrubber
D2——radio
D27——fan
D29——rear wiper

Cab Wiring Harness Diagram——W9


W9/CN8——to right door wiper motor
W9/CN10——to fan
W9/CL——cab wiring harness GND

D24——left wiper
D25——scrubber
D2——radio
D27——fan
D29——rear wiper

W10/CN11——A/C panel
D31——display

Instrument Box Wiring Harness Diagram——W10


W10/CN11——A/C panel
D31——display


W11/CN2——fan horn wiring harness
W11/CN5——to oil pump
W11/CL2——to generator B
W11/CL3——to generator D+
W11/CL4——to starting motor B
W12/CN20——to engine wiring harness
W12/CL6——horn
D34——to main lamp (left)
D35——horn
D36——to main lamp (right)
D37——oil pressure sensor
D38——oil temperature sensor
W13——cable (engine housing GND)

Engine Wiring Harness Diagram——W11

Fan Horn Wiring Harness——W12

W11/CN2——to speed sensor
W11/CN10——to fan horn wiring harness
W11/CN5——to oil pump

W11/CL2——to generator B
W11/CL3——to generator D+
W11/CL4——to starting motor B
W12/CN20——to engine wiring harness
W12/CL6——horn-
W12/CL7——horn+
D34——to main lamp (left)
D35——horn
D36——to main lamp (right)
W13——cable (engine housing GND)
W14——cable (starting motor GND)

8.5 Operation Guide of Diagsmart
8.5.1. Software Startup
Double click Diagsmart.exe in the software directory to start the software.
After starting the software, enter the account and password according to the prompt, select
the offline login mode, and click "Login" to enter the software page:

8.5.2. Software Configuration
Start the software and enter the interface as shown in the figure below.
Click the [System Configuration] button in the lower left corner to enter the system
configuration interface, and select the adapter type according to the current version of
Diagsmart hardware.
3
1
For the software version as shown in the figure above, select [Diagsmart V2-USB] for the
adapter type , and [No] for the message collection default. Click the [Configuration] button,
and click the arrow at the upper left corner to return to the main interface after successful
configuration.

For the software version as shown in the figure above, select [Standard
Version-WIFI/USB-Normal Mode] for the adapter type, and [No] for the message collection
default. Click the [Configuration] button, and click the arrow at the upper left corner to return to
the main interface after successful configuration.
After the configuration is completed, return to the main interface, and click the [Power System]
button on the right side and select [Weichai Hydraulic] to enter the service interface.

8.5.3. Connection to Controller

After entering the service interface, first connect the adapter to the controller.
Select the [Device Connection] module on the left side, and click the [Connect Adapter] below.
When the word [Adapter Connected] appears, it indicates the successful connection between
the computer and Diagsmart.

Then click the [Connect Controller] button. When [Controller Connected] is prompted, it
indicates that the connection between software and controller has been established.
Note: The operation interfaces shown in the above two figures are for the second
generation of Diagsmart hardware, and are slightly different from those of the standard
version of Diagsmart, but the operations of the two versions are basically the same.
8.5.4. Description of Function

Fault diagnosis
Select the [Fault Diagnosis] module to enter the fault diagnosis interface, click the [Clear Fault
Information] button to clear the fault diagnostic information displayed on the current page, and
click the [DTC] button to read the fault information found in the current system.

Note: The fault information will not be automatically updated in real time, and the fault list will
be updated by manually clicking the [DTC] button. The fault with the DTC status of [Current
Fault] is the fault reported by the current system.
Data flow
Select the [Data Flow] module to enter the data flow observation page, select the data
information to be observed, and click [Start Monitoring] to observe the real-time information of
the selected data. To add or reduce the data to be observed, click [Stop Monitoring] first.
Coefficient calibration
Select the [Parameter Calibration] module to enter the parameter calibration page. There is a
column of "CalibrateEnable" for each type of calibration, and "Default" is selected as default,
indicating that calibration is not allowed. When requiring calibration, click "Yes",and the
corresponding calibration quantity will be lighted, indicating that calibration can be performed.

When calibration is required, click the [Read] button in the lower right corner to read the
current system parameters, and then modify relevant parameters as required.
When the modification is completed, there are two methods to write the modified
parameters into the controller:
1. [Download], parameters can be modified and written to the controller during the current
power-on cycle, but the modified value will change back to the original value after the
controller is powered off.
2. [Direct flashing], in this method, the modified value is still valid after the controller is
powered off, but during flashing, the controller will be temporarily disconnected from the
vehicle. Therefore, it is recommended not to flash when the engine is started, or under
the driving state. At the same time, it is not recommended to operate the handle and hand
throttle after clicking [Direct flashing], so as to avoid affecting communication and causing
flashing failure.
Self-learning
Select the [Self-learning] module to enter the self-learning page.
Note: As the key to synchronization function, the self-learning is a critical function for the
hydraulic system. It needs to be performed in the vehicle supporting state, and the engine
speed is not less than 1500rpm.
The self-learning process is relatively simple. Click the [Start] button and operate according to
the prompt information.

Note: After self-learning, the system will automatically save the learning data and
writes it to the controller.

8.6 Fault Diagnosis and Description
8.6.1 WISE40 Vehicle Controller Fault Information
J1939
S/N Fault description
SPN FMI
001 2032 16 Excessive current of left pump forward solenoid valve
002 2031 12 Current of left pump forward solenoid valve cannot return to zero
003 2034 2 Fault in left pump forward solenoid valve or circuit
004 2022 16 Excessive current of left pump reversing solenoid valve
005 2021 12 Current of left pump reversing solenoid valve cannot return to zero
006 2024 2 Fault in left pump reversing solenoid valve or circuit
007 2002 16 Excessive current of right pump forward solenoid valve
008 2001 12 Current of right pump forward solenoid valve cannot return to zero
009 2004 2 Fault in right pump forward solenoid valve or circuit
010 2012 16 Excessive current of right pump reversing solenoid valve

Current of right pump reversing solenoid valve cannot return to
011 2011 12
zero
012 2014 2 Fault in right pump reversing solenoid valve or circuit
013 2052 16 Excessive current of left motor solenoid valve
014 2051 12 Current of left motor solenoid valve cannot return to zero
015 2054 2 Fault in left motor solenoid valve or circuit
016 2042 16 Excessive current of right motor solenoid valve
017 2041 12 Current of right motor solenoid valve cannot return to zero
018 2044 2 Fault in right motor solenoid valve or circuit

Simultaneous power-on error of left forward and reversing
019 9001 2
solenoid valves
Simultaneous power-on error of right forward and reversing
020 9002 2
solenoid valves
021 9003 2 Handle initial non-middle position solenoid valve live error
022 9004 12 Handle middle position solenoid valve live error
023 9005 2 Solenoid valve live error under stop demand of inching pedal
024 9006 2 Solenoid valve live error under travel locking switch
025 9007 2 Abnormal control of solenoid valve

Large error in difference between current set value and actual
026 2033 16
value of left pump forward solenoid valve
Large difference between current set value and actual value of left
027 2023 16
pump reversing solenoid valve
028 2003 16 Large error between current set value and actual value of right
pump forward solenoid valve
Large difference between current set value and actual value of

029 2013 16
right pump reversing solenoid valve
Large difference between current set value and actual value of left
030 2053 16
motor solenoid valve
Large difference between current set value and actual value of
031 2043 16
right motor solenoid valve
032 2120 2 Engine speed not credible
033 2130 2 Left motor speed not credible
034 2140 2 Right motor speed not credible
035 9012 4 Left pump forward solenoid valve short-circuited to ground
036 9012 3 Left pump forward solenoid valve short-circuited to power supply
037 9012 5 Left pump forward solenoid valve open-circuited
038 9013 4 Left pump reversing solenoid valve short-circuited to ground
039 9013 3 Left pump reversing solenoid valve short-circuited to power supply
040 9013 5 Left pump reversing solenoid valve open-circuited
041 9010 4 Right pump forward solenoid valve short-circuited to ground
042 9010 3 Right pump forward solenoid valve short-circuited to power supply.
043 9010 5 Right pump forward solenoid valve open-circuited
044 9011 4 Right pump reversing solenoid valve short-circuited to ground

Right pump reversing solenoid valve short-circuited to power
045 9011 3
supply
046 9011 5 Right pump reversing solenoid valve open-circuited
047 9015 4 Left motor solenoid valve short-circuited to ground
048 9015 3 Left motor solenoid valve short-circuited to power supply
049 9015 5 Left motor solenoid valve open-circuited
050 9014 4 Right motor solenoid valve short-circuited to ground
051 9014 3 Right motor solenoid valve short-circuited to power supply
052 9014 5 Right motor solenoid valve open-circuited
053 2070 4 Brake solenoid valve short-circuited to ground
054 2070 3 Brake solenoid valve short-circuited to power supply
055 2070 5 Brake solenoid valve open-circuited
056 9031 4 Reversing alarm relay short-circuited to ground
057 9031 5 Reversing alarm relay open-circuited
058 9032 4 Fault lamp short-circuited to ground
059 9032 5 Fault lamp open-circuited

060 9037 4 Defrosting solenoid valve short-circuited to ground
061 9037 5 Defrosting solenoid valve open-circuited
062 9038 4 Closed pump solenoid valve high side short-circuited to ground
Closed pump solenoid valve high side short-circuited to power
063 9038 3
supply
064 9038 5 Closed pump solenoid valve high side open-circuited
065 9038 24 Closed pump solenoid valve high side overheating
066 9038 25 Closed pump solenoid valve high side voltage out of limit
067 9039 4 Motor solenoid valve high side short-circuited to ground
068 9039 3 Motor solenoid valve high side short-circuited to power supply
069 9039 5 Motor solenoid valve high side open-circuited
070 9039 24 Motor solenoid valve high side overheating
071 9039 25 Motor solenoid valve high side voltage out of limit
072 9040 4 High side K51/K73 short-circuited to power supply
073 9040 3 High side K51/K73 short-circuited to ground
074 9040 5 High side K51/K73 open-circuited
075 9040 24 High side K51/K73 temperature too high
076 9040 25 High side K51/K73 power supply fault
077 9041 4 High side K7/K29 short-circuited to power supply
078 9041 3 High side HV K7/K29 short-circuited to ground
079 9041 5 High side K7/K29 open-circuited
080 9041 24 High side K7/K29 temperature too high
081 9041 25 High side K7/K29 power supply fault
082 9042 6 EEPROM writing failed
083 9042 7 EEPROM reading failed
084 9042 12 EEPROM initialization failed
085 9042 14 EEPROM check failed
086 9045 2 Left motor speed cycle error
087 9045 4 Left motor speed cycle lost
088 9044 2 Right motor speed cycle error
089 9044 4 Right motor speed cycle lost
090 9046 19 ETC1 message receiving timeout
091 9046 14 EEC1 message byte error
092 2104 3 Handle driving main signal voltage above upper limit
093 2104 4 Handle driving main signal voltage below lower limit
094 2105 3 Handle driving check signal voltage above upper limit
095 2105 4 Handle running check signal voltage below lower limit
096 2106 2 Handle driving voltage signal not credible
097 2084 3 Handle steering main signal voltage above upper limit
098 2084 4 Handle steering main signal voltage below lower limit
099 2085 3 Handle steering check signal voltage above upper limit
100 2085 4 Handle steering check signal voltage below lower limit
101 2101 2 Handle steering voltage main signal not credible
102 2110 3 Handle gear switch voltage above upper limit
103 2110 4 Handle gear switch voltage below lower limit
104 2094 3 Inching pedal main signal voltage above upper limit
105 2094 4 Inching pedal main signal voltage below lower limit
106 2095 3 Inching pedal check signal voltage above upper limit
107 2095 4 Inch pedal check signal voltage below upper limit
108 2096 2 Inching pedal voltage signal not credible
109 2111 3 Hand throttle voltage above upper limit
110 2111 4 Hand throttle voltage below upper limit
111 8001 3 Water temperature sensor voltage above upper limit
112 8001 4 Water temperature sensor voltage below upper limit

Transmission hydraulic oil temperature sensor voltage above
113 8012 3
upper limit
Transmission hydraulic oil temperature sensor voltage below
114 8012 4
upper limit
115 2113 3 Battery voltage above upper limit
116 2113 4 Battery voltage below upper limit
117 9076 11 Engine speed overspeed
118 8200 19 CAN bus busy
119 9700 26 Error of input signal fault group out of limit
120 1100 3 Out-of-limit at 5V power supply
121 1100 4 No out-of-limit at 5V power supply
126 9137 3 Thumb roller voltage above upper limit

127 9137 4 Thumb roller voltage below upper limit
128 9171 3 Fuel level sensor voltage above upper limit
129 9171 4 Fuel level sensor voltage below lower limit
130 9173 1 Low pressure of right oil replenishment
131 9174 1 Low pressure of left oil replenishment
132 9177 26 Emergency shutdown button pressed

Enable switch button of inching self-resetting button type work tool
133 9178 16
stuck
134 9179 5 Shovel blade left tilt solenoid valve open-circuited
135 9179 3 Shovel blade left tilt solenoid valve short-circuited to power supply
136 9179 4 Shovel blade left tilt solenoid valve short-circuited to ground
137 9180 5 Shovel blade right tilt solenoid valve open-circuited

Shovel blade right tilt solenoid valve short-circuited to power
138 9180 3
supply
139 9180 4 Shovel blade right tilt solenoid valve short-circuited to ground
140 9181 5 Shovel blade lifting solenoid valve open-circuited
141 9181 3 Shovel blade lifting solenoid valve short-circuited to power supply
142 9181 4 Shovel blade lifting solenoid valve short-circuited to ground
143 9182 5 Shovel blade lowering solenoid valve open-circuited

Shovel blade lowering solenoid valve short-circuited to power
144 9182 3
supply
145 9182 4 Shovel blade lowering solenoid valve short-circuited to ground
146 9183 5 Shovel blade left slewing solenoid valve open-circuited

Shovel blade left slewing solenoid valve short-circuited to power
147 9183 3
supply
148 9183 4 Shovel blade left slewing solenoid valve short-circuited to ground
149 9184 5 Shovel blade right slewing solenoid valve open-circuited

Shovel blade right slewing solenoid valve short-circuited to power
150 9184 3
supply
151 9184 4 Shovel blade right slewing solenoid valve short-circuited to ground
Floating switch button of inching self-resetting button type shovel
152 9185 16
blade stuck
153 9186 4 Shovel blade left/right tilt signal voltage below lower limit
154 9186 3 Shovel blade left/right tilt signal voltage above upper limit
155 9187 4 Shovel blade lifting/lowering signal voltage below lower limit
156 9187 3 Shovel blade lifting/lowering signal voltage above upper limit
157 9188 4 Shovel blade left/right slewing signal voltage below lower limit

158 9188 3 Shovel blade left/right slewing signal voltage above upper limit
159 9189 4 Ripper handle voltage below lower limit
160 9189 3 Ripper handle voltage above upper limit
161 9190 5 Ripper ascending solenoid valve open-circuited
162 9190 3 Ripper ascending solenoid valve open-circuited to power supply
163 9190 4 Ripper ascending solenoid valve short-circuited to ground
164 9191 5 Ripper lowering solenoid valve open-circuited
165 9191 3 Ripper lowering solenoid valve open-circuited to power supply
166 9191 4 Ripper lowering solenoid valve short-circuited to ground
167 9192 14 Message length error of CAN handle in the shovel blade X/Y axis
168 9193 14 Message length error of CAN handle in the shovel blade Z axis
169 9194 19 Message timeout of CAN handle in the shovel blade X/Y axis
170 9195 19 Message timeout of CAN handle in the shovel blade Z axis
171 9196 12 Engine speed fault
172 9197 1 Left oil replenishing pressure switch open-circuited
173 9198 1 Right oil replenishing pressure switch open-circuited
174 9199 1 Forced reverse switch of fan being pressed too long
175 9200 3 Work tool temperature sensor voltage above upper limit
176 9201 4 Work tool temperature sensor voltage below lower limit
177 9202 3 Ripper enable switch being pressed too long
178 9203 2 Throttle foot pedal validity check error
179 9204 4 Throttle foot pedal main signal sensor voltage below lower limit
180 9205 3 Throttle foot pedal main signal sensor voltage above upper limit
181 9206 4 Throttle foot pedal check signal sensor voltage below lower limit
182 9207 3 Throttle foot pedal check signal sensor voltage above upper limit
183 9208 5 Fan speed regulating solenoid valve open-circuited

Fan speed regulating solenoid valve short-circuited to power
184 9208 3
supply
185 9208 4 Fan speed regulating solenoid valve short-circuited to ground
186 9209 5 Fan reverse solenoid valve open-circuited
187 9209 3 Fan reverse solenoid valve short-circuited to power supply
188 9209 4 Fan reverse solenoid valve short-circuited to ground
189 9210 5 Fan stop solenoid valve open-circuited
190 9210 3 Fan stop solenoid valve short-circuited to power supply

191 9210 4 Fan stop solenoid valve short-circuited to ground
192 9211 5 Shovel blade enable solenoid valve open-circuited

Shovel blade enable solenoid valve open-circuited to power
193 9211 3
supply
194 9211 4 Shovel blade enable solenoid valve short-circuited to ground
195 9212 5 Ripper enable solenoid valve open-circuited
196 9212 3 Ripper enable solenoid valve open-circuited to power supply
197 9212 4 Ripper enable solenoid valve short-circuited to ground

Switching button of inching self-resetting button type working
198 9213 16
handle stuck
199 9214 3 Low pressure of oil replenishment
200 9214 5 Oil replenishing pressure switch open-circuited
201 9215 16 Anit-stall enable button stuck
202 9216 19 Engine run time message timeout
203 9217 16 Offline test enable button stuck
204 9217 19 Offline test initialization timeout

Actual current of the right motor in the offline test not reaching the
205 9217 2
middle value
Actual current of the left motor in the offline test not reaching the
206 9217 3
middle value
Actual forward current of left pump in offline impact test lower than
207 9217 4
the minimum value
Actual forward current of right pump in offline impact test lower
208 9217 5
than the minimum value
Actual reversing current of left pump in offline impact test lower
209 9217 6
Actual reversing current of right pump in offline impact test lower
210 9217 7
211 9217 15 Speed preset button stuck

Replacement of DEUTSCH series rectangular or delta connectors
Note: The figure below shows the male end of a 4-pin square connector, and other similar
DEUTSCH connectors can be used with the same process for service.
1. Hook the pressed plate with the small barb at the end of the removal tool. 2. Pull the
removal tool with force to take out the pressed plate.
3. Use the end of the removal tool to open the clip of the connector and take out the terminal.
4. Replace the connector or terminal if necessary.
5. Push the terminal vertically into the connector and hear a clear "click" sound, indicating
that the terminal is connected in place.
6. Clamp the pressed plate with tweezers, and align the small end of the pressed plate with
the slot in the middle of the connector. After the pressed plate is completely inserted, a "click"
sound of cell clearing can be heard.
Note: The pressed plate of the 2-pin connector is not symmetrical, and the latch position shall
be close to the terminal side.
Replacement of DEUTSCH series circular connector
1. Cover the external wire with a suitable 2 Insert the tool into the hole in the rear of
removal tool. the connector until resistance is felt.
3. Pull the wire with terminals and tools out of

the connector.
4. Hold the core wire, and align the terminal with the corresponding hole of the connector.
5. Push the terminal vertically into the connector. When resistance is felt, pull it back slightly
to make sure that the terminal is locked.
The tool:

ATRT-100
AT11-240-2005 (for size 20 terminals)

Chapter 9 Driving System

9.1.1 Cab Assembly
Fig. 9.1 Cab Assembly
1. Cab assembly 2.Main frame 3.Flange plate assembly 4.Shock absorber 5.Bolt
6.Washer 7.Washer 8.Nut
The cab assembly is connected to the flange plate assembly and the main frame through two
supports respectively at the front and rear, and the shock absorber is used for vibration
reduction. The cab and floor rack is an integrated assembly. During assembly, it is fixed by 8
shock absorbers and 8 bolts (M20X155, S30, with a tightening torque of 460Nm) at 4 shock
absorption points.

Fig9.2 Floor Rack
9. Floor bracket 10.Travel locking lever 11.Anti-skid plate 12.Floor pad 13.Pedal
14.Instrument box
The travel locking lever (10), pedal (13) and instrument box (14) are fixed on the floor rack (9)
by bolts, and the anti-skid plate (11) is fixed on the floor pad (12). Pedal (13) is fixed by 2 bolts
(M12X55, S18, tightening torque: 89Nm), and the instrument box (14) is fixed by 4 bolts
(M12X30, S18, with a tightening torque of 89Nm).
9.1.2 Travel Locking Lever

The travel locking lever is fixed on the floor rack with bolts (M12X30, S18, with a tightening
torque of 89Nm). Before leaving the driver's seat, please put the travel locking lever at the
high position (locking) to prevent the vehicle from sliding. When operating the equipment,
please put the travel locking lever to the low position (unlocking) first.
Fig. 9.3 Travel Locking Lever

9.1.3 Instrument Box Assembly
Fig. 9.4 Instrument Box Assembly
1. Square tuyere 2.Rubber plate 3.Instrument box 4.Plate 5.Plate 6.Bolt (01010-51230)
7.Bracket 8.Square tuyere 9.Round tuyere 10.Bracket
The instrument box is assembled together with cab assembly by bolt (6) (SW18).
9.2 Seat Assembly

9.2.1 Seat Structure
The structure of the seat assembly installed inside the cab is shown in the figure.
The seat assembly includes main structures such as seat and seat bracket, as shown
in the figure below.

Fig9.5 Seat
① - Seat; ⑦, ⑧- Left and right armrests; ②- Bracket; ⑨- Sound insulation sponge; ③, ④, ⑤, ⑥,

⑩, ⑪- Mounting bolts and gaskets
9.2.2 Seat Testing and Adjustment

Forward/backward adjustment of seat:
Pull up the lever shown in the figure and drag the seat forward and backward.
Angle adjustment of seat backrest:

Pull up the handle shown in the figure and adjust the inclination angle of the backrest.

Adjustment of seat bearing (soft and hard):

Turn the handle clockwise (counterclockwise) to adjust the seat bearing. Observe the bearing
capacity indicator on the right and select a proper range.
Adjustment of seat height:

There are 3 adjusting gears for seat height (-30mm ~ 0mm ~ +30mm). Move the seat upward
with both hands to release the seat height lock. Adjust the height to the corresponding gear,
gently lower the seat to lock the seat height, and then the seat height is adjusted.

Adjustment of armrest height:

Loosen the bolts shown in the figure and adjust the armrest to a proper height. Tighten the
bolts shown in the figure, and the armrest height is adjusted.
Adjustment of armrest inclination:

Loosen the bolt shown in the figure and adjust the armrest to a proper angle. Tighten the bolt
shown in the figure, and the armrest inclination is adjusted.

9.3 A/C System

9.3.1 A/C System Structure
Fig9.6 System Composition
System composition
1-Condenser and fan
2-Control pane 3-Evaporator 4-Compressor
assembly
5-Refrigerant pipe 6-Liquid storage tank 7-Warm water pipe 8-belt
9.3.2 Principle for A/C System

For the refrigeration process, the compressor (1) sucks in the refrigerant gas with
low-temperature and low-pressure, compresses the gas into high-temperature and
high-pressure gas and sends it to the condenser (2). The condenser fan (3) conducts the
forced cooling, and the refrigerant gradually changes from gaseous state to liquid state. After
being dried and filtered by the liquid storage drying cylinder (4), the refrigerant is sent to the

expansion valve (5). After being cooled and depressurized by the expansion valve, it flows
into the evaporator (6) in the form of mist. The mist refrigerant in the evaporator (6) absorbs
heat and vaporizes into gaseous refrigerant, thus reducing the surface temperature of the
evaporator. The air blown out from the evaporator fan (7) continuously flows through the
surface of the evaporator (6) and is cooled and sent to the carriage for cooling. After passing
through the evaporator, the gaseous refrigerant is sucked into the compressor again, thus
achieving refrigeration by repeated circulation.
For the heating process, circulating heating is achieved by using hot water or other heat
sources of the engine.
Fig9.7 Schematic Diagram of Cooling
1-Compressor 2-Condenser 3-Condenser fan 4-Liquid storage drying cylinder

5-Expansion valve 6-Evaporator 7-Evaporator fan 8-Heater core
9.4 Removal and Maintenance:

9.4.1 Removal and Installation of Cab Assembly and Instrument Box Assembly
Removal
Loosen the mounting nuts (01580-12016, S30, with a tightening torque of 460Nm) at 4 fixing
points below the cab assembly, and remove the washer, shock absorber, bolts, etc. at one
time
Lift cab (12) and remove.
The weight of cab assembly is 725kg.
Installation
Install the cab assembly in an order reverse to its removal
9.4.2 Removal and Installation of Seat Assembly

Seat removal:
Remove the square head bolts and remove, the seat and bracket as a whole.
Loosen the bolts shown in the figure, and remove the armrest and its fixing ring in sequence.
Remove the 4 fixing bolts shown in the figure, and remove the armrest bracket from the lower
part of the cab.

Repeat the above operations to remove the left and right armrests.
Installation of seat:
The seat assembly is installed in the opposite direction of its removal.
9.4.3 Removal and Installation of A/C assembly

Removal of evaporator
Remove the control panel, and disconnect the harness and other accessories connected to it.
Remove the instrument box and its connecting pipeline harness and other accessories.
Remove the refrigerant pipe and warm water pipe connected to the evaporator.

Remove the evaporator.
Removal/installation of condenser
Remove the shield above the condenser and its mounting bolts.
Remove the A/C pipeline installed on the condenser.
Disconnect the harness connecting the condenser, and remove the condenser.
Installation
Install the condenser in the reverse order of its removal.
9.5 Precautions
Before installation, the plugs at both ends of the hose shall not be removed. The installation
environment shall be clean and moisture-proof. Dirt and moisture shall not enter the cooling
medium circuit.
The bending radius of the installation pipeline shall be greater than 90mm, the hose shall not
be twisted, and the middle of the pipeline shall be fixed with clamps to prevent vibration and
wear.
The inspection shall be carried out before installation, to ensure that the O-ring is installed at
the joint, and then cooling oil shall be applied. The threaded part of the hot water circuit shall
be coated with sealant LS3 or wrapped with raw material tape.
The condenser shall be handled gently without damaging its surface, and the installed inlet
and outlet shall not be inverted.
The hot water pipe valve shall be placed in the open position when discharging water in
winter.
The voltage required by A/C shall be distinguished from the power supply, and shall not be
mixed. The heat sources, sharp objects, and movable objects shall not appear in the wiring
space.
The absolute pressure shall be maintained at -0.1Mpa for half an hour during vacuuming. And
the refrigerant shall only be filled when there is no leakage. During removal and installation,
the engine must not be started to prevent damage to the compressor due to liquid impact.
Whether the air conditioner is used or not, periodical inspection and maintenance shall be
carried out for its pipeline and other devices.
In winter, the heating system must be filled with antifreeze to keep the core from frost cracks.
The refrigerant shall be R134a and shall not be mixed, with the filling amount of 1000g.

Chapter 10 Fault Diagnosis

10.1 Description of Safety Operations and Warnings
10.1.1 During fault diagnosis, the equipment shall be kept in a safe state.
 Park the machine on flat ground and make sure that the safety pin, cushion block and
parking brake are firmly installed.
 Must use the unified signal for operations requiring 2 or more persons, and prohibit any
irrelevant personnel from approaching.
 If the radiator cap is removed when the engine is hot, hot water will spray out and may
cause burns. Therefore, must start the fault diagnosis after the engine cools down.
 Take extreme care not to touch any hot parts or get caught in any rotating parts.
 When disconnecting the wires, make sure to disconnect the negative pole (-) of the
battery first.
 Release the internal pressure before removing the plug or cap from the position with oil
pressure, water pressure or air pressure inside. When installing measuring instruments,
be sure to connect them correctly.
The purpose of fault diagnosis is to accurately determine the root cause of the fault, so as to
repair it quickly and prevent recurrence of the fault. During fault diagnosis, it is critical to learn
the equipment structure and function well. However, in order to effectively carry out fault
diagnosis, it is also a shortcut to ask the operator for information to preliminarily understand
the possible cause for symptoms of the reported fault.
1. Do not disassemble the components in a hurry during fault diagnosis. If the components
are disassembled immediately, it will cause:
• The disassembled parts are irrelevant to the fault or the disassembled parts are
unnecessary.
• The cause of the fault cannot be found.
This wastes manpower, parts, oil and grease, and at the same time makes the user or
operator lose confidence. From this perspective, the fault diagnosis must be carried out in
advance and in accordance with the specified procedures.
2. Ask the user or operator about:
1) Are there other issues not reported?
2) Is there any abnormality in the machine before the fault occurs?
3) Does the fault occur suddenly or is the machine already problematic before?
4) When does the fault occur?
5) Has the machine been repaired before fault occurs? What time was it repaired?
6) Have similar faults occurred before?
3. Inspection before fault diagnosis
1) Check the oil level
2) Check the pipeline or hydraulic device for external leakage.
3) Check the stroke of the joystick.
4) Check the stroke of working valve rod
5) Perform visual inspection for other routine maintenance items. You only need to check
what is necessary.
4. Confirm the faults
1) Confirm the fault degree and judge whether it is a real fault or whether the operation
method is problematic.
2) Do not carry out any inspection or measurement that may make the problem more
serious when operating the machine to reproduce the fault.
5. Fault diagnosis
 Reduce the scope of fault causes according to the inspection and test results of items 2-4,
and then accurately determine the fault location according to the fault diagnosis flow
chart.
★ The basic procedures for fault diagnosis are as follows:
1) Start with the simple.
2) Start where there's a good chance.
3) Inspect other relevant components and information.
6. Methods of eliminating the root causes of faults.
Even if the faults are eliminated, the same faults will still occur if the root cause of the fault is
not eliminated. To prevent such problems, the causes of the fault must be found out and the
root cause of the fault must be eliminated.

Offices, workshops Work place
Step 1
Inspection and determination of faults.

1) When receiving the request for entrusted Ring Ring
maintenance, first ask the following
matters:
·Client name
·Machine model and serial number
·Site details, working hours, etc
2) Master the general diagnosis through inquiry.

·Fault
·Working conditions when fault occurs
·Working environment
Fault occurs
·Previous records, maintenance details, etc.
Step 2
Step 8
Identify possible positions of causes
1) Refer to the Fault Diagnosis in the Repair on site
Installation and Maintenance Manual to find
out where the fault causes might be.
OK!
It's fixed.
Step 3
Prepare diagnostic tools

1) Refer to the Fault Diagnosis Tool List in the
Installation and Maintenance Manual and
Step 7
prepare the necessary tools.
·Test connector ·Identification of fault locations
·Hydraulic instrument components, etc (for fault diagnosis)
2) Refer to Parts Catalog and prepare ·Decide on repair scheme
necessary replaced parts.
1) Determine the simple fault location before fault
diagnosis and repair it.
·Pre-startup inspection items
·Other inspection items
Step 8 2) Refer to the Fault Diagnosis in the Installation and

Maintenance Manual. According to faults of machine to
choose Fault Diagnosis Flow Chart and carry out fault
Repair in workshop diagnosis.
Mechanical Step 6
Manual
Reproduction of faults
·
Start and operate the machine, confirm the faults of machine and
Installation and judge whether there is a fault.
Maintenance
Manual
Step 5
Step 4
Ask the operator for details of faults.

Go to site
· Is there any abnormality in the machine
before the fault occurs?
·
Did the trouble happen suddenly?
·
Has the fault ever been repaired?
10.1.2 Precautions for Operation of Electrical Components

In order to maintain the performance of the machine for a long time and prevent faults or
accidents in advance, correct operation, maintenance, inspection, fault diagnosis and repair
must be carried out. This Chapter describes the electromechanical maintenance procedures

in detail to improve the maintenance quality.
※ Key Points to be Remembered When Using Electrical Equipment

I. Use of Harnesses and Connectors
The harness consists of wires connecting elements, connectors for connecting or
disconnecting wires, and other protectors for protecting wires. Unlike other electrical
components in boxes or cases, harnesses are most susceptible to direct effects of rain, water,
heat, or vibration. In addition, during inspection and maintenance, the harness will be
removed and installed frequently, so it is easily deformed or damaged. Therefore, be careful
when using the harness.
 Main faults of wires and harnesses.

1) Poor contact of connectors (poor contact of plugs and sockets).
Poor contact may be caused by improper insertion of connector and socket, misalignment of
plug or socket due to their deformation, or corrosion or oxidation of contact surface.
Poor
chimerism
2) Poor crimping or brazing of connectors

The plug of the connector and the pin of the socket are in contact at the crimping joint or
brazing point. If the wire is stressed too much and the connection part is disengaged, it will
cause poor contact or breakage.

3) Wire breakage
If you hold the wire with your hand and pull out the plug or lift the component that is still
connected to the wire with a crane or there is a heavy object hitting the wire, it may cause the
crimping part to be disengaged or the welding spot to be damaged or the wire to be broken.
4) High pressure water flows into connector
Although the connector is waterproof (immersion proof), if high pressure water is sprayed
directly into the connector, water may enter the connector in the direction of spraying. Since
the connector is waterproof, it is difficult for water to enter and also difficult to be drained.
Therefore, if water enters the connector, the pin will be short-circuited by water. Therefore, if
water enters the connector, dry the connector immediately before connecting the power
supply, or take other effective measures.
5) There is oil or dirt on the connector
If there is oil or grease on the connector, an oil film will be formed on the contact surface of the
plug or socket, which will cause poor contact because oil is not conductive.
If there is oil or grease on the connector, wipe it off with a dry cloth or dry it with compressed

air, and spray contact restorer.
★ Be careful when wiping the joint of the connector. Do not apply too much force or deform
the pin.
★ If there is oil or water in the compressed air, the contact will become dirty, so the oil and
water shall be completely removed before cleaning with compressed air.
II. Removal, Installation and Drying of Connectors and Harnesses

 Disconnect the connector.
1) Hold the connector when disconnecting the connector.
When disconnecting the connector, hold the connector by hand instead of holding the wire. If
the connector is secured by screws, completely loosen the screws, then pull out the connector
with convex side connector in one hand and the concave side connector in the other. If there
is a lock banking stop on the concave side connector, press the tab down with your thumb and
pull out the connector. Never pull with one hand.
2) When disconnecting the connector from the clamp
When disconnected from the clamp, the connector shall be pulled out in the direction parallel
to the clamp.
★ If the connector is twisted up and down or left and right when pulled, the housing may be
damaged.

3) Handling of disconnected connectors
After the connector is disconnected, put it in a plastic bag to prevent any dust, dirt, oil or water
from entering the connector.
★ If the machine is left for a long time after being disassembled, poor contact is more likely
to occur, so the connector must be put into a plastic bag.
 Connect the connector.

1. Visual inspection of connectors
1) Check the connector pin (joint) for oil, dirt or water.
2) Check the connector pin for deformation, poor contact, rust or damage.
3) Check whether the connector surface is damaged or connector is broken.
★ If there is oil, water or dirt on the connector, wipe it off with a dry cloth. If water enters the
connector, use a dryer to dry the inside of the wire, but be careful not to overheat it,
otherwise the connector will be short-circuited.
★ Replace connector if it is damaged or broken.
2. Install the connector firmly and correctly align it, and insert the connector firmly. If the
connector pin is provided with a lock banking stop, push the connector in until the "click"
sound of the insertion is heard.
3. Calibration of bulge of rubber sleeve and misalignment of wire harness. For connectors
with rubber sleeves, the bulge of the rubber sleeve must be calibrated. In addition, if the
wire harness or clamp is not in the correct position, it must be calibrated to the correct
position.
★ If the connector is not easy to be calibrated, remove the clamp and adjust its position.
4. If the connector clamp has been removed, be sure to install it back in place. Also check
for loose clamps.

 Harness drying
If there is oil or dirt on the harness, wipe it off with a dry cloth. Do not clean it with water or
steam. If the connector must be cleaned with water, the high-pressure water or steam shall
not directly face the harness.
If water enters the connector directly, the following work must be done:
1) Disconnect the connector and wipe off the water with a dry cloth.
★ It is dangerous to dry the connector with compressed air, because oil in the air may cause
poor contact. Therefore, we shall dry the connector with compressed air free of water and
oil.
2) Dry the inside of the connector with a dryer.
If water enters the connector, dry the connector with a dryer.
★ Although it is good to use a dryer for drying, the connector and its accessories are easy to
be deformed and damaged by heat. Please pay attention to adjusting the drying time.
3) Conduct conduction test on connectors.

After drying, with the harness disconnected, conduct conduction test on the connector to
check whether there is a short circuit between pins caused by water.
After the connector is completely dried, spray the contact restorer and reassemble it.

III. Connection and Precautions of Controller (ECU, VCU) and Harness Connector
 Connection of controller and harness connector
ECU and wiring harness are connected reliably and ECU connector is provided with locking
and booster mechanism. Therefore, do not plug or unplug ECU connector forcibly. Please
plug or unplug the connector as required.
1. ECU connector booster and locking mechanism:
2. Installation of ECU connector:

1) Confirm whether the key switch is in LOCK or OFF position. If not, be sure to turn it to
LOCK or OFF position.

2) Pull the ECU connector booster structure to the end(until you hear a "click" or cannot pull
it), as shown in the figure below. At this time, the connector locking mechanism extends
completely.
If the booster mechanism is damaged, pull out the locking mechanism with force until it cannot
be moved, so that the locking mechanism can fully extend, as shown in the following figure:
3) Align the connector with the ECU connector, push it in, and try to pull back the booster
mechanism (without too much force to avoid damage). If it cannot be moved, it may not
be aligned with the ECU connector. Move it up and down and left and right and try to pull
back the booster mechanism. If it still cannot be moved, the locking mechanism may not
be completely withdrawn. Repeat steps 2 and 3 until the booster mechanism can be
easily retracted.

If the booster mechanism is damaged, please directly push the locking mechanism. If it
cannot be pushed or can be pushed but the ECU connector is not pressed with the ECU,
please repeat steps 2 and 3 until it can be pushed and pressed with the ECU.
1) After pulling the locking mechanism to the end (until "click" for some mechanism and
others cannot be moved) as shown in the figure, the ECU connector will be reliably locked
through the locking mechanism. If the connector booster mechanism is damaged, please
push the locking mechanism until the ECU connector is reliably locked through the
locking mechanism.

2) Finally, arrange the harness for other operations.

3. Unplug ECU connector:
1. Confirm whether the key switch is in LOCK or OFF position. If not, be sure to turn to
LOCK or OFF position and wait for about 30s (or hear the sound that ECU main relay is
disconnected).
2. After pulling the connector booster mechanism in the direction shown in the figure, the
locking mechanism will stretch out. Under its action, the ECU connector will move
upwards. Then after pulling the booster mechanism to the end (until "click" for some
mechanism and others cannot be moved), The ECU connector will be completely
separated from the ECU, and the ECU connector can be easily taken out.
 Precautions for use of controller

★ Electrical system fault cannot be handled in rain
★ Before welding on the vehicle, all harness connectors connected to the controller must be
removed. Install the welding ground wire near the welding spot to avoid damage to the
controller circuit board due to heavy current.

★ The controller shall be waterproof, and shock absorber shall be provided between the
controller and the connected parts.
★ Cover the ECU male connector with a sheath to prevent particles and sparks generated
by welding from entering. Do not touch the ECU pin. When plugging or unplugging the
ECU connector, be sure to operate it in place to avoid bending the ECU pin due to
unreliable plugging, forced plugging or improper plugging and affecting the relevant
functions.
★ When plugging and unplugging the ECU connector, be sure to turn the key switch to OFF
position, disconnect the ECU power supply, and wait for about 30s (or hear the sound that
ECU main relay is disconnected) before plugging and unplugging the ECU connector, so
as to avoid burning the ECU or other components due to forced power-off and prevent
ECU from recording invalid fault information during plugging and unplugging. In addition,
the ECU power supply shall be cut off when the sensors related to the electronic control
system are unplugged.
★ Some pins of ECU will output voltage. Before confirming the specific function of relevant
harness, it is strictly prohibited to ground or connect it incorrectly, otherwise ECU will be
damaged seriously.
※ Key Points to be Remembered During Fault Diagnosis of Electrical System

1) Cut off the power supply before disconnecting or connecting the connector.
2) Before troubleshooting, check that all relevant connectors are plugged in correctly.
★ Disconnect or connect the relevant connectors several times for inspection.
3) Connect the disconnected connectors before next step.
★ If the power supply is connected and the connector is still disconnected, there will be
excessive abnormal display.
4) When diagnosing faults of the circuit (measure voltage, resistance, connectivity or
current), move the relevant line and connector several times and check whether the
reading of the test instrument changes.
★ If there is any change, there may be poor circuit contact.
10.1.3 Precautions for Operation of Hydraulic Components

As the accuracy and pressure of the hydraulic device increase, the faults of most hydraulic
devices are caused by dirt (foreign matters) in the oil line. Be careful when filling hydraulic oil
or removing and installing the hydraulic device.
1) Precautions for the working environment
Avoid filling hydraulic oil, replacing filters or repairing the machine in rainy or windy weather or
dusty places.
2) When disassembling or repairing hydraulic devices on site
When disassembling or repairing the hydraulic devices on site, the dust may enter into the
hydraulic devices and affect the performance after repair. Therefore, it is better to replace the
complete set of parts. Disassembling and maintenance of the hydraulic device shall be carried

out in a special dust-free workshop, and its performance shall be tested with special test
equipment.
3) Sealing of pipe orifices

After removing the pipe or equipment, the pipe orifice must be sealed with a cap, tape or
plastic bag to prevent dirt or dust from entering. If the pipe orifice remains open or only
blocked with a rag, the dirt may easily enter or oil leakage may pollute the surrounding
environment, which is never allowed. Do not discharge the waste oil on the ground at will. The
oil must be collected and required to be properly disposed of or taken back by the client.
4) Do not allow dirt or dust to enter when filling hydraulic oil

Be careful not to allow dirt or dust to enter when refilling hydraulic oil. Always keep the oil filler
and its surroundings clean and use clean oil supply pump and oil tank. It's more effective to
use oil filter to filter out the dirt when storing oil.
5) Replace hydraulic oil at high temperature.

The higher the temperature of hydraulic oil or other oil is, the easier it is to flow. Besides,
the oil sludge in the external oil pipeline also tends to flow out with the oil. Therefore, it is
better to replace the oil at high temperature. When replacing the oil, drain the original
hydraulic oil as much as possible (not only from the hydraulic oil tank, but also from the oil
drain plug in the filter and oil line). If the original hydraulic oil is left, the pollutants and sludge
in the original hydraulic oil will be mixed with the new oil, thus shortening the service life of the
hydraulic oil.
6) Flushing operations
After the equipment is disassembled and assembled or the oil is replaced, the impurities, oil
sludge and old oil in the hydraulic oil line shall be removed with flushing oil. Generally, two
flushes shall be carried out: The first with flushing oil and the second with selected hydraulic
oil.
7) Cleaning operations
After repairing the hydraulic device (pumps, control valves, etc.) or when the machine is
running, clean the hydraulic oil to remove oil sludge or impurities in the hydraulic pipeline.
10.2 Inspection Before Fault Diagnosis

Judgment
Item Measures
value
1. Check the fuel level — Oil filling
2. Check the fuel for foreign matters — Clean, discharge
3. Check the hydraulic oil level — Oil filling
4. Check the oil level inside the hydraulic oil — Oil filling
tank — Oil filling
Lubricants,
coolants 5. Check the final drive oil level — Oil filling
6. Check the engine oil level (oil level of oil — Add water
Check pan) — Clean or replace
before 7. Check the coolant level — Adjust
starting 8. Check the clogging of dust indicators
9. Check the stroke of brake pedal
10. Check the battery terminal and wiring for — Tighten or replace
looseness and corrosion — Tighten or replace
Electrical 11. Check the alternator terminal and wiring for — Tighten or replace
device looseness and corrosion —
12. Check the starter motor terminal and wiring
for looseness and corrosion

Hydraulic, 13. Check for abnormal noise and odor — Repair

mechanical 14. Check for oil leakage — Repair
devices 15. Exhaust the air — Bleed air
16. Check the battery voltage (engine
flameout) 20 – 30 V
Replace
17. Check the level of battery electrolyte —
Replenish or
18. Check for fading, scorching or peeling —
replace
wires —
Other Replace
19. Check whether there is any fallen clamp or —
inspection Repair
items suspended wire —
Electrical Disconnect the
device 20. Check whether the wire is wet (check the After a few
connector and dry
connector or terminal carefully) minutes of
it Replace
21. Check whether the fuse is blown or rusted. operation:
Replace
22. Check the alternator voltage (the engine 27.5 – 29.5
operates with half throttle or more than half V
throttle)
Replace
23. Check the operating noise of battery relay —
(turn the starter switch to ON or OFF)
10.2.1 Before Starting the Engine
※ On-site Safety
• Check surroundings for abnormalities which may trigger danger before starting.
• Check the landform and soil texture and select the optimal working methods, and do not
work in the area susceptible to falling objects.
• When working on the highway, special personnel shall be assigned to direct traffic and set
up roadblocks to ensure the safety of traffic and pedestrians.
• If working at the place with buried facilities such as water pipes, gas pipelines, HV cables
etc., contact relevant departments first, to determine the position of pipelines, so as to
prevent damage to them during construction.
• If working in water or passing through a sandbank, check ground mass, water depth and
flow velocity first, and do not work in a water area beyond the allowable water depth.
※ Fire Protection
• Remove garbage such as leaves, deadwood, waste paper and waste materials
thermal combustion.
• Check the fuel, lubricating oil and the hydraulic system for leakage, and repair any leak.
Clear all surplus oil, fuel or other flammable liquids.
• Guarantee that a reliable fire extinguisher is provided.
• Do not operate the machine around open fire.
※ Getting on/off
• Do not jump up and down while getting on/off the machine. Getting on/off of the machine
running is prohibited, or otherwise accidental injuries will be triggered.
• Face the machine while getting on/off the machine, and always maintain three-point
contact (feet and a single hand, or hands and a single foot) among the human body,
handrails and the ladder, to guarantee safety.
• Do not grasp any control lever while getting on/off the machine.
• Check handrails and ladders while getting on/off the machine. Wipe any oil stains or
sludge found on the handrail or ladders immediately. Timely repair the damaged parts,
and tighten the loose bolts.
※ Inside the cab

• Store tools or spare parts inside the tool kit in the machine other than inside the cab in a
scattered manner, to avoid damage or breaking of the control lever or the switch.
• Keep the cab floor, the control lever, the pedal and handrails free from oils, grease, snow
or other dirts.
• Check seat belts, buckles and parts for damage or abrasion, and replace the damaged
components. Seat belts shall not be made of flexible materials, and must be replaced
after 3-year use regardless of the appearance.
• Do not bring inflammable, explosive or dangerous goods into the cab.
• No smoking inside the cab.
※ Precautions for Rearview Mirror, Windows and Lamps

• Wipe all windows and lamps clean to guarantee a clear field of view.
• Use acetaldehyde other than formaldehyde cleaning fluid since it will irritate eyes.
• Adjust the rearview mirrors on both sides, so that you can see clearly on the driver’s seat.
Replace the cracked ones immediately.
• Guarantee that the roof lamp works normally.
10.2.2 Start the Engine

• Do not start the machine if the signboard of “Do Not Operate” is pasted at the Start switch
or the control handle.
• The waste gas emitted from a diesel engine includes some substances harmful to health.
Please start and operate the engine in a well-ventilated area. If the engine is started in an
enclosed area, please guarantee sufficient space for air circulation. The waste gas can be
discharged to the outside via exhaust pipelines in an enclosed area.
• Check and guarantee that the control lever is reliably at Neutral before starting or
operating the machine.
• The engine can only be started after taking seat.
• When starting the engine, after the key is turned to the starting position, the starting time
shall not exceed 20s, and the interval between two starts shall not be less than 2 minutes.
When starting the engine with the starting cable, follow the safety procedures. Improper
cable connection will result in explosion and even personal injury.
• Wear safety glasses or goggles when starting with the starting cable.
• Avoid contact of both machines if starting with the battery of other machines.
• Guarantee reliable bonding if bonding ground wires to the frame of the machine to be
started.
• Bond positive cables first if using starting cables, and remove negative ground wires first.
• Avoid contact between tools and the positive and negative poles simultaneously, which
will trigger spark and may lead to explosion. This is extremely dangerous, so handle with
care.
• When the battery is connected in parallel, the positive pole is connected to the positive
pole, and the negative pole is connected to the negative pole.
10.2.3 Before Operation

• Prohibit approaching of irrelevant personnel towards the machine and working areas.
• Clear the obstacles on the path of the machine and pay attention to wires, ditches etc.
• Prohibit entry of any person in the cab except for the driver or lingering at other positions
of the machine, to prevent falling from the machine and influence on the field of view of
the driver.
• For the machine installed with a reversing alarm bell and a buzzer, guarantee that the
alarm can work normally.
• Firmly buckle the seat belt during driving.
Buckle
seat belt
10.2.4 Operation of the Machine
※ Working Temperature Range

Applicable temperature range of standard machine: -40°C (-40°F) ~ 50°C (122°F). Other
temperature ranges may be applicable to the machine of a special structure. For details on
the applicable temperature ranges for machines of different construction, consult the Shantui
dealers.
※ Precautions for Driving

• The blade shall be 40~50 cm above the ground when driving on a flat road.
• Slow down, turn stably and avoid sudden turning if driving on an uneven pavement.
• Do not use mobile phones during driving.
• If the engine or control lever is abnormal during driving, stop the vehicle immediately for
maintenance.
• Use work lights and roof lamps if working at a dark place and install the lighting devices
on the construction site.
• Stop working in case of poor field of view on a foggy, snowy and rainy day, and go back to
work after the weather is better.
※ Keeping away from HV Cables

Do not drive or operate the machine around cables. There is a risk of electric shock, which
may cause serious personal injury and property damage. If this is inevitable, follow the
following requirements:
• Before construction, inform the local electric power department to take necessary
measures, and the construction can be carried out only after obtaining their permission.
• Those operating close to HV cables may suffer from electric shock, leading to severe fire
and personal injuries. Therefore, certain safety distance (see the right table) must be
maintained between the machine and cables. The safe operation rules specified by local
electric power department shall be clearly known before operating the machine.
• Wear rubber shoes and gloves to prevent any possible emergency. A rubber pad shall be
placed on the driver's seat. Make sure the exposed parts of the body will not touch the
undercarriage.
• When the machine is too close to the cable, a signaler shall be assigned to give a
warning.
• Prohibit approaching of any person when the machine works around HV cables.
• If approaching or contact with cables is inevitable for the machine, to prevent electric
shock, the operator must stay inside the cab, until it is ensured that the power has been
cut off. Prohibit approaching of any person towards the machine.
Tab 0. 1
Cable voltage Safety distance
100V-200V >2m
6600V >2m
22000V >3m
66000V >4m
154000V >5m
187000V >6m
275000V >7m
500000V > 11 m
※ Precautions for Reversing

Follow the following steps before operating the machine or work tools:
• Whistle to warn people around.
• Make sure that there is no other person around the machine, especially behind the
vehicle.
• Assign a person to check if necessary, especially during reversing.
• Assign a person to direct traffic in a dangerous area or in case of poor field of view.
• No one is allowed to enter the path of the machine.
• The provisions above must be followed even if the machine is installed with a reversing
alarm bell and rearview mirrors.
※ Precautions for Construction on Soft Ground

• Do not work too close to cliffs, and deep ditches. If these positions collapse, you and your
machine will have the risk of falling or turnover, leading to death. The bearing capacity of
soil at these positions will be lowered after wind and rain.
• The soil around gullies is relatively loose, and may collapse due to the weight and
vibration of your machine.
※ Driving on Slopes
• When driving on steep hills, embankments or slopes, the vehicle may roll over or slip.
• The blade shall be close to ground while driving on hills, embankments or slopes, and be
about 20~30 cm above the ground. The blade shall be lowered to ground rapidly in case
of emergency, to help stop the machine or to prevent rollover.
• Do not turn on a slope or cross a slope, and do this kind of operation at a flat place. Put
the heavy end of the machine on the upper slope side while working on a slope.
• Rocks and wetlands will seriously affect the traction and stability of the machine. Uneven
rock surfaces may cause sliding at one end of the machine.
• Do not cross grasslands, leaves or wet steel plates, which may lead to slip of the machine.
A very low speed shall be maintained while driving along slope edges.
• Slow down while driving downslope.
• Lower the blade immediately if the engine stalls on a slope and use the parking brake.

• Prohibit downsloping under the effect of dead load or inertia.
10.2.5 Parking of Machine

• The machine shall be parked on a flat and hard ground as far as possible. If parking on a
slope is inevitable, the head shall face the downslope direction. If the gradient is large,
the blade shall be slightly shoveled to prevent the body from sliding down if necessary.
• Ensure safety lever and parking brake are locked. Otherwise, the unlocked control lever
may be triggered, causing sudden action of the work tool, and resulting in serious injury or
damage.
• When leaving the machine, be sure to lower the work tool completely to the ground,
ensure the safety control lever is locked, turn the Start switch to the "OFF" position, shut
down the engine, and lock all devices with the key. Keep your keys with you.
10.2.6 Engine Stop

• The engine is allowed to run for 5 min at a low speed before stop, so that hot positions on
the engine can cool down gradually.
10.2.7 Dragging
• The ropes can only be used for dragging when the machine is started, or otherwise
hydraulic components of the machine will be damaged.
• The ropes of sufficient strength must be used while dragging this vehicle with other
machines.
• Do not drag the machine on a slope.
• Do not use curved or twisted pulling ropes.
• Do not cross or get close to the pulling rope.
• Do not let any person stand between the tractor and the pulled vehicle while bonding the
pulled machine.

• Make the axes of the tractor and the pulled part locate on the same axis, to guarantee
that it is at a correct position.
• The machine not started shall be moved by lifting.
10.2.8 Troubleshooting Under the Machine

• Before fault diagnosis under the machine, the work tool shall be placed on the ground or
at the lowest position.
• It is prohibited to carry out troubleshooting when the machine is not reliably supported.
10.2.9 Keep the Machine Clean

• The machine shall be kept clean and tidy at any moment. The oils and grease spilled, the
tools scattered or the parts damaged may lead to personal injuries due to falling.
• Do not clean up the sensor, plugs or inside the cab with water or steam. Entry of water in
the electrical system may get the machine stuck or lead to sudden movement of it.
10.2.10 Use of Lighting

When diagnosing faults and checking fuel, engine oil, coolant or battery electrolyte, be sure to
use an explosion-proof lamp, otherwise, there may be an explosion.
10.2.11 Handle High Pressure Hoses

• Do not curve or knock HP hoses with hard objects, and do not use curved or cracked
hoses/rigid tubes, or otherwise there may be risks in burst.
• Repair loose or cracked oil pipes, and fire may be triggered in case of oil leakage.
10.3 Vehicle Fault Diagnosis Description

During fault diagnosis, the equipment may be damaged and personnel may be injured. Fault
diagnosis and troubleshooting must be done by trained technicians. See the important
instructions in the Service Manual.
10.3.1 Electrical Technical Specifications
※ Data Communication Interface

• Positive conductor to undercarriage GND (only for J1587) ........................ -3.5 to 5.0 VDC
• Negative conductor to undercarriage GND (only for J1587) ................... - 0.0 to 2.5 VDC
※ J1939 Resistance Value of Trunk Line

• Positive conductor to return conductor ........................................................... - 50 to 70 Ω
• J1939 terminal resistance............................................................................. -110 to 130 Ω
※ All Continuity Inspections

• If less than 10 Ω .................... Normal (without open circuit) sensor technical specification
• Note: To convert all psia pressure sensor values to instrument pressure values, subtract
the barometric pressure value from the absolute pressure value.
※ All short circuits to ground
• If greater than 100kΩ, normal (without short circuit)
※ Short circuit to external power supply
• If less than 1.5 VDC, normal
• ※ Sensor supply voltage
• @ ECM = 4.75 to 5.25 VDC
10.3.2 Description of Fault Diagnosis Table

Fault diagnosis table and relevant circuits
The contents of the figure are as follows, which must be fully understood before fault
diagnosis:
Faults Faults in machines
Relevant information Relevant information of detected faults or fault diagnosis

Standard value under normal
Causes
Presumed causes and state/fault diagnosis record
standard value under
1 Possible causes of faults < Description >
normal state
2 (The number given is a • Standard values used to determine

3 reference number, the possible causes under normal
and it does not indicate conditions
4
priorities) • Judgment descriptions
10.4 Mechanical and Hydraulic System Faults of Complete Vehicle

10.4.1 Work Tool Does Not Work
Faults Work tool does not work
Relevant
Before fault diagnosis, check whether the oil level of hydraulic oil tank is normal
information
Causes Standard value under normal state/fault diagnosis record
1 Whether the Normal traveling, excluding the driving device of implement

traveling is normal pump
Presumed 2 Pilot pressure low Turn the Start switch to "OFF" for preparation. After the
causes and engine idling at a high speed, start fault diagnosis.
standard Pilot pressure 3MPa
value under 3 LS overflow valve Turn the Start switch to "OFF" for preparation. After the
normal state fault engine idling at a high speed, start fault diagnosis.
Operating handle LS overflow valve pressure
Cylinder stroke 21MPa

terminal
10.4.2 Low Speed of All Work Tools

Faults Low speed of all work tools
Before fault diagnosis, check and confirm that the hydraulic system pipeline is free of oil
Relevant
leakage.
information
If the hydraulic drift of work tool is serious, implement the fault diagnosis for "hydraulic
drift of work tool".
Possible Standard value under normal state/fault diagnosis record
Causes
causes
Hydraulic oil temperature If the oil temperature is low, preheat the oil temperature to
low 50-60°C
Check the engine speed. The minimum idle speed is
Engine speed low
750rpm
It is possible that the air enters the oil suction pipeline of the
Presumed Air enters suction pipeline
implement pump. Directly check the pipeline.
causes and
Too high or too low viscosity of hydraulic oil will lead to
standard Whether the viscosity of
insufficient oil suction of pump or incorrect control and
value under hydraulic oil exceeds the
adjustment, so we shall choose hydraulic oil with proper
normal state limit
viscosity.
Pilot control pressure low Pilot pressure 3MPa
Damage of implement
pump (implement pump Check pump flow Flow: 300L/min
cannot work normally due

to abrasion of internal
components)
10.4.3 Abnormal Noise Around the Implement Pump

Faults Abnormal noise around the implement pump
Relevant
information
Causes Standard value under normal state/fault diagnosis
record
1 Air enters suction
Check connection at pump inlet side
pipeline
Presumed 2 Improper viscosity of
causes and Direct inspection
hydraulic oil
standard
3 Pump rotary assembly Check pump flow Flow: 196L/min
value under
fault
normal state
4 Air in hydraulic circuit Check the oil for foam
5 Contact between
Check whether the hydraulic pipeline resonates with the
pipeline and structural
main frame and engine
parts
10.4.4 System Oil Temperature High

Faults System oil temperature high
Relevant
information
Standard value under normal state/fault diagnosis
Causes
record
1 Air flow in the blocked
radiator or passing
Check the radiator, clean or replace it.
through the radiator is
low.
2 Radiator bypass valve
Check bypass valve, repair or replace it.
stuck
Presumed 3 Improper viscosity of
Direct inspection, use recommended hydraulic oil.
causes and hydraulic oil
standard 4 Observe whether the oil is turbid through the oil
There is a lot of gas in
value under window, and check whether there is leakage at the
the hydraulic system
normal state pipeline and cylinder head
5 Low pressure of oil Oil replenishing pressure: 26bar. Refer to the low oil
replenishment replenishing pressure for troubleshooting
6 Check the pressure at the low pressure side of the
traveling system. If it is low, block the valve core with a
Inside the motor flush valve and shield the flush valve. If there is no flush
valve, observe the oil return volume of the motor
housing. If the flow is too large, replace the motor.
7 Working system LS LS pressure: 230 bar, too low, repair or replace LS

pressure low overflow valve
8 The pressure setting of

Too low pressure setting, system fatigue, adjustment or
travel pump HP overflow
replacement of high pressure overflow valve.
valve is low
9 Fan pump worn Check fan pump for noise or flow
10 Low fan speed Refer to the fault of low fan speed
11 Poor oil cleanliness Check the oil cleanliness and moisture
12 Hydraulic hose or
Check whether the pipeline is twisted or blocked
pipeline fault
13 Check whether the air inlet, hydraulic oil and coolant
Temperature sensor fault
temperature sensors work normally
10.4.5 Severe Malfunction of Hydraulic Cylinder

Faults Severe malfunction of hydraulic cylinder
Relevant Before fault diagnosis, check and confirm that there is no oil leakage in the work tool
information pipeline
Causes
record
1 Check the internal leakage of oil cylinder, and refer to
Internal leakage of
Presumed the detection and standard of internal leakage of oil
hydraulic cylinder
causes and cylinder
standard 2 Blockage or leakage of
Repair or replace the safety valves
value under pipeline safety valve
normal state 3 Blockage or leakage of
Repair or replace the anti-suction check valve
anti-suction check valve
4 Working contact internal
Repair or replace the spool
leakage of working valve
10.4.6 Hydraulic System Stalled

Faults Hydraulic system stalled
Relevant Before fault diagnosis, check and confirm that there is no oil leakage in the work tool
information pipeline
Causes
record
1 Check the internal leakage of oil cylinder, and refer to
Internal leakage of
the detection and standard of internal leakage of oil
Presumed hydraulic cylinder
cylinder
causes and 2 Blockage or leakage of
standard Repair or replace the safety valves
pipeline safety valve
value under
3 Blockage or leakage of
normal state Repair or replace the anti-suction check valve
anti-suction check valve
4 Working contact internal
Repair or replace the spool
leakage of working valve
2 Faults inside pull pin There may be faults inside pull pin cylinder, and directly

cylinder check it.
3 Abnormal double-tilt
There may be faults in double-tilt switching valve 2 of
switching valve of dozer
dozer blade, and directly check it.
blade
4 Abnormal function of
There may be faults in double-tilt cylinder of dozer
double-tilt cylinder of
blade, and directly check it.
dozer blade
10.4.7 Low Oil Replenishing Pressure

Faults Low pressure of oil replenishment
Before fault diagnosis, check and confirm the oil level of hydraulic oil tank and check
Relevant
the pipeline for leakage.
information
Perform troubleshooting according to the DTC information if any.
Causes Standard value under normal state/fault diagnosis record
1 Check for DTC Troubleshooting according to DTC

Check whether the The fan pump and the oil replenishing pump are one output
2 fan system works of the gear transfer case. If the output is normal, the power
normally output is normal.
Adjust the oil replenishing overflow valve. If the pressure
Stuck oil replenishing
3 does not change, the valve may be stuck. Repair or replace
Presumed overflow valve
it.
causes and
If the oil level increases, the piston seal of the brake may
standard Check the oil level of
4 fail and the oil enters the housing of the final transmission,
value under final drive
resulting in low oil replenishing pressure.
normal state
Wear of oil
5 Check, repair or replace the oil replenishing pump.
replenishing pump
Motor flushing
6 Check, repair or replace it.
overflow valve
Check the oil replenishing pressure under
Motor flushing forward/backward conditions, and check or maintain the
7
overflow valve stuck flushing overflow valve in case of low or reduced oil
replenishing pressure in a single acting direction.
10.4.8 Traveling Without Any Movement

Faults Traveling without any movement
Relevant
information
Check whether the input signal of control module is normal.
No. Causes Standard value under normal state/fault diagnosis record
Low left and right oil Low oil replenishing pressure, brake not released, oil replenishing
1
replenishing pressure pressure detected, standard value 26±0.3bar
Oil replenishing If the test oil replenishing pressure is low, there may be faults inside the
2
pump fails. oil replenishing pump.
Brake solenoid valve Brake Brake pedal not
3 Brake pressure 26±0.3bar
fault solenoid depressed
valve Depress the brake
Brake pressure 0 bar
energized pedal
If the pressure is abnormal, check the resistance of the brake solenoid
valve. The standard value is 28-36Ω. Repair or replace it,
Check the brake solenoid valve harness and repair or replace it.
4 Power output fault Check whether the work tool and fan work normally.
5 Brake component Disassemble the brake and check the seal, spline, friction plate and
fault brake plate, etc., and repair or replace them.
10.4.9 Single Crawler Belt Does Not Work

Faults Single crawler belt does not work
Relevant
information
Handle forward Min 4bar

Control valve High idle
Handle in neutral
Travel pump electric outlet speed of 0
position
1 proportional relief valve pressure engine
fault Handle back Min 4bar
If the input current is normal and the pressure is abnormal, the control
valve element may be stuck.
Travel pump servo If the detection in Step 1 is normal, the single-side servo valve may be
2
valve fault faulty. Repair or replace it,
Traveling handle in
Traveling High idle 26±0.3bar
neutral position
system speed of
Traveling handle
3 Travel pump worn. pressure engine 420±10bar
forward and backward
If the pressure is abnormal, loosen the oil drain port of the pump
housing and observe whether there are contaminants.
If the above detection is normal, the single-side travel motor may be
4 Travel motor worn faulty. Loosen the oil drain port of the motor housing and observe
whether there are contaminants.
Disassemble the brake and check the seal, spline, friction plate and
5 Brake component fault
brake plate, etc., and repair or replace them.
10.4.10 One-side One-way No Action

Faults One-side one-way no action
Relevant
information
Travel pump electric Control valve High idle Handle forward Min 4bar
1 proportional relief valve outlet speed of Handle in neutral
fault pressure engine 0
position

Handle back Min 4bar

If the input current is normal and the pressure is abnormal, the control
valve element may be stuck.
Travel pump servo If the detection in Step 1 is normal, the single-side servo valve may be
2
valve fault faulty. Repair or replace it,
If 1-2 is normal, the travel pump on one side may be faulty. Loosen the
3 Travel pump worn. oil drain port of the pump housing and observe whether there is
pollutant.
10.4.11 Low Speed or Low Power

Faults Low speed or low power
Check the pipeline for leakage and air intake
Relevant Perform troubleshooting according to the DTC information if any.
information Slow speed after adjustment of travel pump or travel motor, requiring re-calibration or
adjustment.
If the rotation speed of traveling, work tool and fan is low, the gear
1 Power output fault
transfer case may be faulty. Repair or replace it.
2 Poor cleanliness Check whether the blockage alarm of the oil replenishing filter alarms
Traveling handle
Oil replenishing High idle speed
in neutral 26±0.3bar
Low pressure of oil pressure of engine
3 position
replenishment
If the pressure cannot be adjusted to normal, the oil replenishing
overflow valve fails.
Traveling handle
Oil replenishing High idle speed
forward or 26±0.3bar
Motor flushing overflow pressure of engine
4 backward
valve fault
If the pressure cannot be adjusted to normal, the motor flushing
Oil replenishing pump
5 If 1-4 is normal, the oil replenishing pump may be faulty
fails.
Traveling handle
in neutral 26±0.3bar
Travel pump high Traveling main High idle speed position
6 pressure overflow valve circuit pressure of engine Traveling handle
fault forward or 420±10bar
backward
If the above pressure is low, the high pressure overflow valve is stuck

10.4.12 Non-adjustable Driving Speed
Faults No change in driving speed
Relevant Perform troubleshooting according to the DTC information if any.
information The speed is slow after adjusting the traveling motor and needs to be readjusted and
calibrated.
Check the resistance and harness of the motor control solenoid valve.
Motor control solenoid
1 The resistance is 26-28Ω
valve fault
Check whether the solenoid valve is stuck.
2 Poor cleanliness Check whether the blockage alarm of the oil replenishing filter alarms
Travel pump servo
3 Check whether the servo valve gets stuck.
valve fault
10.4.13 Large Vibration When the Complete Machine is Stopped or Started

Faults Large vibration when the complete machine is stopped or started
Relevant Before fault diagnosis, check whether the oil level of hydraulic oil tank is normal.
information Check the pipeline for leakage and air intake
1 Travel pump with gas The gas in the servo valve of the travel pump needs to be exhausted.
Preheat the oil, ensure the temperature reaches the green area on the
2 Low oil temperature
instrument.
Travel pump servo There is a problem during maintenance and adjustment of travel
3
valve adjustment fault pump. Adjust and calibrate the valve again
10.4.14 Serious Deviation of the Complete Machine

Faults Serious deviation of the complete machine
Relevant
information
Traveling handle not in
1 Is the traveling handle in the neutral position
neutral position
Abnormal motor speed
2 Check whether the motor speed sensor is normal
sensor
Abnormal control of Whether the control current of travel pump and control servo valve are
3
travel pump normal
Incomplete exhaust of
4 Exhaust the servo valve
travel pump
Travel pump
Check the output pressure of proportional relief valve, standard:
5 proportional relief valve
4-16bar
fault
Handle in
26±0.3bar
Traveling High idle speed neutral position
system pressure of engine Handle forward
Internal abnormality of 420±10bar
6 or backward
travel pump
If the forward and backward deviation is the same and the pressure on
the slow side is low, the pump will loosen the oil drain port of the pump
housing for personnel to observe whether there are contaminants.
Oil Traveling handle
High idle speed of
replenishing forward or 26±0.3bar
One-side motor flushing engine
7 pressure backward
overflow valve
If the pressure cannot be adjusted to normal, the motor flushing
If it is steered in place, the speed on one side is slow and brakes on
8 One-side brake fault
some sides are stuck.
Faults inside travel
9 If the above is normal, there may be faults inside travel motor.
motor
10.4.15 Abnormal Noise from Travel Pump or Motor

Faults Abnormal noise from travel pump or motor
Relevant
information
Incorrect use of
1 Confirm whether the oil used meets the requirements
hydraulic oil
Poor sealing of oil
2 suction port of oil Check the sealing of oil suction pipeline
replenishing pump
Loose pipeline between
3 Inspection and repair of pipelines
travel pump and motor
The oil replenishing
4 Check whether the filter element of the oil replenishing filter is blocked.
filter is blocked
Oil Traveling handle
High idle speed of
Abnormal oil replenishing in neutral 26±0.3bar
engine
5 replenishing overflow pressure position
valve If the pressure cannot be adjusted to normal, the oil replenishing
Oil
High idle speed of Handle forward
replenishing 26±0.3bar
Motor flushing overflow engine or backward
6 pressure
valve fault
If the pressure cannot be adjusted to normal, the motor flushing oil
overflow valve fails
7 Gas in the travel pump The gas in the servo valve of the travel pump needs to be exhausted.
8 If the above is normal, there may be faults inside travel pump.
pump

9 If the above is normal, there may be faults inside travel motor.
motor
10.5 Transfer Case Fault

Fault Causes Troubleshooting methods
Add appropriate transmission oil:
Too high oil temperature Too much lubricating oil, heating of The normal oil volume of the
inside the transfer case churning oil transfer case is 6L (7.2L with oil
cooler)
1. Few lubricating oil in the case,
and the lubrication at the bearing is
insufficient.
2. The lubricating oil channel inside
High temperature of the case is not smooth, and the oil Check whether the oil passage is
transfer case bearing trap does not collect enough oil, unblocked and the bearing fits
resulting in insufficient lubricating oil;
3. Unreasonable fit tolerance of
bearing, resulting in wear and heating
of bearing collar.
Excessive meshing backlash of
Abnormal sound inside the gears, and abnormal sound Check the fit clearance of gear
transfer case generated during gear teeth teeth
engagement.
10.6 Common Faults of Engine

10.6.1 Difficult Start or Start Fault of Engine (Smoking during Air Exhaust)
1.
Fuel intake filter screen of supply pump or hose
Clear away the dirt and check if the fuel is clean
clogged
2.
Drain off the air, check the sealing of the connector
Air entered into the fuel system
and repair it
3.
Check plunger, fuel outlet valve and repair or
Injection pump damaged
replace the broken parts
4.
Injector damaged Check the atomization of injector, and repair it
5.
Initial angles of valve gear or fuel delivery is wrong Cheek and adjust it
6.
High pressure line damaged or leaked Repair or replace
7.
Check the sealing of the valve and cylinder gasket
Insufficient pressure in cylinder
and the wear of the piston ring. Repair or replace
them

8.
The temperature is too low With the addition of start-assist device
10.6.2 Insufficient Power of Engine
1. ( )
Check the air cleaner and air intake pipe, clean or
Air intake clogged (air cleaner choked)
replace filter element
2.
Check the valve-timing and exhaust pipe, adjust
Exhaust back pressure is too high
and repair
3.
Insufficient pressure in supercharging system Check and block up the leakage of pipeline
4.
Faults in turbocharger Replace the turbocharger assembly
4.1.
Compressor and turbine streets choked up Clean or replace
4.2.
Floating bearing cease to be in effect Replace
4.3. , ,
Carbon deposit or greasy filth in clearance of
Clean
turbine and compressor back
5.
Intercooler damaged Replace or repair
6.
Check the sealing of fuel pipe and connector, fuel
Leakage or choke of fuel line
filter and fuel line, repair, clean or replace the filter
element
7.
Clean the fuel tank, filter parts and fuel pipe.
Poor quality of fuel
Renew the fuel
8.
Excessive wear for injection pump or governor Repair or replace
9.
Smoke-limiter diaphragm of injection pump
Repair or replace
damaged
10. Replace
Air pipe of smoke-limiter damaged
11.
Check the injecting pressure, clean away the
Poor atomizing
carbon deposit in nozzle, adjust and repair in-jector
12.
Incorrect timing of valve gear or fuel delivery Check and adjust it
13.
High-speed of governor is adjusted too low Check the speed-governing and adjust
14.

Oil level in the oil sump is too high Check the oil-dipstick, and drain off unnecessary
oil
15.
Leakage in cylinder gaskets Check the compressed pressure at hot state,
replace cylinder gaskets
16.
Piston ring broken, the clearance of main bearing
Replace worn parts or overhaul the engine
is too large
17.
Overhaul the engine
Cylinder liner or piston worn, or piston scuffing
10.6.3 High Black Smoke Emission of Engine

1.
Air intake isn't free or exhaust back pressure is too
Clean
high
2.
Poor quality of fuel Clean and renew
3.
Incorrect timing of valve gear or fuel supply Adjust according to requirements
4.
Poor atomizing Check, repair or replace injector
5. ( )
Excessive injection quantity Check and adjust (by manufacturer)
6.
Check and block up the leakage of pipeline and
Insufficient pressure in supercharging system
connector
7.
Faults in turbocharger Check and replace
8. ( )
Incorrect working point of smoke-limiter Readjust ( by manufacturer)
10.6.4 High White Smoke Emission of Engine

1.
Poor quality of fuel, contains water Renew fuel
2.
Check working temperature of thermostat, replace
Temperature of cooling water is too low
if necessary
3.
Incorrect timing of valve gear or fuel delivery Check and adjust
4.
Poor atomizing Check and repair
5.
Incomplete combustion, scuffing and the Check piston ring,cylinder liner, cylinder gasket,
compressed pressure is too low and repair them
6.
Wear-in between the piston rings and cylinder Go on wearing-in
liners is not good
7.
The gaps of the piston rings are not staggered Adjust, reassembly
8.
Piston oil rings cease to be in effect Replace
9.
The fit clearance between piston and cylinder liner
Repair or replace
is too large
10.
The sealing ring of turbocharger worn Check and replace
11.
The thrust bearing of turbocharger worn Check and replace
12.
The oil return pipe of turbocharger choked. Clean or repair
10.6.5 Low Engine Oil Pressure

1.
Oil level in oil sump is too low Check oil leakage, add oil
2.
Faults in pressure regulating valve of main oil
Check valve, clean and repair
passage
3.
Strainer, oil pipes, connector gasket choked or
Check strainer and connector , check if there is
broken
any sponge in oil passage, repair
4.
Lub-oil doesn't conform to specifications Renew the lub-oil according to requirements
5.
Intake pipe of oil pump leaked Check the oil pipe and connector, repair or replace
6.
Water temperature in cooling system and oil
Check cooling system, and correct it
temperature are too high
7.
Excessive resistance of oil filter Renew the filter element
8.
Oil cooler choked Check and clean
9.
Main oil passage choked Check and clean
10. ,
The clearance of bearing is too large or bearing
Check and replace
damaged
11. , ,
Excessive wear of parts, need to over haul Check the working time of the engine, over haul
10.6.6 Starting Motor Does Not Work

1.

Insufficient charging for battery Check, charge or replace
2.
Bad contact in connecting wire Check up circuit, tighten terminal
3.
Fuse broken Replace
4.
Bad contact in brush Clean brush surface or replace brush
5.
Short circuit in starting motor Check and repair it, or replace the motor assembly
10.6.7 Powerless Motor

1.
Insufficient voltage of battery Charge or replace
2.
Bearing bush worn Replace bearing assembly
3.
Bad contact in brush Clean brush surface or replace brush
4.
Clean away the dirt and furbished using
Commutator unclean or sintered
sandpaper, or replace commutator assembly
5.
Reweld
Sealing off at wire end
6.
Bad contact for switch Check and repair
7.
wore clutch slipped Adjust working moment of clutch or replace
10.6.8 Electric Generator Fault

1.
Wire connecting broken, short circuit, joint Check the connecting wire of generator or
loosened galvanometer repair
2.
Coil of rotator and stator shorted, broken Repair or replace
3.
Rectifier tube damaged Replace
4.
Terminal damaged, wire broken Repair
5.
Voltage regulated by regulator is too low Repair
6.
Contact of regulator fused Repair or replace
10.6.9 Insufficient Charging of the Electric Generator

1.
Connecting wire broken or shorted, terminal
Repair
loosened
2.
Coil of rotator and stator shorted or broken partially Repair or replace
3.
Belt of generator loosened Check and adjust tension
4.
Rectifier tube damaged,bad contact in brush Repair
5.
Insufficient voltage of regulator Regulate
6.
Field coil or resistance connecting wire broken Repair or replace
7.
Insufficient electrolyte of battery or battery is too
Add electrolyte or renew battery
old
10.7 Common Faults of Electrical System

10.7.1 Engine Start Fault
Faults Engine start fault
The engine start circuit is provided with a neutral safety function and the engine cannot
be started unless the parking control lever is in the locked position.
Relevant
If there is a prompt that "display panel does not light up" or "the battery relay does not
information
make a sound of operation" when the starter switch is set to ON, the main power
system may be faulty. Therefore, check the main power system.
Specific gravity of battery

The battery power is Battery voltage
1 electrolyte
insufficient.
Min. 24V Min. 1.26
2 Start switch fault Open circuit inside starter switch, check harness resistance.
Alternator Voltage
Alternator fault (internal
3 Between terminal R and ground Max. 1V
short circuit)
wire
Starter motor fault When the supply voltage for charging and starting is normal, but the
4
(internal fault) starter motor does not work, the starter motor is faulty.
Harness open-circuited
Prepare with the starter switch off, and then diagnose the faults without
(open circuit of harness
5 turning on the starter switch. Judge the resistance between the main
or poor contact with
circuit of starter motor and the positive pole of battery
connector).
Alternator terminal R and starter motor terminal R wire harness
6 Harness short-circuited
short-circuited to ground
10.7.2 Intake Preheater Does Not Work

Faults Engine intake preheater does not work
Relevant In cold environment, the engine intake preheater works automatically, and the preheat
information indicator on the display lights up, and goes out after preheating.
If the intake heater does not work, there will be corresponding DTC for engine.

Heating relay fault When the voltage of power supply and signal is normal and there is no
1
(internal) working sound, the heater relay is faulty.
Electric intake preheater Connectivity
Intake preheater fault
3
(internal fault) Between terminals Connectivity
(open circuit of harness Electric intake heater terminal and electric intake air of heater relay.
4
or poor contact with Harness between heaters, maximum resistance is 1 Ω
connector).
10.7.3 Display Does Not Light Up When the Starter Switch is Turned ON
Faults The display does not light up when the starter switch is turned on.
Relevant
Turn on the starter switch, and the display lights up normally
information
(open circuit of harness
2 Check the power supply voltage of the display
or poor contact with
connector).
Display fault (internal
3 Replace monitors
fault)
10.7.4 Air Filter Blockage Alarm Lamp Flashes

Faults Air filter blockage alarm lamp flashes
Relevant
If any abnormality is found when the engine is running, the alarm indicator will flash
information
1 Air filter blocked. Clean or replace the air filter.

(open circuit of harness Prepare with the starter switch off, then diagnose the fault without
2
or poor contact with turning on the starter switch
connector).
Display fault (internal Check whether the voltage between the display and the alarm
3
fault) indicator is normal
10.7.5 Engine Oil Pressure Alarm Lamp Flashes

Faults Engine oil pressure alarm lamp flashes

Relevant If abnormality is found during engine operation, the emergency alarm lamp will flash
information and the alarm buzzer will sound.

Oil pressure sensor Check the supply voltage and resistance to ground of oil pressure
1
fault sensor
(open circuit of harness Prepare with the starter switch off, then diagnose the fault without
2
or poor contact with turning on the starter switch.
connector).
Display fault (internal Check whether the bus communication between the display and the
3
fault) engine is normal
10.7.6 Engine Coolant Temperature Alarm Lamp Flashes

Faults Engine coolant temperature alarm lamp flashes
Relevant
If abnormality is found during engine operation, the emergency alarm lamp will flash.
information

Engine coolant
Check the engine coolant temperature when the engine coolant
temperature too high
1 temperature is too high. (The lamp will flash when the coolant
(when the system is
temperature is above 102°C)
normal)
When the coolant temperature pointer is in the white area, the
Coolant temperature
2 indicator will go out. When the pointer is in the red area, the indicator
sensor fault
will be on.
Display fault (internal Check whether the bus communication between the display and the
3
fault) engine is normal
10.7.7 Drive System Oil Temperature Alarm Lamp Flashes

Faults Drive system oil temperature alarm lamp flashes
Relevant
If abnormality is found during engine operation, the emergency alarm lamp will flash.
information

Drive system oil Check the oil temperature of hydraulic system (the lamp will flash
1
temperature too high when the oil temperature is above 130°C)
Oil temperature sensor
2 Check the sensor for faults
fault
Display fault (internal Check whether the bus communication between the display and
3
fault) vehicle controller is normal.
10.7.8 Abnormal Fuel Level Indication

Faults Abnormal fuel level indication

Relevant
information
1 Fuel level sensor fault Check the fuel level sensor and check whether the floats are stuck.
Harness short-circuited
2 Check the connection and disconnection of relevant harness
or open-circuited.
Display fault (internal Check whether the bus communication between the display and
3
fault) vehicle controller is normal
10.8 Common Faults of Driving System

10.8.1 Cab Assembly
S/N Faults Solutions Remarks
When the left and right door frames and
Replace the left and right door sealing
1 doors are not tightly sealed, the sealing
strip.
fails.
Poor sealing of sliding window and Replace the sliding window sealing
2
failure of sealing strip. strip.
Polish the sealant at the joint between
Poor sealing of left and right latch lock
3 the left/right latch lock switch and the
switches
frame
Loose or untight seal of electrical Replace the horn ring pipe and polish
4
threading hole the sealant
Insufficient stroke of door lock cylinder, Adjust stroke of stroke nut for easy
5
difficulty in opening opening
Looseness of locking column, causing
Re-adjust the locking column position
6 eccentricity of lock catch between
and fix it
locking column and lock cylinder
The latch hook deviates from the Readjust the position of the external
7 external latch, and the latch function latch until the latch hook fits the external
fails. latch properly.
10.8.2 A/C System Assembly
※ A/C does not blow cold air

Faults A/C does not blow cold air
Check for refrigerant leakage
Relevant
Check whether the condenser core is blocked
information
Check the heater switch and close the heating valve switch

Fuse fault (inside If the fuse (inside the device) is broken or open-circuited, check
1
device) relevant circuits.
Compressor clutch
2 fault Check compressor clutch
(coil side)
Compressor fault
3 The compressor may be faulty. Direct inspection
(internal)
4 Blower fault Check the faults inside blower
5 Control panel fault When cooling indicator does not light up, replace control panel.
6 Heating valve fault Check the heating valve and replace it

Wire harness
open-circuited (open
Check the resistance between A/C system harness and
7 circuit of harness or
undercarriage grounding and other harnesses
poor contact with
connector).
※ Insufficient Air Flow of the A/C

Faults No or insufficient air flow of A/C
Relevant Check whether the blower works abnormally
information Check whether the evaporator core is blocked

Internal circulation filter
1 Clean the filter screen
screen blocked
2 Air duct fault Check whether the air duct is damaged
Check the position of the temperature sensor and whether there is
3 Evaporator freezes
water in the connector
Check whether there is any foreign matter inside the fan and
4 Faults inside fan
whether the fan blade is normal
Wire harness
Check the resistance between A/C blower harness and
undercarriage grounding and other harnesses
poor contact with
connector)
※ Compressor Does Not Work

Faults A/C compressor does not work
Relevant
Check whether the A/C compressor belt is abnormal
information

Wear or fracture of A/C
1 Check the A/C belt and tension
belt
2 No refrigerant Refill refrigerant R134a, weight 750g

No leakage of A/C
3 Check each pipeline and joint for leakage and pipeline damage
pipeline
Wire harness
Check whether the supply voltage of A/C compressor harness is
normal
poor contact with
connector).
※ A/C Does Not Blow Hot Air

Faults A/C Does Not Blow Hot Air
Relevant
Check whether the A/C heater switch is turned on
information
1 Heater switch fault Check the heater switch

The fresh air filter
2 Check whether the fresh air filter element is blocked by foreign matters
element is blocked
3 Heater pipe fault Check whether the heater pipe falls off or is damaged
Evaporator core
4 Clean core debris
blocked
5 Evaporator core fault Check for lodging of core fins and core rupture
6 Blower fault Check the faults inside blower
※ Detailed Steps of A/C Inspection

1. Check whether the compressor is started: Turn on the A/C and observe whether the
electromagnetic clutch of the compressor rotates with the compressor pulley. See Fig. 10.1 for
the position of the electromagnetic clutch.
Electromag
netic clutch
Fig. 10.1 Electromagnetic Clutch Position
2. Check the system pressure: Connect the A/C pressure gauge to the refrigerant filler of the
A/C pipeline and read the A/C system pressure. See Fig. 10.2 for the normal system pressure

Fig. 10.2 Normal Pressure

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Installation and Maintenance Manual of DH24-B2 Full-hydraulic

II Shantui Construction Machinery Co., Ltd.

Shantui Construction Machinery Co., Ltd. III

Shantui Construction Machinery Co., Ltd. V

VI Shantui Construction Machinery Co., Ltd.

Shantui Construction Machinery Co., Ltd. VII

VIII Shantui Construction Machinery Co., Ltd.

General Hazard Information

Service and Maintenance Precautions

Shantui Construction Machinery Co., Ltd. 1

Fig 0.1 Signboard

Working and Personal Protective Articles

Fig 0.2 Signboard

Precautions for Using Compressed Air and Water

2 Shantui Construction Machinery Co., Ltd.

Precautions for Internal Pressure of Hydraulic System

Preventive Measures against Liquid Penetration

Fig 0.3 Signboard

Prevention of Inhalation Hazards

Fig 0.4 Signboard

Proposal Disposal of Wastes

Fig 0.5 Signboard

Preventive Measures against Crush or Cut Injuries

4 Shantui Construction Machinery Co., Ltd.

Fig 0.6 Signboard

Fig 0.7 Signboard

Preventive Measures against Scald

Fig 0.8 Signboard

Fig 0.9 Signboard

Preventive Measures against Fire and Explosion

Precautions for Using Fuel Substances

6 Shantui Construction Machinery Co., Ltd.

Fire Protection of Oils

Fig 0.10 Signboard

Shantui Construction Machinery Co., Ltd. 7

Fig 0.11 Signboard

• Refueling or injection of lubricating oil shall be made at a well-ventilated place.

Fig 0.12 Signboard

Precautions for Using Battery and Battery Cables

Fig 0.13 Signboard

Fig 0.14 Signboard

Fig 0.15 Signboard

Shantui Construction Machinery Co., Ltd. 9

Fig 0.16 Signboard

10 Shantui Construction Machinery Co., Ltd.

Fire Extinguishers and First-aid Kits (Self-supplied)

Fig 0.17 Signboard

Shantui Construction Machinery Co., Ltd. 11

Fig 0.18 Signboard

(1): Fuel common rail; (2)~(6): HP fuel pipelines

Precautions for Refitting

Precautions for Optional Parts

Fig 0.19 Signboard

Shantui Construction Machinery Co., Ltd. 13

Fig 0.20 Signboard

Inside the cab

Precautions for Rearview Mirror, Windows and Lamps

14 Shantui Construction Machinery Co., Ltd.

Starting the Engine