B876F Service Manual-Version 1, 1st Printed

Service Manual for Backhoe Loader B876F
880*1230 mm 16-mo 18 printed sheets

July 2017, Version 1, Printed for the 1st time
Shandong Lingong Construction Machinery Co., Ltd.
Add: Lingong Industry Park, Linyi Economic Development Zone, Shandong, China
Tel: 0539-8785688 Fax: 0539-8785698
Zip code: 276023 Web: www.sdlg.cn
Service tel: 8008607999 4006587999 0539-8785800
Service fax: 0539-8785671
Service Manual for Backhoe Loader
Contents
0 Safety and Environment ............................................................................... 1
1 General ......................................................................................................... 1-1
2 Engine System ............................................................................................... 2-1

21 Introduction to engine ................................................................................. 2-1
22 Disassembly and assembly of engine system .............................................. 2-2
23 Attentions for use and maintenance of engine ........................................... 2-3
24 Common faults and troubleshooting of engine system ............................... 2-5
3 Electrical and Information System ................................................................ 3-1

31 Introduction to electrical system ............................................................... 3-1
32 Electrical system components .................................................................... 3-8
33 Electrical circuit of machine ........................................................................ 3-26
4 Introduction to Transmission System ............................................................ 4-1

41 ZF transmission system ............................................................................... 4-1
42 Maintenance of transmission-torque converter system ............................ 4-9
43 Drive shaft system ....................................................................................... 4-11
44 Drive axle system ........................................................................................ 4-11
5 Brake System................................................................................................. 5-1

51 Service braking system ................................................................................ 5-1
52 Parking braking system ............................................................................... 5-6
6 Steering System ............................................................................................ 6-1

61 Introduction to steering system.................................................................... 6-1
62 Pressure measurement and adjustment of steering system ........................ 6-3
63 Preparation before repairing the steering system ...................................... 6-4
64 Introduction to main components .............................................................. 6-5
65 Exhaust of steering system .......................................................................... 6-9
66 Fault diagnosis and troubleshooting of steering system ............................. 6-10
I
7 Tires, Frame and Working Device ................................................................. 7-1

71 Summary of frame and working device ................................................... 7-1
72 Disassembly and assembly of loading working device ............................ 7-2
73 Disassembly and assembly of excavating working device .................... 7-10
74 Disassembly and assembly of front and rear tires .................................. 7-18
75 Disassembly and assembly of counterweight ............................................... 7-20
8 Cab and Air Conditioner System ................................................................... 8-1

81 General steps for disassembly and assembly of cab .................................... 8-1
82 Introductions to air conditioner system ................................................... 8-2
83 Routine inspection on air conditioner system ............................................. 8-9
84 Maintenance guide of air conditioner system ............................................ 8-11
85 Common fault diagnosis and troubleshooting of air
conditioner system........................................................................................ 8-16
9 Working Hydraulic System ............................................................................ 9-1

91 Introduction to working hydraulic system ................................................... 9-1
92 Hydraulic system at the loading end ........................................................... 9-3
93 Hydraulic system at the excavating end ...................................................... 9-7
94 Outrigger hydraulic system ........................................................................ 9-9
95 Auxiliary hydraulic system ........................................................................... 9-12
96 Attentions for maintenance of working hydraulic system ........................... 9-13
97 Fault diagnosis and troubleshooting of hydraulic system ................... 9-15
II
Backhoe Loader Service Manual
Contents
Safety and Environment ............................................................................................................1
Preface .............................................................................................................................. 1
Safety during Handling of Machine .................................................................................. 2
Some Simple Safety Rules .....................................................................................................3
Before Operations ..................................................................................................................3
Mounting and Dismounting ...................................................................................................4
Seat belt ..................................................................................................................................5
During Running of Engine .....................................................................................................5
When Leaving Operator’s Seat ..............................................................................................6
Towing and Tow-start ............................................................................................................6
Safety Rules during Repair and Maintenance................................................................... 6
Before any Repair or Maintenance Work: .............................................................................7
Maintenance Position .............................................................................................................8
Loading ArmSsafety Lever ....................................................................................................9
Installation ..............................................................................................................................9
Uninstalling ..........................................................................................................................10
Notice of Attachment ...........................................................................................................10
Operation Safety of Tires ................................................................................................ 11
Air inflation ..........................................................................................................................11
Installation of Tire and Wheel Rim ......................................................................................11
Repair of Tires and Wheel Rims ..........................................................................................12
Operation Safety of Battery ............................................................................................ 12
Battery Charging ..................................................................................................................13
Start with Booster Battery ....................................................................................................13
Operation Safety of A/C Refrigerant............................................................................... 14
Personal Protection Devices.................................................................................................14
Measures in event of Accident: ............................................................................................15
Handling Safety of Oils ................................................................................................... 16
Safety of Hydraulic System..................................................................................................16
Relief of Pressure .................................................................................................................17
Fire Prevention Measure ................................................................................................. 17
Overview ..............................................................................................................................17
Cleanliness ...........................................................................................................................18
Electric System.....................................................................................................................19
Welding and Grinding ..........................................................................................................19
Checking after Fire Accident or High Temperature ........................................................ 20
Health Hazard of Paints, Plastics, and Rubbers.............................................................. 21
Working on Painted Surfaces ...............................................................................................21
I
Rubbers and Plastics ............................................................................................................ 21

Fluoride Pubber ................................................................................................................... 22
Safety transmission ......................................................................................................... 23
Load and unload the Machine.............................................................................................. 23
Transportation on the Ground.............................................................................................. 24
Lifting .................................................................................................................................. 24
Environment ................................................................................................................... 25
Waste Treatment .................................................................................................................. 25
Engine oil and Fluids ........................................................................................................... 26
Filters ................................................................................................................................... 26
Refrigerant ........................................................................................................................... 26
Engine oil and Fuel .............................................................................................................. 27
Chemicals ............................................................................................................................ 27
Rubbers and Plastics ............................................................................................................ 27
Electronic units .................................................................................................................... 27
Works in contaminated Environment .................................................................................. 27
Decontamination after Leakage/Splashing .......................................................................... 27
Decontamination after Accidents......................................................................................... 28
II
Safety and
Environment
Preface
This manual is one part of the entire Maintenance
Manual of B876F Backhoe Loader. Please
carefully read the contents of this part.
Warning:
Make sure to firstly read the section “Safety”
in the manual before the operations.
Safety is related to everyone
Always abide by the instructions of the
Operation and Maintenance Manual of B876F
Backhoe Loader attached in the machine. This
manual is supplemental with the Operation and
Maintenance Manual of B876F Backhoe Loader
SDLG designs and manufactures safe and
efficient machines. However, our endeavors will
come to naught if the operator of our machines
fails to carefully read or abide by the safety
instructions, such as climbing up or down the slip
machine parts without use of ladder, grasping the
hoses instead of handrail, or use incorrect tools
not intended for the specific operation.
To maintain the safe and effective functions of
the machine, make sure to always use appropriate
spare parts designed especially for this machine
(genuine parts from Shandong Lingong
Construction Machinery Co., Ltd.). Our
company (Shandong Lingong Construction
Machinery Co., Ltd.) will not be liable for the
damages of machine nor provide warranty
compensation arising from the use of spare parts
other than the genuine parts from Shandong
Lingong Construction Machinery Co., Ltd..
The working personnel shall bear the safety
consciousness and fulfill the maintenances of
machine, in order to ensure safety and
effectiveness and bring in profit. If failing to
abide by the safety operation instructions or pay
attention to the “warnings” in this manual, the
1
operator shall ensure that own operation method

is safe and reliable. Otherwise, there is a danger
of accident or even danger leading to injury
accident.
Warning Symbol:
This symbol appears along with the specific
key points and warning texts in this manual
and is intended for “Warning! Please be
alerted of your life safety!”.
Safety during Handling of

Machine
Shandong Lingong Construction
Machinery Co., Ltd. is only liable for the
following conditions:
• This machine is used and maintained
correctly as per the instructions in Repair
Manual of B876F Backhoe Loader and
the Operation and Maintenance Manual
of B876F Backhoe Loader.
• The specified maintenances and checking
are fulfilled at specified intervals.
• The lubrication instructions of the
machine specified in the manual are abode
by.
• No safety seal is ever opened by
non-authorized personnel.
• All maintenance and repair works are
fulfilled as per the manners specified by
our company (SDLG).
• Only the genuine parts/accessories or
additional devices meeting the
requirements of our company (SDLG) are
used.
Warning:
The driver of the machine must
sufficiently understand and master the
contents of Operation and Maintenance
Manual of B876F Backhoe Loader
before the operations of the machine.
It’s of great importance for the driver to
carefully read and abide by the
2
instructions of Operation and

Maintenance Manual of B876F
Backhoe Loader.
It will lead to serious injury accidents if
the machine is driven by non-trained
personnel.
It’s prohibited to operate the machine
without Operation and Maintenance
Manual of B876F Backhoe Loader.
Understand the warning labels, symbols,
and instructions on the machine before
using the machine.
Some Simple Safety Rules

• All malfunctions or problems impairing the
safety shall be resolved as soon as possible.
• Always wear the protective helmet, goggles,
gloves, protective boots, and other safety
equipment required for your works.
• Avoid standing in the front or rear side of
the machine while the engine is running.
• While cleaning the outer side of the
windows, always use long-shank rubber
window scraper or brush, in order to prevent
unnecessary climbing up or down the
machine.
• Keep clean the foot plate surfaces,
maintenance site, handrails, and anti-slip
protective parts, without any engine oil,
diesel, sludge, or ice/snow, and ensure the
timely repair and replacement when such
parts are damaged or lost.
• Periodically check all anti-slip protective
parts for secure fixing. If not, take fixing
measure or replace.
Before Operations
Some important rules are as below:
• Implement all safety checking measures
described in the Operation and Maintenance
Manual of B876F Backhoe Loader.
Warning:
Do not drive the machine whenever you
feel tired or are influenced by alcohol,
3
medicine, or other drugs.

• Before starting the engine indoors, ensure
the sufficient ventilation. This machine is
fitted with one diesel engine and its exhaust
gas is harmful to your health. Therefore,
ensure the sufficient ventilation. In event of
insufficient ventilation, run the engine only
when it’s absolutely necessary.
• Before operations or conducting any repair
or maintenance works on the machine, read
all nameplates and instructions on the
machine and the instructions in the
Operation and Maintenance Manual of B876F
Backhoe Loader. Every label contains
important information related to safety,
treatment method, and repair and
maintenance.
• Fasten the seat belt in all operations.
• Always sit in the driver seat to start the
engine.
• All functions must be intact and effective,
namely all malfunctions probably leading to
accidents are resolved, before putting the
machine into operation.
• It’s absolutely prohibited to use the machine
without ventilation device for a long period
Figure 1 Reading Operation and nor operate within an completely enclosed
Maintenance Manual of B876F Backhoe cab without turning on the fan (in order to
Loader. before Operations of Machine prevent hypoxia).
Mounting and Dismounting

• Never jump on or off the machine. Never get
on or off a moving machine.
• When getting on or off the machine, face the
machine and use the handrails and pedals to
ensure that you can support yourself. Keep
at least three-point contact (two hands/one
foot or two feet/one hand) with the handrails
and pedals to ensure body stability.
• Never hold any control levers when getting
on or off the machine.
• The machine is equipped with two-door cab,
make sure the door near the operation lever
is used only for emergency exit and do not
use it as export or exit.
4
• Check the handrails and pedals, and if there

is oil, lubricant or dirt, clean them first to
prevent slipping. Repair the broken parts and
fasten the loose nuts. Never get into the
operator cab from the ladder at the back of
machine or get off from the wheel at the side
of operator cab.
• Never hold any tools or other items when
climbing up and down the backhoe loader;
lift the tools needed to the operation flat roof
by rope.
Figure 2 Access of Machine

Seat belt
• If it’s necessary to clean the seat belt, use
mild soapy water, air dry under fully
stretched state, and then retract the seat belt.
Ensure the correct installation of the seal
belt.
• If the seat belt is worn or is subject to force
application during the accident of machine,
immediately replace the seat belt.
• It’s absolutely to modify the seat belt or its
mounting parts.
• The seat belt is designed for one adult and
Figure 3 Fastening Seat Belt during All not intended for use by multiple persons.
• The seat belt shall always be under retracted
Operations
state when it’s not in use.
During Running of Engine

• Pay attention to the warning lamps. In event
of red warning lamp, immediately take
measures or pay more attention. Please refer
to the instructions in section “Instruments”
of Operation and Maintenance Manual of
B876F Backhoe Loader.
5
When Leaving Operator’s Seat

• Always keep the parking brake control lever
in the lock position.
• Put down the working equipment completely
to the ground and put the direction control
lever and steering wheel in the neutral
position, and then stop the engine and turn
off the starting switch. Set the blocks on the
front and rear wheels if necessary.
• Make sure the backhoe loader withdraw
1 2 3
radically and then stop the engine and the
Figure 4 electric lock.
• Before leaving the machine with machine
1 Direction control lever
2 Steering wheel
unattended, stop the engine.
3 Parking brake lever
Towing and Tow-start
• Towing
If the machine is being towed, shift the
gearshift control lever to neutral gear (N). If
possible, run the engine so that the steering
and brake assist device are still functional. If
the grader is being towed by wire rope, it’s
prohibited for anyone to stay between the
tractor and the grader.
• Tow-start
Because of the torque converter, it’s
impossible to start the grader by towing, as
the tow-start will damage the transmission.
Safety Rules during Repair and

Maintenance
This part includes the general safety rules during
checking and maintenance.
Other rules, consultation, and warning texts are
provided in Operation and Maintenance of
B876F Backhoe Loader.
6
Before any Repair or Maintenance
Work:
It’s really dangerous to implement any repair or
maintenance work incorrectly.
Ensure that you have sufficient knowledge,
correct information, appropriate tools, and
complete equipment to correctly fulfill the repair
and maintenance works.
• If someone is to take over your repair works,
ensure that the detailed work progress
(namely how much has been fulfilled and
how much is to be fulfilled) is provided.
• While cleaning the machine with high
pressure water, do not point the nozzle
directly to the anti-slip surface with anti-slip
coating or labels affixed on the machine.
Warning:
Only use the special foot plate surfaces to
walk on the machine or climb up or down
the machine. Please refer to Operation
and Maintenance Manual of B876F
Backhoe Loader.
• While working on the machine, do not wear
loose articles that will be probably clamped
on the machine, such as headscarf and
jewelry, in order to prevent personal
injuries.
• Always wear the protective helmet, goggles,
gloves, protective boots, and other safety
equipment required for your works.
• Always keep the engine stopped during the
repair or maintenance of the machine, unless
otherwise specified on the signal symbols
and nameplate on this machine or in this
publication.
• Stop the engine before opening the engine
Figure 5
Wearing Labor Protective Devices hood, radiator water tank, or similar part.
Ensure that there is no tool or article that
will probably cause damage left on the
machine.
7
Maintenance Position
1. Park the machine on a horizontal and solid
surface and place it at maintenance position,
as shown in the figure below.
2. Lowe the working devices to the ground.
Figure 6 Maintenance Position of 3. Stop the engine, withdraw the ignition key,
Backhoe Loader and pull up tightly the handbrake.
4. Affix the warning flag.
5. It’s prohibited to tighten the connectors in
the system when the hydraulic system
contains pressure.
6. Block the rolling of wheels, such as use of
wedges.
7. Turn off the battery switch.
No Operation 8. Cool down the machine
Warning
• If the pressure is not relieved before the
opening of the system, the oil will spray
Figure 7 Affixing of Warning Flag
out under high pressure to cause serious
personal injuries. Relieve the pressure
from pressurized pipeline and oil tank, in
order to prevent the safety accidents.
• If it’s necessary to operate on the machine
before it’s cooled down, pay special
attention to hot fluids and machine parts,
in order to prevent scalding.
8
Loading Arm Asafety Lever

Installation
Before working under the lifted loading arm,
install the safety lever of the loading arm in
accordance with the following requirements.
Warning:
Do not walk or work under the rising
equipment, unless it has the support of
equipment. If the device is only
supported by the hydraulic equipment,
you may be hurt due to failure of
hydraulic system or the falling of device
when operating the control lever (Even if
the engine is turned off).
1. Empty loading bucket and lift the loading
arm to the top position.
2. Turn off the engine and plug the ignition
key.
Warning:
If someone inadvertently operates the
control lever, you may be hurt. When
you release the safety lever of loading
arm, ensure that no one is near.
3. Loosen the safety lever.
1) Pull out the pins on lock ring on both
ends of the safety lever, remove the
lock ring.
2) Remove the safety lever from the
frame.
4. Install the safety frame.
1) Connect the safety lever with both ends
of the fixed pin.
2) Put the locking ring back into the end
1 part of pin and insert pin into the hole.
Figure 8 5. Make the safety lever take in effect.
1 Safety Lever 1) To prevent the falling of loading arm
from hurting your fingers, the loading
arm should be carefully controlled and
place it carefully on the support lever.
2) Operate loading boom handle to lower
9
the machine slowly until the safety

lever is pulled firmly and immediately
stop the movement of loading arm.
Caution:
In the process of lowering loading arm,
be careful to operate the control lever.
Operate the control lever quite slightly
to make it fall slowly.
Uninstalling
1. Lift the loading arm to the top in order to
remove the bearing weight of safety bar.
2. Turn off the engine, remove the start key.
Warning:
If someone inadvertently operates the
control lever, you may be hurt. When
you release the safety lever of loading
arm, ensure that no one is near.
3. Remove the safety lever
1) Pull out the pins on lock ring on both
ends of the safety lever, remove the
lock ring.
2) Remove the safety lever from pin shaft.
4. Place the safety lever well.
Fix the lock ring on frame with the safety
lever.
Notice of Attachment
1. Please read the user manual for all of the
attachments and the contents in the manual
that refers to an attachment when the
attachment is assembled and used.
1 2. Do not use attachments that are not sold by
Figure 9 Shandong Lingong Construction Machinery
1 Safety Lever Co. Ltd or the sellers specified by Shandong
Lingong Construction Machinery Co. Ltd.
Using unauthorized attachments may cause
safety problems and go against the normal
operation of the machine, which can
influence the service life of the machine.
3. Shandong Lingong Construction Machinery
Co. Ltd assumes no responsibility for any
10
injury, accident, or destruction of the

machine induced by using unauthorized
attachments.
Operation Safety of Tires
Warning:
It will probably cause explosion and lead
to serious injuries while inflating the
tires installed on wheel rims.
Air inflation
• Do not stand on one side of the tire while
inflating a tire installed on the wheel rim.
During the air inflation, use one air cock
capable of automatic locking and one long
enough hose to keep you out of the danger
zone.
• While inflating the tire, ensure that no one is
standing within the danger zone.
• Make sure to check the tire pressure when
the machine is under unloaded condition.
• If the pressure of one tire installed on the
Figure 10
machine is less than 80% of the normal
No Standing Near Tire during Air
pressure and it’s suspected that the wheel
Inflating
rim or tire is damaged, disassemble the tire
for air inflation.
Installation of Tire and Wheel rim

• Handle the tire only by trained technicians.
• If one tire clearly mismatches with one
wheel rim, do not install the tire onto the
wheel rim.
• Do not assemble the wheel rim parts of
different sizes together nor use damaged or
failed parts.
• Special cautions shall be taken while using
the repaired wheel parts. Any failed or
incorrect welding, heating, or fusion will
probably impair the strength of parts and
cause future malfunction.
• While installing tire on wheel rim, use the
lubricant recommended by the tire
11
manufacturer.
Repair of Tires and Wheel Rims

• It’s prohibited to cut, weld or heat the wheel
parts by any means.
• Take cautions while using the wheel edge
breaker and hydraulic jack. Keep out of the
danger zone while disassembling foreign
material from the tire. It’s really dangerous
while loosening the wheel edge breaker as it
will probably cause serious personal injuries
or death.
Operation Safety of Battery

The battery contains sulfuric acid, which is of
corrosivity to the human bodies and machine
parts. In addition, the battery will release
hydrogen under loaded condition (as power
supply) or during discharging. The hydrogen
combines with the oxygen in the air to form
explosive air mixture.
During all works related to the machine battery,
the combination of explosive air mixture and
corrosive sulfuric acid will greatly increase the
danger of accident.
Therefore, during the operations of the battery,
carefully read and abide by the following rules.
Warning:
Danger of serious corrosion!
Figure 11 Corrosive Sulfuric Acid
Caution:
• The battery will release explosive gas. Do
not smoke near the battery.
• While disassembling the battery, firstly
cut off the grounding wire. To reduce the
danger of fire accident due to fire spark,
finally connect the grounding wire during
the installation of battery.
Figure 12 No Open Fire • It’s absolutely prohibited to tilt
excessively a battery towards any
direction. Otherwise, the battery
12
electrolyte will probably leak out.

• Do not connect in series an excessively
discharged battery with a fully charged
battery, or there is a danger of explosion.
• Do not touch the wiring posts of battery
with any metal object (such as tool, ring,
and watch). Otherwise, there is a danger
of fire accident and personal injury.
• While working near the battery, cover the
top of the battery with a cloth or other
non-conductive material.
• Always install the caps of battery wiring
posts.
• The battery contains substances harmful
to the health and environment. Therefore,
the scrapped battery must be disposed as
per the relevant local/national
regulations. Please refer to the
environment-friendly treatment methods.
Battery Charging
The explosive hydroxide is formed during the
charging of the battery. A short-circuit, open fire,
or spark near the battery will cause powerful
explosion. Before disconnecting the charging
clamps, firstly cut off the charging current. Keep
well ventilated, especially when the battery is
being charged in an enclosed space.
Warning:
Danger of serious corrosion!
The battery electrolyte contains corrosive
sulfuric acid. If the electrolyte is splashed onto
exposed skin, flush away immediately. Use
soapy water and a great amount of clean water to
clean the affected area. If the electrolyte is
splashed into eyes or any other sensitive body
part, flush with a great amount of clean water and
seek for medical treatment immediately.
Start with Booster Battery

To start with booster battery pack, make sure to
abide by the following items:
13
Caution:
• Check and ensure that the booster battery
pack or any other power supply has same
battery with the machine battery.
• If a fully charged battery is connected
with a depleted battery, the battery will
explode due to current surge. As the
battery contains sulfuric acid, it will cause
personal injuries.
Operation Safety of A/C

Refrigerant
Whenever it’s necessary to break up the A/C

system, the repair works and further works shall
be fulfilled by the personnel with special
qualification. Many countries also require special
training and officially authoritative approval.
Please understand and abide by the national
administration rules.
Caution:
The refrigerant will increase the
greenhouse effect. Do not intentionally
drain it to open air.
Personal Protection Devices

When there is a danger of skin contact with
refrigerant, please use tight goggles and
protective gloves and protect other naked skin
(there is a danger of cold injury). The incorrect
treatment will cause serious personal injuries and
environment hazard by the refrigerant R134a.
Therefore, pay special cautions during the
Figure 13 Wearing Goggles and Gloves operation of A/C unit. To prevent the injury for
in event of Contact Danger with the personnel who might come into contact with
Refrigerant refrigerant, the following rules will be of great
help.
Warning:
• The gases are smell-free and odor-free
and will seriously damage the lung even
14
under low concentration.

• Danger of cold injury! Please use
protective gloves.
• The fluid refrigerant will cause cold
injury.
• The low concentration gas refrigerant will
have certain influence, especially on the
nerve system.
• High concentration gas refrigerant has an
anesthetic effect.
• The A/C unit is of high pressure and the
refrigerant will leak unintentionally. Do
not disconnect the hose or disassemble the
filler port cap from the compressor.
• If the leakage is suspected, please contact
a person authorized by the service station
for troubleshooting and repair.
• The smoking, welding, and other open
fire are prohibited in the working site for
handling of refrigerant. The refrigerant
gas will combust and generate a toxic gas
and the inhalation of such gas is really
dangerous. The gas generated during the
heating of the refrigeration has a pungent
odor under high concentration.
Measures in event of Accident:

Inhalation of refrigerant gas
Upon suspicion of escaped gas, please leave the
suspected area, attempt to seek for fresh air, and
transfer the affected personnel out of the danger
area. A small amount of refrigerant vapor will
have certain influence, especially on the nerve
system. A great amount of refrigerant vapor will
have anesthetic effect. Under serious conditions,
seek for medical treatment immediately.
Skin irritation
In event of cold injury, flush with warm water for
a long period. If the unprotected skin comes into
contact with a great amount of fluid refrigerant,
carefully keep warm the injured area with warm
water or cloth. If the symptom is sustained, seek
for medical treatment immediately.
Splashing into eyes
15
Flush the eyes with warm water, till the irritation

feeling disappears. Seek for medical treatment
immediately.
Handling Safety of Oils
Warning:
Danger of scalding! Please wear
protective gloves.
• While replacing the hydraulic oil, engine oil,
or drive oil of the backhoe loader, bear in
mind that the oil is really hot and will
probably cause burn/scalding.
• The engine oil, hydraulic oil, diesel, and fuel
in the backhoe loader is of corrosivity to the
mucous membrane, such as eyes, throat, and
skin. Therefore, pay special attention to keep
these sensitive body parts away from engine
oil.
• While pumping out or draining engine oil or
fuel, take measures to avoid unnecessary
splashing. In the place impossible to collect
oil with a container, use a suction pump or
connect a hose as safety measure. The
careless drainage of engine oil or fuel is not
only harmful to the environment, but also
leads to fire accident.
The scrapped oils shall be disposed by authorized
disposal company. Please refer to the
environment-friendly treatment methods.
Safety of Hydraulic System

The hydraulic system is running at extremely
high pressure. To prevent serous personal
injuries, it’s of great importance to repair the
system in a correct way, namely all personnel
relevant to the machine shall be extremely
careful during the operations and pay close
attention to all defects.
To prevent accidents, please abide by the
following regulations:
• Do not adjust the pressure limiting valve to a
pressure higher than the level recommended
16
by the manufacturer.
• Any expanded hydraulic hose (for instance:
at the joint) indicates the immediate rupture
of the hose and shall be replaced as soon as
possible. Pay attention to the leakage of
hydraulic hoses and connections and repair
before the rupture of parts.
Warning:
If the pressure is not relieved before the
opening of the system, the oil will spray
out under high pressure to cause serious
personal injuries.
Relief of Pressure
The system contains accumulated pressure after
the engine is stopped. Before loosening or
opening any hose connector or plug in hydraulic
system or brake system, make sure to relieve the
residual pressure in the system by pressure relief.
When the engine is stopped, depress the hand
shank repeatedly to relieve the pressure of
accumulator.
• All pressurized oil tank/container shall be
opened with care, in order to relieve any
residual pressure.
• Check the leakage of pipe connectors and
tightening state of connections only after the
pressure of the system is completely
relieved.
• Use steel plate or hard paper board, instead
of hand, to check for leakage.
Fire Prevention Measure
Overview
• Even only there is a low fire, whenever the
actual condition permits, bear in mind your
personal safety and take the following
measures:
1. Start the machine and drive away from
fire or hazardous site.
2. Rotate the ignition key to position “0”
17
to stop the engine.

3. Leave the cab.
4. Turn off the battery switch.
5. Start the fire extinguishing and when
necessary call the fire department.
• The fire and smoking are prohibited in the
vicinity of the machine while adding fuel to
the machine or the fuel system is opened to
come into contact with air.
• The diesel is an inflammable substance and
Figure 14 No Smoking during Refueling can’t be used for cleaning the machine. Use
qualified detergent to clean the machine.
• Some detergents will probably cause fire or
skin irritation. Avoid the inhalation of
detergent vapor.
Cleanliness
The cleanliness is the decisive factor for safe and
reliable operations of all machine systems.
Therefore, keep clean the repair and maintenance
site. The engine oil and water will wet the ground
and ladder. It will easily cause danger if the
electric system contaminated with engine oil or
water comes into contact with tools. The oily
clothing or the clothing contaminated by
lubricating grease is the hazardous substance
leading to serious fire accident.
• Please daily check to ensure that the
machine and devices are free of dust and oil
dirt, such as the slide plate on the bottom of
body. This can reduce the potential hazard
for fire accident and help the detection of
malfunctioned or loosened part easily.
• Special cautions shall be taken while using
high pressure water for cleaning, as the
electronic units and cable insulations will be
damaged under relative moderate pressure
and water temperature. Please properly
protect the cables.
• During the working in the environment with
fire danger, such as the lumber mill or waste
disposal plant, pay special attention to
maintaining the cleanliness. The appropriate
devices (such as muffling baffle, radiator
18
shield, and high power air pre-cleaner) must

be installed during working under such
environment, in order to prevent the danger
of spontaneous combustion due to
accumulated materials.
Electric System
• Check the cables for presence of scratch and
ensure that the cables are not damaged in
that way. This is especially important for
the wires without fuse.
• If the wires without fuse are ever broken,
make sure to check whether the wires are
reconnected and ensure that the connection
mode can greatly reduce the scratching
danger for the wires. Keep the wires
without fuse away from engine oil or fuel
hose.
• While installing any optional device, ensure
that all wires are connected via fuse and the
arrangement and fixing mode of wires can
guard the wires against being scratched.
Welding and Grinding

During any electric welding works, the fire
extinguisher must be easily accessible.
• The welding and grinding works can be
conducted only in the clean portions of the
machine and are prohibited in the portions
containing inflammable fluid, such as the oil
tank and hydraulic pipe. Special cautions
shall be taken when it’s necessary to conduct
welding and grinding at such portions.
• When it’s necessary to weld at the painted
surfaces, firstly remove the paint. The
welding on painted surface will not only
generate gas harmful to health, but also
cause poor welding and even malfunction,
which will finally lead to accident.
• Use personal protective devices. Whenever
the actual condition permits, use an exhaust
fan to exhaust the toxic gas generated during
the welding and grinding.
19
Checking after Fire Accident or

High Temperature
• As a preventative measure, the seal rings
shall be always treated as fluoride rubber. In
addition, please refer to the section
“Fluoride rubber”.
Warning:
Avoid the splashing of water while
cleaning the machine burnt by fie.
Therefore, do not use high pressure
water for cleaning.
• Whenever it’s possible to come into contact
with melted polymer, do not touch the burnt
unit or part directly with hand. Firstly clean
with a great amount of lime water (one
calcium hydroxide solvent or suspension
liquid, namely hydrated lime).
• Use thick protective gloves made of rubber
and wear goggles to protect your eyes.
• If your skin probably comes into contact
Figure 15 Fire Extinguisher with burnt fluoride rubber, please seek for
medical treatment. The skin shall be treated
with hydrofluoric acid burn cream or
similar medicine. The symptoms will
probably appear after several hours from the
contact of burnt fluoride rubber.
• Scrap the protective gloves, cloth, and other
objects probably coming into contact with
burnt fluoride rubber.
• Keep well ventilation during operations.
• If the eyes are irritated, flush with a great
amount of clean water immediately for at
least 15min and then seek for medical
treatment.
20
Health Hazard of Paints, Plastics,

and Rubbers
Working on Painted Surfaces

It’s absolutely prohibited to use flame to weld or
cut on painted surfaces. All paints will
decompose when being heated to generate a great
amount of different substances and the repeated
exposure in such environment will be very
harmful to your health.
Make sure to take the following safety
measures:
• Use sand paper to grind away an area of at
least 10cm (4 inch) in radius around the
welding point or cutting point (please use
the respirator) on the painted surface. If the
paint can’t be ground away by sand paper,
take other measures, such as paint remover.
Caution:
If the paint is removed by paint
remover, use an exhaust fan and wear
the respirator and protective gloves.
• The grinding machine with high speed
grinding disc can heat up the painted surface
and shall be used only along with the use of
an exhaust fan. In addition, wear the mask or
other respirator.
Rubbers and Plastics
Warning:
The rubbers and plastics will release
substances harmful to the health and
environment when being heated. Make
sure to abide by the following safety
rules:
• If no heat insulation measure is taken in
advance, do not weld or cut by flame gun
near the polyester material (plastic or
21
rubber).
• Do not burn the polymeric materials while
scraping them.
• Handle with care the machine after the fire
or high temperature accident.
• Always were gloves, goggles, and mask, or
other respirator.
Fluoride Rubber
Warning:
• There is a danger of serious corrosion!
• When the hydrofluoric rubber is being
heated, even only at approximate 320ºC
(610ºF), it means the accumulation of
hydrofluoric gas and the inhalation of
such gas will seriously corrode the
respiratory tract.
Some seals are designed to resist high
temperature (namely the seals in the engine,
transmission, axle, brake, hydraulic motor, and
pump) and manufactured by fluoride rubber,
which will generate hydrogen fluoride and
hydrofluoric acid when being heated to high
temperature.
The hydrofluoric acid is of strong acidity and
corrosivity. It can’t be flushed or cleaned from
skin and will cause extremely serious burns and
corrosion injuries, which require long time for
recovery. As general principles, the injured
tissues must be removed by surgery.
The hydrofluoric acid will remain on the
machine parts for a long time (several years) after
fire accident.
If one machine or one machine part is subject to
fire accident or other strong heat, it can be
handled only by trained repair personnel.
The high strength rubber gloves and effective
protective goggles shall be used for all operations
on the machine after fire accident.
Warning:
The combustion of painted parts and
plastic/rubber parts will cause harm to
22
health.
For the portions exposed to high temperature, if
it’s suspected that the parts affected are made of
fluoride rubber, make sure to thoroughly flush
with a great amount of lime water (one calcium
hydroxide solvent or suspension liquid, namely
water mixed with hydrated lime), in order to
remove the toxic substances. At completion of
the decontamination works, make sure to clean
the gloves in the lime water and then scrap.
If the machine is exposed to fire accident or other
high temperature source, the safety measures in
the following checklist must be abode by
unconditionally in all cases: Checking after
Fire Accident or High Temperature.
Safety Transmission
Load and unload the Machine

• Load and unload the machine on level
ground and remain a safe distance away from
the road.
• Ensure the tires well during loading and
unloading the machine and make sure it will
not move. Put a cushion under the plate.
• Slope boards should be strong enough with
sufficient length and width to form a safe
loading/ unloading slope. The angle between
the ground and the slope should not be larger
than 15°. Distance between boards should be
adapted to the wheel base of the machine.
• Make sure the boards are fixed firmly and
height of the two sides of the board should
be consistent.
• Keep the board surface clean, without
lubricant, oil, ice and loose materials. Clean
the dirt on the tires.
• Never turn around on the slope board. If it is
necessary, turn outside the board to adjust
Figure 16 Safety Transmission and then drive back.
• Lock the steering mechanism after assembly,
wedge the tires and tie the machine tightly
with cords. Tie the machine with ropes by
defined transportation point.
23
Caution:
If the swing lock does not lock, you have
to fix the bucket with a rope on the
trailer. If there is no bucket, fix the
bucket head on the trailer.
• Check whether the total height of
compliance is accordance with the
requirements after loading. If necessary,
please adjust it.
• Turn off the engine, fixe cab, and cover the
exhaust pipe.
• Put the blocks before and after all tires, fix
the machine with chains to the trailer, and the
fixed points refer to the whole logo.
• Measure the maximum height of the machine
from the ground. If driver knows the
required height, and he can drive away.
Transportation on the Ground

• When transporting the backhoe loader, the
Figure 17 Recycling direction of bucket is consistent with the
driving direction of the vehicle.
• Obey the rules about weight, height, width
and length prescribed by national and local
laws for transporting the machine using a
tow truck. Obey the traffic rules.
• Ensure the weight, height, width and length
of machine regulation before deciding the
transport routine.
• Ensure the allowed limit of weight bearing
when passing bridges or private buildings.
Obey the relative rules when driving on the
public roads.
• The machine may be unloaded when using
other transportation. Please contact with
Shandong Lingong Construction Machinery
Co. Ltd. or their accredited representative.
Lifting
• Select proper lifting equipment according to
the weight of the backhoe loader, otherwise
it is dangerous to surpass the weight limit.
24
• Notices for lifting:

1. All the control levers should be in the
middle position.
2. Stop the engine, lock all the equipment
with keys and then remove the keys.
3. No one is allowed to stay in the
operator cab.
4. is allowed to lift the machine with 4
It
same steel wires (no shorter than 7m).
5. Keep the machine horizontal during
lifting.
6. Prevent damage to hood, operator cab,
and hydraulic pipes.
7. No person or car is allowed to pass
under the machine during lifting.
• Wedge the tire and bind the machine tightly
to prevent movement during transportation
after lifting onto the ship (train).
Environment
For the future environment protection, the entire
world is facing with the huge challenges of
environment issues and the water cleanliness,
weather variation, and use of chemicals have
become the most important issues. The machines
from Shandong Lingong Construction
Machinery Co., Ltd. played own significant role
against these challenges and made own
contribution to the more environment-friendly
development and the cautious utilization of
natural resources.
Waste Treatment
Abide by the following steps during the
treatment of wastes.
• Recycling: It’s the best way from an
environmental protection perspective.
• Material recycling: It’s a good environment
protection means to use recycled material in
new products.
• Energy recovery: It's a good alternative
method to burn the non-recyclable
inflammable material as fuel.
• Disposal: This method can be used for
25
hazardous wastes. The disposal must be

conducted in special sites.
• Burial: It’s a bad method from an
environmental protection perspective and
shall be avoided whenever possible.
• Storage: It's a temporary measure to treat the
wastes until appropriate treatment
technology is developed.
Always choose a method most appropriate to the
environment protection, whenever a possibility is
available, such as the use of biochemical engine
oil.
Always abide by the national and local
environmental protection regulations.
All wastes shall be submitted to the waste
treatment firms authorized by authority for
treatment.
Engine oil and Fluids

The non-reusable engine oil or fluids (such as
coolant) shall be collected by sealed containers
and submitted to the disposal department for
disposal.
Filters
The engine oil and fuel filters shall be fully
drained, placed in sealed containers, and
submitted to the disposal department for
disposal.
Refrigerant
The refrigerant contains substances influencing
the greenhouse effect and can’t be exhausted into
open air. The repair personnel for treatment of
refrigerant must understand the relevant local
laws and regulations as well as the international
regulations. It’s recommended that the repair
personnel for all repair works of the A/C must be
trained. Many countries require that such works
can be fulfilled only by those with certificate
released by authority.
26
Engine oil and Fuel

While draining the engine oil and fuel, take
appropriate measure to prevent unnecessary
splashing. In the place impossible to use drainage
container, please use pump or hose.
Chemicals
The chemicals, paints, sealants, and detergents
shall be treated or disposed by recycling
department.
Rubbers and Plastics

The rubber and plastic parts shall not be burned
directly. Please submit to the recycling
department.
The tires shall be treated as per special
regulations.
Electronic units
The electric units and electronic wastes, such as
circuit boards and bulbs, shall be submitted to the
recycling department for disposal.
Works in contaminated
Environment
The machine working in contaminated
environment/healthily harmful site shall be fitted
with special device suitable for such
environment.
After the working in the contaminated
environment with asbestos or other toxic dust,
the used cab and engine air filters must be placed
in sealed plastic bag (the packaging bag of new
filter) and submitted to disposal department for
treatment.
Decontamination after
Leakage/Splashing
27
Use appropriate absorbing material to collect the

leaked engine oil or fuel, such as water absorbing
pad.
Avoid the leaked engine oil/fuel from draining
into sewage along with rainwater/flood.
The contaminated soil and ground materials must
be removed and collected in appropriate
containers.
The collected soil and absorbing materials shall
be submitted to disposal department for
treatment.
Decontamination after Accidents

Whenever possible, seal the leakages on the
machine.
Use water drainage railing to isolate the leakage
site.
Add absorbing materials, such as water
absorbing sands or wood chips.
Block the leakage fluid from draining into
sewage or drain along with rainwater/flood.
Collect the absorbing materials and floating soil,
place in sealed containers, and submit to disposal
department.
28
Contents
Contents ............................................................................................................................................................. I
0 General......................................................................................................................................................... 1
01 Introduction to Machine .................................................................................................................... 1
02 Performance Parameters ................................................................................................................... 2
03 Overall Dimension .............................................................................................................................. 6
04 Specification ........................................................................................................................................ 7
05 Tools ................................................................................................................................................... 11
06 Marking ............................................................................................................................................. 12
07 Judgment Standards for Part Repairing and Replacement ........................................................ 13
071 Judgment by visual inspection or hand touch...................................................................... 13
072 Determination of measurement method ............................................................................... 14
I
0 General
01 Introduction to Machine
1 2 3 4 5 6 7 8 9 10 11 12 13
Fig. 0-1 Outline Drawing This machine is overall frame tire backhoe
1 Loading hopper loader. On a solid integral chassis, it integrates
2 Boom at the loading end loading mechanism and excavating mechanism.
3 Scoop cylinder With loading and excavation functions, it’s not
4 Engine hood only flexible and convenient for movement but
5 Boom cylinder at the loading end also matches with several working accessories
6 Hydraulic fuel tank (left) fuel tank (right) to meet the changeable engineering requirements.
7 Tool box (left) battery box (right) It’s widely used to municipal, construction,
8 Cab highway, water conservancy, power supply and
9 Left/right outrigger water supply, forestry industry, etc. It’s also
10 Scoop cylinder used to road maintenance, farmland construction,
11 Arm pipe laying, cable laying, landscaping, etc. It’s
12 Excavator bucket multi-purpose and high-efficient engineering
13 Bucket cylinder machine. This machine is mainly used for
following operations:
● Loading operation ● Excavation
operation
● Bulldozing operation ● Leveling operation
● Configure other multi-functional devices to
realize other functions
0-1
02 Performance Parameters
I. Performance Parameters of Machine Table 0-1
Item Parameter Item Parameter
Rated capacity of backhoe bucket (m3) 1 Turning radius (mm) 4118
Rated working load (kg) 1800 Horizontal passing radius 5350
(bucket outside) (mm)
Maximum tractive force (provided by 86 Breakout force(kN) 55
the engine))(kN)
Rated capacity of excavation bucket 0.18 Maximum gradeability (°) 20
(m3)
Maximum excavation force（kN） 55
Driving speed Gear I II III IV
Forward (km/h) 5.9 10.7 21.4 37
Reverse (km/h) 7.4 13 20 —
II. Main Dimensions and Weight Parameters Table 0-2
Vehicle length (bucket on the 7243 Maximum excavation 5393
flat ground) (mm) radius (mm)
Transporting height (mm) 3608 Number of axles 2
Vehicle width (wheel outside) 2265 Tread (front/rear) (mm) 1928/1790
(mm)
Maximum dumping height (- 2693 Wheel base (mm) 2170
45o unloading angle) (mm)
Corresponding unloading 830 Work quality (kg) 7800
distance (-45o Unloading
angle) (mm)
Minimum ground clearance 346
(mm)
Maximum excavation depth 4352
(mm)
III. Engine Table 0-3
Model YC4A105Z-T20 Number of cylinder 4
Type Inline, water-cooling, cylinder bore/stroke (mm) 108/132
four-stroke,
supercharging, direct
injection combustion
chamber
Rated power (/kW) 75 Minimum specific fuel 230
consumption (g/kW.h)
Rated speed (r/min) 2200 Maximum torque (N.m) 420
Displacement (mL) 4837 Emission GB20891-
standard 2007
China II
IV. Drive System Table 0-4
0-2
Item Parameter
Torque Type Single-stage single-phase centripetal type
converter turbine
Torque ratio 2.529
Oil cooling way Air cooling
Gearbox Type Power shift
Shifts of gearbox 4
0-3
Transmission Forward gear I 4.931

ratio Forward gear II 2.681
Forward gear III 1.295
Forward gear IV 0.704
Reverse gear I 3.9
Reverse gear II 2.12
Reverse gear III 1.313
Reverse gear IV —
Front and rear 1:1
output ratio
Working pressure of variable speed 1.8-2.1
(MPa)
Main Type Level A reduction of spiral bevel gear
transmission Reduction ratio (front/rear) 2.214/3.1
Hub reducer Type One-stage planet gear deceleration
Reduction ratio (front/rear) 6/6.4
Drive axle Type Four-wheel driven/Two-wheel driven
and wheel Tire specification (front/rear) 12.5/80-18/18.4-26
Tire pressure Front wheel 0.43±0.01
(MPa) Rear wheel 0.22±0.01
Brake Service braking type Vacuum boosting
system Parking brake type Caliper disc
V. Steering System Table 0-5
Item Parameter
Type Load sensing hydraulic hinge steering
Priority valve VLC-60
Steering pump/pilot pump KP30.31
Steering gear Xce145-160
Steering angle (°) 55
Working pressure of system (Mpa) 15
VI. Loading Device Table 0-6
Item Parameter
Type Parallel eight-bar linkage
Boom cylinder-cylinder bore×diameter of piston 80×55×747
rod×stroke (mm)
Scoop cylinder-cylinder bore×diameter of piston 70×45×802
rod×stroke (mm)
Working pump KP30.31
Type of multi-way valve HC-D6/2
Working pressure of system (Mpa) 22.5
Lifting time (full load) (s) 3.36
Lowering time (empty bucket) (s) 1.77
Unloading time (empty bucket) (s) 1.44
Total time (s) 6.6
0-4
VII. Excavation Working Device Table 0-7

Item Parameter
Boom cylinder-cylinder bore×diameter of piston 120×60×993
rod×stroke (mm)
Arm cylinder-cylinder bore×diameter of piston 110×60×753
rod×stroke (mm)
Bucket cylinder-cylinder bore×diameter of 90×60×723
piston rod×stroke (mm)
Rotary cylinder-cylinder bore×diameter of piston 100×60×245
rod×stroke (mm)
Outrigger oil cylinder-cylinder bore×diameter of 100×60×577
piston rod×stroke (mm)
Working pump KP30.31
Type of multi-way valve HC-D6/3+HC-DVS106/3
Working pressure of system (Mpa) Excavation 22.5/rotation 24
VIII. Filling Capacity Table 0-8
Fuel (L) 135 Engine oil (L) 10
Hydraulic oil (L) 155 Gearbox transmission 20
oil (L)
Axle (main drive and （7.5+0.8*2）/15 Brake system (L) 2
wheel reducer (front/rear)
(L)
0-5
04 Specification
Standard tightening torque
Tightening torque of common bolt Table 0-9
Bolt Yield Nominal diameter of bolt (mm)
strength strength 6 8 10 12 14
class (N/mm²)
Tightening torque (N·m)
4.6 240 4-5 10-12 20-25 36-45 55-70
5.6 300 5-7 12-15 25-32 45-55 70-90
6.8 480 7-9 17-23 33-45 58-78 93-124
8.8 640 9-12 22-30 45-59 78-104 124-165
10.9 900 13-16 30-36 65-78 110-130 180-210
12.9 1080 16-21 38-51 75-100 131-175 209-278
class (N/mm²)
4.6 240 90-110 120-150 170-210 230-290 300-377
5.6 300 110-140 150-190 210-270 290-350 370-450
6.8 480 145-193 199-264 282-376 384-512 488-650
8.8 640 193-257 264-354 376-502 521-683 651-868
10.9 900 280-330 380-450 540-650 740-880 940-1120
12.9 1080 326-434 448-597 635-847 864-1152 1098-1464
class (N/mm²)
4.6 240 450-530 540-680 670-880 900-1100 928-1237
5.6 300 550-700 680-850 825-1100 1120-1400 1160-1546
6.8 480 714-952 969-1293 1319-1759 1694-2259 1559-2079
8.8 640 952-1269 1293-1723 1759-2345 2259-3012 2923-3898
10.9 900 1400-1650 1700-2000 2473-3298 2800-3350 4111-5481
12.9 1080 1606-2142 2181-2908 2968-3958 3812-5082 4933-6577
0-6
Table for cast iron or aluminum bolt tightening torque of connected parts Table 0-10
Bolt grade and torque 8.8
Torque (N.m)
Bolt specification Cast iron Aluminum
M8 20-25 15-20
M10 45-50 25-30
M12 70-80 50-55
M14 110-125 80-90
M16 160-180 120-140
M18 205-230 165-180
Tightening torque of joint body Table 0-11
Joint with copper gasket seal or cone thread seal Joint with O-ring
Joint Tightening torque (N.m) Joint Tightening torque
specification specification (N.m)
M14, G1/4 34±5 M12×1.5 35±3.5
M18, G3/8 73±10 M14×1.5 45±4.5
M20, G1/2 93±10 M16×1.5 55±5.5
M24 142±20 M18×1.5 70±7.0
M27, G3/4 205±30 M20×1.5 80±8.0
M33, G1 421±49 M22×1.5 110±10
M42 872±98 M27×2.0 170±17
M33×2.0 310±31
M36×2.0 310±31
24 Tightening torque of cone seal Table 0-12
Specification Tightening torque (N.m)
M12×1.5 15-20
M14×1.5 25-30
M16×1.5 30-35
M18×1.5 35-45
M20×1.5 40-50
M22×1.5 45-65
M24×1.5 45-65
M26×1.5 65-85
M30×2 85-110
M36×2 120-145
M42×2 170-210
0-7
Tightening torque of hinged bolt Table 0-13

Thread specification Tightening torque (N.m)
M10×1 25-35
M12×1.5 60-75
M14×1.5 80-100
M16×1.5 105-115
M18×1.5 20-130
M22×1.5 140-155
M24×1.5 160-180
M27×2 190-230
M33×2 270-320
Unit conversion table
Length Table 0-14
Unit cm m km inch foot km/h mile
cm 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006
m 100 1 0.001 39.37 3.2808 1.0936 0.00062
km 100000 1000 1 39370.7 3280.8 1093.6 0.62137
inch 2.54 0.0254 0.000025 1 0.08333 0.02777 0.000015
foot 30.48 0.3048 0.000304 12 1 0.3333 0.000189
mile 91.44 0.9144 0.000914 36 3 1 0.000568
mile 160930 1609.3 1.6093 63360 5280 1760 1
1 mm=0.1 cm-1 micrometer=0.001 mm
Area Table 0-15
2
Unit cm2 m2 km2 acre foot2 km/h mile2
cm2 1 0.0001 - 0.000001 0.001076 0.000012 0.155000
m2 10000 1 0.000001 0.01 10.764 1.1958 -

km2 - 1000000 1 10000 1076400 1195800 -
acre 0.01 100 0.0001 1 1076.4 119.58 -
foot2 - 0.092903 - 0.000929 1 0.1111 144.000
km/h 2 - 0.83613 - 0.008361 9 1 1296.00
mile2 6.4516 0.000645 - - 0.006943 0.000771 1
1 acre=100 are-1 mile 2=259 acre=2.59 km2
0-8
Capacity/volume Table 0-16

Unit cm3 m3 dm3 inch3 foot3 km/h3
ml 1 0.000001 0.001 0.061024 0.000035 0.000001
liter 1000000 1 1000 61024 35.315 1.30796
liter 1000 0.001 1 61.024 0.035315 0.001308
inch3 16.387 0.000016 0.01638 1 0.000578 0.000021
foot 3 28316.8 0.028317 28.317 1728 1 0.03704

Km/h3 764529.8 0.76453 764.53 46656 27 1
1 gallon (US system)=3,785.41 cm 3=231 inch3=0.83267 gallon (British system)

Weight Table 0-17
Unit g kg metric ton ounce Ib. (pound)
g 1 0.001 0.000001 0.03527 0.0022
kg 1000 1 0.001 35.273 2.20459
metric ton 1000000 1000 1 35273 2204.59
ounce 28.3495 0.02835 0.000028 1 0.0625
Ib (pound) 453.592 0.45359 0.000454 16 1
1 ton (metric system) =1.1023 tons (US system) =0.9842 ton (British system)
Pressure Table 0-18
Unit Kip/cm2 bar Pa= N/m2 Kpa Pound- Pound-
force/inch2 force/foot2
Kip/cm2 1 0.98067 98066.5 98.0665 14.2233 2048.16
bar 1.01972 1 100000 0.001 0.00015 0.02086
Pa=N/m2 0.00001 0.001 1 0.001 0.00015 0.02086
Kpa 0.01020 0.01 1000 1 0.14504 20.886
Pound- 0.07032 0.0689 6894.76 6.89476 1 144
force/inch2
Pound- 0.00047 0.00047 47.88028 0.04788 0.00694 1
force/foot2
Kg/cm2=735.56 dry measure (mmHg) =0.96784 barometric pressure
Unit description Table 0-19
Unit Abbreviation
Newton metre Nm
Kilopound meter kpm
Kilopascal kPa
Megapascal MPa
kW kW
Kilojoule kj
British thermal unit Btu
Calorie ca
0-9
05 Tools
List of service tools Table 0-20
Common tools Specification Qty. Applied Part
Pneumatic BQ8, BQ10, BQ16, BQ30, MI- 1 group Select different specifications
wrench 17HE as per the size of assembly bolt
Sleeve 10, 13, 15, 16, 18, 21, 24, 36, 46 1 group Select different specifications
as per the size of assembly bolt
Soft hammer 1 If surplus part is assembled,
slightly knock it
Solid wrench 5.5×7, 8×10, 10×13, 11×13, 12×14, 1 group Select different specifications
13×15,13×16,14×16, 16×17, 16×18, as per the size of assembly bolt
17×19, 18×24, 18×21, 22×24, 24×27,
24×30, 27×32, 30×34, 36×41, 41×46
Copper bar 1 If surplus part is assembled,
slightly knock it
Feeler gauge 1 group Measure the adjusting
clearance part
Slotted 1 Slotted screw
screwdriver
Cross head 1 Cross screw
screw-driver
Pliers 1
Adjustable 1
wrench
Crowbar 1
Special tool Specification Qty. Applied parts
Bracket If not provided, configure 2 types Disassemble and assemble the
disassembly platform working device and axle
assembly
Trolley 1 Disassemble and assemble the
axle assembly
Wood wedge 1 Fix the machine in the
block repairing process
0-10
06 Marking
To vividly highlight safety and quality importance, following symbols are hereby made for marking.
Table 0-21
Marking Item Remarks
Safety In the operation process, pay special attention to safety.
During working, pay special attention to internal pressure.
Attention During working, pay special attention to technical

requirements to ensure that the operation quality meets
standard.
Weight Part or device weight and disassembly and assembly mode.
Pay attention to lifting appliance selection and operation
gesture.
Tightening During assembly, pay special attention to the tightening
torque torque of component.
Spreading Spread adhesive and lubricating grease.
Oil, water Fill appropriate oil, water and fuel.
Discharge Discharge oil or water and the discharge volume
0-11
07 Judgment Standards for Part

Repairing and Replacement
071 Judgment by visual inspection or hand
touch
1. Parts with bump, crack, fracture and function loss
should not be used again;
2. Oil seal, dustproof ring, O-ring and seal gasket
disassembled due to leakage should not be used
again due to poor reliability and short service life.
3. Bolt, nut, washer, plug and pipe joint with serious
rusting and the thread subject to abnormally
fastening, scratch, excessive abrasion and sliding
wire should not be used again.
4. The locking wire in the bolt connection should not
be used after being disassembled.
5. The bearing subject to manually rotating blockage,
components with crack, roller path under
excessive abrasion and rolling ball damaged
should not be used again.
6. Gear or spline tooth with crack, sheet-like peeling,
bumping, excessive abrasion, etc. should not be
used again.
7. Shell with crack, shell bearing mounting hole with
crack, abrasion, oval and sheet-like peeling, shell
thread that is damaged and cannot be properly
screwed down, should not be used again.
8. Bearing seat, oil seal seat with matching
surface/seam crack, abrasion, bump, oval and
sheet-like peeling should not be used again.
9. Pin subject to serious abrasion, bumping and crack
should not be used again.
10. Make preliminary judgment by visual inspection,
smell, etc. In any of following conditions: milky
white, acid smell, yellowish color or oil turbidity,
the hydraulic oil should be replaced.
0-12
072 Determination of measurement method

If it’s hard to judge it by visual inspection or hand
touch, make measurement.
Table 0- 22
Part type Inspection item Judgment standard Measures
Size (tolerance) Permissible limit for out of
tolerance
Bearing ID tolerance About 0-－0.02 +0.02 Replace
OD tolerance About 0-－0.02 －0.04
Gear Tooth thickness About 0-0.10 12% of dividing circular Replace
abrasion tooth thickness
(generally 1.2-1.4)
Common OD for common Tolerance Recommendation: lower Replace
parts matching marking as T than lower limit of 0.3T
ID for common Tolerance Recommendation: higher
matching marking as T than upper limit of 0.3T
Multi-way Valve core and valve >0.02 Replace
valve opening fit clearance
Steering gear Valve core and valve >0.02 Replace
pocket fit clearance
Stator and rotor >0.08 Replace
Single stable Valve core and valve >0.02 Replace
valve body fit clearance
Priority valve Valve core and valve >0.02 Replace
body fit clearance
0-13
Contents
2 Engine System.................................................................................................. 2-1
21 Key parameters for engine maintenance ...................................................... 2-1
22 Testing scope and use steps of engine test tools ............................................ 2-2
23 Flowchart for disassembly and assembly of engine ..................................... 2-3
24 Engine fault diagnosis ................................................................................... 2-5
Ⅰ
2 Engine System
21 Key parameters for engine maintenance
Engine Rated speed Engine idle Valve Advance angle of Oil pressure
model of engine speed clearance fuel injection (rated speed)
YC4A105Z- 800-830 0.34-
2200 r/min 18±2° >0.1MPa
T20 r/min 0.36mm
Table 1 Key Parameters of Engine

This table is only for reference. For the machine engine, please refer to the engine label!
2-1
22 Testing scope and use steps of engine test tools

221 Oil pressure test of engine
The engine is second-stage mechanical control engine. For engine test, test the pressure by a special
pressure measuring joint and pressure gauge.
Fig. 7 Oil Pressure Testing Position
4120003068 T e s t 4030000368 .6430000942

joint test hose pressure gauge
VKA3/06LCF SMS20/M1/4- 1Mpa
300 0A
Fig. 8 Engine Testing Tools
2-2
Oil pressure testing steps

1) Drive the excavating and loading device to the repairing site,
lower down the bucket to the ground, pull the parking brake
lever and shut off the engine.
2) Disassemble the engine oil pressure switch and assemble testing
joint 1 and 2 at the disassembly position.
3) Connect one end of test hose 3 with the test joint 2 and the other
end with the pressure gauge 4.
4) Start the engine and respectively record the oil pressure when
the engine is at idle speed and rated speed.
5) After testing, disassemble the test joint, assemble the engine oil
pressure switch and wipe the engine oil leaked.
Reference pressure
The oil pressure is generally >0.1Mpa at idle speed of engine and the
oil pressure is generally 0.25~0.6Mpa at rated speed.
23 Flowchart for disassembly and assembly of engine

Disassembly Preparation
flow
Drain coolant
Drain oil
Disassemble air pre-filter
Disassemble the expansion take hose
Disassemble the engine hood

Lift the cab
Disassemble the radiator
Engine
Disassemble the engine harness
disassembly
Disassemble the engine harness
Disassemble the throttle wire and flameout wire
Disassemble the heater water pipe

Disassemble the air compressor hose
Disassemble the torque converter oil return pipe
Disconnect the transmission and torque converter assembly
Lower the engine
2-3
Assembly flow
Lift the engine
Connect transmission and torque

converter assembly
Fix the shock absorber bolt
Assemble the torque converter oil return

pipe
Assemble the air compressor pipe
Assemble the heater pipe
Assemble the throttle wire and flameout Engine assembly

wire
Assemble the fuel pipe
Assemble the engine harness
Assemble the radiator
Lift the cab
Assemble the engine hood
Assemble the expansion tank pipe
Assemble the air pre-filter
Fill oil
Fill antifreezing solution
Attention: For engine disassembly, firstly cut off the engine power supply and drive the
vehicle to the repairing site! The disassembly and assembly process for engine with different
configurations may be different, the actual structure shall be followed. The flowchart is only
for reference.
2-4
24 Engine fault diagnosis

Fault
Fault type Cause Solution
classification
Starting Carefully check the battery power, charge or
No battery
system replace it
factor Starter motor damage Repair or replace the starter motor
Dredge the oil way (blow it by high-
Air in the oil system
pressure air), fasten all joints and evacuate it
Blockage of oil Dredge the oil way (blow it by high-
system pressure air), fasten all joints and evacuate it
Oil supply The diesel filter is too
Replace the filter element
system dirty
Engine is factor Serious abrasion of
Professionally repair the fuel injection pump
unable to plunger/outlet valve
start Damage of low-
pressure fuel delivery Replace the oil delivery pump
pump
Malposition of
advance angle of fuel Adjust the advance angle of fuel injection
injection
Adjusting
Change of valve
factor Check and adjust the valve clearance
clearance
Too less fuel at
Professional check the fuel injection pump
starting
Blockage of diesel
filter or oil pump Clean or replace it
inlet pipe joint mesh
Insufficient pressure
Repair the oil injector or replace the injector
or poor atomizing of
nozzle coupling parts
fuel injector
Excessive abrasion of
Engine under Adjust the oil supply volume or repair the
injection nozzle
powered plunger and barrel assembly
precise couple
Air in the fuel system Exhaust air in the fuel system
Incorrect advance
Make adjustment as per regulations
angle of fuel injection
Uneven fuel supply Adjust the fuel supply volume of each
of each cylinder cylinder
Unsmooth air filter Clean or replace the filter element
Too high lubricating Drain surplus lubricating oil and keep the
oil level in the engine liquid level within the specified scale of oil
oil pan gauge
Blue smoke The oil injector is not
Abnormal
of diesel closed tightly or burnt
exhaust Clean and calibrate the fuel injector or
engine at the starting
replace the pin valve coupling parts
position, so the diesel
oil enters the oil pan
The seal ring of fuel Replace the seal ring
2-5
pump plunger sleeve

is damaged (P-type
pipe), or the plunger
sleeve and pump is
not tightened
2-6
and fuel flows to the oil

pan along the lubricating
oil way.
Valve seal is damaged, the Replace the valve, pipe and oil seal with
clearance between valve problem (the oil seal with welt seam
and pipe exceeds the limit. must be replaced. After a new valve is
In the air suction process, replaced, if the clearance meets
the oil is inhaled to the requirements, pipe should not be
combustion chamber. replaced.)
The turbocharger seal ring
is damaged, and lubricating
Repair or replace it
oil flows to the combustion
chamber along the air way
Clean the fuel tank and filter and use
Water in the fuel system
qualified diesel oil
White Cylinder valve abrasion Replace the wearing parts
smoke of Poor oil atomizing of oil
diesel injector, non-combustion
Adjust and calibrate the fuel injector and
engine of diesel oil fogdrop in the
advance angle of fuel supply.
combustion chamber
Too high exhaust back

Reduce the exhaust pipe bending and
pressure or exhaust pipe
remove the silencer dust
blockage
Adjust the advance angle of fuel
Late fuel injection
Black injection
smoke of Improper working or
Disassemble, clean and check it
diesel damage of fuel injector
engine Poor quality or wrong
Replace the diesel oil
grade of diesel oil
Serious abrasion of
cylinder sleeve and piston Replace the wearing parts
assembly
Abnormal display of oil
Replace the display device
pressure
Select oil of specified grade and take
Too high oil viscosity warm-up measures when starting the
Too high engine in winter.
oil
Too small or oil fine filter Adjust the lubricating part clearance,
pressure
blockage clean or replace the oil filter
Adjust the spring elasticity of relief valve
Improper adjustment of
Too high or again and keep the oil pressure within the
relief valve
low specified value
lubricating oil The oil pump abrasion or Repair the oil pump and replace the seal
pressure Too low
seal gasket damage gasket
oil
Oil in the oil pump is Check the oil volume, add the oil and
pressure
reduced clean the oil pump suction filter
2-7
Check the lubricating pipe for fracture

Large amount of oil leakage and check and adjust the fit clearance of
crankshaft, camshaft, bearing, etc.
Oil filter or cooler blockage Check and clean the oil filter and cooler
Too low oil viscosity Select oil of proper grade as required
Improper adjustment of Clean the relief valve, adjust or replace
relief valve the spring
Check and replace the oil pressure sensor
Too low oil pressure
and oil pressure gauge
Improper oil viscosity Select proper lubricating oil
The negative pressure of
High combustion chamber is big, Check the cause of negative pressure and
consumption so oil flows up to the make adjustment
of lubricating combustion chamber
oil The test shows that the oil consumption
Speed and running mode
obviously rises with the speed rising.
change
Run the engine as per regulations.
Improper coolant or Select proper coolant and fill it to proper
insufficient water volume liquid level
Use a thin steel sheet to carefully pull the
cooling fin back to original position and
Water radiator blockage recover the straight shape of cooling fin
and clean it by compressed air or water
gun.
Use the surface thermometer to test the
temperature of water temperature sensor,
Wrong water thermometer
and observe the indication of water
or warning lamp
thermometer is consistent with actual
High temperature.
temperature
The fan belt is too loose and it may be
of coolant
slipping, resulting in too low speed of fan
The fan speed is too low, and weak air supply effect. If the belt is
and the blade is deformed too loose, adjust it. If the rubber layer is
or assembled reversely aging, damaged or fiber layer is broken,
replace it. If the fan blade is deformed,
replace it.
Cooling water pump fault Replace the water pump
Thermostat fault Replace the thermostat
Damage of cylinder gasket Replace the cylinder gasket
Overload operation of
Reduce the engine load
diesel engine
Table 5 General Engine Fault Diagnosis
2-8
Service M anual for Backhoe
B Lo
oader
Coonten
nts
3 Electrical annd Inform mation Sysstem .................................................................. 3-1
ntroductioon to electtrical systtem .................................................................... 3-1
31 In
311 Specificcation of electrical
e ssystem ............................................................... 3-1
312 Description of eleectrical syystem.................................................................. 3-1
313 Special instructions for maiintenance of electriccal system m ........................ 3-1
32 Ellectrical system com mponentss ........................................................................ 3-88
321 Instrum
ment panel I-ECU ............................................................................... 3-8
322 Battery ................
. ........................................................................................ 3-144
323 Generattor.................................................................................................... 3-15
324 Starter .......................................................................................................... 3-166
325 Start sw
witch................................................................................................. 3-177
326 Fuel levvel sensor ........................................................................................ 3-18
327 Power switch
s .............................................................................................. 3-199
328 Pressuree switch .......................................................................................... 3-199
329 Differenntial lock stroke s swiitch .................................................................. 3-21
3210 Differeential lock k solenoidd valve and d boom locking soleenoid valv ve ..... 3-222
3212 Torquee converteer oil tempperature seensor ............................................... 3-23
3213 Enginee water tem mperaturee sensor ............................................................ 3-244
3214 Wiper and wiperr motor ............................................................................ 3-244
33 Ellectrical circuit
c of machine
m .......................................................................... 3-266
331 Harnesss design drrawing off machine ................ . ........................................ 3-266
3-1
Service Manual for Backhoe
B Lo
oader
3 Ellectriccal annd
Info
ormatiion Syystemm
31 Introductio
on to elecctrical sy
ystem
311 Sp
pecificatio
on of elecctrical sy
ystem
The elecctrical system
m voltage oof the machiine is 12V.
312 Deescription
n of electtrical system
Service Manual
M for Electrical System desscribes the
principlees, functio
ons and parameters of the
electricaal system and componennts included
d.
This paart also in
ncludes funnctional deescription,
troublesh
hooting an
nd mainteenance method of
electricaal system.
The electrical systtem consissts of electrical and
electroniic componeents includding battery
y, switch,
solenoid
d valve, fusee and relay. The electriccal system
also inclludes the co
omputer-bassed control system to
monitor the machiine state aand control relevant
functions of the macchine.
All maintenan
nce of electrrical system
m must be
in strict line with th

he general description
n.
313 Sp
pecial instructionss for
mainteenance off electriccal system
m
Special instructionss for maint
ntenance off electrical
system-g
general
Wiithout prio
or permitt of SDLG
G, never
change the electriical system

m. The cha
ange may
influencce the mach
hine functiions, causee personal
injury or machine damage.
Wh
hen operatiing the eleectrical sy
ystem, the
negligen
nce will cau
use serious personal in
njury and
3-1
B Lo
oader
machinee damage. When opeerating the electrical

system, the follow
wing descriiption and
d relevant
method descriptiion mustt be abiided by.
Meanwh t guidancee in safety part and
hile, refer to
instructiions for usee.
Fig. 3-1
Beffore operatting the ellectrical sy
ystem, be
sure to take dow

wn watch, ring, bracelet and
other metal objectss.
Nev
ver directly
y connect tthe starter motor to
start thee machine, which mayy cause thee machine

movemeent out of control. Forr starting by
b another
machinee power, th
he machinee should not
n collide
with thee machine under
u poweer starting.
Never ad
dopt the friiction fire m
mode to tesst whether
the cab
ble/joint has
h electrricity, wh
hich may
permaneently damag
ge the elecctronic and electrical
componeents.
Special instruction
i ns for mainntenance off electrical
system-b
battery
Forr quickly ch
harging thee battery, take down
the cov
ver of batttery cavityy. In the charging
process, the so--called hyydrogen gas will
accumullate in thee battery. Short-circcuit, open
fire or sp
park near the
t batteryy will causee powerful
explosio
on.
Firstly disconnect
d the charginng current and then
release th
he charging
g clamp.
Maintain
n good ven
ntilation; eespecially charge
c the
battery in
n closed spaace.
The elecctrolyte of battery
b has ccorrosive su
ulfur acid.
The elecctrolyte splashed on the skin should
s be
cleaned by
b soap and
d much wateer immediaately. If the
3-2
B Lo
oader
electroly
yte enters eyes
e or othher vulneraable body
parts, flu
ush it with much cleaar water im
mmediately
and imm
mediately contact the dooctor for hellp.
If the fully-ccharged baattery is connected

c
with th
he battery exhaustedd, the batttery will
explode due to current
c suurging. Thee battery
containss sulfuric acid, which may causee personal
injury accident.
a
Nev
ver charge the frozen battery, which
w may
cause rissk of explosion!

he engine is running, ne
When th never discon
nnect main
current or
o battery caable.
Before assembling or disasseembly the electrical
system components
c and conneccting mechanism, the
negative pole of batttery must bbe disconneccted.
n! Incorrectt operation may damage control
Attention
componeents like ECU, resultiing in susp
pension of
work.
hecking the electrical ssystem, be sure
When ch s to use
fully-chaarged battery. If the battery is not fully
charged, charge the battery or rreplace a neew battery.
For batteery charging
g, the polarr conductor of battery
must be disconnecteed from the battery.
For charrging the baattery in serries, the battery must
have th
he same volume andd same seervice life
(equivaleent quality).
The reasson is thatt the chargging electricc quantity
required by the batttery varies w
with the agiing degree
of battery
y.
Special instruction
i ns for mainntenance off electrical
system-g
generator
Before any
a AC geenerator or adjuster teest, check
whether the batterry and connductor aree properly
3-3
B Lo
oader
insulated
d, loosened
d or rustedd. The elecctrical test
should be
b done afteer faults disscovered in
n all above
inspectio
ons are corrected.
Check th
he generatorr belt, if neccessary; mak
ke
necessarry adjustmen
nt/repairingg before
troublesh
hooting.
on! Correctlly connect the cable and
Attentio a ensure
that the cable is frree of corrrosion and dust. The
loose caable conneection mayy cause daamage of
generato
or and voltag
ge stabilizerr.
on! Never disconnect the generaator when
Attentio
the engiine is runn
ning, whicch may daamage the
generato
or and voltag
ge stabilizerr.
Fig. 3-2 B
Belt Check on! The positive pole of generattor should
Attentio
not be connected with the chassis, which
w may
damage the geneerator and even thee voltage
stabilizerr.
system-eelectrical co
omponent
If a jointt on the datta bus is daamaged, thee bus must
be replacced.
on: each datta bus has tw
Attentio wo conducttors which
are in paair and spiral to prevennt them fro
om electric
interference. The co
onductor cann only be reepaired by
trained personnel.
p Or
O the whoole conducttor should
be replacced.
The elecctronic equip
pment is seensitive and
d it may be
damaged
d by static electricity ffrom electromagnetic
field or tools or human boddy. Therefo
ore, when
operating
g relevant electronic
e coomponents, be sure to
abide by
y following instructions
i s.
To meet the requireement of EM
MC, be surre to abide
by follow
wing instrucctions:
When an
n electronicc componennt is powered on, the
unit con
nnection sho
ould not bee disconnected. If it’s
3-4
B Lo
oader
disconneected, the electronic componentt may be

damaged
d.
Before maintaining
m the electriccal system, make the
tool conttact with a metal
m mechhanical part connected
with the frame to discharge
d sttatic electriccity of the
tool.
Never to
ouch the join
nt bolt on thhe electronicc unit.
For maaintaining the electrrical system
m, avoid
touching
g the circuiit board. Iff you mustt touch it,
only grassp the edge of circuit bboard.
When reeplacing th
he control uunit, ensuree that the
groundin
ng wire is saafely conneccted.
Never reeplace the non-spiral
n coonductor in
n pair with
the spiraal conductorr in pair.
system
For wellding the machine,
m thhe battery conductor
must be disconnecteed and the jjoint must be
b plugged
out form
m the controll componennt.
For spraaying operattion on thee machine, be careful
to prevent damag
ging the ccable and electrical
componeents.
To wash
h the vehiicle by higgh-pressuree spraying
machine, never align wiith the electronic
componeents. It’s especially important for using
hot wateer and degreasing deterggent.
Auxiliarry starting
Fo
or starting by the ppower from
m another
machine, the machine should not contact with the
machine under power starting.
Starting by starting cable
Before connection, make follow
wing inspecctions:
1. Turn the
t ignition switch on ttwo machin
nes to OFF
position..
3-5
B Lo
oader
2. When starting, the machine sshould not move.

m
wo machines have the ssame system
3. The tw m voltage.
4. The sp n of startingg cable can withstand
pecification
maximum
m rated currrent generatted by the battery.
b
5. Check
k the starting cable fo
for crack, oxidization
o
and otheer problems.
6. The battery
b cable is compplete withou
ut damage
and the joint is complete.
7. Machiines don’t contact withh each other.
Fo
or power cable,
c the ppositive and
d negative
poles sh
hould not contact
c with
th each oth
her, which
may cause personal injury.
Starting cable connection methhod (as show
wn in Fig.
3.3):
1. Conneect the firstt cable (A)) to the possitive pole
(1) of baattery on thee machine too be started.
2. Conn
nect the oth
her end off cable (A)) with the
positive pole (2) off battery on the auxiliary starting
machine.
3. Connect one end of anothe
her starting cable (B)
with the negative po
ole (3) of baattery on thee auxiliary
starting machine.
m
4. Conneect the otherr end of thee cable (B) with
w frame
Fig. 3-3 C
Connect the Starting Ciircuit ng point (4) on the m
groundin machine to be started
and checck whether the
t contact iis good.
Auxiliary
y starting:
Check whether
w the starting cabble is firmly
y fastened
and correectly connected.
1. Start the
t engine on
o the auxiliiary machin
ne.
2. Start the
t engine on the macchine to be started. If
the engin
ne is unablee to be starteed in 30s,
3. Wait for
f about 2s and try to sstart it again
n.
Starting cable disassembly metthod is as follows
f (as
n Fig. 3-4):
shown in
3-6
B Lo
oader
1. Disasssemble th
he cable (B
B) from the
t frame
groundin
ng point (1) of the machine started
s by
auxiliary
y starting.
2. Disassemble the other end of starting cable (B)
from neg
gative pole (2) of battttery on thee auxiliary
machine.
3. Disasssemble the starting cabble (A) from
m positive
pole (3) of battery on
o the auxiliiary machin
ne.
Fig. 3-4 D
Disassemblee the Start Cable
C 4. Disassemble the other end of starting cable (A)
from thee positive po
ole (4) of baattery on th
he machine
started by
b auxiliary starting.
3-7
B Lo
oader
32 Eleectrical system
s coomponents
321 Instrumentt panel I--ECU
I-ECU receives
r infformation ffrom the sensor and
switch of
o the macchine and tthe instrum
ment panel
displays the inform
mation, whicch helps the operator
to know the working
g state of m
machine.
ment panel display
Instrum d in tthe start-up
p process
Self-insp
pection pro
ocess: afterr powering
g on, the
instrumeent pointer points at tthe maximu
um value,
Fig. 3-5 Innstrument Panel
P returns to
t zero and
d points at ccorrect position. 1.5s
after all indicator laamps illumin
inate, it enteers normal
working state. Affter poweriing off, th
he pointer
automatiically return
ns to zero.
Working
g descriptio
on of timerr: at the moment
m of
powering
g on, it dissplays softw
ware version
n number.
For norm
mal working
g after pow
wering on, it
i displays
accumulated working hours. After staarting the
engine, the sand clock sym
mbol is run
nning and
refreshess the value once everyy 6 minutes.. The time
data shou
uld be saved
d once everry minute.
Functions aand requirements of in
nstrument paanel:
a. Instrumeent:
Function Speccific requireements Signal Remarks
R
Engine Rangge: 0-3000, red zone off 2500-3000
0; Collect 8 types off
tachometerr Unit: n/min。 generatorr W trransmissionn
terminal signal raatio
Working tiimer Rangge: 99999.9
9; engine sppeed≥400n/m
min, record
d
the tiime,
The timer chang
ges once evvery 6 minutes, and thee
saverr saves the data once a minute.
Engine w
water Rangge: 40-120℃, red zonne: 103-120℃, alarm
m Sensor
temperaturre pointt: 105℃.
gauge
3-8
B Lo
oader
Torque Rangge: 40-140℃

℃, red zonee 120-140℃
℃. Sensor
converter oil
temperaturre
gauge
Fuel llevel Rangge: 0-1/8-1//4-3/8-1/2-55/8-3/4-7/8-1; Sensor
gauge Red zone: 0-1/8
8.
b. Alarm:
Function Speecific requirrements Color Signal Remarkss
Alarm forr low 1. Before starrting, whenn the switch
h is closed,, Red Grounding
g
oil pressuree thee alarm ind
dicator is illluminating. When thee
swiitch is dissconnected, the alarm
m indicatorr
doeesn’t illumin
nate;
2. After
A startin
ng, when thhe pressure is low and
d
thee switch is closed, thhe alarm indicator
i iss
flasshing and buzzer
b alarm
m is ringing
g. When thee
swiitch is dissconnected, the symb
bol doesn’tt
illuuminate.
3. At the mom
ment whenn the enginee is started
d
andd shut down
n, the indicaator doesn’t illuminate.
Alarm for Whhen the keey is at O on and thee Yellow Grounding
ON positio g
differentiall lock diff
fferential lo
ock switch is closed, the alarm
m
working inddicator is flashing aand buzzerr alarm iss
ringging.
Alarm forr low 1. Before
B i closed orr Red
startting, when tthe switch is Grounding
g
transmissioon oil disconnected, the alarm
m indicato
or doesn’tt
pressure illuuminate;
2. After
A startin
ng, when thhe pressure is low and
d
thee switch is closed
c (for ddelay of 10ss, judge thee
signal is true)), the symbbol is flashiing and thee
buzzzer alarm is ringing ; when thee switch iss
disconnected, the symboll doesn’t illu
uminate.
Alarm forr high Whhen the waater tempeerature is≥1
110 ℃ , thee Red Sensor
temperaturre of alaarm indicato
or is flashingg and the bu
uzzer alarm
m
coolant is ringing.
r
3-9
B Lo
oader
Alarm for Whhen the key

y is at ON
N position, the alarm
m Red W
charging inddicator is illuminatingg; when the
t enginee terminal
indicator speeed is ≥400n
n/min, the aalarm lamp goes out.
Alarm for Whhen the keey is at O
ON positio
on and thee Yellow Grounding
g
oil-water oil--water sepaaration switcch is closed
d, the alarm
m
separation inddicator illum
minates.
Alarm for Whhen the key is at ON p osition, and
d the coarsee Yellow Grounding
g
coarse filtter of filtter switch is blocked, the alarm indicator
i iss
fuel illuuminating.
Alarm for Whhen the oil temperature
t e is higher than
t the sett Red Grounding
g
hydraulic oil vallue, the allarm indicaator is flaashing and
d
temperaturre buzzzer alarm is
i ringing.
Alarm forr low Whhen the oil level is ≤1//8, the alarm
m indicatorr Red Sensor
fuel level is flashing.
f
Alarm for Whhen the eng
gine is faultty, the alarm
m indicatorr Yellow Grounding
g
engine faullt is flashing
f and
d buzzer alaarm is ringin
ng.
Alarm foor air Whhen the key
y is at ON position, th
he air filterr Yellow Grounding
g
filter blockkage resistance is big
b and thee switch is closed, thee
alaarm indicato
or is flashingg.
Alarm for Whhen the key is at ON
N position, the waterr Yellow Grounding
g
transmissioon oil conntent of tran
nsmission oiil is higher than the sett
filter vallue of switcch and the switch is closed, thee
alaarm indicato
or illuminatees.
Central alarm Beffore starting, the oil ppressure an
nd charging
g Red
lamp inddicator lamp
p illuminatees, no alarm is given
n
outt. Under otther conditiions, in any
y of abovee
alaarming cond
ditions, the llamp is flash
hing.
c. Indicatorr
Function Speecific requirrements Color Signal Remarkss
F, N, R, 1,, 2, 3, Neuutral-N, Forrward-F, Reeverse-R;
Power
4 gear indiicator It has
h KD fu
unction andd the signaal is powerr Green
supply
supply.
Power off Whhen the tran
nsmission w
walking po
ower is cutt Power
Red
indicator off, the indicator illuminattes. supply
3-10
B Lo
oader
Pre-heatingg Whhen the engine preheeater is wo

orking, thee Power
Yellow
indicator indiicator illum
minates. supply
Left turn Whhen turning on the alaarm lamp or
o left turn
n Power
Green
indicator switch, the indicator is flaashing. supply
Right turn Whhen turning on the alarrm lamp orr right turn
n Power
Green
indicator switch, the indicator is flaashing. supply
High beam Whhen the fron
nt combinatiion lamp hiigh beam iss Power
Blue
indicator turnned on, the indicator
i illluminates. supply
Whhen the sollenoid valvve locks th
he working
g
Safety lock Power
devvice hydraaulic oil way, the indicatorr Red
indicator supply
illum
minates.
Thee mute switcch is turnedd on, the au
udible alarm
m
Mute indiccator Yellow Grounding
g
is sttopped and the indicatoor illuminattes.
Hand bbrake If thhe hand braake is unrellieved, the indicator iss
Red Grounding
g
indicator flasshing.
Safety belt If thhe safety belt
b is not ffastened, th
he indicatorr
Red Grounding
g
indicator illum
minates.
3-11
B Lo
oader
Make judgment as
a per freequency signal
s of
generator W terminal collectedd by the in
nstrument
panel:
a. When W terminaal signal iis disconneected, the
instrumentt panel hass no displaay (excludin
ng central
alarm lamp
p) and the central alaarm lamp is
i flashing
and gives out audiblee alarm. In this case, the
t user is
unable to reduce thee noise andd the LCD
D displays
OPEN.
b. Before the
t engine starts,
s the oiil pressure is low, the
oil pressurre indicatorr illuminatees, but now
w terminal
signal is deetected, so paragraph
p a is not impllemented;
c. After the engine staarts, the oill pressure iss high, the
oil pressurre indicato
or goes outt, but now
w terminal
signal is deetected, so paragraph
p a is implemeented.
Pin functio
ons
Fig. 3-6 Pins of Instruument Panell

A Pin funcctions
Pin No. Function Pin
n No. Function
F
1 CAN H 11 Left
L turn lighht
2 CAN L 12 Right
R turn ligght
3 5V output 13 Coarse
C filterring of transsmission oill
4 Speedometter signal 14 Tachometer
T speed ratio control 1
5 Tachometeer signal 15 Tachometer
3-12
B Lo
oader
6 Drive oil teemperature gauge signaal 16 Tachometer

7 Engine watter temperaature gauge signal 17 Battery+
B
8 Fuel gaugee signal 18 Ig
gnition swittch+
9 19 Hydraulic
H oiil temperatu
ure alarm
10 Power grouund wire 20 Power
P grounnd wire
B Pin Funcction
Pin No. Functionn Pin No
o. Funcction
1 Differenntial lock wo
orking- 12 Engine fault
2 Low oil pressure- 13 Preh
heating indiccator
3 Safety belt 14 Air filter blockaage-
4 Parking brake- 15 Tach
hometer sppeed ratio control
c 1
5 Safety loock 16 Tach
hometer sppeed ratio control
c 2
6 Transmission oil pressure 17
7 Power off 18
8 High beaam indicato
or 19 Coarrse filter off fuel
9 F 20 Oil-water separrator
10 N 21 Mutte
11 R 22 Back
klight
3-13
B Lo
oader
Pin testing
g method of instrumennt panel
The instru
ument paneel connectinng harness generally
consists off power line, groundingg wire, signaal line and
CAN bus. If the instrrument paneel is faulty, judge the
fault point through th
he instrumennt panel terrminal and
harness.
Terminal Power Ground

ding Connected with
C w C
CAN bus
type line wire signal linee
Normal 24-28V
V 0V
V A
As per workiing Thee resistancee between CAN
C H and
value state CAN L is about 12
20Ω
322 Batttery
It adopts maintenance
m -free plumbbic acid batttery.
Main param
meters:
Rated voltaage: 12V
20h rated capacity:
c 12
20A.h
Idle capaciity: 230min
Low-tempeerature startting currentt: 850A
Open circu
uit voltage: open circ
rcuit voltag
ge of new
Fig. 3-7 B
Battery battery is 12.5V-12.9V
1 V
Common Fault
F of Ba
attery
Fault Phenomeno
on Measure
Short-circuuit The battery
y voltage drrops to integ
gral multiple of 2. Replace
Open-circuuit Charging and
a dischargging are disabled Replace
Lower capacity Self-dischaarging Replace
Over-chargging The electro
olyte level iis lowered Replace
3-14
B Lo
oader
323 Gen
nerator
The AC generator
g supplies
s poower to baattery and
whole macchine.
Voltagee regulator
Fig. 3-8 G
Generator
Specificatiion of generrator:
Specificatiion minal function
B term IG teerminal fun
nction W terminal fuunction
14V-120A Chargging Exciitation Sp
peed signal, charging in
ndication
Methods annd solutions for judgin
ng whether tthe generato
or properly generates ellectricity:
1. Use thhe DC voltaage 200V of
o multimeteer to do insspection, op
pen the elecctric lock, measure
m thee
generator tterminal vooltage (red pen is connnected with
h generator D+ and bllack pen is grounded),,
record the reading off multimeterr (actually the reading
g is the term
minal voltagge of batterry which iss
generally bbelow 26V)). Start the machine,
m m
measure the generator terminal
t volltage again,, record thee
reading off multimeterr (if the generator faills to generaate electricitty normallyy, the readin
ng is aboutt
28V). By ccomparison,, the latter reading
r is sllightly higher than the former
f readding.
2. No eleectricity from
m the generrator:
2.1 Firstly check whetther the driv
ve belt of geenerator is loosened.
l
2.2 Close tthe electric lock and use the wrencch to
check whether the wirring terminaal is correctt, firm and reliable.
r
2.3 Check whether thee generator grounding iis reliable.
2.4 If it’s sstill unable to solve thee problem, please replace the gen
nerator or coontact profeessionals off
manufacturrer.
3-15
B Lo
oader
324 Starrter
The starteer is to co
onvert the battery en
nergy into
mechanicaal energy, so
o as to drivee the enginee flywheel
and drive the
t engine crankshaft.
c
Fig. 3-9 S
Starter
Common ffault diagnoosis and trou
ubleshootingg of starter
The starterr doesn’t woork
After the sstart switch is turned on,
o the startter doesn’t work.
w It maay caused bby blockagee of startingg
relay and start switchh or open-ccircuit of cconnecting wire. If the starter sttill doesn’t work afterr
troubleshooting, it meeans internaal fault of starter. It may
m caused by electroomagnetic coil
c fault off
starter elecctromagnetiic switch, ablation
a andd poor con
ntact of starrter motor, open circuit of motorr
electric bruush, commuutator, armaature and maagnetic field
d.
Starter lackk of power
Although tthe starter can
c drive th
he engine crrankshaft fo
or rotation, but the rotaating speed is too low,,
the engine is unable too smoothly start, whichh means thaat the loading ability is lowered and the actuall
wer is reducced. It may
output pow y be causedd by battery
y feed, looseness of baattery wirin
ng terminal,,
poor contaact due to oxidation corrosion, ablation of
o motor switch,
s ablaation of co
ommutator,,
excessive aabrasion off electric bru
ush or insuffficient elasticity of sprring, partiall short-circu
uit of motorr
armature aand field winding. Too tight enginne assembly
y or low env
vironment ttemperaturee may causee
higher starrting resistannce momen
nt.
The starterr is unable too stop work
king
Release thhe power suupply start witch,
w but tthe starter is
i unable to
o stop workking, it may
y caused byy
faulty of poower supplyy starting sw
witch, startiing relay fau
ult or bindin
ng of motorr switch.
Idle runninng of starterr
Although tthe starter is working, the engine crankshaft doesn’t rotate. It may be caused by slippingg
of one-waay clutch, misalignmen
m nt or blockkage of shiifting fork mechanism
m, insufficieent pushingg
volume of driving geaars, gear fricction or exccessive abraasion, loss of
o shifting ffork shaft, etc.
e Replacee
the clutch tto eliminatee the fault.
Big noise aat starting
At startingg, there is rhhythmic imp
pact, which may caused by holdin
ng circuit oppen of electtromagneticc
3-16
B Lo
oader
switch, daamage of sttarting relay

y, battery lloss of pow
wer or poorr contact off pole, etc. In case off
continuouss friction orr squeal sou
und, it may be motor sttator scrapp
ping rotor oor commutattor ablationn
g abrasion, armature shhaft bendin
or poor conntact of electric brush,, etc. causedd by bearing ng, rotor outt
of round, eetc.
325
5 Start sw
witch
As shown
s in thee figure, theere are four positions
on th
he start swittch: ON/HE
EAT/ON/OF
FF and
theree are totally
y six terminaals B /BR/ R1/
R R2 /C
/AC
CC. When it’s at ON poosition, threee terminals
B/ BR/
B ACC caan be conneected and thee condition
of otther gears iss clear.
Testt method:
Method for jud
dging whethher the elecctric lock iss
dam
maged. Disco
onnect the cconnection of wire andd
Start switch
s
electric lock, and
a disassem
mble the ellectric lockk
Terminal
Position
from
m the vehiccle. Use ressistance 200
0Ω gear off
digittal multimeeter to checkk the functiional gears,,
it’s good if it’’s smooth and it’s faaulty if it’ss
unsm
mooth. Reco
over or repllace it.
Com
mmon fault of
o start swittch:
1. The
T start sw
witch has nno responsee when it’ss
opened.
o
Fau
ult
Cause Meaasure
pheenomenon
The coontact
No
o response
is Rep
place
forr starting
disconneected
It starts
s when The coontact
Fig. 3-10 S
Start switch thee power is is place
Rep
con
nnected disconneected
Intermittent
Poor conntact Rep
place
starrt
3-17
B Lo
oader
326 Fuel leveel sensor

Fuel level
l sensorr mainly connsists of sen
nsor buoy 1
and flloater 2. Thee sensor buooy has reed
d pipe.
With the change of level, thee floater 2 moves
m up
and down along the
t sensor bbuoy 1. When the
floateer is at a possition, the sw
witch of reeed pipe is
conneected, corressponding reesistance gro
oup is
conneected. For ex
xample, whhen switch K30
K is
conneected, resistance R1 andd resistancee R30 are
conneected with th
he circuit annd the fuel gauge
g has
a corrresponding reading.
r
Correesponding table
t of liiquid level,, gear andd
resistaance
Gearr Resistancce (Ω)
Full 6.2±0.6
1-Sensor fl
float 2-floaater 6/8 19.2±0.8
Fig. 3-11 F
Fuel Level Sensor
S 4/8 32.2±1
2/8 55.6±1.4
1/8 80.4±1.6
Emp
pty 109.7±2
Test method:
m
 Short-circcuit methood: disassemble thee
sensor liine at the torque co
onverter oill
temperatu
ure sensorr. If the sensor iss
grounded
d, the instrum
ment showss full range,,
the senssor line is suspen
nding, thee
instrumen
nt will displays minimum
m
reading, which
w meanns that the instrumentt
and line are goodd and the sensor iss
damaged.. Please he sensor;;
replace th
otherwisee, check thee line, if itt’s good, itt
means thaat the instruument is fau
ulty.
 ment method: unplugg

Resistancce measurem
3-18
B Lo
oader
the senso
or plug, usee the multim Ω
meter 200Ω
resistancee grade, slidde the floateer by hands,,
observe the readingss change of multimeterr
and comp
pare data in above tablee.
327 Power sw
witch
When
n the machiine is not uused, the po
ower switchh
discon
nnects the connectioon between
n electricall
system
m and batttery voltagge. When the powerr
switch
h is at thee left of reear frame, the batteryy
discon
nnecting sw
witch is connnected witth negativee
pole (12V)
( of batttery.
Work
king environ
nment temp erature: -40
0℃~+75℃,,
relativ
ve humidity
y no more thhan 90%.
Fig. 3-12 Power Switcch Fault test metho
od: use thee resistance meter too
k the conneection condiition of two
check o terminalss
of pow
wer switch.
328 Pressuree switch
The pressure switch
s mai
ainly detects the airr
ure or oil pressure
pressu p off the machiine system..
When
n the presssure exceedds specific value, thee
switch
h is disconn
nected or cllosed. Due to differentt
model configurattions, the pr
pressure swiitch may bee
different.
3-19
B Lo
oader
Main technical parameters aand perform

mance.
Transsmission box
x pressure sswitch YK-Z
ZF
1. The
T switch contact
c is noormally clossed type.
2. When
W the pressure dropps to 1.4±0.0
06MPa, the
contact is clo
osed.
3. Rated
R voltag
ge: DC24V; rated poweer: 45W.
Fig. 3-13 T
Transmissioon Box Presssure Switchh
Braking light switch 32-5800-002-A
n the brake vvalve. When the brake
It’s asssembled on
pedal is pressed, the brake laamp switch is closed
underr the effect of
o pressure. When the brake
b lamp
line iss connected
d, the brake llamp illumiinates.
Main parameters:
1. Thee switch con
ntact is norm
mally open
2. Wh
hen the presssure rises too 5±2bar, th
he contact
is clossed.
Fault diagnosis method
m
Firstly
y confirm whether
w the brake presssure is
normaal (open thee electric locck, if the service
brakin
ng low-voltage alarm laamp on the instrument
panel illuminatess, it means tthat the brak
king force
is abn
normal; otheerwise, startt the vehiclee till the
brake low-voltag
ge alarm lam
mp goes out). If it’s
normaal, unplug th
he wire of bbrake lamp switch and
Fig. 3-14 B
Brake Lampp Switch use tw 2 Ω gradee test switch
wo pins of 200 h of
3-20
B Lo
oader
multim
meter, presss the brake, close the sw
witch,
neverr pressing th
he brake butt disconnectt the
switch
h.
Oil prressure swittch YK208B

B1
It’s assembled
a o the enggine body to test thee
on
engin
ne oil pressu
ure. When tthe oil presssure is tooo
low, the
t switch is
i closed annd the low oil
o pressuree
alarm
m lamp on th
he instrumennt panel illu
uminates.
Main parameters:
1. Thee switch con
ntact is norm
mally closed type.
2. Wh
hen the presssure rises too 0.08Mpa, disconnectt
the co
ontact.
3. Ratted voltage:: DC24V; raated power: 45W.
Fig. 3-15 O
Oil Pressuree Switch
329 Differenttial lock stroke sw
witch
The differential
d lock strokee switch is assembledd
on th
he differential lock asssembly off rear drivee
axle. For differeential operaation, turn the
t shiftingg
fork of
o differentiial lock, turrn the strok
ke switch too
quick
kly close it,, connect th
the power supply, thee
differrential indicator lamp illluminates.
Fig. 3-16 D
Differential Lock Strok
ke Switch
3-21
B Lo
oader
3210
0 Differeential locck soleno
oid valvee
and boom loccking sollenoid vaalve
The mounting position of differeential lockk

soleno
oid valve iss shown inn the figure. When thee
soleno
oid valve iss powered on, lock th
he rear axlee
drive..
Fig. 3-17 1—Differential lock
l Solennoid The mounting
m position
p off boom locck solenoidd
Valve valve is shown in
i the figurre. When th
he solenoidd
2— Boom locking Soolenoid Valv
ve valve is powered
d on, the booom at excaavating endd
ked.
is lock
The specificatio
on of diffeerential locck solenoidd
valve and boom lock solennoid valve is
i the samee
he resistance of solenoiid valve is 9.3Ω.
and th 9
3-22
B Lo
oader
3211
1 Locking
g solenoid
d valve
The locking
l soleenoid valvee is assemb
bled on thee
multi--way valvee for lockking four swing oill
cylind
der and thee resistancee of lockin
ng solenoidd
valve is 7Ω.
Fig. 3-18 L
Locking Sollenoid Valvee
3212
2 Torque converteer oil
temp
perature sensor
The torque con
nverter oill temperatu
ure sensorr
adoptts WDG13
371 temperrature sensor whosee
resistaance decrreases wiith the rising off
tempeerature. It’s used to chheck the hy
ydraulic oill
tempeerature in th
he torque coonverter.
Temp
perature and
d resistance change is sh
hown in
the table below:
Fig. 3-19 T
Temperaturee Sensor Tem
mperature (℃
℃) 40 50 60
0 80
Resiistance (Ω) 351 226 15
53 76
Tem
mperature (℃
℃) 100 115 12
20 140
Resiistance (Ω) 40.4 26.4 23
3 13.6
Fault diagnosis method:
m
Short-circuit metthod: disasssemble the sensor linee
3-23
B Lo
oader
at thee torque con

nverter oil temperature sensor. Iff
the seensor is gro
ounded, the instrumentt shows fulll
range, the sen
nsor line is suspen
nding, thee
instru
ument will displays
d minnimum read
ding, whichh
means that the instrument aand line aree good andd
the seensor is dam
maged. Pleaase replace the sensor;;
otherw
wise, check
k the line, if it’s good
d, it meanss
that th
he instrument is faulty.
Measu
urement method:
m uuse the multimeterr
resistaance grade.. The red ppen is conn
nected withh
the sm
mall screw on
o the sensoor and the black
b pen iss
groun
nded. Obserrve the resisstance chan
nge with thee
tempeerature.
3213
3 Engine water teemperatu
ure
sensor
The T2
T engine water
w temperrature senso
or is the
same as the torqu
ue converterr oil temperrature
sensor.
3214
4 Wiper and
a wipeer motor
The figure
f show
ws the internnal schemattic diagram
m
and external wiring
w diaggram of wiper.
w Thee
extern
nal wiring function iss shown in
n the tablee
below
w.
Yell Linee Function

n Color
Red ow B Black
No.
Blue
Yellow Black 0 Groundiing Black
(reset)
White
R
Red White
W 24 Front wiper reset w
wire Yellow
(ppositive) (sslow)
25 Front wiper low-sppeed wire Green
Blue (fast) Blackk
(grouund) 26 Front wiper high-sppeed wire Blue
37 Wiper power cord Red
3-24
B Lo
oader
If the wiper doesn’t work:

1. Please
P firstlly check whether th
he fuse iss
blown.
b
2. Check
C whether the volltage of alll functionall
wires
w is correct.
3. Check
C wheth
her the switc
tch function
ns properly.
4. Iff the circu

uit is norm
mal, it mean
ns that thee
wiper
w motor is damagedd, please rep
place it.
Fig. 3-20 Internal Schematic
S Diagram aand
External W
Wiring Diagrram of Wipeer
3-25
B Lo
oader
33 Electtrical cirrcuit of machine

m e
331 Harrness desiign draw
wing of m
machine
Fig.33-21Frame lines
3-26
B Lo
oader
接右支腿接
接近开关 To right
r outrigg
ger approachh switch
针脚号 Pin No.
N
线号 Linee No.
孔位号 Holee No.
线号 Linee No.
插孔号 Holee No.
线号 Linee No.
插孔号 Holee No.
线号 Linee No.
插孔号 Holee No.
线号 Linee No.
插孔号 Holee No.
线号 Linee No.
插孔号 Holee No.
线号 Linee No.
插孔号 Holee No.
线号 Linee No.
插孔号 Holee No.
线号 Linee No.
插孔号 Holee No.
线号 Linee No.
插孔号 Holee No.
线号 Linee No.
接仪表台线
线束 To instrument panel
p harnesss
油位传感器
器 Oil level
l sensorr
孔位号 Holee No.
线号 Linee No.
孔位号 Holee No.
线序号 Linee No.
接右前大灯
灯 To right
r front headlamp
h
接启动机信
信号端 To starter
s signaal port
保险丝盒 To fuse
f box
接蓄电池正
正极 To battery
b posittive pole
3-27
B Lo
oader
接水温传感
感器 To water
w tempeerature sensoor
发电机 Gen
nerator
接 B+端 To B+
B terminall
图 3-19 车
车架线束 Fig. 3-19 Framee Harness
孔位号 Holee No.
线号 Linee No.
接牌照灯 To license platee lamp
孔位号 Holee No.
线号 Linee No.
右尾灯 Righ
ht tail lamp
接左支腿接
接近开关 To left outriggeer approach switch
针脚号 Pin No.
N
线号 Linee No.
后喇叭开关
关 Rearr horn switcch
孔位号 Holee No.
线号 Linee No.
接车架 To frame
f
动臂锁止开
开关 Boo
om lock swittch
孔位号 Holee No.
线号 Linee No.
液压锁紧电
电磁阀 Hyd
draulic lockiing solenoidd valve
差速锁电磁
磁阀 Diffferential lock solenoid vvalve
动臂锁止电
电磁阀 Boo
om locking solenoid
s vallve
变速箱压力
力开关 Tran
nsmission box pressuree switch
孔位号 Holee No.
线号 Linee No.
差速锁开关
关 Diffferential lock switch
孔位号 Holee No.
线号 Linee No.
插孔号 Holee No.
线号 Linee No.
插孔号 Holee No.
线号 Linee No.
接变速箱线
线束 To transmission
t n box harneess
3-28
B Lo
oader
变矩器油温
温传感器 Torq
que converter oil tempeerature senssor
行车制动压
压力开关 Serv
vice braking
g pressure sw
witch
孔位号 Holee No.
线号 Linee No.
行车制动压
压力开关 Serv
vice braking
g pressure sw
witch
孔位号 Holee No.
线号 Linee No.
孔位号 Holee No.
线号 Linee No.
预热继电器
器 Preh
heating relay
y
预热塞 Preh
heating plug
g
接前喇叭 To front
f horn
孔位号 Holee No.
线号 Linee No.
左尾灯 Leftt tail lamp
液压锁紧电
电磁阀 Hyd
draulic lockiing solenoidd valve
差速锁开关
关 Diffferential lock switch
孔位号 Holee No.
线号 Linee No.
孔位号 Holee No.
线号 Linee No.
接左前大粉
粉板 To left front big
g plate
发动机机油
油压力开关
关 Engine oil pressure switchh
3-29
B Lo
oader
CN11 B
CN11-B
CN10-BB
CN50-B
CN9-B
CN10
CN1-B
CN2-B
CN4-B
CN3-B
CN6-B
36
CN5-B
CN61-BB
CN61
-
+
-
+
Fig.
F 3-22 Innstrument Paanel Harnesss
3-30
B Lo
oader
接启动
动开关 To
o start switcch
前后喷
喷水开关 Frront and reaar water spraaying switch
h
背光灯
灯 Baacklight
仪表盘
盘 In
nstrument paanel
后刮雨
雨器 Reear wiper
背光灯
灯 Baacklight
后工作
作灯 Reear working
g lamp
背光灯
灯 Baacklight
液压锁
锁紧 Hy
ydraulic loccking
背光灯
灯 Baacklight
前刮雨
雨器 Frront wiper
接右支
支腿指示灯 To
o right outriigger indicaator lamp
接左支
支腿指示灯 To
o left outrigger indicatoor lamp
背光灯
灯 Baacklight
差速锁
锁开关 Diifferential lo
ock switch
背光灯
灯 Baacklight
警顶灯
灯 Ro
oof warning
g lamp
背光灯
灯 Baacklight
警示灯
灯开关 Warning
W lamp
p switch
背光灯
灯 Baacklight
驱动模
模式选择 Drrive mode selection
s
背光灯
灯 Baacklight
前工作
作灯 Frront working
g lamp
背光灯
灯 Baacklight
远近光
光翘板开关 Hiigh/low beaam rocker sw
witch
孔位号
号 Ho
ole No.
线号 Liine No.
空调 Aiir condition
ner
手刹指
指示灯开关 Haand brake in
ndicator sw
witch
孔位号
号 Ho
ole No.
线号 Liine No.
蓄电池
池继电器 Baattery relay
插孔号
号 Ho
ole No.
3-31
B Lo
oader
线号 Liine No.
插孔号
号 Ho
ole No.
线号 Liine No.
插孔号
号 Ho
ole No.
线号 Liine No.
插孔号
号 Ho
ole No.
线号 Liine No.
前喷水
水壶 Frront waterin
ng can
后喷水
水壶 Reear watering
g can
接前刮
刮雨器电机
机 To
o front wipeer motor
孔位号
号 Ho
ole No.
线号 Liine No.
插孔号
号 Ho
ole No.
线号 Liine No.
插孔号
号 Ho
ole No.
线号 Liine No.
插孔号
号 Ho
ole No.
线号 Liine No.
插孔号
号 Ho
ole No.
线号 Liine No.
插孔号
号 Ho
ole No.
线号 Liine No.
插孔号
号 Ho
ole No.
线号 Liine No.
插孔号
号 Ho
ole No.
线号 Liine No.
插孔号
号 Ho
ole No.
线号 Liine No.
插孔号
号 Ho
ole No.
线号 Liine No.
插孔号
号 Ho
ole No.
线号 Liine No.
插孔号
号 Ho
ole No.
线号 Liine No.
3-32
B Lo
oader
插孔号
号 Ho
ole No.
线号 Liine No.
插孔号
号 Ho
ole No.
线号 Liine No.
插孔号
号 Ho
ole No.
线号 Liine No.
插孔号
号 Ho
ole No.
线号 Liine No.
插孔号
号 Ho
ole No.
线号 Liine No.
插孔号
号 Ho
ole No.
线号 Liine No.
接右转
转向指示灯 To
o right turn indicator laamp
接远光
光指示灯 To
o high beam
m
插孔号
号 Ho
ole No.
线号 Liine No.
手刹指
指示灯开关 Haand brake in
ndicator sw
witch
孔位号
号 Ho
ole No.
线号 Liine No.
蓄电池
蓄电池
接驾驶
驶室线束 To
o cab harnesss
前喷水
水壶 Frront waterin
ng can
后喷水
水壶 Reear watering
g can
换档延
延时继电器 Sh
hifting delay
y relay
孔位号
号 Ho
ole No.
线号 Liine No.
孔位号
号 Ho
ole No.
线号 Liine No.
接前刮
刮雨器电机
机 To
o front wipeer motor
接右转
转向指示灯 To
o right turn indicator laamp
接远光
光指示灯 To
o high beam
m
接手刹
刹指示灯 To
o hand brak
ke indicator lamp
接左转
转向指示灯 To
o left turn in
ndicator lam
mp
3-33
B Lo
oader
接挡位
位选择器 To
o gear selector
接喇叭
叭开关 To
o horn switcch
转向开
开关 Stteering switch
3-34
Contents
4 Introduction to Transmission System .............................................................. 4-1
41 ZF Transmission system .................................................................................. 4-1
411 Basic parameters of transmission and torque converter system ............... 4-1
412 Measurement and adjustment of transmission and torque converter ....... 4-1
413 Common faults and troubleshooting of ZF transmission ......................... 4-4
414 Functions and fault solutions for components of ZF transmission box ... 4-5
415 Other typical faults of ZF transmission box ............................................. 4-7
42 Maintenance of transmission-torque converter system ................................... 4-9
421 Attentions for disassembly and assembly of transmission box ................ 4-9
422 Flowchart for disassembly and assembly of transmission box ................ 4-9
43 Drive shaft system ......................................................................................... 4-11
431 Attentions for drive shaft maintenance ................................................... 4-11
44 Drive axle system .......................................................................................... 4-11
441 Fault diagnosis and troubleshooting of drive axle .................................. 4-11
I
4 Introduction to Transmission System

41 ZF Transmission system
411 Basic parameters of transmission and torque converter system
Table 4-1 Basic parameters of transmission
Item Parameter
Type Single-stage single-phase centripetal turbine
hydraulic torque converter
Torque converter
Test pressure of torque 1.1-1.3
converter (MPa)
Type Fixed shaft power shift transmission
Shifts of gearbox Four front gears and three reverse gears
Transmission
Working pressure of 1.8-2.1
transmission (MPa)
Applicable model 4WG94
412 Measurement and adjustment of transmission and torque converter
1. Shift pressure and shift pressure measurement
Tools:
Shift pressure testing joint: 6410006224
Test hose SMS20/M1/4-3000A: 4030000368
Pressure gauge CPG063-00025-01-S-B04:
Fig. 4-1 Pressure Measuring Tools 6430000943
Drive the backhoe loader at the repairing site,
lower the bucket on the ground and perform
parking brake. Shut off the engine and operate
the gear control lever for 3-5 times to relieve
residual pressure. (Oil temperature: 45-55℃)
a) Disassemble The machine repairing cover
plate.
b) Disconnect the variable pressure switch
connector.
Fig. 4-2 c) Disassemble the pressure sensor (switch)
1 Shift pressure sensor and pressure sensor joint on the
transmission control valve as shown in the
figure, and assemble the variable speed test
4-1
joint at the disassembly position.

Specification of mounting hole: M10×1.
d) Connect one end of test pipe with the shift
pressure test joint and the other end with the
pressure gauge (range of 0-6MPa).
Attentions:
 The pressure gauge pipe should be reliably

connected with instrument and pressure
testing port at two ends, to avoid oil leakage
influencing the measured value during the
test.
 In the test process, the engine speed should
be gradually improved. Avoid suddenly
acceleration, which may damage the
pressure gauge under the impact.
Fig. 4-3 e) Start the engine and step on the brake, shift
1 Forward gear clutch test port gears, observe the stable pressure of fuel
th
2 4 gear clutch test port pressure gauge, i.e. current shift pressure of
3 2nd gear clutch test port backhoe loader under test. As per
4 1st gear clutch test port conditions, judge whether the oil supply
5 3rd gear clutch test port system is normal.
6 Reverse gear clutch test port f) After testing, repeat a) pressure relief steps,
assemble the variable speed control valve
pressure sensor (switch) and pressure sensor
joint and wipe the drive oil leaked.
4-2
2. Oil pressure test at the torque converter outlet

a) Disconnect the oil temperature sensor
connector of torque converter.
b) Disassemble the oil temperature sensor at
the transmission box torque converter oil
outlet as shown in the figure, and assemble
the variable speed test joint at the
disassembly position.
Specification of mounting hole: M14×1.5.
Fig. 4-4
1 Torque converter oil temperature sensor
3. Gear selector test
Tool: multimeter
a) Plug off the gear selector connector and turn
the multimeter to the ON/OFF
measurement. Red pen is connected with the
red or black wire of gear selector, and the
black pen is respectively connected with
gear selector harness of different functions.
Fig. 4-5 Schematic Diagram of ZF Gear Selector b) Check the table to judge whether the gear
Connector selector functions properly.
Logic Diagram for WG90/94 Handle and Transmission Solenoid Valve
S/N of Name of Name of Forward gear Reverse gear Neutral position
handle handle solenoid
terminal port valve
1 2 3 4 1 2 3 4 1 2 3 4
7 AD1 Y3 o o o o
3 AD2 Y4 o o o o o
2 AD3 Y5 o o o
5 AD4 Y1 o o o o
4-3
6 AD5 Y2 o o o o
4 AD6 o o o o
8 AD7 Y6 o o
O represents that the handle port and corresponding solenoid valve are powered.
Table 4-1 Logical Table for ZF Gear Selector

4. Solenoid valve test
a) Disconnect the vehicle power, unscrew the
plug of variable speed control valve cable,
open the variable speed control valve side
cover, loosen the solenoid valve joint, and
insert red wire V/Ω of multimeter to one end of
solenoid valve and the other end of multimeter
in the other wiring terminal to measure the
resistance.
b) The resistance should be in the specified scope
of 90±10Ω. If not, it means that the solenoid
valve is faulty and it should be replaced.
Fig. 4-6 Solenoid Valve Attention: during testing, considering that the
ambient temperature has certain effect on the
resistance, the difference between measured
resistance and the specified resistance is
several Ω, but the solenoid valve can also
work properly.
413 Common faults and troubleshooting of ZF transmission
1. The vehicle is unable to start
S/N Fault point Solution
Check whether the shifting handle is at neutral Shift to neutral position
1
position.
Check whether the EST electric control box and wire Push the plug, a “cracking sound”
2
plug is loosened. can be heard.
3 Check whether the battery is full. Charge or change the battery
Check whether the starting circuit is faulty and the Recover the circuit
4
starting fuse is blown.
4-4
2. The vehicle can be started but not running.

S/N Fault point Solution
Check whether the transmission box has sufficient
1 Adjust the oil level to normal position.
oil and check the oil level in cold and hot state.
Check whether the wire plug of variable speed
2 Tighten the plug.
control valve is tightened.
Check whether the EST electric control box and Push the plug, a “cracking sound” can
3
wire plug are loosened. be heard.
Check whether the plug connecting gear selector
4 Insert the plug.
cable is loosened.
Check whether the gear selector neutral lock switch
5 Turn on the neutral locking switch.
is turned on.
6 Check whether the parking brake is released. Loosen the parking brake.
Check whether the transmission oil pressure on the Check the transmission oil pressure
7
instrument panel is normal. gauge.
Check whether the breather valve on the Clean the breather valve and check
8 transmission box is blocked and whether there is oil whether the oil is too much or too
overflowing out. little.
Check whether the speed sensor plug is loosened
and check whether the speed sensor cable is worn
Tighten the plug, and wrap or replace
9 out.
the worn cable.
Check whether the plug of the speed sensor loosens
and whether the cable thereof is broken
414 Functions and fault solutions for components of ZF transmission box
1. Electric control box
Turn on the electric lock switch and turn the shifting handle to neutral position. The electric control
box is at the standby state. After starting, rotate the shifting handle to select a gear. The electric
control box can automatically judge whether the pre-selected gear can be engaged at the current
speed as per the electric signal from output speed sensor and shifting handle. If the speed is quite
different, the computer can commands the solenoid valve to firstly shift to the lowest speed gear
and then shift to pre-selected speed gear at the cycle of 2.5s. To shift from 1st gear to 3rd gear, the
computer receives the electric signal from shifting handle, the computer identifies speed signal from
the speed sensor and judges whether the speed is reached, if not, the computer will automatically
send the electric signal to the solenoid valve, so that the 2nd gear is engaged; when the speed reaches
14KM/H, the 3rd gear is engaged, so that the impact is reduced.
4-5
Examples of general faults:

 During maintenance of backhoe excavator, the vehicle has no gear and is unable to start after
being flushed by water. Check the electric control system is properly connected without
mechanical fault. The electric control box is affected with damp in the water spraying process.
After drying, the vehicle functions properly. Therefore, the user should pay attention to taking
waterproof protection for computer box and handle during flushing maintenance.
 The vehicle is running normally. After stopping for refueling, the vehicle engine can be started
but the vehicle cannot move. After inspection, the electric control system is normal and the
transmission oil pressure is in the normal scope. Later, the user discovers that the plug below
the electric box is not inserted in place. Originally, there is a snap ring on the electric box for
fixing the electric control box joint. Only if one end of wire is inserted in the pin and the other
end is inserted, a “cracking sound” can be heard, it means the plug is clamped in place.
Otherwise, the plug cannot be tightened due to vehicle vibration in the driving process.
 If the structural component of vehicle is faulty; after welding, the vehicle cannot start. After
inspection, the electric control box is burnt out.
 After driving, several minutes after the electric lock is turned off, the timer on the instrument
panel suddenly discharges smoke and the vehicle cannot move. After inspection, it’s because
that the electric lock is turned off when the engine is not shut down, at this time, the generator
couldn’t charge the battery and the generator sometimes generates very high surge voltage and
transient current of dozens of ampere, so the electric control box is burnt out and the generator
connects the battery circuit to stabilize the circuit voltage. Therefore, close the electric lock
after the engine is shut down.
2. Output speed sensor
The output speed sensor is used to record the rotary movement frequency of output gear so that the
computer compares the pre-selected speed to the actual speed in the shifting process and decides the
gear shifting. When the resistance of output speed sensor is 1020±100, if the resistance is 0 or ∝, it
means short-circuit or open-circuit of sensor, so the sensor needs to be replaced.
 The vehicle has 1st gear and 2nd gear but no 3rd gear and 4th gear. Inspection: after the electric
lock is closed, unscrew the output speed sensor plug and use the multimeter to check the output
speed sensor. If the resistance is 0, it means that the speed sensor is damaged.
 The vehicle has no gear. The inspection shows that the oil level is normal and the cable from
electric control box to speed sensor is broken by metals. After wrapping the cable, the vehicle
returns to normal.
3. Gear selector
4-6
There are two micro-switches inside. It controls direction and speed by turning the handle and
rotating the handle sleeve back and forth.
 A user complains that the 4th gear speed of backhoe loader cannot be reached. The inspection
shows that the oil level of transmission box is normal and the 8# wire of 12-pin plug
connecting the shifting handle is loosened and 8# wire is in poor contact. When the 4th gear is
engaged, the computer only receives the electric signal from 3rd gear; therefore , there is no 4th
gear.
415 Other typical faults of ZF transmission box
1. The vehicle can be started but no gear is engaged.
- Check the oil level.
- Check whether the cable is worn out.
- Check the plug and fuse.
- Check whether the power voltage is stable normal value.
- Check whether the parking brake is normal.
- Check whether the engine and torque converter are normally connected.
- Check whether the transmission oil pressure is normal.
- Check whether the shifting handle is normal.
- Check whether the solenoid valve is normal.
2. The vehicle only has 1st and 2nd gear but no 3rd and 4th gear.
- Check whether the cable plug is correctly connected.
- Check whether the cable is worn out.
- Check whether the speed sensor is normal.
- Check whether the handle is normal.
3. The vehicle has no 1st and 2nd gear and only has 3rd and 4th gear.
- Check whether the service braking switch and emergency braking switch are normal.
4. Abnormal noise of transmission box
- Check the oil level
- Check whether the connecting bolt of transmission, frame and engine is loosened.
- Check whether the drive shaft and support are normal.
- Check whether the hydraulic pump is abnormal.
- Check whether the hinge joint is abnormal.
5. Vehicle power is insufficient
4-7
- Check whether the shift pressure is 1.8-2.1MPa.

- Check whether the engine power is normal.
- Check the oil for abnormality, deterioration, foam, etc.
4-8
42 Maintenance of transmission-torque converter system

421 Attentions for disassembly and assembly of transmission box
Attentions:
● The machine must be at the repairing position.
● The transmission box can only be disassembled after being cooled.
● Use clean container to collect oil and avoid oil splashing.
● In the disassembly process, the pipe joints must be wrapped to prevent impurities entering the
pipe.
● The transmission should be lifted up stably to prevent torque converter falling off.
422 Flowchart for disassembly and assembly of transmission box
Attention: The flowchart is only as the tips for repairing, disassembly and assembly steps.
Specific operation flowchart should be subject to specific models and configures.

1. Disassembly of transmission box
1. Repairing position
2. Disassemble the engine
hood Refer to 8 Cab and Air Conditioner
3. Disassemble the rack and System
cab
4. Disassemble two side plates
of machine
5. Disassemble the hydraulic Refer to 9 Working Hydraulic System
oil tank
6. Disconnect the oil outlet
hose of pump
Transmis 7. Disconnect the oil inlet and
sion box outlet pipe of radiator
8. Disconnect the connecting Variable speed control valve
harness circuit
9. Disassemble the Pressure sensor
intermediate drive shaft
10. Disassemble the rear drive Oil temperature sensor of
shaft torque converter
11. Drain the transmission oil
12. Disassemble the oil filler
pipe
13. Disconnect the brake
cylinder
14. Disconnect the engine
15. Disconnect the frame
16. Straighten the line and lift
it
4-9
2. Assembly of transmission box

1. Lift the transmission box
and make preparation
2. Connect the engine
3. Connect the frame
4. Connect the pump oil
outlet hose
5. Assemble the oil filling
pipe
6. Connect the brake
cylinder
7. Assemble the drive shaft
Circuit of variable 8. Connect the radiation Assembly of
speed control valve inlet and oil return pipe transmission box
9. Connect the wire harness
Pressure sensor
and sensor
Oil temperature sensor 10. Assemble the hydraulic
of torque converter oil tank
11. Lift the cab
12. Lift the engine hood
13. Assemble the side plate
14. Connect the rack
15. Fill transmission oil
16. Check the functions of
transmission box
4-10
43 Drive shaft system

431 Attentions for drive shaft maintenance
Attention: When delivering out the factory, the drive shaft has received dynamic balance
treatment and is marked with arrow. For disassembly or repairing, pay attention not to
damaging the balance, otherwise, perform dynamic balance again.
44 Drive axle system
Attention: for attentions before disassembly of drive axle, refer to 024 lifting and supporting
safety. For drive axle repairing, please refer to Service Manual for Drive Axle.
441 Fault diagnosis and troubleshooting of drive axle
1. Abnormal noise of drive axle
a) Phenomenon and hazard
Abnormal noise of wheel drive axle includes: continuous and intermittent ringing; ringing at
speed change and normal driving; ringing at upslope and downslope; clunking and clear sound.
The abnormal noise of drive axle reflects the abnormal technical state of spare parts, causes
should be discovered to eliminate the fault in time; otherwise, greater fault and accident may be
caused.
b) Cause and solution for abnormal noise of drive axle
The abnormal noise of drive axle is mainly caused by collision or interference of some parts in
rear axle (including wheel reducer).
Due to different strengths and natures of noise from different parts under different states, the
source of abnormal noise should be judged as per conditions and positions and the cause of
abnormal noise should be discovered.
● Firstly, the noise is caused by loose connection of parts and damage of parts, which is usually
caused by abnormal friction and collision, so the sound is quite clear;
● Secondly, the noise is caused by abnormal bearing fit and gear meshing.
● The abnormal gear meshing refers to too small or too big meshing clearance, incorrect meshing
position and insufficient meshing area. At this time, it generates continuous clear sound
increasing with the speed rising. Abnormal bearing fit refers to too big or small bearing
clearance. Too big clearance may generate continuous sound increasing with the speed rising.
● As for abnormal noise of rear axle housing, check whether the part is loosened. Firstly check
whether the meshing area of main drive cone gear is correct.
2. Hot drive axle
4-11
a) Phenomenon and hazard

Hot drive axle refers to that the temperature exceeds the permissible temperature rise scope
after the drive axle mechanically works for a period of time. Generally touch it by hands, and
it’s very hot. The hot drive axle mainly happens at the drive axle housing (excluding drive and
differential mechanism) and wheel reducer. Hot drive axle mainly represents abnormal
technical state of spare parts or abnormal matching relations or abnormal lubrication, which
should be eliminated in time to avoid damaging relevant spare parts.
b) Cause and solution for hot drive axle
● Cause for hot drive axle: the heat is too much and unable to be dissipated.
● The heat source of wheel drive axle is friction heat which is only caused by too small fit
clearance of relative movement parts. The mating parts of drive axle include bearing and gear.
Therefore the root cause for hot drive axle is too small bearing fit clearance or gear meshing
clearance.
● The heat of drive axle is unable to be dissipated, which is mainly caused by that the drive axle
(and wheel reducer) is lacking of oil or the oil quality is poor. Lacking of oil or poor oil quality
not only hinders the timely dissipation of friction heat generated by the drive axle but also
makes the relative movement part in dry friction state, so the friction heat is greatly increased.
● The cause for hot drive axle can be judged as per the hot part. If the bearing is overheating, it’s
caused by bearing. If the whole drive axle housing is hot, it may be caused by abnormal gear
meshing or lack of oil. Fill the lubricating oil meeting the standard in time.
3. Oil leakage of drive axle
a) Phenomena and hazard
The oil leakage of drive axle mainly happens at the axle housing and wheel reducer and the
most leakage happens at the sealing part and matching surface.
b) Cause and solution for oil leakage of drive axle
● Oil leakage of drive axle is mainly caused by damage of sealing element and seal gasket. The
former one is represented by oil leakage caused by damage of drive oil seal and the latter one is
represented by oil leakage at matching surface of rear axle housing and wheel reducer.
● Check the oil seal for aging, crack and breakage; never forcefully drag the big oil seal to
prevent plastic deformation; try to immerse the oil seal in the liquid with temperature similar to
working temperature to heat it and then assemble it by special tools.
4-12
Contents
5 Brake System................................................................................................................................................. 1
51 Service braking system ............................................................................................................................... 1
511 Composition of service braking system ................................................................................................ 1
512 Vacuum pump ....................................................................................................................................... 1
513 Vacuum booster assembly ..................................................................................................................... 3
514 Foot brake pedal ................................................................................................................................... 5
515 Fault, cause and troubleshooting solution of service braking system ................................................... 5
52 Parking braking system ............................................................................................................................. 6
521 Composition of parking braking system ............................................................................................... 6
522 Fault, cause and troubleshooting solution of parking braking system .................................................. 7
I
5 Brake System
The brake system of B876F backhoe loader consists of
service braking system and parking braking system. The
service braking system is to mandatorily slow down or
stop the driving or working backhoe loader, or maintain
stable speed of backhoe loader driving at down slope, as
per the driver’s requirements. The parking braking system
is to ensure stable parking of backhoe loader on various
road conditions (including slope) without automatic
skidding.
51 Service braking system
511 Composition of service braking system
The service braking system of B876F backhoe loader
adopts vacuum assisted braking and it consists of vacuum
pump, vacuum booster assembly, foot brake pedal, etc.
For braking, press the foot brake pedal, the vacuum
booster will help transmitting brake oil from oil pipe to
brake in the rear axle and drive the brake cylinder for
braking; meanwhile, the brake switch under pressure
turns on the brake lamp. Release the brake pedal, the
brake valve cuts off the pressure oil, oil returns to brake
cylinder and the brake lamp goes out.
Fig. 5-1
1 Foot brake pedal 2 Vacuum booster assembly
3 Vacuum pump 4 Rear axle brake oil pipe
512 Vacuum pump

B876F backhoe loader adopts vacuum pump as generator
additional pump. The vacuum pump is the power source
of vacuum assisted braking system, which is driving
5-1
coaxially and rotating in the same direction with the
generator.
Main technical parameters
Max. vacuum degree: 90.7KPa;
Capacity of vacuum tank: 7L;
Vacuum degree under different speed:
Speed Vacuum Evacuation

S/N
r/min degree KPa time
Pump stop
1 0 53.3
time 15S
2 1000 66.7 ≤10S
3 5000 66.7 ≤35S
Working process and principle

As the rotor is inclined in the case, all rotor vanes and the
case inner wall forms variable capacity. When the
capacity is increasing, the negative pressure is formed;
when the capacity is decreasing, and it’s compressed for
exhausting air. When the rotor is rotating, the vane moves
out due to centrifugal force and it forms certain capacity
with the pump case. When the vane surpasses the air
inlet, the capacity is gradually expanding and the negative
pressure is formed at the air inlet. Open the check valve
to draw air in the vacuum tank. The rotor keeps rotating,
when the vane surpasses the center position from air inlet
to air outlet, the capacity is reducing and the air is
Fig. 5-2 Sketch Map for Vacuum Pump gradually compressed. When the vane reaches the air
1 Pump body 2 Rotary vane 3 vent, the compressed air is completely extruded out. The
Rotor 4 Spring 5 Exhaust valve whole process is cyclic. The negative pressure in the
vacuum tank is gradually increasing up to the index
value.
Attention
The internal structure of vacuum pump is
complicated. Maintenance personnel are not allowed
to disassemble and adjust the internal structure of
vacuum pump.
Maintenance of generator vacuum pump
1. Try to keep the appearance of vacuum pump clean and
prevent impurities from entering the pump.
2. Frequently check the oil quality. If the oil is
deteriorated, replace new oil and ensure that the vacuum
pump works properly.
5-2
3. The oil change period shall be decided by the user as
per actual using condition and performance requirement.
Generally, for new pump, it’s suggested changing oil after
running about 3,000km. After breaking-in period, the oil
change frequency can be lowered properly.
4. Generally, after running for 10,000km, the vacuum
pump shall be subject to overhauling. Check the aging
degree of rubber seal, clean the dirt in the pump, and
clean parts in the whole vacuum pump cavity like rotor,
rotary vane. Generally, use gasoline and dry it. For rubber
parts, clean it and use a piece of dry cloth to wipe it.
When cleaning the assembly, handle with care to prevent
bumping.
513 Vacuum booster assembly

B876F backhoe loader adopts double vacuum booster.
Under the pressure difference between negative pressure
when the vacuum pump is working and atmospheric
pressure, the vacuum booster is to force the movement of
rubber diaphragm and promote the piston of brake master
cylinder so as to reduce the force of driver pressing the
brake pedal, improve the driving safety and lower the
labor intensity of driver.
Fig. 5-3 Vacuum Booster Assembly Main technical parameters
Bore of brake master cylinder: 32Φ;
Working medium: Mobil 1310;
Effective stroke of booster piston: 32mm;
Assist rate: 3
An oil cup is provided for two vacuum boosters.
Vacuum booster assembly consists of oil cup, brake
master cylinder, vacuum booster, etc.
Vacuum booster: magnify the output force of brake pedal
to generate the input force of brake master cylinder.
Brake master cylinder: Convert the output force of
vacuum booster into hydraulic output to brake pipe.
Fig. 5-4
1 Oil cup 2 Brake master cylinder
3 Vacuum booster
5-3
Vacuum Membrane Membrane
Stem seal ring pipe front cavity rear cavity
Stem seal
Y-ring
ring
Fig. 5-5
Action process of vacuum booster: press the brake pedal,

push the push rod 1 to control valve seal cup 2, close the
valve port 3, and open the air valve 4. At this time, air
enters the membrane rear cavity through the filter, the
membrane front cavity reaches the vacuum degree
through the vacuum pipe, so the front and rear cavity of
membrane form pressure difference and generate
boosting function. Meanwhile, push the control valve
piston forward, obtain assist rate under the action of
reaction plate. The output force of output shaft is imposed
on the brake master cylinder rear piston to promote the
brake master cylinder piston, generate brake force and
transmit the force to wheel cylinder through the pipe.
Connect the vacuum orifice of vacuum booster. After the
driver presses left brake pedal, the vacuum booster
mandril pushes hydraulic piston assembly in the master
cylinder and moves it leftward. The valve steam seal ring
on the hydraulic piston assembly contacts with the base
plane of master cylinder and then it’s sealed. The
hydraulic piston pushes the valve seat to open the balance
oil outlet valve. The hydraulic oil flows to connecting
pipe of vacuum booster with master cylinder balance oil
outlet, seals the valve of right balance oil outlet, finally
pushes out the hydraulic oil from the oil outlet to brake so
as to realize braking. After the pedal is released, the
hydraulic piston assembly returns to original position
under the action of return spring force and the product
returns to original state.
After the driver presses right brake pedal, the above
principle shall apply.
When the driver presses left and right brake pedal at the
5-4
same time, the valve seat at the balance oil mouth is
opened at the same time to maintain equal oil pressure
and realize brake balance.
Installation instructions
1. The installation must be firm to prevent damaging the
pipe due to looseness.
2. Keep clean and avoid leakage at the joint when
installing oil pipe.
3. After installation, add sufficient brake liquid, exhaust
air in the brake pipe system as per following methods.
a. When exhausting air, pay attention to the oil volume in
the oil tank and randomly supplement oil capacity.
b. Slowly press the brake pedal, firstly put the screw at
the highest position and completely discharge air in oil in
the front and rear branch pump as per the sequence. The
oil shall be absolutely free of foam and the drained oil
must be recycled after filtration.
c. When exhausting air, be sure to take intermittent
multiple emission methods, i.e. after exhausting air, wait
a moment and then keep exhausting air, which is good for
exhausting air.
514 Foot brake pedal

There are left and right foot brake pedals. The left rear
brake is controlled by the left brake pedal and the right
rear brake is controlled by the right pedal. Two pedals can
be locked by steel lock lever for linked operation.
Fig. 5-6
515 Fault, cause and troubleshooting

solution of service braking system
Fault and
Cause Solution
Symptom
1. Oil leakage at the connection

among master pump, branch pump
Oil cup in serious and pipe joint. 1. Eliminate external oil leakage.
shortage of oil 2. Oil leakage at the connection 2. Replace master pump Y-ring
between master pump and vacuum
booster.
Air leakage of 1. Membrane breakage

Replace the vacuum booster
vacuum booster 2. Loose riveting screw
5-5
3. Leakage at vacuum pipe rivet
welding
1. Air in oil
1. Exhaust air in the system
2. Serious abrasion of friction plate of
brake shoe causes too big gap or poor 2. Adjust the gap between friction
contact between friction plate and plate and brake drum
Brake pedal lack of brake drum
power 3. Adjust the gap between master
3. Too big free clearance of master pump and push rod at 1-2mm
pump push rod 4. Check the hose and replace a new
4. Too big expansion of high pressure one
hose
Brake lack of 1. Stem seal ring damage 1. Replace the steam seal ring
power 2. Y-ring damage 2. Replace Y-ring
1. Exhaust air in oil

1. Air in oil, slow return of valve
body. 2. Check the mounting position of
brake shoe of brake and adjust it to
Slow return of 2. Friction between brake shoe and
proper position.
pedal mounting base plate influences the
return. 3. Check the master pump return
condition and eliminate the factor
3. Slow return of master pump.
influencing the return.
52 Parking braking system

521 Composition of parking braking
system
The parking braking function is to impose resistance on
the machine when parking, so as to lock the
transmission output shaft and prevent vehicle sliding.
The system is mainly composed of brake handle,
parking brake, fixing plate, etc.
Fig. 5-7 Parking Braking System The hand brake operating mechanism consists of hand
brake, control lever and flexible control shaft. When the
driver pulls up the control lever, the rod is swinging, the
cylindrical cam at the end of rod is rotating, and the
brake shoes (friction plates) at both sides are expanded
and compressed tightly on the inner circumference of
brake drum rotating with the transmission, so as to
realize the parking brake purpose. The hand brake
indicator is flashing.
The failure rate of parking braking system is generally
not high. However, no proper maintenance is made, the
brake system also may be subject to abnormal
conditions like braking sliding, friction plate abrasion,
5-6
brake drum crack and driving malfunction after the
brake is removed. The sliding condition is mainly
caused by serious abrasion of brake friction plate. Main
reasons for early abrasion of friction plate include oil on
the friction plate or friction plate expansion due to
dampness. Driving malfunction after the brake is
removed is mainly caused by friction plate expansion;
therefore, the friction plate should be cleaned regularly
to keep clean and dry.
522 Fault, cause and troubleshooting
solution of parking braking system
Fault and
Cause Solution
Symptom
1 Re-adjust the gap as per

1 Big gap but small contact area
requirements
between brake caliper and brake disc
Parking brake
2 Clean the brake disc
malfunction 2 Oil on the brake disc
3 Adjust the moving stroke of
3 Small tension of brake caliper
control lever pin shaft
Check the control lever for

Control lever of
bending, clamping or the spring
parking brake can't Parking brake control lever is faulty
breakage; if no, check the fan tooth
be fixed
for slipping.
5-7
I
Contents
6 Steering System........................................................................................................................ 1
61 Introduction to steering system ................................................................................................ 1
611 Structural composition of steering system ...................................................................... 2
62 Pressure measurement and adjustment of steering system ...................................................... 3
621 Pressure measurement of steering hydraulic system ....................................................... 3
622 Pressure adjustment of steering hydraulic system .......................................................... 4
63 Preparation before repairing the steering system ..................................................................... 4
64 Introduction to main components ............................................................................................ 5
641 Steering pump ................................................................................................................. 5
642 Priority valve ................................................................................................................... 6
643 Steering cylinder ............................................................................................................. 7
644 Steering gear ................................................................................................................... 8
65 Exhaust of steering system....................................................................................................... 9
66 Fault diagnosis and troubleshooting of steering system ........................................................ 10
661 Main fault diagnosis ...................................................................................................... 10
662 Examples of typical troubleshooting............................................................................. 19
I
6 Steering System
61 Introduction to steering system
The machine adopts full hydraulic load sensing steering
system. The system mainly consists of steering gear pump,
priority valve, dynamic signal load sensing hydraulic
pressure steering gear, steering column, steering wheel,
steering cylinder and pipe. It possesses advantages like
compact structure, high sensitivity, good stability, flexible
operation, road impact absorption and no need of other
lubricating device. After interruption of oil supply, the
machine can realize manual steering. The working
pressure of steering system is 15MPa.
tankSteering cylinder
Steering gear
To multi-way vale P port
Priority valve
Working pump
Fig. 6-1 Schematic Diagram for Steering System

1
611 Structural composition of steering

system
To steering cylinder
To hydraulic oil
Fig. 6-2 Structural Composition of Steering System
Table 6-1
S/N Name S/N Name S/N Name
1 Priority valve 15 Screw 29 Pressing plate
2 Priority valve fixing 16 Nut 30 Joint
plate
3 Screw 17 Pipe clamp 31 Hose
4 Rubber gasket 18 Pipe clamp 32 Binding wire
5 Washer 19 Pipe clamp 33 Direct joint
6 Bolt 20 Screw 34 O-RING
7 Washer 21 Rubber sleeve 35 Joint
8 Nut 22 Pipe clamp 36 Steering gear
9 Joint 23 Bolt 37 Direct joint
10 Joint 24 Bolt 38 O-RING
11 Hose 25 Steel pipe 39 Hose
12 Steering wheel 26 Rubber block 40 Direct joint
13 Adjustable steering 27 Bolt 41 O-RING
column
14 Washer 28 Steel pipe 42 Hose
2
62 Pressure measurement and

adjustment of steering system
621 Pressure measurement of steering
hydraulic system
Oil temperature: 45-55℃.
Pressure measuring tools: pressure gauge with
range of 40Mpa (4030000370), T-joint, pressure
measuring joint and pipe of corresponding size
(4030000368).
Pressure measuring standard: 15Mpa
Pressure measuring position: no special pressure
measuring interface.
Fig. 6-3 4030000370 pressure gauge
Pressure measuring process:
1. Lower the working device on the ground, lift
the hand brake and block the tires with wood
block or stone.
2. Shut off the engine, operate the control lever
for 10 times and steering wheel for about 5
times, and relieve residual pressure of
hydraulic oil in the pipe.
Fig. 6-4 T-joint
3. Disassemble the hose on the steering cylinder.
4. Connect the T-joint with the steering cylinder
and hose.
5. Connect the pressure measuring joint with the
T-joint and connect the pressure measuring
hose.
6. Connect the pressure gauge with the pressure
measuring hose.
7. Start the engine and turn the front axle to
ultimate position. When the front axle reaches
the ultimate position gradually do acceleration
Fig. 6-5 4030000368 pressure
to the maximum position. Observe the stable
measuring hose pressure of the oil pressure gauge, which is the
current working pressure of steering hydraulic
system of backhoe loader under test.
Fig. 6-6 Pressure testing joint
3
622 Pressure adjustment of steering

hydraulic system
After measuring the oil pressure, if the measured

data is higher or lower than the standard value,
adjust the system pressure. The pressure of steering
system depends on the safety valve opening profess.
The steering gear adopts integrated design and its
safety valve is in the steering gear, as shown in the
figure. Disassembly of steering gear may damage
the reliability of steering gear, so it’s not
recommended to disassemble the steering gear.
1
Fig. 6-7
1 Safety valve position
63 Preparation before repairing the
steering system
1. Relieve pressure
Drive the machine to flat and vast ground,
clockwise and anti-clockwise rotate the steering
wheel for 5-6 times, and relieve oil pressure in the
steering system.
2. Use wood wedge to block the tires of loader.
3. Prepare proper oil container.
准备好适当的接油容器。
Fig. 6-8
1 Steering wheel
4
64 Introduction to main components

641 Steering pump
The steering system and working hydraulic system
share a triple pump. For detailed description and
disassembly and assembly process, please refer to
working hydraulic system.
Fig. 6-9 Connection Diagram of Working Pump Pipeline

1 Priority valve 2 Working pump 3 Hydraulic oil tank
5
642 Priority valve

The steering system adopts priority valve VLC-60.
The priority valve is a differential stress component,
no matter how the load pressure and fuel pump
supply change, the priority valve can maintain the
same pressure difference at two ends of variable
throttle in the steering gear, so that the flow
supplied to steering gear is the steering wheel speed
multiplying the steering gear displacement.
P port of priority valve is connected with oil outlet
hose of steering pump, CF port is connected with P
port of steering gear, EF port is connected with P
port of multi-way valve and LS port is connected
with LS port of steering gear.
1 2 3 4 5
Fig. 6-10 External View of Priority Valve
1 T port 2 LS port 3 EF port 4 P port 5 CF port
Table 6-2 Technical parameters of priority valve

Name Parameter
Nominal flow 60L/min
Control 7.6Bar
pressure
Signal Dynamic signal
Fig. 6-11 Schematic Diagram for Priority Valve
6
643 Steering cylinder

The steering cylinder can converts liquid pressure
into mechanical energy of reciprocal rectilinear
motion. The steering cylinder is fixed on the frame
through the pin shaft. And the extending and
retracting of cylinder realizes the steering function
of vehicle. The steering cylinder mainly consists of
cylinder body, piston rod, cylinder head, piston and
cylinder seal kit.
Fig. 6-12 Structural Drawing of Steering Cylinder

1 Piston rod 2 Cylinder hood 3 Cylinder bock 4 Piston
Fig. 6-13 Appearance of Steering Cylinder
7
644 Steering gear

The machine adopts Xcel45-160 dynamic signal
load sensing full hydraulic steering gear and its
appearance and internal schematic diagram are as
follows.
Fig. 6-14 Appearance of Xcel45-160 Steering Gear

1 R port 2 P port 3 LS port 4 L port 5 T port
Main Technical Parameters of Steering Gear
Table 6-3
Model Xcel45-160
Connection mode British standard
involute splines
Equivalent 160ml/r
displacement
Maximum inlet 19MPa
pressure
Maximum continuous 1.0MPa
back pressure
Pressure of overload 21MPa
valve
Steering torque 1.3-2.2Nm
Fig. 6-15 Schematic Diagram for Steering Gear

P port of steering gear is connected with CF port of priority valve. L and R ports are respectively
connected with the steering cylinder and T port oil returns to the fuel tank after being cooled in the
radiator. LS port is connected with LS port of priority valve, and steering gear spline is connected
with the steering column.
Steering gear mainly consists of servo rotary valve and metering motor. The servo rotary valve
includes valve element, valve sleeve and valve body; the metering motor includes stator and rotor.
In the normal steering operation, the stator and rotor play the function of hydraulic motor.
8
65 Exhaust of steering system

After replacing the steering pump, steering gear,
priority valve, steering cylinder and hydraulic oil
pipe in the steering circuit, be sure to exhaust air in
the steering system:
1. Stop the machine at correct repairing position
and open the filler cap on the hydraulic oil
tank.
2. Start the engine, keep it idle running for several
minutes and pay attention not to starting any
hydraulic function in this process.
3. After the hydraulic oil in the hydraulic system
is fully circulated, slightly rotate the steering
wheel for several times. Prevent the steering
cylinder running close to the end.
4. Keep the engine idle running, carefully rotate
the steering wheel to keep the steering oil
cylinder extending and retracting for 3-5 times
at full stroke, and exhaust air in the pipe. If
necessary, disassemble the oil inlet or oil return
pipe of steering cylinder to make the hydraulic
oil overflow and fully exhaust air in the
hydraulic cylinder. Pay attention not to
building up pressure in the hydraulic system in
the whole exhaust process.
5. After exhausting air, set the machine and
working device at the standard position and
check the oil volume and tighten the filler cap.
6. Stop the engine, check and confirm whether the
hydraulic pipe has leakage.
Fig. 6-16
1 Filler port
9
66 Fault diagnosis and

troubleshooting of steering system
661 Main fault diagnosis
Table 6-4 Cause for hard steering fault
S/N Cause Fault Position Reference Drawing Remarks
The one-way valve of

steering gear is damaged
1
and blocks the entry of
steering gear
The steering gear shuts off

and steering one-way valve
2
steel ball is unable to return
to original position.
The priority valve LS pipe

is twisted or too long, and
3
the damping hole is
blocked or leaked.
The steering column is

4 damaged and the steering
torque is big.
The steering column

interferes with the steering
gear connection part. After
5
assembly, the steering gear
valve element generates
axial or radial force
10
Table 6-5 Cause for hard steering fault (continued)

The priority valve overflow
valve pressure is too low or
the main valve element is
blocked or damping is
6
blocked. The main valve
element of priority valve is
blocked or the main spring
elasticity is low.
The overload valve pressure

in the steering gear
7
combination valve block is
low.
The oil return filter is

8
blocked.
The pump is seriously

abraded or damaged and the
9 volume efficiency, pressure
and flow fail to meet the
system requirements.
The steering system pipe is

blocked, forming serious
10
throttle and resulting in hard
steering.
11
Table 6-6 Cause for vehicle off-tracking fault
Check whether the oil

1
cylinder is loosened.
2 Leakage of oil cylinder.
The two tire pressure is

3
greatly different
Leakage of two-way
4 overload valve or
two-way make-up valve
5 There is air in the oil.
12
Table 6-7 Cause for incorrect steering fault
1 There is air in the system.
The cylinder pin is

2
loosened.
3 Thermal impact.
The priority valve main

4
valve element is blocked.
5 Leakage of oil cylinder
Low pump efficiency

6 results in instable
pressure.
13
Table 6-8 Cause for steering wheel without pressure or steering wheel immobility
The steering column is

1 separated from steering
wheel nut.
The steering column

mandrel is separated from
2
the steering gear valve
element.
Too low oil level of fuel

3
tank.
14
Table 6-9 Cause for steering wheel immobility or slow action
Serious leakage of
one-way overload valve
1
or two-way make-up
valve.
Serious leakage of
2
cylinder piston.
Table 6-10 Cause for idle stroke of steering wheel

Steering wheel nut is

1
loosened.
The connection between

steering column and
2
steering gear is abraded or
damaged.
3 There is air in the oil.
Leakage of two-way
4 overload valve and
two-way make-up valve
15
5 Leakage of oil cylinder
The abrasion clearance of

oil cylinder and steering
6
linkage is big or
damaged.
Table 6-11 Cause for abnormal returning or followed rotating

The steering column and

steering gear are tightly
1
connected or interfere
with each other.
Large oil return back

2 pressure causes poor
returning.
16
Large pollution particles

enter the valve element
3 and valve sleeve,
resulting in returning
malfunction.
Steering gear spring piece

4 is damaged or has low
elasticity.
Table 6-12 Cause for steering wheel vibration or auto-rotation

The assembly relation is
wrong. For disassembly
and repairing, the spline
tooth (that is
1 corresponding to
universal driving shaft pin
groove) is corresponding
to the internal spline tooth
of rotor tooth groove.
The oil inlet is connected

2 with R or L port, the
steering motor of steering
gear automatically
rotates.
Table 6-13 Other faults

Fault Position Reference
Symptom Cause Remarks
Drawing
If it doesn’t
work for a long
time, the
Transient instable steering at the start steering gear
component may
have great
temperature
17
difference with
the system.
There is air in
Wriggle of steering cylinder
the system.
R and L ports
Steering wheel direction is contrary are reversely
connected
One-way valve
Steering wheel bounces of steering gear
is damaged
18
662 Examples of typical troubleshooting

Fault 1: hard steering
Cause Countermeasures
Creeping of oil cylinder, bubble in the Yes

hydraulic oil and irregular sound
Exhaust air in the system and check

There is air in the system the oil inlet
It’s unable to manually rotate the Check whether the steel ball is
Yes one-way valve blocked
Hard steering and steering cylinder Replace KF combination valve
FK overloading leakage
immovability Internal leakage of oil cylinder Check the oil cylinder for internal
leakage
Yes
Check whether the
steering column is
Make flexible
judgmen No No Yes
t as per Check whether the Check the feedback
system pressure oil pipe for Pipe blockage Clean or replace
the fault
phenom meets requirements smoothness
enon No
No
Adjust the system pressure and The priority valve spring is broken or
Whether the steering wheel
observe whether the pressure valve element is stuck Clean, repair or replace
is hard at rapid steering is changed
Yes
The system pressure is low Adjust the system pressure to

No
specified value
Yes
Whether the hydraulic oil level is The hydraulic oil level is low Fill oil to specified scope
too low
No
Yes
Whether the oil suction Pipe blockage Clean or replace
pipe is blocked
No
The steering pump is abraded Repair or replace
19
Fault 2: no end of steering
After the steering cylinder rotates to ultimate

position, forcefully rotate the steering wheel, if
the steering wheel can be rotated slightly, it has Low pressure of Properly increase the
no end of steering overload valve pressure of overload
是
Fault 3: the steering cylinder fails to reach the ultimate position valve
The steering cylinder fails to reach the ultimate Low pressure of safety
position and it shows hard steering valve Properly increase the
是 pressure of safety valve
20
Table of Contents
7 Frame, Tires and Working Device ................................................................................................ 1
71 Summary of frame and working device .......................................................................................... 1
711 Summary of frame ................................................................................................................. 1
712 Summary of loading working device ..................................................................................... 1
713 Summary of excavating working device ............................................................................... 2
72 Disassembly and assembly of loading working device .................................................................. 2
721 Disassembly of loading working device ................................................................................ 2
722 Assembly of loading working device .................................................................................... 6
73 Disassembly and assembly of excavating working device ........................................................... 10
731 Disassembly of excavating working device ........................................................................ 10
732 Assembly of excavating working device ............................................................................. 14
74 Disassembly and assembly of front and rear tires......................................................................... 18
741 Disassembly and assembly of front tire ............................................................................... 18
742 Disassembly and assembly of rear tire ................................................................................ 19
75 Disassembly and assembly of counterweight ............................................................................... 20
751 Disassembly of counterweight ............................................................................................. 20
752 Assembly of counterweight ................................................................................................. 20
I
7 Frame, Tires and

Working Device
71 Summary of frame and
working device
711 Summary of frame
The frame of this machine uses monolithic box
structural design and is characterized by
compact structure and good overall stability. The
sectional bar is used for key parts, which
effectively guarantees the fitting accuracy of
sliding movement. Assembling adjustment is no
longer required. Meanwhile, the use of sectional
bar eliminates connection risks of plate welding,
guarantees strength and improve work efficiency
greatly. The design of elastic vertical outrigger
not only has rock-solid support, but also is
applicable to work in narrow space.
The excavating device with lateral sway allows
2 1
to excavate square pit without moving the
Fig. 7-1 machine and greatly improves excavation scope
1 Stabilizing outrigger and work efficiency. During excavation, the
2 Frame outrigger can absorb the impact of weight.
Without outrigger, the weight of medium load or
downward force produced during excavation
will damage hub and tires and the whole
machine body will bounce. Stabilizing outrigger
can keep car body steady and minimize impact
force produced during excavation.
712 Summary of loading working
device
Loading end is composed of bucket, front drag
rod, boom, rear drag rod, rocker arm, boom
cylinder, rotating bucket cylinder and hinge pin
etc. The design of high-performance parallel link
mechanism of loading end has energy transfer
efficiency more than 70%. Bucket can maintain
the state of complete translation when lifting to
the highest position from ground. Materials will
not scatter even when completely loaded.
Structural design of continuous bending box
boom comprehensively uses high-strength steel
plate, which has extremely high resistance to
Fig. 7-2 deformation and damage and durability under
1 Bucket 2 Front drag rod the premise of low self weight. Meanwhile,
3 Front drag rod 4 Boom outline curve of boom with special design
5 Rear drag rod 6 Rear rocker arm allows to load materials to the middle of most
7 Hinge pin trucks easily.
7-1
713 Summary of excavating working

device
Excavating end is mainly composed of bucket,
bucket cylinder, connecting rod, boom, boom
cylinder, rocking bar, arm, arm cylinder,
connecting hinge pin, etc.
Special link mechanism design is used for the
excavating end. Rotation angle of bucket
exceeds 200°. It can change to loading work
from excavation easily.
Fig. 7-3 Internal-mounted design of oil cylinder and oil

1 Bucket 2 Connecting rod tube can effectively prevent damage by external
3 Rocking bar 4 Arm collision during in-depth work. Wagging boom
5 Boom 6 Boom cylinder is supplied with special damping buffer device,
which can guarantee steady and smooth
excavation.
72 Disassembly and assembly of

loading working device
721 Disassembly of loading working
device
Attention:
1 Before disassembly of oil tube of working
device, shut down engine and use control
lever to release residual pressure.
2 Do not fully screw off bolt rashly in the
process of disassembly. First loosen it
slightly till oil overflow to avoid oil spill
caused by incomplete oil discharge.
3 When disconnecting hose, use sealing cap
to seal the mouth of hose and tie the hose
fast to oil tube to avoid leakage of
hydraulic oil from main oil line.
Bucket disassembly
1 lace the vehicle on solid and flat ground.

Fig. 7-4 Bucket bottom completely down to the 2 et loading device down to make bucket
ground bottom completely down to the ground.
7-2
3 Disassemble connecting oil tube of left and

right four-in-one oil cylinder.
4 Remove hinge pin 3 connecting drag rod
and bucket and locking bolt.
5 Remove hinge pin connecting boom and
bucket and locking bolt.
6 Lift bucket with sling to the appropriate
place.
Fig. 7-5
1 Locking bolt 2 Connecting oil tube3 Hinge pin
Disassembly of front drag rod

1 Fully contract rotating bucket cylinder and
put a wood block under rotating bucket
cylinder.
2 Disassemble hinge pin connecting rotating
bucket cylinder and front drag rod and
check ring. After completion of
disassembly, use sling to capture drag rod
to prevent it from falling off.3
Disassemble hinge pin connecting
drag rod 2 and boom and check ring.
4 Lift drag rods 1 and 2 with sling to the
appropriate position.
Fig. 7-6
1 Front drag rod 2 Front drag rod
3 Connecting hinge pin and check ring 4
Boom
Disassembly of rotating bucket cylinder
1 First use sling to capture rotating bucket

cylinder before disassembly to prevent oil
cylinder from sliding down suddenly.
Fig. 7-7
1 Rotating bucket cylinder 2 Sling
7-3
2 Disassemble oil tube of rotating bucket

cylinder.
3 Disassemble hinge pin connecting rotating
bucket cylinder and rocking bar, gasket and
check ring.
4 Lift rotating bucket cylinder to the
appropriate place.
Fig. 7-8
1 Connecting hinge pin and check ring
2 Connecting oil tube Disassembly of rear drag rod and rear rocker
arm
1 Disassemble locking ring fixed on the

hinge pin of rear rocker arm and remove
locking plate.
Fig. 7-9
1 Locking plate
2 Locking ring
2 Disassemble hinge pin connecting rear
rocker arm and boom and check ring.
3 Disassemble hinge pin connecting rear
rocker arm and rear drag rod and check ring
and remove rear rocker arm.
Fig. 7-10
1 2 3
1 Connecting hinge pin and check ring 2
Connecting hinge pin and check ring
3 Rear rocker arm
7-4
4 Disassemble hinge pin connecting rear drag

rod and boom and locking bolt and remove
rear drag rod.
Fig. 7-11
1 Connecting hinge pin 2 Locking bolt
3 Boom
Disassembly of boom cylinder
1 Disassemble connecting oil tube of boom

cylinder.
2 Disassemble hinge pin connecting boom
cylinder and boom and locking bolt.
Attention:
Use sling to capture boom cylinder before
disassembly to prevent boom cylinder from
falling down suddenly after completion of
Fig. 7-12 hinge pin disassembly.
1 Connecting hinge pin and locking bolt
2 Boom cylinder
3 Sling

cylinder and frame and locking bolt and
remove boom cylinder.
Fig. 7-13
2 Boom cylinder
7-5
Boom disassembly
and frame and locking bolt.
2 Lift boom to the appropriate position.
Attention:
Use sling to capture boom before disassembly
to prevent boom from sliding down after
completion of hinge pin disassembly.
The stationarity of boom must be guaranteed
in the lifting process to prevent the
occurrence of safety accident caused by tilt.
Fig. 7-14
1 Connecting hinge pin and locking bolt 722 Assembly of loading working
2 Boom device
Attention:
Check surface defects of each hinge pin, sleeve
and inner bore such as surface scratching and
bruise mark before assembly. Apply lubricating
grease on the fitting surface of hinge pine during
assembly.
Assembly of rear rocker arm
1 Place boom on the frame horizontally.

2 Use gasket, check ring and middle pin of
rear rocker arm to fix rear rocker arm on
the right side of boom.
3 Use gasket, check ring and middle pin of
rear rocker arm to fix rear rocker arm on
the left side of boom.
Fig. 7-15
1 Boom 2 Rear
rocker
arm
3 Connecting 4 Gasket
hinge pin
5 Check ring
7-6
Assembly of front drag rod
1 Use gasket, check ring and pin of front

rocker arm to fix front drag rod 3 on left
and right booms.
2 Use gasket, check ring and pin of front
rocker arm to fix front drag rod 2 on left
and right front drag rod 3 and put wood
block under front drag rod 2.
Fig. 7-16 Attention:

1 Hinge pin 2 Front drag rod Pay attention to the gap between end faces of
3 Front drag rod 4 Gasket front drag rods 2 and 3. Add adjusting shim
5 Check ring between end faces as required and guarantee
that the gap between end faces is between 0.5
and 1.5 through the selection of adjusting
shim.
Assembly of rotating bucket cylinder

1 Use rear hinge pin of rotating bucket
cylinder, gasket, check ring and adjusting
shim to fix the rear end of left and right
rotating bucket cylinder on rear rocker arm.
2 Use front pin of rotating bucket cylinder,
gasket, check ring and adjusting shim to fix
piston rod of left and right rotating bucket
cylinder on front drag rod.
Fig. 7-17
Attention:
Pay attention to the gap between end faces of
1 Front drag rod 2 Rotating bucket
rotating bucket cylinder and rear rocker arm
cylinder
and that between end faces of piston rod of oil
3 Rear hinge pin 4 Gasket
cylinder and front drag rod. Add adjusting
5 Check ring
shim between end faces as required and
guarantee that the gap between end faces is
between 0.5 and 1.5 through the selection of
adjusting shim.
Bucket assembly
1 Use bucket pin and shim to connect bucket
to front drag rod and boom.
2 Use locking bolt and nut to fix bucket pin.
Attention:
front drag rod and bucket and that between
end faces of boom and bucket. Add adjusting
Fig. 7-18 shim between end faces as required and
1 Front drag rod 2 Bucket pin guarantee that the gap between end faces is
between 0.5 and 1.5 through the selection of
7-7
3 Bucket adjusting shim.
Boom assembly
1 Lift the assembled loading device to the
corresponding position of frame and make
boom pin hole aligned to the corresponding
pin hole on the frame for next assembly.
Attention:
The stationarity of loading device must be
guaranteed in the lifting process to prevent
Fig. 7-19 the occurrence of safety accident caused by
1 Loading device tilt.
2 Use rear pin of boom, bolt, nut and locking
pin to connect the left side of boom to the
left side of frame.
3 Use rear pin of boom, bolt, nut and locking
pin to connect the right side of boom to the
right side of frame.
4 Use bolt and nut to fix rear pin of boom on
the corresponding position of frame.
Attention:
boom and frame and locking pin. Add
adjusting shim between end faces as required
Fig. 7-20
and guarantee that the space between end
1 Rear pin of boom 2 Locking bolt
faces is between 0.5 and 1.5 through the
3 Boom
selection of adjusting shim.
Assembly of rear drag rod

1 Fix one rear drag rod on rear rocker arm at
the left end of loading device with gasket,
check ring and shim of rear rocker arm pin.
2 Fix one rear drag rod on rear rocker arm at
the right end of loading device with gasket,
check ring and shim of rear rocker arm pin.
3 Fix rear end of rear drag rod in the
corresponding position of frame. Use bolt
and nut to fix rear pin of drag rod on frame.
Fig. 7-21
1 Rear pin of drag rod 2 Rear drag rod
Attention:
3 Rear rocker arm
rear drag rod and rear rocker arm and that
of rear pin of drag rod and pin lock and
frame. Add adjusting shim between end faces
as required and guarantee that the gap
between end faces is between 0.5 and 1.5
through the selection of adjusting shim.
7-8
Assembly of boom cylinder

1 Use connecting hinge pin and locking bolt
of boom to fix boom cylinder on left and
right frame.
Fig. 7-22
2 Boom cylinder
2 Use front pin, bolt and nut of boom

cylinder to connect left and right boom
cylinder and boom.
Attention:
boom cylinder and boom. Add adjusting shim
between end faces as required and guarantee
Fig. 7-23 shim.

2 Boom cylinder
3 Sling
7-9

excavating working device
731 Disassembly of excavating
working device
Attention:
1 Before disassembly of oil tube of working
device, shut down engine and use control
lever to release residual pressure.
2 Do not fully screw off bolt rashly in the
process of disassembly. First loosen it
slightly till oil overflow to avoid oil spill
caused by incomplete oil discharge.
3 When disconnecting hose, use sealing cap
to seal the mouth of hose and tie the hose
fast to oil tube to avoid leakage of
hydraulic oil from main oil line.
Bucket disassembly and assembly
1 Place the vehicle on solid and flat ground.

2 Get excavating device down to make
bucket bottom completely down to the
ground.
Fig. 7-24
Bucket completely down to the ground
3 Remove locking bolt and nut of hinge pin
of connecting rod.
4 Remove locking bolt and nut of bucket pin.
5 Remove bucket and lift it with sling to the
Fig. 7-25
1 Connecting rod pin 2 Locking nut
3 Locking nut 4 Bucket pin
7-10
Removal of connecting rod and rocking bar

1 Drop the end of arm completely to the
ground. Put a wood block between arm and
ground contact position.
2 Fully retract bucket cylinder and put a
wood block under bucket cylinder.
Disassemble hinge pin and locking bolt 4
and remove connecting rod.
3 Disassemble hinge pin connecting rocking
bar and arm and locking bolt 2 and remove
rocking bar.
Fig. 7-26
1 Connecting rod 2 Hinge pin and locking
bolt
3 Rocking bar 4 Hinge pin and locking
bolt Disassembly of bucket cylinder
1 Disconnect oil tube of bucket cylinder after

pressure relief through the control of
control lever.
2 Use sling to capture bucket cylinder.
3 Remove cylinder hinge pin and locking bolt
2 and lift bucket cylinder to the appropriate
position.
Fig. 7-27
1 Bucket cylinder 2 Hinge pin and
locking bolt Arm removal
1 Use sling to capture arm to prevent arm
from falling suddenly after completion of
hinge pin disassembly.
Fig. 7-28
1 Arm
7-11
2 Disassemble hinge pin and locking bolt 2 at

the front end and support boom with
tooling after disassembly.
3 Disassemble hinge pin connecting rear end
of arm and boom and locking bolt 1.
4 Use sling to lift arm to the appropriate
position.
Fig. 7-29
1 Hinge pin and locking bolt2 Hinge pin and
locking bolt
3 Arm cylinder
Disassembly of arm cylinder
1 Disconnect small- and large-cavity oil tubes

of arm cylinder.
Fig. 7-30
1 Oil tube
2 At this time, there are be tooling supporting

the other end of boom.
3 Use sling to lift arm cylinder to the
4 Remove hinge pin connecting arm cylinder
and boom and locking bolt.
5 Lift arm cylinder to the appropriate
position.
Fig. 7-31
1 Arm cylinder
2 Hinge pin and locking bolt
7-12
Removal of boom cylinder

1 Use sling to capture boom before removal
of boom cylinder and remove boom
cylinder and connecting hinge pin and
locking bolt 1.
2 Remove support, reduce sling height and
make the front end of boom down to the
ground. Put a wood block on the contact
ground.
3 Disconnect connecting oil tube of boom
cylinder and plug hose mouth.
Fig. 7-32
4 Remove hinge pin connecting boom

cylinder and swing frame and locking bolt.
5 Use sling to lift boom cylinder to the
Fig. 7-33
1 Connecting hinge pin Boom disassembly
1 Disassemble oil tube of working device

fixed on boom.。
2 Disassemble check ring and hinge pin
connecting boom and swing frame.
3 Lift boom to the appropriate position.
Fig. 7-34
1 Check ring and connecting hinge pin
7-13
732 Assembly of excavating working

device
Attention: Check surface defects of
each hinge pin, sleeve and inner bore such as
surface scratching and bruise mark before
assembly.
Apply lubricating grease on the fitting surface of
hinge pine and shaft sleeve during assembly.
Boom assembly
1 Use sling to align swing frame hole to
boom pin hole.
2 Use hinge pin, shim and check ring to
connect boom and swing frame.
Attention:
boom and swing frame. Add adjusting shim
Fig. 7-35 shim.
1 Hinge pin, shim and check ring
Assembly of boom cylinder
1 Use sling to lift boom cylinder and use

hinge pin, shim, bolt and nut to fix small
cavity of boom cylinder on boom.
Fig. 7-36
7-14
2 Align to swing frame hole and use hinge

pin, shim, bolt and nut to fix large cavity of
boom cylinder on swing frame.
3 Connect oil tube of boom cylinder.
Attention:
boom cylinder and swing frame. Add
and guarantee that the gap between end faces
is between 0.2 and 0.5 through the selection of
adjusting shim.
Fig. 7-37
1 Hinge pin 2 Locking nut
Arm assembly
1 Use sling to move arm to its position, align
boom to arm pin hole and use hinge pin,
shim, bolt and nut to connect boom and
arm.
Attention:
boom and arm. Add adjusting shim between
end
1 faces as required and guarantee that the
gap between end faces is between 0.2 and 0.5
Fig. 7-38 through the selection of adjusting shim.
Assembly of arm cylinder

1 Use hinge pin, shim, bolt and nut to fix
large cavity end of arm cylinder on boom.
small cavity end of arm cylinder on arm.
3 Connect oil tube of arm cylinder.
Attention:
arm cylinder and boom and arm. Add
Fig. 7-39 Upper joint adjusting shim between end faces as required
1 Arm 2 Arm cylinder and guarantee that the gap between end faces
3 Boom is between 0.2 and 0.5 through the selection of
adjusting shim.
7-15
Assembly of bucket cylinder

large cavity end of bucket cylinder on arm.
Attention:
cylinder and arm. Add adjusting shim
Fig. 7-40 shim.
1 Bucket cylinder
Installation of connecting rod and rocking bar
1 Use hinge pin, shim, bolt and nut to fix left
and right rocking bars on arm.
connecting rod and bucket cylinder on
rocking bar.
Attention:
rocker arm and arm and connecting rod. Add
Fig. 7-41 is between 0.2 and 0.5 through the selection of
1 Connecting rod 2 Hinge pin and locking adjusting shim.
bolt Bucket assembly
3 Rocking bar 4 Hinge pin and locking 1 Use hinge pin, shim, bolt and nut to
bolt connect arm and bucket assembly.
2 Use hinge pin, shim, bolt and nut to
connect connecting rod and bucket
assembly.
3 Connect oil tube of bucket cylinder.
7-16
Attention:
bucket and arm and connecting rod. Add
is between 0.2 and 0.5 through the selection of
adjusting shim.
Fig. 7-42
1 Connecting rod pin 2 Locking nut
3 Locking nut 4 Bucket pin
7-17

front and rear tires
front tire
Disassembly of front tire
1. Place the machine in maintenance position

1 (for details, refer to safety and
environment page 7).
2. Support the machine with loading working
device, as shown in the left figure.
3. Use supporting device to place it under
front axle.
4. Loosen wheel nut.
5. Install forklift tool of wheel and remove

front tire.
Fig. 7-43
1 Support of loading working device
Installation of front tire
1 Assemble tire and install tire on rim. Apply

lubricating grease in rim before tire
installation; remove foreign matters in
inner cavity before tire and rim installation.
2 Install tire.
3 Tighten the nut.
Attention:
Tighten the nut clockwise and tighten slightly
each time to avoid tire inclination. Tighten it
diagonally. During lifting, no one is allowed
to stand under tire. Pay attention to lifting
Fig. 7-44 position and avoid falling off.
1 Tire assembly
2 Rim nut Tightening torque: 310±45N.m
4 Air inflation
Inflation pressure of front tire 0.43±0.01MPa

During inflation, charge tire pressure to about
0.05~0.1Mpa above the specified air pressure
value and then release to the specified air
pressure. Guarantee that tire and rim and outer
tire seat are fitted closely.
7-18
5 Recover the machine and check and

confirm that there is no wrong information.
6 Check functions.

rear tire
Disassembly of rear tire
1 Place the machine in maintenance position
1 (for details, refer to safety and
environment page 7).
2 Support rear tire of the machine with
excavating working device or outrigger and
make it above the ground, as shown in the
left figure.
3 Use supporting device to place it under rear
axle.
4 Loosen wheel nut.
5 Install forklift tool of wheel and remove
rear tire.
Installation of rear tire

1 Assemble tire and install tire on rim. Apply
lubricating grease in rim before tire
installation; remove foreign matters in
inner cavity before tire and rim installation.
2 Install tire.
3 Tighten the nut.
Attention:
Tighten the nut clockwise and tighten slightly
each time to avoid tire inclination. Tighten it
diagonally.
During lifting, no one is allowed to stand
under tire. Pay attention to lifting position
and avoid falling off.
Tightening torque: 710±50N.m

4 Air inflation
Attention:
During inflation, charge tire pressure to
about 0.05~0.1Mpa above the specified air
pressure value and then release to the
specified air pressure. Guarantee that tire
and rim and outer tire seat are fitted closely.
7-19
Inflation pressure of rear tire 0.22±0.01MPa.

5 Recover the machine and check and
confirm that there is no wrong information.
6 Check functions.

counterweight
751 Disassembly of counterweight
1 Disassemble bolt connecting counterweight
and frame.
Attention:
First use sling to capture counterweight
before disassembly to prevent counterweight
from falling after completion of bolt
disassembly.
90.05kg
2 Reduce counterweight, disassemble it from
Fig. 7-47 the machine and then lift it up and remove.
1 Counterweight 752 Assembly of counterweight
2 Bolt 1. Connect counterweight to hoisting
equipment and install it on the machine.
2. Install counterweight on the machine with 2
bolts.
3. Remove sling.
7-20

Ⅰ
Table of Contents
8 Cab and Air Conditioner System ......................................................................................................................1
81 General steps for disassembly and assembly of cab ..................................................................... 1
82 Introductions to air conditioner system ......................................................................................... 2
821 Working principles and layout of air conditioner system .......................................................................2
822 Control principle of air conditioner ..........................................................................................................4
823 Matters needing attention in air conditioner installation and use .........................................................8
83 Routine inspection on air conditioner system ............................................................................... 9
84 Maintenance guide of air conditioner system .............................................................................. 11
841 Basic process .............................................................................................................................................11
842 Refrigerant discharge of system ..............................................................................................................11
843 Removal of pipeline or pressure switch ..................................................................................................11
844 Refrigerant oil ...........................................................................................................................................12
845 Refrigerant filling method .......................................................................................................................13
85 Common fault diagnosis and troubleshooting of air conditioner system .................................. 16
Refrigeration failure of system ......................................................................................................................16
Inadequate refrigerating capacity of system ................................................................................................17
Self discontinuous working of refrigeration system ....................................................................................17
Common fault diagnosis and troubleshooting..............................................................................................19
Flow chart of common breakdown maintenance of air conditioner system ..............................................22

8 Cab and Air Conditioner System

81 General steps for disassembly and assembly of cab
Capture cab
Disassemble pipeline of foot brake
valve
Disassemble pipeline of steering gear
Disconnect cable accelerator (the
second stage)
Disconnect flexible axle of
transmission (mechanical control)
Disconnect cab harness
Disconnect flexible axle of multiway
Cab disassembly valve (mechanical control)
Disconnect flexible axle of parking
brake
Disconnect water pipe of fan heater
Disconnect fuel oil liquid level sensor
Disassemble fixed bolt of cab
Lift up cab
Assembly steps are basically opposite to disassembly. Pay attention to hoisting safety.
8-1
82 Introductions to air conditioner system

821 Working principles and layout of air conditioner system
1.1 Heating system
Heating system of air conditioner of loader-digger is composed of engine, heater valve, heater water
pipe, evaporator and joint etc.
Circulating cooling liquid of engine is used as heat source. After drawn from engine, circulating
cooling liquid enters heater core of air conditioner system and return to heat sink after circulated by
heater core. Fan blows over heater for heat exchange constantly. Hot air is released via air outlet
and circulated constantly, thus achieving the purpose of heat supply for cab.
Evaporat
Heater valve
Heater water pipe
Engine
Enter the cab – hot air
Engine circulating water
Heater
core
Return to engine
Return air of cab – cold air
Fig.8-1 Heating principle
8-2
1.2 Cooling system

With cooling agent absorbing a lot of latent heat in cab when changing from liquid state to
gaseous state while passing through evaporator during circulation in the system and bringing
such heat to condenser via compressor for release rapidly, which is then blown to external air
by fan, cooling system of loader achieves the purpose of reducing indoor temperature of cab. It
can be divided into five processes below:
1. Compression process: compress low-temperature and low-pressure cooling agent in gaseous
state flowing through evaporator into high-temperature and high-pressure cooling agent in
gaseous state and transmit it to condenser.
2. Condensation process: cool high-temperature and high-pressure cooling agent in gaseous state,
change it into medium-temperature and high-pressure cooling agent in liquid state and transmit
it to drying bottle.
3. Drying process: filter medium-temperature and high-pressure cooling agent in liquid state,
remove foreign matters and moisture in cooling agent, transmit it to throttle valve and store a
small part of cooling agent.
4. Expansion process: transform filtered medium-temperature and high-pressure cooling agent in
liquid state into low-pressure vaporific liquid/gaseous mixture with throttle principle and
transmit it to evaporator.
5. Evaporation process: low-pressure vaporific liquid/gaseous mixture flows to evaporator,
absorbs surrounding heat and vaporizes, thus achieving the purpose of cooling. Then, it is
inhaled via low-pressure intake-tube of compressor and circulates constantly in this way.
Temperatur
e controller Expanding
panel valve
Evaporator
Condenser
Layout of air conditioner system Fig.8-2 Cooling principle Liquid

Compressor
CompressorLayout
belt of B876F air conditioner system shown as below: storage pot
Fig.8-2 Cooling principle
8-3
822 Control principle of air conditioner

2.1 Control principle of fan
Air flow switch:
Power air flow switch is a three-way rotary switch. Control power supply is cut off in position “0”
and switched on in other positions. Air flow of fan is corresponding to low, medium and high states.
Fig.8-4 Air flow switch

High grade of fan
Fuse Red Red
Positive pole of main power
High grade of fan

Negative pole of main power
Power line High grade control line of fan
Medium grade control line of fan
Brown Low grade control line of

High grade of fan fan
Yellow
Medium grade of fan
Green Coil control of
Low grade of fan relay
High grade control
White
line of fan
Refrigeration control
Speed regulation
resistance
Positive pole of sensor relay
White Evaporation
Motor Defrost sensor
Air Sensor ground
conditioner Purple
controller Refrigeration output Diode
Green Red/black Black Speed

regulation
/black Black resistance
Fresh air control Fresh air control
output output
Input of Grey
refrigeration Purple
indicator light Black Black
Purple Blue
Low- and high-pressure
switch of air conditioner Condens
ation
motor
Electromagnetic clutch of
compressor
Black
Black
Bonding
Fig.8-5 Schematic diagram of high grade
8-4
Medium grade of fan

Fuse Red Red


Yellow
Medium grade of fan
High grade control
White
line of fan
Speed regulation
resistance
White Evaporation
Air Sensor ground
conditioner Purple

regulation
output output
Input of Grey
Purple Blue
ation
motor
compressor
Black
Black
Bonding
Fig.8-6 Schematic diagram of medium grade

Low grade of fan
Fuse Red Red


Yellow
Medium grade of fan
Low grade of fan High grade control
relay
White
line of fan Refrigeration control
Speed regulation
resistance
White Evaporation
Air Sensor ground
conditioner Purple

regulation
output output
Input of Grey
Purple Blue
ation
motor
compressor
Black
Black
Bonding
Fig.8-7 Schematic diagram of low grade
8-5
2.2 Working principle of air conditioner system

When rotary temperature detect switch is turned to a position and refrigeration indicator light is on,
it means that refrigeration starts. Temperature sensor detects cab temperature. When the
temperature decreases to that required, indicator light goes out and compressor stops work. At this
time, indoor temperature of cab is the temperature set. When indoor temperature is higher than this
temperature, indicator light is on, compressor starts up automatically and the system starts
refrigeration. When indoor temperature is lower than this temperature, indicator light goes out and
the system stops work.
Fig.8-8 Temperature detect switch

Fuse Red Red


Yellow
Medium grade of fan
High grade control
White
line of fan
Speed regulation
resistance
White Evaporation
Air Sensor ground
conditioner Purple

regulation
output output
Input of Grey
Purple Blue
ation
motor
compressor
Black
Black
Bonding
Fig.8-9 Schematic diagram of air conditioner
8-6
2.3 Control principle of fresh air
Fresh air change-over switch:
Control the running of fresh air executor and control the internal and external air circulation. The
fresh air and recirculated air inlet are controlled by the air door motor at the ventilation device. And
the control panel is on the right panel in the cab.
Fig.8-10 Fresh air change-over switch

Fuse Red Red


Yellow
Medium grade of fan
High grade control
White
line of fan
Speed regulation
resistance
White Evaporation
Air Sensor ground
conditioner Purple

regulation
Fresh air control /black Fresh air control Black resistance
output output
Input of
refrigeration Grey
Purple
Purple Blue
ation
motor
compressor
Black
Black
Bonding
Fig.8-11 Schematic diagram of fresh air
8-7
823 Matters needing attention in air conditioner installation and use

1. To extend service life of air conditioner system, it is recommended to operate air conditioner
for once or twice each month in seasons when air conditioner is not used. Each operation
should last for 15 to 20 minutes. It can be operated with the use of hot air in winter.
2. Steps for correct startup of air conditioner system: shut down air flow switch of evaporating fan
and turn refrigeration knob to position 0 before engine startup; first turn on air flow switch of
evaporating fan and adjust refrigeration knob after engine startup.
3. For types with air conditioner filter element, filter element shall be cleaned periodically
according to working conditions. When air volume decreases obviously, filter element must be
cleaned. When air volume still decreases obviously after filter element is cleaned, it is
recommended to replace filter element.
4. To guarantee refrigeration performance of air conditioner, condensation core shall be cleaned
periodically and condenser shall be kept clean so that it can exert the best heat dissipation
performance.5. Cooling agent shall be filled by specialized persons according to specified
technological requirements.
6. B876F loader-digger has a reserved adding interface of air conditioner and optional air
conditioning module matched with the machine for users to choose.
7. When adding air conditioner system, it is required to use the reserved power interface. It is
prohibited to change the original circuit privately.
8. A sealing element is installed at the interface of pipeline of new fluid reservoir, which cannot
be removed before pipeline connection to avoid failure of drying agent which will influence the
life of air conditioner system.
9. For replacement of parts during maintenance of air conditioner system, it is required to try to
avoid disassembly of pipeline and release of refrigerant. When a part can be repaired, it is not
recommended to replace the part; when a secondary part can be replaced, it is not
recommended to replace the assembly. Maintenance and replacement of parts shall be operated
in strict accordance with technological requirements. Non-standard process for replacement of
parts will cause secondary potential failure.
8-8
83 Routine inspection on air conditioner system

Main inspection methods:
Check with hand touch whether the temperature of each part is normal.
Check leakage position and surface condition with eyes.
Judge working conditions of the system through liquid mirror.
Check electrical components with the method of circuit disconnection and connection.
Check whether there is any abnormal sound or smell with eyes and nose.
Inspection time
Inspection item Inspection contents Every

Daily half a Yearly
year
Poor fixation and gap √ √

Tube assembly
Loosening of junction and nut and bolt √ √
Loosening of junction and loosening and √ √

Connecting bolt
split of nut and bolt
Loosening and bending √ √
Driving belt Degradation: abrasion, scar and cracking √ √
Noise, peculiar smell or abnormal heating √
Radiating fin lodging √

Condenser assembly
Blockage with foreign matters (such as √ √ √
garbage, dust and worm grass)
Startup check, air flow and switch control √ √

Air flow switch of air
conditioner
Switch function √ √
Leakage at pipe junction √ √
Cooling agent leakage Internal leakage of parts and components √

(compressor, condenser, evaporator and
receiver-drier)
Check dose of cooling agent (observe √ √

Dose of cooling agent
liquid window)
Compressor (including that without load) √

Noise
Condenser fan, evaporator fan √
8-9
Temperature Existence of temperature difference shows √

difference of fluid blockage of dryer
reservoir
8-10
84 Maintenance guide of air

conditioner system
841 Basic process
Discharge refrigerantreplace parts and add refrigerant
oilvacuumizeadd refrigerantdebugging and
operation
842 Refrigerant discharge of system
low-pressure end (L) 1. Confirm that rotary switch of pressure gauge is
high-pressure end (H) in OFF state.
2. Connect pressure gauge and refrigerant filling
port. Connect red pipe joint of pressure gauge to
蓝红 high-pressure end (H) and blue pipe joint to
low-pressure end (L).
3. Discharge refrigerant: rotate the knob of high
and low pressure sides of pressure gauge slowly
and make refrigerant discharged via yellow pipe
of pressure gauge in gaseous state.
Attention: refrigerant shall not be
discharged in liquid state. Wear gloves for operation
Coupling end of vacuum pump, filling to prevent hand frostbite.
end of refrigerant, discharge end of
refrigerant
Fig.8-12
843 Removal of pipeline or pressure
switch
1. If it is necessary to remove pipeline or pressure
switch, it shall be guaranteed that no refrigerant
is in the system before removal. If refrigerant
exists, pressure gauge shall be used to discharge
refrigerant.
2. If it is required to remove pipeline or pressure
switch for the replacement of parts, the whole
replacement process shall be clean without
pollution and prevent system pollution.
3. When the part for replacement connects to pipe
joint or pressure switch, check whether O ring is
intact. If it is damaged, it shall be replaced with a
new one.
Attention: O ring special for R134a system must
be used. Its material shall be hydrogenated nitrile
rubber (H-NBR).
Special O ring. Material: hydrogenated

nitrile rubber (H-NBR)
Fig.8-13
8-11
4. When fluid reservoir is replaced, pipeline shall
be connected according to the arrow.
Refrigerant inlet end shall be connected to the
pipeline at condenser end and refrigerant outlet
end shall be connected to the pipeline at
evaporator end.
Attention: the arrow in the left figure
indicates the arrow of refrigerant flow.
Evaporator condenser
Fig.8-14
Fluid reservoir 844 Refrigerant oil
1. Refrigerating machine oil shall be supplemented
for the system when evaporator, condenser, fluid
reservoir and pipeline are replaced.
Attention: the model of refrigerating

machine oil is PAG100. It is prohibited to use
refrigerating machine oil of other models.
Pipeline Supplemental amount

Replaced component
of refrigerant oil (ml)
Evaporator 30
Condenser 70
Fluid reservoir 30
Steam pressure pipe 30
Condenser
Pressure cooling pipe, cold
storage pipe and steam 10
storage pipe
Fig.8-15 2. Replace compressor

3. Discharge refrigerant oil in the faulted
compressor and measure the volume of
refrigerant oil.
(Discharge refrigerant oil 100ml)
Fig.8-16
8-12
4. Discharge refrigerant oil in the new compressor

and refill refrigerant oil. Oil volume is that in
the faulted compressor.
Fig.8-17
5. Refill 10ml in the new compressor

(100+10=110ml).
Fig.8-18
Low-pressure end (L) 845 Refrigerant filling method
High-pressure end (H)
Attention: the following is refrigerant
filling method of air conditioner system without
Blue Red refrigerant.
1. Vacuumize the system
a) Connect pressure gauge and refrigerant filling
port. Connect red joint of pressure gauge to
high-pressure end (H) and blue joint to
low-pressure end (L).At this time, rotary switch
of pressure gauge is in OFF state.
b) Connect yellow pipeline of pressure gauge and
Connecting pipe of vacuum pump vacuum pump.
Fig.8-19 Pressure gauge c) Switch on the power of vacuum pump, then
open the rotary switch of pressure gauge and
vacuumize for 25 to 30 minutes on high and
low pressure sides at the same time.
d) Pressure maintaining. Maintain pressure for 5
to 10 minutes and check pressure change. If
pressure changes obviously, find the leakage
point. If it does not change, continue to
vacuumize.
Attention: during pressure maintenance,

first shut down rotary switch of pressure gauge and
8-13
then close vacuum pump.
e) Vacuumize again. First open vacuum pump and
then switch on the knob of pressure gauge.
Vacuumize again for 15 to 20 minutes on high
and low pressure sides at the same time. If
ambient humidity is high (rainy days etc.),
extend the time for vacuumization for 20 to 30
minutes.
f) Maintain pressure again. Shut down rotary
switch of pressure gauge and close vacuum
pump. Maintain the pressure for 5 minutes.
Attention: failure to vacuumize in strict

accordance with the required time will cause
residual moisture in the system and system failure
such as fluid reservoir failure and ice blockage of
evaporator.
2. Refrigerant filling of system

a) After completion of vacuumization, remove
yellow pipeline of pressure gauge from vacuum
pipe and connect refrigerant tank.
Attention: refrigerant model is R134a. It is

prohibited to fill refrigerant of other models.
Unqualified refrigerant will cause critical damage
of the system.
Recommended brand of refrigerant: Xi’an Jinleng.
Blue Red b) Switch on discharge knob of yellow pipeline so

as to spray some refrigerant and discharge air in
yellow pipeline.
c) Open the rotary switch at high and low pressure
ends of pressure gauge so that refrigerant is
sucked up into air conditioner system under the
action of negative pressure.
Discharge knob connecting to
refrigerant filling
Fig.8-20
Blue Red d) When pressure display of pressure gauge has

no change, shut down rotary switch at
high-pressure end.
e) Start up engine, start air conditioner system and
adjust air flow switch and cooling knob to the
maximum. Pay attention to observe whether
Shut down the knob at high-pressure compressor clutch is working under the
end condition of actuation and whether condensate
Fig.8-21 fan works normally.
8-14
f) Switch on the rotary switch at low pressure end

Blue Red of pressure gauge so that refrigerant is sucked
up into air conditioner system from low
pressure end.
g) After completion of filling of the first tank, shut
down the rotary switch of pressure gauge,
replace refrigerant tank and continue to fill
refrigerant from low pressure end. Each time
Switch on the knob at low-pressure when a new tank is replaced, operation b must
end be repeated.
Fig.8-22 h) Observe the flowing status of cooling agent
through liquid mirror in the process of
refrigerant filling. When liquid mirror shows
reduction to a few bubbles (clear and
countable), cooling agent is enough.
Attention: after engine startup, it is

prohibited to fill refrigerant from high-pressure end.
3. Operation debugging.
Start up and operate air conditioner system and
guarantee that the system has no leakage and
operates normally.
8-15
85 Common fault diagnosis and troubleshooting of air conditioner

system
During fault examination and maintenance of air conditioner system, it is required to find out the
reason for abnormal work according to abnormal phenomenon of operation of air conditioner and
then take repair measures. Common faults of air conditioner system are refrigeration failure,
inadequate refrigerating capacity and discontinuous working of the system.
Refrigeration failure of system
After engine startup, diesel engine works with idle operation. Turn change-over switch to
refrigeration position, temperature detect switch to maximum refrigeration position and fan switch
to H (high-speed) position. After stable operation of air conditioner system for 2min, there shall be
cold air blown from air outlet. Otherwise, the following inspection shall be conducted:
Whether circuit fuse of air conditioner is blown, circuit is shorted out, each connector clip has a
good contact, evaporator fan and compressor clutch work, temperature switch is turned on and
relay has actuation.
Whether high- and low-pressure switches on fluid reservoir are faulted; work scope of switch:
high pressure up to 2.65MPa and low pressure up to 0.20MPa. When system pressure is too
high, high-pressure switch acts; or when there is no cooling agent in the system, low-pressure
switch acts. Cut off working power supply of clutch and judge whether high- and low-pressure
switches are faulted. High- and low-pressure switches can be shorted out. If clutch has
actuation and the system starts work, it indicates that high- and low-pressure switches are
faulted and should be replaced.It is not allowed to make high- and low- pressure switches
work shorted out for a long time during inspection; otherwise, it might damage the whole
system.
When driving belt of compressor is too loose, compressor belt shall drop by 14-20mm under
110N pressure. During adjustment, first screw down and rotate nut till the appropriate tight
force of belt is achieved.
Attention should be paid to the following during use and maintenance of compressor:
1. Air inlet and outlet of compressor must be installed upward. The allowable angle of
deflection is less than 45゜.
2. Connecting hose of the system should be fixed tightly and cannot contact with
high-temperature components so as to avoid hose damage.
There is no cooling agent in refrigeration system. When cooling agent leaks seriously, high- and
low-pressure combination meter can be used for detection. If high and low pressures are very
low, no cold air will be blown even if compressor works.
When air temperature is 32-37゜ and rotating speed of compressor is 1800-2000r/min, normal
pressure of the system is
Pressure of high-pressure gauge is 1.27-1.52MPa.
Pressure of low-pressure gauge is 0.12-0.15MPa.
Find out the leakage point of refrigeration system with cooling agent leak detector and take
corresponding treatment measures and then vacuumize refrigeration system and fill cooling
agent.
When refrigeration system is blocked off by dirt and cooling agent cannot flow, thus losing
refrigeration function, low pressure of high- and low-pressure combination meter has vacuum
indication and high pressure is on the high side. Such case mostly occurs in fluid reservoir or
expansion valve. Disposal method: replace fluid reservoir or expansion valve.
When system compressor is damaged and high temperature and high-pressure cooling agent
cannot be discharged, high- and low- pressure combination meter indicates almost equal high
and low pressures. Disposal method: replace compressor or disassembly it for repair.
Attention should be paid to the following during troubleshooting of refrigeration system:
8-16
1. Try to wear protective glasses or protective mask during troubleshooting. Wear gloves to
prevent cooling agent from splashing on skin and causing frostbite of skin.
2. Shut down diesel engine first and then connect high- and low- pressure combination meter
to compressor for detection.
3. Do not touch high-temperature and motion parts of diesel engine.
4. When system components are replaced, system joint and inner chamber should be kept
clean. Before pipeline installation, refrigerating machine oil should be applied on seal ring
of joint. When pipe joint is screwed down, it is required to use torque spanner. For
tightening torque, see the table below. When system parts and components are replaced,
refrigerating machine oil should be supplemented.
Inadequate refrigerating capacity of system
Condensation effect is poor. There are oil contamination and dirt on condenser. Foreign matters
might influence outward heat dissipation of condenser. When high- and low-pressure
combination meter is used for detection, it shows that high and low pressures are very high. It is
required to clean condenser and remove foreign matters. When condenser is cleaned, attention
should be paid not to damage the fin of condenser.
Evaporating fan of evaporator has a small air volume and cold air volume will be very low.
Cool air is inadequate. It is mainly because that there are obstructions in air flue, which make
air inlet and outlet not unblocked.
Cooling agent in refrigeration system is inadequate. When high- and low-pressure combination
meter is used for detection, it shows that high and low pressures are on the low side. Bubble
writhe can be observed through liquid mirror of liquid reservoir. Cooling agent should be
supplemented.
Excessive filling of cooling agent makes evaporating temperature increase. Some cooling agent
must be released.
If air exists in refrigeration system, when high- and low-pressure combination meter is used for
detection, it shows that high and low pressures are on the high side. Condenser temperature is
high and heat dissipation effect is poor. Cooling agent must be discharged and the system
should be vacuumized. Cooling agent should be refilled.
Warm-water electromagnetic valve is damaged. During refrigeration, warm-water
electromagnetic valve should be closed when not connected to power. Water pipe is warm with
hand touch and discharging tube has normal temperature. After warm-water electromagnetic
valve is damaged, both water inlet and discharging tube are warm with hand touch.
Refrigeration and heating in evaporator work simultaneously and refrigeration effect is poor.
Warm-water electromagnetic valve should be replaced.
Self discontinuous working of refrigeration system
The main reason for self discontinuous working of refrigeration system is that moisture exists
in refrigeration system. A small number of moisture freezes at expansion valve and causes
blockage, thus causing system to stop work and work again after ice melts. After refrigeration,
moisture freezes again at expansion valve. Recirculation causes self discontinuous working of
the system.Troubleshooting method: first release cooling agent, replace liquid reservoir and
vacuumize refrigeration system in dry environment. The time for vacuumization is relatively
longer. First vacuumize for 30min and maintain pressure for 30min; then vacuumize for 30min
again and finally fill cooling agent.Circuit has poor contact. Electricity is in intermittent
state. Circuit should be checked carefully.
Matters needing attention during troubleshooting of air conditioner system
1. When air conditioner system works, it is prohibited to close all air outlets, which will cause
air-out failure of system.
2. Foreign matters easily blocking air inlet such as cotton yarn, waste paper and plastic film
cannot be placed in the cab. Serious blockage of air inlet and failure of ventilation will
8-17
cause system apparatus failure and might even cause fire breakout of system apparatus.
3. Cooling agent should be discharged from low pressure side. Good ventilation of work site
should be guaranteed so as to prevent suffocation accident of personnel.
4. Liquid inlet and outlet of liquid reservoir should have right connection; otherwise, the
system will fail in refrigeration.
8-18
Common fault diagnosis and troubleshooting

Troubleshooting
S.N. Fault phenomenon Fault reason
method
Poor contact of
connector clip
Damage of air flow
switch, relay and cold
1 Fan not rotating Repair or replace
and hot switch
Fuse blown or
inadequate pressure of
storage battery
Obstruction on suction
side. Rib plate of
2 Normal operation of fan evaporator and Clear
condenser blocked by
dust.
Circuit disconnection
and poor contact cause
the failure of
compressor clutch in
actuation. Repair
Belt tightening device
of belt is loose or split.
Repair
Compressor not rotating or difficult in Belt is too loose.
3
operation Coil of compressor
clutch is broken and out Replace attract coil.
of operation. Discharge or fill
High- and low-pressure cooling agent
switch of liquid
reservoir acts and
cooling agent is too
much or too little.
Cooling agent leakage Resolve the problem

of leakage and
4 Inadequate cooling agent Too little cooling agent supplement cooling
filled agent
When air temperature is 32-37゜ and rotating
speed of compressor is 1800-2000r/min, normal
Measure high pressure and low pressure pressure of the system is
according to readout of high- and Pressure of high-pressure gauge is
5 low-pressure meter. 1.27-1.52MPa.
Pressure of low-pressure gauge is
0.12-0.15MPa.
Low pressure is Frost on the surface of Expansion valve Replace expansion
8-19
on the high side low pressure pipe opening too large valve
Poor contact of thermal Install thermal bulb
bulb of expansion valve correctly
Excessive cooling agent Discharge some
in the system cooling agent
Use leak detector to
find the leakage
Pressure indicated on Vibration causes
point, screw down
low-pressure meter loosening of pipe joint,
the loose part
lower than the normal leakage and inadequate
carefully and
value cooling agent.
supplement cooling
agent as specified.
Low-pressure rubber Empty the system,
Pressure indicated on
tube blocked or replace liquid
low-pressure meter is
expansion valve with reservoir and refill
sometimes negative.
ice blockage cooling agent.
Low pressure is
on the low side Temperature controller Replace temperature
Evaporator freezing
failure controller
Inlet side of
expansion valve is Expansion valve Clean or replace
cool and attached by blocked expansion valve
frost
Outlet side of
Sensitive heating pipe
expansion valve is not
and thermal bulb of Replace expansion
cool. Pressure on
expansion valve with air valve
low-pressure meter is
leakage
sometimes negative.
Empty the system,
Air conditioner Air in air conditioner vacuumize again,
system system maintain pressure and
fill cooling agent
Discharge a certain
amount of cooling
Excessive filling of Excessive filling of
agent and make
High pressure is cooling agent cooling agent
cooling agent in the
on the high side system moderate
6
Clean condenser and
remove foreign
Poor condensation Poor condensation matters.
effect of condenser effect of condenser Check and replace
damaged condensate
fan
Vibration causes Use leak detector to
High pressure is Pipeline
loosening of pipe joint, find the leakage
8-20
on the low side leakage and inadequate point, screw down
cooling agent. the loose part
carefully and
supplement cooling
agent as specified.
Low pressure is Low-pressure pipeline Clean or replace
sometimes negative. blocked and damaged pipeline
Compressor and
high-pressure pipe not Compressor failure Replace compressor
hot
7 Poor refrigeration effect Stop valve damaged Replace stop valve
8-21
Flow chart of common breakdown maintenance of air conditioner system

Abnormal refrigeration
system
Check air outlet of evaporator
Small air flow or no air at air outlet Normal air flow at air outlet
Check fan motor of evaporator Check rotation status of

compressor
Fan motor not rotating Fan motor rotates but air flow is small Normal rotation of compressor Compressor not rotating or rotating abnormally
Check filling amount of cooling

Check as per agent
Check as per Check as per item
item one in the item two in the three in the table
table table
Normal or excessive cooling agent Inadequate cooling agent
Check as per item

Check system pressure four in the table
Abnormal system pressure Normal system pressure
Check as per Check as per

item five in the item six in the
table table
8-22
Seervice Man
nual for Bacckhoe Load
der
Coonten
nts
9 W m........................................................................................................................ 1
Working Hydrraulic System
91 Introduction g hydraulic ssystem .......................................................................................... 1

n to working
9111 Schemaatic diagram

m for workingg hydraulic system
s .............................. ...................................... 1
9112 Layoutt of working hydraulic syystem ..................................................... ...................................... 2

2
92 Hydraulic system at thee loading end

d .................................................................................................... 3
3
9221 ..................... ...................................... 3

Layoutt of hydraulic system at tthe loading end................
e
9222 m for hydraullic system att the loading end ............. ...................................... 4
Schemaatic diagram 4
9223 ng valve ............................. .............................................................. ...................................... 4

Loadin 4
9224 Workin nt of hydraullic system at the loading end ............................... 5

ng pressure measuremen
m
9225 Measurrement of oill cylinder setttlement ................................................ ...................................... 6

6
93 Hydraulic system at thee excavating end............................................................................................... 7

7
9331 ng end ............................... ...................................... 7

Layoutt of hydraulic system at tthe excavatin 7
9332 Excavaating valve ........................ .............................................................. ...................................... 8

8
94 Outrigger hydraulic

h sysstem ................................................................................................................... 9
9
9441 Layoutt of outriggerr system ...... .............................................................. ...................................... 9

9
9442 Rotatioon-outrigger valve .......... .............................................................. .................................... 100
95 Auxiliary hyydraulic systtem .................................................................................................................. 122
9551 y hydraulic ssystem .................................................... .................................... 122

Layoutt of auxiliary
9552 d valve .......... .............................................................. .................................... 13

Two-stage solenoid
I
Seervice Man
der
96 Attentions for

f repairing
g of hydrauliic system .................................................................................... 144
97 Fault diagnosis and trou

ubleshootingg of hydraulic system ................................................................ 155
9771 Buckett falling ............................. .............................................................. .................................... 15
9772 Boom sinking

s .............................. .............................................................. .................................... 166
9773 om ............... .............................................................. .................................... 177

Slowly lifting of boo
9774 y of boom..... .............................................................. .................................... 200

Lifting incapability
9775 Slow movement

m of bucket......... .............................................................. .................................... 200
9776 Movem
ment incapab ket .......................................................... .................................... 200
bility of buck
II
Seervice Man
der
9 Work
king
Hydrau
H ulic S
System
m
91 Introdu
uction to working
w g
hyd
draulic system
s
911
1 Schem matic diagram
m forr
worrking hydraulic ssystem
Fiig. 9-1 Scheematic Diaggram for Wo

orking Hydrraulic Systeem
9-1
Seervice Man
der
912
2 Layo
out of woorking hydraulicc
system
Fig. 9--2 Layout oof Working Hydraulic System

S
1. Right opperating mechanism asssembly at thhe excavatin ng end
2. Left opeerating mechhanism asseembly at thee excavatingg end
3. Operatinng mechanissm assemblly at the loaading end
4. Outriggeer cylinder operating
o mechanism
m 55. Auxiliary
y hydraulic system
9-2
Seervice Man
der
92 Hydrauulic sysstem at
a thee
ading end
loa d
921
1 Layouut of hyd
draulic system
s att
the loading end
e
Fiig. 9-3 Layo

out of Hydrraulic Systemm at the Loading Systeem
1. Operatinng mechanissm assemblly at the loaading end 2. Loading vaalve
3. Boom cyylinder 4. Scoop
S cylind
der
9-3
Seervice Man
der
922
2 Schem matic diagramm forr
hyd
draulic sy
ystem at the loadiing end
The workinng pressuree of hydraulic system att the loadin
ng end is 22.5Mpa and tthe schemaatic diagram
m
is shown as below:
Fig. 9-4 Schematic Diagram ffor Hydraullic System at

a the Loadiing End
923
3 Load
ding valvee
The loadinng valve maainly consissts of valve body, four--in-one cyliinder slide vvalve link, boom slidee
valve link, main overfflow valve and two-waay overload d fill valve and
a so on. T Three slide valve linkss
are conneccted in series.
Filller port Connnection posiition
To small ccavity of fou
ur-in-one
A1
cylinder
To big caavity of four-in-one
B1
cylinder
To bigg cavity of scoop
s
A2
cylinder
To smaall cavity off scoop
B2
cylinder
To smaall cavity off boom
A3
cylinder
To bigg cavity of boom
b
B3
cylinder
9-4
Seervice Man
der
9244 Work king pressuree

measurement of hyd
draulic system att
thee loading end
Oil temperature
t e: 45-55℃.
Presssure measu
uring tools:: pressure gauge
g withh
rang
ge of 40Mpa (40030000370)), T-jointt
(41220001850), pressuree measurring jointt
(40330000416),p
pressure measurin
ng pipee
(40330000368).
Presssure measu
uring standaard: 22.5Mp
pa
Presssure measuuring devicce: loading
g valve oill
inlett P.
Fig. 9-5 40030000370 Pressure

P Gaauge Presssure measuuring processs:
1. Drive the backhoe looader to th he repairingg
site, lower down the bucket on the groundd
and perform m parking brake to shut off thee
engine. Opperate the w working devvice handlee
for 3-5 tim
mes to relievve residual pressure off
hydraulic oil
o in the pippe.
2. Disassemble loading valve P1 pump inlett
pipe. Assemble T-joinnt 4120001 1850 at thee
disassembly position, connect th he test jointt
4030000416 and oil tuube disassembled withh
the T-joint..
Fig. 9-6 41120001850 T-joint
T 3. Connect on ne end of ttest hose with
w the testt
joint and the
t other eend with th he pressuree
gauge.
4. Start the enngine, operaate the buckket or boomm
cylinder att the loadinng end to the
t bottom,,
gradually do accelleration to o maintainn
continuous overflowiing of load ding valve,,
and observve the stablee pressure of pressuree
gauge.
5. After testting, repeaat step 1) pressuree
relieving step, ddisassemble T-joint,,
assemble the oil tubbe disassem mbled andd
Fig. 9-7 40030000416 test
t joint wipe the hyydraulic oil leaked.
Notte: To confirm
c acccurate meeasurement,,
meaasure the booom controll lever at th
he lifting orr
loweering positio
on repeateddly.
Fig. 9-8 40030000368 test

t hose
9-5
Seervice Man
der
925
5 Meassurementt of oil cylinderr
setttlement
Oil temperaature: 50±3 ℃.
Pressure measuring
m to ols: timer, meter
m ruler.
Measuremeent standardd:
Scoop cylin nder≤20mm m/h;
Lift cylindeer≤50mm/hh.
Measuring position: boom cy ylinder andd
bucket cyliinder.
Measuremeent process::
1. Load ratedd working m mass in the bucket andd
turn it overr, operate thhe boom cyllinder to liftt
the bucket to the maxximum posiition. Movee
the multi-wway valve tto the centrral positionn
and the enggine flames out.
2. Measure th he extensionn length off piston rodd
of boom cy ylinder andd bucket cylinder oncee
every 15m min and record thee data inn
correspond ding tables. T Total test tiime is 3h.
9-6
Seervice Man
der
93 Hydrau ulic sysstem at

a thee
exccavating end
9311 Layo out of hyddraulic system att
thee excavatiing end
Fig. 9-9 Layo

out of Hydrraulic System at the Ex
xcavating Ennd
1.Bucket ccylinder 2..Boom cylin
nder 3.Ouutrigger cyliinder 4. Rottary cylindeer
9-7
Seervice Man
der
932
2 Excavating vaalve
The excavvating valvee mainly consists of vaalve body, boom
b slide valve link,, arm slide valve link,,
scoop slidee valve linkk, main overrflow valve,, two-way overload
o filll valve and so on. The boom slidee
valve link and buckeet slide valve are connnected in series.
s The two and bbucket slidee valve aree
connected in parallel.
Filler port
p Coonnection position
p
To big cavity ofo boom
A1
1
cylindeer
T
To small cavvity of
B1
boom cylin nder
T
To small cavvity of
A2
2
bucket cyliinder
To bbid cavity of
o bucket
B2
2
cylindeer
T
To small cavvity of
A3
3
bucket cyliinder
Too big cavity of arm
B3
3
cylindeer
CP
P Too clamping cylinder
c
CT
T Oil return tank
Fig. 9-100 Schematicc Diagram fo

for Hydrauliic System att the Excavaating End
9-8
Seervice Man
der
94 Outrigg
ger hydraaulic sysstem
941
1 Layo
out of outtrigger sy
ystem
Fiig. 9-11 Lay

yout of Hyddraulic Systeem at the Ex
xcavating E
End
1. Hydraaulic lock 2. Cylinder
9-9
Seervice Man
der
942
2 Rotattion-outrrigger va
alve
It mainly cconsists of valve body y, rotary slidde valve lin
nk at the ex
xcavating ennd, left outrrigger slidee
valve, righht outrigger slide valve link, main overflow valve
v and tw
wo-way oveerload fill valve and soo
on. Three sslide valve links
l are co
onnected in sseries.
Before opeeration at thhe excavatin
ng end, be suure to lowerr down the outrigger.
o
Filler port Coonnection position

p
Too big cavity of left
A1
1
ooutrigger cyllinder
T
To small cav vity of
B1
1 left outrig
gger
cylinder
T
To big caviity of
A2
2 right outriggger
cylinder
T
To small cav vity of
B2
2 right outriggger
cylinder
To left rottary
A3
3
cylinder
To right rootary
B3
3
cylinder
Fig. 9-122 Schematicc Diagram fo

for Hydrauliic System att the Excavaating End
9-10
Seervice Man
der
9-11
Seervice Man
der
95 Auxiliarry hydraaulic system

951
1 Layo
out of auxxiliary hydraulic
h c
system
Fig. 9-1
13 Layout oof Auxiliary
y Hydraulic System
1 Cylinder 2 Two-stage so
olenoid valvee
9-12
Seervice Man
der
952
2 Two--stage sollenoid va
alve
Fiig. 9-14 Sch

hematic Diaagram for Tw
wo-stage So
olenoid Vallve
Item Param
meter
Rating
g pressure 50Bar
Ratin
ng flow 16L/m
min
Voltage scope DC9V~

~16V
Using
U
tempperature -30℃-1
105℃
sccope
Fig. 99-15 Two-sstage Soleno

oid Valve
9-13
Seervice Man
der
96 Attentio
ons forr repairring off
draulic system
hyd s
1 Avoid filling hydraullic oil, repllacing filterr
or repairing the machhine in rainy or windyy
weather and dusty placce.
2 Disassembly and reepairing off hydraulicc
device sh hould be done in dust-freee
workshop and the peerformance should bee
appraised by
b special teesting devicce.
3 Pay attentio on to sealinng opening.
4 It would bee better to cchange oil when
w the oill
is hot. Whhen changinng the oil, try t to drainn
the old oil.
5 When disassemblingg or assem mbling thee
hydraulic device
d or cchanging oil, flush thee
pollutant, oil sludge and old oil in thee
hydraulic oil
o by the fflushing oil. In normall
condition, flush
f it for ttwo times: firstly
f flushh
it with flusshing oil and then fllush it withh
specified hydraulic oill.
6 In the disasssembly andd maintenan nce processs
of hydrauliic system, ffasten it as per torquee
required inn this manuual. Too biig or smalll
torque may y cause leakkage of hydrraulic oil.
7 Before repairing thhe hydrauliic system,,
relieve thee pressure in the systtem as perr
following steps:
s
(1) Start the machine
m annd drive it to flat andd
vast groun nd, lift thee boom to maximum m
position an
nd lean backk the buckett.
(2) Slowly pussh the handdle rightward to makee
the bucket bend forwaard slowly to drain oill
ket cylinder..
in the buck
(3) After the bucket rottates to th he position,,
slowly pussh the handdle forward d to slowlyy
lower the boom
b and drain oil inn the boom m
cylinder. Flatly put thee bucket onn the groundd
and move thet control lever left an nd right forr
5-6 times to relievee oil pressure in thee
system.
9-14
Seervice Man
der
97 Fault diaggnosis andd

oubleshooting
tro of ydraulicc
hy
sysstem
971
1 Buck
ket fallingg
Fauult phenomenon: Wheen the control lever iss
in th
he middle, th he bucket w
will automattically bendd
forw
ward, which means buck cket droppinng.
Fauult analysiss: When thhe bucket is i retractedd
and the handle is in the m middle, due to the deadd
weigght of buccket, the bbig cavity of buckett
cylinnder is under pressuree. At this timme, as longg
as thhe pressuree oil in thee big cavity y is leakedd
relattively to the filler pport, the bucket
b mayy
autoomatically leean forwardd.
Fauult cause:
1 Pipe faultt: Obviouss external leakage off
pipe, joint and mounnting surface from bigg
cavity of bucket cyylinder to multi-wayy
valve.
2 Cylinder fault:f In caase of internnal leakagee
of bucket cylinder, the small cavity off
bucket cylinder corrresponding to returnn
opening is also subjectt to leakagee.
3 Multi-way y valve faultlt:
 The buckeet reversingg valve slid de valve off
multi-way valve fails tto return to the middlee
position, so
s the sm mall cavity of buckett
cylinder an
nd P port, biig cavity an
nd filler portt
of multi-waay valve aree connectedd.
 Too low overload pressure of buckett
cylinder biig cavity ooverload vaalve on thee
multi-way valve.
 Leakage off make-up vvalve of biig cavity off
bucket cyliinder.
 Excessive abrasion of reverssing valvee
element or valve openning causes that the fitt
clearance between
b vallve elementt and valvee
opening exxceeds the ddesign valu ue, resultingg
in pressuree oil leakagge of buck ket cylinderr
big cavity.
Fauult detection n and troubbleshooting g
1 Check the pipe leakaage: Start th he machine,,
lift the booom to certaain height, retract thee
bucket to maximum position, observeo thee
pipe, joint and mountting surfacee and so onn
from big cavity off bucket cylinderc too
multi-way valve foor obvious externall
leakage.
2 Judge the oil cyllinder forr internall
leakage: operate
o the handle to lower thee
9-15
Seervice Man
der
boom to thhe lowest poosition, lean
n the buckett
back to thee maximum m position, shut
s off thee
engine andd disconnectt the small cavity hosee
of bucket cylinder
c annd draw it back
b to thee
hydraulic oil
o tank. SStart the machine andd
operate thhe handle to lean the t buckett
backward and obserrve whetheer there iss
hydraulic oil
o continuouously overfloowing from m
the big cav
vity filler poort of bucket cylinder..
If so, it means
m seriouus internal leakage off
bucket cy ylinder. Dissassemble, repair orr
replace thee cylinder. If there is no internall
leakage of cylinder, mmake furtherr judgment.
3 Judge wheether the ovverload va alve and oill
makeup area
a damaaged: do accceleration,,
operate thee handle too lift the boom, andd
observe wh hether the ppressure gauuge readingg
reaches thee design vallue in the boom
b liftingg
process. Iff not, disasssemble and d clean thee
overload valve
v or mmake-up vaalve of bigg
cavity of bucket
b cyliinder. Use a pressuree
gauge witth range oof 40Mpa with thee
pressure port
p of biig cavity of buckett
cylinder. Start the engine, operate
o thee
handle and d leave thee bucket att maximum m
forward position,
4 Check whether the m multi-way slide valvee
is broken n: If the aabove cond ditions aree
eliminated,, the buckeet still may y drop off,,
stop the machine
m andd lower the boom andd
bucket to the lowest position, disassemble
d e
the bucket slide valvee of multi--way valve,,
and carefullly check thhe matching g conditionn
of valve rood and valvve opening. Excessivee
abrasion off reversing vvalve elemeent or valvee
opening caauses that thhe matching g clearancee
of valve eleement and vvalve openiing exceedss
the design value, ressulting in pressure
p oill
leakage of big cavity oof bucket cyylinder.
972
2 Boom
m sinkingg
Fauult phenomenon: Wheen the control lever iss
in thhe middle position,
p thhe boom au utomaticallyy
loweers down, exceeding
e tthe sedimen
nt standardd
of cyylinder.
Fauult analysis:: When the boom is lifted up andd
stop
pped at anyy height, duue to dead d weight off
boom m, the big
g cavity off boom cy ylinder hass
corrresponding oil pressuree. At this time,
t if thee
presssure oil of
o big cavvity leaks to returnn
openning, the boom
b mayy automaticcally lowerr
dowwn.
9-16
Seervice Man
der
Fau
ult cause:
1 Pipe faultt: Obviouss external leakage off
pipe, joint and mounnting surface from bigg
cavity of booom cylindeder to multi-way valve.
2 Cylinder fault:
f In caase of internnal leakagee
of boom cy ylinder, thee small caviity of boom
m
cylinder coorrespondinng to return opening iss
also subjecct to leakagee.
3 Multi-way y valve or hhandle faultt:
 The boom reversing vvalve rod off multi-wayy
valve cannot return, soo that the big cavity off
boom cylin nder and ppump inlet, big cavityy
and return opening aree connected d.
 Excessive abrasion off multi-way y reversingg
valve elemment or valvve opening causes thatt
fit clearan
nce betweenn valve ellement andd
valve open ning exceeeds the dessign value,,
resulting inn pressure oil leakagee in the bigg
cavity of booom cylindeder.
Fau
ult detectionn and troubbleshooting g
1 Check the pipe leakaage: Start th he machinee
and lift thhe boom too maximum m position,,
observe wh hether therre is obviou us externall
leakage of the pippe fitting, joint andd
mounting surface
s and so on from m big cavityy
of boom cy ylinder to mmulti-way vaalve.
2 Judge wheether the ooil cylinderr is leaked::
Lift the boom to thee maximum m position,,
shut off the engine and open the smalll
cavity of boom
b cylindder to draw
w it back too
the hydrau ulic oil tank
nk. Start the machine,,
operate th he handle, lift the boom,b andd
observe whether
w theere is hyd draulic oill
overflowinng continuoously. If so o, it meanss
internal leakage oof boom cylinder,,
disassemble, repair or replacce the oill
cylinder. Iff there is nno internal leakage off
nder, make further anaalysis.
the oil cylin
3 Judge the multi-wayy valve fault: Lowerr
the boom and buccket to th he bottom,,
disassemble the booom valvee rod off
multi-way valve andd carefully check thee
matching condition
c off valve rod
d and valvee
opening.
973
3 Slowly lifting of boom
m
Fau ult phenommenon: At rated speed d of diesell
engiine, operatee the handlee to keep th
he time forr
liftin
ng the booom from thhe lowest position too
max ximum posiition longerr than stand dard liftingg
timee.
Fau ult analysiis: As peer characteristics off
9-17
Seervice Man
der
hydrraulic poweer elements,, the reason n for slowlyy
liftin
ng of boom is that the fflow from pump p to thee
hydrraulic oil cyylinder is inssufficient.
Fau ult cause:
 Serious extternal leakaage of joint, pipe, valvee
and matching surfacee, etc. from m the pumpp
mouth to big cavity off boom cylin nder.
 There is mu uch bubble in the hydrraulic oil orr
it’s blackeening and deteriorated d seriouslyy
and loses viscosity.
v
 For the reasons like oil filter blockageb orr
rubber fallling in the oil suction pipe, oill
suction pippe blockage,, etc. the oil suction off
working pu ump is inssufficient, resulting
r inn
insufficientt output flow w of workin ng pump.
 Serious intternal leakaage of worrking pumpp
causes insu ufficient outtput flow.
 Serious internal leakagge of boom cylinder.
 Too low pressure
p of main safetty valve off
multi-way valve.
 Serious internal leakagge of oil in nlet line andd
oil return liine of multii-way valve body.
 Excessive abrasion off reversing valve stem m
or valve op pening of m multi-way valve
v boom,,
so the fit clearance
c beetween valv ve core andd
valve opening exceedss the design n value.
 Insufficientt opening o f multi-way y valve rod.
Fau ult detection n and troubbleshooting g
1 Check the externall leakage: Start thee
machine an nd lift the bboom, obserrve whetherr
there is seerious exterrnal leakag ge at joint,,
pipe, valvee and matchhing surfacee, etc. from m
the pump mouth to big cavity y of boom m
cylinder.
2 Check thee oil: If therre is extern nal leakage,,
make basicc inspectionn. If the hydrraulic oil inn
the fuel taank is aboove the miinimum oill
level, theree is much airr bubble or blackeningg
of hydrauliic oil, etc.
3 Check the sound: Juddge if the hy ydraulic oill
is normal anda start thhe engine, and a operatee
the handle to retract thhe bucket anda load thee
hydraulic system.
s Meaanwhile, paay attentionn
to that whether there is squeal sound s from
m
the working g pump, if sso, it meanss serious oill
suction inssufficiency of working g pump. Att
this time, check
c the ooil filter an
nd oil hose,,
etc.
4 Check thee internal leakage of o workingg
pump: wh hen no squeeal is heard from thee
working pu ump, operaate the hand dle to keepp
9-18
Seervice Man
der
the pump load
l for 1-22 minutes, shut
s off thee
engine and touch the w working pum mp shell byy
hands carefully. If thee working pump shelll
is hot, it means
m seriou
ous internal leakage off
working pump,
p resuulting in insufficientt
output floww.
5 Test the pressure:
p U
Use a pressure gaugee
with range of 40M MPa to co onnect thee
pressure po ort of multi--way valve P, start thee
machine, operate
o the handle, co ombine thee
pressure of hydraulicc system, observe
o thee
pressure gauge
g and check whether
w thee
reading reaches the design pressure. If itt
fails to reeach the de design presssure, makee
following inspections.
i .
6 Test the in nternal leakkage of cylinder: startt
the machin ne and operaate the hand dle to lowerr
the boom to lowest poosition, lean n the buckett
back to thee maximum m position, shut
s off thee
engine and d open thee big cavitty hose off
boom cyliinder to dr draw oil baack to thee
hydraulic oil
o tank, andd then start the engine,,
operate thee handle too lower the boom andd
observe wh hether the bbig cavity fluid
fl port off
boom cy
ylinder hhas hydrraulic oill
overflowin ng. If at this time,, there iss
hydraulic oil overflow wing contiinuously, itt
means serious internnal leakagee of boom m
cylinder. Disassemble
D e the oil cylinder
c forr
repairing or replacemeent.
7 Check main safety vaalve: Disassemble andd
clean main n safety valvve. At this time, if thee
valve elemment or valvee opening is i deformedd
to unrecov verable statee, replace main
m safetyy
valve.
8 Check thee multi-waay valve: After A abovee
attempts, the
t system pressure still fails too
reach the design preessure, it’s suggestedd
disassembling the bboom valv ve rod off
multi-way valve, andd carefully check thee
matching condition oof valve body, b valvee
rod, valve hole and vvalve stem m and valvee
opening.
9 When the hydraulic
h syystem pressure reachess
the design value, the boom is sllowly liftedd
and the faultf is nnot eliminaated, makee
following detections
d aand eliminatte faults:
Opeerate the handle
h to llower the boom andd
buckket to the loowest part, open the en nd cover att
the end of mu ulti-way val alve boom slide valvee
with
hout spring g, axially m move the valve rod,,
9-19
Seervice Man
der
obseerve whetheer the movem ment distan
nce of valvee
rod is abnormal and wheether the returning
r iss
flexiible.
Exch hange the guide
g pipe oof control buucket valvee
rod with the gu uide pipe oof control boom
b valvee
rod, start the machine,
m opperate the handle andd
obseerve whetheer the boom m is lifting properly.
p Iff
normmal, disasseemble and clean the boomb valvee
blocck of handlee.
974
4 Liftin
ng incapaability off boom
Fau ult phenomeenon: Undeer rated speed of diesell
engiine, the control lever liifts up the boom
b at fulll
loadd, but the bo
oom can’t bee lifted up.
Fau ult analysiss: The mosst direction n reason off
liftin
ng incapabiility of booom is that th he pressuree
in biig cavity off boom cylinnder is too low.
l
Fau ult cause:
The main safeety valve overload pressure p off
multti-way valve is too low w.
The working pump sufffers seriou us internall
leakkage, so thatt the systemm is unable to build upp
presssure or reacch the settinng value.
Serious internall leakage off boom cylin nder.
Therre is seriou us internal leakage between
b oill
inlett and oil return
r wayy of multi--way valvee
body y, so that the
t system is unable to t build upp
presssure or reacch the settinng value.
Fau ult detectionn and troubbleshooting g:
Mainly focus on the aabove four points too
elim
minate the fault
fa of booom lifting in ncapability..
Refeer to “slow wly lifting of boom”” for faultt
deteection and ellimination.
975
5 Slow movemeent of bucket
Refeer to slowly
y lifting of bboom for analysis
a andd
solu
ution.
976
6 Moveement incapabiility off
buccket
Refeer to the lifting
l incap
apability off boom forr
anallysis and sollution.

9-20

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Service Manual for Backhoe Loader B876F

880*1230 mm 16-mo 18 printed sheets

Shandong Lingong Construction Machinery Co., Ltd.

1 General ......................................................................................................... 1-1

2 Engine System ............................................................................................... 2-1

3 Electrical and Information System ................................................................ 3-1

4 Introduction to Transmission System ............................................................ 4-1

5 Brake System................................................................................................. 5-1

6 Steering System ............................................................................................ 6-1

7 Tires, Frame and Working Device ................................................................. 7-1

8 Cab and Air Conditioner System ................................................................... 8-1

9 Working Hydraulic System ............................................................................ 9-1

Rubbers and Plastics ............................................................................................................ 21

operator shall ensure that own operation method

Safety during Handling of

instructions of Operation and

Some Simple Safety Rules

medicine, or other drugs.

Mounting and Dismounting

• Check the handrails and pedals, and if there

Figure 2 Access of Machine

During Running of Engine

When Leaving Operator’s Seat

Safety Rules during Repair and

Before any Repair or Maintenance

Loading Arm Asafety Lever

the machine slowly until the safety

injury, accident, or destruction of the

Operation Safety of Tires

Installation of Tire and Wheel rim

Repair of Tires and Wheel Rims

Operation Safety of Battery

electrolyte will probably leak out.

Start with Booster Battery

Operation Safety of A/C

Whenever it’s necessary to break up the A/C

Personal Protection Devices

under low concentration.

Measures in event of Accident:

Flush the eyes with warm water, till the irritation

Handling Safety of Oils

Safety of Hydraulic System

Fire Prevention Measure

to stop the engine.

shield, and high power air pre-cleaner) must

Welding and Grinding

Checking after Fire Accident or

Health Hazard of Paints, Plastics,

Working on Painted Surfaces

Rubbers and Plastics

Load and unload the Machine

Transportation on the Ground

• Notices for lifting:

hazardous wastes. The disposal must be

Engine oil and Fluids

Engine oil and Fuel