Professional Documents
Culture Documents
CLG930E/936E
Hydraulic Excavator
Service Manual
Applicable type and model:CLG930E /Commins 6C8.3 (EPA Tier 2/EU Stage)
Contents
Safety................................................................................................................................1-1
Basic Information ............................................................................................................2-1
Structure function and maintenance .............................................................................3-1
Parameter .........................................................................................................................4-1
Adjustment and Test .......................................................................................................5-1
Fault Diagnosis................................................................................................................6-1
Removal and Installation ................................................................................................7-1
Attached drawing ............................................................................................................8-1
Contents December 30, 2017
CLG930E/936E
1-1
December 30, 2017 Safety
CLG930E/936E
Safety
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1-4
1.1 Safety Precautions December 30, 2017
CLG930E/936E
Goggles, safety glasses or mask can protect Prevent foreign matters from entering the
your eyes from the hazards of high-pressure fluid components of the system when inspecting the
during the maintenance of the battery and the opened oil tanks or water tanks. Please empty
hazards of flying debris generated during the the clothes pockets and move wrenches and
work of the engine and the operation of tools. nuts with great care before removing the cover.
Please wear the protection mask when removing
spring, elastic parts or add acid to the battery.
Please wear the safety cap and goggles when
conducting welding operations or using the
welding gun for cutting.
Please wear safety goggles and leather gloves Use proper container when draining liquid. Do
when checking for leakages. Do not use bare not use the food or drink containers because
hands to check the leakage, but use plate or they may be drunk by others by mistake.
paper plate to check the leakage.
1-6
1.1 Safety Precautions December 30, 2017
Precautions for Accumulator Application CLG930E/936E
Prevent Burn
Battery
Do not perform welding or flame cutting onto the Pipeline, Pipe and Hose
pipe containing flammable liquid. Before welding
or cutting, the operation shall be performed until
flammable liquid is cleaned completely. Do not warp or knock the high-pressure pipeline,
and do not install the abnormally warped or
Accumulated flammable materials such as fuel, broken pipes or hoses onto the machine.
lubricant or other scattered materials on the
machine shall be cleaned up. Repair the loose or damaged pipelines of fuel
and lubricant and pipes and hoses of hydraulic
Do not operate the machine near open fire. system in time. Leakage will cause fire hazard,
Make sure the battery is far away from open fire and if repair or replacement is necessary, please
and sparks, and do not smoke at the place of contact the authorized dealer by LiuGong
battery charing. Machinery Co., Ltd.
When the machine is started with a jump If following problems occur, replacement should
method, the (+) cable must be connected to be necessary.
battery (+) terminal which is connected with ● Damage or leakage of joint.
starter motor coil, and (-) of external power is
connected with (-) of the starter. If there is no ● The outer layer of hose is worn or cracked,
starter negative terminal, it shall be connected to and inner steel wires are exposed.
the engine housing. ● Partial bulge of hose.
Do not charge the frozen battery to avoid ● Hose with obvious twisting or flattening.
explosion.
● Hose guide wire is embedded into the outer
layer.
Diethyl Ether
● Misplacement of the end joints.
Make sure all clamps, guard and heat shield are
installed correctly to avoid shaking or cause
overheating by friction with other parts.
Do not use diethyl ether to start the engine When removing the connecting pipe of the
compressor, open fire is forbidden, or it will
generate toxic gas, resulting in poisoning.
Any approach which attempts to start the engine
by use of diethyl ether may cause serious
damage to engines or casualties.
1-10
1.1 Safety Precautions December 30, 2017
Fire Extinguisher and First-aid Kit CLG930E/936E
Be sure to equip fire extinguisher, carefully read Top Safeguard and Front Safeguard
its use instructions, and be sure to know how to
use it. The protectors are installed in order to prevent
The construction site must have first-aid kit in the driver from injuring by the falling or splashing
stock. Conduct regular inspection and add some objects under some special circumstances. Be
medicines if necessary. sure to close the window before hazardous work.
All personnel except the driver must be kept
You should know how to handle it when fire away hazardous zone. Please add top and front
hazard or injury occurs. guard devices as necessary.
Select some personnels' phone number (such as
doctor, first-aid center, fire station and so on) for
1
use in emergency. Post the contact number list
onto the specified locations to ensure that the
staff knows correct contact information .
1.2 Precautions for Lifting When using more than 2 wire ropes for lifted
load, the larger the lifting angle of each wire
and Matching Operations roper is, the smaller the lifted load is. The figure
below shows maximum load of different lifting
1. One designated personnel sends out angle by 2 wire ropes weighting 9.8KN (1000Kg).
cooperative signal to fully keep the contacts When the lifting angle of 2 wire ropes are 0
among cooperative operating personnel. The degree, the maximum load is 19.6KN (2000 Kg);
signalman shall stay in a safe place where when the lifting angle is 120°, the maximum load
can be seen by the driver as well as can is 9.8KN (1000 Kg); If the lifting angle is 150° and
understand operating state easily, and the load is 19.6KN (2000 Kg), the wire rope
definitely send out specified signal in the requires to bear the load of 39.2KN (4000 Kg).
method in advance.
● It is forbidden to stand under the lifted load.
● It is forbidden to climb on the lifted load.
2. Check the slings and other appliances before
lifting operation.
3. Wear gloves during lifting operation. (Leather
gloves are the best)
4. Measure the weight by inspection and
guarantee the lifted load keeping steady.
5. Appropriate slings shall be used for the
weight of lifted load or lifting mode. Load may
fall down if thicker wire ropes are used for 8. A liner shall be used for avoiding being
lighter load. damaged by the wire ropes when installed on
6. Try to avoid lifting by a single wire rope. Lifted the lifted load with edge angles. For the lifted
load may rotate or fall off due to looseness. load which easily slides, an anti-skid device
Apply 2 or more wire ropes for lifting in shall be used.
symmetric mode. 9. Use genuine eyebolts and shackle, etc. to fix
eyebolts, wire ropes and iron chains, etc.
10. Hang the wire rope in the central part of hook
for lifting.
If only a single wire rope is used for lifting,
the lifted load may rotate, and swing back 11. If the wire rope is hung on the edge of hook
due to pull of the wire rope or deviate from for lifting, the rope may slide and even fall off
the lifting position, resulting in dangerous from the hook when lifting. The central part of
accident! hook has maximum intensity.
12. Do not use wire rope under the distortion
7. Lifting angle shall be below 60° in principle.
state.
Pay attention to avoiding overlarge lifting angle
between the wire rope and hook when lifting
heavy objects (above 25kg).
1-13
December 30, 2017 1.2 Precautions for Lifting and Matching Operations
CLG930E/936E Precautions for Operating Mobile Crane
● Stop rolling up after the wire rope is 4. Always confirm the directions of both
tensional, and confirm the condition of lifted directional display panel (east/west/south/
objects away from the ground and contact north) and the operation button.
conditions between slings and padded 5. Do not lift the load in a tilted angle or travel
objects. when the load swings.
● If the lifted load is unstable, or wire rope and 6. Do not operate lifting and lowering or
lifting chain are distorted, firstly lower the horizontal and vertical travel at the same
lifted load, and then lift again. time.
● The lifted load can not be tilted. 7. Do not use slings to drag for transport.
14. The following matters shall be noted during 8. Try to lift a little amount before lifting, and
the lowering operation. then lift after confirming it is safe.
● When lowering the lifted load, firstly stop at 9. Take moving route into consideration in
30cm above the ground or shelve, and then advance, and lift to a safe height.
lower down gently.
10. Place control switch on the position not
● Remove the slings after confirming the load affecting operation or passing.
is placed steadily.
11. Do not shake control switch forcefully after
● After the sling being arranged and cleaned, operating the crane.
put it in the designated place.
12. Remember the position of main power switch
so as to cut off the power rapidly in
Precautions for Operating Mobile emergency.
Crane
Basic Information
5. Fault Diagnosis
2. Workshop Guide
Second version
Publication month
Publication year
When the version is revised, the year and month will embody revision date of the version, and the last
numbers will reflect revision times of the Manual. For example, 001 represents the first revision, 002
represents the second revision, and so on.
2-5
December 30, 2017 2.3 General Torque Specifications
CLG930E/936E
Bolts involved in this machine shall be tightened in accordance with the torque requirements specified in
the following table, unless special declaration.
Table 1 CLG 930E excavator bolt torque chart
M8 25.2±1.2 2.57±0.12
M8 25.2±1.2 2.57±0.12
Material of
Carbon steel and alloy steel Aluminum product
fastenings
Tightening torque Tightening torque
Thread size
N.m kgf.m N.m kgf.m
G1/8 8.75±1.25 0.90±0.12 / /
G1/4 36±2 3.67±0.2 29.3±2.2 3.0±0.2
G3/8 73.5±4.5 7.5±0.46 49±3 5.0±0.3
G1/2 110±10 11.2±1.0 55±5 5.6±0.5
G3/4 165±15 16.8±1.5 74±4 7.5±0.4
G1 225±25 23.0±2.55 / /
G1-1/4 275±25 28.0±2.55 / /
G1-1/2 285±15 29.1±1.5 / /
Tightening torque
Thread size
N.m kgf.m
M12 24±2 2.4±0.2
The Manual uses ISO International System of Units, and ISO international units are converted into
British units as shown in following figure:
The wire in circuit diagram is marked in combination with wire No., wire categories, color abbreviation
codes and wire gauge for maintenance. For example:
Indicates heat-resistant, lower-voltage wire for vehicles, red, with the number of 108
and a diameter of 50.0mm2.
Wire gauge (Note: the ones with no marked wire gauge are all 0.85mm2)
Wire categories
Wire No.
Wire No.
Wire No. is digital code for marking wire with three Arabic numbers in accordance with certain rules.
Wire Categories
The wire categories selected for engineering machinery are AEX, AV, AVS, AVSS, and QVR in general.
For applicable range of ambient temperature of various wires, see following table.
Remark: the code composed of two colors indicates double-color wire, for example: "RD/GN" indicates
red-green wire.
Wire Specifications
Allowable current and voltage drop of AV wire, and approximate performances of AVS, AVSS and QVR
shall be executed uniformly according to following table.
Ambient
30°C 40°C 50°C 60°C 70°C
temperature
Allowable
current/voltage A mV/m A mV/m A mV/m A mV/m A mV/m
drop
0.85 18 463 16 412 14 360 11 283 8 206
1.25 23 407 21 372 18 319 14 248 10 177
2 31 338 28 305 24 262 20 218 14 153
3 42 291 38 263 33 228 27 187 19 132
5 57 248 51 222 44 192 36 157 25 109
8 74 213 66 190 57 164 47 135 33 95
Nominal 15 103 176 92 157 80 137 65 111 46 79
sectional
area (mm2) 20 135 148 121 133 105 116 85 94 60 66
30 188 121 168 108 146 94 119 77 84 54
40 210 112 188 110 163 87 133 71 94 50
50 246 103 220 92 190 80 155 65 110 46
60 272 97 243 87 211 75 172 62 121 43
85 335 90 300 80 260 70 212 57 150 40
100 399 83 356 74 309 65 252 53 178 37
2-13
December 30, 2017 2.6 Coating Materials
CLG930E/936E
For general corresponding rules between circuit type and wire color, see the following table.
Circuit type Color abbreviation codes
Power line OR, RD
Signal line WH
Grounding BK, GY
Communication line RD/GN, YL/BU
The following table indicates the reference value of the weight of each component. When the hoisting
equipment is used, please refer to the following table to select the sling.
Weight (kg)
Components
CLG930E CLG936E
Engine assembly (excluding coolant and engine oil) 743 743
Engine (excluding coolant and engine oil) 617 617
Hydraulic pump 130 186
Radiator assembly (excluding coolant, engine oil and fuel) 220 260
Hydraulic oil tank (without hydraulic oil) 235 253
Fuel tank (without fuel) 273 288
Revolving frame 2644 2942
Cab 385 665
Seat in Cab 38.6 31
Counterweight 5500 6500
Main control valve 230 230
Swing motor & reduction gear 424 424
Travel motor & reduction gear 399 399
Center joint 57 57
Boom 2134 2530
Arm 1086 1230
Boom cylinder assembly (single) 265 (integrated steel pipe) 294.7 (integrated steel pipe)
Arm cylinder assembly 345 (integrated steel pipe) 481 (integrated steel pipe)
Bucket cylinder assembly 250 (integrated steel pipe) 285 (integrated steel pipe)
Track assembly (single side) 1869.2 2108
Track frame assembly 4059 4192
Guide wheel assembly 242 242
Swing bearing 445 504
Idler tensioner 235 235
Carrier roller 35 35
Sprocket 80 80
Track roller 51.5 66
2-15
December 30, 2017 2.8 Specifications for Oil Application
CLG930E/936E
Application
Oil category Oil specifications Ambient temperature
locations
Bucket, swing bearing of Molybdenum-disulfide lithium-base
-20~40°C(-4~104°F)
Lubricant arm and boom, and grease 2# ★a
swiveling gear EP2 or RO2 -20~40°C(-4~104°F)
5W-40(API CH-4) -35~40°C(-31~104°F)
Engine crankcase, fuel
Diesel engine oil injection pump and 10W-30(API CH-4) -30~30°C(-22~86°F)
regulator -25~40°C(-13~104°F)
15W-40(API CH-4) ★
0# ★ Above 4°C (above 39.2°F)
-10# Above -5°C (above 23°F)
Diesel fuel -20# Above -14°C (above 6.8°F)
-30# Above -29°C (above -20.2°F)
-50# Above -44°C (above -47.2°F)
Anti-freeze (100% original liquid) and
Anti-freeze -30~40°C(-22~104°F)
water with proportion of 42:58
Swing reduction gear SAE85W-140(API GL-4) -20~45°C(-4~113°F)
Gear oil
Travel reduction gear SAE80W-90 (API GL-4) -20~45°C(-4~113°F)
ISO VG 32 -20~20°C(-4~68°F)
Hydraulic oil Hydraulic system ISO VG 46 ★ -20~40°C(-4~104°F)
ISO VG 68 -10~40°C(14~104°F)
a. The oil marked with ★ is the oil filled when the machine is transported out of the factory
1. The oil of the same specification but of different brands can't be used together. If another
brand of oil must be used, please clean the system first.
2. The lubricant should be changed on time. Even though the oil is very clean, yet it may
deteriorate if it is placed for a long time.
3. The selection of fuel should depend on the lowest temperature of the place where the machine
is used.
4. Except oil specifications in above table, when using the oil purchased in the market, please
contact the LiuGong dealers.
3-1
December 30, 2017 Structure function and maintenance
CLG930E/936E
2
3
1
1
2 3
7
9
3-4
3.1 Power System December 30, 2017
3.1.2 Water Radiator, Hydraulic Oil Radiator, Inter-cooler and Fuel Radiator CLG930E/936E
5
6
8
9
10
11
Judgment standards
No. Item Measures
Standard size Allowable limit
Installation Installation Installation Installation
Free length
7 Tensioner length load length load Replacement
- 995mm 190.12KN - -
3-6
3.2 Track Travel System December 30, 2017
3.2.2 Idler CLG930E/936E
Judgment standards
3.2.2 Idler
3-7
December 30, 2017 3.2 Track Travel System
CLG930E/936E 3.2.2 Idler
3.2.5 Sprocket
3.2.6 Track
8 9 10 11 12 13
14
15
16
4. Swing motor & reduction 9. Return oil filter 14.Right hand pilot valve T1: oil return of
gear 10.Main control valve 15.Left hand pilot valve electromagnetic valve
5. Right travel motor & 11.Left travel motor & 16.Travel pilot valve A1: Pilot unlock
reduction gear reduction gear P1: oil inlet of A2: Travel shift
6. Main pump 12.Four-step solenoid valve electromagnetic valve A3: Arm second speed
7. Accumulator 13.Center joint A7: Transient power
8. Breather valve boosting
3-16
3.3 Hydraulic System December 30, 2017
3.3.2 Hydraulic Element CLG930E/936E
1. Drive shaft Pi1-P1 pump pilot oil port B1- Main oil pump suction port
2. Minimum flow adjusting nut Pi2-P2 pump pilot oil port B3- Pilot pump suction port
3. Main pump regulator Psv - Main pump servo port Dr - Housing return oil
4. Electric proportional pressure- a1, a2, a3, a4- Pressure test port
reducing valve
5. Max.flow adjustment
Main pump assembly is composed of the main pump (pumps P1 and P2) and a pilot pump (pump P3).
The main fuel pump is a double variable plunger pump and provides high pressure oil for the main oil
circuit so that to supply pressure oil to hydraulic element such as main oil circuit. The pilot pump is a
constant gear pump and supplies oil for the pilot system and the main pump control system.
3-17
December 30, 2017 3.3 Hydraulic System
CLG930E/936E 3.3.2 Hydraulic Element
930E 936E
Displacement cm3/rev
160×2 140×2
Pressure Rated 34.3
MPa Max. 37.3
Rotate speed Rated 1900
r/min Max. 2000
Weight kg 130 185
Category Anti-wear hydraulic oil
Temperature range -20~+95°C
Hydraulic oil Viscosity range 10~200cSt(mm2/s)
Recommended Oil-return line Nominal size 10mm
strainer Suction line 80 ~ 150 mesh filter screen
The main pump is directly driven by the engine via a coupling, and the pilot gear pump is connected
behind the pump P2 in series, is indirectly driven by the drive shaft and rotates at the same speed to the
main pump during working.
The main pump is composed of two plunger The rotation mechanism consists of driving shaft
pumps, namely pump P1 and pump P2, which (111·113), cylinder block (141), plunger, piston
are connected by a coupling (114). The rotation shoes (151·152), return plate (153), spherical
of the motor is delivered to the drive shaft (111) bushing (156), return spring (157). The driving
at the front to simultaneously drive the two shaft is supported with the bearings (123, 124) at
pumps. The oil suction port and oil discharge both ends. The piston shoe is rived on the head
port are converged at the cover (namely valve of plunger in advance to form the spherical joint;
block (312)) of the two pumps, and the pump P1 at same time, it reduces the thrust force
and pump P2 share one suction port. generated in axial direction through load
pressure; to ensure the low friction and flexible
Because the structure principles and working
movement between piston shoe and piston shoe
principles of the two pumps P1 and P2 are the
disc (211), adopt the annular oil groove of
same, the pump P1 will be described as
pressure balance (static pressure) on piston
example.
shoe. On the other hand, to enable the piston
The pump P1 is roughly composed of a rotating shoe subassembly (151, 152) can freely move
mechanism for driving the pump to rotate, a on the piston shoe disc (211) without any
swashplate mechanism for adjusting discharge separation, press the return disc (153) and
capacity and a valve cap mechanism for spherical bushing with the return spring (157)
alternately making oil suction and discharge onto the piston shoe disc. This end of the other
actions. cylinder block is also pressed onto the oil
distribution disc (313-314) by the return spring
(157).
3-20
3.3 Hydraulic System December 30, 2017
3.3.2 Hydraulic Element CLG930E/936E
Action principles When the slide valve (652) moves, the discharge
pressure P1 is directed to the large-diameter
1. Flow control
portion of the servo piston through Port C1. The
As shown in the right figure, the discharge flow of discharge pressure P1 is usually brought in the
the piston pump can be controlled at will based small-diameter portion of the servo piston, but
on the stroke S of the adjusting handle for the area difference allows the servo piston (532)
maximum flow to move right to reduce the angle of inclination.
When the servo piston (532) moves right, Point
D moves right too. The slide valve (652) is
equipped with a return spring (654) which
produces a pull to move the slide valve left.
Discharge flow Q
Stroke of adjusting handle for maximum flow (2) Flow increase action
When the adjusting lever (675) is loosened, the
guide spring (646) pressure allows the guide
(1) Flow decrease action piston (643) to move left and the link (2) (613)
If the adjusting handle (675) for maximum flow is pivots on Point B. The pin (897) is pushed by the
tightened, the pilot piston (643) moves right via return spring (654) towards to the large-hole
the piston rod (642). The pin (875) fixed to the portion [C] of the link (2) through the slide valve
link (2) (613) is embedded in the grooved portion (652), the pin (874) and the feedback link (611).
[A] of the guide piston (643), so with the Therefore, with the rotation of the link (2) (613),
movement of the pilot piston (643), the link (2) the feedback link (611) pivots on Point D and the
pivots on Point B (fixed by the plug (614) and the slide valve (652) moves left.
pin (875). There is a projecting pins (897) fixed to When the slide valve (652) moves, Port C1 port
the feedback link (611) in the large-hole portion opens towards the tank port, so that the pressure
[C] of the link (2) (613), so with rotation of the link of the large-diameter chamber of the servo
(2) (613), the pin (897) moves right. The pin piston reduces. Due to the effect of the discharge
(548) fixed to the tilt pin (531) which allows the pressure P1 of the small-diameter portion, the
sloping plate to shake is embedded in the servo piston (532) moves left, so that the flow
double-sided width portion [D] of the feedback increases.
link (611). Therefore, when the pin (897) moves,
As the servo piston (532) moves, Point D also
the feedback link (611) pivots on Point D. The
moves left, the feedback link (611) pivots on
feedback link (611) connects with the slide valve
Point C, and the slide valve (652) moves right.
through the pin (874), so the slide valve (652)
The movement continues until the slide valve
moves right.
(652) closes the opening of the sleeve (651), and
stops there stationarily.
3-23
December 30, 2017 3.3 Hydraulic System
CLG930E/936E 3.3.2 Hydraulic Element
Discharge flow Q
Discharge flow Q
Discharge pressure (P1) Loosen the hex nut (808), and tighten (or loosen)
the fixing screw C (954) for adjustment. Keep
other control characteristics unchanged. Only
If the shut-off pressure is set at the value through change the maximum flow.
which the machine side is about to release,
energy-saving effects can be obtained. (2) Adjustment of maximum flow (with the
regulator’s adjusting lever for maximum flow)
When the pressure P1 directed to the safety
Loosen the lock knob (637), and tighten (or
valve (1) fixed to the cut-off valve reaches the
setting pressure for the safety valve (1), the loosen) the knob (675) for adjustment. Keep
other control characteristics unchanged. Only
safety valve (1) will start opening. The cut-off
change the maximum flow.
slide valve (647) moves left.
If the cut-off slide valve moves, the discharge During the 1) and 2) adjustment above, the low-
flow command is prioritized.
pressure P1 will be directed to the large-diameter
portion of the servo piston, then the servo piston 2. Adjustment of minimum flow (main pump)
moves right to minimize the pump’s inclination
Loosen the hex nut (808), and tighten (or loosen)
angle (discharge flow).
hex screw (953) for adjustment. Like the
Adjustment by adjuster adjustment of the maximum flow, keep other
This adjuster uses its adjusting screw to adjust control characteristics unchanged. But note that
if it is pulled too tight, the power needs to be
the maximum flow, minimum flow, horsepower
increased at the maximum discharge pressure
control characteristics and flow control
characteristics. (overflow).
3-25
December 30, 2017 3.3 Hydraulic System
CLG930E/936E 3.3.2 Hydraulic Element
Discharge flow Q
Stroke of adjusting handle for maximum flow S
rate)
Discharge flow Q
When the abrasion loss of each part exceeds the following references, replacement or re-adjustment is
needed. But a part must be replaced when it has obvious damage in appearance.
Free height of cylinder block spring: L Assembly height of plate and spherical bushing:
H-h
3-28
3.3 Hydraulic System December 30, 2017
3.3.2 Hydraulic Element CLG930E/936E
Maintenance standards of cylinder, valve block and swashplate (skid shoe plate).
Cylinder (sliding section) Finish to necessary roughness 3-Z (Ra=0.8)
Swashplate (skid shoe plate)
Roughness on each surface of Standard face roughness (corrected value) 0.4-Z (Ra=0.1) below (abrading)
cylinder (sliding section)
2. Pilot Pump
Pilot pump (P3 pump) is a quantitative type gear pump and provides the hydraulic system with pilot oil.
Pilot pump specifications
The housing comprises a front housing (1) and a gear housing (2), with a pair of drive gear (3) and driven
gear (4) installed inside as well as a relief valve used for setting output pressure.
The relief valve comprises a strainer (5), a cone valve (7), a valve seat (6), a spring (8), a ring (9), an
adjusting screw (10) and a locknut (11).
To prevent oil from leaking outside, an angular seal (14) and an O-ring (13) are installed on the front
housing (1).
Working principle
Oil sucked in from the oil suction inlet B3 is discharged from oil discharge outlet A3 through the
drive•driven gear. Discharged oil is kept at setting pressure through the relief valve. Unwanted
discharged oil is discharged from the oil leakage port Dr of the main pump housing by means of the relief
valve.
Adjustment of the setting pressure of relief valve
Tightening the adjusting screw (10) by 90° increases the setting pressure by 5MPa.
Appearance drawing and structure diagram of main control valve see attached drawing for details, and
lists for specifications and parts are shown as follows:
Item Specifications
Model KMX15RB
Standard flow 300L/min
+1
Working pressure of main relief valve
34.3 0 MPa
+1
Pressurization pressure of main relief valve
37.3 0 MPa
Setting pressure of oil port relief Boom, arm and bucket 39.2±0.5MPa
valve Spare 30.0±0.5MPa
Working oil temperature -20~90°C
Maximum pressure of leaking oil 0.3MPa
The ports of the main control valve are shown in following table
Port
Symbols Port name
dimension
G-1 R2 Oil filler joint
(P0)
G-3/4 (P3)
(P5)
Port
Symbols Port name
dimension
Atr Right travel motor interface (reversing)
Btr Right travel motor interface (forward)
(Ao) Backup port
(Bo) Backup port
Ak Interface (excavation) at bucket cylinder piston head side
Bk Interface (unloading) at bucket cylinder piston rod side
Ab Interface (lifting) at boom cylinder piston head side
Bb Interface (lowering) at boom cylinder piston rod side
M10
AtL Left travel motor interface (backward)
BtL Left travel motor interface (forward)
As Swing motor interface (left rotation)
Bs Swing motor interface (right rotation)
Aa Interface (extension) at arm cylinder piston rod side
Ba Interface (retraction) at arm cylinder piston head side
P1 Pump port (P1 side)
P2 Pump port (P2 side)
Straight travel
Travel (right)
Travel (left)
Slewing
Slewing priority
Boom 1
Boom 2
Bucket
Spare
Arm 1 Arm 2
Bypass stop
Working Principle
[Main circuit]
When all spools are in neutral state, the working oil fed from the hydraulic pump (front) flows into the
pump interface P1, is guided to the main passage (1) and returns to the working oil tank from the return
interface (R1) by the neutral bypass (2) (natural M neutral M-shaped slide valve function) of each spool
of linear travel (308), left travel (301), boom 1(303), bucket (304) and arm (306).
The signals of the negative control relief valve (610) at the boom 1 side are transmitted into the hydraulic
pump adjuster at the P1 side from the interface N1 to control the pump output flow as the minimum flow.
The working oil fed from the hydraulic pump (back) flows into the pump interface P2, is guided to the
main passage (3), and returns to the working oil tank from the return interface (R1) by the neutral bypass
(2) (neutral M-shaped slide valve function) of each spool of flowing into the right travel (301), rotation
(305), boom flow merging (boom 2: 307), backup (309) and arm 1 (302).
In addition, the signals of the negative control relief valve (610) at the arm 1 side are transmitted into the
hydraulic pump adjuster at the P2 side from the interface N2 to control the pump output flow as the
minimum flow.
Whichever out of the 9 main spools is switched, the neutral bypass (2) will be immediately closed. The
signal pressure at the interface N1 or N2 in the negative control circuit is the tank pressure, and controls
the pump output flow as the maximum flow.
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3.3 Hydraulic System December 30, 2017
3.3.2 Hydraulic Element CLG930E/936E
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December 30, 2017 3.3 Hydraulic System
CLG930E/936E 3.3.2 Hydraulic Element
2. Traveling
[Pilot circuit]
When the left or right travel spool is switched, the side passage is closed, and thus the pressure at the
interface Py (signal interface for travel) rises.
[Main circuit]
When the pilot interface XBtL for the left travel spool (301) is pressurized,
The neutral bypass (2) at the boom 1 side is closed, and the working oil fed from the hydraulic pump
(front) is fed into the left travel motor from the interface BtL.
Similarly, when the pilot interface XBtr for the right travel spool (301) is pressurized, the neutral bypass
(2) at the arm 1 side is closed, and the working oil fed from the hydraulic pump (back) is fed into the right
travel motor from the interface Btr.
On the other hand, the return oil respectively from the left and right travel motors passes through the left
(right) travel spool from the interface AtL (Atr), and then returns to the working oil tank from the return oil
interface (R1).
When the travel on the opposite side (pressurizing the pilot interfaces XAtr and XAtL) is operated, the
process is the same as the above.
Swing motor
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3.3 Hydraulic System December 30, 2017
3.3.2 Hydraulic Element CLG930E/936E
3. Arm
Small load
Arm dead-weight
LG922E930E03056
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3.3 Hydraulic System December 30, 2017
3.3.2 Hydraulic Element CLG930E/936E
When the pressure on the side of arm cylinder piston head (H) rises
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CLG930E/936E 3.3.2 Hydraulic Element
4. Boom
The return oil makes pressure rise through the self weight of the booms. To maintain sufficient pressure,
the cone valve (303-317) inside the spool is pushed towards the right of Figure by means of the internal
spool passage, and the return oil flows out of the spool. This pressure oil acts as the working oil for the
boom lowering operation and is again fed into the boom cylinder piston rod side (R), which is called the
boom regeneration function. Part of the return oil flowing into the internal spool passage from the hole (a)
returns to the working oil tank by means of the hole (b).
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CLG930E/936E 3.3.2 Hydraulic Element
5. Bucket
6. Swing
Swing motor
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3.3 Hydraulic System December 30, 2017
3.3.2 Hydraulic Element CLG930E/936E
7. Spare
8. Straight Travel
When the travel spool (301) is operated together with other spools.
The condition where the travel spool (301) and the rotary spool (305) are simultaneously operated is
described below. (When pilot pressure oil is supplied to the interfaces XAtL, XAtr and XAs)
[Pilot circuit]
The side passage of right travel and left travel spools (301) and the side passage of the rotary spool at
the downstream side are closed, pilot pressure oil from the interface PG is supplied to the interface PTa,
and the linear travel spool (308) is switched.
[Main circuit]
When the linear travel spool (308) is switched, the right travel and left travel spool (301) is preferentially
communicated with the interface P2, the parallel passage of the rotary , boom 2 standby , arm 1 oil
passage/boom 1 bucket and arm 2 oil passage is preferentially communicated with the interface P1, so
that working oil supplied from the interface P2 mainly flows into the interface AtL and the interface Atr
and is evenly supplied to two travel motors.
On the other hand, working oil supplied from the interface P1 is also supplied to the swing motor via the
interface As.
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CLG930E/936E 3.3.2 Hydraulic Element
When the pressure oil in the interface P2 is lower than that of the interface P1, one part of working oil
supplied from the interface P1 is supplied to the P2 side. So the rapid decrease of travel speed can be
prevented.
The lock valve selector pair (252) is installed among the arm cylinder piston rod side (R), the arm 1 spool
(302) and the arm 2 spool (306) to reduce the internal leakage of the spool caused by cylinder pressure.
Likewise, a lock valve selector pair (252) is also installed between the boom cylinder piston head side
(H) and the boom 1 spool (303) to reduce the internal leakage of the spool caused by cylinder pressure.
1. (1) Spool neutral state
The condition where the boom 1 spool (303) is selected is shown below. (The condition of arm 2 spool
(306) is also the same.)
When the boom 1 spool (303) is neutral, the spool (252-511) inside the lock valve selector pair is kept in
the position as shown in Figure by the pretightening force of the spring (252-321) and is pressed in the
valve seat of the valve bushing (252-541) inside the lock valve selector pair.
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3.3 Hydraulic System December 30, 2017
3.3.2 Hydraulic Element CLG930E/936E
In this position, working oil at the boom cylinder piston head side (H) flows in from hole (a), flows across
the periphery of the spool (252-511) of the lock valve selector pair and presses the valve seat of valve
body of the cone valve (513) at hole (b) so as to reduce internal leakage.
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CLG930E/936E 3.3.2 Hydraulic Element
The main relief valve is installed on the valve body A (101) and has the following functions:
1. Working oil fills the cavity of chamber (a) by means of the holes in the valve seat (541) and small
holes in the valve plunger (512) through the passage (P), and the valve plunger (512) is pressed
against the valve seat (541) to form reliable seal.
2. When the pressure inside the passage (P) exceeds the pretightening force of the spring (621), the
cone valve (611) is opened, so working oil flows into the low pressure passage (R) from the periphery
of the cone valve (611) and across the holes in the valve bushing (103).
3. The pressure inside the cavity (a) drops due to the opening of the cone valve (611), and the valve
plunger (512) is opened. Therefore, working oil in the passage (P) directly flows into the low pressure
passage (R).
When pressure oil above 3MPa is supplied into the interface Pz, the pressure oil pushes the plunger
(614) to move leftwards to change the setting load of the spring (621), and the pressure starts to rise.
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CLG930E/936E 3.3.2 Hydraulic Element
The interface relief valve is installed between the cylinder interface and the low pressure passage.
Besides the function as a relief valve, the interface relief valve also has the function as a check valve for
preventing cavitation and replenishing oil.
1. Function as a relief valve
a. Working oil fills the cavity of chamber (B) via hole (A) of the plunger (301) and presses the valve
plunger (511) against the valve seat (541), and the valve seat (541) is pressed against the valve
seat of the valve body to form reliable seal.
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3.3.2 Hydraulic Element CLG930E/936E
b. When the pressure inside the passage (P) exceeds the elastic force of the spring (621), the cone
valve is opened, so working oil flows into the low pressure passage (R) from the periphery of the
cone valve (611) and across the hole (C).
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CLG930E/936E 3.3.2 Hydraulic Element
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3.3 Hydraulic System December 30, 2017
3.3.2 Hydraulic Element CLG930E/936E
c. The pressure inside the cavity of chamber (B) drops due to the opening of the cone valve (611),
and the valve plunger (512) is opened. Therefore, working oil in the passage (P) directly flows into
the low pressure passage (R).
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CLG930E/936E 3.3.2 Hydraulic Element
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3.3 Hydraulic System December 30, 2017
3.3.2 Hydraulic Element CLG930E/936E
12. Function of Negative Control Relief Valve When the pressure of the interface P is greater
than the setting pressure of the spring (321) as
The negative control relief valve is installed shown in Figure, the cone valve (511) is opened,
between the most downstream of the neutral by- and working oil in the interface P flows to the low
pass and the low pressure passage. The function pressure passage (R) through the periphery of
of the negative control relief valve is shown the cone valve (511).
below.
(1) If the pressure of the interface P is smaller
than the setting pressure of the spring (321), the
cone valve (511) is in the state shown in Figure
below. The pressure bearing section φB of the
cone valve (511) is cancelled by the section φA
of damping rod (512), and the pressure bearing
area is φB-φA at the moment. Working oil in the
interface P flows to (R) through the orifice (c).
Pressure
Flow
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3.3 Hydraulic System December 30, 2017
3.3.2 Hydraulic Element CLG930E/936E
Maintenance References
center joint is mainly used for connection of hydraulic access with close range, and for connecting
relatively fixing parts and rotating parts, which is characterized by high pressure resistance, wear
resistance, multiple accesses, mutual noninterference for rotating 360°, simple connection, safety,
reliability, etc.
The structure of the center joint is shown in the figure below:
X2: travel motor-rh high-speed/low- B1: travel motor-lh B port B2: travel motor-rh B port
speed switching port P A2: travel motor-rh A port L: left and right travel motor oil drain
A1: travel motor-lh port A port
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3.3.2 Hydraulic Element CLG930E/936E
Working Principle
The center joint is composed of the swing body, swing shaft, end cover and other parts, and swing body
(or swing shaft) is fixed on upper part (or lower part) of the vehicle body, but swing shaft (or swing body)
is installed on lower part (or upper part) of vehicle body and can rotate 360° freely. Slot annular grooves
on swing shaft with the same number of oil line, and hydraulic oil entering into oil inlet of swing body
connects with radial hole on swing shaft through oil groove on swing body, and supplies travel motor.
Because the annular grooves on swing body and swing shaft are closed, no matter whether swing body
or swing shaft rotates along with vehicle body, the mutually corresponding oil port is always independent
and smooth, which guarantees normal flowing of hydraulic oil. See details in following figure
Body port
Shaft port
Fault Analysis
If the explosion-proof valve is selected, it is The relief valve (3) is used for protecting
directly installed on the cylinder (boom cylinder cylinders from being damaged under the action
big cavity and arm cylinder small cavity) to of external force. When external force impacts
prevent the control cylinder from suddenly the cylinder, impact pressure passes through the
dropping without the action of gravity after hose (6) strainer and outputs pressure signals to the
bursting to cause accidents. balanced valve (4) through the relief valve (3) to
open the balanced valve. The pressure of the
During normal working, oil enters the cylinder
cylinder is released. The check valve at the lower
through the check valve (5). During reverse
right corner ensures enough pressure to open
action, oil needs to cooperate with the pilot signal
the balanced valve (4) can be created after the
to enter the control port of the balanced valve (4)
impact pressure passes through the relief valve
through the check valve (5) at the lower right
(3).
corner so as to open the balanced valve. Oil
flows out of explosion relief valve through The setting pressure of the relief valve (3) is the
balanced valve (4). maximum pressure that the cylinder cannot be
damaged. When the impact pressure does not
After the hose bursts suddenly, hydraulic oil in
reach the relief pressure of the relief valve (3),
the hydraulic cylinder cannot pass through the
the relief valve (3) cannot overflow, and the
valve due to the blocking of the spool of the
explosion relief valve cannot be opened in the
balanced valve (4). When the system uses two
reverse direction.
identical cylinders, one small balance line is used
to balance the pressure between the cylinders.
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3.3 Hydraulic System December 30, 2017
3.3.2 Hydraulic Element CLG930E/936E
After the hose bursts, the cylinder can be slowly 3.3.2.5 Hand Pilot Valve
lowered by adjusting the relief valve (3).
However, after the cylinder is lowered to the First side
Maximum pressure is 6.9 MPa
safety position, the safety pressure of the relief pressure
valve (3) needs to be reset. The safety pressure Secondary 0~4.4 (maximum control pressure)
of the relief valve (3) for protecting the cylinder side pressure MPa
from being damaged has been set while leaving Allowable
the factory. After adjustment, the relief valve Maximum 0.3 MPa
backpressure
needs to be reloaded to the test bench to set the
Rated flow
safety opening pressure. rate
20L/min
Operating
±19°
angle
Mass 1.9kg
The safety pressure of the relief valve (3) is
In order to obtain well responsiveness,
used for protecting the cylinder from being appropriate pipeline is the one with
damaged. Do not adjust without permission. inner diameter as φ8 and length as
After adjustment for specific reasons, please Pipeline
about 3m. In addition, return oil shall
restore to the factory setting pressure. not be affected by other backpressures
and directly enter into tank.
1. Control lever
2. Pilot valve
The hand pilot control valve is composed of a
control lever (1) and a pilot valve (2). It can
control two working devices, left pilot controls
rotation and arm, and right pilot controls bucket
and boom.
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December 30, 2017 3.3 Hydraulic System
CLG930E/936E 3.3.2 Hydraulic Element
Maintenance References
Note: although seals such as O-rings are expected to be replaced after removal, it doesn't matter to
reuse them after being confirmed undamaged.
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3.3.2 Hydraulic Element CLG930E/936E
A hydraulic damping device is arranged inside To make sure the mechanical travel moves
this valve. When the machine is operated to stably, pilot oil pressure reaching the travel
move forwards or backwards and the road is control valve stem control port needs to be
bumpy, machine vibration is easily caused, so stable, i.e. oil pressure coming out of the oil port
the driver’s operation must be affected, and the (10) needs to be stable, which is realized by the
driver cannot operate well to make the machine pressure-reducing valve composed of the Spring
vibrate more severely to form a vicious circle. holder (7), the spring (14) and the spool (9).
The controllability of travel pilot valve without this
When the oil pressure of the oil inlet joint P rises,
device is poor, and the driver always has no
the pressure of the oil port (10) will also rise
choice but to stop the machine to eliminate
within a short period of time. Because the oil
machine vibration.
pressure of the oil port (10) rises, the force
The hydraulic damper is composed of a spring making the spool (9) move upwards increases,
(2), a spring (3), a spring cavity (4), a steel ball so the pressure adjusting spring pushes the
(5) and a damping piston (6); and the pressure- spool (9) upwards to reduce the communication
reducing valve is composed of a spring holder amount between the port P and the oil port (10).
(7), a spring (14) and a spool (9). Because the communication amount between
the port P and the oil port (10) is reduced,
When the travel pedal presses leftwards as
damping increases, i.e. the pressure drop from
shown in the figure, the cam adjusting gp (11)
the port P to the oil port (10) increases, and the
tilts to press the push rod (12) downwards, the
pressure of the oil port (10) is ensured to be
push rod (12) moves downwards to drive the
unchanged, even when the pressure of the oil
damping piston (6) and the spring valve seat (7)
inlet joint P has rised. When the pressure of the
to overcome the resistance applied by the
oil inlet interface P decreases, the pressure of
hydraulic damper and the elastic forces of the
the oil port (10) will also decrease within a short
springs (8) and (14) to move downwards, and the
period of time. Because the oil pressure of the oil
pressure adjusting spring (14) forces the spool
port (10) decreases, the force making the spool
(9) to move downwards so the oil port (10) is
(9) move upwards decreases, so the pressure
communicated with the oil inlet joint P. When the
adjusting spring pushes the spool (9) downwards
oil port (10) is communicated with the oil inlet
to increase the communication amount between
joint P, pilot pressure oil enters along the oil inlet
the port P and the oil port (10), i.e. damping of
joint P, reaches the travel control valve stem
communication between the port P and the oil
control port through the oil port (10), and pushes
port (10) decreases, the pressure drop from the
the travel control valve stem so that high
port P to the oil port (10) decreases, and the
pressure oil from the main pump flows across the
pressure of the oil port (10) is ensured to be
travel control valve stem to the travel motor. The
unchanged, even when the pressure of the oil
travel motor rotates to drive the mechanical
inlet joint P has decreased.
travel to move.
The travel control valve rod makes low pressure
oil at the other end flow back the oil port of the
travel pilot valve (15), the pressure adjusting
spring is not stressed due to the action of the
return spring, the spool is also in the upper
position, and the oil port (15) is communicated
with the return interface T at the moment. Low
pressure oil enters to the oil port (15) enters the
return cavity along the oil port (15) and returns to
the system oil tank from the return interface T.
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3.3 Hydraulic System December 30, 2017
3.3.2 Hydraulic Element CLG930E/936E
It is not easy to locate the fault. Problem points to be considered in several aspects are listed in the table
below. Because this valve is difficult to repair, please refer to the cause and countermeasure columns in
the table.
1. Maximum working
7.0MPa 12. Electrical specification
pressure
2. Allowable back
Below 1.0 Mpa (1) Solenoid valve type Oil immersed type
pressure
Reversing valve – 16 L/ JIS C 3214 Class-H
(2) Coil insulation type
3. Maximum flow min (180°C)
(Equivalent to 1 spool) Proportional valve – Tyok Electronics Japan
10L/min (3) Connector type
Econoseal J Series
Reversing valve -70cm³/
4. Leakage min 12-1 Solenoid directional
Specifications
(Equivalent to 1 spool) Proportional valve – 125 valve
cm³/min
Equivalent to JIS D 0203
5. Waterproofness (1) Rated voltage DC 24 V
S2
JIS D 1601-1995
(2) Allowable voltage
6. Vibration resistance Category 3 Class B 20.4~30 V
fluctuation range
Grade 70
Equivalent to ISO Less than 17W (at 24V and
7. Working oil (3) Rated power consumption
VG32~68 20°C)
8. Oil temperature Diode (equivalent to
-20~90°C (4) Overvoltage limiter
applicable range Hitachi U05E)
10. Allowable pollution
Below NAS Level 10 (5) Continuous rating Below 29V
degree
12-2 Electro-hydraulic
11. Interface JIS B 2351 G1/4 proportional pressure- Specifications
specifications reducing valve
JIS B 2351 G3/8 (1) Rated power 700mA
(2) Coil resistance 17.5 Ω (at 20°C)
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3.3 Hydraulic System December 30, 2017
3.3.2 Hydraulic Element CLG930E/936E
1 2
5 4
This valve is composed of four switch-type solenoid valves, which are respectively A1~A4. A1~A4
solenoid valves share oil inlet port P and oil return port T, according to electronic control signals, A1~A4
output pressure oil is connected with return oil T.
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CLG930E/936E 3.3.2 Hydraulic Element
(5) The flow is too large (5) Decrease the flow to the correct value
Travel motor & reduction gear includes two sections: travel hydraulic motor (hereinafter referred to as
travel motor) and reduction gear, which will be described below respectively.
Travel Motor
4. Safety valve
Keep a metal-sealed valve seat (57-2) in the inner hole section of the motor cover (24), tighten the
socket (57-1) fixed on the motor cover (24), insert the valve (57-3) for cooperating the valve seat (57-2)
with the inner hole of the socket (57-1) into the connecting plunger (57-4) from the inner hole of the valve
(57-3) to the oil circuit of the pilot body (57-6) through the adjusting spring (57-6), and also insert the pilot
body (57-6). It is composed of a plunger (57-7) pressed by the plug (57-5) and a shim (57-5) used for
spring adjustment.
57-1 Socket 57-5 plug screw 57-8 Gasket 57-11 support ring
57-2 valve 57-6 Pilot part body 57-9 Adjusting spring 57-12 O-ring
57-3 valve seat 57-7 plunger 57-10 O-ring 57-13 support ring
57-4 connecting plunger
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CLG930E/936E 3.3.2 Hydraulic Element
5. Brake valve
Spool switching pressure: 0.59 ~ 0.95MPa
Check valve opening pressure: 0.015MPa
Section view of brake valve
Check valve
(1) Spool
Shut off oil discharge from hydraulic motor according to the switching of the spool group (26),
automatically exert countercurrent action, and hold the action effects of acceleration, stop and balance
on the hydraulic motor.
(2) Check valve (hidden in spool)
This valve is located in the oil supply passage of the hydraulic motor and also exerts the oil discharge
locking function. Therefore, this valve not only plays a role as a suction valve, but also can act on the
travel motor as a holding valve.
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3.3.2 Hydraulic Element CLG930E/936E
Entry guide
position
Working Principle
High pressure hydraulic oil sent from the hydraulic pump enters from the oil inlet port (AV and VB) and
flows into the port through the brake valve component, motor cover (24) and oil distribution plate. The
rotating directions of the oil outlet port and output shaft are shown in the table above.
(a) (b)
LG922E930E03101
This high pressure oil is shown in the figure above and acts on each plunger within the range of Y-Y axis
180° from top dead center and bottom dead center of the connecting plunger.
F1=P×A (P: pressure, A: plunger area)
This force F1 becomes axial force F2 and radial force F31~F34(or F35 ) (see above figure (b) )
according to the swashplate with angle of inclination a, and the radial force acts as turning force at Y-Y
axis and generates
T=r1·F31+r2·F32+r3·F33+r4·F33 Torque
(Add r5·F35 while 5 plungers apply the high pressure. )
This torque is transmitted to the spline of the main shaft (9) through the cylinder block (13) and is finally
transmitted to the main shaft (9).
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When high oil pressure selected by the balanced component directly assembled in the motor cover (24)
acts on the piston brake (21), the parking brake is loose. Braking torque will always exist when no
pressure acts. This braking torque is generated by the friction force between the meshing plate (19)
inserted in the housing (1) and the friction plate (20) and is transmitted to the cylinder block (13) through
the spline of the cylinder block.
When no pressure acts on the piston brake (21), the piston brake (21) is supported by the brake spring
(55), and the piston brake pushes the meshing plate (19) and the friction plate (20) towards the housing
(1). The generated friction force pushes the self-rotating cylinder block (13) to drive the main shaft (9) to
generate braking torque.
Structure of brake valve
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If the pressure greater than the spring (34) is input on the high-speed travel command Pa, the spring will
be compressed, and the spool (31) will move rightwards. So P and C are conducted. The highest
pressure among the motor pressure MA, MB and high-speed travel command is selected to be guided
into the tilt piston (6) through the check valve (44). Therefore, the swashplate (12) will tilt as an imaginary
line along the axis of L line connecting 2 pivots (11) until touching the tilt baffle block (1-1). As a result,
the import and export of the piston (18) will decrease, and the capacity of the motor becomes small. The
motor can operate at high speed without increasing the oil flow of the oil pump. At the moment, the
capacity ratio of this model is 1.71 times.
On the contrary, if the pressure on the high-speed travel command Pa is zero, the spool (31) will return
to left under the force of the spring (34), oil guided into the tilt piston (6) will return to the oil tank through
the throttle valve (46), and the thrust disappears.
9 pistons (18) are evenly distributed on the swashplate (12) to press the swashplate (12). The acting
point of the converged force is almost in the center of the swashplate (12), as shown in the figure. The
pivot (11) is in the position deviating the center S. The rotating force generated by S and piston makes
the swashplate return to the original position, and the machine travels at low speed.
If the specified pressure is exceeded, the counterforce of the pin (32) will make the spool (31) return to
left. Oil pressing the tilt piston (6) will return to the oil tank. The swashplate becomes tilting, the motor
capacity becomes large, and low-speed travel is restored. Once this pressure is lower than the setting
pressure, the spool (31) will return to right, and the machine travels at high speed.
Point of
strength
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3.3 Hydraulic System December 30, 2017
3.3.2 Hydraulic Element CLG930E/936E
Two safety valves are configured in a cross way and have the following functions.
(1) When the hydraulic motor is stopped, the braking pressure generated at the motor output side is held
below a certain valve in order to prevent load inertia.
(2) When the hydraulic motor is started, it is driven by the setting pressure. Hold quick acceleration.
During stop, the generated pressure is held at low pressure for short time in order to relieve braking
impact. The circuit pressure is held at the specified setting pressure in order to achieve smooth meshing
of reduction gear, track sprocket section, etc., i.e. boost buffering action.
When the travel motor is stared, if the pressure at the port A of the safety valve rises, this pressure acts
on the connecting piston (57-4) inside the valve through the small hole of the valve (57-2) while acting on
the effective diameter section of the valve seat (57-3) of the valve (57-2), it rises to the port A pressure,
and the valve (57-2) resists the adjusting spring (57-9) through the area difference between the effective
diameter section of the valve seat and the hole diameter section of the connecting piston to reach the
specified setting pressure.
When the travel motor is braked, the piston (57-7) at the rear is located at the left side due to driving
pressure. If the port A pressure rises, the pressure acts on the piston (57-7) through the small hole of the
valve and the small hole of the connecting piston (57-7), and the piston will move rightwards until
touching the housing. During this time, the valve (57-2) holds the port A pressure resisting the adjusting
spring (57-9) at relatively low pressure, and oil is discharged from the port B side. After the piston (57-7)
touches the housing, it acts just like the motor is started.
Hole
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CLG930E/936E 3.3.2 Hydraulic Element
1. Holding state
When the switching valve is in neutral state, ports VA and VB are connected with the oil tank, and the
valve (26) is held in the central position by the springs at both ends. Therefore, the passages VA -> MA
and VB -> MB are closed. Ports MA and MB connected both sides of the hydraulic motor are also closed.
Moreover, the parking brake release passage is connected with the oil tank, and the parking brake
changes into the working state. The hydraulic motor stops rotating due to brake spring force.
If a torque greater than the brake spring force is generated, the parking brake will slip, holding pressure
will be generated at the port MA or MB side, and the hydraulic motor will slightly rotate due to the holding
pressure.
When the hydraulic motor slightly rotates, high pressure oil in the closed circuit will run away, and
cativation will be generated at the low pressure side of the closed circuit. The check valve built in the
spool is started to prevent cavitation, the passage VA -> MA or VB -> MB is formed to replenish oil
equivalent to leakage from the oil tank.
Spring Spring
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3.3 Hydraulic System December 30, 2017
3.3.2 Hydraulic Element CLG930E/936E
Spring Spring
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December 30, 2017 3.3 Hydraulic System
CLG930E/936E 3.3.2 Hydraulic Element
Spring Spring
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3.3 Hydraulic System December 30, 2017
3.3.2 Hydraulic Element CLG930E/936E
Spring Spring
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December 30, 2017 3.3 Hydraulic System
CLG930E/936E 3.3.2 Hydraulic Element
Replacement
Standard
Item Schematic recommended Handling method
size (mm)
value (mm)
Notes: 1. The roughness of each rotation meshing surface is controlled to be lower than the standard
roughness through grinding.
2. When the spherical meshing section between the plate spring and cylinder is rough, the complete set
of group shall be replaced.
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3.3 Hydraulic System December 30, 2017
3.3.2 Hydraulic Element CLG930E/936E
Working Principle of Reduction Gear At the moment, because the support K2 is fixed
on the car body, the gear d transmits power to
The reduction gear weakens the rotating speed the annular gear ring, and the annular gear ring a
transmitted by the hydraulic motor and converts rotates.
it into strong rotating force. This reduction gear
adopts double planetary gear reduction
mechanism.
The planetary mechanism is composed of sun
gears, planetary gear (planetary) supports and
an annular gear ring. After the sun gear (s) at the
force entry side rotates, the planetary gear
rotates on its axis and is simultaneously meshed
with the fixed annular gear to make revolution
movement. Revolution movement is transmitted Secondary-level
to the support (k) to transmit torque. reducing mechanism
Planetary gear
Whether the reference scan be reused once
Support again is defined according to measurement
values in component disassembly. However,
these are general references. If the component
Input Output appearance has obvious bruises or color
Sun gear changes for property before disassembly, the
range of switching components is preferentially
decided according to the disassembly purpose
and the expected residual life.
Annular gear ring
Support
Sun gear
Planetary
pinion
Symb
Item Reference value Allowable value Treatments
ols
Abrasion of planetary Smooth and no abnormal
A —— Replace 3 as one group
main shaft wear and sintering.
There is no chips and
Tooth face · tooth crown Smooth and no abnormal Replacement (3 planetary
B cracks more than
state wear and sintering. gears as one group)
Φ1.6mm
Axial clearance of inner
Above -0.08 mm
C race of angular contact —— Shim adjustment
less than 0.02mm
bearing (2)
Thickness of thrust shim
D 3.5±0.2mm 0.1mm abrasion Replacement
1 (18)
Thickness of thrust shim
E 5.5±0.2mm 0.1mm abrasion Replacement
2 (11)
Thickness of thrust plate
F 4.5±0.16mm 0.15mm abrasion Replacement
(23)
G Gear oil 500 hours at start, 1.000 per hour at second start Replacement
The swing motor & reduction gear includes a rotary hydraulic motor (hereinafter referred to as swing
motor) and a reduction gear.
Model M5X180
3) 180.1
Displacement (cm
Working pressure(Mpa) 26
Maximum speed (r/min) 1550
Output torque (N.m) 745
Maximum parking torque (N.m) 967
Releasing parking pressure(Mpa) 2.7
Weight (kg) 67.5
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3.3 Hydraulic System December 30, 2017
3.3.2 Hydraulic Element CLG930E/936E
Swing Motor
LG922E930E03116
10 Piston 101 Drive shaft 161 O-ring 390 Nameplate 469 Screw plug
20 H2 valve body 111 Cylinder 162 O-ring 391 Pin 712 Brake spring
assembly 114 Spring bearer 163 O-ring 400 Anti-turnover 742 Brake block
31 Time delay valve plate 171 Hexagon socket valve 743 Isolation panel
33 Hexagon socket 123 Fixing plate head cap bolt 401 Hex screw 983 Plug
head cap bolt 124 Swashplate 301 H2 housing 443 Roller bearing 984 Plug
51 Relief valve 131 Valve fixing plate 351 H2 piston 444 Roller bearing 985 Plug
80 Seal package 151 Screw plug 355 H2 spring 452 Pin
100 Valve body
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December 30, 2017 3.3 Hydraulic System
CLG930E/936E 3.3.2 Hydraulic Element
When high pressure oil enters the cylinder block cavity through the oil port (a) (inlet of the thrust plate 1),
hydraulic pressure acting on the plunger generates axial force F. Pressure F
Pressure F acts on the shoe (3) through the plunger (2), and the shoe (3) acts on the swashplate (4)
through hydrostatic support. Force F1 vertically acts on the swashplate (4), and force F2 vertically acts
on the cylinder center. Force F2 is transmitted to the cylinder block (5) through the plunger and causes
rotation movement around the cylinder block. Because there are (9) equally arranged plungers inside the
cylinder block, the rotating moment will be successively transmitted to the cylinder drive shaft through
several plungers connected to the high pressure oil port. When the direction of oil flow is opposite, the
direction of the cylinder is also opposite.
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3.3 Hydraulic System December 30, 2017
3.3.2 Hydraulic Element CLG930E/936E
1. Control Valve
Air suction preventing check valve
In order to prevent insufficient oil supply when the motor works, hydraulic oil in the oil tank can directly
enter the swing motor through the oil replenishing line (2) and the oil replenishing check valve.
2. Relief valve
During the acceleration or braking process of the swing motor, the relief valve is opened and the
pressure of the swing circuit is held at a constant value. A small buffering piston is arranged in the relief
valve, and acts within short time after the relief valve starts to work and holds the pressure of the swing
circuit at a relatively small value. Therefore, a relatively mild acceleration and braking process can be
obtained.
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CLG930E/936E 3.3.2 Hydraulic Element
The Cylinder block (111) is connected with the drive shaft (101) through one gear, and the friction plate
(742) is connected with the outer side of the cylinder block through one gear. When the brake spring
(712) acts on the friction plate 742 through the separation pad (743) and the brake plunger (702), friction
force is generated between every two of the friction plate, housing, separation pad and brake piston.
This friction force acts on the drive shaft to exert braking action on it.
On the other hand, when the unlock pressure enters the cavity formed between the brake plunger and
the housing, the hydraulic oil pressure overcomes the spring force to make the brake plunger move; the
friction plate and the housing are separated to release the brake.
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3.3 Hydraulic System December 30, 2017
3.3.2 Hydraulic Element CLG930E/936E
Notes: 1. The roughness of each rotation meshing surface is controlled to be lower than the standard roughness through
grinding.
2. When the spherical meshing section between the plate spring and cylinder is rough, the complete set of group
shall be replaced.
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CLG930E/936E 3.3.2 Hydraulic Element
Reducer
102 Valve body D2 231 No.1 carrier D 601 hexagon head bolt 909 Pin
104 Rear axle cover E 282 No.2 pin B 602 Hexagon socket head 910 Pin
201 Drive shaft B 283 No.1 pin B cap bolt 912 snap ring
202 Gear ring E 284 Push plate E 801 oil seal 913 snap ring
203 No.2 planetary gear D 390 Nameplate 802 O-ring 915 Bearing seal ring
204 No.2 sun gear D 391 Pin 903 Screw plug 922 Screw plug
210 No.1planetary gear D 402 Self-aligning roller 904 Hexagon socket head 925 Exhaust valves
211 No.1sun gear D bearing cap bolt 926 Grease fitting
230 No.2 carrier D 403 Positioning pin plug 905 O-ring 930 Hex screw
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3.3 Hydraulic System December 30, 2017
3.3.2 Hydraulic Element CLG930E/936E
Maintenance
Part Check Treatments
references
When the size of single
Sun gear pitting corrosion and
Planetary gear Pitting corrosion and dents on tooth surface dent is above φ1 mm or Replacement
Inner gear occupied 5% of total
area
Replacement
(Notice: Replace them
when the reduction gear
Oil seal Lip surface is damaged or abraded Damaged or abraded
is disassembled for the
purpose of inspection,
etc.)
Notice: Do not extract it from the drive shaft
1. Check whether the race surface and roller of
the bearing have pitting corrosion, abrasion, etc.
Support within the visible range. Replacement
bearing (front 2. Check whether dust caused by excessive (Note: Do not reuse
Abnormal condition
side) of drive abrasion exists in gear oil. bearing extracted from
shaft 3. Check whether excessive abrasion dust is the shaft.)
adhered between the roller and the cage.
4. Check whether it can smoothly rotate by
hand.
Drive shaft
Check whether the race surface and roller of the
bearing (rear Having pitting corrosion Replacement
bearing have pitting corrosion
side)
Slide bearing
Check whether planetary gear No.2 and pin
section of
No.2 of carrier group No.2 are loose in the Looseness is above 0.5 Replacement
planetary gear
peripheral direction.
No.2
Check whether the sliding face zone with the
Side plate type Having obvious bruises Replacement
sun gear No.2 has obvious bruises
Needle bearing
set and pin
No.1 for Check whether the rotation face has pitting Having pitting corrosion
Replacement
supporting corrosion and abrasion and abrasion
planetary gear
No.1
This reduction gear has few parts and adopts the design method that the life of each section is balanced,
i.e. although all parts can be supplied individually, it is necessary to replace all of them due to structural
or functional causes during replacement. These are shown in the table below. Please pay special
attention to them.
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CLG930E/936E 3.3.2 Hydraulic Element
Thrust washer
Lateral plate
No.2 Carrier
Carrier No.1
Thrust plate
Thrust plate
Drive shaft
Pin gauge
Spring pin
Spring pin
Numb
No.2 Pin
Pin No.1
er Part name
Inner and outer races in the roller bearing must be replaced simultaneously.
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3.3 Hydraulic System December 30, 2017
3.3.2 Hydraulic Element CLG930E/936E
Confirm relief of
command pressure
Swing motor has whirling Motor axle damage Replace swing motor
Oil leakage from Oil seal has been Remove the reduction
the shaft damaged gear and replace oil seal
8. Arm cylinder
9. Cushion collar
10.Bucket cylinder
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December 30, 2017 3.3 Hydraulic System
CLG930E/936E 3.3.2 Hydraulic Element
3 Boom cylinder
8 Arm cylinder
10 Bucket cylinder
1 Small cavity oil port 6 Cushion collar 11 Passage
Cylinder extension: pressure oil enters the large When the boom and bucket cylinder extends out
cavity, return oil enters the small cavity, pressure and the cushion collar (6) approaches to the end
oil acts on the big end of the piston, and the
of the extension stroke, the through-flow area of
piston moves towards the rod cavity so that the the passage (11) decreases, so that the
piston rod extends out. displacement of the cylinder decreases, and the
Cylinder retraction: pressure oil enters the small movement speed of the piston slows down and
cavity, return oil enters the small cavity, pressure reaches the stroke end slowly. The boom and
oil acts on the rod end of the piston, and the bucket cylinder is only cushioned during
piston moves towards the no-rod cavity so that extension.
the piston rod retracts. 2. Arm cylinder cushion:
Cylinder cushion device of boom and arm
The extension of the arm cylinder is same to the 2. Because air is highly compressible, the
boom and bucket cylinder, as described above. residual air in hydraulic cylinder can affect its
When the arm cylinder retracts and the cushion operating.
collar (9) approaches to the end of the extension
stroke, the through-flow area of the passage (12)
decreases, so that the displacement of the
cylinder decreases, and the movement speed of
If the hydraulic cylinder with air not emptied
the piston slows down and reaches the stroke
needs to be quickly operated or pressurized,
end slowly. The arm cylinder is cushioned during
because high heat generated by adiabatic
extension and retraction.
compression of air will cause seal burn-out,
Precautions on loading,transport leakage generated inside the hydraulic
cylinder cannot maintain the load, etc., and
1. Hydraulic cylinder must be transported there is a possibility of major accidents.
horizontally, and placed on wood block, and it
is better to use original packaging if possible. For air exhaust of hydraulic cylinder, please
refer to "Air exhaust of various devices" in
2. Impact, collision, etc. are not allowed during
"Test and adjustment" chapter.
the process of storage and transportation.
The surface of exposed piston rod and other )
Structure
Exterior drawing of hydraulic oil tank
Return oil filter is composed of a return oil filter Its function is mainly to reflect the oil level in the
element 7 and a bypass valve 6, the return oil tank and the oil range for the system. As shown
filter element 7 can filter out particles with overall in the figure, a safety oil level refers to the
size greater than 10 μmin oil so the oil keeps system oil level that is above the red line, and the
certain cleanliness. The bypass valve 6 plays the following indicates there is insufficient oil for the
action of protecting the return oil filter element 4. system.
When the filter element works for a period of time
and there are too may oil pollutants on its
surface, the liquid resistance passing through the
return oil filter element 4 will increase, the
bypass valve 6 will be opened during liquid
resistance pressure setting, oil directly returns to
the oil tank 8 without filtering, so that the damage
of the strainer of the return oil filter element 4 by Safe oil level: above red line
flushing can be avoided, and it can be used after
many times of cleaning. The system works under
this state, then the back pressure of the system
is too high, and unsuccessful oil return will cause
slow and powerless working. To avoid this
problem, the return oil filter element shall be
frequently cleaned or replaced.
2. Magnet
Effect of magnet:
1. Magnetize the oil tank;
2. Absorbing magnetizable solid particles in oil
together with the tank, which are mainly
some metal particles, such as the metal
powder particles formed due to the abrasion
between actuating mechanisms.
3. Air Filter
Working principle
Oil suction process: the oil is drawn from the oil tank 8 oil suction port IV through the oil suction filter
element 1 to the pump 2.
Oil return process: Oil is transferred to the actuating mechanisms after being pressurized by the pump
2, then passes through the cooler 5 for cooling from the actuating mechanisms and flows to the oil port
XI or passes through the back pressure valve Ch1 and flows to oil port X, and returns to the tank 8, after
being filtered by the oil return filter element 7. When the system oil pressure is too high, part of oil passes
through the cooler 5 for cooling from the relief valve 3 or flows to the oil port X from the back pressure
valve Ch1, and returns to the tank 8 after being filtered by the oil return filter element 7. Oil passing
across the back pressure valve indicates return oil pressure is too high, which is caused by too high
liquid resistance flowing across the radiator 5.
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CLG930E/936E 3.3.2 Hydraulic Element
PTO gear pump adopts the internationally-used floating shaft sleeve structure with features of high
pressure, low noise, high efficiency and flexible installation.
Performance parameters
Model PGP517 Displacement ml/r 28
Rated pressure (bar) 250 Maximum pressure (bar) 275
Minimum speed (r/min) 500 Maximum speed (r/min) 3100
Input power (kW) (1500r/min) 19.3 Weight (kg) 8.5
Structure
Maintenance references
1. Intermediate part
When the pump efficiency decreases too much and the intermediate part chamber cleaning is more than
0.127mm, replace the intermediate part. And check whether the set pressure of system safety valve is
too high and whether there is abnormal hydraulic impact to confirm the fault cause and then conduct
troubleshooting.
2. Gear
When the gear surface and end surface have obvious scratches, grooves and burrs which can not be
repaired, replace the gear. Or the wear is more than 0.051mm, replace the gear. And check the oil
cleanliness, check whether the input connection is normal and whether there is abnormal hydraulic
impact.
3. Drive gear
Replace the drive gear when the spline is worn or damaged. Replace the oil seal when the contacting
part wear with the journal is more than 0.051mm.
4. Shaft sleeve assembly
When the shaft sleeve surface has obvious scratches, cavitation, deformation, etc. or the it is worn too
much, replace the shaft sleeve. And check the oil cleanliness, check whether the suction oil is sufficient,
whether the input connection is normal and whether there is abnormal hydraulic impact.
5. Dowel pin
When the positioning pin or pin hole is damaged during removal and installation, or the matching
clearance is poor, replace the positioning pin or replace the parts matching with the positioning pin.
6. Seals
No matter when the pump is removed or installed, replace the O-ring, seal components, oil seal, etc. in
the pump.
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December 30, 2017 3.3 Hydraulic System
CLG930E/936E 3.3.2 Hydraulic Element
1. Strictly ensure the oil cleanliness. The hydraulic system involved the pump in should have filter
device with filter fineness of less than 25μm.
2. Anti-wear hydraulic oil is recommended. At 40°C, the oil kinematic viscosity is 42~74mm2/s and
when using the oil, keep the oil temperature range of (-20~80)°C.
3. Elastic coupling is recommended to install the pump drive shaft and the prime motor output shaft with
coaxiality difference of less than 0.1mm; for the shaft sleeve coupling, the coaxiality difference
should be less than 0.05mm.
4. The pump suction oil level is not more than 0.5m.
5. The pump rotation direction can not be mistaken, that is, the pump oil inlet and outlet can not be
mistaken.
6. Avoid start or stop with load.
7. If the pump is not used for a long time, separate the pump with the prime motor to stop the pump.
When reusing the pump, do not apply the maximum load immediately and run with no load at low
rotating speed for not less than 2 minutes.
8. Inlet, outlet port shall be installed firmly and sealing device is secured, otherwise it may cause oil leak
or air suction, which will affect the pump's performance.
9. The highest pressure and maximum rotating speed mean the allowable peak values in a short period
during operation, which should be avoided for applying for a long time, otherwise, the pump service
life will be influenced.
10. Before operation, run the new pump or repaired pump with no load and conduct impact running for a
short time. Then check the working condition of the pump and no leakage, excessive heat and noise
is allowed.
1. Take protective measures for exposed thread oil port and input shaft.
2. The package should be firm, reliable and shockproof.
3. Avoid storage condition of high temperature and high humidity.
Fault Diagnosis
The main hydraulic circuit is the passage transmitting the hydraulic energy from the tank to the actuators.
The complete main hydraulic circuit includes: suction passage, drain passage, return passage and
leakage passage.
Suction passage
As the solid arrow shown in the following figure, the oil enters the hydraulic pump from the suction port of
the tank passing through the suction filter.
1. Hydraulic oil tank 2. Suction rubber hose 3. Suction steel tube 4. Main pump
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December 30, 2017 3.3 Hydraulic System
CLG930E/936E 3.3.3 Hydraulic Principle
Drain passage
7
6
8
9 1
4 3
5
1. P1 hose assembly 4. Left travel motor hose assembly 7. Arm cylinder hose assembly
2. P2 hose assembly 5. Boom cylinder hose assembly 8. Swing motor hose assembly
3. Main control valve 6. Bucket cylinder hose assembly 9. Right Travel motor hose assembly
As shown at the arrow, the oil pumped from the P1 pump enters the P1 port of the main control valve,
and the oil pumped from the P2 pump enters the P2 port of the main control valve. After being distributed
by the main control valve, the oil enters the actuators. The diagram only presents one of the oil flow
directions.
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3.3 Hydraulic System December 30, 2017
3.3.3 Hydraulic Principle CLG930E/936E
Return passage
1
2
3 6
All the return oil of the actuators returns to the hydraulic oil tank through the return passage. As shown
in the figure above, under normal conditions, a large amount of return oil flows from No.2 return passage
to the hydraulic tank 5 after passing through the check valve 3 and the oil cooler 4.
When a large amount of return oil passes through the oil cooler 4, as the return oil amount increases,
such as arm opening action. The return back pressure increases rapidly, to prevent the oil cooler from
being damaged by the increased pressure. The check valve 6 on the return passage 1 is opened. Return
passage 1 helps to shunt and prevent the oil cooler from damage.
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December 30, 2017 3.3 Hydraulic System
CLG930E/936E 3.3.3 Hydraulic Principle
LG922E930E03138
The drained oil at the lower part, which is absorbed to the upper part through the center joint 3, is mainly
from the two travel motors.
LG936E03018
The leaked oil at the upper part is mainly composed of three parts:
1. The leaked oil from the two travel motors is back to the tank through the center joint 1;
2. Oil drainage of the swing motor 2;
3. Oil drainage from the main pump 3.
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3.3 Hydraulic System December 30, 2017
3.3.3 Hydraulic Principle CLG930E/936E
1. Pilot pump 3. Pilot valve group 5. Left hand pilot valve 7. Travel pilot valve
2. Hydraulic oil tank 4. Four-step solenoid valve 6. Right hand pilot valve 8. Main control valve
group
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December 30, 2017 3.3 Hydraulic System
CLG930E/936E 3.3.3 Hydraulic Principle
The pressure of the pilot loop is from the pilot pump 1, which sets the system pressure as 3.9MPa using
the build-in filter screen and relief valve.
The pilot oil flows out from the A3 port of the pilot pump 1, and enters the electronic proportional
pressure-reducing valve to carry out electronic control to the main pump power; at the same time, it
enters the accumulator passing through the filter of the pilot valve group 3 and the check valve. The
check valve can keep the pressure. The accumulator can place the work implement on a safe ground in
case of failure of the machine, stabilize the pilot system pressure and absorb the pulsation when the
machine is working, and supplement the system pressure drop timely when several actions act at the
same time;
The pilot oil which flows out from the pilot valve group 3 enters the P1 port of the four-step solenoid
group 4. The return oil of all the solenoids in the four-step solenoid group 4 flows back to the tank
through the T1 port. A1 pressure control pilot valve cut-off;A2 traveling control transmission;A3 control
flat ground mode;A7 control pressurization.
The pilot oil which flows out from the four-step solenoid valve A1 enters the left-hand pilot valve 5, right-
hand pilot valve 6, travel pilot valve 7 at the same time, and controls the valve rod of the main control
valve 8 by operating the pilot valves.
Left-hand pilot valve 5 controls the machine arm and the revolving action. Right-hand pilot valve 6
controls the machine boom and the bucket action. Travel pilot valve 7 controls the travel action of the
machine.
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3.3 Hydraulic System December 30, 2017
3.3.3 Hydraulic Principle CLG930E/936E
3.3.3.3 Negative Flow Control Circuit (with the Control Spool in the Neutral)
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December 30, 2017 3.3 Hydraulic System
CLG930E/936E 3.3.3 Hydraulic Principle
1. Center position passage 4. Relief valve 7. Negative flow control oil 10.Hydraulic oil tank
2. Oil return passage 5. Orifice 8. Oil return passage 11.Right pump
3. Negative flow control oil 6. Relief valve 9. Center position passage 12.Left pump
The negative flow control system is an energy saving system. When the system does not work, the
pressure oil output from the left pump (12) and the right pump (11) of the main pump enters into return
passage (2) and (8) and returns to the hydraulic tank (10) through the orifice (5) respectively after
passing through the neutral passage (1) and (9) of main valve, and at the same time, the feedback
pressure generated before flowing through the orifice (5) enters the negative flow control port of the main
pump respectively after passing through the line (3) and (7), which minimizes the swashplate swing
angle of the main pump to reduce the output flow of the main pump and then save the energy.
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3.3 Hydraulic System December 30, 2017
3.3.3 Hydraulic Principle CLG930E/936E
3.3.3.4 Negative Flow Control Circuit (with the Control Spool Moving)
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December 30, 2017 3.3 Hydraulic System
CLG930E/936E 3.3.3 Hydraulic Principle
In case of any action, such as revolving, as shown in the figure above, the revolving spool (13) moves
toward the left with the action of the pilot pressure, the right pump output pressure of the main pump
flows through the check valve (14), the right position of the revolving spool (13) moves to the swing
motor, the original neutral passage (9) is closed by the revolving spool, the negative flow control line (7)
is minimized, and the right pump swashplate swing angle of the main pump increases to supply oil to the
swing motor; the left pump of the main pump keeps in the smallest swing angle with the action of the
negative feedback control pressure (3).
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3.3 Hydraulic System December 30, 2017
3.3.3 Hydraulic Principle CLG930E/936E
1. Boom cylinder 6. Pilot control oil line 11.Solenoid valve 15.Right pump
2. Boom cylinder big 7. Boom spool 1 12.Pilot valve group 16.Pilot pump
chamber oil pipe 8. Check valve 13.Tank 17.Boom spool 2
3. Boom cylinder small 9. Pilot control oil line 14.Left pump 18.Check valve
chamber oil pipe 10.Hand pilot valve
4. Boom lock valve
5. Pressure passage
When the hand pilot valve (10) handle is rotated backward, the pilot pressure reaches the port 4 of the
hand pilot valve (10) after passing through the solenoid valve (11) of the pilot valve group (12) from the
pilot pump (16), and reaches the control ports of the boom spool 1 (7) and boom spool 2 (17)
respectively after passing through pilot line (6) and (9); at the same time, the control oil in the right
control chamber of the boom spool 1 (7) flows back to the tank (13) after passing through spool (7) oil
pipe at the other end and the oil port 2 of the hand pilot valve (10); the boom spool 1 (7) and the boom
spool 2 (17) reverse to corresponding positions with the action of the pilot control pressure;
The pressure oil output from the left pump (14) of main pump reaches the big chamber of boom cylinder
(1) after passing through the check valve (8), boom spool 1 (7) and pressure passage (5) boom locking
valve (4); at the same time, the pressure oil of the right pump (15) after passing through the boom spool
2 (17), the check valve (18) merging into boom spool 1(7), spool reaches the big chamber of boom
cylinder (1); the oil in the boom cylinder (1) small chamber flows back to tank (13) after passing through
boom cylinder small chamber oil piping (3) and boom spool 1(7), thus, with the action of the pressure oil,
the piston rod of the boom cylinder stretches out to lift the boom.
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3.3 Hydraulic System December 30, 2017
3.3.3 Hydraulic Principle CLG930E/936E
1. Boom cylinder 6. Pilot control oil line 11.Solenoid valve 15.Right pump
2. Boom cylinder big 7. Boom spool 1 12.Pilot valve group 16.Pilot pump
chamber oil pipe 8. Check valve 13.Tank 17.Boom spool 2
3. Boom cylinder small 9. Pilot control oil line 14.Left pump 18.Check valve
chamber oil pipe 10.Hand pilot valve
4. Boom lock valve
5. Pressure passage
When the hand pilot valve (10) handle is rotated forward, the pilot pressure reaches the port 2 of the
right-hand pilot valve (10) after passing through the pilot valve group (12) and the solenoid valve (11)
from the pilot pump (16), and reaches the control ports of the boom spool 1 (7) and boom locking valve
(4) respectively after passing through the pilot line (9); at the same time, the control oil in the left control
chamber of the boom spool 1 (7) flows back to the tank (13) after passing through the hand pilot valve
(10) oil port 4, and the boom spool 1 (6) towards to right with the action of the pilot control pressure;
The pressure oil in the left pump of the main pump (14) flows through the check valve (8), the boom
spool 1 (7), and the small chamber oil pipe (3) of the boom cylinder to the small chamber of the boom
cylinder (1); the oil in the big chamber of the boom cylinder (1) flows through the boom cylinder big
chamber oil pipe line (2), boom locking valve (4), and the part return tank (13) of the boom spool 1 (7) to
the small chamber of the boom cylinder (1), and another part of the hydraulic oil joints in the small
chamber of the boom cylinder (1) after passing the check valve in the boom spool 1 (7). Thus, with the
action of the pressure oil, the boom cylinder makes the piston rod withdraw, pull the boom downward
and realize the function of return oil regeneration.
During the declining process, the boom spool 1 (7) has a certain amount of return oil, a certain pressure
still exists in the negative flow of the left pump (14), which minimizes the discharge capacity of the left
pump (14), and then the energy is saved.
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3.3 Hydraulic System December 30, 2017
3.3.3 Hydraulic Principle CLG930E/936E
When the left-hand pilot valve handle is rotated forward, the pilot pressure reaches the port 2 of the hand
pilot valve (10) after passing through the pilot valve group (12) and solenoid valve (11) from the pilot
valve (16), and reaches the control ports of the arm spool 1 (18) and the arm spool 2 (6) respectively
after passing through the switching valve (9) and pilot piping (8); at the same time, the control oil in the
control chamber-rh of the arm spool 1 (18) and arm spool 2 (6) flows back to the tank (13) after passing
through the piping, switching valve (9), and the port 4 of the left hand pilot valve (10); the arm spool 1
(18) and arm spool 2 (6) reverse to corresponding positions with the action of the pilot control pressure;
The pressure oil output from the left pump (14) of the main pump reaches the small chamber of the arm
cylinder (1) after passing through the check valve (7), arm spool 2 (6), arm locking valve (4), and arm
cylinder small chamber oil pipe (3); at the same time, the pressure oil of the right pump (15) reaches the
arm spool 1 (18) and pressure passage (19) to joint after passing through the check valve; the pressure
oil of the arm spool 2 (6) reaches the small chamber of the arm spool (1) after passing through the arm
locking valve (4) and the arm cylinder small chamber oil pipe (1); the oil in the arm cylinder (1) big
chamber flows back to the tank (13) after passing through the arm cylinder big chamber oil piping (2),
arm spool 1 (18) and the arm spool 2 (6), thus, with the action of the pressure oil, the piston rod of the
arm cylinder withdraws to make the arm stretch out.
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3.3 Hydraulic System December 30, 2017
3.3.3 Hydraulic Principle CLG930E/936E
When the left-hand pilot valve (10) handle is rotated backward, the pilot pressure reaches the port 4 of
the hand pilot valve (10) after passing through the pilot valve group (12) and solenoid valve (11) from the
pilot valve (16), and reaches the control ports of the arm spool 1 (18) and the arm spool 2 (5) and the
control port of the arm locking valve (4) respectively after passing through the switching valve (9) and
pilot piping (8); at the same time, the control oil in the arm spool 2 (6) and arm spool 1 (18) flows back to
the tank (13) after passing through the piping, switching valve (9), and the port 2 of the left-hand pilot
valve (10); the arm spool 1 (18) and arm spool 2 (6) reverse to corresponding positions with the action of
the pilot control pressure; the pilot pressure oil opens the reverse control valve of the arm locking valve
(4) at the same time to connect the control pressure of the arm locking valve and that of the tank, and
unlock the arm small chamber return oil.
The pressure oil output from the left pump (14) of the main pump reaches the big chamber of the arm
cylinder (1) after passing through the pressure passage, check valve (7), arm spool 2 (6), and the arm
cylinder big chamber oil pipe (2); at the same time, the pressure oil of the right pump (15) reaches the
arm cylinder (1) big chamber jointing the pressure oil of the arm spool 2 (6) after passing through the arm
spool 1 (18) and the arm cylinder big chamber oil pipe (2); with the light load, the regeneration control
valve (17) does not switch, and at this moment, the oil in the small chamber of the arm cylinder (1) flows
back to the arm spool 1 (18) after passing through the arm cylinder small chamber oil piping (3) and the
arm locking valve (4); a part of oil reaches the big chamber of the arm cylinder (1) after passing through
the internal check valve of the arm 1 (18) , another part of the oil flows back to the tank after passing
through the regeneration control valve orifice, this circuit can accelerate the moving speed, and the
function is called "regeneration". Thus, with the action of the pressure oil, the piston rod of the arm
cylinder stretches out to make the arm withdraw.
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3.3.3 Hydraulic Principle CLG930E/936E
With the heavy load, when the oil inlet pressure of the arm cylinder big chamber exceeds the set
pressure of the regeneration control valve (17) spring, the regeneration control valve (17) will reverse, at
this moment, the arm cylinder small chamber return oil can flow to the tank directly, and then the
"regeneration" function is unavailable.
When the left-hand pilot valve handle is rotated backward, the pilot pressure reaches the port 4 of the
hand pilot valve (10) after passing through the pilot valve group (12) and solenoid valve (11) from the
pilot valve (16), and reaches the control ports of the arm spool 1 (18) and the arm spool 2 (6) and the
control port of the arm locking valve (4) respectively after passing through the switching valve (9) and
pilot piping (8); at the same time, the control oil in left control chamber of the arm spool 1 (18) and arm
spool 2 (6) flows back to the tank (13) after passing through the switching valve (9), and the port 2 of the
left-hand pilot valve (10); the arm spool 1 (18) and arm spool 2 (6) reverse to corresponding positions
with the action of the pilot control pressure; the pilot pressure oil opens the reverse control valve of the
arm locking valve (4) at the same time to connect the control pressure of the arm locking valve and that
of the tank, and unlock the arm small chamber return oil;
The pressure oil output from the left pump of the main pump (14) reaches the big chamber of the arm
cylinder (1) after passing through the check valve (7), arm spool 2 (6) and the arm cylinder big chamber
oil pipe (2); at the same time, the pressure oil of the right pump (15) reaches the big chamber of the arm
cylinder (1) jointing the pressure oil of the arm spool 2 (6) after passing through the arm spool 1 (18) and
the arm cylinder big chamber oil pipe (2); the oil in the arm cylinder (1) small chamber connects and
flows back to the tank after passing through the arm cylinder small chamber oil piping (3), arm locking
valve (4) and the arm spool 1 (18), thus, with the action of the pressure oil, the piston rod of the arm
cylinder stretches out to make the arm withdraw.
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3.3 Hydraulic System December 30, 2017
3.3.3 Hydraulic Principle CLG930E/936E
Operate the right-hand pilot valve (10) handle to make it rotate toward left, and the pilot pressure
reaches the port 1 of the hand pilot valve (10) after passing through the pilot valve group (12) and
solenoid valve (11) from the pilot pump (16), and reaches the control port of the bucket spool (6) after
passing through the pilot control oil line (8); at the same time, the pressure oil output from the hand pilot
valve (10) makes the shut-off valve (19) switch to left after passing through the shuttle valve (9) and the
pilot control line (4) to shut off the return oil of the right pump (15); and the control oil in the control
chamber-rh of the bucket spool (6) flows back to the tank (13) after passing through the piping and the
port 1 of right-hand pilot valve (10). With the action of the pilot control pressure, the bucket spool (6)
switches to the corresponding position;
The pressure oil of the left pump (14) reaches the big chamber bucket cylinder (1) after passing through
the check valve (7), bucket spool (6) and the bucket big chamber oil pipe (2); the oil in the small chamber
of the bucket cylinder (1) flows back to the tank after passing through the bucket cylinder small chamber
oil piping (3) and the bucket spool (6), thus, with the action of the pressure oil, the piston rod of the
bucket cylinder stretches out to make the bucket withdraw.
The pressure oil output from the right pump (15), together with the oil from the left pump (14), enters the
bucket spool (6) after passing through the neutral passage (17), check valve (18) and the pressure
passage (5) to realize the jointing inside the valve.
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3.3 Hydraulic System December 30, 2017
3.3.3 Hydraulic Principle CLG930E/936E
Operate the right-hand pilot valve (10) handle to make it rotate toward right, and the pilot pressure
reaches the port 3 of the hand pilot valve (10) after passing through the pilot valve group (12) and
solenoid valve (11) from the pilot pump (16), and reaches the control port of the bucket spool (4) after
passing through the pilot line (8); at the same time, the pressure oil output from the port 3 of the hand
pilot valve (10) makes the shut-off valve (19) switch to left after passing through the shuttle valve (9) and
the pilot control line (4) to shut off the return oil of the right pump (15); and the control oil in the left control
chamber of the bucket spool (6) flows back to the tank (13) after passing through the piping and the port
1 of hand pilot valve-rh (10). With the action of the pilot control pressure, the bucket spool (6) switches to
the corresponding position;
The pressure oil of the left pump (14) reaches the small chamber bucket cylinder (1) after passing
through the check valve (7), bucket spool (6) and the bucket small chamber oil pipe (3); the oil in the big
chamber of the bucket cylinder (1) flows back to the tank after passing through the bucket cylinder big
chamber oil piping (2) and the bucket spool (6), thus, with the action of the pressure oil, the piston rod of
the bucket cylinder stretches out to make the bucket withdraw.
The pressure oil output from the right pump (15), together with the oil from the left pump (14), enters the
bucket spool (6) after passing through the neutral passage (17), check valve (18) and the pressure
passage (5) to realize the jointing inside the valve.
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3.3 Hydraulic System December 30, 2017
3.3.3 Hydraulic Principle CLG930E/936E
1. Left hand pilot valve 8. Pilot control pressure 15.Return oil check valve 21.Swing motor & reduction
2. Switching valve piping 16.Swing motor oil gear
3. Pilot control oil line 9. Negative flow feedback supplement piping 22.Motor unlock piping
4. Pilot control oil line pressure piping 17.Swing logic valve 23.Time delay valve
5. Motor unlock control line 10.Pilot valve group 18.Swing spool 24.Motor unlock control line
6. Orifice 11.Tank 19.Swing motor A port piping 25.Center position passage
7. Solenoid valve 12.Left pump 20.Swing motor B port piping 26.Shut-off valve
13.Right pump
14.Pilot pump
When the left-hand pilot valve (1) handle is rotated to left, the pilot pressure reaches the port 1 of the
hand pilot valve after passing through the pilot valve group (10) and solenoid valve (7) from the pilot
pump (14), and reaches the control port of the swing spool (18) after passing through the pilot line (4); at
the same time, the control oil in the control chamber-rh of the swing spool (18) flows back to the tank (10)
after passing through the piping (3) and the oil port 3 of the left-hand pilot valve (1). With the action of the
pilot control pressure, the swing spool (18) switches to the corresponding position; at this moment, the
pilot pressure oil generates the pressure after passing through the piping (8), throttle valve (6) and the
swing spool (18) stops after reversing; the control pressure provided by the pilot valve group (10)
reaches the time delay valve (23) unlocked by the swing motor after passing through the pilot control
pressure piping (8), throttle port (6) and the motor unlock control piping (5) and (24), and pushes the
reverse valve of the time delay valve to reverse; the control pressure oil output from the pilot valve group
(10) enters the locking cylinder of the motor after passing through the motor unlock piping (22) to realize
the unlocking;
The pressure oil of the right pump (13) reaches the swing motor and & reduction gear (21) after passing
through the swing logic valve (17), swing spool (15), and the swing motor B port line (20); the oil of the
swing motor & reduction gear (21) A port flows back to the tank after passing through the swing motor A
port line (19) and the swing spool (18), thus, with the action of the pressure oil, the swing motor &
reduction gear drive the platform to rotate toward the left.
The pressure oil output from the left pump (12) of the main pump flows back to the tank after passing
through the neutral passage (25) and the shut-off valve (26); the front feedback pressure at the throttle
port acts on the variable mechanism of the left pump (12) through the negative flow feedback pressure
line (9), which minimizes the discharge capacity of the left pump (12).
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3.3 Hydraulic System December 30, 2017
3.3.3 Hydraulic Principle CLG930E/936E
The main function of the priority valve (16) is to distribute the pressure oil output to the swing spool (15)
and the arm spool 1 (18) by the right pump (13). As shown in the circuit diagram, the throttle passage is
at the right position.
When the left handle of the hand pilot valve (8) is operated at about 45° toward rear right, the pilot
pressure reaches the port 3 and port 4 of the left hand pilot valve from the pilot pump (14) after passing
through the pilot valve group (10) and the solenoid valve (9), and reaches the swing spool (15) and the
corresponding control ports of the arm spool 1 (18) and the arm spool 2 (2) after passing through the
switching valve (7) and the pilot piping (3) and (5) respectively. At this moment, the control oil of the
swing pilot control oil passage (3) reaches the pilot control port PSP of the swing priority valve (16) after
passing through the shuttle valve (6), which makes the valve move to the right throttle position.
The pressure oil output from the left pump (12) of the main pump reaches the big chamber of the arm
cylinder (1) after passing through the arm spool 2 (2).
At the same time, a part of the pressure oil of the right pump (13) reaches the swing motor (17) after
passing through the swing spool (15), and another part enters the arm cylinder (1) big chamber after
passing through the throttle passage-rh of the swing priority valve (16) and the arm spool 1 (18); as the
throttling action of the swing priority valve (16), the flow entering the arm spool 1 (18) is restricted, and
then the swing priority to the arm is achieved.
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3.3 Hydraulic System December 30, 2017
3.3.3 Hydraulic Principle CLG930E/936E
1. Left hand pilot valve 8. Pilot control pressure 15.Return oil check valve 21.Swing motor & reduction
2. Switching valve piping 16.Swing motor oil gear
3. Pilot control oil line 9. Negative flow feedback supplement piping 22.Motor unlock piping
4. Pilot control oil line pressure piping 17.Swing logic valve 23.Time delay valve
5. Motor unlock control line 10.Pilot valve group 18.Swing spool 24.Motor unlock control line
6. Orifice 11.Tank 19.Swing motor A port piping 25.Center position passage
7. Solenoid valve 12.Left pump 20.Swing motor B port piping 26.Shut-off valve
13.Right pump
14.Pilot pump
When the left hand pilot valve (1) handle is rotated to right, the pilot pressure reaches the port 3 of the
hand pilot valve after passing through the pilot valve group (10) and solenoid valve (7) from the pilot
pump (14), and reaches the control port of the swing spool (18) after passing through the pilot line (3); at
the same time, the control oil in the left control chamber of the swing spool (18) flows back to the tank
(10) after passing through the piping (20) and the oil port 1 of the left-hand pilot valve (13). With the
action of the pilot control pressure, the swing spool (18) switches to the corresponding position; at this
moment, the pilot pressure oil generates the pressure after passing through the piping (8), throttle valve
(6) and the swing spool (18) stops after reversing; the control pressure provided by the pilot valve group
(10) reaches the time delay valve (23) unlocked by the swing motor after passing through the pilot
control pressure piping (8), throttle port (6) and the motor unlock control piping (5) and (24), and pushes
the reverse valve of the time delay valve to reverse; the control pressure oil output from the pilot valve
group (10) enters the locking cylinder of the motor after passing through the motor unlock piping (22) to
realize the unlocking;
The pressure oil of the right pump (13) reaches the swing motor and & reduction gear (21) after passing
through the swing logic valve (17), swing spool (18), and the swing motor A port piping (19); the oil of the
swing motor & reduction gear (21) B port flows back to the tank after passing through the swing motor B
port piping (20) and the swing spool (18), thus, with the action of the pressure oil, the swing motor &
reduction gear drive the platform to rotate toward the right.
The pressure oil output from the left pump (12) of the main pump flows back to the tank after passing
through the neutral passage (25) and the shut-off valve (26); the front feedback pressure at the throttle
port acts on the variable mechanism of the left pump (12) through the negative flow feedback pressure
line (9), which minimizes the discharge capacity of the left pump (12).
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3.3 Hydraulic System December 30, 2017
3.3.3 Hydraulic Principle CLG930E/936E
1. Left travel motor & 13.Travel pilot valve 25.Motor brake 37.Solenoid valve
reduction gear 14.Travel fast and slow gear 26.Control passage 38.Pilot return lines
2. Right travel motor & control line 27.Check valve 39.Four-step solenoid valve
reduction gear 15.B port pipeline, right 28.Transmission reversing group
3. Motor brake travel motor valve 40.Hydraulic oil tank
4. Unlock pressure oil 16.A port pipeline, right 29.Variable displacement 41.Pilot pump
passage travel motor cylinder 42.Left pump
5. Motor A port oil passage 17.Motor A port oil passage 30.Center revolving joint 43.Right pump
6. Balanced valve 18.Control passage 31.Pilot control oil line 44.Pressure switch
7. Travel motor A port 19.Balanced valve 32.Pilot control oil line 45.Pilot valve group
piping-lh 20.Oil return passage 33.Solenoid valve 46.Right travel spool
8. Travel motor B port 21.Check valve 34.Left travel spool 47.Control passage
piping-lh 22.Transmission reversing 35.Pressure passage 48.Control passage
9. Control passage valve 36.
10.Motor B port passage 23.Control passage
11.Pilot control oil line 24.Variable displacement
12.Pilot control oil line cylinder
When the travel fast-slow gear control switch is in the "Rabbit" state and the travel pilot valve (13) is
operated toward forward, the pilot pressure reaches the port 1 and port 3 of the travel pilot valve (13)
after passing through the pilot valve group (45) and the solenoid valve (33) from the pilot pump (41), and
reaches the control ports of the travel -lh spool (35) and the travel -rh spool (46) after passing through
the pilot lines (31) and (11) respectively; at the same time, the control oil in the control chamber-lh of the
travel -lh spool (35) and the travel -rh spool (46) flows back to tank (40) after passing through the piping
(32) and (12), oil port 2 and 4 of the travel pilot valve (13) and the pilot return line (38); with the action of
the respective pilot control pressure, the travel -lh spool (35) and the travel -rh spool (46) reverse to
corresponding position respectively, at this moment, the travel fast-slow gear control switch is in the
"Rabbit" state of the fast gear, namely, energizing the solenoid valve (37) of the four-step solenoid valve
group (39) to make it reverse; the pilot control pressure reaches the transmission reverse valve (28) and
(22) of the travel motor-lh and the reducer (1) as well as the travel motor-rh and reducer (2) after passing
through the piping, center swing joint (30) and the travel fast-slow gear control line (14) to push the
reverse valve to reverse; at this moment, the oil inlet pressure of the motor-rh enters the variable cylinder
(24) of the travel motor-rh after passing through the check valve (21), transmission reverse valve (22)
and the control passage (23), while the oil inlet pressure of the motor-lh enters the variable cylinder (29)
of the travel motor-lh after passing through the check valve (27) and the transmission reverse valve (28),
thus, with the action of the oil inlet pressure, the left and right motors are in the position with the least
discharge capacity, which is called "fast gear" state;
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3.3 Hydraulic System December 30, 2017
3.3.3 Hydraulic Principle CLG930E/936E
The pressure oil output from the left pump (42) of the main pump reaches the port A of the left travel
motor & reduction gear (1) after passing through the pressure passage (36), left travel spool (35), center
swivel joint (30) and the port B piping (8) of left travel motor; the pressure oil enters the motor by passing
through the motor port B passage (10); at the same time, the pressure oil pushes the balanced valve (6)
to reverse by passing through the control passage (9), and the pressure oil enters the motor brake (3) to
unlock after passing through the balanced valve (6) and the control passage (4); the return oil of the
motor connects with the hydraulic oil tank (40) after passing through the return passage (5) and balanced
valve (6) to port A , and then passing through the port A piping (7) of left travel motor, the center swivel
joint (30) and the left travel spool (35); at the same time, the pressure oil of the right pump (43) reaches
the port A of the right travel motor & reduction gear (2) after passing through the check valve (45), right
travel spool (46), center swivel joint (30) and the port B piping (16) of right travel motor; the pressure
enters the motor by passing through the motor port A passage (17); at the same time, the pressure oil
pushes the balanced valve (19) to reverse by passing through the control passage (18), and the
pressure oil enters the motor brake (25) to unlock after passing through the balanced valve (19) and the
control passage (26); the return oil of the motor reaches the port B of the balanced valve (19) after
passing through the return passage (20) and the balanced valve (19), and then connects with the
hydraulic oil tank (40) after passing through the port B piping (15) of right travel motor, center swivel joint
(30) and the right travel spool (46); thus, with the action of the pressure oil, the left and right motors and
the reduction gear drive the machine to move backward slowly.
As the reversing of the right travel spool (46), the return passage outputting the control pressure from the
pilot valve group (45) port B is stopped and the pressure is produced, this pressure acts on the pressure
switch (44) after passing through the control passage (47) and (48), and then the pressure switch (44)
transmits the electrical signal to realize the function of travel warning.
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December 30, 2017 3.3 Hydraulic System
CLG930E/936E 3.3.3 Hydraulic Principle
BLANK PAGE
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3.3 Hydraulic System December 30, 2017
3.3.3 Hydraulic Principle CLG930E/936E
1. Left travel motor & 13.Travel pilot valve 25.Motor brake 37.Solenoid valve
reduction gear 14.Travel fast and slow gear 26.Control passage 38.Pilot return lines
2. Right travel motor & control line 27.Check valve 39.Four-step solenoid valve
reduction gear 15.B port pipeline, right 28.Transmission reversing group
3. Motor brake travel motor valve 40.Hydraulic oil tank
4. Unlock pressure oil 16.A port pipeline, right 29.Variable displacement 41.Pilot pump
passage travel motor cylinder 42.Left pump
5. Motor A port oil passage 17.Motor A port oil passage 30.Center revolving joint 43.Right pump
6. Balanced valve 18.Control passage 31.Pilot control oil line 44.Pressure switch
7. Travel motor A port 19.Balanced valve 32.Pilot control oil line 45.Pilot valve group
piping-lh 20.Oil return passage 33.Solenoid valve 46.Right travel spool
8. Travel motor B port 21.Check valve 34.Left travel spool 47.Control passage
piping-lh 22.Transmission reversing 35.Pressure passage 48.Control passage
9. Control passage valve 36.
10.Motor B port passage 23.Control passage
11.Pilot control oil line 24.Variable displacement
12.Pilot control oil line cylinder
When the travel fast-slow gear control switch is in the slow gear - "Tortoise" state and the travel pilot
valve (13) is operated toward backward, the pilot pressure reaches the port 2 and port 4 of the travel pilot
valve (13) after passing through the pilot valve group (45) and the solenoid valve (33) from the pilot
pump (41), and reaches the control ports of the left travel spool (35) and the left travel spool (46) after
passing through the pilot lines (32) and (12) respectively; at the same time, the control oil in the control
chamber-lh of the left travel spool (35) and the right travel spool (46) flows back to tank (40) after passing
through the piping (31) and (11), oil port 1 and 3 of the travel pilot valve (13) and the pilot return line (38);
with the action of the respective pilot control pressure, the left travel spool (35) and the right travel spool
(46) reverse to corresponding position respectively, and at this moment, the travel fast-slow gear control
switch is in the "Tortoise" state of the slow gear, namely, power off the solenoid valve (37) of the four-step
solenoid valve group (39) to make it reset (as shown in the figure); the control pressure (14) is back to
the tank after passing through the solenoid valve (37) of the pilot valve group (39); the transmission
reverse valve (28) and (22) reset with the action of the spring, and the control pressure in the variable
cylinder (29) and (24) of the left and right travel motor connect with the drainage port and are back to the
tank after passing through the transmission reverse valve (28) and (22) respectively, thus, with the action
of the spring force, the variable cylinders of the left and right motors make the motor in the position with
the maximum discharge capacity, namely, the "slow gear" state;
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3.3 Hydraulic System December 30, 2017
3.3.3 Hydraulic Principle CLG930E/936E
The pressure oil output from the left pump (42) of the main pump reaches the port A of the left travel
motor & reduction gear (1) after passing through the pressure passage (36), travel -lh spool (35), center
swivel joint (30) and the Port A piping (7) of left travel motor; the pressure oil enters the motor by passing
through the motor A port passage (5); at the same time, the pressure oil pushes the balanced valve (6)
to reverse by passing through the control passage (9), and the pressure oil enters the motor brake (3) to
unlock after passing through the balanced valve (6) and the control passage (4); the return oil of the
motor connects with the hydraulic oil tank (40) after passing through the return passage (10) and
balanced valve (6) to the B port, and then passing through the travel motor B port piping-lh (8), the
center swivel joint (30) and the travel -lh spool (35); at the same time, the pressure oil of the right pump
(43) reaches the B port of the travel motor-rh & reduction gear (2) after passing through the check valve
(45), travel -rh spool (46), center swivel joint (30) and the travel motor B port piping-rh (15); the pressure
enters the motor by passing through the motor B port passage (20); at the same time, the pressure oil
pushes the balanced valve (19) to reverse by passing through the control passage (18), and the
pressure oil enters the motor brake (25) to unlock after passing through the balanced valve (19) and the
control passage (26); the return oil of the motor reaches the A port of the balanced valve (19) after
passing through the return passage (17) and the balanced valve (19), and then connects with the
hydraulic oil tank (40) after passing through the travel motor A port piping-rh (16), center swivel joint (30)
and the travel -rh spool (46); thus, with the action of the pressure oil, the left and right motors and the
reduction gear drive the machine to move backward slowly.
As the reversing of the right travel spool (46), the return passage outputting the control pressure from the
pilot valve group (39) port B is stopped and the pressure is produced, this pressure acts on the pressure
switch (44) after passing through the control passage (47) and (48), and then the pressure switch (44)
transmits the electrical signal to realize the function of travel warning.
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CLG930E/936E 3.3.3 Hydraulic Principle
BLANK PAGE
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3.3 Hydraulic System December 30, 2017
3.3.3 Hydraulic Principle CLG930E/936E
1. Left travel motor & 7. Pilot control oil line 12.Pilot control oil line 17.Left pump
reduction gear 8. Pilot control oil line 13.Orifice 18.Right pump
2. Travel pilot valve 9. Straight travel valve 14.Pilot control oil line 19.Pilot pump
3. Right hand pilot valve 10.Orifice 15.Pilot control oil line 20.Right travel spool
4. Solenoid valve 11.Pilot control oil line 16.Pilot valve group 21.Right travel motor &
5. Boom spool 1 reduction gear
6. Left travel spool
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December 30, 2017 3.3 Hydraulic System
CLG930E/936E 3.3.3 Hydraulic Principle
Under normal travel state (namely without other actions), the left pump (17) supplies oil to the left travel
spool (6) and the right pump (18) supplies the oil to the right travel spool (20). With the both sides
traveling, when any actions of the swing or working implement are operated synchronously, the control
pressure (11) of the straight travel valve (9) is produced because of the stopping function of the spool
reversing of the travel spool and the boom or the work implement, which pushes the straight travel valve
(9) to reverse, at this moment, the output oils of the left and right pumps are distributed again by passing
through the straight travel valve (9); the pressure oil output from the right pump (18) is supplied to the left
and right travel valve, and the pressure oil output from the left pump (17) is supplied to the work
implement preferentially, then, the redundant oil is supplied to travel, thus, it is equal to that the left and
right travel is supplied by one oil source, which keeps them traveling straightly.
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3.4 Work Implement December 30, 2017
3.4.1 Maintenance References of Main Parts CLG930E/936E
Judgment standards
No. Item Standar Tolerance Standard Permissible Measures
d size Shaft Hole clearance clearance
CLG930E CLG936E
Measuremen CLG930E CLG936E
No. Tolerance
t position
Standard size Shaft Hole Shaft Hole
-0.036 +0.054 -0.036 +0.054
1 — φ100 φ110
-0.071 0 -0.071 0
+1 +1
Arm side 127 137
0 0
2
0 0
Cylinder side 125 135
-0.5 -0.5
-0.036 +0.054 -0.036 +0.054
3 — φ110 φ110
-0.071 0 -0.071 0
+0.5 +0.5
Boom side 370 417
0 0
4
0 0
Arm side 366 413
-1 -0.5
5 — 216.8 260 ±0.5 ±0.5
6 — 552.1 554 ±1 ±1
7 — 981.3 985 ±1 ±1
8 — 3042.3 3190 ±2 ±3
9 — 2803.8 2994.2 ±1 ±1.5
10 — 450 575 ±0.5 ±1
11 — 680 700 ±0.5 ±0.5
12 — 680 695 ±0.5 ±0.5
13 — 450 585 ±0.5 ±0.5
14 — 1601 1692 — —
-0.036 +0.224 -0.036 +0.159
15 — φ90 φ100
-0.071 +0.17 -0.071 +0.072
0 0
Link itself 358 396
-0.5 -0.5
16 When pressing
0 0
and installing 380 418
-0.7 -0.7
the bushing
-0.036 +0.224 -0.036 +0.159
17 — φ90 φ100
-0.071 +0.17 -0.071 +0.072
0 0
Arm itself 358 396
-0.5 -0.5
18 When pressing
0 0
and installing 380 418
-0.7 -0.7
the bushing
Minimum 1799 1850 ±2 ±4
19
Maximum 2934 3070 ±4 ±7
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December 30, 2017 3.4 Work Implement
CLG930E/936E 3.4.3 Maintenance References of Bucket Part
4
5
2
1
Engine
Throttle actuator
Power-on signal
of electric lock Main controller
Battery relay
Engine oil pressure signal
Electric lock start signal
Accelerator knob signal
Battery
1. Start the engine (Note: The starting signal of the starter relay is
controlled by the ECM, and the starter relay is
When the electric lock is turned to the "Start"
driven jointly by the main controller control
position, the electric lock starting signal is
starting signal and the pilot handle control signal.
detected by the main controller, and then the
When the machine is free of failure, and the
main controller sends main controller control
excavator is started following the correct steps,
starting signal to transmit the power supply
the starting process of the engine is described as
signal to the power end of the start motor, then
above.)
the engine is started.
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CLG930E/936E 3.6.2 Display System
At the same time, the main controller detects the 1. Alarm information when the complete
accelerator knob signal, and sets the machine fails;
corresponding engine speed of the accelerator
2. Working condition information of the machine
knob as the set speed, then sends the speed
(including the engine speed, hydraulic oil
control signal to the engine controller via the
temperature, etc.).
CAN bus, so as to control the oil feed pump and
make the current speed become the set speed 3. Maintenance information of the machine.
steadily.
The keys for special purposes (part of the keys
2. Engine speed control are equipped with LED indicator) on the control
panel of the display are used to operate the
Each gear of the accelerator knob corresponds
control system of the machine.
to an engine speed, and the engine controller
controls the oil injection quantity according to the
speed control signal sent by the main controller,
so as to control the engine speed.
3. Stop the engine
When the electric lock is turned to the "OFF"
position, the engine stops.
Engine controller
3.6.2.1 Display
LCD
Button panel
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December 30, 2017 3.6 Electrical System
CLG930E/936E 3.6.2 Display System
Icon
Icon Content Description
color
Blue The accelerator has 12 gears changing from "1" to "12", and
Normal display
Accelerator
when the accelerator knob is failed, the icon in this place is
gear
nothing
Idling function When the idling function is enabled, the icon will be displayed
Icon
Icon Content Description
color
Battery is not It will warn when the battery is not charged, and at this
charged moment, check the charging circuit and eliminate the failure
Fuel contains
It will warn when the fuel contains water
water
Engine oil
High alarm of engine oil pressure
pressure
Warning information display
Engine oil
It will warn when the engine oil level is low
level
Red
Air filter alarm Blockage alarm of air filter
Hydraulic oil It will warn when the hydraulic oil temperature exceeds the
temperature limit
It will warn when the hydraulic oil level is low, and this function
Hydraulic oil
requires that the hydraulic oil level switch is equipped on the
level
machine
Over lifting It will warn when the lifting load is higher than the system
load specified value
Maintenance The icon will be displayed when there are some maintenance
service items not finished by the user
When the machine is failed, the failure will be displayed in the
Warning
form of text or the LiuGong DTCs.
information
In case of the warning caused by the system failures, the red
display
alarm bell icon will flicker all the time.
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CLG930E/936E 3.6.2 Display System
Icon
Icon Content Description
color
Scope % Color Description
When the icon is filled with red color
accompanied by the warning information
≤10 Red
of "Low fuel level", indicate that the fuel
level is too low
Fuel Level
When the icon is filled with yellow color,
10~20 Yellow it indicates that the fuel level is slightly
low
When the icon is displayed normally, it
Virtual gage
20~100 Green
indicates that the fuel level is normal
Range °C Color Description
Normal
≤30 Blue
temperature
Normal
30~100 Green
Coolant temperature
temperature 100~102 Yellow High temperature
Overhigh
102~105 Red
temperature
Extremely high
?105 Red
temperature
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3.6 Electrical System December 30, 2017
3.6.2 Display System CLG930E/936E
3.6.2.3 Display Key Panel For the machine equipped with the attachment,
the B/ATT mode is invisible in the selecting menu
unless the B/ATT is enabled.
When the B mode or the ATT mode is selected,
the system will pop up the following information
prompt box:
Yes No
4. LED indicator is equipped on both sides b. User presses the mute key - the travel
of the travel speed control key (rabbit/ buzzer is turned off and the LED indicator
tortoise) goes off
Press the key to switch between the low speed c. Vehicle stops running - travel buzzer mute
state and high speed state, and the requests to turn off, namely, invalid
corresponding icon (rabbit/tortoise) on the main d. Vehicle runs again - travel buzzer sounds,
interface and the two corresponding LED and the LED indicator is illuminated again
indicators (beside the key) will switch (namely, the previous mute operation is
synchronously. invalid)
The travel icon on the display and the LED Moreover, there are eleven common/navigation
indicator is only consistent with the state keys on the panel:
selected by the user, not the state of the travel
solenoid valve. Similarly, the selected state 1. The 4 keys are F1, F2, F3 and F4
(indicating icon or light) is not affected by respectively, which are defined as the display
whether the vehicle is in the running state or soft keys
whether the travel solenoid valve is failed. 2. Four navigation keys (up/down/left/right)
3. Selection key is marked as "O" - the function
5. A LED indicator is equipped for the of which is similar to the clicking or selecting
automatic idle speed control key at the top function of the mouse left button
right corner 4. Confirm key (green), mark "√" signal - for OK,
Press the key to trigger the automatic idle speed entrance or confirm function
function. The corresponding icon on the main 5. Cancel key (red) is marked as "×" - used to
interface and LED indicator (beside the key) will cancel, exit or negate
be illuminated synchronously.
Current fault Press the key and the system will enter the current failure interface.
Set Press the key and the system will enter the setting interface.
Display setting Press the key and the system will enter the display setting interface.
Press the key and the system will enter the maintenance interface, which
Maintenance mainly displays the information of the item requiring maintenance. The key
will be displayed all the time even if there is no maintenance item.
Maintenance help Press the key and the system will enter the maintenance help interface.
Press the key and the system will enter the main interface. Press the X key
Main interface (with no small windows popped up) to return to the main interface no
matter what interface is displayed.
Press the key and the system will enter the service mode menu interface.
Note: The key shares a same position with the internal buzzer mute key,
Service mode menu and it will be hidden when the internal buzzer mute key icon is displayed.
This key and the corresponding functions can be visible only when the
mute key is pressed to make the buzzer silent.
Machine state Press the key and the system will enter the machine state interface.
Specific machine state Press the key and the system will enter the specific machine state
interface interface.
Press the key and the system will make the parameter configuration
Parameter window pop up under the machine state interface. Invoking this key will
configuration mode make the display enter a specific working mode, under which the user can
select the parameters expected to monitor in the popped up window list.
Historical failure Press the key and the system will enter the historical failure interface.
Press the key and the system will enter the maintenance history interface.
Maintenance history If there is no maintenance history record at present, the soft key function
will be off (icon is gray).
Press this key and the system will enter the maintenance operation
New maintenance
interface. Under this interface, the user can perform the maintenance
record
operation and record.
This key and its function can be visible only in the maintenance operation
interface, and can be used only when one or more maintenance items are
Save maintenance
selected. Press this key and a new maintenance record will be created,
record
and the interface will be switched to the "Save this record" interface under
the maintenance history interface synchronously.
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CLG930E/936E 3.6.2 Display System
● Language setting Under the ATT mode, move the cursor to this
option, and press the 0-type key to activate the
● Lifting overload monitoring functions of this option. Then, the user can adjust
● Automatic transient power boosting the level from 1 to 4 between the L level and H
level using the left/right navigation keys.
Breaking hammer flow adjustment After that, press the "√" key to confirm. Press the
Attachment flow adjustment
"X" key to cancel the current setting.
Set date/time
3. Date/time set
Language settings
When this option is selected, the following date/ Select the required language using the
time setting dialog box will pop up. The time is navigation keys (up/down) and press the "0" -
displayed in 24-hour. Press the navigation key to type key or "√" to confirm. Press the "×" key to
select the year, month, day, hour, minute and cancel the current setting.
second respectively, and then press the 0 type
confirmation key to make the virtual numeric
keyboard pop up and enter the number to be set. Breaking hammer flow adjustment
Language
1. Contrast
Generally, the contrast of the LCD screen is 1. Maintenance items
implemented according to the factory setting.
This list mainly displays the item names which
However, the user can adjust the contrast by
moving the cursor bar. are about to expire or have expired but not
maintained. Refer to the following list for the
2. Brightness setting maintenance item and the interval.
User can move the cursor bar to set the LCD Maintenance item Interval
backlight brightness. There are two independent
settings, which are the day mode and night Replace engine oil 250h
mode. Replace engine oil filter element 250h
When the vehicle work light is on, the system will Replace fuel filter element 250h
enter the night mode, and meanwhile, the icon Fill the lubricant for the swing bearing 500h
will changed as the "Moon": . Check the fuel oil filter 500h
3. Buzzer volume Clean the exterior of the radiator 500h
Replacing the return oil filter element of
User can move the cursor bar to set the buzzer hydraulic
500h
volume in the display.
Replace the air filter element 500h
Note: In case of the failure of the system, the Replace the pump filter element 1000h
buzzer will warn in the highest volume regardless
Replace the swing reduction gear oil 1000h
of the volume set by the user.
Replace the pilot engine oil filter 1000h
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3.6 Electrical System December 30, 2017
3.6.2 Display System CLG930E/936E
Engine
Throttle actuator
Display
Accelerator knob
Fuel sensor
Temperature sensor
Hydraulic system
Select the corresponding work mode by the display, and then the controller implements the
corresponding functions of the selected mode. The work mode is classified into 6 kinds as follows.
● P --- Heavy load mode, it is applicable for the heavy load condition to take efficiency as priority.
● E --- Economic mode, it is applicable for the general operation to take the oil consumption as priority.
● F --- Fine mode, it is applicable for the operation with fine actions.
● L --- Lifting mode, it is applicable for the operation to lift the materials.
● B --- Breaking hammer mode, it is applicable for the operation to use breaking hammer.
● ATT --- Attachment mode, it is applicable for the operation of the attachment such as the hydraulic
crusher and grapple.
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3.6 Electrical System December 30, 2017
3.6.3 Electrical Control System CLG930E/936E
Engine
Throttle actuator
Display
Accelerator knob signal
Main controller
CAN bus Handle pilot pressure
switch signal
Attachment pressure
switch signal
Display
Under the P, E and F mode, it will increase the The automatic power boosting function can be
digging force of the excavator within certain time. selected from the display menu. When the P1
Under the L mode, it will increase the digging pump pressure signal is detected by the main
force of the excavator continuously. Under the B controller or the P1 pump pressure signal is
and ATT mode, this function is unavailable. greater than or equal to 34MPa and maintains for
When the vehicle is running, the transient power over 3 seconds, the main controller will output
boosting function will be unavailable. the power boosting solenoid valve control signal
to increase the digging force.
The transient power boosting function is divided
into manual power boosting and automatic When the conditions of the automatic power
power boosting. boosting function are met, the machine will
increase the digging force for 8s, then the button
1. Manual power boosting will reset automatically. 10s later, whether the
The operator presses the transient power power boosting function being enabled depends
boosting button to increase the digging force for on if the conditions of the transient power
8s, then the button will reset automatically. 10s boosting are met or not.
later, whether the power boosting function being
enabled depends on if the transient power
boosting button is pressed or not.
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3.6 Electrical System December 30, 2017
3.6.3 Electrical Control System CLG930E/936E
Display
Main pump
Function:
When the coolant or the hydraulic oil temperature is high, in order to protect the engine and the hydraulic
element from overheating, the pump current and the engine speed will be reduced to protect the engine
and the hydraulic element.
The overheating protection function is divided into level 1, level 2 and level 3.
Protection
Working conditions Measures Reset conditions
level
Work mode: P
Hydraulic oil temperature: less
Hydraulic oil temperature Engine speed: keep as original
Level 1 than 82°C
above 86°C or the coolant Pump current: reduce the pump current
protection Coolant temperature: less than
temperature above 102°C Display: Warning appears
100°C
Warning buzzer: Sounds
Work mode: P, E, F, L, B and ATT
Hydraulic oil temperature: less
Hydraulic oil temperature Engine speed: keep as original
Level 2 than 82°C
above 88°C or the coolant Pump current: reduce the pump current
protection Coolant temperature: less than
temperature above 10°C Display: Warning appears
100°C
Warning buzzer: Sounds
Hydraulic oil temperature: less
Work mode: P, E, F, L, B and ATT
than 82°C
Hydraulic oil temperature Engine speed: gear 1st speed
Level 3 Coolant temperature: less than
above 95°C or the coolant Pump current: pump current in 1st gear
protection 100°C
temperature above 108°C Display: Warning appears
Accelerator knob: back to the 1st
Warning buzzer: Sounds
gear position for once
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CLG930E/936E 3.6.3 Electrical Control System
3.6.3.5 Traveling Speed Control 2. When the travel speed is high, the main
Function controller will change the travel speed
automatically based on the pressure output
by the pump. If the pump pressure is higher
than 28MPa for at least 1s, the travel speed
Display will be changed as slow speed automatically.
If the pump pressure is less than15MPa for at
least 1s, the traveling rotate speed will
(Travel speed automatically recover to high speed.
CAN bus command)
Travel speed
Switch signal of
pedal pilot pressure
High speed
P1 pump pressure signal
Main controller
P2 pump pressure signal
Function:
3.6.3.6 Various ComponentS Refer to the following table for the corresponding
relation between the temperature sensor
Pressure Switch resistance and the temperature:
Voltage / V
Pressure/bar
1. COMBINATION CUSHION
2. Sensor
3. Connector Door control switch
The relation between the 50 bar pressure sensor
output current and the pressure is as the
following figure:
Voltage / V
Pressure/bar
1. Switch
2. Connector
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3.6 Electrical System December 30, 2017
3.6.3 Electrical Control System CLG930E/936E
A-direction
B-direction
1. Block
2. Floater
3. Connector
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December 30, 2017 3.6 Electrical System
CLG930E/936E 3.6.3 Electrical Control System
Fuel level
Floater Output
Percentage
Floater Output position resistance (Ω)
Percentage
position resistance (Ω) 70% L14-L15 400±4
0% Below L1 1100±11 75% L15-L16 350±3.5
5% L1-L2 1050±10.5 80% L16-L17 300±3
10% L2-L3 1000±10 85% L17-L18 250±2.5
15% L3-L4 950±9.5 90% L18-L19 200±2
20% L4-L5 900±9 95% L19-L20 150±1.5
25% L5-L6 850±8.5 100% L20-L21 100±1
30% L6-L7 800±8
35% L7-L8 750±7.5
40% L8-L9 700±7
45% L9-L10 650±6.5
50% L10-L11 600±6
55% L11-L12 550±5.5
60% L12-L13 500±5
65% L13-L14 450±4.5
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3.6 Electrical System December 30, 2017
3.6.3 Electrical Control System CLG930E/936E
Accelerator knob
Lead Pin
Power line
Slot
Earthing cable
Signal line
Controller
Black White
LG922E930E3195
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3.6 Electrical System December 30, 2017
3.6.3 Electrical Control System CLG930E/936E
1. J1
2. J2
When the travel speed control key on the display is pressed, the J2-10 pin of the main controller will
output 24V voltage to the travel transmission solenoid valve coil to make the travel speed switch to the
high-speed state.
When the travel speed control key on the display is pressed again, the J2-10 pin of the main controller
will output 0V voltage to the travel transmission solenoid valve coil to make the travel speed switch to the
low-speed state.
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December 30, 2017 3.6 Electrical System
CLG930E/936E 3.6.4 Descriptions of Partial Circuits
When the transient power boosting button is pressed, the J1-13 pin of the main controller (IPC controller)
will output 24V voltage to the power boosting solenoid valve for 8s, and then the button will reset
automatically, namely, the J1-13 pin of the main controller (IPC controller) outputs 0V voltage to the
power boosting solenoid valve. 10s later, whether the power boosting function is enabled depends on if
the transient power boosting button is pressed.
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3.6 Electrical System December 30, 2017
3.6.4 Descriptions of Partial Circuits CLG930E/936E
When the electric lock (also called as ignition switch) is turned to "On" position, the battery relay coil
circuit is conducted, making the battery relay main contact closed, and the main controller and the
engine controller are powered on to work.
When the electric lock is turned to Start position, the starter relay K1 coil circuit is conducted, making the
starter relay K1 main contact closed, and then the engine is started.
When the electric lock is turned to the "Start" position, the pilot shut-off valve switch will always be in
closed state and the safety relay K10 main contact will be closed making the pilot control starter relay K7
main contact closed.
When the electric lock is turned to the "Start" position and the starting signal is detected by the main
controller, the J2-23 pin of the main controller will output 0V voltage to the controller control starter relay
K8 coil, making the controller control starter relay K8 main contact always in closed state.
1. Starter motor circuit:
"Battery positive-battery relay main contact -50A fuse-starting relay K1 main contact-starting motor
starting end-starting motor-grounding"
2. Battery relay coil circuit
"Battery terminal positive - 50A fuse - Electric lock power supply 20A fuse (fuse box) - ignition
switchB1end - ignition switch B2 end - battery relay coil - earthing"
3. Starting relay K1 coil circuit:
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3.6 Electrical System December 30, 2017
3.6.4 Descriptions of Partial Circuits CLG930E/936E
"Battery positive -50A fuse-electric lock power 20A fuse (fuse box)-ignition switch B1 end-ignition switch
S end-pilot control starting relay K7 main contact (fuse box)-controller control starting relay K8 main
contact (fuse box)-starting relay K1 coil-grounding"
4. Pilot control starter relay K7 coil circuit:
"Battery positive-battery relay main contact- -50A fuse - pilot stop 10A (fuse box) - safety relay K10 main
contact (fuse box)-pilot stop valve switch main contact point-pilot control starting relay K7 coil (fuse box)-
grounding"
5. Starter relay K10 coil circuit:
"Battery positive -50A fuse-electric lock power 20A fuse (fuse box)-ignition switch B1 end-ignition switch
B2 end-safety relay K10 coil (fuse box) -grounding"
6. Controller control starter relay K8 coil circuit:
"Controller-J2-23 pin - controller control starting relay K8 coil (fuse box)-grounding"
Note: When the electric lock is turned to "On" position, the B1 end and the B2 end of the ignition switch
are conducted. When the electric lock is turned to "Start" position, the end B1 and the end B2 of the
ignition switch are conducted with the end S.
When the trenching function key on the display is pressed, the J1-25 pin of the main controller (IPC
controller) outputs 24V voltage to the trenching solenoid valve coil.
When the trenching function key on the display is pressed again, the J1-25 pin of the main controller
(IPC controller) outputs 0V voltage to the trenching function solenoid valve coil.
Note: the trenching function is only available under the P, E and F mode.
When the trenching function is enabled. The trenching solenoid valve is powered on, and the swing logic
valve is in the maximum opening when the boom is operated upward. Namely, the swing speed is not
restricted. That is what we often called the swing has the priority to the boom lifting.
When the trenching function is pressed again. The trenching solenoid valve is powered off, and the
swing logic valve is in the minimum opening when the boom is operated upward. Namely, the swing
speed is restricted. When the lifting and swing operation of the boom are carried out at the same time,
the flow distributed to the boom lifting is larger. That is what we often called the boom lifting has the
priority to the swing.
When the flattening function key on the display is pressed, the J1-27 pin of the main controller (IPC
controller) outputs 24V voltage to the arm speed-2 gear solenoid valve coil.
When the flattening function key on the display is pressed again, the J1-27 pin of the main controller
(IPC controller) outputs 0V voltage to the arm speed-2 gear solenoid valve coil.
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3.6 Electrical System December 30, 2017
3.6.4 Descriptions of Partial Circuits CLG930E/936E
Note: the flattening function is only available under the P, E and F mode.
When the flattening function key is pressed, the flattening solenoid valve coil is powered on. When the
arm logic valve of the arm 2 valve stem is in the maximum opening, the arm speed will increase which
facilitates the grader operation.
When the flattening function key is pressed again, the flattening solenoid valve coil is powered off. When
the arm logic valve of the arm 2 valve stem is in the minimum opening, the arm speed will decrease
which facilitates the loading operation.
J2-28 pin of the main controller (IPC controller) will monitor the P end of the alternator.
The electric energy outputted from the B end of the alternator charges the battery via the wire 120 and
108 and the battery relay. The PWM signal is output from the P end of the alternator to the main
controller (IPC controller), which is used to judge whether the alternator generates electricity normally. A
light can be installed on the outside of the alternator L end to judge whether the alternator generates
electricity normally. The light will come on when the alternator does not generate electricity. The light will
go off when the alternator generates electricity. Here, we do not judge from the L end, so the L end of the
alternator is suspended.
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December 30, 2017 3.6 Electrical System
CLG930E/936E 3.6.4 Descriptions of Partial Circuits
The main controller (IPC controller) will output PWM signals to the pump proportional solenoid valve
according to the matching strategy of pump power and engine output power.
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3.6 Electrical System December 30, 2017
3.6.4 Descriptions of Partial Circuits CLG930E/936E
4-1
December 30, 2017 Parameter
CLG930E/936E
Parameter
The machine is applicable for digging and loading the earth of levels I - IV (the earth and rock are divided
into 16 levels in accordance with the digging difficulty, in which the earth level is below IV level).
According to the requirements of different engineering operations, this machine can also be installed
with backhoe shovel, crowd shovel, hydraulic breaker, plum claw and other various work implements.
Altitude: ≤3048m
Ambient temperature: -32 °C ~ 45°C
Fording depth: no matter what kind of position (horizontal or slope) the machine is located in, the fording
depth is not allowed to exceed the center of the carrier roller.
All rated operations of the machine are obtained when the machine operates on a hard and horizontal
supporting surface. If the working ambient conditions of the machine differ from the above standard
conditions (for example, working on soft or uneven ground or slopes), the operator shall consider these
conditions.
Unit(s) Parameters
Item
CLG930E CLG936E
Engine model Cummins 6C8.3 Cummins 6C8.3
Operating weight kg 31800 35000
Standard bucket capacity m3 1.4 1.6
Travel speed (high/low) km/h 0~5.5, 0~3.0 0~5.5, 0~3.4
Swing speed r/min 10.3 10
Climbing ability 35° (70%) 35° (70%)
Pressure to the ground (track width is 600mm) KPa 60 65.3
J: Overall length mm 10650 11167
Overall width (track width is 600mm) mm 3190 3190
Overall height mm 3525 3530
D:Height of cab roof mm 3175 3175
2995. (excluding side anti- 2995. (excluding side anti-
E:Overall width of the upper platform mm
collision bar) collision bar)
*H: Counterweight ground clearance mm 1215 1172
*C: Minimum ground clearance mm 500 532
I:Tail end length of the upper platform mm 3200 3500
Rotating radius of tail end mm 3230 3500
G:Underframe axle base mm 4050 4050
F:Underframe length mm 4980 4944
A:Underframe track distance mm 2590 2590
B:Underframe width (track width is 600mm) mm 3190 3190
Note: The sizes with * exclude grouser height.
4-5
December 30, 2017 4.1 Basic Parameters
CLG930E/936E
Components Parameters
Parameters
Components Item Unit(s)
CLG930E CLG936E
Model Cummins 6C8.3 Cummins 6C8.3
Turbo charged and air to
Turbo charged and air to air
Type air inter-cooling/water
inter-cooling/water cooling
cooling
U.S. EPA Tier 2, CARB
U.S. EPA Tier 2, CARB Tier
Emission Tier 2, EU Stage II,
2, EU Stage II, JMLIT Step 2
JMLIT Step 2
Cooling mode Water cooling Water cooling
Ignition sequence 1-5-3-6-2-4 1-5-3-6-2-4
Cylinder bore × stroke mm 114 X 134.9 114 X 134.9
Cylinder displacement L 8.29 8.29
Engine Compression ratio 18:1 18:1
Rated power 160kW/2200RPM 186kW/2200RPM
Net power 148KW 174KW
Maximum torque N.m 975/1500 RPM 1158/1500 RPM
Engine oil level L 26.5 26.5
Net weight of diesel engine kg 617 617
Maximum idling speed r/min 2200 2200
Minimum idling speed r/min 850 1100
Rated fuel consumption rate g/kW.h 244 234
Starter motor 24V-7.8kW 24V-7.8kW
Alternator 24V-70A 24V-70A
4-6
4.1 Basic Parameters December 30, 2017
CLG930E/936E
Components Parameters
Parameters
Components Item Unit(s)
CLG930E CLG936E
Double-axial, full power, Double-axial, full power,
negative flow, electronically negative flow,
Main pump
controlled variable plunger electronically controlled
pump variable plunger pump
Maximum system flow L/min 2×266 2×300
Setting
MPa 34.3 34.3
pressure
Main relief
valve When
instantaneously MPa 37.3 37.3
supercharging
Big cavity/small
MPa 39.2 39.2
Setting cavity of boom
pressure of Big cavity/small
MPa 39.2 39.2
outlet safety cavity of arm
valve Big cavity/small
MPa 39.2 39.2
cavity of bucket
Hydraulic
system Setting pressure of swing motor
MPa 26.2 26.2
relief valve
Setting pressure of travel motor
MPa 34.3 34.3
safety valve
Pilot pump Gear pump Gear pump
Pilot circuit MPa 3.9 3.9
Quantity - bore × rod
Boom mm 2-φ140×φ100×1342 2-φ140×φ100×1505
diameter × stroke
cylinder
Buffer When stretching out When stretching out
Quantity - bore × rod
mm 1-φ150×φ110×1755 1-φ170×φ120×1785
Arm diameter × stroke
cylinder When stretching out and When stretching out and
Buffer
retracting retracting
Quantity - bore × rod
Bucket mm 1-φ140×φ100×1135 1-φ145×φ100×1220
diameter × stroke
cylinder
Buffer When stretching out When stretching out
Work Boom (standard configuration) mm 6200 6400
implement Arm (standard configuration) mm 3050 3200
4-7
December 30, 2017 4.1 Basic Parameters
CLG930E/936E
Components Parameters
Parameters
Components Item Unit(s)
CLG930E CLG936E
Track shoe width mm 600 600
Track assembly Piece 2 2
Number of track plate (each bar) 48 48
Track tension device Piece 2 2
Travel device
Sprocket Piece 2 2
Guide wheel assembly Piece 2 2
Track roller 9 at each side 9 at each side
Carrier roller 2 at each side 2 at each side
Electrical System voltage V 24 24
System Battery 2×12V 2×12V
Refrigerating capacity W 5000 5000
Cooling air output m3/h 550 550
Heating capacity W 5800 5800
Heating air output m3/h 400 400
Voltage V.DC 24 24
Total power W ≤310 ≤310
Air conditioning
Compressor shaft consumption
system kW 3.02 3.02
power
Refrigerant R134a R134a
Refrigerant filling quantity g 950±50 950±50
10S15C (Denso 10S15C (Denso
Compressor
compressor) compressor)
ND-OIL8 (Denso special ND-OIL8 (Denso special
Refrigeration oil
compressor oil) compressor oil)
4-8
4.1 Basic Parameters December 30, 2017
CLG930E/936E
Scope of work
4-9
December 30, 2017 4.1 Basic Parameters
CLG930E/936E
Parameters
Name
CLG930E CLG936E
Engine model Cummins 6C8.3 Cummins 6C8.3
Turbo charged and air to air inter- Turbo charged and air to air inter-
Form
cooling/water cooling cooling/water cooling
Number of cylinder 6 6
Cylinder diameter x stroke 114mm X 134.9mm 114mm X 134.9mm
Displacement 8.29L 8.29L
Compression ratio 18:1 18:1
Ignition sequence 1-5-3-6-2-4 1-5-3-6-2-4
Rated power 160kW/2200RPM 186kW/2200RPM
Maximum torque 975 N.m /1500 RPM 1158 N.m /1500 RPM
Engine oil volume 26.5L 26.5L
Low idling Minimum allowable values 69kPa Minimum allowable values 69kPa
Engine oil pressure Minimum allowable values 205 Minimum allowable values 205
Rated speed
kPa kPa
Fan 6-Φ813 8-Φ813
Starter motor 24V-7.8kW 24V-7.8kW
Air intake heater 24V-190A 24V-190A
Alternator 24V-70A 24V-70A
Intake valve 0.30mm 0.30mm
Valve lash
Exhaust valve 0.61mm 0.61mm
Open temperature 84°C 84°C
Thermostat
Full open temperature 91°C 91°C
4-11
December 30, 2017 4.3 Performance Parameters of Complete Machine
CLG930E/936E
Performance standard
Item Unit(s)
CLG930E CLG936E
Engine speed (A/C Minimum speed (idling) 1050±30 1100±30
r/min
OFF) Maximum speed (idling) 2150±30 2000±30
Rabbit position/forward 13.1±1.5 12.5±1.5
Rabbit position/backward 13.1±1.5 12.5±1.5
Travel speed Sec/20m
Tortoise position/forward 21.9±2.5 20.9±2.5
Tortoise position/backward 21.9±2.5 20.9±2.5
Tortoise position/
34.5±2.5 32.5±2.5
forward
Tortoise position/
34.5±2.5 32.5±2.5
backward
Left track
Rabbit position/
20.5±1.5 19.5±1.5
forward
Rabbit position/
20.5±1.5 19.5±1.5
Travel speed backward
Sec/3rev
(Idling speed) Tortoise position/
34.5±2.5 32.5±2.5
forward
Tortoise position/
34.5±2.5 32.5±2.5
backward
Right track
Rabbit position/
20.5±1.5 19.5±1.5
forward
Rabbit position/
20.5±1.5 19.5±1.5
backward
Tortoise position ≤100 ≤150
Travel deviation mm/20m
Rabbit position ≤100 ≤200
Swing speed Sec/3rev 18.5±1.5 18±1.5
Swing service brake Counterclockwise ° ≤130 ≤130
angle Clockwise ° ≤130 ≤130
Swing bearing Vertical direction mm ≤0.65 ≤0.65
clearance Horizontal direction mm ≤55 ≤55
Stretching of boom cylinder 3.42±0.4 3.4±0.5
Action time of Shrinking of boom cylinder / /
hydraulic cylinder Stretching of arm cylinder 3.07±0.4 3.5±0.5
(turn off A/C, sec
engine speed is Shrinking of arm cylinder 2.49±0.4 3.1±0.5
maximum) Stretching of bucket cylinder 2.28±0.4 2.5±0.5
Shrinking of the bucket cylinder 1.86±0.4 1.9±0.5
4-12
4.3 Performance Parameters of Complete Machine December 30, 2017
CLG930E/936E
Performance standard
Item Unit(s)
CLG930E CLG936E
Retracting of boom cylinder (mm) ≤30 ≤30
Stretching of arm cylinder (mm) ≤30 ≤30
mm/
Cylinder settlement Retracting of arm cylinder (mm) ≤50 ≤50
10min
Retracting of bucket cylinder (mm) ≤50 ≤50
Performance standard
Item Unit(s)
CLG930E CLG936E
Setting pressure of main relief valve MPa 34.3-35.3 34.3-35.3
Pressurization pressure of main relief valve MPa 37.3-38.3 37.3-38.3
Main loop pressure Left swing MPa 26.2-27.2 26.2-27.2
Right swing MPa 26.2-27.2 26.2-27.2
Drive (travel hold pressure) MPa 34.3-35.3 34.3-35.3
Lifting of the boom MPa 39±0.5
Lowering of the boom MPa 39±0.5
Pressure testing of oil Retracting of the arm MPa 39±0.5
port relief valve Stretching of arm MPa 39±0.5
Tuck-in of the bucket (large cavity) MPa 39±0.5
Stretching of the bucket (small cavity) MPa 39±0.5
266×2 (2 300×2 (2
Main pump flow L/min
pumps) pumps)
Swing motor oil draining (drainage) Drainage pressure MPa ≤0.2 ≤0.2
Travel motor oil draining (drainage) Drainage pressure MPa ≤0.2 ≤0.2
4-14
4.3 Performance Parameters of Complete Machine December 30, 2017
CLG930E/936E
5-1
December 30, 2017 Adjustment and Test
CLG930E/936E
The standard data values obtained from the tests involved in this chapter are as follows:
1. The diesel engine meets the China Stage II, the standard speed is as follows:
Model CLG930E Model of diesel engine Cummins 6C8.3
10th
Gears 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear 7th gear 8th gear 9th gear 11th gear 12th gear
gear
Idling speed
1050±30 1200±30 1300±30 1400±30 1700±30 1800±30 1900±30 1950±30 2000±30 2050±30 2100±30 2150±30
(r/min)
Mode P
Hold pressure
0~20 100±10 200±10 300±10 520±10 570±10 570±10 580±10 590±10 570±10 570±10 580±10
current (mA)
Idling current 100±1
0~20 100±10 100±10 100±10 100±10 100±10 100±10 100±10 100±10 100±10 100±10
(mA) 0
Idling speed (r/
1050±30 1200±30 1300±30 1400±30 1550±30 1650±30 1780±30 1850±30 1900±30 1950±30 2000±30 2050±30
min)
Mode E
Hold pressure
0~20 100±10 200±10 300±10 410±10 500±10 570±10 570±10 570±10 580±10 580±10 570±10
current (mA)
Idling current
0~20 100±10 100±10 100±10 100±10 100±10 100±10 100±10 100±10 100±10 100±10 100±10
(mA)
Gears 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear 7th gear 8th gear 9th gear 10th gear 11th gear 12th gear
Idling speed
1100±30 1200±30 1300±30 1400±30 1600±30 1700±30 1800±30 1850±30 1900±30 1950±30 2000±30 2000±30
(r/min)
Mode P
Hold pressure
0~20 100±20 200±20 300±20 500±20 550±20 610±20 610±20 630±20 630±20 640±20 650±20
current (mA)
Idling current
0~20 100±10 100±10 100±10 100±10 100±10 100±10 100±10 100±10 100±10 100±10 100±10
(mA)
Hold pressure
0~20 100±20 200±20 300±20 370±20 420±20 500±20 510±20 510±20 530±20 530±20 540±20
current (mA)
Idling current
0~20 100±10 100±10 100±10 100±10 100±10 100±10 100±10 100±10 100±10 100±10 100±10
(mA)
2. For the standard performance parameters of the complete machine, please see the section 4.3.
Firstly test whether diesel engine speed reaches technical specification before all other tests,
because if the diesel engine speed is not adjusted correctly, the data of all other performances
will be unreliable.
5-4
5.1 Performance Test of Complete Machine December 30, 2017
5.1.1 Diesel Engine Speed CLG930E/936E
Turn off the air conditioner and the automatic B. Machine status and parking site
idling, there is no load, and turn the gear to the
1. Solid and flat parking site.
position to be tested.
2. Maintain hydraulic oil temperature between
C. Test method 45°C and 55°C.
1. Open the diesel engine hood. 3. Set the engine at the maximum speed (turn
off A/C).
2. Stick the reflective sheeting on the output
end of the diesel engine crankshaft or the fan 4. The pump working current is within the
shaft, but it is required to multiply by the normal range.
speed ratio of the fan and the diesel engine 5. The complete machine works in the normal
at this moment. mode.
3. By illuminating the place sticking with 6. The working pressure and the pilot pressure
reflective sheeting with tachometer, diesel of the pump are within the normal range.
engine speed can be obtained from the
instrument. C. Travel speed test
4. Repeatedly measure for 3 times and
1. Park the machine at solid and flat site.
calculate average value.
2. Maintain the hydraulic oil temperature
between 45°C and 55°C.
3. Operate the right swing until the upper
mechanism is vertical to the lower one.
4. Operate the boom, arm and bucket until the
bucket bottom is on the ground.
5-5
December 30, 2017 5.1 Performance Test of Complete Machine
CLG930E/936E 5.1.3 Travel Speed
5. Lower the boom until the right track is raised 5.1.3 Travel Speed
for about 100 ~ 200 mm from the ground to
keep the track away from the ground during
operation as shown in following picture. Mark A. Tools and testing instruments
on the appropriate position of the track.
1. Stopwatch.
2. Tape (50m).
3. Test is performed by two people.
4. Draw a 30m line on the ground starting from 5.1.4 Travel Deviation
the track front end, and then draw another
line approx. 10m away from the starting point
and make it paralleled with the machine. As A. Tools and testing instruments
shown in the Figure below
1. Tape (30m).
2. Tool used for marking the location of the
machine.
3. Operate work implements, stretch boom, arm 7. Push forward the left and right travel control
and bucket cylinder, as shown in Figure lever to the topmost at the same time. The
below. excavator reaches the position about 5m
away from the starting point, where mark A
on the track on the relative location of the
ground. Similarly, mark B and C correctly
when the excavator reaches the position
about 15m away from the starting point and
to the finishing point. As shown in the Figure
below
6. Turn the travel speed selection switch to gear 10. Turn the travel speed selection switch to gear
"1" (tortoise position). "2" (rabbit position), repeat steps 7~9 and
measure the travel deviation value at gear "2"
(rabbit position).
11. Turn the lower mechanism by 180°, repeat
the steps 3 ~10, and measure the travel
deviation values when the excavator travels
backwards and compare them with the
standard values in the Table below.
12. Refer to attached table for travel deflection
test table.
5-8
5.1 Performance Test of Complete Machine December 30, 2017
5.1.5 Swing Service Brake Angle CLG930E/936E
5.1.5 Swing Service Brake Angle C. Swing service brake angle test
5. Adjust the boom height to make the bottom of 5.1.7 Swing Bearing Clearance
the bucket at the height of boom hydraulic
cylinder articulated axle, as shown in Figure
Below. 1. Swing bearing clearance (vertical
direction)
1. Dial indicator.
2. Dial indicator bracket (can be rotated freely).
3. Tape measure.
4. Measurement is performed by two people.
C. Measurement of swing bearing clearance 8. Release the bucket completely, and lift or
(vertical direction) lower the boom so that the bucket tooth is off
the ground about 450mm as shown in Figure
1. Park the machine at solid and flat site. below.
2. As shown in the Figure below, install magnet
base on swing bearing support, and the
probe of dial indicator contacts mounting bolt
of swing bearing outer ring.
In front of machine
5.1.8 Action Time of Cylinder 2. Set the accelerator linkage or knob to the
maximum speed position of engine.
3. The height of bucket tooth is in accordance
with that of the front pin of the arm.
4. The arm cylinder retracts completely.
Be sure to move the machine (with standard
configuration) out of the route of other
machines before test, in order to ensure that
there is no obstacle within the maximum
swing radius. Other personnel cannot
approach the machine when the machine is
stated for adjustment or test.
D. Measurement of the arm cylinder action 7. Operate arm pilot valve to the maximum
time stroke and release the arm at the fastest
speed (the cylinder retracts). The timekeeper
begins to time as soon as the arm is acting,
and records the time from action start to arm
cylinder reaching buffer stroke starting point.
This test method is for excavator of standard
configuration. If the tested machine 8. Repeat the steps 6 and 7, and totally
equipment has optional configuration, check measure three times. Calculate the average
and confirm that there is no interferences values of time for arm retracting and
between the frontal attachments and the cab! stretching out for three times respectively
and compare them with the standard values
1. Park the machine at solid and flat site. in the Table below.
2. Set the accelerator linkage or knob to the 9. Refer to attached table 7 for arm cylinder
maximum speed position of engine. action time test table.
3. Lift the boom cylinder to certain height. E. Measurement of the bucket cylinder action
time
4. The bucket cylinder must be retracted to
make sure the bucket can't bump against the 1. Park the machine at solid and flat site.
earthing with arm cylinder is forward and
back. 2. Set the accelerator linkage or knob to the
maximum speed position of engine.
3. Lift the boom to highest position.
4. Adjust the arm to make the angle between
the arm and its cylinder about 90 °.
5. Lower the boom till the height of the front pin
of arm in accordance with rear pin of the
boom.
6. Retract the bucket completely (stretch the
cylinder).
4. Adjust the boom height until the distance 9. Repeat step 8 and totally measure three
reaches 1.5m between bucket tooth and the times. Calculate the average value of moving
ground, as shown in the Figure Below. distances of arm cylinder piston rod.
10. Refer to attached table for cylinder settlement
test table.
3. When upper mechanism swings by 90°, Pressure gauge, with measuring range
release control lever to stop these two kinds 0~10MPa;
of actions, as shown in Figure below.
Measure the time of swinging by 90° and the B. Machine status and parking site
height of bucket tooth (H).
1. Solid and flat parking site
2. Maintain hydraulic oil temperature at 50±5°C
Dust cover
5-18
5.1 Performance Test of Complete Machine December 30, 2017
5.1.14 Secondary Pilot Pressure CLG930E/936E
Press the air-bleed valve stem on the breather 5.1.14 Secondary Pilot Pressure
valve, as shown in the figure below:
b. Connect the pressure gauger at position 5. Pressure gauge, with measuring range
Figure (1) below. 0~10MPa;
6. Tee (material No. 32C0411)
Press the air-bleed valve stem on the breather 2. Set the accelerator linkage or knob to the
valve, as shown in the figure below: maximum speed position of engine. Turn off
the A/C and turn off the automatic idling.
3. Full-stroke operates the corresponding
control lever and measures the pilot
pressure, including:
Press the exhaust
valve stem
a. Boom lifting and lowering
b. Arm retracting and stretching
c. Bucket retracting and stretching
d. Left and right swing
e. Forward and backward travel
4. Operate control lever and record
measurement value.
b. Connect the pressure gauge. Connect the 5. Repeatedly measure for 3 times and
tee (material No. 32C0411) and pressure calculate average value.
gauge in the pilot line. Start the diesel
engine, and confirm there is no obvious oil
leakage at the connection of pressure
gauge.
1. Pressure gauge
2. Secondary pilot hose
5-20
5.1 Performance Test of Complete Machine December 30, 2017
5.1.15 Output Pressure of Solenoid Proportional Valve CLG930E/936E
5.1.15 Output Pressure of Turn off the diesel engine, and loosen the dust
cover on the breather valve, as shown in Figure
Solenoid Proportional Valve below:
b. Remove the plug from the main pump, 5.1.16 Setting Pressure of Main
refer to the following Figure for the
position. Connect the O-ring (Material No.:
Relief Valve
12B0428) and transition joint (Material No.:
00A0969), and then connect the pressure
gauge.
2. Set the accelerator linkage or knob to the 8. Pressure gauge, with measuring range
maximum speed position of engine. Turn off 0~10MPa
the A/C and turn off the automatic idling.
B. Machine status and parking site
3. Full-stroke operation of corresponding
control lever and measurement of the 1. Solid and flat parking site.
pressure of the solenoid proportional valve, 2. Maintain hydraulic oil temperature at 50±5°C.
include:
a. Boom lifting and lowering C. Measurement of output pressure of
solenoid proportional valve
b. Arm retracting and stretching
c. Bucket retracting and stretching 1. Install the pressure gauge. Specific
operations are as follows:
d. Left and right swing
(1) Release the residual pressure in oil tank:
e. Forward and backward travel
4. Repeatedly measure for 3 times and
calculate average value.
5-22
5.1 Performance Test of Complete Machine December 30, 2017
5.1.16 Setting Pressure of Main Relief Valve CLG930E/936E
Turn off the diesel engine, and loosen the dust g. Start the diesel engine, and confirm there
cover on the breather valve, as shown in Figure is no obvious oil leakage at the connection
below: of pressure gauge.
The method for connecting right pump with the
pressure gauge is the same as that of left pump.
Dust cover
Attached table 1
Attached table 2
Deviation (mm)
Testing items Average Remarks
1 2 3
value
Forward gear I
Forward gear II Hydraulic oil temperature at
Travel deviation value initial measurement:
Backward gear I °C
Backward gear II
5-25
December 30, 2017 5.1 Performance Test of Complete Machine
CLG930E/936E 5.1.17 Attached List
Attached table 3
Attached table 4
Attached table 5
Attached table 6
Measured value
Testing Working condition Standard
Average Remarks
items for measurement 1 2 3 requirements
value
Lifting
Boom
Lowering
Hydraulic oil
Action time of Retracting temperature at
the work Arm
Stretching initial
implement (s)
measurement: °C
Excavation
Bucket
Unloading
Attached table 7
5.2 Other Tests 3. Press down the engine timing pin and slowly
rotate the crankshaft simultaneously so as to
locate the top dead center of No.1 cylinder.
5.2.1 Adjustment of Valve Lash Insert the turning gear into the flywheel
housing and make it engage with the
flywheel gear ring. Then, rotate the engine by
1. Disconnect the support clip, hose clamp and hand or using 127-cm [1/2-in] ratchet wrench
exhaust bypass valve induction tube. or a crowbar.
Remove the crankcase ventilating pipe and
other parts which may affect removal of valve
chamber cover.
Gear chamber
Step A
5. Intake valve lash: 0.30 mm [0.012 in].
Exhaust valve lash: 0.61 mm [0.024 in].
Check/adjust the valve when the engine is at the
cold state (the temperature is less than 60
Be sure to disconnect the engine timing pin
°C[140°F]).
to prevent it from being damaged. Mark the
shock absorber and rotate the crankshaft by
360°.
Torque value: 24 n.m [212 in-lb] Torque value: 24 n.m [212 in-lb]
Step B
Pictures of blow-by tools: 3. Operate the engine with rated speed and full
load until stable values are obtained.
Blow-by conversion chart (7.67-mm [0.302-in] measuring orifice, blow-by tool part number 3822566)
5.2.3 Measurement and 5. Lower the boom until the right track is raised
for about 100 ~ 200 mm from the ground to
Adjustment of Track Tension keep the track away from the ground during
operation as shown in following picture.
Measurement of the track tension
Steel ruler.
If the track tension is abnormal, adjust it 1. Loosen the filling valve 2, discharge the
according to the following steps. grease and then tighten it. As the figure
below:
1. Increase the tension
5.2.4 Inspection and Adjustment 4. Insert the pressure gauge (6 MPa measuring
range) with pressure hoses into the pressure
of Minus Feedback Pressure N1 measurement joint (4) and measure the
pressure on the main pump feedback
Check pressure port N1.
Feedback
pressure N1
Measurement steps:
Exhaust project
Steps
element
hydraulic pump
pipeline
5-39
December 30, 2017 5.2 Other Tests
CLG930E/936E 5.2.7 Exhaust of Various Devices
Exhaust the air in the pump 3. Loosen the exhaustion plug and check for oil
outflow.
When maintaining the main pump or replacing
the hydraulic oil lines, exhaust the air according 4. If no oil outflow, fill the hydraulic oil to the
to the methods below: pump housing body.
5. Make the diesel engine run at idle. If there is
no bubble any more, tighten the exhaustion
plug and the exhaust is over.
The hydraulic oil pressure and the hot oil
may cause personal injury.
When the diesel engine is stopped, the
hydraulic oil can still be in the hydraulic If the pump runs without full oil in the pump
system. If the pressure is not released before body, the abnormal heat may be produced
maintaining any hydraulic system, serious resulting in the early damage for the pump.
personal injury may be caused.
Exhaust the air in the cylinder
Be sure that all the accessories are put on the
ground, and the oil has been cooled before 1. Start the diesel engine and operate it for 5min
removing any components or lines. with low idling.
2. Operate the diesel engine in low speed and
The oil filler cap can be removed only when
telescope the cylinder to the position about
the diesel engine has been stopped, and the
100 mm away from the stroke end for 4-5
oil filler cap has been cooled enough that can
times.
be touched by hands.
1. Exhaustion plug
1. Park the machine on the flat ground, lower
the bucket to the ground and pull the pilot
control level to the locked position.
2. Shut down the diesel engine and take the key
out.
5-40
5.2 Other Tests December 30, 2017
5.2.7 Exhaust of Various Devices CLG930E/936E
Exhaust the air in the travel motor 3. Operate the diesel engine in low speed and
swing the work implement by 90° to make it
locate in the side of the track.
1. Auxiliary pedal
5-41
December 30, 2017 5.2 Other Tests
CLG930E/936E 5.2.8 Inspection of Diode
(2) Connect the red probe (+) to the negative 5.2.9 Adjustment of Compressor
pole (N) of the diode, and the black probe (-)
to the positive pole (P) of the diode, then the
Belt Tensioner
diode is in negative biased. If the diode is
normal, the multimeter will display 0L or a
very large value.
(3) During the measurement, if the values
Before inspection, move the machine to the
measured for two times are very small, it
level ground, and lower the work implement
indicates a short circuit in the diode; if the
to the ground and turn off the diesel engine.
values measured for two times are very large
or shows 0L, there is an open circuit in the
diode. Check
2. Use the Ohm grade of the digital multimeter
1. Open the engine hood, remove the left and
to measure the diode:
right fan shields above the compressor.
(1) Connect the red probe (+) to the positive pole
2. Press the middle parts of the belt between
(P) of the diode while the black probe (-) to
the diesel engine pulley and compressor
the negative pole (N) of the diode, and then
pulley to measure the flexibility (f) of the belt.
the diode is in positive biased. Read out the
When the pressure is Wd = 58.5N (about 6
measured resistance value.
kg), the produced flexibility of the belt shall
(2) Connect the red probe (+) to the negative be f = 5~8 mm.
pole (N) of the diode while the black probe (-)
to the positive pole (P) of the diode, and then
the diode is in reverse biased and read the
measured resistance value.
(3) If the two measured resistance values are
quite different, it indicates that the
performance of the diode is good; otherwise,
it indicates that the performance of the diode
is poor or the diode is damaged -- internal
short or open circuit.
5-43
December 30, 2017 5.2 Other Tests
CLG930E/936E 5.2.10 Performance Test of Travel Motors and Reduction Gears
Left side
3
1
Right side
Notice:
(1) If the belt cannot be tensed due to excessive
stretches, or found scratches and cracks,
replace with a new belt timely.
(2) If the belt is replaced, re-adjust the tension of
the belt after the machine works for 1 hour.
(3) After the bolt is tightened, check the tension
of the belt according to the methods above.
4. Reinstall the removed components upon the
completion of belt flexibility measurement.
Test conditions:
1. Air is not allowed in the lines
2. Hydraulic oil temperature is approx 50±5°C.
5-44
5.2 Other Tests December 30, 2017
5.2.10 Performance Test of Travel Motors and Reduction Gears CLG930E/936E
Operation status
Test
No. Contents Operation Gears Criteria
Horizontal Vertical ground
direction direction
About 4 seconds
Left and right pumping
pressure difference < 3
Low MPa, without dragging
Oil drainage <0.2 MPa,
Flat walking Max < 0.69 MPa
1
and stop Left and right pumping
About 4 seconds
pressure difference < 3
High MPa, without dragging
Oil drainage <0.2 MPa,
Max < 0.69 MPa
About 3 seconds
Atmospheric pressure
<34.3MPa,
Unilateral
3 High Max<34.3MPa
drive
Oil drainage Max < 0.69
MPa
Go forward
Synchronous switching,
by switching
Low without dragging
6 between high
High Oil drainage <0.2 MPa,
and low
Max < 0.69 MPa
velocity
About 3 seconds
Go forward
and
7 Low
backward
slope
6-1
December 30, 2017 Fault Diagnosis
CLG930E/936E
Fault Diagnosis
6.4.29 DTC 131703 Sensor Power (5V) Shorted to the Battery .........................................................6-99
6.4.30 DTC 131704 Sensor Power (5V) Shorted to the Ground .......................................................6-102
6.4.31 DTC 141105 Pump Proportional Solenoid Valve Feedback Open-Circuited .........................6-106
6.4.32 DTC 141006 Pump Proportional Solenoid Valve Feedback Overcurrent ..............................6-109
6.4.33 DTC 141104 Pump Proportional Solenoid Valve Shorted to Ground ....................................6-112
6.4.34 DTC 141105 Pump Proportional Solenoid Valve Feedback Open-circuited ..........................6-115
6.4.35 DTC 151004 Attachment Confluence Solenoid Valve Shorted to Ground .............................6-118
6.4.36 DTC 151005 Attachment Confluent Solenoid Valve Open-circuited or Shorted to
the Battery ..........................................................................................................................................6-121
6.4.37 DTC 151204 A2 Travel Speed Solenoid Shorted to Ground ..................................................6-124
6.4.38 DTC 151205 A2 Travel Shift Solenoid Valve Open-Circuited or Shorted to the Battery.........6-127
6.4.39 DTC 151304 A3 Flattening Solenoid Valve Shorted to Ground ..............................................6-131
6.4.40 Fault Code 151305 A3 Flattening Solenoid Valve Open-Circuited or Shorted to the Battery .6-134
6.4.41 DTC 151404 A8 Trenching Solenoid Valve Shorted to the Ground........................................6-138
6.4.42 DTC 151405 A8 Trenching Solenoid Valve Open-Circuited or Shorted to the Battery ...........6-141
6.4.43 DTC 151504 A5 Flow Adjusting Solenoid Shorted to Ground ................................................6-145
6.4.44 DTC 151505 A5 Flow Adjusting Solenoid Valve Open-Circuited or Shorted to the Battery....6-148
6.4.45 DTC 151605 A6 Flow Adjusting Solenoid Open-circuited or Shorted to the Battery ..............6-152
6.4.46 DTC 151704 A7 Power Boosting Solenoid Valve Shorted to the Ground ..............................6-156
6.4.48 DTC 151705 A7 Power Boosting Solenoid Valve Open-Circuited or Shorted to the Battery..6-159
6.4.49 DTC 151804 A4 Travel Lifting Solenoid Valve Shorted to the Ground ..................................6-163
6.4.50 DTC 151805 A4 Travel Lifting Solenoid Valve Open-Circuited or Shorted to the Battery ......6-166
6.4.50 DTC 151905 A5 or A6 Solenoid Valve Feedback Open-Circuited .........................................6-170
6.4.51 DTC 151906 A5 or A6 Solenoid Valve Feedback Overcurrent ..............................................6-173
6.4.52 DTC 171004 SHORT CIRCUIT TO GROUND OF BATTERY RELAY ..................................6-176
6.4.53 DTC 171104 Auto Preheating Relay Shorted to the Ground ..................................................6-179
6.4.54 DTC 171105 Auto Preheating Relay Open-Circuited or Shorted to the Battery .....................6-182
6.4.55 DTC 171204 Start Cut-off Relay Shorted to Ground ..............................................................6-185
6.4.56 DTC 171205 Start cut-off Output Open-circuited or Shorted to the Battery ...........................6-188
6.4.57 DTC 201004 Travel Alarm Shorted to Ground .......................................................................6-191
6.4.58 DTC 211003 P1 Pump Pressure Sensor Voltage Above the Range Value ...........................6-194
6.4.59 DTC 211004 P1 Pump Pressure Sensor Voltage Below the Range Value ...........................6-197
6.4.60 DTC 211003 P2 Pump Pressure Sensor Voltage above the Range Value ...........................6-200
6.4.61 DTC 211104 P2 Pump Pressure Sensor Voltage below the Range Value ............................6-203
6.4.62 DTC 211203 N1 Negative Flow Pressure Sensor Voltage Above the Range Value .............6-206
6.4.63 DTC 211204 N1 Negative Flow Pressure Sensor Voltage Below the Range Value ..............6-209
6-3
December 30, 2017 Fault Diagnosis
CLG930E/936E
6.4.64 DTC 211303 N2 Negative Flow Pressure Sensor Voltage Above the Range Value .............6-212
6.4.65 DTC 211304 N2 Negative Flow Pressure Sensor Voltage Below the Range Value ..............6-215
6.4.66 DTC 221001 Actuator Feedback Voltage below the Range Value ........................................6-218
6.4.67 DTC 221003 Actuator Feedback Voltage Above the Range Value .......................................6-222
6.4.68 DTC 221007 Actuator Getting Stuck ......................................................................................6-226
6.4.69 DTC 221013 Actuator outside the Calibrated Range .............................................................6-229
6.4.70 DTC 221104 Actuator AC1 Shorted to Ground ......................................................................6-234
6.4.71 DTC 221204 Actuator AC2 Shorted to Ground ......................................................................6-237
6.4.72 DTC 221305 Actuator AC1 Open-Circuited ...........................................................................6-240
6.4.73 DTC 221306 Actuator AC1 Overcurrent ................................................................................6-243
6.4.74 DTC 221405 Actuator AC2 Terminal Open-Circuited ............................................................6-246
6.4.75 DTC 221406 Actuator AC2 Overcurrent ................................................................................6-249
6.4.76 DTC 231012 Abnormal Controller Heartbeat .........................................................................6-252
6.4.77 DTC 231014 CAN Bus Communication Error ........................................................................6-254
6.4.78 DTC 241014 Accelerator Knob outside the Measurement Range ..........................................6-256
6.4.79 DTC 251004 Fuel Pump Relay Shorted to Ground.................................................................6-259
6.4.80 DTC 251005 Fuel Pump Relay Open-Circuited or Shorted to the Battery..............................6-263
6.4.81 DTC 261011 GPS Antenna Fault............................................................................................6-267
6.4.82 DTC 261111 GPS Module Fault .............................................................................................6-269
6.4.83 DTC 261211 GSM Signal Fault ..............................................................................................6-270
6.4.84 DTC 261311 GPRS Connection Fault ....................................................................................6-271
6.4.85 DTC 261411 SIM Card Read Fault .........................................................................................6-272
6.4.86 DTC 261512 Abnormal GPS Heartbeat ..................................................................................6-273
6.4.87 DTC 261611 Automatic Locking Level 1 Abnormal GPS Heartbeat, the Machine is
Limited for Use ...................................................................................................................................6-276
6.4.88 DTC 261614 Forced Locking Level 1 Payment Expired, the Machine is Limited for Use.......6-279
6.4.89 DTC 261711 Automatic Locking Level 2 Abnormal GPS Heartbeat, and the Machine is Prohibited
for Use ...............................................................................................................................................6-280
6.4.90 DTC 261714 Forced Locking Level 2 Overdue Payment, and the Machine is Prohibited for
Use ....................................................................................................................................................6-283
6.4.91 DTC 261814 Please Pay the Due Loan on Time ....................................................................6-283
6.6 Fault Diagnosis of the Hydraulic System and Mechanical System ..................6-359
6.6.1 System Table of the Hydraulic System and Mechanical System ..............................................6-359
6.6.2 Excessive Barking Angle for H1 Slewing Stop..........................................................................6-360
6.6.3 Abnormal Noise from H2 Pump Mounting Position...................................................................6-361
6.6.4 H3 Start the Engine, and All Operations have no Response ....................................................6-362
6.6.5 H4 Hydraulic Oil Emulsification, ...............................................................................................6-363
6.6.6 H5 Abnormal Hydraulic Oil Temperature Rise ..........................................................................6-364
6.6.7 H6 Slewing abnormally to Left and Right Directions .................................................................6-365
6.6.8 H7 No Response for Slewing Single Direction Operation .........................................................6-366
6.6.9 H8 Swing cannot be Stopped ...................................................................................................6-367
6.6.10 H9 Fail to Actuate Unilateral Travel Mechanism .....................................................................6-368
6.6.11 H10 Travel Deviation ..............................................................................................................6-369
6.6.12 H11 Slow Speed of the Boom, Arm or Bucket ........................................................................6-370
6.6.13 H12 Weak Actions of the Boom, Arm or Bucket .....................................................................6-371
6.6.14 H13 Significantly Reduced Engine Speed or Engine Stalling .................................................6-372
6-3
December 30, 2017 6.1 Precautions for Fault Diagnosis
CLG930E/936E
● Park the machine on the flat ground, check whether the locking pin, block and parking brake are
fixed firmly.
● When two or more workers operate the machine, follow the agreed signal strictly, and any
unauthorized people are not allowed to get close to the machine.
● If the radiator cover is removed when the engine is still hot, the hot coolant may spray out which will
cause scald. Therefore, start the fault diagnosis when the engine is cooled.
● Specially notice that do not touch any hot components or avoid being jammed by any rotating
components.
● When disconnecting the wire, be sure to disconnect the negative pole (-) of the battery firstly.
Be sure to release the inner pressure first when removing the plug or cover where the oil pressure, water
pressure or air pressure may exist. When installing the measuring device, make sure that it is connected
correctly.
6-4
6.2 Basic Fault Detection before Maintenance December 30, 2017
CLG930E/936E
Do the following tests before having your authorized LiuGong dealer repair your machine or when your
machine is not functioning properly. Doing these tests can help the maintenance personnel to repair your
machine as soon as possible.
Do the following tests when the engine is running and shuts down, respectively.
If the machine runs in a closed space, be sure to discharge the exhaust gases before starting the
engine for maintenance of the machine.
No irrelevant personnel is allowed to be close to the machine working and detection area.
Some tests may be required to be done when the machine is traveling. Therefore, before starting
any test, make sure the driver has been trained specially and has been qualified.
Some tests may need the help of the specialized testing tools. Therefore, before starting any test, make
sure the operators understand these tools fully.
Before performing any of the following tests, make sure all routine examination items have been
completed.
Start the engine and do the testing by following the relevant guidance steps. When detecting the
hydraulic system components, make sure that the hydraulic system has been fully heated and all
hydraulic components have reached normal operating temperature.
Wiper Check whether the front wiper works normally. (Yes or No)
Fan Check whether the internal circulation fan works. (Yes or No)
Lighting equipment (work light,
3 revolving signal light, brake Check whether the outdoor light and dome light work normally.
light, dome light, etc.)
Instrument, meter and Check whether all the indicators come on.
indicator If not, do not start the engine.
Operate all the switches and control units to check whether they can work
Switches and control units normally.
If not, do not start the engine.
Cab Check whether all the control levers are in the correct positions.
Safety warning label Check whether the safety warning labels on the machine can be seen clearly.
4 Check whether the cab windows and doors can be opened smoothly. Whether
Door lock and engine hood the door lock can be locked or not.
lock Check whether the engine hood can be closed. Whether the engine hood can
be locked.
6-6
6.2 Basic Fault Detection before Maintenance December 30, 2017
CLG930E/936E
Start the engine and listen to the engine for abnormal noise.
When the engine runs at idle, whether the oil pressure indicator goes out.
5 Engine system Check whether the engine speed is normal. Whether the operation is smooth.
After the engine runs for a period, check whether the engine temperature is
within the normal working range.
After the engine is preheated and started, observe whether the exhaust gas is
discharged. If any, what is color of the exhaust gas? Grayish white, white or
black?
Check whether the engine working temperature is within the normal range.
6 Engine runs at idle speed After the engine runs at idle for several minutes, check whether the A/C
refrigerates.
Start the engine and check the battery voltage on the display to guarantee that
7 Charging of battery
the voltage is not less than 24V.
6-7
December 30, 2017 6.3 Classification of Faults
CLG930E/936E
1. DTC
If the machine display shows DTC, perform the fault diagnosis corresponding to the code according to
the displayed DTCs
In the Electrical System Faults, the typical electrical faults are introduced. The location drawing for main
faulted parts, relevant circuit diagram and the detailed diagnosis procedures are equipped.
The faults introduced in this chapter are shown in the following table
The Faults of Hydraulic System and Mechanical System mainly introduce the diagnosis methods for the
common faults in the hydraulic system.
The faults introduced in this chapter are shown in the following table
Component location
Front
Battery
Attached drawing
Alternator
Start motor
6-11
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.1 DTC 101001 Extremely Low Battery Voltage
Notice: Be sure to turn off the electric lock before checking whether the battery cables are
secured reliably.
Inspection method
Turn the battery terminals by hand or with the tools, and check them for looseness;
Visually check the terminals for rust.
Whether the battery terminals become loose or rusty?
YES NO
Tighten or derust
Go to Step 6 Go to Step 2
Step 2 Check whether the battery voltage is too low
Notice: Make sure the ignition switch is at the OFF position before assembling and
removing the battery cables. When assembling, install the positive terminals before the
negative terminals. Removal is the reverse of installation. This can avoid damage to the battery
terminals and the wrench due to short-circuit spark.
Notice: During the detection period, turn the start key switch to the OFF position
6-12
6.4 Fault Code December 30, 2017
6.4.1 DTC 101001 Extremely Low Battery Voltage CLG930E/936E
Inspection method
Low battery voltage may caused by the three reasons: 1. Battery is not charged for a long time; 2
Battery is broken; 3. Feeding.
Check the battery in the following procedures:
1. Check the battery hydrometer. If the hydrometer becomes black, the battery needs to be charged. If
the hydrometer becomes white, the battery has been damaged. If the hydrometer is in the green
status, the battery is good.
2. Measure the battery voltage with the multimeter: Turn the multimeter to its DC voltage function
(200V), and connect the red probe to the positive battery terminal and the black probe to the
negative battery terminal. The schematic diagram for detection is as follows:
Black probe
Red probe
Notice: Pay special attention to the following when conduct the measurement with the
engine running: 1. Being scalded by overheated engine block. 2. Prevent the harnesses,
clothing and others from being drawn into the belts and the flywheel. 3. It is prohibited for the
complete machine to actuate.
Notice: Properly pack up the harness and leads: prevent the harness from being folded and
bent forcedly. It shall be kept away from moving components as far as possible to prevent
tensile failure and wear. Avoid friction with sharp metal edges. Keep away from oil and water as
far as possible. Keep away from high temperature parts (e.g. engine block) as far as possible.
6-13
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.1 DTC 101001 Extremely Low Battery Voltage
Inspection method
1. Check the battery charging harness (# 120) for wear and its terminals for looseness
2. Check the charging harness for open-circuit with the multimeter: Method A: Turn the start key
switch to the OFF position. Turn the multimeter to its resistance function (200Ω), and measure the
resistance of the battery charging harness (# 120) (normally, <10Ω). For the alternator location and
the starter motor location, see the attached drawing
Method B: Turn the start key switch to the ON position and turn the multimeter to its voltage function,
and then measure the voltage between the alternator terminal B and the grounding (normally, the
battery voltage about 25V).
Whether the charging harness is open-circuit or not (the coupling ends become loose)?
YES NO
Repair the harness or re-connect it
Go to Step 6 Go to Step 4
6-14
6.4 Fault Code December 30, 2017
6.4.1 DTC 101001 Extremely Low Battery Voltage CLG930E/936E
Step 4 Check whether the alternator fails or the output voltage is low
Notice: Pay special attention to the following when conduct the measurement with the
engine running: 1. Being scalded by overheated engine block. 2. Prevent the harnesses,
clothing and others from being drawn into the belts and the flywheel. 3. It is prohibited for the
complete machine to actuate.
Inspection method
After the complete machine is started, there are two possible causes for the alternator fault:
1. The belt is too loose.
2. Is there a fault in the alternator?
Check the battery in the following procedures:
1. Stop the engine and check whether the alternator belt becomes loose.
2. Start the engine, and measure the voltage between the alternator terminal B and the grounding with
the multimeter (normally, higher than the battery voltage)
Whether the alternator fails or its output voltage is low?
YES NO
1. Tighten or replace the drive belt
2. Contact local LiuGong dealer or authorized
service center.
Go to Step 6 Go to Step 5
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-15
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.2 DTC 101001 High Battery Voltage
Component location
Front
Battery
Attached drawing
Alternator
Start motor
6-17
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.2 DTC 101001 High Battery Voltage
Notice: During the detection period, turn the start key switch to the OFF position.
Inspection method
Measure the battery voltage with the multimeter: Turn the multimeter to its DC voltage function (200V),
and connect the red probe to the positive battery terminal and the black probe to the negative battery
terminal. The schematic diagram for detection is as follows:
Black probe
Red probe
Notice: Pay special attention to the following when conduct the measurement with the
engine running: 1. Being scalded by overheated engine block. 2. Prevent the harnesses,
clothing and others from being drawn into the belts and the flywheel. 3. It is prohibited for the
complete machine to actuate.
Inspection method
Start the engine and measure the voltage (normally no more than 30V) between the alternator terminal
B+ and the grounding, by using a multimeter switching to the DC voltage position (200V), with
connecting the red probe to the alternator terminal B+ while the black probe to the grounding. For the
alternator location, see the figure
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-19
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.3 DTC 101017 Low Battery Voltage
Component location
Front
Battery
Attached drawing
Alternator
Start motor
6-21
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.3 DTC 101017 Low Battery Voltage
Notice: Be sure to turn off the electric lock before checking whether the battery cables are
secured reliably.
Inspection method
Turn the battery terminals by hand or with the tools, and check them for looseness;
Visually check the terminals for rust.
Whether the battery terminals become loose or rusty?
YES NO
Tighten or derust
Go to Step 6 Go to Step 2
Step 2 Check whether the battery voltage is too low
Notice: Make sure the ignition switch is at the OFF position before assembling and
removing the battery cables. When assembling, install the positive terminals before the
negative terminals. Removal is the reverse of installation. This can avoid damage to the battery
terminals and the wrench due to short-circuit spark.
Notice: During the detection period, turn the start key switch to the OFF position
6-22
6.4 Fault Code December 30, 2017
6.4.3 DTC 101017 Low Battery Voltage CLG930E/936E
Inspection method
If the voltage below 18V, this indicates the battery voltage is too low. Low battery voltage may caused
by the three reasons: 1. Battery is not charged for a long time; 2 Battery is broken; 3. Insufficient
electricity. Check the battery in the following procedures:
1. Check the battery hydrometer. If the hydrometer becomes black, the battery needs to be charged. If
the hydrometer becomes white, the battery has been damaged. If the hydrometer is in the green
status, the battery is good.
Measure the battery voltage with the multimeter: Turn the multimeter to its DC voltage function (200V),
and connect the red probe to the positive battery terminal and the black probe to the negative battery
terminal. The schematic diagram for detection is as follows:
Black probe
Red probe
Notice: Pay special attention to the following when conduct the measurement with the
engine running: 1. Being scalded by overheated engine block. 2. Prevent the harnesses,
clothing and others from being drawn into the belts and the flywheel. 3. It is prohibited for the
complete machine to actuate.
Notice: Properly pack up the harness and leads: prevent the harness from being folded and
bent forcedly. It shall be kept away from moving components as far as possible to prevent
tensile failure and wear. Avoid friction with sharp metal edges. Keep away from oil and water as
far as possible. Keep away from high temperature parts (e.g. engine block) as far as possible.
6-23
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.3 DTC 101017 Low Battery Voltage
Inspection method
1. Check the battery charging harness (# 120) for wear and its terminals for looseness
2. Check the charging harness for open-circuit with the multimeter: Method A: Turn the start key
switch to the OFF position. Turn the multimeter to its resistance function (200Ω), and measure the
resistance of the battery charging harness (# 120) (normally, <10Ω). For the alternator location and
the starter motor location, see the attached drawing
Method B: Turn the start key switch to the ON position and turn the multimeter to its voltage function,
and then measure the voltage between the alternator terminal B and the grounding (normally, the
battery voltage about 25V).
Whether the charging harness is open-circuit or not (the coupling ends become loose)?
YES NO
Repair the harness or re-connect it
Go to Step 6 Go to Step 4
Step 4 Check whether the alternator fails or the output voltage is low
Notice: Pay special attention to the following when conduct the measurement with the
engine running: 1. Being scalded by overheated engine block. 2. Prevent the harnesses,
clothing and others from being drawn into the belts and the flywheel. 3. It is prohibited for the
complete machine to actuate.
6-24
6.4 Fault Code December 30, 2017
6.4.3 DTC 101017 Low Battery Voltage CLG930E/936E
Inspection method
After the complete machine is started, there are two possible causes for the alternator fault:
1. The belt is too loose.
2. Is there a fault in the alternator?
Check the battery in the following procedures:
1. Stop the engine and check whether the alternator belt becomes loose.
2. Start the engine, and measure the voltage between the alternator terminal B and the grounding with
the multimeter (normally, higher than the battery voltage)
Whether the alternator fails or its output voltage is low?
YES NO
1. Tighten or replace the drive belt
2. Contact local LiuGong dealer or authorized
service center.
Go to Step 6 Go to Step 5
Step 5 Check whether the controller power voltage is too low
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-25
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.4 DTC 111001 System Charging Fault
Component location
Alternator
Front
Step 1 Check the alternator terminal P for electrical signal output (whether the alternator fails.).
Inspection method
1. Stop the engine and check whether the alternator belt becomes loose.
2. Start the engine and turn the multimeter to its voltage function, and then measure the voltage
between the alternator terminal P and ground (Normally, 14±0.5V).
Whether the alternator terminal P has no electrical signal output (the alternator fails)?
YES NO
Tighten or replace the belt
Contact your local LiuGong dealers and authorized
service centers.
Go to Step 3 Go to Step 3
6-27
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.4 DTC 111001 System Charging Fault
Notice: Properly pack up the harness and leads: prevent the harness from being folded and
bent forcedly. It shall be kept away from moving components as far as possible to prevent
tensile failure and wear. Avoid friction with sharp metal edges. Keep away from oil and water as
far as possible. Keep away from high temperature parts (e.g. engine block) as far as possible.
Inspection method
1. Check the # 928 harness (between the alternator terminal P and the J2-28 port) for wear.
2. Disconnect the connectors from the terminal P and the controller and check the harness for open-
circuit. Turn the multimeter to its resistance function, and measure the resistance of the harness (#
928) between the controller port J2-28 and the terminal P (normally, <10Ω).
Is the harness open-circuit?
YES NO
Repair and wrap the harness
Go to Step 3 Go to Step 3
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-28
6.4 Fault Code December 30, 2017
6.4.5 DTC 121015 Oil Pressure Switch Disconnected CLG930E/936E
LG922E930E06011
LG922E930E060
Component location
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position, and disconnect the oil pressure switch connector:
1. Check the connector pins for looseness, rust, bending and damage.
2. Turn the multimeter to its resistance function, and measure the resistance between the oil pressure
switch connector terminals 1 and 2 (normally, <10Ω).
Whether the oil pressure switch fails?
YES NO
Repair or replace the oil pressure switch.
Go to Step 4 Go to Step 2
Step 2 Check the harness for open-circuit
Notice: Properly pack up the harness and leads: prevent the harness from being folded and
bent forcedly. It shall be kept away from moving components as far as possible to prevent
tensile failure and wear. Avoid friction with sharp metal edges. Keep away from oil and water as
far as possible. Keep away from high temperature parts (e.g. engine block) as far as possible.
Inspection method
1. Check the harness (# 902) and the grounding wire (# 283) between the controller (J2-02) and the oil
pressure switch for wear.
2. Disconnect the oil pressure switch connector and the controller connector, and check the harness
for open-circuit:
(1) Turn the multimeter to its resistance function, and measure the resistance between the grounding
wire (#283) switch terminal and the grounding (normally, <10Ω).
(2) Turn the multimeter to its resistance function, and measure the resistance of the harness between
the connector (C2-02) connected to the controller J2-02 and the switch (normally, <10Ω).
Is the harness open-circuit?
YES NO
Repair and wrap the harness
Go to Step 4 Go to Step 3
6-30
6.4 Fault Code December 30, 2017
6.4.5 DTC 121015 Oil Pressure Switch Disconnected CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the oil pressure switch connector and disconnect the controller connector. Turn the multimeter
to its resistance function, and measure the resistance between the connector C2-02 connecting to the
controller port J2-02 and the grounding (normally, <10Ω).
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-31
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.6 DTC 121018 Low Oil Pressure
LG922E930E06011
LG922E930E060
Component location
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
When the oil pressure is normal, check the oil pressure detection circuit or the oil pressure switch
according to DTC "121015 - Oil Pressure Switch Disconnected"
Whether the oil pressure monitoring system fails?
YES NO
Repair the oil pressure detection circuit or replace
the oil pressure switch.
Go to Step 3 Go to Step 3
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-33
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.7 DTC 121305 Hand Pilot Pressure Switch Disconnected
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LG925E4F06027
6-34
6.4 Fault Code December 30, 2017
6.4.7 DTC 121305 Hand Pilot Pressure Switch Disconnected CLG930E/936E
Component location
Front
LG925E4F06028
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the hand pilot pressure
switch:
1. Check the connector pins for looseness, rust, bending and damage.
2. Turn the multimeter to its resistance function, and measure the resistance between the hand pilot
pressure switch connector terminals 1 and 2 (normally, <10Ω).
Gray wire
Red probe
(2) Turn the multimeter to its resistance function, and measure the resistance between the controller
terminals J1-8 and hand pilot pressure switch harness (normally, <10Ω).
To the black probe
White wire
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
(3) Connect the hand pilot pressure switch connector and disconnect the controller connector. Turn the
multimeter to its resistance function, and measure the resistance between the harness at the
controller terminal J1-8 and the grounding (normally, <10Ω).
To the black probe
White wire
When the resistance is abnormal, this indicates the connector is poorly contacted.
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-37
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.8 DTC 121405 Foot Pilot Pressure Switch Disconnected
3
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LG925E4F06027
6-38
6.4 Fault Code December 30, 2017
6.4.8 DTC 121405 Foot Pilot Pressure Switch Disconnected CLG930E/936E
Component location
Front
LG925E4F06028
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position, and disconnect the foot pilot pressure switch connector:
1. Check the connector pins for looseness, rust, bending pin and damage.
2. Turn the multimeter to its resistance function, and measure the resistance between the foot pilot
pressure switch connector terminals 1 and 2 (normally, <10Ω).
Gray wire
Red probe
(2) Turn the multimeter to its resistance function, and measure the resistance between the controller
terminals J2-13 and foot pilot pressure switch harness (normally, <10Ω).
To the black probe
White wire
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the foot pilot pressure switch connector and disconnect the controller connector. Turn the
multimeter to its resistance function, and measure the resistance between the harness at the controller
terminal J2-13 and the grounding (normally, <10Ω).
White wire
When the resistance is abnormal, this indicates the connector is poorly contacted.
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-41
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.9 DTC 121604 Air Filter Switch Shorted to Ground
Component location
Front
LG925E4F06042
6-42
6.4 Fault Code December 30, 2017
6.4.9 DTC 121604 Air Filter Switch Shorted to Ground CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the air filter switch:
1. Check the connector inside for moisture, oil dirt and other.
2. Turn the multimeter to its resistance function, and measure the resistance between the air filter
switch terminals (normally, >100kΩ).
Whether the air filter switch fails?
YES NO
Repair or replace the air filter switch.
Go to Step 3 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the air filter switch connector and disconnect the controller connector. Turn the multimeter to
its resistance function, and measure the resistance between the controller port J2-27 and the grounding
(normally, >100kΩ)
When the resistance is abnormal, this indicates there is an insulation fault in the connector.
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-44
6.4 Fault Code December 30, 2017
6.4.10 DTC 121615 Air Filter Clogging CLG930E/936E
Component location
Front
LG925E4F06042
6-45
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.10 DTC 121615 Air Filter Clogging
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
If the air filter is normal, check the air filter detection circuit or air filter alarm switch for fault in
accordance with the fault diagnosis of the 121604- Air Filter Switch Shorted to Ground.
Whether the air filter monitoring system fails?
YES NO
Repair the air filter detection circuit or replace the
air filter alarm switch
Go to Step 3 Go to Step 3
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-46
6.4 Fault Code December 30, 2017
6.4.11 DTC 131000 High Engine Speed CLG930E/936E
Component location
Speed sensor
Front
6-47
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.11 DTC 131000 High Engine Speed
Notice: Be careful! Hot engine block and hydraulic oil can cause serious scald.
Inspection method
Check whether the fuel being used is the specified one.
Whether the fuel is used improperly or not?
YES NO
Replace the fuel
Go to Step 3
Go to Step 4
Step 3 Check the detection circuit or speed sensor for fault
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Check the speed detection circuit or speed sensor for fault in accordance with the fault diagnosis of the
131005- Engine Speed Sensor Fault.
Whether the detection circuit speed sensor is faulty?
YES NO
Repair the detection circuit or replace the speed
sensor. Go to Step 4
Go to Step 4
6-48
6.4 Fault Code December 30, 2017
6.4.11 DTC 131000 High Engine Speed CLG930E/936E
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-49
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.12 DTC 131100 Extremely High Coolant Temperature
Component location
Coolant temperature
sensor
Front
6-50
6.4 Fault Code December 30, 2017
6.4.12 DTC 131100 Extremely High Coolant Temperature CLG930E/936E
Notice: Be careful! Hot engine block and coolant can scald you seriously
Inspection method
Check the engine coolant for overheating with a thermometer.
Whether the engine coolant overheating or not?
YES NO
Look for the cause for the engine coolant
overheating. Go to Step 2
Go to Step 3
Step 2 Check the engine coolant temperature monitoring system for fault
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
If the coolant temperature is normal, check the coolant temperature detection circuit or coolant
temperature sensor for fault in accordance with the fault diagnosis of 131103- Coolant Temperature
Sensor Voltage Outside the Range Value.
Whether the engine coolant temperature monitoring system fails or not?
YES NO
Repair the coolant temperature detection circuit or
replace the coolant temperature sensor. Go to Step 3
Go to Step 3
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-51
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.13 DTC 131103 Coolant Temperature Sensor Voltage Above the Range Value
Coolant temperature
(Celsius degree )
Resistance (Ohm)
6-52
6.4 Fault Code December 30, 2017
6.4.13 DTC 131103 Coolant Temperature Sensor Voltage Above the Range Value CLG930E/936E
Component location
Coolant temperature
sensor
Front
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the coolant temperature sensor connector and disconnect the controller connector. Turn the
multimeter to its resistance function, measure the resistance between the controller port J1-19 and J2-
22, and compare the result with the parameter table (normally, <4K).
An abnormal resistance indicates that there is poor contact in the connector
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-54
6.4 Fault Code December 30, 2017
6.4.14 DTC 131104 Coolant Temperature Sensor Voltage Below the Range Value CLG930E/936E
LG922E930E06027
Coolant temperature sensor parameter table
Coolant temperature
(Celsius degree )
Resistance (Ohm)
6-55
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.14 DTC 131104 Coolant Temperature Sensor Voltage Below the Range Value
Component location
Coolant temperature
sensor
Front
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the coolant temperature sensor connector and disconnect the controller connector. Turn the
multimeter to its resistance function, measure the resistance between the controller port J1-19 and J2-
22, and compare the result with the parameter table (normally, >10Ω)
When the resistance is abnormal, this indicates there is an insulation fault in the connector
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-57
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.15 DTC 131115 High Coolant Temperature
LG922E930E06027
Component location
Coolant temperature
sensor
Front
6-58
6.4 Fault Code December 30, 2017
6.4.15 DTC 131115 High Coolant Temperature CLG930E/936E
Notice: Be careful! Hot engine block and coolant can scald you seriously
Inspection method
Check whether the engine coolant temperature is too high with a thermometer
Whether the engine coolant overheating or not?
YES NO
Look for the cause for high coolant temperature.
Go to Step 3 Go to Step 2
Step 2 Check the engine coolant temperature monitoring system for fault
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
If the coolant temperature is normal, check the coolant temperature detection circuit or coolant
temperature sensor for fault in accordance with the fault diagnosis of 131103- Coolant Temperature
Sensor Voltage Above the Range Value.
Whether the engine coolant temperature monitoring system fails or not?
YES NO
Repair the coolant temperature detection circuit or
replace the coolant temperature sensor.
Go to Step 3 Go to Step 3
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-59
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.16 DTC 131116 High Coolant Temperature
Component location
Coolant temperature
sensor
Front
6-60
6.4 Fault Code December 30, 2017
6.4.16 DTC 131116 High Coolant Temperature CLG930E/936E
Notice: Hot engine block and coolant can scald you seriously
Inspection method
Check whether the engine coolant temperature is too high with a thermometer
Whether the engine coolant overheating or not?
YES NO
Look for the cause for high coolant temperature.
Go to Step 3 Go to Step 2
Step 2 Check the engine coolant temperature monitoring system for fault
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
If the coolant temperature is normal, check the coolant temperature detection circuit or coolant
temperature sensor for fault in accordance with the fault diagnosis of 131103- Coolant Temperature
Sensor Voltage Above the Range Value.
Whether the engine coolant temperature monitoring system fails or not?
YES NO
Repair the coolant temperature detection circuit or
replace the coolant temperature sensor.
Go to Step 3 Go to Step 3
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-61
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.17 DTC 131200 Extremely High Hydraulic Oil Temperature
Component location
Front
Hydraulic oil
temperature sensor
6-62
6.4 Fault Code December 30, 2017
6.4.17 DTC 131200 Extremely High Hydraulic Oil Temperature CLG930E/936E
Notice: Be careful! Hot engine block and hydraulic oil can cause serious scald.
Inspection method
Check the hydraulic oil is not too high by using a thermometer.
Whether the hydraulic oil temperature is extremely high or not?
YES NO
Troubleshoot the high hydraulic oil temperature.
Go to Step 3 Go to Step 2
Step 2 Check the hydraulic oil temperature monitoring system for fault
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
If the hydraulic oil temperature is normal, check the hydraulic oil temperature detection circuit or
hydraulic oil temperature sensor for fault in accordance with the DTC 131203 - Hydraulic Oil
Temperature Sensor Voltage Above the Range Value.
Whether the hydraulic oil temperature monitoring system fails?
YES NO
Repair the hydraulic oil temperature detection
circuit or replace the hydraulic oil temperature
sensor.
Go to Step 3 Go to Step 3
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-63
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.18 DTC 131203 Hydraulic oil Temperature Sensor Voltage Above the Range Value
LG922E930E06030
Coolant temperature
(Celsius degree )
Resistance (Ohm)
6-64
6.4 Fault Code December 30, 2017
6.4.18 DTC 131203 Hydraulic oil Temperature Sensor Voltage Above the Range Value CLG930E/936E
Component location
Front
Hydraulic oil
temperature sensor
Inspection method
1. Check the harnesses (# 831 and # 922) between the controller (J1-31 and J2-22 ) and the hydraulic
oil temperature sensor for wear.
2. Disconnect the connectors from the hydraulic oil temperature sensor and the controller. Turn the
multimeter to its resistance function, and measure the resistance of the harness (# 831/# 922)
between the controller (J1-31/J2-22 ) and the hydraulic oil temperature sensor, respectively
(normally, <10Ω)
Is the harness open-circuit?
YES NO
Connect the harness again and wrap the harness
Go to Step 4 Go to Step 3
Step 3 Check the connector for fault
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the hydraulic oil temperature sensor connector and disconnect the controller connector. Turn
the multimeter to its resistance function, and measure the resistance between the controller port J1-31
and J2-22, comparing the result with the parameter table (normally, <4kΩ).
An abnormal resistance indicates that there is poor contact in the connector
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-66
6.4 Fault Code December 30, 2017
6.4.19 DTC 131204 Hydraulic Oil Temperature Sensor Voltage Below the Range Value CLG930E/936E
LG922E930E06030
Coolant temperature
(Celsius degree )
Resistance (Ohm)
6-67
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.19 DTC 131204 Hydraulic Oil Temperature Sensor Voltage Below the Range Value
Component location
Front
Hydraulic oil
temperature sensor
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the knob switch to the OFF position, and disconnect the sensor connector:
1. Check the connector for looseness, rust, bending and damage.
2. Turn the multimeter to its resistance function (20kΩ), and measure the resistance between the
sensor connector terminals 1 and 2, comparing the result with the parameter table (normally, <4kΩ).
Whether the hydraulic oil temperature sensor fails?
YES NO
Repair or replace the sensor.
Go to Step 4 Go to Step 2
Inspection method
1. Check the harnesses (# 831 and # 922) between the controller (J1-31 and J2-22 ) and the hydraulic
oil temperature sensor for wear.
2. Disconnect the connectors from the hydraulic oil temperature sensor and the controller. Turn the
multimeter to its resistance function, and measure the resistance between the harness (# 831/#
922) sensor terminal and the grounding, respectively (normally, >100K).
Whether the harness is shorted to ground or not?
YES NO
Connect the harness again and wrap the harness
Go to Step 4 Go to Step 3
Step 3 Check the connector for fault
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the hydraulic oil temperature sensor connector and disconnect the controller connector. Turn
the multimeter to its resistance function, and measure the resistance between the controller port J1-31
and J2-22, comparing the result with the parameter table (normally, >10Ω).
When the resistance is abnormal, this indicates there is an insulation fault in the connector
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-69
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.20 DTC 131215 High Hydraulic Oil Temperature
Component location
Front
Hydraulic oil
temperature sensor
6-70
6.4 Fault Code December 30, 2017
6.4.20 DTC 131215 High Hydraulic Oil Temperature CLG930E/936E
Notice: Be careful! Hot engine block and hydraulic oil can cause serious scald.
Inspection method
Check the hydraulic oil is not too high by using a thermometer.
Whether the hydraulic oil temperature is too high or not?
YES NO
Troubleshoot the high hydraulic oil temperature.
Go to Step 3 Go to Step 2
Step 2 Check the hydraulic oil temperature monitoring system for fault
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
If the hydraulic oil temperature is normal, check the hydraulic oil temperature detection circuit or
hydraulic oil temperature sensor for fault in accordance with the DTC 131203 - Hydraulic Oil
Temperature Sensor Voltage Above the Range Value.
Whether the hydraulic oil temperature monitoring system fails?
YES NO
Repair the hydraulic oil temperature detection
circuit or replace the hydraulic oil temperature
sensor.
Go to Step 3 Go to Step 3
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-71
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.21 DTC 131216 Extremely High Hydraulic Oil Temperature
Component location
Front
Hydraulic oil
temperature sensor
6-72
6.4 Fault Code December 30, 2017
6.4.21 DTC 131216 Extremely High Hydraulic Oil Temperature CLG930E/936E
Notice: Be careful! Hot engine block and hydraulic oil can cause serious scald.
Inspection method
Check whether the hydraulic oil is not very high with a thermometer.
Whether the hydraulic oil temperature is extremely high or not?
YES NO
Troubleshoot the high hydraulic oil temperature.
Go to Step 3 Go to Step 2
Step 2 Check the hydraulic oil temperature monitoring system for fault
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
If the hydraulic oil temperature is normal, check the hydraulic oil temperature detection circuit or
hydraulic oil temperature sensor for fault in accordance with the DTC 131203 - Hydraulic Oil
Temperature Sensor Voltage Above the Range Value.
Whether the hydraulic oil temperature monitoring system fails?
YES NO
Repair the hydraulic oil temperature detection
circuit or replace the hydraulic oil temperature
sensor.
Go to Step 3 Go to Step 3
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-73
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.22 DTC 131303 Fuel Level Sensor Voltage Above the Range Value
LG922E930E06032
Oil level
Component location
Front
Notice: When replacing the components, please be sure to use LiuGong parts.
Notice: High temperature and high pressure oil or water can cause personal injury! When
replacing the sensor, please shut down the engine first and wait until the engine and gearbox
housing are sufficiently cooled.
Notice: When installing the fuel level sensor into the fuel tank, wipe off the water and keep
it clean.
Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the fuel level sensor:
1. Check the connector for looseness, rust, bending and damage.
2. Turn the multimeter to its resistance function, and measure the resistance between the fuel level
sensor connector terminals 1 and 2 (normally, <2kΩ, for the specific resistance, see the figure.).
Gray wire
(2) Turn the multimeter to its resistance function, and measure the resistance between the connector
terminals J2-30 and sensor harness (normally, <10Ω).
White wire
YES NO
Connect the harness again and wrap the harness
Go to Step 4 Go to Step 3
Step 3 Check the connector for fault
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the fuel-level sensor connector and disconnect the controller connector. Turn the multimeter to
its resistance function, and measure the resistance between the harness at the controller port J2-30
and the grounding (normally, <2 kΩ, for the specific resistance, see fuel level sensor parameter table).
When the resistance is abnormal, this indicates the connector is poorly contacted.
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-78
6.4 Fault Code December 30, 2017
6.4.23 DTC 131304 Fuel Level Sensor Shorted to Ground CLG930E/936E
LG922E930E06032
Oil level
Component location
Front
Notice: When replacing the components, please be sure to use LiuGong parts.
Notice: High temperature and high pressure oil or water can cause personal injury! When
replacing the sensor, please shut down the engine first and wait until the engine and gearbox
housing are sufficiently cooled.
Notice: When installing the fuel level sensor into the fuel tank, wipe off the water and keep
it clean.
Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the fuel level sensor:
1. Check the connector for looseness, rust, bending and damage.
2. Turn the multimeter to its resistance function, and measure the resistance between the fuel level
sensor connector terminals 1 and 2 (normally, <2kΩ, for the specific resistance, see the figure.).
Gray wire
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the sensor connector and disconnect the controller connector. Turn the multimeter to its
resistance function, and measure the resistance between the J2-30 port and the grounding (normally,
>10Ω).
When the resistance is abnormal, this indicates there is an insulation fault in the connector
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-83
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.24 DTC 131317 Low fuel level
LG922E930E06032
Oil level
Component location
Front
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-86
6.4 Fault Code December 30, 2017
6.4.25 DTC 131603 Water-in-Fuel Sensor Voltage Above the Range Value CLG930E/936E
Component location
Front
Fuel-in-water
sensor
6-87
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.25 DTC 131603 Water-in-Fuel Sensor Voltage Above the Range Value
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the water-in-fuel sensor:
1. Check the connector for looseness, rust, bending and damage.
2. Turn the multimeter to its resistance function, and measure the resistance between the water-in-fuel
sensor connector terminals 1 and 2 (normally, <4.6M/306.5K).
Whether the water-in-fuel sensor fails?
YES NO
Repair or replace the sensor.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the water-in-fuel sensor connector and disconnect the controller connector. Turn the
multimeter to its resistance function, and measure the resistance between the harness at the controller
port J1 and the grounding (normally 2.62kΩ--4.6MΩ).
When the resistance is abnormal, this indicates the connector is poorly contacted.
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-89
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.26 DTC 131604 Water-in-Fuel Sensor Voltage Below the Range Value
Component location
Front
Fuel-in-water
sensor
6-90
6.4 Fault Code December 30, 2017
6.4.26 DTC 131604 Water-in-Fuel Sensor Voltage Below the Range Value CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the water-in-fuel sensor:
1. Check the connector for looseness, rust, bending and damage.
2. Turn the multimeter to its resistance function, and measure the resistance between the water-in-fuel
sensor connector terminals 1 and 2 (normally, >2.62K).
Whether the water-in-fuel sensor fails?
YES NO
Repair or replace the sensor.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the water-in-fuel sensor connector and disconnect the controller connector. Turn the
multimeter to its resistance function, and measure the resistance between the controller port J2-21 and
the grounding (normally, >2.62kΩ).
When the resistance is abnormal, this indicates there is an insulation fault in the connector
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-92
6.4 Fault Code December 30, 2017
6.4.27 DTC 131605 Water-in-fuel Sensor Open-circuit CLG930E/936E
Component location
Front
Fuel-in-water
sensor
6-93
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.27 DTC 131605 Water-in-fuel Sensor Open-circuit
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the water-in-fuel sensor:
1. Check the connector for looseness, rust, bending and damage.
2. Turn the multimeter to its resistance function, and measure the resistance between the water-in-fuel
sensor connector terminals 1 and 2 (normally, <4.6M).
Whether the water-in-fuel sensor fails?
YES NO
Repair or replace the sensor.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the water-in-fuel sensor connector and disconnect the controller connector. Turn the
multimeter to its resistance function, and measure the resistance between the harness at the controller
port J2-21 and the grounding (normally, <4.6M).
When the resistance is abnormal, this indicates the connector is poorly contacted.
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-95
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.28 DTC 131615 Water-in-fuel
Component location
Front
Fuel-in-water
sensor
6-96
6.4 Fault Code December 30, 2017
6.4.28 DTC 131615 Water-in-fuel CLG930E/936E
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-97
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.29 DTC 131703 Sensor Power (5V) Shorted to the Battery
Component location
Front
Accelerator
potentiometer
Accelerator actuator
Controller
LG925E4F06193
P1 Pump
pressure
sensor
P2Pump
pressure
sensor
Front
LG925E4F06176
6-99
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.29 DTC 131703 Sensor Power (5V) Shorted to the Battery
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-100
6.4 Fault Code December 30, 2017
6.4.30 DTC 131704 Sensor Power (5V) Shorted to the Ground CLG930E/936E
Component location
Front
Accelerator
potentiometer
Accelerator actuator
Controller
LG925E4F06193
P1 Pump
pressure
sensor
P2Pump
pressure
sensor
Front
LG925E4F06176
6-102
6.4 Fault Code December 30, 2017
6.4.30 DTC 131704 Sensor Power (5V) Shorted to the Ground CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position and disconnect the connectors from the accelerator knob and
actuator:
1. Check the connector for moisture, oil dirt and other
2. Turn the multimeter to its resistance function, and measure the resistance between the accelerator
knob connector terminals 1 and 2 (normally, >10Ω).
3. Measure the resistance between the terminals 3 and 5 of the accelerator actuator connector
(normally, >10Ω).
Whether the accelerator knob or actuator fails?
YES NO
Repair or replace the accelerator knob and the
accelerator actuator.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
1. Connect the accelerator knob connector, and disconnect connector from the pump pressure sensor
and the controller connector, turn the multimeter to its resistance function, and measure the
resistance between the controller ports J1-28 and J1-22(normally, >10Ω).
2. Connect the pump pressure sensor connector and disconnect the accelerator knob and the
controller connector. Turn the multimeter to its resistance function, and measure the resistance
between the controller port J1-28 and J-22 (normally, >10Ω).
When the resistance in any step above is abnormal, this indicates an insulation fault develops in the
connector.
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-104
6.4 Fault Code December 30, 2017
6.4.31 DTC 141105 Pump Proportional Solenoid Valve Feedback Open-Circuited CLG930E/936E
Component location
Front
Pump proportional
solenoid valve
6-105
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.31 DTC 141105 Pump Proportional Solenoid Valve Feedback Open-Circuited
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position and disconnect the pump proportional solenoid valve
connector
1. Check the connector for moisture, oil dirt and other
2. Turn the multimeter to its resistance function, and measure the resistance between the pump
proportional solenoid valve connector terminals 1 and 2 (normally, 16~40Ω).
Whether the pump proportional solenoid valve fails?
YES NO
Repair or replace the pump proportional solenoid
valve.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the pump proportional solenoid valve connector and disconnect the controller connector. Turn
the multimeter to its resistance function, and measure the resistance between the controller ports J2-01
and J2-05 (normally, 16~40Ω).
When the resistance is abnormal, this indicates the connector is poorly contacted.
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-107
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.32 DTC 141006 Pump Proportional Solenoid Valve Feedback Overcurrent
Component location
Front
Pump proportional
solenoid valve
6-108
6.4 Fault Code December 30, 2017
6.4.32 DTC 141006 Pump Proportional Solenoid Valve Feedback Overcurrent CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position and disconnect the pump proportional solenoid valve
connector
1. Check the connector for moisture, oil dirt and other
2. Turn the multimeter to its resistance function, and measure the resistance between the pump
proportional solenoid valve connector terminals 1 and 2 (normally, 16~40Ω).
Whether the pump proportional solenoid valve fails?
YES NO
Repair or replace the pump proportional solenoid
valve.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the pump proportional solenoid valve connector and disconnect the controller connector. Turn
the multimeter to its resistance function, and measure the resistance between the controller ports J2-01
and J2-05 (normally, 16~40Ω).
When the resistance is abnormal, this indicates there is an insulation fault in the connector
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-110
6.4 Fault Code December 30, 2017
6.4.33 DTC 141104 Pump Proportional Solenoid Valve Shorted to Ground CLG930E/936E
Component location
Front
Pump proportional
solenoid valve
6-111
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.33 DTC 141104 Pump Proportional Solenoid Valve Shorted to Ground
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position and disconnect the pump proportional solenoid valve
connector
1. Check the connector for moisture, oil dirt and other
2. Turn the multimeter to its resistance function, and measure the resistance between the pump
proportional solenoid valve connector terminals 1 and 2 (normally, 16~40Ω).
Whether the pump proportional solenoid valve fails?
YES NO
Repair or replace the pump proportional solenoid
valve.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the pump proportional solenoid valve connector and disconnect the controller connector. Turn
the multimeter to its resistance function, and measure the resistance between the controller port J2-01
and the grounding (normally 16~40Ω).
When the resistance is abnormal, this indicates there is an insulation fault in the connector
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-113
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.34 DTC 141105 Pump Proportional Solenoid Valve Feedback Open-circuited
Component location
Front
Pump proportional
solenoid valve
6-114
6.4 Fault Code December 30, 2017
6.4.34 DTC 141105 Pump Proportional Solenoid Valve Feedback Open-circuited CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position and disconnect the pump proportional solenoid valve
connector
1. Check the connector for moisture, oil dirt and other
2. Turn the multimeter to its resistance function, and measure the resistance between the pump
proportional solenoid valve connector terminals 1 and 2 (normally, 16~40Ω).
Whether the pump proportional solenoid valve fails?
YES NO
Repair or replace the pump proportional solenoid
valve.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the pump proportional solenoid valve connector and disconnect the controller connector. Turn
the multimeter to its resistance function, and measure the resistance between the controller ports J2-01
and J2-05 (normally, 16~40Ω).
When the resistance is abnormal, this indicates the connector is poorly contacted.
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-116
6.4 Fault Code December 30, 2017
6.4.35 DTC 151004 Attachment Confluence Solenoid Valve Shorted to Ground CLG930E/936E
Component location
Front
Attachment
confluent solenoid
valve (position)
6-117
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.35 DTC 151004 Attachment Confluence Solenoid Valve Shorted to Ground
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position and disconnect the attachment confluence solenoid valve
connector
1. Check the connector for moisture, oil dirt and other
2. Turn the multimeter to its resistance function, and measure the resistance between the attachment
confluence solenoid connector terminals 1 and 2 (normally, 16~40Ω).
Whether the attachment confluence solenoid valve fails?
YES NO
Repair or replace the attachment confluence
solenoid valve.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the attachment confluent solenoid valve connector and disconnect the controller connector.
Turn the multimeter to its resistance function, and measure the resistance between the harness at
controller port J2-12 and the grounding (normally, 16~40Ω).
When the resistance is abnormal, this indicates there is an insulation fault in the connector
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-119
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.36 DTC 151005 Attachment Confluent Solenoid Valve Open-circuited or Shorted to the
Component location
Front
Attachment
confluent solenoid
valve (position)
6-120
6.4 Fault Code December 30, 2017
6.4.36 DTC 151005 Attachment Confluent Solenoid Valve Open-circuited or Shorted to the BatteryCLG930E/
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position and disconnect the attachment confluence solenoid valve
connector
1. Check the connector for moisture, oil dirt and other
2. Turn the multimeter to its resistance function, and measure the resistance between the attachment
confluence solenoid connector terminals 1 and 2 (normally, 16~40Ω).
Whether the attachment confluence solenoid valve fails?
YES NO
Repair or replace the attachment confluence
solenoid valve.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the attachment confluent solenoid valve connector and disconnect the controller connector.
Turn the multimeter to its resistance function, and measure the resistance between the harness at
controller port J2-12 and the grounding (normally, 16~40Ω).
When the resistance is abnormal, this indicates the connector is poorly contacted.
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-122
6.4 Fault Code December 30, 2017
6.4.37 DTC 151204 A2 Travel Speed Solenoid Shorted to Ground CLG930E/936E
Front
Controller
A2-marked solenoid
valve can be located.
Controller connector
Front
6-123
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.37 DTC 151204 A2 Travel Speed Solenoid Shorted to Ground
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position and disconnect the connector from the travel speed solenoid
valve.
1. Check the connector for looseness, rust, bending and damage.
2. Measure the resistance between both ends of the travel shift solenoid valve (normally,16~40Ω )
Whether the travel shift solenoid valve fails?
YES NO
Repair or replace the travel shift solenoid valve.
Go to Step 4 Go to Step 2
Step 2 Check whether the power harness of the travel shift solenoid valve is shorted to ground
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the travel shift solenoid valve connector and disconnect the controller connector. Turn the
multimeter to its resistance function, and measure the resistance between the harness at the controller
port J2-10 and the grounding (normally, 16-40Ω). When the resistance is abnormal, this indicates there
is a fault in the connector.
Definition of
connector pin
serial number
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-125
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.38 DTC 151205 A2 Travel Shift Solenoid Valve Open-Circuited or Shorted to the Battery
Front
Controller
A2-marked solenoid
valve can be located.
Controller connector
Front
6-126
6.4 Fault Code December 30, 2017
6.4.38 DTC 151205 A2 Travel Shift Solenoid Valve Open-Circuited or Shorted to the Battery CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position and disconnect the connector from the travel speed solenoid
valve.
1. Check the connector for looseness, rust, bending and damage.
2. Measure the resistance between both ends of the travel shift solenoid valve (normally,16~40Ω ).
Whether the travel shift solenoid valve fails?
YES NO
Repair or replace the travel proportional solenoid
valve.
Go to Step 5 Go to Step 2
Step 2 Check whether the power harness of the travel shift solenoid valve is shorted to ground
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the travel shift solenoid valve connector and disconnect the controller connector. Turn the
multimeter to its resistance function, and measure the resistance between the harness at the controller
port J2-10 and the grounding (normally, 16-40Ω). When the resistance is abnormal, this indicates there
is a fault in the connector.
Definition of
connector pin
serial number
Step 4 Check whether the travel speed solenoid valve is shorted to the battery
Inspection method
Turn the start switch to the ON position for fault diagnosis.
Disconnect the connectors from the controller and A2 travel shift solenoid valve to switch on the
switches of all electrical equipment, and then measure the voltage of the harness of A2 travel shift
solenoid valve. The voltage should be 0.
Whether the travel speed solenoid valve is shorted to the battery or not?
YES NO
Repair or replace the travel shift solenoid valve.
Go to Step 5 Go to Step 2
6-128
6.4 Fault Code December 30, 2017
6.4.38 DTC 151205 A2 Travel Shift Solenoid Valve Open-Circuited or Shorted to the Battery CLG930E/936E
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-129
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.39 DTC 151304 A3 Flattening Solenoid Valve Shorted to Ground
Front
Controller
A3-marked solenoid
valve can be located.
Controller connector
Front
6-130
6.4 Fault Code December 30, 2017
6.4.39 DTC 151304 A3 Flattening Solenoid Valve Shorted to Ground CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position and disconnect the connector from the flattening solenoid
valve:
1. Check the connector for looseness, rust, bending and damage.
2. Measure the resistance between the both ends of the flattening solenoid valve. The resistance
should be 16~40Ω.
Whether the flattening solenoid valve fails?
YES NO
Repair or replace the flattening solenoid valve.
Go to Step 4 Go to Step 2
Step 2 Check whether the power line of the flattening solenoid valve is shorted to ground
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the flattening solenoid valve connector and disconnect the controller connector. Turn the
multimeter to its resistance function, and measure the resistance between the harness (# 827) at the
controller port J1-27 and the grounding (normally, 16-40Ω). When the resistance is abnormal, this
indicates there is a fault in the connector.
Definition of
connector pin
serial number
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-132
6.4 Fault Code December 30, 2017
6.4.40 Fault Code 151305 A3 Flattening Solenoid Valve Open-Circuited or Shorted to the Battery CLG930E/
Front
Controller
A3-marked solenoid
valve can be located.
Controller connector
Front
6-133
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.40 Fault Code 151305 A3 Flattening Solenoid Valve Open-Circuited or Shorted to the
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position and disconnect the connector from the flattening solenoid
valve:
1. Check the connector for looseness, rust, bending and damage.
2. Measure the resistance between the both ends of the flattening solenoid valve(normally, 16~40Ω).
Whether the flattening solenoid valve fails?
YES NO
Repair or replace the flattening solenoid valve.
Go to Step 5 Go to Step 2
Inspection method
1. Check the harness (No. 827) and the grounding wire (No. 222) between the controller (J1-27) and
the flattening solenoid valve for wear.
2. Disconnect the connectors from the flattening solenoid valve and the controller. Check the harness
for open-circuit:
(1) Turn the multimeter to its resistance function, and measure the resistance between the connector
terminals J1-27 and flattening solenoid valve harness (normally, <10Ω).
(2) Turn the multimeter to its resistance function, and measure the resistance between the flattening
solenoid valve connecting terminal and the grounding wire (normally, <10Ω).
Definition of
connector pin
serial number
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the flattening solenoid valve connector and disconnect the controller connector. Turn the
multimeter to its resistance function, and measure the resistance between the harness at the controller
port J1-27 and the grounding (normally, 16-40Ω). When the resistance is abnormal, this indicates there
is a fault in the connector.
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 5 Go to Step 4
Step 4 Check whether the flattening solenoid valve is shorted to the battery
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the ON position for fault diagnosis.
Disconnect the connectors from the controller and A3 flattening solenoid valve to switch on the
switches of all electrical equipment, and then measure the voltage of the harness of A3 flattening
solenoid valve. The voltage should be 0V.
Whether the flattening solenoid valve is shorted to the battery or not?
YES NO
Find out the short circuit position and re-connect
the harness and wrap it
Go to Step 5 Go to Step 5
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-136
6.4 Fault Code December 30, 2017
6.4.41 DTC 151404 A8 Trenching Solenoid Valve Shorted to the Ground CLG930E/936E
Front
Controller
A8-marked solenoid
valve can be located.
Controller connector
Front
6-137
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.41 DTC 151404 A8 Trenching Solenoid Valve Shorted to the Ground
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position and disconnect the connector from the digging solenoid valve.
1. Check the connector for looseness, rust, bending and damage.
2. Measure the resistance between both ends of the digging solenoid valve(normally,16~40Ω).
Whether the digging solenoid valve fails?
YES NO
Repair or replace the digging solenoid valve.
Go to Step 4 Go to Step 2
Step 2 Check whether the power line of the digging solenoid valve is shorted to ground
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the digging function solenoid valve connector and disconnect the controller connector. Turn
the multimeter to its resistance function, and measure the resistance between the harness (# 825) at
the controller port J1-25 and the grounding (normally, 16-40Ω). When the resistance is abnormal, this
indicates there is a fault in the connector.
Definition of
connector pin
serial number
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-139
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.42 DTC 151405 A8 Trenching Solenoid Valve Open-Circuited or Shorted to the Battery
Front
Controller
A8-marked solenoid
valve can be located.
Controller connector
Front
6-140
6.4 Fault Code December 30, 2017
6.4.42 DTC 151405 A8 Trenching Solenoid Valve Open-Circuited or Shorted to the Battery CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position and disconnect the connector from the digging solenoid valve:
1. Check the connector for looseness, rust, bending and damage.
2. Measure the resistance between both ends of the digging solenoid valve(normally,16~40Ω).
Whether the digging solenoid valve fails?
YES NO
Repair or replace the digging solenoid valve.
Go to Step 5 Go to Step 2
Step 2 Check whether the power line of the digging solenoid valve is shorted to ground
Inspection method
1. Check the connecting harness (No.825) and the earthing wire (No. 225) between the controller (J1-
25) (in the figure) and the trenching solenoid valve for wear.
2. Disconnect the connectors from the digging solenoid valve and the controller, and check the
harness for open-circuit:
(1) Turn the multimeter to its resistance function, and measure the resistance between the controller
port J1-25 and trenching solenoid valve harness (normally, <10Ω).
(2) Turn the multimeter to its resistance function, and measure the resistance between the grounding
wire (#225) trenching solenoid valve terminal and the grounding (normally, <10Ω).
Definition of
connector pin
serial number
Whether the power harness of the digging solenoid valve is shorted to ground or not?
YES NO
Connect the harness again and wrap the harness.
Go to Step 5 Go to Step 3
6-142
6.4 Fault Code December 30, 2017
6.4.42 DTC 151405 A8 Trenching Solenoid Valve Open-Circuited or Shorted to the Battery CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the digging function solenoid valve connector and disconnect the controller connector. Turn
the multimeter to its resistance function, and measure the resistance between the harness (# 825) at
the controller port J1-25 and the grounding (normally, 16-40Ω). When the resistance is abnormal, this
indicates there is a fault in the connector.
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 5 Go to Step 4
Step 4 Check whether the trenching function solenoid valve is shorted to the battery
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the ON position for fault diagnosis.
Disconnect the connectors from the controller and A8 digging solenoid valve to switch on the switches
of all electrical equipment, and then measure the voltage of the harness of A8 digging solenoid valve.
The voltage should be 0V.
Whether the trenching solenoid valve is shorted to the battery or not?
YES NO
Find out the short circuit position and re-connect
the harness and wrap it
Go to Step 5 Go to Step 5
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-143
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.43 DTC 151504 A5 Flow Adjusting Solenoid Shorted to Ground
Front
Controller
A5-marked solenoid
valve can be located.
Controller connector
Front
6-144
6.4 Fault Code December 30, 2017
6.4.43 DTC 151504 A5 Flow Adjusting Solenoid Shorted to Ground CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the flow adjusting solenoid
valve.
1. Check the connector for looseness, rust, bending and damage.
2. Measure the resistance between both ends of the A5 flow adjusting solenoid valve (normally16-
40Ω).
Whether the flow adjusting valve fails?
YES NO
Repair or replace the flow adjusting solenoid valve.
Go to Step 2
Go to Step 4
Step 2 Check whether the power harness of flow adjusting solenoid valve is shorted to ground
Definition of
connector pin
serial number
Whether the harness of flow adjusting solenoid valve is shorted to ground or not?
YES NO
Connect the harness again and wrap the harness.
Go to Step 4 Go to Step 3
6-145
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.43 DTC 151504 A5 Flow Adjusting Solenoid Shorted to Ground
Notice: When replacing the components, please be sure to use LiuGong parts.
Notice: Shutdown operation is needed.
Inspection method
Connect the flow adjusting solenoid valve connector and disconnect the controller connector. Turn the
multimeter to its resistance function, and measure the resistance between the ports of J2-8 and J2-24
of controller (normally, 16~40Ω). When the resistance is abnormal, this indicates there is a fault in the
connector.
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-146
6.4 Fault Code December 30, 2017
6.4.44 DTC 151505 A5 Flow Adjusting Solenoid Valve Open-Circuited or Shorted to the Battery CLG930E/
Front
Controller
A5-marked solenoid
valve can be located.
Controller connector
Front
6-147
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.44 DTC 151505 A5 Flow Adjusting Solenoid Valve Open-Circuited or Shorted to the
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the flow adjusting solenoid
valve.
1. Check the connector for looseness, rust, bending and damage.
2. Measure the resistance between both ends of the A5 flow adjusting solenoid valve (normally16-
40Ω).
Whether the flow adjusting valve fails?
YES NO
Repair or replace the flow adjusting solenoid valve.
Go to Step 5 Go to Step 2
Inspection method
1. Check the harness (# 908) and the feedback wire (# 924) between the controller (J2-9) (attached
drawing) and the flow adjusting solenoid valve for wear.
2. Disconnect the connectors from flow adjusting solenoid valve and the controller. Check the harness
for open-circuit:
(1) Turn the multimeter to its resistance function, and measure the resistance between the connector
terminals J2-8 and flow adjusting solenoid valve port A5-1 (normally, <10Ω).
(2) Turn the multimeter to its resistance function, and measure the resistance between the connector
terminals J2-24 and flow adjusting solenoid valve port A5-2 (normally, <10Ω).
Definition of
connector pin
serial number
Notice: When replacing the components, please be sure to use LiuGong parts.
Notice: Shutdown operation is needed.
Inspection method
Connect the flow adjusting solenoid valve connector and disconnect the controller connector. Turn the
multimeter to its resistance function, and measure the resistance between the harness at the controller
port J2-8 and the grounding (normally, 16~40Ω). When the resistance is abnormal, this indicates there
is a fault in the connector.
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 5 Go to Step 4
Step 4 Check whether the flow adjusting solenoid valve is shorted to the battery
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the ON position for fault diagnosis.
Disconnect the connectors from the controller and flow adjusting solenoid valve to switch on the
switches of all electrical equipment, and then measure the voltage of the harness of flow adjusting
solenoid valve. The voltage should be 0V.
Whether the flow adjusting solenoid valve is shorted to the battery or not?
YES NO
Find out the short circuit position and re-connect
the harness and wrap it
Go to Step 5 Go to Step 5
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-150
6.4 Fault Code December 30, 2017
6.4.45 DTC 151605 A6 Flow Adjusting Solenoid Open-circuited or Shorted to the Battery CLG930E/936E
Front
Controller
A6-marked solenoid
valve can be located.
Controller connector
Front
6-151
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.45 DTC 151605 A6 Flow Adjusting Solenoid Open-circuited or Shorted to the Battery
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the flow adjusting solenoid
valve.
1. Check the connector for looseness, rust, bending and damage.
2. Measure the resistance between both ends of the A6 flow adjusting solenoid valve (normally16-
40Ω).
Whether the flow adjusting valve fails?
YES NO
Repair or replace the flow adjusting solenoid valve.
Go to Step 5 Go to Step 2
Inspection method
1. Check the harness (# 909) and the feedback wire (# 924) between the controller (J2-9) (attached
drawing) and the flow adjusting solenoid valve for wear.
2. Disconnect the connectors from flow adjusting solenoid valve and the controller. Check the harness
for open-circuit:
(1) Turn the multimeter to its resistance function, and measure the resistance between the control
connector terminal J2-9 and flow adjusting solenoid valve port A6-1 (normally, <10Ω).
(2) Turn the multimeter to its resistance function, and measure the resistance between the controller
connector terminal J2-24 and flow adjusting solenoid valve connector port A6-2 (normally, <10Ω).
Definition of
connector pin
serial number
Notice: When replacing the components, please be sure to use LiuGong parts.
Notice: Shutdown operation is needed.
Inspection method
Connect the flow adjusting solenoid valve connector and disconnect the controller connector. Turn the
multimeter to its resistance function, and measure the resistance between the ports of J2-9 and J2-24
of controller connector in the harness (normally, 16~40Ω). When the resistance is abnormal, this
indicates there is a fault in the connector.
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 5 Go to Step 4
Step 4 Check whether the flow adjusting solenoid valve is shorted to the battery
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the ON position for fault diagnosis.
Disconnect the connectors from the controller and flow adjusting solenoid valve to switch on the
switches of all electrical equipment, and then measure the voltage of the harness of flow adjusting
solenoid valve. The voltage should be 0V.
Whether the flow adjusting solenoid valve is shorted to the battery or not?
YES NO
Find out the short circuit position and re-connect
the harness and wrap it
Go to Step 5 Go to Step 5
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-154
6.4 Fault Code December 30, 2017
6.4.46 DTC 151704 A7 Power Boosting Solenoid Valve Shorted to the Ground CLG930E/936E
Front Controller
A7-marked solenoid
valve can be located.
Controller connector
Front
6-155
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.46 DTC 151704 A7 Power Boosting Solenoid Valve Shorted to the Ground
Step 1 Check the transient power boosting solenoid valve for fault
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position and disconnect the connector from the connector of the
transient power boosting solenoid valve.
1. Check the pins for moisture, oil dirt and other.
2. Measure the resistance between both ends of the transient power boosting solenoid valve. The
resistance should be 16-40Ω
Whether the transient power boosting solenoid valve fails?
YES NO
Repair or replace the transient power boosting
solenoid valve.
Go to Step 4 Go to Step 2
Step 2 Check whether the power line of the power boosting solenoid valve is shorted to ground.
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the transient power boosting solenoid valve connector and disconnect the controller
connector. Turn the multimeter to its resistance function, and measure the resistance between the
harness at the controller port J1-13 and the grounding (normally, 16~40Ω). When the resistance is
abnormal, this indicates there is a fault in the connector.
Definition of
connector pin
serial number
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-157
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.48 DTC 151705 A7 Power Boosting Solenoid Valve Open-Circuited or Shorted to the
Front Controller
A7-marked solenoid
valve can be located.
Controller connector
Front
6-158
6.4 Fault Code December 30, 2017
6.4.48 DTC 151705 A7 Power Boosting Solenoid Valve Open-Circuited or Shorted to the Battery CLG930E/
Step 1 Check the transient power boosting solenoid valve for fault
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position and disconnect the connector from the connector of the
transient power boosting solenoid valve.
1. Check the pins for moisture, oil dirt and other.
2. Measure the resistance between both ends of the transient power boosting solenoid valve. The
resistance should be 16-40Ω
Whether the transient power boosting solenoid valve fails?
YES NO
Repair or replace the transient power boosting
solenoid valve.
Go to Step 5 Go to Step 2
Inspection method
1. Check the harness (No.813) and the grounding wire (No.224) between the controller (J1-13) (in the
figure) and the power boosting solenoid valve for wear.
2. Disconnect the connectors from the power boosting solenoid valve and the controller, and check
the harness for open-circuit:
(1) Turn the multimeter to its resistance function, and measure the resistance between the controller
port J1-13 and power boosting solenoid valve harness (normally, <10Ω).
(2) Turn the multimeter to its resistance function, and measure the resistance between the grounding
wire (#224) power boosting solenoid valve terminal and the grounding (normally, <10Ω).
Definition of
connector pin
serial number
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the transient power boosting solenoid valve connector and disconnect the controller
connector. Turn the multimeter to its resistance function, and measure the resistance between the
harness at the controller port J1-13 and the grounding (normally, 16~40Ω). When the resistance is
abnormal, this indicates there is a fault in the connector.
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 5 Go to Step 4
Step 4 Check whether the power boosting solenoid valve is shorted to the battery
Inspection method
Turn the start switch to the ON position for fault diagnosis.
Disconnect the connectors from the controller and A7 transient power boosting solenoid valve to switch
on the switches of all electrical equipment, and then measure the voltage of the harness of A7 transient
power boosting solenoid valve. The voltage should be 0V.
Whether the power boosting solenoid valve is shorted to the battery?
YES NO
Find out the short circuit position and re-connect
the harness and wrap it.
Go to Step 5 Go to Step 5
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-161
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.49 DTC 151804 A4 Travel Lifting Solenoid Valve Shorted to the Ground
J2
Front
Controller
A4-marked solenoid
valve can be located.
Controller connector
Front
6-162
6.4 Fault Code December 30, 2017
6.4.49 DTC 151804 A4 Travel Lifting Solenoid Valve Shorted to the Ground CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position and disconnect the connector from the travel lifting solenoid
valve.
1. Check the pins for moisture, oil dirt and other.
2. Measure the resistance between both ends of the travel lifting solenoid valve. The resistance
should be 16~40Ω.
Whether the travel lifting solenoid valve fails?
YES NO
Repair or replace the travel lifting solenoid valve.
Go to Step 4 Go to Step 2
Step 2 Check whether the power line of the travel lifting solenoid valve is shorted to ground.
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the travel lifting solenoid valve connector and disconnect the controller connector. Turn the
multimeter to its resistance function, and measure the resistance between the harness at the controller
port J2-26 and the grounding (normally, 16~40Ω). When the resistance is abnormal, this indicates there
is a fault in the connector.
Definition of
connector pin
serial number
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-164
6.4 Fault Code December 30, 2017
6.4.50 DTC 151805 A4 Travel Lifting Solenoid Valve Open-Circuited or Shorted to the Battery CLG930E/
J2
Front
Controller
A4-marked solenoid
valve can be located.
Controller connector
Front
6-165
December 30, 2017 6.4 Fault Code
CLG930E/936E6.4.50 DTC 151805 A4 Travel Lifting Solenoid Valve Open-Circuited or Shorted to the Battery
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position and disconnect the connector from the travel lifting solenoid
valve:
1. Check the connector for looseness, rust, bending and damage.
2. Measure the resistance between both ends of the travel lifting solenoid valve (normally,16~40Ω )
Whether the travel lifting solenoid valve fails?
YES NO
Repair or replace the travel lifting solenoid valve.
Go to Step 5 Go to Step 2
Step 2 Check whether the power harness of the travel lifting solenoid valve is shorted to ground
Inspection method
1. Check the harness (No. 826) and the grounding wire (No. 223) between the controller J2-26
(attached drawing) and the travel lifting solenoid valve for wear.
2. Disconnect the connectors from the travel lifting solenoid valve and the controller, and check the
harness for open-circuit:
(1) Turn the multimeter to its resistance function, and measure the resistance between the controller
port J2-26 and travel speed solenoid valve harness (normally, <10Ω).
(2) Turn the multimeter to its resistance function, and measure the resistance between the grounding
wire (# 223) travel lifting solenoid valve terminal and the grounding (normally, <10Ω).
Definition of
connector pin
serial number
Whether the power harness of the travel lifting solenoid valve is shorted to ground?
YES NO
Connect the harness again and wrap the harness.
Go to Step 5 Go to Step 3
6-167
December 30, 2017 6.4 Fault Code
CLG930E/936E6.4.50 DTC 151805 A4 Travel Lifting Solenoid Valve Open-Circuited or Shorted to the Battery
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the travel lifting solenoid valve connector and disconnect the controller connector. Turn the
multimeter to its resistance function, and measure the resistance between the harness (#826) at the
controller port J2-26 and the grounding (normally, 16~40Ω). When the resistance is abnormal, this
indicates there is a fault in the connector.
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 5 Go to Step 4
Step 4 Check whether the travel lifting solenoid valve is shorted to the battery
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the ON position for fault diagnosis.
Disconnect the connectors from the controller and A4 travel lifting solenoid valve to switch on the
switches of all electrical equipment, and then measure the voltage of the harness of A4 travel lifting
solenoid valve. The voltage should be 0 V.
Whether the travel lifting solenoid valve is shorted to the battery or not?
YES NO
Find out the short circuit position and re-connect
the harness and wrap it
Go to Step 5 Go to Step 5
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-168
6.4 Fault Code December 30, 2017
6.4.50 DTC 151905 A5 or A6 Solenoid Valve Feedback Open-Circuited CLG930E/936E
Solenoid valve
assembly. Both
A5-marked solenoid
and A6-marked Controller
solenoid can be
located
Front
Controller connector
Front
6-169
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.50 DTC 151905 A5 or A6 Solenoid Valve Feedback Open-Circuited
Notice: When replacing the components, please be sure to use LiuGong parts.
Notice: Shutdown operation is needed.
Inspection method
3. Turn the start switch to the OFF position, and check the pins for moisture, oil dirt and other.
4. Measure the resistance of A5 or A6 flow adjusting solenoid valve. The resistance should be
16~40Ω.
Whether the flow adjusting valve fails?
YES NO
Repair or replace the flow adjusting solenoid valve.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Check the connectors between the A5/A6 flow adjusting solenoid valve and the controller for
looseness and their pins for rust, bending and damage one by one manually.
Disconnect the controller connector and connect the connector of the A5, A6 flow adjusting solenoid
valve, and then measure the resistance between the controller connector terminals J2-8, J2-9 and J2-
24 respectively. The resistance should be 16-40Ω. Otherwise, there is a fault in the connector.
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-171
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.51 DTC 151906 A5 or A6 Solenoid Valve Feedback Overcurrent
Solenoid valve
assembly. Both
A5-marked solenoid
and A6-marked Controller
solenoid can be
located
Front
Controller connector
Front
6-172
6.4 Fault Code December 30, 2017
6.4.51 DTC 151906 A5 or A6 Solenoid Valve Feedback Overcurrent CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Notice: Shutdown operation is needed.
Inspection method
3. Turn the start switch to the OFF position, and check the pins for moisture, oil dirt and other.
4. Measure the resistance of A5 or A6 flow adjusting solenoid valve. The resistance should be
16~40Ω.
Whether the flow adjusting valve fails?
YES NO
Repair or replace the flow adjusting solenoid valve.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Check the connectors between the A5/A6 flow adjusting solenoid valve and the controller for
looseness and their pins for rust, bending and damage one by one manually.
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-174
6.4 Fault Code December 30, 2017
6.4.52 DTC 171004 SHORT CIRCUIT TO GROUND OF BATTERY RELAY CLG930E/936E
Component location
Front
Battery relay
6-176
6.4 Fault Code December 30, 2017
6.4.52 DTC 171004 SHORT CIRCUIT TO GROUND OF BATTERY RELAY CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position and turn the multimeter to its resistance function (200Ω), and
then measure the resistance between the relay terminals B and E (normally, >10Ω, about 142Ω).
Is battery relay malfunctioning?
YES NO
Replace the battery relay
Go to Step 3 Go to Step 2
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-177
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.53 DTC 171104 Auto Preheating Relay Shorted to the Ground
Component location
K9 auto preheating
relay. It can be pulled
out during detection`
Step 1 Check whether the harness connecting the controller is shorted to ground
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-180
6.4 Fault Code December 30, 2017
6.4.54 DTC 171105 Auto Preheating Relay Open-Circuited or Shorted to the Battery CLG930E/936E
Component location
K9 auto preheating
relay. It can be pulled
out during detection`
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position for fault diagnosis
Open the fuse box, and pull out the auto preheating relay.
Measure the resistance between the ports 85 and 86 of the auto preheating relay coil. The resistance
should be 320-360Ω.
Connect the ports 85 and 86 to the power supply (24V), and measure the ports 30 and 87 by turning the
multimeter to its on-off function. The relay should switch on.
Whether the auto preheating relay fails?
YES NO
Replace the auto preheating relay.
Go to Step 4 Go to Step 2
6-182
6.4 Fault Code December 30, 2017
6.4.54 DTC 171105 Auto Preheating Relay Open-Circuited or Shorted to the Battery CLG930E/936E
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-183
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.55 DTC 171204 Start Cut-off Relay Shorted to Ground
Controller
Controller connector
Front
6-184
6.4 Fault Code December 30, 2017
6.4.55 DTC 171204 Start Cut-off Relay Shorted to Ground CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position for fault diagnosis
Open the fuse box, and pull out the auto preheating relay.
Measure the resistance between the ports 85 and 86 of the start cut-off relay coil. The resistance
should be 320-360Ω.
Connect the ports 85 and 86 to the power supply (24V), and measure the ports 30 and 87 by turning the
multimeter to its on-off function. The relay should switch on.
Whether the start cut-off relay fails?
YES NO
Replace the relay.
Go to Step 4 Go to Step 2
Step 2 Check whether the power harness of the start cut-off relay is shorted to ground
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the connector of the start cut-off relay and disconnect the controller connector, and then turn
the multimeter to its resistance function and measure the resistance between the harness at the
controller port J2-23 and the grounding (normally, 320-360Ω). If the resistance is abnormal, this
indicates that there is a fault in the connector.
Definition of
connector pin
serial number
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-186
6.4 Fault Code December 30, 2017
6.4.56 DTC 171205 Start cut-off Output Open-circuited or Shorted to the Battery CLG930E/936E
Controller
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position for fault diagnosis
Open the fuse box, and pull out the auto preheating relay.
Measure the resistance between the ports 85 and 86 of the start cut-off relay coil. The resistance
should be 320-360Ω.
Connect the ports 85 and 86 to the power supply (24V), and measure the ports 30 and 87 by turning the
multimeter to its on-off function. The relay should switch on.
Whether the start cut-off relay fails?
YES NO
Replace the relay.
Go to Step 5 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Insert the start cut-off relay into the fuse box properly and disconnect the controller connector, and then
turn the multimeter to its resistance function and measure the resistance between the harness (# 923)
at the controller port J2-23 and the grounding. The resistance should be between 320-360Ω.
Otherwise, check the connector:
1. Check the connector at the grounding of the start cut-off relay for poor contact
2. Check the connector of the start cut-off relay for looseness or damage.
Whether the connector is faulty?
YES NO
Adjust or replace the connector.
Go to Step 5 Go to Step 4
Step 4 Check whether the start cut-off relay is shorted to the battery
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the ON position for fault diagnosis.
Disconnect the connectors from the controller and the start cut-off relay and turn on the switches of all
electrical equipment, and then measure the voltage of the harness connecting the start cut-off relay.
The voltage should be 0V.
Whether the start cut-off relay is shorted to the battery or not?
YES NO
Find out the short circuit position and re-connect
the harness and wrap it
Go to Step 5 Go to Step 5
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-189
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.57 DTC 201004 Travel Alarm Shorted to Ground
Component location
Front
Travel alarm
6-190
6.4 Fault Code December 30, 2017
6.4.57 DTC 201004 Travel Alarm Shorted to Ground CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position, and disconnect the travel alarm connector:
1. Check the connector for moisture, oil dirt and other
2. Turn the multimeter to its resistance function, and measure the resistance between the alarm
connector terminals 1 and 2 (normally, >10Ω).
Check the backup alarm for fault
YES NO
Replace the alarm.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the travel alarm connector and disconnect the controller connector. Turn the multimeter to its
resistance function, and measure the resistance between the controller port J1-01 and the grounding
(normally, >10Ω)
When the resistance is abnormal, this indicates there is an insulation fault in the connector
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-192
6.4 Fault Code December 30, 2017
6.4.58 DTC 211003 P1 Pump Pressure Sensor Voltage Above the Range Value CLG930E/936E
6.4.58 DTC 211003 P1 Pump Pressure Sensor Voltage Above the Range
Value
System description
The pressure sensor (pressure transmitter) converts the detected hydraulic oil pressure parameter into
the electric signal, which is input to the controller, then the controller detects electric signal and
calculates the hydraulic oil pressure value which is displayed on the display instrument.
Component location
P1 pump
pressure sensor
P2 pump
pressure sensor
Front
6-193
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.58 DTC 211003 P1 Pump Pressure Sensor Voltage Above the Range Value
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Check the connector for moisture, oil dirt or insulation fault.
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Start the engine, and measure the voltage of No. 931 harness using voltage band of the multimeter with
the boom lifted (normal range 0.5-4.5V) .
Whether the pump pressure sensor fails?
YES NO
Replace the pump pressure sensor
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-195
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.59 DTC 211004 P1 Pump Pressure Sensor Voltage Below the Range Value
6.4.59 DTC 211004 P1 Pump Pressure Sensor Voltage Below the Range
Value
System description
The pressure sensor (pressure transmitter) converts the detected hydraulic oil pressure parameter into
the electric signal, which is input to the controller, then the controller detects electric signal and
calculates the hydraulic oil pressure value which is displayed on the display instrument.
Component location
P1 pump
pressure sensor
P2 pump
pressure sensor
Front
6-196
6.4 Fault Code December 30, 2017
6.4.59 DTC 211004 P1 Pump Pressure Sensor Voltage Below the Range Value CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
1. Check the connector at the sensor grounding for poor contact
2. Check whether the connector becomes loose.
3. Check the connector pins for rust, bending or damage.
Whether the connector is faulty?
YES NO
Repair or replace the connector.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Start the engine, and measure the voltage of No. 931 harness using voltage band of the multimeter with
the boom lifted (normal range 0.5-4.5V) .
Whether the pump pressure sensor fails?
YES NO
Replace the pump pressure sensor
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-198
6.4 Fault Code December 30, 2017
6.4.60 DTC 211003 P2 Pump Pressure Sensor Voltage above the Range Value CLG930E/936E
6.4.60 DTC 211003 P2 Pump Pressure Sensor Voltage above the Range
Value
System description
The pressure sensor (pressure transmitter) converts the detected hydraulic oil pressure parameter into
the electric signal, which is input to the controller, then the controller detects electric signal and
calculates the hydraulic oil pressure value which is displayed on the display instrument.
Component location
P1 pump
pressure sensor
P2 pump
pressure sensor
Front
6-199
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.60 DTC 211003 P2 Pump Pressure Sensor Voltage above the Range Value
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Check the connector for moisture, oil dirt or insulation fault.
Whether the connector is faulty?
YES NO
Repair or replace the connector.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Start the engine, and measure the voltage of No. 932 harness using voltage band of the multimeter with
the boom lifted (normal range 0.5-4.5V) .
Whether the pump pressure sensor fails?
YES NO
Replace the pump pressure sensor
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-201
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.61 DTC 211104 P2 Pump Pressure Sensor Voltage below the Range Value
6.4.61 DTC 211104 P2 Pump Pressure Sensor Voltage below the Range
Value
System description
The pressure sensor (pressure transmitter) converts the detected hydraulic oil pressure parameter into
the electric signal, which is input to the controller, then the controller detects electric signal and
calculates the hydraulic oil pressure value which is displayed on the display instrument.
Component location
P1 pump
pressure sensor
P2 pump
pressure sensor
Front
6-202
6.4 Fault Code December 30, 2017
6.4.61 DTC 211104 P2 Pump Pressure Sensor Voltage below the Range Value CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
1. Check the connector at the sensor grounding for poor contact
2. Check whether the connector becomes loose.
3. Check the connector pins for rust, bending or damage.
Whether the connector is faulty?
YES NO
Repair or replace the connector.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Start the engine, and measure the voltage of No. 932 harness using voltage band of the multimeter with
the boom lifted (normal range 0.5-4.5V) .
Whether the pump pressure sensor fails?
YES NO
Replace the pump pressure sensor
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-204
6.4 Fault Code December 30, 2017
6.4.62 DTC 211203 N1 Negative Flow Pressure Sensor Voltage Above the Range Value CLG930E/936E
6.4.62 DTC 211203 N1 Negative Flow Pressure Sensor Voltage Above the
Range Value
System description
The pressure sensor (pressure transmitter) converts the detected hydraulic oil pressure parameter into
the current signal input to the controller which detects the hydraulic oil pressure value which is displayed
on the display instrument.
Component location
Front
N Negative flow
pressure sensor
(position)
6-205
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.62 DTC 211203 N1 Negative Flow Pressure Sensor Voltage Above the Range Value
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Check the connector for moisture, oil dirt or insulation fault.
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Start the engine, and measure the voltage of No. 919 harness using voltage band of the multimeter with
the boom lifted (normal range 0.5-4.5V) .
Whether the N2 negative flow pressure sensor fails?
YES NO
Replace the N1 negative flow pressure sensor.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-207
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.63 DTC 211204 N1 Negative Flow Pressure Sensor Voltage Below the Range Value
6.4.63 DTC 211204 N1 Negative Flow Pressure Sensor Voltage Below the
Range Value
System description
The pressure sensor (pressure transmitter) converts the detected hydraulic oil pressure parameter into
the current signal input to the controller which detects the hydraulic oil pressure value which is displayed
on the display instrument.
Component location
Front
N1 Negative flow
pressure sensor
(position)
6-208
6.4 Fault Code December 30, 2017
6.4.63 DTC 211204 N1 Negative Flow Pressure Sensor Voltage Below the Range Value CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
1. Check the connector at the sensor grounding for poor contact
2. Check whether the connector becomes loose.
3. Check the connector pins for rust, bending or damage.
Whether the connector is faulty?
YES NO
Repair or replace the connector.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Start the engine, and measure the voltage of No. 919 harness using voltage band of the multimeter with
the boom lifted (normal range 0.5-4.5V) .
Whether the N1 Negative Flow Pressure Sensor Fails?
YES NO
Replace the N1 negative flow pressure sensor.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-210
6.4 Fault Code December 30, 2017
6.4.64 DTC 211303 N2 Negative Flow Pressure Sensor Voltage Above the Range Value CLG930E/936E
6.4.64 DTC 211303 N2 Negative Flow Pressure Sensor Voltage Above the
Range Value
System description
The pressure sensor (pressure transmitter) converts the detected hydraulic oil pressure parameter into
the current signal input to the controller which detects the hydraulic oil pressure value which is displayed
on the display instrument.
Component location
Front
N Negative flow
pressure sensor
(position)
6-211
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.64 DTC 211303 N2 Negative Flow Pressure Sensor Voltage Above the Range Value
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Check the connector for moisture, oil dirt or insulation fault.
Whether the connector is faulty?
YES NO
Repair or replace the connector.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Start the engine, and measure the voltage of No. 933 harness using voltage band of the multimeter with
the boom lifted (normal range 0.5-4.5V) .
Whether the N2 negative flow pressure sensor fails?
YES NO
Replace the N2 negative flow pressure sensor.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-213
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.65 DTC 211304 N2 Negative Flow Pressure Sensor Voltage Below the Range Value
6.4.65 DTC 211304 N2 Negative Flow Pressure Sensor Voltage Below the
Range Value
System description
The pressure sensor (pressure transmitter) converts the detected hydraulic oil pressure parameter into
the current signal input to the controller which detects the hydraulic oil pressure value which is displayed
on the display instrument.
Component location
Front
N Negative flow
pressure sensor
(position)
6-214
6.4 Fault Code December 30, 2017
6.4.65 DTC 211304 N2 Negative Flow Pressure Sensor Voltage Below the Range Value CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
1. Check the connector at the sensor grounding for poor contact
2. Check whether the connector becomes loose.
3. Check the connector pins for rust, bending or damage.
Whether the connector is faulty?
YES NO
Repair or replace the connector.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Start the engine, and measure the voltage of No. 933 harness using voltage band of the multimeter with
the boom lifted (normal range 0.5-4.5V) .
Whether the N2 negative flow pressure sensor fails?
YES NO
Replace the N2 negative flow pressure sensor.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-216
6.4 Fault Code December 30, 2017
6.4.66 DTC 221001 Actuator Feedback Voltage below the Range Value CLG930E/936E
6.4.66 DTC 221001 Actuator Feedback Voltage below the Range Value
System description
The accelerator control system mainly consists of the accelerator potentiometer (accelerator knob),
controller and accelerator actuator. The schematic diagram is shown below: #907 and #904 are drive
control lines. The controller is driven by 2 pins. If either pin is open-circuit, this can cause the accelerator
system fault. The accelerator potentiometer is used to control the engine speed. As shown in the figure,
Pin 1 of the R1 connector is connected to the 5V power, Pin 2 is connected to the controller-sensor
ground terminal and Pin 3 is connected to the accelerator signal feedback terminal. The accelerator
actuator controls the engine accelerator opening through the flexible shaft to control the engine speed.
The terminals are shown in the figure. Pin 3 of the M1 connector is the controller power (5V), pin 5 is
grounded, pin 2 is used for the accelerator feedback signal, pin 1 is used to control the accelerator
motor’s forward rotation and pin 4 is used to control the accelerator motor’s reverse rotation.
6-217
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.66 DTC 221001 Actuator Feedback Voltage below the Range Value
Component location
Front
Accelerator actuator
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Disconnect the connectors from the accelerator actuator:
4. Check the connector pins for looseness, rust, bending and damage. Check the connector inside for
moisture, oil dirt and other.
5. Turn the multimeter to its resistance function (20kΩ) and measure the resistance between the
actuator connector pins 3 and 5 (normally, about 4-5kΩ), and then, using the multimeter, measure
the resistance between the pins 2 and 3 and that between the pins 2 and 5. The sum of the
resistance between the pins 2 and 3 and that between the pins 2 and 5 equals the resistance
between the pins 3 and 5.
Whether the accelerator actuator fails?
YES NO
Repair or replace the accelerator actuator.
Go to Step 4 Go to Step 2
6-218
6.4 Fault Code December 30, 2017
6.4.66 DTC 221001 Actuator Feedback Voltage below the Range Value CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the actuator connector and disconnect the controller connector. Turn the multimeter to its
resistance function and measure the resistance between the controller port J1-28 and J2-18 (normally,
4~5kΩ), and then measure the resistance between the ports J1-28 and J2-22 and that between the
ports J2-28 and J2-22. The sum of the resistance between the pins 2 and 3 and that between the pins
2 and 5 equals the resistance between the pins 3 and 5.
An abnormal resistance indicates that there is fault in the connector.
Whether the connector is faulty?
YES NO
Replace the connector
Go to Step 4
Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-220
6.4 Fault Code December 30, 2017
6.4.67 DTC 221003 Actuator Feedback Voltage Above the Range Value CLG930E/936E
6.4.67 DTC 221003 Actuator Feedback Voltage Above the Range Value
System description
The accelerator control system mainly consists of the accelerator potentiometer (accelerator knob),
controller and accelerator actuator. The schematic diagram is shown below: #907 and #904 are drive
control lines. The controller is driven by 2 pins. If either pin is open-circuit, this can cause the accelerator
system fault. The accelerator potentiometer is used to control the engine speed. As shown in the figure,
Pin 1 of the R1 connector is connected to the 5V power, Pin 2 is connected to the controller-sensor
ground terminal and Pin 3 is connected to the accelerator signal feedback terminal. The accelerator
actuator controls the engine accelerator opening through the flexible shaft to control the engine speed.
The terminals are shown in the figure. Pin 3 of the M1 connector is the controller power (5V), pin 5 is
grounded, pin 2 is used for the accelerator feedback signal, pin 1 is used to control the accelerator
motor’s forward rotation and pin 4 is used to control the accelerator motor’s reverse rotation.
6-221
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.67 DTC 221003 Actuator Feedback Voltage Above the Range Value
Component location
Front
Accelerator actuator
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Disconnect the connectors from the accelerator actuator:
1. Check the connector pins for looseness, rust, bending and damage. Check the connector inside for
moisture, oil dirt and other.
2. Turn the multimeter to its resistance function (20kΩ) and measure the resistance between the
actuator connector pins 3 and 5 (normally, about 4.29kΩ), and then, using the multimeter, measure
the resistance between the pins 2 and 3 and that between the pins 2 and 5. The sum of the
resistance between the pins 2 and 3 and that between the pins 2 and 5 equals the resistance
between the pins 3 and 5.
Whether the accelerator actuator fails?
YES NO
Repair or replace the accelerator actuator.
Go to Step 4 Go to Step 2
6-222
6.4 Fault Code December 30, 2017
6.4.67 DTC 221003 Actuator Feedback Voltage Above the Range Value CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the actuator connector and disconnect the controller connector. Turn the multimeter to its
resistance function and measure the resistance between the controller port J1-28 and J2-18 (normally,
4~5kΩ), and then measure the resistance between the ports J1-28 and J2-22 and that between the
ports J2-28 and J2-22. The sum of the resistance between the pins 2 and 3 and that between the pins
2 and 5 equals the resistance between the pins 3 and 5.
An abnormal resistance indicates that there is fault in the connector.
Whether the connector is faulty?
YES NO
Replace the connector
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-224
6.4 Fault Code December 30, 2017
6.4.68 DTC 221007 Actuator Getting Stuck CLG930E/936E
System description
The accelerator control system mainly consists of the accelerator potentiometer (accelerator knob),
controller and accelerator actuator. The schematic diagram is shown below: #907 and #904 are drive
control lines. The controller is driven by 2 pins. If either pin is open-circuit, this can cause the accelerator
system fault. The accelerator potentiometer is used to control the engine speed. As shown in the figure,
Pin 1 of the R1 connector is connected to the 5V power, Pin 2 is connected to the controller-sensor
ground terminal and Pin 3 is connected to the accelerator signal feedback terminal. The accelerator
actuator controls the engine accelerator opening through the flexible shaft to control the engine speed.
The terminals are shown in the figure. Pin 3 of the M1 connector is the controller power (5V), pin 5 is
grounded, pin 2 is used for the accelerator feedback signal, pin 1 is used to control the accelerator
motor’s forward rotation and pin 4 is used to control the accelerator motor’s reverse rotation.
6-225
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.68 DTC 221007 Actuator Getting Stuck
Component location
Front
Accelerator actuator
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Check the harness connector for looseness.
Check the harness connector pins for rust, bending and damage.
There is moisture, oil dirt or insulation fault in the connector.
Whether a fault developing in the connector or not?
YES NO
Repair or replace the connector.
Go to Step 3 Go to Step 2
6-226
6.4 Fault Code December 30, 2017
6.4.68 DTC 221007 Actuator Getting Stuck CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position, and visually check whether the engine accelerator flexible
shaft (including its mounting plate) becomes loose
Start the excavator and turn the accelerator knob, and then check whether the accelerator flexible shaft
is operating properly.
Whether the accelerator actuator gets stuck?
YES NO
Repair or replace the accelerator actuator
Go to Step 3 Go to Step 3
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-227
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.69 DTC 221013 Actuator outside the Calibrated Range
System description
The accelerator control system mainly consists of the accelerator potentiometer (accelerator knob),
controller and accelerator actuator. The schematic diagram is shown below: #907 and #904 are drive
control lines. The controller is driven by 2 pins. If either pin is open-circuit, this can cause the accelerator
system fault. The accelerator potentiometer is used to control the engine speed. As shown in the figure,
Pin 1 of the R1 connector is connected to the 5V power, Pin 2 is connected to the controller-sensor
ground terminal and Pin 3 is connected to the accelerator signal feedback terminal. The accelerator
actuator controls the engine accelerator opening through the flexible shaft to control the engine speed.
The terminals are shown in the figure. Pin 3 of the M1 connector is the controller power (5V), pin 5 is
grounded, pin 2 is used for the accelerator feedback signal, pin 1 is used to control the accelerator
motor’s forward rotation and pin 4 is used to control the accelerator motor’s reverse rotation.
6-228
6.4 Fault Code December 30, 2017
6.4.69 DTC 221013 Actuator outside the Calibrated Range CLG930E/936E
Component location
Front
Accelerator actuator
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Check whether the number of teeth of the flywheel is correct in the control parameter.
Whether the number of teeth of the flywheel is correct or not?
YES NO
Re-adjust the number of teeth of the flywheel in the
control parameter.
Go to Step 6 Go to Step 2
6-229
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.69 DTC 221013 Actuator outside the Calibrated Range
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
1. Check the sensor for looseness.
2. Disconnect the speed sensor connector:
(1) Check the connector pins for looseness, rust, bending and damage. Check the connector inside for
moisture, oil dirt and other.
(2) Start the engine and turn the knob to increase the accelerator gradually. Turn the multimeter to its
AC voltage function, and measure the voltage on the sensor output ports (normally, when the
engine speed at 1000~2270r/min, the speed sensor outputs an AC voltage between 3~28V).
Whether the speed sensor is faulty?
YES NO
Tighten or repair, or replace the speed sensor.
Go to Step 6 Go to Step 3
According to the accelerator control system schematics, check whether the sequence of the
harnesses between the actuator and the controller is correct.
Whether the harness is connected wrong or not.
YES NO
Connect the harness again and wrap the harness
Go to Step 6 Go to Step 6
6-231
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.69 DTC 221013 Actuator outside the Calibrated Range
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-232
6.4 Fault Code December 30, 2017
6.4.70 DTC 221104 Actuator AC1 Shorted to Ground CLG930E/936E
System description
The accelerator control system mainly consists of the accelerator potentiometer (accelerator knob),
controller and accelerator actuator. The schematic diagram is shown below: #907 and #904 are drive
control lines. The controller is driven by 2 pins. If either pin is open-circuit, this can cause the accelerator
system fault. The accelerator potentiometer is used to control the engine speed. As shown in the figure,
Pin 1 of the R1 connector is connected to the 5V power, Pin 2 is connected to the controller-sensor
ground terminal and Pin 3 is connected to the accelerator signal feedback terminal. The accelerator
actuator controls the engine accelerator opening through the flexible shaft to control the engine speed.
The terminals are shown in the figure. Pin 3 of the M1 connector is the controller power (5V), pin 5 is
grounded, pin 2 is used for the accelerator feedback signal, pin 1 is used to control the accelerator
motor’s forward rotation and pin 4 is used to control the accelerator motor’s reverse rotation.
6-233
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.70 DTC 221104 Actuator AC1 Shorted to Ground
Component location
Front
Accelerator actuator
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position and disconnect the accelerator actuator connectors:
1. Check the connector for looseness, rust, bending and damage.
2. Measure the resistance between the accelerator actuator connector terminals 1 and 4 using
multimeter resistance function (normally, <100kΩ).
Whether the accelerator actuator fails?
YES NO
Repair or replace the accelerator actuator.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the accelerator actuator connector and disconnect the controller connector. Turn the
multimeter to its resistance function, and measure the resistance between the controller port J2-07 and
the grounding (normally, >100K).
When the resistance is abnormal, this indicates there is an insulation fault in the connector
Whether the connector is faulty?
YES NO
Replace the connector
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-235
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.71 DTC 221204 Actuator AC2 Shorted to Ground
System description
The accelerator control system mainly consists of the accelerator potentiometer (accelerator knob),
controller and accelerator actuator. The schematic diagram is shown below: #907 and #904 are drive
control lines. The controller is driven by 2 pins. If either pin is open-circuit, this can cause the accelerator
system fault. The accelerator potentiometer is used to control the engine speed. As shown in the figure,
Pin 1 of the R1 connector is connected to the 5V power, Pin 2 is connected to the controller-sensor
ground terminal and Pin 3 is connected to the accelerator signal feedback terminal. The accelerator
actuator controls the engine accelerator opening through the flexible shaft to control the engine speed.
The terminals are shown in the figure. Pin 3 of the M1 connector is the controller power (5V), pin 5 is
grounded, pin 2 is used for the accelerator feedback signal, pin 1 is used to control the accelerator
motor’s forward rotation and pin 4 is used to control the accelerator motor’s reverse rotation.
6-236
6.4 Fault Code December 30, 2017
6.4.71 DTC 221204 Actuator AC2 Shorted to Ground CLG930E/936E
Component location
Front
Accelerator actuator
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position and disconnect the accelerator actuator connectors:
1. Check the connector for looseness, rust, bending and damage.
2. Turn the multimeter to its resistance function, and measure the resistance between the actuator
connector terminal 1 and the grounding (normally, >100kΩ)
Whether the accelerator actuator fails?
YES NO
Repair or replace the accelerator actuator.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the accelerator actuator connector and disconnect the controller connector. Turn the
multimeter to its resistance function, and measure the resistance between the controller port J2-04 and
the grounding (normally, >100K).
When the resistance is abnormal, this indicates there is an insulation fault in the connector
Whether the connector is faulty?
YES NO
Replace the connector
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-238
6.4 Fault Code December 30, 2017
6.4.72 DTC 221305 Actuator AC1 Open-Circuited CLG930E/936E
System description
The accelerator control system mainly consists of the accelerator potentiometer (accelerator knob),
controller and accelerator actuator. The schematic diagram is shown below: #907 and #904 are drive
control lines. The controller is driven by 2 pins. If either pin is open-circuit, this can cause the accelerator
system fault. The accelerator potentiometer is used to control the engine speed. As shown in the figure,
Pin 1 of the R1 connector is connected to the 5V power, Pin 2 is connected to the controller-sensor
ground terminal and Pin 3 is connected to the accelerator signal feedback terminal. The accelerator
actuator controls the engine accelerator opening through the flexible shaft to control the engine speed.
The terminals are shown in the figure. Pin 3 of the M1 connector is the controller power (5V), pin 5 is
grounded, pin 2 is used for the accelerator feedback signal, pin 1 is used to control the accelerator
motor’s forward rotation and pin 4 is used to control the accelerator motor’s reverse rotation.
6-239
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.72 DTC 221305 Actuator AC1 Open-Circuited
Component location
Front
Accelerator actuator
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position and disconnect the accelerator actuator connectors:
1. Check the connector for looseness, rust, bending and damage.
2. Measure the resistance between the accelerator actuator connector terminals 1 and 4 using
multimeter resistance function (normally, <100kΩ).
Whether the accelerator actuator fails?
YES NO
Repair or replace the accelerator actuator.
Go to Step 4 Go to Step 2
Inspection method
1. Check the connecting harness (#907/904) between the controller and the accelerator actuator for
wear.
2. Disconnect the connectors from the accelerator actuator and the controller, respectively. Measure
the resistance value of the connecting harness (#907/904) between the controller and the actuator
using multimeter resistance function (normally, <10Ω).
Is the harness open-circuit?
YES NO
Connect the harness again and wrap the harness
Go to Step 3
Go to Step 4
Step 3 Check the connector for fault
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the accelerator actuator connector and disconnect the controller connector. Turn the
multimeter to its resistance function, and measure the resistance between the controller port J2-07
harness and J2-04 (normally, <100K).
When the resistance is abnormal, this indicates the connector is poorly contacted.
Whether the connector is faulty?
YES NO
Replace the connector
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-241
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.73 DTC 221306 Actuator AC1 Overcurrent
System description
The accelerator control system mainly consists of the accelerator potentiometer (accelerator knob),
controller and accelerator actuator. The schematic diagram is shown below: #907 and #904 are drive
control lines. The controller is driven by 2 pins. If either pin is open-circuit, this can cause the accelerator
system fault. The accelerator potentiometer is used to control the engine speed. As shown in the figure,
Pin 1 of the R1 connector is connected to the 5V power, Pin 2 is connected to the controller-sensor
ground terminal and Pin 3 is connected to the accelerator signal feedback terminal. The accelerator
actuator controls the engine accelerator opening through the flexible shaft to control the engine speed.
The terminals are shown in the figure. Pin 3 of the M1 connector is the controller power (5V), pin 5 is
grounded, pin 2 is used for the accelerator feedback signal, pin 1 is used to control the accelerator
motor’s forward rotation and pin 4 is used to control the accelerator motor’s reverse rotation.
6-242
6.4 Fault Code December 30, 2017
6.4.73 DTC 221306 Actuator AC1 Overcurrent CLG930E/936E
Component location
Front
Accelerator actuator
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position and disconnect the accelerator actuator connectors:
1. Check the connector for looseness, rust, bending and damage.
2. Measure the resistance between the accelerator actuator connector terminals 1 and 4 using
multimeter resistance function (normally, <10kΩ).
Whether the accelerator actuator fails?
YES NO
Repair or replace the accelerator actuator.
Go to Step 4 Go to Step 2
Inspection method
1. Check the harness (#907/#904) between the controller (J2-07 ,J7-04)and the accelerator actuator
for wear respectively.
Disconnect both the controller and the solenoid valve
2. Check the two harnesses for short-circuit: Turn the multimeter to its resistance function, and
measure the resistance of the harness (#907/#904) between the actuator terminals (normally,
>100K).
3. Check whether the harness is shorted to the battery. Turn the start switch to the ON position and
switch off the switches of all electrical equipment, and then measure the voltage between the
harness (#907/#904) actuator connecting terminal and the grounding (normally, 0V).
Whether the harness is shorted to the battery.
YES NO
Connect the harness again and wrap the harness
Go to Step 4 Go to Step 3
Step 3 Check the connector for fault
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the accelerator actuator connector and disconnect the controller connector. Turn the
multimeter to its resistance function, and measure the resistance between the controller port J2-07 and
J2-04 (normally, >10Ω).
When the resistance is abnormal, this indicates there is an insulation fault in the connector
Whether the connector is faulty?
YES NO
Replace the connector
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-244
6.4 Fault Code December 30, 2017
6.4.74 DTC 221405 Actuator AC2 Terminal Open-Circuited CLG930E/936E
System description
The accelerator control system mainly consists of the accelerator potentiometer (accelerator knob),
controller and accelerator actuator. The schematic diagram is shown below: #907 and #904 are drive
control lines. The controller is driven by 2 pins. If either pin is open-circuit, this can cause the accelerator
system fault. The accelerator potentiometer is used to control the engine speed. As shown in the figure,
Pin 1 of the R1 connector is connected to the 5V power, Pin 2 is connected to the controller-sensor
ground terminal and Pin 3 is connected to the accelerator signal feedback terminal. The accelerator
actuator controls the engine accelerator opening through the flexible shaft to control the engine speed.
The terminals are shown in the figure. Pin 3 of the M1 connector is the controller power (5V), pin 5 is
grounded, pin 2 is used for the accelerator feedback signal, pin 1 is used to control the accelerator
motor’s forward rotation and pin 4 is used to control the accelerator motor’s reverse rotation.
6-245
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.74 DTC 221405 Actuator AC2 Terminal Open-Circuited
Component location
Front
Accelerator actuator
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position and disconnect the accelerator actuator connectors:
1. Check the connector for looseness, rust, bending and damage.
2. Measure the resistance between the accelerator actuator connector terminals 1 and 4 using
multimeter resistance function (normally, <100kΩ).
Whether the accelerator actuator fails?
YES NO
Repair or replace the accelerator actuator.
Go to Step 4 Go to Step 2
Inspection method
1. Check the connecting harness (#907/904) between the controller and the accelerator actuator for
wear.
2. Disconnect the connectors from the accelerator actuator and the controller, respectively. Measure
the resistance value of the connecting harness (#907/904) between the controller and the actuator
using multimeter resistance function (normally, <10Ω).
Is the harness open-circuit?
YES NO
Connect the harness again and wrap the harness
Go to Step 4 Go to Step 3
Step 3 Check the connector for fault
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the accelerator actuator connector and disconnect the controller connector. Turn the
multimeter to its resistance function, and measure the resistance between the controller port J2-07
harness and J2-04 (normally, <100K).
When the resistance is abnormal, this indicates the connector is poorly contacted.
Whether the connector is faulty?
YES NO
Replace the connector
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-247
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.75 DTC 221406 Actuator AC2 Overcurrent
System description
The accelerator control system mainly consists of the accelerator potentiometer (accelerator knob),
controller and accelerator actuator. The schematic diagram is shown below: #907 and #904 are drive
control lines. The controller is driven by 2 pins. If either pin is open-circuit, this can cause the accelerator
system fault. The accelerator potentiometer is used to control the engine speed. As shown in the figure,
Pin 1 of the R1 connector is connected to the 5V power, Pin 2 is connected to the controller-sensor
ground terminal and Pin 3 is connected to the accelerator signal feedback terminal. The accelerator
actuator controls the engine accelerator opening through the flexible shaft to control the engine speed.
The terminals are shown in the figure. Pin 3 of the M1 connector is the controller power (5V), pin 5 is
grounded, pin 2 is used for the accelerator feedback signal, pin 1 is used to control the accelerator
motor’s forward rotation and pin 4 is used to control the accelerator motor’s reverse rotation.
6-248
6.4 Fault Code December 30, 2017
6.4.75 DTC 221406 Actuator AC2 Overcurrent CLG930E/936E
Component location
Front
Accelerator actuator
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to the OFF position and disconnect the accelerator actuator connectors:
1. Check the connector for looseness, rust, bending and damage.
2. Measure the resistance between the accelerator actuator connector terminals 1 and 4 using
multimeter resistance function (normally, <10kΩ).
Whether the accelerator actuator fails?
YES NO
Repair or replace the accelerator actuator.
Go to Step 4 Go to Step 2
Inspection method
1. Check the harness (#907/#904) between the controller (J2-07 ,J7-04)and the accelerator actuator
for wear respectively.
Disconnect both the controller and the solenoid valve
2. Check the two harnesses for short-circuit: Turn the multimeter to its resistance function, and
measure the resistance of the harness (#907/#904) between the actuator terminals (normally,
>100K).
3. Check whether the harness is shorted to the battery. Turn the start switch to the ON position and
switch off the switches of all electrical equipment, and then measure the voltage between the
harness (#907/#904) actuator connecting terminal and the grounding (normally, 0V).
Whether the harness is shorted to the battery.
YES NO
Connect the harness again and wrap the harness
Go to Step 4 Go to Step 3
Step 3 Check the connector for fault
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the accelerator actuator connector and disconnect the controller connector. Turn the
multimeter to its resistance function, and measure the resistance between the controller port J2-07 and
J2-04 (normally, >10Ω).
When the resistance is abnormal, this indicates there is an insulation fault in the connector
Whether the connector is faulty?
YES NO
Replace the connector
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-250
6.4 Fault Code December 30, 2017
6.4.76 DTC 231012 Abnormal Controller Heartbeat CLG930E/936E
System description
The controller is the core part of the excavator’s electrical control system and is responsible for the
complete machine operation mode and status, information processing, and various electronic control
functions.
Component location
Controller
Controller connector
Front
6-251
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.76 DTC 231012 Abnormal Controller Heartbeat
Inspection method
Dismantle the controller connector J1 (black)
Turn the multimeter to its voltage function, and measure the voltage between port 2, 3, 4, 5 & 6 of J1
and the ground, respectively. The voltage should be about 24V, otherwise, the controller power is not
sufficient.
Whether there is no power to the controller?
YES NO
Re-connect the harness
Go to Step 3 Go to Step 3
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-252
6.4 Fault Code December 30, 2017
6.4.77 DTC 231014 CAN Bus Communication Error CLG930E/936E
System description
The CAN bus can achieve real-time data exchange of various control units of the excavator.
Component location
GPS antenna
Display
GPS
6-253
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.77 DTC 231014 CAN Bus Communication Error
Inspection method
Dismantle the display connector C4 and the GPS connector C3.
Turn the multimeter to its on-off function, and check the harness (#751/# 752) between the port 5 (C3)
and the port 1 (C4)/between the port 8 (C3) and the port 8 (C4) for open-circuit.
Whether the display harness fails?
YES NO
Re-connect the harness
Go to Step 3 Go to Step 3
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-254
6.4 Fault Code December 30, 2017
6.4.78 DTC 241014 Accelerator Knob outside the Measurement Range CLG930E/936E
System description
Component location
Throttle Potentiometer
Controller
6-255
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.78 DTC 241014 Accelerator Knob outside the Measurement Range
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
1. Check the connector pins for looseness, rust, bending and damage. Check the connector inside for
moisture, oil dirt and other.
2. Turn the start switch to ON position, and measure the voltage (5V normal) of No.828 harness using
20V voltage band of the multimeter.
3. Turn the start switch to ON position, and measure the voltage of No.829 harness using 20V voltage
band of the multimeter, rotate the accelerator knob gradually from 1-12 position and measure the
voltage output of No.829 harness.
Whether the accelerator knob fails?
YES NO
Repair or replace the accelerator knob.
Go to Step 4 Go to Step 2
Step 2 Check the harness for short-circuit and open-circuit
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the actuator connector and disconnect the controller connector:
1. Turn the multimeter to its resistance function, and measure the resistance between the controller
port J1-28 and the grounding (normally, 4-5kΩ).
2. Turn the multimeter to its resistance function, and measure the resistance between the controller
ports J1-28 and J1-29 (normally, >10Ω).
An abnormal resistance indicates that there is fault in the connector.
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 4
Step 4 Check whether this fault is eliminated
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-257
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.79 DTC 251004 Fuel Pump Relay Shorted to Ground
K12
6-258
6.4 Fault Code December 30, 2017
6.4.79 DTC 251004 Fuel Pump Relay Shorted to Ground CLG930E/936E
Component location
Attached drawing
Controller
Controller connector
Front
6-259
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.79 DTC 251004 Fuel Pump Relay Shorted to Ground
Step 1 Check whether the harness connecting the controller port J2-6 is shorted to ground
Definition of
connector pin
serial number
Whether the harness connecting the controller port J2-6 is shorted to ground?
YES NO
Re-connect the harness, and wrap it.
Go to Step 3 Go to Step 2
6-260
6.4 Fault Code December 30, 2017
6.4.79 DTC 251004 Fuel Pump Relay Shorted to Ground CLG930E/936E
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-261
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.80 DTC 251005 Fuel Pump Relay Open-Circuited or Shorted to the Battery
K12
6-262
6.4 Fault Code December 30, 2017
6.4.80 DTC 251005 Fuel Pump Relay Open-Circuited or Shorted to the Battery CLG930E/936E
Component location
Attached drawing
Controller
Controller connector
Front
6-263
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.80 DTC 251005 Fuel Pump Relay Open-Circuited or Shorted to the Battery
Definition of
connector pin
serial number
6-264
6.4 Fault Code December 30, 2017
6.4.80 DTC 251005 Fuel Pump Relay Open-Circuited or Shorted to the Battery CLG930E/936E
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-265
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.81 DTC 261011 GPS Antenna Fault
System description
Use the GPS (Global Positioning System) to position the machine and use the GSM mobile
communication network to achieve the two-way data exchange with the central control center to realize
remote monitoring and control.
Component location
GPS antenna
Display
GPS
System description
Use the GPS (Global Positioning System) to position the machine and use the GSM mobile
communication network to achieve the two-way data exchange with the central control center to realize
remote monitoring and control.
Component location
GPS antenna
Display
GPS
System description
Use the GPS (Global Positioning System) to position the machine and use the GSM mobile
communication network to achieve the two-way data exchange with the central control center to realize
remote monitoring and control.
Component location
GPS antenna
Display
GPS
System description
System description
Use the GPS (Global Positioning System) to position the machine and use the GSM mobile
communication network to achieve the two-way data exchange with the central control center to realize
remote monitoring and control.
6-272
6.4 Fault Code December 30, 2017
6.4.86 DTC 261512 Abnormal GPS Heartbeat CLG930E/936E
Component location
GPS antenna
Display
GPS
Step 1 Check whether the GPS connector becomes loose and falls off.
Inspection method
Manually check the GPS connector for looseness or fall-off
Whether the GPS connector becomes loose and falls off?
YES NO
Tighten the GPS connector.
Go to Step 3 Go to Step 2
Inspection method
Turn the start switch to the ON position.
Dismantle the GPS connector C3. Make sure no pin of the connector is bent. Turn the multimeter to its
voltage function, and measure the voltage between the connector terminal 4 and the grounding. The
voltage should be 24V. Otherwise, a fault develops in the harness (No. 149).
Whether the power cable has fault?
YES NO
Rewire.
Go to Step 3 Go to Step 3
6-273
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.86 DTC 261512 Abnormal GPS Heartbeat
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-274
6.4 Fault Code December 30, 2017
6.4.87 DTC 261611 Automatic Locking Level 1 Abnormal GPS Heartbeat, the Machine is Limited for Use
System description
Use the GPS (Global Positioning System) to position the machine and use the GSM mobile
communication network to achieve the two-way data exchange with the central control center to realize
remote monitoring and control.
6-275
December 30, 2017 6.4 Fault Code
CLG930E/936E 6.4.87 DTC 261611 Automatic Locking Level 1 Abnormal GPS Heartbeat, the Machine is
Component location
GPS antenna
Display
GPS
Step 1 Check whether the GPS connector becomes loose and falls off.
Inspection method
Manually check the GPS connector for looseness or fall-off
Whether the GPS connector becomes loose and falls off?
YES NO
Tighten the GPS connector.
Go to Step 3 Go to Step 2
Inspection method
Turn the start switch to the ON position.
Dismantle the GPS connector C3. Make sure no pin of the connector is bent. Turn the multimeter to its
voltage function, and measure the voltage between the connector terminal 4 and the grounding. The
voltage should be 24V. Otherwise, a fault develops in the harness (No. 149).
Whether the power cable has fault?
YES NO
Rewire.
Go to Step 3 Go to Step 3
6-276
6.4 Fault Code December 30, 2017
6.4.87 DTC 261611 Automatic Locking Level 1 Abnormal GPS Heartbeat, the Machine is Limited for Use
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-277
December 30, 2017 6.4 Fault Code
CLG930E/936E6.4.88 DTC 261614 Forced Locking Level 1 Payment Expired, the Machine is Limited for Use
System description
Use the GPS (Global Positioning System) to position the machine and use the GSM mobile
communication network to achieve the two-way data exchange with the central control center to realize
remote monitoring and control.
System description
Use the GPS (Global Positioning System) to position the machine and use the GSM mobile
communication network to achieve the two-way data exchange with the central control center to realize
remote monitoring and control.
6-279
December 30, 2017 6.4 Fault Code
CLG930E/936E6.4.89 DTC 261711 Automatic Locking Level 2 Abnormal GPS Heartbeat, and the Machine is
Component location
GPS antenna
Display
GPS
Step 1 Check whether the GPS connector becomes loose and falls off.
Inspection method
Manually check the GPS connector for looseness or fall-off
Whether the GPS connector becomes loose and falls off?
YES NO
Tighten the GPS connector.
Go to Step 3 Go to Step 2
Inspection method
Turn the start switch to the ON position.
Dismantle the GPS connector C3. Make sure no pin of the connector is bent. Turn the multimeter to its
voltage function, and measure the voltage between the connector terminal 4 and the grounding. The
voltage should be 24V. Otherwise, a fault develops in the harness (No. 149).
Whether the power cable has fault?
YES NO
Rewire.
Go to Step 3 Go to Step 3
6-280
6.4 Fault Code December 30, 2017
6.4.89 DTC 261711 Automatic Locking Level 2 Abnormal GPS Heartbeat, and the Machine is Prohibited for
Inspection method
Turn the start switch to the ON position and re-check for fault.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
6-281
December 30, 2017 6.4 Fault Code
CLG930E/936E6.4.90 DTC 261714 Forced Locking Level 2 Overdue Payment, and the Machine is Prohibited
6.4.90 DTC 261714 Forced Locking Level 2 Overdue Payment, and the
Machine is Prohibited for Use
System description
Use the GPS (Global Positioning System) to position the machine and use the GSM mobile
communication network to achieve the two-way data exchange with the central control center to realize
remote monitoring and control.
System description
System description
The battery functions: Store the electric energy; when the engine starts and powers the motor; for
gasoline engine, it can power the igniter; stabilize the system voltage; when the alternator does not
generate electricity or the voltage is low, the battery powers the electric equipment; when the alternator
is overloaded because of too many electric equipment, the battery assists the alternator to power; the
battery is equivalent to a big capacitor, it will protect the components and parts in case of transient
overvoltage.
Hydrometer
OK
Change
Replace
Component location
6-283
December 30, 2017 6.5 Fault Diagnosis of Electrical System
CLG930E/936E 6.5.1 Troubleshooting Solution for E1-Battery Power Loss
Notice: Check the battery hydrometer color when the ignition switch is in OFF position.
Inspection method
1. Check the color of the battery hydrometer through the opening on the cover of the battery, black
means that the battery needs to be charged.
2. Measure the voltage on both ends of the battery with a multimeter: use DC voltage gear (200V) of
multimeter, connect the red probe to the positive terminal and the black probe to the negative
terminal. Under the normal condition, the voltage is 24V. If the voltage is too low, the battery needs
to be charged.
Whether the battery needs to be charged or not?
YES NO
Charge the battery
Go to Step 3 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
The machine does not work for a long time and the battery has not been charged so it is lack of power
seriously. Check it by referring to E2.
Is the battery aging and lack of power?
YES NO
Replace it with a new one.
Go to Step 3 Go to Step 3
Step 3 Check whether this fault is eliminated
Inspection method
After replacing a new battery, connect the battery firmly.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
steps or contact the local LiuGong dealers and
Maintenance is over authorized service centers.
Return
6-284
6.5 Fault Diagnosis of Electrical System December 30, 2017
6.5.2 E2 Abnormal Battery CLG930E/936E
System description
The battery functions: Store the electric energy; when the engine starts and powers the motor; for
gasoline engine, it can power the igniter; stabilize the system voltage; when the alternator does not
generate electricity or the voltage is low, the battery powers the electric equipment; when the alternator
is overloaded because of too many electric equipment, the battery assists the alternator to power; the
battery is equivalent to a big capacitor, it will protect the components and parts in case of transient
overvoltage.
Common maintenance: the electric quantity of the battery can be learned by the change of the
hydrometer color. Green – normal, black – requiring to be charged, white – the battery is scrap.
Hydrometer
OK
Change
Replace
Component location
6-285
December 30, 2017 6.5 Fault Diagnosis of Electrical System
CLG930E/936E 6.5.2 E2 Abnormal Battery
Notice: Check the battery hydrometer color when the ignition switch is in OFF position.
Inspection method
Check the color of battery hydrometer through the opening on the cover of the battery.
Is the color of battery hydrometer green?
YES NO
The battery level is normal.
Go to Step 4 Go to Step 2
Notice: Check the battery hydrometer color when the ignition switch is in OFF position.
Inspection method
Check the color of battery hydrometer through the opening on the cover of the battery.
Is the color of battery hydrometer black?
YES NO
Charge the battery
Go to Step 4 Go to Step 3
Notice: Check the battery hydrometer color when the ignition switch is in OFF position.
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Check the color of battery hydrometer through the opening on the cover of the battery.
Is the color of battery hydrometer white?
YES NO
Repair or replace battery
Go to Step 4 Go to Step 4
6-286
6.5 Fault Diagnosis of Electrical System December 30, 2017
6.5.2 E2 Abnormal Battery CLG930E/936E
Inspection method
Check the color of battery hydrometer through the opening on the cover of the battery.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
steps or contact the local LiuGong dealers and
Maintenance is over authorized service centers.
Return
6-287
December 30, 2017 6.5 Fault Diagnosis of Electrical System
CLG930E/936E 6.5.3 E3 Automatic Slowdown Failed
Component location
Display
Handle pressure switch Accelerator knob
Pressure switch
of appurtenances
6-288
6.5 Fault Diagnosis of Electrical System December 30, 2017
6.5.3 E3 Automatic Slowdown Failed CLG930E/936E
Step 1 Operate the automatic idle speed control key to cancel the automatic idle speed function.
Inspection method
Turn the ignition switch to ON state, and then check the alarm on the display.
Whether 121305, 121405, 231012, 231014 alarm appears on the display or not?
YES NO
Overhaul the machine in accordance with the
corresponding fault diagnosis and troubleshooting
steps of the DTC.
Go to Step 4 Go to Step 4
6-289
December 30, 2017 6.5 Fault Diagnosis of Electrical System
CLG930E/936E 6.5.3 E3 Automatic Slowdown Failed
System description
In the condition where there is no fault on the machine and the excavator is started in the correct steps,
the pilot shut-off valve switch will be in normally closed state.
When the electric lock is turned to "On" position, the battery will power B1 end of the electric lock via
No.004 wire, 50A fuse, No.005, electric lock power supply 20A fuse and N0.110 wire. Connect B2 end of
the electric lock in the electric lock. B2 end controls the battery relay closed via No.145 wire, diode D6
and No.155 wire. B2 end powers the holding coil of the oil cut-off valve via No.146 and the coil
commander. In the meantime, B2 end powers 86 end of the starter relay K10 via No.144, the starter
relay K10 will be closed. The starter relay K10 will control pilot control relay K7 closed via end 81 of the
starter relay K10, No.300 wire, pilot shut-off valve switch and No.310 wire.
When the electric lock is turned to "Start" position, the end S gets connected to the power. The end S
powers the end 30 of the pilot control relay K7 via No.180 wire, and powers starter relay K1 and oil shut-
off valve relay K2 simultaneously via end 30 of the pilot control relay K7, end 87 of the pilot control relay
K7, No.525 wire, 87 A end of controller control starter relay K8 and No.181 wire; starter relay K1 and oil
shut-off valve relay K2 will be closed during the power supply. The battery powers push-pull coil of the oil
cut-off valve via battery relay, No.105 wire, 50A fuse, No.136 wire, No.138 wire, oil shut-off valve relay
K2, No.183 wire and the coil commander, promoting oil shut-off valve will be closed and connecting to
the diesel fuel supply passage of the engine. In the meantime, the battery controls starter Motor closed
via the battery relay, No.105 wire, 50A fuse, No.136, starter relay K1, No.182 and end 50 of the starter
Motor, the starter Motor will rotate. Drive the crankshaft of engine to rotate. Then engine is energized.
6-291
December 30, 2017 6.5 Fault Diagnosis of Electrical System
CLG930E/936E 6.5.4 E4 Engine cannot be Started
6-292
6.5 Fault Diagnosis of Electrical System December 30, 2017
6.5.4 E4 Engine cannot be Started CLG930E/936E
K7 K8
6-293
December 30, 2017 6.5 Fault Diagnosis of Electrical System
CLG930E/936E 6.5.4 E4 Engine cannot be Started
Component location
Starting motor
Fuse box
Pilot cut-off
valve switch
Inspection method
Check the fuel level.
Whether the fuel level is too low or not?
YES NO
Refuel.
Go to Step 15 Go to Step 3
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
1. Turn the start switch to ON state, and then check the display for the alarm with the fault code of
101001and 101017.
2. Measure the storage battery voltage with the multimeter: Turn the multimeter to its DC voltage
function (200V), and connect the red probe to the positive storage battery terminal and the black
probe to the negative storage battery terminal. See the schematic diagram for detection as follows:
Black probe
Red probe
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Measure the resistance between each two contacts of safety relay K10 with a multimeter.
1. Remove the safety relay K10, and then measure the resistance among all contacts.
The resistance between 85 and 86 (coil resistance) is approx. 320-360Ω.
The resistance between 30 and 87 is infinite.
The resistance between 30 and 87a is less than 10Ω.
2. Switch on 24V power to both ends of 85 and 86, and measure the resistance between each two
contacts.
The resistance between 30 and 87 is less than 10Ω.
The resistance between 30 and 87a is infinite.
Whether safety relay K10 fails?
YES NO
Replace the safety relay.
Go to Step 15 Go to Step 8
6-297
December 30, 2017 6.5 Fault Diagnosis of Electrical System
CLG930E/936E 6.5.4 E4 Engine cannot be Started
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Measure the resistance among all contacts of pilot control starter relay K7 with a multimeter.
1. Remove pilot control start relay K7, and then measure the resistance among all contacts.
The resistance between 85 and 86 (coil resistance) is approx. 320-360Ω.
The resistance between 30 and 87 is infinite.
The resistance between 30 and 87a is less than 10Ω.
2. Switch on 24V power to both ends of 85 and 86, and measure the resistance between each two
contacts.
The resistance between 30 and 87 is less than 10Ω.
The resistance between 30 and 87a is infinite.
Whether the starter relay K7 controlled by the pilot fails or not?
YES NO
Replace the pilot control starter relay.
Go to Step 15 Go to Step 9
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Measure the resistance among all contacts of starter relay K8 controlled by controller with a multimeter.
1. Remove start relay K8 controlled by controller, and then measure the resistance among all
contacts.
The resistance between 85 and 86 (coil resistance) is approx. 320-360Ω.
The resistance between 30 and 87 is infinite.
The resistance between 30 and 87a is less than 10Ω.
2. Switch on 24V power to both ends of 85 and 86, and measure the resistance between each two
contacts.
The resistance between 30 and 87 is less than 10Ω.
The resistance between 30 and 87a is infinite.
Whether starter relay K8 controlled by controller fails or not?
YES NO
Replace the starter relay controlled by a controller.
Go to Step 15 Go to Step 10
6-298
6.5 Fault Diagnosis of Electrical System December 30, 2017
6.5.4 E4 Engine cannot be Started CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Measure the resistance among all contacts of starter relay K1 with a multimeter.
1. Remove the start relay K1, and then measure the resistance among all contacts.
The resistance of coil is about79-81Ω.
The resistance of the main contact is infinite.
2. Supply 24V power to both ends of the coil and measure the resistance between two main contacts.
The resistance of the main contacts is less than 10Ω.
Oil cut-off valve relay K2 for fault?
YES NO
Replace oil cut-off valve relay.
Go to Step 15 Go to Step 11
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Measure the resistance among all contacts of starter relay K1 with a multimeter.
1. Remove the start relay K1, and then measure the resistance among all contacts.
The resistance of coil is about 80Ω.
The resistance of the main contact is infinite.
2. Supply 24V power to both ends of the coil and measure the resistance between two main contacts.
The resistance of the main contacts is less than 10Ω.
Whether starter relay K1 fails or not?
YES NO
Replace the starter relay.
Go to Step 15 Go to Step 12
6-299
December 30, 2017 6.5 Fault Diagnosis of Electrical System
CLG930E/936E 6.5.4 E4 Engine cannot be Started
Notice: Remove the wiring on the input end 50 and end 30 on the starter motor.
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
1. Turn the start switch to ON position, and then measure the voltage to earth of wire 108 on the end
50, and make sure it is 24V.
2. Turn the start switch to START position, and then measure the voltage between the harness (# 182)
at end 30 and the grounding, and the voltage is 24V.
If the input signals are normal, but the starter motor does not rotate, it can be judged that there is a fault
in the starter motor.
Whether the start motor has fault or not?
YES NO
Replace the starter motor.
Go to Step 15 Go to Step 13
6-300
6.5 Fault Diagnosis of Electrical System December 30, 2017
6.5.4 E4 Engine cannot be Started CLG930E/936E
Inspection method
Operate the machine, and check whether each action is normal.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
steps or contact the local LiuGong dealers and
Maintenance is over authorized service centers.
Return
6-302
6.5 Fault Diagnosis of Electrical System December 30, 2017
6.5.5 E5 Preheater does not Work CLG930E/936E
System description
The preheating function is divided into manual preheating and automatic preheating. Manual preheating
means to turn the start switch from OFF position to HEAT position, preheating relay K3 is closed, and the
battery supplies power to the pre-heater of the engine. Automatic preheating means that the controller
can make judgment based on the external environment to determine whether it requires preheating or
not. When preheating is required in accordance with the judgment, the output of J2-11 on controller is
24V, which drives the automatic preheating relay K9 to be closed to make preheating relay K3
energized, so that the preheating relay K3 is closed and the battery supplies power to the pre-heater of
the engine. The figure below is the electrical circuit diagram of engine preheater.
6-303
December 30, 2017 6.5 Fault Diagnosis of Electrical System
CLG930E/936E 6.5.5 E5 Preheater does not Work
6-304
6.5 Fault Diagnosis of Electrical System December 30, 2017
6.5.5 E5 Preheater does not Work CLG930E/936E
Component location
Preheater
Ignition switch
Fuse box
Engine controller
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Measure the resistance between each two contacts of preheating relay K3 with a multimeter.
1. Remove the preheat relay K3, and then measure the resistance among all contacts.
The resistance of coil is about 61-63Ω.
The resistance of the main contact is infinite.
2. Supply 24V power to both ends of the coil and measure the resistance between two main contacts.
The resistance of the main contacts is less than 10Ω.
Is there a fault in the preheating relay?
YES NO
Replace the preheating relay.
Go to Step 7 Go to Step 3
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to HEAT position, when the voltage measured between the terminal of pre-heater
and the ground is 24V, if the pre-heater still does not work, it can be determined as the internal fault of
the pre-heater.
Is there a fault in the pre-heater?
YES NO
Replace the preheater.
Go to Step 7 Go to Step 7
Inspection method
Operate the machine, and check whether each action is normal.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
steps or contact the local LiuGong dealers and
Maintenance is over authorized service centers.
Return
6-308
6.5 Fault Diagnosis of Electrical System December 30, 2017
6.5.6 E8 All the Work Implements, Revolving and Traveling cannot Move CLG930E/936E
6.5.6 E8 All the Work Implements, Revolving and Traveling cannot Move
System description
Power on, pull up the shut-off switch of pilot solenoid valve to connect wire 300 and 481, at this time, the
electrical circuit of the pilot shut-off solenoid valve is connected, and the oil path of the pilot shut-off
solenoid valve is open, so the hydraulic system starts running. The following is the electrical circuit
diagram of the pilot shut-off.
6-309
December 30, 2017 6.5 Fault Diagnosis of Electrical System
CLG930E/936E 6.5.6 E8 All the Work Implements, Revolving and Traveling cannot Move
Component location
Ignition switch
Fuse box
Pilot cut-off valve switch
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Unplug the fuse 1 by a fuse clip, visually check whether the fuse is blown or check whether both ends
of the fuse are connected by the multimeter on the diode gear.
Note: There may be grounding fault, so please refer to step 5.
Is fuse 1 blown?
YES NO
Replace the fuse
Go to Step 6 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
While pulling up the shutoff switch of pilot solenoid valve, the pin 2 and pin 3 on the shutoff switch of
pilot solenoid valve are connected, and at this time measure the shutoff switch with a multimeter on the
diode position.
Is the switch closed?
YES NO
Repair or replace the shut-off switch of the pilot
solenoid valve.
Go to Step 6 Go to Step 3
6-310
6.5 Fault Diagnosis of Electrical System December 30, 2017
6.5.6 E8 All the Work Implements, Revolving and Traveling cannot Move CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Measure the resistance between each two contacts of safety relay K10 with a multimeter.
1. Remove the safety relay K10, and then measure the resistance among all contacts.
The resistance between 85 and 86 (coil resistance) is approx. 320-360Ω.
The resistance between 30 and 87 is infinite.
The resistance between 30 and 87a is less than 10Ω.
2. Switch on 24V power to both ends of 85 and 86, and measure the resistance between each two
contacts.
The resistance between 30 and 87 is less than 10Ω.
The resistance between 30 and 87a is infinite.
Is there a fault in the safety relay?
YES NO
Repair or replace safe relay.
Go to Step 6 Go to Step 4
Inspection method
Operate the machine, and check whether each action is normal.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
steps or contact the local LiuGong dealers and
Maintenance is over authorized service centers.
Return
6-313
December 30, 2017 6.5 Fault Diagnosis of Electrical System
CLG930E/936E 6.5.7 E9 Display Panel Showing Nothing
Component location
Fuse box
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Unplug the fuse 15 by a fuse clip, visually check whether the fuse is blown or check whether both ends
of the fuse are connected by the multimeter on the diode gear.
Note: There may be grounding fault, so please refer to step 3.
Is fuse 15 blown?
YES NO
Replace the fuse.
Go to Step 2
Go to Step 5
6-315
December 30, 2017 6.5 Fault Diagnosis of Electrical System
CLG930E/936E 6.5.7 E9 Display Panel Showing Nothing
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to ON position, check the power supply with the multimeter, when all the following
conditions are satisfied, if the display is still off, it can be determined as internal fault of the display.
1. The voltage to ground of the display C4 (6) is 24V
2. The voltage to ground of the display C4 (7) is 24V
3. The voltage to ground of the display C4 (26) is 24V
4. The voltage to ground of the display C4 (5) is 0V
5. The voltage to ground of the display C4 (10) is 0V
Whether the display is faulty?
YES NO
Replace the display.
Go to Step 5 Go to Step 5
Inspection method
Operate the machine, and check whether each action is normal.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
steps or contact the local LiuGong dealers and
Maintenance is over authorized service centers.
Return
6-317
December 30, 2017 6.5 Fault Diagnosis of Electrical System
CLG930E/936E 6.5.8 E8- Incorrectly Displayed Hydraulic Oil Temperature
Coolant temperature
(Celsius degree )
Resistance (Ohm)
Component location
Front
Hydraulic oil
temperature
sensor
6-318
6.5 Fault Diagnosis of Electrical System December 30, 2017
6.5.8 E8- Incorrectly Displayed Hydraulic Oil Temperature CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the knob start switch to OFF position and disconnect sensor connector:
1. Check the connector for looseness, rust, bending and damage.
2. Turn the multimeter to its resistance function (20kΩ), and measure the resistance between the
sensor connector terminals 1 and 2, comparing the result with the parameter table (normally, <4kΩ).
Whether the hydraulic oil temp sensor fails?
YES NO
Replace the hydraulic oil temp sensor.
Go to Step 4 Go to Step 2
Inspection method
Operate the machine, and check whether each action is normal.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
steps or contact the local LiuGong dealers and
Maintenance is over authorized service centers.
Return
6-320
6.5 Fault Diagnosis of Electrical System December 30, 2017
6.5.9 E11 Fuel Gauge cannot Display correctly CLG930E/936E
LG922E930E06032
Oil level
Component location
Front
Notice: When replacing the components, please be sure to use LiuGong parts.
Notice: High temperature and high pressure oil or water can cause personal injury! When
replacing the sensor, please shut down the engine first and wait until the engine and gearbox
housing are sufficiently cooled.
Notice: When installing the fuel level sensor into the fuel tank, wipe off the water and keep
it clean.
Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the fuel level sensor:
1. Check the connector for looseness, rust, bending and damage.
2. Turn the multimeter to its resistance function, and measure the resistance between the fuel level
sensor connector terminals 1 and 2 (normally, <2kΩ, for the specific resistance, see the figure.).
Gray wire
(2) Turn the multimeter to its resistance function, and measure the resistance between the connector
terminals J2-30 and sensor harness (normally, <10Ω).
White wire
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Connect the fuel-level sensor connector and disconnect the controller connector. Turn the multimeter to
its resistance function, and measure the resistance between the harness at the controller port J2-30
and the grounding (normally, 2 kΩ, for the specific resistance, see the attached drawing).
White wire
When the resistance is abnormal, this indicates the connector is poorly contacted.
Whether the connector is faulty?
YES NO
Replace the connector.
Go to Step 4 Go to Step 4
Inspection method
Turn the start switch to the ON position and re-check the DTC.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
steps or contact the local LiuGong dealers and
Maintenance is over authorized service centers.
Return
6-325
December 30, 2017 6.5 Fault Diagnosis of Electrical System
CLG930E/936E 6.5.10 E10 Windshield Wiper out of Work
Component location
Wiper switch
Wiper motor
Fuse box
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Disconnect connector S1, check the connection condition of pins with the multimeter when the wiper
switch is turned to different positions, when there is no fault in the wiper switch, the connection
condition of pins are shown as follows:
1. When the wiper switch is in the 0 position, the resistance between pin 5 and pin 7 of S1 is less than
10Ω, the resistance between pin 1 and pin 3 is infinite, and the resistance between pin 5 and pin 3
is infinite.
2. When the wiper switch is in the 1 position, the resistance between pin 5 and pin 3 of S1 is less than
10Ω, the resistance between pin 1 and pin 3 is infinite, and the resistance between pin 7 and pin 3
is infinite.
3. When the wiper switch is in the 2 position, the resistance between pin 1 and pin 3 of S1 is less than
10Ω, the resistance between pin 5 and pin 3 is infinite, and the resistance between pin 7 and pin 3
is infinite.
Is the wiper switch damaged?
YES NO
Replace the wiper switch
Go to Step 6 Go to Step 3
6-328
6.5 Fault Diagnosis of Electrical System December 30, 2017
6.5.10 E10 Windshield Wiper out of Work CLG930E/936E
Notice: Properly pack up the harness and leads: prevent the harness from being folded and
bent forcedly. It shall be kept away from moving components as far as possible to prevent
tensile failure and wear. Avoid friction with sharp metal edges. Keep away from oil and water as
far as possible. Keep away from high temperature parts (e.g. engine block) as far as possible.
Inspection method
Remove the battery cable (-), and turn the start switch to OFF position, measure the resistance of the
following circuit, and the resistance shall be less than 10Ω in normal condition.
1. Wiper switch S1 (female 1) - X3 (female3)- wiper motor M4 (female 2)
2. Wiper switch S1 (female 5) - X3 (2) -wiper motor M4 (female 3)
3. Wiper switch S1 (female 7) - X3 (1) -wiper motor M4 (female 1)
4. Wire 102 on the main contact of battery relay - X2(14) - main contact and end 86 of wiper relay K6 -
X1(24) - wiper switch S1 (female 3) -X3(4)- wiper motor M4 (female 6)
5. End 85 on the wiper relay K6 - X2(4) - X5(1) - door control wiper switch- X5(2) - frame ground
(GND)
Is the harness open-circuit?
YES NO
Connect the harness again and wrap the harness
Go to Step 6 Go to Step 4
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Turn the start switch to ON position, check the power supply of the wiper motor with the multimeter;
when all the following conditions are satisfied, if the wiper motor is still off, it can be determined as
internal fault of the wiper motor.
1. When the wiper switch is in position 0, the voltage to ground of M4 (female 6) is 24V, and the
voltage to ground of M4 (female 4) is 0V.
2. When the wiper switch is in position 1, the voltage to ground of M4 (female 3) is 24V.
3. When the wiper switch is in position 2, the voltage to ground of M4 (female 2) is 24V.
Is the wiper motor damaged?
YES NO
Replace the wiper switch
Go to Step 6 Go to Step 6
Inspection method
Operate the wiper system and check whether each action is normal.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
steps or contact the local LiuGong dealers and
Maintenance is over authorized service centers.
Return
6-330
6.5 Fault Diagnosis of Electrical System December 30, 2017
6.5.11 E13 Backup Alarm unable to Sound CLG930E/936E
Component location
Front
Traveling alarm
Notice: properly pack up the harness and leads: prevent the harness from being folded and
bent forcedly. It shall be kept away from moving components as far as possible to prevent
tensile failure and wear. Avoid friction with sharp metal edges. Keep away from oil and water as
far as possible. Keep away from high temperature parts (e.g. engine block) as far as possible.
Inspection method
Remove the battery cable (-), and turn the start switch to OFF position, measure the resistance of the
following circuit, and the resistance shall be less than 10Ω in normal condition.
1. Main controller J1 (female 1) – travel alarm N3 (female 1)
2. Travel alarm N3 (female 2) – frame ground
3. Main controller J2 (female 13) – foot controlled oil circuit pressure switch P10 (female 1)
4. Foot controlled oil circuit pressure switch P10 (female 2) - frame GND
Is the harness open-circuit?
YES NO
Connect the harness again and wrap the harness
Go to Step 4 Go to Step 2
6-332
6.5 Fault Diagnosis of Electrical System December 30, 2017
6.5.11 E13 Backup Alarm unable to Sound CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Start the complete machine but do not pull up the pilot shut-off valve switch, unplug connector P10 of
the foot controlled oil circuit pressure switch, and measure the voltage value of N3 (female 1) over the
ground with a multimeter. The voltage is 24 V under normal conditions.
Whether the travel alarm is damaged?
YES NO
Replace the travel alarm
Go to Step 4 Go to Step 4
Inspection method
Operate the wiper system and check whether each action is normal.
Has this fault been eliminated?
YES NO
Troubleshoot again the faults according to the
steps or contact the local LiuGong dealers and
Maintenance is over authorized service centers.
Return
6-333
December 30, 2017 6.5 Fault Diagnosis of Electrical System
CLG930E/936E 6.5.12 E14 A/C Panel unable to Display
System description
Vent
Vent servo
motor
Foot vent
Water tempera-
ture sensor
Bottom view
Internal air
sensor
Expansion valve
inlet
Internal-to-external
air switching motor
Expansion valve
outlet
6-335
December 30, 2017 6.5 Fault Diagnosis of Electrical System
CLG930E/936E 6.5.12 E14 A/C Panel unable to Display
Rear view
Frost-prevention
probe
Switch
Fan motor
LG922E930E06130
6-336
6.5 Fault Diagnosis of Electrical System December 30, 2017
6.5.12 E14 A/C Panel unable to Display CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Check whether the voltage of the base machine harness (# 128) with mutually plugged A/C harness in
the cab is 24V with a multimeter.
Check the wire # 128 having 24V voltage?
YES NO
Find out the reason according to Step 2. Check whether A/C 30A fuse is damaged.
Go to Step 2 Go to Step 3
Step 2: Wire grounding fault - failed to connect with the ground wire;
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Check whether the base machine harness (# 210) with mutually plugged A/C harness in the cab is
grounded well with a multimeter.
Is there an open circuit in the grounding wire?
YES NO
Troubleshoot the grounding circuit of base
Find out the reason according to Step 3
machine harness.
Go to Step 4
Go to Step 6
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Check A/C 30A fuse, visibly check whether the fuse is blown or check whether both ends of the fuse
are connected by the multimeter on the diode gear.
Is A/C 30A fuse blown?
YES NO
Replace A/C 30A fuse. Find out the reason according to Step 4.
Go to Step 6 Go to Step 4
6-337
December 30, 2017 6.5 Fault Diagnosis of Electrical System
CLG930E/936E 6.5.12 E14 A/C Panel unable to Display
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Check 5A fuse of the evaporator as wire harness in the cab. Visibly check whether the fuse blows or
check whether both ends of the fuse are connected by the multimeter on the diode gear.
Whether the A/C panel fuse is faulty?
YES NO
Replace fuse of the A/C panel
Go to Step 6 Go to Step 5
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Press the blowing rate switch, the air volume should be displayed in the A/C panel, and turn on the
LCD; after pressing other keys, indicators come on or corresponding icons are displayed on the LCD.
Whether the A/C panel is faulty?
YES NO
Replace the A/C panel
Go to Step 6 Go to Step 6
Inspection method
Operate the machine, and check whether each action is normal.
Has this fault been eliminated?
YES NO
Look for the electrical system fault or contact local
Maintenance is over
LiuGong dealers and authorized service centers.
6-338
6.5 Fault Diagnosis of Electrical System December 30, 2017
6.5.13 E13 A/C no Wind or Abnormal Air Volume CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Measure the resistance between each two contacts of blower main relay with a multimeter, and judge
whether relay is damaged according to the resistance value provided in the following table.
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Press the air regulation switch on the A/C panel, and feel whether outlet airflow is changed with
adjustment of the blowing rate switch.
Whether outlet airflow is changed with adjustment of the blowing rate switch?
YES NO
Replace the power transistor
Go to Step 3 Go to Step 6
6-339
December 30, 2017 6.5 Fault Diagnosis of Electrical System
CLG930E/936E 6.5.13 E13 A/C no Wind or Abnormal Air Volume
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Unplug the blower motor plug at the back of the evaporator assembly, and check whether there is short
circuit or open circuit of blower coil winding with a multimeter.
Whether the blower is faulty?
YES NO
Replace the blower. Find out the reason according to Step 4
Go to Step 6 Go to Step 4
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Check whether connectors of A/C harness are connected stably, and whether there is open circuit or
short circuit caused by damage of wires.
Whether A/C wiring is abnormal?
YES NO
Check circuit fault points and repair them.
Go to Step 6 Go to Step 5
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
If the A/C panel is checked to be normal through step 1 to step 4, it may have been damaged.
Whether the A/C panel is faulty?
YES NO
Replace the A/C panel.
Go to Step 6 Go to Step 6
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Check whether the electromagnetic coil of the compressor clutch relay is open with a multimeter.
Whether the compressor clutch relay is faulty?
YES NO
Replace the compressor clutch relay
Go to Step 8 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
The internal sensor may fail and diagnose the fault of internal sensor
Whether the internal air sensor fails?
YES NO
Replace the internal air sensor.
Go to Step 3
Go to Step 8
6-341
December 30, 2017 6.5 Fault Diagnosis of Electrical System
CLG930E/936E 6.5.14 E16 Poor A/C Refrigeration
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Unplug the pressure protection switch wiring harness on the high-pressure side connector of the
expansion valve, and use a multimeter to check whether both ends of the pressure switch is connected.
When the system pressure is larger than 0.196 MPa and less than 3.14 MPa, the pressure switch shall
be connected.
Is the high/ low pressure protective switch not damaged?
YES NO
Replace the high and low voltage protection
switch.
Go to Step 8 Go to Step 4
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Unplug the compressor clutch plug, and use a multimeter to check whether the compressor clutch coil
is open. Whether the compressor grounding wire is in good condition?
Whether there is a fault in the compressor clutch?
YES NO
Replace the A/C compressor.
Go to Step 8 Go to Step 5
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Remove the A/C belt, and rotate the A/C compressor pulley by hand to check whether clamping
stagnation and abnormal noise happens on the compressor A/C pulley.
Whether the compressor is faulty?
YES NO
Replace the A/C compressor.
Go to Step 8 Go to Step 6
6-342
6.5 Fault Diagnosis of Electrical System December 30, 2017
6.5.14 E16 Poor A/C Refrigeration CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Check whether connectors of A/C harness are connected stably, and whether there is open circuit or
short circuit caused by damage of wires.
Is there a fault in the A/C wiring?
YES NO
Check circuit faults and repair them
Go to Step 8 Go to Step 7
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
If the A/C panel is checked to be normal through step 1 to step 7, it may have been damaged.
Whether the A/C panel is faulty?
YES NO
Replace the A/C panel.
Go to Step 8 Go to Step 8
Inspection method
Operate the machine, and check whether each action is normal.
Has this fault been eliminated?
YES NO
Look for the cooling system fault or contact local
Maintenance is over
LiuGong dealers and authorized service centers.
6-343
December 30, 2017 6.5 Fault Diagnosis of Electrical System
CLG930E/936E 6.5.15 E15 Air Conditioning Abnormal Alarm E11--Inner Gas Sensor Break Line
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
1. Press OFF on the A/C panel, the LCD does not display, and the A/C stops running;
2. Press the increase and decrease keys of the temperature setting switch in the meantime for over 3
seconds, the LCD will display DTCs;
3. If E11 fault code occurs, check whether the circuit of the inner gas sensor located in the return air
valve is open with a multimeter.
Whether the circuit of the internal air sensor is open circuit?
YES NO
Replace the internal air sensor.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Check whether the wire from the internal air sensor to the A/C panel is open with a multimeter.
YES NO
Check fault points and repair them
Go to Step 4 Go to Step 3
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
If there is no problem found through checking by step 1, 2, it may be an internal fault of the A/C panel.
6-344
6.5 Fault Diagnosis of Electrical System December 30, 2017
6.5.15 E15 Air Conditioning Abnormal Alarm E11--Inner Gas Sensor Break Line CLG930E/936E
YES NO
Replace the A/C panel
Go to Step 4 Go to Step 4
Step 4: Check whether this fault is eliminated.
Inspection method
Operate the machine, and check whether each action is normal.
YES NO
Look for the fault of air conditioning system or
Maintenance is over contact local LiuGong dealers and authorized
service centers.
6-345
December 30, 2017 6.5 Fault Diagnosis of Electrical System
CLG930E/936E 6.5.16 E18 Air Conditioning Abnormal Alarm E12--Inner Gas Sensor Short Circuit
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
1. Press OFF on the A/C panel, the LCD does not display, and the A/C stops running;
2. Press the increase and decrease keys of the temperature setting switch in the meantime for over 3
seconds, the LCD will display DTCs;
3. If E12 fault code occurs, check the internal sensor located in the return air valve for short circuit with
a multimeter?
Whether the internal air sensor is short circuit?
YES NO
Replace the internal air sensor.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Check whether the wire from the internal air sensor to the A/C panel is short-circuit with a multimeter.
YES NO
Check fault points and repair them
Go to Step 4 Go to Step 3
6-346
6.5 Fault Diagnosis of Electrical System December 30, 2017
6.5.16 E18 Air Conditioning Abnormal Alarm E12--Inner Gas Sensor Short Circuit CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
If there is no problem found through checking by step 1, 2, it may be an internal fault of the A/C panel.
YES NO
Replace the A/C panel
Go to Step 4 Go to Step 4
Step 4: Check whether this fault is eliminated.
Inspection method
Operate the machine, and check whether each action is normal.
YES NO
Look for the fault of air conditioning system or
Maintenance is over contact local LiuGong dealers and authorized
service centers.
6-347
December 30, 2017 6.5 Fault Diagnosis of Electrical System
CLG930E/936E 6.5.17 E17 Air Conditioning Abnormal Alarm E17--Water Temperature Sensor Break Line
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
1. Press OFF on the A/C panel, the LCD does not display, and the A/C stops running;
2. Press the increase and decrease keys of the temperature setting switch in the meantime for over 3
seconds, the LCD will display DTCs;
3. If E15 DTC occurs, check whether the water temperature sensor circuit located in the inflow side of
the warm wind radiator is open with a multimeter.
Whether the water temperature sensor is open circuit?
YES NO
Replace the water temperature sensor.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Check whether the wire from the water temperature sensor to the A/C panel is open circuit with a
multimeter.
YES NO
Check fault points and repair them
Go to Step 4 Go to Step 3
6-348
6.5 Fault Diagnosis of Electrical System December 30, 2017
6.5.17 E17 Air Conditioning Abnormal Alarm E17--Water Temperature Sensor Break Line CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
If there is no problem found through checking by step 1, 2, it may be an internal fault of the A/C panel.
YES NO
Replace the A/C panel
Go to Step 4 Go to Step 4
Inspection method
Operate the machine, and check whether each action is normal.
YES NO
Look for the fault of air conditioning system or
Maintenance is over contact local LiuGong dealers and authorized
service centers.
6-349
December 30, 2017 6.5 Fault Diagnosis of Electrical System
CLG930E/936E 6.5.18 E18 Air Conditioning Abnormal Alarm E16--Water Temperature Sensor Short Circuit
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
1. Press OFF on the A/C panel, the LCD does not display, and the A/C stops running;
2. Press the increase and decrease keys of the temperature setting switch in the meantime for over 3
seconds, the LCD will display DTCs;
3. If E16 DTC occurs, check whether the water temperature sensor circuit located in the inflow side of
the warm wind radiator is short with a multimeter?
Whether the water temperature sensor is short circuit?
YES NO
Replace the water temperature sensor.
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Check whether the wire from the water temperature sensor to the A/C panel is short-circuit with a
multimeter.
YES NO
Check fault points and repair them
Go to Step 4 Go to Step 3
6-350
6.5 Fault Diagnosis of Electrical System December 30, 2017
6.5.18 E18 Air Conditioning Abnormal Alarm E16--Water Temperature Sensor Short Circuit CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
If there is no problem found through checking by step 1, 2, it may be an internal fault of the A/C panel.
YES NO
Replace the A/C panel
Go to Step 4 Go to Step 4
Step 4: Check whether this fault is eliminated.
Inspection method
Operate the machine, and check whether each action is normal.
YES NO
Look for the fault of air conditioning system or
Maintenance is over contact local LiuGong dealers and authorized
service centers.
6-351
December 30, 2017 6.5 Fault Diagnosis of Electrical System
CLG930E/936E 6.5.19 E19 Air Conditioning Abnormal Alarm E18--Solar Sensor Short Circuit
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
1. Press OFF on the A/C panel, the LCD does not display, and the A/C stops running;
2. Press the increase and decrease keys of the temperature setting switch in the meantime for over 3
seconds, the LCD will display DTCs;
3. If E18 DTC occurs, check whether the circuit of the solar sensor is short with a multimeter?
Whether the solar sensor is short circuit?
YES NO
Replace the solar sensor
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Check whether the solar sensor to the A/C panel is short-circuit with a multimeter
YES NO
Check fault points and repair them
Go to Step 4 Go to Step 3
6-352
6.5 Fault Diagnosis of Electrical System December 30, 2017
6.5.19 E19 Air Conditioning Abnormal Alarm E18--Solar Sensor Short Circuit CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
If there is no problem found through checking by step 1, 2, it may be an internal fault of the A/C panel.
YES NO
Replace the A/C panel
Go to Step 4 Go to Step 4
Inspection method
Operate the machine, and check whether each action is normal.
YES NO
Look for the fault of air conditioning system or
Maintenance is over contact local LiuGong dealers and authorized
service centers.
6-353
December 30, 2017 6.5 Fault Diagnosis of Electrical System
CLG930E/936E 6.5.20 E20 Air Conditioning Abnormal Alarm E43--Air Blowing Valve Abnormal
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
1. Press OFF on the A/C panel, the LCD does not display, and the A/C stops running;
2. Press the increase and decrease keys of the temperature setting switch in the meantime for over 3
seconds, the LCD will display DTCs;
3. If E43 DTC occurs, check whether the circuit of the air-out servo motor on the evaporator as is
short or open with a multimeter.
Whether the air-out servo motor is faulty?
YES NO
Replace the air-out servo motor
Go to Step 4 Go to Step 2
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Check whether the circuit from the air-out servo motor to the A/C panel is short or open with a
multimeter
YES NO
Check fault points and repair them
Go to Step 4 Go to Step 3
6-354
6.5 Fault Diagnosis of Electrical System December 30, 2017
6.5.20 E20 Air Conditioning Abnormal Alarm E43--Air Blowing Valve Abnormal CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
If there is no problem found through checking by step 1, 2, it may be an internal fault of the A/C panel.
YES NO
Replace the A/C panel
Go to Step 4 Go to Step 4
Inspection method
Operate the machine, and check whether each action is normal.
YES NO
Look for the fault of air conditioning system or
Maintenance is over contact local LiuGong dealers and authorized
service centers.
6-355
December 30, 2017 6.5 Fault Diagnosis of Electrical System
CLG930E/936E 6.5.21 E21 Abnormal Alarm of the A/C E44 – Abnormal Air Mixing Door
6.5.21 E21 Abnormal Alarm of the A/C E44 – Abnormal Air Mixing Door
Step 1: Air mixing door (A/M) servo motor fault (internal fault).
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
1. Press OFF on the A/C panel, the LCD does not display, and the A/C stops running;
2. Press the increase and decrease keys of the temperature setting switch in the meantime for over 3
seconds, the LCD will display DTCs;
3. If E44 DTC occurs, check whether the circuit of the air-out servo motor on the evaporator as is
short or open with a multimeter?
Whether the servo motor of the air mixing ventilation door (A/M) is faulty?
YES NO
Replace the servo motor of the air mixing
ventilation door (A/M)
Go to Step 2
Go to Step 4
Step 2: Circuit short circuit of the servo motor of the air mixing door (A/M).
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
Check whether the circuit from the servo motor of the air mixing ventilation door to the A/C panel is
short or open with a multimeter.
Whether the servo motor circuit of the air mixing ventilation door (A/M) is faulty?
YES NO
Check fault points and repair them
Go to Step 4 Go to Step 3
6-356
6.5 Fault Diagnosis of Electrical System December 30, 2017
6.5.21 E21 Abnormal Alarm of the A/C E44 – Abnormal Air Mixing Door CLG930E/936E
Notice: When replacing the components, please be sure to use LiuGong parts.
Inspection method
If there is no problem found through checking by step 1, 2, it may be an internal fault of the A/C panel.
Is it internal fault of the A/C panel?
YES NO
Replace the A/C panel
Go to Step 4 Go to Step 4
Inspection method
Operate the machine, and check whether each action is normal.
YES NO
Look for the fault of air conditioning system or
Maintenance is over contact local LiuGong dealers and authorized
service centers.
6-357
December 30, 2017 6.6 Fault Diagnosis of the Hydraulic System and
Mechanical System
Arm 1 Arm
Arm 2 cylinder
Bucket
cylinder Bucket Spare
Boom Boom
Boom 1 Boom 2 cylinder
cylinder
Travel Swing
motor-lh Travel-lh Swing motor
Straight Travel
Travel-rh motor-rh
travel
Yes
Yes
Yes
Check the slewing pilot Clean and replace the pilot line
valve for clogging Yes
No
Yes
Yes
Yes
No
Yes
No
The hydraulic pump Hydraulic pump fault:
sounds abnormally. Yes Remove and repair it.
Check whether the abnormal Yes
sound comes from the
hydraulic pump or pump
installation position. Yes
Check whether the pilot Check whether any oil flows Pilot relief valve fault:
pressure is normal. No out from the pilot pump. Yes
Repair or replace it
No
Hydraulic oil
emulsification
Yes
Sample the oil and drop the Let the hydraulic oil sit
This may be due
sample droplets onto the hot for a period of time, and
Yes to water in the
iron plate, and then check remove the water or
hydraulic oil.
for bubbles. replace the oil.
Yes
Yes
No
Yes
No
Slewing abnormally to
left and right directions
Yes
No
No
Yes
Yes
No reponse for
slewing single
direction opeation
Yes
Yes Yes
Clogging or Clean or repair the
leakage occurs. pilot line.
Yes
Check whether the swing valve The swing valve element gets stuck:
element gets stuck. Yes Remove or replace it.
No
Yes
Fail to actuate
unilateral travel
mechanism
Yes
No
Yes
No
Troubleshoot
according to H3.
6-367
December 30, 2017 6.6 Fault Diagnosis of the Hydraulic System and
Mechanical System
Travel deviation
Yes
Check whether the travel pilot Travel pilot line and pilot valve fault:
pressure is normal. No Clean, repair and replace it.
Yes
Yes
Yes
Yes
No
Yes No
Yes
Check whether the
Check whether the
confluent valve element
above-mentioned valve Yes
spring is functioning
element gets stuck.
properly.
No
Yes
Confluent valve element
gets stuck: Remove and No Replace spring
repair it.
Check whether the boom, Check the pilot line Pilot valve fault:
arm or bucket pilot pressure No inside for clogging or No Remove and repair it.
is normal. leakage.
No
Check whether the main
relief valve and the port relief Relief valve fault: Remove,
valve are functioning No repair or replace it.
properly.
Yes
Yes
Yes
Troubleshoot according to
Yes
the H11 fault.
6-370
6.6 Fault Diagnosis of the Hydraulic System and Mechanical System December 30, 2017
6.6.14 H13 Significantly Reduced Engine Speed or Engine Stalling CLG930E/936E
Turn off the engine, make preparations, rotate the engine at high speed and then take fault
diagnosis.
Check the harness connectors for looseness in advance.
Yes
Yes
7.1 Overview.....................................................................................................................7-3
7.1.1 General Torque Specifications......................................................................................................7-3
7.1.2 Coating Material ............................................................................................................................7-8
7.8 Cab..........................................................................................................................7-287
7.8.1 Removal and Installation of Cab ...............................................................................................7-287
7.8.2 Removal and Installation of Floor Frame Assembly..................................................................7-293
7-3
December 30, 2017 7.1 Overview
CLG930E/936E 7.1.1 General Torque Specifications
7.1 Overview
This chapter introduces the removal and installation methods for main parts of this machine.
The removal and installation of a component introduce the methods for removing and installing the
component from and on the complete machine. The disassembly and assembly of a component
introduce the method for disassembling the component into subcomponents and the method of
assembling them.
Bolts involved in this machine shall be tightened in accordance with the torque requirements specified in
the following table, unless special declaration.
CLG 930E excavator bolt torque chart
M8 25.2±1.2 2.57±0.12
M8 25.2±1.2 2.57±0.12
Material of
Carbon steel and alloy steel Aluminum product
fastenings
Tightening torque Tightening torque
Thread size
N.m kgf.m N.m kgf.m
G1/8 8.75±1.25 0.90±0.12 / /
G1/4 36±2 3.67±0.2 29.3±2.2 3.0±0.2
G3/8 73.5±4.5 7.5±0.46 49±3 5.0±0.3
G1/2 110±10 11.2±1.0 55±5 5.6±0.5
G3/4 165±15 16.8±1.5 74±4 7.5±0.4
G1 225±25 23.0±2.55 / /
G1-1/4 275±25 28.0±2.55 / /
G1-1/2 285±15 29.1±1.5 / /
Tightening torque
Thread size
N.m kgf.m
M12 24±2 2.4±0.2
Polyurethane sealant 1924 Used for waterproof of starter motor and assembling clearance
Removal
Before removal, remove the battery negative pole (-) cable first in order to avoid generating
electric arcs.
When the machine is under operation, the antifreeze is in the high-temperature state. Make sure
the diesel engine stops working and antifreeze is cooled before removing the water radiator or
opening the water radiator cap in order to prevent possible personal injuries.
Before removal, rotate the machine revolving frame to an angle suitable for removal, park the
machine on flat and hard ground, and lower and shut down the work implement.
Figures Procedure
1. Remove the engine hood (1). Refer to
"Removal and Installation of Engine hood" in
this chapter for details.
7-10
7.2 Power System December 30, 2017
7.2.1 Removal and Installation of Diesel Engine Assembly CLG930E/936E
Figures Procedure
2. Remove three bottom plates (2), (3) and (4).
Figures Procedure
5. Disconnect the water pipe at upper part of the
engine, and disconnect the refill water pipe (8)
9 and the water outlet pipe (9), respectively.
11
7. Remove the inter-cooler steel pipes (12) and
12 (13).
8. Remove the turbocharger intake hose (14);
Notice: After disconnecting the intake
line, the pipe lines and the air inlets of the
engine must be masked to prevent engine wear
13 due to dust and other foreign matters entering
the air intake system.
14
16
17
7-12
7.2 Power System December 30, 2017
7.2.1 Removal and Installation of Diesel Engine Assembly CLG930E/936E
Figures Procedure
12. Disconnect the frame harness from the engine:
(1) Disconnect the A/C compressor harness
connector (18);
18
(2) Disconnect the air intake heater harness (19);
(3) Disconnect the choke solenoid connector (20);
(4) 1 Disconnect the frame harness mounting
19 support (21);
(5) 1 Disconnect the speed sensor connector (22);
21 20
22
23
7-13
December 30, 2017 7.2 Power System
CLG930E/936E 7.2.1 Removal and Installation of Diesel Engine Assembly
Figures Procedure
14. Remove the cooling pipe from the A/C
compressor (24).
(1) If the the mounting bracket of the A/C
compressor can be removed directly without
removal of the cooling pipe, remove. Remove
the mounting bracket together with the A/C
compressor from the engine, and fix them to
24 the side.
(2) If the cooling pipe needs to be removed, refer
to the Removal of A/C Compressor Assembly
for the detailed procedures.
Notice: Before the cooling pipe is
removed, collect the refrigerant with the
automatic refrigerant recovery equipment.
15. Remove the engine fan (25);
25
26
7-14
7.2 Power System December 30, 2017
7.2.1 Removal and Installation of Diesel Engine Assembly CLG930E/936E
Figures Procedure
17. Remove the water filter fixing bracket (28) from
the covering parts pillar and bind the water filter
on the engine to avoid interference during
hoisting of engine;
28
31
32
7-15
December 30, 2017 7.2 Power System
CLG930E/936E 7.2.1 Removal and Installation of Diesel Engine Assembly
Figures Procedure
20. Remove the engine oil inlet pipe (34);
21. Remove the engine oil return pipe (33) and its
fixing bracket(35);
Notice: When removing the oil return pipe
on the engine, the oil port must be plugged or
33 34 the oil return pipe must be fixed at a position
above the fuel liquid level in the fuel tank in
order to prevent fuel in the fuel tank backflow.
After removing the fuel line, the oil ports on the
line and on the engine must be masked to
35
prevent engine damage due to dust and other
foreign matters entering the fuel system.
22. Remove the two oil pipes (36) ,(37) from oil
filter;
36 Notice: A little oil will leak during removal
of oil pipe and needs to be collected with
container to avoid polluting the environment;
Notice: The pipe and filter inlet & outlet
shall be sealed after removal of oil pipe to
37 avoid foreign matters entering into lubrication
system, resulting in engine damaged.
23. Lift the main pump (38) with a lifting sling, and
remove flange plate (39)
Install the bolts, and move the main pump and the
flange outwards together so that the coupling
bushing is separated from the engine flywheel.
38
39
7-16
7.2 Power System December 30, 2017
7.2.1 Removal and Installation of Diesel Engine Assembly CLG930E/936E
Figures Procedure
24. Remove 4 shock absorber mounting bolts (40)
on the engine bracket.
40
Installation
The installation sequence of the diesel engine is just opposite to its removal sequence.
Properly clean the air intake line before assembly.
For tightening torques in specific positions, execute the following table, and the others are subject to
general tightening torque;
Refill antifreeze, restore the assembly of the negative battery cable, operate the engine, check the line
for leakages and check whether the water radiator is filled with antifreeze.
With regard to table for the bolt tightening torque at special position, see 2.3.1.
If remove the coupling sleeve from the main pump, the main pump spline should be aligned with
the coupling sleeve when assembling.
Removal
Before removal, rotate the machine revolving frame to an angle suitable for removal, lower the
work implement to ground, shut down to park the machine, relieve accumulator pressure, open
the hydraulic oil tank cover to relieve pressure inside, and pump out the hydraulic oil from tank.
Before removal, remove the negative (-) battery cable first in order to avoid electric arcs.
Seal up the lines, fittings or hoses with plugs or caps when they are in disassembling state, in
order to prevent pollution source from entering the hydraulic system.
Clean the area around the assembly oil ports before removing lines, fittings or hoses.
7-18
7.2 Power System December 30, 2017
7.2.2 Removal and Installation of the Hydraulic Oil Radiator CLG930E/936E
Figures Procedure
1. Rotate the machine revolving frame to an
angle suitable for removal, lower the work
implement to ground, shut down to park the
machine, relieve accumulator pressure, open
the hydraulic oil tank cover to relieve pressure
in the oil tank, and pump out hydraulic oil in the
oil tank.
1
2. Remove the engine hood (1); and refer to
"Removal and Installation of Engine hood" in
this chapter for details.
Figures Procedure
5. Remove the mounting bolts (6) on the side of
the hydraulic oil radiator.
Installation
Removal
1. Before removal, park the machine on flat and hard ground, and lower and shut down the work
implement.
2. Before removal, remove the battery negative pole (-) cable first in order to avoid electric arcs.
After removing the air intake line, the air inlet of the intercooler, intercooler pipe and engine must
be masked immediately to prevent dust and other foreign matters from entering the air intake
system to cause engine wear.
Figures Procedure
1. Turn the revolving frame to the desired angle
for removal. Remove the air prefilter (1), the air
filter cover (2), the engine hood (3), the air grill
(4) and left rear door (5).
7-21
December 30, 2017 7.2 Power System
CLG930E/936E 7.2.3 Removal and Installation of the Intercooler
Figures Procedure
2. Remove the bracket, sealing sponge (6),
crossbeam (7) and inter-cooler pipe (8).
Figures Procedure
7. Hang the inter-cooler (13) with the rope.
Remove the mounting bolts (12) and remove
the intercooler from the radiator assembly
horizontally and gradually, and then rotate it to
the desired angle and take it down from the
engine.
Notice: During this period, be sure to
prevent the intercooler core from being
scratched.
Installation
Removal
Before removal, rotate the machine revolving frame to an angle suitable for removal, park the
machine on flat and hard ground, and lower and shut down the work implement.
Before removal, remove the battery negative pole (-) cable first in order to avoid electric arcs.
When the machine is under operation, the antifreeze is in the high-temperature state. Make sure
the diesel engine stops working and antifreeze is cooled before removing the water radiator or
opening the water radiator cap in order to prevent possible personal injuries.
Figures Procedure
1. Remove the engine hood (1). Refer to
"Removal and Installation of Engine hood" in
this chapter for details.
1
7-24
7.2 Power System December 30, 2017
7.2.4 Removal and Installation of Water Radiator CLG930E/936E
Figures Procedure
2. Remove the bottom plate (2) under the
radiator;
Figures Procedure
6. Disconnect the overflow pipe (6), the
degassing pipe (7), the water inlet pipe (8) and
the water refill pipe (9) from the water radiator.
7. Remove the air shroud upper cover plate(10) .
8. If the coolant level sensor is installed, pull out
the sensor connector.
Figures Procedure
11. Hook the water radiator (14) with a steel wire
rope, and lift it out of the radiator frame.
Notice: Be careful not to scratch the water
radiator core during lifting.
Installation
Removal
Before removal, park the machine on flat and hard ground, and lower and shut down the work
implement.
Before removal, remove the negative (-) battery cable first in order to avoid electric arcs.
Prepare two appropriate fuel drums for receiving fuel during disassembly which can be reused.
Figures Procedure
1. Operate the excavator and rotate the upper
structure to the direction for convenience of
removal and diesel oil draining. Open the oil
drain valve (1) to drain the diesel oil in the tank;
Notice: Collect diesel oil with with
suitable barrel, and the capacity of 936E
reusable fuel tank is about 620L,and the
capacity of 930E reusable fuel tank is about
510L.
1
Figures Procedure
3. Disconnect three fuel pipes at the bottom of the
fuel tank: fuel drain pipe (4), fuel suction pipe
(5) and fuel return pipe (6).
Notice: After removal, the mouths of the
fuel pipes and the fuel port on the fuel tank
must be masked immediately to prevent dust
and other foreign matters from entering the
fuel system to cause engine damages.
Figures Procedure
6. Remove the 6 mounting bolts (10) at the
bottom of fuel tank;
Installation
Preparation steps
Installation
Figures Procedure
1. Lubricate the sleeve seal lip with anti-adhering
grease (part No.: 3824879). Assemble
injector, seal sleeve, new copper seal washer
and packing clamp.
Use just one copper washer.
anti--bonding
Maintenance skills
complex agent
Applying a thin layer of clean engine oil between
the washer and the injector can help to keep the
washer in position when installing.
Figures Procedure
4. Install the fuel return pipe.
5. Install the high-pressure fuel pipe.
Notice: Fuel pressure in the fuel pipeline is
enough to penetrate the skin and cause
serious personal injuries. Gloves and
protection clothes shall be worn.
Preparation steps
Removal
Figures Procedure
Overview
Crankshaft front oil seal is installed into front gear
chamber cover. Adopt two lays
TeflonTM seal. During assembly, sealing surface of
the crankshaft must be cleaned and there is no
engine oil in the surface.
Installation
Figures Procedure
1. Plastic guide mounting tool will be remained in
the oil seal of the engine oil.
2. Oil seal will be placed on the oil seal
installer(part No.: 3824499) with the dust lip
outwards.
3. Before installation, Loctite 277 or equivalent is
painted for one layer on outside diameter of the
oil seal.
Last procedures
7. Install front gear chamber cover.
8. Install the shock absorber.
9. Install the drive belt.
10. Connect the battery.
11. Operate the engine, and check for leakages.
7-34
7.2 Power System December 30, 2017
7.2.8 Removal and Installation of the Engine Rear Seal CLG930E/936E
Removal
Figures Procedure
1. Two 3-mm [0.12-in] holes at a 180-degree
angle are drilled via the metal from the outside
of rear crankshaft oil seal
Notice: When drilling, make sure don’t
damage the crankshaft.
Installation
Figures Procedure
1. Install the oil seal replacement tool guide and
the oil seal on the crankshaft.
Removal
Figures Procedure
1. Remove the cylinder head screw in
the order as shown in the Figure.
Front
Installation
Figures Procedure
Figures Procedure
Front
Front
7-39
December 30, 2017 7.2 Power System
CLG930E/936E 7.2.9 Removal and Installation of the Cylinder Head Assembly
Figures Procedure
8. Only tighten 6 short screws (at
exhaust side) in the numbering
sequence.
9. Check again the torque for all 6 short
screws in the numbering sequence.
Torque value: 105 n.m [77 ft-lb]
Front
7-40
7.2 Power System December 30, 2017
7.2.9 Removal and Installation of the Cylinder Head Assembly CLG930E/936E
Figures Procedure
16. Rotate the bolts in step 2 by 90° as
shown on the bolt head in the
numbering sequence.
90°
7-41
December 30, 2017 7.3 Track Travel System
CLG930E/936E 7.3.1 Removal and Installation of the Track Roller
Removal
Figures Procedure
1. Support the complete machine so that the
platform forms 90° angle with the track frame,
and support one side track beam.
Figures Procedure
3. Remove the track roller mounting bolts.
Installation
Removal
Figures Procedure
1. Loosen the filling valve (1), discharge grease in
the tensioner, and reduce track tensioning
level.
Figures Procedure
3. Loosen carrier roller mounting bolts with a
wrench, and remove the carrier roller. Take out
the carrier roller from the mounting hole.
Installation
Removal
Figures Procedure
1. Move the complete machine forwards so that
the main pin (1) is located at the front section
of the sprocket.
2
Danger: Because the pressure of
the internal grease is high, the valve may
fly off, therefore, do not loosen the filling
valve 2 more than two circles.
7-46
7.3 Track Travel System December 30, 2017
7.3.3 Removal and Installation of the Track Assembly CLG930E/936E
Figures Procedure
3. Squeeze out the main pin with a pin squeezing
machine (3).
Installation
Installation steps:
Installation sequence is just reverse to the removal sequence.
★ Refer to the "Measurement and Adjustment of Track Tension" in the chapter of "Test and Adjustment"
to adjust the track tension properly.
7-47
December 30, 2017 7.3 Track Travel System
CLG930E/936E 7.3.4 Removal and Installation of the Sprocket
Removal
Figures Procedure
1. Refer to "Removal of Track Assembly" section
to remove the track assembly. Rotate the work
implement by 90°, and jack up the complete
machine with the work implement. Rotate the
track to the sprocket (1) side. Unfold the track.
Installation
Removal
Figures Procedure
1. Refer to "Removal of Track Assembly" section
to remove the track assembly.
Figures Procedure
3. Lift up the idler and tensioner assembly (1) and
move it forwards for removal.
Installation
Removal
Figures Procedure
1. Remove the work implement assembly. For
details, see the Removal and Installation of
Work Implement Assembly
2. Remove the counterweight assembly. For
details, see the Removal and Installation of
Counterweight Assembly
3. Disconnect hoses (1)-(4).
Label the disconnected hoses to prevent mistakes
during reinstallation.
4. Lift the boom cylinder assembly (5) temporarily.
5. Remove the plate (6) and the pin shaft (7), and
then remove the boom cylinder assembly (5).
6. Remove the opposite boom cylinder assembly
in the same steps.
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December 30, 2017 7.3 Track Travel System
CLG930E/936E 7.3.6 Removal and Installation of the Revolving Frame
Figures Procedure
7. Remove bolts (8) from the center joint.
8. Disconnect hoses (9) (10) and tubes (11) (14).
9. Label the disconnected hoses and tubes to
prevent mistakes during reinstallation.
10. Lift the platform as temporarily.
11. Remove 40 mounting bolts and remove the
revolving frame assembly.
Installation
Removal
Figures Procedure
1. Remove the revolving frame assembly. For
details, see the Removal of Revolving Frame
2. Remove the 40 mounting bolts (1) for removing
the swing bearing.
Installation
Figures Procedure
Soft part of outer race The installation procedures are just opposite to the
removals.
The front of the machine
Removal
If the engine is in the high-temperature state when the machine works, remove the engine hoods
after the engine cools down.
Be careful not to damage rubber seal strip and sponge during the removal of engine hood.
Figures Procedure
1. Lower and shut down the work implement;
2. Open the engine hood;
Figures Procedure
4. After laying the engine hood flat, remove 4
bolts (3) mounting the engine hood.
Installation
Removal
Before the removal of the counterweight, move the machine to the level ground to make sure no
heavy sways when lifting the counterweight in order to avoid of personal injury.
Figures Procedure
1. Remove the engine hood and rearview
instrument circuit.
Figures Procedure
3. Remove the 4 counterweight mounting bolts
M42(1) and washers with a torque wrench.
Installation
Removal
Before removing hydraulic lines, lower the work implement to the ground completely, shut down
the engine, turn the key to the KEYON position, operate all hydraulic control levers several times
to release the residual pressure from the hydraulic system,and then press the exhaust button of
hydraulic oil tank breather valve to release the internal pressure from the oil tank.
Before removing the lines, fittings or hoses, make the marks so as to prevent wrong installation
while restoring. Clean the periphery of the assembled oil port as required, and put a drip pan to
receive oil.
Seal the lines, fittings or hoses with plugs or caps when they are in disassembling state, so as to
prevent pollution source from entering the hydraulic system.
Figures Procedure
1. Remove the bottom plate (1);
7-59
December 30, 2017 7.5 Hydraulic System
CLG930E/936E 7.5.1 Removal and Installation of Center Joint
Figures Procedure
2. Remove the 4 travel pipes (2);
3. Remove 2 oil return pipes (3);
4. Remove the 2 pilot pipes (4);
Figures Procedure
10. Move the center joint out with the lifting slings
and the hoisting equipment. Lifting weight:
about 57kg.
Installation
Disassembly
Choose a clean location. Lay rubber plates or cloth, etc. for removal, and be careful not to
damage parts.
Figures Procedure
1. Remove the four bolts (1) and washers (2).
Notice: Be careful to fix the center joint to
prevent hard objects from scratching the
sealing surface of each oil port.
Figures Procedure
3. Remove the sealing end cover O-ring (4)
Notice: Be careful not to damage the O-
ring.
Figures Procedure
6. Extract the spindle (6) out of the center joint
body (8) with a puller.
7. Remove the bushing (9) .
Notice: Hook the claw end of the puller to
the flange face, and push the spindle out of the
end cover.
Notice: While taking out the bushing, be
careful not to damage the sealing surface of
the spindle.
Assembly
The assembly sequence is just opposite to the removal sequence. Pay attention to the assembly of the
following items.
1. Repair the damaged section during removal, and prepare replaceable parts in advance.
2. Thoroughly clean each part with cleaning oil, and dry with compressed air.
3. The clean working oil must be applied to the spindle section and the center joint body before
assembly.
4. O-ring, oil seal and other seals shall be replaced in principle.
5. Prepare torque wrenches used for mounting bolts and oil plugs at each section, and tighten them
with the torques specified in the table below.
Removal
Before removing hydraulic lines, lower the work implement to the ground completely, shut
down the engine, turn the key to the KEYON position, operate all hydraulic control levers
several times to release the residual pressure from the hydraulic system,and then press the
exhaust button of hydraulic oil tank breather valve to release the internal pressure from the oil
tank.
Before removing the lines, fittings or hoses, make the marks so as to prevent wrong installation
while restoring. Clean the periphery of the assembled oil port as required, and put a drip pan to
receive oil.
Seal the lines, fittings or hoses with plugs or caps when they are in disassembling state, so as
to prevent pollution source from entering the hydraulic system.
Figures Procedure
1. Rotate the revolving frame, and evacuate a
removal and installation space for fuel tank
bottom plate.
7-66
7.5 Hydraulic System December 30, 2017
7.5.3 Removal and Installation of Hydraulic Oil Tank CLG930E/936E
Figures Procedure
2. Remove the fuel tank bottom plates (1).
Figures Procedure
7. Remove the oil return pipe (5);
8. Remove the pump oil return pipe (6).
Figures Procedure
14. Remove 5 oil suction tube flange mounting
bolts (12), and remove 6 fuel tank mounting
captive bolts (13).
Installation
Removal
Before removing hydraulic lines, lower the work implement to the ground completely, shut down
the engine, turn the key to the KEYON position, operate all hydraulic control levers several times
to release the residual pressure from the hydraulic system,and then press the exhaust button of
hydraulic oil tank breather valve to release the internal pressure from the oil tank.
Before removing the lines, fittings or hoses, make the marks so as to prevent wrong installation
while restoring. Clean the periphery of the assembled oil port as required, and put a drip pan to
receive oil.
Seal the lines, fittings or hoses with plugs or caps when they are in disassembling state, so as to
prevent pollution source from entering the hydraulic system.
Figures Procedure
1. Rotate the revolving frame, and evacuate a
removal and installation space for fuel tank
bottom plate.
7-70
7.5 Hydraulic System December 30, 2017
7.5.4 Removal and Installation of Main Control Valve Assembly CLG930E/936E
Figures Procedure
2. Remove the fuel tank bottom plates (1).
Figures Procedure
5. Remove the bottom plate (4) under the main
control valve.
Figures Procedure
12. Shift the main control valve out with lift
equipment such as a sling. Lifting weight:
about 231kg.
Installation
Related drawings
Please refer to the structure drawing relating to the introduction of the main control valve in the
section "Structural Function and Service". The numbers involved below are subject to the part
numbers in the structure drawing.
1. As hydraulic elements are precisely machined parts, select an especially clean place to carry
out the removal and installation.
2. In addition to such handling of the control valve, be careful enough not to let dust and sand
intrude inside.
3. When removing the control valve from the base machine, seal every interface with a cover.
Before removal, confirm again such covers are completely installed, and thoroughly clean the
outside of the whole component as. Operation should be performed on an appropriate operation
platform, on which should be covered with clean paper sheets or rubber plates before starting
operation.
4. The force support in carrying and moving the control valve should be acted on the solid
positions of the body and should never be acted on the projecting positions such as the spool
and spring cover. Be careful in the operation.
5. Although various tests (such as the overflow properties test, internal leakage test and
passage loss test) can be carried out after the removal and assembly of elements, these must be
carried out on a hydraulic test device. Do not perform removal in a place where test adjustments
can’t be done due to restrictions, even though the removal is available based on the structure.
Prepare clean cleaning oil, working oil and grease, etc, in advance.
Disassembly
The numbers in the bracket ( ) behind the part name represent the part number in the structure
drawing.
7-74
7.5 Hydraulic System December 30, 2017
7.5.5 Disassembly and Assembly of the Main Control Valve CLG930E/936E
Figures Procedure
1. Place the control valve on an operation
platform.
Notice: Conduct removal at cleaning site
and do not break the flange face.
7-75
December 30, 2017 7.5 Hydraulic System
CLG930E/936E 7.5.5 Disassembly and Assembly of the Main Control Valve
Figures Procedure
2. The removal of the main spool: the travel
(301), bucket (304), rotation (305), optional
(309), arm 2 (306), boom 2 (307) and rotation
priority (311).
a. Loosen the hexagon socket bolt (273), and
remove the spring cover (201 or 202) and O-
ring (261).
b. Remove the spool, spring, spring holder
(332), stopper (335 or 339) and bolt with
liners (336) from inside the valve body in the
spool group state.
Notice: Do not break the valve body when
take the valve body out of the spool group.
Figures Procedure
3. Removal of the boom 1 spool (303):
a. Loosen the hexagon socket bolt (273), and
remove the spring cover (201) and O-ring
(261).
b. Remove the boom 1 spool (303), springs
(320 and 328), spring holder (332), stopper
(335) and bolt with liners (336) from inside
the valve body A (101) in the spool group
state.
Notice: When removing the spool group
from the valve body A (101), be careful not to
damage the valve body.
c. Use a bench vice containing a shield over
the jaw to sandwich a protection plate (such
as an aluminum plate) between the bench
vice and the spool so that the boom 1 spool
(303) is fixed. Remove the bolt with liners
(336) from the spool group, and disassemble
the spring (320 and 328), stopper (335) and
spring holder (332).
d. After the removal of 3 items above, do not
perform further removal of the boom 1 spool
(303).
7-77
December 30, 2017 7.5 Hydraulic System
CLG930E/936E 7.5.5 Disassembly and Assembly of the Main Control Valve
Figures Procedure
4. Removal of arm 1 spool (302):
a. Loosen the hexagon socket bolt (273), and
remove the spring cover (201) and O-ring
(261).
b. Remove the arm 1 spool (302), springs (320
and 328), spring holder (332), stopper (335)
and bolt with liners (336) from inside the
valve body B (102) in the spool group state.
Notice: When removing the spool group
from the valve body B (102), be careful not to
damage the valve body.
c. Use a bench vice containing a shield over
the jaw to sandwich a protection plate (such
as an aluminum plate) between the bench
vice and the spool so that the arm 1 spool
(302) is fixed. Remove the bolt with liners
(336) from the spool group, and disassemble
the spring (320 and 328), stopper (335) and
spring holder (332).
d. After the removal of 3 items above, do not
perform further removal of the arm 1 spool
(302).
7-78
7.5 Hydraulic System December 30, 2017
7.5.5 Disassembly and Assembly of the Main Control Valve CLG930E/936E
Figures Procedure
5. Removal of straight travel spool (308):
a. Loosen the hexagon socket bolt (273), and
remove the spring cover (201) and O-ring
(261).
b. Remove the straight travel spool (308),
springs (322 and 323), spring holder (332),
stopper (335) and bolt with liners (336) from
inside the valve body A (101) in the spool
group state.
Notice: When removing the spool group
from the valve body A (101), be careful not to
damage the valve body.
c. Use a bench vice containing a shield over
the jaw to sandwich a protection plate (such
as an aluminum plate) between the bench
vice and the spool so that the straight travel
spool (308) is fixed. Remove the bolt with
liners (336) from the spool group, and
disassemble the spring (322 and 323),
stopper (335) and spring holder (332).
d. After the removal of ? items above, do not
perform further removal of the straight travel
spool (308).
6. Removal of bypass stop valve (310):
a. Loosen the hexagon socket bolt (273), and
remove the spring cover (203) and O-ring
(262).
b. Remove the bypass stop spool (310),
springs (372 and 373), spring holder (331),
stopper (337) and bolt with liners (333) from
inside the valve body B (102) in the spool
group state.
Notice: When removing the spool group
from the valve body B (102), be careful not to
damage the valve body.
c. Use a bench vice containing a shield over
the jaw to sandwich a protection plate (such
as an aluminum plate) between the bench
vice and the spool so that the bypass stop
spool (310) is fixed. Remove the bolt with
liners (333) from the spool group, and
disassemble the spring (372 or 373), stopper
(337) and spring holder (331).
7-79
December 30, 2017 7.5 Hydraulic System
CLG930E/936E 7.5.5 Disassembly and Assembly of the Main Control Valve
Figures Procedure
7. Removal of spring covers (204, 205, 206):
Loosen the hexagon socket bolt (273), and remove
the spring covers (204, 205, 206) and O-ring (264).
When removing the bucket spool cover (206), first
loosen the plug (258) before removing the spool
cover from the valve body B (102). Remove the
plunger (211) after removing the spool cover.
7-80
7.5 Hydraulic System December 30, 2017
7.5.5 Disassembly and Assembly of the Main Control Valve CLG930E/936E
Figures Procedure
8. Removal of main relief valve (601) and
interface relief valves (602, 604):
Remove the main relief valve (601) and interface
relief valves (602, 604) from valve body.
Main relief valve (601)
Interface relief valve (602)
Interface relief valve (604)
After the relief valves are removed from the valve
bodies, do not perform further removal of the relief
valves.
7-81
December 30, 2017 7.5 Hydraulic System
CLG930E/936E 7.5.5 Disassembly and Assembly of the Main Control Valve
Figures Procedure
9. Removal of lock valve selector pair (252):
Loosen the hexagon socket bolt (252-171), and
remove the lock valve selector pair (252) and O-
ring (252-161).
After the lock valve selector pair (252) is removed
from the valve body, do not perform further
removal of the lock valve selector pair.
Figures Procedure
11. Removal of arm regeneration stop valve (257):
Remove the bushing (257-253), spring (257-231),
spring holder (257-232), spool (257-211) and valve
bushing(257-212) from the valve body B (102).
7-83
December 30, 2017 7.5 Hydraulic System
CLG930E/936E 7.5.5 Disassembly and Assembly of the Main Control Valve
Figures Procedure
12. Removal of logic control valve (251), rotary
logic valve group (254) and arm 2 logic valve
group (256):
a. Loosen the hexagon socket bolt (251-120),
and remove the logic control valve (251) and
O-rings (251-112.-113).
b. Remove the rotary logic valve group (254)
and arm 2 logic valve group (256) from the
valve body.
c. After the logic control valve is removed from
the valve body and the logic valve groups
are removed, do not perform further
removal.
7-84
7.5 Hydraulic System December 30, 2017
7.5.5 Disassembly and Assembly of the Main Control Valve CLG930E/936E
Figures Procedure
13. Removal of check valve:
a. CP1, C2, CCb, LCb, LCo, LCk, LCa, LCAT2
b. CMR1, CMR2
Remove the plug (553), and then remove the cone
valve (512) and spring (521).
c. CRa, CRb
Remove the plug (552), and then remove the cone
valve (513) and spring (523).
d. CCk, CCo
Remove the plug (551), and then remove the cone
valve (514) and spring (521).
e. Remove the plug (550), and then remove
the steel ball (541), spring (543) and spring
holder (542).
7-85
December 30, 2017 7.5 Hydraulic System
CLG930E/936E 7.5.5 Disassembly and Assembly of the Main Control Valve
Figures Procedure
14. Removal of flange (209):
Loosen the hexagon socket bolt (971), and remove
the flange (209) and O-ring (165).
15. Removal of the plate (210):
Loosen the hexagon socket bolt (274), and remove
the plate (210) and O-ring (165).
16. Removal of the orifice plug for signal oil circuit:
Except special circumstances, do not generally
remove the plug (151) and orifice plug (156).
3. If there are deformations and pits on the 8. When a defective part exists, replace the
valve seat surface of the check valve body relief valve by group.
and valve block, eliminate them in the
Assembly
abrading method.
The number in the () after a part name
represents a symbol in the structure drawing.
Precautions in assembling O-ring seals
Do not keep abrasive paste remaining in the
valve body and valve block. 1. Note that the seals must have neither
forming defects nor the scars generated in
4. Confirm that sliding and mating parts are able use.
to flexibly rotate by hand and no impurities
2. Apply grease or working oil in the positions of
are left in all grooves and passages.
the seals and similarly shaped seals to
5. Replace the spring with a new one in case of ensure sufficient lubrication.
a break or deformation.
3. Do not stretch the seals to a permanent
6. When the relief valve acts ineffectively, repair deformation that they cannot recover.
it according to the removal and assembly of
4. When installing an O-ring, do not install it in a
the relief valve.
distorted way. A distorted O-ring is difficult to
7. Replace all seals and O-rings with new ones. naturally recover after being installed, which
is the cause of oil leakage.
Inspection of relief valve
5. For the mounting bolts of all parts, fix them
1. Make sure the spool and valve seat head with a tool such as a torque wrench
seal surface of each valve have no defects according to the mounting torque as shown
and the mating surfaces are in uniform in Maintenance Criteria.
contact.
1. Install the check valve:
2. Make sure the spool and valve seat of the
main valve are easily and freely slid by hand. 1. Install the cone valves (511, 512, 513, 514)
and springs (521, 522, 523).
Install O-ring (561) in the plug (551, 552), and
fasten it in specified torque.
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December 30, 2017 7.5 Hydraulic System
CLG930E/936E 7.5.5 Disassembly and Assembly of the Main Control Valve
The following is the assembly of combination of 2. Install the O-ring (251-112.-113) on the valve
cone valve, spring and plug used. body (251-101) of logic control valve, fasten
it in specified torque with hexagon socket
bolt(251-120) and the mounting torque is 49-
Cone Installatio 65N·m.
Spring Plug
valve n site
511 521 551 8 places 5. Install the logic control valve (251) and
512 522 553 2 places arm 2 logic valve group (256):
513 523 552 2 places
1. Install arm 2 logic valve group (256) on the
514 521 551 2 places
valve body A (101).
2. Install the O-ring (251-112.-113) on the valve
Inner body (251-101) of logic control valve, fasten
Plug Mounting torque it in specified torque with hexagon socket
hexagon
No. (Nm) bolt(251-120) and the mounting torque is 49-
spanner
65N·m.
(551) 12mm 230~260
(552) 12mm 230~260 6. Install negative control relief valve (610):
(553) 10mm 130~150
Install the negative control relief valve (610) in
2. Install the steel ball (541), spring holder (542) the valve body, fasten it in the specified torque
and spring (543): shown in the following, and the mounting torque
is 69-78N·m.
Install an O-ring (166) on the plug (550), fasten it
in specified torque, and the mounting torque is
7. Install arm regeneration stop valve (257):
25-29N·m.
Install the valve bushing (257-212), spool (257-
2. Install the plate (210):
211), spring holder (257-232), and spring (257-
231) on the valve body B (102). Install the O-ring
Install the O-ring (165) on valve body B (102),
(257-265) on the bushing (257-253), fasten it in
fasten the hexagon socket bolt (274) in the
specified torque, and the mounting torque is 69-
specified torque, and the mounting torque is 98-
78N·m.
120N·m.
When the orientation of the plate is downward, 8. Install lock valve selector pair (252):
exchange the orientation of the control valve.
Install the O-ring (252-161) on the lock valve
3. Install the flange (209): selector pair (252), fasten it in specified torque
with hexagon socket bolt (252-171), and the
Install an O-ring (165) on the flange (209), fasten mounting torque is 10-14N·m.
the hexagon socket bolt (971) in the specified
torque, and the mounting torque is 49-65N·m.
9. Install main relief valve (601) and port 2. Upon completing the assembly of item 1,
relief valve (602, 604); install the spool group onto the valve body A
(101).
Install the main relief valve (601) and interface
relief valve (602, 604) onto the valve body, and
fasten it in the following specified torque.
12. Installation of the arm 1 spool (302): 1. Use the bench vice provided with shield on
the vice jaw, sandwich guard plate (aluminum
1. Use the bench vice provided with shield on plate, etc.) between the bench vice and
the vice jaw, sandwich guard plate (aluminum spool, and fasten the intermediate part of
plate, etc.) between the bench vice and each spool. Install the spring holder (332),
spool, and fasten the intermediate part of the spring, and stopper (335 or 339), fasten the
arm 1 spool (302). Install the spring holder bolt with liner (336) in specified torque, and
(332), spring (320, 328), and stopper (335), the mounting torque is 16-18N·m.
fasten the bolt with liner (336) in specified
torque, and the mounting torque is 16-
18N·m.
Before installing the bolt with liner (336),
apply #262 thread seal on it.
The spool will deform if it is sandwiched
Before installing the bolt with liner (336),
improperly, so do not clamp bench vice
apply #262 thread seal on it.
tightly.
The arm 1 spool (302) will deform if it is
sandwiched improperly, so do not clamp 2. Upon completing the assembly of item 1,
bench vice tightly. install the spool group into the valve body A
(101) and valve body B (102).
2. Upon completing the assembly of item 1,
then install the spool group onto the valve B
(102).
When installing the spool group on the valve
body A (101) and valve B (102), do it slowly
and prudently.
While installing the spool group onto the
Never push the spool into the valve body
valve body B (102), do it slowly and
forcibly.
prudently.
Never push the spool into the valve body 14. Installation of the bypass stop spool
forcibly. (310):
13. Installation of main spool: 1. Use the bench vice provided with shield on
the vice jaw, sandwich guard plate (aluminum
Travel (301), bucket (304), swing (305), backup plate, etc.) between the bench vice and , and
(309), arm 2 (306), arm 2 (307) and swing priority fasten the intermediate part of bypass stop
(311). spool (310). Install the spring holder (331),
spring (372, 373), and stopper (337), fasten
the bolt with liner (333) in specified torque,
and the mounting torque is 16-18N·m.
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7.5 Hydraulic System December 30, 2017
7.5.5 Disassembly and Assembly of the Main Control Valve CLG930E/936E
Removal
Before removing hydraulic lines, lower the work implement to the ground completely, shut down
the engine, turn the key to the KEYON position, operate all hydraulic control levers several times
to release the residual pressure from the hydraulic system,and then press the exhaust button of
hydraulic oil tank breather valve to release the internal pressure from the oil tank.
Before removing the lines, fittings or hoses, make the marks so as to prevent wrong installation
while restoring. Clean the periphery of the assembled oil port as required, and put a drip pan to
receive oil.
Seal the lines, fittings or hoses with plugs or caps when they are in disassembling state, so as to
prevent pollution source from entering the hydraulic system.
Figures Procedure
1. Rotate the revolving frame, and evacuate a
removal and installation space for fuel tank
bottom plate.
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7.5 Hydraulic System December 30, 2017
7.5.6 Removal and Installation of Main Pump Assembly CLG930E/936E
Figures Procedure
2. Remove the fuel tank bottom plates (1).
Figures Procedure
5. Remove the angle block (4), angle block (5)
and angle block (6). Remove the oil filter
bracket (7).
Figures Procedure
11. Lift up the main pump with sling and hoisting
equipment, and remove 12 bolts of the
mounting flange (13).
Installation
The structural chart and parts of the pilot pump are listed as follows:
The parts numbers of the pilot pump involved in this section are not in accordance with the following
figure but the specified numbers.
LG936E07097
307 Spool 312 Locknut 361 End cover 700 Seal ring
308 Valve seat 351 Pump body 433 Bolt 710 O-ring
309 Snap ring 353 Drive gear 434 Bolt 725 O-ring
310 Spring 354 Driven gear 435 Bolt 732 O-ring
311 Adjusting bolt 355 Oil filter 466 Screw plug 850 Snap ring
887 Pin
Disassembly
Precautions
1. The digits in the bracket behind the part number represent the serial number of the part in the
exploded view of the pump.
2. Be careful not to mix the parts various types of pumps.
3. To avoid damage to the inclination pin head, remove the inclination pin with the special clamp.
4. The joint surface between the inclination pin and the auxiliary piston is coated with polystirene. Avoid
damage to the auxiliary piston.
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7.5 Hydraulic System December 30, 2017
7.5.7 Removal and Installation of Main Pump Assembly CLG930E/936E
5. Considering the bearing life, do not pull out the needle roller bearings as far as possible.
6. Do not loosen the valve body and the hexagonal nuts on the support table for the sloping plate.
Doing so can change the flow setting.
7. The following dismantling includes those of the pump body and the regulator.
Figures Procedure
1. Select the site for removal.
Notice: Select a clean and tiny site, place
rubber plate or working cloth on the operation
platform to prevent damaging the parts.
2. Please remove the dirt, rust from the pump
—— surface using cleaning oil.
3. Remove the oil plug cap (468) from the pump
housing and pump out the oil in the pump body.
Notice: For the tandem pump, drain the oil
from the pin clamp of front pump and rear
pump.
4. Dismantle the hexagon socket bolt to remove
the regulator, and then remove the gear pump.
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December 30, 2017 7.5 Hydraulic System
CLG930E/936E 7.5.7 Removal and Installation of Main Pump Assembly
Figures Procedure
5. Remove the PTO device
Figures Procedure
9. Put the regulator on the operation platform
horizontally with the mounting face downward,
and separate the pump housing (271) and oil
distributor (312).
Notice: When the mounting face of the
regulator facing downwards, put rubber plate
on the operation platform so as to prevent the
mounting face from being damaged.
Notice: When separate the pump housing
from the oil distributor, take down the 1st gear
(116) simultaneously
Figures Procedure
13. Remove hexagon socket bolt (406) to remove
the sealing cap (F) (261).
Notice: There is a hole (M6 threaded hole)
for unplugging on the sealing cap (F) for ease
of taking it out after installing the bolt.
Notice: As the sealing cap (F) is
equipped with oil seal, do not damage the oil
seal at removal.
14. Knock the rear end of the drive shaft (111, 113)
gently so as to separate the drive shaft from
swashplate supporting platform (251).
Figures Procedure
16. Knock the fitting flange part of the swashplate
supporting platform (251) on the pump housing
side gently to separate the swashplate
supporting platform and the pump housing.
17. Remove the mating plate (313, 314) from the
mating cover (311, 312).
Notice: The mating plate may fall off while
it is in the 9th and 11th operation.
Disassembly of regulator
Figures Procedure
For the part number involved in the following, refer
to the part drawing of regulator in the main pump
assembly introduction of "structure function and
maintenance".
1. Select one disassembly site.
Notice: Select one cleaning site.
Notice: In order to protect the parts from
being damaged, rubber plate or operation-used
cloth, etc. shall be laid on the operation
platform.
2. Wash out the dust, rust, etc. on the surface of
regulator with cleaning oil.
3. Remove the hex screw (438) and take down
the cap (C) (629).
Notice: The cap (C) (629) has been
installed with the adjusting wheel (C) (627),
adjusting screw (C) (628), locknut (630), hex
nut (801, 802), and adjusting screw (924).
Notice: Never loosen these screws or
nuts. If they are loosened, the setting
pressure—flow will be changed.
4. After removing the cap (C) (629), remove the
outer ring spring (625), inner ring spring (626)
and spring holder (C) (624) from the
compensator part, and pull out the regulating
ring (Q) (645), guide spring (646) and spring
holder (644) from the pilot part.
Notice: It is easy to remove the regulating
ring (Q) (645) by using M4 screw.
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7.5 Hydraulic System December 30, 2017
7.5.7 Removal and Installation of Main Pump Assembly CLG930E/936E
Figures Procedure
5. Remove hex screw (436438), and remove the
pilot cover (641); after removing pilot cover
(641), please take out the pin (898) and Pf
bushing (631) from the compensator, and then
remove the set spring (655) from the pressure
regulator part.
Figures Procedure
8. Remove lever (2) (613), but do not pull out pin
(875).
Notice: It can make the operation easier to
use a pair of tweezers.
10. Remove lever (1) (612), but do not pull out pin
(875).
11. Remove the pilot plunger (643) and spool (652)
12. Remove the plunger bushing (622),
compensator plunger (621) and compensator
rod (623).
These are the complete operating steps.
Notice: During removal of plunger bushing
(622), it can be extruded from the compensator
rod (623) end on the opposite side to plunger
bushing (622).
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7.5 Hydraulic System December 30, 2017
7.5.7 Removal and Installation of Main Pump Assembly CLG930E/936E
Figures Procedure
Figures Procedure
4. Pull out the upper cover (4) of pilot pump
upwards slowly and gently.
Notice: be careful in operation and not to
damage the mounting face.
O-ring
Notice: The damaged O-ring cannot be
reused.
Figures Procedure
7. Grasp one end of drive gear, and pull out the
driven gear (6) straight up slowly.
Notice: Make the mark and note the fitting
direction of drive gear.
Notice: Protect supporting shaft on two
ends of gear and the mounting face matched
with it from damage.
Assembly
1. Repair the damaged section during removal, and prepare replaceable parts in advance.
2. Thoroughly clean each part with cleaning oil, and dry with compressed air.
3. Assembly must be carried out after the slide part and bearing are applied with clean working
oil.
1. The assembly sequence is just opposite to the removal sequence. Pay attention to the assembly of
the following items.
2. Repair the damaged section during removal, and prepare replaceable parts in advance.
3. Thoroughly clean each part with cleaning oil, and dry with compressed air.
4. The clean working oil must be applied to the spindle section and the center joint body before
assembly.
5. O-ring, oil seal and other seals shall be replaced in principle.
6. Prepare torque wrenches used for mounting bolts and oil plugs at each section, and tighten them
with the torques specified in the table below.
7. On the occasion where pumps are in series, components of front pump and rear pump shall not mix
together.
8. Mounting Torque Table is as follows:
Specifications and torque of pilot pump
Disassembly
If removal and installation shall be conducted, pay special attention not to damage machined
surface, that excessive force will cause eccentricity or serious damage to part.
If the part is difficult to install during assembly, it is possible to tap it with soft hammer (do not
use a metal hammer).
Handle them gently during removal and installation to avoid damaging shaft diameter or tooth
surface
Figures Procedure
1. Place the pump in the vise with drive gear
facing down. During assembly and removal
Notice: Do not tension the machined
surface. Make line on each part and align the
marking line in case of reinstallation.
Figures Procedure
3. Lift up the rear cover.
Notice: If it is necessary to pry up, take
care not to damage the machined surface.
Figures Procedure
6. Mark the position relation among gears by
making line.
Figures Procedure
9. Pry out oil seal.
Notice: Take care not to damage seal hole
surface inside front cover.
Assembly
Figures Procedure
1. Clean the seal hole thoroughly. The sealant
shall be used during installation of metal outer
diameter seal.
Notice: use grease instead of sealant on
the rubber outer oil seal
Figures Procedure
4. Inspect O-ring. It is recommended to use new
one instead of keeping seal ring in the seal
groove.
Figures Procedure
7. Set the protective sleeve to drive gear. Apply a
small amount of grease to lubricate the seal
during assembly.
Figures Procedure
10. Installed intermediate body.
Figures Procedure
13. Installed rear cover
14. Install the bolt and washer, and tighten the bolt
to the cover in diagonal manner with specified
torque.
Notice: Do not apply grease to thread prior
to assembly.
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December 30, 2017 7.5 Hydraulic System
CLG930E/936E 7.5.9 Removal and Installation of the Travel Pilot Valve Assembly
Removal
Before removing hydraulic lines, lower the work implement to the ground completely, shut down
the engine, turn the key to the KEYON position, operate all hydraulic control levers several times
to release the residual pressure from the hydraulic system,and then press the exhaust button of
hydraulic oil tank breather valve to release the internal pressure from the oil tank.
Before removing the lines, fittings or hoses, make the marks so as to prevent wrong installation
while restoring. Clean the periphery of the assembled oil port as required, and put a drip pan to
receive oil.
Seal the lines, fittings or hoses with plugs or caps when they are in disassembling state, so as to
prevent pollution source from entering the hydraulic system.
Figures Procedure
1. Remove the bottom plate (1) under the foot
pilot.
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7.5 Hydraulic System December 30, 2017
7.5.9 Removal and Installation of the Travel Pilot Valve Assembly CLG930E/936E
Figures Procedure
2. Remove the 6 pilot pipes (2).
Figures Procedure
5. Remove 4 bolts with wrench to remove pedal
(7).
Installation
For the part numbers involved in the section, this part drawing below shall prevails.
101 Housing 212 O-ring 301 Slide valve 423 Positioning screw
102 Housing 213 O-ring 311 Spring seat 431 Seat
153 Oil plug 214 Push rod 313 Washer 471 Positioning screw
191 Valve seat 215 Washer 324 Spring 472 Locknut
194 Steel ball 217 Washer 335 Spring 473 Hexagon socket bolt
201 Valve cover 218 Spring seat 336 Spring 501 Rubber sleeve
202 Screw plug 220 Hexagon socket bolt 337 Spring 520 Pedal
203 Grease fitting 224 Piston 412 Bushing 521 Pedal sleeve
210 Grease fitting 225 Steel ball 413 Cam shaft 522 Hexagon socket bolt
211 O-ring 271 Hex screw 420 Cam
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December 30, 2017 7.5 Hydraulic System
CLG930E/936E 7.5.10 Disassembly and Assembly of Travel Pilot Valve
Disassembly
Special tool
!"#
1. There shall be a capacious site to place the removed components and parts. Prepare a stable
workbench where components and parts will not fall off and roll during operation.
2. Prepare tools and related materials.
3. All components and parts have been processed precisely.Be careful in the operation and pay
attention to hold and put swiftly and do not crash or drop the components.
4. Do not consider that all components and parts are solid and firm. During removal, the excessive
beat, pry and cut will lead to trimming, deformation and damage, which causes unable to assemble,
oil leak as well as performance reduction. Therefore, operate with cautions and patience.
5. No corresponding disposal or random placement in removing midway after removing, which will
cause rusted components and parts because of humidity and impurity. When the operation must be
interrupted, pay attention to take the measures of rust protection and dust prevention.
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7.5 Hydraulic System December 30, 2017
7.5.10 Disassembly and Assembly of Travel Pilot Valve CLG930E/936E
Figures Procedure
1. Clean the pilot valve with white kerosene,
Notice: All connectors are blocked with
plugs.
2. Fix the pilot valve on the bench vice with buffer
plate (the copper plates or other soft plates).
Remove the pedal cover (521) from pedal
(520), and remove it from the upper side.
Figures Procedure
5. Remove rubber bushing (501) from the upper
side of valve cap (201).
Figures Procedure
8. Unscrew positioning screw (471) and locknut
(472) on the cam (420), and remove them in
pair.
Notice: Record the position relationship
between the cam and valve cap (201).
Notice: During removal, please note the
push rod (214) may be ejected.
Figures Procedure
11. Remove push rod (214) from plug (202).
Notice: Record the position relation
between plug and push rod.
Notice: Be careful not to damage the
surface of the push rod.
Notice: During removal, pay attention that
the plug may be ejected.
Figures Procedure
14. Remove the buffer springs (336), (337) from
the buffer housing.
Notice: Record the position relationship
between the buffer spring and the bumper
housing hole.
16. Take out the steel ball (225) with magnet, etc.
Notice: Keep the steel balls without lose.
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December 30, 2017 7.5 Hydraulic System
CLG930E/936E 7.5.10 Disassembly and Assembly of Travel Pilot Valve
Figures Procedure
17. Loosen the hexagon socket bolt (220) with the
inner hexagon spanner.
Figures Procedure
20. Remove the pressure reducing valve group
and reset spring (335) from the housing.
Notice: Record the position relationship
with the valve body hole.
Figures Procedure
22. Fix the cam group on the bench vices, loosen
the locknut (472) with spanner, and remove the
locknut and positioning screw (471).
Notice: Because the positioning screw
must be adjusted as per the central position
when assembling, it will be kept in form of cam
group in the subsequent process if the screw
is not required to be replaced.
Figures Procedure
25. Remove lubricating oil cup (203) from plug
(202).
Figures Procedure
28. Fix the housing (101) on the bench vice with
buffer plates (the copper soft plate, etc.), and
then loosen the oil plug (153) with inner
hexagon spanner. (Only for PVD8PC)
29. Pull out the valve seat (191) from the housing
(101). (Only for PVD8PC)
● Put all components and parts into a coarse cleaning container with white kerosene, and clean them.
(Coarse cleaning)
● If all parts are cleaned initially in the unclean oil, those parts can be damaged easily, therefore, clean
them after fully immersed and the impurities and grease are floating.
● The unclean white kerosene will damage components and parts and reduce the performance after
reassembly, therefore keep the white kerosene clean completely.
● Put all components and parts into a cleaning container with white kerosene, and clean while rotating
them until the inside is clean (after cleaning operation). Clean the white kerosene adhering on
components and parts with clean cone screw.
● If drying with compressed air, the components and parts can be damaged and rusted because of
impurity and moisture in compressed air, so do not use it.
Assembly
1. The same as the removal get the operation platform, tools and related data ready.
2. During assembling, give the same attention to the general precautions as the removing.
3. Metal scraps and foreign matters of all parts during assembling shall be eliminated. Moreover,
ensure there is no trimming, damage, bruise, etc. on the components and parts. If there is above-
mentioned situation, please remove it with oil stone.
4. In principle, replace with new products for the O-ring and NHU seal ring.
5. When installing the O-ring and NHU seal ring, pay attention not to damaging them. (For easy
assembly, please apply little grease)
6. When assembling components and parts, please use grease to prevent dropping.
7. Fasten the bolts, etc. according to mounting torque as shown in assembly sectional diagram.
8. All connectors shall be sealed with plugs after installing to avoid intrusion of impurities.
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December 30, 2017 7.5 Hydraulic System
CLG930E/936E 7.5.10 Disassembly and Assembly of Travel Pilot Valve
Figures Procedure
1. Fix the housing (101) with buffer plates (the
copper plates and other soft materials) on the
bench vice, and install the steel ball (194) into
the housing (101). (Only for PVD8PC)
Notice: Attract the steel balls to the weak
magnets, or install them with tweezers, etc.
Figures Procedure
4. Install washer (313), washer (217), spring
(324) for secondary pressure setting, and
spring holder (311) to the slide valve (301) in
sequence.
Notice: Notice: Washer 2 is used for
presetting and adjustment of spring for
secondary pressure setting; the thickness of
each slide valve is different. It may also not be
used.
Acute angle
side
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December 30, 2017 7.5 Hydraulic System
CLG930E/936E 7.5.10 Disassembly and Assembly of Travel Pilot Valve
Figures Procedure
6. Install the reset spring (335) into valve body.
Notice: Install it according to the position
before removal.
Figures Procedure
9. Install the O-ring (211) and O-ring (213) on the
valve body.
Figures Procedure
12. Install the spring seat (218) into buffer housing.
Notice: Install it according to the position
before removal.
Figures Procedure
15. Install piston (224).
Notice: Install it according to the position
before removal.
17. Install NHU oil cup (210) into push rod bushing.
Notice: Note the direction when installing
NHU seal ring.
Notice: It is easier to install it when NHU
seal ring is applied with a layer of grease
before installing.
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December 30, 2017 7.5 Hydraulic System
CLG930E/936E 7.5.10 Disassembly and Assembly of Travel Pilot Valve
Figures Procedure
18. Install lubricating oil cup (203) into push rod
bushing.
19. Install the push rod (214) into the push rod
bushing.
Notice: The push rod surface shall be
applied with hydraulic oil before installing.
Notice: Do not force to insert it because it
may damage the lip edge of NHU seal ring.
Figures Procedure
21. Compress the bushing (412) on the valve cap
(201) with the special tool 1, and then knock at
it with a hammer to press it into the cover.
Notice: When compressing the bushing,
note not to knock out the inner side of cover.
Figures Procedure
23. Install and fasten the hexagon socket bolt
(271) according to the specific torque.
Notice: The cover should be installed
horizontally without deflection.
Notice: Install the positioning screw (471)
to the cam (420), and install the locknut (472)
temporarily.
Figures Procedure
25. Press the cam (420); meanwhile insert the
camshaft (413) into the cam from outside.
Figures Procedure
28. Adjust the height of the positioning screw
(471), parallel the cam (420) upside with the
cover underside, and turn the cam right and
left. After confirm that the cam will not be loose
in the neutral position, install and fasten the
locknut 472 according to the specified torque.
Notice: Attach the 4 push rods (214) to
appropriate positions with the positioning
screws. When over-tightening the positioning
screws, the control lever shall be loose in the
neutral position and acute movement will
happen when starting the engine and attention
shall be paid to this.
29. After tilting the cam, the push rod top side shall
be applied with the grease; meanwhile the
grease cup (203) of the plug (202) shall be
filled with grease.
Notice: When applying and filling the
grease, please do not damage the push rod
and the surface of the plug, and conduct with
soft flat material.
Figures Procedure
31. Install the seat (431), and install and fasten the
hexagon socket bolt (473) according to the
specified torque.
Before removing hydraulic lines, lower the work implement to the ground completely, shut down
the engine, turn the key to the KEYON position, operate all hydraulic control levers several times
to release the residual pressure from the hydraulic system,and then press the exhaust button of
hydraulic oil tank breather valve to release the internal pressure from the oil tank.
Before removing the lines, fittings or hoses, make the marks so as to prevent wrong installation
while restoring. Clean the periphery of the assembled oil port as required, and put a drip pan to
receive oil.
Seal the lines, fittings or hoses with plugs or caps when they are in disassembling state, so as to
prevent pollution source from entering the hydraulic system.
Figures Procedure
1. Pull out rubber jacket (1) of pilot valve, unplug
wire (2), remove locknut (3) of control lever,
and then remove the control lever.
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7.5 Hydraulic System December 30, 2017
7.5.12 Removal and Installation of Hand Pilot Valve Assembly CLG930E/936E
Figures Procedure
2. Remove 4 mounting bolts (4) from the console,
and move the console cover out.
Install the left-hand pilot valve assembly according to opposite procedures of removal. Wherein
tightening torque of connector: 36±2Nm;
Tightening torque of hose joint: M18×1.5: 37±2Nm.
By referring to removal and installation of left-hand pilot valve, remove and install right-hand pilot valve.
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7.5 Hydraulic System December 30, 2017
7.5.12 Disassembly and Assembly of the Hand Pilot Valve Assembly CLG930E/936E
This section introduces disassembly and assembly of two types of hand pilot valves, and the two types
can be installed on the machine. Please identify the type firstly, and then disassemble and assemble it in
accordance with the corresponding type.
All components and parts have been processed precisely. Pay attention to handling with care
and not crashing or dropping components and parts.
Remove without beating, prying and cutting; otherwise the components will be produced with
trimming, deformation and damage, which will result in failing to assemble, oil leak and
performance reducing. Therefore, please operate with caution and patience.
Suggest continuous operating. If the operation is interrupted, please adopt the rust-proof and
dust-proof measures.
For the part numbers involved in the section, this part drawing below shall prevails.
PV48K1 model
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December 30, 2017 7.5 Hydraulic System
CLG930E/936E 7.5.12 Disassembly and Assembly of the Hand Pilot Valve Assembly
PV48KC1 model
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7.5 Hydraulic System December 30, 2017
7.5.12 Disassembly and Assembly of the Hand Pilot Valve Assembly CLG930E/936E
Disassembly
Figures Procedure
1. Clean the pilot valve with white kerosene.
Notice: Seal the connectors with plugs.
2. Fix the pilot valve on the bench vive.
3. Remove the ripple protection cover (501).
Notice: Be careful not to break the ripple
protection cover (501).
Figures Procedure
5. Rotate the connector (301) to the left with
clamp and then loosen it.
Notice: When the elastic force of the
restoring spring (221) is large, the cover (151),
the push rod bushing (211) and the push rod
(212) may be ejected at the time of unscrewing
the connector (301). When pulling out the
connector, they may also be ejected out.
Figures Procedure
7. The push rod bushing (211) may be blocked in
the valve body (101) because of the weak
restoring spring (221) and the O-ring slide
resistance, and please remove it with a straight
screwdriver.
Notice: Utilize the bushing peripheral
groove under the condition of the bushing
(211) not being damaged result from deflection.
Notice: The push rod bushing (211) may
be ejected because of the elastic force of the
restoring spring (221).
Figures Procedure
11. Pull out the valve seat (291) from the interface
plate (111). (Only for PV48KC1)
As shown in the figure, hold the valve seat and pull it out.
Pay attention not to damaging the joint surface of steel ball.
Sel Steel
ball
Steel ball
ball
Valve seat
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7.5 Hydraulic System December 30, 2017
7.5.12 Disassembly and Assembly of the Hand Pilot Valve Assembly CLG930E/936E
Figures Procedure
13. Loosen the hexagon socket bolt (125) with the
inner hexagon spanner.
Figures Procedure
16. For removal of the pressure reducing valve,
depressing the spring holder (216) to
compress the secondary pressure spring (241)
and meanwhile make the spring holder (216)
crosswise a bit and pass via the bigger hole
side, and then remove the slide valve (201).
Then separate the slide valve (201), the spring
holder (216), the secondary pressure spring
(241) and the washer (217).
Notice: don't damage the surface of the
slide valve (206).
The room for further compressing of the spring
holder (216) is no more than 6 mm.
Keep it well in the group form until reassembly.
218
246 212
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7.5 Hydraulic System December 30, 2017
7.5.12 Disassembly and Assembly of the Hand Pilot Valve Assembly CLG930E/936E
Figures Procedure
18. Pull out the push rod (212) from push rod
bushing (211).
1. Put components and parts into a cleaning container filled with white kerosene and clean them
roughly.
2. Put components and parts into a cleaning container filled with white kerosene, rotate slowly and
clean them until insides of them are completely clean. Wipe up white kerosene adhering to
components and parts with clean rag after cleaning.
3. Components and parts need soaking sufficiently, and clean them after impurities and grease float.
4. Unclean white kerosene can damage components and parts, and it can cause degradation of their
performance after assembling them, so it shall guarantee the cleanness of white kerosene.
5. Impurities and moisture in compressed air can cause rust, therefore do not dry them with
compressed air.
Apply anti-rust onto components and parts If they are placed without rust prevention after rinse, this may
cause rust and then affect their performances.
Assembly
Metal scraps and foreign matters of all parts during assembling shall be eliminated. Moreover,
ensure there is no trimming, damage, bruise, etc. on the components and parts. If there is above-
mentioned situation, please remove it with oil stone.
O-rings and protective washers shall be replaced with new ones in principle.
While installing the O-ring and the protective washer, take care not to damage them. (Please
apply a little lubricating grease for easy installation and smoothness)
When assembling components and parts, please use grease to prevent it dropping.
All connectors shall be sealed with plugs after installing to avoid impurities.
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7.5 Hydraulic System December 30, 2017
7.5.12 Disassembly and Assembly of the Hand Pilot Valve Assembly CLG930E/936E
The table below shows tightening torque value of mounting torque of bolts, etc. Measure
mounting torque value with torque wrench.
Functional Thread
Tool(s) Size (mm) Mounting torque (N·m)
parts specification
Hexagon socket
Inner hexagon spanner 6 M8 20.6±1.5
bolt
Inner hexagon spanner
5 ROH oil plug G1/8 11.8±1.0
Only (PV48KC1 specification)
22 Adjusting nut M14
Wrench 68.6±4.9
32 Disc M14
Special clamp is shown in figure
24 Joint M14 47.1±2.9
LG922E930E07283.
Figures Procedure
1. Place mounting surface of interface plate (111)
upward and fix the pilot valve with the copper
board.
2. Install bushing (131) and O-ring (122) on valve
body (101).
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CLG930E/936E 7.5.12 Disassembly and Assembly of the Hand Pilot Valve Assembly
Figures Procedure
3. Put the gasket (121) between interface board
(111) and valve body (101), and fix it with
hexagon socket bolt (125).
Notice: Pay attention to the assembling
position, when assemble the spring pin (126) in
the hole of the valve body(101).
Notice: The gasket(121) shall be replaced
with a new one.
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7.5.12 Disassembly and Assembly of the Hand Pilot Valve Assembly CLG930E/936E
Figures Procedure
4. Fix the hexagon socket bolts (125) with an
inner hexagon spanner according to specified
torque.
Notice: While installing, screw them in
pairs alternately and slowly.
Figures Procedure
7. Fix the oil plug (293) as per specified torque
with an inner hexagon spanner. (Only for
PV48KC1)
Figures Procedure
9. Install the restoring spring (221) into the valve
body (101). Install pressure reducing valve
group into the valve body (101).
Notice: Install it according to the position
before removal.
211
11. Install the seal ring (213) onto the push rod
bushing (211).
Notice: Please install the seal ring (213) in
lip direction as shown in the figure below.
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CLG930E/936E 7.5.12 Disassembly and Assembly of the Hand Pilot Valve Assembly
Figures Procedure
12. Install the push rod (212) into the push rod
bushing (211).
Push rod
bushing If there is a spring (246) and a spring holder
Sealing
(218) used for two segmented breaking, install
them onto the push rod (212).
Figures Procedure
13. Install the push rod group into the valve (101).
Notice: When elasticity of the restoring
spring (221) is weak, the spring may not pop up
because of sliding resistance of the O-ring
(214).
Notice: When the restoring spring (221) is
strong, the cover (151) can be used to install 4
joints (301) temporarily at the same time.
Notice: pay attention to the pop out of the
push rod bushing group and the cover (6).
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CLG930E/936E 7.5.12 Disassembly and Assembly of the Hand Pilot Valve Assembly
Figures Procedure
14. Install it on (151).
15. Install the connectors (301) onto the valve
body (101) according to specified torque with
clamp.
101
Figures Procedure
17. Here is the way to adjust nuts (312). Clamp
opposite sides of the disc (302) with wrench
and install it on, then fix the adjusting nut (312)
as per specified torque.
Notice: While installing, do not move the
disc (302).
7.5.13 Removal and Installation of the Travel Motor & Reduction Gear,
Removal
Before removing hydraulic lines, lower the work implement to the ground completely, shut down
the engine, turn the key to the KEYON position, operate all hydraulic control levers several times
to release the residual pressure from the hydraulic system,and then press the exhaust button of
hydraulic oil tank breather valve to release the internal pressure from the oil tank.
Attach the identification label to each pipe to prevent wrong installation in the subsequence
procedures.
Before removing the lines, fittings or hoses, make the marks so as to prevent wrong installation
while restoring. Clean the periphery of the assembled oil port as required, and put a drip pan to
receive oil.
Seal them with plugs or caps when the lines, connectors or hoses are in disassembling state to
prevent pollution sources from entering the hydraulic system.
Figures Procedure
1. Refer to the method for the removal of the track
assembly to remove it.
2. Remove the 5 bolts (1) and remove the
blanking plate from the travel motor.
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7.5.13 Removal and Installation of the Travel Motor & Reduction Gear, CLG930E/936E
Figures Procedure
3. Disconnect the return pipe (2) and the elbow
joint (3).
4. Disconnect the two high-pressure pipes (4).
5. Disconnecting the pilot pipe (5).
Figures Procedure
8. Remove 18 mounting bolts (7).
9. Remove the travel motor.
Lifting weight: about 399kg.
Installation
Figures Procedure
1. Install the travel motor in track beam, and the
motor oil port shall orient the underframe side.
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7.5.13 Removal and Installation of the Travel Motor & Reduction Gear, CLG930E/936E
Figures Procedure
2. Clean bolt hole, apply thread locker Tonsan
1277 to mounting bolt, tighten the bolt timely,
and apply corresponding pretightening force to
the bolt in symmetrical cross strengthening
method.
Tightening torque is 1020±90N.M.
Figures Procedure
5. Tighten the plate mounting bolts of the travel
motor.
Tightening torque: 305±25Nm.
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7.5.14 Disassembly and Assembly of the Travel Motor & Reduction Gear CLG930E/936E
7.5.14 Disassembly and Assembly of the Travel Motor & Reduction Gear
Special tool
LG936E4F07118
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7.5 Hydraulic System December 30, 2017
7.5.14 Disassembly and Assembly of the Travel Motor & Reduction Gear CLG930E/936E
Bearing installer
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CLG930E/936E 7.5.14 Disassembly and Assembly of the Travel Motor & Reduction Gear
Disassembly
Precautions
6. Kerosene and other combustible materials are used for cleaning the parts.
7. The dismantled parts are coated with gear oil, resulting in slipping off.
Be sure to treat the parts. Slipping off of any part can cause personal injury or the part damage.
8. The hydraulic machine is precise and has many small gaps in structure. It needs to be dismantled
and re-assembled in a clean area without dust. In addition, keep the tools and cleaning agents clean.
9. After the motor is removed from the machine, clean the area around each interface and then remove
each plug. Be sure to prevent oil dirt and water from entering into the motor.
10. Before dismantling, study the figure above. Prepare the necessary components based on the part to
be dismantled.
11. The piston and the cylinder block are not paired. To re-use them, mark the piston and the cylinder
block during removal. So as to match them when assembling.
Always prevent your hand from being clamped into the parts. Prevent your feet from being hit by
any lifted part.
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7.5.14 Disassembly and Assembly of the Travel Motor & Reduction Gear CLG930E/936E
Figures
Disasse 2. Remove the spring (28), spring seat (27) and spool group (26)
mbly Notice: Mark the spool group (26) and the rear cover (24). Failure to do so can
steps cause reverse installation.
3. Remove the plug (42), O-ring (43), throttle valve spring (41) and throttle valve (40).
4. Remove the safety valve (57).
Notice: During this period, the valve seat (57-3) can easily slip off. Check whether
the valve seat falls into the rear cover (24) or is lost.
5. Loosen the pilot valve screw plug (35), and remove the O-ring (36), the spring (34), the
spring holder(33), the pilot spool (31) and the pin (32).
6. Remove the connector (58).
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CLG930E/936E 7.5.14 Disassembly and Assembly of the Travel Motor & Reduction Gear
Guide bar
Figures
Notice: The following sections describe how to dismantle the motor separately.
After the reduction gear is assembled, it can be dismantled similarly. The main shaft
will not shake significantly, so it is better to dismantle the motor with the reduction
gear.
1. Place the motor shaft horizontally. Remove the hexagon socket bolts M18 × 50 (56), but
leave two of them diagonally.
2. Install two guide bars in the diagonal positions. (Purpose: They are used to prevent
Disasse
slipping off when removing and to guide when assembling.)
mbly
steps 3. Loosen the two reserved hexagon socket bolts M18 × 50 (56) gradually.
4. Remove the rear cover (24) and the brake spring (55). Make sure the cylinder (13) is
carefully taken away together with the rear cover (24).
Notice: Always prevent your hand from being clamped into the parts. Prevent
your feet from being hit by any lifted part.
Notice: Do not let the mating plate (54), the brake spring (55), the bearing bush
(51), the gasket (52), the O-rings (50), (47) and (49) fall to the ground.
Notice: There is a gasket (52) in the bearing bush. Avoid its loss during removal.
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7.5.14 Disassembly and Assembly of the Travel Motor & Reduction Gear CLG930E/936E
Figures
5. Do not bring the cylinder block (13) out when the mating plate (54) is removed.
Notice: Mark the mating plate (54) and the rear cover (24). Failure to do so can
cause reverse installation.
Disasse
6. Press the cylinder block downward with tool and expose the bearing inner ring; notice not
mbly
bruise the cylinder block (13) surface; refer to above figure.
steps
Notice: To protect the cylinder (13) surface, put a rubber pad between the cylinder
surface and the tool.
7. Hook the bearing (51) inner race with the puller to remove it.
Oil hole
Figures
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CLG930E/936E 7.5.14 Disassembly and Assembly of the Travel Motor & Reduction Gear
8. The piston brake can be pulled out with the tool. To remove the piston brake (21), install
the tool into the M6 screw hole on the surface of the piston brake (21). Roll the paper into
a barrel and insert it into the plunger hole, and then mark the outer surface of the cylinder
Disasse block.
mbly
9. Remove the rotating group (including the cylinder (13), the plunger (18), the shoe brake
steps
(17), the ball joint (16), the spring seat (15) and the cylinder spring (14)).
Notice: Always prevent your hand from being clamped into the parts. Prevent
your feet from being hit by any lifted part.
Figures
Mark
Fitting mark
10. Remove the mesh plate (19) and the friction plate (20).
11. Remove the plunger (18), the shoe brake (17) and the ball joint (16) from the rotating
group.
12. Remove the spring seat (15) and the cylinder spring (14) from the cylinder.
Disasse Notice: Install the plunger (18) into the cylinder (13) according to the marks. Make
mbly sure that the plunger is installed into the hole which is the same as the one before
steps dismantling.
Notice: Avoid damage to each contact surface. If damaged, do not use the
plunger again.
Notice: The plunger and the shoe are pressed together. They cannot be
dismantled.
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7.5 Hydraulic System December 30, 2017
7.5.14 Disassembly and Assembly of the Travel Motor & Reduction Gear CLG930E/936E
Oil hole
Figures
Figures
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CLG930E/936E 7.5.14 Disassembly and Assembly of the Travel Motor & Reduction Gear
Notice: When the parts associated with the bearing, such as bearings (10) (51),
main shaft (9), housing (1), rear cover (24) or the like, need to be replaced, adjust the
gasket (52).
Determine the gasket gap accurately, and then replace the gasket with the
corresponding one.
Disasse
mbly Adjust the bearing clearance to the range of 0-0.1mm.
steps Notice: Generally, the pivot (11) does not need to be removed. If necessary, mark
the corresponding swashplate (12).
Notice: Generally, the oil seal (3) does not need to be removed. If necessary,
replace it a new one.
To do so, remove the locating ring (4) and then remove the oil seal (3).
Figures
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7.5 Hydraulic System December 30, 2017
7.5.14 Disassembly and Assembly of the Travel Motor & Reduction Gear CLG930E/936E
Disasse Notice: Make sure the main shaft (9) is not inclined.
mbly (2) Measure the size F on the side of the rear cover (24)
steps
Notice: Be sure to measure four points on the circumference in a crisscross
pattern and take their average.
(3) If the gasket (52) thickness is defined as S, the gap Y may be calculated as follows: Y=F-
(E=S)
(4) Make sure the gap Y is within 0-0.01mm, and select one or two gaskets (52).
Figures
Disasse
The safety valve is an important part in performance and safety. It is very difficult to re-set its
mbly
pressure. If a malfunction happens, do not dismantle it but replace the valve assembly.
steps
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December 30, 2017 7.5 Hydraulic System
CLG930E/936E 7.5.14 Disassembly and Assembly of the Travel Motor & Reduction Gear
Grease
Figures
Notice: The valve seat (57-3) is fitted in the gap of the inner hole of the sleeve (57-
Disasse 1). Do not let the valve seat (57 -3) fall off when removing the safety valve (57) from the
mbly motor cover (24).
steps Further, when the safety valve (57) is assembled into the motor cover, to prevent the
valve seat (57 -3) from falling off, grease the joint surface.
Assembly
Precautions
1. Clean the parts thoroughly with cleaning fluid and dry them with an air gun.
2. Be sure to apply the hydraulic oil to the sliding parts before assembling them.
Always prevent your hand from being clamped into the parts. Prevent your feet from being hit by
any lifted part.
Figures
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7.5 Hydraulic System December 30, 2017
7.5.14 Disassembly and Assembly of the Travel Motor & Reduction Gear CLG930E/936E
1. Grease the outer ring of the oil seal (3) and the inner ring of the housing (1), and then tap
the oil seal (3) into the housing (1) gently using the seal installer.
2. Fix the oil seal (3) with the locating ring (4).
Assemb 3. Install the outer race of the front bearing into the housing (1) (clearance fit). Press the
ly steps inner race in the main shaft (9) (interference fit).
Notice: To press in the inner race easily, you can heat it to 100°(or below).
Figures
4. Fix the main shaft (9) to the housing (1). Be sure to grease the seal contact surface.
5. Assemble the obliquely-rotating plungers (6), (7) and (8).
Notice: Be sure to set the obliquely-rotating plunger right and then insert it.
Assemb Notice: When inserting the obliquely-rotating plunger, grease its sealed portion.
ly steps Avoid damage to the plunger.
6. When assembling the pivot (11), be sure to install it on the side which is consistent with
the matching mark of the swashplate (12). In addition, for long-term operation, install it in
the direction in which the sliding mark on the sphere is consistent with the contact mark
of the swashplate (12).
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CLG930E/936E 7.5.14 Disassembly and Assembly of the Travel Motor & Reduction Gear
Figures
7. Grease the three spherical surfaces of the swashplate (12) fully before assembling.
8. Install the plunger group (18), shoe brake (17), ball joint (16), spring holder(15), cylinder
spring (14) and cylinder (13) into an assembly, and then insert the assembly into the
main shaft (9).
Assemb
Notice: Always prevent your hand from being clamped into the parts. Prevent
ly steps
your feet from being hit by any lifted part.
Notice: Be sure to insert the plunger group (18) into the same hole as that before
dismantling the cylinder.
9. Insert the front bearing inner race into the main shaft (9) using the special tools (A1, A2).
Figures
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7.5 Hydraulic System December 30, 2017
7.5.14 Disassembly and Assembly of the Travel Motor & Reduction Gear CLG930E/936E
10. Assemble the mesh plates (19) and the friction plates (20) alternately. The first one and
the last one should be the mesh plate (19).
11. Insert the piston brake (21) with D-rings (22) and (23) in the housing (1) with the special
tools.
Assemb Notice: Grease the D-rings (22) and (23).
ly steps
Notice: Insert the piston brake (21) evenly with the special tools. The piston brake
is equipped with D-rings (22) and (23). Install the large-diameter D-ring (23) first, and
then install the small-diameter D-ring (22). The installation state of the small-diameter
D-ring (22) cannot be visually confirmed. Do not force to install it.
The hole on the housing (1) can be cut sometimes.
Guide
pin
Figures
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December 30, 2017 7.5 Hydraulic System
CLG930E/936E 7.5.14 Disassembly and Assembly of the Travel Motor & Reduction Gear
Notice: When the related parts need to be replaced, adjust the gaskets.
Determine the gasket thickness according to the Dismantling Essentials 3-2-2, Item (2) -18
[Requirements for Thickness of Gaskets for Tapered Roller Bearings], and then assemble
them.
12. Fix the guide pin to the diagonal position 2 of the housing (1).
13. According the matching marks made during dismantling, install the mating plate into the
motor cover, and then install the gasket (52), the front bearing (51) outer race, the brake
spring (55) and the O-rings (50), (47) and (49).
Assemb 14. Insert the motor cover (24) into the housing (1) along the guide pin. To allow the motor
ly steps cover to be installed parallel to the diagonal position (2), tighten it with the M18 × 50 (56)
hex bolts. If you finish, tighten the hex bolts other than the guide pin position (2). Then,
remove the guide pin, and tighten the hex bolts at the remaining two positions.
Notice: Always prevent your hand from being clamped into the parts. Prevent
your feet from being hit by any lifted part.
Notice: When the front bearing (51) outer race is removed, remember to install the
gasket (52).
Make sure the motor cover is equipped with the O-rings (47), (49) and (50).
Notice: Tighten the hex bolt M18 × 50 (56) to 324 ± 32.4N·m.
15. Install the connector (58).
Figures
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7.5 Hydraulic System December 30, 2017
7.5.14 Disassembly and Assembly of the Travel Motor & Reduction Gear CLG930E/936E
16. Install the spring (34), the spring holder(33), the pilot spool (31) and the pin (32) in the
motor cover (24), and then tighten the pilot valve screw plug (35) with O-ring (36).
Notice: Tighten the pilot valve screw plug (35 ) to 49.0~58.8N·m.
17. Install safety valve (57)
Notice: The valve seat (57-3) is installed at the position with clearance fit. During
installation, to prevent it from slipping off or falling off, grease the joint surface.
Notice: Tighten the safety valve (57) to 98.1~118N·m.
18. Install the check valve (40) and its spring (41) in the motor cover (24), and then tighten
Assemb the pilot valve screw plug (42) with O-ring (43).
ly steps
Notice: Tighten the plug (43) to 14.7N·m.
Notice: When the new check valve is needed, grease the sealing portion.
19. According to the matching marks made when dismantling, install the spool assembly (26)
into the motor cover (24), and then install the spring holder(27) and the spring (28)
sequentially.
Notice: The spool assembly (26) is directional. Insert the spool assembly with
care.
20. Tighten the M43 plug (29) with O-ring (30) . Tighten the M42 screw plug (29) to
441~461N·m.
Initial operation
The serial numbers behind the names of the parts below should be based on the following drawings:
Disassembly
Precautions
1. Like the precautions 1) -4) for dismantling the traveling motor.
2. When the reduction gear is removed from the machine, the reduction gear may be polluted by oil dirt.
Be sure to clean the reduction gear surface and dry it.
To avoid scalding, do not dismantle the reduction gear until its temperature drops to the room
temperature.
3. Unscrew and remove the drain plug and the fill plug G3 / 4 (26), and drain the gear oil in the
reduction gear.
Dismantling the reduction gear when its gear oil is hot can cause the pressured oil to spray out.
4. To re-install the parts easily, be sure to mark the outside of each corresponding surface.
Figures Procedure
1. Remove the reduction gear from the traveling
motor and reduction gear.
2. Lift the reduction gear onto the work bench.
Remove three hexagon socket bolts M10×30
(25)installed in the rear cover equally. Then install
the lift rings.
Notice: Always prevent your hand from
being clamped into the parts. Prevent your feet
from being hit by any lifted part.
Notice: Be sure to lift the reduction gear
up horizontally.
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CLG930E/936E 7.5.14 Disassembly and Assembly of the Travel Motor & Reduction Gear
Figures Procedure
3. Remove the rear cover of the reduction gear.
(1) Remove the remaining hexagon socket bolts
M10 × 30 (25).
Figures Procedure
5. Remove the bracket 2.
(1) Remove the sun gear 2 (15).
Notice: Do not put your hands between the
gears. Doing so can cause hand injury.
(2) Install three M10 eyebolts on the bracket 2 (9).
Lift up the brackets (9,10, 11,12, 13 and 14)
overall.
Notice: Always prevent your hand from
being clamped into the parts. Prevent your feet
from being hit by any lifted part.
Notice: Be sure to lift the reduction gear
up horizontally.
Figures Procedure
(3) Install three M10 eyebolts into the ring gear
equally and lift out the housing assembly
(including ring gear (3), housing (1), bearing
(2), floating seal ring (5), hexagon socket bolts
M18 × 110 (4)) horizontally
Notice: Always prevent your hand from
being clamped into the parts. Prevent your feet
from being hit by any lifted part.
Notice: Be sure to lift the reduction gear
up horizontally.
7. Removal of housing
(1) Install three eyebolts into the housing (1)
equally. Let the ring gear (3) face down and the
housing (1) face upward, and then lift them
onto the work bench. Mark the outside of the
housing and ring gear (3).
Notice: Always prevent your hand from
being clamped into the parts. Prevent your feet
from being hit by any lifted part.
Notice: Be sure to lift the reduction gear
up horizontally.
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7.5.14 Disassembly and Assembly of the Travel Motor & Reduction Gear CLG930E/936E
Figures Procedure
(2) Remove the floating seal ring (5).
(3) Remove the hexagon socket bolts M18 × 110
(4), but leave two on the diagonal positions.
(4) Unscrew the two reserved bolts and tap the
housing and ring gear gently with the hammer
to separate the housing from the ring gear
easily.
Notice: Always prevent your hand from
being clamped into the parts. Prevent your feet
from being hit by any lifted part.
Notice: Avoid damage to the sliding metal
surface of the floating seal ring (5) and the O-
ring.
Notice: The bearing (2) outer race is fitted
with the housing (1) inner diameter closely. Do
not remove the bearing (2) unless it has to be
replaced. Do not re-use the bearing removed
from the housing (1). Be sure to replace it.
8. Remove the floating seal ring on the side of the
motor head.
Remove the floating seal ring (5) on the side of the
motor head.
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CLG930E/936E 7.5.14 Disassembly and Assembly of the Travel Motor & Reduction Gear
Figures Procedure
9. Remove the bracket 1.
Notice: If the gear pin 1 (10) needs to be
re-used, before removing, make the same mark
on both the gear pin 1 and the mounting hole.
For follow-up matching.
(1) Tap the spring pin 6 × 36 (21) into the gear pin
1 (20).
(2) Remove the gear pin 1 (20) from the bracket 1
(16).
(3) Remove the thrust shim 1 (18), the planetary
gear 1 (17) and the needle bearing (19) from
the bracket 1 (16).
Notice: Do not put your hands between the
gear and the bracket. Doing so can cause hand
injury.
Notice: If the gear pin 1 (20) or the
planetary gear 1 (17) needs to be replaced,
replace all the three ones.
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7.5 Hydraulic System December 30, 2017
7.5.14 Disassembly and Assembly of the Travel Motor & Reduction Gear CLG930E/936E
Figures Procedure
Figures Procedure
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7.5 Hydraulic System December 30, 2017
7.5.14 Disassembly and Assembly of the Travel Motor & Reduction Gear CLG930E/936E
Assembly
Precautions
1. 1 Clean the parts thoroughly with cleaning fluid and dry them with an air gun. Degrease the surface
with sealant using the thinner or the like.
2. Check whether each part is normal.
3. Coat each hex bolt with #242 and tighten it.
4. Before assembling each assembly, apply a thin layer of gear oil to it.
5. Remove the residue from the thread position with sealant using a screwdriver and degrease the
thread position.
Always prevent your hand from being clamped into the parts. Prevent your feet from being hit by
any lifted part.
Part
Part name Dimension Tightening torque (N·m)
symbol
378±37.8 N·m
4 Hex bolt M18×110
# 242 sealant coating
68.6±6.9N·m
25 Hex bolt M10×30
# 242 sealant coating
26 Hexagon screw plug G3/4 147±14.7N·m
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CLG930E/936E 7.5.14 Disassembly and Assembly of the Travel Motor & Reduction Gear
Figures Procedure
1. Assembly of bracket 2 Ass’y.
(1) Insert the planetary gear 2 (10), needle bearing
(12) and thrust shim 2 (11) into the bracket 2
(9).
Notice: Do not put your hands between the
gear and the bracket. Doing so can cause hand
injury.
(2) Insert the gear pin 2 (13) into the bracket 2 (9)
toward the direction of the spring pin hole.
(3) Insert the spring pin 10 × 50 (14) into the
bracket 2 (9) and the gear pin 2.
(4) Caulk the two positions which are symmetrical
in 180°.
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7.5.14 Disassembly and Assembly of the Travel Motor & Reduction Gear CLG930E/936E
Figures Procedure
Two caulking
positions which
are symmetrical in Based on the
Notice: For the direction of inserting the
Spring pin 180°, as shown in caulking, the spring pin and the caulking method, refer to
opening, as shown the figure. spring pin is
hidden by 0.5.
the left figure.
in the figure.
Figures Procedure
Figures Procedure
4. Assembly of housing 1Ass’y
Sealant #515
(1) Apply the sealant #515 to the joint surfaces
between the housing (1) and the ring gear (3).
(2) Install the M20 eyebolts on the housing (1) and
lift it with the hoist. Install the ring gear (3)
based on the matching marks.
Notice: Always prevent your hand from
being clamped into the parts. Prevent your feet
from being hit by any lifted part.
Notice: Be sure to lift up the component
horizontally.
Figures Procedure
5. Angular contact bearing’s gasket thickness
requirements.
Notice: This must be done when any one
of the motor (case), the housing (1), the
(angular contact) bearing (2) and the lock
washer (7) needs to be replaced. If not the
above conditions, the gasket can be used as
usual.
(1) Install the two bearing (2) outer races in the
housing.
(2) Install the two bearing (2) outer races evenly
and measure the inner race’s assembly size.
Notice: When measuring the inner race’s
assembly size, rotate the bearing for more than
5 times before measuring.
(3) Measure the motor housing’s bearing size (B).
(4) Measure the motor housing’s lock washer
groove size (C).
(5) Measure the thickness (D) of lock washer (7).
Notice: Be sure to measure four points on
the circumference in a crisscross pattern and
take their average. Dimensional accuracy:
0.01mm.
(6) When the gasket (6) to be used is S thick, the
gap X is as follows. X=(B+C)-(A+D+S)
(7) In this case, the gasket with a gap X
(0.08~0.02mm) is selected.
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7.5 Hydraulic System December 30, 2017
7.5.14 Disassembly and Assembly of the Travel Motor & Reduction Gear CLG930E/936E
Figures Procedure
6. Assembly of housing Ass’y
Stamping
(1) Let the main shaft of the motor face upward
and put it onto the work bench. Select the
gasket (6) according to Section 4-3-2, Item (5)
[Requirements for Angular Contact Bearing
Thickness]. Then, put the gasket (6) on the
bearing mounting end face of the motor
housing.
Notice: Always prevent your hand from
being clamped into the parts. Prevent your feet
from being hit by any lifted part.
Notice: Be sure to lift up the component
horizontally.
(2) Install the three eyebolts (M10) in the ring gear.
Align the motor center and fall vertically. Insert
the bearing installed in the inner diameter of
the housing into the motor, and then align the
bearing inner race using the punching machine
to press the bearing inner race until it is
installed in place.
Notice: Always prevent your hand from
being clamped into the parts. Prevent your feet
from being hit by any lifted part.
Notice: Be sure to lift up the component
horizontally.
(3) Strain the groove of the lock washer (7) while
pressing the flange of the housing (1).
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December 30, 2017 7.5 Hydraulic System
CLG930E/936E 7.5.14 Disassembly and Assembly of the Travel Motor & Reduction Gear
Figures Procedure
(4) Fix the support ring (8) to the outside of the
lock washer (7).
Figures Procedure
(2) Insert the sun gear 2 (15).
Notice: Do not put your hands between the
sun gear and the other gear. Doing so can
cause hand injury.
Notice: The reason why the bracket 2Ass'y
is assembled at the position shown in the left
figure is that oil lubrication can be performed
well. Be sure to observe it.
Figures Procedure
(3) Insert the thrust plate (23) into the bracket (16).
Notice: Let the sharp corner point toward
the side of the rear cover (24).
Sharp
corner
Thrust shim
Figures Procedure
10. Filling of gear oil
(1) Pour the gear oil (SAE90, API classification
GL-4 or GL-5, 9.5 L) into the port G3/4.
(2) Install the hexagonal plug G3 / 4 (26) in the
rear cover (24) and tighten it to 147.1 ±
14.7N·m.
Notice: For coating the bolts with sealant
#242, refer to the #242 coating method in the left
figure.
7.5.15 Removal and Installation of the Swing Motor & Reduction Gear
Removal
Before removing hydraulic lines, lower the work implement to the ground completely, shut down
the engine, turn the key to the KEYON position, operate all hydraulic control levers several times
to release the residual pressure from the hydraulic system,and then press the exhaust button of
hydraulic oil tank breather valve to release the internal pressure from the oil tank.
Before removing the lines, fittings or hoses, make the marks so as to prevent wrong installation
while restoring. Clean the periphery of the assembled oil port as required, and put a drip pan to
receive oil.
Seal them with plugs or caps when the lines, connectors or hoses are in disassembling state to
prevent pollution sources from entering the hydraulic system.
Figures Procedure
1. Remove the oil filler pipe (1);
2. Remove hose (2) of main oil filler;
3. Remove the oil return pipe (3).
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7.5 Hydraulic System December 30, 2017
7.5.15 Removal and Installation of the Swing Motor & Reduction Gear CLG930E/936E
Figures Procedure
4. Remove 2 pilot pipes (4) of time delay valve.
Figures Procedure
7. Remove the grease hose (7) on the bottom of
swing motor reduction gear.
Installation
7.5.16 Disassembly and Assembly of the Swing Motor & Reduction Gear
102 Valve body D2 230 No.2 carrier D 403 Positioning pin plug 909 Pin
104 Rear axle cover E 231 No.1 carrier D 601 hexagon head bolt 910 Pin
201 Drive shaft B 282 No.2 pin B 602 Hexagon socket head 912 snap ring
202 Gear ring E 283 No.1 pin B cap bolt 913 snap ring
203 No.2 planetary gear D 284 Push plate E 801 oil seal 915 Bearing seal ring
204 No.2 sun gear D 390 Nameplate 802 O-ring 922 Screw plug
210 No.1planetary gear D 391 Pin 903 Screw plug 925 Exhaust valves
211 No.1sun gear D 402 Self-aligning roller 904 Hexagon socket head 926 Grease fitting
bearing cap bolt 930 Hex screw
905 O-ring
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December 30, 2017 7.5 Hydraulic System
CLG930E/936E 7.5.16 Disassembly and Assembly of the Swing Motor & Reduction Gear
Special tool
Remove the clamp used for bearing (401). Remove the clamp used for bearing (402).
Perforation
Disassembly
The chapter introduces the disassembly of swing motor & reduction gear in two parts, including:
1. Disassembly of swing motor
2. Disassembly of reduction gear
Choose a clean location. The disassembly platform shall be covered by rubber plate or cloth, etc.
in order to protect components from being damaged.
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December 30, 2017 7.5 Hydraulic System
CLG930E/936E 7.5.16 Disassembly and Assembly of the Swing Motor & Reduction Gear
Remove the motor in accordance with the following sequence. The number in the brackets following the
component name is the symbol shown in the installation profile view.
Figures Procedure
1. Tie the periphery of motor with steel wire rope,
lift it by crane, and then clean it with colorless
and transparent light oil. Blow and dry it with
compressed air after the cleaning.
Notice: Protect the motor from foreign
matters entering its inside. Wash mud and dust
adhered to the motor, and seal each hole with
adhesive tape.
2. Drain all working oil in the motor body from oil
drain hole.
3. Put the shaft end of drive shaft (101)
downwards, and then fix it on the operation
platform which is easy to be disassembled. At
this time, make the mark at the junction
position between motor body (301) and valve
body (303).
4. Loosen pressure-reducing valve (051) and
remove it from valve body (303).
Notice: O-ring may be destroyed while
loosening pressure-reducing valve, therefore,
be sure to replace the O-ring.
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7.5 Hydraulic System December 30, 2017
7.5.16 Disassembly and Assembly of the Swing Motor & Reduction Gear CLG930E/936E
Figures Procedure
5. Remove ROMH oil drain plug (469) from valve
body (303), and then remove spring (355) and
plunger (351).
Notice: Protect the plunger valve seat from
being damaged.
Figures Procedure
7. Remove the brake spring (712) from the brake
plunger.
Figures Procedure
10. Remove friction plate (742) and metal plate
(743) of separator from motor body (301).
Figures Procedure
12. Carry out the following operation steps in
accordance with the requirements.
Drive out the inner ring of cylindrical roller bearing
from drive shaft with press machine.
Notice: The inner ring of cylindrical roller
Punch press
bearing can also be knocked by hammer and
steel bar, but it is needed to knock the inner
ring uniformly and protect the bearing from
Drive shaft being damaged.
Notice: The removed bearing cannot be
reused.
13. Knock the outer ring of cylindrical roller bearing
gently with hammer and steel bar from one a
side of housing of oil seal (491), so as to
remove it from the motor body (301).
Notice: The removed bearing cannot be
reused.
14. Remove the cylindrical roller bearing (444)
from valve body (303) with sliding weight
bearing detacher.
Notice: The removed bearing cannot be
reused.
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7.5 Hydraulic System December 30, 2017
7.5.16 Disassembly and Assembly of the Swing Motor & Reduction Gear CLG930E/936E
Figures Procedure
1. Lift the reduction gear with lifting device, and
then lay the drive shaft on the level ground.
Drain the gear oil from oil drainage port on the
gear.
2. Loosen hex screw (602) and remove the motor.
3. Remove No. 1 sun gear (211).
4. Remove No. 1 planetary carrier group
Notice: Collect the gear oil with clean
container, and check the oil for wear powder.
Figures Procedure
9. Disassembly of No. 2 planetary carrier group.
Notice: It is not required to disassemble
No.2 planetary carrier group hereto.
Check the components carefully in accordance
with the guidance mentioned by maintenance
criteria. We recommend to replace No.2 planetary
carrier group in set as possible as you can. But if
the replacement of some part is inevitable, please
LG922E930E07441 operate in accordance with the following steps.
a. Remove the innermost spring pin (910) and
No. 2 spring pin (282).
b. Remove No.2 planetary gear (203) from the
side.
10. Remove spring backup ring (913) from drive
shaft (201).
Notice: Mark the gear and pin to avoid
mistake during the installation.
Notice: If No.2 spring pin (282) is removed,
never reuse it.
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7.5 Hydraulic System December 30, 2017
7.5.16 Disassembly and Assembly of the Swing Motor & Reduction Gear CLG930E/936E
Figures Procedure
11. Place the reduction gear erectly. Support the
periphery of housing, make the drive shaft
surface downward, and knock the center of
shaft with plastic hammer to remove the shaft
from the housing.
Notice: Hereto, check the drive shaft, and
if there is no abnormality, it is not required to
disassemble it further.
Check the components carefully in accordance
with the guidance mentioned by maintenance
criteria. We recommend to replace in set as
possible as you can. But if the replacement of
some part is inevitable, please operate in
accordance with the following steps.
12. As it is shown in the figure, remove bearing
seal ring (915) and the bearing (401) from the
drive shaft bearing.
13. Remove the oil seal (401) from the housing
(102).
Notice: While removing the drive shaft,
protect it from being damaged.
Notice: If the bearing seal (915) and oil
seal (801) are removed, never reuse them.
Assembly
The chapter introduces the assembly of swing motor & reduction gear in two parts, including:
1. Assembly of swing motor
2. Assembly of reduction gear
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December 30, 2017 7.5 Hydraulic System
CLG930E/936E 7.5.16 Disassembly and Assembly of the Swing Motor & Reduction Gear
2. Before the assembly, please check each component in accordance with maintenance criteria.
3. Each component shall be cleaned with detergent and then blow it dry with compressed air.
4. Before the assembly, revolving junction part and bearing, etc. must be applied with clean
working oil.
6. Tighten the captive bolts and oil drain plug, etc. with torque wrench according to the
tightening torque shown in the following table.
If the liquid filling material is used. Peel the surface of the component with knife or similar
objects. and grind the surface with oil stone.
If it does not conform to the above part number, please refer to the assembly profile view.
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7.5 Hydraulic System December 30, 2017
7.5.16 Disassembly and Assembly of the Swing Motor & Reduction Gear CLG930E/936E
Figures Procedure
1. Place the motor body (301) on the platform
suitable for operation with one side of the valve
body (303) upwards.
2. (This step can not be executed until the
cylindrical roller bearing is removed).
Install the inner ring of cylindrical roller bearing
(443) into the drive shaft (101) in the shrink-on
method.
Notice: Pay attention to the direction of
dowel pin of cylindrical roller bearing.
3. Install the inner ring of cylindrical roller bearing
(444) into the drive shaft (101) in the shrink-on
method.
4. Install the oil seal (491) in the motor body (301)
with tool.
Notice: Pay attention to the direction of oil
seal.
(Refer to the assembly profile view.)
Apply a thin layer of grease on the sealing part of
oil seal.
Notice: Knock it uniformly to protect the
periphery from being damaged.
One side of the output shaft
Figures Procedure
6. Install the drive shaft on the motor body (301).
Notice: Install it carefully to protect the
sealing part of oil seal from being damaged.
Notice: Twine the spline of shaft with
plastic adhesive tape.
Figures Procedure
9. Install the plunger group (121, 122) assembled
on plate (123) on the cylinder (111), and install
it together with drive shaft (101) cooperatively.
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December 30, 2017 7.5 Hydraulic System
CLG930E/936E 7.5.16 Disassembly and Assembly of the Swing Motor & Reduction Gear
Figures Procedure
10. Reset the motor body (301) with the oil seal
downward, and then install separator metal
plate (743) and friction plate (742) into the
motor body (301) in sequence.
Install 4 separator metal plates and 3 friction plate
in total.
Figures Procedure
12. Install the brake plunger (702) in the motor
body (301).
Figures Procedure
15. Install valve plate (131) into valve body (303),
and then into O-ring.
Notice: Apply a thin layer of grease on
joint surface of valve plate. (Prevent falling off)
Figures Procedure
17. Install plunger (351) and spring (355) into valve
body (303), and then install ROMH oil drain
plug (469) equipped with O-ring (488) into
valve body (303).
Notice: Check whether the plunger moves
smoothly.
Figures Procedure
1. Assembling the drive shaft assembly
a. Install bearing seal (915) into drive shaft
(201).
b. Apply the grease inside of bearing (401),
and press it into drive shat.
Notice: Before assembly, apply the grease
on both sides of bearing.
Figures Procedure
Figures Procedure
5. Lift the reduction gear erectly, and make drive
shaft downward.
6. Install the bearing with clamp (402).
7. Install the circlip (913).
8. Fill the grease into housing from grease filler.
Notice: Test the installation depth of drive
shaft from bearing surface with the clamp
according to the requirements in 5.3.4.
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7.5 Hydraulic System December 30, 2017
7.5.16 Disassembly and Assembly of the Swing Motor & Reduction Gear CLG930E/936E
Figures Procedure
9. Install No. 2 planetary carrier group.
a. Install thrust washer (286).
b. Insert planetary gear (203).
c. Gently knock No. 2 pin (282) into planetary
gear with plastic hammer.
Figures Procedure
10. Apply liquid seal on the joint surface of housing
(102).
11. Install No. 2 planetary gear group into housing
(102).
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7.5 Hydraulic System December 30, 2017
7.5.16 Disassembly and Assembly of the Swing Motor & Reduction Gear CLG930E/936E
Figures Procedure
12. Install gear ring (202) into housing (102).
Fix gear ring with four screws temporarily, and pay
attention to using washer when screwing, in case
of damage the housing.
13. Install No. 1 planetary carrier group.
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December 30, 2017 7.5 Hydraulic System
CLG930E/936E 7.5.16 Disassembly and Assembly of the Swing Motor & Reduction Gear
Figures Procedure
14. Install No.1 sun gear (211)
15. Temporarily remove the bolt, and apply liquid
seal on the installation surface of housing
(102).
16. Install rear housing (104) to gear ring (202),
and tighten hex bolt.
17. Fill gear oil into reduction gear from the filler,
temporarily install the dipstick, and test gear oil
capacity.
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7.6 Work Implement December 30, 2017
7.6.1 Removal and Installation of the Bucket CLG930E/936E
Removal
Figures Procedure
1. Start up the engine, operate the machine to
make bucket back lie on the ground, and then
shutdown the engine;
Notice: Place a pad between the bucket
and ground.
Figures Procedure
4. Remove the pin shaft (3) with copper hammer
and raping bar;
Notice: It needs the cooperation of two
people, one person hammers the pin shaft out
of pin hole from one end of the pin shaft with
copper hammer and raping bar, and the other
person holds the pin shaft on the other end.
Notice: O-ring, which is installed between
front bracket of arm and the bucket, needs to
be removed and put at a safe place.
Installation
Removal
Figures Procedure
1. Remove the bucket. See "the Removal and
Installation of Bucket for details".
2. Retract arm cylinder completely, retract boom
cylinder to make work implement drop until the
front bracket of arm falls onto the ground,
select proper state to place sleeper between
link and arm as well as between bucket
cylinder body and arm during the process.
Figures Procedure
7. Place a sleeper between right lever and arm,
knock on small end of the pin shaft (4) with
copper hammer and rapping bar, push the pin
shaft (4) to right lever, and remove the pin shaft
(4).
Notice: There are adjusting washers
between bucket cylinder and link, and between
the link and lever, and it is necessary to
remove and put them in a safe place.
8. Tighten the piston rod and the cylinder body
with wire rope.
Installation
Removal
Before removal of oil pipe, open the arm and bucket completely, keep the distance between the
bucket and the ground about 300~400mm, shut down the engine, operate the lever to relieve
pressure, release the pressure of the accumulator, and loosen the hydraulic oil tank cover slowly
to release the pressure in the hydraulic oil tank.
Figures Procedure
11. Remove the bucket. See the Removal and
Installation of Bucket for details in this chapter;
12. Remove link and lever. See "Removal and
Installation of Link and Lever for details in this
chapter".
13. Remove the bucket cylinder. See "Removal
and Installation of Bucket Cylinder for details"
14. Start the engine, stretch the arm cylinder to the
most, operate boom cylinder, and put down
work implement to make front bracket of the
arm fall on the ground.
Notice: The pad needs to be placed
between the arm and ground.
15. Lift up arm cylinder with lifting rope and
hoisting equipment.
16. Remove the bolt, nut and plate (1) with
spanner.
17. Remove the pin shaft (2) with copper hammer
and rapping rod.
Notice: There is adjusting washer between
arm cylinder and arm, and it needs to take it
down and place it at a safe place.
18. Start the engine, retract arm cylinder piston
rod, and fasten piston rod with wire rope in
case of stretching out.
Notice: Do not release the pressure
19. Lift arm cylinder to certain space with hoisting
equipment, place the sleeper between arm
cylinder body and the boom, and put arm
cylinder on the sleeper.
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December 30, 2017 7.6 Work Implement
CLG930E/936E 7.6.3 Removal and Installation of Arm
Figures Procedure
20. Remove lifting rope on the cylinder.
21. 1 Install the pin (2) into pin hole, and lift the arm
(5) with lifting rope and equipment through the
pin (2).
22. 1 Remove captive bolt, nut and plate (3) of
boom bracket hinge pin.
23. Remove hinge pin shaft (4) with copper
hammer and rapping rod.
24. Slowly put the bucket arm on the ground with
the sling.
Notice: The sleeper needs to be placed
between the arm and ground.
25. Start the engine, and lift and swing the boom to
remove the arm.
Installation
Removal
Before removal of oil pipe, open the arm and bucket completely, keep the distance between the
bucket and the ground about 300~400mm, shut down the engine, operate the lever to relieve
pressure, release the pressure of the accumulator, and loosen the hydraulic oil tank cover slowly
to release the pressure in the hydraulic oil tank.
Clean the periphery of the assembled oil port before removing lines and fittings.
Seal the lines, fittings or hoses with plugs or caps when they are in disassembling state, so as to
prevent pollution source from entering the hydraulic system.
Figures Procedure
1. Start the engine, operate the machine to make
arm cylinder and bucket cylinder stretch out,
and operate boom cylinder to make the lever
fall on ground.
2. Release residual pressure in hydraulic oil line.
(See "Test and Adjustment" for release of
residual pressure in hydraulic oil line)
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December 30, 2017 7.6 Work Implement
CLG930E/936E 7.6.4 Removal and Installation of the Boom
Figures Procedure
3. Remove hydraulic hose (1) on both ends of
bucket cylinder with inner hexagon spanner,
and pay attention to wrapping the connector
with towel or cloth to prevent oil splashing.
Fasten the hose on boom tube with the strap
Notice: Hold hydraulic oil leaked from the
line with oil bucket to prevent contaminating
the ground.
Figures Procedure
6. Operate the machine to place the boom on the
ground.
Notice: The pad needs to be placed
between front bracket of the boom and ground.
10. Lift the left boom cylinder (5) with lifting rope
and equipment.
11. Push boom cylinder and hinge pin shaft (6) of
boom to the position that does not affect the
moving of boom cylinder (5) with copper
hammer and rapping rod.
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December 30, 2017 7.6 Work Implement
CLG930E/936E 7.6.4 Removal and Installation of the Boom
Figures Procedure
12. Start the engine, retract piston rod of left boom
cylinder, and fasten piston rod with wire rope to
prevent it stretching out. Lower left boom
cylinder to revolving frame, and place the
sleeper between the cylinder and frame.
13. Lower the right boom cylinder (7) with the
same method.
14. Lift the stretching part on both ends of boom
middle bracket pin shaft with lifting rope and
equipment.
Figures Procedure
19. Remove boom and frame hinge pin (11) with
special tools.
20. Operate hoisting equipment to remove the
boom.
Installation
Removal
Figures Procedure
1. Remove the bucket. See the Removal and
Installation of Bucket for details in this chapter;
2. Start up the engine, operate the machine to
retract arm cylinder and bucket cylinder
completely, and operate boom cylinder to make
work implement fall on the ground.
Figures Procedure
9. Release residual pressure in hydraulic oil line.
(See "Test and Adjustment" for release of
residual pressure in hydraulic oil line)
10. Disconnect the harness (8) and fix it on the
boom with strap.
11. Disconnect the connection between hose (9)
and boom tube.
Notice: Wrap the connector with towel or
cloth to prevent oil splashing.
Notice: Hold hydraulic oil leaked from
the line with oil-holding equipment to
prevent the contamination.
Figures Procedure
13. Remove the boom and frame hinge pin (8) with
special tools (9).
Installation
Removal
Before removing hydraulic lines, lower the work implement to the ground completely, shut down
the engine, screw the key to the KEYON position, operate all hydraulic control levers several
times to release the residual pressure from the hydraulic system, and then loosen the hydraulic
oil tank cover to release the internal pressure from the oil tank.
Before removing the lines, fittings or hoses, make the marks so as to prevent wrong installation
while restoring. Clean the periphery of the assembled oil port as required, and put a drip pan to
receive oil.
Seal the lines, fittings or hoses with plugs or caps when they are in disassembling state, so as to
prevent pollution source from entering the hydraulic system.
Use lifting points as many as possible. Lifting ring is not allowed to bear shear force, and if there
is no appropriate lifting point, a wide lifting rope that is able to bear enough weight shall be used.
Figures Procedure
1. Referring to "the removal and installation of
bucket" & "the removal and installation of link
and lever" in this chapter, remove the bucket,
link and lever.
2. Operate the machine to lower arm end to the
ground.
Notice: Separate the cylinder from the arm
with tie, and avoid direct touch and bump to
cause appearance wear.
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December 30, 2017 7.6 Work Implement
CLG930E/936E 7.6.6 Removal and Installation of Bucket Cylinder Assembly
Figures Procedure
3. Retract bucket cylinder, and fix piston rod with
wire rope to prevent it from stretching out.
Figures Procedure
7. Knock the little end of pin with copper bar and
take it out.
Do not stand at receding side of the pin shaft;
otherwise the sudden falling of the pin shaft will
cause personal injury.
8. Take down bucket cylinder and horizontally
place it on the sleeper.
Installation
Welding is not allowed on the cylinder, and the cylinder can not be ground wire for welding, in case the
parts may be damaged due to electric arcs produced between piston rod and cylinder head, and
between piston and cylinder body.
Installation sequence is just reverse to the removal
The tightening torque of pin shaft captive bolts: M12: 120±10Nm.
Clean the threaded hole before installation, and apply anaerobic thread locker (Tonsan 1277) on thread
surface.
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December 30, 2017 7.6 Work Implement
CLG930E/936E 7.6.6 Removal and Installation of Bucket Cylinder Assembly
Tightening torque of the oil pipe flange captive bolt: M10: 73.5±3.5Nm;
1. Clean up the pin hole and pin shaft surface before installation.
2. If it is difficult to knock the pin shaft, adjust the installation position of the bucket and knock it
again.
3. Protect the seal ring from being damaged during the installation.
5. Check the surface of piston rod, and it is not allowed to have tape, paint, concrete, etc. to
adhere on the surface of piston rod in case of damaging seal ring during action.
6. Any dirt is not allowed to enter into hydraulic system during removal and installation of
hydraulic cylinder. Oil port must be sealed in a reliable method. Such as rubber cap or sealing
plug
7. Hydraulic cylinder shall not bear abnormal stress after installation, and be guaranteed not to
bear unnecessary load. Otherwise, this will affect service life of cylinder.
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7.6 Work Implement December 30, 2017
7.6.7 Removal and Installation of Arm Cylinder Assembly CLG930E/936E
Removal
Before removing hydraulic lines, lower the work implement to the ground completely, shut down
the engine, screw the key to the KEYON position, operate all hydraulic control levers several
times to release the residual pressure from the hydraulic system, and then loosen the hydraulic
oil tank cover to release the internal pressure from the oil tank.
Before removing the lines, fittings or hoses, make the marks so as to prevent wrong installation
while restoring. Clean the periphery of the assembled oil port as required, and put a drip pan to
receive oil.
Seal the lines, fittings or hoses with plugs or caps when they are in disassembling state, so as to
prevent pollution source from entering the hydraulic system.
Use lifting points as many as possible. Lifting ring is not allowed to bear shear force, and if there
is no appropriate lifting point, a wide lifting rope that is able to bear enough weight shall be used.
Figures Procedure
1. Lift the arm cylinder steadily with nylon strap
and hoisting equipment.
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December 30, 2017 7.6 Work Implement
CLG930E/936E 7.6.7 Removal and Installation of Arm Cylinder Assembly
Figures Procedure
2. Remove captive bolt of piston rod pin, and
remove the plate (1).
3. Knock the little end of pin with copper bar and
take it out.
Notice: Do not stand at receding side of
the pin shaft; otherwise the sudden falling of
the pin shaft will cause personal injury.
Figures Procedure
8. Knock the little end of pin with copper bar and
take it out.
Notice: Do not stand at receding side of
the pin shaft; otherwise the sudden falling of
the pin shaft will cause personal injury.
9. Slowly lift arm cylinder and place it on the
sleeper.
Installation
Welding is not allowed on the cylinder, and the cylinder can not be ground wire for welding, in case the
parts may be damaged due to electric arcs produced between piston rod and cylinder head, and
between piston and cylinder body.
Installation sequence is just reverse to the removal
The tightening torque of pin shaft captive bolts: M12: 120±10Nm.
Clean the threaded hole before installation, and apply anaerobic thread locker (Tonsan 1277) on thread
surface.
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December 30, 2017 7.6 Work Implement
CLG930E/936E 7.6.7 Removal and Installation of Arm Cylinder Assembly
Tightening torque of the oil pipe flange captive bolt: M10: 73.5±3.5Nm.
1. Clean up the pin hole and pin shaft surface before installation.
2. If it is difficult to knock the pin shaft, adjust the installation position of the bucket and knock it
again.
3. Protect the seal ring from being damaged during the installation.
5. Check the surface of piston rod, and it is not allowed to have tape, paint, concrete, etc. to
adhere on the surface of piston rod in case of damaging seal ring during action.
6. Any dirt is not allowed to enter into hydraulic system during removal and installation of
hydraulic cylinder. Oil port must be sealed in a reliable method. Such as rubber cap or sealing
plug
7. Hydraulic cylinder shall not bear abnormal stress after installation, and be guaranteed not to
bear unnecessary load. Otherwise, this will affect service life of cylinder.
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7.6 Work Implement December 30, 2017
7.6.8 Removal and Installation of Boom Cylinder Assembly CLG930E/936E
Removal
Before removing hydraulic lines, lower the work implement to the ground completely, shut down
the engine, screw the key to the KEYON position, operate all hydraulic control levers several
times to release the residual pressure from the hydraulic system, and then loosen the hydraulic
oil tank cover to release the internal pressure from the oil tank.
Before removing the lines, fittings or hoses, make the marks so as to prevent wrong installation
while restoring. Clean the periphery of the assembled oil port as required, and put a drip pan to
receive oil.
Seal the lines, fittings or hoses with plugs or caps when they are in disassembling state, so as to
prevent pollution source from entering the hydraulic system.
Use lifting points as many as possible. Lifting ring is not allowed to bear shear force, and if there
is no appropriate lifting point, a wide lifting rope that is able to bear enough weight shall be used.
Figures Procedure
1. Fix the boom cylinder (1) with nylon sling and
travel crane.
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December 30, 2017 7.6 Work Implement
CLG930E/936E 7.6.8 Removal and Installation of Boom Cylinder Assembly
Figures Procedure
2. Remove the captive bolt of piston rod pin and
take down the sleeve (2).
3. Remove grease line (3).
Figures Procedure
6. Disconnect hydraulic hose (4) of boom
cylinder.
Installation
Welding is not allowed on the cylinder, and the cylinder can not be ground wire for welding, in case the
parts may be damaged due to electric arcs produced between piston rod and cylinder head, and
between piston and cylinder body.
Installation sequence is just reverse to the removal
The tightening torque of pin shaft captive bolts: M12: 120±10Nm.
Clean the threaded hole before installation, and apply anaerobic thread locker (Tonsan 1277) on thread
surface.
Tightening torque of the oil pipe flange captive bolt: M10: 73.5±3.5Nm;
1. Clean up the pin hole and pin shaft surface before installation.
2. If it is difficult to knock the pin shaft, adjust the installation position of the bucket and knock it
again.
3. Protect the seal ring from being damaged during the installation.
5. Check the surface of piston rod, and it is not allowed to have tape, paint, concrete, etc. to
adhere on the surface of piston rod in case of damaging seal ring during action.
6. Any dirt is not allowed to enter into hydraulic system during removal and installation of
hydraulic cylinder. Oil port must be sealed in a reliable method. Such as rubber cap or sealing
plug
7. Hydraulic cylinder shall not bear abnormal stress after installation, and be guaranteed not to
bear unnecessary load. Otherwise, this will affect service life of cylinder.
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7.6 Work Implement December 30, 2017
7.6.9 Disassembly and Assembly of Cylinder CLG930E/936E
Method for disassembly and assembly of the cylinder introduced in the chapter is common approach of
excavator cylinder. Refer to the following figure for component names involved in the text. Different
cylinders may have some differences.
Disassembly
Preparations
Fixed device
2. Estimate the total weight of the hydraulic
cylinder and accessories, prepare
appropriate lift equipment, and the hook
distribution shall keep the lifting stable.
8. Remove the cushion collars of telescope 11. Remove the dust ring and circlip
side.
(1) When removing the dust ring, put the screw
(1) Remove the piston nut. driver against the opening of the dust ring
circlip, knock it to the bottom of circlip, and
(2) Knock the elastic snap ring with plastic
then pry the circlip to take it out.
hammer or other tools to remove it without
damaging piston rod and cushion collar. (2) Continue to knock the screw driver until it
running through the whole dust ring, then tip
(3) Slide the cushion collar to the piston rod
and pry the entire dust ring for removing.
screw, and then the baffle rings (double-slice
type) fall off. 12. Remove the slide bushing.
(4) Remove the cushion collar. There is a gap on (1) Find the juncture of the slide bushing.
the buffer ring, then remove the buffer ring by
(2) Support the upper end of the slide bushing
using the gap.
opening with screw driver, and then knock on
9. Removal of piston seal. the screw driver with the hammer until it pass
through the whole slide bushing.
(1) The guide rings and wiper rings shall be
removed simply by hands. (3) Remove the entire slide bushing with screw
driver.
(2) Make the screw driver up-right with the seal
ring and knock it with hammer, then cut off 13. Remove the lifting eye dust ring and the
and remove it. bushing.
(3) Take out the O-ring with iron needle. (1) Remove the dust ring from the lifting eye
hole. Same as the removal of the cover dust
ring, remove it with screw driver or other
tools.
Thread
(2) Remove the bushing with the heel plate, as
shown in figure.
Piston rod
Mounting
clamp
Bushing
10. Remove the end cover seal.
(1) Remove the primary seal: Put iron needle
against the upper edge of the seal ring and
extend the iron needle to the bottom of seal
ring groove, and run through the primary
sealing element, then tip and pry the entire
sealing element for removing.
(2) Remove the buffer ring: first remove the
buffer ring (black), and the following removal
is the same as the removal of primary seal.
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December 30, 2017 7.6 Work Implement
CLG930E/936E 7.6.9 Disassembly and Assembly of Cylinder
Slide bushing
O-ring
Qualified Fail Fail
O-ring Snap ring
protrudes sinks
upward downward
7-275
December 30, 2017 7.6 Work Implement
CLG930E/936E 7.6.9 Disassembly and Assembly of Cylinder
Jig
Piston
Seal ring
Seal ring
Snap ring
Front buffer
7-276
7.6 Work Implement December 30, 2017
7.6.9 Disassembly and Assembly of Cylinder CLG930E/936E
(4) For the piston rod with rear cushion collar, 6. Tighten the end cover
install relevant components and parts
Tighten it according to the required tightening
according to the following orders:
torque on the assembling drawing.
a. Install the gap direction of the buffer ring
(1) The thread type: tighten it with the hook
into the ring recess towards the thread
wrench.
side.
b. Install the facing process parts of the
cushion collar according to the following
figure.
Riveting Punch
c. Put the baffle ring (double-slice) into the
slip groove.
Set screw
d. Press the cushion collar towards the baffle
ring sufficiently, and then install the clip.
Knock it into the slip groove gently with Steel ball
(6) Install the setscrew and steel ball on nut. (1) Conduct full-stroke movement more than six
times slowly after the machine body is
After fastening piston nut, put steel ball in it, then installed to keep the hydraulic cylinder full of
tighten setscrew. Rivet two parts of the periphery oil.
with the cushion head.
(2) If the oil cylinder is filled with exhaust vents,
5. Install the piston rod into the cylinder body. try to pressurize the exhaust vent side (return
(1) Fix the cylinder body vertically or horizontally. side) to release the air.
Note O-ring
7-278
7.7 Air Conditioning System December 30, 2017
7.7.1 Removal and Installation of A/C Evaporator Assembly CLG930E/936E
Removal
Before the removal of the air compressor assembly, recycle the refrigerant in the A/C system by
using the refrigerant filling device, and ensure that there is no pressure in the A/C system, and
then remove it. During the recycle of the refrigerant, please wear the goggles correctly to prevent
personal injury.
During the removal and installation of pipe line, it is prohibited to wear cottony gloves, in order to
avoid the refrigerant leakage caused by the foreign matter adhesion on the O-ring position.
During the removal of the A/C warm water pipe, please use the special clamp or plug and seal the
water pipe port to protect the engine coolant from running off.
When the lines, connectors or hoses are in the disassembling state, shield them with plugs or
covers to prevent pollution sources from entering into the A/C system.
Figures Procedure
1. Remove six captive bolts (1) of bottom plate on
lower part of floor plate, and take down bottom
plate (2).
7-279
December 30, 2017 7.7 Air Conditioning System
CLG930E/936E 7.7.1 Removal and Installation of A/C Evaporator Assembly
Figures Procedure
2. Disconnect the connector (3) connecting with
A/C high-low pressure switch.
Figures Procedure
6. Open access door on driving side with the key,
and take out air filter (11) outside air
conditioner.
Figures Procedure
9. Remove three bolts (17) from the lower cover
plate, and remove that plate (18).
11. Remove the rear air ducts (21) and (22) on top
of evaporator assembly.
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7.7 Air Conditioning System December 30, 2017
7.7.1 Removal and Installation of A/C Evaporator Assembly CLG930E/936E
Figures Procedure
12. Remove the four air ducts (23)(24)(25) at the
side of evaporator assembly.
28
7-283
December 30, 2017 7.7 Air Conditioning System
CLG930E/936E 7.7.1 Removal and Installation of A/C Evaporator Assembly
Figures Procedure
15. Remove the connectors (29) and (30)
connected with A/C harness and located on
29
rear part of evaporator assembly.
30
32
31
Installation
Removal
Before the removal of the air compressor assembly, recycle the refrigerant in the A/C system by
using the refrigerant filling device, and ensure that there is no pressure in the A/C system, and
then remove it. During the recycle of the refrigerant, please wear the goggles correctly to prevent
personal injury.
During the removal and installation of pipe line, it is prohibited to wear cottony gloves, in order to
avoid the refrigerant leakage caused by the foreign matter adhesion on the O-ring position.
When the lines, connectors or hoses are in the disassembling state, shield them with plugs or
covers to prevent pollution sources from entering into the A/C system.
Figures Procedure
1. Remove 4 captive bolts (1) of diesel engine fan
guard. Move shield-lh of the fan (2).
7-285
December 30, 2017 7.7 Air Conditioning System
CLG930E/936E 7.7.2 Removal and Installation of A/C Compressor Assembly
Figures Procedure
2. Unscrew locking bolt (3) of A/C belt tension
pulley.
Figures Procedure
6. Separately remove captive bolt (7) of A/C
refrigerating tube on the side of A/C
compressor, and move refrigerating tubes (8)
and (9) out.
Installation
7.8 Cab
Removal
Figures Procedure
1. Open the hood left rear door(1), shut down the
disconnect switch (2), remove the buttery
guard (3), remove the battery shield (4) from
the battery.
Figures Procedure
4. Remove 4 air ducts (11) connected with A/C
evaporator (10);
Figures Procedure
15. Remove decoration plate (22) installed on the
floor;
16. Remove the decoration (23);
Figures Procedure
21. Disconnect water pipe (28) on washing end of
wiper washer reservoir in the rear of the cab
from washer reservoir (29);
22. Remove the clamp (30) from fixed water pipe
(28);
23. Tidy water pipe (28) and fix on outer wall of the
cab, located at water pipe outlet on right rear
side of the cabin outside the cabin.
Figures Procedure
26. If equipped with cab with roll over protection
structure, it needs to remove the pin (33)
located below cab rear end, and then remove
the nut (34) and take the plate (35) .
Figures Procedure
29. If the cab is equipped with falling-object
protective structure, hook the circular tube
beam (40) of protective cover using sling (39);
30. Start hoisting equipment, and slowly lift the
cabin.
Notice: The cab weight is 680kg, so please
select applicable sling
Notice: please be careful about the
operation, and during the lift, the water pipes
and harness shall not drag other components.
Installation
Removal
When removing the hose, mark on the hose and connectors to facilitate the matching when
assembling;
Seal up the removed connectors and hoses with covers or plugs to prevent water and dust, etc.;
Clean up the periphery of the assembled oil port.
Figures Procedure
1. Remove the cab. For specific operations, refer
to "Removal and Installation of Cab"
2. Remove the boot (1);
3. Remove two captive bolts (2) on front and rear
part of console upper cover (3) respectively;
4. Move console upper cover (3) upward, and
remove its internal electrical connectors;
5. Pull the harness out of left console;
6. By referring to above steps, pull the harness
out of right armrest.
Figures Procedure
9. Remove the plate (7) and plate (8) on lower
part of the cab.
Figures Procedure
13. Remove pilot clamp (14), clamp (15), clamp
(16) and bracket (18) at the bottom of floor
plate;
14. Disconnect 4 pilot lines (17);
15. Remove the 6 pilot pipe (19) connecting with
the foot pilot valve (20).
16. Arrange 12 pilot hydraulic lines stretching out
from inside of the cab, and ensure there is no
pulling phenomenon with other parts during
lifting process.
Installation
Attached drawing
. . . . .
8-7
December 30, 2017 8.4 A/C Schematic Diagram
CLG930E/936E
% % % % % % % % $ $ $ $ $ $ $ $ $
% % % % % % % % % % $ $ $ $ $ $ $ $
0
0
7+
0 30
7+
0
3
LG922E930E08003
8-8
8.4 A/C Schematic Diagram December 30, 2017
CLG930E/936E
Statement