4180 Service Manual

Service Manual
CLG4180 Grader
Applicable type and model: CLG4180

Contents
错误！超链接引用无效。错误！超链接引用无效。 ..........................................
1-1
错误！超链接引用无效。错误！超链接引用无效。 .............................................
4-1
Drive System................................................ 5-1
Hydraulic System ......................................... 6-1
Electrical System.......................................... 7-1
A/C System .................................................. 8-1
Frame System.............................................. 9-1
Work Implement ......................................... 10-1
Cab System................................................ 11-1
1-1
Machine Information
1. Overview ..........................................................................................................1-2
1.1 Standard recommended torque......................................................................................1-2
1.2 Unit conversion table......................................................................................................1-4
1.3 Use and main technical parameters of machine ............................................................1-5
1.3.1 Use and working environment requirements........................................................1-5
1.3.2 Main technical parameters ...................................................................................1-6
1.3.2.1 Figure of overall dimensions ........................................................................1-6
1.3.2.2 Machine parameters ..................................................................................1-10
1.4 Transportation of the machine .....................................................................................1-13
1.5 Hoisting of the machine................................................................................................1-14
1.6 Removal process for grader service ............................................................................1-17
1.6.1 Removal process for grader service...................................................................1-17
1.6.2 Specific removal process and instruction ...........................................................1-17
2. Safety .............................................................................................................1-21
3. Service ........................................................................................................... 1-36
3.1 New vehicle running-in.................................................................................................1-36
3.2 Regular service ............................................................................................................1-37
3.3 Tyre inflation pressure..................................................................................................1-39
3.4 Pressure release ..........................................................................................................1-40
3.5 Technical specifications to Lubricating oil ....................................................................1-40
3.6 Important service programs .........................................................................................1-42
1-2
1. Overview
1.1 Standard recommended torque
1. Overview
1.1 Standard recommended
torque
Bolts involved in this machine shall be fastened in
accordance with the torque requirements specified
in the following table, unless special declaration.
Standard Thread Torque in Metric System
Standard Torque (N⚫m)

Thread size
Grade 8.8 strength Grade 10.9 strength
M6 10.5±1.5
M8 26±4
M10 52±7 72±6
M12 90±12 120±10
M14 145±20 195±15
M16 225±35 305±25
M18 310±45 415±35
M20 410±50 600±50
M22 600±80 800±70
M24 760±100 1020±100
M27 1100±150 1500±100
M30 1500±200 1850±150
M33 2050±300 2900±400

M36 2650±350 3100±250
In general, the required torque for tightening grade Standard Thread Torque in British System
10.9 will meet the tightening requirements of grade
12.9. Thread size Standard torque (N⚫m)
5/16 25±7
Standard Thread Torque in British System
3/8 45±7
Thread size Standard torque (N⚫m)
7/16 70±15
1/4 12±4
1/2 100±15
1-3
1. Overview
1.1 Standard recommended torque
Standard Thread Torque in British System Pipe Thread in British System
Thread size Standard torque (N⚫m) Thread Torque of knurled nut

(N⚫m)
9/16 150±20
G1/4"X19 25-28
5/8 200±25
G3/8"X19 41-48
3/4 360±50
G1/2"X4 72-82
7/8 570±80
G5/8"X14 96-110
1 875±100
G3/4"X14 124-137
Standard torque of nut for hose coupler G1"X11 151-165
Metric Thread G1.1/4"X11 192-206
G1.1/2"X11 261-275
Thread Torque of knurled nut
(N⚫m) G2"X11 343-357
M12X1.5 10-20
M14X1.5 20-35 JIC Thread in American System

M16X1.5 25-40 Torque of knurled nut
Thread
M18X1.5 30-45 (N⚫m)
M20X1.5 35-50 7/16"X20 15-16
M22X1.5 40-70 1/2"X20 19-21
M24X1.5 40-70 9/16"X18 24-28
M26X1.5 60-100 3/4"X16 49-53
M30X2.0 80-120 7/8"X14 77-85
M36X2.0 100-150 1.1/16"X12 107-119
M42X2.0 150-220 1.3/16"X12 127-140
M45X2.0 180-250 1.5/16"X12 147-154
M52X2.0 200-300 1.5/8"X12 172-181
1.7/8"X12 215-226
Pipe Thread in British System 2.1/2"X12 332-350

(N⚫m)
G1/8"X28 11-12
1-4
1. Overview
1.2 Unit conversion table
American Standard ORFS Thread

American Standard ORFS Thread
Torque of knurled nut (N⚫m)
Thread
(N⚫m)
1.7/16"X12 125-135
9/16"X18 14-16
1.11/16"X12 170-190
11/16"X16 27-27
2"X12 200-225
13/16"X16 43-47
1"X14 60-68
1.3/16"X12 90-95
1.2 Unit conversion table
Name Unit Conversion Unit Conversion Ratio
Inch (in) Millimeter (mm) 25.4
Length Millimeter (mm) Inch (in) 0.03937
Foot (ft) Meter (m) 0.3048
Meter (m) Foot (ft) 3.28084

2 2 6.4516
Square Inch (in ) Square centimeter (cm )
Area
Square centimeter (cm2) 2 0.1550
Square Inch (in )
UK gallons (gal) Liter (L) 4.54609
Liter (L) UK gallons (gal) 0.219969

Volume
US gallons (gal) Liter (L) 3.78541
Liter (L) US gallons (gal) 0.264172
Liter (L) cubic decimeter 1
Pound (lb) Kilogram (kg) 0.453592

Mass
Kilogram (kg) Pound (lb) 2.204622
Pound· inch (lbf ·in) N·mN⚫m 0.112985

Torque
N·mN⚫m Pound· inch (lbf ·in) 8.85075
1-5
1. Overview
1.3 Use and main technical parameters of machine
Name Unit Conversion Unit Conversion Ratio
Pounds per square inch Bar (bar) 0.06895

(psi)
Bar (bar) Pounds per square inch 14.5038

(psi)
Pounds per square inch

MPa 0.006895
Pressure (psi)
Pounds per square inch
MPa 145.038
(psi)
MPa Bar (bar) 10
Bar (bar) MPa 0.1
Pascals (Pa) Bar (bar) -5

10
Bar (bar) Pascals (Pa) 5
10
Foot per second (ft/s) Meter per second (m/s) 0.3048
Speed
Meter per second (m/s) Foot per second (ft/s) 3.28084
UK gallons per minute

Liter per minute (l/min) 4.54609
(gal/min)
UK gallons per minute
Flow (gal/min)
US gallons per minute
(gal/min)
US gallons per minute
(gal/min)
5/9*(Fahrenheit degree
Fahrenheit degree ℉ Celsius degree ℃
Temperature ℉ -32)
Celsius degree °C*9/
Celsius degree ℃ Fahrenheit degree ℉
5+32
1.3.1 Use and working environment requirements

Use: this grader is used to level road surface and reshape road section and embankment. It is used to level
roads, squares, etc. This grader is a common construction machine, therefore it is not used in the presence of
flammable and explosive hazard, excessive dust and toxic gas.
Work conditions: (1) Altitude: ≤ 3,048 m
(2) Ambient temperature: -15 ℃ to 40 ℃ (no extra or auxilary cooling start device)
(3) Fording depth: ≤ 430 mm
1-6
1. Overview
1.3.2 Main technical parameters
1.3.2.1 Figure of overall dimensions

Figure of overall dimensions (standard)
1-7
1. Overview
Figure of overall dimensions (optional: front blade）

1-8
1. Overview
Figure of overall dimensions (optional: rear ripper）

1-9
1. Overview
Figure of overall dimensions (optional: front blade and rear ripper）

1-10
1. Overview
1.3.2.2 Machine parameters
Main technical parameters

Machine weight kg 15500
Front wheel kg 4650
Rear wheel kg 10850

Parameters of the
Max. traction (wheel kN 86
machine spin)
Ground pressure of kg ≥ 7800
blade
Minimum turning radius mm 7800
Diesel engine Dongfeng Cummins 6BTAA5.9-C190
Rated power kw 142
Rated revolution speed rpm 2200
Number of cylinders In-line 6 cylinder
Cylinder diameter X mm 102 × 120

Engine system stroke
Total displacement of
L 5.9
pistons
Max.torque N.m 800N.m/1500r/min
Torque reserve 30%
Specific fuel consump-

g/kw.h 235
tion (stand test)
Fuel 0# or 35# light diesel oil
Fan diameter mm 762
Type ZF 6WG200
Torque converter Model Single turbine 3 elements
Torque ratio 2.15
Cooling method Air-cooling pressure circulation type
Type ZF 6WG200
Gearbox Model Counter shaft power shift
Gearshift 6th gear forward, 3rd gear reverse

1-11
1. Overview
Main technical parameters （Continued）

Transmission oil
Working pressure MPa 1.6 － 1.8
pump (gear pump)
Forward VI gear km/h ≥ 43.4
Forward V gear km/h ≥ 29.7
Forward IV gear km/h ≥ 22.5

Highest speed at dif- Forward III gear km/h ≥ 14.2
Forward II gear km/h ≥ 11.6

ferent gears
Forward I gear km/h ≥ 7.2
Backward I gear km/h ≥ 7.2
Backward II gear km/h ≥ 14.2
Backward III gear km/h ≥ 29.7

Main transmission mode Bevel gear reduction
Differential and final
drive Super gear and planetary gear speed
Wheel speed reduction mode
reduction.
Model 4WD
Drive shaft and
Tyre 17.5-25
wheels
Tyre air pressure MPa 0.35
1-12
1. Overview
Main technical parameters

Brake pump MICO
Service brake (foot-operated braking Wholly hydraulic shoe brake
Brake oil pressure MPa 10 ± 0.3
Opening pressure of MPa 12.3 ± 0.35

charge valve
Shut-off pressure of MPa 15 ± 0.35
charge valve
Brake system Low pressure alarm
pressure of service MPa 11.5
brake
Accumulator air pre- MPa 9.2
compression
Parking brake and emergent brake Manual and electric disc types
Oil pressure of the sys-

MPa 15
tem
Low pressure alarm
pressure of parking MPa 3.5
brake
Accumulator air pre-
MPa 9.2
compression
Model Load sensing metering pump
Nu,ber of steering cylin-

Steering hydraulic der--internal radius X mm 2- φ 32 × 275
distance
system
Working pressure of the
MPa 15 － 17
system
Steering angle ° 45°±1°for both left and right sides
Working pump Permco gear pump
Working hydraulic Multiple valve husco
system Max. flow L 126L/2200r/min
Max. working pressure MPa 18

of the system
1-13
1. Overview
1.4 Transportation of the machine
Main technical parameters （Continued）

Length × width × thick-
mm 3,960 × 610 × 19
ness
Blade Max. lifting height of the mm 450
blade
Max. shovel depth of the mm 555
blade
System voltage V 24
Electrical system Battery 2 － 6 － QW － 120T

Bulb voltage V 24
Diesel engine start Start at 24V
Fuel L 270
Hydraulic oil L 186
22 (Actual amount of oil filling according

Oil fill capacity Crank case L
to oil-ruler scale)
45 (Actual amount of oil filling according
Transmission system L
to oil-ruler scale)
Worm box, rear axle and 85 (Actual amount of oil filling according
L
tandem to oil-ruler scale)
Warm wind
Working medium Engine cooling liquid
Cooling volume kilocalorie/ 5,000

Air conditioning sys- hour
Cold air
tem
Working medium R12A
kilocalorie/
Cooling volum 3,500
hour
System voltage V 24
1.4 Transportation of the placed onto the transportation vehicle cannot

exceed those stipulated in the local relevant rules.
machine Before the loading, remove ice, snow or other slip-
Before the transportation, find the details about the pery matters on platform and vehicle. This will help
passage height, width and permissible load. The to prevent slip during the loading and the movement
total height, width and weight after the machine is during the transportation.
1-14
1. Overview
1.5 Hoisting of the machine
Caution: observe national laws and local regulations

on height, width, length and weight during the load-
ing and transportation. If the machine is transported
to the place of cold weather, please ensure that
there is appropriate anti-freeze fluid the cooling sys-
tem.
⚫ Before the loading and transportation, use
wedges to secure the wheels of trucks or trail-
ers (the figure shows a trailer).
⚫ Cover the opening of the air emission device to

avoid the rotation of the turbocharger like a
windmill during the transportation and prevent
the damage to the turbocharger.

Warning: Inappropriate hoisting and fastening will
cause the load to move and lead to death. Install
⚫ When the machine is moved on to a truck or a frame locking devices before the hoisting.
trailer, direction change is prohibited in the pro- ⚫ Please refer to the"main technical parameters"
cess. section for the Machine weight. There should
⚫ After the machine is successfully loaded, use be the calculation of the Max. carrying capacity
the frame locking devices to fasten the front of the crane and the hoisting rope to ensure the
and back frames. hoisting safety.
⚫ Lower all working devices to the floor of the ⚫ The four hoisting ropes of the hoisting device
transportation vehicle, and change the gearshift should be of the same length to ensure the
operation handle to the empty gear. equal forces to the four hooks.
⚫ Press down the parking brake button, and con- ⚫ There should be the hoisting point marks on the
nect the parking brake device. front and back frames of the machine.
⚫ Shut down the engine, shift all switches to cen-
tral positions or "OFF" position, and pull out the
key to the starting switch.
⚫ Close and lock all doors, take out the key.
⚫ Swift the negative switches of power supply to
the shutdown position.
⚫ When use a truck or trailer transports the
machine, use wedges to secure its wheels and
use steel wire ropes to fasten the machine to
avoid movement during the transportation.
1-15
1. Overview
lifting ring
lifting ring
Before the hoisting, use the frame locking devices

to fasten the front and back frames to avoid the
movement of the machine.
Caution: the machine must be at the position of right
ahead.
⚫ The hoisting device should be stably fastened
to the hoisting lugs with hoisting marks on the
machine.
Schematic diagram of hoisting complete
machine:
1-16
1. Overview
Warning: Inappropriate hoisting may cause the

deflection of the machine and lead to death and
damage.
1-17
1. Overview
1.6 Removal process for grader service
1.6 Removal process for grader 1.6.2 Specific removal process and
service instruction
1. Complete machine positioning
1.6.1 Removal process for grader Lift the blade as and ripper as to the highest
service point, lower the Work implement to the lowest
point.
Removal steps of complete machine
Lay position fo complete machine
Hood removal
Removal of rear drive shaft
Drain and removal of fuel tank
Removal of oil cooler
Removal of hydraulic tank as
Removal of cab as
Removal of engine as
Removal of rear counterweight
Removal of blade or front counterweight
Removal of blade lift cylinder and blade swing cylinder
Removal of work implement as Note: If only remove blade cylinder and its hydraulic
lock, ripper cylinder and its hydraulic lock, left and
Removal of front axle as right lift cylinder and their hydraulic lock, and swing
cylinder and its hydraulic lock, lower the blade as,
ripper as and Work implement as to the lowest
Removal of hinge as
point.
Removal of rear axle as 2. Removal of engine hood

Remove according to "9.6.3 Hood Removal
Steps" section.
1-18
1. Overview
4. Draining and removal of fuel tank

Remove according to "4.4.2 Removal and
Installation of Fuel Supply System" section.
3. Removal of rear drive shaft

Installation of Rear Axle Drive Shaft" section.
5. Radiator removal
Installation of Radiator As".
6. Removal of hydraulic oil tank as

Remove according to "6.3.1.2 Removal and
Installation Steps of Hydraulic Oil Tank".
1-19
1. Overview
7. Removal of cab as 9. Removal of rear counterweight

Remove according to "11.4 Cab removal" sec- Remove according to "9.5.2 Removal Steps of
tion. Rear Counterweight".
8. Removal of engine as 10. Remove of blade and front counterweight

Remove according to "4.6 Removal and Instal- Remove according to "10.3.1 Removal Steps of
lation of Engine As". Blade Body As" section and "9.4.2 Removal
Steps of Front Counterweight" section.
1-20
1. Overview
12. Removal of work implement

Remove according to sections of "10.2.1 Steps
of Separating Work implement As from Front
Frame", "10.2.3 Steps of Separating Blade As
from Work implement-Skel" and "10.2.5
Removal Steps of Work implement-Skel".
11. Removal of blade lift cylinder and circle

sideshift cylinder
Remove according to "6.3.10.2 Removal and
Installation Steps of Left Blade Lift Cylinder"
section and "6.3.14 Circle Side shift Cylinder"
section
Note: If only remove worm box or blade, remove
them from the complete machine directly.
13. Removal of front axle as

Installation of Front Axle
1-21
2. Safety
Note: Only the connecting pin between front axle

and front frame needs to be removed from the com-
plete machine, other parts can be removed from the
2. Safety
complete machine directly.
Safety warning decals
14. Removal of articulated hitch
Safety warning sign/mark will appear on the
Remove according to "9.3.2 Removal of Articu-
lated Hitch” machine, safety sign, manual or any other important
safety informations. If the decal appeared, you
should obey the instruction in the safety information,
and guard for the possibility of personal injury or
death.
Words on safety sign

Words on safety sign such as "danger", "warning" or
"caution" appeared on the machine shall have the
following definitions:
DANGER
Danger: this word means danger will occurred
immediately, and if no avoidance, it may cause
15. Removal of rear axle as death or serious personal injury.
Installation of Steering Case and Chain Adjust- Warning
ment
Warning: this word means existing potential danger,
and if no avoidance, it may cause death or serious
personal injury.
1-22
2. Safety
Caution
Caution: This word means existing potential danger,
and if no avoidance, it may cause slight or medium
personal injury.
"Caution" is also used for reminding the safety
attentions of unsafe operation possibly causing per-
sonal injury. "Danger" represents the worst danger-
ous condition. Safety sign of "danger" or "Warning"
is set near the specified dangerous location. Gen-
eral notices is listed on the safety sign "Caution".
General notices for safety

Please read and be familiar with all safety rules to Do not wear loose clothes, jewelries or long hair.
avoid the occurrence of severe damage or even Because they may be drawn into the control system
death. or the mobile parts and lead to severe damage or
Only trained and qualified persons are permitted to even death.
operate and maintain the machine.
During the operation and maintaining the machine,

Before maintaining and repairing the machine, please wear the cap, ear cover and safety glasses
please hang the labels of "Do not operate" or similar of hard material as well as safety shoes, mask and
warnings on the starting switch or the operation gloves.
lever.
1-23
2. Safety
the irrelevant matters in place, such as the lunch

boxes and tool boxes.
Protect foreign matters from entering the compo-
nents of the system when to inspect the opened oil
tanks or water tanks. Please empty the clothes
pockets and move wrenches and nuts with great
care before the dismantling of the box.
Goggles, safety glasses or mask can protect your

eyes from the hazards of high-pressure fluid during
the service of the accumulator and the hazards of
flying debris generated during the work of the
engine and the operation of tools. Please wear the
protection mask when to dismantle and remove
spring, elastic parts or add acid to the battery.
Please wear the safety cap and goggles when to Learn about the gesture singles and the signal
conduct welding operations or use the welding gun
sources at the working site and only receive the sig-
for cutting.
nals from one person.
During the service of air conditioners and the device
that may contain the coolant air, keep away from
open fire or lighted cigarettes. The inhalation of the
flames or the smog of a lighted cigarette that con-
tacts the coolant may lead to death.
Never keep the service and repair solution in glass
containers.
Please observe relevant laws and regulations when
to dispose hazardous materials such as lubricant,
fuel oil, coolant, solution, filter, accumulator and
other materials.
Take great care during the operation of the cleaner.
Do not use flammable materials as the cleaner of
the parts, such as diesel oil, petroleum and other
Ensure all protection plates and covers of the inflammables.
machine are fasten to the machine. Normally, the
protection plates and covers are removed during the
service and repair of the machine. If there is any
damage, please repair it before the operation of the
machine.
Please ensure that there is no chip, greasy dirt, tool
or other matters irrelevant to the machine on the
machine, especially on the instrument panel. Put
1-24
2. Safety
the pressure provided by the grader to the working

devices may lead to the spouting of the hydraulic oil.
Please wear safety glasses and leather gloves
when to check leakages. Do not use the naked
hands to check the leakage but plate or paper plate.
Report all necessary repair work in a timely manner.

Persons without permission or authorization cannot
stay onto or around the machine.
It is prohibited to refit the machine without Liugong's
consent, and Liugong will not be responsible for the
aftermath due to refit. Even if the pressured liquid is leaked from a hole as
small as a pin hole, it may penetrate the muscles
Compressed air and lead to death. If spattered by the spouted high-
Compressed air may lead to personal injury. When pressure oil, please contact a doctor and take a
use the compressed air for cleaning, wear the medical treatment immediately.
mask, protection suits and shoes. Do not point the
compressed air to others or oneself. The com-
pressed air may penetrate the skin and lead to
severe injury or even death. The Max. pressure of
the compressed air for cleaning should be lower
than 0.2MPa.
High-pressure solution
Warning: When servicing or changing the pipes of
hydraulic system, you shall check the system pres-
sure had been released in order to prevent from
scalding by high-pressure oil. hydraulic oil under
pressure will damage your skin severely when it
spattered on you.
Take care when dismantle the hydraulic pipelines or
connectors. When the oil spouts, the released high- Safe disposal of waste liquid
pressure oil may lead to the continuous movement
Inappropriate disposal of waste liquid will endanger
of the hoses.
environment and ecology. Please observe local
Normally, before shutting off the hydraulic pipelines, laws and regulations when to dispose the waste liq-
place the relevant working devices in order and uid.
release the residue pressure from the pipelines.Oth-
erwise, when to dismantle the hydraulic pipelines,
1-25
2. Safety
It is mandatory and necessary to collect the liquid have a nameplate, or the words of the nameplate
spattered during the inspection, service, test, adjust- are missed and unable to be identified with the
ment and repair with containers. kinds, or if the steel seal marks are incomplete or
Before opening any fluid cavity or resolve the parts cannot be read clearly, or if there is defect with the
containing liquid, the proper container shall be pre- body and therefore cannot ensure safe use.
pared well firstly. The accumulator is only charged with nitrogen. It is
Use proper container when liquid draining. Do not prohibited to charge the accumulator with oxygen,
use the food or drink containers because they compressed air or other flammable air to avoid
maybe taken as drinks by others. explosion.
Slowly charge the nitrogen into the accumulator to
avoid the breakage of the capsule.
The air valve of the accumulator shall be mounted
upward vertically. The accumulator must be stably
fastened to the supporter. Do not use the welding
method to fasten the accumulator.
Do not drill the accumulator any time or carry open
fire or heat sources close to the accumulator.
Never conduct any welding operation on the accu-
mulator.
Since the accumulator is a high-pressure container,
it must be replaced and repaired by professional
operators.
Release the air before discarding the waste accu-
mulator.
Asbestos
If sucked in asbestos dust, it will endanger your
health. This product is not containing asbestos, and
Liugong Machinery Co. Ltd recommended to use
genuine Liugong spare parts. If materials that you
need to deal with containing asbestos fiber, please
abide by the following rules:
⚫ Never use compressed gas when cleaning.
Water can be used for descending the dust.
⚫ It can uses the vacuum cleaner with high filter-
ing properties.
⚫ Do not grind the materials containing asbestos
dust.
Battery application precautions ⚫ Please observe local laws and regulations
when to dispose asbestos.
High-pressure nitrogen, a dangerous article, is
⚫ Bath your body after contacted with asbestos.
mounted in the accumulator, therefore read the fol- ⚫ If required, it can uses effective protective
lowing requirements and properly use the accumu- mask.
lator.
The accumulator must be checked before the
charging of nitrogen. It is prohibited to charge the
accumulator with air if the accumulate does not
1-26
2. Safety
Make sure there's no foreign matters in the vanes of

Prevention of extruding or cutting off engine fan. Fan vanes will thrown or cut out the
Do not make your hands, arms or any other bodies tools and other things that dropped or pushed in it.
placed among the moving parts. e.g. between work Unless otherwise stated, any adjustment is not per-
implement and cylinder, between machine and mitted to be performed when machine or engine is
working implement. running.
Working under the work implement, you shall sup- If the repair procedure must be performed when
port the machine properly. Do not support the work machine running, do not let the machine in an unat-
implement depending on hydraulic cylinder. If con- tended status. Arrange one operator seated in the
trol mechanism moving or hydraulic oil line leaking, seat, and prepare to shut down the engine at all
it will cause the work implement drops. times.
If it is necessary to remove the shield, you must fix Do not use twisted or worn wire rope. Wear gloves
well the shield after the repair. when using and transporting.
For safety, you shall check all protectors, such as When forcing to extrude the bayonet, you shall
door, safety shield and hood, etc. to make sure they make sure no one standing around it. You shall
are correctly installed to avoid from the hurt caused wear safety goggles in order to protect you eyes.
by moving parts. E.g: revolving vane of engine has Knocking object with hammer, please make sure the
the risk of sharing the fingers, therefore shut down flying debris will not hurt others.
the engine or keeping a safety distance when ser-
vicing.If any door, hood and other protector dam-
Prevent burns
aged, it shall be repaired or replaced before
operating the machine. Running for some time, parts of the machine will
hot, and those parts shall be inspected or repaired
after cooled down.
Coolant
Under working temperature, the cooling liquid of the
engine has been pressed and at high temperature,
the radiator and all the pipes connected to the radia-
tor contain hot water or vapor, if you touch them,
serious burn would occur.
1-27
2. Safety
Remove the tank cover slowly to release the pres-

sure of hydraulic oil tank, averting scalded by hot oil.
Before all disassembling pipes, connector, or rele-
vant parts, relieve the system pressure.
Battery
The battery may generates flammable smog or air
that leads to explosion, therefore keep it away from
open air and sparkles.
Battery and electrode may contains lead, and do not
touch it with bare hands directly.Wash your hands
just after battery repair.
Do not smoke when inspecting the level of battery
electrolyte.
Electrolyte is a kind of acidic material, and please
During checking the cooling liquid level, the engine do not let your skin and eyes touched by electrolyte.
shall be closed down and the filler cap shall be Once touched, you should use water to wash it and
cooled to meet that it can be manually screwed off. timely to seek medical advice.
Slowly loosen the filler cap of cooling system to You shall wear safety goggles and glove when
release the pressure. inspecting battery.
Coolant contains alkali which may causing injury,
and do not make it contact with your skin, eyes and
mouth.
Oil
Hot oil and parts will cause personnel injury, and do
not make the hot oil and parts contacting with your
skin.
Protection for fire and explosion

All fuels, such as most of lubricants and some cool-
ing agent, are flammables.
Fuel leaks on the hot surface or electrical elements
may cause fire.
No smoking when refilling or within refiling area, and
Under working temperature, the oil tank is hot and the place storing flammables.
contains pressure.
When opening oil filler cap of hydraulic oil tank, the
engine shall be stopped, and cool the filler cap
down until it can be opened by bare hands.
1-28
2. Safety
Clean and tight all electrode connector. Daily Piping, pipe and hose
inspect the wire for loose or wear. Before start, Do not warp or knock the high-pressure pipe, and
make sure tighten the loosen power supply, and do not install the abnormally warped or broken pipe
repair or replace the worn electric wires. or hose onto the machine.
Scheduled inspect the electrical circuit to avoid from Repair the pipe and hose of loosen or broken fuel
overload or short circuit that will causing fire hazard. and lubricant circuit and hydraulic system in time.
Stored the fuel, lubricant into containers with rele- Leakage will cause fire hazard, and if you need
vant marks, preventing from operating and used by repair or replace, please contact the authorized
non-staff personnel. dealer by LiuGong Machinery Co., Ltd.
Put the cleaning cloth or other combustible materi- If following problems occurred, it shall be replaced.
als with oil impregnated into protective container, ⚫ Damage or leakage of connector.
and set at a safe place. Do not perform welding or ⚫ There is corrosion with the outer of the hose
flame cutting onto the pipe containing flammable liq- and the exposure of the reinforced steel wires.
uid. Before welding or cutting, the operation shall be ⚫ Local eminence of hose uplift
perform until it is cleaned by flammable liquid. ⚫ Obvious twist and flattening of the hose.
Accumulated combustible materials such as fuel, ⚫ Reinforced hose guide wire is embedded into
lubricant or junk on the machine shall be clean up. the outer layer.
Do not operate the machine near open fire. ⚫ Misplacement of the end connectors.
Make sure the battery is far away from open fire and Make sure all pipe clamps, guard board and heat
sparks, and do not smoke at the place of battery shield are installed, for preventing from shaking or
charing. overheating by friction with other parts.
Do not charge the frozen battery to avoid of explo- When removing the connecting pipe of the com-
sion. pressor, it is forbidden to be approached with open
fire, or it will generate toxic gas, and result in poi-
Diethyl ether
soning.No smoking when maintaining and servicing,
Warning: Ether is forbidden for starting machine otherwise, the generated toxic gas will burn the
Any attempt action of using ether to start the engine body or sucked by human, and it also cause per-
may cause serious damage of engine or personnel sonal injury and death.
injury or death.
Fire extinguisher and first aid kit
Fire extinguisher provided by the machine shall con-
form to the related local laws and regulations, and it
shall be maintained and improved for satisfying the
1-29
2. Safety
requirements. For more information, please contact

your local authorities.
You should know how to do when fire occurred or
human injured.
The construction site must have first-aid kit in stock.
regular inspection shall be performed, supple-
mented some medicines if required.
Selected some contacts of phone number (such as
doctor, first-aid center, fire station and so on) use for
communication in emergency. Paste the contact list
onto specified location to ensure all staff known that
the contact information and correct ways.
Tyre
service, removal, repair and install of tyre and hub
shall apply special tools and technology, therefore
the service and service shall be implemented by
tyre repair shop.
Inspect and maintain the fire extinguisher frequently.

Follows the recommended method of application
listed on the operation panel.
Prevention of injured by thunder

Never try to access the machine when lightning
near it.
If you seating in the cab while the thunderstorm
occurred, please keep inside the cab; and if you're Pneumatic tyre can explode due to the heating and
on the ground, please stand away from the the firing of its internal air. It is due to gas expansion
machine. or burning because of heating caused by rim heat-
ing or electric welding, external flame, or frequent
braking.
Power of tyre explosion is much bigger than that of
bleeding, the explosion will make the tyre, hub and
drive parts burst apart for 500m away, and the
explosive force and debris will cause personnel
injury and property loss.
Do not get close to the heated tires. Ensure the dis-
tance to the minimum extent (at least 15 meters).
1-30
2. Safety
(As shown in the figure) stand outside the shadow Do not use the attachments unauthorized by Liu-
area. gong. Using unauthorized attachments will cause
safety issues, adversing the normal operation of
machine and influencing its service life.It is forbid-
den to make any refit on the attachments without
permissions, otherwise all at your peril.
Liugong Machinery Co., Ltd will be not responsible
for the Injury, accident and damage of machine due
to using unauthorized attachments.
2. Operationsafety
Access the machine
Before getting of/off the machine, please clean the
oil dirt and mud on handrail or stairs. In addition,
broken parts shall be repair, and the loosen bolt
shall be tightened.
Only the place with handrail or stairs can be
It is suggested to inflate the tyre using dry nitrogen
gas(N2). If tyre already has inflated air, it is sug- accessed.
gested to use nitrogen for air pressure adjustment, When getting of/off the machine, you will face to the
and the nitrogen can be mixed with atmospheric machine, holding the handrail while stepping stairs,
gas. Tyre inflated with nitrogen can reduce the pos- to keep the three-point contact (two feet one hand
sibility of explosion due to nitrogen gas is noninflam- or two hands one foot).
mable.In the same way, nitrogen is helpful to
prevent from oxidation and rubber age deterioration
and corrosion of rim parts.
In order to prevent from over-inflation, it needs cor-
rect inflating device and operation trainings for the
application. Because of incorrect device or improper
applications, it may cause tyre or rim broken.
Incorrect tyre rim service will cause tire blow-out,
and such a explosive power will result in serious
death. Only trained personnel by proper tools and
procedures can maintain and service the tyre rim.
Precautions for attachments

It shall be installed and commissioned by qualified
personnel; the operator shall be trained, and his/her
It is prohibited to jump out from machine.
operation and service shall be performed strictly
according to the operation instructions for It is prohibited to get on/off the machine during oper-
attachments. ation.
When installing and using the spare attachment, Never serve the control lever as handrail for getting
please read related instructions, manuals and infor- on/off the machine.
mations about the attachments. Do not take tools or other things to climb up and
Incorrect installation or purchase of attachments will down the machine.
not only cause safety issues, but also have the neg- Before starting the engine
ative effect on service life and operation of the You shall inspect your machine carefully before
machine. working, and make all systems are in the good oper-
1-31
2. Safety
ation conditions. And dispel all other personnels

standing around your machine away from the work-
space.
Keep the stairs and handrail clean.Before getting on
the machine, please clear all dirt mud and tiny
sands stuck on your shoes.
Check if all structural parts and covering parts are
not damaged due to collision.
Check if all safety devices, such as door, guard
board, cover, etc., are installed properly as as to
prevent from damaging by moving parts, and if bro-
ken, please repair it in time.
Check if hydraulic system does not leak, and
inspect the hose, steel pipe is not worn.
Check if all fastener parts are not loosen or lost. Make sure operator is seated and fastened the seat
Check if electric wire harness is not worn or broken, belt securely, and then start the machine.
the fuse is in good condition, and the connector is
firmly fastened.
Check if the fluid level of engine and fuel system is
normal, and drain out the water and sediments from
oil-water separator. Discharge waste liquid accord-
ing to local regulations.
Replace all broken or lost parts, and necessary
lubricating work shall be done in accordance with
the lubrication point listed on schedule service table.
Purge all loose masses out of driver cab, because
the loose mass will affect the operation and result-
ing in accidents.
Make sure all windows are cleaned and the wipers
can work in normal.
Adjust the seat to appropriate position to make the Before starting the engine, please make sure that
operator seated comfortably and easy to operate the hydraulic operating lever is at the neutral posi-
the machine. Check if the anchorage of seat belt tion, and the speed change operation lever is at the
and safety belt is not damaged. Safety belt shall be neutral position.When starting engine, you shall
replaced after three-year's application. press the horn as a warning.
Make sure illuminating systems of machine is in nor-
mal operation, and the working site have sufficient
lighting.
Engine starting
If warning sign of "Do not operate" pasted on control
lever, then the engine shall be not started.
1-32
2. Safety
viding sufficient ventilation after windows and doors

opened, then you need to install a fan.
You shall start the engine only seated in the cab,

and it is forbidden to short circuit the starter motor to
start the engine. Such a operation will damage the Before operating machine
electrical system of machine through bypass start-
No one is permitted to stay on/around the machine,
ing system, and even personnel injury or death.
and please fasten the seat belt firmly.
Observe the instrument and warning indicator after
Make sure all windows, lampshade, reverse mirror
engine started, and make sure that they are in nor-
are clean, and fix the opened or closed window and
mal operation, and their readings are in working
door well.
range.
Adjust the position of rear view mirror for having the
Observe and listen carefully to the machine for any
best visual field from the operator's seat, especially
fault, if existing fault or abnormal condition, stop the
the filed near the machine.
machine immediately, and resolve the fault before
further operation. Clear all obstacles on the driving path of machine.
Take care for the high-voltage line, canal and other
dangers.
Make sure all the horns, backup alarm (if equipped)
and other warning devices can work normally.
Machine Operation
Learn about the Max. capacity and range of the
machine.
Engine exhaust will cause decease or death. If it is

necessary to start the engine in a closed or unventi-
lated place, you need to open the windows and
doors to guarantee the sufficient ventilation so as to
prevent from poisoning of gas. If it still cannot pro-
1-33
2. Safety
of the grade and make sure that the tyres will not
touch the blade when turning.
Start and operate the machine in a sitting position

with the wearing of safety belt. Operate the opera-
tion lever only when to start the engine. Prevent from working on the edge of cliff, under the
Before starting the machine, a driver should make dike or dump, and on the road surface with insuffi-
sure that nobody will be hurt.In case of extra seat, cient support capacities, or at the overhanging
safety belt and Roll Over Protection System objects, in order to avoid collapse.
(ROPS), the accommodation of a passenger is
strictly prohibited.
Before starting formal work, you should drive the

machine to a wide site, and check the working con-
dition of all control levers and protectors are normal.
If found out any item (such as noise, vibration,
smell, incorrect display of instrument, air and oil
leaks, etc) needed to be repaired during operation,
you should make a report for the item needing
repair immediately.
During driving, lift all working devices as high as
possible. The blade should be kept within the width
1-34
2. Safety
Avoid any condition that may cause machine roll-

over. Machine may roll over when working on hills,
banks or slopes. The machine might also roll over
when passing canals, dumps or other unexpected
obstacles.
The machine should work in straightly forward or
backward manner on a slope. Do not turn on the
slope or move in a crosswise way to avoid machine
roll-over.
When to work continuously in rain, remember that

the environment has changed, and therefore more
care are necessary.
Take more care when to work in snow or clean
snow, because even a small slope may lead to side
slide. When the snow is pushed to one side of the
grade, pay attention to the obstacles buried under
the snow.
If the machine starting side lapsing from slopes, you

shall unload materials and drive the machine down-
hill.
Do not slide at a neutral position when moving on a
descending slope. Alway take control of the
machine and use brake when necessary.
It is a must to know the rated working volume of the
machine. In work, if its working volume is exceeded,
1-35
2. Safety
this will not only damage the machine but also lead If to stop the machine on a slope, it is necessary to
to accidents. put wedges underthe wheels to avoid movement.
The machine only undertake the specified work, and And then lower the working devicesonto the ground.
if exceeded its serviceable range for other opera-
tion, it will damage the machine.
Pay more attentions to the works beside the high-
voltage line. When the machine existing in the work-
ing site where have the danger of contacting electric
cable, you shall consult the power company before
starting, and check the feasibility of the action
according to the current laws and regulations.
When towing, make sure trailers with sufficient
strength. Trailer only can connect to the towing bar
and hinges, and it is prohibited anyone stepping
across the steel wire or similar devices between
trailer and towed vehicle.
Operate the driving brake to stop the machine.

Move the speed change operation lever to the "neu-
tral" position.
Implement parking brake.
Turn the disconnect switch to the OFF position in
order to prevent from battery being damaged and
discharged due to the leakage of electricity from
some elements or short circuit of the battery.
Before leaving the machine, lower the blade, the
front earth mover and the rear earth loosener (if
equipped) onto the ground completely to conduct
parking brake. Lock all equipment with keys.
Remove the key and take it with you.
Before lifting, make sure no one is standing
between the machine and trailer. Traction frame or
traction pin of towing equipment shall centered align
and connect with the the towing bar on the machine.
Stop the engine
Do not shut down the engine immediately after its
working, because this will make the engine deterio-
riate,at a faster speed and have shorter service life.
Make the engine keep working for 5 minutes for
cooling down gradually.
Park the machine
The machine should be stopped on flat ground with
its working devices lowered on the ground. Because
there will be no hazard of stone drops or landslide. If
there is low terrain, there should be no hazard of Lower down the work implement when engine
flood. cut-out
1-36
3. Service
3.1 New vehicle running-in
Caution: For the machine equipped with electric- axles, hubs, parking brake, central shaft,
hydraulic control rod, the engine start switch shall hydraulic oil, engine coolant and oil. If there is
be placed at ON position in order to lower the work overheating, find out the reasons andeliminate
implement. After it lowered down, the start switch them.
shall be turned to OFF position. ⚫ Check the fastening of bolts and nuts of differ-
Move all control levers to the "Down" position so as ent parts.
to lower the work implement down onto the ground Conduct following operations after 8 hours of
or trailer. When the control lever released, they will the new vehicle running-in
return to the "Keep" position. ⚫ Check the fastening of different parts fully.
Especially the bolts of diesel engine cylinder
cover, the bolts of the air discharging pipes and
3. Service the captive bolts of front and rear axles, the
nuts of hubs, the connection bolts of transmis-
sion shaft, the captive bolts of diesel engine, the
3.1 New vehicle running-in captive bolts of transmission box, and the bolts
New vehicle running-in is of significant role to pro- at the hinge of the front and rear frames.
long the service life of the machine, eliminate poten- ⚫ Check the tightening grade of the fan belt,
tial failures and avoid the occurrence of great power generator belt and the belt of compres-
failures. Users should must conduct the operation sor of air conditioner.
and service of the machine in accordance with the ⚫ Check the oil level of the transmission box, driv-
new vehicle running-in instructions as stipulated in ing axle and diesel engine.
the Manual after purchasing the machine, and then ⚫ Check whether there is any leakage with the
use the machine normally. hydraulic system and braking system.
Requirements of new vehicle running-in ⚫ Check the connection and fastening of the
drawbars of all operation levers and accelera-
⚫ The new vehicle running-in period is 100 hours.
tors.
⚫ After starting, keep the machine idle away for 5
⚫ Check the temperatures and connection of dif-
minutes at first. The machine should start at a
ferent components of the electrical systems, the
steady and slow speed with small acceleration,
power supply of power generator, the lighting
and then its speed should be increased gradu-
and the working condition of turning signal
ally.
lamps, etc.
⚫ During the running-in period, there should be
even running-in of each gear composed of for-
ward I, II, III, IV, V and VI gears and backward I, Notes: please follow related operation
II and III gears. procedures and regulations when checking dif-
⚫ Except in the urgent situations, there should be ferent oil levels.
no sudden start, acceleration, turning or brak-
Conduct following work when the new vehicle
ing.
running-in completes:
⚫ During the running-in period, it is better to
scrape loose materials and not to conduct ⚫ Check the fastening of different parts fully.
heavy or quick operations. During the running- Especially the bolts of diesel engine cylinder
in period, the working load should not exceed cover, the bolts of the air discharging pipes and
70 percent of the rated requirements. The driv- the captive bolts of front axle, the nuts of hubs,
ing speed should not exceed the 70 percent of the connection bolts of transmission shaft, the
the rated Max. speed. captive bolts of diesel engine, the captive bolts
⚫ Pay attention to the lubrication of the machine, of transmission box, and the bolts at the hinge
and replace or add the lubricant oil and grease of the front and rear frames.
in stipulated time and cycles. ⚫ Check the tightening grade of the fan belt,
⚫ Pay attention to the temperatures of the trans- power generator belt and the belt of compres-
mission box, torque converter, front and rear sor of air conditioner.
1-37
3. Service
3.2 Regular service
⚫ Check the leak proofness of the hydraulic system and braking system.
⚫ Check the transmission oil of the transmission box and the lubricant oil of the driving axles.
⚫ Replace the precision filter of the transmission box and clean the rough filter of the transmission box.
⚫ Wash the returning oil core of the hydraulic oil tank.
Notes: when to replace the transmission oil of the transmission box and the lubricant oil of the
drive axles as well as the secondary filter of the transmission box, the relevant procedures and regula-
tions should be followed.
3.2 Regular service
Notes: Read and understand all safety documents, warnings and instructions before conduct-
ing any operations or taking any service steps.
LiuGong requires that the service work must be conducted according to the time cycle that firstly expire in the
working timer or the calender (date, week, month, etc).
In the working environment of extreme coldness, excessive dust or humidity, there should be more lubrication
service stipulated in "regular service".
During the service, it is better to repeat the service items listed in original service items. For example, when
conducting the service for every 500working hours or 3 months, there should be the service for 250working
hours or1month,50working hours or every week and every10working hour or every day.
Service for 10 working hours or every day:
⚫ Check the battery and the battery switch.
⚫ Check engine oil level.
⚫ Check coolant level.
⚫ Check hydraulic oil level.
⚫ Check fuel level.
⚫ Remove the water and impurities from the oil pre-filter and the rough filter of the engine.
⚫ Tour inspections. (Refer to details about the"Tour Inspections" in the "Important Service Programs"）
⚫ Visual inspection of the engine fan and driving belt.
⚫ Check the working performance of lamps and instruments.
⚫ Check the air pressure and damage of tyres.
⚫ Check the working performance of the backup alarm.
⚫ Add the lubricant grease to drive shafts as per the instructions of the machine lubrication figure pasted
onto the machine.
Service for 50 working hours or every week:
Firstly, conduct the above-mentioned service operations
⚫ Check the oil level of the transmission box.
⚫ Check the distance between brake drum and brake shoe at the first 50 working hours, and make adjust-
ments if it is not proper. Conduct the check every 250 working hours.
⚫ Fasten all the binder bolts of all drive shafts.
⚫ For machines equipped with air conditioner, clean the filter screens of the return air inlet and the fresh air
gate of the evaporator; check the tightening degree of the transmission belt of the compressor. and check
whether there are foreign matters such as greasy dirt and grime that may influence the radiation of heat by
the condenser.
1-38
3. Service
3.2 Regular service
⚫ Keep the binding posts of the battery clean and ⚫ Check whether there is crack and looseness
apply the Vaseline to avoid the corrosion of the with the force welding seams and captive bolts
acid smog to the binding posts. of working devices and front and rear frames.
⚫ Check the lubrications of all lubrication points, ⚫ Check the oil level of front and rear axles.
and add the lubricant grease to drive shafts as ⚫ Check the air intake system of the engine.
per the instructions of the machine lubrication ⚫ Replace the engine oil and engine oil precision
figure pasted onto the machine. filter.
⚫ Check the nitrogen pre-charging pressure of ⚫ Change the coolant filter of the engine.
the accumulator at the first 50 working hours. ⚫ At the first 250 working hours, clean and wash
Service for 100 working hours or every two the returning oil filter spool of the hydraulic sys-
weeks: tem. Then, at every 1,000 working hours,
change the returning oil filter spool of the
Firstly, conduct the above-mentioned service opera-
hydraulic system.
tions
⚫ Check the tension and damage of the transmis-
⚫ At the working date of the first 100 working sion belt of the engine and the belt of the com-
hours, replace the transmission box oil and pressor of the air conditioner.
replace it every 1,000 working hours; If the ⚫ For the machine equipped with air conditioner,
working hours are not up to the stipulated num- check whether there are sufficient refrigerants
bers, replace the transmission box oil at least inside the liquid storage tank of the air condi-
once each year. When to replace the transmis- tioner.
sion box oil, change the transmission box oil ⚫ For the machine equipped with air conditioner,
precision filter, and clean the rough filter inside clean the air filters inside and outside the cab.
the bottom of the transmission box. ⚫ Check the driving brake ability and parking
⚫ At the working date of the first 100 working drive ability.
hours, replace the drive shaft gear oil and ⚫ Check the nitrogen pre-charging pressure of
change it every 1,000 working hours; If the the accumulator at the first 250 working hours.
working hours are not up to the stipulated num-
Service for 500 working hours or three months:
bers, replace the drive shaft gear oil at least
once each year. Firstly, conduct the above-mentioned service opera-
⚫ Cleaning the engine cylinder head. Clean the tions
radiator unit. ⚫ Check the concentration of anti-freezing solu-
⚫ Clean and wash the oil filling filter screen of the tion and the concentration of the coolant addi-
oil tank. tive.
⚫ Check the nitrogen pre-charging pressure of ⚫ Check the fuel pre-filter and the rough and pre-
the accumulator (optional) at the first 100 work- cision filters of the engine.
ing hours. ⚫ Tighten the binder bolts of the front and rear
⚫ Operate the swing arms at least once every 100 axles and frames.
working hours to ensure there is lubrication ⚫ Check whether the captive bolts of the frame
grease on the contact surface and avoid exces- hinge pin is loosened.
sive abrasion of the latch cylinder. ⚫ Check the nitrogen pre-charging pressure of
Service for 250 working hours or one month: the accumulator (optional) at the first 500 work-
ing hours. Check the nitrogen pre-charging
Firstly, conduct the above-mentioned service opera-
pressure of the accumulator every 1,000 work-
tions
ing hours.
⚫ Check the tightening torque of the captive bolts
Service for 1,000 working hours or six months:
of hubs.
⚫ Check the tightening torque of the mounting Firstly, conduct the above-mentioned service opera-
bolts of the transmission box and the engine. tions
⚫ Adjust valve clearance of the engine.
1-39
3. Service
3.3 Tyre inflation pressure
⚫ Check the tension pully bearing and fan bearing ⚫ Check the fan hub and repair or change it if
of the engine. necessary.
⚫ When to replace the transmission box oil, ⚫ Inspect the turbocharger.
change the transmission box oil filter, and clean
the rough filter inside the bottom of the trans-
mission box.
3.3 Tyre inflation pressure
⚫ Change the drive shaft gear oil and the filter It is recommended to inflate the tires with dry nitro-
element of the drive shaft gear oil filter. gen and adjust the tire pressures. This is applied to
⚫ Change the filter element of the returning oil fil- all the machines equipped with rubber tires. Since
ter of the hydraulic system. nitrogen is a type of inert gas, it will not help to com-
⚫ Clean and wash the fuel tank. bust in the tyres.
⚫ Screw up the captive bolts of the battery and
Using nitrogen （N2） can not only reduce risk of
clean the top of the battery.
explosion but also help to prevent oxidation and
⚫ Check the nitrogen pre-charging pressure of
rubber ageing as well as corrosion of rim parts. This
the accumulator (optional).
prolongs the service life of the tyres up to more than
⚫ For the machine equipped with air conditioner,
four years.
change the air filter outside the cab.
Service for 2,000 working hours or every year:
Firstly, conduct the above-mentioned service opera- Warning
tions
It is necessary to train the operators to use the
⚫ Change the hydraulic oil, clean the oil tank and
inflatable equipment. Using improper tire inflation
the oil suction filter screen and check the oil technique can cause personal injury or even death.
suction pipes.
Don’t set the pressure of the inflatable equipment to
⚫ Check the working performance of the driving
be higher than the recommended tire pressure by
brake system and the parking brake system.
140kPa(20 psi).
Dismantle the friction plate and check its corro-
sion when necessary. Check and adjust tyre inflation pressure. This
⚫ Check the tightness of the distribution valve and should be done when tyres are fully cooled. Keep all
the working cylinder through the measurement other person away from the dangerous area
of the natural settlement of the cylinder. (around the tires).
⚫ For the cab equipped with air conditioner, check The pressure of the nitrogen–inflated tires is the
whether there is rupture and wear with the cool- same as that of the air-inflated tires. It is recom-
ing pipes and water pipes of the air conditioning mended to select the tire inflation pressure based
system or the oil immersion of such system, on the machine operating conditions ．
and check whether pipe joints and clamps are The tire inflation pressure listed in the table means
loosened.
the one at normal temperature.
⚫ For the cab equipped with air conditioner,
change the air filter inside the cab.
⚫ Check the flexibility of the steering system.
MPa Psi
⚫ Change the coolant liquid of the engine, clean
and washing the cooling system of the engine, 17.5-25 0.35 ± 0.01 50 ± 1.5
and change the engine coolant liquid filter.
Service for 6,000 working hours: When driving in very cold environment, the tyre
⚫ Check the shock absorber of the crank pulley of pressure will tremendously change. Even if the tire
the engine, and change it if necessary. has been inflated to the correct pressure at normal
⚫ Clean, repair or change the nozzle of the temperature, it will be under-inflated at freezing tem-
engine. perature. Low tire pressure can shorten the tyre’s
⚫ Clean and calibrate the fuel pump. service life.
1-40
3. Service
3.4 Pressure release
3.4 Pressure release
Warning
The hydraulic oil lines are under pressure all the
time. Therefore, it is necessary to release the pres-
sure in the lines when to check or replace the lines.
If not, the high-pressure oil will spout out and lead to
severe personal injury.
B
Though the engine is shut down, yet the parts and
oil as well as the cooling water in the radiator are at
high temperature and lead to severe burns. Wait for
the temperature to drop down prior to the operation.
When to dismantle the filling oil port cover and the ⚫ Loosen the locknuts between the hydraulic lines
filling oil port cover of the radiator, the oil or water to release the residue pressure inside the
may spout out. Therefore, move the covers slowly hydraulic devices and then screw them up. In
to release the internal pressure. the meantime, collect the residue oil inside the
Specific operation methods: working devices.
⚫ Park machine on a firm level ground. Lower all ⚫ Please refer to the "Accumulator service" sec-
working devices down to the ground. tion in the Grader User Manual for details about
⚫ Within 15 seconds after the machine shuts the release of pressure of the accumulator.
down, turn the switch to the "ON" position, and
operate the operation levers (of working 3.5 Technical specifications to
devices and driving devices) to different direc-
tions fully to release the pressure inside the Lubricating oil
working devices.
⚫ Slowly release the filling oil port cover A or fill- Interval between the change time of the
ing water port cover B of the radiator at the top lubricating oil and approximate filling vol-
of the hydraulic oil tank to release the internal ume.
pressure.
Notes: during the check, service, test and

adjustment of the machine, when to remove any
hydraulic oil lines or dismantle any parts that
A contain liquid, prepare proper containers to col-
lect such liquid. Dispose all liquid properly.
1-41
3. Service
3.5 Technical specifications to Lubricating oil
Interval between the change time of the lubricating oil and filling volume.
Interval between oil change time

Type Approximate filling volume (litre)
(working hours)
Engine crankcase 250 （or one month） 22
Gearbox system 1,000 （or six month） 45
Hydraulic oil 2,000 （or one year） 186
Axle, balancing tank and worm

1,000 （or six month） 80
tank
Fuel 230 （per shift）
Note: oil change interval, first to shall prevail.
Oil Specifications
Name
Type Parts
Oil for summer Oil for winter
For rolling bearing, sliding bearing,

★ Molybdenum disulfide lithium-based pins of working devices, pins of tilting
Grease
grease Molybdenum Disulfide Lithium Grease cylinder, pins of frames, swing frame
2# of rear axle, spline of drive shaft, uni-
versal joints, and water pump shafts
Torque converter ★ Engine oil above Mobil Delvac 1300 or For torque converter and power shift
oil SAE15W-40CF gearbox
For hydraulic system, steering hydrau-

Hydraulic oil ★ HM46 Anti-wear HM46 Anti-wear
lic system and braking system of work-
hydraulic oil hydraulic oil
ing devices
Engine oil ★ 15W-30 above the 5W-30 above the For diesel engine
grade SAE/CF-4 grade SAE/CF-4
Engine South 0# light fuel oil 0# light fuel oil

For diesel engine
fuel North 0# light fuel oil -35# light fuel oil
Gear oil ★ SAE85W-90GL-5 heavy-duty vehicles Drive axle, balancing tank and worm
gear oil tank
Remark: the oil marked with ★ is the oil filled when

the machine is transported out of the factory. Notes: the oil of the same specification
but different brands cannot be used together. If
1-42
3. Service
3.6 Important service programs
-
1
another brand of oil is to be used, please clean ⚫ 9
the system first. ⚫
If the machine is used in low-temperature and a

extremely cold region, the hydraulic oil should be g
the HV46 anti-corrosion hydraulic oil. The gearbox ⚫ e
oil should use ATF220 or DEXRON- Ⅲ or Donax TC
transmission oil. t
⚫ o
The lubricating oil should be changed in a timely

a
manner. Even though the oil is very clean, yet it may ⚫
l
deteriorate if it is placed for a long time.
l
The selection of fuel oil should depend on the low- ⚫
est temperature of the place where the machine is ⚫

w
used.
o
⚫
r
k
3.6 Important service programs ⚫ i
n
Tour inspections g
d
Notes: Pay close attention to leakages. If e
any leakage, find out the leakage source and v
repair it. If you have doubt about or find the leak- i
age, please frequently check the changes in the c
liquid level. e
Check whether there is leakage in the hoses of s
-19⚫
the cooling system and the hydraulic system. a
Repair and replace the hoses timely if neces- n
sary. d
Check the engine chamber. Clean and remove
-19⚫ l
the scraps and foreign matters piles in the i
engine chamber. Remove the scraps and for- n
eign matters on the radiator. k
Check whether there is any visual damage to s
-19⚫ .
the engine.
Check whether there is any damage to tyres.
-19⚫
Check whether the valve caps are missed or
not.
Check whether there is any leakage in the drive
-19⚫
axle, differential, wheel brakes and transmis-
sion. If any, fix the problem.
Check whether there is any leakage in the
-19⚫
hydraulic oil tank, all hoses and pipes. In the
meantime, check whether there is any leakage
in all blockage, seals, joints and nozzles. Fix the
problem and replace hoses if necessary.
Check whether there is any corrosion and dam-
Ensure all doors, inspection covers and protec-
tion plates are solid. Check whether there is
any damage to doors, inspection covers and
protection plates.
Check steps, corridors and handrails. Remove
all scraps. Repair all damages or replace dam-
aged parts.
Check whether there is any visual damage to
the roll over protection system. If there is any
damage, please contact LiuGong's agency.
Check all lights and replace the broken bulbs
and broken light glass.
Check the cab and keep its interior clean.
Check whether the instrument and indicator
lamps on the instrument panel is broken or not.
Replace all broken parts.
Check seat safety belts, strips and mounting
fasteners, and replace all worn or broken parts.
Check rear view mirror and windows to make
sure that the driver's vision will not be affected.
Clean windows if necessary.
4. Engine System
4.1 Overview of engine .......................................................................................4-2
4.2 Basic parameters of engine ..........................................................................4-2
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4.3.1 Introduction of intake and exhaust system .................................................................4-3
4.3.2 Removal and installation of intake and exhaust system ............................................4-4
4.4 Removal and installation of fuel supply system ............................................4-5
4.4.1 Introduction of fuel supply system ..............................................................................4-5
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4.5 Introduction, removal and installation of cooling system ............................. 4-13
4.5.1 Working principle of cooling system .........................................................................4-13
4.5.2 Removal and installation of fan components ...........................................................4-13
4.5.3 Removal and installation of radiator as ....................................................................4-14
4.6 Removal and installation of engine as ........................................................4-16
4.6.1 Removal and installation of engine as .....................................................................4-16
4.6.2 Removal and installation of engine and gearbox & torque converter as ..................4-22
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接引用无效。
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4.8.2 Replacement of fuel prefilter ....................................................................................4-29
4.8.3 Replacement of engine oil filter ................................................................................4-29
4.8.4 Maintenance of air filter ............................................................................................4-30
4.8.5 Replacement of air filter safety element ...................................................................4-31
4-2
4.1 Overview of Engine
4.1 Overview of Engine Fuel system adopts BEIYOU 7100 high pressure oil
pump/RQV_K speed regulator and has higher fuel
CLG4180 adopts Dongfeng Cummins fuel engine economy.
(6BTAA5.9-C190) with four strokes, in-line 6 cylin- It adopts integrated design. Water pump housing, oil
ders and displacement of 5.9L as its power system, pump housing, water intake pipe of water pump, oil
which meets the emission requirements of China Ⅱ cooler housing, air intake manifold, thermostat seat,
stage. small coolant circulating pipe and fuel filter base,
This fuel engine adopts the air intake type of turbo etc. are cast directly onto the cylinder block and
charger and air-air intercooler to make the air intake cover to decrease components, which reduces
adequate, combustion more sufficient and power faults, makes maintenance easier and cost less.
greater. Use air as the heat exchange medium, cool
the air intake with high temperature after super-
charged to the required temperature through the air-
4.2 Basic Parameters of
air intercooler to meet the requirements of emission Engine
regulation, and improve the engine power perfor-
mance and economy.
Basic parameters of engine

fuel engine Dongfeng Cummins 6BTAA5.9-C190
Rated power kw 142
Rated revolution speed Rpm 2200
Number of cylinders In-line 6 cylinder
Engine sys- Cylinder bore X stroke mm 102X120
Total displacement of pistons L 5.9

tem
Max.torque N ⚫m 800N⚫m/1500r/min
Torque reserve 30%
Specific fuel consumption rate (stand g/kw.h 235

test)
Fuel 0 # or 35 # light fuel
Fan diameter mm 762

4-3
4.2 Basic Parameters of Engine
Typical data of engine

Dry weight (with flywheel and alternator, without starter kg 413
and air compressor)
Max. overspeed performance rpm 4200

Typical data Instantaneous inertial of rotating components (without fly- kg.m^2 0.25
wheel)
Distance from center of gravity to front end surface of cyl-
mm 328
inder block
Distance from center of gravity to center line of crankshaft
mm 155
(on the crankshaft)
Performance parameters of engine

Min. idle regulation speed rpm 900
Max. speed regulation speed (10% of rpm 2460

rated load)
Max. overspeed performance rpm 4500
Max. height allowable for continuous run-

m 2200
ning
Performance
Max. torque during full-shutdown of
N ⚫m 430
accelerator
parameters
Speed regulation rate % ≤ 8
High idle Deg 120±10°
Accelerator handle
Low idle Deg 85±10°
angle
Rotation angle Deg 35±5°
Shutdown handle Free position Deg 110±5°

angle Shutdown position Deg 72±5°
4-4
4.3 Removal and Installation of Intake and Exhaust System
4.3.1 Introduction of intake and exhaust system
4.3 Removal and Installation charger, it enters the intercooler to cool down, then
it flows into the cylinder of fuel engine through
of Intake and Exhaust Sys- intake manifold.
tem Main function of intercooler is to cool the air intake
with high temperature after supercharged to the
required temperature to meet the requirements of
4.3.1 Introduction of intake and emission regulation, and improve the engine power
performance and economy. High intake temperature
exhaust system indicates that the density of air into the engine
Intake and exhaust system is like human respiratory decreases, which will cause increase of exhaust
system, which is in charge of the intake an exhaust smoke, reduction of power, increase of heat release
of fuel engine. Its main functions are: filter the impu- to cooling system and raise of engine temperature.
rity in the air to supply adequate and clean air to fuel Too low intake temperature will cause the non-com-
engine; at the same time, reduce noise of fuel pression ignition of fuel engine, ignition lag and
engine to ensure smooth exhaust. Main compo- abnormal combustion, which will generate black
nents of intake and exhaust system include: air pre- smoke, knock, unstable running and diluted oil due
filter, air filter, turbocharger, muffler, air intake to fuel penetration. So intercooler is an indispens-
manifold and exhaust manifold. able part.
Intake process: impurity of large particles is Exhaust process: air in the cylinder is mixed with
removed from the air through prefilter, then the air fuel, then it becomes exhaust gas after burning; the
enters the filter to remove unnecessary impurity of gas is back to the atmosphere after passing through
99.5%; after the air is supercharged through turbo- exhaust manifold, turbocharger and muffler.
Compressedair flow
Engine Turbocharger
cylinder oilinlet
Air inlet Turbine
condenser Compresso r
Exhaust
Airinlet gas
emission
Compressorpulley
Oil outlet Exhaust
reliefvalve
Figure 4 -1 Air flow route

4-5
4.3 Removal and Installation of Intake and Exhaust System
4.3.2 Removal and installation of intake and exhaust system
4.3.2 Removal and installation

of intake and exhaust system
1. Removal step of intake and exhaust system:
Remove the end cover on the air filter;
Loose the lock on the fixed guard to open the

cover;
Shake around to pull out the main filter element

by the axial direction; clean or replace main fil-
ter element according to relevant requirements.
For cleaning of air filter and replacement of filter
element, please refer to 4.8.4-Maintenance of
air filter and 4.8.5-Replacement of air filter
Open the lock buckle on the air filter; element.
2. Assembling steps of air filter:

Assemble the filter according to reverse steps
of removal.
4-6
4.4 Removal and Installation of Fuel Supply System
4.4.1 Introduction of fuel supply system
4.4 Removal and Installation Fuel filter device is the best guarantee for long-time
continuous running of engine. Water is the most
of Fuel Supply System important affecting factor in all the pollutants of the
fuel, which can enter fuel when filling fuel. When the
moisture in the hot air is condensed on cold metal
4.4.1 Introduction of fuel supply wall of fuel reservoir, or inappropriate cleaning is
system conducted, water will be generated. The water in
the fuel has serious affect. It can damage the injec-
Fuel supply system supplies clean fuel to engine tor nozzle or decrease the fuel. Exceeding impurity
and it is the key part for engine to work normally. and water in the fuel is the main reason to damage
Fuel supply system mainly includes fuel tank, suc- and wear the high pressure oil pump and injector.
tion filter screen, oil pipe lines, oil-water separator So oil-water separator and fuel filter should be
and fuel filter, etc. installed on the front engine to separate oil and
water, and remove most impurity in the fuel.
1. Fuel filter
2. Oil-water separator

of fuel supply system
1. Removal steps of fuel tank
Remove the hood AS before removing the fuel
tank; please refer to chapter "9.6.3-Removal
Steps of Hood" to conduct the removal, after
this removal, remove the fuel tank as the follow-
ing steps.
4-7
4.4.2 Removal and installation of fuel supply system
Bypassing the engine, put the return tube into

the waste fuel drum on the other side;
Remove the tube clamp bolts on the fuel tank

(wrench specification10mm);
Shield the fuel hose after draining fuel;
Remove the return tube connector on the

engine side; Remove the screw on the other side of fuel
hose (wrench specification 19mm) and take
down the fuel hose;
4-8
Install the screw onto the oil drain hole of fuel Remove the clamp fixing rubber hose on the
tank; water spreading side (socket specification
10mm) ；
Unscrew the clamp bolts of rubber hose spread

water to lower hose (wrench specification 10 Pry the rubber hose out with crowbar;
mm);
4-9
Lift the rubber hose to the highest position and

bend the hose into 2 sections;
Move the rubber hose in front of the waste oil
drum, put the hose into the container to drain
the coolant;
Remove the clamp close to the radiator side on

the inter-cooler pipe with long type socket
(specification 10mm);
Remove the inter-cooler tube on the left

machine, the detailed steps are as follows;
Remove the clamp near close to the engine

side; take down the tube of inter-cooler;
Remove the 4 bolts fixing the tube clamp of the

inter-cooler (wrench or socket specification
16mm);
4-10
Remove the inter-cooler tube on the right Remove the clamp on the inter-cooler tube
machine, the detailed steps are as follows; sides with long type socket;
Remove the 4 bolts fixing the tube clamp of the Take down the inter-cooler tube;
inter-cooler (wrench or socket specification
16mm);
4-11
Take down the big and small rubber tube AS;
Remove the clamp of big and small rubber tube

close to the engine side; Cut off the harness tie of fuel tank level sensor
with scissor;
Remove the clamp of big and small rubber tube

close to the radiator side; Remove the harness connector of fuel tank
level sensor;
4-12
4.4.3 Cleaning of fuel tank
Remove the 4 bolts on both sides of fuel tank

(socket specification 24mm);
Unscrew the fuel hose (wrench specification

19mm);
Install 2 lifting rings on the 2 lifting lug on the top
of fuel tank (thread specification M16); use 2 lift-
ing rope to lift the fuel tank;
2. Assembling steps of fuel tank:

Assemble according to reverse steps of removal.
Installation of fuel tank has the following require-
ments: oil inlet and return port must be separated;
return port must be lower than oil level, oil inlet port
must be 25 mm away from the tank bottom. The bot-
tom is the sediment space of water and impurity and
the lowest bottom must be installed with blowdown
valve, reserve 5% of expansion space to avoid over-
flow after fuel expansion and has the ventilation
function to avoid too high pressure of internal oil
Bend the fuel hose into two sections and bind tank; the ventilation port should be dust proof and
them with 1 tie; water proof.
4.4.3 Cleaning of fuel tank

Sometimes, we should clean the removed fuel tank;
here we will introduce the cleaning steps of fuel tank
briefly.
1. Remove the flange cover on the front end of
fuel tank, use clean fuel to wash the inner oil
tank surface.
2. Unscrew the drain plug under the fuel tank to
drain the oil.
3. Wash the surface repeatedly until the oil is
exhausted.
4-13
4.5 Introduction, Removal and Installation of Cooling System
4.5.1 Working principle of cooling system
Flange cover
Drain plug
1. Water radiator
4.5 Introduction, Removal 2. Hydraulic oil cooler

3. Torque converter oil cooler
and Installation of Cooling 4. Fan components
System 5. Air-air inter-cooler
Coolant in the radiator is pressed into the cylinder
block and cylinder cover water sleeve through the
4.5.1 Working principle of cool- inlet hole of cylinder block after supercharged; the
ing system coolant returns to cooler through the cylinder cover
outlet hole after absorbing large amount of heat
Main function of cooling system is to emit the heat
from the engine. Due to the strong suction of fan, air
from the main components during operating process flow passes through the cooler with high speed from
of grader to the atmosphere to make sure normal the front to rear. Therefore, in the process of heated
running of machine. coolant flowing through the radiator core, heat is
Main components of cooling system include water emitted to the atmosphere constantly; cooling water
radiator (water tank), hydraulic oil cooler, torque flows through the radiator bottom, and then it is
converter oil cooler, air-air inter-cooler and fan,etc. pumped out by water pump and pressed into the
CLG4180 grader adopts the arrangement form of water sleeve of engine. This is how the cycle works
post cooling system to make maintenance easier to emit heat into the atmosphere and make the fuel
and independent hydraulic motor drive fan to ensure engine cool down constantly.
high efficiency cooling; the fan speed is adjustable
and without noise.
of fan components
1. Removal steps of radiator fan:
4-14
4.5.3 Removal and installation of radiator AS

of radiator AS
1. Removal and installation of radiator AS
Please remove the engine hood, fuel tank and
fan firstly according to steps of 9.6.3-Removal
Steps of Engine Hood, 4.4.2-Removal and
installation of Fuel Supply System and 4.5.2-
Removal and Installation Steps of Fan Compo-
nents;
Open the left and right door of engine hood;

Hang the 2 handrails of cover by lifting rope;
Remove the 2 bolts P1 under the cover firstly (
socket specification 13 mm), than remove the 2
bolts P2 above the hood;
Take down the cover; unplug the harness connector
of plate license light during this process;
Notice: Please use lifting rope to lift cover and avoid
potential hazard due to manual materials handling
(such as bruised, injured by a crashing object)!
Remove 2 oil pipes of torque converter and 2
hoses of hydraulic oil cooler;
Remove the 6 bolts (socket specification 13mm)

and take down the fan;
Remove 3 oil pipes on the cooler motor;
2. Assembling steps of radiator fan:
Assemble according to reverse steps of
removal;
4-15
4.5.3 Removal and installation of radiator AS
Refer to "6.3.3-Radiator Control Valve" to iden- Pull out the hose and screw 2 lifting rings into
tify and remove the hoses; the radiator AS, hang the rings by 2 steel cable
and lift it up slowly until the cable is exactly ten-
sioned;
Loose the rubber hose clamp P1;

Loose 2 clamp bolts of upper hose;
Unscrew 4 captive bolts of radiator AS (socket
specification 24 mm);
Lift slowly, check whether there are non-
removed hoses and rubber hoses around the
radiator during lifting process; if yes, remove
them before lifting, otherwise, components will
be damaged or accidents will be caused;
Put the radiator onto firm ground and shield all
oil ports;
2. Assembling steps of radiator AS:

removal;
4-16
4.6 Removal and Installation of Engine AS
4.6.1 Removal and installation of engine AS
4.6 Removal and Installation

of Engine AS
of engine AS
1. Removal of engine AS
Remove the above mentioned components
firstly, remove engine AS according to these
steps: 8.2.2.1.1 Relief of in air conditioning
system, 8.2.2.1.2 Removal of Compressor
Connecting Pipes, 9.6.3-Removal Steps of
Hood, 4.4.2-Removal and Installation of Fuel
Remove all the wires on the alternator;
Supply System, 4.5.2-Removal and Installa-
tion of Fan Gp, 4.5.3-Removal and Installa-
tion of Radiator AS, 5.6.2-Removal and
Installation of Pump Driving Shaft;
Remove the wires connecting with the gearbox;
Remove the accelerator cable;

The components below are on the right side of
engine:
Unplug all the wires of air filter blockage sensor;

4-17
Remove all the wires on the alternator; Unscrew the clamp of A/C intake pipe on the
fuel engine and unplug the water pipe;
Unscrew the clamp of A/C return pipe and

unplug the water pipe;
Unplug the sensor harness on the gearbox;

4-18
The components below are on the left side of

engine:
Unplug the wires on the torque converter oil

temperature sensor;
Unplug the wires on the gearbox oil pressure
switch;
Unplug the harness on the shutdown electro-

magnet;
Unplug the gearbox harness and cut off the
fixed ties of harness;
4-19
Unplug the wires on the oil pressure alarm

switch;
Unplug the harness;
Unscrew the wire nuts and unplug the wires;
Remove the cooling pump hydraulic hose;
Unscrew captive bolts of pipe clip (socket spec-

ification 13mm);
4-20
Check the pump drive shaft for separation; if

not, please refer to 5.6.2-Removal and Installa-
tion of Pump Drive shaft to separate the shaft;
Unscrew the 4 captive bolts on gearbox bracket

( socket specification 33mm);
Unscrew the 2 bolts on upper shock absorber

(socket specification 19mm);
Loosen the hose bolts and take down the hose;
Loosen the rubber hose clamp on the engine

side and unplug the rubber hose;
Unplug the dipstick on the filler tube;

4-21
engine during the lifting process; if yes, remove

them before lifting, otherwise, components will
be damaged;
Hang the engine with 2 steel cables (lifting

weight of the cables must be over 1t);
Put the engine AS onto firm ground; support the

front end of engine with bracket; make sure the
engine AS is placed stably and then loosen the
steel cables;
Lift the engine slowly, check whether there are

non-removed harness and pipes around the
4-22
4.6.2 Removal and installation of engine and gearbox & torque converter AS
Screw the dipstick onto the filler tube; Remove the hose on the left side of gearbox
(open-end wrench specification 50mm);
2. Assembling steps of engine AS:
removal;

of engine and gearbox & torque
converter AS
1. Separation steps of engine and gearbox &
torque converter AS:
Unscrew the connector (open-end wrench

specification 41mm);
Remove the hose on the gearbox bracket

(open-end wrench specification 55mm);
4-23
Unscrew the 4 captive bolts on gearbox bracket

( socket specification 30mm);
Unscrew 1 bolt on the view port cover of fly-

wheel housing left side of the engine, and
loosen the other one (open-end wrench specifi-
cation 16mm);
Lift the engine AS, put the gearbox bracket

under it;
4-24
Screw 4 M10 bolts or screws with length of

50mm on the front end flange of engine;
One person rotate the flange clockwise or anti-
clockwise with crowbar and the other person
observes whether the screw on the flywheel is
rotated into the view port;
Separate the engine from the gearbox;
Stop rotation after the screw is in the viewport;

Unscrew the screw with inner hexagon wrench;
Repeat the steps above for 4 times;
Remove the connecting flange;
Unscrew the 12 bolts connecting the engine

and gearbox ( socket specification 15mm);
Remove the flange;

4-25
4.7 Common Faults and Reasons Analysis of Engine
4.7.1 Common simple fault diagnosis methods of engine
2. Assembling steps of engine and gearbox &

torque converter AS:
removal;
Please contact the maintenance station
authorized by Commins, if the reason
4.7 Common Faults and can not be found by simple diagnosis
Reasons Analysis of Engine method. Don't remove it blindly.
4.7.1 Common simple fault

diagnosis methods of engine
There are various engine faults, and the reasons
are different. The following will introduce common
faults and make a simple analysis of causes for ref- 2. Idle speed is not stable
erence of readers. It is suggested to do fault diagno- The reasons and repair methods are as the fol-
sis according to the following principles: eradicate
lowing:
faults by the sequence of conducting before think-
ing, from simple work to tedious work, from surface 1. Too low idling: check/adjust low idling bolts
to inside. Don't remove and dismantle the machine for firm;
to a large extent blindly. 2. Air exists in the fuel system: bleed air in the
fuel system and check the suction tube for
1. Motor can run but the fuel engine can not be leakage;
started 3. Fuel delivery pump is faulty: check/replace
The reason maybe include the following points: the pump;
1. Too low environmental temperature will 4. Injection pump timing is wrong: check/correct
cause incapable of compression ignition, the timing;
so pre-heat the engine; or the air intake 5. Injection nozzle is blocked or fails to work:
preheating device is damaged, so check replace the injector;
and repair the preheating devices;
6. Engine fixing bracket is damaged: replace
2. If there is sir in the fuel system, repair accord- the fixing bracket;
ing to the following steps:
7. Injection pump is faulty or damaged: remove
1) Exhaust the pump and check the pump calibration;
2) Tighten the connectors with potential
leakage risk 3. Underpowered fuel engine
3. Fuel pipeline or filter is blocked; The reason maybe include the following points:
4. Air intake is blocked; 1. Oil supply is poor, for example, the fuel pipe-
5. Oil pump has fault; lines are blown or blocked;
6. Fuel has poor quality and is mixed with 2. Air intake is poor, the air filter is blocked and
water; maintenance of air filter is not timely;
7. Injection nozzle is damaged or blocked. 3. Air intake is blown, maybe the turbocharger
or valve is blown;
4. Fuel has poor quality; fill the temporary fuel
tank with good quality fuel for comparison;
5. Fuel delivery pump is faulty;
4-26
6. Turbocharger is faulty; between the piston top surface and cyl-

7. Be operated in the highland area with low inder bottom is too large;
pressure, so the low pressure and thin air 2) Air is blown between the cylinder cover
will cause the insufficient power of fuel and cylinder sleeve;
engine; 3) Piston, piston ring and cylinder sleeve
8. Valve is blown; are worn seriously;
9. Cylinder is worn in early time. 4)When assembling the piston ring, the
opening is not staggered, or the piston
4. fuel engine emits black smoke ring is broken and clamped in the ring
Results: slot;
1. This is caused by poor combustion. Engine 5) The valve is not closed thoroughly. The
with this fault has bad economy and will possible reasons are: spring force of
pollute the environment. valve is not enough even the spring is
2. This is caused by the black soot, so it will pol- broken, so the valve seat is loose and
lute the injector, valve, valve seat, piston, falls down; the valve seat has stripping
piston ring, cylinder sleeve, nozzle ring damages; skip of valve transverse arm
and turbine of turbocharger, which not only makes the valve out of control; and
influences the service life of components, valve rod and guide pipes are dam-
but worsens the combustion status. aged or the rod is bent, etc.
3. Sometimes black smoke will be exhausted, 6) Too low fuel and water temperature
this is because some components have makes correspond components of rele-
fault in the fuel engine, for example, rotor vant kinematic pairs work in the condi-
of turbocharger and the housing have friction of quite clearance, which causes
tion, the valve spring is broken or the injec- blown air when the combustion cham-
tor nozzle is cracked. If these conditions ber is compressed.
are not resolved in time, faults will become 3. Air intake system is faulty:
more serious and damages will be caused. 1)Air filter is blocked seriously.
Cause Analysis: 2) Air inlet has serious leakage, especially
1. Overload of fuel engine: the rubber hose connecting the com-
1) Fuel engine power setting is high pressor outlet and inter-cooler inlet is
(including part load power); broken.
2) Main movement parts have fault to 3) Cooling efficiency of inter-cooler is low,
cause large wasted power, such as which can not make the turbocharged
journal sticking, piston seizure, etc. air cool throughly and cause insuffi-
cient air in the combustion chamber.
3) Fuel supply is not even for injection
The reasons for low cooling efficiency
pump of every cylinder, or some cylin-
of inter-cooler include: coolant tem-
der doesn't work and causes overload
perature of inter-cooler is too high;
of cylinder;
coolant tube in the cooler is broken
4) Area climate changes, but the power while the welding for repair is too
correction is not conducted. much.
2. Compression pressure is too low: 4) Compressor efficiency of turbocharger
1) When assembling the fuel engine, the is too low and the fuel engine has
adjustment of compression ratio is insufficient suction air.
small, that is, when the piston reaches
the TDC position, the distance 5. Fuel engine emits white smoke
The possible reasons include:
4-27
1. Water flows into the cylinder; The reasons and maintenance methods
2. Fuel quality is poor; include:
3. Injector has oil dripped; 1. External leakage: check for oil leakage with
visual inspection;
4. Coolant temperature is too low.
2. Too much oil in the crankcase: check
6. Fuel engine emits blue smoke whether the vernier gauge position
If the blue smoke is emitted, it indicates that exceeds the specified position;
after the oil enters combustion chamber, one 3. Oil doesn't meet application regulations:
part oil is used to burn and form carbon deposit; check the oil specification; check whether
the other part oil is not burnt and discharged the diluted fuel causes decreased viscosity
into the atmosphere as particles, so the blue of oil; check and shorten the oil replace-
smoke is generated. There are four possible ment period;
reasons for oil entering the combustion cham- 4. Oil cooler is leaked: check whether oil exists
ber. in the coolant;
1. Oil in the bucket lever bearing support of 5. Turbocharger leaks oil into the air intake or
upper cylinder cover enters the combus- exhaust system: check the inlet and outlet
tion chamber, and there are two ways: of turbocharger for oil leakage;
1)Clearance between the valve and valve
guide pipe is too large; 8. Water temperature of fuel engine is high
2) Seal between the injector and injector Probability of this fault is high, and the reasons
seat hole of cylinder cover is poor (the are various:
upper part is sealed by rubber seal ring 1. Cooling system is leaked, so check the cool-
and lower step part between the head ing system for leakage;
shoulder of injector and injector seat 2. Water temperature gauge or water tempera-
hole of cylinder cover is sealed by steel ture sensor fault:
gasket).
Generally, compared with the oil tempera-
2.Oil in the crankcase of lower piston rushes
ture table, oil temp is higher about 15 ℃
into the combustion chamber. than the water;
3. Oil in the chamber of turbocharger enters the 3. Water pump fault:
compressor camber, along with super-
Remove the upper hose, start the fuel
charged air, it passes through inter-cooler,
pressure stabilizing chamber and air intake engine and observe the water spray quan-
by-pass and finally reach the combustion tity;
chamber. 4. Thermostat is out of control: fully-opened at
4. There are solder skips, open welding and about 85 ℃ ;
drilling-through of thread hole, etc. prob- 5. Radiator is blocked: inside and outside;
lems in the air intake passage, which make 6. Fan belt is loose;
the oil in the crankcase into the passage. 7. Fan fault;
Especially, the problem is more seriously
when the solder skips and open welding 8. Air exists in the cooling system;
happen on the baffle between the air 9. Engine overload.
intake passage and main oil passage;
Because pressure oil is in the main oil pas-
sage.
7. Large oil consumption of fuel engine

4-28
4.8 Maintenance and Replacement of Engine Quick-wear Parts
4.7.2 Daily maintenance and tips for engine
4.7.2 Daily maintenance and

tips for engine
Fuel engine should be maintained and checked
daily before it works. For content and steps, refer to
the order:
Oil level-coolant level-cooling fan-exhaust oil-water
separator-visual inspection on the respirator tube of
crankcase-air filter resistance indicator.
Tip: exhaust water and sediment from the oil-
water separator of engine frequently. Maintain
periodically fuel prefilter element and replace it.
Keep the fuel tank and pipeline clean. Keep the
fuel tank ventilation hole and its nearby clean,
avoid pollutant, dust and water entering the fuel Figure 4 -2 Remove the filter
tank. Never use water to clean the engine.
3. Take down the seal gasket on the thread con-
nector of mounting bracket. Clean the seal sur-
4.8 Maintenance and face of mounting bracket with a piece of non-
fibre cloth.
Replacement of Engine
Quick-wear Parts
Working condition of most construction machinery
is: frequent work, too much work and rugged envi-
ronment; this condition makes relevant components
easily damaged. Engine system quick-wear parts of
CLG4180 grader mainly include: fuel pre-filter, oil-
water separator, fuel filter, oil filter, air filter, fuel
injection pump and turbocharger, etc. The following
introduces the maintenance and replacement
method of some quick-wear parts.
4.8.1 Replacement of fuel filter

1. Clean the nearby area of fuel filter and the Figure 4 -3 Clean the seal surface of
mounting bracket firstly. mounting bracket
2. Remove the filter from the mounting bracket 4. Install a new seal gasket to the thread connec-
with belt wrench. tor of filter mounting bracket; coat a layer of
engine oil on the seal surface of filter; fill the fil-
ter with clean fuel.
4-29
4.8.2 Replacement of fuel prefilter
3. Remove the transparent cup on the lower side

of fuel prefilter.
4. Clean the cup and then install it onto the new
fuel prefilter element.
5. Fill the fuel prefilter with fuel, and coat a layer of
engine oil onto the seal gasket, then install it
onto the mounting bracket.
4.8.3 Replacement of engine oil

filter
1. Clean the nearby area of oil filter mounting
bracket.
Figure 4 -4 Prepare a new filter 2. Remove the oil filter with belt wrench.
5. Screw the filter onto the mounting bracket; 3. Clean the contact surface of seal gasket on the
tighten the filter by 1/2~3/4 cycle after the seal mounting bracket with a piece of non-fibre cloth
gasket of filter just touches the mounting If the old O-ring is sticked onto the mounting
bracket. Do not tighten the filter with excessive bracket, remove it.
method in mechanical method to avoid damag-
ing filter.
Figure 4 -6 Clean the mounting bracket

4. Install the new O-ring; fill the oil filter with clean
Figure 4 - 5 Install the filter oil and coat a layer of clean oil onto the surface
of seal gasket.
4.8.2 Replacement of fuel prefil-
ter
1. Clean the nearby area of filter and the mounting
bracket firstly.
2. Remove the prefilter from the mounting bracket
and then clean the seal surface of mounting
bracket with a piece of non-fibre cloth.
4-30
4.8.4 Maintenance of air filter
▲Note: before installation, fill the oil filter with

clean oil. If an empty oil filter is installed, engine
will be damaged for lack of lubricant.
5. Install the oil filter onto the mounting bracket,
tighten it to the surface of seal gasket of filter to
contact with the mounting bracket; then use belt
wrench to tighten the oil filter to the specified
requirements.
▲Note: excessive mechanical tightening may
be damage the thread or the seal of oil filter ele-
ment.
4.8.4 Maintenance of air filter

Air filter is located under the fixed hood (as the
Figure 4 -7 Install the oil filter
arrow indicated area in the figure)
▲Note: maintain the air filter if the alarm light 1. Removal of air filter has been introduced in
goes on due to blockage of air filter. “4.3.2-Removal and Installation of Intake and
Engine must be shut down to avoid being damaged Exhaust System”. For removal of main filter ele-
when maintaining the air filter. ment, refer to “Removal Steps of Intake and
Exhaust System”.
4-31
4.8.5 Replacement of air filter safety element
2. Clean the inner wall of air filter housing.

3. Clean the main filter element; use compressed
air (pressure of less than 300kPa) to wash the
element along the crease mark from the inside
main filter element to outside, then wash
repeatedly along the crease mark from the out-
side and inside of main filter element respec-
tively.
5. Install the clean main filter element to the air fil-

ter housing to make sure the main element end
seal is contacted evenly.
6. Clean and install the air filter cover to make
sure the seal gasket in the air filter inner cover
is contact with the air filter housing evenly.
7. After cleaning the main filter element, start the
engine; if the alarm light for blockage of air filter
is still on, or black smoke is emitted, replace
with a new safety element.
8. Replace the main filter element after being
cleaned for 6 times; at least replace once per
Caution: do not knock when year. Replace the main filter element and safety
cleaning main filter element, element at the same time.
or it will damage the engine.
4.8.5 Replacement of air filter

safety element
1. Shut down the engine and open the engine
hood.
2. Open the air filter cover.
4. After cleaning the main filter element, use the 3. Remove the main filter element.
electric light to inspect. If small hole or particle 4. Remove the safety element.
is found, or the gasket or seal is damaged,
replace with a new main element.
4-32
4.8.5 Replacement of air filter safety element
Safety filter
element
Caution: replace safety

filter element with new
element, do not use it
again after cleaning.
5. Clean the inner wall of air filter.

6. Install a new safety element; make the seal ring
on the end face of safety element contact
evenly and the seal good.
7. Install the main filter element and air filter cover.
Caution: replace the main filter element and
safety element at the same time.
After cleaning the main filter element, start the
engine; if the alarm light for blockage of air filter is
still on, or black smoke is emitted, replace with a
new element.
5. Power Train System
5.1 Drive system parameters ............................................................................... 5-2
5.2 Gearbox &torque converter as ....................................................................... 5-4
5.3 Rear axle and tandem.................................................................................... 5-4
5.3.1 Working principle of steering case ..............................................................................5-4
5.3.2 Removal and installation of steering case and adjustment on chains.........................5-4
5.4 Front axle ....................................................................................................... 5-6
5.4.1 Function of front axle...................................................................................................5-6
5.4.2 Structure diagram of front axle ....................................................................................5-7
5.4.3 Removal and installation of front axle .........................................................................5-8
5.4.4 Removal of front axle wheel hub............................................................................... 5-11
5.4.5 Adjustment of front axle steering linkage ..................................................................5-18
5.4.6 Adjustment of clearance and torque after assembly of hub ......................................5-19
5.4.7 Adjustment of pre-tightening torque for wheel hub inner bearing .............................5-23
5.5 Tyre ..............................................................................................................5-24
5.5.1 Tyre function..............................................................................................................5-24
5.5.2 Structure of tyre assembly and its related parameters..............................................5-24
5.5.3 Tyre common fault mode...........................................................................................5-26
5.6 Drive shaft .................................................................................................... 5-27
5.6.1 Structure of pump drive shaft ....................................................................................5-27
5.6.2 Removal and installation of pump drive shaft ...........................................................5-28
5.6.3 Structure of rear axle drive shaft ...............................................................................5-29
5.6.4 Removal and installation of rear axle drive shaft ......................................................5-29
5.7 Worm box..................................................................................................... 5-30
5.7.1 Function of worm box................................................................................................5-30
5.7.2 Structure diagram of worm box .................................................................................5-31
5.7.3 Removal of worm box ...............................................................................................5-32
5.7.4 Installation of worm box ............................................................................................5-36
5-2
5.1 Drive system parameters
5.7.5 Adjustment on worm box installation ........................................................................ 5-43
When the front axle turns, the maximum steering angle of the inside corner is 45°, and the maximum steering
angle of the outside corner is 36°; the inside swing angle of the right and left lean-joints is 17°;
Type ZF 6WG200
Model Single turbine 3 elements
Torque converter
Torque ratio 2.15
Cooling method Air-cooling pressure circula-

tion type
5-3
Type ZF 6WG200
Model Counter shaft power shift
Transmission
6th gear forward, 3rd gear
Gearshift
reverse
Forward VI gear ≥ 43.4 km/h
Forward V gear ≥ 29.7 km/h
Forward IV gear ≥ 22.5 km/h
Forward III gear ≥ 14.2 km/h
Highest speed at different Forward II gear ≥ 14.2 km/h
gears
Forward I gear ≥ 7.2 km/h
Backward I gear ≥ 7.2 km/h
Backward II gear ≥ 14.2 km/h
Backward III gear ≥ 29.7 km/h
Main transmission mode Bevel gear reduction
Differential and final drive Super gear and planetary
Wheel speed reduction mode
gear speed reduction.
5-4
5.2 Gearbox &torque converter as
5.3.1 Working principle of steering case
5.2 Gearbox &torque con- b： If the machine does not need to be over-
hauled, only the middle section of the rear
verter as axle needs to be repaired, operate accord-
ing to the steps of “Removal of Rear Axle
from Machine”;
5.3 Rear axle and tandem 3. Repair the components of the rear axle accord-
ing to the Service Manual of Xuzhou Meritor
Rear Axle;
5.3.1 Working principle of steer-
ing case Remove the rear axle from rear frame:

of steering case and adjust-
ment on chains
1. If only the rear axle tandem needs to be
repaired, it is not necessary to remove the rear
axle from the machine.
2. If the middle of the rear axle needs to be
repaired, it is necessary to remove the rear axle
from the machine or rear frame. There are two
circumstances:
a: If the machine needs to be overhauled,
remove according to the removal steps of Remove the 4 fastening bolts on the 2 bottom plates
main components from front frame and of the rear frame, and remove the 2 bottom plates;
rear frame. After removal, only the rear
frame, rear axle and tyres are reserved.
The final state is:
Operate according to the steps of “Removal of

Rear Axle from Rear Axle Stand”;
5-5
5.3 Rear axle and tandem
5.3.2 Removal and installation of steering case and adjustment on chains
Use an air gun and open-end wrench to screw the 8

fastening bolts and nuts out from the rear axle and
rear frame; suspend the rear frame slowly;
Thread the lifting rope through both sides of the

front end and rear end of the rear axle, at 3 posi-
tions in total as shown in the figure; lift the rope
slowly till it is stretched tight;
Use a wire rope to suspend the two lifting eyes in

the middle of the rear axle; loosen the top nut, but
do not screw it out; remove the other 9 fastening
nuts on the tyres; remove the fastening nuts on the
other side by the above steps;
5-6
5.4 Front axle
5.4.1 Function of front axle
Unscrew the top nut and detach the 4 tyres from the
rear axle orderly;
Notice: During detachment, nobody is allowed to
stand within 1.5m from the tyres; otherwise, the
tyres may hit him/her.
5.4 Front axle
5.4.1 Function of front axle

The front axle as is installed on the front frame by
being connected with the front frame via a pin and it
is used to carry the weight on the machine; when
driving the grader, steer the grader and guarantee
its stable operation under the forces of the steering
cylinder and the tilt cylinder.
5-7
5.4 Front axle
5.4.2 Structure diagram of front axle
5.4.2 Structure diagram of front

axle
1. Bolt 22. Bolt

2. Elastic shim 23. Ball pivot
3. COVER 24. Nut
4. Gasket 25. Cotter pin
5. Lock plate 26. Bolt
6. COVER 27. Washer
7. Shim 28. Plate
8. Conical roller bearing 29. Pin
9. Front wheel hub 30. V-ring
10. Conical roller bearing 31. Shim
11. Oil seal 32. Thrust washer
12. Backup ring 33. Bearing
13. Screw 34. Wheel tilt linkage
14. Bearing bush 35. Swing frame
15. Right steering knuckle 36. Left steering knuckle
16. Steering pin 37. Lean-joint
17. Grease fitting 38. Bolt
18. Bolt 39. Nut
19. Bolt 40. Steering linkage
20. Nut 41. Bolt
21. Washer 42. Elastic shim
5-8
5.4 Front axle
5.4.3 Removal and installation of front axle
43. Washer 57. Pin

44. Disk 58. Dust ring
45. Cap 59. Bearing
46. Clamp ring 60. Cotter pin
47. Bolt 61. Nut
48. Ball joint seat 62. Washer
49. Ball base 63. V-ring
50. Dust cover 64. Thrust washer
51. Lock ring 65. Bearing
52. Grease fitting 66. Shim
53. Cotter pin 67. Thrust washer
54. Lean-joint 68. Thrust roller needle bearing
55. Ring shim 69. V-ring
56. Bushing 70. Pin

of front axle
Remove the 2 hydraulic hoses of the right steering

cylinder and the 2 hydraulic hoses of the tilt cylinder;
Notice: Because certain pressure exists in the
Use M12 bolts in the middle of the axle stand and tilt hydraulic hoses, you can unscrew the hydraulic
rod, and screw on the nuts, wherein, the length of hoses only after the pressure is totally released by
the M12 bolts is more than 95 and the strength of unscrewing the hose nuts for one to two circles and
the M12 bolts is Grade 10.9; knocking the connectors; otherwise, hydraulic fluid
may spray out;
Notice: Proceed with the next steps after the axle
stand and the tilt rod are connected via bolts; other-
wise, potential safety hazard may occur because of
tilt tyres during removal;
5-9
5.4 Front axle
Shield the fillers of the above four hoses and insert

the hoses into the front frame holes;
Shield the fillers of the above four hoses and insert

the hoses into the front frame holes;
Screw out the 2 bolts on the stop plate (Parts
spec:M16×40-8.8-Zn., wrench or socket
spec:24mm), and remove the stop plate;
Remove the 2 hydraulic hoses of the left steering

cylinder;
Use a wire rope to suspend the front frame till the

tyres are lifted off the ground;
5-10
5.4 Front axle
2 persons respectively push the tyres to roll them

forward;
Use an iron bar to knock the pin that connects the

front axle with the front frame;
Lay down the front frame; use hooks to hook on the
two lifting holes in the middle of the front axle and lift
the front frame to a wide field;
Suspend the front frame slowly to detach the front

axle from the front frame;
Loosen the top nut, but do not screw it out; remove

the other 9 fastening nuts on the tyres; remove the
fastening nuts on the other side by the above steps;
5-11
5.4 Front axle
5.4.4 Removal of front axle wheel hub
Screw out the top nuts to detach the tyres from the Lift the axle carrier to overturn the axle carrier;
front axle;
Notice: During detachment, nobody is allowed to
stand within 1.5m from the tyres; otherwise, the
tyres may hit him/her.
Lift the axle carrier on the support;
Installation steps of front axle assembly:

Lay the axle carrier on the ground; thread the lifting
removal;
rope through the front axle;
5.4.4 Removal of front axle

wheel hub
Method 1: remove the axle as and put it in place
according to the steps of “Removal of Front
Axle As”. This method is suitable for overhaul of
the front axle, such as overhaul of the connect-
ing pin between the front axle and the front
frame, replacement of the front axle hub as and
lean-joint as, etc.
5-12
5.4 Front axle
Method 2: If only the front axle hub as and lean-

joint as need to be repaired, the steering cylin-
der and the tilt cylinder can be replaced directly
on the machine; the replacement steps are:
Remove the tyres: use a crowbar and a hex socket

to remove the 10 nuts (Parts spec:M22×1.5-10-
Zn.D, socket spec:33mm), and use a lifting tool to
drop down the tyres;
Place the machine: place 2 approximately 50mm-
thick wooden strips on the ground to support the Removal of front axle wheel hub assem-
blade, adjust the lift cylinder, descend the blade bly:
body till it contacts the wooden strips, and suspend
the front wheels 10~30mm.
Remove the cover: use a wrench or open-end

wrench to screw off the bolts (Part spec: M6×16-8.8-
Zn.D, wrench spec:10mm) of the cover on the hub.
5-13
5.4 Front axle
Remove the lock plates: use a slotted screwdriver Remove the bolts: use an inner hexagon socket to
and a hammer to remove the 3 lock plates. remove M20 bolts (Part spec M20 ×50-10.9-Zn.D,
wrench spec: 30 mm).
Remove the bolts: Use a wrench or open-end

wrench to remove 6 M12 bolts (Part spec: M12×45- Use M20 bolts to remove the cap. There are adjust-
8.8-Zn.D, wrench spec: 18mm). ing shims on the cap. Avoid losing the adjusting
shims.
5-14
5.4 Front axle
Remove the bearing cone: use a puller and wrench

to remove the bearing cone from the axle by the fol-
lowing steps: Adjust the puller, fix the screw rod of
the puller in the threaded holes of the M20 bolts
(arrange a washer on the threaded end of the puller
to protect the threads from damage), fix the pulling
end of the puller on the snap ring, and pull out the
bearing cone and the snap ring by rotating the
screw rod on the puller with a wrench.
Remove the hub: use a copper bar to knock on the

circumference of the inner side of the hub uniformly
(rotate and knock the hub simultaneously) till the
hub is removed.
Assemble the snap ring: after the bearing cone and

the snap ring are pulled out, detach the bearing
cone from the snap ring and install the snap ring on
the axle immediately.
5-15
5.4 Front axle
the following steps: Connect the edge of the copper

bar with the bearing cup, knock the copper bar
(change the position of the copper bar at the sym-
metry point of the circumference of the bearing cup
to ensure that the bearing can be knocked out more
easily) with the hammer till the bearing cup is
knocked out, erect the hub and continue to knock
the hub when the end face of the bearing cup is
flush with the end face of the hub, till the bearing
cup is completely detached from the hub cone.
Clean up the grease: Clean up the grease in the

axle and the hub.
Detach the other bearing cup: turnover the hub,

place it on the ground, and knock out the other
bearing cup by the above steps.
Assembly steps of the front axle hub:
Inspect the new bearing: Take out the new bearing,

check for impurities, and assemble it if no abnormal-
Remove one bearing cup: use a copper bar and a ity is found. If any abnormality is found, replace the
hammer to remove one bearing cup in the hub by bearing.
5-16
5.4 Front axle
Make preparations prior to assembly of the bearing Assemble one bearing cup: Use a tooling and cop-
cup: Apply a little grease in the place where the per bar to assemble the bearing cup on the hub (the
bearing cup is to be assembled on the hub. bearing cup needs being screwed to the bottom).
Assemble the other bearing cup: Turn over the hub
on the ground, and assemble the other bearing cup
by the above steps.
Assemble the bearing cups: Assemble the bearing

cups on the hub, and use a copper bar to tighten
them gently.
Clean the external circle surface of the snap ring,
apply gear oil to the external circle, and sheath the
oil seal on the snap ring then to the steering
knuckle; apply a little grease on the axle.
5-17
5.4 Front axle
Assemble the bearing cones adjacent to the snap Assemble the other bearing cone: Two persons
ring. Pay attention to the direction: The bearing assemble the hub on which the new bearing cup is
cones with bigger taper are assembled inwards. assembled on the axle. Pay attention to the hub
Use a copper bar and tooling to assemble the bear- direction: The side of the hub that has bolt threads
ing cones in place. faces outwards.
The figure shows the state where the bearing cone Assemble the other bearing cone: One person fixes
adjacent to the snap ring is assembled. the hub, and the other person gently presses the
other bearing cone on the axle.
5-18
5.4 Front axle
5.4.5 Adjustment of front axle steering linkage
Assemble the other bearing cone: Gently press the Check the bearing assembly: Use a copper bar to
bearing cone on the axle, and use a tooling and knock on the circumference of the inner side of the
copper bar to assemble the bearing cone in place. rub gently for 3 to 4 times (The positions that are
knocked should be distributed on the external circle
of the rub), rotate the rub after knocking, and check
the assembly. If there is no clamping stagnation and
abnormal sound, proceed with the next step; if any
abnormity is found, it is necessary to remove the rub
and the bearing to recheck the bearing as, and
assemble the bearing after no abnormity is found, till
the bearing as passes examination.
5.4.5 Adjustment of front axle

steering linkage
Tilt cylinder
The figure shows the state where the bearing cone

is assembled.
Steering
cylinder
1. Linkage 2. Bolt 3. Nut 4. Clamp ring 5.Spherical hinge base

6. Cap
1. Firstly, stretch out and draw back the steering

cylinder and the tilt cylinder, swing the carrier
and rotate the tyres. The axle as is placed hori-
5-19
5.4 Front axle
5.4.6 Adjustment of clearance and torque after assembly of hub
zontally prior to use. Use a tape to measure the 5.4.6 Adjustment of clearance
distance between the right steering knuckle and
the left steering knuckle and keep a record; and torque after assembly of
2. The theoretical value of the distance between hub
the right steering knuckle and the left steering
knuckle of the front axle is:1650±10 mm ；
3. Judge whether the measured distance between
the right steering knuckle and the left steering
knuckle of the front axle is within the range of
the design theoretical value. If the measured
value exceeds the design theoretical value,
make adjustments;
4. Adjust the steering linkage distance. Unscrew
the nuts (3) on the clamping rings (4) at both
ends of the linkage (1), use a handle to seize
the nut blocks on the linkage (1), and slowly
rotate the linkage (1) forwards or backwards till
the distance between the right steering knuckle
and the left steering knuckle of the front axle is
within the range of the design theoretical value; Re-assemble the glands and shims (Take care not
screw the nuts (3) and the bolts (2) on the to miss the shims on the glands);
clamping rings (4).
5. Open the glands (6) on the ball hinge seats (5)
at both ends of the linkage, take out the upper
ball seat, fill grease into its chamber and then
cover the upper ball seat and glands;
6. Stretch out and draw back the steering cylinder
and tilt cylinder and test the rotation flexibility of
the front axle.
Assemble the glands and shims on the hub;

5-20
5.4 Front axle
Use a torque wrench to tighten M20 bolts (Part After knocking, grip the bolt on the hub with the
spec: M20×50-10.9-Zn.D, wrench spec: 30mm) to hands, rotate the hub forcefully, check the number
480N⚫m; of turns of the hub, and 3/4-5/4 turns are qualified.
Use a copper bar to knock the circumference of the If the number of the turns is smaller than 3/4, it is
inner side of the hub for four to 4-6 times (The posi- necessary to remove the M20 bolts, glands and
tions that are knocked should be distributed on the shims to reduce the thickness of the shims; if the
external circle of the rub); number of the turns is bigger than 5/4, it is neces-
sary to increase the thickness of the shims. After
adjustment, reassemble the M24 bolts, glands and
shims. After assembly, recheck the number of turns
and adjust it to 3/4-5/4 by increasing or reducing the
thickness of the shims.
5-21
5.4 Front axle
After the number of turns is adjusted to 3/4-5/4, Assemble the lock plates: place new lock plates on
remove the M20 bolts, apply thread locker to them the tooling.
along with 6 M12 bolts (Part spec: M12×45-8.8-
Zn.D, wrench spec: 18mm) all over the circumfer-
ence;
Use a hammer and tooling to assemble the lock

plates on 2 adjacent bolts. Each hub needs 3 lock
plates to lock 6 M12 bolts.
After thread locker is applied, use the torque wrench
to tighten the 7 bolts, and the requirements for
torque are: Torque for M12 bolt is 90 N⚫m, and for
M20 bolt is 480 N⚫m.
5-22
5.4 Front axle
The figure shows the state where the lock plates are Apply a circle of seal along the mounting holes of
assembled. the cover; stick the gasket to the cover and apply
seal to the gasket;
Assemble the cover: use a 10 mm wrench to reas-

semble the cover on the hub, i.e. tighten the bolts
(Part spec: M6×16-8.8-Zn.D, wrench spec: 9 mm)
Fill grease: Fill grease till it spills over.

5-23
5.4 Front axle
5.4.7 Adjustment of pre-tightening torque for wheel hub inner bearing
5.4.7 Adjustment of pre-tighten-

ing torque for wheel hub inner
bearing
Assemble the tyres: assemble the tyres on the

hubs, assemble the bolts, and use the torque
wrench to tighten the bolts to the torque of 600 N⚫m.
1. Cover 2. Cover 3. Bolt 4. Bolt 5. Lock plate 6. Bolt 7. Spring washer 8. Gasket 9. Shim 10. Conical roller bearing
11. Grease fitting 12. Front wheel hub 13. Shaft sleeve 14. Oil seal 15. Screw 16. Backup ring 17.Steering knuckle
1. Examine and repair the front axle hub. If the bearing in the hub needs replacement, when
replacing and assembling new tapered roller
5-24
5.5 Tyre
5.5.1 Tyre function
bearing, assemble bushing (13), tapered roller

bearings (10), oil seal (14), front wheel hub
5.5.2 Structure of tyre assembly
(12), tapered roller bearings (10), shims (9), and its related parameters
cover (2), bolts (3), lock plates (5) and bolts (4)
orderly;
5.5.2.1 Structure of tyre rim assem-
2. Before filling lubricant into the shaft in the
chamber of the hub, make the torque of the 2 bly
tapered roller bearings (10) reach 7.5-9 N.m by
increasing and reducing the number of the
shims and the torque of bolts (3) and bolts (4);
3. Assemble backup ring (16), screws (15), gasket
(8), cover (1), spring washer (7), bolts (6) and
grease fitting (11); fill lubricant into the chamber
of the hub through the grease fitting (11).
5.5 Tyre
5.5.1 Tyre function

The tyre as is fixed on the front axle and the rear
axle of a grader with the hub bolts. They have the
functions of carrying the load of the grader, drawing
the grader to drive, changing the driving direction,
absorbing shock to keep comfort, etc.
Structure details of tyre rim assembly

1. Tyre assembly
2. Rim assembly
5-25
5.5 Tyre
5.5.2 Structure of tyre assembly and its related parameters
5.5.2.2 Structure of rim assembly Structure details of rim assembly

1. Rim base
2. Snap ring
3. Lock ring
5.5.2.3 Technical parameters rated

to tyre assembly
New Width
of new
Part Tyre tyre
Model tyre Inflation
Tyre tread inflatio Max. load (kg) Matched rim
s ply inflatio
n pressure
nam and spec ratin n
diamet (Kpa)
e g sectio
er
n
(mm)
(mm)
41C0167:
25-14.00/1.5
L-3 bulk
Tyre 17.5-25- 41C0166:
12 (corru- 1350 445 50Km/h:225 50Km/h:3650
25-14.00/1.5
asse 12/L-3/ gated tyre,
10Km/h:350 10Km/h:6150 41C1389:
mbly G-12 TT i.e. bias
tyre) 25-14.00/1.5
41C1405:
25-14.00/1.5
5-26
5.5 Tyre
5.5.3 Tyre common fault mode
5.5.3 Tyre common fault mode 1. There is a manufacturing defect (such as

delaminating, nonuniform density of cords,
1. Sidewall protrusion Causes for sidewall pro- etc.);
trusion: 2. The tyres are seriously damaged under
1. During manufacture, the density of the tyre external force (impact, puncture, etc.);
cords is not uniform, and the connection 3. Drive at excessive load or speed (design
among the tyre cords is poor; tyre speed);
2. During installation, the tyre cords at the 4. During use, the air pressure is over low or
bottom of the tyre bead are scratched; over high;
3. During use, the tyre cords are bruised,
6. Tyre indentation - Cause of tyre indentation:
punctured, scratched, etc.
1. It is caused by poor manufacture or
2. Abnormal wear improper use;
1. Wear in the center: The tyre pressure is 2. The tread is punctured or the sidewall is
over high, and the pressure at the center of scratched;
the tread to the ground is over high; 3. The rim is deformed by impact or the iron
2. Wear on both sides: The tyre pressure is rim welded joint snaps;
over low, and the pressure at the two tyre 4. The sealing of the valve cock gasket or
shoulders to the ground is over high; valve core is poor.
3. Concentrated wear: The locking and brak-
ing of the brake is not uniform, the rim is
deformed, the assembly parts are abnor-
mal, etc.
3. Ply separation- Cause:

1. During molding, the components are not
compacted and there is greasy dirt or for-
eign matter on the surfaces of semi-fin-
ished parts;
2. Drive at excessive load or speed (design
tyre speed);
3.Roll off at low pressure.
4. Tyre surface deformation cause for tyre sur-

face deformation:
1. The thickness of the glue on the tread

base is below the standard;
2. During use, the inflation pressure is over
high or the crown is punctured.
5. Flat tyre- Cause of flat tyre:

5-27
5.6 Drive shaft
5.6.1 Structure of pump drive shaft
5.6 Drive shaft
5.6.1 Structure of pump drive

shaft
1. Bolt 10. Flange

2. Grease fitting 11. Bolt
3. Bracket 12. Washer
4. Backup ring 13. Washer
5. Ball bearing 14. Drive shaft
6. Spacer ring 15. Washer
7. Seal ring 16. Bolt
8. COVER 17. Bolt
9. Bolt 18. Protection shield
5-28
5.6 Drive shaft
5.6.2 Removal and installation of pump drive shaft

of pump drive shaft
Screw off four fastening bolts from the pump bracket

(Part spec: M16×40-8.8-Zn.D, Spec of remover
sleeve: 24 mm);
Screw off the 4 fastening bolts of the hood (Part
spec: M6×16-8.8-Zn.D, socket spec: 10mm) and
remove the hood;
Screw off the two fastening bolts from the mounting

plate;
Screw off the 4 fastening bolts of flange (Part spec:

M10×35-10.9-Zn.D, socket spec: 16mm) and
remove the hood;
5-29
5.6 Drive shaft
5.6.3 Structure of rear axle drive shaft
Lay the pump as on the ground, and shield the filler

of the steel oil filling pipe;
Assembly steps of the pump drive shaft as: The
reverse order of the removal steps.
5.6.3 Structure of rear axle

drive shaft
Tie the lifting rope to the pump as;
1. Drive shaft
2. Bolt

of rear axle drive shaft
Pull out the pump and lift it;
5-30
5.7 Worm box
5.7.1 Function of worm box
Under the rear frame, screw off the 4 fastening bolts

(Part spec: 1/2-20UNF×55, socket spec: 16mm)
connecting the rear drive shaft and the gearbox;
screw off the 4 fastening bolts that connect the rear
drive shaft with the rear axle; remove the rear drive
shaft.
Assembly steps of the rear drive shaft as: The
reverse order of the removal steps.
5.7 Worm box
5.7.1 Function of worm box

This worm box is used to drive the work implement.
It drives the work implement to rotate clockwise or
anticlockwise, so as to meet the work requirements
of the work implement. This worm box can bear
large load and impact. It is highly adaptive to all
working conditions.
5-31
5.7 Worm box
5.7.2 Structure diagram of worm box
5.7.2 Structure diagram of

worm box
1. Bolt 13. Gasket

2. Washer 14. Oil seal
3. Cover 15. Gear shaft
4. Sleeve 16. Plug
5. Support 17. Washer
6. O - ring 18. Plug
7. Shim 19. Washer
8. Conical roller bearing 20. Screw
9. Worm 21. Round dipstick
10. Housing 22. Plug
11. Adjusting shim 23. O - ring
12. Conical roller bearing 24. Screw
5-32
5.7 Worm box
5.7.3 Removal of worm box
25. Washer 33. Washer

26. Conical roller bearing 34. Nut
27. Worm gear 35. Gasket
28. Steel sleeve 36. Bolt
29. Adjusting shim 37. Cap
30. Gasket 38. O - ring
31. Housing cover 39. Foam gasket
32. Bolt 40. Cap
M24; bolt part spec: M24×120-8.8-Zn.D, socket

5.7.3 Removal of worm box spec: 36mm)
Screw in 2 lifting rings (M10 thread). 2 persons use

a crowbar to remove the worm box from the work
implement;
Use a crowbar and a socket to remove the two bolts

in front of the worm box (Part spec: M24×80-10.9-
Zn.D, socket spec: 36mm);
Use a wrench to seize the 2 bolts at the back, and
use a crowbar and a socket to remove the 2 lock-
nuts at the back of the worm box (locknut part spec:
5-33
5.7 Worm box
Place a drip pan just below the oil drain hole; use an
inner hexagon spanner to remove the plug at the oil
drain hole (wrench spec: 10mm);
Use an inner hexagon spanner to remove 8 screws

of the cover (Part spec: M8×16-8.8-Zn.D, spanner
spec: 13mm);
Drain the gear oil in the worm box body through the
oil drain hole; screw back the plug;
Pry off the cover with a hammer and a straight

screwdriver
Use an inner hexagon spanner to remove the 2
screws that connect the hydraulic motor with the
worm box, and remove the hydraulic motor (Part
spec: M10×35-10.9-Zn.D2, spanner spec: 16mm);
5-34
5.7 Worm box
Use a hammer and screwdriver to flatten the turn-up Take down the adjusting shim
of the washer, use a hammer and an iron bar to
chisel and loosen the nuts, and remove the nuts and
the washer.
Turn over the worm box 90° to make the gear shaft
horizontal, put a cardboard under the top end of the
gear shaft, and use a hammer to knock the gear
Use a wrench to remove 12 cover bolts (Part spec: shaft, loosen it and remove it;
M10×30-8.8-Zn.D, wrench spec: 16mm);
Screw two bolts into two fabrication thread holes,
eject out the cover and the bearing out slowly and
remove them;
5-35
5.7 Worm box
Use an iron bar and a hammer to knock out the

bearing cup gently at the two semi-circles of the
housing;
Level the worm box and remove the steel sleeve;
Remove the adjusting shim from the bearing cone;
Take out the turbine from housing
Align the screw rod tip of the puller with the center
hole at the top end of the gear shaft, fix the pull end
of the puller on the skeleton oil seal through the
backlash, use the wrench to screw out the screw
rod of the puller, and pull out the bearing cone and
the seal (Notes: the skeleton oil seal and the bear-
ing cone will be damaged when they are pulled out,
so replace new skeleton oil seal and the bearing
cone during assembly).
5-36
5.7 Worm box
5.7.4 Installation of worm box
Use an inner hexagon spanner to remove 8 screws

that connect the support with the housing (Part
spec: M10×70-8.8-Zn.D, wrench spec: 15mm), Use the copper bar and worm bearing cup to press
screw up two screws (M10, the length of the front in the tooling and knock the bearing cup into the
thread is not less than 70mm) into the fabrication housing hole (Notes: It is not allowed to press in the
thread holes on the support to eject out the support; bearing cup by knocking the worm assembly);
Use an inner hexagon spanner to remove the mid- Put in the worm as that is equipped with the bearing
dle plug (Part spec: M18×1.5-6g, inner hexagon cone, and the bearing cup orderly;
spanner spec: 8mm); use a socket wrench to
remove the two right and left plugs (Part spec: M10,
socket spec: 16mm): Use the wrench and bolts
(M18×1.5-6g, length of thread not less than 40mm)
to eject out the worm assembly through the thread
holes and remove the bolts; use the wrench and
bolts (M10, length of thread not less than 30mm) to
eject out the worm bearing cup in the chamber
through the thread holes on both sides and remove
the two bolts;
5-37
5.7 Worm box
Use the copper bar and the bearing cup to press in Lay the worm box housing flat, align the support
the tooling and tighten the bearing cup; with the thread holes and assemble it on the hous-
ing, insert the other 6 screws (pre-apply thread
locker), and use 52±7N⚫m torque to screw up the
eight screws; rotate the worm, no clamping stagna-
tion and loosening of the worm allowed; otherwise
increase or reduce the shims;
Insert screws in the two diagonal holes, assemble

the shims and the O-ring on the support, and apply
thread locker on screws;
Apply grease on the lip of the oil seal of the skele-

ton;
5-38
5.7 Worm box
Sheath the oil seal of the skeleton into the gear Use a hammer and a tooling to press the bearing
shaft, press it to the bottom and take care not to turn cone into the gear shaft; install the shims on the
up the lip of the oil seal; the oil seal opening should gear shaft;
face the non-gear end, and it is not allowed to
assemble the oil seal in the reverse direction;
5-39
5.7 Worm box
Turn over the worm box housing, and use a cotton Place the worm gear into the gear box housing; 2
cloth to clean the assembly part between the hous- persons lift the worm box housing together, align the
ing and the bearing cup; use a tooling and hammer worm gear with the gear shaft spline, drop the worm
to press the bearing cup into the housing and press gear and take care not to drop out the washers;
it to the bottom and then place the shims in;
Use a copper bar and a tool to knock the turbine to

the bottom
Use a copper bar and a tool to knock the steel
sleeve to the bottom; install the shims on the gear
shaft;
Sheath the steel sleeve into the gear shaft (take

care to place the side with the bigger size facing
down so that positioning is realized) and lay it flat;
Apply a circle of seal on the housing, use the gasket
and then apply another circle of seal;
5-41
5.7 Worm box
Use a hammer to knock the housing cover uniformly

to press it entirely into the housing; screw up each
bolt to the torque of 52N⚫m according to the order of
crossing diagonal lines;
Install two M10 bolts respectively on two corre-

sponding fabrication holes; use two bolts to assem-
ble the cover on the housing;
5-42
5.7 Worm box
Use a hammer and tooling to knock the bearing to

the bottom; sheath the shims into the gear shaft;
Apply a circle of seal on the housing cover, use the

gasket and then apply another circle of seal; align
Screw in the nuts, and use a hammer and an iron with the mounting holes and assemble the cover,
bar to knock and tighten the nuts till the gap of the and use an inner hexagon spanner to press the
nuts aligns with the protrusion of the lock washers; eight screws and the shims to a torque of 26N⚫m;
use a screwdriver to pry up the lock washer;
5-43
5.7 Worm box
5.7.5 Adjustment on worm box installation
5.7.5 Adjustment on worm box

installation
Pad up the worm box, enable the gearbox to rotate,

and use a tooling and wrench to test whether the
worm box can rotate freely;
Washer
Before installing the worm gear on the worm, guar-

antee an axial play of 0.030.10 of the worm by
adjusting the thickness of the washers, and pre-load
a pre-tightening torque of 1.5-2.6N⚫m to the bear-
ings at both ends of the worm;
5-44
5.7 Worm box
5.7.5 Adjustment on worm box installation
Washer
Turbine
worm rod
Gasket
Adjust the thickness of the shims to make the con-

tact area between the shims and the worm gear
teeth surface locate in the middle of the teeth; the
contact patterns between the shims and the worm
are not less than 45% as per the teeth height and
not less than 40% as per the teeth length;
Test and oil filling of worm box

After the worm box is assembled and there is no for-
eign matter in it, fill in 80W-90 heavy-load wheel
gear oil (GL-5) to carry out no-load operation test,
and the worm speed is 200r/min at this time; oper-
ate the worm box for 10min respectively clockwise
and anti-clockwise; the operation of the worm box
should be stable, without impact, abnormal noise or
leakage; the temperature rise of the housing is not
more than 40 ℃ . After no-load operation, drain the
test oil, rinse off the worm box and fill in SAE 80W-
90/LS lubricant, wherein, the cleanliness of the
lubricant is 20/17 ISO.4406. Fill about 3L of lubri-
cant, till the lubricant level exceeds the symbol.
6-1
Table of Contents
6. Hydraulic System
Table of Contents
6.1 Main Technical Parameters of Hydraulic System........................................... 6-5
6.2 Overview of Hydraulic System ....................................................................... 6-6
6.2.1 Hydraulic oil.................................................................................................................6-8
6.3 Summary of Working Hydraulic System.........................................................6-9
6.3.1 Hydraulic oil tank.......................................................................................................6-12
6.3.1.1 Installation position and functional structure of hydraulic oil tank....................6-12
6.3.1.2 Removal and assembly steps of hydraulic oil tank from and to the machine..6-13
6.3.2 Work pump................................................................................................................6-16
6.3.2.1 Installation position and working principle of working pump............................6-16
6.3.2.2 Internal structure and maintenance instructions of working pump ..................6-18
6.3.2.3 Removal and assembly steps of working pump from and to the machine ......6-21
6.3.3 Left control valve .......................................................................................................6-23
6.3.4 Right control valve.....................................................................................................6-25
6.3.4.1 Installation position and functional structure of control valve on the right side 6-25
6.3.4.2 Removal and assembly steps of control valve on the right side from and to the
machine.......................................................................................................................6-26
6.3.5 Swing motor ..............................................................................................................6-30
6.3.5.Installation position and functional principle of swing motor...............................6-30
6.3.5.2Internal structure of swing motor ......................................................................6-31
6.3.5.3 Removal and assembly steps of swing motor from and to the machine .........6-33
6.3.6 Swivel joint ................................................................................................................6-33
6.3.6.1 Installation location and internal structure of swivel joint.................................6-33
6.3.6.2 Removal and assembly steps of swivel joint from and to the machine ...........6-36
6.3.7 Blade angle changing cylinder-lh ..............................................................................6-37
6.3.7.1 Installation position and internal structure of blade angle changing cylinder-lh ..6-
37
6.3.7.2 Removal and assembly steps of blade angle changing cylinder-lh from and to the
machine.......................................................................................................................6-38
6.3.8 Blade angle changing cylinder-rh..............................................................................6-39
6.3.8.1Installation position and internal structure of blade angle changing cylinder-rh ...6-
39
6-2
Table of Contents
6.3.8.2 Removal and assembly steps of blade angle changing cylinder-rh from and to the
machine ...................................................................................................................... 6-40
6.3.9 Blade outlet cylinder ................................................................................................. 6-41
6.3.10 Blade lift cylinder-lh ................................................................................................ 6-42
6.3.10.1 Installation position and internal structure of blade lift cylinder-lh................. 6-42
6.3.10.2 Removal and assembly steps of blade lift cylinder-lh from and to the machine 6-
43
6.3.11Blade lift hydraulic lock-lh ........................................................................................ 6-45
6.3.11.1 Installation position and internal structure of blade lift hydraulic lock-lh........ 6-45
6.3.11.2 Removal and assembly steps of blade lift hydraulic lock-lh from and to the
machine ...................................................................................................................... 6-46
6.3.12 Blade lift cylinder-rh ................................................................................................ 6-47
6.3.13 Blade lift hydraulic lock-rh....................................................................................... 6-47
6.3.14 Circle sideshift cylinder........................................................................................... 6-47
6.3.15 Circle sideshift hydraulic lock ................................................................................. 6-49
6.3.16 Front wheel tilt cylinder........................................................................................... 6-49
6.3.16.1 Installation position and internal structure of front wheel tilt cylinder............ 6-49
6.3.16.2 Removal and assembly steps of front wheel tilt cylinder from and to the machine
6-51
6.3.17 Front wheel tilt hydraulic lock ................................................................................. 6-52
6.3.17.1 Installation position and internal structure of front wheel tilt hydraulic lock .. 6-52
6.3.17.2 Removal and assembly steps of front wheel tilt hydraulic lock from and to the
machine ...................................................................................................................... 6-53
6.3.18 Hitch steer cylinder ................................................................................................. 6-54
6.3.18.1 Installation position and internal structure of hitch steer cylinder ................. 6-54
6.3.18.2 Removal and assembly steps of hitch steer cylinder from and to the machine 6-
55
6.3.19 Blade cylinder ......................................................................................................... 6-56
6.3.19.1 Installation position and internal structure of blade cylinder ......................... 6-56
6.3.19.2 Removal and assembly steps of blade cylinder from and to the machine.... 6-57
6.3.20 Blade hydraulic lock................................................................................................ 6-59
6.3.20.1 Installation position and internal structure of blade hydraulic lock................ 6-59
6.3.20.2 Removal and assembly steps of blade hydraulic lock from and to the machine ..
6-59
6.3.21 Ripper cylinder........................................................................................................ 6-60
6.3.21.1 Installation position and internal structure of ripper cylinder......................... 6-60
6-3
Table of Contents
6.3.21.2 Removal and assembly steps of ripper cylinder from and to the machine ....6-62
6.3.22 Ripper hydraulic lock...............................................................................................6-62
6.3.22.1 Installation position of ripper hydraulic lock...................................................6-62
6.3.22.2 Removal and assembly steps of ripper hydraulic lock from and to the machine..
6-62
6.3.23 Description of functional principles of work hydraulic system .................................6-63
6.4.1 Introduction to steering hydraulic system principle .................................................6-101
6.4.2 Steering priority valve..............................................................................................6-104
6.4 Introduction to Steering Hydraulic System ................................................... 6-99
6.4.1 Introduction to steering hydraulic system principle .................................................6-101
6.4.2 Steering priority valve..............................................................................................6-104
6.4.2.1 Installation position and functional structure of steering priority valve ..........6-104
6.4.2.2 Removal and assembly steps of steering priority valve from and to the machine..
6-105
6.4.2.3 Brief introduction to steering priority valve working principle.........................6-105
6.4.3 Metering pump ........................................................................................................6-106
6.4.3.1 Installation position and functional structure of metering pump ....................6-106
6.4.3.2 Brief introduction to metering pump working principle...................................6-107
6.4.4 Steering cylinder ..................................................................................................... 6-110
6.4.4.1 Installation position and functional structure of steering cylinder .................. 6-110
6.4.4.2 Removal and assembly steps of steering cylinder from and to the machine 6-111
6.4.4.3 Brief introduction to steering cylinder working principle ................................ 6-112
6.4.5 Test and detection of steering hydraulic system pressure ...................................... 6-112
6.4.6 Common faults and service method of steering hydraulic system .......................... 6-115
6.5 Introduction to Brake Hydraulic System ..................................................... 6-118
6.5.1 Introduction to brake hydraulic system principle .....................................................6-120
6.5.2 Charge valve ...........................................................................................................6-126
6.5.2.1 Installation position and function of charge valve..........................................6-126
6.5.2.2 Overview of internal structure of charge valve ..............................................6-126
6.5.2.3 Removal and assembly steps of charge valve from the machine .................6-128
6.5.2.4 Brief introduction to charge valve working principle ......................................6-128
6.5.3 Accumulator ............................................................................................................6-132
6.5.3.1 Installation position and function of accumulator...........................................6-132
6.5.3.2 Removal and assembly steps of accumulator from and to the machine .......6-133
6.5.3.3 Introduction to working principle of accumulator ...........................................6-135
6-4
Table of Contents
6.5.4 Service brake valve ................................................................................................ 6-136

6.5.4.1 Installation position and functional structure of service brake valve ............. 6-136
6.5.4.2Removal and assembly steps of service brake valve from the machine ....... 6-138
6.5.4.3 Brief introduction to service brake valve working principle ........................... 6-138
6.5.5 Parking brake valve ................................................................................................ 6-146
6.5.5.1 Installation position and functional structure of parking brake valve............. 6-146
6.5.5.2 Removal and assembly steps of parking brake valve from and to the machine. 6-
147
6.5.5.3 Brief introduction to parking brake valve working principle........................... 6-150
6.5.6 Parking brake system ............................................................................................. 6-151
6.5.6.1 Introduction to parking brake system............................................................ 6-151
6.5.6.2 Pressure detection for parking brake system ............................................... 6-153
6.5.7 Service brake system ............................................................................................. 6-154
6.5.7.1 Introduction to service brake system ............................................................ 6-154
6.5.7.2 Pressure detection for service brake system................................................ 6-156
6.5.8Common faults and service method of brake hydraulic system .............................. 6-158
6.6 Introduction to Hydraulic Cooler System.................................................... 6-159
6.6.1 Introduction to hydraulic cooling system principle .................................................. 6-162
6.6.2 Cooling pump ......................................................................................................... 6-164
6.6.2.1 Installation position and working principle of cooling pump .......................... 6-164
6.6.2.2 Removal and assembly steps of cooling pump from and to the machine..... 6-164
6.6.3 Safety valve AS ...................................................................................................... 6-166
6.6.3.1 Installation position and internal structure of safety valve as........................ 6-166
6.6.3.2 Removal and assembly steps of safety valve AS from the machine ............ 6-168
6.6.3.3 Brief introduction to safety valve AS working principle ................................. 6-169
6.6.4 Fan motor ............................................................................................................... 6-170
6.6.4.1 Installation position and internal structure of fan motor ................................ 6-170
6.6.4.2 Removal and assembly steps of fan motor from and to the machine........... 6-171
6.6.4.3 Introduction to working principle of fan motor ............................................... 6-172
6.6.5 Return oil filter ........................................................................................................ 6-174
6.6.6 Test and detection of hydraulic cooling system pressure ....................................... 6-175
6-5
6.1 Main Technical Parameters of Hydraulic System
6.1 Main Technical

Parameters of Hydraulic
System
Main technical parameters of CLG4180 hydraulic system

Hydraulic oil L 186
Working medium
Cleanliness NAS 1638 ≤ 9 grade
Working pump CC/r 30/30
Working hydraulic Multi-way valve L/min 70
system Max. overflow of system L/min 26L/2200r/min
Max. working pressure

MPa 18
of the system
Metering pump CC/r 200
Number of steering cyl-

inder--internal radius X mm 2- φ 32 × 275
Steering hydraulic
distance
system Working pressure of the
Mpa 15 － 17
system
45°±1°for both left and
Steering angle °
right sides
6-6
6.2 Overview of Hydraulic System
Main technical parameters of CLG4180 hydraulic system

Max. pressure of ser-
MPa 10.3 ± 0.3
vice brake
Opening pressure of
MPa 12.8 ± 0.35
charge valve
Shut-off pressure of
MPa 15.9 ± 0.35
charge valve
Brake system
Low pressure alarm
pressure of driving brak- MPa 10
ing
Accumulator air pre- MPa 9.2
compression
Low pressure alarm
pressure of parking MPa 10
brake
Charge flow L/min 10.2±1.9
6.2 Overview of Hydraulic

System
The hydraulic system, the actuator of grader, con-
sists of the functional modules of work device
hydraulic system, steering hydraulic system, brake
hydraulic system and hydraulic cooling system, and
the system is provided with a typical open constant
flow pump hydraulic circuit. Of which the system
gives priority to oil supply to the steering circuit
through the priority valve to ensure the steering
function; similarly, the system gives priority to oil
supply to the brake circuit through the charge valve
to ensure the braking function; the work hydraulic
system controls the coordinated actions of various
cylinders and motors through the control valve to
meet the need of grader for adapting to different
operating conditions; the hydraulic cooling system
drives the fan through the motor and takes away
heat from the diffuser to cool the hydraulic oil and
ensure oil temperature within the reasonable scope
of work. The following is CLG4180 grader hydraulic
system schematic:
6-7
Fig. 6.2.1 Schematic of CLG4180 hydraulic system

6-8
6.2.1 Hydraulic oil
6.2.1 Hydraulic oil adapt to this variation and maintain stable perfor-
mance as required in order to guarantee the stability
Hydraulic oil is the working medium for delivering of operating state but not likely to cause great
energy in the hydraulic system, and it also has the changes or damages due to changes in external
functions of lubrication, sealing, cooling, rust protec- conditions, we have the following requirements for
tion, etc. In the CLG4180 grader hydraulic system, the technical parameters of hydraulic oil:
due to variation in pressure, speed and temperature
within a wide range, the applied hydraulic oil can
Main technical parameters of CLG4180 hydraulic oil

Summer: HM46 antiwear
Shell Tellus
hydraulic oil
Brand
Winter: HV46 antiwear
Hydraulic oil hydraulic oil
Oil quantity L 186
Cleanliness NAS 1638 ≤ 9

Change interval H 2000
Caution: Hydraulic oils of the same brand and differ-

ent specifications cannot be mixed, and hydraulic
oils of the same specification and different brands
cannot be mixed, either. If you must use hydraulic
oil of another brand for some reason, please clean
up the system first. For details, please refer to the
Maintenance Instructions.
In addition, whether the hydraulic oil is or not
directly affects the working performance of the
hydraulic system and the service life of hydraulic
components. According to statistics, at least 75% of
faults of the hydraulic system are due to the cleanli-
ness of hydraulic oil not up to standard. Therefore,
precautions for hydraulic oil pollution is necessary.
For grader, we shall firstly prevent pollutants from
entering the hydraulic system from the source: We
recommend to filter the oil products with the oil filter
vehicle in the process of refueling or renewing of
fuel to ensure that the oil products entering the
hydraulic system can meet the standard required by
us: ≤ NAS 1638 Class 9 standard.
Fig. 6.2.2 Oil filter vehicle

6-9
6.2.1 Hydraulic oil
6.3 Summary of Working Hydraulic System

The work implement hydraulic system is used to
control the movement of various work implements
(blade, ripper, dozer, etc.) of grader, including blade
lifting and lowering to the left/right, blade rotation,
blade sideshift relative to or along with the circle,
change of blade cutting angle, circle rotation, con-
traction & release of ripper and dozer, etc. The sys-
tem is a dual-pump and double-circuit hydraulic
system (see work hydraulic system schematic). It
consists of a sealed tank, a tandem hydraulic gear
pump, two sets of five-linked control valve, as well
as hydraulic cylinder, motor, hydraulic lock, line, etc.
of each work implement. Each circuit has its own
hydraulic pump, but hydraulic oil is from the same
tank, hydraulic oil for work is absorbed from the fuel
tank by two pumps, pumped oil is supplied to two
circuits, respectively, and the coordinated actions of
various cylinders and motors are controlled through
the control valve to meet the operational require-
ments of grader for adapting to different operating
conditions. CLG4180 grader work hydraulic system
schematic and layout drawing are as follows:
6-10
6.2.1 Hydraulic oil
Fig. 6.3.1 Work hydraulic system principle

6-11
6.2.1 Hydraulic oil
1. Hydraulic oil tank 8. Swing motor

2. Working pump 9. Swivel joint
3. Multi-way valve 10. Blade outlet cylinder
4. Blade ascending and descending cylinder 11. Blade angle changing cylinder
5. Circle sideshift cylinder 12. Blade lift hydraulic lock
6. Tilt hydraulic lock 13. Hitch steering cylinder
7. Front wheel tilt cylinder
Fig. 6.3.2 - Work Hydraulic System Layout Drawing
1. When the work system has no action, that is, device to flow to the oil tank to ensure normal
the control valve is in the neutral position, operation of the hydraulic system.
hydraulic oil is pumped out from the hydraulic 3. The bidirectional hydraulic lock installed to the
oil tank via the working pump, passing through blade tilt circuit and two blade lift circuits can
the priority valve, charge valve, left and right prevent displacement due to the weight and
control valves and return oil filter, respectively, load of equipment itself, and it ensures driving
back to the oil tank, forming a circulation circuit. safety and blade working precision.
2. When one or two control levers are pulled, 4. Since oil is supplied to the lift cylinder-lh and lift
hydraulic oil opens the check valve in the con- cylinder-rh by two circuits of the same flow, the
trol valve and enters corresponding hydraulic lifting of both lift cylinders is fundamentally syn-
cylinder or hydraulic motor to work. The role of
the check valve is to restrict oil in the working
6-12
6.3.1 Hydraulic oil tank
chronized at the same speed, so the working 6.3.1 Hydraulic oil tank
performance of grader is improved.
5. The safety valve integrated on the control
6.3.1.1 Installation position and
valve-lh and control valve-rh mainly plays a role
in overload protection of the system. functional structure of hydraulic oil
tank
The hydraulic oil tank, positioned on the front frame
in the middle of the machine, at the rear side of the
cab, is mainly used to store hydraulic oil for hydrau-
lic system operating cycle. Oil in the tank can pre-
cipitate pollutants, separate air and cool. Below is
the main structure diagram of hydraulic oil tank:
Fig. Structure diagram of hydraulic oil tank

1. Oil tank body 7. Drain plug
2. Return tube clamp 8. Dipstick
3. Direct return opening 9. Breather plug
4. Baffle 10. Filler cap
5. Tank cleaning cover 11. Return oil filter
6. Suction tube
6-13
Of which the return oil filter mainly filters the oil

returned to the hydraulic oil tank to avoid pollution
caused by dirt intruding the system again via the oil
tank; hydraulic oil is filled from the filler cap into the
tank after being filtered through the oil filter vehicle;
the breather plug is mainly used to avoid too much
oil flowing out of the tank during removal of oil suc-
tion line, before this, the plug must be removed first,
and must be reinstalled prior to machine starting;
the dipstick is mainly used for observation of the
level of oil in the tank; the drain plug is mainly used
to drain oil in the tank through this position; the suc-
tion tube mainly connects the oil tank with the pump
suction to supply oil to the pump; the tank cleaning
cover mainly cleans dirt inside the tank through this
position; the baffle plate mainly makes oil form iso- Remove 4 captive bolts (specification M10×20-
lated circulation of cold and hot oil in the tank to pre- 8.8-Zn.D, removal wrench or socket specifica-
vent a large number of bubbles from being tion 15mm) from the refueling breather AS on
generated due to too much oil sloshing. the hydraulic oil tank;
6.3.1.2 Removal and assembly steps

of hydraulic oil tank from and to the
machine
1. Removal steps of hydraulic oil tank AS from the
machine:
One person holds on to the ladder on the right

side of the cab to ensure that the ladder will not
fall in the following process of removal;
The other person screws out 4 captive bolts
(specification M10×40-8.8-Zn.D, removal
wrench or socket specification 15mm) from the
ladder;
Move the ladder away;
6-14
One person holds on to the plate-rh on the right Put a waste oil barrel on the right side of the
side of the cab to sure that the plate-rh will not cab to contain hydraulic oil;
fall in the following process of removal; Screw off the hose from the charge valve, and
The other person screws out 2 captive bolts lead the hose to the waste oil barrel to collect
(specification M10×30-8.8-Zn.D, removal oil;
wrench or socket specification 16mm) on the
right side;
(Complement graph)
Screw out 1 captive bolt (specification M8×16-
8.8-Zn.D, removal wrench or socket specifica-
tion 13 mm) behind the cab;
Remove the plate-rh;
After hydraulic oil is drained from the hydraulic

oil tank, lift the filler tube of hydraulic oil tank
with a lifting rope;
Find the position of charge valve;

6-15
Screw out 4 captive bolts (specification Screw out 4 return hoses with an open-end
M12×40-8.8-Zn.D, removal wrench or socket wrench (specification 36mm);
specification 18mm) from the split flange;
Screw out the tee with the open-end wrench;

Screw out 4 captive bolts (specification
M14×40-8.8-Zn.D, removal wrench or socket
specification 21mm) from the hydraulic oil tank;
6-16
6.3.2 Work pump
Lift up the hydraulic oil tank slowly away from Put the tank on the storage rack or keep the
the original position; note that the lifting process complete tank flat;
must be smooth, it is not allowed to damage the Shield all ports of the return tube, and shield the
cab glass; outlet tube port;
2. Assembly of hydraulic oil tank AS:
removal.
6.3.2 Work pump

working principle of working pump
The working pump is a tandem gear pump located
in the middle of the machine, below the cab, driven
by the engine to supply oil to the hydraulic system,
so as to realize various cylinder actions and supply
oil sources to steering and braking circuits.
Fig. - Gear Pump Working Principle Schematic

The gear pump works by using the meshing move- side with larger port is the suction port, and the side
ment of a pair of gears and causing volume with smaller port is the outlet.
changes in the suction and discharge chambers. It
is the suction port with a closed volume always in a
growing state, and it is the outlet with a closed vol-
ume always in an ever-reduced state. Generally, the
6-17
6.3.2 Work pump
Fig. Schematic of working pump

1. Working pump 4. Pump mounting bracket
2. Suction port P1 5. Outlet P2
3. Suction port P2 6. Outlet P1
6-18
6.3.2 Work pump
6.3.2.2 Internal structure and main-

tenance instructions of working
pump
The following is an exploded view of working
pump internal structure:
1. Cover 11. Slide bearing

2. Pump body 12. Cylindrical pin
3. Intermediate 13. Square seal
4. Cover 14. E-ring seal
5. Drive gear 15. E-ring
6. Driven gear 16. Stud bolt
7. Secondary drive gear 17. Nut
8. Connecting shaft 18. Washer
9. Side plate 19. Relief valve
10. Oil seal
Fig. Structure diagram of working pump
Of which serial number 19 (relief valve) only pro- with pressure value of 20MPa which has been set at
vides overpressure protection for the rear pump, delivery, externally nonadjustable.
6-19
6.3.2 Work pump
The following is a simple instruction for mainte-

nance of the working pump cover oil seal:
Simple Instruction for Maintenance of Cover Oil
Seal
1. Preparation before the removal and installa-

tion:
1) Check to confirm the portion where oil leaks
from the gear pump.
2) Clean up the external surface of the gear
pump with oil-base cleaning agent (such
as kerosene), and ensure that impurities
will not contaminate the inside of gear
pump when the seal is replaced.
2. Removal steps for front cover 3) Slightly remove the cover with a flat screw-
1) Draw two intersecting marker lines (they will driver (you can keep down the shaft head).
have guiding function in the process of
assembly) from the rear cover, pump body
to front cover with a marking pen.
4) Fix the cover to the assembly bench, with the

spigot side up, and take out the circlip for
hole with snap ring pliers.
2) Remove the nuts and gaskets.
6-20
6.3.2 Work pump
7) Polish the cover oil seal hole with metallo-

graphic abrasive paper, clean up and blow-
dry.
5) Take out the outboard bearing by hand or

with tools.
8) Apply Loctite retaining compound 680 evenly

to the excircle of oil seal (if the excircle of
oil seal is rubber, the application step is
omitted), and press the oil seal in with spe-
cial tools.
6) Remove the sealing skeleton with a flat

screwdriver.
9) Install the outboard bearing.

6-21
6.3.2 Work pump
12) Fix the nut diagonally, tightening torque

271N⚫m.
10) Install the snap ring for hole into the snap
ring recess.
Notice: The photos used in the instruction are sche-
matics, they may be inconsistent with the real
objects, only reference for maintenance.

of working pump from and to the
machine
1. Removal steps of working pump from the
machine:
Remove the hood in the “Removal of Hood” steps;
11) Install into the cover sub-assembly by the

marker lines.
Machine state after removal of hood;

Remove the hydraulic oil tank in the steps of
“Removal of Hydraulic Tank As“;
6-22
6.3.2 Work pump
Remove the hose at the suction tube;
Cover
Machine state after removal of hydraulic oil tank;

Screw off 4 captive bolts (removal socket specifica-
tion 10mm) from the hood, and remove the hood;
Shield the suction tube with a plastic bag, etc. to

prevent foreign materials from entering in the sub-
sequent process of removal; Screw off 4 captive bolts (removal socket specifica-
tion 16mm) at the flange;
6-23
6.3.3 Left control valve
Tie the lifting rope to the pump AS;
Screw off 4 captive bolts (removal socket specifica-

tion 24mm) from the pump bracket; First, pull out the pump slowly, and then hoist the
pump slowly;
Screw off the two captive bolts from the mounting

plate; Put the pump AS on the ground;
2. Assembly steps of pump drive shaft AS:

removal.

The control valve on the left side is a five-linked
mechanical control valve mainly used to control the
oil transformation and on-off of branch circuits in the
work hydraulic system, having features as follows:
The first link circuit controls the left blade lift cylinder
action, and the valve plate in this link is next to
return opening T2;
6-24
The second link circuit controls the ripper cylinder The fifth link circuit controls the swing motor action,
action, this feature is optional, and its valve plate is and the valve plate in this link is next to the fourth
next to the first link valve; link valve and inlet P1.
The third link circuit controls the blade outlet cylin- Of which the safety valve integrated in the control
der action, and the valve plate in this link is next to valve is for system overpressure protection, with set
the second link valve; value of 18MPa at delivery, and the check valve is
The fourth link circuit controls the blade angle trans- used to prevent oil from flowing backward and avoid
formation cylinder action, and the valve plate in this affecting the working pump.
link is next to the third link valve;
Fig. Schematic of Left Control Valve Hydraulic

6-25
6.3.4 Right control valve
The fourth link circuit controls the blade cylinder

action, this feature is optional, and its valve plate is
next to the third link valve;
The fifth link circuit controls the blade lift cylinder-rh
action, and the valve plate in this link is next to the
fourth link valve and inlet P2.
Of which the safety valve integrated in the control
valve is for system overpressure protection, with set
value of 18MPa at delivery, and the check valve is
used to prevent oil from flowing backward and avoid
affecting the working pump.
Fig. - Diagram of Control Valve Oil Port On

the Left Side

functional structure of control valve
on the right side
The control valve on the right side is a five-linked
mechanical control valve mainly used to control the
oil transformation and on-off of branch circuits in the
work hydraulic system, having features as follows:
The first link circuit controls the front wheel tilt cylin-
der action, and the valve plate in this link is next to
return opening T3;
The second link circuit controls the hitch steering
cylinder action, and its valve plate is next to the first
link valve;
The third link circuit controls the blade swing cylin-
der action, and the valve plate in this link is next to
the second link valve;
6-26
Fig. - Hydraulic Schematic of Control Valve On the Right Side

of control valve on the right side
from and to the machine
1. Removal steps for left and right control
valves of machine:
Removal of left and right ladders and left and right
plates:
One person holds on to the ladder on the right side

Fig. - Diagram of Control Valve Oil Port On of the cab to ensure that the ladder will not fall in the
the Right Side following process of removal;
6-27
The other person screws out 4 captive bolts Screw off 5 bolts from the linkage with a 13mm
(removal wrench or socket specification 16 mm) open-end wrench;
from the ladder;
Move the ladder away;
Screw off 4 setscrews from the dust cover with a

cross screwdriver;
One person holds on to the plate-rh on the right side
of the cab to sure that the plate-rh will not fall in the
following process of removal;
The other person screws out 2 captive bolts
(removal wrench or socket specification 16 mm) on
the right side;
(Complement graph)
Screw out the 1 captive bolt (removal wrench or
socket specification 13 mm) on the rear side of cab;
Remove the plate-rh;
Remove the left ladder and left plate refer to above
steps;
Removal of left control valve:
Take out the dust cover;
6-28
Waste oil
barrel
Identify the outside hose with “outside of control Identify inside hose with “inside of control valve-lh“,
valve-lh“, and be careful to mark firmly (Remark: and be careful to mark firmly (Remark: Directly iden-
Directly identify with letters if parts are separately tify with letters if parts are separately removed or
removed or modified); modified);
After screwing out the hose by 1-2 circles with the After screwing out the hose by 1-2 circles with the
open-end wrench, knock down the joint position with open-end wrench, knock down the joint position with
the wrench to completely relieve pressure of the wrench to completely relieve pressure of
hydraulic oil, screw out the hose, and fill the oil into hydraulic oil, screw out the hose, and fill the oil into
the waste oil barrel; the waste oil barrel;
Outer
Inner
side
side
Identify the hose with “A1”, “B1” “A2”, “B2”…… in down the joint position with the wrench to com-
turn from outside to inside, from bottom to top pletely relieve pressure of hydraulic oil, screw out
Removal of 10 hoses: After screwing out the hose the hose, and shield the oil port;
by 1-2 circles with the open-end wrench, knock
6-29
16mm open-end wrench and removes the control

valve-lh;
Removal of right control valve:
Refer to the removal steps of control valve-lh, of
which the identification is changed to:
2 persons are needed to lift the control valve AS

(weight 17Kg) and hold, then the third person
screws off 4 bolts on the control valve-lh with a
Outer
Inner
side
side
2. Assembly of left and right control valve: Assemble according to reverse steps of
Assemble in the reverse sequence of removal, removal.
of which the hose assembly part must be con-
nected with each connector of the control valve
as based on the identification of each hose with-
out error.
Assembly of left and right ladders and left and
right plates:
6-30
6.3.5 Swing motor
6.3.5 Swing motor teeth of stationary stator (external gear) than cycloi-
dal rotor (internal gear), one end of the spline shaft
is connected with the inner gear, the other end is
6.3.5.Installation position and func- connected with the output shaft to play the role of
tional principle of swing motor transmitting actions of both. On one hand, the
cycloidal rotor revolves on its axis O1 during mesh-
The swing motor is located above the circle of work
ing, and on the other hand, it makes reverse orbit
implement, having the main function of driving the action at high speed around stator axis O. After orbit
worm box and circle to rotate to adapt to different action for a circle, the working volume sealed
operating conditions for grader. The swing motor is between teeth completes oil feeding and discharge
a gear-within-gear cycloid motor, usually consisting once, at the same time, the cycloidal rotor revolves
of a pair of meshed gear pairs, spline shaft, output on its axis by one tooth.
shaft and flow distribution shaft. There is one more
Eccentricity
Rotor
Stator
Conjugating cycloidal tooth profile

6-31
6.3.5 Swing motor
Fig. - Swing Motor Working Principle Diagram and Oil Port Diagram
6.3.5.2Internal structure of swing

motor
The following is an exploded view of swing motor
internal structure:
6-32
6.3.5 Swing motor
6-33
6.3.6 Swivel joint
1. Dust ring 21. Flow distribution linkage shaft

2. Housing 22. Valve plate
3. Shaft seal 23. Flow distribution plate
4. Output shaft 24. O-ring
5. Key 25. O-ring
8. Conical roller bearing 26. Dowel pin
9. Spacer sleeve 27. Wave spring
10. Stop nut 28. Limit post
11. O-ring 29. Cover
12. Universal driving shaft 30. Bolt
13. Butterfly ring 31. Sign
14. Plate 32. Rivet
15. O-ring 33. Oil filler cap
16. Stator 34. Washer
17. Gear pin 35. Screw plug
18. Rotor 36. Washer
19. Steel ball 37. O-ring
20. Flow distribution plate
Fig. - Structure Diagram of Swing Motor
6.3.5.3 Removal and assembly steps Removal of 3 hoses: After screwing out the hose by
1-2 circles with the open-end wrench, knock down
of swing motor from and to the the joint position with the wrench to completely
machine relieve pressure of hydraulic oil, screw out the hose,
and shield the oil port;
1. Removal steps of swing motor from the Disconnect the 2 screws connecting the hydraulic
machine: motor with worm box with a 16mm inner hexagon
wrench, and remove the hydraulic motor;
2. Installation steps of swing motor:

Assemble in the reverse sequence of removal,
Screw of which the hose assembly part must be con-
nected with each joint of the swing motor as
based on the identification of each hose without
error.
6.3.6 Swivel joint
6.3.6.1 Installation location and

internal structure of swivel joint
Identify the connecting hoses for 3 oil ports of swing The swivel joint is located in the center of the circle
motor as “A5“, “B5“, “T1“, and note to identify firmly; of work implement, mainly used to connect the
grader work implement fixed part with the hydraulic
6-34
6.3.6 Swivel joint
system line of the rotating part, making the upper

and lower parts of system line have relative rota-
tional action at 360° without interference.
Fig. - Hydraulic Schematic and Oil Port Diagram of Swivel Joint

6-35
6.3.6 Swivel joint
6-36
6.3.6 Swivel joint
1. Grease fitting 8. Backup ring

2. Screw 9. O-ring
3. Cover 10. O-ring
4. O-ring 11. Plate
5. Rotator 12. Washer
6. Cylinder body 13. Bolt
7. Support ring 14. Connector
Fig. – Exploded View of Swivel Joint

of swivel joint from and to the
machine
1. Removal steps of swivel joint from the
machine:
Identify the 10 hoses connecting oil ports on the

swivel joint as “J1”, “J2”, “J3”、 “J4”, “J5”, “J6”,
“J7”, “J8”, “J9”, “J10”, and note to identify firmly;
Removal of 10 hoses: After screwing out the
hose by 1-2 circles with the open-end wrench,
knock down the joint position with the wrench to
completely relieve pressure of hydraulic oil,
Remove 2 mounting plate captive bolts below screw out the hose, and shield the oil port;
the swivel joint with a 16mm open-end wrench;
6-37
6.3.7 Blade angle changing cylinder-lh
Screw out 3 captive bolts from the swivel joint 6.3.7 Blade angle changing cyl-
with a 18mm open-end wrench, and remove the
swivel joint; inder-lh
2. Assembly steps of swivel joint:
of which the hose assembly part must be con- internal structure of blade angle
nected with each joint of the swivel joint as changing cylinder-lh
based on the identification of each hose without The blade angle changing cylinder-lh, located on
error.
the left side of the blade support in the middle part
of the machine, is an actuator of the blade tilting
device, mainly used to adjust the blade tilt angle to
adapt to the requirements of different operating con-
ditions. This cylinder is a typical double-acting cylin-
der.
1. Grease fitting 6. Seal AS

2. Knuckle bearing 7. Piston
3. Backup ring 8. O-ring
4. Nylon locknut 9. Cylinder body
5. Guide ring 10. Piston rod
6-38
6.3.7 Blade angle changing cylinder-lh
11. Support ring 16. O-ring

12. O-ring 17. Dust ring
13. Seal 18. Bushing
14. Lip type seal 19. Connector
15. Cylinder head
Fig. – Exploded View of Blade Angle Changing Cylinder-lh
6.3.7.2 Removal and assembly steps Assembly Steps of blade angle changing cylin-
der-lh:
of blade angle changing cylinder-lh
from and to the machine of which the hose assembly part must be con-
The removal and assembly steps of blade angle nected with two connectors of the blade angle
changing cylinder-lh from and to the machine are as changing cylinder-lh as based on the identifica-
follows: tion of each hose without error.
Front Rear
side side
W/O rod
chamber W/I rod
chamber
Cotter Nut and bolt

pin

blade angle changing cylinder-lh as “W/O rod cham-
ber” and “W/I rod chamber”, and note to identify
firmly;
Removal of 2 hoses: After screwing out the hose by
the joint position with the wrench to completely
relieve pressure of hydraulic oil, screw out the hose,
Knock out the cotter pin at the front end of cylinder,
and screw out the nut (open-end wrench specifica-
tion 46mm);
Screw out 2 nuts at the rear end of cylinder (open-
end wrench specification 16mm), and remove the
bolts; knock out the pin;
Remove the cylinder;
6-39
6.3.8 Blade angle changing cylinder-rh
6.3.8 Blade angle changing cyl- of the machine, is an actuator of the blade tilting
device, mainly used to adjust the blade tilt angle to
inder-rh adapt to the requirements of different operating con-
ditions. This cylinder is also a typical double-acting
6.3.8.1Installation position and cylinder.
internal structure of blade angle

changing cylinder-rh
The blade angle changing cylinder-rh, located on
the right side of the blade support in the middle part
1. Knuckle bearing 10. Cylinder body

2. Grease fitting 11. Support ring
3. Backup ring 12. O-ring
4. Nylon locknut 13. Seal
5. Guide ring 14. Lip type seal
6. Seal AS 15. O-ring
7. O-ring 16. Dust ring
8. Piston 17. Cylinder head
9. Piston rod 18. Bushing
6-40
6.3.8 Blade angle changing cylinder-rh
19. Connector
Fig. - Structure Diagram of Blade angle changing cylinder-rh
6.3.8.2 Removal and assembly steps changing cylinder-rh as based on the identifica-
tion of each hose without error.
of blade angle changing cylinder-rh
1. Removal steps of blade angle changing cyl-
inder-rh from the machine:
Front
Right side
side
W/I rod W/O rod
chamber chamber
Nut and bolt Cotter

pin

blade angle changing cylinder-rh as “W/O rod
chamber” and “W/I rod chamber”, and note to iden-
tify firmly;
Knock out the cotter pin at the front end of cylinder,
and screw out the nut (open-end wrench specifica-
tion 46mm);
Screw out 2 nuts at the rear end of cylinder (open-
end wrench specification 16mm), and remove the
bolts; knock out the pin;
Remove the cylinder;
2. Assembly steps of blade angle changing

cylinder-rh:
nected with two connectors of the blade angle
6-41
6.3.9 Blade outlet cylinder
6.3.9 Blade outlet cylinder along the blade axis to adapt to the requirements of
different operating conditions. This cylinder is also a
The blade outlet cylinder, located on the blade sup- typical double-acting cylinder. The following is an
port in the middle of the machine, is an actuator of exploded view of cylinder internal structure:
the blade tilting device, mainly used to drive the
blade to make lateral movement relative to the circle
1. Piston rod 9. O-ring

2. Dust ring 10. Backup ring
3. Seal ring 11. Cylinder body
4. Support ring 12. O-ring
5. D-shape seal ring 13. Support ring
6. Guide seelve 14. Seal AS
7. Bolt 15. Piston
8. Washer 16. Nylon locknut
Fig. Structure Diagram of Blade Outlet Cylinder
For the removal and assembly steps of blade outlet
cylinder from the machine, please refer to “Removal
and Assembly Steps of Work Implement“.
6-42
6.3.10 Blade lift cylinder-lh
6.3.10 Blade lift cylinder-lh nects the swing bearing and rotating support. As an
actuator of the blade lift device, it is mainly used to
drive the blade to be lifted and lowered, and adjust
6.3.10.1 Installation position and the working depth of blade to adapt to the require-
internal structure of blade lift cylin- ments of different operating conditions of grader.
This cylinder is also a typical double-acting cylinder.
der-lh The following is an exploded view of cylinder inter-
The blade lift cylinder-lh, located on the left side of nal structure:
the swing bearing in the middle of the machine, con-
1. Flange support 12. O-ring

2. Nut 13. Grease fitting
3. Washer 14. Connector
4. Bolt 15. Cylinder head
5. Gasket 16. Cylinder body
6. Piston rod 17. Piston
7. Dust ring 18. O-ring
8. Seal ring 19. Seal as
9. O-ring 20. Support ring
10. Support ring 21. Nylon locknut
11. Seal 22. Jacket
6-43
Fig. - Structure Diagram of Blade Lift Cylinder-lh
6.3.10.2 Removal and assembly

steps of blade lift cylinder-lh from
and to the machine
1. Removal steps of blade lift cylinder-lh from
the machine:
Remove 2 bolts (removal socket, open-end wrench

specification mm) from the bearing cap at the lower
end of cylinder;
Before removal, put the blade on the ground;

Notice: Do not make the work implement rise high
into the air; otherwise, the work implement will
instantly fall in the subsequent process of cylinder
removal, causing safety accidents;
Removal of lift cylinder-lh:
Make pairing identifications of “I” and “II” respec-

tively on the assembly surfaces on the left and right
sides of the fork. For subsequent recovery, be sure
to assemble them in pairs by identifications;
Lift the cylinder with a lifting rope and hold, make

the lifting rope slowly rise until it just tightens the cyl-
inder;
6-44
Screw out 4 captive bolts (specification M16×65- Lift down the cylinder;
10.9-Zn.D, removal wrench or socket specification
24mm), and remove the fork cap;
Reinstall the bearing cap, gasket, bolts and nuts to

the lower end of the cylinder;
Knock out the cylinder with a plastic hammer or
wood block;
Notice: You cannot knock the cylinder with a ham-
mer, copper bar and other hard tools; otherwise, it
will cause damage to cylinder;
6-45
6.3.11Blade lift hydraulic lock-lh
Remove 2 tubes from the hydraulic lock (open-end

wrench specification 30mm);
Shield 2 oil ports;
2. Assembly of blade lift cylinder:

Reinstall the fork cap by pairing identifications;
removal;

internal structure of blade lift
hydraulic lock-lh
The blade lift hydraulic lock-lh is installed to the
blade lift cylinder-lh, this bidirectional hydraulic lock
has the main function of pressure maintenance by
locking the blade lift cylinder-lh to prevent displace-
ment due to the weight and load of blade itself, and
Hoist the cylinder onto a wooden pallet, and avoid it ensures driving safety and blade working preci-
knocking against the piston rod in the process of sion.
placement;
6-46
Fig. - Hydraulic Lock Schematic and Oil Port Diagram

The exploded view of hydraulic lock internal struc- Fig. Internal Structure Diagram of Hydrau-
ture is as follows: lic Lock

steps of blade lift hydraulic lock-lh
1. Removal steps of blade lift hydraulic lock-lh
from the machine:
1. Check valve
2. Piston
3. Valve body gp
4. Check valve
5. Plug Bolt
6. Plug
7. O-ring
8. O-ring
6-47
6.3.12 Blade lift cylinder-rh
Identify the 3 hoses connecting oil ports on the The removal and assembly steps of blade lift
blade lift hydraulic lock-lh as “V1”, “V2”, “C2”, hydraulic lock-rh from and to the machine are as fol-
and note to identify firmly; lows:
screw out the hose, and shield the oil port;
Screw out 4 bolts with a 13mm open-end
wrench;
Remove the hydraulic lock, and shield the cylin-
der mounting port;
2. Assembly steps of blade lift hydraulic lock-

lh:
Bolt
nected with three connectors of the blade lift
hydraulic lock-lh as based on the identification Identify the 3 hoses connecting oil ports on the
of each hose without error. blade lift hydraulic lock-rh as “V1“, “V2“, “C2“, and
note to identify firmly;
6.3.12 Blade lift cylinder-rh 1-2 circles with the open-end wrench, knock down
The blade lift cylinder-rh, located on the right side of the joint position with the wrench to completely
the swing bearing in the middle of the machine, con- relieve pressure of hydraulic oil, screw out the hose,
nects the swing bearing and rotating support. As an and shield the oil port;
actuator of the blade lift device, it is mainly used to Screw out 4 bolts with a 13mm open-end wrench;
drive the blade to be lifted and lowered, and adjust Remove the hydraulic lock, and shield the cylinder
the working depth of blade to adapt to the require- mounting port;
ments of different operating conditions of grader.
Assembly steps of blade lift hydraulic lock-rh:
This cylinder is also a typical double-acting cylinder.
For exploded view, please refer to section 6.3.10. Assemble in the reverse sequence of removal,
For the removal and installation steps of blade lift
nected with three connectors of the blade lift
cylinder-rh, please refer to section 6.3.10.
hydraulic lock-rh as based on the identification
of each hose without error.
6.3.13 Blade lift hydraulic lock-
rh 6.3.14 Circle sideshift cylinder
The blade lift hydraulic lock-rh is installed to the The circle sideshift cylinder, located in the middle of
blade lift cylinder-rh, this bidirectional hydraulic lock the machine, connects the swing bearing and rotat-
has the main function of pressure maintenance by ing support. As an actuator of the circle sideway
locking the blade lift cylinder-rh to prevent displace- device, it is mainly used to drive the circle to make
ment due to the weight and load of blade itself, and sideway relative to the longitudinal symmetry plane
it ensures driving safety and blade working preci- of grader to adapt to the requirements of different
sion. operating conditions of grader. This cylinder is also
For the hydraulic principle, oil port diagram and a double-acting cylinder. The following is an
exploded view of this part, please refer to 6.3.11. exploded view of cylinder internal structure:
6-48
6.3.14 Circle sideshift cylinder
1. Flange support 12. O-ring

2. Nut 13. Grease fitting
3. Washer 14. Connector
4. Bolt 15. Cylinder head
5. Gasket 16. Cylinder body
6. Piston rod 17. Piston
7. Dust ring 18. O-ring
8. Seal ring 19. Seal as
10. Support ring 21. Nylon locknut
11. Seal 22. Jacket
Fig. - Structure Diagram of Circle Sideshift Cylinder
The removal and assembly steps of circle sideshift
cylinder from and to the machine are as follows:
For the removal and assembly steps of circle side-
shift cylinder, please refer to section 6.3.11. It is
important to note that during removal and assembly
of the cylinder, please install the lifting rope to the
position as shown in figure:
6-49
6.3.15 Circle sideshift hydraulic lock
Bolt
Other removal steps follow “Removal of Lift Cylin- Identify the 3 hoses connecting oil ports on the cir-
der-lh and Lift Cylinder-rh“. cle sideshift hydraulic lock as “V1“, “V2“, “C2“, and
6.3.15 Circle sideshift hydrau- Removal of 3 hoses: After screwing out the hose by
lic lock the joint position with the wrench to completely
The circle sideshift hydraulic lock is installed to the relieve pressure of hydraulic oil, screw out the hose,
circle sideshift cylinder, this bidirectional hydraulic
lock has the main function of pressure maintenance Screw out 4 bolts with a 13mm open-end wrench;
by locking the circle sideshift cylinder to prevent dis- Remove the hydraulic lock, and shield the cylinder
placement due to the weight and load of blade itself, mounting port;
and it ensures driving safety and blade working pre- Assembly steps of circle sideshift hydraulic
cision. lock:
For the hydraulic principle, oil port diagram and Assemble in the reverse sequence of removal,
exploded view of the hydraulic lock, please refer to of which the hose assembly part must be con-
6.3.11. nected with three connectors of the circle side-
The removal and assembly steps of circle sideshift shift hydraulic lock as based on the
hydraulic lock from and to the machine are as fol- identification of each hose without error.
lows:
6.3.16 Front wheel tilt cylinder

internal structure of front wheel tilt
cylinder
The front wheel tilt cylinder, installed to the front
axle in the front of the machine, connects the front
axle stand and lean-joint. As an actuator of the front
wheel tilt device, it is mainly used to drive two front
wheels of grader to tilt toward one side simultane-
ously to adapt to the requirements of different oper-
ating conditions of grader. This cylinder is also a
6-50
double-acting cylinder. The following is an exploded

view of cylinder internal structure:
1. Radial spherical plain bearing 10. O-ring

2. Grease fitting 11. Backup ring
3. Nylon locknut 12. D-shape seal ring
4. Support ring 13. Support ring
5. Seal AS 14. O-ring
6. Piston 15. Seal ring
7. O-ring 16. Cylinder head
8. Cylinder body 17. Dust ring
9. Piston rod
Fig. - Structure Diagram of Front Wheel Tilt Cylinder
6-51
6.3.16.2 Removal and assembly After screwing out the hose by 1-2 circles with
the open-end wrench, knock down the joint
steps of front wheel tilt cylinder position with the wrench to completely relieve
from and to the machine pressure of hydraulic oil, screw out the hose,
and fill the oil into the waste oil barrel;
1. Removal steps of front wheel tilt cylinder
from the machine:
Screw off 2 nuts of the screws at the tilt cylinder

piston rod end with two 16mm open-end
Use M12 bolts in the middle of the axle stand wrenchs, and knock out the pin;
and tilt rod, and screw on the nuts, wherein, the
length of the M12 bolts is more than 95 and the
strength of the M12 bolts is Grade 10.9;
Proceed with the next steps after the axle stand
and the tilt rod are connected via bolts; other-
wise, potential safety hazard may occur
because of tilt tyres during removal;
Inner side Outer side
Screw off 2 nuts of the screws on the other side

of tilt cylinder with two 16 mm open-end
wrenchs, and knock out the pin;
Take out cylinder;
2. Installation of tilt cylinder:

Identify the hose outside as “outside of tilt cylin- of which the hose assembly part must be con-
der”, identify the hose inside as “inside of tilt cyl- nected with each connector of the hydraulic
inder”, and note to identify firmly; lock as based on the identification of each hose
without error.
6-52
6.3.17 Front wheel tilt hydraulic lock
6.3.17 Front wheel tilt hydraulic The hydraulic principle and oil port diagram of
hydraulic lock are as follows:
lock

internal structure of front wheel tilt
hydraulic lock
The front wheel tilt hydraulic lock is installed at the
inside of the side plate-rh in the front of front frame,
this bidirectional hydraulic lock has the main func-
tion of pressure maintenance by locking the front
wheel tilt cylinder, allowing positions of two front
wheels to be locked when they tilt toward any side
to adapt to requirements of various operating condi-
tions of grader.
The exploded view of internal structure is as follows:
1. Check valve 3. Valve body

2. Piston 4. O-ring
6-53
6.3.17 Front wheel tilt hydraulic lock

steps of front wheel tilt hydraulic Tilting Tilting
V2 V1
lock from and to the machine
Removal and assembly steps of front wheel tilt
hydraulic lock from and to the machine are as fol-
lows:
Tilting Tilting
C2 C1
Identify 4 hoses as “tilt V1”, “tilt V2”, “tilt C1”, “tilt C2”
as per the oil port identifications of the hydraulic
lock, and note to identify firmly (Remark: Directly
identify with letters if parts are separately removed
or modified);
Screw off 6 bolts from the upper cover of front frame the joint position with the wrench to completely
with a 13mm open-end wrench, and remove the relieve pressure of hydraulic oil, screw out the hose,
cover; and shield the oil port;
Find the hydraulic lock installed to the front frame, Screw off 2 bolts from the hydraulic lock with a
leaning against the cylinder side of tilt cylinder; 13mm open-end wrench, and remove the hydraulic
lock;
Assembly of tilt hydraulic lock
nected with each connector of the hydraulic
6-54
6.3.18 Hitch steer cylinder
lock as based on the identification of each hose rear frames of grader. This cylinder is mainly used
without error. to drive the hitch steering of front and rear frames of
grader to form different intersection angles of the
front and rear frames of the machine, reduce the
6.3.18 Hitch steer cylinder machine turning radius and improve the machine
trafficability to adapt to the requirements of different
6.3.18.1 Installation position and operating conditions of grader. This cylinder is also
a double-acting cylinder. The exploded view of cylin-
internal structure of hitch steer cyl-
der internal structure is as follows:
inder
The hitch steer cylinder, located below the cab in
the middle of the machine, connects the front and
1. Grease fitting 9. O-ring

2. Backup ring 10. Cylinder body
3. Radial spherical plain bearing 11. Piston rod
4. Connector 12. Seal
5. Nylon locknut 13. O-ring
6. Support ring 14. Support ring
7. Piston 15. Cylinder head
8. Seal as 16. Seal ring
6-55
6.3.18 Hitch steer cylinder
17. Washer 19. Dust ring

18. Bolt
Fig. Structure diagram of hitch steer cylinder

steps of hitch steer cylinder from
and to the machine
Since the assembly or removal of hitch steer cylin-
der to the machine is divided into left and right direc-
tions, the removal and assembly steps of hitch steer
cylinder-lh and hitch steer cylinder-rh from and to
the machine are respectively as follows:
Removal and assembly of hitch steer cylinder-lh
W/O rod W/I rod

chamber chamber
Remove the setscrews and nuts from cylinder;
Identify the 2 hoses connecting oil ports on the hitch

steer cylinder-lh as “W/I rod chamber” and “W/O rod
chamber”, and note to identify firmly;
the joint position with the wrench to completely Knock linking pin shaft out from lower side with long
relieve pressure of hydraulic oil, screw out the hose, iron bar and hammer.
6-56
6.3.19 Blade cylinder
For removal and assembly steps of cylinder, refer to

“Removal and Assembly of Hitch Steer Cylinder-lh“.

internal structure of blade cylinder
The blade cylinder, located in the forefront of the
machine, is mainly used to drive the blade in front of
the front axle of grader to be lifted or lowered, make
the blade contact with the ground and shovel/push
mud or similar materials forward to adapt to the
requirements of different operating conditions of
Pull down the setscrew from the hitch cylinder, grader. This cylinder is also a double-acting cylin-
knock out the pin, and remove the cylinder; der. The exploded view of cylinder internal structure
is as follows:
Assembly steps of hitch steer cylinder-lh:
Assemble in the reverse sequence of removal
steps, of which the hose assembly part must be
connected with 2 joints of hitch steer cylinder-lh
according to the identification of each hose
without error;
Removal and assembly of hitch steer cylinder-rh
W/I rod
W/O rod
chamber
chamber
Identify the 2 hoses connecting oil ports on the hitch

steer cylinder-lh as “W/I rod chamber” and “W/O rod
6-57
1. Backup ring 11. Cylinder body

2. Dust ring 12. Piston rod
3. Piston rod seal 13. Piston
4. Bolt 14. O-ring
5. Washer 15. Seal as
6. Support ring 16. Locknut
8. Backup ring 18. Radial spherical plain bearing
9. Piston rod seal 19. Grease fitting
10. Cylinder head 20. Connector
Fig. - Structure Diagram of Blade Cylinder

steps of blade cylinder from and to
the machine
1. Removal steps of blade cylinder from the
machine:
6-58
Pin
Put the blade to the lowest level, and make it Lift the cylinder and link with a lifting rope and
contact with the ground; hold, raise the cylinder slowly until the lifting
rope just contacts with the cylinder;
Knock out the pin between cylinder and link;
Put down the cylinder and link, and remove the
lifting rope after confirming that they are placed
smoothly;
W/O rod W/I rod

chamber chamber

blade cylinder as “W/I rod chamber” and “W/O
rod chamber”, and note to identify firmly; Pin
knock down the joint position with the wrench to Bind the cylinder body with a lifting rope;
Knock out the pin between cylinder and blade
bracket, and lift out the cylinder;
2. Assembly steps of blade cylinder:

nected with two joints of the blade cylinder as
error.
6-59
6.3.20 Blade hydraulic lock
6.3.20 Blade hydraulic lock rectional hydraulic lock has the main function of
pressure maintenance by locking the blade cylinder,
making the blade device in a position to adapt to the
6.3.20.1 Installation position and requirements of different operating conditions of
internal structure of blade hydraulic grader.
lock The hydraulic principle and oil port diagram of
hydraulic lock are as follows:
The blade hydraulic lock is installed at the inside of
the side plate-lh in the front of front frame, this bidi-
Removal and assembly steps of blade hydraulic

lock from and to the machine are as follows:

steps of blade hydraulic lock from
and to the machine
1. Removal of blade hydraulic lock:
Put the blade to the lowest level, and make it

contact with the ground;
6-60
6.3.21 Ripper cylinder
Bolt
Screw off 6 bolts from the upper cover of front Identify 4 hoses as “push A1”, “push A2”, “push
frame with a 13mm open-end wrench, and U1”, “push U2” as per the oil port identifications
remove the cover; of the hydraulic lock, and note to identify firmly
(Remark: Directly identify with letters if parts are
separately removed or modified);
Screw off 2 bolts from the hydraulic lock with a
13mm open-end wrench, and remove the
hydraulic lock;
2. Assembly of blade hydraulic lock:

Find the hydraulic lock installed on the left side lock as based on the identification of each hose
of front frame; without error.

internal structure of ripper cylinder
The ripper cylinder, located at the aftermost of the
machine, connects the rear frame of grader and a
ripper. This cylinder is mainly used to drive the lifting
and lowering of grader ripper, make the ripper con-
tact with the ground for ripper operation on hard
ground through multiple ripper teeth. This cylinder is
6-61
also a double-acting cylinder. The exploded view of

cylinder internal structure is as follows:
1. Backup ring 11. Cylinder head

2. Radial spherical plain bearing 12. Cylinder AS
3. Dust ring 13. Piston rod
4. Piston rod seal 14. Piston
5. Backup ring 15. Seal as
6. O-ring 16. O-ring
7. Bolt 17. Locknut
8. Washer 18. Support ring
9. Support ring 19. Grease fitting
10. Piston rod seal 20. Jacket
Fig. Structure diagram of ripper cylinder
6-62
6.3.22 Ripper hydraulic lock
6.3.21.2 Removal and assembly 6.3.22 Ripper hydraulic lock

steps of ripper cylinder from and to
the machine 6.3.22.1 Installation position of rip-
per hydraulic lock
1. Removal steps of ripper cylinder from the
machine: The ripper hydraulic lock is installed to the bottom
plate at the rear of rear frame, this bidirectional
hydraulic lock has the main function of pressure
Lifting rope maintenance by locking the ripper cylinder, making
W/O rod position the ripper device locked in a position to adapt to the
chamber requirements of different operating conditions of
Bolt on the grader.
cover For the hydraulic principle and oil port diagram of
hydraulic lock, please refer to section 6.3.20.
W/I rod 6.3.22.2 Removal and assembly

Hinge pin
chamber
steps of ripper hydraulic lock from
and to the machine
1. Removal steps of ripper hydraulic lock from
Put the ripper to the lowest level, and make it con- the machine:
tact with the ground;
Identify the 2 hoses connecting oil ports on the rip-
per cylinder as “W/I rod chamber” and “W/O rod
Bind the ripper cylinder with a lifting rope, raise the
lifting rope slowly until it just tightens the cylinder;
Screw out 4 captive bolts from 2 covers on the cylin-
der bracket above;
After screwing out the pin bolt below, knock out the
pin; The ripper hydraulic lock is located below the
rear frame;
2. Assembly of ripper cylinder:
nected with each joint of the ripper cylinder as
error.
6-63
6.3.23 Description of functional principles of work hydraulic system
Remove the hydraulic lock;
2. Assembly of ripper hydraulic lock:

lock as based on the identification of each hose
without error.
6.3.23 Description of functional

Ripper Ripper principles of work hydraulic
U2 A2 system
1. Circle drive
Identify the 2 hoses connecting oil ports at the
lower side of the hydraulic lock as “Ripper A2” 1) Circle has no action need
and “Ripper U2”, and note to identify firmly; When the control lever of the fifth link valve
Removal of 2 hoses: After screwing out the of the left control valve controlling circle
hose by 1-2 circles with the open-end wrench, actions is in the neutral position, the leaf
knock down the joint position with the wrench to valve is in an oil conducting state in the
completely relieve pressure of hydraulic oil, neutral position, namely that hydraulic oil
screw out the hose, and shield the oil port; output by the pump is directly returned to
the oil tank via priority valve EF port, con-
Screw out 2 mounting bolts of the hydraulic
trol valve P1 and T2 ports, the fluid does
lock;
not participate in the work, it realizes low
Ripper U1 Ripper pressure unloading of system flow with the
A1 valve in the neutral position, and at this
time, the circle has no action response.
Identify the 2 hoses connecting oil ports at the

upper side of the hydraulic lock as “Ripper A1”
and “Ripper U1”, and note to identify firmly;
6-64
2) Circle rotates clockwise

When the control lever of the fifth link valve
is pushed forward, the lower position of the
leaf valve is opened and enters the oil con-
duction state, the oil output by the pump is
supplied into A5' port of motor via priority
valve EF port, control valve P1 port, check
valve and A5 port, so that the motor drives
the worm box which drives the circle to
rotate clockwise, the fluid from motor B5' is
returned to the control valve via control
valve B5 port, and flows back to the
hydraulic oil tank via T2 port, thus the fluid
completes a working circuit. Since the
swing motor has volumetric efficiency
during operation, leakage is inevitable, and
a small amount of leaking oil flows back to
the tank via the housing drainage port T1
of motor.
6-65
3) Circle rotates counterclockwise

is pulled back, the upper position of the
supplied into B5' port of motor via priority
valve EF port, control valve P1 port, check
valve and B5 port, so that the motor drives
the worm box which drives the circle to
rotate clockwise, the fluid from motor A5' is
returned to the control valve via control
valve A5 port, and flows back to the
hydraulic oil tank via T2 port, thus the fluid
completes a working circuit. Similarly,
since the swing motor has volumetric effi-
ciency during operation, leakage is inevita-
ble, and a small amount of leaking oil flows
back to the tank via the housing drainage
port T1 of motor.
6-66
2. Blade angle changing driving

1) No need for blade tilt angle transformation
action
When the control lever of the fourth link
valve of the left control valve controlling
blade tilt angle transformation action is in
the neutral position, the leaf valve is in an
oil conducting state in the neutral position,
namely that hydraulic oil output by the
pump is directly returned to the oil tank via
priority valve EF port, control valve P1 and
T2 ports, the fluid does not participate in
the work, it realizes low pressure unload-
ing of system flow with the valve in the
neutral position, and at this time, the blade
tilt angle transformation has no action
response.
6-67
2) Decrease in blade tilt angle back to the hydraulic oil tank via T2 port to
When the control lever of the fourth link complete a working circuit.
valve is pushed forward, the lower position
of the leaf valve is opened and enters the
oil conduction state, the oil output by the
pump is supplied into J10 port of the swivel
joint via priority valve EF port, control valve
P1 port, check valve and A4 port, then
divided into two circuits of oil by the swivel
joint, supplied into the W/I rod chambers of
blade angle transformation cylinder-lh and
blade angle transformation cylinder-rh via
J6 and J7 ports respectively, so that the
cylinder piston rod stretches out and drives
the link mechanism to finally complete
adjustment of decrease in blade tilt angle;
meanwhile, the fluids in the W/O rod
chambers of blade angle transformation
cylinder-lh and blade angle transformation
cylinder-rh flow together via J5 and J4 of
swivel joint to J2 port and back to the con-
trol valve via control valve B4, finally flow
6-68
3) Increase in blade tilt angle hydraulic oil tank via T2 port to complete a
When the control lever of the fourth link working circuit.
valve is pulled back, the upper position of
the leaf valve is opened and enters the oil
conduction state, the oil output by the
P1 port, check valve and B4 port, then
divided into two circuits of oil by the swivel
joint, supplied into the W/O rod chambers
of blade angle transformation cylinder-lh
and blade angle transformation cylinder-rh
via J5 and J4 ports respectively, so that the
cylinder piston rod retracts and drives the
link mechanism to finally complete adjust-
ment of increase in blade tilt angle; mean-
while, the fluids in the W/I rod chambers of
blade angle transformation cylinder-lh and
blade angle transformation cylinder-rh flow
together via J6 and J7 of swivel joint to J10
port and back to the control valve via con-
trol valve A4, finally flow back to the
6-69
3. Blade sideshift driving

1) No need for blade sideshift action
When the control lever of the third link
blade sideshift action is in the neutral posi-
tion, the leaf valve is in an oil conducting
state in the neutral position, namely that
hydraulic oil output by the pump is directly
returned to the oil tank via priority valve EF
port, control valve P1 and T2 ports, the
fluid does not participate in the work, it
realizes low pressure unloading of system
flow with the valve in the neutral position,
and at this time, the blade sideshift has no
action response.
6-70
2) Blade movement to the left

P1 port, check valve and A3 port, then
supplied into the W/O rod chamber of
blade lead-out cylinder via J3 port, so that
the cylinder piston rod retracts and drives
the blade sideshift device to move to the
left; meanwhile, the fluid in the W/I rod
chamber of blade lead-out cylinder flows
back to the control valve via J8 and J9
ports of swivel joint, B3 port of control
valve respectively, finally flows back to the
hydraulic oil tank via T2 port to complete a
working circuit.
6-71
3) Blade movement to the right

pump is supplied into J9 port of swivel joint
via priority valve EF port, control valve P1
port, check valve and B3 port, then sup-
plied into the W/I rod chamber of blade
lead-out cylinder via J9 port, so that the
cylinder piston rod stretches out and drives
the blade sideshift device to move to the
right; meanwhile, the fluid in the W/O rod
chamber of blade outlet cylinder flows
back to the control valve via J3 and J1
ports of swivel joint, A3 port of control
working circuit.
6-72
4. Ripper driving
1) Ripper has no action need
When the control lever of the second link
ripper cylinder action is in the neutral posi-
and at this time, the ripper has no action
response.
6-73
2) Ripper lowering action

pump is supplied into U1 port of the ripper
hydraulic lock via priority valve EF port,
control valve P1 port, check valve and A2
port, then supplied into ripper hydraulic
lock U1 port, the W/I rod chamber of ripper
cylinder via U2 port, so that the cylinder
piston rod stretches out and drives the rip-
per device to move down; meanwhile, the
fluid in the W/O rod chamber of ripper cyl-
inder flows back to the control valve via A2
and A1 ports of ripper hydraulic lock, B2
port of control valve respectively, finally
flows back to the hydraulic oil tank via T2
port to complete a working circuit.
6-74
3) Ripper lifting action

valve is pulled back, the lower position of
pump is supplied into A1 port of the ripper
hydraulic lock via priority valve EF port,
control valve P1 port, check valve and B2
port, then supplied into the W/O rod
chamber of ripper cylinder via A2 port, so
that the cylinder piston rod retracts and
drives the ripper device to move up;
meanwhile, the fluid in the W/I rod
chamber of ripper cylinder flows back to
the control valve via U2 and U1 ports of
ripper hydraulic lock, A2 port of control
working circuit.
6-75
5. Blade (lh) drive

1) Blade has no action need on the left side
When the control lever of the first link valve
of the left control valve controlling blade lift
cylinder-lh action is in the neutral position,
the leaf valve is in an oil conducting state
in the neutral position, namely that hydrau-
lic oil output by the pump is directly
and at this time, the blade (lh) has no
action response.
6-76
2) Blade (lh) lowering driving

supplied into V2 port of the hydraulic lock
port, check valve and A1 port, then sup-
plied into the W/I rod chamber of blade lift
cylinder-lh via C2 port, so that the cylinder
piston rod stretches out and drives the
blade (lh) to move down; meanwhile, the
fluid in the W/O rod chamber of blade lift
cylinder-lh flows back to the control valve
via C1 and V1 ports of hydraulic lock, B1
6-77
3) Blade (lh) rising driving

plied into the W/O rod chamber of blade lift
cylinder-lh via C1 port, so that the cylinder
piston rod retracts and drives the blade (lh)
to move up; meanwhile, the fluid in the W/I
rod chamber of blade lift cylinder-lh flows
back to the control valve via C2 and V2
ports of hydraulic lock, A1 port of control
working circuit.
6-78
6. Blade (rh) driving

1) Blade has no action need on the right side
of the right control valve controlling blade
lift cylinder-rh action is in the neutral posi-
returned to the oil tank via charge valve O
and at this time, the blade (rh) has no
action response.
6-79
2) Blade (rh) lowering driving

via charge valve O port, control valve P2
port, check valve and A10 port, then sup-
plied into the W/I rod chamber of blade lift
cylinder-rh via C2 port, so that the cylinder
piston rod stretches out and drives the
blade (rh) to move down; meanwhile, the
fluid in the W/O rod chamber of blade lift
cylinder-rh flows back to the control valve
via C1 and V1 ports of hydraulic lock, B10
6-80
3) Blade (rh) rising driving

plied into the W/O rod chamber of blade lift
cylinder-rh via C1 port, so that the cylinder
piston rod retracts and drives the blade
(rh) to move up; meanwhile, the fluid in the
W/I rod chamber of blade lift cylinder-rh
flows back to the control valve via C2 and
V2 ports of hydraulic lock, A10 port of con-
trol valve respectively, finally flows back to
the hydraulic oil tank via T3 port to com-
plete a working circuit.
6-81
7. Blade driving
1) Blade has no action need
valve of the right control valve controlling
blade cylinder action is in the neutral posi-
returned to the oil tank via charge valve O
and at this time, the blade has no action
response.
6-82
2) Blade lowering action

pump is supplied into U1 port of the blade
hydraulic lock via charge valve O port,
port, then supplied into the W/I rod
chamber of blade cylinder via U2 port, so
that the cylinder piston rod stretches out
and drives the dozer as to move down;
meanwhile, the fluid in the W/O rod
chamber of blade cylinder flows back to
the control valve via A2 and A1 ports of
blade hydraulic lock, B9 port of control
working circuit.
6-83
3) Blade lifting action

pump is supplied into A1 port of the blade
chamber of blade cylinder via A2 port, so
that the cylinder piston rod retracts and
drives the dozer as to move up; mean-
while, the fluid in the W/I rod chamber of
blade cylinder flows back to the control
valve via U2 and U1 ports of blade hydrau-
lic lock, A9 port of control valve respec-
tively, finally flows back to the hydraulic oil
tank via T3 port to complete a working cir-
cuit.
6-84
8. Circle sideshift driving

1) Circle has no sideshift action need
circle sideshift cylinder action is in the neu-
tral position, the leaf valve is in an oil con-
ducting state in the neutral position,
charge valve O port, control valve P2 and
neutral position, and at this time, the circle
has no sideshift action response.
6-85
2) Circle movement to the left

pump is supplied into V2 port of the
chamber of circle sideshift cylinder via C2
port, so that the cylinder piston rod
stretches out and drives the circle to move
to the left; meanwhile, the fluid in the W/O
rod chamber of circle sideshift lift cylinder
flows back to the control valve via C1 and
V1 ports of hydraulic lock, B8 port of con-
trol valve respectively, finally flows back to
the hydraulic oil tank via T3 port to com-
plete a working circuit.
6-86
3) Circle movement to the right

pump is supplied into V1 port of the
chamber of circle sideshift cylinder via C1
port, so that the cylinder piston rod retracts
and drives the circle to move to the right;
meanwhile, the fluid in the W/I rod
chamber of circle sideshift cylinder flows
ports of hydraulic lock, A8 port of control
working circuit.
6-87
9. Hitch steer driving

1) No need for hitch steer action
hitch steer cylinders-lh & rh actions is in
the neutral position, the leaf valve is in an
oil conducting state in the neutral position,
charge valve O port, control valve P2 and
neutral position, and at this time, there is
no hitch steer action response.
6-88
2) Hitch steer-lh driving

pump is respectively supplied into the W/I
rod chamber of hitch steer-rh cylinder and
W/O rod chamber of hitch steer-lh cylinder
port, check valve and A7 port, so that the
hitch steer-rh cylinder piston rod stretches
out, the hitch steer-lh cylinder piston rod
retracts and drives the machine toward
hitch steer-lh; meanwhile, the fluid in the
W/O rod chamber of hitch steer-rh cylinder
and that in the W/I rod chamber of hitch
steer-lh cylinder flow together, then return
to the control valve via control valve B7
port, finally flow back to the hydraulic oil
cuit.
6-89
3) Hitch steer-rh driving

pump is respectively supplied into the W/O
rod chamber of hitch steer-rh cylinder and
W/I rod chamber of hitch steer-lh cylinder
port, check valve and B7 port, so that the
hitch steer-rh cylinder piston rod retracts,
the hitch steer-lh cylinder piston rod
stretches out and drives the machine
toward hitch steer-rh; meanwhile, the fluid
in the W/I rod chamber of hitch steer-rh
cylinder and that in the W/O rod chamber
of hitch steer-lh cylinder flow together, then
return to the control valve via control valve
A7 port, finally flow back to the hydraulic oil
cuit.
6-90
10. Front wheel tilt driving

1) Front wheel tilt has no action need
of the right control valve controlling front
wheel tilt cylinder action is in the neutral
position, the leaf valve is in an oil conduct-
ing state in the neutral position, namely
that hydraulic oil output by the pump is
directly returned to the oil tank via charge
valve O port, control valve P2 and T3
ports, the fluid does not participate in the
work, it realizes low pressure unloading of
system flow with the valve in the neutral
position, and at this time, there is no front
wheel tilt action response.
6-91
2) Front wheel tilts to the right

supplied into V2 port of the front wheel tilt
chamber of the front wheel tilt cylinder via
C2 port, so that the cylinder piston rod
stretches out and drives the front wheel tilt
device, so that the front wheel tilts to the
right; meanwhile, the fluid in the W/O rod
chamber of front wheel tilt cylinder flows
ports of front wheel tilt hydraulic lock, B6
6-92
3) Front wheel tilts to the left

supplied into V1 port of front wheel tilt
chamber of front wheel tilt cylinder via C1
port, so that the cylinder piston rod retracts
and drives the front wheel tilt device, so
that the front wheel tilts to the left; mean-
while, the fluid in the W/I rod chamber of
front wheel tilt cylinder flows back to the
control valve via C2 and V2 ports of front
wheel tilt hydraulic lock, A6 port of control
working circuit.
6-93
6-94
6.3.24 Test and detection of work hydraulic system pressure
6.3.24 Test and detection of hydraulic system pressure, making it easy to under-
stand the performance of the hydraulic system as
work hydraulic system pres- well as fault detection and maintenance. The
sure detailed explanation and instruction for these pres-
sure test points are as follows.
CLG4180 grader work hydraulic system is provided
with quick connection pressure test interfaces at all 1. Control valve-lh pressure test port X2
critical points in the circuit to facilitate detection of
The red circle in the figure above is the pressure 3) Make different actions according to the differ-
test port of control valve-lh for detecting system ent operating conditions to read values in
pressure, it has the main function of measuring cor- the pressure gauge;
responding operating pressure values of circle driv-
ing, blade tilt angle transformation driving, blade
sideshift driving, ripper device driving and blade-lh
lift driving under different operating conditions, the
method is as follows:
1) Unscrew the pressure test joint counterclock-
wise, and remove the screw cap;
2) Connect a pressure gauge with range of
0~40MPa or 0~25MPa into the pressure
test port X2;
6-95
4) After completion of measurement, remove reaches the maximum 18MPa, at this time,
the pressure gauge, and reinstall the pres- the system safety valve is opened, the sys-
sure test joint screw cap. tem pressure is limited within 18MPa to
Notice: protect hydraulic components.
A. The pressure test point has a pressure value B. In the case that the actions are turned to the
of about 0MPa in the case that no action is limiting position, i.e. keeping down pres-
made, namely that the system fluid does sure, the maximum system pressure value
not apply work but directly unloads the oil is inconsistent with the above recom-
return tank at low pressure to realize green mended value, then you need to make
energy saving; when any action of the sys- adjustments as shown below and refer to
tem is turned to the limiting position and the Control Valve Maintenance Manual:
then maintained, the system pressure Adjust the pressure set value of safety
6-96
valve under the operating condition of increases with counterclockwise action

keeping down pressure, the pressure and decreases with clockwise action.
2. Control valve-rh pressure test port X3

6-97
The red circle in the figure above is the pressure

test port of control valve-rh for detecting system
pressure, it has the main function of measuring cor-
responding operating pressure values of front wheel
tilt driving, hitch steer driving, circle sideshift driving,
dozer driving and blade-rh lift driving under different
operating conditions, the method is as follows:
1) Unscrew the pressure test joint counter-
clockwise, and remove the screw cap;
2) Connect a pressure gauge with range of
0~40MPa or 0~25MPa into the pressure
test port X3;
3) Make different actions according to the dif-
ferent operating conditions to read values
in the pressure gauge;
6-98
4) After completion of measurement, remove mended value, then you need to make
the pressure gauge, and reinstall the pres- adjustments as shown below and refer to
sure test joint screw cap. the Control Valve Maintenance Manual:
Notice: Adjust the pressure set value of safety
valve under the operating condition of
A. The pressure test point has a pressure
keeping down pressure, the pressure
value of about 0MPa in the case that no
increases with counterclockwise action
action is made, namely that the system
and decreases with clockwise action.
fluid does not apply work but directly
unloads the oil return tank at low pressure
to realize green energy saving; when any
action of the system is turned to the limit-
ing position and then maintained (maxi-
mum accelerator), the system pressure
reaches the maximum 18MPa, at this time,
the system safety valve is opened, the sys-
tem pressure is limited within 18MPa to
protect hydraulic components.
B. In the case that the actions are turned to
the limiting position, i.e. keeping down
pressure, the maximum system pressure
value is inconsistent with the above recom-
6-99
6.4 Introduction to Steering Hydraulic System
6.4 Introduction to Steering and it can protect the steering hydraulic system
against damage by external pressure impact; when
Hydraulic System the external force makes the steering cylinder gen-
erate pressure impact and the steering system is
The system is a quantitative single pump hydraulic under overpressure, for example, overpressure due
system (see steering hydraulic system schematic). to bumpy road, the relief valves and check valves
It consists of a quantitative gear pump, priority are opened so that the oil flows from the high pres-
valve, metering pump, two steering cylinders, line, sure side of the steering system into the low pres-
etc. The quantitative gear pump used for the system sure side, so as to protecting the steering cylinder.
is shared with the work hydraulic system, and the oil The steering cylinder, a common double-acting sin-
required by the system is sucked out and conveyed gle piston rod cylinder, is the final actuator of steer-
from the hydraulic oil tank by the working pump. The ing. The return oil filter filters the oil of steering
role of the priority valve is to make the oil pumped system, it is internally integrated with a filter and a
out of the working pump give priority to the steering bypass check valve. During normal operation, return
hydraulic system before excess oil enters the work oil in the system flows back to the hydraulic oil tank
hydraulic system; the built-in safety valve of priority via the filter; when the filter is clogged, the check
valve limits the oil pressure of steering system to valve is open, and the oil flows back to the tank via
17.2MPa, so as to protect the steering system. The the bypass oil circuit at the check valve. CLG4180
metering pump used in the system is of a cycloidal grader steering hydraulic system schematic and lay-
rotary valve type load sensitive type, internally out drawing are as follows:
installed with two relief valves and two check valves,
6-100
Fig. 6.4.1 - Steering Hydraulic System Schematic

6-101
6.4.1 Introduction to steering hydraulic system principle
1. Hydraulic oil tank 4. Metering pump

2. Tandem pump 5. Steering cylinder
3. Priority valve
Fig. 6.4.2 - Steering Hydraulic System Layout Drawing
6.4.1 Introduction to steering

hydraulic system principle
1) When there is no steering, there is no signal
pressure LS, the pressure differential ∆P
between both ends of the priority valve
spool is the maximum, the spool moves to
the left, so that the opening of EF duct is
enlarged, and the opening to CF duct
decreases. When CF duct is completely
closed, the oil in the enclosed cavity
returns to the tank through LS port, ∆P
drops to zero, the spool moves to the right
under the action of spring force, open the
duct to CF port a little, repeat the above
process, and the spool makes reciprocat-
ing motion to maintain dynamic balance.
So almost all the fluids are supplied into
EF duct, but there is always only a small
amount of oil passing through CF duct.
6-102
Fig. 6.4.3 - Flow Direction of System Fluids Without Steering

2) During steering, P1 port is connected with L
(or R) port, the ducts of LS and tank are
closed, and the duct to L (or R) is opened.
LS oil pressure acts on the left side of
spool, ∆P decreases instantly, the spool
moves to the right, so that the opening of
CF duct is enlarged, the opening of EF
duct decreases until closed.
6-103
6-104
6.4.2 Steering priority valve
Fig. 6.4.4 - Flow Direction of System Fluids During Steering (Steering to the Left)
3) The case when steering is stopped is the 6.4.2 Steering priority valve
same as that when the steering wheel
does not rotate, see (1).
4) When the steering system pressure exceeds 6.4.2.1 Installation position and
the steering safety valve (i.e. built-in relief functional structure of steering pri-
valve of priority valve) set pressure ority valve
17.2Mpa, the steering system opens the
overflow of steering safety valve. The steering priority valve, installed to the front
frame under the cab in the middle of the machine,
5) When the pressure at EF port reaches the
has the main function of giving priority to distribution
main safety valve (i.e. built-in relief valve of
of fluid pumped out by the working pump to the
working pump) set value 21MPa, the
steering system to guarantee that the steering sys-
whole hydraulic system overflows.
tem has stable responses under various conditions.
Its three-dimensional exploded view is as follows:
Fig. 6.4.5 - Exploded view of Steering Priority Valve

1. Screw plug 11. O-ring
2. O-ring 12. Valve body
3. Adjusting screw 13. Choke plug
4. Spring guide 14. Spool
5. Spring 15. Choke plug
6. Safety valve spool 16. O-ring
7. Safety valve seat 17. Screw plug
8. Screw plug 18. Screw plug
9. Strainer 19. O-ring
10. Pressure ring 20. Spring
6-105
6.4.2 Steering priority valve

of steering priority valve from and
to the machine
1. Removal of priority valve:
Priority Priority
LS T
Priority
EF Priority
P’
3) Screw off 2 bolts from the priority valve with a

13mm open-end wrench, and remove the
priority valve.
Priority
CF 2. Installation of priority valve:
Assemble in the reverse sequence of removal, of
1) Identify 5 hoses with “priority CF”, “priority which the hose assembly part must be connected
EF”, “priority LS”, “priority T”, “priority P” as with each connector of the priority valve as based
per the oil port identifications of the priority on the identification of each hose without error.
valve, and be careful to mark firmly
(Remark: Directly identify with letters if 6.4.2.3 Brief introduction to steering
parts are separately removed or modified);
priority valve working principle
2) Removal of 5 hoses: After screwing out the
hose by 1-2 circles with the open-end 1. When there is no steering and steering is
wrench, knock down the joint position with stopped, LS port of priority valve is connected
the wrench to completely relieve pressure with the hydraulic oil tank, namely that the left
of hydraulic oil, screw out the hose, and end of spool is connected with the tank, the
shield the oil port; right end is connected with working pump outlet
P1, the pressure differential ∆P between both
ends of the priority valve spool is the maximum,
the spool moves to the left, so that the opening
of EF duct is enlarged, and the opening to CF
duct decreases. When CF duct is completely
closed, the oil in the enclosed cavity returns to
the tank through LS port, ∆P drops to zero, the
spool moves to the right under the action of
spring force, open the duct to CF port a little,
repeat the above process, and the spool makes
reciprocating motion to maintain dynamic bal-
ance. So almost all the fluids are supplied into
EF duct, but there is always only a small
amount of oil passing through CF duct.
6-106
6.4.3 Metering pump
2. During steering, the working pump outlet P1 of spool, ∆P decreases instantly, the spool
port is connected to L (or R) port, the duct from moves to the right, so that the opening of CF
LS to the tank is closed, and the duct to L (or R) duct is enlarged, the opening of EF duct
is opened. LS oil pressure acts on the left side decreases until closed.
Oil flow direction when not steer- Oil flow direction when steering
ing or steering is stopped
Fig. 6.4.6 - Steering Priority Valve Working

Principle
6.4.3 Metering pump

functional structure of metering
pump
The metering pump, installed at the lower end of
steering gear box AS, has the main function of con-
trolling the front wheel steering of the machine, its
three-dimensional exploded view is as shown in Fig.
6.4.7. The metering pump is a closed-center rotary
valve with reactive hydraulic metering pump, con-
sisting of two parts, i.e. a control part consisting of
No. 10 spool and valve bushing pair, No.13 valve
body, etc., and a steering part consisting of No.19
stator and rotor pair, etc. During steering, fluid flows
from the control part to the steering part, and flows
to the steering cylinder via the control part. At the oil
inlet, there is a check valve capable of preventing oil
backflow caused by system pressure impact.
6-107
6.4.3 Metering pump
Fig. 6.4.7 - Exploded View of Metering Pump

1. Screw 14. O-ring
2. Spring washer 15. Baffle
3. Spring washer 16. Universal driving shaft
4. O-ring 17. Steel ball
5. Dust ring 18. Pin
6. X-sealing ring 19. Rotor, stator pair
7. Retainer 20. Spacer
8. Needle bearing 21. Cover
9. Slip ring 22. Bolt
10. Spool and valve bushing pairs 23. Valve body
11. Leaf spring 24. Screw
12. Pull pin 25. O-ring
13. Valve body
6.4.3.2 Brief introduction to meter- the W/O rod chamber of steering cylinder-rh via
the metering pump to drive the front wheel to
ing pump working principle turn. Inside the metering pump, pressure oil is
1. During left steering, the steering wheel drives supplied into the stator and rotor pair (No.19 in
the spool in the spool and valve bushing pair the Exploded view of Metering Pump) via the
(No.10 in the Exploded view of Metering Pump) spool and valve bushing pair to push the rotor
in metering pump to rotate, so that the oil port in to rotate with the steering wheel and press the
the spool and valve bushing pair is opened; oil into the steering cylinder; in this process,
fluid in the priority valve CF port is supplied into pressure oil drives the stator and rotor pair to
the W/I rod chamber of steering cylinder-lh and rotate, the stator and rotor pair drives the valve
6-108
6.4.3 Metering pump
bushing in the spool and valve bushing pair to the steering system into the low pressure side
rotate. Close the oil circuit between spool and to balance high and low intensities of pressure
bushing pair, and steering is stopped. and pressure differentials; meanwhile, the relief
2. During right steering, the case is similar to that valve pressure is set to 18MPa, slight fluctua-
during left steering, you can analyze it in combi- tion in pressure due to roads in driving will not
nation with left steering. open the relief valve, thus ensuring the stability
of the machine under transport condition. The
3. The metering pump is internally installed with flow direction of fluid in left steering due to pres-
two relief valves and two check valves, and it sure impact during driving is as shown in figure.
can protect the steering hydraulic system
4. The oil inlet end of metering pump is provided
against damage by external pressure impact;
when the external force makes the steering cyl- with a check valve which can prevent oil back-
inder generate pressure impact and the steer- flow caused by system pressure impact during
ing system pressure is above 18MPa, for steering. For example, the front wheel rotates in
example, overpressure due to bumpy road, the the opposite direction due to the action of
relief valves and check valves are opened so bumpy road and other external forces during
that the oil flows from the high pressure side of steering.
Oil flow direction during left Oil flow direction when front wheel
steering turn left for road reason
Fig. 6.4.8 - Metering Pump Working Principle Schematic
5. Manual steering is allowed after engine flame-
out or working pump failure. During manual
steering, the stator and rotor pair of metering
pump plays the role of oil pump, presses oil in
one cavity of the steering cylinder into the other,
and the cylinder piston rod propels the guide
pulley to realize steering.
6-109
6.4.3 Metering pump
Oil flow direction during manual steering (left)
Fig. 6.4.9 - Working Schematic of Metering

Pump Manual Steering
6-110
6.4.4 Steering cylinder

functional structure of steering cyl-
inder
The steering cylinder, installed to the front axle, is
the final actuator of steering, its structural exploded
view is as follows:
Fig. 6.4.10 - Exploded View of Steering Cylinder

1. Cylinder body 10. Nut
2. Grease fitting 11. Cylinder head
3. Knuckle bearing 12. O-ring
4. Locknut 13. Backup ring
5. Guide ring 14. O-ring
6. Seal as 15. Dust ring
7. Piston 16. Lip type seal
8. O-ring 17. Guide ring
9. Piston rod
6-111
6.4.4.2 Removal and assembly steps 3) Identify 2 hoses connecting oil ports of the
steering cylinder-rh with “A1”, “B1”, and
of steering cylinder from and to the note to identify firmly;
machine 4) Removal of 2 hoses: After screwing out the
hose by 1-2 circles with the open-end
1. Removal of steering cylinder:
wrench, knock down the joint position with
the wrench to completely relieve pressure
of hydraulic oil, screw out the hose, and
shield the oil port;
1) Identify 2 hoses connecting oil ports of the

steering cylinder-lh with “A2”, “B2”, and
2) Removal of 2 hoses: After screwing out the 5) Remove the cotter pin at the ball joint of
hose by 1-2 circles with the open-end steering cylinder-lh or steering cylinder-rh;
wrench, knock down the joint position with 6) Screw off the nut with a 36mm open-end
the wrench to completely relieve pressure wrench, knock the ball joint so as to sepa-
of hydraulic oil, screw out the hose, and rate from the steering knuckle;
7) Screw out 2 bolts with a 13mm open-end

wrench, and remove the disc above;
8) Pry out the steering cylinder with a crowbar.
6-112
6.4.5 Test and detection of steering hydraulic system pressure
2. Assembly of steering cylinder: steering knuckle-rh form another set of four-link

Assemble in the reverse sequence of removal, mechanism, this structure ensures coordinated
of which the hose assembly part must be con- actions of two sets of four-link mechanism consist-
nected with each connector of left and right ing of steering cylinders, so as to guarantee coordi-
steering cylinders as based on the identification nate steering of two front wheels.
of each hose without error. For left steering, pressure oil is supplied into the
large cavity of steering cylinder-lh and the small
6.4.4.3 Brief introduction to steering cavity of steering cylinder-rh, and both wheels swing
to the left to realize left steering; for right steering,
cylinder working principle pressure oil is supplied into the small cavity of steer-
The steering cylinder, steering knuckle and front ing cylinder-lh and the large cavity of steering cylin-
axle stand form 2 sets of four-link mechanisms der-rh, and both wheels swing to the right to realize
which are the final actuators of steering; the steer- right steering.
ing linkage, front axle stand, steering knuckle-lh and
Oil flow direction during Oil flow direction during

left steering right steering
Fig. 6.4.11 Oil Flow Direction in Steering Cylinder During Steering
6.4.5 Test and detection of

steering hydraulic system pres-
sure
The steering hydraulic system has the maximum
pressure of 17.2MPa, and the pressure test port is
located at the priority valve CF port.
6-113
Pressure joint
Priority valve is
installed at the left
side of front frame at
lower side of cab
Fig. 6.4.12
The steering system pressure detection method is at delivery, and shall not be adjusted by non-
as follows: professionals.
⚫ Park the machine on a flat, open ground, and lift
the blade and other work implements off the
ground.
⚫ Connect the 20MPa pressure gauge connector
with the pressure test connector on the priority
valve.
⚫ Place the gearbox handle in neutral position,
start the engine, turn the steering wheel to the
left (or right). During front wheel steering,
observe the pressure gauge reading, and the
pressure value shall be between 15 and
17MPa.
⚫ When you turn the steering wheel to the bottom
to the left (or right), continue to turn the steering
wheel in this direction, observe the pressure
gauge reading, and the pressure value shall be
17.2±0.5MPa. This pressure value has been set
6-114
Fig. 6.4.13
If it must be adjusted, the pressure adjustment
method is as follows:
⚫ Remove the screw plug (serial number 1) and
O-ring (serial number 2) from the priority valve;
⚫ When you turn the steering wheel to the bottom
to the left (or right), continue to turn the steering
wheel in this direction;
⚫ At this time, adjust the adjusting screw (serial
number 3) while observing the pressure gauge
reading, and adjust the pressure to 17.2MPa;
during adjustment, clockwise rotate the screw,
the pressure increases, counterclockwise rotate
the screw, then the pressure decreases.
⚫ Install the O-ring (serial number 2) and screw
plug (serial number 1) to the priority valve.
6-115
6.4.6 Common faults and service method of steering hydraulic system
Fig. 6.4.14
6.4.6 Common faults and Main technical parameters of steering

hydraulic system
service method of steering
hydraulic system Power steering torque
(6.3Bar back pres- 2.8 ～ 4.0 N⚫m
The steering hydraulic system indicators shall meet sure)
the following table under normal operating condi-
tions: Maximum allowable 136 N⚫m
manual steering torque
Main technical parameters of steering
In the event of a steering hydraulic system failure
hydraulic system during operation, you can refer to the table below for
service:
Maximum system pres-
172Bar
sure
Working pressure of
150~170Bar
the system
Maximum operating
21Bar
back pressure
Maximum operating
93 °C
temperature
Allowable spread with
28 °C
system
6-116
Common fault and troubleshooting method of steering hydraulic system
Faults Symptom Cause Troubleshooting
Oil leakage in junction surface of Check the junction

Dirt on junction surface
parts surface and clean up
Oil leakage Shaft seal ring is dam- Replace the seal
Oil leakage at the cover
aged ring
Insufficient bolt (plug)
Oil leakage in bolt (plug) Tighten bolt (plug)
tightening torque
Check the oil pump
Insufficient oil supply
Steering wheel is heavy when and oil supply line
turned quickly and light when Check whether the
turned slowly Main priority valve spool
main priority valve
binding
spool is flexible
Cylinder creep Remove air in the

system;
Air in steering system
Foam in oil, Check the oil pump
inlet for air leakage
Heavy steering
Irregular noise
Check for steel ball

Heavy steering, no steering cyl- Manual steering check
inder action valve failure Check whether it is
cushioned by dirt
FK overload valve leak- Check the cylinder
age for internal leakage;
No cylinder action
Internal cylinder leakage Replace the FK
combination valve
Leakage cushioned by Clean and check the
No-load steering is light, heavy
safety valve or safety safety valve in prior-
load steering is heavy
valve spring failure ity valve
High hydraulic oil viscos-
Heavy steering
ity
6-117
Common fault and troubleshooting method of steering hydraulic system(Continued)
No steering back to neutral posi- Leaf spring failure Replace the leaf
tion spring
Pressure oscillation is signifi- Pull pin bend or broken

Replace the pin or
cantly increased, even no steer- Rupture at linkage shaft linkage shaft
ing cotterway
When you turn the steering
Incorrect mutual align-
Steering failure wheel, it immediately rotates in Reassembly
ment of linkage shaft
the opposite direction or swings
and rotor
from side to side
Vehicle off tracking during mov- Two-way overload valve
ing cushioned by dirt
No steering when steering wheel Spring failure Check the overload
is turned
valve
Priority valve binding, no
No turning oil at CF port
LS port clogging
Exocentric installation of
steering column and
Pressure drop in the neutral posi- spool
No automatic return Troubleshooting in
tion increases, when the steering Steering column axially
to the neutral posi- abuts the spool to the
wheel stops rotating, the meter- accordance with
tion of steering bottom
ing pump is not unloaded (vehi- specific conditions
wheel
cle off tracking occurs) Great steering column
steering resistance
Leaf spring break
No steering of steering cylinder Increase the pres-

No steering to the Low pressure of safety
to the extreme position, steering sure of safety valve
extreme position valve
is heavy as reflected properly
When you turn the steering
wheel forcibly after the steering Increase overload
No end point Low overload valve
cylinder rotates to the extreme
valve pressure
position, the steering wheel can pressure
appropriately
slightly rotate (without feeling
that it is the end point)
6-118
6.5 Introduction to Brake Hydraulic System
Common fault and troubleshooting method of steering hydraulic system(Continued)
During power steering, the cylin-

der piston moves to the extreme
No feel of end point Large radial or axial
position, the driver does not have Replace the stator
obvious feel of end point; during clearance of stator and
during steering and rotor pair
manual steering, the steering rotor pair
wheel rotates but the cylinder is
still
6.5 Introduction to Brake

Hydraulic System
The system is a single-circuit split-body valve brake
system, divided into service brake and parking
brake (see the brake hydraulic system schematic).
The system mainly consists of charge valve, service
brake valve, service brake, parking brake valve,
parking brake, etc. The hydraulic pump of this sys-
tem is a tandem pump shared with the work hydrau-
lic system. After the machine is started, the tandem
pump of the work hydraulic system sucks oil from
the oil tank, the pressure oil output by the pump
charges two service brake accumulators and a
parking brake through the charge valve first; oil
charge of accumulator only takes a very short
period of time, then the charge valve is cut off, and
oil is supplied to the work hydraulic system.
Of which the service brake is of a shoe type, acting
on four rear wheels of grader. Depress the service
brake valve, oil flows from the service brake accu-
mulator to the service brake via the service brake
valve, the brake shoe stretches for braking of the
complete machine. The parking brake is of a caliper
disc type, acting on the gearbox & torque converter
AS. Press the button on the parking brake valve, the
parking brake valve is energized, oil flows from the
parking brake accumulator to the parking brake via
the parking brake valve, the brake caliper disc is
released, and brake is removed; when the brake
system pressure is less than 10MPa, the brake cali-
per disc cannot be released completely, the parking
brake low pressure alert switch on the parking brake
valve is on, and the indicator on the dashboard is
lightened up. CLG4180 grader brake hydraulic sys-
tem schematic and layout drawing are as follows:
6-119
Fig. 6.5.1 - Brake Hydraulic System Schematic

6-120
6.5.1 Introduction to brake hydraulic system principle
Fig. 6.5.2 - Brake Hydraulic System Layout Drawing

1. Hydraulic oil tank 6. Charge valve
2. Tandem pump 7. Service brake accumulator
3. Parking brake accumulator 8. Service brake
4. Parking brake valve 9. Parking brake valve
5. Service brake valve
6.5.1 Introduction to brake

hydraulic system principle
1. When the accumulator pressure is less than
12.8MPa, the charge valve is opened to charge
the accumulator, the oil flow direction is as
shown in figure: the oil output by the pump is
supplied to two service brake accumulators and
a parking brake accumulator through the
charge valve.
6-121
Fig. 6.5.3 - Oil Flow Direction in Charge Mode of Charge Valve

2. When the accumulator pressure is up to
15.9MPa, the charge valve cuts off oil supply to
the accumulator, and oil flows to the work
hydraulic system.
6-122
Fig. 6.5.4 - Oil Flow Direction in Cut-off Mode of Charge Valve

3. During service braking, the brake fluid flow
direction is as shown below. When the accumu-
lator pressure is less than 12.8MPa after brak-
ing, oil in the charge valve charges the
accumulator as per (1); when the accumulator
pressure is above 159Bar, oil in the charge
valve is supplied to the work hydraulic system
as per (2).
6-123
Fig. 6.5.5 - Oil Flow Direction During Service Braking

6-124
Fig. 6.5.6 - Oil Flow Direction With Service Brake Removed

4. When the parking brake valve is energized, C
port is connected to B port, brake fluid flows to
the parking brake via the parking brake valve,
the parking brake caliper disc is released, and
brake is removed. When the parking brake
valve is de-energized, B port is connected to T4
port, oil in the parking brake flows back to the
hydraulic oil tank via the parking brake valve,
the brake caliper disc is clamped for braking of
complete machine.
6-125
Fig. 6.5.7 - Oil Flow Direction With Parking Brake Removed

6-126
6.5.2 Charge valve
Fig. 6.5.8 - Oil Flow Direction During Parking Braking
6.5.2 Charge valve 6.5.2.2 Overview of internal struc-

ture of charge valve
6.5.2.1 Installation position and The internal structure of charge valve is as follows:
function of charge valve
The charge valve is located on the right side of front
frame under the cab, when the oil pumped out from
the working pump flows through the charge valve, it
first charges the accumulator, when the accumula-
tor pressure is up to 159Bar, oil is supplied to the
work hydraulic system; when the accumulator pres-
sure drops to below 128Bar due to frequent braking,
etc., charge the accumulator again, and always
guarantee that the accumulator pressure is above
128Bar.
6-127
6.5.2 Charge valve
1. Plug 19. Washer

2. O-ring 20. Plug
3. Rod 21. O-ring
4. Spring 22. Spring
5. Oil seal 23. Bracket
6. Spool 24. Steel ball
7. Valve body 25. Spool
8. O-ring 26. Valve bushing
9. Plug 27. O-ring
10. Nut 28. O-ring
11. Bolt AS 29. Steel ball
12. O-ring 30. Bracket
14. Spool 32. Bolt
15. Valve seat 33. O-ring
16. O-ring 34. Plug
17. Washer 35. Plug
18. Filter
Fig. 6.5.9 - Exploded view of Charge Valve
6-128
6.5.2 Charge valve
6.5.2.3 Removal and assembly steps 2. Assembly of charge valve:

of charge valve from the machine Assemble in the reverse sequence of removal, of
which the hose assembly part must be connected
1. Removal of charge valve: with each connector of the charge valve as based
on the identification of each hose without error.
6.5.2.4 Brief introduction to charge

valve working principle
1.
Charging mode of charge valve:
The charge valve charges the accumulator by
controlling the oil flow direction depending on
the movement of internal spool.
When the working pump starts operating, the
pressures of both upper and lower cavities of
spool (4) are low, the spring (2) makes the
spool (4) in the lower position, the duct between
port P and port O is closed at a small angle,
1) The charge valve is located on the right side resulting in an obvious throttling effect and high
of the front frame; identify the 5 connecting pump outlet pressure.
hoses for oil ports of charge valve as “A2”,
High pressure oil filtered by the filter (6) pushes
“P3”, “T2”, “O”, “P”, and note to identify
the check valve spool (12) open to charge the
firmly;
accumulator via oil port A. The control valve
2) Removal of 5 hoses: After screwing out the spring (7) makes the low pressure relief ball
hose by 1-2 circles with the open-end valve (10) open and high pressure relief ball
wrench, knock down the joint position with valve (8) closed, and the control valve spool
the wrench to completely relieve pressure can only make one of the pressure relief ball
of hydraulic oil, screw out the hose, and valves open. The opened low pressure relief
shield the oil port; ball valve (10) enters the oil chamber (1) while
oil flows through the accumulator; meanwhile,
oil is supplied into the oil chamber (5) via an
internal passage of the spool (4) and pushes
the spool (4) to move up, so that a part of oil
flows to oil port O, when a balance between
pressure in upper and lower chambers of the
spool (4) and spring force is reached, the spool
stops moving. The spring (2) ensures that the
pump outlet oil pressure is always higher than
the accumulator oil pressure, so as to ensure
the priority of charging function.
3) Unscrew off two bolts from charge valve with

a open-end wrench (16 mm), and take out
the charge valve;
6-129
6.5.2 Charge valve
Fig. 6.5.10 - Inside of Charge Valve in Charging Mode

6-130
6.5.2 Charge valve
Fig. 6.5.11 - System Oil Flow Direction in Charging Mode

2. Charge valve cut-off mode: chamber (5) and moves up, the duct between P
When the accumulator pressure is up to port and O port is enlarged, and oil is supplied
15.9MPa, the control valve spool (9) moves into the work hydraulic system via O port. The
down, so that the high pressure relief ball valve fluid pressure at P port drops, the check valve
(8) is opened and the low pressure relief ball (12) is closed, obstructing the oil circuit
valve (10) is closed. Oil in the oil chamber (1) is between P port and accumulator.
connected to T port via the high pressure relief When the charge valve operates in the cut-off
ball valve (8), then flows into the hydraulic oil mode, if the pressure required by all the posi-
tank, and oil chamber (1) pressure is relieved. tions of work hydraulic system to which oil is
The spool (4) overcomes the pressure of spring supplied by O port is lower than the pressure of
(2) under the action of pressure oil in the oil spring (2), the oil pressure at working pump out-
6-131
6.5.2 Charge valve
let is equal to the pressure of spring (2); when When the accumulator pressure is below
the pressure required for a position of the work 12.8MPa, the spring (7) opens the low pressure
hydraulic system to which oil is supplied by O relief ball valve (10), and the charge valve oper-
port is higher than the pressure of spring (2), ates after switching to the charging mode.
the oil pressure at working pump outlet is equal
to the pressure in this position.
Fig. 6.5.12 - Inside of Charge Valve in Cut-off Mode

6-132
6.5.3 Accumulator
Fig. 6.5.13 - System Oil Flow Direction in Cut-off Mode
6.5.3 Accumulator The accumulator shall be precharged with nitrogen

before use, precharge pressure 9.2MPa. It has the
main function of supplying brake pressure oil source
6.5.3.1 Installation position and for braking of complete machine.
function of accumulator
The brake system has a total of three accumulators,
two of them are 1.6L service brake accumulators,
located on the right side of front frame under the
cab; the other is a 1L parking brake accumulator,
located on the left side of front frame under the cab.
6-133
6.5.3 Accumulator

of accumulator from and to the
machine
1. Removal of parking brake accumulator:
3) Screw off 3 captive bolts from the accumula-

tor baffle with a 13mm socket or open-end
wrench, and remove the accumulator baf-
fle;
1) Refer to “Pressure Relief” steps in “Removal

of Parking Brake Valve” for pressure relief,
and you must not conduct subsequent
steps until ensuring that the accumulator
pressure is completely released;
2) Hose removal: After screwing out the hose
by 1-2 circles with a 24mm open-end
4) Screw off 2 captive nuts (on the inside of the

bracket) from U-bolts with a 13m open-end
wrench, and remove the U-bolts;
State of hose after removal;

6-134
6.5.3 Accumulator

5) Remove the accumulator;
2. Assembly of parking brake accumulator:

removal;
The removal and assembly steps of service
brake accumulator are as follows: 4) Screw off 3 captive bolts from the accumula-
tor baffle with a 13mm socket or open-end
3. Removal of service brake accumulator (also wrench, and remove the accumulator baf-
known as rear axle brake accumulator): fle;
1) Refer to “Pressure Relief” steps in “Removal
of Service Brake Valve” for pressure relief,
and you must not conduct subsequent
steps until ensuring that the accumulator
pressure is completely released;
5) Screw off 4 fixing nuts (on the inside of the

bracket) from 2 U-bolts with a 13m open-
end wrench, and remove 2 U-bolts;
Remove 2 accumulators;
2) Identify 3 hoses connecting oil ports at 2 4. Assembly of service brake accumulator:

accumulators with “A2”, “P1”, “A4”, and Assemble according to reverse steps of
note to identify firmly; removal;
6-135
6.5.3 Accumulator
6.5.3.3 Introduction to working prin- pression and expansion of high-pressure nitrogen.

The charge valve guarantees that pressure in the
ciple of accumulator accumulator is above 12.8MPa, when braking is
Both parking brake accumulator and service brake required, the accumulator can supply a large
accumulator are air bag accumulators, the air bag is amount of pressure oil within a short period of time
filled with high-pressure nitrogen to store and to guarantee the braking speed.
release pressure energy depending on the com-
Inflation valve Inflation valve

Service
brake accu- Service
mulator brake accu-
mulator
Housing
Housing
Air bag
Air bag
Oil inlet valve Oil inlet valve
Fig. 6.5.14 - Accumulator Structure Diagram

6-136
6.5.4 Service brake valve

functional structure of service brake
valve
The service brake valve, installed on the right side
of platform in the cab, is the final actuator of service
brake, its structure drawing is as follows:
Brake pedal
Mounting
plate for ser-
vice brake
valve
Service brake
valve
Fig. 6.5.15 - External View of Service Brake Valve As

6-137
1. Plug 9. Washer
2. O-ring 10. Spring
4. Spool 12. Spring
5. Valve body 13. Valve bushing
6. Oil seal 14. Jacket
7. COVER 15. Bolt
8. Valve seat AS
Fig. 6.5.16 - Exploded View of Service Brake Valve
6-138
6.5.4.2Removal and assembly steps wrench, knock down the joint position with
of service brake valve from the of hydraulic oil, screw out the hose, and
machine shield the oil port;
1. Removal of service brake valve:

1) Pressure relief:
Service
brake
valve
4) Screw out 4 captive bolts from the service

brake valve with a 13mm open-end
wrench, and remove the service brake
Shut down the complete machine, depress valve;
the service brake pedal for 15 to 20 times
2. Assembly of service brake valve?
for full pressure relief of hydraulic line;
nected with each connector of the service brake
valve as based on the identification of each
hose without error.
6.5.4.3 Brief introduction to service

brake valve working principle
When brake is removed, the service brake valve
spool is in the uppermost side position, and A port is
connected to T7 port. Oil in the brake at four rear
wheels flows back to the tank via the brake valve,
and brake force is removed.
The service brake valve is located on the

right side of the platform plate at the bot-
tom of the cab;
service brake valve with “A1”, “P1”, “T1”,
and note to identify firmly;
6-139
Fig. 6.5.17 - Service Brake Valve With Brake Removed

6-140
Fig. 6.5.18 - Oil Circuit Condition of Service Brake With Brake Removed
In the braking transition stage of service brake, the
service brake valve spool is in the neutral position,
A, T7 and P5 ports are not connected with each
other. Oil in the brake at the four rear wheels and oil
in the accumulator are sealed in the oil circuit to
guarantee a smooth transition from brake removal
to brake.
6-141
Fig. 6.5.19 - Service Brake Valve in Braking Transition Stage of Service Brake
6-142
Fig. 6.5.20 - Oil Circuit Condition of Service Brake in Braking Transition Stage of Service
Brake
In the braking stage of service brake, the service
brake valve spool is in the downside position, A and
P5 ports are connected. Oil in the accumulator flows
to the brake at the four rear wheels via the service
brake which makes the brake shoe stretch for
machine braking. When the service brake valve
spool passes across the neutral position, braking is
initiated; the lower the service brake valve spool
position is, namely that the lower the brake pedal
position is, the greater the braking force is; the
faster the service brake valve spool moves down,
namely that the faster the brake pedal is depressed,
the faster braking is accordingly.
6-143
Fig. 6.5.21 - Service Brake Valve in Braking of Service Brake

6-144
Fig. 6.5.22 - Oil Circuit Condition of Service Brake in Braking of Service Brake
In the brake maintenance stage of service brake,
the service brake valve spool is maintained in the
downside position, A and P5 ports are connected.
The oil pressure in the oil chamber at the downside
of service brake valve spool, the spring force and
foot brake force are balanced, and the machine is
maintained in a braking state; if you need to brake
for a long time, you need to use the parking brake
after putting into neutral position. When you release
the parking brake pedal, the spring force of the oil
chamber at the downside of service brake valve
spool resets the spool, and braking is removed.
6-145
Fig. 6.5.23 - Service Brake Valve in Brake Maintenance Stage of Service Brake
6-146
6.5.5 Parking brake valve

functional structure of parking
brake valve
The parking brake valve, installed on the left side of
front frame under the cab, is the final actuator of
parking brake, its internal structure is as follows:
1. Screw 5. Valve body

2. Cap 6. Pressure joint
3. Check valve 7. Solenoid valve
4. Plug
Fig. 6.5.24 - Exploded view of Parking Brake Valve
6-147

of parking brake valve from and to
the machine
1. Removal of parking brake valve:
1) Pressure relief:
Press and pull the hand brake repeatedly
Park the complete machine on the level

ground, open the hinged cylinder, adjust
the left side of the complete machine to the
maximum angle to ensure a greater space
for maintenance;
Until the accumulator hose is completely

soft;
Turn on the key to the 1st gear;

6-148
Unscrew the accumulator collar nut with a

24mm open-end wrench to slowly drain out
hydraulic oil;
2) Removal of parking brake valve gp:
Cut off the tie that ties up wires with scis-

sors;
Tear the harness connector apart;
Removal of 2 pressure switch wires;
Removal steps
Identify 4 hoses connecting oil ports of the

parking brake valve with “B3”, “T3”, “A3”,
First remove the boot, and remove 2 con- “P3”, and note to identify firmly;
necting plugs; Removal of 4 hoses in turn from bottom to
top: After screwing out the hose by 1-2 cir-
cles with the open-end wrench, knock
down the joint position with the wrench to
completely relieve pressure of hydraulic
oil, screw out the hose, and shield the oil
port;
6-149
Remove 2 bolts from the mounting plate Assembly of upside pressure switch wire: Insert
with a 18mm open-end wrench or double 2 connecting plugs (wire sizes 413#, 129#) into
offset ring wrench, and remove the parking the pressure clamp, ensure secure connection
brake valve; after assembly, and install the boot into the
pressure switch;
2. Assembly of parking brake valve: Assembly of downside pressure switch wire:
Assemble the parking brake valve in the Insert 2 connecting plugs (wire sizes 410#,
reverse sequence of “Removal of Parking 129#) into the pressure clamp, ensure secure
Brake Valve Gp”, of which the hose assembly connection after assembly, and install the boot
part must be connected with each connector of into the pressure switch;
the parking brake valve based on the identifica-
tion of each hose without error;
Connect separated harness connectors;
Screw down the hose at the accumulator;

6-150
Start the machine, pull up the hand brake, and

check all connectors for oil leakage; if there is
any oil leakage in connectors, shut down the
machine, and continue to tighten the collar nut
where there is oil leakage;
Tie down the wires with a tie to avoid wire

looseness;
If there is no oil leakage, adjust the lift cylinder,

lift the blade to a reasonable position, align the
hinge plate, and straighten the grader.
6.5.5.3 Brief introduction to parking

brake valve working principle
For parking braking, B and T8 ports of the parking
brake valve are connected, oil in the parking brake
flows back to the hydraulic oil tank via the parking
brake valve, the disc parking brake is clamped for
braking of the complete machine.
Condition after oil pipe and wires are well con-
nected;
6-151
6.5.6 Parking brake system
Fig. 6.5.24 - Condition of Oil Circuit In sure oil flows from the accumulator to the parking
Parking Braking brake via the parking brake valve, and the brake
clamp is released. Namely that when pressure oil in
When parking brake is removed, B and C ports of
the parking brake accumulator flows to the parking
the parking brake valve are connected, oil in the
brake, parking braking is removed, at this time, a
parking brake accumulator flows to the parking
pressure between 12.8 and 15.9MPa shall be possi-
brake via the parking brake valve, the disc parking
bly detected at the parking brake pressure test port
brake is released, and machine braking is removed.
SW3.
If the system pressure is below 10Mpa for some
reason when parking braking is removed, the disc
parking brake cannot be completely released at this
time, the parking brake low pressure alarm switch is
on, sending an alarm signal.
Fig. 6.5.25 - Condition of Oil Circuit When

Parking Braking is Removed
6.5.6.1 Introduction to parking brake

system
The parking brake system mainly consists of accu-
mulator, parking brake valve, parking brake, etc.
The accumulator supplies pressure oil for braking
removal; the parking brake valve is used to control
the parking braking and its removal of the complete
machine; the parking brake, a caliper disc brake
coming with the gearbox & torque converter as, is a
brake actuator. For parking braking, pressure oil in
the parking brake flows back to the hydraulic oil tank
through the parking brake valve, and the brake
clamp is clamped; when parking braking is
removed, the two-position three-way directional
valve in the parking brake valve is reversed, pres-
6-152
Fig. 6.5.26 - Oil Flow Diagram in Braking of Parking Brake System

6-153
Fig. 6.5.27 - Oil Flow Diagram With Braking of Parking Brake System Removed
6.5.6.2 Pressure detection for park-

ing brake system
Steps of parking brake system pressure detection: Parking brake valve is
installed at the left side
1. Park the machine on a flat, open ground, and of cab platform
lay the blade and other work implements on the

ground.
2. Connect 20MPa pressure gauge connector with
pressure test connector SW3 on the brake
valve as.
3. With the gearbox handle placed in neutral posi- Parking brake system
tion, start the engine, when you press the park- pressure should be
within 12.9-15.9 Mpa
ing brake button, there shall be a reading on the
pressure gauge, and its value shall be between
12.8-15.9 MPa.
6-154
6.5.7 Service brake system
Parking brake
pressure mea-
suring
Please identify accord-

ing to steel seal
6.5.7.1 Introduction to service brake

system
The service brake system mainly consists of accu-
mulator, charge valve, service brake valve, service
brake, etc. The accumulator supplies brake pres-
sure oil; the charge valve maintains sufficient oil
pressure for the accumulator, and the service brake
valve controls the service braking and removal of
complete machine; the service brake, a shoe brake
acting on four rear wheels of grader, is an actuator
of braking. When service braking is removed, pres-
sure oil in the service brake flows back to the
hydraulic oil tank through the service brake valve,
as shown in Fig. 6.5.28; for service braking, the
three-position three-way directional valve in the ser-
vice brake valve is reversed, pressure oil flows from
the accumulator to the service brake via the service
brake valve for braking of complete machine, as
shown in Fig. 6.5.29.
6-155
Fig. 6.5.28 - Oil Flow Diagram With Braking of Service Brake System Removed
6-156
Fig. 6.5.29 - Oil Flow Diagram in Braking of Service Brake System
6.5.7.2 Pressure detection for ser-

vice brake system Parking brake
valve is installed at
1. Steps of service brake system accumulator the left lower side
pressure detection: of cab platform
⚫ Park the machine on a flat, open ground,
and lay the blade and other work imple-
ments on the ground.
⚫ Connect 20MPa pressure gauge connec-
tor with pressure test connector SW2 on Service brake accu-
the brake valve as mulator pressure
⚫ With the gearbox handle placed in neutral should be within
position, start the engine, when you press 12.9-15.9 Mpa
the service brake pedal, there shall be a
reading on the pressure gauge, and its
value shall be between 12.8-15.9 MPa.
6-157
Service brake pres-

sure measuring joint
SW2
Service brake
pedal
2. Drive axle brake pressure

⚫ Connect 20MPa pressure gauge connec-
tor with pressure test connector on the tan-
dem
⚫ With the gearbox handle placed in neutral
position, start the engine, when you
depress the service brake pedal, there
shall be a reading on the pressure gauge,
its value shall be 10.3±0.3MPa, and at the
same time, the stop lights on the battery
box-lh and battery box-rh at the rear of the
machine shall come on Stoplight is located at the
rear part of battery boxes
at both sides of vehicle
Drive axle pressure

measuring joint is
located in the middle
of tandem
6-158
6.5.8Common faults and service method of brake hydraulic system
6.5.8Common faults and

service method of brake
hydraulic system
For common faults of brake hydraulic system, you
can refer to the table below for service:
Fault phenomenon Possible causes Trouble mode
1. Pump failure 1. Check the pump
2. Brake valve failure 2. Check the brake valve
Service brake underpow- 3. Air in brake line 3. Deflate
ered 4. Leakage in brake line 4. Check the brake lines
5. Large clearance between brake 5. Readjust according to the

drum and brake shoe requirements of use
6. Oil on brake shoe 6. Clean up brake shoe
1. Air valve leakage 1. Check air valve, supplement

Accumulator doesn't nitrogen
work 2. Air Bag is broken, nitrogen leakage 2. Remove and check the air bag or
in capsule replace it
1. Insufficient system oil pressure in a 1. Solvable after machine running

Service brake low pres- short period of time for machine
for a period of time
starting
sure warning lights
2. The machine has system failure and 2. Inspection after stopping
oil pressure drop during operation machine
Parking brake valve failure Check the brake valve, check the
No normal release of pressure at pressure test port SW3
parking brake
Parking brake cylinder leakage Replace cylinder oil seal parts
6-159
6.6 Introduction to Hydraulic Cooler System

The system is a single-pump single-motor quantita-
tive hydraulic system (see the hydraulic cooling sys-
tem schematic). It consists of a cooling pump, a fan
motor, a safety valve AS, an oil cooler, etc. The
hydraulic cooling system starts operating immedi-
ately after the machine is started, the cooling pump
absorbs oil from the hydraulic oil tank and supplies
high pressure oil to the fan motor which drives the
fan to cool all the coolers. Low pressure oil flow out
of the motor is cooled by the oil cooler, then filtered
by the return oil filter and flows back to the hydraulic
oil tank. A safety valve and a check valve are inte-
grated in the safety valve as, the safety valve mainly
performs overload protection on the fan motor,
namely that when the cooling pump outlet pressure
is above 18MPa, the safety valve is opened, the
pressure of high pressure oil is relieved by the
safety valve to guarantee that the motor operating
pressure is lower than 18MPa; the check valve is
mainly used to avoid vacuum at the oil inlet end of
the motor, namely that when the engine is suddenly
shut down so that the cooling pump suddenly stops
rotating but the cooler motor is still running, the oil
pressure at the motor outlet is higher than the oil
pressure at the inlet, at this time, the check valve is
opened, and oil flows from the motor outlet to motor
inlet to avoid vacuum at the motor inlet. In the
hydraulic system of grader, only oil in this system is
connected to the oil cooler for cooling, while oil in
the work hydraulic system, steering system and
brake system does not pass through the oil cooler.
CLG4180 grader hydraulic cooling system sche-
matic and layout drawing are as follows:
6-160
Fig. 6.6.1 - Hydraulic Cooling System Schematic

6-161
Fig. 6.6.2 - Hydraulic Cooling System Layout Drawing

1. Suction pipe 5. Fan motor
2. Cooling pump 6. Hydraulic oil spreading
3. Safety valve AS 7. Return pipe
4. Fan
6-162
6.6.1 Introduction to hydraulic cooling system principle
6.6.1 Introduction to hydraulic to the fan motor which drives the fan to cool all
the coolers. Low pressure oil flow out of the
cooling system principle motor is cooled by the oil cooler, then filtered by
1. After the machine is started, the engine drives the return oil filter and flows back to the hydrau-
lic oil tank.
the cooling pump which absorbs oil from the
hydraulic oil tank and supplies high pressure oil
Fig. 6.6.3 - Oil Flow Direction In Normal Cooling

2. When the cooling pump outlet pressure is
higher than 18MPa, the safety valve is opened,
the pressure of high pressure oil is relieved by
the safety valve to ensure that the motor oper-
ating pressure is lower than 18MPa.
6-163
6.6.1 Introduction to hydraulic cooling system principle
Fig. 6.6.4 - Oil Flow Direction at Pump Outlet Pressure of More Than 18MPa
3. When the engine is suddenly shut down so that
the cooling pump suddenly stops rotating but
the cooler motor is still running, the oil pressure
at the motor outlet is higher than the oil pres-
sure at the inlet, at this time, the check valve in
the safety valve is opened, and oil flows from
the motor outlet to motor inlet to avoid vacuum
at the motor inlet.
6-164
6.6.2 Cooling pump
6.6.2 Cooling pump in Fig. 6.6.5. During operation, when the gear
rotates in the illustrated direction, the volume of the
sealed working chamber of suction chamber down-
6.6.2.1 Installation position and side is gradually increased to form partial vacuum,
working principle of cooling pump oil in the tank is sucked in, filling up the slot in tooth
space, and oil is brought into the pressure oil cham-
The cooling pump, installed at the power take-off
ber upside with gear rotation. On the side of pres-
port of the transfer case on the left of engine, has sure oil area, the volume of sealed working
the main function of supplying pressure oil source to chamber constantly decreases, oil is squeezed out,
the cooler motor to cool all the coolers of the so as to supply high pressure oil to the fan motor
machine. and drive the fan to cool all the coolers.
The cooling pump is a one-way quantitative gear
pump, and its working principle sketch is as shown
Fig. 6.6.5 - Schematice Diagram of Cooling Pump Working Principle

of cooling pump from and to the
machine
1. Removal and assembly of cooling pump
6-165
6.6.2 Cooling pump
1) Identify 2 hoses connecting oil ports on the

cooling pump with “P”, “A”, and note to
identify firmly;
3) Unscrew off two bolts from cooling pump with
a open-end wrench (16 mm), and take out
the cooling pump;
2. Assembly of cooling pump:

nected with two connectors of the cooling pump
as based on the identification of each hose
without error.
6-166
6.6.3 Safety valve AS
6.6.3 Safety valve AS protection of hydraulic cooling system. Its internal

structure is as shown in Fig. 6.6.6 and Fig. 6.6.7.

internal structure of safety valve as
The safety valve as, installed in the middle of the left
side of rear frame, has the main function of overload
Fig. 6.6.6 - Exploded view of Safety Valve As

1. Valve body gp 10. Positioning screw
2. Connector 11. Bolt
3. Pressure joint 12. Washer
4. Connector 13. O-ring
5. O-ring 14. O-ring
6. Connector 15. Support
7. Single slide valve 16. Safety valve
8. Spring 17. Bolt
9. O-ring
6-167
Of which the internal structure of No.16 safety valve

is as follows:
Fig. 6.6.7 - Exploded view of Safety Valve

1. O-ring 7. Screw cap
2. O-ring 8. Nut
3. Valve body 9. Copper pad
4. Spool 10. Cap
5. Pad 11. Screw
6. Spring 12. Pad
6-168

of safety valve AS from the machine
1. Removal of safety valve AS:
Safety valve AS
3) Screw out 2 captive bolts from the safety

valve AS with a 16mm open-end wrench,
and remove the safety valve AS.
2. Assembly of safety valve AS:

Location of safety valve AS; Assemble in the reverse sequence of removal,
nected with each connector of the safety valve
as based on the identification of each hose
without error.

safety valve AS with “A1”, “A2”, “B2”, “B2”,
and note to identify firmly;
6-169
6.6.3.3 Brief introduction to safety pressure is lower than 18MPa. The check valve is
mainly used to avoid vacuum at the oil inlet end of
valve AS working principle the motor, namely that when the engine is suddenly
A safety valve and a check valve are integrated shut down so that the cooling pump suddenly stops
inside the safety valve AS. The safety valve mainly rotating but the cooler motor is still running, the oil
performs overload protection on the fan motor, pressure at the motor outlet is higher than the oil
namely that when the cooling pump outlet pressure pressure at the inlet, at this time, the check valve in
is above 18MPa, the safety valve is opened, the the safety valve as is opened, and oil flows from the
pressure of high pressure oil is relieved by the motor outlet to motor inlet to avoid vacuum at the
safety valve to guarantee that the motor operating motor inlet. Specific working condition is as below:
Oil flow direction when oil pressure of Oil flow direction when oil pressure Oil flow direction when the motor
pump outlet is lower than 18 MPa of pump outlet is more than 18MPa stop running
Fig. 6.6.8 - Working Condition of Safety Valve As

6-170
6.6.4 Fan motor
6.6.4 Fan motor

internal structure of fan motor
The fan motor, installed at the tail of the machine,
has the main function of cooling all coolers of the
machine. Its internal structure is as shown below:
Fig. 6.6.9 - Exploded View of Fan Motor

1. Cover 11. Elastic retainer ring for shaft
2. Pump body 12. Motor washer
3. Cover 13. Motor oil seal
4. Primary main gear 14. Secondary seal ring
5. Driven gear 15. Needle bearing
6. External shaft 16. Oil blocking screw
7. Side plate 17. Cylindrical pin
8. Elastic retainer ring for holes 18. Square seal
9. Outboard ball bearing 19. Washer
10. Bearing snap ring 20. Hex bolt
6-171
6.6.4 Fan motor
21. Cotter pin 23. Woodruff key

22. Nut 24. Drainage port plug

of fan motor from and to the
machine
1. Removal of fan motor;
1) Open the left and right door of engine hood;
2) Hang the 2 handrails by lifting rope;
3) Remove the 2 bolts P1 under the rear hood
firstly (parts number00B0075, specification
M8×20-8.8-Zn.D, socket specification 13
mm), than remove the 2 bolts P2 above
the hood;
State after rear door is removed;
4) Take down the cover; unplug the harness

connector of plate license light during this
process;
Notice: Please use lifting rope to lift cover and avoid cooler motor with “A”, “B”, “T”, and note to
potential hazard due to manual materials handling identify firmly;
(such as bruised, injured by a crashing object)! 6) Removal of 3 hoses: After screwing out the
6-172
6.6.4 Fan motor
6.6.4.3 Introduction to working prin-

ciple of fan motor
The fan motor is a one-way quantitative gear motor.
During operation, pressure oil output by the cooling
pump flows in from the motor oil inlet P port, drives
the gear in the motor to rotate, the gear drives the
fan through the power output shaft, so as to cool all
the cooling systems. Low pressure oil after applying
work flows to the cooler via the motor return port T
port for cooling; oil leaked into the motor housing
directly flows back to the hydraulic oil tank via return
port O, the specific working condition is as shown in
figure on the right:
7) Remove 3 connectors from the cooler motor,

and shield 3 oil ports to avoid foreign mate-
rials entering the motor;
8) Screw out 4 bolts from the motor mounting

plate with a 16mm open-end wrench or
socket;
9) Take out the cooler motor.
2. Assembly of cooler motor:

nected with each joint of the cooling motor as
error.
6-173
6.6.4 Fan motor
Fig. 6.6.10 - Oil Flow Direction in Fan Motor Operation

6-174
6.6.5 Return oil filter
6.6.5 Return oil filter return oil in the hydraulic system flows back to the
hydraulic oil tank via the filter; when the filter is
The return oil filter, installed to the return port of clogged, the check valve is opened, and oil flows
hydraulic oil tank, has the main function of filtering back to the tank via the bypass oil circuit at the
the oil flowing back from the hydraulic system back check valve; the specific working condition is as
to the hydraulic oil tank. shown below:
A filter and a bypass check valve are integrated in
the return oil filter. During normal operation, system
Fluid flow direction during Fluid flow when filter is

normal working blocked
Fig. 6.6.11 - Working Condition of Return Oil Filter

6-175
6.6.6 Test and detection of hydraulic cooling system pressure
6.6.6 Test and detection of The safety valve overflow pressure test method is
as follows: To test the pressure, remove the oil pipe
hydraulic cooling system pres- from safety valve to fan motor, and block the oil port
sure in corresponding position on the safety valve with a
plug; start the complete machine for idle running,
The hydraulic cooling system has the maximum and the pressure value shall be 18Mpa. This pres-
operating pressure of 18Mpa, with a pressure test sure value has been set at delivery, generally not to
port on the safety valve. The pressure value shall be be adjusted.
around 12MPa when the machine operates nor-
mally.
Connect the
cooler inlet
Pressure
hole
Safety
Connect valve
the fan
return port
Oil inlet
Connect the motor

inlet, remove the inlet
hose and block the
inlet when measuring
Fig. 6.6.12 - Three-dimensional Diagram of Safety Valve As

If the difference between the pressure measured by pressure decreases; adjust the overflow pressure to
the above method and 18Mpa is great, you can 18MPa, screw down the locknut, and install the cop-
adjust the safety valve set pressure on the safety per packing and screw cap.
valve as, refer to the figure below, and the adjust-
ment method is as follows: Remove the screw cap
(serial number 1) and copper packing (serial num-
ber 2) from the safety valve; unscrew the locknut
(serial number 3); rotate the screw (serial number 6)
with a slot type screwdriver, the clockwise rotating
pressure is increased, and the counterclockwise
6-176
Fig. 6.6.14 - Safety Valve

6-177
HYDRAULIC SYSTEM SCHEMATIC

7-1
Table of Contents
7. Electrical System
Table of Contents
7.1 Parameters of electrical system .....................................................................7-3
7.2 Overview of electrical system......................................................................... 7-3
7.2.1 Precautions for maintenance ......................................................................................7-3
7.2.2 Operation instruction of digital multimeter...................................................................7-4
7.2.3 Introduction to electrical system..................................................................................7-4
7.3 Battery............................................................................................................ 7-5
7.3.1 Battery parameter .......................................................................................................7-5
7.3.2 Battery overview..........................................................................................................7-5
7.3.3 Negative switch ...........................................................................................................7-5
7.3.4 Removal and installation of battery .............................................................................7-6
7.3.5 Battery maintenance ...................................................................................................7-7
7.4 Alternator........................................................................................................7-9
7.4.1 Engine parameter........................................................................................................7-9
7.4.2 Engine description.......................................................................................................7-9
7.4.3 Engine terminal wiring.................................................................................................7-9
7.5 Starter motor ................................................................................................7-10
7.5.1 Start motor parameter ...............................................................................................7-10
7.5.2 Start motor overview .................................................................................................7-10
7.5.3 Start motor terminal wiring ........................................................................................7-10
7.6 Start switch (electric lock)............................................................................. 7-11
7.7 Centralized control box ................................................................................ 7-11
7.8 Parking brake system................................................................................... 7-14
7.8.1 Overview of parking brake system ............................................................................7-14
7.8.2 Parking brake button .................................................................................................7-14
7.9 Shift control system......................................................................................7-15
7.9 Overview of shift control system ..................................................................................7-15
7.9.2 SG-6S shift selector ..................................................................................................7-17
7-2
Table of Contents
7.9.3 Transmission control solenoid valve......................................................................... 7-22

7.9.4 Output speed sensor ................................................................................................ 7-24
7.10 Lights ......................................................................................................... 7-24
7.10.1 Front floodlight........................................................................................................ 7-24
7.10.2 Work light................................................................................................................ 7-25
7.10.3 Rear combination light............................................................................................ 7-26
7.10.4 Dome light and licence plate light........................................................................... 7-27
7.11 Rocker switch ............................................................................................. 7-28
7.12 Sensor........................................................................................................ 7-36
7.12.1 Water temperature sensor and oil temperature sensor .......................................... 7-36
7.12.2 Pressure switch ...................................................................................................... 7-38
7.12.3 Fuel level sensor .................................................................................................... 7-40
7.12.4 Intake air filter alert switch ...................................................................................... 7-42
7.13 Instrument .................................................................................................. 7-43
7.13.1 Water temperature gauge and oil temperature gauge............................................ 7-45
7.13.2 Fuel gauge.............................................................................................................. 7-46
7.13.3 Voltmeter ................................................................................................................ 7-47
7.13.4 Hourmeter............................................................................................................... 7-49
7.13.5 Warning indicator.................................................................................................... 7-49
7.14 Wiper system ............................................................................................. 7-51
7.15 Sound system ............................................................................................ 7-53
7.16 Preheating system ..................................................................................... 7-55
7.17 Main circuit fuse ......................................................................................... 7-57
7.18 Main power circuit ...................................................................................... 7-57
7.19 Starter circuit .............................................................................................. 7-61
7.20 Choke circuit .............................................................................................. 7-64
7.21 Schematic diagram of electrical units......................................................... 7-67
7.22 Schematic diagram of electric connector positions .................................... 7-68
7-3
7.1 Parameters of electrical system
7.2.1 Precautions for maintenance
7.1 Parameters of electrical rectly distinguish colors and wire gauge, it will
help repair.
system 3. Please connect the connectors correctly: letter
codes of connectors should be correspond to
colors of wire during connection. Doing so may
Electrical system cause damage to the connector, and may even
System voltage 24V cause the harness burned.
4. Please grasp the connector body when plug-
ging the connectors. Do not pull out the wire
7.2 Overview of electrical with too much force. Make sure the fitting and
good contact of lock buckles when connecting
system the connectors.
This part is composed on the basis of relevant elec- 5. Make sure the connectors are dry and protec-
trical system principle diagram and electrical work- tive measure should be taken to meet the
ing principle during production. Please be subject to requirements of damp proof and water proof.
the delivery attached documentation from Liugong 6. Understand the schematic circuit diagram
dealers when purchasing machine if modifications which indicates mutual relationships and func-
of product are various according to different types of tions of each elements and devices of the elec-
machine. trical system. This will be helpful to make a
Maintenance personnel must master general knowl- quick and correct judge of fault and save main-
edge of maintenance electrician and be familiar with tenance time. Don't remove and dismantle the
electrical system and working principle of Liugong machine to a large extent blindly.
land leveller before fault diagnosis and mainte- 7. Understand "land" means correctly: battery
nance. negative is the "land", engineering machinery
generally use negative ground, namely connect
7.2.1 Precautions for mainte- the battery’s negative to the whole body (
including scraping frame, cab and other metallic
nance conductors connected together).Therefore,
Before maintenance, please do understand and when the negative of the battery connects the
keep safety and warning information & precautions whole body tightly and reliably, the whole body
in mind in case of personal injuries or damages to is the "ground ." (Note: surface of the measur-
electrical elements and its relevant equipments. ing ground position can be coated with butter, it
Please obey the following precautions strictly during should be appropriate to avoid the bad ground;
the maintenance of electrical system. paint, oil, dust etc are not allowed).
Read and understand the Manual for Testing Equip- 8. Bind harnesses and wires correctly: a. avoid
ments to use the testing equipments correctly. folding and bending harnesses with excessive
force; b. keep away from the movable parts and
1. Complete machine power should be cut off
avoid breaking and wear; c. avoid friction with
before maintenance; and then disconnect wires
sharp metal edges and corners; d. keep away
and connectors. If not, harness will be damaged
from oil and water to the greatest extent; e.
and the fuse will be blown; even fire will be
keep away from the parts of high temperature
caused because of short circuit of wires.
(such as the engine body).
2. Correctly identify the wire colors and functions:
9. If wire or harness are found to be worn, they
wire colors and wire gauge are corresponding
should be replaced and wrapped immediately,
to three-digit line mark in the schematic. Cor-
and fix the harness in place not be worn.
7-4
7.2 Overview of electrical system
7.2.2 Operation instruction of digital multimeter
10. Correctly replace the safety device: when Put the range switch to the“ ” position.
replace the safe device (also known as fuse), Black probe connects to jack"COM" and red to
you must use one in the same specification, it
jack"V Ω".
does not allow use of copper wire for emer-
gency treatment. Chip type fuse and flat plate Red probe connects to the positive terminal of
type fuse used in this product should meet rele- diode, black to the negative terminal and then
vant regulations of QC/T 420 Fuses for Auto. reading will displayed or it will display for
Therefore, please use the authentic parts from reverse connection.
Liugong when replacing fuses during mainte- Notice: appropriate measured range should be
nance. selected when measuring voltage and current to
avoid damages to instruments. It is prohibited to
measure voltage on the current and resistance posi-
7.2.2 Operation instruction of tion. (For detailed operation instructions, safety
digital multimeter requirements and precautions, please refer to the
operation instructions of digital meter.)
7.2.3 Introduction to electrical

system
The electrical system consists of cab wiring, rear
frame wiring, front frame wiring, battery wiring, light
group system, wiper system, audio system, etc.
This manual mainly introduces the installation posi-
tion of electrical system elements, control principle
of circuit, working mode of the elements and fault
diagnosis & overhauling of the circuit, etc.
The rated voltage of the electrical system is 24V.
Wires with a sectional area of below 5 mm2 are Jap-
anese standard wires, i.e. AVSS, AVS wires, wires
1. Measurement method of DC voltage
with a sectional area of above 5 mm are QVR wires,
Put the range switch to the position of required and all wires are provided with wire sizes.
voltage range (DC 20V position is usually used
Wire recognition
for the system voltage of machine is DC 12 V).
For example: 602WH1.25 602: wire code WH:
Black probe connects to jack"COM" and red to
jack"V Ω". color 1.25: wire gauge (mm2)
Red probe connects to the measured point, Abbr. code for colors
black to the grounding and the display value is
the voltage value of this point.
WH: White GY: Gray OR: Orange
2. Measurement method of resistance
Black probe connects to jack"COM" and red to
jack"V Ω".
Put the range switch to the position of required
voltage range.
Bridge the meter probe over both sides of the
measured resistance and the display value is
the value of measured resistance.
3. Measurement method of diode
7-5
7.3 Battery
7.3.1 Battery parameter
7.3 Battery Installation position diagram is as below
7.3.1 Battery parameter
Type 6-QW-120T
Qty 2 series
Earthing Cable (-)
Rated voltage 12V
20 hourly rate Battery box-lh Battery box-rh

120Ah
capacity
Reserve capac- 230min
ity
Low-tempera-
ture starting cur- 850A （﹣ 10 ℃）
rent
Negative Hydrometer
Battery discon- Disconnect switch (disconnect Positive
cable terminal cable
nection mode the negative from the frame)
terminal
Length 406mm
Width 172mm
High 211mm
Overall height 231mm
Reference 29.2±0.5Kg
weight
7.3.3 Negative switch
7.3.2 Battery overview
The electrical system of complete vehicle is pro-
vided with 24V voltage by two 12V batteries con-
nected in series. The batteries supply power to the
complete vehicle before the engine starts, and sup-
ply start current to the start motor. The batteries are
installed in the left and right battery boxes at the tail
of complete vehicle. The battery cable(-) is con-
nected to the disconnect switch connected to the
frame ground, and the disconnect switch controls
the connection and disconnection of battery.
7-6
7.3 Battery
7.3.4 Removal and installation of battery
The disconnect switch is installed in the left battery

box. When the switch lever points to the "I" position
on the switch panel, the disconnect switch is in the
Rated voltage 24V ON state.
Current continuously
≤ 200A 7.3.4 Removal and installation
passing main contact
Transient current (5 s) 1200A of battery
Working ambient tem-
﹣ 40 ℃～ +120 ℃
perature
When the battery is to be removed, the fol- 2. Do not place the battery upside down or later-
lowing steps shall be observed: ally;
1. Disconnect the disconnect switch, No.2; 3. Prior to installation, check the hydrometer, and
2. Remove the connecting cable between the bat- confirm that it is green;
tery cable(-) and disconnect switch, No.1;
3. Remove the cable between the battery cable(+)
and start motor, No.5;
4. Remove the connecting cable between two bat-
teries, No.4;
5. Remove steel angles (No.3) and battery hooks
(No.6) for fixing batteries.
The installation sequence is opposite to the
removal steps, and you shall confirm that the
disconnect switch is in the OFF position prior to
installation.
Attention shall be paid to the following

during battery installation:
1. The battery shall not be tilted at more than 40°;
7-7
7.3 Battery
7.3.5 Battery maintenance
Visual inspection of battery hydrometer state
Color Green Black Bright color
State of Charge larger than 65% Charge smaller than 65% Electrolyte level is too low
charge
Measure Load test Charge the battery, then do Replace the battery
the load test
Battery open-circuit voltage inspection
Inspection items Reasons Solution
Above 12.5 V, hydrometer is

Normal
green
Between 11-12.4 V, hydrometer
Undercharge Charge
is black
Voltage
1. Over discharging Charge
(Hydrometer is green)
10. About 5 V or less 2. Short circuit (Hydrome- Replace
ter is green)
3. Open circuit (Hydrom- Replace

eter is green)
Battery maintenance requirements Recharge the battery

1. For a vehicle parked for more than 15 days, the 1. Causes for battery undercharge: With the vehi-
disconnect switch shall be disconnected; cle not started, long turn-on time of electric
2. The battery shall be installed without looseness, appliances on the vehicle and other abnormal
and there shall be no spilled acid, cracks, dam- uses, electric leakage and vehicle lay-off for a
age resulted from bump or dirt at the surface of long time, or generator charging fault lead to
battery case or the junction with positive and failed charging of battery, causing under-
negative terminals; charged battery and black battery hydrometer,
even vehicle starting failure, and the battery
3. Check the charge state of battery every 3 needs to be charged.
months, and the battery with a voltage of more
2. Check the battery appearance before charging:
than 12.50V is a normally charged battery. The
battery with a voltage of less than 12.50V is an a. For no charging of a battery with broken case
undercharged battery. or acid leakage, find out the cause, and
For a vehicle stored for more than 1 year (bat- replace the battery.
4.
tery never charged), the battery must be b. For no charging of a battery with broken ter-
replaced and scrapped. minal post, find out the cause, and replace
the battery.
7-8
7.3 Battery
c. Do not charge a battery with white hydrome- 2) The correspondence between charging time
ter, replace the battery. and battery voltage before charging is
d. Before charging, clean the terminal posts, shown in the table below (for reference,
and remove scale on the surface. the smaller the charging current is, the lon-
ger the charging time is).
3. Precautions during charging
a. Wear safety goggles.
b. Maintain a ventilated environment during
charging, and charge at a normal tempera- Battery voltage Charging time
ture.
c. Do not smoke during charging, and avoid 12.55 ～ 12.45V 2 hours
introduction of fire.
d. Connect the positive cable first during wiring 12.45 ～ 12.35V 3 hours
for charging; disconnect the negative cable 12.35 ～ 12.20V 4 hours
first during disconnection prior to charging.
4. Recharge the battery operation 12.20 ～ 12.05V 5 hours
a. Confirm that the battery terminal posts are 12.05 ～ 11.95V 6 hours
clean, and the charging circuit is in good
connection. Connect the charger positive 11.95 ～ 11.80V 7 hours
to the battery positive, and connect the
charger negative to the battery cable(-). Do 11.80 ～ 11.65V 8 hours
not charge the batteries in series (24V).
11.65 ～ 11.50V 9 hours
b. It is recommended to charge the battery at
constant voltage of 16.0V (no more than 11.50 ～ 11.30V 10 hours
16.2V at most, current limited to 25A a lot
of water will be electrolyzed when this limit 11.30 ～ 11.00V 12 hours
is exceeded, causing liquid level drop,
Below 11.00V 14 hours
white charge indicator, battery scrap) until
the hydrometer shows green. The green
3) When charging is completed, check the color
battery hydrometer indicates that the bat-
of battery hydrometer. The green hydrom-
tery has been fully charged.
eter indicates that the battery has been
c. If there is no condition for charging at con- fully charged. If the hydrometer is black,
stant voltage, constant current charging is check whether the charging cable is in
allowed per the following spec: solid connection, the connection points are
1) Select 1/10 amp charging current (12A for clean and the voltage at the end of
37B0108 battery) of rated capacity (C20), charging reaches 16V, place it for 24h,
the voltage at the end of charging should measure the voltage, compare the relation-
be reached but cannot exceed 16V (volt- ship between voltage and charging time
age less than 16V at the end of charging is and continue to charge.
easy to cause the hydrometer to show 4) At the end of charging, if you find that the
black even after charging is completed). hydrometer shows white, it may be due to
When the charger cannot guarantee that bubbles in the hydrometer, and you can
the charging voltage is limited to below expel them by gently shaking the battery. If
16V, the charged battery terminal voltage it still shows white after shaking, it indi-
must be manually monitored every hour; cates that the electrolyte has been lost,
otherwise, it can cause water loss in bat- and the battery has been scrapped and
tery due to overvoltage charging and affect shall be replaced.
the life of battery and even failure.
7-9
7.4 Alternator
7.4.1 Engine parameter
⚫ For a battery with a voltage of less than 7.4.2 Engine description

11.0V, the battery may not be charged
at the beginning of charging. As the The generator is an equipment supply power to the
proportion of sulfuric acid in a seriously electrical appliances of the complete vehicle. Before
undercharged battery is close to that of the engine starts, the battery supplies power to the
pure water, the internal resistance of electrical appliances of the complete vehicle. After
the battery is very high. As battery the engine starts, the generator supplies power to
charging proceeds, the proportion of the electrical appliances of the complete vehicle and
sulfuric acid in the battery rises, and charges the battery. It is forbidden that only the gen-
the charging current of battery can erator supplies power to the complete vehicle when
return to normal gradually. the connecting cable between the battery and gen-
⚫ If acid is sprayed from the battery vent erator is disconnected.
during charging, the charging shall be
stopped immediately.
If the battery temperature exceeds 45°
7.4.3 Engine terminal wiring
⚫
during charging, stop charging; reduce

the charging current by half and con-
tinue to charge after the battery tem-
perature drops to room temperature.
⚫ Check the hydrometer state once
every hour during battery charging.
The green battery hydrometer indi-
cates that the battery has been fully
charged, and stop charging.
7.4 Alternator
7.4.1 Engine parameter
Alternator
Type Alternator Terminal Wiring
Rated voltage 28V B+ Red
Rated current 70A E Grey
B+ terminal and tight- L White

M6、 4.5 ～ 6.5N.M
ening torque
Judgment method for engine faults:
L terminal Equipped with DJ7011-
1. Adjust the digital multimeter to DC 200V range;
6.3-20
2. Turn on the disconnect switch without turning
E terminal and tighten- on the electric switch lock and starting the
M5、 2.3 ～ 4.5N.M
ing torque engine, connect the red pen to the generator
“B+” terminal and the black pen to the generator
earthing point, and after the reading of the mul-
timeter is stable, read the voltage value which
shall be between 24V and 26V;
7-10
7.5 Starter motor
7.5.1 Start motor parameter
3. Start the engine. Ensure that all the electrical 7.5.3 Start motor terminal wir-
appliances on the vehicle are disconnected,
and repeat the measurement in Step 2; the ing
measured value shall be higher than that in
Step 2, which shall be about 28V. It proves that
the generator works normally;
If the measured result in Step 3 has no change
compared with that in Step 2, turn off the engine
and check the following:
a. Check the tension of generator pulley, and
apply a force of 100N between two pulleys;
the deflection of new belt shall be about
510mm, and that of old belt is about
714mm. Too loose belt will cause “lost
rotation” of generator, resulting in insuffi-
cient generating capacity, undercharged
battery and other faults.
b. Check whether the terminals of generator are
tightened, and the terminals of generator Judgment method for start motor faults
connected with the battery are tightened.
If the start circuit is on, the start motor has no action,
If the above detected items are normal, please
and judge whether the start motor is damaged
contact Lg dealers and Commins service pro-
according to the following steps.
viders.
1. Check the connecting wiring from the battery
“+” terminal to battery for loose or oxidized ter-
7.5 Starter motor minals;
2. Confirm that the voltage of terminal 30 is above
7.5.1 Start motor parameter 24 V.
3. Confirm that the voltage of terminal 50 is about
24 V.
4. If all above conditions are normal. It shows that
the start motor has fault, please contact Com-
Rated output 24V， 6KW
mins service providers for solution.
Rated work time 30S
Terminal 30# and tight-

M10，13.5 ～ 15.8N⚫m
ening torque
Terminal 30# and tight-

M5， 2 ～ 2.5N⚫m
ening torque
7.5.2 Start motor overview

The start motor, installed on the engine, is a device
that converts the electric energy of battery into
mechanical energy, which drives the engine to
rotate, thereby starting the engine.
7-11
7.6 Start switch (electric lock)
7.5.3 Start motor terminal wiring
7.6 Start switch (electric IV position: Start, the second position which the start
switch key is turned to clockwise after being
lock) inserted; the engine start circuit is on, the start
motor rotates to start the engine, and the key
returns to ON position when released.
Gear table is as below
Gear position Connected contact
I B1-B2-G1
II B1-B2
Start switch
III B1-B2-M
IV B1-B2-M-S-G2
7.7 Centralized control box
The start switch (also called electric switch lock) is

on the right control box panel of cab seat, including
four positions clockwise: I, II, III and IV.
I position: Auxiliary, used for engine preheating sys-
tem; when the key is turned to this position counter-
clockwise, the engine air intake preheating system
works to heat intake air for 45s, and the key auto- Fuse setting table
matically returns to “OFF” position when released.
II position: OFF, the position which the start switch Rate
Serial Wire
key stays in normally; when the key is in this posi- d Function
numb
tion, the circuit of complete vehicle is cut off (except curre No.
er
some electrical appliances directly connected to the nt
battery).
III position: ON, the first position which the start A/C (hung at
30A 133
switch key is turned to clockwise after being harness）
inserted; when the key is in this position, the electri- 30A 120 Close down
cal appliances of complete vehicle is switched on.
50A 121 Start
7-12
Fuse setting table （Continued） Fuse setting table （Continued）
Serial Rate Serial Rate

d Wire Function d Wire Function
numb numb
curre No. curre No.
er er
nt nt
F1 10A 108 Electric lock F26 10A 134 Rear work light
F2 10A 107 Spare

Relay position diagram
F3 10A 148 Pin switch
F4 10A 124 Centralized lubrica-

tion system
F5 7.5A 141 Radio
F6 10A 129 Break pressure switch
F7 10A 147 Backup
F8 7.5A 139 Transmission control
F9 10A 109 Flash relay
F10 10A 137 Instrument
F11 10A 142 Cigarette lighter
F12 10A 128 Warning indicator
Position light and

F13 10A 144
dome light
F14 15A 140 Wiper and washer
F15 7.5A 145 Heater
F16 10A 130 Electric horn
F17 7.5A 132 Parking brake
F18 7.5A 160 Spare Relay function details

F19 10A 161 Blade work light No. Relay function description Remark
F20 15A 162 Spare 1 Flash relay
F21 10A 131 Brake light 2 Main power relay
F22 15A 135 Front floodlight 3 Choke relay
F23 10A 136 Work light 4 Start contactor
F24 10A 151 Rotating beacon
F25 10A 150 Front work light

7-13
Relay function details （Continued） Main power relay parameter table
No. Relay function description Remark Terminal spec (30 and

9.5*1.2mm
87)
5 Neutral interlock relay
Fault judgment: Adjust the digital multimeter to ohm
6 Start protection relay
range, and measure the resistance of relay termi-
(standby)
Mini type nals 85 and 86, which shall be 310Ω±10％; connect
7 Break lamp relay the circuit of terminals 85 and 86, and the terminals
30 and 87 shall be connected.
8 Head lamp relay
3. Choke relay
9 Top lamp relay The schematic diagram is as follows
10 Backup relay
Relay parameter details

1. Flash relay
The B terminal is connected to the power sup-
ply positive 24V, the E terminal is connected to
the power supply negative, and the L terminal is
connected to the turn signal light load. Flicker
frequency: 60120 times/min.
2. Main power relay
The schematic diagram is as follows:
Technical parameter table is as below
Choke relay parameter table

Main power relay parameter table
Rated voltage 24V
Rated voltage 24V
Allowable current of 20A
normally open contact
Coil resistance 310Ω±10％
Allowable of normally 10A
Terminal spec (85 and 6.3*0.8mm closed contact
86)
7-14
7.8 Parking brake system
7.8.1 Overview of parking brake system
Choke relay parameter table nected, the contact terminals 3 and 5 are con-
nected. If not connected, cut off power and measure
Coil resistance 255±15Ω whether the resistance between the coil terminals 1
and 2 is normal. Replace the relay if abnormal.
Fault judgment: Adjust the digital multimeter to ohm
range, and measure the resistance of relay termi-
nals 85 and 86, which shall be 255±15Ω; in normal 7.8 Parking brake system
state, the terminals 30 and 87a are connected, and
the terminals 30 and 87 are disconnected; connect
the circuit of terminals 85 and 86, and the terminals
7.8.1 Overview of parking brake
30 and 87 shall be connected. system
4. Start contactor The parking brake system consists of a parking
Technical parameter table is as below brake switch, parking brake solenoid and gearbox.
When the parking brake switch is pressed, the park-
ing brake is actuated to cut off the power output
Start Relay Parameter Table
from the gearbox, and the caliper disc brake of
Rated voltage 24V gearbox works at the same time. It can prevent the
complete vehicle from moving backward after park-
Rated load current of main 100A ing.
contact circuit
Spec for main contact termi- 2-M6 7.8.2 Parking brake button
nal
The parking brake switch is a switch preventing the
Spec for coil terminal 2-M4 complete vehicle from moving during parking. The
parking brake is actuated when the switch is
Fault judgment: When the start circuit is connected, pressed, and the vehicle can move after the switch
listen to the contactor pull-in sound; if there is no is pulled up.
pull-in sound, respectively measure whether there is
24V voltage at both ends of coil terminal to earth Installation position diagram is as below
with the multimeter; if any, the main contact is dam-
aged, replace the contactor. If not, cut off power and
measure the resistance of coil terminal, which shall
be about 6.5Ω; if the resistance value is abnormal,
the coil is damaged, replace the contactor.
5. Mini-relay
Relay parameter table
Coil rated voltage 24V
Contact circuit load

10A/20A
(resistivity)
Fault judgment: In normal state (not energized), the

contact terminals 3 and 4 are connected, and the
resistance between the coil terminals 1 and 2 is
about 300Ω. After the coil terminals 1 and 2 are con-
7-15
7.9 Shift control system
7.9 Overview of shift control system
Schematic wiring diagram is as blow
1. Shift control solenoid

When the switch is pressed, the contacts 1 and 2 2. SG-6S shift selector
are disconnected, and the contacts 3 and 4 are dis- 3. E module
connected; when the switch is pulled up, the con- 4. Connection harness
tacts 1 and 2 are connected, and the contacts 3 and
5. Output speed sensor
4 are connected. Meanwhile, signals are sent to the
gear and parking brake solenoid. Schematic diagram of transmission control system
is as below

7.9 Overview of shift control
system
For the shift control system, the electrical control
part of 6WG200 gearbox produced from ZF Fried-
richshafen AG is mainly introduced. The shift selec-
tor output circuit of shift control system drives the
combined motions of shift control solenoid located
on the gearbox, so as to gain the gear selected by
the operator. The shift selector has downshift pro-
tection function. If downshift operation is needed
when the gearbox is above 3rd gear, the E module
controls the opening and closing of shift selector
return lock according to the feedback signal of
speed sensor, and the downshift operation can be
done only after the speed drops below the downshift
point of each gear.
7-16
7.9 Overview of shift control system
7-17
7.9.2 SG-6S shift selector

Overall dimension drawing is as below
7-18
The installation position diagram is as fol-

lows:
Symbols of schematic
Interface definition
AD1: Solenoid valve 1 (output)
AD6: Neutral start interlock (output)
AD7: E module W signal (output)
AD9: Backup signal (output)
ED1: Downshift interlock protection (input)
ED3: Clutch disengagement (power cutoff) (input)
Working principle
Gear diagram The output signal of shift selector is determined by
the internal circuit, the output signal of different gear
The shift selector has 6 forward gears and 3 reverse
controls different solenoid group, and the clutch is
gears. N represents Neutral Gear.
controlled through the solenoid so as to control
gearbox shift. The shift selector has downshift pro-
tection function. When the gearbox is in 3rd gear
and above, the E module starts working, and judges
the engine speed through the output speed sensor
signal of torque converter turbine; when needed,
downshift operation can be done only after the
speed is below the downshift speed point of
selected gear. Otherwise, the return solenoid of shift
selector works, and downshift operation is unavail-
able. For example, if the speed is above the 3rd and
4th gear shift point when the gearbox is downshifted
to 3rd gear from 4th gear, the shift selector cannot
be pulled back to forward 3rd gear.
7-19
Terminal Signal Guide wire color

No.
4 AD5 Back 13
5 AD1 Back 1
6 AD4 Back 4
7 AD2 Back 2
8 AD3 Back 3
3. Wiring table of shift selector connector X2

The above figure is the shift output signal figure of
shift selector. According to the above figure, the dig-
ital multimeter can be used for fault judgment on
shift selector. Terminal Signal Guide wire color
No.
Fault detection of SG-6S shift selector
1 Power Black 6 (with 5A fuse)
1. Pin diagram of shift selector X1 and X2 connectors
supply
2 Hang None
3 VM1 Black 8, brown
4 ED1 Back 9
5 ED3 Back 5
6 AD9 Back 7
7 AD7 Back 10
8 AD6 Green yellow
4. Use the multimeter for detection, and the detec-

tion steps are as follows:
2. Wiring table of shift selector connector X1 a. Turn off the electric switch lock, remove
the mounting bolt of SG-6S shift selector,
detect for good earthing, adjust the digital
multimeter to ohm 200Ω range, and con-
Terminal nect the pens to the No.3 hole earthing
Signal Guide wire color wire (brown wire) of X2 connector and to
No.
any earthing bolt in cab respectively. In
1 Hang None theory, the resistance to earth shall be 0,
the actual measured resistance value shall
2 Hang None be milliohm level, and the multimeter dis-
plays 0.00X or 0.0XΩ; if the resistance
3 VM2 Brown (earthing cable)
value is bigger obviously, check whether
7-20
the harness is connected reliably and the (brown wire) of X1 connector according to
earthing point is secure. the wiring table of shift selector connector,
b. After confirming good earthing, turn on the and the digital multimeter shall display
electric switch lock without starting the between “24” and “31”V.
engine, adjust the digital multimeter to f. Place the shift selector to N2 position, and
DCV 200V range, measure whether the find out AD2 and AD6 output +24V voltage
lever power is connected normally, respec- signal at N2 position according to the shift
tively connect the digital multimeter pens output signal figure of shift selector. Adjust
to the No.1 hole (black 6 wire) and No.3 the digital multimeter to DCV 200V range,
hole (brown wire) of X2 connector, and the respectively connect the red pen to the
multimeter shall display between “24” and No.7 hole (black 2 wire) of X1 connector
“31”V. and and No.8 hole (greenyellow wire) of
c. Disconnect the shift selector connector X1, X2 connector, and the black pen to the
and adjust the digital multimeter to DCV No.3 hole (brown wire) of X1 connector
200V range. The following combinations according to the wiring table of shift selec-
shall be detected when each gear of shift tor connector, and the digital multimeter
selector is placed (the following abbrevia- shall display between “24” and “31”V.
tions indicate wire color and wire size): g. Place the shift selector to forward 1st gear,
Black 1, black 2, black 3, black 4, black 5, and find out AD2, AD3 and AD4 output
black 6, black 7, black 8, black 9, black 10, +24V voltage signal at forward 1st gear
black 13, Brown, and greenish-yellow. according to the shift output signal figure of
(Caution: the emergency brake switch shift selector. Adjust the digital multimeter
must be pulled up! As the complete vehicle to DCV 200V range, respectively connect
is beyond emergency braking state at the the red pen to the No.6 hole (black 4 wire),
moment, the complete vehicle must be No.7 hole (black 2 wire), and No.8 hole
parked in a flat road, and chocks shall be (black 3 wire) of X1 connector, and the
placed below wheels to ensure that the black pen to the No.3 hole (brown wire) of
complete vehicle will not move.） X1 connector according to the wiring table
d. Place the shift selector to N position, and of shift selector connector, and the digital
find out AD6 output +24V voltage signal at multimeter shall display between “24” and
N position according to the shift output sig- “31”V.
nal figure of shift selector. Adjust the digital h. Place the shift selector to forward 2nd
multimeter to DCV 200V range, respec- gear, and find out AD2, AD4 and AD5 out-
tively connect the red pen to the No.8 hole put +24V voltage signal at forward 2nd
(greenyellow wire) of X2 connector, and gear according to the shift output signal
the black pen to the No.3 hole (brown wire) figure of shift selector. Adjust the digital
of X1 connector according to the wiring multimeter to DCV 200V range, respec-
table of shift selector connector, and the tively connect the red pen to the No.4 hole
digital multimeter shall display between (black 13 wire), No.6 hole (black 4 wire),
“24” and “31”V. and No.7 hole (black 2 wire) of X1 connec-
e. Place the shift selector to N1 position, and tor, and the black pen to the No.3 hole
find out AD6 output +24V voltage signal at (brown wire) of X1 connector according to
N1 position according to the shift output the wiring table of shift selector connector,
signal figure of shift selector. Adjust the and the digital multimeter shall display
digital multimeter to DCV 200V range, between “24” and “31”V.
respectively connect the red pen to the i. Place the shift selector to forward 3rd gear,
No.8 hole (greenyellow wire) of X2 con- and find out AD3, AD4 and AD7 output
nector, and the black pen to the No.3 hole +24V voltage signal at forward 3rd gear
according to the shift output signal figure of
7-21
shift selector. Adjust the digital multimeter the digital multimeter shall display between
to DCV 200V range, respectively connect “24” and “31”V.
the red pen to the No.6 hole (black 4 wire), m. Place the shift selector to reverse 1st gear,
No.8 hole (black 3 wire) of X1 connector and find out AD1, AD2, AD4 and AD9 out-
and the No.7 hole (black 10 wire) of X2 put +24V voltage signals at reverse 1st
connector, and the black pen to the No.3 gear according to the shift output signal
hole (brown wire) of X1 connector accord- figure of shift selector. Adjust the digital
ing to the wiring table of shift selector con- multimeter to DCV 200V range, respec-
nector, and the digital multimeter shall tively connect the red pen to the No.5 hole
display between “24” and “31”V. (black 1 wire), No.6 hole (black 4 wire),
j. Place the shift selector to forward 4th gear, No.7 hole (black 2 wire) of X1 connector
and find out AD4, AD5 and AD7 output and the No.6 hole (black 7 wire) of X2 con-
+24V voltage signal at forward 4th gear nector, and the black pen to the No.3 hole
according to the shift output signal figure of (brown wire) of X1 connector according to
shift selector. Adjust the digital multimeter the wiring table of shift selector connector,
to DCV 200V range, respectively connect and the digital multimeter shall display
the red pen to the No.4 hole (black 13 between “24” and “31”V.
wire) and No.6 hole (black 4 wire) of X1 n. Place the shift selector to reverse 2nd
connector and the No.7 hole (black 10 gear, and find out AD1, AD4 and AD9 out-
wire) of X2 connector, and the black pen to put +24V voltage signals at reverse 2nd
the No.3 hole (brown wire) of X1 connector gear according to the shift output signal
according to the wiring table of shift selec- figure of shift selector. Adjust the digital
tor connector, and the digital multimeter multimeter to DCV 200V range, respec-
shall display between “24” and “31”V. tively connect the red pen to the No.5 hole
k. Place the shift selector to forward 5th gear, (black 1 wire) and No.6 hole (black 4 wire)
and find out AD3 and AD7 output +24V of X1 connector and the No.6 hole (black 7
voltage signal at forward 5th gear accord- wire) of X2 connector, and the black pen to
ing to the shift output signal figure of shift the No.3 hole (brown wire) of X1 connector
selector. Adjust the digital multimeter to according to the wiring table of shift selec-
DCV 200V range, respectively connect the tor connector, and the digital multimeter
red pen to the No.8 hole (black 3 wire) of shall display between “24” and “31”V.
X1 connector and the No.7 hole (black 10 o. Place the shift selector to reverse 3rd gear,
wire) of X2 connector, and the black pen to and find out AD1 and AD9 output +24V
the No.3 hole (brown wire) of X1 connector voltage signals at reverse 3rd gear accord-
according to the wiring table of shift selec- ing to the shift output signal figure of shift
tor connector, and the digital multimeter selector. Adjust the digital multimeter to
shall display between “24” and “31”V. DCV 200V range, respectively connect the
l. Place the shift selector to forward 6th gear red pen to the No.5 hole (black 1 wire) of
of forward gear, and find out AD5 and AD7 X1 connector and the No.6 hole (black 7
output +24V voltage signal at forward 6th wire) of X2 connector, and the black pen to
gear according to the shift output signal the No.3 hole (brown wire) of X1 connector
figure of shift selector. Adjust the digital according to the wiring table of shift selec-
multimeter to DCV 200V range, respec- tor connector, and the digital multimeter
tively connect the red pen to the No.4 hole shall display between “24” and “31”V.
(black 13 wire) of X1 connector and the
No.7 hole (black 10 wire) of X2 connector,
and the black pen to the No.3 hole (brown
wire) of X1 connector according to the wir-
ing table of shift selector connector, and
7-22
7.9.3 Transmission control solenoid valve
7.9.3 Transmission control The symbols of shift control valve sche-

matic are shown as follows:
solenoid valve
There are five solenoids (M1-M5) in the shift control
valve, which are arranged as shown in the following
figure. When the operator selects a gear, the signal
from the shift selector is sent to the solenoid group,
ECU gives the corresponding gear engagement sig-
nal according to software computation, and it is real-
ized by outputting the driving voltage to the
solenoid. The solenoid is mainly used to control the
opening/closing of clutch oil flow in the gearbox, so
as to realize the gear engagement or reversing of
gearbox.
The corresponding relationship between

the solenoid and shift selector is as fol-
lows:
Handle signal Solenoid valve
AD1 Y1/M1
AD2 Y2/M2
AD3 Y3/M3
AD4 Y4/M4
AD5 Y5/M5
VM2 (-)
The working diagram of solenoid and clutch is

as shown in the following figure, and “●” indi-
cates that the corresponding solenoid works.
7-23
7.9.3 Transmission control solenoid valve
The above figure gives the working condition of energized, the clutch K2 works. When both M2 and
solenoid for each gear, and the working condition of M4 are energized, the clutch K1 works. When nei-
the corresponding meshed clutch. For instance, the ther M2 nor M4 is not energized, the clutch K3
machine is in forward 1st gear, the solenoids M2, works.
M3 and M4 in the shift control valve work, and the
clutches K1 and KV in the gearbox are meshed at Solenoid test
the same time. The above figure shows the control The resistances of solenoids are about 90Ω, and X9
relationship between solenoids and clutches. They is the solenoid group connector, located on the shift
are basically such that the solenoid M5 controls the control valve. After unscrewing X9 connector, you
clutch K4, M3 controls KV, M1 controls KR, the sole- can see six ferrules, A, B, C, D, E and F from the
noids are energized, and the clutches work. The connector socket, where F is common for five sole-
solenoids M2 and M4 jointly control the clutches K1, noids. Detect at X9 connector (the end of shift con-
K2 and K3. When M4 is energized and M2 is not
7-24
7.10 Lights
7.9.4 Output speed sensor
trol valve) by the ohm 200Ω range of digital remove the old speed sensor from the machine,
multimeter. The resistance values of A-F, B-F, C-F, clean the mounting washer, install it on the new
D-F and E-F shall be between 85Ω and 100Ω. Or, it speed sensor, and screw up the new speed sensor
can be judged that the solenoid is damaged. into the sensor mounting hole.
7.9.4 Output speed sensor 7.10 Lights

The output speed sensor, installed on the gearbox
The lighting system of grader consists of two front
housing, is used to detect the speed of gearbox out-
floodlights, two work lights, two rear combination
put gear. The speed sensor consists of coil, perma-
lights, license plate light and dome light in the cab.
nent magnet and pole. The coil is wound outside the
pole, and the pole is connected with the permanent
magnet. The magnetic field is formed around the 7.10.1 Front floodlight
permanent magnet, magnetic lines of force pass
through air gap and act on the teeth of gear, forming
a closed magnetic circuit. When the gear is rotating,
the magnetic field acts on the tooth gap and tooth
repeatedly, so the change in air gap is sometimes
big and sometimes small; the flux changes with the
air gap, and the changing flux induces sinusoidal
signal in the coil, which is in proportion to speed.
The signal is sent to ECU for processing through
harness connection.
Working principle of output speed sensor is as
below:
The floodlights fall into a left one and a tight one,

installed at both sides of front frame. The floodlight
is a combination light, including high/low beam, turn
signal light and position light, which are respectively
controlled by the high/low beam switch, turn signal
switch and position light switch.
Gearbox housing surface
Front floodlight parameter
Name of internal Power

combination light
The installation of speed sensor is very important, Front High beam lamp 75W
and the L value is generally kept at about
0.5+0.3mm. As shown in the above figure, if L size floodlight Low beam lamp 70W
is big, due to limited action of magnetic field, gener-
Turn signal light 21W
ally that the action of magnetic field decreases as
the distance increases, the coil fails to induce sig- Position light 10W
nals. If L is small, the speed sensor may be cut by
high-speed rotating gear due to mechanical error. If Connector
DJ7061-6.3-11
the sensor is replaced from the complete machine, model
7-25
7.10 Lights
7.10.2 Work light
Schematic wiring diagram of front flood-

light
7.10.2 Work light
Rear work light

Front work light
Work light
7-26
7.10 Lights
7.10.3 Rear combination light
The rear combination light consists of rear position

light, stop light, turn signal light and backup light,
Blade work light respectively controlled by the position light switch,
stop light relay, turn signal switch and backup alert
relay.
Front floodlight parameter

Name of internal Power
combination light
Rear com-
Turn signal light 21W
bination
Brake light 21W
light
Backup light 21W
Rear position light 5W
Connector DJ7021-1.5-11 (two cores)

model DJ7041-1.5-11 (four cores)
The complete vehicle is provided with 8 work lights,
including 2 front work lights, 2 rear work lights, 2
work lights and 2 blade lighting lights. Among then,
the front work light switch controls 2 front work light,
the rear work light switch controls 2 rear work lights,
the work light switch controls 2 work lights and 2
blade lighting lights.
Work light parameter

24V, 70W, the lighting angle is adjustable.
Wiring terminal: two M4*12 bolts
7.10.3 Rear combination light
Rear combina-
tion light
7-27
7.10 Lights
7.10.4 Dome light and licence plate light
Schematic wiring diagram of rear combi-

nation light
Right rear combination light
Turn signal sw Right turn signal light
Backup alarm relay Backup signal light

Brake light
Rear position light
Right rear combination light
Earthing cable
Turn signal sw Left turn signal light
Backup alarm relay

Backup signal light
Break lamp relay Brake light
Rear position light
Position light switch
7.10.4 Dome light and licence The dome light is in the cab, used for the internal
lighting of cab, controlled by its self-provided switch.
plate light The license plate light is at the tail, used for lighting
the license plate, controlled by the position light
switch.
Dome light parameter

24V， 10W
Mounting screw: M5*18
Connector model: DJ7022-6.3-11
7-28
7.11 Rocker switch
Schematic wiring diagram of dome light 7.11 Rocker switch
Front floodlight Position light switch Front work light
Dome light
Earthing cable
Power supply
Work light
Rear work light
Licence plate light parameter

24V， 10W
Connector model: AMP282104-1
Schematic wiring diagram of licence plate

Front washer Silence switch
light
Front wiper Rotating beacon

Hazard flasher Centralized lubrication
(optional)

License plate light
Earthing cable
The switches control the connection and disconnec-

tion of electrical appliances of lights, wipers and
washers. The switches are installed on the instru-
ment panel and control box panel in the cab. The
outline and interface drawings of all the switches
are as follows:
7-29
7.11 Rocker switch
Switch
Rocker switch assembly
Shifts Lock Res Symbol Symbol Special

No. Name Type descriptio buckl
et pattern color notes
n e
0 Lock
1 Mandatory lubri- JK932-162 Green
cating switch I ① --- ⑤ Belt
0
Rotating beacon
2 JK939-002 I ① --- ⑤ Amber
switch
0
3 Silence switch JK939-002 Amber
I ① --- ⑤
4 Cover
7-30
7.11 Rocker switch
Schematic wiring diagram is as blow:
Buzzer
Silence switch
Alerting signal
Rotating beacon
Rotating beacon switch
Power supply
Forced lubrication
Earthing cable
Forced lubrication sw (optional)
Rotating beacon
Switch
7-31
7.11 Rocker switch
Shifts Lock
Res Symbol Symbol Special
n e
0
Hazard flasher
1 JK939-157 Red
switch I ① --- ⑤
② --- ⑥
0 ⑤ --- ⑦
2 Front wiper JK939-047 Green
I ③ --- ⑤
switch
2 ① --- ③
0
3 Front washer JK939-009 Green
switch I ① --- ⑤ Belt
② --- ⑥
4 Cover

7-32
7.11 Rocker switch
Washer motor
Washer switch
Earthing cable
Power supply
Front wiper switch Wiper motor high gear

Wiper motor low speed gear
Reset switch
Earthing cable
Hazard flasher
Hazard flasher switch
Hazard flasher
Flash relay

7-33
7.11 Rocker switch
Shifts Lock
Res Symbol Symbol
No. Name Type descriptio buckl Special notes
et pattern color
n e
0 Controls work
1 Work light JK939-157 Green lights and
switch I ① --- ⑤ blade work
② --- ⑥ lights
0
Rear ceil-
2 ing light JK939-002 Green
Power supply
Work light Power supply
switch
Blade work light

Work light
Power supply
Ceiling light Earthing cable
switch Position light
Front work light
7-34
7.11 Rocker switch

n e
0 Controls
work
Head lamp I ③ --- ⑤ lights
1 JK939-028 Green
and
switch
blade
II ① --- ③
work
lights
0
2 Position light JK939-002 Green

7-35
7.11 Rocker switch
Low beam lamp

Head lamp High beam lamp
switch
Power supply
Power supply
Position
light switch Earthing cable
Position light
Switch
Switch

n e
0
Front ceiling
1 JK939-002 Green
light switch I ① --- ⑤
7-36
7.12 Sensor
7.12.1 Water temperature sensor and oil temperature sensor
Rear ceiling
light switch
7.12 Sensor Installation position diagram is as below
Sensors are signal acquisition components in the

complete vehicle, used for the display and alarm of
instruments. The CLG4180 grader is provided with
the coolant temp sensor, oil temp sensor, engine oil
pressure switch, transmission oil pressure switch,
fuel lever sensor, intake air filter alert switch, service
brake pressure switch and parking brake pressure
switch. Water temp
sensor
7.12.1 Water temperature sen-
sor and oil temperature sensor
The coolant temp sensor and oil temp sensor take
charge of monitoring the changes in engine coolant
temperature and torque converter oil temperature
when the complete vehicle is operating, and display
the changes in coolant temperature and oil tem-
perature on the instruments, for the driver to judge
the operating conditions of complete vehicle.
7-37
7.12 Sensor
7.12.1 Water temperature sensor and oil temperature sensor
Sensor output property list

1. Property list Ⅰ
Torque converter
oil temp sensor
Engine coolant Torque

converter oil
temp sensor
temp sensor
Material Thermistor Thermistor
Rated voltage 6V ～ 24V 6V ～ 24V

Thread size 1/2-14NPTF M14X1.5
Wiring termi- 6.3*0.8 6.3*0.8

nal
Resistance in
90 ℃ 120 ℃
work tem-
=51.2±4.3 =36.5±2.7
perature (Ω)
Max. tem-
120 150
perature ( ℃ )
Output prop-
Property list Ⅰ Property list Ⅱ
erty list
2. Property list Ⅱ
7-38
7.12 Sensor
7.12.2 Pressure switch
Fault detection
Adjust the digital multimeter to “Ω” 200Ω range, con-
nect one pen to the sensor wiring terminal and other
pen to the nearest frame ground, measure resis-
tance, and find out the temperature value according
to the property list. Measure the temperature of cyl-
inder body near the sensor by a thermometer. Com-
pare the difference between two temperature
values. If the difference is within 5 ℃ , it indicates
that the sensor is ok.

The pressure switches are used to detect pressure
signals, and output alert signals for the alarm dis-
play of instruments. The complete vehicle is pro-
vided with engine oil pressure switch, transmission
oil pressure switch, service brake pressure switch
and parking brake pressure switch.
Installation position diagram is as below
Engine oil
pressure switch
7-39
7.12 Sensor
Service brake
pressure switch
Transmission oil
pressure switch
Parking break
pressure switch
Engine oil Transmission oil Service brake pressure switch and

pressure switch pressure switch parking brake pressure switch
Material Galvanized steel Galvanized steel Galvanized steel
Highest voltage 42V 42V 42V
Switch power 100VA 100VA 100VA
Rated current 4A 4A 4A
Thread size NPT1/8 M10*1 NPT1/8
Wiring terminal AMP6.3*0.8 AMP6.3*0.8 AMP6.3*0.8
Normally closed Normally closed con-

Switch contact Normally closed contact
contact tact
Operating value
0.059 1.45 10
(MPa)
Pressure adjusting Action during lift-
Action during lifting Action during lowering
state ing
Adjusting range,
[0.01,0.1]±0.02 [1,2]±0.1 [5,15]±0.5
allowable tolerance
7-40
7.12 Sensor
7.12.3 Fuel level sensor
Working principle
As shown in the above figure, the left is a diaphragm

pressure switch with a group of normally open con-
tacts, the right is a piston pressure switch with a
group of normally closed contacts, and the following
will explain the working principle of pressure switch
by taking the left one in the above figure as an
example. The measured medium acts on the dia-
phragm (2) after passing the pressure switch junc-
tion (1); if the pressure of the measured medium is
higher than the preload of compression spring (3),
the plunger (4) will drive the contact disc (5) to
move, so as to close the circuit between contacts
(6). When the drop of the measured medium pres-
sure is greater than hysteresis, the switch will be
opened again. For the pressure switch with normally
closed contacts, its contacts act reversely. The actu-
ation pressure of pressure switch can be adjusted
by turning the adjusting stud (7). The actuation
pressure of pressure switch has been adjusted
when leaving factory, and marked with colored
paint. The adjusting screw can not be adjusted at
will, or the actuation value will change to cause
safety accidents.

The dry reed fuel level sensor consists of shaft
made of polished aluminum-alloy pipe, annular
magnetic float capable of moving up and down
along the shaft, and internal printed circuit board.
Two permanent magnets are embedded in the float.
7-41
7.12 Sensor
Overall dimension drawing is as below

7-42
7.12 Sensor
7.12.4 Intake air filter alert switch
Installation position diagram is as below Technical parameter table is as below
Fuel level sensor
Material Galvanized steel
Rated voltage 24V
Continuous work volt- 15-40V

age
Electrical connection DJ7021-1.5-11
mode
1# pin description Signal cable (blue)
2# pin description Earthing cable (black)
Working medium Fuel
Output property list

Upper plane position of Below L1 L1-L2 L2-L3 L3-L4 L4-L5
float
Output resistance (Ω) 78±2 70±1 64±2 56±2 48±2
Upper plane position of L5-L6 L6-L7 L7-L8 L8-L9 Above L9

float
Output resistance (Ω) 40.5±2 33±2 25±2 17±2 9±2
7.12.4 Intake air filter alert Installation position diagram

switch
The intake air filter alert switch is provided together
with the air filter. When the air filter is clogged, it out-
puts alert signal to the alert indicator in the cab.
Intake air
filter alert
switch
7-43
7.13 Instrument
Intake air
filter alert
7.13 Instrument
The instrument system of complete vehicle is used
to display the complete vehicle state messages and
various alarm messages of coolant temperature, oil
temperature, voltage, fuel level, etc. The instru-
ments include: coolant temp gauge, oil temp gauge,
fuel level gauge, voltmeter, service hour meter and
alert indicator.
7-44
7.13 Instrument
Distribution diagram 1 of instruments and

signal sources
7-45
7.13 Instrument
7.13.1 Water temperature gauge and oil temperature gauge
Distribution diagram 2 of instruments and

signal sources
7.13.1 Water temperature gauge

and oil temperature gauge
The coolant temp gauge and oil temp gauge are
used together with the 7.12.1 engine coolant temp
sensor and torque converter oil temp sensor. They
are used to display the coolant temperature of
engine and the oil temperature of torque converter.
7-46
7.13 Instrument
7.13.2 Fuel gauge
Installation position diagram is as below Technical parameter table is as below
Engine Torque
coolant temp converter oil
gauge temp gauge
Rated voltage 21.5V ～ 30V 21.5V ～ 30V
Engine coolant Temperature

temp gauge
Torque converter 40 ～ 120 ℃ 50 ～ 150 ℃
oil temp gauge display range
"+" Terminal wir-
Power supply Power supply
ing
“-” Terminal wir-
Earthing Earthing
ing
"S" Terminal
Sensor Sensor
wiring
Instrument dis- Property list Property list
play property list Ⅰ Ⅱ
Property list Ⅰ
Dial scale ( ℃ ) 40 50 60 70 80 90 100 110 120
Resistance (Ω) 287.4 193.3 134 95.2 69.1 51.3 38.6 29.4 22.7
Pointer deflection
0 3.3 8.3 15.5 25.8 40 58 75.2 88.2
angle (°)
Angle tolerance (°) ±3.6 ±3.6 ±3.6 ±3.6 ±3.6 ±3.6 ±3.6 ±3.6 ±3.6
Property list Ⅱ
Dial scale ( ℃ ) 50 80 90 100 110 120 130 140 150
Resistance (Ω) 322.8 112.5 83 62.2 47.5 36.5 28.9 23.1 18.6
Pointer deflection
0 12.4 19.8 29.6 42 56.8 69.7 80.2 88.1
angle (°)
Angle tolerance (°) ±3.6 ±3.6 ±3.6 ±3.6 ±3.6 ±3.6 ±3.6 ±3.6 ±3.6
7.13.2 Fuel gauge fuel amount in the fuel tank, and used together with
the 7.12.3 fuel level sensor.
The fuel level gauge is used to display the residual
7-47
7.13 Instrument
7.13.3 Voltmeter
Technical parameter table is as below Fuel level gauge （Continued）

“-” Terminal wiring Earthing
Fuel level gauge
"S" Terminal wiring Sensor
Rated voltage 21.5V ～ 30V
Instrument display Property list
"+" Terminal wiring Power supply property list
Property list
Dial scale 0 1/4 1/2 3/4 1/1
Resistance (Ω) 60~90 0.5
Pointer deflection angle

0 22 44 66 87.4
(°)
Angle tolerance (°) ﹢ 0 ﹢ 5.4

﹣ 5.4 ﹣ 0
7.13.3 Voltmeter
The voltmeter is used to display the voltage of elec-
trical system.
7-48
7.13 Instrument
7.13.3 Voltmeter
Voltmeter
Rated voltage 18V ～ 32V
"+" Terminal wiring Power supply
“-” Terminal wiring Earthing

7-49
7.13 Instrument
7.13.4 Hourmeter
7.13.4 Hourmeter
Technical parameter table is as below indicator, engine oil pressure alert indicator and
transmission oil pressure alert indicator is on, the
buzzer in the instrument desk will sound to remind
Service hour meter
the driver to stop the vehicle and check. The mute
switch can control the buzzer volume.
Work voltage 8V ～ 60V
Measuring range 0 ～ 99999.9h Installation position diagram is as below

Precision ±0.1%
Adapter terminal 4.8*0.6
7.13.5 Warning indicator

The alert indicators are used for the indication and
alarm of complete vehicle messages, including left
and right turn indicators, high beam indicator,
charging indicator, service brake low-pressure alert Warning indicator
indicator, parking brake low-pressure alert indicator,
engine oil pressure alert indicator, transmission oil
pressure alert indicator, engine coolant temp alert
indicator (not enabled) and main alert indicator (not
enabled). When any of the service brake low-pres-
sure alert indicator, parking brake low-pressure alert
7-50
7.13 Instrument
Rated voltage Rated power

Icon Instruction for position for position Color Pin
light light
Green, flick-
Left steering 24V 2W J1/J2
ering
Service brake low volt- 24V 2W Red J5/J6

age warning
Engine coolant temp 24V 2W Red K1/K2

alert
Parking brake low volt-

24V 2W Red K5/K6
age warning
Right steering 24V 2W Green, flick- K9/K10

ering
Front floodlight high

24V 2W Blue J3/J4
beam
Charge indicator 24V 2W Red J7/J8
Chief alert indicator 24V 2W Red K3/K4

7-51
7.14 Wiper system
Rated voltage Rated power

Icon Instruction for position for position Color Pin
light light
Engine oil pressure

24V 2W Red K7/K8
alert
Transmission oil pres- 24V 2W Red K11/

sure warning K12
Pin description diagram is as below the wiper switch and reservoir washer switch. The
wiper has a high-speed position and a low-speed
position, capable of resetting automatically. The
motor has five externally connected wires, where
the red is power wire (common brush lead of high-
speed armature and low-speed armature, con-
nected with No.140 wire), the black is negative wire
(connected with earth through motor housing, con-
nected with No.240 earthing wire), the blue is the
other brush lead of high-speed armature (connected
with No.431 wire), the green is the other brush lead
of low-speed armature (connected with No.432
wire), and the white is reset wire (connected with
No.308 wire).
7.14 Wiper system

The wiper system of CLG4180 grader consists of
reservoir, wiper, nozzle and switch. The wiper is
installed on the front glass of cab, and the reservoir
is installed below the cab, respectively controlled by
7-52
7.14 Wiper system
Schematic
Washer switch Front wiper switch
Front wiper motor
Washer motor

7-53
7.15 Sound system
Wiper
Motor connector KET32510008
Washer reservoir
Work voltage 24V
Power 30W
Motor connector DJ7021-1.5-21
7.15 Sound system

The sound system consists of radio, speaker and
Technical parameter table is as below antenna. You can use the radio cassette player after
turning on the electric switch lock. A standard USB
Wiper interface is reserved for the radio, available for con-
necting USB devices, only supporting MP3 audio
Work voltage 24V files.
Power 50W Schematic
Left speaker
Right speaker
Left speaker
Left speaker
Right speaker
Radio
Right speaker
Power supply+
Power supply+
7-54
7.15 Sound system
Installation position diagram

Technical parameter table
Radio Speaker Antenna
Rated voltage 24V
Max. work current 5A
Resistor 4Ω
Power 10W
DJ7082A-3.5-10
Connector DJ7021-1.5-21
DJ7082-3.5-10
Function illustration diagram 1. Power supply

2. Sound mode/switching source
3. Volume adjusting
4. Radio reset key 1/track position
5. Radio preset key 2
6. Radio reset key 3/pause and play
7. Radio preset key 4 / PREV
8. Radio preset key 5 / NEXT
9. Radio reset key 6/track scan
10. Forward search / Previous song / adjusting hour
11. Automatic station storage/enter and exit setting screen
12. Backward scan/next track/adjust minute
13. Standard audio input interface
14. USB interface
7-55
7.16 Preheating system
15. Radio band selection

Fault detection The engine of CLG4180 grader is provided with an
Fault mode: The player panel displays normally, but air intake preheating unit, which is applicable to heat
there is no sound or the sound volume is too small. air into the engine at low temperature, thus improv-
Ensure that the player is in radio or play state, and ing start performance. The preheating system con-
detect whether there is voltage at the speaker posi- sists of electric switch lock, fuse, preheating
tive and negative terminals by digital multimeter; if contactor, preheating indicator and preheating unit.
any, check the speaker. Whether the speaker is Turn the electric switch lock to “I” position (see 7.6)
good or not can be judged by detecting the resis- before start; at the moment, the electric switch lock
tance of speaker positive and negative terminals, sends signal to the coil terminal of preheating con-
which shall be equal to or close to the rated resis- tactor to close the contact terminal of preheating
tance of speaker; if the resistance is 0 or the contactor, the battery power passes 150A fuse to
speaker is open, the speaker is damaged. If there is supply power to the preheating unit, and the pre-
no voltage at the speaker positive and negative ter- heating indicator in the cab comes on at the same
minals, check whether the wiring and connector are time. The preheating process will keep about 45s,
loose or open. and the electric switch lock needs to be maintained
at “I” position manually all the time.
Schematic
Electric lock Preheating indicator lamp
Pre-heating R8 pre-heating
contactor
Disconnec t switch
7-56
Installation position diagram – preheating Installation position diagram – preheating

device contactor, fuse and preheating indicator
Pre-heating device
Pre-heating
contactor
Fuse 150A
Preheating indicator lamp
Technical parameter table - preheating Preheating contactor parameter table

contactor
Spec for main contact termi- 2-M8
nal
Preheating contactor parameter table
Spec for coil terminal 2-M4
Rated voltage 24V
Rated load current of main 200A

contact circuit
7-57
7.17 Main circuit fuse
7.17 Main circuit fuse main power circuit, air conditioning system and pre-
heating system. Their settings are 80A, 60A, 30A
The CLG4180 grader is provided with fuses for four and 150A respectively.
main circuits, which are screw-down plate fuses.
They protect the charging circuit, complete vehicle Installation position diagram is as below
Dual fuse box
Dual fuse box
Technical parameters
30A Fuse piece 60A Fuse piece 80A Fuse piece 150A Fuse piece
Rated voltage 32V 32V 32V 32V
Color Orange Yellow White Gray
7.18 Main power circuit

The main power circuit consists of battery, discon-
nect switch, fuse, electric switch lock and main
power contactor. When the disconnect switch is
closed and the electric switch lock is turned to “ON”
position, the battery supplies power to the electrical
appliances of complete vehicle.
7-58
Schematic
Electric lock Main power

Centralized
control box contactor
Secondary fuses of
complete vehicle
1.Electric
lock
Alternator
Disconnect switch
Schematic diagram introduction through No.105 wire and supplies power to the
When the disconnect switch is closed, the battery complete vehicle as it is connected with the control
supplies power to the electric switch lock through box of complete vehicle; at the moment, electrical
No.100 wire, 60A fuse and No.105 wire first and appliances can work normally. Before the engine
then through No.118 wire and 10A fuse; when the starts, the battery supplies power to electrical appli-
electric switch lock is turned to “ON” position (see ances. After the engine starts, the No.102 wire at B+
7.6 for the description of positions), the main power terminal supplies power to electrical appliances,
contactor coil supplies power through No.123 wire and charges the battery at the same time.
of electric switch lock, the main power contactor
contacts are closed, and No.122 wire is energized
7-59
Fault detection of main power circuit

If there is no power on the complete vehicle after
turning on the electric switch lock, check according
to the following steps.
1. Turn on the electric switch lock, and listen to the
pull-in sound of main power contactor; if any, go
to next step; if not, go to Step 4.
2. Detect whether 60A fuse is blown, and replace
the fuse if blown; if the fuse is ok, measure
whether there is 24V voltage at No.105 wire of
contactor terminal; if any, go to next step; if not,
check whether the wiring of No.100 and No.105
wires is loose or open.
3. The contact terminal of main power contactor is
faulty, replace main power contactor.
4. Repeat Step 2, detect whether 60A fuse is
blown, and replace the fuse if blown; if the fuse
is ok, measure whether there is 24V voltage at
No.118 wire of electric switch lock fuse terminal;
if any, go to next step; if not, check whether the
wiring of No.100 and No.105 wires is loose or
open.
5. Check the 10A fuse of electric switch lock is
blown; if any, replace the fuse; if not, go to next
step.
6. Measure whether there is 24V voltage at
No.108 wire of electric switch lock terminal; if
not, check whether No.108 wire is loose; if any,
go to next step.
7. Measure whether there is 24V voltage at the
terminal 123 of electric switch lock; if not, it is
judged that the electric switch lock is faulty, and
replace it; if any, go to next step.
No.123 wire of main power contactor coil termi-
nal; if not, check whether No.123 wire is loose;
if any, go to next step.
9. Measure whether No.200 earthing wire of main
power contactor coil terminal is conducted; if
not, check whether No.200 wire is loose; if any,
it is judged that the main power contactor is
faulty, and replace it.
7-60
Fault detection flow chart
Open electric lock to listen if any

pull-in sound of main power
contactor
Yes No
Whether fuse 60A blown or not Whether fuse 60A blown or not
No Yes No Yes
Whether there is 24V

Whether there is 24V voltage at
voltage at No.105 wire of Replace fuse Replace fuse
No.118 wire of fuse terminal
contactor terminal
No Yes Yes No Loose wire
Replace the
Loose wire
contactor
Whether fuse 10A blown or not
No Yes
Replace fuse
Whether there is 24V voltage at No.108

wire
No Loose wire
Yes
Replace the Whether there is 24V voltage at No.123 wire of

Loose wire
contactor electric lock terminal
No
No Yes
Yes
Electric lock
fault
Whether No.200 earthing wire of Whether there is 24V voltage at

Loose wire
contactor terminal is conducted No.123 wire of contactor terminal
Yes No
7-61
7.19 Starter circuit
7.19 Starter circuit Close the disconnect switch, turn the electric switch
lock to “START” position when the shift selector is in
The start circuit consists of battery, disconnect N position, and the complete vehicle will start.
switch, fuse, start contactor, neutral interlock relay,
electric switch lock, start motor, shift selector, etc. Schematic
Neutral interlocking relay Electric lock

Start contactor
Main power contactor
Neutral signal of gear selector
Starter
Disconnect switch motor
Schematic diagram introduction cuit of start motor is connected, the battery supplies
The CLG4180 can be started only when the lever is large start current to the start motor through the bat-
in N position. If the disconnect switch is closed, a tery cable (+), and the start motor starts so as to
signal is outputted to the neutral interlock relay start the engine.
when the lever is in N position, and the neutral inter-
lock relay is closed. When the electric switch lock is Fault detection of start circuit
turned to “START” position (see 7.6 for the descrip- Fault phenomenon: unable to start
tion of positions), No.125 wire of electric switch lock 1. Detect whether the battery cable (+) is loose or
is energized, the start contactor coil terminal 423 is broken; if any, tighten immediately or replace
energized through neutral interlock relay contact ter- the cable.
minal, the start contactor is closed, the battery sup-
2. Measure whether the voltage at the terminal 30
plies power to the start motor control terminal
through No.100 wire, 60A fuse, No.105 wire, No.118 of start motor is above 24V with digital multime-
wire, 50A fuse, No.121 wire and No.424 wire, the ter; if not, check whether the battery is under-
solenoid switch in start motor is closed, the main cir- charged (see 7.3) according to the battery
detection method.
7-62

terminal 50 of start motor; if any, the start motor
is damaged, and let the dealer detect the start
motor; if not, go to next step.
terminal 121 of start contactor; if not, go to next
step; if any, go to Step 6.
5. Check whether 50A and 60A fuses are blown; if
any, replace fuses; if not, check whether
No.100, No.105, No.118 and No.121 wires are
loose.
terminal 423 of start contactor when turning the
electric switch lock to START position; if any, go
to next step; if not, go to Step 8.
7. Measure whether the terminal 220 of start con-
tactor is conducted to earth; if any, it is judged
that the start contactor is faulty, and replace it; if
not, No.220 wire is loose.
terminal 125 of neutral interlock relay when
turning the electric switch lock to START posi-
tion; if any, go to Step 12; if not, go to next step.
9. Measure whether there is 24Voltage at the ter-
minal 125 of electric switch lock when turning
the electric switch lock to START position; if
any, No.125 wire is loose; if not, go to next step.
10. Check whether there is 24V voltage at the ter-
minal 108 of electric switch lock; if any, the elec-
tric switch lock is faulty, and replace it; if not, go
to next step.
11. Check whether 10A fuse is blown; if any,
replace fuses; if not, check whether wires are
loose.
No.512 wire of neutral interlock relay terminal; if
any, go to next step; if not, the shift selector is
faulty, and detect according to the detection
method of shift selector (see 7.9.2).
13. Measure whether neutral interlock relay No.200
wire is connected to earth; if connected, the
neutral interlock relay is faulty, and replace it; if
not, check whether the wire is loose or open.
7-63
Whether there is above 24V voltage at

the terminal 30 of start motor
No Yes
Battery insufficient Whether there is 24V voltage at the

Yes Start motor damaged
voltage terminal 50 of start motor
No
Whether there is 24V voltage at the terminal

121 of start contactor
Yes No

Whether fuse 50A and fuse 60A
Yes voltage at the terminal
blown or not
Whether start
contactor 220 is
No No Yes
conducted to earth
Whether there is 24V voltage

No Yes
at the terminal 125 of neutral Loose wire Replace fuse
interlocking relay
Yes
Loose wire Replace start contactor

No

No.512 wire
voltage at the terminal
125 of electric lock
Replace fuse Loose wire
Yes No Shift selector fault
No Yes
Yes No
Whether No.220 wire
is conducted to earth
Loose wire 125
voltage at No.108 wire
Yes No
Whether fuse 10A blown or

not
No
Yes
Replace the Replace neutral

Loose wire
electric lock interlocking relay
7-64
7.20 Choke circuit
7.20 Choke circuit and choke solenoid. It controls the throttle to pen
during start, and to close during parking.
The choke circuit consists of battery, disconnect
switch, electric switch lock, choke contactor, fuse Schematic
Electric lock
Main power
Choke contactor contactor
Disconnect switch
Coil
commander
Choke solenoid
Schematic diagram introduction nal 125 of electric switch lock is energized, the
Close the disconnect switch, turn the electric switch choke contactor is closed, the pull and push coil 425
lock to “ON” position (see 7.6 for the description of of choke solenoid is energized, the choke solenoid
positions), and the battery supplies power to the is pulled in, and the throttle opens, so the complete
holding coil of choke solenoid through 100, 60A vehicle is started. After start process, the electric
fuse, 105, 118, 108 and 123. When the electric switch lock returns to “ON” position, and the termi-
switch lock is turned to “START” position, the terminal 123 of choke solenoid holding coil is still ener-
gized to keep the choke solenoid in working state,
7-65
7.20 Choke circuit
so the complete vehicle can keep operating. When

parking is needed, turn off the electric switch lock,
the power of terminal 123 is cut off, the choke sole-
noid is powered off, and the fuel supply to engine is
cut off, so as to realize choking.
Fault detection of choke circuit

Fault phenomenon: unable to start
1. Turn the electric switch lock to “ON” position,
measure whether there is 24V voltage at
No.123 wire of choke solenoid terminal by digi-
tal multimeter; if not, go to next step; if any, go
to Step 5.
No.123 wire of electric switch lock terminal; if
any, No.123 wire is loose; if not, go to next step.
terminal 108 of electric switch lock; if any, the
electric switch lock is faulty, and replace it; if
not, go to next step.
any, replace fuses; if not, check whether wires
are loose or open.
5. Turn the electric switch lock to “START” posi-
tion, and measure whether there is 24V voltage
at No.425 wire of choke solenoid terminal; if
any, the choke solenoid is damaged, and con-
tact the dealer; if not, go to next step.
No.425 wire of choke contactor terminal; if any,
No.425 wire is loose or open; if not, go to next
step.
7. Measure whether there is 24V voltage at choke
contactor terminal 120; if not, go to next step; if
any, go to Steps 9.
any, replace fuses; if not, check whether wires
are loose or open.
No.125 wire of choke contactor; if any, go to
next step; if not, repeat Steps 3 and 4.
10. Measure whether No.200 wire of choke contac-
tor is conducted to earth; if any, the chock con-
tactor is faulty, and replace it; if not, check the
wire is loose or open.
7-66
7.20 Choke circuit
Whether there is above 24V voltage at

the terminal 30 of start motor
No Yes
Battery insufficient Whether there is 24V voltage at the

Yes Start motor damaged
voltage terminal 50 of start motor
No
Whether there is 24V voltage at the terminal

Yes No

Whether fuse 50A and fuse 60A
Yes voltage at the terminal
blown or not
Whether start
contactor 220 is
No No Yes
conducted to earth
No Yes Whether there is 24V voltage

Loose wire Replace fuse
at the terminal 125 of electric
lock
Yes
Loose wire Replace start contactor

No

No.512 wire
Loose wire 125
Replace fuse Loose wire
Yes No Shift selector fault
No Yes
Yes No
Whether No.220 wire
is conducted to earth
Loose wire 125
voltage at No.108 wire
Yes No
Whether fuse 10A blown or

not
No
Yes
Replace the Replace neutral

Loose wire
electric lock interlocking relay
7-67
7.21 Schematic diagram of electrical units
7.21 Schematic diagram of

electrical units
1. Front combination light 11. Engine coolant temp sensor

2. Blade work light 12. Speaker
3. Front work light 13. Radio
4. Work light 14. Service brake pressure switch
5. Front wiper 15. Parking break pressure switch
6. Rear work light 16. Fuel level sensor
7. Engine oil pressure switch 17. Battery
8. Torque converter oil temp sensor 18. Disconnect switch
9. Torque converter oil pressure switch 19. Intake air filter alert switch
10. Rear combination light 20. Reverse alarm
7-68
7.22 Schematic diagram of electric connector positions
21. Electric horn 23. Centralized control box

22. Dome light
7.22 Schematic diagram of

electric connector positions
No. 1: X1、 X2、 X3、 X5、 X6、 X7、 X8

No. 2: X9、 X10、 X11、 X12
No. 3: X4、 X13、 X14、 X15、 X16、 X17、 X18、
X19
No. 4：X53
7-69
7-70
7-71
8. A/C System
8.1 A/C system overview......................................................................................8-3
8.1.2 Working principle for A/C.............................................................................................8-3
8.1.3 Introduction to all parts of A/C .....................................................................................8-4
8.2 Removal and installation of air conditioner ....................................................8-5
8.2.1 Installation position introduction of A/C components...................................................8-5
8.2.2 Removal and installation of A/C components for ........................................................8-6
8.2.2.1 Compressor disassembly ..................................................................................8-6
8.2.2.2 Removal and installation of evaporator mounting as ...................................... 8-11
8.2.2.3 Replacement of A/C control panel...................................................................8-12
8.2.2.4 Inspect and replacement of A/C fuse ..............................................................8-12
8.2.2.5 Removal and replacement of receiver.............................................................8-13
8.2.2.6 Removal and installation of evaporator motor.................................................8-14
8.2.2.7 Removal and installation of expansion valve ..................................................8-15
8.2.2.8 Removal and installation of condenser motor .................................................8-15
8.2.2.9 Removal and installation of condenser core ...................................................8-16
8.3 Heater system overview...............................................................................8-17
8.3.1 Heater system introduction .......................................................................................8-17
8.3.1.1 Heater system parameters ..............................................................................8-17
8.3.1.2 Heater working principle..................................................................................8-17
8.3.1.3 Introduction to parts of heater system .............................................................8-18
8.3.2. Removal and installation of heater system parts .....................................................8-18
8.3.2.1 Introduction to mounting positions of heater system parts ..............................8-18
8.3.2.2 Removal and installation of heater system parts.............................................8-19
8.4 A/C maintenance..........................................................................................8-21
8.4.1 A/C detection.............................................................................................................8-21
8.4.2 Tension inspection of A/C compressor pulley............................................................8-22
8.4.3 A/C regular maintenance...........................................................................................8-22
8.4.3.1 Maintenance every 50 working hours or every week: .....................................8-22
8.4.3.2 Maintenance every 250 working hours or every month:..................................8-22
8.4.3.3 Maintenance every 1,000 working hours or every six months: .......................8-22
8.4.3.4 Maintenance every 2,000 working hours or every year:..................................8-22
8-2
8.5 Fault diagnosis and maintenance of A/C system ......................................... 8-23

8.5.1 Fault diagnosis process and troubleshooting ........................................................... 8-23
8.5.1.1 Fault diagnosis process .................................................................................. 8-23
8.5.1.2 Troubleshooting .............................................................................................. 8-24
8.5.2 Electrical schematic of A/C system........................................................................... 8-27
8.5.3 A/C refrigerant filling method .................................................................................... 8-27
8.5.4 Tightening torque for lines connectors of A/C system .............................................. 8-29
8-3
8.1 A/C system overview
8.1.1 A/C system parameters

8.1.1 A/C system parameters
Working medium Coolant cooling water

Heating sys-
Cooling volume 5000 W
tem
Max. wind speed
Refrigerant R134a
A/C system Cooling volum 3500 W
Refrigerant filling quantity 950±50 g
Voltage 24 V
8.1.2 Working principle for A/C pressure refrigerant mist, and then enters the
evaporator.
1. Compression process
4. Evaporator process
Refrigerant absorbs heat in the evaporator and
Low-temperature low-pressure refrigerant liquid
then changes into low-temperature low-pres-
formed by the throttling of expansion valve is
sure refrigerant vapor, is sucked into the com-
vaporized in the evaporator, the air in the cab is
pressor and compressed into high-temperature
driven by the evaporator fan unit to pass the
high-pressure refrigerant vapor, and then is dis-
evaporator surface, refrigerant absorbs the heat
charged into the condenser.
of air in the cab to reduce the air temperature,
2. Condensation process and condensate water is separated out. Refrig-
erant absorbing heat is evaporated into low-
After high-temperature high-pressure refriger-
temperature low-pressure refrigerant vapor, is
ant vapor enters the condenser, air is forced by
sucked into the compressor and compressed
the condenser fan unit to pass the condenser
again, and one refrigeration cycle is completed.
surface and take away refrigerant heat, and
refrigerant is condensed into medium-tempera- The compressor keeps rotating, the above
ture high-pressure refrigerant liquid. refrigeration process is cycled continuously,
and the heat in the cab is taken away by refrig-
3. Throttling process erant in the evaporator, so as to complete cool-
Medium-temperature high-pressure refrigerant ing and dehumidification of the complete
liquid is filtered by dryer and throttled through vehicle.
the expansion valve (refrigerant is sprayed from
the pores of expansion valve and expanded
suddenly), changes into low-temperature low-
8-4
8.1.3 Introduction to all parts of A/C
Fig.1 Working principle diagram for A/C system
8.1.3 Introduction to all parts of tube type evaporator and laminated type evap-
orator. The evaporator of A/C system is a lami-
A/C nated type evaporator.
1. Compressor The compressor is a core compo- 3. Refrigerant receiver dryer: The receiver drier is
nent of the A/C system. It is used to compress a necessary unit to ensure the normal operation
low-temperature low-pressure refrigerant vapor of compressor and refrigerating system. Its
into high-temperature high-pressure refrigerant functions include: 1. storage, 2. filtration, 3. dry-
vapor. The compressor used for the system is a ing.
swash plate one. The type is SE-5H14, the dis- 4. Condenser: The condenser is a heat-exchange
placement is 138cm³, the refrigeration oil is unit which absorbs the heat of high-pressure
PAG100. overheated refrigerant vapor from the compres-
2. Evaporator: The evaporator is used to allow sor, condenses into liquid and overcools. The
throttled low-temperature low-pressure refriger- condenser is generally air-cooled. Condensers,
ant liquid to absorb large heat from the sur- according to different structures, can fall into fin
rounding air during evaporation in the and tube type condenser, serpentine type con-
evaporator, so as to realize the purpose of cool- denser, parallel flow condenser, ect.
ing or cooling and dehumidification in the cab. 5. Expansion valve: The expansion value is a
Evaporators, according to different structures, throttling unit, used for throttling and step-down
fall into: serpentine type evaporator, fin and
8-5
8.2 Removal and installation of air conditioner
8.2.1 Installation position introduction of A/C components
as well as flow adjustment; meanwhile, it can

also prevent wet compression, liquid impact
and abnormal overheating. Common throttling
units include internal balanced thermostatic
expansion valve, external balanced thermo-
static expansion valve, H type thermostatic
expansion valve, expansion throttle pipe, etc.
6. A/C pipe: The connection lines of A/C system
include high-pressure pipes and low-pressure
pipes. Among them, the compressor to con-
denser pipe, condenser to receiver pipe, and
receiver to evaporator pipe are high-pressure
pipes, and the evaporator to compressor pipe is
low-pressure pipe.
7. Pressure switch: The pressure switch, con-
Fig. 2 A/C control panel
nected in series in the compressor circuit, con-
trols the turn-on and turn-off by monitoring the
system pressure, so as to realize the purpose
of protecting the compressor. The pressure
8.2 Removal and installation
switch is used to a high/low-pressure combina- of air conditioner
tion switch, the upper limit value of high pres-
sure is 2.65Mpa, and the lower limit value of low
pressure is 0.196Mpa. 8.2.1 Installation position intro-
8. Thermostat: The thermostat is used to detect duction of A/C components
the temperature of evaporator core surface and
1. Compressor The compressor, installed on the
control the turn-on and turn-off of compressor,
engine, is driven to work by directly using the
which can effectively avoid evaporator freezing
driving force of engine through belt connection.
which may damage the evaporator core. When
Mounting position refer to Fig. 3 below.
the temperature is lower than 0 , the compres-
sor is off and stops working; when the tempera-
ture reaches above 5
, the compressor is on
again.
9.
A/c panel: The A/C panel is located on the cab
top and below the seat. The top is air supply
and cold air control panel; the left is air supply
knob, which can be operated when the electric
switch lock is turned on, including three posi-
tions, i.e. high-speed position, medium-speed
position and low-speed position in order; the
right knob is a cooling switch and cooling tem-
perature adjusting knob, which can be operated
when the engine is working, and turning the
knob will increase the cooling effect gradually. Fig. 3 Compressor mounting of A/C
There are three indicators on the panel, which
are power, fault and cooling indicators respec- 2. Evaporator assembly: The system of air condi-
tively, refer to Fig. 2. tioner is overhead, and the evaporator as is
installed on the top of cab. The evaporator as
8-6
8.2.2 Removal and installation of A/C components for
includes evaporator, condenser, receiver, pres- 8.2.2 Removal and installation

sure switch, thermostat, etc. Such integrated
installation effectively saves installation space, of A/C components for
refer to Fig. 4.
A/C evaporator
8.2.2.1 Compressor disassembly
condenser
mounting as
8.2.2.1.1 Drain refrigerant from the A/C
system.
To avoid the injury of refrigerant, goggles
and gloves should be worn and naked light or
smoking is prohibited.
Tip: Recycle the refrigerant if there are appropri-
ate equipments. Refrigerant recycle method for
34711-2K machine produced by US SPX.ROB-
INAIR Company will be introduced in 8.2.2.1.4
section.
1. Before operation, close the high-pressure and
Fig. 4 Installation position of evaporator low-pressure valves at the instrument of mani-
condensation assembly fold meter, unscrew high-pressure and low-
Air outlet and control panel: The air conditioner pressure connector valves completely (turn
3.
counterclockwise to end), refer to Figures 6 and
is overhead, and the air outlet and control panel
7.
are installed on the top of cab. This installation
method omits the design of air duct, which
effectively saves the cab space, refer to Fig. 5.
Close the low- and
high-pressure valve
of instrument
Fig. 6
Fig. 5 Installation position of A/C air outlet

and control panel
8-7
Close the low- and Open the joint

high-pressure joint valve, and tighten
valve, and counterclockwise.
clockwise turn it to
the end
Fig. 7 Fig. 9
2. Unscrew the plugs from the high-pressure and 3. Slightly loosen high-pressure and low-pressure
low-pressure filling fillers of compressor, and valves on the manifold meter to let refrigerant
connect the high-pressure and low-pressure flow out slowly. When loosening the valves,
valves of manifold meter respectively to the loosen the low-pressure valve first and then the
high-pressure and low-pressure filling fillers of high-pressure valve. As the pressure at the
compressor (or fillers of high-pressure and low- high-pressure valve end is high, refrigerant
pressure pipes). Open the connector valves flows fast. Pay attention to controlling the valve
after connection (tighten clockwise), refer to opening. High flow speed will cause the injec-
Fig. 8 and 9. tion of refrigerant oil along with refrigeration, so
control to avoid injection of the oil. Refrigerant
can be drained for about 10-15 min, refer to Fig-
ures 10 and 11.
Fig. 8
Fig. 10
8-8
Fig. 11 Fig. 13
4. After draining refrigerant, take down high-pres-
sure and low-pressure valves, and install plugs,
refer to Fig. 12.
Fig. 14
2. Seal the compressor fillers and lines to prevent
foreign matters from entering, refer to Figures
Fig. 12 15 and 16.
8.2.2.1.2 Remove lines connecting the

compressor
1. I. Loosen the connecting threads of compressor
lines by a wrench, and take down the lines,
refer to Figures 13 and 14.
8-9
Fig. 15 Fig. 17
2. Loosen the M16 mounting bolts connecting the
compressor bracket and swing link, and take
down the compressor belt, refer to Fig. 18.
Fig. 16
8.2.2.1.3 Removal and replacement of

compressor Fig. 18
1. Loosen the nut of adjusting screw rod M14, 3. Remove 4 M10 mounting bolts of compressor,
refer to Fig. 17. and then take down the compressor for over-
haul or replacement, refer to Fig. 19.
8-10
Lubricant
reservoir
Fig. 19 Fig. 20
4. The assembly steps of compressor are just 3. Press the recycle switch.
opposite to the removal steps. 4. If more than 150Ib (68kg) refrigerant has been
recollected since last replacing dry filter, the
8.2.2.1.4 Introduction to refrigerant recy- instrument will display: filtered weight is xxx Ib
cle method for 34711-2K machine pro- (xx kg). Press the start button.
duced by US SPX.ROBINAIR Company 5. Connect the high and low pressure conduits to
The recovered refrigerant will pass through the oil the A/C system, and open the connection
separator and the filter dryer in turn, and finally into valves.
the refrigerant tank. When the dried refrigerant flows
6. Rotate both the low and high pressure valves to
through the humidity indicator, it will turn green.
the Recover / Vacuum location, and then press
If possible, it is better to run the A/C system for the Start button to continue.
about 10 minutes before recycling the refrigerant.
Then shut down the system to start recycling the
refrigerant.
1.
Connect the multipurpose power supply
2.
Turn on the main power switch, and empty the
refrigerant recovery tank on the right of the
device.
Fig. 21
7. If the system pressure is below 25psi (1.72bar),
the instrument will display : The system pres-
sure is low until the pressure rises or press the
Start button. You can press the button to exit.
8-11
8. If there is refrigerant in the low pressure conduit

of the device, the instrument will start cleaning
program and display: being cleaned. If you want
to skip or stop cleaning program, you can press
the Start button again.
9. When the amount of the system recollection
reaches 13in.Hg. (0.44bar) , the vacuum com-
pressor will automatically shut down.
10. Next, the instrument will automatically recover
lubricant, and the instrument will show: lubri-
cant is being recycled. Oil recovery needs 90s
or so.
11. After completion of the recovery of lubricant,
check the lubricant recovery tank, and write
down amount of the lubricant recovered from Fig. 22
the system. The system needs to be charged After removing the air outlet, disconnect two
3.
with more lubricant after being vacuumed.
harnesses butted with the air conditioner, refer
12. To confirm whether the refrigerant is completely to Fig. 23.
recollected, wait for 5 minutes and observe
whether the pressure of the multifunction instru-
ment will rise higher than 0 in.Hg. (0bar) after
the recollection. If the pressure is picked up ,
you need to press the start button again to
repeat the recovery process until the system
pressure can be maintained for 2 minutes, then
press the stop button to exit the recovery .
8.2.2.2 Removal and installation of

evaporator mounting as
1.
Drain refrigerant from the A/C system, refer to
8.2.2.1.1.
2. Remove the A/C air outlet in the cab: Remove
10 screws of top air outlet in the cab by a Fig. 23
Cross-screwdriver, refer to Fig. 22. 4. Remove two pipes connected on the evapora-
tor as by a monkey wrench or proper wrench.
Make sure to seal the pipes and pipe connec-
tors on the evaporator after removal, to prevent
foreign matters from entering, refer to Fig. 24.
8-12
Fig. 24 Fig. 26
5. Unscrew 6 retaining nuts on the evaporator by a 2. After removing the air outlet, disconnect two
wrench, take down the nuts, and then remove connecting harnesses, and then take down the
the evaporator as for overhaul or replacement, A/C panel for overhaul or replacement, refer to
refer to Fig. 25. Fig. 27.
Fig. 25 Fig. 27
6. The assembly steps of evaporator as are just
opposite to the removal steps. 8.2.2.4 Inspect and replacement of
A/C fuse
8.2.2.3 Replacement of A/C control 1. Find the grey A/C fuse box located at the cab
panel bottom, see Fig. 28 and Fig. 29.
1. Remove the A/C air outlet in the cab: Remove
10 screws of top air outlet in the cab by a cross-
screwdriver, refer to Fig. 26.
8-13
Fig. 28 Fig. 30
8.2.2.5 Removal and replacement of

receiver
1. Drain refrigerant from the A/C system, refer to
8.2.2.1.1.
2. Unscrew off 8 bolts from the A/C FRP cover on
cab roof with a cross-screwdriver.
Fig. 29
2. Open the fuse box, take down the fuse (30A),
and check if fuse is blown. If not blown, install
the fuse back to the original place. See Fig. 30,
if the fuse is blown, replace it.
Fig. 31
3. Remove the FRP cover.
8-14
Fig. 32 Fig. 34
4. Unscrew off two mounting nuts from refrigerant 6. Replace with a new refrigerant receiver.
receiver.
evaporator motor
1. The same as Step 2 and Step 3 in 8.2.2.5 sec-
tion.
2. Pull out harness connector of evaporator motor.
Fig. 33
5. Pull out harness connector.
Fig. 35
3. Unscrew off two mounting nuts from evaporator
motor.
8-15
Fig. 36 Fig. 38
4. Take out the motor for service or replacement.
condenser motor
1.
The same as Step 2 and Step 3 in 8.2.2.5 sec-
tion.
2.
Unscrew four mounting screws from the wire
mesh with a cross-screwdriver.
Fig. 37
5. Install evaporator motor.

expansion valve
1. Drain refrigerant from the A/C system, refer to
8.2.2.1.1. Fig. 39
2. The same as Step 2 and Step 3 in 8.2.2.5 sec- 3. Remove the wire mesh.
tion.
3. Unscrew off two mounting nuts from expansion
valve, and take down the expansion valve for
service or replacement.
8-16
Fig. 40 Fig. 42
4. Take out the condenser motor. 6. Install the condenser motor in the reverse order
of removal.

condenser core
1. The same as Steps 1-3 in 8.2.2.5 section.
2. Remove four mounting bolts form condenser
core with a cross-screwdriver.
Fig. 41
5. Pull out motor harness connector, and maintain
or replace the motor directly.
Fig. 43
3. Remove the connecting screw between con-
denser core and refrigerant receiver.
8-17
8.3 Heater system overview
8.3.1 Heater system introduction
Fig. 44 Fig. 45
4. Take out the condenser core for cleaning, ser-
vice or replacement.

8.3.1 Heater system introduc-
tion
8.3.1.1 Heater system parameters
Heating sys-
Working medium Coolant cooling water
tem
Cooling volume 5000 W
Voltage 24 V
8.3.1.2 Heater working principle

The heating system of CLG4180 grader uses
engine coolant as heat source. It realizes heat
exchange between the air blown in by the blower as
and engine coolant through its heat exchanger
(generally called heater core), and heated air is
blown into the cab.
8-18
8.3.2. Removal and installation of heater system parts
Fig. 46 Working principle of heater system
8.3.1.3 Introduction to parts of 8.3.2. Removal and installation

heater system of heater system parts
1. Heater as: the heater as is a component inte-
grating the heat exchanger core, blower and 8.3.2.1 Introduction to mounting
controller. Among them, the heat exchanger
core is used for heat exchange, i.e., release of positions of heater system parts
heat from engine coolant; the blower is used to 1. Heater as: the heater as is installed at the bot-
quicken air flow, so as to increase the heat tom of seat, and services as seat support. See
exchange efficiency of heat exchanger; the con- Fig. 47:
troller controls the turn-on and turn-off of
blower.
2. Heater water intake valve: the heater water tak-
ing valve is connected to the engine, function-
ing as opening and closing. Manual valve is
used in this A/C currently.
3. Warm water hose: it leads water into the heater
exchanger in the cab, and then takes cooled
water back to the engine.
8-19
Fig. 48
2. Remove seat. Remove 4 mounting bolts of M10
seat by an air gun or 16# wrench, refer to Fig.
49.
Fig. 47

heater system parts
8.3.2.2.1 Removal of heater assembly

Caution: before removing the heater, it is
necessary to choke the engine, and allow the
engine to be cooled to or close to natural state.
1. Clamp two water pipes by clamp device to pre-
vent engine coolant from excessive runoff, and
remove two heater water pipes at the cab bot-
tom, refer to Fig. 48.
Fig. 49
3. Move way the seat and remove 4 M8 mounting
bolts of heater as, disconnect the harness con-
nected from the heater to cab, and remove the
8-20
heater as for overhaul or replacement, refer to

Fig. 50.
Fig. 52
4. Pull out the connector of connecting harness
Fig. 50 between motor and panel
4.
The assembly steps of heater as are just oppo-
site to the removal steps.
8.3.2.2.2 Removal and installation of

motor
1.
Remove the heater as according to 8.3.2.2.1.
2.
Place the heater upside down, and unscrew off
the mounting screw from the silver-white bot-
tom plate.
Fig. 53
5. Remove the motor mounting screws.
Fig. 51
3. Take out the silver-white bottom plate.
8-21
8.4 A/C maintenance
8.4.1 A/C detection
8.4 A/C maintenance

8.4.1 A/C detection
Warning: Breathing in refrigerant vapor by
lighted cigarette or other smoking methods or
smoke from flame in contact with refrigerant will
cause death. Smoking is not allowed during
maintenance of air conditioner or at the place
where refrigerant vapor may exist.
1. Start the engine, and keep the engine running
at high idle speed.
2. Turn on the A/C switch, adjust the air condi-
Fig. 54 tioner to cooling mode, and control the air sup-
6. Take out the motor for service or replacement, ply speed at high speed by adjusting the air
and then install it in the reverse order of speed switch.
removal. 3. Keep the A/C system operating stably for 2 min.
4. Open the rear hood, and touch the air inlet hose
8.3.2.2.3 Removal and installation of and air outlet pipe in order to check refrigerant
heater panel in the system. If the system contains refrigerant,
1. The same as Steps 1-4 in 8.3.2.2.2 section. the air outlet pipe is warmer than the air inlet
2. Remove the mounting screw from heater con- pipe. If the system contains no refrigerant or lit-
trol panel with a cross-screwdriver. tle refrigerant, the cooling effect is very poor,
refer to Fig. 56.
Fig. 55
Fig. 56
3. Take down the heater control panel for service
or replacement.
8-22
8.4 A/C maintenance
8.4.2 Tension inspection of A/C compressor pulley
8.4.2 Tension inspection of A/C 8.4.3.2 Maintenance every 250 work-

compressor pulley ing hours or every month:
⚫ Check the tension and damage of the transmis-
1. Tension of compressor belt: Apply a load
sion belt of the engine and the belt of the com-
W=1.5Kg on the center of tangent edge of belt
pressor of the air conditioner.
and two pulleys (compressor pulley and engine
⚫ Check whether there is sufficient refrigerant in
pulley), perpendicular to the belt edge, and the
the A/C receiver.
deflection f of belt shall be 5 ± 1 mm. See Fig.
⚫ Clean the inner and outer air filters of the cab.
57 below.
8.4.3.3 Maintenance every 1,000

working hours or every six months:
⚫ Replace the outer air filter of cab.
8.4.3.4 Maintenance every 2,000

working hours or every year:
⚫ Check whether the cooling pipe and water pipe
of A/C system are broken, worn out or
immersed by oil stains, and check whether the
connector and clamp are loose.
Fig. 57
When the belt cannot be tensioned (apply a load
W=1.5Kg on the center of tangent edge of belt and
two pulleys (compressor pulley and engine pulley),
perpendicular to the belt edge, and the deflection f
of belt is greater than 5 ± 1mm), replace the belt. If
the belt has rough edges or cracks, replace the belt.
8.4.3 A/C regular maintenance

8.4.3.1 Maintenance every 50 work-
ing hours or every week:
⚫ Clean the strainers of evaporator return air out-
let and new air outlet; check the tension of com-
pressor drive belt, and check the condenser for
oil stains, dirt and other foreign matters which
will affect the heat dissipation of condenser.
8-23
8.5 Fault diagnosis and maintenance of A/C system
8.5.1 Fault diagnosis process and troubleshooting
8.5 Fault diagnosis and

maintenance of A/C system
8.5.1 Fault diagnosis process
and troubleshooting
8.5.1.1 Fault diagnosis process
8-24
8.5.1.2 Troubleshooting
Items Fault conditions Judge cause Troubleshooting
1. Poor contact of connector 1. Repair or replace;

2. Damaged air volume 2. Repair or replace relay;
1 The fan doesn't run switch, relay. 3. Replace the fuse, see 8.2.2.4
3. Blown fuse or low battery section for inspection and
voltage. replacement methods of fuse
1. Obstacles at suction side. 1. Clear

2 Abnormal fan operation Clogged fins of evapora-
tor or condenser by dust.
1. Failed pull-in of compres- 1. Check and repair

sor clutch due to open cir- 2. Adjust belt tension or replace
cuit or poor contact. belt
2. Loose or fallen compres- 3. Repair or replace the coil
sor belt tensioner, or
loose belt. 4. Drain or fill refrigerant, see
Failed operation or difficult
3 8.2.2.1 section for compres-
operation of compressor 3. Open or failed compres-
sor replacement, and see
sor clutch coil. 8.5.3 section for refrigerant
4. Active high-pressure and filling method
low-pressure switches of
receiver, but excessive or
insufficient refrigerant.
1. Refrigerant leakage. Eliminate air leakage and fill suffi-

4 Insufficient refrigerant 2. Insufficient refrigerant fill- cient refrigerant, see 8.5.3 sec-
ing amount. tion for refrigerant filling method;
8-25
When the temperature is 32

--37 , the compressor
The determination of high pres- speed is 1,800-2,000 rpm.
sure and low pressure Pressure range of high-pres-
depends on the readings of sure gauge:
high pressure and low pres- 1.27Mpa—1.52Mpa
sure gauges. Pressure range of low-pres-
sure gauge:
0.12Mpa—0.15MPa
Low- 1. Replace expansion valve see
pres- Too large opening of expan- method 8.2.2.7
sure sion valve. Poor contact of Install the sensing bulb cor-
There is frost on low- 2.
is on expansion valve sensing bulb.
pressure pipe surface. rectly.
the Excessive refrigerant in the
high system. 3. Drain part of refrigerant
side
1. Locate the leak by a leak

Low-pressure gauge Loose pipe connector due to detector and tighten the
value is lower than nor- vibration, and leakage to loose part carefully. Add
mal value cause insufficient refrigerant. refrigerant to the specified
amount.
1. Drain the system, replace

The pressure of low refrigerant receiver, and refill
Clogged low-pressure hose or
pressure gauge is in refrigerant, see 8.2.2.5 sec-
ice blockage in expansion
negative pressure state tion for receiver replacement
valve.
occasionally. method; See 8.5.3 section for
Low- refrigerant filling method
pres- The evaporator is fro-
sure Thermostat failure Replace thermostat
zen.
is on
the The expansion valve
Clean or replace expansion valve
low inlet side is cold, with Expansion valve has block
replace method see 8.2.2.7
side frost attached.
5
The expansion valve

outlet side is not cold, Air leakage of expansion
and the pressure of low Replace expansion valve,see
valve sensing pipe or sensing
pressure gauge is in method 8.2.2.7
bulb.
negative pressure state
occasionally.
Drain the system, re vacuumize,

Air into the A/C system. hold pressure and fill refrigerant,
High see 8.5.3 section for refrigerant
- filling method
pres-
sure
is on
the
8-26
The cooling of system is good

at the beginning, and cold air is Locate the leak by a leak detec-
insufficient after a period of Loose connector due to vibra- tor, tighten the loose part care-
6 time; there are bubbles in the tion as the vehicle is traveling fully, and add refrigerant, fill
receiver observation hole; the on bad road often, leakage. refrigerant 8.5.3 method refer-
“readings” of high and low ence.
pressure gauges are low.
The system does not cool,
warm air comes from air outlet, Replace the expansion valve, and
there is no temperature differ- Improper use. Worn-out and fill refrigerant again. See 8.2.2.7
ence between the expansion leaked expansion valve sens- section for expansion valve
7
valve inlet and outlet through ing bulb, to cause closed replacement method, and see
hand feeling, and the reading valve hole. 8.5.3 section for refrigerant filling
of low pressure gauge is very method.
low.
Turn on the A/C system intermit-
The air at outlet is not cold, and tently, which can eliminate instan-
the compressor temperature Impurities in the system, taneous clogging if clogging is not
8 rises. The pointer of low pres- clogged strainer of expansion serious. Or remove the expansion
sure gauge drops quickly, close valve, light frost or “sweat” at valve, clean with alcohol, empty
to “0”, and the reading of high expansion valve. the system and fill refrigerant
pressure gauge is high. again. fill refrigerant 8.5.3 method
reference.
Empty the system, replace the
The cold air volume is insuffi-
expansion valve, and fill refriger-
cient, and the evaporator is
Inactive orifice in expansion ant again. See 8.2.2.7 section for
9 frosted; the readings of high
valve. expansion valve replacement
and low pressure gauges are
method, and see 8.5.3 section for
low.
refrigerant filling method.
The cooling capacity
decreases gradually after the Saturated drying agent in the Empty the system, replace the
system operates for a period of
receiver, and ice blockage at receiver, and fill refrigerant again.
10 time, the reading of high pres-
the throttling position of the fill refrigerant 8.5.3 method
sure gauge is high, and the
expansion valve reference.
reading of low pressure gauge
is lower than 0.4MPa.
1. Check whether the thermo-

After turning on the A/C sys- stat is damaged by a multi-
Poor contact of thermostat or
tem, there is air rather than meter;
11 damaged compressor mag-
cold air, and the reading of high
netic clutch coil. 2. Replace the compressor
pressure gauge is unchanged.
magnetic clutch.
8-27
8.5.2 Electrical schematic of A/C system
The compressor clutch acts

frequently, the engagement Small opening of thermostat
time is short, the temperature to automatically force the Check the thermostat, and keep it
12
in the cab does not drop, and compressor to stop, causing open to the coldest position.
the readings of high and low insufficient cold air volume.
pressure gauge are normal.
8.5.2 Electrical schematic of A/

C system
8.5.3 A/C refrigerant filling pressure conduits to the A/C system, then open
the connection valves.
method 3. Connect the main power of the multifunction
Refrigerant recycle method and related precautions device and then turn on the main power switch.
for 34711-2K machine produced by US SPX.ROB- 4. Press the vacuum button, and then press the
INAIR Company are as following. start button.
1.
Drain or recycle refrigerant already in A/C sys-
tem before refilling. See 8.2.2.1.1 section for
drain method, and see 8.2.2.1.4 for recycle
method.
2.
Place valves of the multifunction device in the
closed state, and connect the high and low
8-28
8.5.3 A/C refrigerant filling method
9. Enter the amount of refrigerant 0.95kg required

to charge by number buttons, and then press
the Start button again.
10. The instrument will show after filling: charge
has completed, the amount of filling is x.xx lb
(kg).
11. Close high and low pressure valves, and
remove the filling conduits.
Notice: When the remaining refrigerant in the refrig-
erant storage tank is less than 3 lbs (1.36kg), it can't
charge the system with refrigerant, the refrigerant
storage tank should be supplied with refrigerant at
this time.
The following is reference table of pressure & tem-
Fig. 58 perature correspondence relationship
5. Press the start button again to confirm vacuum-
ing for 15 minutes, or change time to vacuum
by numeric buttons, and then press the Start
button once more.
6. When the set time is up , the vacuuming will
automatically stop . Press the stop button to exit
the process. Press the start switch to resume
continue vacuuming , or exit by pressing the
stop button. Now it is ready to charge the sys-
tem with refrigerant.
7. Press the charge system.
Fig. 59
8. Rotate the low pressure valve to the Closed
position, and the high pressure valve to the Oil
Inject / Charge position. Press the start button.
8-29
8.5.4 Tightening torque for lines connectors of A/C system
Ambinent Temp High-pressure Gauge Range Low-pressure Gauge Range
8.5.4 Tightening torque for lines

connectors of A/C system
Thread size Tightening torque
5/8-18UNF M16×1.5 15.7-19.6N⚫m
3/4-16UNF M22×1.5 19.6-24.5N⚫m
7/8-14UNF M24×1.5 29.4-34.3N⚫m

Water inlet and outlet threads 19.6-24.5N⚫m
9-1
Table of Contents
9. Frame System
Table of Contents
9.1 Frame Overview.............................................................................................9-2
9.2 Frame Structure Diagram............................................................................... 9-2
9.3 Structure Diagram of Articulated Hitch ........................................................... 9-2
9.3.1 Hitch test requirements ...............................................................................................9-4
9.3.2 Removal of articulated hitch........................................................................................9-4
9.3.3 Installation of articulated hitch.....................................................................................9-8
9.4 Front Counterweight.......................................................................................9-8
9.4.1 Overview and structure of front counterweight............................................................9-8
9.4.2 Removal steps of front counterweight.........................................................................9-8
9.4.3 Installation of front counterweight ...............................................................................9-9
9.5 Rear Counterweight .....................................................................................9-10
9.5.1 Overview and structure of rear counterweight ..........................................................9-10
9.5.2 Removal steps of rear counterweight........................................................................9-10
9.5.3 Installation of rear counterweight ..............................................................................9-12
9.6 Hood AS.......................................................................................................9-12
9.6.1 Overview and structure of hood ................................................................................9-12
9.6.2 Introduction to connection of hood and rear frame ...................................................9-14
9.6.3 Removal steps of hood .............................................................................................9-14
9-2
9.1 Frame Overview
9.1 Frame Overview converter system, rear axle AS, cooling system,
hood AS, rear counterweight or scarifier and other
The frame system includes front frame and rear parts.
frame. Front frame is a welded box type structure
for mounting cab, front axle system, working imple-
ment system, front counterweight or blade and other 9.2 Frame Structure Dia-
parts. Rear frame is a welded frame structure for
mounting engine system, transmission and torque
gram
Fig. 1: CLG4180 Frame system

1. Front frame 2. Rear frame
9.3 Structure Diagram of

Articulated Hitch
The articulated hitch is the key part to connect front
frame and rear frame and make front and rear
frames to function in relatively steering.
9-3
9.3 Structure Diagram of Articulated Hitch
Fig II: Structure diagram of articulated hitch
No. Name Qty No. Name Qty No. Name Qty
1 Bolt 14 11 Cap 1 21 Bolt 3
2 Washer 16 12 Shaft 1 22 Shim 6
3 Cover 1 13 Bolt 6 23 Shim 3
4 Shim 6 14 Washer 6 24 Washer 8

9-4
9.3.1 Hitch test requirements
No. Name Qty No. Name Qty No. Name Qty
5 Shim 3 15 Bearing 1 25 Lock

4
GE90ES plate
6 Shaft 1 16 Bolt 1 26 Plate 1
Bearing
7 Nut block 2 17 GEG90E 1 27 Washer 1
S
8 Bolt 4 18 Cap 1 28 Bolt 1
Grease Support
9 2 19 1
fitting sleeve
Grease
10 1 20 Washer 4
fitting
9.3.1 Hitch test requirements

1. Adjust the clearance between bearing cover
and interface of the front frame to 0-0.05mm.
9.3.2 Removal of articulated

hitch
2. Apply thread locking adhesive to Serial No. 1, Instructions to removal: first to remove the following
21 and 28 bolts, and tor Serial No. 1 and 21 before remove articulated hitch: blade AS, front axle
bolts to required torque values. AS, working implement AS, cab, hydraulic fluid tank,
remove hood AS, radiator AS, fuel tank AS and
engine AS on rear frame, remain rear axle, rear
frame and tyre.
Removal and installation steps:
1.
Lift front frame with steel wire rope and make
rear frame at horizontal state.
9-5
9.3.2 Removal of articulated hitch
Notice: Hold against rear axle to prevent it from 4. Screw out the four captive bolts on the plate of
spinning or it may cause safety issues. the lower hinges pin.
2.
Remove setscrews and fixing nuts from left and
right articulated cylinders.
5. Screw out the setscrews and fixing nuts from

the upper hinge pin with a open end wrench
3. Knock linking pin shaft out from lower side with (removal tool24mm);
long iron bar and hammer.
9-6
6. Screw out the bolt P1 from the lower hinge pin,

remove the thin plate; screw out 3 bolts P2;
remove four locking plates with a straight screw
driver; screw out 8 bolts, remove the thick plate;
7. Install tooling on rear frame with 8 bolts fixing

the original thick plate;
Force out lower hinge pin with the bolts of the
tooling;
Remove hinge pin; remove tooling;
8. Place a piece of paper or wood board under

lower hinge hole of the rear frame in order to
prevent upper hinge pin dropping into the hole
in later removal;
9-7
9. Knock the upper hinge pin out of the fitting hole 11. Lay front frame on ground with brace support;
with a long iron bar; Notice: The ground must be firm, make sure the
frame is steady before removing the steel wire rope;
12. Take out the supporting sleeve from the lower

hinge pin hole;
10. Move front frame up and down to separate with

rear frame smoothly;
Notice: In the process of front and rear frames sepa-
ration, keep clear within 0.5m, or safety issue may
arise;
9-8
9.4 Front Counterweight
9.3.3 Installation of articulated hitch
9.3.3 Installation of articulated

hitch

9.4.1 Overview and structure of
front counterweight
Overview: Front counterweight is mounted on the
front panel of front frame through binder bolts.
13. Remove setscrews from hinge cylinders and

remove two hinge cylinders;
Fig. III: Front counterweight

1. Counterweight
2. Lifting eye
3. Washer
4. Bolt (M20)
9.4.2 Removal steps of front

counterweight
1. Hook up 2 lifting rings of counterweight with
wire rope;
Lift slowly to tense the wire rope just right;
9-9
9.4.3 Installation of front counterweight
2. Unscrew off 8 captive bolts P1 at the left and

right side of counterweight, to move front coun-
terweight away;
9.4.3 Installation of front coun-

terweight
Assemble according to reverse steps of removal;
9-10
9.5 Rear Counterweight
9.5.1 Overview and structure of rear counterweight

rear counterweight
Rear counterweight is location at the rear side of
rear frame through binder bolt.
Fig. IV: Rear counterweight

1. Rear counterweight 4. Nut
2. Bolt (M16) 5. Washer
3. Washer 6. Bolt (M16)
9.5.2 Removal steps of rear Refer to battery removal procedures in electric

system.
counterweight 2. Tie two flat ropes to rear 2/3 position of rear
1. Open rear counterweight cover, remove electric counterweight;
wires on left and right batteries, take out two
batteries;
9-11
9.5.2 Removal steps of rear counterweight
3. Unscrew 4 captive bolts P1 from the bottom of 4. Slowly lower down, pull out wire;
counterweight; Notice: Rear counterweight must be lower down
Unscrew 2 captive bolts P2 from the bottom of very slowly, and pull out wire in the process of low-
counterweight; ering the counterweight, wire will be pulled broken if
lowering too fast;
9-12
9.6 Hood AS
9.5.3 Installation of rear counterweight
9.5.3 Installation of rear coun-

terweight
9.6 Hood AS
hood
The hood AS is divided into two major parts of fixed
hood and rear cover and mounted on the surface of
rear frame through connecting bolts.
5. Lift away rear counterweight after pulling wire
completely out;
6. Put rear counterweight on the solid ground sur-

face;
9-13
9.6 Hood AS
9.6.1 Overview and structure of hood
Fig. V: Hood AS
1. Hood 2. Cover
9-14
9.6 Hood AS
9.6.2 Introduction to connection of hood and rear frame
9.6.2 Introduction to connec-

tion of hood and rear frame
Section view of hood:
Introduction to connecting location of frame and 9.6.3 Removal steps of hood

hood AS:
1. Screw out 4 captive bolts from exhaust tail pipe,
remove the exhaust tail pipe;
No. Position Bolt
Connecting location of hood

1 M10
and cover
Connecting location of hood
2 M10
and rear frame
Connecting location of
3 M12
cover and rear frame
Connecting location of
4 M12
cover and rear frame
9-15
9.6 Hood AS
9.6.3 Removal steps of hood
4. Screw in 2 rings, and put lifting rope through

them;
2. Screw out 4 captive bolts from air filter, remove

the air filter;
5. Open the left and right door of hood;
Hang the 2 handrails of rear hood by lifting
rope;
Remove 2 bolts P1 under the rear hood firstly,
than remove 2 bolts P2 above the hood;
Take down the rear hood; unplug the harness
connector of plate license light during this pro-
cess;
Notice: Please use lifting rope to lift rear hood and
avoid potential hazard due to manual materials han-
dling (such as bruised, injured by a crashing object);
3. Unscrew four captive bolts from hood upper

plate;
6. Unscrew off four captive bolts from hood rear

end;
9-16
9.6 Hood AS
9.6.3 Removal steps of hood
9. Lift the hood away from the complete machine;
7. Unscrew off two captive bolts at the left and

right side of hood front end;
10. Unscrew 2 slings into the hood, and put lifting
rope through them;
8. Unscrew off 4 brackets and 8 captive bolts

between the hood, and remove the brackets;
9-17
9.6 Hood AS
9.6.4 Installation of Hood
11. Unscrew off four captive bolts at the left and

right side of hood;
12. Lift the hood away from the complete machine;
9.6.4 Installation of Hood

10-1
10. Work Implement

10.1 System Parameters of Rolling Disc Work Implement ................................ 10-2
10.2 The System of Rolling Disc Work Implement ............................................ 10-2
10.2.1 Steps for separation of work implement AS and front frame ...................................10-3
10.2.2 Installation for work implement AS and front frame.................................................10-5
10.2.3 Steps for separating blade AS and work implement framework..............................10-5
10.2.4 Installation of blade AS and work device frame ......................................................10-8
10.2.5 Removal steps work implement framework.............................................................10-8
10.2.6 Installation steps of the work implement framework..............................................10-10
10.2.7 Removal steps of blade AS ...................................................................................10-12
10.2.8 Installation steps of blade AS ................................................................................10-14
10.2.9 Maintenance and repair of grader bushing............................................................10-17
10.3 Blade (optional)........................................................................................ 10-18
10.3.1 Removal steps of blade body AS ..........................................................................10-19
10.3.2 Installation of blade body AS.................................................................................10-21
10.4 Ripper (optional) ...................................................................................... 10-21
10.4.1 Ripper removal ......................................................................................................10-22
10.4.2 Ripper installation..................................................................................................10-22
10-2
10.1 System Parameters of Rolling Disc Work Implement
10.1 System Parameters of rotate around the traction frame driven by slewing
driving devices, which in turn makes the blade slew
Rolling Disc Work Imple- in 360°. These two guide plates at the back of
blade, which hold against chute of guide, can side-
ment shift under the force which is generated by blade
sideshifting the cylinder. During the process of shov-
eling, small blade cutting angles can reduce cutting
System Parameter of Rolling Disc Work resistance while big blade cutting angles can adjust
Implement leveling precision and the effect of blending.
Blade Width 3960mm
Blade Vertical Ascending ≥ 150 mm/s

Speed Descending ≥ 100 mm/s
Blade Side- Stretching ≥ 100 mm/s

shifting Speed Retracting ≥ 150 mm/s
Blade Working
90°(left) 90° (right)
Angle
Maximum Lift-
ing Height of 450mm
the Blade
Maximum Dig-
ging Depth of 555mm
the Blades
10.2 The System of Rolling

Disc Work Implement
Grader work implement is composed of scraping
work implement and additional work implement
(such as scarifier and blade).
Grader rolling disc work implement adopts a work-
ing mechanism of world-wide popular swinging-arm
connecting rod. It features good rigidity, precise
positioning, and wide working ranges. It standardly
configurates full-sealing and adjusting-free rolling-
disc slewing device, the slewing of which is smooth
and accurate, which makes it easy to adapt to terri-
ble working environments. Grader work implement
is shown as Picture 10-1: the head of traction frame
is a ball hinge, which is hinged onto the head of the
frame so that traction frame can rotate and swing
around the ball hinge in all directions. The turning
circle which is set up on the traction frame can
10-3
10.2 The System of Rolling Disc Work Implement
10.2.1 Steps for separation of work implement AS and front frame
Fig.10-1 Work Implement System

1. Blade outlet cylinder 6. Blade swinging cylinder
2. Right cutting angle shifting cylinder 7. Left blade ascending and descending cylinder
3. Right blade ascending and descending cylinder 8. Left cutting angle shifting cylinder
4. Traction frame 9. Blade
5. Worm box
Work implement operating system can make the 10.2.1 Steps for separation of
blade do the following 6 kinds of movement:
work implement AS and front
① Blade left lifting and lowering; ② Blade right lifting
and lowering; ③ Blade swing ④ Blade sideshift (left frame
and right relative to swing ring); ⑤ Blade sideshift Notice: Remove worm box or not is dependent on
together with swing ring, that is pulling out traction whether you need it or not; if the worm box only
frame; ⑥ Change of blade cutting angle. needs to be removed or fixed, then these operations
Among which, ① , ② , ④ , ⑤ are generally controlled can be executed on the machine directly (for more
by cylinder while ③ are controlled by cycloidal specific steps please refer to “Removal and
Installation of Worm Box”).
motor and ⑥ by cylinder.
Warning! 1. Detach the two captive bolts on the pipe clamp
(P1) and the two captive bolts on the mounting
High speed is forbidden when moving on an
plate (P2); detach pipe clamp and mounting
uneven road.
plate in order.
No abrupt acceleration or deceleration under
any conditions.
10-4
10.2.1 Steps for separation of work implement AS and front frame
2. Remove 3 hydraulic hoses on rotary motor and 4. Hoist the work implement by two lifting ropes.
4 hydraulic hoses on the rotary joint.
5. Unscrew off four setscrews from bearing inner

3. Pull the seven hydraulic hoses out from the cover, and then knock out bearing inner cover.
traction frame, and put them in appropriate
places, then screen each oil port.
10-5
10.2.2 Installation for work implement AS and front frame
6. Hoist away the work implement by proper lifting

appliances to finish the work implement AS and 10.2.2 Installation for work
the detachment of front frame. Put the work
implement AS in an appropriate place. implement AS and front frame
10.2.3 Steps for separating

blade AS and work implement
framework
1.
Knock out the cotter pin of left and right angle
shifting cylinder and screw out screws.
Detach the four hydraulic hoses on the left and
right angle shifting cylinder.
2.
Knock out the cotter pin on the left and right
blade bearing and screw out the screw.
10-6
10.2.3 Steps for separating blade AS and work implement framework
3. Knock out the cotter pin from poppet cylinder, 5. Remove the six hydraulic hoses on the rotary
and then screw off the nut; joint.
Remove two hydraulic hoses from poppet cylin-
der.
6. Unscrew off three captive bolts from swivel

joint, and place swivel joint properly.
4. Remove the captive bolt from mounting bottom
plate under the swivel joint.
10-7
10.2.3 Steps for separating blade AS and work implement framework
7. Knock out the side cotter pin under the left and
right blade bearing, and screw out the screw.
10. Knock out the right bearing of blade from the

right and put it in a proper place.
8. Step 8: Put 2 wire ropes, shackles and bolts
through the third mounting holes on blade left
side and right side;
Lift the blade slowly to tense wire rope just right.
11. Hoist the blade away from the turning circle by

0.5m, then put down the blade and detach the
steel wire rope; hoist the work implement away
from the blade and place it properly.
9. Knock out the left bearing of blade from the left

then put it in a proper place.
10-8
10.2.4 Installation of blade AS and work device frame
10.2.4 Installation of blade AS

and work device frame
10.2.5 Removal steps work

implement framework
Notice: Remove worm box or not is dependent on
whether you need it or not; if the worm box only
needs to be removed or fixed, then these operations
can be executed on the machine directly (for more
specific steps please refer to “Removal and
Installation of worm box”).
1. Shield 4 screw threads on both sides of the
turning circle by screws.
2. Slowly lift up the work implementwork

implement by lifting ropes.
10-9
10.2.5 Removal steps work implement framework
3. Put the work implement on the ground and turn 4. Unscrew off the captive bolt from inner ring of
it over, then put it on the floor. dust cover.
5. Unscrew off 36 captive bolts from swing bear-

ing.
10-10
10.2.6 Installation steps of the work implement framework
6. Unscrew off 36 captive bolts from swing bear- 1. Screw two M18 rings into swing bearing gear
ing. ring, and then lift the swing bearing to the trac-
tion fame.
Apply screw thread-locking adhesive onto 36
captive bolts on swing bearing; and then pre-
tighten these bolts.
Notice: Air gun pre-tightening torque should be con-
trolled below the maximum torque, that is less than
380 N⚫m.
7. Screw 2 rings into the gear ring of swing bear-

ing, then hoist the swing bearing away and
place it properly.
2. Set the torque wrench to the torque of

415±35N·m and tighten bolts in order with star-
shaped method.
10.2.6 Installation steps of the

work implement framework
Notice: You can choose to remove the worm box or
not as needed; if only remove and repair the worm
box, remove it from the complete machine directly,
refer to "Removal and assembly of worm box" for 3. Hang the circle above the traction frame with
detailed steps. This section only introduce the instal- lifting rope, align the circle with the screw hole
lation steps of work device frame equipped with of swing bearing by using a crowbar, and then
worm box. lower the circle and remove the lifting rope.
10-11
10.2.6 Installation steps of the work implement framework
4. Install 36 captive bolts on to swing bearing, pre- 6. Overturn the traction frame by 180° with lifting
tighten them with a air gun, and tighten them in rope.
order with star-shaped method after set the
torque wrench to the torque of 305±25 N·m.
7. Tighten the grease joints at both sides.
5. Install captive bolt onto dust cover inner ring

properly.
10-12
10.2.7 Removal steps of blade AS
8. Tighten three captive bolts (socket spec: 16

mm) on the swivel joint, and install the swivel
joint properly.
2. Lift the blade with proper hoisting gear and turn

it over.
Notice: Don’t stand anywhere near the blade by
9. Install six hydraulic hoses on to the swivel joint, 0.5m while it is turned over, otherwise your security
and only tighten two hoses at the left lower side. would be at risk.
The other end should be shield properly to
avoid impurities causing pollution.
10.2.7 Removal steps of blade

AS
1. Removed the joint hinge pin of the left and right
angle cylinder, then detach the left and right
angle shifting cylinder.
10-13
10.2.7 Removal steps of blade AS
5. Tilt the outlet cylinder by a crowbar to make it

put in a horizontal state, then knock the bearing
of left blade out by an iron rod.
3. Remove captive bolt from upper plate of left

blade support.
4. Remove the captive bolt from outlet cylinder

with a socket. 6. Detach the outlet cylinder by a crowbar.
10-14
10.2.8 Installation steps of blade AS
7. Pull out the bearing of the left blade along the

guide rail by hand.
8. Pull out the outlet cylinder from the bearing of

the right blade.Hoist the outlet cylinder by hoist-
ing gears and then put it in a proper place.
10.2.8 Installation steps of

blade AS
1. Press the U-groove plate into blade right bear-
ing rail, and fix the U-groove with bolts and
washers.
10-15
2. Push the right blade bearing into the blade body 4. Go two steel wire ropes, shackle and bolts
rail, pay attention to the direction: outwards the through the mounting hole on the left and right
bearing seat, and then fix the plate with bolts side of the blade; slowly hoist blade until the
referring to the first step. Install left blade bear- wire ropes become tight.
ing in the same way as installation of right blade
bearing. Install the blade outlet cylinder into the
blade left bearing.
5. Connect left bearing and circle, first install gas-

kets and shims to the circle, then move the left
bearing on to the circle, and install parts like
3. Tighten with nuts first, insert the cotter pin, and gaskets and nuts. Tighten the nuts and then
install the plate, then fix the plate with bolts and loosen the nuts just right to insert pin. Finally
gaskets. put the bolt through the circle and left bearing,
install gaskets and nuts in order, and tighten the
nut. Make sure that clearance between gasket
and blade bearing is 2±1 mm.
10-16
Nut
6. Install blade left and right angle changing cylin-

ders: install the bigger chamber end of left
blade angle changing cylinder on to the work
device, and the other end to the left bearing,
and knock the pin into the hinge hole between
cylinder and left bearing, with screws, locknuts,
locating pins, and tightening nuts. Install the
right angle changing cylinder in the same way.
10-17
10.2.9 Maintenance and repair of grader bushing
7. Connect 4 hoses to the left and right blade 9. Install the washer to the outlet cylinder, and
angle changing cylinders respectively, and the start the complete machine to protrude the out-
other 2 hoses to blade sideshift cylinder, and let cylinder passing through the support hole,
then tighten them. and then tighten the outlet cylinder with wash-
ers, shims, nuts, and pins.
10.2.9 Maintenance and repair

of grader bushing
Once the grader has been used for a while, the
blade would begin to swing as a result of the abra-
sion of the bushing, which would affect the working
precision of the grader, in which case the bush
should be changed in time.
8. Install joint bottom plate onto swivel joint.
Removal of grader bushing:
1.
Put the machine and the blade in some proper
places.
10-18
10.3 Blade (optional)
10.2.9 Maintenance and repair of grader bushing
2. Detach the screws on the fixing pressure plate Installation of grader bushing
by a wrench. Detach the bolts, washer and 1. Mount the adjusting shims onto the guide
plate in order and place them properly. according to your needs.
3. Take the bushing out and adjust these shims. 2. Install bushing.
4. Detach other bushing following the directions of 3. Install plate in case that bushing would come off
Step Two and Step Three. from the guide.
4. Install washers and bolts. Fix plate.
5. Install bushing onto other places following Step
One to Step Four.
Fig.10-2 Configuration Scheme of Grader Bushing

1. Bolt 4. Shim
2. Washer 5. Bushing
3. Plate
10.3 Blade (optional) age device connected to mounting bracket, blade

body connected to linkage device and cutting edge
Blade is one of optional work devices of grader, it located at the bottom of blade body.
consists of mounting bracket, work cylinder and link-
10-19
10.3.1 Removal steps of blade body AS
Fig. 10-3 Blade structure diagram

1. Cutting edge 4. Linkage
2. Blade body 5. Link
3. Working cylinder 6. Mounting bracket
10.3.1 Removal steps of blade

body AS
1. Put the lifting rope through cylinder and then
hang it on the crane hook;
Lift the crane slowly to tense the lifting rope just
right.
Notice: Don't tense the lifting rope too hard, other-
wise, there exists potential risk when remove hose
with high hydraulic oil pressure.
10-20
10.3.1 Removal steps of blade body AS
2. Unscrew off six captive bolt from front frame 4. Unscrew off three captive bolts with an air gun.
cover, and remove the cover.
3. Remove two hoses A14 and B14 from cylinder

and remove hose close to the hydraulic lock
inside front frame.
5. Knock out other six nuts with air gun and open-
end wrench, but do not remove the bolt;
10-21
10.4 Ripper (optional)
10.3.2 Installation of blade body AS
Notice: It is not permitted to take down the six bolts

after their nut are removed, otherwise, security inci-
dents may caused due to blade sudden falling
during removal;
10.3.2 Installation of blade body

AS

Ripper is also one of optional work devices of
grader, with simple and maintenance friendly single-
link structure, generally used to loosen hard soil,
break road surface or split rocks. It mainly consists
of tip, teeth, mounting bracket, work cylinder con-
nected to mounting bracket, ripper frame connected
to rear frame.
6. No person is allowed to stand between blade

AS and front axle parts, and to stay ≤ 0.5 m
away from blade when separate blade AS from
front frame.
Put blade AS on the solid ground surface;
Notice: When separating blade AS from front frame,
no person is allowed to stand between blade AS
and front axle parts, and to stay ≤ 0.5 m away from
blade, otherwise, there exists potential risk.
10-22
10.4.1 Ripper removal
Fig. 10-4 Ripper structure diagram

1. Tip 4. Ripper frame
2. Tooth 5. Ripper mounting bracket
3. Ripper tooth rack 6. Working cylinder
10.4.1 Ripper removal

1. Place the machine properly.
2. Hitch the ripper with proper lifting tools to avoid
it falling.
3. Unscrew off the bolt and nut with wrench,
remove the bolt, shim and nut orderly and place
them properly.
4. After remove all mounting bolts, place the ripper
properly with lifting tools.
10.4.2 Ripper installation

1. Place the machine properly.
2. Lift ripper with proper lifting tools to the position
corresponding to the hole on rear frame.
3. Align the ripper to the hole on rear frame, and
install the washers, bolts, nuts, etc. orderly to
connect ripper and rear frame.
4. Remove the sling after installation.
11. Cab System
11.1 Cab overview ............................................................................................. 11-2
11.2 Possible damage of cab ............................................................................ 11-2
11.3 Maintenance and inspection of cab ........................................................... 11-2
11.4. Cab removal ............................................................................................. 11-3
11.4.1 Cab removal ........................................................................................................... 11-3
11.4.2 Removal of control box ........................................................................................... 11-6
11.5 Removal of driver seat .............................................................................. 11-6
11.5.1 Removal of seat ..................................................................................................... 11-6
11.6 Removal of interior trim ............................................................................. 11-7
11.7 Convertible cab (optional) ......................................................................... 11-8
11-2
11.1 Cab overview
11.1 Cab overview 11.2 Possible damage of

cab
If machine is turned over or cab frame is damaged
(for example, it hits sharp objects during transport
process), cab needs to be replaced in order to keep
cab in protective state.
Please check cab after accident happens, including
cab frame, seat, seat belt, all auxiliary equipment,
and all lines in cab. Before re-operation of the
machine, all damaged elements must be replaced.
Caution: Do not weld or rectify cab frame.
11.3 Maintenance and

inspection of cab
Warning: Incorrect inspection of roll

device or maintenance may lead to injury or
even death. If cab must be replaced, the
replacement of cab parts or installation of fas-
teners must be in accordance with required
procedures.
The cab as is fixed on the frame by bolts through
rubber cushion, and provided with adjustable damp-
ing seat, control box, etc. It mainly includes a cab, Warning: Do not modify cab in any ways.
platform, control box, etc. The cab glass is stuck to
the cab frame by special glass sealant, having a Such as welding. Informal modification of
certain sealing and heat insulation effects, and good cab, such as drilling, cutting or increase the
visibility. The cab door is provided with inside and device etc, will reduce the protection strength
outside handles. The cab door is sealed by rubber of cab structure. Do not repair cab except that
seals, and the ceiling is provided with decorative cab is damaged and needs to be replaced.
sound and heat insulation materials. The control
box is assembled at the right of seat.
A seat, installed in the cab, can be adjusted up and
Warning: If complete machine is turned
down, forward and backward, and the backrest
angle and headrest height can be adjusted to meet over during operation process, operator may
control comfort. This seat is also provided with a be injured or even died in the absence of roll
seat belt. Correct use and wear of seat belt can help device. Dismantlement of roll device is only
you get higher safety performance. allowed for maintenance or cab replacement.
Do not start the machine in the absence of roll
ROPS and FOPS are optional for the cab. Selecting
device.
the cab with ROPS and FOPS functions and wear-
ing seat belt can better protect the operator’s safety.
11-3
11.4. Cab removal
11.4.1 Cab removal
Warning: Wearing seat belt is safer prac-

tice. You machine is configured with ROPS
cab, or ROPS can protect you. Correct use
and wear of seat belt can help you get higher
safety performance.
Operate the followings after the machine runs the

first 20 hours and per 500 hours
1. Check seat and mounting assembly unit of seat
belt, make sure mounting bolt of seat belt tight-
ened, and use new parts if needed.
2. Check damaged and rusted parts in cab or cab
assembly unit. Aging of parts may lead to dam-
age of cab and parts
11.4. Cab removal

11.4.1 Cab removal
Unscrew mounting bolts of cab;

11-4
11.4. Cab removal
11.4.1 Cab removal
Depress the control lever, and pull the steering

wheel to tilt the control platform backward to end;
Pull out the harness connector, and separate the

connected harness;
Check whether the A/C pipe is removed and hung
on the cab door;
Unscrew the nut at earthing cable, and pull out the

harness;
11-5
11.4. Cab removal
11.4.1 Cab removal
Take the cab away;

Notice: In the process of taking away, no persons
shall be in the range of 1.5-2 m from the cab or
below the cab, or they may be injured by falling cab.
Use a ladder with the same height, install lifting

rings on lifting eyes at the cab top, and connect
steel wire ropes to the lifting rings;
Lift the cab slowly, and avoid severe cab shaking,

and damage to glass due to bump against the plat-
form or seat;
11-6
11.5 Removal of driver seat
11.4.2 Removal of control box
Insert bolts into the cab from the bottom, and put
down the cab after pulling up harness to avoid
11.5 Removal of driver seat
crushed harness or pipe.
Cab assembly installation: 11.5.1 Removal of seat
removal;
11.4.2 Removal of control box
Unscrew mounting bolts of driver seat;
Unscrew mounting bolts of control box; The control

box will be removed.
Control box installation:
removal;
Pass ropes through armrests, and check whether

ropes are reliable;
Take the seat away;
11-7
11.6 Removal of interior trim
11.5.1 Removal of seat
Notice: In the process of taking away, no persons Install nuts to the heater;
shall be in the range of 1 m from the driver seat or Driver seat installation:
below the driver seat, or they may be injured by fall- Assemble according to reverse steps of
ing driver seat; removal;
11.6 Removal of interior trim
Remove decorative caps from the dome decoration

as by a straight screwdriver, unscrew mounting
screws by a Philips screwdriver, and remove the
dome decoration as.
Removal of dome decoration as:
removal.
11-8
11.7 Convertible cab (optional)
11.5.1 Removal of seat
11.7 Convertible cab

(optional)
Convertible cab is optional for this type of machine.

4180 Service Manual

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4180 Service Manual

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Service Manual

Applicable type and model: CLG4180

Standard Thread Torque in Metric System

Standard Torque (N⚫m)

M10 52±7 72±6

M12 90±12 120±10

M14 145±20 195±15

M16 225±35 305±25

M18 310±45 415±35

M20 410±50 600±50

M22 600±80 800±70

M24 760±100 1020±100

M27 1100±150 1500±100

M30 1500±200 1850±150

M33 2050±300 2900±400

Standard Thread Torque in British System Pipe Thread in British System

Thread size Standard torque (N⚫m) Thread Torque of knurled nut

Metric Thread G1.1/4"X11 192-206

M14X1.5 20-35 JIC Thread in American System

M20X1.5 35-50 7/16"X20 15-16

M22X1.5 40-70 1/2"X20 19-21

M24X1.5 40-70 9/16"X18 24-28

M26X1.5 60-100 3/4"X16 49-53

M30X2.0 80-120 7/8"X14 77-85

M36X2.0 100-150 1.1/16"X12 107-119

M42X2.0 150-220 1.3/16"X12 127-140

M45X2.0 180-250 1.5/16"X12 147-154

M52X2.0 200-300 1.5/8"X12 172-181

Pipe Thread in British System 2.1/2"X12 332-350

Thread Torque of knurled nut

American Standard ORFS Thread

1.2 Unit conversion table

Name Unit Conversion Unit Conversion Ratio

Inch (in) Millimeter (mm) 25.4

Length Millimeter (mm) Inch (in) 0.03937

Foot (ft) Meter (m) 0.3048

Meter (m) Foot (ft) 3.28084

Liter (L) UK gallons (gal) 0.219969

Liter (L) US gallons (gal) 0.264172

Liter (L) cubic decimeter 1

Pound (lb) Kilogram (kg) 0.453592

Pound· inch (lbf ·in) N·mN⚫m 0.112985

Name Unit Conversion Unit Conversion Ratio

Pounds per square inch Bar (bar) 0.06895

Bar (bar) Pounds per square inch 14.5038

Pounds per square inch

Bar (bar) MPa 0.1

Pascals (Pa) Bar (bar) -5

UK gallons per minute

1.3 Use and main technical parameters of machine

1.3.1 Use and working environment requirements

1.3.2 Main technical parameters

1.3.2.1 Figure of overall dimensions

Figure of overall dimensions (optional: front blade）

Figure of overall dimensions (optional: rear ripper）

Figure of overall dimensions (optional: front blade and rear ripper）

1.3.2.2 Machine parameters

Main technical parameters

Front wheel kg 4650

Rear wheel kg 10850

Diesel engine Dongfeng Cummins 6BTAA5.9-C190

Rated power kw 142

Rated revolution speed rpm 2200

Number of cylinders In-line 6 cylinder