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SDLG LG6210E, Maintenance Manual

The SDLG LG6210E Maintenance Manual is essential for proper upkeep of your equipment. This comprehensive manual covers all necessary maintenance procedures to keep your SDLG LG6210E running smoothly. Download your free manual from the official website today for easy access to important maintenance information.

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Maintenance Manual

──LG6210E

 Hydraulic Excavator

 

V 

5.1 Overview ............................................................................................................................................ 142

 

Cooling System,instruction

 ............................................................................................................................... 142

 

Cooling system, operating

 ................................................................................................................................ 143

 

Coolant ............................................................................................................................................................ 143

 

Draining the cooling system ............................................................................................................................. 145

 

5.2 Radiator, including assembly and connection .............................................................................. 145

 

Coolant, replacing

 .............................................................................................................................................. 145

 

Draining the coolant ......................................................................................................................................... 145

 

Filling the coolant in the cooling system .......................................................................................................... 146

 

5.3 Coolant pumps; thermostat ............................................................................................................. 146

 

Thermostat, replacing

 ........................................................................................................................................ 146

 

Thermostat, checking

 ........................................................................................................................................ 147

 

5.4 Fan; fan cover; fan coupler .............................................................................................................. 148

 

Fan belt and / or generator belt, compressor belt, replace all belts

 .............................................................. 148

 

6

 

E

NGINE CONTROL

 ......................................................................................................................................... 150

 

6.1 Overview ............................................................................................................................................ 150

 

Normal conditions (auto position)

 .................................................................................................................... 150

 

Emergency ...................................................................................................................................................... 150

 

6.2 Speed control .................................................................................................................................... 151

 

Engine speed control switch description

 ......................................................................................................... 151

 

Engine speed control switch, checking

 ........................................................................................................... 151

 

Checking .......................................................................................................................................................... 151

 

Ⅳ

 POWER TRANSMISSION ............................................................................................................................ 152

 

1

 

G

EAR BOX

 .................................................................................................................................................... 152

 

1.1 Track gearbox ................................................................................................................................... 152

 

Track gearbox, instruction

 ................................................................................................................................ 152

 

Notes of track gearbox operation

 ..................................................................................................................... 155

 

Installation ....................................................................................................................................................... 155

 

Tightening torque ............................................................................................................................................. 156

 

Replacement procedure of gear oil .................................................................................................................. 156

 

Operation Checking ......................................................................................................................................... 157

 

Track gearbox, maintenance standards

 ........................................................................................................... 157

 

Seal washer ..................................................................................................................................................... 157

 

Components, replacement standard ................................................................................................................ 157

 

Common tools ................................................................................................................................................. 158

 

Special tools .................................................................................................................................................... 159

 

Gasket thickness measurement fixtures

 .......................................................................................................... 159

 

Track gear box, removing

 .................................................................................................................................. 159

 

Track gear box, installing

 .................................................................................................................................. 160

 

Track gear box, replacing the lid

 ...................................................................................................................... 161

 

Track gearbox removing

 .................................................................................................................................... 162

 

Track gear box, assembly

 .................................................................................................................................. 166

 

Preparation ...................................................................................................................................................... 166

 

Tightening torque ............................................................................................................................................. 166

 

Track gearbox, troubleshooting

 ........................................................................................................................ 172

 

1.2 Rotary g rotary pinion gear shaft ..................................................................................... 173

 

Rotary gear box, instruction

 .............................................................................................................................. 173

 

Model Code ..................................................................................................................................................... 173

 

Rotary gear boxes, cross sections ................................................................................................................... 174

 

Function ........................................................................................................................................................... 175

 

Operating ......................................................................................................................................................... 175

 

Turn gearbox, lubricating

 .................................................................................................................................. 176

 

Notes about lubrication .................................................................................................................................... 176

 

Maintenance standard of rotary gear box

 ........................................................................................................ 177

 

Seals................................................................................................................................................................ 177

 

Replacement standard of parts ........................................................................................................................ 177

 

General Tools .................................................................................................................................................. 179

 

Special tools .................................................................................................................................................... 180

 

Rotary gearbox, disassembling

 ........................................................................................................................ 184

 

Note ................................................................................................................................................................. 184

 

Disassembly .................................................................................................................................................... 184

 

Rotary gear box assembly

 ................................................................................................................................. 188

 

Note ................................................................................................................................................................. 188

 

Tightening torque ............................................................................................................................................. 188

 

Assembly ......................................................................................................................................................... 189

 

Troubleshooting of rotary gearbox

 ................................................................................................................... 195

 

2

 

H

YDROSTATIC DRIVE 

(H

YDRAULIC MOTOR

,

 INCLUDING THE OPERATING SYSTEM

)

 ............................................. 197

 

Summary of Contents for LG6210E

Page 1: ...LG6210E Maintenance Manual Shandong Lingong Construction Machinery Co Ltd...

Page 2: ...n the market The schematic diagram for E tool can be found in this manual All the lifting devices such as the belt sling and ratchet wheel shell must confirm to the appropriate national regulations re...

Page 3: ...16 Coolant specifications 17 Engine speed control switch specifications 17 Electrical system specifications 17 Engine control specifications 18 Gauge control unit I ECU specifications 19 Connecting pi...

Page 4: ...et arm cylinder specifications 49 Bucket cylinder specifications 50 3 TOOLS 51 NET 8940 00200 remote control valve connector replacement tools 51 NET 8940 00190 Moving motor guide pins 52 NET 8940 002...

Page 5: ...onditioning cleaning 87 Main filter of air conditioning replacing 88 Cab pre filter cleaning 89 Cab pre filter replacing 90 Lubrication refer to the lubrication chart 90 Rotary motor gear box changing...

Page 6: ...pipeline 123 Lubricating oil pump 124 Oil cooling tank 125 3 FUEL SYSTEM 126 3 1 Overview 126 Fuel system indication 126 Fuel flow system diagram 127 Fuel injection system indication 128 Oil supply pu...

Page 7: ...ightening torque 156 Replacement procedure of gear oil 156 Operation Checking 157 Track gearbox maintenance standards 157 Seal washer 157 Components replacement standard 157 Common tools 158 Special t...

Page 8: ...t lubrication 239 Maintenance and replacement standard of parts 239 Gasket 239 Replacement standards of parts 240 Cross safety valve pressure adjustment 241 General Tools 242 Special tool 242 Rotary m...

Page 9: ...wheel specification 284 Guiding wheel measuring 285 Measuring thread surface and flange wear 286 Guiding wheel dissembly or assembly tools 287 Guiding wheel dissembling 287 Guide wheel assembly 289 Fr...

Page 10: ...ator seat instructions 329 Operator seat tightening torque 330 Seat replacing 330 3 AIR CONDITIONING UNITS 331 3 1 Overview 331 Air conditioning unit specifications Refer to Overview 331 Air condition...

Page 11: ...working notes 374 Hydraulic system indication 374 Hydraulic schematic diagram 375 Hydraulic components description 376 1 2 Fuel tank pipeline hydraulic oil cooling filter ventilation device 378 1 2 1...

Page 12: ...pressure relief valve disassembly 432 Phase 2 throttle pressure relief valve description 433 Overload operation for selection 433 Anti cavitation operation 435 Stage 2 section adjustable gate valve 43...

Page 13: ...ntrol 484 Reducing function of oil flow 485 Increasing function of oil flow 486 Regulator full power control 486 Oil flow re set function 487 Regulator low angle low oil flow command priority function...

Page 14: ...embly and assembly 595 Maintenance capacity limit 597 5 3 Bucket arm with a linkage 597 Bucket arm specification 597 Bucket arm instruction 597 Bucket arm removing 599 Linkage instructions 600 Linkage...

Page 15: ...rview of Electrical System 688 Electrical system instruction 688 Special repair of electrical system maintenance overview 689 Electrical system work descriptions electronic components batteries 689 Sp...

Page 16: ...16 I ECU replace ECU 717 V ECU replace ECU 717 6 INSTRUMENT SENSOR WARNING AND INFORMATION SYSTEM 718 6 1 Transmitter monitoring system 718 Description of engine oil pressure sensor 718 Fuel level sen...

Page 17: ...CH15 754 SCH16 755 SCH17 758 SCH18 759 2 FUSE RELAY CIRCUIT CUT OFF 760 2 1 Fuse 760 Fuse instruction 760 Slow melt fuse instruction 761 Replacement process of fuse 762 Relay box specification 762 Res...

Page 18: ...s can be found in the manual All the lifting devices such as belts slings ratchet housing etc must comply with related national regulations for these devices If the lifting devices tool or operation m...

Page 19: ...ety belt properly l Wear the safety belts when doing all the operations Clothing and Personal Protective Items l Avoid wear loose clothing jewelry and loose long hair They can be caught on control lev...

Page 20: ...ilated areas l Keep oil and fuel in determined place and do not allow unauthorized people to enter Properly dispose of scrap liquid l Improper treatment method for the wasted liquid may cause environm...

Page 21: ...before starting work In addition there are special local regulations proper for the machine s maintenance of such operations and working in this environment Preparation Warn other people in the work s...

Page 22: ...the machine rolling Before starting work put the flat shovel stone crusher bucket or other work equipments to the ground If they can not be lowered we must insert a safety pin or blocks to prevent wo...

Page 23: ...dy stable l Never hold any control levers when getting on or off the machine l Never hold any tools or other items when climbing up and down the loader lift the tools needed using rope to the operatio...

Page 24: ...luid under pressure may penetrate the skin causing serious injury Release the pressure before disconnecting the hydraulic unit and the other pipes in order to avoid danger Before exerting pressure tig...

Page 25: ...rical system begins to work or remove the wire from pole l The main switch of battery is installed at the tools box at the right side of machine l When removing the components be careful not to damage...

Page 26: ...ne if the ground wire is connected wrong components such as electrial units or storing unit may be damaged Take the following measures when welding 1 Cut off the power with battery breaker 2 Cut off t...

Page 27: ...ly release the pressure and then slowly loosen the screw High pressure grease of chassis spring group may burst open which may bring you harm Be careful when opening the grease valve Do not loosen the...

Page 28: ...people get on the machine Before operating the machine clear the position of other people around the machine Always make the walking alarm in working condition When moving turning or operating machin...

Page 29: ...ydraulic pump 27 Control panel Forward 4 Operation lever 16 Track motor and gears 28 Cab 5 Operator seat 17 Radiator and fuel cooler 29 Bucket 6 Rotary gear circle 18 Main control valve 30 Linkage 7 R...

Page 30: ...1 96 0 19 3 92 0 39 M5 2 94 0 29 5 88 0 59 7 84 0 78 M6 4 90 0 49 9 8 0 98 13 72 1 37 M8 11 76 1 17 23 541 2 35 32 36 2 94 M10 22 55 2 25 48 05 4 9 63 74 6 86 M12 39 22 3 92 85 32 8 83 110 81 10 78 M...

Page 31: ...156 90 15 69 442 28 44 12 7 8 250 07 25 00 702 15 70 60 1 372 65 37 26 1048 33 104 93 1 1 8 530 54 53 05 1492 57 149 06 1 1 4 727 65 72 76 2048 61 204 95 1 3 4 968 89 96 88 2724 29 272 62 1 1 2 1257 2...

Page 32: ...torque Nm 1 8 9415 11012 24 51 1 96 1 4 9415 11022 49 03 4 90 3 8 9415 11032 73 54 4 90 1 2 9415 11042 107 87 9 80 3 4 9415 11052 176 52 9 80 1 9415 11062 205 94 19 61 Tightening torque of rotating nu...

Page 33: ...ecification Model BF4M2012C Brand DEUTV Model 4 stroke 4 cylinder Direct injection water cooling direct spraying diesel turbocharger Rated output rpm kW 2000 120 Max torque rpm N m 1500 671 Hole of cy...

Page 34: ...min Fuel tank Capacity L 350 Filter 60 Valve clearance specifications Table 8 Specification Engine model Inlet mm Outlet mm BF6M2012C 0 3 0 05 0 5 0 05 Fuel pressure specifications Table9 Specificati...

Page 35: ...Axle core model 1 CF Wave shape plates Radiator core volume W H D mm 735 320 4 145 4 Dry weight kg Air cooler Axle core model Core material Hose model Radiator core volume W H D mm 729 155 145 4 Dry...

Page 36: ...Maintenance Manual LG6210E Hydraulic Excavator 18 Engine control specifications Table14...

Page 37: ...MP 172888 2 House AMP 174655 2 Terminal AMP 171662 1 Wire sealing AMP 172888 2 Connecting pins specifications Table15 Gauge control unit I ECU connector specification No Specification No Specification...

Page 38: ...ttrouble joint E12 Engine camshaft speed signal grounding M12 J1939 H control bus E13 Engine camshaft speed sensor M13 J1939 H control bus E14 Adjustor M14 Shoottrouble joint E15 M15 No connection E16...

Page 39: ...16 Pin connector AMP 1 963215 1 Terminal AMP 929939 1 Wire sealing AMP 828904 1 Table19 Connector JA pin shaft specification No specifications No specifications 1 Engine starting key Acc 9 Fuse used f...

Page 40: ...2 power checking 4 39 Hammer pressure switch 5 40 Floating position pressure switch 6 41 Traveling pressure switch 7 42 Coolant level switch 8 43 Max model of power selecting switch 9 Manual auto swit...

Page 41: ...Solenoid valve signal of hydraulic hammer 56 Speed control grounding 22 Solenoid valve of flow cutting 57 No connecting 23 Strengthened Solenoid valve 58 24 No connecting 59 25 60 26 Close signal of...

Page 42: ...to Density of sour liquid at 27 C 81 F MIN 1 265 g ccm MAX1 300 g ccm AC generator specifications Table22 AC generator specifications Items Specifications Manufacuturer BOSCH Model and name NC B1 28V...

Page 43: ...or less Insulation resistance 1 M Security starting relay specifications Table25 Specifications Items Specifications Rated voltage DC 24V Operating temperature 40 85 C Wire resistance 275 10 Pulling...

Page 44: ...s Table29 Specifications without loading Items Specifications Starting torque 2 5kgNm Rated voltage DC24V n1 speed 34 3 rpm n 2 speed 52 5 rpm Current n1 speed 0 7A Current n2 speed 1 3A Cutting switc...

Page 45: ...ntal temperature 40 90 C Rated current 1500 rpm 10A 6000 rpm 35A Insulation resistance 100 M Contact resistance 100 M Connector AMP EJ Serial 2 RECEP Housing and Positive terminal 3 Manual auto switch...

Page 46: ...conditioner condenser F 8 15 A Air conditioner F 23 5 A Radio with CD player F 9 10 A Extra working lamp Back F 24 5 A Power outlet F 10 15 A Extra working lamp cab F 25 10 A X1 flow control valve F 1...

Page 47: ...NO R6 RE3502 Additional lights OPT Always closed NC R7 RE9104 Quick installation 1 OPT Always open NO R8 RE9105 Quick installation 2 OPT Always open NO Table 36 Specification Items specifications Rate...

Page 48: ...n Table 40 Specifications Items Specifications Input voltage DC 20 32V Output voltage DC 13 1V Output current Maximum 4A Operating temperature 30 70 Track gearbox specification Table 41 Specifications...

Page 49: ...tructed value Mpa 39 2 2 9 1 when 15 l min Pressure reducing Maintenance limit value 39 2 2 9 2 when 15 l min Parking brake type Wet brake disc application spring hydraulic release Oil flow imp 200 Ma...

Page 50: ...Rotation pressure of spool Map 0 44 0 098 Braking delay time s 5 3 0 Shell draining when pressure 26 5Mpa 90 l min 23 Engine pressure Map 0 3 Oil capacity Liter 0 8 Weight with valve kg 52 5 Frame and...

Page 51: ...ith internal gear Teeth EA 92 Weight kg 281 Outer diameter mm 1327 Height mm 110 Bearing Material SUJ 2 Outer ball diameter mm 31 75 Number of rollers EA 109 Fig 8 Rotary gear ring structure A injecti...

Page 52: ...12 Front window is closed 1505 Front window is open Width External mm 980 Internal mm 933 Height from the basic position of seat to the top mm 1117 Front window is closed 1010 Front window is open Dis...

Page 53: ...ment stroke S I P Forward ba ckward mm 80 80 Lower sliding rail adjustment stroke S I P Forward ba ckward mm 90 90 Attention S I P indicates the position of seat Recommended hydraulic oil specificatio...

Page 54: ...Please refer to Main control valve specifications Hydraulic tank specifications Table 52 Specifications Items Unit Specification Type Closed type Capacity L Hydraulic tank hydraulic oil level 160 All...

Page 55: ...ype SP10 or the same products Compressor clutch type electromagnetic Direction of rotation clockwise Rated voltage DC24V Power consumption 42w Belt type A Drier capacity cc 335 Safety devices Dual pre...

Page 56: ...kgf cm 50 Minimum pressure supply kgf cm Maximum control pressure 5 Allowed rear pressure kgf cm 10 10 Control pressure range kgf cm 0 40 0 35 Maximum flow L min 10 Hydraulic fluid Mineral hydraulic o...

Page 57: ...anging Choice 2 order pressure reducing valve AL2 Low 20 6 0 5 0 at 200l min _ High 35 8 1 5 1 at 28l min 35 8 1 5 2 at 28l min BL2 35 8 1 5 1 at 28l min 35 8 1 5 2 at 28l min Rotary motor switching v...

Page 58: ...ducing pressure on the machine will be different from the measure values on the test platform and the reasons are as follows Rear pressure Specially in the rotary pressure of pressure reducing Pressur...

Page 59: ...se pressure kgf cm Accumulator specifications Table 60 Specification Description Unit Specification Type of gas N2 Gas volume cc 320 Boost pressure of gas Mpa 1 47 0 1 Maximum operating pressure 4 4 4...

Page 60: ...ions Unit Specification Maximum operating pressure kgf cm 50 Maximum flow l min 16 Range of temperature 20 95 Normal voltage V DC28 Power source D28 Allowable Pressure DC20 30 8 Normal current A 1 0 a...

Page 61: ...Type hydraulic Operating angle Degree 19 throttle 1 3 25 throttle 2 4 Hydraulic oil Mineral hydraulic oil Engine oil temperature range 20 95 Weight kg 2 3 Remote control valve pedal specifications Tab...

Page 62: ...ems Unit Instruction Type Mineral hydraulic oil Operating angle Degree Backward 12 4 forward 12 4 Engine oil temperature range 20 90 Main operating pressure Mpa 3 2 0 2 Weight kg 3 2 Hydraulic oil coo...

Page 63: ...pressure loss when flow rate is 100lpm Mpa 0 07 Minimum cracking pressure of spool Mpa 0 69 Rotary oil pump specifications Table 66 Specification Items Unit Specification Model P315BB20FM1007L Type Fi...

Page 64: ...ication Maximum operating pressure kgf cm 350 Operating flow Lpm 50 Allowed regressive pressure kgf cm 210 Internal leakage at pressure 140 kgf cm and viscosity 20 cSt Cc min 70 Oil temperature 20 90...

Page 65: ...l flow Maximum oil flow l min Pressure loss kgf cm P1 A1 A1 T 16 5 maximum P2 A2 A2 T 1 2 5 maximum P2 A2 A2 T 1 2 5 maximum Leakage rate 50cc min Solenoid valve Rated voltage DC 28V Voltage fluctuati...

Page 66: ...ght kg 1890 Boom cylinder specifications Table 71 Specification Items Unit Specification Boom cylinder Quantity EA 2 Inner diameter live bar stroke mm 125 80 1235 Align the center distance of the pin...

Page 67: ...B 860 Width 440 Weight kg 1085 Bucket arm cylinder specifications Table 73 Specification Items Unit Specification Stick cylinder Quantity EA 2 Internal diameter live lever stroke mm 135 95 1540 Mat T...

Page 68: ...Specification Bucket cylinder Quantity EA 1 Internal diameter live lever stroke mm 120 80 1065 Make the center distance of the pin centered Fully retracted A mm 1655 2 Fully stretched B mm 2720 4 Mat...

Page 69: ...T 8940 00200 remote control valve connector replacement tools Items Quantity Name remarks 1 1 Socket wrench SAE 4130 QT 2 1 Baffle SAE 4130 QT Fig 17 Cylinder length A Retracted length B Stretched len...

Page 70: ...ns Items Quantity Name Remarks 1 2 Guide bar SAE 4130 25 35 HRC 2 2 Screw M8 16 NET 8940 00270 rotating ring replacement tool Items Quantity Name Remarks 1 2 Ring SAE 1045 QT 2 2 Rod SAE 1045 QT 3 2 S...

Page 71: ...pins of track motor Items Quantity Name Remarks 1 2 Guide bar SAE 4130 25 35 HRC 2 2 Screw M8 16 NET 8940 00300 Rotary gear alignment pins Items Quantity Name Remarks 1 2 Guide bar SAE 4130 25 35 HRC...

Page 72: ...structions Maintenance position Park the machine in a horizontal solid place The appropriate positions of machine are described in a variety of maintenance instructions Fig 23 Maintenance position A F...

Page 73: ...Maintenance Manual LG6210E Hydraulic Excavator 55 Fig 27 Maintenance position E Fig 28 Maintenance position F...

Page 74: ...ricating fuel other liquids 1 1 Overview Recommend lubricants Note 1 Recommended engine oil level VDS 3 or Global DHD 1 VDS 2 or ACEA E5 VDS 2 or API CH 4 VDS 2 Note is installed in the factory ASTM A...

Page 75: ...uel is needed to be filled in the tank during periodic inspection and maintenance Note When the sulfur percentage of fuel is below 0 3 fuel should be replaced every 500 hours If the sulfur percentage...

Page 76: ...for detailed information on coolant 2 Maintenance 2 1 Warranty services Guarantee View During the first test further examination of the machine is very important which is the reason to implement two g...

Page 77: ...ecking 4 Coolant level checking 5 Hydraulic oil level checking 6 Replace the fuel and filter of engine 7 Fuel filter replacing 8 Oil water separator filter element replacing 9 Fuel tank draining 10 Hy...

Page 78: ...machine to ensure safe operation Improper lubrication maintenance and operation of the machine will be dangerous which will cause casualties of you and other persons in present Note For more informat...

Page 79: ...level checking 4 Engine oil level checking 5 Coolant level checking 6 Hydraulic oil level checking 7 Additional fuel filter oil water separator core checking draining 8 Additional oil filter core chec...

Page 80: ...king 6 Replace the fuel and filter of engine 7 Fuel filter replacing 8 Filter element of oil water separator replacing 9 Fuel tank dust draining 10 Main filter element of air filter cleaning 11 Batter...

Page 81: ...oil draining filter replacing 17 Hydraulic oil absorbing mesh cleaning 18 Inlet gap checking adjusting 19 Main filter of air conditioning cleaning 20 Lubrication refer to the lubrication chart 21 Rot...

Page 82: ...18 Hydraulic oil absorbing mesh cleaning 19 Hydrauic tank replacing ventilation filter 20 Hydrauic tank replacing the oil 21 Inlet gap checking adjusting 22 Frozening point of coolant 23 Main filter o...

Page 83: ...hydraulic oil cooler 16 Hydraulic tank oil return filter replacing 17 Hydraulic oil draining filter replacing 18 Hydraulic oil absorbing mesh cleaning 19 Hydrauic tank replacing ventilation filter 20...

Page 84: ...ttery status checking 14 Seat belts and tension of seat belt checking replacing it if necessary 15 External radiator external hydraulic oil cooler 16 Hydraulic tank oil return filter replacing 17 Hydr...

Page 85: ...ash lamp 6 Wiper 7 Appliances 8 Speakers 9 Rear mirror 10 Stickers signs and mirrors 11 Warning system 12 Fuel tank hoses and pipes Check whether there are leakage gripping and scratches 13 Temperatur...

Page 86: ...oil level is low re fill the right amount of oil through the filler 2 Note Engine oil capacity 19 5 liters Coolant level checking 1 Open the engine hood 2 Check the coolant level in expansion tank Lev...

Page 87: ...add hydraulic oil Note Refilling capacity of hydraulic tank maintenance 160L Engine oil and filter replacing Tool 9996672 oil filter wrench Note Change the oil every 250 operating hours Draining Impor...

Page 88: ...turn by hands Filling oil 5 Fill the engine oil through the engine oil filler 6 Make the engine warm up check whether oil leaks 7 Check the oil level of the dipstick Figure 9 Engine oil filter replac...

Page 89: ...or on the machine 2 Check the water and sediment in oil water separator tank 2 3 Open the water draining valve 1 when necessary drain the water and sediment 4 Perform exhausting operation Refer to fue...

Page 90: ...ter by hand until the seal contacts tightly and then tighten a half circle 9 Tighten the filter tank by hand until the seal contacts tightly and then tighten a half circle 10 Perform exhausting operat...

Page 91: ...rvo filter replacing Note After 500 operating hours replace the servo hydraulic filter element and replace one time every 1000 operating hours 1 Turn the left side door on the machine 2 Put a containe...

Page 92: ...th new one 5 Install the main filter and air filter cover 6 Close the side door Main filter of air filter replacing Note After cleaning at most 5 times the main filter should be replaced or at least i...

Page 93: ...xiliary filter also being brought out from the main filter 4 Remove the safety filter element of air filter and clean the filter housing 5 Install a new security filter element and main filter 6 Close...

Page 94: ...ed in the battery electrolyte which is even more important in cold weather 6 Check whether the cable terminals and the electrode is clean fixed firmly or coated with Vaseline or similar product Belts...

Page 95: ...l radiator oil cooler outside cleaning WARNING Compress air Do not point directly to exposed skin Use protective equipment 1 Open the left door on the machine 2 Remove the screws 1 and open the radiat...

Page 96: ...c oil maintenance of the system requires to be very clean Even small impurities go into the system it will also cause damage and failure of system Before adding the new hydraulic oil into the hydrauli...

Page 97: ...O ring with hydraulic fluid 3 Install the new filter Hydraulic oil absorbing filter cleaning Note Clean once every 2000 hours to clean replace it if necessary 1 Release the residue pressure in the hyd...

Page 98: ...rubber cover 1 and nut 2 3 Remove the cover by rotating respirator cover 3 and remove the filter components 4 of respirator Installing 4 Install the new filter respirator respirators cover 3 nuts 2 an...

Page 99: ...ll impurities go into the system it will also cause damage and failure of system Before adding the new hydraulic oil into the hydraulic tank filler should be cleaned 1 Release the residue pressure in...

Page 100: ...ARNING Risk of burns stop diesel engine and let it cool then make the necessary operations 1 Park the machine in the maintenance position B Refer to maintenance position 2 Open the engine hood 3 Remov...

Page 101: ...ust be fully meshed with the gear of camshaft 9 Set the overlap angle of engine valve Rotate the crankshaft with the steering gear until it reaches the overlap angle of cylinder valve1 Valve overlap m...

Page 102: ...ractor on adjustment screws 3 Turn the adjustment screw until the gap between the rocker and the valve is zero Reset the protractor to zero 4 For the inlet valve rotate the adjustment screw counterclo...

Page 103: ...se O ring and gasket 13 After the maintenance work is completed start the engine check for leakage and operation state Coolant freezing point checking 1 Using a refractometer to measure the proportion...

Page 104: ...e After emptying the cooling system do not prevent freezing There may also be accumulated coolant within the system Note Use environmentally safe manner to deal with the waste oil fluid Filling the em...

Page 105: ...ng 1 Move driver s seat to the front position and fold the backrest forward front 2 Remove the screws and pre filter cover of cab 3 Remove the floor mats 4 Remove the five screws 1 and cover 2 5 Disco...

Page 106: ...te Note Be careful not to damage the components Note If the air filter is clogged airflow reduces and cooling and heating capacity will decrease Therefore clean regularly Main filter of air conditioni...

Page 107: ...filter with a new one Note Be careful not to damage the components Note If the air filter is clogged airflow reduces and cooling and heating capacity will decrease Therefore clean regularly Cab pre f...

Page 108: ...Remove the screws and pre filter cover of cab 3 Remove the filter and blow the filter with compressed air maximum pressure of 0 2 Mpa Note If the air filter is clogged airflow reduces and cooling and...

Page 109: ...r draining completely remove gear oil draining hose 2 and install the gear oil drain valve cover 1 5 Install the bottom cover and tighten to specified torque 6 Pull out the dipstick use a gear oil gea...

Page 110: ...the machine 2 Remove the lid 3 Check the grease level Note If the grease is contaminated or water is under discoloration grease should be replaced Cab door lid hinges fittings and locks lubricating 1...

Page 111: ...A are loose then the track plate is likely to be damaged 4 Check loosening Replace with new bolts and nuts if necessary tighten the bolts to the specified torque Note Tightening torque 833 5 49 Nm No...

Page 112: ...ack tension between the track plate in the center of track frame and the assembling surface of track bearing wheel 4 Adjust the track tension according to soil characteristics Recommended track tensio...

Page 113: ...position Rotate the gearbox until draining is at the bottom and plug and filling plug is located in the horizontal axis 2 Remove the two plugs on the end cap and drain the gear oil into a suitable co...

Page 114: ...s The purpose of this chapter is to explain how to evaluate the performance of various hydraulic excavators of our company Tolerance listed is used for new machines For a machine in use the requiremen...

Page 115: ...et arm cylinder Bucket cylinder is completely extended Bucket cylinder Fig 92 Measurement conditions bucket arm cylinder A B A Bending out B A B Bending inside Fig 91 Measurement conditions bucket arm...

Page 116: ...e 3 5 0 3 4 1 From fully retracted to fully extended Bending out 2 5 0 3 3 0 From fully extended to fully retracted Bucke t Bending inside 3 5 0 3 4 1 From fully retracted to fully extended Bending ou...

Page 117: ...cket cylinder is completely retracted Bucket cylinder is completely extended Measuring Full stroke operates rotary operation lever Measure the entire rotation of the upper body at a constant speed for...

Page 118: ...is under it directly Rotate the upper structure to make the angle between arm and boom as 180 Measuring Full stroke operates rotary operation lever and turn 180 When the two markers is aligned togethe...

Page 119: ...ating make sure all the screw mounting screws have been tightened Removal condition 1 Put the rotary gear on a flat surface and then put magnetic base on bearing sleeve every 120 2 Put three dial indi...

Page 120: ...ing sleeve of rotary gear to zero 5 Lower the excavator to the ground gradually keep the arm stretched out and raise the bucket to the height of cab floor Read that value on the dial indicator 6 Make...

Page 121: ...ge gap Total 2 Total 2 If the measured value between A and B are quite different it is most likely to be wrong and repeat the measurements several times Note The most important factors for rotary gear...

Page 122: ...avating device to the move gesture Measuring 1 Operate two travelling control lever with full stroke 2 Measuring the distance A between the machine track and the line 3 Repeat three times and get mean...

Page 123: ...31 3 34 35 Right 1 speed Left 18 3 20 1 21 Right 2 3 Emergence measures 2 3 1 Jump connection starting Start the engine with the actuating cable Check the following before connecting the actuating ca...

Page 124: ...ed with each others Important Ensure that the actuating cable is connected correctly Connect the actuating cable with the engine as far away from the battery After engine is started the actuating cabl...

Page 125: ...The engine is 4 stroke six cylinder turbocharged direct injection water cooled diesel engine equipped with inflatable cooling and wet replaceable cylinder The electronically controlled diesel engine...

Page 126: ...t throttle 5 Coolant exit To the radiator 6 Leaking gas pipe 7 Air inlet From the air filter 8 Turbocharger 9 Gas export 10 Exhaust manifold 11 Intake manifold 12 Air inlet From air cooler 13 Lug Fron...

Page 127: ...ger 6 Intake manifold 7 Exhaust manifold 8 Starter 9 Polyester belt 10 Oil pipe supply 11 Oil return pipe 12 Engine oil pan 13 Engine speed sensor 14 Fuel pressure retaining valve 15 Crankcase ventila...

Page 128: ...lever is not locked If the lock lever is not locked in a safe situation ensure that the machine will not be operated accidentally Purpose of the basic examination The purpose of the basic examination...

Page 129: ...symptoms Troubleshooting operation The first step in troubleshooting is to collect the information on the failure symptoms from the operator try to pinpoint the cause by examination in a certain order...

Page 130: ...n the ECUvalues 9 Software function Instruct the prerequisites of the ECU control and monitoring functions in the software 1 1 Cylinder head Cylinder cover indication BF6M2012CEngine Cylinder cover is...

Page 131: ...tion can easily turn the valve even under heavy load Lubrication rocker arm and oil circuit is a whole Oil supply can be done through lever Table 1 Angle of valve seat Import Exhaust 30 45 Decisive cy...

Page 132: ...projection will determine the thickness of gasket of the cylinder cover refer to table There are three different thickness of gasket which is identified by the hole 4 1 hole 1 2 mm 2 hole 1 3 mm Fig 6...

Page 133: ...r cover Tool 1 Install the cylinder cover to the crankcase sealing surfaces of cylinder cover gasket must be clean and without dust Note pin sets 2Coat the cylinder cover bolts with a thin layer of oi...

Page 134: ...s an asymmetrical cross section A The cross section of the second piston is tapered Install piston rings the mark TOP on the port must be up The third ring is an oil ring with beveled edges Piston rin...

Page 135: ...on and reduce emissions of hydrocarbons Valve is rotated by centrifugal movement The new flat tapered will make the valve rotate effortlessly under load Lubrication of rocker arm is part of the lubric...

Page 136: ...pen the engine hood 3 Remove the turbocharger inlet pipe 1 4 Remove the ventilation pipe 1 of crankcase 5 Remove the cable bracket 1 6 Remove the rocker cover 1 7 Turn the right side door on the machi...

Page 137: ...ate the crankshaft using the steering gear 1 until it reaches the overlap angle of cylinder valve Valve overlap means that the exhaust valve opens while the intake valve is open If the cylinder is fau...

Page 138: ...stment screw counterclockwise 90 For the exhaust valve rotate the adjustment screw counterclockwise 150 5 Hold the adjusting screw and tighten the lock nut Tightening torque refer to Engine tightening...

Page 139: ...1 5 Engine Assembly Engine Assembly Table 3 tightening torque unit kgf m No Installation location Tightening torque 1 Screws fan and flywheel side 70 7 2 Liner 3 Washer 4 Nut 5 Plate 6 Engine mountin...

Page 140: ...cooler 4 1 shut off valve pressure relief valve 4 2 oil cooler bypass valve 4 3 oil filter 4 4 Oil Pressure Sensor 5 main oil 6 crankcase bearings main bearings 7 linkage bearing 8 camshaft bearings 9...

Page 141: ...p 2 1 0 35 bar 4 Oil filter With bypass valve 5 5 Oil filter bypass valve Opening pressure p 2 5 0 3 bar 6 Main oil pressure limiting valve Opening pressure p 5 0 0 5 bar 7 Exhaust turbocharger Lubric...

Page 142: ...charger Lubrication of rocker is carried out by the lifters and pushrods Lubricating oil pump Rotary oil pump is installed inside the front cover Inner rotor 1 is fixed on the crankshaft driven by the...

Page 143: ...5 0 3 bar 3 Drain valve Loosen the filter cover one or two laps Oil in oil filter housing will be drained to oil span 4 Radiator bypass valve Protect the cooler to prevent high pressure point Opening...

Page 144: ...he stability of low pressure oil is important for power output of engine When the power of engine is not enough measure the pressure of low pressure oil controlled by the pressure control valve 10 The...

Page 145: ...mps to reach injector 5 through the pipelin The end of the supply tube fitted with a pressure valve 4 Fig 28 Fuel tube 1 Hand pump 2 Fuel tank 3 Pre filter 4 Check Valve 5 Inejector 6 Return hose of e...

Page 146: ...injection pressure can get to 1350 bar Which can get e a good emission values in line with European standards for Class II requirements Oil supply pump Oil supply pump is a rotary pump driven by the...

Page 147: ...ystem leakage 1 Park the machine in the maintenance position B refer to maintenance position 2 Use battery break to cut off the main power 3 Turn the main pump counterclockwise to make the plunger unl...

Page 148: ...ns stop diesel engine and let it cool then make the necessary operations 1 Open the hood and radiator cover 2 Remove the hose boost air cooler 3 Remove the screw 1 and fan protective pieces 4 Use a so...

Page 149: ...o fuel system oil leakage 10 Start the engine and check for leakage 11 Close the hood and radiator cover Fuel filter replacing Tool 9996671 oil filter wrench Fuel filter is clogged which may cause eng...

Page 150: ...t the cable connector 1 3 Loosen the drain valve 2 and drain the sediment from the oil water separator tank 3 4 Use an 9996671 oil filter wrench to loosen oil water separator tank 3 then remove it 5 U...

Page 151: ...just the gap A 10mm Tightening torque Level gauge 11 1 5 0 2 kgf m Screws 7 52 2 5 2 kgf m Emissions cock 4 1 6 1 9 kgf m Drain valve clamp 4 0 6 kgf m Flange screw 14 2 EA 6 5 0 7 kgf m Fig 39 Struct...

Page 152: ...vator 134 3 4 Injectors oil supply pipelines Injector indication Injection nozzle has 6 holes which is designed to provide a fixed standard of the injection surface shape regardless of the angle of in...

Page 153: ...rs on new injector Install injector and connecting yoke For the tightening torque refer to fuel system tightening torque 7 According to the fuel system exhaust the air in the system andrefer to the fu...

Page 154: ...e electronic control unit E ECU of engine 6 Stop the engine 7 Store the operation cards connect the cable of injector The engine is running but without load 8 Begin the testing of SIEDIA engine 9 Star...

Page 155: ...specifications Note Under the maintenance mode of instrument electronic control unit I ECU check the load of engine Note Engine speed 1900 rpm Note Move the bucket arm and bucket to its full stroke po...

Page 156: ...d for combustion is filtered by pre filter air filter then provide into the combustion chamber of engine through the air cooler To provide convenience to the operator blocking of the intake system wil...

Page 157: ...d and the muffler Seal clamp installing 1 Assemble the turbocharger side pipe into the side pipes of muffler side about 25 mm as shown 2 Insert the seal gasket matching with clamp into the clamp 3 Tig...

Page 158: ...the outlet pipes and hoses of boost air cooler 6 Close the hood 4 3 Inflatable cooler and connecting pipe Boost air cooler indication The function of the intercooler is to reduce the temperature of ai...

Page 159: ...all diesel engines Boost air cooler connections hoses rigid tube replacing WARNING Risk of burns stop diesel engine and let it cool then make the necessary operations 1 Open the hood 2 Remove the inle...

Page 160: ...diator frame As the fan rotates the air goes through the radiator oil cooler and inflatable cooler and then be absorbed into the engine Fig 54 Cooling devices 1 inlet of coolant 2 inlet of pressurized...

Page 161: ...maged in the condition of frozening cavitation and corrosion Coolant is prepared by adding antifreeze Fig 55 Cooling System 1 1 cooling fan 2 radiator 3 vent hose 4 outlet hose of coolant 5 thermostat...

Page 162: ...is not less than 40 of the total refer to the table Min frosting protection Percentage of coolant 25 C 13 F 40 35 C 31 F 50 46 C 51 F 60 Concentrated coolant VCS of SDLG can not contain a high percen...

Page 163: ...e container to collect the coolant Then tighten the screws again 5 2 Radiator including assembly and connection Coolant replacing WARNING Risk of burns stop diesel engine and let it cool then make the...

Page 164: ...Re adding volume of the cooling system is about 32 L Note Fill the coolant into 2 3 of the volume of the expansion tank 5 Start the engine run the operating temperature fill the coolant so that cooli...

Page 165: ...cylinder thermostat 1 6 Install a new thermostat with a new gasket 2 7 For installation its order is opposed to the order of dissambly 8 After completing the repair work start the engine and check fo...

Page 166: ...of liquid Note If the multimeter shows the continuity when the liquid temperature is between 107 113 C then it is normal to turn on off 5 4 Fan fan cover fan coupler Fan belt and or generator belt com...

Page 167: ...ting screws for 2 laps 5 Use the belt adjusting nut 3 to remove the compressor belt 1 Note Belt tension of adjuster is very strong Therefore after removing the belt pay attention to injury Fig 66 Fig...

Page 168: ...ressor 8 Install the fan protective pieces and the hose of boost air cooler 9 Close the engine hood and radiator cover 6 Engine control 6 1 Overview Normal conditions auto position Engine speed is con...

Page 169: ...witch can control engine speed and maximum horsepower according to the programs of each mode of VECU Engine speed control switch changes to voltage input of VECU according to the selected location shi...

Page 170: ...ruction Track gear box is made up of 2 order planetary gear devices which can turn the high speed of hydraulic motor to low speed high torque rotational force in the centre of sprocket teeth Fig 1 2 o...

Page 171: ...tor 153 Table 1 Direction of rotation E axis view Import Export Clockwise A B Counterclockwise rotation A Fig 2 Port connector 1 Gear oil level checking throttle PF 3 4 2 Gear oil filling and discharg...

Page 172: ...ousing 2 corner bearing 3 seal 4 shims 5 locator 6 screws 7 parallel pin 8 ring gear 9 coupler 10 No 2 planetary gear drive 11 No 2 bracket 12 No 2 planetary gear 13 No 2 needle bearing 14 thrust wash...

Page 173: ...number of teeth of secondary epicyclic gear Zr the number of teeth of ring gear Notes of track gearbox operation Installation Check that the mating surfaces are clean Check and confirm the motor gear...

Page 174: ...tial 250 hours Note Regardless of the operating hours gear oil is changed at least once a year Note Do not mix gear oil with different types and levels or brands Note Drain the gear oil when oil is no...

Page 175: ...earbox is high after running Use the thermometer to measure Never touch by hands to prevent burns Note In continuous operation the temperature of tank must be below 90 C Track gearbox maintenance stan...

Page 176: ...angle Ball roller or sleeve bearings is worn or erosed Rotating by hand is not smooth 3 Gasket Sliding surface is rusted or damaged O ring is distorted or damaged 15 25 2 off 1 off Pin is broken worn...

Page 177: ...er screws 2 and remove the cover 1 2 Remove the track 3 Put a piece of wood in the track and put the drum on the block next to lift the sprocket teeth away from track 4 Disconnect the hydraulic hoses...

Page 178: ...ox which will help to re install Track gear box installing Note Carefully check whether there are burrs mud and rust on the mating surfaces between chassis and gearbox 1 Entangle around the gear box w...

Page 179: ...e the cover on the track gear box cove 4 Remove the cover on the gear box cover 3 5 Install two screws to a new gearbox cover 6 Install the new cover on the track gearbox Note Before replacing the cov...

Page 180: ...lyze all failures Determine the most fundamental cause of the malfunction 2 Put the oil level throttle and oil drain throttle on the on the vertical axis Remove the plug 32 and empty the gear oil Tool...

Page 181: ...Remove thrust ring 17 Tools hug bolts M10 plastic hammer WARNING These parts are very heavy Pay attention to the appropriate safety notice Note Mark the matching signs for the gear 22 pins 25 and bra...

Page 182: ...priate safety 6 Remove No 2 planetary gears 10 from the main shaft 302 Dissemble the No 2 planetary gear drive devices Hit the spring pin 16 into No 2 pin 15 Remove thrust washer 14 2 planetary gear 1...

Page 183: ...ools hug bolts M12 plastic hammer 8 Remove the screws 6 retainer 5 and shim 4 Tools 19 mm socket wrench M12 Note Do not reuse the screws 9 Switch the lug bolts into the housing 1 then remove the entir...

Page 184: ...r box assembly Preparation Clean all parts with detergent and dry them with compressed air Reprocess the damaged parts and prepare all the components prior to assembly and replacement Coat the sliding...

Page 185: ...surface of seal 3 Adjustment method of washers Measure the bushing on the fixer 5 as shown in Fig Size B Install thickness measurement tool C inside the inner bearing gasket tighten the four screws 6...

Page 186: ...down Install the thrust washer 14 No 2 planetary gear 12 and needle roller bearings 13 to the No 2 bracket Insert No 2 pins 15 Tap the spring pin 16 into the No 2 bracket 11 of the pin hole then pin 1...

Page 187: ...tor shaft 8 No 1 planetary gear transmission Insert the thrust ring 17 into No 1 bracket 19 Install the assembled No 1 bracket to No 2 epicyclic gear 20 and install retaining ring 21 Install the thrus...

Page 188: ...chnology Note Check whether the No 1 planetary gears rotates smoothly WARNING These parts are very heavy Pay attention to the appropriate safety notes 9 Insert No 1 planetary gear 18 into the No 2 pla...

Page 189: ...n them to the specified torque Tools Ring bolts PT 1 2 L shaped wrench 10 mm M12 torque wrench plastic hammer Note Coat the mating surface of ring gear 8 with Loctite 5699 Note Coat the thread of scre...

Page 190: ...Floating seal is leaking O ring is distorted Sliding surface is worn Replace the floating sealing device Housing is leaking Cover is damaged Cracks or pin hole leaks Replace the cover Replace the hous...

Page 191: ...porting the drive shaft and ring gear containing planetary gear Model Code Abnormal operating sound Gear is damaged Replace the floating sealing device Abnormal operating temperature Bearing or gear i...

Page 192: ...14 seals 15 screw 16 bearing Fig 3 Rotary gear boxes cross sections 17 bearing 18 retaining ring 19 housing 20 ring gear 21 pin 22 screw 23 metal plate 24 screw 25 thrust ring 26 No 2 epicyclic gear 2...

Page 193: ...icyclic gear 37 No 1 planetary gear 30 No 1 pin 31 and the rack of No 1 bracket 29 In the same way the power is transferred to the output shaft 10 through the No 2 planetary gear 3 No 2 pin 5 and No 2...

Page 194: ...ermometer to check the temperature During continuous operation the temperature of housing must be below the ambient temperature 60 C Gear oil specifications Use the gear oil that equivalent to SAE 90...

Page 195: ...ver D Remove the oil level gauge A fill the gear box with a can that can exhaust the air of pipes Maintenance standard of rotary gear box All parts are machined precisely be careful to operate Store t...

Page 196: ...g surface of the needle roller bearings Some worn parts 3 4 No 2 planetary gear No 2 Pin assembly Wear on the outer diameter of bushing 25 Thrust ring Wear on the contact surface of shaft Diameter cle...

Page 197: ...ols No Explain Size Quantity 1 Wrench 17 19 mm 24 27 mm 1 1 2 Socket wrench 1 3 General wrench 10 mm 14 mm 1 1 4 Torque Wrench 3923 17652 Nm 11768 47072 Nm 1 1 5 Fixed ring clamp 35 42 90 1 6 Bearing...

Page 198: ...e 13 special tools No Explain Part Number Number 1 Bearing assembly fixtures 8920 00280 1 2 Bearing assembly fixtures 8932 00600 1 3 Oil seal assembly fixtures 8920 00550 1 4 Oil seal assembly guide f...

Page 199: ...the remaining pressure within the hydraulic pipelines the method is to press air respirator on the hydraulic tank Installed the vacuum pump on the hydraulic tank to maintain vacuum After disconnectin...

Page 200: ...gearbox housing is not easy to be removed 11 Enhance the rotary unit with the sling 1 and put is safely into the work plate 12 Remove the screws 2 enhance the rotary motor with a sling 1 and install i...

Page 201: ...e sealing surface of the upper structure with the seal compound and then install the rotary unit Note Coat the assembly screw 1 with Loctite 277 and tighten them according to the specified torque 15 F...

Page 202: ...together with the correct position in order to facilitate assembly Be careful not to mix the secondary components of parts namely planetary gear bearings gears and thrust washers Thoroughly clean all...

Page 203: ...ining ring 35 then the thrust washer 34 planetary gear 30 needle bearing 32 and thrust washer 33 Remove the thrust washer 27 Remove the spring pin 36 from the bracket 29 to remove the pin 31 Note Make...

Page 204: ...e bracket 2 Remove the planetary gear 3 and thrust washer 8 Note Make the mating marks on the gear 3 pins 5 and bracket 2 Note Do not mix gears thrust washers bushings and marketing components Note Do...

Page 205: ...cal bearing 16 and collar 11 from the shaft 10 with press tool Note If it is difficult to remove the spherical bearing 16 as shown in the figure use a bearing remover Note Be careful not to damage the...

Page 206: ...e position of oil level gauge and the pipeline is as shown Use torque wrench to tighten the mounting screws to the specified torque Clean all parts with detergent and dry them with compressed air Repr...

Page 207: ...the collar 11 and then install it to the shaft 10 Note Coat the O ring 13 with grease NLGI 2 2 Press the spherical bearing 16 down to the shaft 10 with press tool Note Heat the spherical bearings to...

Page 208: ...8 1 25 WARNING The parts are heavy When operating these components should take appropriate safety precautions 5 Install the oil seal protection A to the shaft gear 10 6 Install the cover assembly 12 t...

Page 209: ...ring 18 on the shaft 10 Note After assembling bearings and retaining ring check whether the tank 19 is rotated smoothly 10 No 2 planetary gear transmission device Insert the thrust washer 8 and the s...

Page 210: ...ing pin 9 Put the thrust washer 27 on the surface of bracket 29 Install the pin 31 on the thrust washer 33 including the bearing 32 gear 30 thrust washers 34 and retaining ring 35 A Pile Note Check th...

Page 211: ...ubber Support the tank 19 13 Transmission device of No 1 planetary gear and No 1epicyclic gear Install the first planetary gear assembly 28 to the ring gear 20 Install the retaining ring 38 into the e...

Page 212: ...Coat the thread of screw 22 with Loctite 277 Align the installation throttle of the drain pipe and plug holes in a straight line 15 Install the motor to the plate 23 and then install screws 24 Note Al...

Page 213: ...he thread of pipe and plug with PTFE tape or Loctite 577 Troubleshooting of rotary gearbox Table 24 Rotary gearbox troubleshooting Mating surface is leaking Mating surface is damaged Liquid washer is...

Page 214: ...output shaft O ring is distorted Replace the gear oil Abnormal operating sound Gear is damaged Replace the floating sealing device Abnormal operating temperature Bearing or gear is damaged Gear oil is...

Page 215: ...ves Back pressure valve is used to start smoothly and stop the travel motor It controls the traveling speed according to the oil output of pump by blocking or suppressing circuit of the travel motor t...

Page 216: ...B PF1 Oil supply oil return P1 P4 PT1 4 Pressure checking P5 PT 1 8 Oil supply of displacement conversion valve P PF 1 4 Release pressure of the brake D1 D2 PF 1 2 Draining Table 12 Direction of rotat...

Page 217: ...71 parallel pin 93 spring 101Release valve piston 102 well 103 holder 104 plug 105 shims 106 Spring 108 O ring 109 O ring 110 O ring 111 prop ring 117 prop ring 119 O ring 120 seals 201rear flange 223...

Page 218: ...will be divided two sub force F2 and F3 In the sub force the radial force F3 generates torque T F3 ri respectively relative to Y1 Y2 The total torque T F3 ri will be sent to the cylinder body 4 by th...

Page 219: ...irection Stopping or stopping to rotate Brake When oil flow from the main control valve is blocked the pressure of the throttle A will rapidly decrease When this happens the oil in the chamber b will...

Page 220: ...lve pressure reducing cycle will repeat Secondary control of release valve will stop the hydraulic motor smoothly Over speeding When the machine travels on the slope the machine s weight inertia tends...

Page 221: ...h the brake piston 12 to the right to connect the engagement piece 16 and the friction plate 15 on the main shaft 302 of gear box and the cylinder body 4 When the plates are squeezed together the form...

Page 222: ...ation of cylinder increases resulting in high speed low torque When moving at high speed the speed switches to low speed automatically When the load traction increases at high speed the oil pressure o...

Page 223: ...100 kgf mm2 or higher Pipeline system Before connecting the pipelines to the motor check and confirm there is no impurities in the throttle or the pipe Before starting clear the air in the lines and m...

Page 224: ...llowed value 2 Shaft The surface wear of contact framework seal 32 Wear of spline 3 Swash plate The sliding surface of piston sleeve 6 is damaged The sliding surface of piston sleeve 62 is damaged 4 C...

Page 225: ...base is damaged The gap relative to the piston 101 is too large 20 1 Rear flange Balance spool 223 or hole is damaged The gap between hole and the spool is too large Piston 281 or hole is damaged The...

Page 226: ...driver L 150 mm 1 9 Clamp plier Extending Retracting 1 10 Crane Lifting capacity 300kg 11 Ring bolts M16 PF 1 2 12 Desk press Working capacity 300kg 13 Compressed air Hose and nozzle Spraying force 3...

Page 227: ...machine parked in the maintenance position F refer to maintenance position 2 When the engine is running hydraulic pipe is under high pressure Stop the machine and drain the residual hydraulic pressure...

Page 228: ...t position in order to facilitate assembly Be careful not to mix the secondary components of parts namely planetary gear bearings gears and thrust washers Thoroughly clean all internal parts and housi...

Page 229: ...remove the shaft 2 5 Gearbox hydraulic motor shaft and oil seal Remove the valve piece 9 level pin 241 brake spring 13 and bearing 50 from rear flange 201 and the hydraulic motor Remove the O ring 32...

Page 230: ...ol 223 and the sliding surface of the flange 201 Because rear flange 201 and balance spool 223 is attributed to optional assembly type even if only one is damaged replace all of them 7 Check valve rem...

Page 231: ...e the plug 280 from rear flange 201 Remove the O ring 296 from the plug 280 Remove the piston 281 from rear flange 201 Note Be careful not to damage the piston bore Note Because rear flange 201 and pi...

Page 232: ...e plug 104 Remove the spring fixer 103 spring 106 and piston 101 from the casing 102 in order Remove the seal gasket 120 from the piston 101 Remove the well in the other side in the same way Note If o...

Page 233: ...emove O ring 35 39 from the piston 12 o Note Do not reuse O ring 35 39 after removal 12 Rotating group removing Put an oil pan under the main shaft 302 Note Due to the wear way the piston must be inst...

Page 234: ...gement piece 16 and the friction plate 15 installed on the outer surface of cylinder 4 Remove the piston assembly 5 piston sleeve 6 bearing plates 7 thrust ball 8 and needle 51 from the cylinder 4 13...

Page 235: ...leeve 62 from the main shaft 302 Note Rotary combination components must be replaced as a set Refer to parts catalog to find out more details 18 Remove seals 32 from the main shaft 302 19Cylinder body...

Page 236: ...ir reprocessing of damaged parts prior to assembly and all replacement parts are ready Apply gear oil with a clean slide parts bearings and gears Apply with clean motor oil hydraulic parts and compone...

Page 237: ...ool may lead to internal leakage and motor performance is dropped Install the O ring 236 Note Coat the O ring with grease Install the stopper 225 and spring 228 to the two plug 224 then tighten the pl...

Page 238: ...surface of spool is damaged the entire assembly must be replaced Install the O ring 296 into the plug 280 Note Coat the O ring with grease Tighten the plug 280 into the rear flange 201 to the required...

Page 239: ...ve kit Be careful to assemble correctly Use the same method to assemble the other side of the release valve 6 Seals 32 Install the seal gasket 32 into mounting holes of the main shaft 2 Note Coat the...

Page 240: ...earings with grease 10 Cylinder Put the cylinder body 4 on the desktop press machine Install the spring 14 and washers 11 into the cylinder 4 Note As shown in the figure insert the sharp edge of the w...

Page 241: ...nstall the swash plate 3 thrust ball 8 collar fixed plate 7 needle 51 cylinder 4 and piston assembly 5 6 to the shaft 2 Then install the elevator and make the shaft vertical Elevator A Part Number 893...

Page 242: ...ith a plastic hammer install the brake piston 12 to the main shaft 302 to prevent the piston distorted Note Coat the O ring 35 39 with grease 16 Install ball bearing 50 valve 9 level pin 241 and sprin...

Page 243: ...se the grease will be mistaken as oil leaks Note Rear flange 201 must be installed to make the parallel pins 342 and pin holes installed on the spindle 302 aligned 19 Tighten the screws 243 to the mai...

Page 244: ...relief valve is with low pressure Check other equipments except for the travel devices do not work Repair it if necessary Adjust the specification Safety solenoid valve fails Check the solenoid valve...

Page 245: ...aft is damaged Remove the scars with sandpaper Seal gasket leaks Cracking or pin hole leaks Sliding surface is damaged Replace seal assembly Replace seal assembly Tank leaks Cracking or pin hole leaks...

Page 246: ...ce rear motor assembly Setting of pressure limit valve is not balanced Adjust the pressure Replace the pressure limit valve Happen at low pressure Displacement of left right motor is different Flow le...

Page 247: ...low to high speed Solenoid valve fails High pressure shruttle valve fails Check whether the spool is normal Check repair or replace Servo hydraulic valve fails Adjust the specified pressure Dual spee...

Page 248: ...hat they can slide smoothly on the swash plate Valve plate 131 is attached to the cylinder surface by the mechanical force of spring 114 and hydraulic pressure acted on the bushing Install a mechanica...

Page 249: ...ump A B 1 5 16 12 UN 2B 19 1 300 Anti cavitation M 1 5 16 12 UN 2B 19 1 300 Pressure measurement PA PB 9 16 18 UNF 2B 12 7 1 48 Draining oil DB 3 4 16 UNF 2B 14 3 1 82 Brake releasing PG 9 16 18 UNF 2...

Page 250: ...hing plate305cover 443 roller bearing712 brake spring 051pressure relief valve 124 bottom plate 351spool 444 roller bearing742friction plate 051 1 O ring 131valve plate 355spring 451pin 743mating piec...

Page 251: ...ive shaft 6 Top dead point A is the starting point of high pressure rotary cycle at 180 the piston moves out of the cylinder hole slide to the next dead point throttle B along the swash plate and they...

Page 252: ...r pressure g Pg pressure reducing valve begins to open Then the pressure of valve chamber increases which leads to the movement of piston 302 and the spring 321 force also increases Pressure P of pres...

Page 253: ...is compressed pressure P of pressure reducing increases gradually until the piston 302 reaches the end of the adjustment plug Figure 4 When the piston 302 touches to the end of the adjustment plug 40...

Page 254: ...ng Figure 1 shows the damping valve is in neutral position relative to the normal rotation Figure 2 shows the valve operating conditions of brake pressure is at throttle A Oil of throttle A flows from...

Page 255: ...essure decreases Y point in Figure 4 When the pressure P is less than the force Ps of spring 321 spool 311 moves to the right and then spring 322 starts to move the base 311 to the right but the respo...

Page 256: ...ion plate 742 is connected to cylinder 111 by the spline and rotate with it together the cylinder is connected with shaft 101 by spline Engagement piece 743 is fixed into the curved slot of motor hous...

Page 257: ...eaks Check whether the direction of rotation is correct according to manipulation of the handle Check whether there is abnormal sound or vibration during rotation After operating in a short time check...

Page 258: ...in the range of values Table51 Items Standard size Recommended replacement value Remedy Gap between piston and cylinder hole D d 0 027 0 052 Replace piston and or cylinder Gap between piston and track...

Page 259: ...ess level If the sliding surface of the cylinder block valves spherical bushing or fixed plate becomes rough replace these parts as a secondary component Cross safety valve pressure adjustment Remove...

Page 260: ...59282 1 Rotary motor replace Pressure relief valve of travel motor replacing 1 Park the machine parked in the maintenance position C refer to maintenance position 2 When the engine is running hydrauli...

Page 261: ...y motor housing with hydraulic oil 10 Elimination remaining sealing mixture on the rotary gear box 1 Coat the surface of rotary gear with sealing compound 2 11 Install the rotary motor 12 Install the...

Page 262: ...leakage Rotary motor has been removed replacing the seals 1 Remove the locating ring 1 2 2 Remove the cover 1 from the rotary motor 3 Remove the shell from the rotary motor 4 Install a new seal 1 to...

Page 263: ...n switch ON and operate the operation lever smoothly 3 to 4 times Drain the residual hydraulic pressure within the pipeline the method is to press air respirator on the hydraulic tank Install the vacu...

Page 264: ...der on the plate 2 10 As shown in figure install the special tools 1 to the brake piston 2 and then tighten the screw 3 to the housing Tighten the screws on special tool 1 to pull the brake piston 2 v...

Page 265: ...intenance position 2 When the engine is running hydraulic pipe is under high pressure Stop the machine and drain the residual hydraulic pressure within the pipeline the method is turn the ignition swi...

Page 266: ...n the components in order to instruct the correct position when installing Note Put the removed components in a clean area to prevent to damage them 4 Removing the pressure reducing valve 051 from the...

Page 267: ...special tool Tool part number 14559282 Note Use special tools to vertically pull out the brake piston 702 9 Place the motor with side part down the side as shown in the figure Remove the rotation grou...

Page 268: ...he roller bearing 443 Note Be careful not to damage the sliding surface of the shaft If the bearings have been removed re install with a new bearing 14 Remove the bearing 443 from the housing 301 with...

Page 269: ...ect all exposed sealing surface and external shrinkage hole from damage and contamination We strongly recommend that all fuel seals and O rings are replaced Before installation lubricate all the seals...

Page 270: ...the housing 301 Note Be careful not to damage the oil seal lip 5 Insert the bearing 443 into housing 301 6 Insert the bearing 101 into housing 301 Note Be careful not to damage the oil seal lip 7 Ins...

Page 271: ...ly into the cylinder 111 Install the rotation group in the housing 301 10 Put the motor at a vertical position the bearing shell faces down First insert an mating piece 743 then insert a friction plat...

Page 272: ...all the spring 712 in the brake piston 702 in 14 Use a hammer and steel rod to install the bearing 444 in the valve box 303 Note Use a hammer and steel rod to hit edges of the bearing evenly until it...

Page 273: ...03 and install the the plug 469 of O ring 488 in the valve box 303 Note Check the spool 351 to ensure that it can move smoothly 18 Put the O ring placed on the pressure reducing valve 051 and install...

Page 274: ...h the precision machining be fully careful not to damage them Note When assembling it is recommended to replace new O rings and oil seals Motor troubleshooting It is extremely difficult to find the fa...

Page 275: ...ve the spool 3 Check the base if it is damaged replace it Pressure increases 1 Overload 2 Moving parts will be stuck 3 Fuel pressure is released without brakes 4 Brake piston is stuck 5 Spool is stuck...

Page 276: ...ugh 1 A friction plate is damaged 2 Brake piston is stuck 3 Brake releases the pressure and can not be cut off 4 Spline of friction plate is damaged 1 Disassemble it and check Replace it if wear is ov...

Page 277: ...n of sealing lips shaft repair or replace parts 3 If the draining pipes is blocked remove it 4 Disassemble and repair it Hydraulic is leak from the mating surface Table72 Troubleshooting Fault Reason...

Page 278: ...r engine power to the hydraulic pumpm and buffer rotational vibration Engine torque is transferred to the connection ring connecting to the engine flywheel Gear rack of flexible coupling Shaft of hydr...

Page 279: ...oupling installation Note Note that do not let the dust and impurity enter around the flexible coupling assembly 1 After inserting the spring pin install flexible coupling assembly to the flywheel 11...

Page 280: ...ch is sent to the central channel and go on left or right motor through CD or HF valve to drive motor Discharged oil goes back to storage tank through the throttle valve G while high speed track contr...

Page 281: ...ts assembly Table 76 Tightening torque unit kgf m Specification Torque Specification Torque Specification Torque A Clearance 15mm E Axis L Upper frame B Blocking device F Screw J Screw 26 7 2 7 C Nut...

Page 282: ...its shape as screwdriver 6 Spatula A Made with saw blade made of the cutting tools B About 120 mm C PVC insulation tape D Completely remove the edge 7 Vise It can adjusted to the vise more than 150mm...

Page 283: ...5 Special tools Dry bearing assembler Table 78 Special tools Unit mm A B C D O N M L Components NO 129 104 100 30Thru 25 33 45 103 8920 01520 Plug dimension and tightening torque Table 79 Tightening t...

Page 284: ...e ON position and smoothly operation lever 3 to 4 times Note Drain the residual pressure within the hydraulic lines the method is based on air respirator of the hydraulic tank Note After disconnecting...

Page 285: ...The method is that turn the ignition switch on the ON position and smoothly operation lever 3 to 4 times 3 Remove the screw 1 and motor cover 2 4 Remove the high pressure hose bottle valve 1 of motor...

Page 286: ...tle valve 3 Remove the hydraulic pipe connected to the shaft of rotary joint and block every hose and the throttle valve 4 Remove the fixed screws of rotary joints shaft 5 Turn the ring bolts on the c...

Page 287: ...2 and axis 1 13 Remove the O ring 6 from the shaft 1 14 Remove the bushing mounted on the axis with assembly and disassembly device Replace it only when necessary Be careful not to damage the bushing...

Page 288: ...a cleaning solvent thoroughly and use compressed air to clean channel Polish scratches with fine sandpaper or fine cloth Note In particular prevent dirt and external objects enter the seal groove of...

Page 289: ...ulic oil 7 Install axis to braker then operate the press tool slowly and insert the shaft 8 Mount the shaft with press tool Remove it before the interference in horizonal supporting it Note Axis and t...

Page 290: ...and axis mounting fixture 2 Check shaft axis and rotation torque X Starting Torque 25 kgf m Rotary Torque 20 kgf m 13 Connect adaptor 3 with each brottle valve to test the internal external leakage Pr...

Page 291: ...Find any oil leakage and replace it 4000h In principle no matter how the appearance of conditions is disassembly and examination must be carried out All the seals Replace all the seals such as square...

Page 292: ...in this case oil leakage will occur The wear depth of sealing contact surface is more than 0 1mm A 0 1mm Shaft Outer surface is not damaged or worn The new shaft is 1 5s when the outer surface is made...

Page 293: ...ure throttle valve Discharge throttle valve recirculating throttle valve etc Similar to high pressure throttle valve Install the change over valve and pressure gauge to the shaft throttle valve and ax...

Page 294: ...of swing joints circuit has defective Check the circuit between the pump and valves repair or replace them Check pumps valves and the central channel with the pressure gauge Check the leakage between...

Page 295: ...e upper structure with screws while sleeve of inner bearing sleeve with inner gear is mounted on the chassis with screws Rotate the drive gear and the inner bearing sleeve to mesh together to drive th...

Page 296: ...replacing 1 Park the machine in maintenance position B refer to maintenance position 2 Remove the screws 2 and release the nuts 1 3 Remove the grease pipe of ring gear 3 Remove the reverse order to i...

Page 297: ...he pipe part 3 Remove the screw A of the mounting sleeve bearing of outer rotation ring 4 Removing the cab counterweight and protective devices Tie the upper structure with a rope and use a crane to l...

Page 298: ...ompare the excavator lifting capacity table in the Operation Maintenance Manual If you have questions please contact your regional distributor for advice Additional weight can be installed according t...

Page 299: ...the system 1 Put the vehicle on a flat solid ground without no obstructions or interference Put the working device on the ground 2 Make sure the security locking lever is fixed firmly on the locking p...

Page 300: ...ture chassis 1 Underframe 4 Track pin 7 Supporting wheels 2 Guide sprocket wheel 5 Springs 8 Chain wheel 3 Supporting sprocket 6 Track protection devices 9 Track plates A 27 3 D 27 3 G 27 3 38 3 8 B 7...

Page 301: ...lling slowly when the ground is uneven or there are many obstacles on the ground 600mm3 teeth track plate 600mm3 teeth track plate HD 700mm3 teeth track plate 800mm3 teeth track plate B Soft ground On...

Page 302: ...0E Hydraulic Excavator 284 2 1 Front idle control including the front fork Guiding wheel specification Fig 10 structure guide wheel 1 Guiding wheel 6 O ring 2 Shaft 7 Pin 3 Support 8 Plug 4 Bushing 9...

Page 303: ...Maintenance Manual LG6210E Hydraulic Excavator 285 Guiding wheel measuring Fig11 Measure the wear of guiding wheel...

Page 304: ...30 0 33 0 44 1 5 7 Clearence between guiding wheel and bushing 78 0 15 0 12 0 03 0 0 09 0 15 Replace bushing Measuring thread surface and flange wear Tread surface 1 Clean the thread surface a of guid...

Page 305: ...ixture e Sleeve disassembler fixture f Guiding wheel supporting fixture g Shaft pressing fixture h Sleeve disassembler fixture i Engine fuel SAE 10W 30 j Hammer k PTFE tape 1 roll Guiding wheel dissem...

Page 306: ...ing 4 and then push the sleeve out with fixture 6 Remove the seal ring 5 and O ring 6 respectively from the guide wheel 1 and support 3 7 Remove O ring 9 from the shaft 2 8 Confirm the the sealing sur...

Page 307: ...heel 1 Coat the contact surface of seal ring 5 with a layer of engine fuel 6 Install the support 3 and sealing ring 5 and O ring 6 7 Insert the pin 7 with a hammer k 8 Before filling the oil carry out...

Page 308: ...tool Warning Work includes heavy parts if you do not concentrate it can cause serious injury 1 Removing the track Refer to Ttrack chain assembly removing 2 Push the guide wheel assembly out of track...

Page 309: ...ith Loctite liquid 277 Note Confirm the protrusion of piston side of track tension spring is in the track hole 6 Install track Refer to the track chain assembly installing 2 2 Sprocket teeth Sprocket...

Page 310: ...get the average 4 If the measured value A is beyond the wear limitation replace the sprocket Sprocket replacement Tool 14 290 046 Track pin shaft press tool Warning Work includes heavy parts if you do...

Page 311: ...n moving it backwards stop the track 3 Measure the tension A of track between track plates and the mounting surface of roller in the track frame center track Warning Track adjusting cylinder contains...

Page 312: ...Adjust the tension of workplace track Item Distance A Common soil 320 340 Ground with stones 300 320 Soft ground Swamp soil 340 360t Track chain specification Track chain Track chain wear limitation...

Page 313: ...ction and bushing Standard dimension Allowed deviation Clearence Replace large bushing Crankshaft Hole Standard dimension Repair limitation 59 0 1 0 0 16 0 23 0 16 0 33 0 1 6 Clearence between connect...

Page 314: ...in from the three connections of main pin 2 measure dimensions of four connections 1 Tools Tape measuring tool 3 Measure 2 times and get the average Measure the left and right by turns Tools Tape meas...

Page 315: ...e the height of connection 2 in the center of connection 2 3 D1 and D2 in the direction of measurement measured two dimensions D1 and D2 between the 4 Measure in the direction of D1 and D2 measure sma...

Page 316: ...ean connections 2 Measure the gap 4 between inner connection 2 and external connection 3 t with a thickness gauge 1 3 Measure 2 times and get the average Measure the left and right by turns 4 If the m...

Page 317: ...sting track tension or releasing the trackbe careful especially Keep face hands and body away from the nozzle and valve Do not loosen the valve more than 1 lap If you release more than 2 rings valves...

Page 318: ...steel plate Track chain installing Tool 1 As an assistant start the machine at the same time insert a stick in the main pin hole on the end of the track and to help track align with the sprockets Not...

Page 319: ...2 5 Insert the main pins 6 into the aligned holes 16 8 with a hydraulic press tool A 6 Assemble the remove track plates Tightening torque 833 49 N m Note Before installing the bolts of track plate mak...

Page 320: ...ce the degree of track tension Put a wooden plate under the gease mouth to receive the discharged grease After releasing the track then tighten the grease mouth Note Do not release the valve more than...

Page 321: ...press tools Press the main pin Warning Do not close to the guide wheels track components may hit your feet 7 Lift underframe track with mining equipment rotate tracks and remove track chain assembly T...

Page 322: ...insert a steel bar into main pin hole of track terminals Guide the track until the main pin holes is close to the guiding wheel 4 Slowly run the track and then place a wooden block under the track Not...

Page 323: ...mbly removing Tool 14290046 Track pin press tool Warning Work includes heavy parts if you do not concentrate it can cause serious injury 1 Put the machine in service position F where there is enough s...

Page 324: ...ng rail Description of the top roller Supporting sprocket measuring Fig 67 Structure supporting sprocket 1 Roller shell 9 Locking plate 2 Cramshaft 10 O ring 3 Cover 11Plug 4 Bushing 12Screw 5 Bushing...

Page 325: ...learence between roller and bushing 63 0 150 0 120 0 030 0 0 09 0 15 0 Replace bushing 6 Tightening torque to install the bolts M10 265 29 Nm Measure the wear of outside diameter of supporting sprocke...

Page 326: ...lace supporting sprocket Top rollers dissembly and assembly tools Table 11 Tools unit mm Symbol Tools Note a Screw driver b Forceps c Forceps d Press tool 20t e Wrench f Top roller supporting fixture...

Page 327: ...e sealing surface is not damaged or rusty Make sure the wear rollers are in the allowable range Make sure the wear of shaft and bushing is in the allowable range Confirm the interference between the b...

Page 328: ...plate 9 Tighten the mounting screws 12 to the specified torque and bend the lock plate 9 7 Install the O ring 10 to cover 3 8 Insert cover 3 into the roller housing 1 In this case be careful not to d...

Page 329: ...re than 1 lap If you release more than 2 laps the valves and grease may be ejected under the action vigorously 3 Use of mining equipment to enhance the track away off top roller Increase the tension o...

Page 330: ...Measure the tension of track Measure the maximum sagging Table12 Adjust the tension of workplace track unit mm Item Distance A Common soil 320 340 Ground with stones 300 320 Soft ground Swamp soil 340...

Page 331: ...ace 2 Outside diameter of thread 160 144 3 Flange width 20 5 13 5 4 Clearence between shaft and bearing Standard dimension Allowed deviation Clearence Replace bushing Crankshaft Hole Standard dimensio...

Page 332: ...ng wheel 2 Measure the wear of flange width of 1 of bearing wheel with caliper 2 3 Measure both left and right side by turns If the measured value exceeds the wear limitation repair or replace support...

Page 333: ...the holes of chassis and bottom roller 1 and tighten them the screws temporarily Note If there is any unusual circumstances such as feeling that screws has too much resistance remove the screws and c...

Page 334: ...eeve disassembler fixture f Shaft pressing out fixture g Sleeve disassembler fixture h Rough grease 3 10 kgf m i PTFE tape 1 roll j Lubricant ISO VG 220 n General tools 6mm s Oil capacity 500mL Roller...

Page 335: ...ool b 4 Remove seals 2 and O ring 3 from the collar 1 5 Remove seals 2 and O ring 3 fromr roller housing 4 6 Put the roller 4 on support block d put the fixtures of sleeve assembly and disassembly dev...

Page 336: ...stall the O ring 8 and gasket 7 to the side of shaft 3 Coat the inside part of collar 1 with a layer of thin grease and insert the shaft 6 And don t damage O ring 4 Install O ring 3 and sealing ring 2...

Page 337: ...ssure is between 2 3 kgf cm2 air bubbles will not produce within 15 seconds 11 Fill the lubricant j through the plug hole of bushing 1 After filling install plugs with PTFE tape 9 and tighten them use...

Page 338: ...valves and grease may be ejected under the action vigorously 3 Remove the top roller screws on the supporing frame of top rollers 4 Enhance the underframe track away from the ground with excavation eq...

Page 339: ...d with stones 300 320 Soft ground Swamp soil 340 360t 2 7 Spring kit tensioning device Spring group description Fig 107 Structure spring group 1 Cylinder body 7 Washer 13Spring washer 2 Spring 8 Prop...

Page 340: ...er 1 in order Warning Use security special tools When compressing by press tool or releasing spring be careful not to slide the spring 3 Prepare press with more than 25 tons energy 4 Compress spring 2...

Page 341: ...ylinder 1 Align the screw hole of moving rod 17 and cylinder 1 and tighten the screws 16 2 Put the spring 2 and yoke 5 on the cylinder 1 that has been installed with the rod 17 and piston 3 slowly com...

Page 342: ...ate 10 and screw 11 to the cylinder 3 Tightening torque Grease valve 7 0 25 kgf m Track tension spring Tensioner assembly replacing Tool 14 290 046 Track pin shaft press tool Warning Work includes hea...

Page 343: ...nsion of track Replace guide wheel unit and install the entire assembly Tightening torque of screw connection 265 29 Nm Note When installing the connection screws please coat the screw thread with Loc...

Page 344: ...torage tank 4 Slightly lift the cab after making sure the security of surrounding and then move and lift it Note Cab Weight Approximately 335 kg Cab installing 1 Connect cable to the hook of the cab a...

Page 345: ...op or they are subjected to external influences and silicone oil may leak out which may reduce its performance Note External part of fiber plastic devices is natural rubber which has low anti oil powe...

Page 346: ...difference of plastic fiber device 5 must be within 1 mm 0 04 in 3 Tighten the lock nut 6 to the specified torque Tightening torque 26 7 2 7 kgf m 4 Install floor washers Note If the external tempera...

Page 347: ...ator seat 1 Level adjustment knob 10 Pillow A Backrest tilt angle adjustment 2 Backrest tilt angle adjustment knob 11 Backrest B Vertical line 3 Height of console adjustment 13 Handrail D Pillow tilt...

Page 348: ...ustment handle move the operator seat torwards left 4 Loosen the mounting bolts of front of the operator seat 5 Disconnect the sliding cable under the operator seat Adjustable lumbar support Fig 3 Ope...

Page 349: ...to Overview Air conditioning unit instruction Air cooled and heated model This advanced integrated air conditioning system consists of heating and cooling system installed in the same unit which is de...

Page 350: ...ivalent to the excessive heat This is achieved by boiling which means that part of the water is converted to steam Steam get away excess water with heat However the boiling point of water is too high...

Page 351: ...cab air through the evaporator where the heat will be delivered to the refrigerant Compressor pump presses refrigerant to the condenser where heat is exhausted outside by in the engine radiator fan or...

Page 352: ...liquid according to changes of temperature and pressure the cooling process continues for a long time Figure 8 Component location A Ambient temperature sensor D Air conditioner control switch I Conde...

Page 353: ...the indoor air circulate outdoor and indoor air which is transmitted sent to the cab The speed to exhaust air flow is adjusted by the motor speed 3 Relay Fig 9 Refrigerant process 1 Air conditioning...

Page 354: ...emperature sensor is installed in right side of the driver s seat Sensors control the opening and closing angle of valve the speed of the blower motor and set temperature of compressor by perceiving t...

Page 355: ...convert heat to the outdoor air and is located next to the engine radiator to blowe air by radiator fan 16 Bidirectional switch Bidirectional switch is installed in the high pressure pipe on top of T...

Page 356: ...conditioning switch Automatic air conditioning switch Fig 10 Air switch A Positive B Back 1 Display window 6 Indoor outdoor selecting switch 2 Temperature and items selecting switch 7 Fan speed selec...

Page 357: ...Signal 8 Fan speed 1 Shift 8 8 Water temperature sensor 9 Lightening 9 Face closing 9 Inner temperature of cab sensor 10 Grounding 10 Face starting1 2 10 Driver of air mixture valve Hot air 11 Battery...

Page 358: ...m checking Fault reason 1 E1 Car inner temperature sensor Abnormal input 2 E2 Ambient temperature sensor Abnormal input 3 E3 Driver of air mixture valve Abnormal input 4 E4 Water temperature sensor Ab...

Page 359: ...tch When the power switch is the ON this switch is used to convert the compressor ON OFF switch Auto model of the switch is automatically located in ON or OFF position 5 Air flow selecting switch This...

Page 360: ...compressor operation and all throttle control functions are automatic based on system conditions In manual mode the blower fan speed and air mixing door is controlled by a separate switch Fig 11 Auto...

Page 361: ...ng Air mixture throttle control Automatic mode Air mixture throttle adjusts the opening closing angle according to system conditions Ambient temperature indoor and outdoor temperature etc Blower fan s...

Page 362: ...indoor temperature and setting temperature Gas inlet control Table 5 Manual mode Indoor Outdoor Indoor circulation 90 10 Outdoor air 50 50 Automatic mode Heating mode Outdoor air is flowing inside Co...

Page 363: ...t code for the operator through the display window Status display model of air conditioning system is divided into operator mode and maintenance mode Press the troubleshooting switch more than 5 secon...

Page 364: ...ir Note Item 4 to 9 are shown in the maintenance mode Emergency mode If air conditioning system detects any errors the system will switch to emergency mode Note The control function of emergency mode...

Page 365: ...ue to the high temperature transfering from the rod 14 to the separator 1 Sphere 6 is pushed down by rod 14 the refrigerant of valve flows to valve B through the hole E When refrigerant temperature is...

Page 366: ...porator 3 Connecting to the evaporator 4 From the evaporator 5 Extension valve Compressor Compressor instruction Compressor is the main working components of air conditioning unit which acts as pump i...

Page 367: ...mission shaft is in the front plate Seal device composes by the O ring seal chip of seal lip and graphite gasket Fuel plug is on the top of the compressor Note When the system is filled with refrigera...

Page 368: ...acity Therefore it is important that air can not be blocked and there is no impurity on condenser chips Dry Filter Dry cleaner instructions Drier Dryer is installed in the outlet of condenser and inle...

Page 369: ...em from excessive pressure and temperature It will be released at or above 105 C 221 F or pressure 35 kgf cm2 Depending on the mirror is installed to check the status of the refrigerant flow Mirror is...

Page 370: ...move the protective plug install new O ring to the hose 5 Remove the protection plug on the receiver dryer Coat all the O rings with the oil and connect the hose Tightening torque 20 N m 6 Fill the sy...

Page 371: ...on Counterclosewise Current A 1 0 0 8 5 4 Speed rpm 4200 3800 Ceramic resistor It adjusts the fan speed of blower motor according to resistance value Rate voltage DC24V Operation temperature 30 80 C 2...

Page 372: ...pecification Rate voltage DC24V Loading of lamp 150W Loading of resistor 12 5A Loading of motor 12 5A Operation temperature 30 90 C 22 194 F Fig 24 Ceramic resistor View A View B Circuit diagram A Ter...

Page 373: ...24V Operation temperature 40 80 C 40 176 F Rated loading 1 5 kgf cm Rated current Original 0 1A Working time Original 2 5 1s Operation torque DC24V Original 6 kgf cm Locking current Original 0 55 Stop...

Page 374: ...cm Rated current Rated 0 1A Working time Rated 90 2 5 1s Operation torque DC24V DC24V 6 kgf cm Locking current Rate voltage locking 0 4A Limit the breakpoints Noloading 5V P1 89 2 5 P2 38 2 5 PBR pos...

Page 375: ...pecification Rate voltage DC24V Operation temperature 30 85 C 22 185 F Property of sensor R25 10 K 5 B 0 50 3880 2 Fig 27 Three point relay 1 Air blower 1 speed 2 Air blower 2 speed 3 Air blower 3 spe...

Page 376: ...e than 1shift pipe temperature sensor will detect the air temperature through the evaporator When the pipe temperature is below 1 C the connector of compressor is turned off when the pipe temperature...

Page 377: ...s maintenance Periodic inspection If the cooling or heating system is not used for a long time please refer to the table of regular maintenance and perform the required inspections In non production s...

Page 378: ...trained personnel Please contact an authorized service company of our company If liquid refrigerant contacts with your eyes or skin do not wipe the involved area Flush the affected area with plenty of...

Page 379: ...Operation condition 12 Heater valve 12 Outdoor filter Pollution 6 Indoor filter Pollution 6 Inspection methods Check gas leakage of the refrigerant hose connector When there is oil near pipe joints g...

Page 380: ...eam to clean the condenser Refrigerant will be overheated When cleaning with water protect the electrical components Ambient temperature sensor The sensor is locked in the battery box send signals to...

Page 381: ...ing valve push hard protective well A until it clicks Note When connecting be careful not to bend pipe Disconnection method of quick joints Hold the quick joint body A and lift protective well B After...

Page 382: ...tion After 5 minutes read the scale of meter If the inspection is completed stop the engine and remove the meter kit Use the test values of meter to troubleshoot Operating conditions Ventilation holes...

Page 383: ...s not work Reading of pressure Probable reason Low pressure gauge blue Low High pressure gauge red High 1 Excessive air or refrigerant int the system 2 Air channal is blocked 3 Overfull oil Reading of...

Page 384: ...nd high pressure gauge red indicates the same pressure 1 Connector of compressor does not work 2 Compressor does not work 3 Electronic failure circuit breaker or pressure switch do not work Troublesho...

Page 385: ...is mixed Check expansion valve and replace storage drier Low compression of compressor 0 4 0 6 0 69 0 98 Low pressure is exceeding the normal value If the air condition is closed high low pressure wi...

Page 386: ...pen the valve of repair tank and then open the manifold valve in the low pressure side then if the meter reading in the high pressure side is less than 3 kgf cm2 open the valve in the high pressure si...

Page 387: ...acuum pump and continue to drain until the meter reading is 760 mm Hg Turn off the high low manifold valve and stop the vacuum pump Refrigerant filling After removing the vacuum pump connect the centr...

Page 388: ...ide to completely fill the refrigerant system If the refrigerant is completely full close the valve in the low pressure side Note the refrigerant flows in the mirror check the pressure and view leakag...

Page 389: ...the boom and the rapid returning to the system of flow ensure the best performance 1 Complex system combinating the flow of dual hydraulic pumps to ensure the time of quick cycle and high productivity...

Page 390: ...aulic components in the maintenance of repair plant Always wear clean overalls with pants and strictly require personal hygiene Work on the hydraulic components should be separated from other work whi...

Page 391: ...s used for the transportation of hydraulic oil can be used for this purpose Oil should be covered or stored in controlled temperature conditions If the oil needs to be stored outdoor oil drums must be...

Page 392: ...eralls with pants and reuqire personal hygiene strictly Perform the thorough troubleshooting to avoid unnecessary repair work It is needed to move the machine to a clean place If possible do not disas...

Page 393: ...lve spool Servo pressure system is used for control A servo pump provides pressure for control lever and pedal When the machine is operated the control valve reduces servo pressure to a control pressu...

Page 394: ...ow speed low speed high speed l Move straight when operating at the same time l Automatic transformation between low speed and high speed Steering plate Rotate priority circuit The rotation and the bu...

Page 395: ...motor running for 2 speed Low speed high torque High speed low torque Excavation unit Confluence of boom lifting Regeneration of the pressure when the boom descends The confluence of oil circuit of b...

Page 396: ...ank description Table2 Tightening torque unit kgf m No Tightening torque 3 2 5 0 3 4 1 5 0 2 10 4 5 0 5 14 52 2 5 2 16 6 5 0 7 17 0 3 0 6 Fig 2 Hydraulic tank structure 1 Hydraulic oil tank 8 Spring 1...

Page 397: ...Bypass pipe 1 is open the hydraulic oil returns directly to the tank rather than through the filter Note Bypass valve set pressure 1 5 0 15 kgf cm2 SCBA Preventing the negative pressure inside the tan...

Page 398: ...then fall boom down to the ground In the maintenance of hydraulic systems prevent hydraulic oil overflow because the pressure inside the tank Press internal buttons several times to release the press...

Page 399: ...the 24 volt outlet 10 Disconnect the hose from the adapter 11Remove the adapter and air breathing apparatus immediately Hydraulic oil level gauge replacing WARNING Hydraulic oil with high temperature...

Page 400: ...t Tools Torx T30 3 Installation new ventilation unit with new rubber kit Note When installing vent observe torque Tightening torque 2 94 N m 5 88 N m 1 2 2 pipeline fixtures connection block locator S...

Page 401: ...thdraws the Pi supplys and the selecting valve is open pressure oil flow of auxiliary servo hydraulic will not flow to throttle A boom junction logic valve is closed P1 oil flow of pump was stopped Fi...

Page 402: ...nto the oil returning circuit Note When replacing and re assembling the check valve must be installed to open toward the direction of oil flow Note If they are installed in the opposite direction too...

Page 403: ...Hydraulic circuit Standard Remote control valve operation lever pipeline Fig 16 Servo hydraulic pipelines remote control valve 1 A Shuttle valve block 16 D valve block 31 B B Shuttle line valve block...

Page 404: ...1 P3 T T3 Remote valve 13 lef t side 1 Shuttle valve block 16 SL Turn left 2 AO Bucket arm extends 3 SR Ture right 4 AL Bucket arm withdraws P Valve block 31 P5 T T5 Shuttle valve block 16 BU1 Main co...

Page 405: ...nent Valve throttle Componen t Valve throttle Instruction Remote valve 15 pedal 1 Shuttle valve block 15 ar4 Moving to left Backwards 2 bl4 Moving to left Forwards 3 ar3 Moving to right Backwards 4 br...

Page 406: ...raulic circuit Standard Fig 20 Solenoid valve pipeline A Main control valve right DShuttle line valve block 16 G Accumulator valve block 9 B Main control valve front Servo hydraulic selector valve 33...

Page 407: ...Detailed viewJ Pgi S2 Rotary motor 3 PG S3 Proportional solenoid valve 45 P Servo hydraulic selector valve 33 P Valve 11 Detaile d viewJ A1 Valve block Detailed viewJ P1 A2 Main valve 2 ViewB Py A3 C...

Page 408: ...T2 Td4 Protection valve of hosepipe burst 48 Large arm T Hydraulic oil pump pipeline Note About throttle connection refer to P590 Hydraulic circuit Standard Table 6 Valve connection Component Valve th...

Page 409: ...of draining oil 27 Detailed view F OUT Hydraulic tank 21 View C Td9 Valve block of battery 9 PS Servo hydraulic filter 8 Detailed view D OUT Solenoid 12 ViewH G Rapid coupler Central channel 17 G Rota...

Page 410: ...Maintenance Manual LG6210E Hydraulic Excavator 392 Fig 23 Hydraulic pump pipeline...

Page 411: ...Py Main valve 2 View D Px1 dr 1 Hydraulic tank 21 View A Td5 Main valve 2 View E dr 2 Main valve 2 View B dr4 Main valve 2 View D dr 3 Hydraulic tank 21 View A Td6 Main valve 2 View B dr 4 Td7 Main v...

Page 412: ...Maintenance Manual LG6210E Hydraulic Excavator 394 Fig 24 Main valve pipeline...

Page 413: ...Maintenance Manual LG6210E Hydraulic Excavator 395 Hydraulic main pipeline Note About throttle connection refer to P590 Hydraulic circuit Standard Fig 25 Valve connection Main pipeline...

Page 414: ...hannel Travelling motor Instruction Valve Direction Valve C Left A Left front D Turn right B Right front E Left B Left back F Turn right A Right back B Left right P Speed control G Left D1 Draining of...

Page 415: ...main control valve 9 Hose main pump main control valve 10 Main pump 11 Oil absorbing pipe hydraulic tank main pump tank 12 Check valve the main control valve hydraulic oil tank 4 5 kgf cm2 13 Coupler...

Page 416: ...e and the check valve prevent the backing of the hydraulic oil filled in the accumulator Nitrogen within the accumulator is compressed by hydraulic oil released from the gear pump When the hydraulic p...

Page 417: ...essure within the accumulator can be used only when the start switch is ON and the safety lever is open by lowering left console WARNING Before any maintenance excessive pressure must be removed from...

Page 418: ...and joints must be plugged Oil drained from the hose the oil pipeline and joint should be collected in the container 1 Park the machine in a level ground lower the bucket to the ground and stop the en...

Page 419: ...ection with the oil flow and throttle Spool is pushed by the electromagnetic coil and spring to restrict the channel with oil flow for each throttle When the power is supplied to the electromagnetic c...

Page 420: ...re P1 of the guide throttle gets to A1 and then to the remote valve control valve When the control lever is moved to the locked position the switch is twisted to the OFF the spring force will push the...

Page 421: ...d valve A3 is started the basic servo hydraulic pressure from P2 is guided to A3 and convert walking valve to automatic transfer position of 1 2 speed Valve block 2 Hydraulic diagram 12 Close the boom...

Page 422: ...t of the oil pump P2 Optional Equipment A3 When pressing the selector switch the solenoid valve A3 is started guide the basic servo hydraulic pressure to control valve operate a selected mining unit C...

Page 423: ...r exert gravity on the scattered components Before assembly take anti rust measures for parts check all surfaces without scratches dents or wear Any damaged parts should be replaced Disassembly proced...

Page 424: ...cing Note Disconnected hose pipe and joints must be plugged From the hose the oil drained from pipeline and joint should be collected in the container WARNING Hydraulic oil with high temperature and h...

Page 425: ...e 11 Troubleshooting NO Problems Reason Rectification 1 Spool can t move Electromagnetic voltage is too low Check the circuit Test the electromagnetic coil Electromagnetic coil is burnt out Replace th...

Page 426: ...Bucket extending servo hydraulic throttle Cylinder withdraws R Main oil return pipe throttle BL4 Travelling left throttle forward Rs1 Rotary motor oil filling throttle AL4 Travelling left throttle bac...

Page 427: ...valve signal releasing throttle pi Bucket arm confluence signal throttle 4pa2 Boom ascending servo hydraulic throttle Pg1 Pressure source of travelling straight and auto slowing signal 4pa3 Bucket wi...

Page 428: ...Maintenance Manual LG6210E Hydraulic Excavator 410 confluence checking backward pressure checking load checking...

Page 429: ...boom gate valve down 4 Stick retracted into the gate valve section Section 5 Stick out the door valve 6 bucket valve within the curved section of the door Fig 40Main control valve hydraulic diagrams...

Page 430: ...x1 5 5 0 5 PR PL BL3 23 M10x1 5 AL1 BL1 AL2 BL2 AL3 AR1 BR1 AR2 BR2 AR3 BR3 AL4 BL4 38 M12x1 75 10 1 R PF1 21 2 Rs1 PF3 8 4 0 4 Pi Po PF 1 4 3 0 3 al1 al2 al3 al4 ar1 ar2 ar3 bl1 bl2 bl3 bl4 br1 br2 b...

Page 431: ...Maintenance Manual LG6210E Hydraulic Excavator 413 Main control valve partial view Fig 41 Main control valve Partial view1...

Page 432: ...Maintenance Manual LG6210E Hydraulic Excavator 414 Fig 42 Main control valve Partial view2...

Page 433: ...spool 43 O ring 10 Bucket arm spool 44 O ring 11 Selecting spool 45 O ring 12 Parallel check valve 46 O ring 13 Parallel check valve spring 47 O ring 14 Hose assembly 196 19 6 48 O ring 15 Check valve...

Page 434: ...Lock nut 98 9 8 31 Foot pressure reducing valve 58 8 5 9 61 3 Lock nut 98 9 8 32 Signal hole 62 Bearing check valve Bucket 196 19 6 33 Plug 98 9 8 63 Loading check valve Optional bucket 196 19 6 34 Sp...

Page 435: ...Worn parts need to be repaired small scratches dents scars can be polished with sharp edges or coarse sandpaper Prepare to replace all the parts Coat the sliding part with clean hydraulic oil Replace...

Page 436: ...ase sealing surface replace the valve If it is stuck replace it If damaged heated or discolored replace it 3 Rebound springs rear Check whether there is rust corrosion and other damages of the springs...

Page 437: ...and assembly of the valve prepare the following tools Table 16 Tools No Tool Dimension mm Quantity 1 Wise 1 2 Pin 27 1 3 32 1 4 41 1 5 46 1 6 Hex wrench 4 1 7 5 1 8 6 1 9 8 1 10 10 1 11 12 1 12 14 1 1...

Page 438: ...Fixture use method fD Fixture Use 28 2 41 Main spool 15 9 32 Straight transition spool Main spool removing Order of assembly is oppose to the order of disassembly When disassembling mark the original...

Page 439: ...d vise spool spool cap release 3 Tools 12 mm hex wrench Tightening torque 15 kgf m Note Remove the oil from the spool and frame Note When assembling note the orientation of the spring guide 4 Remove t...

Page 440: ...draulic tailstock B is open chamber 3 with low pressure the supply of oil flow will form a pressure difference before and after the nozzle 2 such a the pressure of chamber 1 d2 is larger than the the...

Page 441: ...ained at 50 5 C because the unnecessary pressure relief Loading of valve will lead to rapid increase of temperature WARNING Hydraulic oil with high temperature and high pressure can cause serious inju...

Page 442: ...en the locking nut 2 twist the adjustment screw 1 twist clockwise until it is fully in right place Y and Z 3 Loosen the lock nut 4 twist the adjustment screw 3 twist as follows With increasing pressur...

Page 443: ...lockwise to reduce pressure 3 Firmly keep the adjusting screw 1 stable and then tighten the locking nut 2 Note Lock nut 2 Tightening torque 6 kgf m 4 Restall the servo valve hydraulic hose connected t...

Page 444: ...of chamber 2 d1 Circuit pressure is controlled at a stable level while the main rotary tailstock A is open to allow the flow of hydraulic oil to flow to the tank channel Anti cavitation operation Area...

Page 445: ...mm 5 Well 27mm Main pressure relief valve replacing WARNING Hydraulic oil with high temperature and high pressure can cause serious injury WARNING Put the excavator unit down to the ground and turn of...

Page 446: ...sure can cause serious injury WARNING Hydraulic oil under high pressure hose may cause serious injury Sprayed liquid will hurt the exposed skin Measuring Connect the oil pressure gauge 600 kgf cm2 on...

Page 447: ...or head optional excavator unit bucket arm cylinder left travelling motor motor head Track motor pressure measurement throttle Please refer to Track motor instructions Rotary motor pressure measuremen...

Page 448: ...pump a3 throttle 2 Install a T tube 12 and hose 11 13 14 on servo hydraulic pump a3 throttle 3 Disconnect the hose 5 from the fixed parts 6 and plug it 4 Install a jump hose 14 on the faster 6 5 Disco...

Page 449: ...ssure relief valve will be opened below the required pressure Operate the cylinder to be measured to its end of stroke 1Reduce displacement of pump 2 Increase the pressure of the main valve above450 k...

Page 450: ...tor throttle pressure relief valve adjusting Refer to rotary motor adjustment Pressure adjustment of throttle pressure relief valve Refer to Pressure adjustment of throttle pressure relief valve Throt...

Page 451: ...hydraulic signal Off Piston E moves to the right due to the action of the spring F Oil from the cylinder throttle flows into chamber 2 through the nozzle 3 of the piston A Because d1 d2 the main rotar...

Page 452: ...sure of hydraulic throttle is usually larger than fuel tank main rotary tailstock B is still fixed in the base safely However if the pressure of cylinder throttle is lower than the pressure of the tan...

Page 453: ...ifference that are equivalent to d1 d2 pressure Oil flow from pipeline of the tank flows to hydraulic throttle to prevent bubbles Stage 2 section adjustable gate valve For selection Please refer to th...

Page 454: ...pressure adjustment 1 Connect the servo hydraulic hose to the pressure relief valve PI servo hydraulic signals Open 2 Loosen the lock nut 2 twist the adjustment screw 1 as follows Twist clockwise to i...

Page 455: ...stock 11 5 Remove the adjustment screw 12 and the piston 13 Boom locking valve instructions Spool in neutral position 3Pi servo hydraulic signal OFF The location of the pistonA is shown in the picture...

Page 456: ...ff Chamber 1 connects with chamber 2 through nozzle 4 and the pressure Pc is obtained rotary tailstock E will be opened High pressure oil supply pipe flows to cylinder piston side Fig 78 Boom rising P...

Page 457: ...nects with channel of fuel tank via that spool moves to the left the hydraulic oil of chamber 1 flows through the channel 5 and 6 to open the valve D and then flows to the fuel tank pipe through the c...

Page 458: ...1 and remove cover assembly 2 Note Re assembly make sure O ring installed in the shell imports then Re assembled cover 2 Pull out the spring 3 and with the transfer tailstock 4 Tools 10 mm hex wrench...

Page 459: ...om oil regeneration valve instruction Servo hydraulic pressure ar1 will push the spool to the left of boom boom down the pressurized oil flow from the pump opens the load valve flows through the U sha...

Page 460: ...ose to order of disassembly Disassembly mark the parts to make assembly easier 1 Remove the sealing cap 1 pull out the spring 2 and the tailstock 3 Tools 30 mm socket wrench inside Tightening torque 6...

Page 461: ...ugh nozzle 4 the pressure in the chamber 1 is Pc Because the area d1 d2 tail base B can not move chamber 2 and chamber 3 is separated to make bucket arm in the position Operation of spool Bucket arm e...

Page 462: ...chamber 1 is Pc and with the tail base B will open Hydraulic oil Pv in high pressure supply pipe supplies to the cylinder rod 3 side Bucket withdraws Pc Pv 4Pi servo hydraulic signals ON Fig 96 Bucke...

Page 463: ...lve removing Assembly order is reverse to order of disassembly Disassembly mark the parts to make assembly easier 1 Screw 1 and remove the shaft cover 2 Tools Hex wrench 6 mm Tightening torque 5 kgf m...

Page 464: ...l flow from the pump to open the load valve flow through the U shaped pipe spool notch loop and section doors AL3 flow to the cylinder piston side Fig 100 Bucket arm oil regeneration valve A Check vav...

Page 465: ...to check valve Check the open oil flow convergences into the oil through throttle AL3 by a limited pipeline At this time the oil flow in spring chamber 3 to throttle Pa Dr through the check valve E An...

Page 466: ...hydraulic pressure is applied to throttle pa servo hydraulic pressure forces was expanded several times by the piston area which can move spools C with the spring force and close the channel 2 With t...

Page 467: ...ack to the pump regulator Due to delayed response of the pump a large mount of hydraulic oil flows and pressure fp exceeds than the set pressure of the spring B rotary base A will open and hydraulic o...

Page 468: ...d bucket arm confluence check valve removing Order of assembly is oppose to the order of disassembly When disassembling mark the parts to make assembly easier 1 Remove the sealing cap 1 pull out the s...

Page 469: ...the position of boom descending Servo hydraulic signal OFF Fig 108 Remove bucket arm flow regeneration and bucket arm confluence check valve Fig 108 Remove the plug and check valve Fig 110 Logic valv...

Page 470: ...rough the nozzle E If Pa Pb Pressure in chamber Z becomes Pb through the nozzle E of lifting valve D so check valve C is closed Lifting D remains in original place due to the area between difference b...

Page 471: ...ut the piston 2 3 and spring 4 Pull out the sleeve 13 the method is to gently hit the left side of shaft cover t Tools 36 mm hex socket wrench Fig 111 Logic valve in the neutral position and the posit...

Page 472: ...ssembly and assembly Order of assembly is oppose to the order of disassembly Disassembly mark the parts to make assembly easier 1 Remove the sealing cap 1 pull out the spring 2 spring seat 3 and the s...

Page 473: ...sassembly mark the parts to make assembly easier 1 Remove the sealing cap 1 pull out the spring 2 and spool 3 Tools 41 mm hex socket wrench Tightening torque 10 kgf m Note Note the notch in the spool...

Page 474: ...embly mark the parts to make assembly easier 1 Remove the sealing cap 1 pull out the spring 2 and valve 3 4 Tools 12 mm hex wrench Tightening torque 20 kgf m Note There is no check valve 4 in the boom...

Page 475: ...k if there is damage for hoses and pipes Check whether there are impurities in hydraulic oil of filter Table20 Troubleshooting Failure Reason Illustruction Machine can t move Starting speed is slow id...

Page 476: ...ties Logic valve is faulty There is duct between main the tailstock and the base Damaged tailstock and the surface of base Spring is broken or fatigue Remove and clean valve If damaged replace the tai...

Page 477: ...ool is stuck Reverting spring is broken or fatigue Servo hydraulic circuit is blocked Measure basic auxiliary servo hydraulic pressure Replace the control valve Remove and clean Disassemble clean and...

Page 478: ...pen or there are impurities in reducing valve and base Check whether there are impurities on the railstock Make sure each component is smooth sliding Clean all parts thoroughly Releasing pressure is n...

Page 479: ...Maintenance Manual LG6210E Hydraulic Excavator 461 Table 22 Mode code K3V 112 DT 1XJR 9N2D V K3V K3V seires 112 Dimension Displacement cm3 rev DT S Single pump D Doublepump...

Page 480: ...l Table 23 Throttle connection Throttle name Dimension A1 2 Oil output SAE 6000 3 4 B1 Absorb oil SAE 2500 2 1 2 Dr Drain oil PF 3 4 20 Pi1 Servo hydraulic PF 1 4 15 Psv Servo hydraulic attachment PF...

Page 481: ...314 valve plates 7 127 Bearing isolation 401 screw 7 141 cylinder valve block 406 Screw 7 151 piston 466 variable pitch prop plug 79 152 package pin 468 variable pitch 80 153 Set plate 490plug 8 156 S...

Page 482: ...needs to explain the front pump The pump includes a rotating assembly swash plate and valve body components Transmission components include front transmission shaft 111 cylinder stopper 141 piston or...

Page 483: ...assembly includes valve block 312 the valve plate 313 and valve plate pin 885 Valve plate connects with the valve block two half moon throttle drains oil and collect oil from the valve block of cylind...

Page 484: ...f they are tightened tightly the required horsepower will increase to achieve the maximum oil pressure or release Pumps maintenance standards Precaution for use Table 24Notice for precautions Item Spe...

Page 485: ...nd throttle Check direction of rotation as well as direction of pumping oil draining oil Check the liquid level of hydraulic oil tank When starting let the engine idle to drain the air in the circuit...

Page 486: ...n damaged Similarly should check whether the pump contains drained oil Check the abnormal sound or vibration Check the oil pump is with abnormal sound or vibration If it is check whether it is the sou...

Page 487: ...ace the piston or cylinder The gap between the piston and track plates Filling crack Cross section 0 1 0 3 Replace the piston and the track plate assembly Track plate thickness t 4 9 4 7 Replace the p...

Page 488: ...Note Overlapp cylinder and valve plate together to correct the surface roughness Tightening torque Table28 Tightening torque Instruction Dimension Tightening torquekgf m B mm Tool Screw material SCM...

Page 489: ...ug depends on pump type Table29 Tool Tool Dimens ion The necessary tools Marked with asterisk Specification Pump type Name B mm K3V 63 K3V 112 K3V 140 K3V 118 0 Screw PT plug PO plug Set screw Hex wre...

Page 490: ...00 mm Torque wrench Tighten to the rated torque Pump removing Note Clean the pump thoroughly before removing the components Choose a clean workplace Mark the pump housing and other parts so that point...

Page 491: ...down remove the pump housing 271 from the valve body 312 Note Swing a rubber pad to prevent the surface from being bumped 7 Pull the cylinder 141 out from the pump housing 271 over the transmission sh...

Page 492: ...ousing 271 12 Tap the end of transmission shaft 111 113 with a plastic hammer to remove it from the swash plate support 13 Remove the valve plate 313 314 from the valve stopper 312 14 If necessary rem...

Page 493: ...the replacing parts all ready Coat sliding parts bearings and so on with clean hydraulic oil Replace O rings and seals Use a torque wrench tighten the screws and plugs with the specified torque Be ca...

Page 494: ...talled with bearings 123 isolated pieces of the bearing 127 and clamps 824 on the swash plate support 251 Note Do not use hammers to beat transmission shaft Hit the raceway of outer bearing with a pla...

Page 495: ...7 Install the valve body 312 in the pump housing 271 and tighten the screw 401 Clockwise observed from this side of the input shaft Install the stopper the regulator facing up oil output flange towar...

Page 496: ...perly connected After starting the engine run at low idle for some time to completely exhaust the air out of circuit Note If there is air in the hydraulic system sliding parts may be damaged Installat...

Page 497: ...he filter and oil drain to see if there is abnormal wear debris Table32 Troubleshooting pump oil flow very slowly discharge pressure can not rise Reason Correction Specification Regulator is faulty In...

Page 498: ...ry pump is damaged Oil absorbing pipe absorbs the air Pumping throttle are blocked Please refer to Regulation Section Please refer to servo hydraulic valve Regulation specification Table34 Mode code K...

Page 499: ...ies number Table 35 Throttle connection Throttle name Dimension Pi Vacuum servo hydraulic pressure signal throttle PF1 4 P2 auxiliary pump servo hydraulic pressure throttle PF1 4 PF Servo hydraulic pr...

Page 500: ...lug 629 cover 801 nuts 601shell 630 Locking nut 814 clamp 611Feedback rod 631 bushing 836 clamp 612 levers 641 Servo hydraulic cover 858 clamp 613 levers 643 Servo hydraulic cover 874 898 pin 614 Plug...

Page 501: ...ted by a series of two pump pressure and the load Therefore regardless of the load on the two state oil pump engine are automatically protected from overloading Power Shift Control Horsepower setting...

Page 502: ...pressure Pi If servo hydraulic pressure corresponding to required oil flow is marked oil pump will only drain required oil flow so unnecessary power consumption can be avoided Fig 156 controller stru...

Page 503: ...A inside servo hydraulic piston is equipped with pin 875 the pin is fixed on rod 2 613 Therefore when the servo hydraulic piston moves bar 2 rotates around point B fixed by the pole plug 614 and pins...

Page 504: ...pressed to C by spool 652 under the action of oil return spring 654 sales 874 and feedback lever rotates around point D 611 with bar 2 through spool 654 pin 874 and feedback lever 611 and the spool m...

Page 505: ...e rod 1 includes the pin 897 fixed on the feedback rod 611 feedback rod rotates around the point D when rod 1 is rotating spool 652 moves to the on the right When the spool moves the oil pressure P1 f...

Page 506: ...y when the tilt angle reduces If the tilt angle command is very large it will not contact with the pin 897 of large holes 8 and it can move freely This mechanical choice technology allows small tilt a...

Page 507: ...o hydraulic piston 643 is stuck Disassemble and clean the regulator 3 Spool 652 is stuck Disassemble and clean the regulator 4 Piston 621 is stuck in the piston box 622 Disassemble and clean the regul...

Page 508: ...he screws to move the control curve to the right and increase the input horsepower as shown in the chart Because the rotating adjustment screw C 628 N circles will change the settings of inner the spr...

Page 509: ...readings at bending Load of sync 2 pump 1800 rpm I Input current of power shift valve high frequency vibration 80 Hz 200 mA Pf Power conversion pressure reference value Pd Negative control pressure f...

Page 510: ...gulators There is no need to loosen or remove the adjustment screw for cleaning It is recommended to replace the regulator as components because it includes small precision machining components and th...

Page 511: ...4 14 17 Hex wrench PT plug Material S45C Note Use Loctite 577 liquid PT1 16 PT1 8 PT1 4 PT3 8 PT1 2 70 105 175 350 500 4 5 6 8 10 Hex wrench PO plug Material S45C PF1 4 PF 1 2 PF 3 4 PF 1 PF 1 1 4 PF1...

Page 512: ...adjusted on an experimental platform 5 After removing the sub component of cover C 629 remove the outer spring 625 inner spring 626 and the spring seat C 624 from the compensation part Pull out the ad...

Page 513: ...and remove the outer pole plug 614 and adjustment plug 615 Pole plug 614 and adjustment plug 615 can be easily removed with M6 screw 9 Remove rod 2 613 Use a long needle nose pliers to make operation...

Page 514: ...emove the piston box 622 Note As the component is very small be careful not to lose them Regulator assembly Preparation Clean all parts with detergent and dried with compressed air Note Parts are smal...

Page 515: ...o feedback rod to make the operation more convenient Note Be careful not to mistake the direction of the feedback rod 1 Rod 1 side 2 Rod 2 side Rod plug of regulator side 5 Put servo hydraulic piston...

Page 516: ...ydraulic lid 641 and tighten it with screw 436 438 11 Install the spring seat 644 servo hydraulic spring 646 and the adjustment ring Q 645 into the servo hydraulic hole Then install the spring seat 62...

Page 517: ...Container capacity 300 liters Drain hose You can use the hose for engine oil WARNING The parts are heavy When operating these components take appropriate safety precautions 1 Park the machine in the...

Page 518: ...5 7 9 11 and cover 2 4 6 8 10 12 7 Loosen coupling fastening nut 1 of the muffler and remove the nut 3 Move the pipe 2 to the left about 3 cm 8 Hold the muffler 1 with a crane 4 9 Remove mounting brac...

Page 519: ...ct the wiring harness of proportional valve 3 Disconnect the servo hydraulic hose 1 2 4 Remove assembly screws 5 of the absorbing tube 13 Install ring bolts 1 and a sling hold it with a crane and remo...

Page 520: ...inserted on the shaft Note Coat the screw 1 with Loctite 277 Tightening torque 206 9 8 21 1 kg m 151 6 7 2 lbf ft 21 Install the hydraulic pump assembly Remove the tee plug from the old pump install t...

Page 521: ...rate lever several times to release the remaining pressure in the hydraulic lines Note Oil drained from hoses and fittings must be collected in a container Disconnected hose and connectors must be plu...

Page 522: ...Manual LG6210E Hydraulic Excavator 504 mp structure 353 driver gear 466 plug 354 driven gear 700 ring 355 filter 710 O ring 361 Front shell 725 O ring 433 Screw 732 O ring 434 locking nut 850 snap rin...

Page 523: ...installing a new pump replace the O ring 710 Before connecting to the pump check whether there are impurities throttle and hose Use a torque wrench tighten screws fasteners and the plug to the rated t...

Page 524: ...mm Note Tightening torque 160 kgf cm Adjustment 1 Loosen the nut 312 twist the screw 311 to adjust 2 Adjust screw 2 in the following way To increase the pressure twist clockwise To reduce the pressur...

Page 525: ...1 and imported hose 3 of pump 5 Remove the mounting screws 2 of servo pump 6 Remove the servo pump General Safety Precautions Replace the O ring Use a torque wrench to tighten the screws to the specif...

Page 526: ...d reduce oil flow from P to A Twist the engine speed control switch to select the control mode At this time the controller outputs current value which is enough to make use of proportional solenoid va...

Page 527: ...tromagnetic coil Adjustment screw Setting before shipment of original plants When adjusting the screw twist throttle A clockwise to enhance pressure Tightening torque Table 41 Tightening torque unit m...

Page 528: ...Spring 325 Valve housing 351 Port M3 6 1 24 361 O ring 362 O ring 363 O ring 407 Screw M6 120 466 Plug PF 1 4 370 490 Plug NPTF 1 16 90 725 O ring 732 O ring 801 solenoid valve M22 1 450 50 802 Seali...

Page 529: ...H G F I orderly Oil temperature 50 60 C Measuring Connect the pressure check throttle with oil pressure gauge 60 kgf cm2 to measure the servo hydraulic auxiliary pressure Adjustment Loosen the lock n...

Page 530: ...nect the pins 2 of solenoid valve on the wire 4 Disconnect the hose 1 of solenoid valve p 5 Remove the screws 3 and proportional solenoid valve p Note Prepare a small container to prevent leakage of h...

Page 531: ...Fine F1 1500 20 415 Variable 22 8 ON 4 F2 1400 20 3 F3 1300 20 2 Idle L1 1000 20 305 Variable 30 6 OFF 1 L2 835 20 Note Valve auxiliary pressure under different current may be different from the spec...

Page 532: ...ification Table44 Specification Item Unit Specification Left remote control valve Operation lever Model PV48K Type Hydraulic Stroke Degree Rear and front right25 left19 Operation force kgf cm Rear and...

Page 533: ...216 and gasket 2 217 Spring of set auxiliary pressure has been pre set so the auxiliary pressure is 5 10 kgf cm 271 142 pounds square inch psi depending on type Spool is pushed on the pushing rod 212...

Page 534: ...ins the hydraulic oil of throttle P from the guide output throttle 1 2 3 4 of hydraulic pump or hoses of fuel throttle T Auxiliary pressure setting spring 241 acts on the spool to determine the output...

Page 535: ...le B 25 4 4 lever 14 Black line C Tilt angle of handle 5 Rear switch 15 White line D Double operating angle 25 6 Double switch left 16 Orange line E Tilt direction of handle 1 lever 7 Double switch le...

Page 536: ...122 O ring 214 O ring 323 handle 457 sleeve 125 screws 216 springs base 402 handle 458 column tube 126 spring pin 217 washer 2 403 Plug 459 terminal 131bushing 221 Spring 404 column tube 460 terminal...

Page 537: ...r mode Operation modes on two column mode are used for left and right operation lever Bucket arm extends 1 Pull the lever here to let the bucket arm extend Turn right 2 2 Pull the lever here to let th...

Page 538: ...ydraulic hammer Hydraulic hammer 8 descends Pull the lever here to lower the hydraulic hammer WARNING Pattern maps of remote stem should be consistent with the control mode of machine Or it will lead...

Page 539: ...ected to throttle 1 oil from the servo pump flows through throttle 1 to form the pressure When the pressure of throttle 1 is equivalent to the value of the set spring force of tilt the handle the flui...

Page 540: ...ever Table46 Maintenance standard Checking item for maintenance Standard Specification Leakage When handle is in the neutral position and the hydraulic oil leaks more than 1000 ml per minute or when o...

Page 541: ...the specified torque Operation stability When there is abnormal sound or self excited oscillation when operating in the basic pressure declines sharply please refer to the cause of the failure take m...

Page 542: ...move it in a clean working environment Prepare tools and materials General Considerations All components should be assembled precisely so be very careful not to cause the damage to the parts in the pr...

Page 543: ...from the housing 101 Important Be careful not to damage the bellows 4 Loosen the lock nut 315 and the adjusting nut 312 Tighten each nut with a wrench 5 Remove the handle 402 6 Remove the disc 302 Fig...

Page 544: ...the joint the metal plate 151 plug 211 and putters 212 may be flying due to compression of the rebound spring 221 8 Remove the metal plate 151 9 When the rebound spring 221 is released the plug 211 re...

Page 545: ...and rebound springs 221 from the shell Note Record the relative position between rebound valve sub assemblies and the spring 11 Fix the servo hydraulic valve with vise throttle 111 up Loosen the scre...

Page 546: ...to damage the surface of spool Press down on the spring seat not more than 6 mm 15 Separate spool 201 spring seat 216 the auxiliary pressure 241 and spring washer 2 217 16 Remove the lever 212 from th...

Page 547: ...is to pull the well from the top 20 Remove the handle 402 cover Remove screws 431 with cap remove the cover of the handle 402 21 Remove the switch base 22 Remove the switch 455 Important Record the r...

Page 548: ...e maximum cleanliness Wipe the parts with a clean cotton cloth Important Do not use compressed air to dry components as these parts may be damaged or rusted because of the air humidity 24 Anti rust of...

Page 549: ...ith grease to keep it in place Tighten the screws to the specified torque listed in the table After assembly close all the throttles to prevent debris from entering the valve Assembly 1 Install bushin...

Page 550: ...wo screws should be tightened alternately and evenly 5 Install the the gasket assembly 217 the auxiliary pressure spring 241 and the spring seat 216 on the spool 201 Important The spring seat pressure...

Page 551: ...l Install the valve sub assembly into the shell 101 Note Install these components to the original position 8 Install the O ring 214 in the plug 211 9 Install the seal 213 to the plug 211 Note Assembly...

Page 552: ...ause of the resistance of the O ring 12 When the rebound spring is pressed and assemble four plugs assembly use metal plate 151 and tighten the connector 301 temporarily Important Sub components of pl...

Page 553: ...tant Rotate it the position where it can touch with four levers Note Do not rotate it to exteed this position 16 Assemble adjustment nut 312 Tighten the adjustment nut to the specified torque Importan...

Page 554: ...n the screws 18 Place the handle cover tighten the screws 431 with cap 19 Install the bellow pipe well at the bottom of the handle 402 20 Install the adjustment nut 312 to handle and place it into the...

Page 555: ...but oil is also commonly used type of grease can be used Grease should be coated once every six months 23nstall the lower end of the bellows pipe 501 in the housing 101 I Remote control valve joystick...

Page 556: ...the housing Disassemble and repair or replace the handle Auxiliary pressure is not stable Sliding part is blocked Pipeline pressure of tank fluctuates Hydraulic oil has the air Repair or replace parts...

Page 557: ...control valve spool and output pressure secondary pressure of the hydraulic servo valve is applied to the other side To accomplish this function the servo hydraulic valves include the following compon...

Page 558: ...To change the spring force lever 214 slides into plug 202 which acts on the spring in turn The displacement of lever is changed by using the cam 420 a pedal or lever is attached on it the cam can be r...

Page 559: ...plug 223 bushing 412 bushing 201 cover 224 Pistons 413camshaft 202 plug 225 ball 420 cam 203 oil seal cap 271 screws 423set screws 210 U package 301 spool 471 set screws 212 O ring 311 spring seat 47...

Page 560: ...Tightening torque 151 NPTF 1 16 70 10 271 M 12 800 100 423 M 6 70 10 472 M 10 340 35 Operation Remote control valve pedal is based on the hydraulic circuit diagrams and cross sections to illustrate th...

Page 561: ...ng 314 Then the throttle P connects with throttle 1 oil provided by throttle 1 forms the pressure When the pressure throttle P increases equivalent to the auxiliary pressure When set spring pressure c...

Page 562: ...on working chamber is discharged through the nozzle and it was generated by the pressure Operating contrary position According to the following sections operate the pedal in the opposite direction the...

Page 563: ...led Both directions has permanent shock 1 When it rotates in the opposite direction from the neutral position the lever is pushed up by the damping spring When operating 2 Neutral position 3 Operating...

Page 564: ...Maintenance Manual LG6210E Hydraulic Excavator 546 Table52 Maintenance standard Item Standard Specification Fig 263 Auiliary pressure and operating force...

Page 565: ...cam camshaft and bushsing is greater than 2mm 0 008 they should be replaced Gap is formed due to loose part screw tighten them to the specified torque Operation stability When there are abnormal sound...

Page 566: ...cification Hex wrench 3 423 Screw M6 6 9 1 5 471 M10 6 271 Screw M8 29 4 2 9 Wrench 17 472 Locking nut M10 33 3 3 4 Driver Width1 210 Sealing For removing 211 Wiper plate Width2 215 Washer For removin...

Page 567: ...Remove the bellows pipe 501 of the lower part from the cover 201 3 Loosen the screw 423 with a hex wrench Use Loctite liquid 242 releasing torque is high Be careful not to damage the threads 4 Align...

Page 568: ...bound spring 335 is released the plug 202 was left inside the shell because of the sliding resistance O ring 212 Use a screwdriver to pull it out To prevent the plug casing on the outside diameter of...

Page 569: ...y record the piston 10 224 the relative positions between the seperated piston and housing and then remove it 11 Pull out damping spring 336 337 from the shell Record the relative position of the damp...

Page 570: ...bushing may fly due to elasticity of rebound spring 335 Be careful not to damage inner part of the shell 15 Pull out bushing 223 from the shell with a needle nose pliers Record the relative position o...

Page 571: ...ucture of spool 301 on a flat surface vertically Lower spring seat 311 and use a screwdriver to remove the two semi circular gasket 215 Be careful not to damage the surface of spool Do not lower the s...

Page 572: ...ntrol valve assembly with detergent to remove the accumulation of thick dust Important Let the parts soak in detergent to soften the dirt Do not use contaminated detergent to the clean the internal co...

Page 573: ...ring will be replaced with a new one When fixing O ring fixed be careful not to damage it When assembling coat the part with grease to keep it in place Tighten the screws to the specified torque list...

Page 574: ...335 the housing Assemble it back to the original position 5 Assemble No 1 pressure reducing valve into the shell Assemble it back to the original position 6 When installing the valve assembly note to...

Page 575: ...inal position Confirm the ring in the horizontal position Be careful not to damage the hole of shell 9 Align the locking ring assembly fixture 2 with the shell holes press the spring with the bushing...

Page 576: ...it back to the original position 13 Assemble the damping spring 337 into the shell Assemble it back to the original position Be careful that shock spring 336 337 is entangled 14 Assemble the piston 22...

Page 577: ...aper Coat the seal and scraper with a thin coat of grease before assembly 17 Install the grease seal cap 203 in the plug 18 Insert the lever 214 into the plug 202 Coat the surface of lever with hydrau...

Page 578: ...to the interior 21 Assemble the cover to the housing 101 Assemble it back to the original position Aligh the damping spring 336 337 with the cover in a straight line 22 Assemble cover and tighten the...

Page 579: ...lid Assemble it back to the original position 25 Pass the camshaft 413 through the cover 201 and cam 420 26 Coat the threads with Loctite 241 or similar liquid products and tighten it to the rated tor...

Page 580: ...ion 29 Tilt the cam so that the top of lever and plug are coated with grease When coating the grease use soft materials scraper to avoid scratching the surface of the lever and the plug 30 Install the...

Page 581: ...re Reason Remedy Auxiliary pressure does not increase Basic pressure is too low Spring 241 has fracture or aging The gap between the spool and the shell is too large There are gaps in the handle Adjus...

Page 582: ...parts Replace the spring Replace the damping piston assembly Remove inspect repair valve Replace clamping piston Damping torque is too large Sliding component has failure Hole of damping piston is bl...

Page 583: ...bucket arm 70 69 71 I Coupling pin of linkage bucket 80 79 81 J End pin of bucket cylinder linkage 80 79 81 K Coupling pin of linkage bucket 80 79 81 Coat the grease Lubricating point Lubricating per...

Page 584: ...g and the pin Cylinder specification Fig 323 Bucket arm cylinder with 2 washers Fig 324 Bucket arm cylinder exploded view 1 column 7 retaining ring 13screw 19support ring 25 anti trust seal 2 bushing...

Page 585: ...parts of cover 5 If the pressurized hydraulic oil is filled into the cylinder by turns power will act on the piston and further cause the stretch or shrink of piston rod 3 Washer in the linkage side...

Page 586: ...ows through the pipe B A in a steady constant speed and returns to the hydraulic tank Next if the cushion plunger 9 inserts into the pipeline B before the end of stroke the hydraulic oil flows the gap...

Page 587: ...onth or more cylinder linkage should be coated with grease to prevent rust oxidation of chrome plated parts Use hydraulic oil to clean packages Note Other oils will shorten the life of the package Coa...

Page 588: ...45 between the flushing gun with the linkage Common tools Table58Tool and fixture Tool fixture Specification Hydraulic hammer Steel hydraulic hammer Large wooden or plastic mallet Screwdriver Large sm...

Page 589: ...ealing of anti dust brush plate Table59 Sealing of anti dust brush plate unit mm Cylinder Component No A B C N M L Boom 8920 00840 106 94 89 5 25 30 Bucket arm 8920 01310 121 109 104 5 25 30 Bucket 89...

Page 590: ...75 69 10 5 16 16 8 Dry bearing cylinder Sealing washer Table61 Guide of seal cover unit mm Cylinder Component No f A f B f C f D O N M L Boom 8920 00290 97 85 95 65D 40 70 5 15 125 5 Bucket arm 8920 0...

Page 591: ...Table62 Bushing fixture cylinder unit mm Cylinder Component No f A f B f C f D N O M L Boom 8920 01150 106 94 80 65 25 7 5 1 5 47 5 Bucket arm 8920 01150 106 94 80 65 25 7 5 1 5 47 5 Bucket 8920 0115...

Page 592: ...pments A suitable working environment Cylinders is one of precision mechanical products equipped with rubber and plastic materials packages and seals Therefore be careful to operate and ensure that cy...

Page 593: ...ed because the rod bushing and piston may hinge together due to the weight of the linkage At this point a bracket is needed to support the rod to prevent such damage Hydraulic source When disassemblin...

Page 594: ...r head assembly from the cylinder A Remove the mounting screws of cylinder head assembly B Removed piston rod and cylinder head assembly from the cylinder Important When removing the piston rod and cy...

Page 595: ...ssemble 4 Remove ring wear 4 from the piston 5 Remove O ring anti dust seals packages and washers Note Remove wear ring and piston package is no longer available Cylinder head assembly disassembly Imp...

Page 596: ...e Cracks Replace Disgraded part of auilixary piston Cracks Replace Screw Being stuck Replace or reset Bending Measure the bending degree Plate shape surface Check the items below Whether the metal pla...

Page 597: ...e plate the new piston Important After the re plating it should be re polished re plating thickness should be at least 0 25 mm Note If the worn depth is up to basic metal in the re adjustment process...

Page 598: ...ould replace the connecting rod Cylinder assembly Install seals of cylinder head Important When inserting prevent damage to seals check whether there are sharp edges on the well of linkage rod package...

Page 599: ...rop ring into well B and method is to press inside diameter D 6 Install dust brush seal 2 in the cover with clamp Fig 343 Prop ring assembly 1 Prop ring Fig 341 Degraded seal assembly 1 Damp ring 2 Pr...

Page 600: ...g 2 Note Note the position of ring 2 Piston assembly Important Check the piston ring without sharp corners If so use a whetstone to remove these sharp edges Fig 347 Piston assembly 1 Prop ring 4 Wear...

Page 601: ...al pipes of piston Piston package kit includes a pad ring 11 Assemble piston package on the pad ring 12 Install the wear ring to the piston r 13 Assemble the anti impurities seal to the piston 14 Inst...

Page 602: ...h ends of the bushing 17 Assemble grease gun with a muzzle 18 Assemble cylinder using the same method Fig 353 Bushing removing 1 bushing 4 Basic metal 2 Metal piece X Press with the press tool 3 pisto...

Page 603: ...ghten the piston to the specified torque 35 5 kgf m Note About the cylinder with a pad plunger eg small arm cylinder refer to cylinder with pad valve page 24Assemble the lock washer and lock nut accor...

Page 604: ...he piston seal Note Piston rod and cylinder must remain parallel Carefully insert the seal cover so as not to damage the O ring Align the cylinder and the screw hole of seal cover in a straight line t...

Page 605: ...m 30 Bend the lock washer toward two ends to fix it in the piston and the well of locking nut 31 Assemble set screws and clamp ball Note Tighten the set screw to the specified torque Tighten 1 0 0 2...

Page 606: ...minutes check whether there is leakage and the welding part For internal leakage test connect the cylinder in accordance with figure 2 After completing the test install a plug in each throttle Note F...

Page 607: ...mpurities Hole of dustproof seal contains scar Other abnormalities of dustproof seal Remove impurities Replace the dustproof seal Piston rod Sliding surface of piston rod contains scars Hard chrome pl...

Page 608: ...ding surface of sliding ring contains impurities Other abnormalities of sliding ring seal kit in order to avoid duplication because different parts of life care replacement of the slip ring 5 2 Boom w...

Page 609: ...ity Gap1 0 25 0 9 1173 0369 0 1 Gap2 1 0 2 5 1173 01630 1 1173 0139 0 1 Gap3 1 0 4 0 1173 01630 3 Gap4 0 4 0 8 Gap5 0 5 2 5 1173 03460 2 1173 0139 0 1 Note Gap1 Max0 5mm Note Other Max1 0mm Table67 In...

Page 610: ...oom to the ground 2 Cut off 4 connection hoses 25 of boom plug the port of hose 3 Remove the locking screw 26 of boom connecting pins 4 Hold up the boom cylinder with a crane 27 remove the locking scr...

Page 611: ...work lamp 9 Hold the boom up with the crane remove the boom pin 34 with tool A Enhance the boom make the machine run backwards and lower the boom safely Boom installing 1 Align the hole of upper stru...

Page 612: ...y crane align pin holes Insert pin 33 tighten the screws of lock plate 2 Connect cylinder hose 32 stall the boom Fig 375 Boom lifting cylinder single washer 1 column 8 retaining ring 15 seals wiper 22...

Page 613: ...of boom with the hammer Install lock hoop 31 and screws 28 Securely tighten the locking screw and then tighten the locking screw 28 5 Connect lubrication hose 30 Boom cylinder disassembly and assembl...

Page 614: ...t tightening counterclosewi se Screw Set screw M 64 35 5 M 60 15 3 M 16 26 7 2 7 1 0 0 2 Note Before tightening use Three Bond 1360K or Lottile 242 on the linkage an thread Leakage volume of hydraulic...

Page 615: ...g 2 80 0 030 0 168 0 0 79 0 180 0 3 00 1 0 Maintenance capacity limit Preparation before disassembly See cylinder disassembly and assembly Disassembly See cylinder disassembly and assembly Inspection...

Page 616: ...Min Max Washer No 1 0t Quantity Washer No 0 5t Quantity Gap1 0 0 1 0 Fig 379 Bucket small structure 1 Pin with lock cover 7 Dustproof seal 13Screws 2 Pin with hole 8 Washer 14 Nut 3 Pin with base 9 Wa...

Page 617: ...il hose air bearing are included Bucket arm removing 1 Restract bucket arm 15 completely put the valve block on the point A 2 Remove the lock plate 16 and pin 17 of bucket arm cylinder 3 After startin...

Page 618: ...the lock plate 16 Figure 382 lock plate assembly Linkage instructions Table73 Gap and washer mm Item Gap Necessary washer Position Min Max Washer No 1 0t Quantity Washer No 0 5t Quantity Gap1 1 0 2 5...

Page 619: ...e with a sling to prevent it from falling off 4 Remove the locking screw of pin 10 connecting with bucket arm 5 Remove pin 10 and linkage 9 Linkage installing 1 Put the terminal of bucket arm down to...

Page 620: ...3 Hang the cylinder with a crane 21 4 Disconnect the hose of bucket arm cylinder 22 5 Remove the lock plate and the cylinder pin 23 Fig 386 Bucket arm cylinder with two washers 1 column 7 retaining ri...

Page 621: ...e cylinder throttle 24 and tie the hose on the pipelines firmly Bucket arm cylinder installing 1 Move the bucket arm cylinder 18 to the installation location 2 Align the holes straight and then instal...

Page 622: ...y and assembly Page Special tools See cylinder disassembly and assembly Page Tightening torque Table 75 Tightening torque unit kgf m A B C D Piston nut tightening closewise Locking nut tightening coun...

Page 623: ...ushing 1 100 0 036 0 090 0 195 0 06 0 0 096 0 285 0 58 5 Gap between linkage pin and bushing 2 80 0 030 0 076 0 168 0 07 9 0 180 0 30 0 1 0 Gap between rear pin and bushing 2 80 0 030 0 076 0 168 0 07...

Page 624: ...ee cylinder troubleshooting page Bucket cylinder Bucket removing 1 Put the excavating device down to make the bucket on ground fully 2 Remove locking screw 2 of the linkage pin and locking screw 2 of...

Page 625: ...e rotary operation lever slowly until the right boss of bucket arm contacts with the boss of bucket face to face no gap 4 Pull the safety lock lever into the locked position to prevent the movement of...

Page 626: ...view Description of bucket cylinder See instructions of cylinders page 501 See Overview section Coat the screw 13 of seal cover 5 with Three Bond 1360K or Loctite 242 Fig 397 Bucket cylinder with a cu...

Page 627: ...linder 5 Disconnect the hose 11 closed the port of hose with a sealing cap and tie the hose on the pipe properly in order to avoid the leakage of oil from the main hydraulic oil Bucket cylinder instal...

Page 628: ...cking nut tightening counterclosewise Screw Set screw M 64 35 5 M 60 15 3 M 16 26 7 2 7 1 0 0 2 Coat the screw 13 of seal cover 5 with Three Bond 1360K or Loctite 242 Leakage volume of hydraulic oil T...

Page 629: ...ap between rear pin and bushing 2 80 0 030 0 07 6 0 168 0 07 9 0 180 0 30 0 1 0 Maintenance capacity limit See cylinder disassembly and assembly Preparation before disassembly See cylinder disassembly...

Page 630: ...hoses and other devices The information provided in this manual is to introduce the structure and working principle of crush hammer and hydraulic shear About the purchase and installation of related...

Page 631: ...Component Throttle Instructio n Main control valve 2 ViewA B al2 Shruttle device 59 2 Pd Servo hydraulic selector valve 33 A bl2 Shruttle device 59 1 Servo hydraulic selector valve ViewA A Main contro...

Page 632: ...enoid valve 45 Detailed view G P Valve block of accumulator 9 S3 T Solenoid valve 11 T A Main pump 1 Pi1 Main pump 1 View G Pi1 Main control valve 2 Fl X1 Proportional solenoid valve 45 A Hammer and s...

Page 633: ...etailed viewO S1 Main control valve 2 Pg1 Solenoid valve 11 P2 S2 Swing motor PG S3 X1 Proportional solenoid valve 45 P Servo hydraulic selector valve 33 P PS Main pump 1 A3 PS1 Main control valve 2 P...

Page 634: ...h A valve 8 solenoid coil 2 spools B 9 screws 3 springs C 10 O ring 4 plug 11 O ring 5 Locator C 12 O ring 6 rod 13 nameplate 7 DC solenoid valve Hammer oil return filter Table82 Specification oil ret...

Page 635: ...Maintenance Manual LG6210E Hydraulic Excavator 617 Description of the solenoid valve X1 3 section solenoid valve Fig 404 X1 3 section solenoid valve...

Page 636: ...line of pump Fig 405 Hammer and shears 1 2 pump oil flow pipe laying A servo hydraulic selector valve 40 C shuttle device 59 B 2 pump oil flow solenoid valve 43 D hydraulic tank 21 Table83 Throttle co...

Page 637: ...mmer and hydraulic shear proportional solenoid valve Table84 Proportional solenoid valve specification Instruction Unit Specification Max Working pressure kgf cm2 90 Allowed retreated pressure kgf cm2...

Page 638: ...lve 1 Fig 407 Hammer and hydraulic shears 1 solenoid valves A valve 9 DC solenoid valve 2 spool 10 solenoid coil 3 locator A 11 O ring 4 locator B 12 O ring 5 gasket 13 O ring 6 spring 14 O ring 7 Nut...

Page 639: ...ture C 20 9 Viscosity range cSt 5 500 Power source D28G Normal voltage V 28 Normal current A DC 28 V and 20 C it is 1 0 Hammer and shears with 2 pump oil flow pipe 2 Fig 408 Hammer and hydraulic shear...

Page 640: ...source D28G Normal voltage V 28 Normal current A DC 28 V and 20 C it is 1 0 Hammer and hydraulic shear shuttle valve A type Fig 409 Hammer and hydraulic shear shuttle valve A type 1 Valve body 4 O ri...

Page 641: ...4 spring 13 O ring 5 O ring 14 cover 6 O ring 15 screws 7 prop ring 16 plug 8 plug 17 plug 9 O ring Table 88 specifications the solenoid valve 1 Instruction Unit Specification Max flow kgf cm2 500 Max...

Page 642: ...itional Equipment Additional base mechanical and hydraulic quick mount Hydraulic Quick Installation instruction The quick installation accessories include a flat plate assembly which can be fixed on t...

Page 643: ...ocking wedge is self regulated to provide seamless lock Locking wedge 4 is released the servo pressure is transmitted to piston rod side If necessary increase the release of pressure through the termi...

Page 644: ...xcavator 626 Table90 Gap and washer Position Gap mm Necessary washer of max gap Max Min Washer No 1t No Washer No 0 5t No Gap1 0 0 2 5 Fig 413 Quick Installation pin 1 pin with locking cover 3 nut 2 s...

Page 645: ...on cylinder A 4 Hose assembly connected to the quick installation cylinder B 5 Hose assembly connected to the quick installation cylinder B 6 Hose assembly connected to the quick installation cylinder...

Page 646: ...Maintenance Manual LG6210E Hydraulic Excavator 628...

Page 647: ...ook the bucket lock it according to installation instructions of bucket or tool Fig 416 Quick installation the pipeline of the basic machine 1 to the main control valve Y 5 to the valve block 1 P6 2 t...

Page 648: ...nstructions of the bucket Place required gaskets under the plate and then reinstall the bucket or tools According to the allowable error lock the position of wedge Measure between screw base and the p...

Page 649: ...mall fault and don t only rely on self intuition and experience to deal with problems but find cause of the malfunction maintain and adjust according to the principles of troubleshooting to prevent gr...

Page 650: ...or is the first time Whether there is some machine that has similar problems If yes what components are repaired or replaced Collect all the facts of the complaints Check the machine Before you start...

Page 651: ...t the failure has been removed Search for possible causes Before reaching a conclusion check the most likely cause once again Try to identify the actual reason of the failure According to your own con...

Page 652: ...lywheel check whether the rubber pieces or parts are still there Coupling element is damaged remove and replace Rack spline of coupling component is worn or screws are loose Replace coupling assembly...

Page 653: ...Drop some oil on the hot plate check whether there are bubbles Water is mixed with oil Hydraulic oil is mixed with other brands Is only one brand of hydraulic oil Yes No No Replace with special hydra...

Page 654: ...ulic oil cleaner Ensure air circulation pipe is not blocked Hydraulic oil cooling fan speed is within the specified value Check and close release pressure re adjust or replace relief valve Is the main...

Page 655: ...correct Hydraulic oil viscosity is too high Replace hydraulic oil with the appropriate viscosity Pumping mesh is blocked Clean pumping mesh Check whether there are air intruding the pump pipeline Che...

Page 656: ...the operation lever the system doesn t work Ye No No Hydraulic oil is used more than the required replacement time Replace hydraulic oil and filters If conditional clean the hydraulic system The oil f...

Page 657: ...ied to the servo chamber of master valve Repair or replace master valve Filter of control valve connector is clogged Clean the connector filter If the servo hydraulic pipes of remote control valve is...

Page 658: ...avator 640 Table 98 The movements of digging devices is too slow Check whether the remote control valve is operating properly Repair or replace master valve Repair the cylinder seal of mining equipmen...

Page 659: ...d or leakage Clear or repair the leaking hydraulic lines Whether the basic servo hydraulic pressure is within the specified value Servo hydraulic pump is faulty Servo hydraulic pump is supplying oil S...

Page 660: ...of control box is lowered unlocked position Check whether the safety limit switch is working well Check whether servo hydraulic pressure of the servo solenoid valve throttle Pi is at the required pre...

Page 661: ...main pumping throttle has air Repair the main pumping throttle Pumping mesh is blocked Clean the mesh Repair or replace the main pump Check whether the servo hydraulic set is normal Repair or replace...

Page 662: ...e tap power Major released pressure is normal Repair or replace the main pump Repair or replace mining main relief valve Only one actuator is unable to provide mining power Replace the throttle releas...

Page 663: ...her failure phenomena is missing Check the spool of control valve Check the remote control valve Check the shuttle valve Rotary brake release pressure is normal Check the servo hydraulic pipeline Rota...

Page 664: ...ary release valve is with unusual sound Disassemble and repair or replace Check whether the rotary piston is stuck or bearing is worn out Rotary motor is faulty Disassemble and repair Rotary gear box...

Page 665: ...ning but the machine does not work Repair or replace rotary motor Repair main control valve Swing device is normal Check servo hydraulic pipeline Displacement of rotary motor is normal Check whether t...

Page 666: ...ut braking force is normal After exchanging the the left right servo hydraulic hoses will the failure happen Check servo hydraulic set is normal Repair or replace the control valve Repair or replace t...

Page 667: ...or replace the main pump Whether it is smooth within the central channel Repair replace traveling motor Replace seal of steering knuckle Check whether the servo hydraulic set is normal Repair or repl...

Page 668: ...drained pipelines of two umps will the failure happen Adjust oil pump regulator or repair the pump After exchanging the oil drained pipelines of the central channel input will the failure happen Repa...

Page 669: ...lace the load check valve After turning off the motor this phenomenon is still there Output pressure of remote control valve is not adjusted correctly Repair or replace the remote control valve Replac...

Page 670: ...ction Inserted connector Quick connection Such as pressure test connector Limit device Limit device tiny viscous control Adjustable limit device Fuel tank and accumulator Gas tank Open type Accumulato...

Page 671: ...ic pressure reducing Gas control Control by gas pressure reducing Power source Gas engine Electrical motor Pump Hydraulic pump fixed displacement and single direction Hydraulic pump variable displacem...

Page 672: ...f piston rod is named as Positive Valve The valve to prevent oil return which needs extremely low pressure The valve to prevent oil return which needs certain pressure value Shruttle valve Pressure li...

Page 673: ...the parallel lines next to the valve symbols Internal processes and the flow direction are shown in the square When the other parts are relevant to the charts the line leading to the valve will be dr...

Page 674: ...ected so that the negative side of the cylinder is connected to the imports and the positive side is connected with fuel tank Hydraulic circuit throttle No Part Throttle Item No Throttle Instruction 1...

Page 675: ...lecting throttle AR1 5 S Boom descending throttle Small chamber 77 B Boom hit position throttle BR1 5 L Boom ascending throttle Large chamber 77 A Boom hit position throttle AR2 7 L Bucket inner bent...

Page 676: ...ttle ar2 16 Bl1 Bucket inner bent servo hydraulic throttle br2 16 BO1 Bucket arm stretches out servo hydraulic throttle 4Pi 58 4 Signal throttle of bucket arm lock valve bl4 15 2 Left traveling thrott...

Page 677: ...dr1 21 Td5 Oil draining port dr2 2 dr4 Oil draining port dr3 21 Td6 Oil draining port dr4 21 Td7 Oil draining port dr5 21 Td8 Oil draining port Y 36 P3 Rapid assembly valve Fr 1 Pi2 Denying pump contr...

Page 678: ...C Left track throttle Forward B Left 17 E Left track throttle Backward A Right 17 F Right track throttle Forward B Right 17 D Right track throttle Backward 5 Boom cylinder L 2 BR1 Input throttle of b...

Page 679: ...ck of accumulator 11 Solenoid valve A1 31 P1 Pressure source of remote control valve A2 2 Py Pressurized servo hydraulic throttle Main A3 17 B High speed travelling signal throttle P1 9 PS1 Basic pres...

Page 680: ...f bucket arm stretches out Cylinder withdraws 3 16 SR Servo hydraulic throttle of swing right 4 16 AL Servo hydraulic throttle of bucket arm withdraws Cylinder stretches P 31 P5 Pressure source of rem...

Page 681: ...source of bucket arm withdrawing AL2 58 1 Auxiliary pressure source of valve blocks AO 13 2 Auxiliary pressure input throttle Bucket arm extends AO1 2 bl3 Bucket arm extending servo hydraulic throttle...

Page 682: ...k throttle Forward D 2 BR3 Right track throttle Backward E 2 AL4 Left track throttle Backward F 2 AR3 Right track throttle Forward B 11 A3 High speed signal of basic pressure source G 3 Dr Oil drainin...

Page 683: ...Pressure input of auto slow down Travelling 2 Pressure switch throttle 3 2 Pa Bucket oil regeneration valve signal 29 Filter connecto r Filter connecto r 31 Valve block 1 P1 11 A1 Basic pressure inpu...

Page 684: ...e X1 penal T4 15 T Fuel tank oil return Remote control valve traveling penal 52 T Fuel tank oil return Remote control valve X12 penal T5 13 T Fuel tank oil return Remote control valve left operation l...

Page 685: ...g brake PG Proportional solenoid valve for pump control Moving straight circuit and h automatic idle Pg Solenoid valve of the main pressure turbocharger 2 speed walking signal solenoid valve Boom lock...

Page 686: ...h the oil cooler and the oil filter 22 where impurities are removed and then discharged into the tank Hydraulic circuit standard A main pump 25 sieve 2 main control valve 26 breathing apparatus 3 rota...

Page 687: ...67 Central bypass valve 19 check valve 3 k 68 foot pressure reducing valve 20 check valve 4 5k 69 throttle pressure reducing valve 21 hydraulic tank 70 Bucket oil regeneration valve 22 oil return filt...

Page 688: ...Maintenance Manual LG6210E Hydraulic Excavator 670...

Page 689: ...l 3 Pb of spool on the logical valve 62 spool valve Then P1 goes to the upper side of logic valve through check valve and the spool of logic valve Due to the area difference the valve position 62 rema...

Page 690: ...on valve 70 is pushed to the left the oil return circuit is limited Bucket arm oil regeneration valve 71 in the center of the spool is opened some oil circuits converges with oil supply and flows to s...

Page 691: ...Maintenance Manual LG6210E Hydraulic Excavator 673...

Page 692: ...and is oriented to the throttle 2 a of central bypass valve left 67 move the spool to block vacuum flow signal 2 Fr of pump P2 to the fuel tank so oil flow PR of P2 pump increases and flows to the buc...

Page 693: ...Maintenance Manual LG6210E Hydraulic Excavator 675...

Page 694: ...ully pushed in the end Bucket arm operation lever operates at full stroke the maximum the auxiliary servo hydraulic pressure is applied to the throttle 33 Pi of servo hydraulic selector valve 33 move...

Page 695: ...Maintenance Manual LG6210E Hydraulic Excavator 677...

Page 696: ...brake SW Oil flows to oil regeneration valve 70 through throttle 2 Pa move the spool to the left t o limit oil return flow of bucket arm Thus keep rotary priority in the swing stick while operating B...

Page 697: ...Maintenance Manual LG6210E Hydraulic Excavator 679...

Page 698: ...ve 71 in the center of bucket arm spool which will make some returned oil converge with supply oil then goes into the bucket cylinder rod Therefore the oil flow of P1 pump will be directed for the swi...

Page 699: ...6210E Hydraulic Excavator 681 Color of pipeline index Red High pressure oil Blue Low voltage servo hydraulic basic pressure oil Brown Servo hydraulic auxiliary oil Green Oil draining circuit pump abso...

Page 700: ...Maintenance Manual LG6210E Hydraulic Excavator 682...

Page 701: ...fixed low speed the basic servo hydraulic pressure leading to the transition valve throttle 17 B is stopped by stoppers 11 and solenoid valve block A3 1 2 speed automatic conversion solenoid valve A3...

Page 702: ...ormation of low high speed and to prevent overspeeding In walking the main booster is done automatically by the controller Negative pipeline Fr and Fl is disconnected to increase oil output rate of P1...

Page 703: ...Maintenance Manual LG6210E Hydraulic Excavator 685...

Page 704: ...the operation P2 pump PR supplies to traveling left and P1 L supplies to travelling left During the traveling moving straight transition valve 66 is closed During the traveling operate Bucket withdra...

Page 705: ...Maintenance Manual LG6210E Hydraulic Excavator 687...

Page 706: ...nd the design and structure of all its components This section also includes the function description troubleshooting and maintenance methods Electrical system is composed of electrical electro mechan...

Page 707: ...arefully Also refer to Security and manual guidance WARNING Before starting work in the electrical system watches rings bracelets and other metal objects must be removed from the body WARNING Do not s...

Page 708: ...batteries contain sulfuric acid solution it will result in personal injury accidents WARNING Never charge the frozen battery For the risk of explosion When the engine is running do not disconnect the...

Page 709: ...should have enough tension and measure according to the diagram Important Always apply a safe way to connect the cable to ensure that the cable does not have corrosion dirt Loose cable connection cou...

Page 710: ...e static electricity of tool Do not touch the connector pins on the electronic unit When maintaining electrical systems avoid touching the circuit board If you have to contact with it only seize the e...

Page 711: ...e machine Note The cable should not exceed 3M otherwise it will not achieve the desired results Start with the starting cables Before connecting please check the followings The ignition switch on 2 ma...

Page 712: ...irmly and correctly connected Refer to Figure Start the engine on a auxiliary machine Start the engine of the starting machine If the engine can not be started in 30 seconds wait about two seconds try...

Page 713: ...cute the command If a function failure occurs in a system a signal will be transmitted to the information bus which can read this information in the driver s instrument with MCD SERDIA unit Informatio...

Page 714: ...main communication operations are on the CAN J1939bus Instrument Control Unit I ECU Function instruction Instrument electronic control components I ECU is located at the right of the steering wheel in...

Page 715: ...be on if not check damaged bulbs and check the plug connector connector A B on printed circuit board After staring engine Before starting the battery charging warning light and engine oil pressure war...

Page 716: ...power control Automatic idle Automatic and once touch for power boost Safety starting and stopping Automatic speed control Input signal Table1 Pin No Components Instruction Input type VB9 SW9103 Auto...

Page 717: ...3 MA9107 Boost solenoid valve Digit VB26 RE3301 Close signal of starting relay Digit VB27 MA9120 Floating position solenoid valve Digit VB61 SE2502 Air filter sensor Digit VB67 SE2303 Fuel level senso...

Page 718: ...river to engine speed and operating mode according to operating conditions and environment so that the machine performance and the efficiency of oil get been optimized V ECU receives information on th...

Page 719: ...arm small arm confluence closing solenoid valve ON Running speed selecting solenoid valve ON Step1 2 Engine speed control switch Input current of power shift proportional valve for I mode Engine speed...

Page 720: ...e following three steps range Step 3 4 5 uses 70 of the rated output horsepower of engine but in each step the model will provide a constant current for the power gearshift proportional valve PWM9101...

Page 721: ...f Noloadin g Full loadin g 10 P 2040 2080 2025 200 OFF OFF 9 H 1930 2000 1950 265 OFF OFF 8 G1 1835 1905 1860 305 OFF OFF 7 G2 1740 1810 1765 305 OFF OFF 6 G3 1640 1705 1670 305 OFF OFF 5 F1 1450 1510...

Page 722: ...work Interval 5 second Movement location oriented pressure switch does not work Input current of powe shift proportional valve is corresponding to modle I1 Engine speed is corresponding to mode I1 Aut...

Page 723: ...d high speed Low speed mode If running speed selecting switch is at low position no mark or the engine speed control switch is in the F mode steps 3 5 regardless of the load on the motor running speed...

Page 724: ...valve is off Software functions of electrical system of equipped with I ECU Fault code display Note About the detailed description of the fault code refer to Fault code troubleshooting This feature s...

Page 725: ...indness If acid contacts your skin or eyes rinse immediately with plenty of water and immediately see a doctor Note When removing the battery at first cut off the cable with black pipes usually a nega...

Page 726: ...Turn off the master switch 2 Remove the four screws on the battery cover and remove the battery cover 4 Removing the cable of battery 5 Replace with new batteries Note There is risk of personal injury...

Page 727: ...d the V ECU communicates with I ECU about information the state of charging Current flows timer starting switch is ON the working timer begins to work 4 Starting system 4 1Overview Starting operations...

Page 728: ...ne MO3301 Starter safety locking If the starting switch is in START position continuously V ECU VB26 Coil RE3301 of activated starting relay cuts off the current in the starting switch When the engine...

Page 729: ...2 Terminal 50 tightening torque 1 2 Nm 3 Starting engine 4 Solenoid valve relay Battery relay instructions Relay opens or closes the solenoid valve according to the low power signal received from the...

Page 730: ...he machine in the maintenance position 2 Remove four screws 1 fixingthe right front cover 3 Remove the five screws 1 and EDB cover 2 4 Pull out the starting relay RE3301 1 5 Replace with a new one 6 R...

Page 731: ...ward or backward make sound to warn workers for the danger When walking function is working the pressure switch installed in walking the hydraulic circuit will activate the alarm Press the walking ala...

Page 732: ...is running positively the windows are opened at first stop the wiper and fix it on the bracket on the stopping position Otherwise the front window is closed it may crash blades resulting in failure W...

Page 733: ...itches Motor rotates once the wiper blade is operated interactively through the lever body 1 auxiliary parking supply Y 2 Parking supply GN 3 GND SB 4 n2 speed BL 5 n1 speed R Window limit switch indi...

Page 734: ...witch is OFF you can still use the automatic lubrication optional fuel filling pump optional and cab lights Starting switch specification Switch provides the power to starting stopping of engine and t...

Page 735: ...with two M12 screws and nuts V ECU replace ECU Note Before removing V ECU make sure the main switch is turned off 1 Move operator seat to a front position and unfold backrest forward 2 Remove the plas...

Page 736: ...ounding 4 ventilation holes 5 M14 x 1 5 6 hybrid circuit 7 grounding of shelling 8 customization of clients IC 9 feedback goes through 10 3500 pF feed goesthrough Oil pressure is monitored by the inst...

Page 737: ...te engine oil temperature sensor is not necessary The temperature sensor senses the changes of temperature by the changes of thermistor caused by temperature Sensors provides the necessary information...

Page 738: ...the machine warning the driver whether any abnormality occurs Instrument can adjust the different perspectives of driver and designed lighting for night operations All bulbs should be checked daily t...

Page 739: ...warning LC9103 hydraulic oil temperature warning light Alarm indication If the machine is abnormal in working condition the buzzer will warn the driver to take immediate measures WARNING Do not ignor...

Page 740: ...arning light will be also lit Press the key to shut off the buzzer you can press the key twice to delete 7 Radio CD player voltage divider 7 1 CD and MP3 player with radio Table12 1 Power volume 10 Pr...

Page 741: ...t speaker 12 Power signal of controoler 5 Left speaker 13 Grounding controller 6 14 Left speaker 7 Antenna 15 8 Spare 16 Grounding 7 2 Voltage divider DC DC Transformer indication 24V of battery reduc...

Page 742: ...Supply 31G Positive connection Parts catalog generators batteries electronic unit Mark Name Circuit AL3201 Generator Circuit SCH01 BA3101 Battery1 Circuit SCH01 BA3102 Battery2 Circuit SCH01 EMR2 Engi...

Page 743: ...mp Circuit SCH07 LA3528 Right side of boom working lamp Circuit SCH07 LA3601 Rotary signal lamp Circuit SCH014 Parts list indicating lights warning lights Mark Name Circuit IM3803 Fuel level gauge Cir...

Page 744: ...onal Circuit SCH16 MA9111 X3 right solenoid valve Optional Circuit SCH16 MA9117 X1 hydraulic hammer selecting solenoid valve Circuit SCH15 MA9118 X 1 Shear selecting solenoid valve Circuit SCH15 MA912...

Page 745: ...ond speed relay Circuit SCH10 RE8705 Third speeed relay Circuit SCH10 RE8706 Fourth speed relay Circuit SCH10 RE9104 Rapid assembly 1 relay Optional Circuit SCH16 RE9105 Rapid assembly 2 relay Optiona...

Page 746: ...it SCH03 SW3503 Indoor lamp switch Circuit SCH14 SW3504 Standard working lamp switch Circuit SCH07 SW3505 Auxillary working lamp switch Circuit SCH07 SW3602 Upper wiper switch Circuit SCH13 SW3603 Bot...

Page 747: ...ity Name Circuit FU01 10A IECU Circuit SCH02 FU02 10A Front lamp Circuit SCH07 FU03 15A Boom lamp Circuit SCH07 FU04 10A Wiper Circuit SCH13 FU05 10A P03904 Circuit SCH02 FU06 10A Cigretter lighter Ci...

Page 748: ...FU30 15A EMR2 Circuit SCH02 Components table other items Mark Name Circuit ANT3901 Antenna Circuit SCH12 CR3901 Radio Circuit SCH12 PO3901 12V power base Circuit SCH12 PO3904 Diagnosis base Circuit SC...

Page 749: ...rning sensor Circuit SCH04 SCH07 Working light Circuit SCH07 SCH08 Machine control Circuit SCH08 SCH10 Air conditioning control unit Circuit SCH10 SCH12 Audio and speaker Circuit SCH12 SCH13 Wiper and...

Page 750: ...Name Mark Name BA3101 Battery1 BA3102 Battery2 FC01 Slow melt fuse FC02 Slow melt fuse FC03 Slow melt fuse FC04 Slow melt fuse AL3201 Generator RE3101 Battery relay SW330 1 Starting switch RE3301 Sta...

Page 751: ...Maintenance Manual LG6210E Hydraulic Excavator 733 Fig 63 Element position...

Page 752: ...aintenance Manual LG6210E Hydraulic Excavator 734 SCH02 Fig 64 Circuit of SCH02 Mark Name Mark Name IECU Gauge controller VECU Vehicle EMR2 Engine controller PO3904 Diagnosis base SEROIA Diagnosis bas...

Page 753: ...Maintenance Manual LG6210E Hydraulic Excavator 735 Fig 65 Element position...

Page 754: ...lic Excavator 736 SCH03 Fig 66 Circuit of SCH03 Mark Name Mark Name SW330 1 Starting switch SW270 1 Engine speed control switch SW270 3 Auto idle switch RE2501 Preheator relay RE3301 Starting relay SW...

Page 755: ...cavator 737 8 HE2501 Air preheator MO330 1 Starting engine SE2701 Engine speed sensor crane SE2703 Engine speed sensor Camshaft MA9108 Operation locking solenoid valve VECU Vehicle controller EMR2 Eng...

Page 756: ...Mark Name Mark Name LM3811 Coolant temperature gauge IM3803 Fuel level gauge LM3812 Hour meter HE2501 Preheating component LC3803 Central warning indicator lamp LC3201 Battery charging indicator lamp...

Page 757: ...or lamp LC2602 Coolant low level indicator lamp SE2303 Coolant level sensor SE2603 Coolant level sensor SE2606 Coolant temperature sensor SE2203 Engine fuel pressure sensor SE2508 Boost pressure senso...

Page 758: ...Maintenance Manual LG6210E Hydraulic Excavator 740 SCH07 Fig 70 Circuit of SCH07 Mark Name Mark Name SW350 Standard working lamp switch SW350 Auxillary working lamp switch...

Page 759: ...ing lamp LA3527 Left side of boom working lamp LA3528 Right side of boom working lamp LA3521 Left front part of cab working lamp LA3522 Right front part of cab working lamp LA3514 Rear of cab working...

Page 760: ...frame working lamp LA3513 Right side of upper frame working lamp LA3527 Left side of boom working lamp LA3528 Right side of boom working lamp Optional LA3521 Front left side of cab working lamp Optio...

Page 761: ...Maintenance Manual LG6210E Hydraulic Excavator 743 Fig 71 Element positions...

Page 762: ...W420 2 Travelling speed switch SW9103 Auto manual pump control switch SW270 3 Auto idle switch SW9118 Operation lever switch MA4212 Starting engine solenoid valve MA9105 Boom conflux cutoff solenoid v...

Page 763: ...Maintenance Manual LG6210E Hydraulic Excavator 745 R9101 Manual resistor1 Fig 73 Element positions...

Page 764: ...8701 Cooling fan motor MO870 3 Inlet actuator MO8704 Face actuator MO870 5 Right foot actuator MO8706 Left foot actuator MO870 7 Mixed actuator SE8701 Air refrigerant pressure monitor SE8702 Refrigera...

Page 765: ...6210E Hydraulic Excavator 747 RE8703 First speed relay RE8704 Second speed relay RE8705 Third speeed relay RE8706 Fourth speed relay MA8701 Compressor relay R8701 Resistor RE8702 Compressor relay Fig...

Page 766: ...e switch SA3901 Left speaker SA3902 Rigt speaker PO3901 12V power base SE4306 Travelling pressure sensor RE3611 Horn relay SW3609 Right operation lever horn switch SW3610 Left operation lever horn swi...

Page 767: ...Maintenance Manual LG6210E Hydraulic Excavator 749 Fig 77 Element positions...

Page 768: ...g 80 Circuit of SCH13 Mark Name Mark Name SW360 2 Upper wiper switch SW360 3 Bottom wiper switch Optional SW360 8 Cleaner switch CU3601 Wiper controller SE3602 Upper limit switch SE3603 Boottom limit...

Page 769: ...Maintenance Manual LG6210E Hydraulic Excavator 751 1 2 MO360 3 Bottom wiper motor Fig 79 Element position...

Page 770: ...l LG6210E Hydraulic Excavator 752 SCH14 Fig 80 Circuit of SCH14 Mark Name Mark Name SW360 7 Turning signal lamp switch LA3601 Turning signal lamp SW350 3 Indoor lamp switch LA3501 Indoor lamp HE3801 C...

Page 771: ...Maintenance Manual LG6210E Hydraulic Excavator 753 Fig 81 Element position...

Page 772: ...57 Shear selecting lamp SW910 7 Shear hydraulic hammer selecting switch SW910 8 Strengthening hydraulic hammer switch MA9107 Booster valve MA9117 X1 hydraulic hammer selecting solenoid valve MA9118 X...

Page 773: ...Maintenance Manual LG6210E Hydraulic Excavator 755 Fig 83 Element position SCH16...

Page 774: ...10 5 Rapid assembly switch 2 Optional SW916 0 Rapid assembly buzzer STOP CONFIRM Optional RE9104 Rapid assembly 1 relay Optional RE9105 Rapid assembly 2 relay Optional RE9106 X3 Rapid assembly safety...

Page 775: ...Maintenance Manual LG6210E Hydraulic Excavator 757 Fig 85 Element position...

Page 776: ...lic Excavator 758 SCH17 Fig 87 Circuit of SCH17 Mark Name Mark Name SE9140 Boom floating position switch Optional SW915 8 Boom translation switch pump Optional MA9120 Boom floating position solenoid v...

Page 777: ...Maintenance Manual LG6210E Hydraulic Excavator 759 Fig 87 Element position SCH18 Fig 88 Circuit of SCH18 Mark Name Mark Name SW2304 Fuel filling pump switch Optional MO230 2 Fuel filling pump Optional...

Page 778: ...nergy Application circuit No Energy Application circuit F1 10A I ECU F16 10A Starting switch F2 10A Working lamp Ceiling F17 5A Cab lamp F3 15A Working lamp Boom F18 10A Diagnose connector F4 10A Wipe...

Page 779: ...of rotator F14 5A Overloading selecting switch F29 15A Travelling warning heater of oil water separator F15 F30 15A E ECU Slow melt fuse instruction When current with large capacity flows slow melt fu...

Page 780: ...he screws 9 fixes the fuse housing on the supporting frame 2 Open the cover 2 with clamp 3 Open the side cover with screwdriver 4 Remove the bolt 4 from the connector 5 to remove the fuse 1 5 Install...

Page 781: ...s message 2 Engine oil pressure low 02 EMR2 sends this message 3 Air filter clogged 03 VB61 Air filter clogging sensor is ON 4 Preheater driver 04 VB50 VB13 Preheater relay circuit is short open 5 Pre...

Page 782: ...210E Hydraulic Excavator 764 13 V ECU power 41 VA15 VA16 voltage is low 14 Fuse Solenoid relay 42 VA09 voltage is low 15 Fuse PWM 43 VA11 voltage is low 16 Fuel level sensor 44 VB67 signal 4 5V or sig...

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