950C Manual de Operacion

201909001
Service Manual
CLG950E
Hydraulic Excavator
Applicable type and model: CLG950E

Cummins QSG (EPA Tier 4f/ EU Stage Ⅳ /EU Stage Ⅴ )
C o n t e n ts
Safety Tips .............................................................. 1-1

Basics...................................................................... 2-1
Structure Function and Maintenance ................... 3-1
Parameters.............................................................. 4-1
Testing and Adjustment ........................................ 5-1
Fault diagnosis ....................................................... 6-1
Removal and Installation ....................................... 7-1
Attached drawing ................................................... 8-1
1-1
September 3, 2019 Safety Tips
CLG950E
1 Safety Tips
1.1 Safety Precautions ...................................................................................................1-4

1.2 Precautions for Llifting and Matching Operations ..................................................1-13
1-2
Safety Tips September 3, 2019
CLG950E
1-3
CLG950E
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should
also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair on this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintain and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"WARNING" as shown following.
The meaning of this safety alert symbol is as follows:

Attention. Be alert. Your safety is involved.
The message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
LiuGong cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are therefore not all inclusive. If a tool, procedure, work
method or operating technique not specifically recommended by LiuGong is used, you must satisfy
yourself that it is safe for you and others. You should also ensure that the product will not be damaged or
made unsafe by the operation, lubrication, maintenance or require procedures you choose.
The information, specification, and illustrations in this publication are on the basis of information
available at the time when it was written. The specification, torques, pressures, measurements,
adjustments, illustrations, and other items can change at any time. These changes can affect the service
given to the product. Obtain the complete and most current information before starting any job. LiuGong
has the most current information available.
CALIFORNIA PROPOSITION 65
Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer,
birth defects and other reproductive harm.
Battery post, terminal and related accessories contain lead and lead compounds, Always wash hands
after handling.
1-4
1.1 Safety Precautions CLG950E
1.1Safety Precautions Do not wear casual clothes, jewelries or keep a

long hair. Because they may be drawn into the
control system or the mobile parts and lead to
Please read and be familiar with all safety severe damage or even death.
precautions to avoid the occurrence of severe
damage or even death.
LG950E4f01003
LG950E4f01001 Only trained and qualified persons are permitted

to operate and maintain the machine.
If you feel uncomfortable, feel sleepy after taking
medicine or have drunk, do not operate the When for operating or maintenance, the operator
machine. In the case, it may cause your shall wear helmet and safety glasses of rigid
misjudgement and possibility of accidents. materials and safety shoes, face mask, and
Please hang the labels of "Do not Operate" or gloves.
similar warnings on the starting switch or the
operation lever before the maintenance of the
machine.
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LG950E4f01004
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LG950E4f01002
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1-5
CLG950E 1.1 Safety Precautions
Goggles, safety glasses or mask can protect Please ensure that there is no chip, greasy dirt,
your eyes from the hazards of high-pressure fluid tool or other foreign matters irrelevant to the
during the maintenance of the battery and the machine on the machine, especially on the
hazards of flying debris generated during the instrument panel, channel and ladder. Put the
work of the engine and the operation of tools. scattered things in place, such as the lunch
Please wear the protection mask when removing boxes and tools. Prevent foreign matters from
spring, elastic parts or add acid to the battery. entering the components of the system when
Please wear the safety cap and goggles when inspecting the opened oil tanks or water tanks.
conducting welding operations or using the Please empty the clothes pockets and move
welding gun for cutting. wrenches and nuts with great care before
removing the cover.
LG950E4f01005
LG950E4f01007
If you work under loud noise, please wear
appropriate hearing protection devices, such as Learn about the gesture singles and the signal
earmuff or earplug, to avoid damage to hearing sources at the plant and only receive the signals
due to loud noise. from one person.
Never keep the maintenance and repair solution
in glass containers.
Please observe relevant laws and regulations
when disposing hazardous materials such as
lubricant, fuel, coolant, solution, filter, battery and
other materials.
LG950E4f01006
Make sure all guard plates and covers of the

machine are fastened to the machine.
LG950E4f01008
When using detergent, be careful. Do not use

inflammable materials as detergents, such as
diesel or gasoline. It may catch fire.
1-6
Report all necessary repair work timely. Even if the pressured liquid is leaked from a hole
as small as a pin hole, it may penetrate the
Persons without permission or authorization
muscles and lead to death. If shot by the spouted
cannot stay onto or around the machine.
high-pressure oil, please contact a doctor and
It is prohibited to modify the machine without take a medical treatment immediately.
LiuGong's consent, and LiuGong will not be
responsible for the aftermath due to modification.
Compressed air
Compressed air may cause personal injury.

When using the compressed air for cleaning,
wear the mask, protection suits and shoes. The
maximum pressure of the compressed air for
cleaning should be lower than 0.2 MPa.
High-pressure solution
LG950E4f01010
Safe disposal of waste liquid
Prevent from being scalded by high-pressure Inappropriate disposal of waste liquid will
oil. When overhauling or replacing the pipes endanger environment and ecology. Please
of hydraulic system, check whether the observe local laws and regulations when dispose
pressure of system had been released. the waste liquid.
Hydraulic oil under pressure will damage
It is mandatory and necessary to collect the
your skin severely when it spattered on you.
liquid with containers spattered during the
inspection, maintenance, test, adjustment and
Take care when remove the hydraulic pipelines repair of machine. Proper container shall be
or connectors. When the oil spouts, the released prepared well before opening any fluid cavity or
high-pressure oil may lead to the continuous disassembling the parts containing liquid. Use
movement of the hoses. proper container when draining liquid.
Do not use the food or drink containers because
they may be drunk by others by mistake.
LG950E4f01009
Please wear safety glasses and leather gloves

LG950E4f01011
when checking for leakages. Do not use bare
hands to check the leakage but plate or paper
plate.
1-7
Precautions for accumulator application Asbestos
The dangerous high-pressure nitrogen is If asbestos dust is sucked in, it will endanger
contained in the accumulator, so read the your health. This product does not contain
following requirements and properly use the asbestos and LiuGong Machinery Co. Ltd
accumulator. recommends using genuine LiuGong spare
parts. If materials that you need to deal with
The accumulator shall be checked before charge
contain asbestos fiber, please observe the
of nitrogen. It is prohibited to charge the
following rules:
accumulator with gas if the accumulator does not
have a nameplate, or the words on the ● Never use compressed gas when cleaning.
nameplate are missed so that its type can not be Water can be used for descending the dust.
identified, or if the steel seal marks are
● You can use the vacuum cleaner with high
incomplete or cannot be read clearly, or if there is
filtering properties.
defect with the housing and therefore safe use
cannot be ensured. ● Do not grind the materials containing
asbestos dust.
The accumulator can only be filled with nitrogen
other than oxygen, compressed air or other ● In possible case, the machine shall be
flammable air to avoid explosion. operated in the upstream air.
Slowly charge the nitrogen into the accumulator ● Please observe local laws and regulations
so as to avoid the breakage of the rubber bag. when disposing asbestos.
The air valve of the accumulator shall be ● Take a bath after contacting with asbestos.
installed upward vertically. The accumulator shall
● If necessary, effective protective mask can be
be stably fixed on the bracket without being
used.
welded.
Do not drill any hole on the accumulator or carry
open fire or heat sources close to the
accumulator.
Do not conduct any welding operation on the
accumulator.
Since the accumulator is a high-pressure
container, it shall be replaced and repaired by
professional operators.
Release the air before discarding the waste LG950E4f01012
accumulator.
1-8
Preventing extruding or cut off When knocking object with hammer, please
make sure the flying debris will not hurt others.
Do not have your hands, arms or any other
bodies placed between moving parts. For Preventing burns
example, between work implement and cylinder,
between machine and working implement. After running for some time, parts of the machine
will be hot and those parts shall be inspected or
When working under the work implement, you repaired after it is cooled down.
shall support the equipment properly. Do not
support the work implement depending on Coolant
hydraulic cylinder. If control mechanism moves
or hydraulic oil line leaks, work implement will At working temperature, the coolant of the
drop. If it is necessary to remove the shield, you engine is at high temperature and has pressure,
shall fix it well after the repair. the radiator and all the pipes connected to the
radiator contain hot water or vapor, if you touch
Revolving vane of engine has the risk of cutting
them, serious burn would occur.
the fingers, so shut down the engine or keeping a
safety distance when repairing.
LG950E4f01014
LG950E4f01013
When checking the coolant level, the engine
shall be shut off and the filler cap shall be cooled
Make sure there's no foreign matter in the vanes
to the extent that it can be opened by bare
of engine fan. Fan vanes will throw out or cut off
hands.
the tools and other things that dropped or
pushed in it. Slowly loosen the filler cap of cooling system to
release the pressure.
Unless otherwise stated, any adjustment is not
permitted to be performed when machine or Coolant contains alkali which may causing injury
engine is running. and do not let it contact your skin, eyes and
mouth.
If the repair procedure must be performed when
machine is running, do not let the machine stay
in an unattended status. Arrange one operator
seated in the seat and prepare to shut down the
engine at any time.
Do not use twisted or worn wire rope. Wear
gloves during operation and move.
When forcing to extrude the bayonet, you shall
make sure no one is standing around it. You shall
wear safety goggles in order to protect your
eyes.
1-9
Oil Battery
Hot oil and parts will cause personnel injury, and Smog discharged from the battery may cause
do not let the hot oil and parts contact your skin. explosion. Do not smoke when inspecting the
level of battery electrolyte.
Electrolyte is a kind of acidic material, and
please do not let your skin and eyes contact
electrolyte.
LG950E4f01015
At working temperature, the hydraulic oil tank is

hot and contains pressure. When opening oil
filler cap of hydraulic oil tank, shut off the engine LG950E4f01016
and cool the filler cap down until it can be
opened by bare hands. Remove the tank cover
You shall wear safety goggles and gloves when
slowly to release the pressure of hydraulic oil
inspecting battery.
tank so as to prevent from being scalded by hot
oil.
Release pressure of the system before
disassembling all pipes, connector, or relevant
parts.
1-10
Safeguard from fire and explosion When the machine is started with a jump
method, the (+) cable must be connected to
All fuels, such as most of lubricants and some battery (+) terminal which is connected with start
cooling agent are flammables. motor coil, and (-) of external power is connected
Fuel leaking onto the hot surface or electrical with (-) of the starter. If there is no starter
elements may cause fire. negative terminal, it shall be connected to the
engine housing.
Do not smoke when refilling or within refiling
area, and in the place storing flammables. Do not charge the frozen battery to avoid
explosion.
Clean and tighten all the electrode connectors.
Daily inspect the wire for looseness or wear. Diethyl ether (Warning: Do not use diethyl ether
Before start, tighten the loose power supply to start the engine)
switch, and repair or replace the worn electric Any approach which attempts to start the engine
wires. by use of diethyl ether may cause serious
damage to engine or casualties.
LG950E4f01017
LG950E4f01018
Store the fuel, lubricant into containers with
relevant marks to avoid use by non-working
Pipeline, pipe and hose
personnel.
Put the cleaning cloth or other combustible Do not warp or knock the high-pressure pipeline,
materials with oil soaked into protective and do not install the abnormally warped or
container, and set it at a safe place. broken pipe or hose onto the machine.
Do not perform welding or flame cutting onto the Repair the loose or damaged pipe and hose of
pipe containing flammable liquid. Before welding fuel and lubricant pipeline and hydraulic system
or cutting, it shall be shall be cleaned completely in time. Leakage will cause fire hazard, and if
with flammable liquid. repair or replacement is necessary, please
contact the authorized dealer by LiuGong
Accumulated flammable materials such as fuel, Machinery Co., Ltd.
lubricant or other scattered materials on the
machine shall be cleaned up. If following problems occur, it shall be replaced.
Do not operate the machine near open fire. Make ● Damage or leakage of connector.
sure the battery is far away from open fire and ● The outer layer of hose is worn or cracked,
sparks, and do not smoke at the place of battery and reinforced steel wires are exposed.
charing.
● Partial bulge of hose.
● Hose with obvious twisting or flattening.
1-11
● The hose reinforcement steel has embedded Preventing injury by thunder

to the outer layer.
Never try to access the machine when there is
● Misplacement of the end connectors. lightning near it.
Make sure all clamps, guard and heat shield are If the thunder occurs when you sit in the cab,
installed correctly to prevent shaking or please stay in cab; if you're on the ground,
overheating by friction with other parts. please keep away from the machine.
When removing the connecting pipe of the
compressor, open fire is forbidden, or it will Cab protector
generate toxic gas, resulting in poisoning.
Top guard and front guard
Fire extinguisher and first-aid kit
The protectors are installed in order to prevent
Be sure to equip fire extinguisher, carefully read falling or splashing objects from injuring the
its use instructions, and be sure to know how to driver under some special circumstances. Be
use it. sure to close the window before doing hazardous
work. All personnel except the driver must be
The construction site must have first-aid kit in away from hazardous zone. Please add top
stock. Conduct regular inspection and add some guard and front guard device as necessary.
medicines if necessary.
You should know how to handle it when fire
hazard or injury occurs. 1
Select some personnels' phone number (such as
doctor, first-aid center, fire station and so on) for
use in emergency. Post the contact number list
onto the specified locations to ensure that the
staff knows correct contact information . 2
LG950E4f01020
1. Top guard devices

2. Front guard devices
LG950E4f01019
Inspect and maintain the fire extinguisher

frequently. Follow the recommended method of
application listed on the instruction panel.
1-12
Measures in emergency Precautions for accessories
Use the escape hammer placed in the cab to It shall be installed and commissioned by
break window glass and get out of cab when qualified personnel; the operator shall be trained,
encountering emergency situations. and his/her operation and maintenance shall be
performed strictly according to the operation
instructions for accessories.
1 When installing and using the spare accessory,
please read related instructions, manuals and
informations about the accessories.
2
Incorrect installation or purchase of accessories
will not only cause safety issues, but also have
the negative effect on service life and operation
of the machine.
Do not use the accessories unauthorized by
LG950E4f01021
LiuGong. Using unauthorized accessories will
cause safety issues, do harm on the normal
1. Escape hammer
2. Fire extinguisher (optional)
operation of machine and influence its service
life.
Inner space of cab It is forbidden to make any refit on the
accessories without permissions; otherwise you
This LiuGong device is equipped with and meet
shall bear the responsibility.
the industry standard of: "SAE J154" and "ISO
3411" cab, and standard provided the LiuGong Machinery Co., Ltd will not be
requirements to the cab space. responsible for the injury, accident and damage
of machine due to using unauthorized
Any refit of cab shall not occupy the specified
accessories.
space. Installation of added radio, fire
extinguisher and other devices must make the
specified space kept well. Any object brought
into the cab shall not occupy the specified space.
Lunch-box or other things shall be fixed. When
driving on uneven ground or tilting, those articles
shall not strike the cab and damage it.
1-13
CLG950E 1.2 Precautions for Llifting and Matching Operations
1.2Precautions for Llifting When using more than two wire ropes for lifting
load, the larger the lifting angle of each wire
and Matching Operations roper is, the larger the bearing force is. The
following figure shows the maximum weights at
1) One designated personnel sends out different lifting angles when using two wire ropes
cooperative signal to fully keep the contacts with a bearing force controlled within 9.8kN
among common operating personnel. The {1000kg}. If kept vertical, two wire ropes can lift
signalman shall stay in a safe place where 19.6kN{2000kg} in total; however, when the
the driver can see easily and understand suspension angle of two wire ropes
operating state from the driver seat, and presents120°, the lifting weight becomes 9.8
definitely send out signal in the form kN{1000 kg}. On the other hand, if lifting angle is
specified in advance. The signalman shall 150°, for lifting a load of 19.6 kN{2000 kg}, the
stand in front of lifted load and safely guide two wire ropes will bear a super force of up to
lifting operation. 39.2 kN{4000 kg}.
● It is forbidden to stand under lifted load.

● It is forbidden to climb on lifted load. KN
(Kg)
2) Check sling, etc. before lifting operation. 19.6
18.6
(2000) 16.7
(1900)
3) Wear gloves during lifting operation. 19.6 (1700) 13.7
(1400) 9.8
(Leather gloves are the best) (2000)
(1000) 4.9
9.8
4) Visually measure the weight to confirm (1000) (500)
center of gravity of lifted load.
5) Use slings suitable for the weight of lifted 30 60 90 120 150
load or lifting mode. Load may fall down if LG950E4f01022
too thick wire ropes are used for lighter load.
8) Use a pad to avoid damage of wire ropes
6) Try to avoid lifting by single wire rope. Lifted when installing them on lifted load with
load may rotate or fall off due to looseness. edges and corners. For lifted load which
Use two or multiple wire ropes for lifting in easily slides, antiskid device shall be used.
symmetric mode.
9) Use genuine eyebolt, and use shackle, etc.
Lifted load may rotate, swing back due to pull to fix eyebolt, wire rope, iron chain, etc.
of wire rope or deviate from lifting position if
10) Hang the wire rope in the central part of
only a single wire rope is used for lifting, so
hook for lifting.
as to cause dangerous accident, which shall
be noted. If the wire rope is hung on the edge of hook
for lifting, the rope may slide and even fall off
7) Lifting angle shall be below 60° in principle. from the hook when lifting. The central part of
Pay attention to avoid overlarge lifting angle hook has maximum strength.
between the wire rope and hook when lifting
heavy objects (above 25kg).
1-14
1.2 Precautions for Llifting and Matching Operations CLG950E
11) Do not use wire rope in distortion state. Precautions for operating bridge crane
Heavy objects of above 25kg must be lifted by

the crane.
1) Before operation, check wire rope, brake,
clutch, controller, slide rail, over-winding
protector, residual-current circuit breaker
against electric shock, crane anti-collision
device and power warning lamp to
100% 88% 79% 71% 41% guarantee safety.
2) Follow signal indication during lifting.
LG950E4f01023
3) Operate the crane in a safe position.
12) The following matters shall be noted during 4) Always confirm the directions of directional
lifting operation. display panel (east/west/south/north) and
operation button.
● Roll up wire rope slowly till it is tightened. The
hand may be caught easily when touching 5) Do not lift load in a tilted angle or travel
lifting tools by hands, so do not hold them, when the load swings.
but press them from above. 6) Do not operate lifting or horizontal and
● Stop rolling up after the wire rope is vertical travel at the same time.
tightened, and confirm the condition of lifted 7) Do not use slings to drag.
objects away from the ground and contact
conditions between slings and padded 8) Try to lift a little before lifting, and then lift
objects. after confirming it is safe.
● If lifted load is unstable, or wire rope or lifting 9) Take moving route into consideration in
chain is distorted, first lower lifted load, and advance, and lift to a safe height.
then lift again. 10) Place control switch on the position not
● Lifted load can not be tilted. affecting operation or passing.
13) The following matters shall be noted to 11) Do not shake control switch forcefully after
during lowering operation. operating the crane.
When lowering lifted load, first stop at 30cm 12) Remember the position of main power
above the ground, and then lower it gently. switch so as to cut off the power rapidly in
emergency.
Remove slings after confirming the load is placed
steadily. 13) If the crane stops operating due to power
failure, etc., power switch shall be cut off. In
After clearing the distortion or dirt on wire rope addition, if power switch is disconnected due
and chain used during lifting, place them in to the start of residual-current circuit against
designated positions. electric shock, confirm whether relevant
machineries of the switch are in operating
Precautions for operating mobile crane states before contacting again.
Read operation and maintenance manual of 14) Stop the operation when finding obstacles
various models carefully in advance to operate around the machine.
the crane safely.
1-15
CLG950E 1.2 Precautions for Llifting and Matching Operations
15) After the operation is finished, place the

crane on designated position, and lift the
hook to the height of 2m from the ground. Do
not hang slings on the hook when placing.
Selection of rope
1) By referring to following table, select most

suitable wire rope according to the weights
of lifting parts.
Wire rope
(Wire rope meeting "Z" standard without plating)
(JIS G3525 No. 6 6×37-A type)
Diameter of wire
Permissible load
rope
mm kN t
10 8.8 0.9
12 12.7 1.3
14 17.3 1.7
16 22.6 2.3
18 28.6 2.9
20 35.3 3.6
25 55.3 5.6
30 79.6 8.1
40 141.6 14.4
50 221.6 22.6
60 318.3 32.4
Note: Allowable load value is 1/6 of breaking

load of used wire rope (safety coefficient is 6).
1-16
1.2 Precautions for Llifting and Matching Operations CLG950E
2-1
September 3, 2019 Basics
CLG950E
2 Basics
2.1 How to Read the Manual..........................................................................................2-3

2.2 Marking of Revised Version .....................................................................................2-5
2.3 General Torque Specifications.................................................................................2-6
2.4 Unit Conversion Table..............................................................................................2-9
2.5 Cable Identification Methods..................................................................................2-10
2.6 Coating Materials ...................................................................................................2-12
2.7 Weight Table ..........................................................................................................2-13
2.8 Oils Use Specifications ..........................................................................................2-14
2-2
Basics September 3, 2019
CLG950E
2-3
CLG950E 2.1 How to Read the Manual
2.1How to Read the Manual
Composition of service manual
The Manual is used by green hands or technical service personnel with rich experience for reference. Of
which includes all technical information required by workshop maintenance, and for easy understanding
and convenient reading, it is divided into technical guide and workshop guide, which is used for
reference of relevant chapters and sections as required.
Service Manual
3. Structure 7. Remov-
4. 5. Test 6. Fault
1. Safety Function and 8. Attached
2. Basics Parameters and al and
Maintenance Diagnosis Drawing
Adjustmet Installation
Fault Hydraulic System

…… Electrical and Mechanical Electric Fault
Power System System Code System Fault
LG950E4f02001
1. Technical guide
1) Safety
2) Basics
3) Structure function and maintenance standards--This chapter mainly introduces components'
structure, function principle, maintenance limit, troubleshooting, cautions for maintenance, etc.
4) Test and adjustment--This chapter introduces the method of machine test. Which has two sections:
"Complete machine performance test" and "Other tests". The contents that each test item contains
are: Tools and testing instrument, machine state and parking site, troubleshooting procedures
5) Fault diagnosis--The fault involved in this chapter is the whole system fault, and the fault in chapter
"structure function and maintenance" is component failure. Fault code and electrical system fault are
in tabular form; The template of the hydraulic fault is in the form of fault tree
2. Workshop guide
1) Removal and installation--This chapter is to guide the customer to remove and install the fault part
after determine it. Which has two sections: " Removal and installation of component" and
"Disassembly and assembly of component".
2-4
2.1 How to Read the Manual CLG950E
2) Schematic diagrams of electrical system, air conditioning system and hydraulic system
Other reference manuals
For basic information of structure, operation and maintenance of the machine, refer to the following three
manuals, which are distributed to the users in the form of spare parts.
● Parts manual
● Use and maintenance manual
● Yammar engine parts manual
● Service manual of Yammar diesel engine
● Yammar engine fault diagnosis
Suggestions on the use and reading ideas of this manual
This manual takes the "fault symptom" as the starting point and provide you with the solution of
troubleshooting. Please follow the diagram for troubleshooting.
Fault phenomenon
Hydraulic fault Work implenment and

Electric fault Diesel engine fault Fault code
undercarriage system
corresponding fault phenomenon
Diesel engine
6.6 Failure diagnosis Electric sale document
of hydraulic system system fault
and mechanical system
Maintenance Fault code

Test per the requirements limit
Test and
adjustment
Find out abnormal Find and learn about
components abnormal components
Structure function
and maintenance
Learn about abnormal components
Removal and
installaiton Troubleshoot per
procedures
Blue shows specific Remove or repair
chapters in the text
Test and
adjustment
LG950E4f02002
2-5
CLG950E 2.2 Marking of Revised Version
User's Guidance
● Because the influences to the machine from area or processing are different, it shall confirm which
machine is applicable, and what work implements it has.
● Some accessories and optional parts in the Manual may not be transported to relevant areas, and
consult your local LiuGong dealer if required.
● The materials and technical specifications in the Manual are changed with variation of products, and
all information, diagrams and specifications in the Manual are the latest product information obtained
at the time of publication. The company reserves the right to make modification without any notice. If
it needs to obtain the latest technical information, please consult the dealer of LiuGong in local area
or Service Department of LiuGong Excavator Marketing Co., Ltd.
2.2Marking of Revised Version
The meaning of version number for service manual of LiuGong is as follows:
Second version
Publication month
Publication year
When the version is revised, the year and month reflects revision date of the version, and the last
numbers reflects revision times of the Manual. For example, 001 represents the first revision, 002
represents the second revision, and so on.
2-6
2.3 General Torque Specifications CLG950E
2.3General Torque Specifications
Bolts involved in this machine shall be tightened in accordance with the torque requirements specified in
the following table, unless special declaration.
Wrench Torque
No. Description Bolt specification
size (mm) N.m lbft
Captive bolt of the engine shock
1 M24-10.9 36 1020 752.3
absorber
2 Captive bolt of engine mount M16-10.9 24 305 224.9
3 Silencer mounting bolt M16-10.9 24 305 224.9
4 Radiator frame mounting bolt M20-10.9 30 600 442.5
5 Captive bolt of fuel tank M16-10.9 24 305 224.9
6 Captive bolt of hydraulic oil tank M16-10.9 24 305 224.9
M10-10.9 (hexagon
7 Mounting bolt for pump 8 30 22.1
socket)
8 Main control valve mounting bolt M16-10.9 24 305 224.9
9 Captive bolt of swing reduction gear M20-10.9 30 600 442.5
10 Captive bolt of battery M16-8.8 24 225 165.9
Connecting bolt of driver cab damper
11 M20-10.9 30 600 442.5
and platform
12 Connecting bolt of driver cab with floor M12-10.9 18 120 88.5
Captive bolt of revolving frame and
13 M24-10.9 36 1020 752.3
swing bearing
Captive bolt of underframe swivel
14 M24-10.9 36 1020 752.3
bearing
15 Traveling motor mounting bolt M24-10.9 36 1020 752.3
16 Captive bolt of sprocket M24-10.9 36 1020 752.3
17 Captive bolt of carrier roller M18-10.9 27 415 306.1
18 Captive bolt of track roller M22-10.9 34 800 590
19 Captive bolt of track shoe M24-12.9 36 1020 752.3
20 Captive bolt of guard M24-10.9 36 1020 752.3
21 Counterweight mounting bolt M42-10.9 64 460 339.3
2-7
CLG950E 2.3 General Torque Specifications
Tightening torque of 24°Cone with O-ring sealed hose connector
Hose inner Tightening torque

Series Thread size diameter
mm N.m lbft
M12×1.5 5 16±1 11.8±0.7
M14×1.5 6.3 16±1 11.8±0.7
M16×1.5 8 26±2 19.2±1.5
M18×1.5 10 37±2 27.3±1.5
M22×1.5 12.5 47±2 34.7±1.5
Light-type
M26×1.5 16 89±4 65.6±3.0
M30×2 19 116±5 85.6±3.7
M36×2 25 137±6 101±4.4
M45×2 31.5 226±11 166.7±8.1
M52×2 38 347±16 255.9±11.8
M14X1.5 5 26±2 19.2±1.5
M16X1.5 6.3 42±2 31.0±1.5
M18X1.5 6.3 53±2 39.1±1.5
M20X1.5 8 63±3 46.5±2.2
M22X1.5 10 79±4 58.3±3.0
Heavy type
M24X1.5 12.5 84±4 62.0±3.0
M30X2 16 126±6 92.9±4.4
M36X2 19 179±8 132.0±5.9
M42X2 25 263±12 194.0±8.9
M52X2 31.5 368±17 271.4±12.5
Tightening torque of flange-type sealed hose connector bolt
Bolt performance Tightening torque

Series Bolt
level N.m lbft
M8 25.2±1.2 18.6±0.9
M10 52.5±2.5 38.7±1.8
8.8
M12 96.6±4.6 71.2±3.4
M16 220±10 16.3±7.4
Light-type
M8 33.6±1.6 24.8±1.2
M10 73.5±3.5 54.2±3.5
10.9
M12 136±6 100.3±4.4
M16 310±15 228.6±11.1
2-8
2.3 General Torque Specifications CLG950E
Bolt performance Tightening torque

Series Bolt
level N.m lbft
M8 25.2±1.2 18.6±0.9
M10 52.5±2.5 38.7±1.8
M12 8.8 96.6±4.6 71.2±3.4
M16 220±10 16.3±7.4
M20 420±20 309.8±14.5
Heavy type
M8 33.6±1.6 24.8±1.2
M10 73.5±3.5 54.2±3.5
M12 10.9 136±6 100.3±4.4
M16 310±15 228.6±11.1
M20 577±27 425.5±19.9
Tightening torque of thread angle type sealed hose connector
Material of
Carbon steel, alloy steel Aluminum product
fastenings
Tightening torque Tightening torque
Thread size
N.m kgf.m N.m lbft
G1/8 8.75±1.25 0.90±0.12 / /
G1/4 36±2 3.67±0.2 29.3±2.2 21.6±1.6
G3/8 73.5±4.5 7.5±0.46 49±3 36.1±2.2
G1/2 110±10 11.2±1.0 55±5 40.6±3.7
G3/4 165±15 16.8±1.5 74±4 54.6±3
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 / lbft
Connector tightening torque
Thread size Tightening torque

N.m lbft
M12 24±2 17.7±1.5
M14 30±2 22.1±1.5
M16 30±2 22.1±1.5
M18 30±2 22.1±1.5
2-9
CLG950E 2.4 Unit Conversion Table
2.4Unit Conversion Table
The Manual uses ISO International System of Units, and ISO international units are converted into
British units as shown in following figure:
Parameters Metric unit British unit Multiple

mm In 0.03937
Length
mm ft 0.003281
L US gal 0.2642
Capacity L US qt 1.057
m3 Yd3 1.308
Weight kg lb 2.205
N kgf 0.10197
Intensity
N lbf 0.2248
Nm kgf·m 1.0197
Torque
Nm lbf·ft 0.7375
MPa kgf/cm3 10.197
Pressure
MPa psi 145.0
kW PS 1.360
Power
kW HP 1.341
Temperature °C °F °C×1.8+32
km/h mph 0.6214
Speed
min-1 rpm 1.0
L/min US gpm 0.2642
Flow
mL/rev cc/rev 1.0
2-10
2.5 Cable Identification Methods CLG950E
2.5Cable Identification Methods
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)
Color abbreviation code
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.
S/N Wire type Wire name Description Heat resistance

Low-voltage wire for road 70°C{158°F} heat-resisting, copper
1 QVR ≤70°C{158°F}
vehicles core PVC-insulated
Thin-wall insulated low- The thickness of insulation layer is
2 AVSS ≤80°C{176°F}
voltage wire for vehicles 0.30~0.40mm{0.012~0.016 In}
Thin-wall insulated low- The thickness of insulation layer is
3 AVS ≤80°C{176°F}
voltage wire for vehicles 0.50~0.70mm{0.020~0.028 In}
Insulated low voltage wire for The thickness of insulation layer is
4 AV ≤80°C{176°F}
vehicles 0.60~2.0mm{0.024~0.079 In}
Heat-resisting low voltage Heat resistance and cross-linking
5 AEX ≤110°C{230°F}
wire for vehicles polyethylene
Color abbreviation codes
Color English Abbreviation Color English Abbreviation

Black BLACK BK Blue BLUE BU
Grey GREY GY Green GREEN GN
2-11
CLG950E 2.5 Cable Identification Methods
Color English Abbreviation Color English Abbreviation

Red RED RD Yellow YELLOW YL
Brown BROWN BR Pink PINK PK
Violet VIOLET VT Orange ORANGE OR
White WHITE WH Light blue LIGHT BLUE LTBU
Red/green RED/GREEN RD/GN Yellow/blue YELLOW/BLUE YL/BU
Remarks: The code composed of 2 colors indicates double-color wire

For example: "RD/GN" shows 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{86} 40°C{104°F} 50°C{122°F} 60°C{140°F} 70°C{158°F}
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
sectional 15 103 176 92 157 30 137 65 111 46 79
area 20 135 148 121 133 105 116 85 94 60 66
(mm2)
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 60 155 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
Circuit type and color abbreviation code
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
Earthing BK,GY
Communication line RD/GN,YL/BU
2-12
2.6 Coating Materials CLG950E
2.6Coating Materials
Name Specification Main features and purposes

Oxygen-weary type thread lock • Features: anaerobic and fast air drying.
1277
sealant • Purposes: used for parts not frequently removed
Thread-locker 1243 Used for removable parts (speed sensor in general)
• Features: rust protection for a long time.
LONG#2 light
Long-term anti-rust agent • Purposes: used for mounting face of main pump, sensor,
yellow
hydraulic fitting, etc.
Molybdenum disulfide lithium
2# Lubrications for swing bearing and work implement pin
grease
• Features: strong ability of cleaning
High efficient detergent 1755
• Purposes: used for main pump, swing motor and travel motor
• Features: heat absorption and vaporization,
Refrigerant R134a
• Purposes: used for fluorine filling of air conditioner, etc.
• Feature: it has features of high-temperature resistance, self-
lubrication and medium resistance and is used for medium
Anaerobic pipe thread sealant 1567 (sealing oil, air, vapor, water) pipeline cone/taper thread
• Purposes: used for water temperature sensor and oil
pressure sensor
Cleaning agent for
HD-10 Used for cleaning oil pipe connectors, etc.
electromechanical equipment
Diesel engine sealant 1515 Used for mounting face of diesel engine flange
Polyurethane sealant 1924 Used for waterproof of start motor and assembling clearance
Mobilux EP None Used for rust protection of rear cover hinge
2-13
CLG950E 2.7 Weight Table
2.7Weight Table
The following table indicates the reference value of the weight of each component. When the lifting
equipment is used, please refer to the following table to select the sling.
Component Weight (kg) Weight (lb)

Engine assembly (excluding coolant and engine oil) 1000 2205
Engine (excluding coolant and engine oil) 860 1896.3
Hydraulic pump 267.5 589.8
Radiator assembly (excluding coolant, engine oil and fuel) 383 844.5
Hydraulic oil tank (without hydraulic oil) 272 599.8
Fuel tank (without fuel) 298 657.1
Revolving frame 3575 7882.9
Cab 480 1058.4
Cab seat 73 161
Counterweight 9000 19845
Main control valve 380 837.9
Swing motor&reduction gear 276.5 609.7
Travel motor & reduction gear 647 1426.6
Center connector 51 112.5
Boom 3637 8019.6
Arm 1516 3342.8
Boom cylinder assembly 434 957
Arm cylinder assembly 644 1420
Bucket cylinder assembly 399 879.8
Track assembly (single side) 2832 6244.6
Track frame assembly 5950 13119.8
Idler assembly 240 529.2
Swing bearing 660 1455.3
Idler tensioner 311 685.8
Carrier roller 32 70.6
Sprocket 85 187.4
Track roller 80 176.4
2-14
2.8 Oils Use Specifications CLG950E
2.8Oils Use Specifications
Time interval of oil change and approximate filling volume
Oil change interval

Category Approximate filling volume (L)
(Operating hour)
Engine oil 500 37.8L{10 US gal}
Gear oil of swing reduction gear 1000 14L{3.7 US gal}
Gear oil of travel reduction gear 1000 15L×2{4 US gal}
Fuel tank290L{76.6 US gal}
Hydraulic oil 2000
(System520L{137.4 US gal})
Fuel ? 163.8L{1.8 US gal}
Cooling system 2000 50L{13.2 US gal}
Technical specification for oil
Fuel
Application parts Oil specification Ambient temperature
category
Bucket, swing bearing Molybdenum disulfide lithium grease 2# ★ -20~40°C(-4~104°F)
Lubricant of arm and boom, and
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 10W-30(API CH-4) -30~30°C(-22~86°F)
injection pump and
oil
regulator
15W-40(API CH-4) ★ -25~40°C(-13~104°F)
0# ★ Above 4°C (above 39.2°F)

-10# Above -5°C (above 23°F)
Diesel -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% stock solution) 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)
The oil marked with ★ is the oil filled when the machine is transported out of the factory
2-15
CLG950E 2.8 Oils Use Specifications
The oil with the same specification but different brands cannot be used together. If another brand
of oil is to be used, please clean the system first.
The lubricant should be changed in a timely manner. Even though the oil is very clean, yet it may
deteriorate if it is placed for a long time
The selection of fuel should depend on the lowest temperature of the place where the machine is
used.
Except for the oil specifications in above table, when using the oil purchased in the market,
please contact with dealers of LiuGong.
2-16
2.8 Oils Use Specifications CLG950E
3-1
September 3, 2019 Structure Function and Maintenance
CLG950E
3 Structure Function and Maintenance
3.1 Power System ..........................................................................................................3-3

3.1.1 Diesel engine related parts..........................................................................................................3-3
3.1.2 Water radiator, hydraulic oil cooler and intercooler fuel cooler ...................................................3-4
3.2 Undercarriage System .............................................................................................3-5

3.2.1 Track frame and tensioner ..........................................................................................................3-5
3.2.2 Idler .............................................................................................................................................3-7
3.2.3 Carrier roller ................................................................................................................................3-8
3.2.4 Track roller ................................................................................................................................3-10
3.2.5 Sprocket ....................................................................................................................................3-12
3.2.6 Track .........................................................................................................................................3-13
3.2.7 Swing bearing............................................................................................................................3-14
3.3 Hydraulic System ...................................................................................................3-15

3.3.1 Layout diagram of hydraulic device...........................................................................................3-15
3.3.2 Hydraulic element......................................................................................................................3-17
3.3.3 Hydraulic working principle......................................................................................................3-154
3.4 Work Implement ...................................................................................................3-200

3.4.1 Maintenance references of main parts ....................................................................................3-200
3.4.2 Maintenance references of arm part .......................................................................................3-203
3.4.3 Maintenance references of bucket part ...................................................................................3-206
3.5 A/C System ..........................................................................................................3-208

3.6 Electrical System..................................................................................................3-209
3.6.1 Engine control .........................................................................................................................3-209
3.6.2 Display system ........................................................................................................................3-210
3.6.3 Electrical control system..........................................................................................................3-228
3.6.4 Descriptions of partial circuits..................................................................................................3-242
3-2
Structure Function and Maintenance September 3, 2019
CLG950E
3-3
CLG950E 3.1 Power System
3.1Power System
3.1.1Diesel engine related parts
LG950E4f03001
1. DPF (Diesel Particle Filter) 5. Fan side engine shock absorber

2. Rear engine support-rh 6. Front left engine bracket
3. Flywheel housing side engine shock absorber 7. Left rear engine bracket
4. Front engine support-rh 8. The coupling
3-4
3.1 Power System CLG950E
3.1.2Water radiator, hydraulic oil cooler and intercooler fuel cooler
LG950E4f03002
1. Fuel radiator 7. Degassing pipe

2. Hydraulic oil radiator 8. Fan
3. Shroud 9. Refill water pipe
4. Intercooler 10.Water radiator outlet pipe
5. Water radiator 11.Washer reservoir
6. Water radiator inlet pipe
3-5
CLG950E 3.2 Undercarriage System
3.2Undercarriage System
3.2.1Track frame and tensioner

9
1 2 3 4
8
7 6 5
LG922E930E03006
1. Idler 5. Track roller

2. Track frame 6. Track
3. Carrier roller 7. Tensioner
4. Sprocket
Judgment standards
No. Items Measures
Standard size Tolerance limit
Installation Installation Installation Installation
Free length
length load length load
7 Tensioner Replace it
1080mm(42. 288.4KN(64
- - -
5In) 648321bf)
3-6
3.2 Undercarriage System CLG950E
Judgment standards
No. Items Maintenance limit Measures
Standard size
Tolerance
+4mm
132mm (0.157In ) 118mm Overlaying
Track frame
(5.20 In ) 0mm (4.65 In ) repair
Vertical width of (0 In)
8 guiding idler
plate 0mm
Overlaying
(0 In) 105mm
Idler 130mm(5.12In ) repair or
-1mm (4.13 In )
replacement
(-0.04)
+4mm
(0.16In ) 248mm(9.76 Overlaying
Track frame 292mm(11.50In )
0 In ) repair
Horizontal width (0 In)
9
of idler plate
0 Overlaying
290mm 235mm(9.25
Idler (0 In) repair or
(11.41In ) In )
-1.5(-0.06In ) replacement
3-7
3.2.2Idler
8
5
9 3
LG936E4F03005
Standard
No. Check items Measures
Standard size Maintenance limit
Outer diameter
1 674mm(26.54In) ——
of bulge
Outer diameter
2 630mm(24.80In) 620mm(24.41In)
of wheel face
Thickness of Overlaying
3 —— ——
wheel face or
Difference of replacement
4 22mm(0.87In) 27mm(1.06In)
wheel faces
5 Overall width 204mm(8.03In) ——
Width of wheel
6 51.5mm(2.03In) ——
face
3-8
Standard
No. Check items Measures
Tolerance Limit
Standard Standard
clearanc
size Shaft Hole clearance
Clearance e
7 between shaft 0mm +0.35mm +0.385mm
and bushing 95mm(3. (0 In) (+0.014 In) (+0.015 In)
——
74In) -0.035mm(- +0.3mm +0.3mm
0.0014In) (+0.012 In) (+0.012In)
Standard Tolerance Standard Interfere
size Shaft Hole interference nce limit
Interference Replacing
8 between idler +0.178mm +0.054mm +0.178mm
bushing
and bushing 107mm(4 (+0.007 In) (+0.002 In) (+0.007 In)
——
.21In) +0.143mm 0mm +0.089mm
(+0.006 In) (0In) (+0.004 In)
Clearance Standard value Clearance limit
between
bushing and
9 neck strap (the
sum of 0.5-1.0mm(0.02-0.04In) ——
clearances on
both sides)
3.2.3Carrier roller
5 3
8
4
6
LG936E4F03006
3-9
Measure
No. Check items Standard
s
Outer diameter Standard size Maintenance limit
1
of bulge 185mm （7.28 In） ——
Outer diameter
2 of wheel 160mm （6.30 In） 148mm （5.83 In）
surface
Width of wheel
3 52.5mm （2.07In） ——
surface
Thickness of
4 —— ——
wheel surface
5 Bulge width 95mm （3.74 In） ——
Tolerance Limit
Standard Standard
clearanc
e
Clearance Replaceme
+0.315mm nt
6 between shaft -0.125mm +0.175mm
（+0.012
and bushing 65mm （-0.005In）（+0.007In）
In） ——
（2.56In） -0.14mm +0.075mm （-
+0.2mm
（-0.006In） 0.003In）
（0.008In）
Standard Tolerance Standard Interfere
Interference size Shaft Hole interference nce limit
between carrier +0.115mm +0.03mm +0.115mm
7
roller and 70mm （+0.005In）（+0.001In）（+0.005In）
bushing ——
（2.76In） +0.075mm 0mm +0.045mm
（+0.003In）（0In）（+0.002In）
Standard value Clearance limit
Axial clearance
8 0.5-1.0mm
of carrier roller ——
(0.02-0.04In)
3-10
3.2.4Track roller
3
8
7
1
2
5 6
4
LG936E4F03007
3-11
No. Check items Standard Measures

1 Outer diameter of flange
250mm(9.84In) ——
Outer diameter of wheel
2 200mm(7.87In) 188(7.40In)
face
Replace it
3 Thickness of wheel face —— ——
4 Overall width 280mm(11.02In) ——
5 Width of wheel face 54.5mm(2.15In) ——
6 Flange width 35mm(1.38In) ——
Standard Tolerance Standard Clearance
size Shaft Hole clearance limit
Clearance between shaft 0mm +0.42mm +0.442mm
7
and bushing 85mm(3.34I (0In) (+0.017In) (+0.0174 In)
——
n) -0.022mm +0.37mm +0.37mm
(-0.0009) (+0.015In) (+0.0146 In)
Standard Tolerance Standard Interferenc
size Shaft Hole interference e limit Replacing
Interference between bushing
8 +0.159mm +0.054mm +0.159mm
track roller and bushing 100mm (+0.006In) (+0.002In) (+0.006 In)
——
(3.94In) +0.124mm 0mm +0.07mm
(+0.005In) (0In) (+0.003 In)
Clearance between Standard value Clearance limit
bushing and neck strap
9
(the sum of clearances 0.5-1.0mm(0.02-0.04In) ——
on both sides)
3-12
3.2.5Sprocket
$
$ LG936E4F03008
Unit: mm

1 Wear loss on sprocket Maintenance limit 6mm(0.24 In)
Standard size Maintenance limit Replace it
2 Width of sprocket
90mm(3.54 In) 85mm(3.35 In)
3-13
3.2.6Track
LG950E4f03003

1 Caterpillar track pitch
215.9mm(8.50In) 219mm(8.62 In)
2 Height of track link 129mm(5.08 In) 12mm0(4.72 In)
Overlaying or
3 Height of track shoe rib 36mm(1.42 In) 26mm(1.02 In)
replacement
4 24mm(0.94 In)
5 Length of track shoe top 18mm(0.71 In)
6 18mm(0.71 In)
3-14
3.2.7Swing bearing
LG936E4F03010

Axial clearance of bearing Standard clearance Maintenance limit
1 (When installed onto the 0.5-1.6mm(0.0197- Replace it
chassis) 3.2mm(0.126 In)
0.062In)
3-15
CLG950E 3.3 Hydraulic System
3.3Hydraulic System
3.3.1Layout diagram of hydraulic device
LG950E4f03005
3-16
3.3 Hydraulic System CLG950E
LG950E4f03004
1. Bucket cylinder assembly P1: Inlet oil of octuple solenoid valve

2. Arm cylinder assembly T1: Return oil of octuple solenoid valve
3. Boom cylinder assembly P2: Boom lift pilot signal
4. Swing motor&reduction gear A1: Pilot unlock
5. Right travel motor & reduction gear A2: Travel shift
6. Valve block assembly
A3: Standby
7. Pilot valve gp
8. Main pump A4: Standby
9. Fan pump A5: Pump No.2 flow adjustment
10.Breather valve A6: Pump No.1 flow adjustment
11.Gear pump A7: Transient power boosting
12.Hydraulic oil tank A8: Boom priority
13.Fan control valve 17.Left travel motor
14.Fan motor 18.Center connector
15.Main control valve 19.Pilot Valve (RH)
16.Octuple solenoid valve 20.Pilot Valve (LH)
21.Travel pilot valve
3-17
3.3.2Hydraulic element
Main pump assembly
1. Structure and function of main pump assembly
2 3 4
3
6
3
D
D
7
8 LG950EIII03013
1. P1 pump negative feedback pilot oil port Pi1 5. Electric proportional pressure-reducing valve
2. P2 pump negative feedback pilot oil port Pi2 6. Pilot pump drainage port Dr2
3. Adjuster 7. Main pump servo port Psv
4. Minimum flow adjusting screw 8. Main pump oil suction port D0
3-18
a2
a5
2
1
LG950EIII03014
1. Oil return port of housing Dr1 2. Drive shaft
Structure of main pump assembly
Main pump as 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
all hydraulic parts work. The pilot pump is a constant gear pump and supplies oil for the pilot system and
the main pump control system.
2. Main pump (pumps P1 and P2)
2-1 Main oil pump specifications
Displacement 200×2cm3/rev(200×2cc/rev)
Rated 32.3(4683.5psi)
pressure
Max. 35.0(5075psi)
Rated 1900r/min
Rotate speed
Max. 2200r/min
Weight 255(562lb)
Category Anti-wear hydraulic oil
Temperature
-20~+95°C(-4°F~203°F)
range
Hydraulic oil
Viscosity range 10~1000cSt(mm2/s)
Recommended Oil-return line Nominal size 10mm (0.0003937In)
strainer Suction line 80 ~ 150 mesh filter screen
3-19
2-2 Structure and working principle of main pump
The main fuel 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 fuel pump during working.
The figure below shows the structural diagram of the main pump assembly, and the numbers in () behind
concerned parts in the figure below shall prevail.
543
725 545
534 702 532 531 157 732 901 465 535 467 807 954 412 541
792 789 723 725
548 981 885
406 983
214 080
806 726
953
536
ᯣ䶘 X-X
889 SECTION X-X
δS=2/1ε
405
A A
724 262
888 156 409
886 153 709
251 212 211 152 728 469 151 141 752 410
LG950EIII03015
3-20
123
Identification groove on outer surface of outer ring
466 314
408 824 828 128 469 113 497 469 271
729 Valve plate for c.clockvise rotation
728 728
171
Flange socket (5-M10x1.5)
124 Tightening torque:23N·n
127
823
192
191
B B
711
827
04
774
130
830
111
261
312 124
825 125
313
Valve plate for clockwise rotation
126
411
129 752 122 824 889
468 467
418 263 733 SECTION A-A
731 725
128
887
SECTION B-B
LG950EIII03016
3-21
Parts list of main oil pump
S/N Part name S/N Part name

111 Drive shaft 497 Plug
113 Driven shaft 531 Pin
122 cylindrical roller bearing 532 Spool
123 cylindrical roller bearing 534 Limiting screw plug
124 Needle bearing 535 Block
125 Cone 536 Nut
126 Washer 541 Valve seat
127 Washer 543 Plug
128 Snap ring 545 Steel ball
129 Snap ring 548 Feedback pin
130 Assistor 702 O-ring
141 Cylinder block 709 O-ring
151 Plunger 711 O-ring
152 Skid shoes 723 O-ring
153 Cover 724 Seal ring
156 Bushing 725 O-ring
157 Cylinder block spring 726 O-ring
171 Pump body 728 O-ring
191 Drive gear 729 O-ring
192 Driven gear 731 O-ring
211 Swashplate 732 O-ring
212 Support plate 733 O-ring
214 Pin bushing 752 Lip type seal
251 Support 774 Oil seal
261 Front housing 789 Snap ring
262 Cover 792 Snap ring
263 Cover 806 Nut
271 Pump body 807 Hex nut
312 Pump body 823 Snap ring
313 Oil distribution plate 824 Snap ring
405 Hex screw 827 Snap ring
409 Hex screw 885 Pin
3-22

465 Plug 901 Screw
466 Plug 953 Setscrew
468 Plug 981 Nameplate
469 Plug 983 Pin
This pump is of 2-pump parallel (in parallel) configuration structure connecting with the driving gear (191)
- driven gear (192), which transfers the rotation of prime mover to the driven shaft (113) via the driving
shaft (111) - driving gear (191) - driven gear (192) so as to drive 2 pumps. The pilot gear pump can be
mounted on the rear end of driven shaft (113) and the 4th pump can be mounted at rear end of driving
shaft (111); the 5th pump structure can be mounted at PTO part by help of the driving gear.
The pump is roughly divided into: main part rotating mechanism of pump for rotating movement, swash
plate mechanism for output flow variation, oil distribution cover mechanism for changeover of oil suction
and discharge, and the structures to take the power from PTO mechanism so as to drive the 5th pump.
(1) Rotating mechanism
The rotating mechanism is made from driving shaft (111), driven shaft (113), cylinder block (141), plunger
- piston shoes (151-152), return disc (153), spherical surface bush (156), bearing isolating ring (126-127-
128), driving gear (191), driven gear (192) and return spring (157). The piston shoes (152) are riveted
with the plunger (151) to form the spheric connection while reducing the thrust force generated from load
pressure; the oil channel for pressure balance (hydrostatic pressure) is set on the piston shoes so as to
reduce the sliding friction on piston shoes disc (211). On the other hand, to enable smooth sliding of
plunge - piston shoe pair (151-152) mechanism on the piston shoe disc (211), it is pressed on the piston
shoe disc (211) by the return spring (157) by help of the return disc (153) and spheric surface bush
(156). This end of cylinder block (141) is also pressed onto the oil distribution disc (313-314) by the
return spring (157).
(2) Swash plate mechanism
The swashplate mechanism consists of swashplate (212), skid shoe disc (211), swashplate support
stand (251), inclined bushing (214), inclined pin (531) and servo piston (532). The swash plate is
supported onto the swash plate supporting stand (251) which forms cylindrical component with the
opposite side of piston shoe sliding surface. The pressure oil controlled by the regulator is led into the oil
chambers at both ends of servo piston (532) to enable leftward/rightward movement of servo piston; it
also enables the swash plate (212) swinging on the support stand (251) by help of the ball part of
inclined pin (531) so as to change the inclination angle of swash plate (α).
(3) Oil distribution cover mechanism
The oil distribution cover mechanism consists of oil distribution cover (312), oil distribution disc (313-314)
and oil distribution disc pin (885). The oil distribution disc with two incomplete waist type oil distribution
windows is mounted on the oil distribution cover (313-314) to fulfill the changeover actions of oil supply
to and oil discharge from the cylinder block (141). The oil changed over by the oil distribution disc (313-
314) is connected to external pipeline via oil distribution cover (312).
(4) POT mechanism
The PTO mechanism consists of the 2nd gear and the 3rd gear. Transfer the rotation to the gears via the
driving gear to drive the 5th gear.
3-23
When the driving shaft (111) is driven by the prime mover (motor, engine and etc.), it rotates with the
cylinder block (141) by use of spline connection. By help of the driving gear (191), the driven gear (192)
enables the driven shaft (113) rotating with the cylinder block (141). When the swash plate (212) is
inclined, the plunger pair (151-152) mounted in the cylinder block (141) rotates with the cylinder block
(141), and conducts reciprocating motion related to the cylinder block (141) at same time. That is to say,
considered for 1 plunger pair (151-152), in the range of rotation for 1 circle of cylinder block (141), the
plunger pair (151-152) moves for 180° towards the direction away from the oil distribution disc (313-314)
(oil suction travel), while for the residual 180°, it will move towards the oil distribution disc (313-314) (oil
discharge travel). When the inclination angle of swash plate (α) is zero, the plunger pair (151-152) will
not move so that there is no oil output.
At same time, the rotation of driven shaft (113) is transferred to the pilot gear pump (04) via the spline;
the rotation of driving shaft (111) as the driven shaft (113) is transferred to the 4th pump via the spline,
and then transferred to the 5th pump by help of the rotation of driving gear so as to separately drive the
pilot gear pump (04), the 4th pump and the 5th pump.
2-3 Main pump adjuster
Overview
The main oil pump adjuster is installed on the main oil pump and is composed of the following control
mechanisms.
1. Power control
As the piston pump’s own discharge pressure P1 rises, the inclination angle (discharge flow) of the
piston pump automatically reduces. As a result, the input torque is controlled below the fixed value.
When the speed is constant, the input horsepower keeps constant.
2. Flow control
The inclination angle (discharge flow) of the piston pump can be controlled at will by adjusting the
adjusting lever for maximum flow on the regulator. Tightening the adjusting handle for maximum flow
reduces the discharge flow Q. Otherwise, loosening the adjusting handle for maximum flow
increases the discharge flow Q.
Using this mechanism, adjusting the adjusting lever for maximum flow as required by the operation
can allow the piston pump to discharge the desired flow only, avoiding consuming power in vain.
3. Pressure shut-off control
This is a control mode to automatically reduce the inclination angle (discharge flow) of the pump
when its own pressure reaches the set value.
Using this mechanism can get energy-saving effects.
The regulator has three or more control mechanisms. When various control mechanisms are used in
a composite manner, the low-inclination-operation (low flow) command is prioritized according to the
calculation of the mechanical equation described later.
3-24
Structure of adjuster
LG950E4f03006
3-25

413 Bolt 653 Spring holder
436 Bolt 654 Return spring
412 Bolt 655 Pressure regulating spring
438 Bolt 656 Cover
439 Screw 698 Cover
496 Plug 708 O-ring
611 Link 724 O-ring
612 Link 725 O-ring
613 Link 728 O-ring
614 Plug 730 O-ring
615 Adjusting plug 732 O-ring
621 Compensation piston 733 O-ring
622 Piston sleeve 734 O-ring
623 Rod 735 O-ring
624 Spring holder 753 O-ring
625 Spring 755 O-ring
627 Adjusting handle 763 O-ring
628 Adjusting bolt 801 Nut
629 Cover 802 Nut
630 Locknut 814 Ring washer
631 Sleeve 836 Ring washer
641 Valve cap 874 Pin
643 Valve stem 875 Pin
644 Spring holder 876 Pin
645 Adjusting handle 887 Pin
646 Spring 897 Pin
651 Valve bushing 898 Pin
652 Spool 924 Bolt
3-26
Regulator 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 following figure, the discharge discharge pressure P1 is usually brought in the
flow of the piston pump can be controlled at will small-diameter portion of the servo piston, but
based on the stroke S of the adjusting lever 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.
Therefore, the pin (897) is pressed towards the
Q Discharge flow
large-hole portion [C] of the link (2)(613). Thus,

with the movement of the point D, the feedback
link (611) pivots on the point C, and the slide
valve (652) moves left. This movement allows
the sleeve (651) to close the opening of the slide
valve (652) gradually until the opening is closed
Stroke S of adjusting lever for completely. Then, the servo piston stops.
maximum flow
LG950EIII03018 B Movement to increase the flow
A Motion to reduce flow When the adjusting lever (675) is loosened, the
guide spring (646) pressure allows the guide
If the adjusting handle (675) for maximum flow is piston (643) to move left and the link (2) (613)
tightened, the pilot piston (642) moves right via pivots on Point B. The pin (897) is pushed by the
the piston rod (643). The pin (875) fixed to the return spring (654) towards to the large-hole
link (2) (613) is embedded in the grooved portion portion [C] of the link (2) through the slide valve
[A] of the guide piston (643), so with the (652), the pin (874) and the feedback link (611).
movement of the pilot piston (643), the link (2) Therefore, with the rotation of the link (2) (613),
pivots on Point B (fixed by the plug (614) and the the feedback link (611) pivots on Point D and the
pin (875). There is a projecting pins (897) fixed to slide valve (652) moves left.
the feedback link (611) in the large-hole portion When the slide valve (652) moves, Port C1 port
[C] of the link (2) (613), so with rotation of the link opens towards the tank port, so that the pressure
(2) (613), the pin (897) moves right. The pin of the large-diameter chamber of the servo
(548) fixed to the tilt pin (531) which allows the piston reduces. Due to the effect of the discharge
sloping plate to shake is embedded in the pressure P1 of the small-diameter portion, the
double-sided width portion [D] of the feedback servo piston (532) moves left, so that the flow
link (611). Therefore, when the pin (897) moves, increases.
the feedback link (611) pivots on Point D. The
feedback link (874) connects with the slide valve As the servo piston (532) moves, Point D also
through the pin (652), so the slide valve (652) moves left, the feedback link (611) pivots on
moves right. Point C, and the slide valve (652) moves right.
The movement continues until the slide valve
(652) closes the opening of the sleeve (651), and
stops there stationarily.
3-27
2. Power control The movement of the servo piston (532) is

conveyed to the feedback link (611) through
As shown in the following figure, when the load
Point D. The feedback link (611) pivots on Point
pressure increases, the inclination angle of the
F and the slide valve (652) moves left. The spool
piston pump can be reduced to prevent the prime
valve (652) keeps moving till the opening with
mover from being overloaded.
the sleeve (651) closes. Stop the action on the
position where the opening is just closed.
B Movement to reset the flow
If the piston pump’s own discharge pressure P1

Q Discharge flow
reduces, the compensation rod (623) will be

pushed back by the external spring (625) and the
internal spring (626). The link (1) (612) pivots on
Point E. As the link (1) (612) rotates, the
feedback link (611) pivots on Point D, and the
slide valve (652) moves left. Therefore, Port C1
port opens towards the tank port, so that the
Discharge pressure (P1)
pressure of the large-diameter portion of the
LG950EIII03019 servo piston reduces. The servo piston (532)
moves left, so that the discharge flow of the
The movement of horsepower control is the piston pump increases.
same as the flow control. This is briefly described
below. The movement of the servo piston (532) is
transmitted to the slide valve (652) by the
A Movement to prevent overloading feedback mechanism. The piston continues to
move until the slide valve (652) closes the
When the piston pump’s own discharge pressure opening of the sleeve (651).
P1 rises, because P1 can be applied to the step
of the compensation piston (621), the 3. Priority mechanism of low inclination
compensation rod (623) is pushed right until the operation (low flow) command
elastic force of the external spring (625) and the As mentioned above, the inclination command of
internal spring (626) balances against the flow control and horsepower control is
hydraulic pressure, and then the compensation transferred to feedback connecting rod (611) and
rod stops moving. The movement of the sliding valve (652) through the large hole part
compensation rod (623) is conveyed to the link (Part C and F) connecting rod (1) (612),
(1) (612) through the pin (875). The link pivots on connecting rod (2) (613); since the parts C and F
the pin (875) [Point E] fixed to the pump housing adopts the structure of extruded pin (φ4) on the
(601). There is a projecting pin (897) (fixed to the large hole (φ9), the pin (897) only contacts with
feedback link (611)) in the large hole [F portion] the connecting rod with small inclination angle;
of the link (1) (612). As the link (1) (612) rotates, the connection rod φ9 hole in large inclination
the feedback link (611) pivots on Point D, and the command state will not contact with the pin (897)
slide valve (652) moves right. and present the free state. The low inclination
When the slide valve (652) moves, the discharge commands for flow control and horsepower
pressure P1 is introduced into the large-diameter control are prioritized through this mechanical
portion of the servo piston through the port C1. selection mode.
Then, the servo piston (532) moves right, so that
the discharge flow of the piston pump is reduced
to prevent the prime mover from being
overloaded.
3-28
4. Pressure shut-off control Adjustment

As shown in the following figure, when the This adjuster uses its adjusting screw to adjust
pump’s own discharge pressure P1 reaches the the maximum flow, minimum flow, horsepower
setting pressure for shut-off, its inclination angle control characteristics and flow control
(discharge flow) is reduced to the minimum. characteristics.
1. Adjustment of maximum flow
1) Adjustment of maximum flow (pump body)
Q Discharge flow
Q Discharge flow

LG950EIII03020
If the shut-off pressure is set at the value through Stroke S of adjusting lever for
which the machine side is about to release, maximum flow
LG950EIII03021
energy-saving effects can be obtained.
When the pressure P1 directed to the safety Loosen the hex nut (808), and tighten (or loosen)
valve (1) fixed to the cut-off valve reaches the the fixing screw C (954) for adjustment. Keep
setting pressure for the safety valve (1), the other control characteristics unchanged. Only
safety valve (1) will start opening. The cut-off change the maximum flow.
slide valve (647) moves left. 2) Adjustment of maximum flow (with the
If the cut-off slide valve moves, the discharge regulator’s adjusting lever for maximum
pressure P1 will be directed to the large-diameter flow)
portion of the servo piston, then the servo piston Loosen the lock knob (637), and tighten (or
moves right to minimize the pump’s inclination loosen) the knob (675) for adjustment. Keep
angle (discharge flow). other control characteristics unchanged. Only
change the maximum flow.
During the 1) and 2) adjustment above, the low-
flow command is prioritized.
3-29
2. Adjustment of minimum flow (main pump) Loosen the hex nut (630), and tighten (or loosen)
the adjusting screw C (628) for adjustment.
When the adjusting screw C (628) is tightened,
as shown in the following figure, shift the control
diagram right, and increase the input
horsepower. Additionally, turn the adjusting
Q Discharge flow
screw C (628) by N turns. As a result, the setting

of the internal spring (626) changes. Therefore,
turn the adjusting screw (QI) (925) in the
opposite direction by N × A turns.
2) Adjustment of inter spring

LG950EIII03022
Loosen the hex nut (808), and tighten (or loosen)

Discharge flow Q
hex screw (953) for adjustment. Like the

adjustment of the maximum flow, keep other
control characteristics unchanged. But note that
if it is pulled too tight, the power needs to be
increased at the maximum discharge pressure
(overflow).
3. Adjustment of input horsepower Discharge pressure (P1)
LG950E4f03007
The regulator uses the constant horsepower
control method. To change the horsepower
Loosen the hex nut (801), and tighten (or loosen)
setting, adjust the adjusting screws (628) and
the adjusting screw QI(925) for adjustment. If the
(QI) (925).
adjusting screw C(628)needs to be tightened, as
1) Adjustment of outer spring shown in the following figure, the flow and input
horsepower will increase.
Q Discharge flow

LG950EIII03022
3-30
4. Adjustment of pressure shutoff control 3. Electric proportional pressure-reducing

characteristics valve
Loosen the hex nut (7), and tighten (or The electro-proportional pressure-reducing valve
loosen) the spring seat (4) for adjustment. (KDRRE5KR-V3-V) is used for changing the
When the spring seat (4) is tightened, as control curve (P-Q curve) of the main oil pump
shown in the following figure, shift the (P1/P2), providing the control curve for the main
control diagram right. oil pump under different operating conditions
(such as H, S, L mode). Its input pressure is Psv
(i.e. pilot pressure), and its output pressure is Pf
inversely proportional to input current.
Q Discharge flow

LG950EIII03023
Failure causes due to the regulator and

troubleshooting
When any poor movement happens, if it is

determined that it caused by the regulator, refer
to the "Removal and Installation" section for
inspection under disassembled condition.
When prime motor is overload
(1) Members of the compensation piston (621)

and compensation rod ---- Disassembly,
cleaning
(2) Slide valve (652)
member…….………disassembly, cleaning
When the maximum flow cannot be achieved,
(1) Check whether the adjusting lever for

maximum flow is functioning properly
(2) Rod piece of guide piston(643)
.……………………Disassembly, cleaning
(3) Slide valve (652)
member……….………Disassembly, cleaning
(Note) If any part is scratched badly, replace it
3-31
4. Main pump maintenance references
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.
Maintenance
Check items Standard size Treatment
limit
Clearance of space in plunger and oil
0.0375mm 0.078mm
cylinder Replace the plunger or cylinder
(0.00148In) (0.00307In)
(D-d)
Loose of gap part of plunger and
0~0.1mm 0.35mm Replace the plunger and piston
piston shoes
(0~0.0039In) (0.0138In) shoes subassembly.
(δ)
5.4mm 5.0mm Replace the plunger and piston
Thickness of skid shoes (t)
(0.213In) (0.197In) shoes subassembly.
Free height of return spring 41.8mm 41.0mm
Replace the return spring.
(L) (1.646In) (1.614In)
Assembly height of plate and
23.8mm 22.8mm Replace the return disc or spherical
spherical bushing
(0.937In) (0.898In) bushing.
(H-h)
Cylinder block pitch diameter
35.17mm(Ø5) 35.57mm Replace the cylinder block and
(Spline in cylinder block)
(1.385In) (1.400In) spherical bushing
Spline in spherical bushing
D
d
LG950EIII03025 LG950EIII03026
Space clearance inside piston and cylinder: D-d Free height (L) of cylinder spring: L
3-32
H
h
t
LG950EIII03027
LG950EIII03028
Looseness of clearance section between plunger ball head
and skid shoe: δ Assembly height of plate and spherical bushing: H-h
Thickness of skid shoe: t
Maintenance standards of cylinder, valve block and swashplate (skid shoe plate).
Surface roughness requiring

Cylinder block (sliding section) trimming 3-Z
Oil distribution disc (sliding part) (JIS B 0601-1994)
Swash plate (piston shoe disc part) Standard surface roughness
Roughness of each surface (corrected value) Less than 0.4Z (grinding)
(JIS B 0601-1994)
5. Fault cause and treatment of main pump
General precautions:
(1) Considerations before eliminating the abnormality
Carefully judge the nature of abnormality before operation. Especially judge whether the problem is
from circuit or regulator
or attached valve. Further consider whether the problem is from pump or pump.
(2) Carefully read the maintenance key points before disassembly, and disassemble in correct
sequence.
(3) Even if only to disassemble certain part, notice preventing the dust ingress.
(4) The components are of precision machining, so it shall be noticed not to bruise them during
operation.
Pump inside is usually installed with adjuster, attachment valve and attachment pump, so the fault
reason can not be found out easily. Please check according to the following large items to find out the
fault.
(1) Check the filter and oil drainage
Please check the filter elements. Confirm whether too much abnormal impurity is exhausted.
It's inevitable to mix little metal powder from the friction between the piston and the cylinder into the
filter. If the powder is too much, check the piston ring bearing. Check the oil in the pump housing at
the same time.
3-33
(2) Confirm whether there is abnormal vibration or noise

Check whether there is abnormal noise and vibration. When checking pressure reduction of the
adjuster and attachment valve, confirm whether the frequency beat is regular. If there is abnormal
noise, the inside of the adjuster or pump may be damaged.
(3) When using two pumps
When the single pump or motor uses the circuit of two sets, or the double pump is used, please
check the piping conditions of each pump. According to the result, decide whether it is the pump fault
or return pipe fault.
(4) Measure the pressure of each part
When the control has problem, measure the pressure of each point to find out the faulty position
instead of performing open check at will.
1. Motor overload
S/N Cause analysis Treatment Precautions

Rotate speed--The pressure value
1 Set the value to the design value
is higher than the design value
The set torque of the adjuster is
2 Recheck the adjuster
too high
Check the filter and the oil
Burns and damages of pump
3 Replace the damaged parts drainage to confirm whether there
inside parts
is abnormal powder from abrasion
Piping and pipe layout of the Arrange the regulator piping
4
regulator are wrong correctly
2. The main pump oil level is too low and the discharge pressure can not rise

1 Fault of adjuster Repair the adjuster See below for troubleshooting
Burns and damages of pump
2 Replace the damaged part Check of filter and oil drainage
inside parts
Remove the attachment pump to
3 Fault of attachment pump Replace the damaged part
check the shaft coupling part
Check the attachment valve
4 Fault of the attachment valve Especially check the lift valve, the
left valve seat and the spring
Piping and pipe layout of the Arrange the regulator piping
5
regulator are wrong correctly
3. Abnormal noise or vibration

1-1 Low boost pressure
Prevent empty pumping. Check
1-2 Fault of attachment pump
1 Empty pumping whether the action oil is white and
1-3 Air sucked into the suction pipe
thick
1-4 Large suction resistance
Rivet part of piston ring bearing is Replace the piston, piston ring
2
damaged bearing and plate
3-34

3 Cylinder block cracks Replace the cylinder block
4 Pump installation is poor Correct installation
5 Adjuster beat Correct adjuster piping
Pressure-reducing valve beat of
6 Maintenance of attachment valve
attachment valve
6. Pilot pump
Pilot pump (P3 pump) is a quantitative type gear pump and provides the hydraulic system with pilot oil.
6-1 Pilot pump specifications
Model ZX15LDLZ2-07A
Displacement cm3/r 15(15cc/rev)
0.2 29
Set pressure MPa
3.9 0 (565.5 0 psi)
Rotation speed r/min 1900
Suction side pressure MPa 0.05 ~ -0.01(7.25 ~ -1.45psi)
Rotation direction of shaft (from drive shaft) Anticlockwise
Weight kg 3.1(6.84lb)
6-2 Pilot pump construction
External view of pilot pump
A3
B3
A3
a3 a3
LG950EIII03029
3-35
Section view of pilot pump
14 4 2
14 18
B3
19
A3
10
11 20
a3
15 7 6 5
13 17 1 3 8 9 19 12
16
LG950EIII03030

1 Front casing 12 Locknut
2 Gear casing 13 VP oil plug
4 Driven gear 15 Angular seal ring
5 Strainer 16 O-ring
6 Valve seat 17 O-ring
7 Cone valve 18 Bolt with washer
8 Spring 19 Bolt with washer
9 Ring 20 Bolt with washer
10 Adjusting screw 21 Lock ring
11 Locknut
3-36
6-3 Principle of pilot pump

Diagram of pilot pump hydraulic circuit
A3
a3
᧛ѱ⋯⌫
TO MAIN PUMP
B3 LG950EIII03031
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(725psi).
3-37
Main Control Valve
1. Main control valve specifications
Items Specification
Model KMX32N/B45013A
Standard flow 360 L/min(95.112US gpm)
1
32.3 0
Working pressure of main relief valve
145
MPa(4683.5 0 psi)
1
35.3 0
Pressurization pressure of main relief valve
145
MPa(5118.5 0 psi)
Oil port setting pressure of Boom, arm and bucket 38.2±0.5MPa(5539±72.5psi)

relief valve Standby 30.0±0.5MPa(4350±72.5psi)
Hydraulic oil temperature -20~90 °C(-4~194°F)
Maximum pressure of oil leakage 0.3MPa(43.5psi)
3-38
2. Appearance of main control valve
LG950E4f03008
3-39
LG950E4f03009
3-40
LG950E4f03010
3-41
LG950E4f03011
3-42
LG950E4f03012
3-43
LG950E4f03013
3-44
The ports of the main control valve are as

follows
Port
Mounting torque Symbols Port name
dimension
R3 Oil replenishing port
R4 Oil replenishing port
150 - 180 N•m
G-1 (P3) -
(110.625-132.75lbf·ft)
(P4) -
(Ck2) -
PAa Arm 1 (retraction) pilot port
PBa Arm 1 (stretching) pilot port
PAb Boom (lowering) pilot port
PBb Boom (lifting) pilot port
PAc Bucket (excavation) pilot port
PBc Bucket (unloading) pilot port
PAL Left travel (reversing) pilot port
PBL Left travel (advancing) pilot port
PAr Right travel (reversing) pilot port
PBr Right travel (advancing) pilot port
PAs Rotation (left rotation) pilot port
PBs Rotation (right rotation) pilot port
69 - 78 N•m PAa2 Arm 2 (retraction) pilot port
G-3/8
(50.888-57.525lbf·ft) PBa2 Arm 2 (stretching) pilot port
PBb2 Boom flow merging (lifting) pilot port
(PAo) Backup pilot port
(PBo) Backup pilot port
PAbs Boom (lowering) travel limit stop pilot port
PAcs Bucket (excavation) stroke limit block pilot port
Pca Bypass stop spool pilot port (P2 side)
(Pcb) Bypass stop spool pilot port (P1 side)
Dra Oil leakage port
Drb Oil leakage port
(PTa) -
(PTb) -
Psp Rotation priority pilot port
P Pilot pressure port
Pa Pilot pressure port
Px Signal interface for work implements
Py Signal interface for travel
Pns Movable priority valve pilot port
34 - 38 N•m P2c1 Lock valve pilot port (boom piston head side)
G-1/4
(25.075-28.025lbf·ft) P2c2 Lock valve pilot port (arm piston rod side)
N1 Negative control signal pressure port (boom 1 side)
N2 Negative control signal pressure port (arm 1 side)
Dr3 Oil leakage port
Dr3' Oil leakage port
Dr4 Oil leakage port
15 - 19 N•m
G-1/8 PL1 Main overflow valve pressure rise pilot port
(11.063-14.013lbf·ft)
3-45
Port
Mounting torque Symbols Port name
dimension
P1g Pump port (P1 side)
P2g Pump port (P2 side)
Aa Port (retraction) at arm cylinder piston head cavity
Ba Port (extension) at arm cylinder piston rod cavity
Ab Port (lowering) at boom cylinder piston rod cavity
Bb Port (lifting) at boom cylinder piston head cavity
140 - 180 N•m Ac Port (excavation) at bucket cylinder piston head cavity
M14
(103.25-132.75lbf·ft) Bc Port (unloading) at bucket cylinder piston rod cavity
Ar Right travel motor port (reversing)
Br Right travel motor port (advancing)
AL Left travel motor port (reversing)
BL Left travel motor port (forward)
(Ao) Backup port
(Bo) Backup port
(P1) Pump port (P1 side)
83 - 110N•m (P2) Pump port (P2 side)
M12
(61.213-81.125lbf·ft) T1 Return port
T2 Return port
49 - 65 N•m As Rotary motor (leftward)
M10
(36.138-47.938lbf·ft) Bs Rotary motor (rightward)
The port in () is normally plugged.

3-46
Structure of main control valve
Section A-A LG950E4f03014

3-47
Section B-B LG950E4f03015

3-48
123
Identification groove on outer surface of outer ring
466 314
408 824 828 128 469 113 497 469 271
729 Valve plate for c.clockvise rotation
728 728
171
Flange socket (5-M10x1.5)
124 Tightening torque:23N·n
127
823
192
191
B B
711
827
04
774
130
830
111
261
312 124
825 125
313
Valve plate for clockwise rotation
126
411
129 752 122 824 889
468 467
418 263 733 SECTION A-A
731 725
128
887
SECTION B-B
LG950EIII03016
3-49
Section D-D LG950E4f03017

3-50
Section E-E
LG950E4f03018
3-51
Section F-F LG950E4f03019

3-52
Section G-G
LG950E4f03020
3-53
Section H-H
LG950E4f03021
3-54
Section K-K Section L-L
LG950E4f03022
3-55
Parts list of main control valve
Mounting Mounting
Quant Quanti
torque No. Part name torque No. Part name
ity ty
(N•m) (N•m)
Straight travel spool
101 Valve body A 1 391 1
assembly
102 Valve body B 1 392 Bypass stop spool 2
7.8-9.8 151 Oil plug 2 393 Spool of boom 2 1
69-78 155 Oil plug 14 394 Spool of arm 2 1
Rotary priority valve
13-17 158 Oil plug 7 395 1
spool
34-39 159 Oil plug 1 511 Cone valve 10
161 ○-ring 11 512 Cone valve 2
165 ○-ring 16 515 Cone valve gp 1
168 ○-ring 7 522 Spring 10
201 Spring cover 9 523 Spring 2
202 Spool cover 8 524 Spring 2
203 Cover 2 525 Spring 1
204 Cover 1 541 Steel ball 1
205 Boom priority valve cover 1 542 Spring holder 1
25-29
208 Spool cover 1 (18.4- 550 Oil plug 1
21.4lbf·ft)
370-410
34-39 211 Oil plug 1 (272.9- 551 Oil plug 8
302.4lbf·ft)
230-260
212 ○-ring 2 (169.6- 552 Oil plug 2
191.8lbf·ft)
370-410
78-98 251 Oil plug 2 (272.9- 553 Oil plug 2
302.4lbf·ft)
69-78
Lock valve selection
9.8-14 252 2 (50.9- 554 Oil plug 2
subassembly
57.5lbf·ft)
200-250
262 ○-ring 8 (147.5- 557 Oil plug subassembly 2
184.4lbf·ft)
200-250
263 ○-ring 12 (147.5- 558 Oil plug 2
184.4lbf·ft)
264 ○-ring 7 561 ○-ring 12
3-56
Mounting Mounting
Quant Quanti
ity ty
(N•m) (N•m)
265 ○-ring 2 562 ○-ring 7
267 ○-ring 1 563 ○-ring 2
120-140
52-62 273 Inner hexagon bolt 40 (88.5- 601 Main relief valve 1
103.3lbf·ft)
120-140
52-62 274 Inner hexagon bolt 12 (88.5- 603 Port relief valve 8
103.3lbf·ft)
Negative flow control
52-62 275 Inner hexagon bolt 5 611 2
relief valve
120-140
301 Travel spool 2 (88.5- 652 Oil plug 2
103.3lbf·ft)
Arm 1 spool
302 1 663 ○-ring 2
subassembly
Boom 1 spool
303 1 664 ○-ring 2
subassembly
Sealing ring protection
304 Bucket spool 1 665 2
gasket
305 Swing spool 1 751 Flange 2
Cover plate without pipe
308 Backup spool 1 754 1
opening
Cover plate without pipe
37-41 313 Oil plug 1 755 2
opening
326 Spring 2 761 ○-ring 2
140-160
327 Spring 2 (103.3- 762 Inner hexagon bolt 8
118lbf·ft)
332 Spring holder 22 763 ○-ring 1
83-110
335 Shim 3 (61.2- 764 Inner hexagon bolt 4
103.3lbf·ft)
83-110
37-41 336 Bolt with a liner 11 (61.2- 765 Inner hexagon bolt 8
103.3lbf·ft)
390-470
337 Rod 2 (287.6- 972 Inner hexagon bolt 4
346.6lbf·ft)
390-470
15-19 351 Orifice plug 2 (287.6- 973 Inner hexagon bolt 3
346.6lbf·ft)
390-470
15-19 352 Orifice plug 1 (287.6- 974 Inner hexagon bolt 1
346.6lbf·ft)
3-57
Mounting Mounting
Quant Quanti
ity ty
(N•m) (N•m)
355 Piston 1 991 Nameplate 1
356 Piston 1 992 Rivet 2
371 Spring 7
372 Spring 1
373 Spring 1
374 Spring 1
375 Spring 1
3-58
Main control valve hydraulic circuit
P1g (P1)(P2) P2g Pa （T2）T1 R3
R4
CMR2
CMR1
PL1
PBr
[PT4] Travel-rh
Straight (PTb) PAr
travel Py
Ar
Br
CP2
LCS
Pns
Dr4
PBL PBs
Travel-lh PAL PAs
Swivel
BL As
AL Bs
CPI
P
Px LCb Psp Swing
PBb priority
Dra
PAb
Boom 1 PBb2 Boom 2
PAbs
Ab
Cob Drb
Bb
P2c1 (Ck2]
LCs
Dr3’ LCc (PBo]
PBc
Bucket (PAo] Backup
PAc
PAcs
Bc
Ac
[Ao]
[Bo]
PBa2 PBa
Arm 2 Arm 1
PAa2 PAa
Aa
(CLOSE) Bs
Bypass stop (Pcb) P2c2

(OPEN)
Dr3
Bypass
Pca
stop
N1
N2
[P4] [P3] LG950EIII03048

3-59
3. Working principle
(1) When the spool is in the neutral position

[Main circuit]
When all spools are at middle position, the hydraulic oil output from hydraulic pump (P1) flows in through
port P1 and is guided into the main passage (1), then flows through the center bypass (2) (neutral
position M-shape slide valve function) in the spools of boom 1, bucket, arm 2, minus flow overflow valve
at boom 1 side, and then returns into the hydraulic oil tank via the oil return port (1).
The signals of the negative flow relief valve at the boom 1 side are transmitted into the hydraulic pump
adjuster at the P1 side from the port N1 to control the pump output flow as the minimum flow.
The hydraulic oil fed from hydraulic pump at P2 side flows from pump port P2 and is guided into main
passage (3); it flows through the spool center bypass (2) of rotary, boom confluence (boom 2), standby,
arm 1, and the minus flow overflow valve at arm 1, and then returns to the hydraulic oil tank through the
oil return port (1).
The signals of the negative flow relief valve at the arm 1 side are transmitted into the hydraulic pump
adjuster at the P2 side from the port N1 to control the pump output flow as the minimum flow.
When any of 9 main spools is to be changed, the center bypass (2) will be closed, the oil through port N1
or N2 in minus flow circuit will be cut off.
BOOM
CONFLUENCE
TRAVEL PBb2
RIGHT SWING OPTION ARM 1
PBr PBs (PBo) PBa
CUT
R3
T1
(3)
(2)
PAr PAs PAs

(PAo)
SWING
PRIORITY LG950EIII03049
3-60
BOOM 1 BUCKET
TRAVEL TRAVEL
STRIGHT LEFT ARM 2
(PTa) PBL PBa 2
(1)
P1g
(3)
P2g
(2)
CUT
(PTb) PAL PAc PAa2
LG950EIII03050
3-61
(2) Traveling
[Main circuit]
When the pilot port (P BL) of leftward travel spool is pressurized, the center bypass (2) at arm 2 side will
be closed, and the hydraulic oil from the pump port P1 will flow to leftward travel motor through BL port.
On the other hand, the return oil from the travel motor flows through port AL, and return the hydraulic oil
tank via the return port (T1).
PBL
PAL
AL BL
Travel motor Travel motor

LG950EIII03051
(3) Arm
1) The arm stretches out
[Main circuit]
During the arm extending operation, pilot pressure oil is fed into the port ?Ba and ?Ba2. When P Ba is
applied with pressure oil, the spool is switched to the left as shown in figure below. Thus the hydraulic oil
from the pump port P2 is guide to the center bypass (2) via the main passage (3). By switching the arm 1
spool (302), the central bypass is cut off. So the hydraulic oil from the parallel passages pushes open the
check valve (511) and flows into the arm 1 spool (302) via U-shape passage. Then the hydraulic oil flows
from the periphery of arm 1 spool (302) into port Ba so that the arm cylinder piston rod cavity (R) will be
fed with hydraulic oil.
On the other hand, the hydraulic oil flowing from the pump port P1 is guided into the center bypass (2)
via the main passage (1). By switching the arm 2 spool (394), the neutral bypass (2) is cut off. So the
hydraulic oil from the parallel passages pushes open the check valve and flows into the arm 2 spool
(394) via U-shape passage. Then the hydraulic oil from arm 2 spool (394) converges with port Ba via the
inner passage.
3-62
The return oil from arm cylinder piston head cavity (H) flows to the oil tank oil circuit of arm 1 via Aa port,
and then return to hydraulic oil tank through oil return port (T1).
Arm 2
PAa2
PBa2
PAa
PBa
Arm 1
Aa
511 Ba
LCa1
Parallel channel
U-shape channel
H R
LG950EIII03052
3-63
2) The arm retracts

[Main circuit]
During the arm retracting operation, pilot pressure oil is fed into the port ?Aa and ?Aa2. When P Aa is
applied with pressure oil, the spool is switched to the right side shown in figure below. Thus the hydraulic
oil from the pump port P2 is guide to the center bypass (2) via the main passage (3). By switching the
arm 1 spool (302), the central bypass is cut off. So the hydraulic oil from the parallel passages pushes
open the check valve (511) and flows into the arm 1 spool (302) via U-shape passage. Then the
hydraulic oil flows from the periphery of arm 1 spool (302) into port Aa so that the arm cylinder piston
head cavity (H) will be fed with hydraulic oil.
On one hand, the hydraulic oil flowing from the pump port P1 is guided into the center bypass (2) via the
main passage (1). By switching the arm 2 spool (394), the central bypass is cut off. So the hydraulic oil
from the parallel passages pushes open the check valve and flows into the arm 2 spool (394) via U-
shape passage. Then the hydraulic oil from arm 2 spool (394) converges with port Aa via the inner
passage.
On the other hand, the return oil from arm cylinder piston rod cavity (R) returns to port Ba after
pressurized by the dead weight of arm. The hydraulic oil returned to port Ba flows into the spool through
the hole (a) at periphery of arm 1 spool (302). When the small load pushes open the shell type check
valve, a part of oil flows from spool hole (c) to the U-shape passage and converges with port Aa. The rest
hydraulic oil returns to the hydraulic oil tank through oil return port (T1). This is called the arm
regeneration function.
When the pressure in arm cylinder piston head cavity (h) increases, the piston (d) and spool
subassembly (e) is switched to the right side. At same time, the shell type check valve is closed due to
back pressure. In this way, the bucket regeneration function is deactivated; the return oil from arm
cylinder piston rod cavity (R) flows into the spool through the hole (a) on periphery of arm 1 spool (302),
and the flows out through the hole (b) on periphery, and then return to hydraulic oil tank through oil return
port (T1).
3-64
On the other hand, similar as the arm extension operation, the hydraulic oil from the pump port P1
converges with port Aa through inner passage.
Figure When load is small
Arm 2
PAa2
PBa2
(a)
(c)
PAa
PBa
Arm 1
Aa
Ba
511
Parallel channel
LCA1
U-shape channel
H R
Dead weight of arm
LG950EIII03053
3-65
Figure When the pressure on the side of arm cylinder piston head cavity (H) rises
Arm 2
PAa2
PBa2
(d)
(e) (f) (a)
PAa
PBa
(b)
Arm 1
Aa
Ba
LCa1
H R
LG950EIII03054
3-66
(4) Boom
1) The boom is lifted
[Main circuit]
When operating the boom for lifting, the pilot pressure oil is fed into port P Bb and the boom 1 spool
(303) is switched to the left side shown in figure below. The hydraulic oil from the pump port P2 is guide
to the center bypass (2) via the main passage (1). By switching the boom 1 spool (303), the central
bypass (2) is cut off. So the hydraulic oil from the parallel passages pushes open the check valve (511)
and flows into the boom 1 spool (303) via U-shape passage. When the travel of boom 1 spool (308) is
small, the hydraulic oil flows into spool through the hole (d) on periphery of the spool, and then to port Bb
via hole (e) on periphery. When the boom 1 spool (303) travel is large, the hydraulic oil flows to port Bb
through the periphery of the spool.
At same time, the pilot pressure oil is fed into port P Bb2 and the boom 2 spool (393) is switched to the
left side shown in figure below. For the hydraulic oil from the pump port P2, since the center bypass (2) of
boom 2 spool (393) is cut off by switching, the hydraulic oil flowing to the parallel passage flows to the
boom 2 spool (2) through U-shape passage. Then the hydraulic oil pushes open the check valve through
the periphery of boom 2 spool (393) and converges with port Bb, and then are fed into the boom cylinder
piston head cavity (H). (Thus is called as boom confluence function)
On the other hand, the return oil from boom cylinder piston rod cavity (R) flows in through port Ab, and
returns to hydraulic oil tank through oil return port (T1).
R H
LCb1
Parallel channel
Ab
511 Bb
Boom 1
PABs
PBb
(Bbs)
PAb
(d) (e)
PBb2
Boom 2
PSp
Dra
Ccb
Drb
Csp
LG950EIII03055
3-67
2) The boom is lowered

[Main circuit]
When operating the boom for lowering, the pilot pressure oil is fed into port P Ab and the boom 1 spool
(303) is switched to the right side shown in figure below. The hydraulic oil flowing from the pump port P1
is guided into the center bypass (2) via the main passage (1). By switching the boom 1 spool (303), the
neutral bypass is cut off. So the hydraulic oil from the parallel passages pushes open the check valve
(511) and flows into the boom 1 spool (303) via U-shape passage. Then the hydraulic oil flows into port
Ab through the periphery of boom 1 spool (303), and is fed into the boom cylinder piston rod cavity (R).
On the other hand, the return oil from boom cylinder piston head cavity (H) flows through the notch
groove of boom 1 spool.
The return oil pressure increases due to the dead weight of working mechanism applied on the piston
rod cavity, and the pressurized oil returns into port Bb. Then it flows in the spool through the hole (d) on
periphery of the spool, and pushes open the cone valve A inside the spool to the left side shown in figure
below, and flows out to the periphery of the spool. After that, the hydraulic oil used for lowering operation
of boom again is fed into the boom cylinder piston rod cavity (R) (Such is called as boom regeneration
function).
In case of dead weight effect become weak, the pressure in piston rod cavity pressure increases and the
cone valve is closed, so the pressure in spool inner passage increases. It pushes open the boosting
check valve (B) and the return oil from port Bb fully returns to the hydraulic oil tank through oil tank port
(T1).
During boom lowering and arm extension operation, the pilot pressure is fed into port P Abs and the
travel of boom 1 spool is limited.
Dead weight
R H
LCb1
Ab
Bb
PAbS
PBb
B
(Bbs)
PAb
LG950EIII03056
3-68
(5) Bucket
1) Bucket excavation
[Main circuit]
During operating the bucket for excavation, the pilot pressure oil is fed into port P Ac and the bucket
spool (304) is switched to the right side shown in figure below. The hydraulic oil flowing from the pump
port P1 is guided into the center bypass (2) via the main passage (1). By switching the bucket spool
(304), the neutral bypass is cut off. So the hydraulic oil flowing into the parallel passages pushes open
the check valve (511) and flows into the bucket spool (304) via U-shape passage. Then it flows to port Ac
through periphery of the spool and then into the bucket cylinder piston head cavity (H).
On the other hand, the return oil from the bucket cylinder piston rod cavity (R) flows into the port Bc, and
then flows to the oil-return port (T1) via the periphery of the spool to return to the hydraulic oil tank.
When operating the boom for lifting and the bucket excavation at same time, the pilot pressure oil is fed
into port P Acs and the travel of bucket spool (304) is limited.
H R
U-shape channel Parallel channel

Ac Bc
PBc PAcs
PAc
LG950EIII03057
3-69
2) Bucket unloading
[Main circuit]
When operating the bucket for unloading, the pilot pressure oil is fed in port P Bc and the bucket spool
(304) is switched to the left side shown in figure below. The hydraulic oil flowing from the pump port P1 is
guided into the center bypass (2) via the main passage (1). By switching the bucket spool (304), the
neutral bypass is cut off. So the hydraulic oil flowing into the parallel passages pushes open the check
valve (511) and flows into the bucket spool (304) via U-shape passage. Then it flows to port Bc through
periphery of bucket spool and is fed into bucket cylinder piston rod cavity (R).
On the other hand, the return oil from the bucket cylinder piston rod head cavity (H) will flow in from port
Ac, and then return to the hydraulic oil tank from the oil-return port (T1) through the spool periphery.
H R
Parallel channel
U-shape channel
Ac Bc
PBc PAcs
PAc
LG950EIII03058
(6) Swing
1) Only rotating
[Main circuit]
When only operating for rotation, the pilot pressure oil is fed into port P As (or port P Bs) to switch the
rotation spool. The hydraulic oil from pump port P2 is guided into rotating motor through port As (or Bs).
The return oil from the rotating motor returns the hydraulic oil tank from port Bs (or As) via the return port
(T1).
3-70
2) Swing priority
[Pilot circuit]
The pilot pressure oil is fed from port P Sp to switch the rotating priority spool (395).
[Main circuit]
For switching by rotating priority spool, the opening area of rotating priority spool decreases; the
hydraulic oil of pump port P2 almost fully flows back into the rotating cavity and give priority to the
rotating operation.
Swing priority valve element
36S
Working oil flows from the P2
The opening area decreased

LG950EIII03059
(7) Straight travel

When the travel spool is operated together with other spools.
The condition where the travel spool and the rotary spool are simultaneously operated is described
below.
(Port P AL, P Ar, P As are fed with pilot pressure oil.)
[Pilot circuit]
Close the bypass passage of two travel spools and the bypass passage of rotating spool at downstream;
the pilot pressure oil fed from port Pa is fed into port P Ta for switch to the straight-line travel spool.
[Main circuit]
If switching to straight-line travel spool, the pump port P2 connects with two travel spools in priority, while
the pump port P1 connects with the parallel passage for rotating • boom 2 • standby • arm 1 oil circuit/
boom 1 • bucket • arm 2 oil circuits in priority. Thus the hydraulic oil from pump port P2 mainly flows into
port AL and port Ar, and it will be equally fed into two travel motors.
3-71
On the other hand, the hydraulic oil from pump port P1 is fed into rotating motor through port As.
When the pressure oil of pump port P2 is lower than the pressure in pump port P1, the hydraulic oil from
pump port P1 will be partly fed to P2 side. In This way, the stalling of travel speed can be prevented.
P2g
P1g
P2 P1
(PTb)
PTa
PAL
PBL
LG950EIII03060
(8) Function of lock valve selection subassembly

The lock valve selection subassembly is mounted between the arm cylinder piston rod cavity (R) and
arm 1 spool (302), and between the boom cylinder piston head cavity (H) and boom 1 spool (303) to
reduce the inner leakage rate from spool due to pressure of oil cylinder.
3-72
1) Spool neutral state

Only the conditions related to boom 1 spool is described here. (Same for arm 1 spool.)
When the boom 1 spool is at neutral position, the lock valve selection subassembly keeps at the position
shown in figure below. The spool (511) in the lock valve selection subassembly is pressed onto the valve
sleeve (541) by the pre-tightening force of spring (512).
At this time, the hydraulic oil from boom cylinder piston head cavity (H) presses the cone valve onto the
valve seat of valve body through the hole (a), spool periphery and hole (b) to reduce the inner leakage at
the spool.
511 512
Piston crown channel (H) of P2c1
boom cylinder
LCb1
Dr3’
HV
(a) (b) 541

PAbs
PBb
(Bbs)
Boom 1
Boom 1
LG950EIII03061
3-73
2) Boom lowering operation

When operating the boom for lowering, the pilot pressure oil is fed in port P 2c1 and P Ab. If the pilot
pressure oil is fed, the spool (511) in the lock valve selection subassembly is switched to the right as
shown in figure below. Through the movement of spool, the hole (a) is cut off, so the hydraulic oil from
boom cylinder piston head cavity (H) will not flow in spring chamber (RH). Then the oil of cavity in spring
chamber (RH) flows leak oil port (Dr3) by help of the hole (b).
Thus the cone valve is pushed open by the boom cylinder piston head cavity (H) and the function of lock
valve selection subassembly is can celled.
511
P2c1
Piston crown
LCb1
channel (H) of Dr3’

boom cylinder
HY
(a) (b)
(RH)
PAbs
PBb
(Bbs)
PAb
LG950EIII03062
3) When the boom is operated to lift

When operating the boom for lifting, the pilot pressure oil is fed in port P Bb; the pressure oil flowing from
the boom 1 spool pushes open the cone valve (513) and the hydraulic oil flows into port Bb.
(9) Boom priority valve
During operating the rotation and the boom lifting at same time, the pilot pressure oil flows in through
port P As (or P Bs), P Bb and P ns. The pilot pressure oil flowing from P ns presses the piston (356) and
spool (107) , so the passage (a) → (b) is cut off.
?In this way, the hydraulic oil from pump port P2 jacks up the cone valve (102); then (E) chamber is filled
with hydraulic oil through passage (c) and (d), so the cone valve (101) is pressed onto the valve body.
Therefore the hydraulic oil flowing from pump port P2 into rotating spool is limited; the limited part is fed
to the boom confluence spool at downstream, and the boom lifting action will take priority.
3-74
On the other hand, during single operation for rotation, the since the pilot pressure oil does not flow from
Pns, the passage (a) → (b) is not cut off; the oil in (E) chamber is discharged through this passage; the
hydraulic oil from pump port P2 jacks up the cone valve (102) and is fed into the rotating spool
Pns
356
107
(b) (E)
Bs As
(a) (d)
(c) 102
P22g
ᰁഔ PBs PAs
SWING
LG950EIII03063
(10) Function of main relief valve

The main overflow valve is mounted on valve body B. The function is shown as follows.
1) The hydraulic oil flows into (A) cavity through the hole of valve plunger housing (101) and valve
plunger (511) from the passage (P); the valve plunger (511) is pressed onto the valve plunger
housing (101) to form reliable sealing.
2) When the pressure in passage (P) exceeds the preset tightening force of spring (512), open the
cone valve (401), so the hydraulic oil flows through the hole of valve seat (2) (641) and the cone
valve (401) periphery to the low pressure passage (R).
3) The pressure inside the cavity (A) drops due to the opening of the cone valve (401), and the valve
plunger (511) is opened. In this way, the hydraulic oil in passage (P) directly flows to low pressure
passage (R).
3-75
4) When the hydraulic oil of more than 2.2MPa is fed to port P L1, it will push the plunger (302) moving
downward and increase the set pre-tightening force of spring (512), and it will change as pressure
rise state
PL1
302
512
401
641 511
(A)
101
P LG950EIII03064
(11) Function of port relief valve

The port relief valve is installed between the cylinder port and the low pressure passage. Besides the
function as a relief valve, the port relief valve also has the function as a check valve for preventing
cavitation and replenishing oil. The functions are shown as follows.
3-76
1) Function as a relief valve

a. Hydraulic oil fills the cavity (B) via hole 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.
B
A
301
7
511 541
LG950EIII03065
b. When the pressure in passage (P) exceeds the pre-tightening force setting of spring (621 or 622),
the cone valve (611) is pushed open, and the hydraulic oil flows through the hole (C) from the
periphery of cone valve to the low pressure passage (R).
C
R
611 621
LG950EIII03066
3-77
c. By opening of the cone valve (611), the pressure in (B) cavity decreases and the plunger (511) will
be open. In this way, the hydraulic oil in passage (P) directly flows to low pressure passage (R).
511 B
611 LG950EIII03067
4) Function as a check valve for preventing cavitation and replenishing oil

In case of negative pressure in passage (P), the hydraulic oil is fed from passage (R). When the
pressure of the passage (R) is higher than the pressure of the passage (P), the valve seat (541) moves
rightwards. So the hydraulic oil flows through valve seat (541) periphery and passage (R) to the passage
(P) so as to prevent the cavitation corrosion.
541
LG950EIII03068
3-78
(12) Function of minus flow overflow valve

The negative flowrate relief valve is installed between the most downstream of the neutral by-pass and
the low pressure passage. The functions of minus flow overflow valve are shown as follows.
1) If the pressure of port P is less than the set pressure of spring (621), the cone valve (611) will be in
the state shown in figure below. The pressure bearing area of cone valve (611) is the part of φB
minus the part of φA of damping rod (631) not applying the pressure oil, so the pressure bearing
area is φB - φA.
611 621
R
P
ØB
ØA
631 LG950EIII03069
3-79
2) In this state, the hydraulic oil of passage (P) flows through damping hole (C) to passage (R).
C LG950EIII03070
3-80
3) When the pressure of passage P exceeds the pressure setting of spring (621), the cone valve (611)
is opened; then the working oil of passage (P) flows through the cone valve (611) periphery to the
low pressure passage (R).
621
R
611 LG950EIII03071
3-81
The relationship between flow Q of hydraulic oil from passage (P) to low pressure passage (R) and the
pressure P is shown in figure below.
Figure 25
O Q
LG950EIII03072
4. Maintenance references
Part name Check items Criteria and handling

(1) For following parts and components, replace
them if they are damaged
• Valve holes in the valve body and spool slide
section, especially spool shoulder related to
(1) Where there is scratch or grinding crack •
Valve body pressure maintenance
rusting • corrosion
• Sealing part of each overflow valve for the
port contacting O-ring
• Each overflow valve sealing part
• Other damages affecting normal function
(1) Where there is scratch or grinding crack • (1) If any sticking scar on sliding part of
rusting • corrosion periphery, it shall be replaced (especially for
Spool (2) Insert the spool into the valve hole, and the part contacting the seal)
observe the condition where the spool (2) If the O-ring has damage or the spool action
rotates while moves to make travel is not smooth, repair or replace them
Replace the spring if any bending defect of
(1) Whether the cone valve or spring is spring
damaged (1) Repair or replace if failed to completely
Cone valve
(2) Mount each cone valve into the valve body sealing
hole and observe the action conditions (2) It is normal if no sticking, and action freely
and smoothly
3-82
Part name Check items Criteria and handling

(1) Whether there is rusting • corrosion •
Around spring deformation • breakage of spring, spring (1) Replace the part with detectable damage
seat, oil plug and cover
(1) Whether the appearance has rusting •
(1) Replace it
Main relief valve breakage
(2) Replace if there is any damage
Port relief valve (2) Contact face of the valve seat
(3) Replace if there is any damage
Negative control (3) Contact surface of each cone valve
(4) Replace it
relief valve (4) Abnormal spring
(5) Replace all of them in principle
(5) ○-ring, retaining ring and sealing parts
5. Fault cause and treatment
General precautions
1) Once abnormal phenomena is detected, try to check whether the control valve is out of control, or
the pump, auxiliary pump or circuit is faulty. Therefore, measure the pilot pressure, pump output
pressure, load pressure, etc. In addition, always comply with the removal and installation process
above to perform removal and check.
2) Because dust is very harmful to the hydraulic part, especially pay attention to preventing dust.
Always prevent dust even if perform removal of some parts.
3) Be careful to handle moving part. For the slight damage, oilstone is also needed for repair.
4) During operation, please be careful not to damage the gasket surface of the O-ring. It is quite
possible that this damage causes oil leakage.
5-1 Control valve
Symptom Cause Treatment

1. No action of (1) Poor action of main overflow valve
(1) Test the pressure of main overflow valve
traveling or rotation; • Garage stuck between the main overflow
• Disassemble, clean and replace complete
slow action spool and valve seat
subassembly if damaged
(inadequate force) • Garage stuck between cone valve and
• Ditto
or slow response valve seat
• Amend the sticking part with oil stone
• Sticking of main overflow valve spool
• Replace the spring
• Breakage or reduced elastic force of spring
• Remove the garage
• Blocking of damping hole of main overflow
• Tighten the lock nut according to specified
valve spool
torque after re-adjustment
• Adjusting screw is loose
(2) Blocking of damping hole on pilot circuit by
(2) Remove the garage
garage near the control valve
3-83

2. When the spool is at (1) Too large clearance between valve body
(1) Replace the spool or valve body
neutral position, the and spool
dead weight falling (2) The spool has not completely returned to
amount of cylinder is neutral position (2) Test the pilot secondary pressure
large • Garage stuck between valve body hole and • Disassemble, clean and amend the sticking
spool or sticking part with oil stone
• Spring fracture or reduced pre-tightening • Replace the spring
force • Remove the garage
• Garage blocking in pilot circuit
(3) Poor action of main overflow valve (3) Test the pressure of main overflow valve
Refer to above item (1.1) Refer to above item (1.1)
(4) Poor action of port overflow valve (4) Test the pressure of port overflow valve
(5) Poor action of lock valve selection (5) Replace the lock valve selection
subassembly subassembly
(6) Poor action of lock valve subassembly
• Garage stuck between valve body and cone
• Disassemble, clean and replace the cone
valve
valve in case of large damage
• Sticking and jamming of cone valve
• Amend the sticking part with oil stone
• Spring fracture or reduced pre-tightening
• Replace the spring
force
3. When operating the (1) Poor action of load check valve spool
cylinder for lifting, • Garage stuck between cone valve and • Disassemble, clean and replace the valve
the action moves valve body body in case of large damage
toward the opposite • Sticking and jamming of cone valve • Amend the sticking part with oil stone
direction (i.e. • Spring fracture or reduced pre-tightening • Replace the spring
lowering) force
4. Only bucket, boom (1) Poor action of main spool
and arm are not • Tool large clearance between spool and (1) Test the pilot secondary pressure
operating valve body • Replace the spool
(inadequate force) • Garage stuck between spool and valve • Disassemble and clean
or the operation is body • Amend the sticking part with oil stone or
slow • Sticking and jamming of spool replace
• Return spring fracture or reduced pre- • Replace the return spring
tightening force of spring • Remove the garage
• Garage blocking in pilot circuit
(2) Poor action of main overflow valve (2) Test the pressure of main overflow valve
(3) Poor action of port overflow valve (3) Test the pressure of port overflow valve
5. Rotating priority
Poor action of rotating priority spool • Amend the sticking part with oil stone or
function is not
• Sticking and jamming of spool replace
operating
6. Confluence of boom (1) Poor operation of each confluence spool (1) Test the pilot secondary pressure
and arm are not • Sticking and jamming of spool • Amend the sticking part with oil stone or
operating • Return spring fracture or lack of pre- replace
tightening force • Replace the return spring
3-84

7. Straight-line travel is (1) Poor operation of straight-line travel spool
(1) Test the pilot secondary pressure
not operating • Refer to above item (1.1)
• Refer to above item (1.1)
• Blocking of damping hole (352)
• Remove the garage
• Too large clearance between valve body
• Replace the spool
and spool
8. Minus flow relief
(1) Poor operation of minus flow relief valve
valve is not (1) Test the pressure of minus flow relief valve
• Garage stuck between cone valve and
operating; failed to • Disassemble, clean, replace the
valve body
changing minimum subassembly in case of large damage
• Spring fracture or lack of pre-tightening
flow when putting • Replace the spool
force
the operation level • Disassemble, clean and remove the garage
• Blocking of damping hole of cone valve
at neutral position
5-2 Relief valve

1. No pressure rise at • Confirm whether the foreign matter is stuck
The main spool of each relief valve or pilot
all at fitting part of each spool
cone valve is stuck or blocked, or opened
• All parts and components shall be able to
always, or the garage is tuck at the valve seat
freely and smoothly move
part
• Thoroughly clean all parts and components
2. Unstable overflow • Repair the faulty parts and components
The valve seat of pilot cone valve for each
pressure • Thoroughly clean all parts and components
overflow valve has been damaged
• Remove the scar on surface
3. Failed to achieve (1) Wear due to garage (1) Disassemble and clean
correct set pressure (2) Locknut and adjusting screw have been
(2) Adjust pressure
loose
4. Oil leakage (1) Replace any damaged or worn part
(1) Damage of each valve seat and wear of ○-
Confirm the parts and components moves
ring
smoothly and then assemble
(2) Sticking of parts and components due to (2) Confirm there is no scratching, bruise or
garage foreign matter, and then assemble
3-85
Center connector
Center swivel 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.
(1) Structure
The structure of the center joint is shown in the figure below.
Structural drawing of center joint
5 6 7 8 9
10 11 12
2 3 4
LG950EIII03073
1. Hex bolt 5. Shim 9. Elastic retainer ring for shaft

2. Cover 6. O-ring 10.Rotation seal ring
3. Revolving body 7. Snap ring 11.O-ring
4. Swing shaft 8. Shim 12.Dust ring
3-86
LG950EIII03074
A: Right travel motor reversing oil port D: Left travel motor forward oil port
B: Left travel motor reversing oil port F: High speed/low speed shift switching oil port
C: Right travel motor forward oil port G:Oil drain port
3-87
(2) Working principle

The center swing joint is composed of the revolving body, revolving shaft, end cover and other parts, and
revolving body (or revolving shaft) is fixed on upper part (or lower part) of the vehicle body, but revolving
shaft (or revolving body) is installed on lower part (or upper part) of vehicle body and can rotate 360°
freely. Slot annular grooves on revolving shaft with the same number of oil line, and hydraulic oil entering
into oil inlet of revolving body connects with radial hole on revolving shaft through oil groove on revolving
body, and supplies travel motor. Because the annular grooves on revolving body and revolving shaft are
closed, no matter whether revolving body or revolving 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
A1 B1 C1 D1 Body port
A2 B2 C2 D2 Shaft port
LG950EIII03075
(3) Fault cause and treatment
Fault
S/N Fault cause Countermeasures
phenomenon
1. Dust impurities enter the neck to 1. Take dust-prevention measures for base
damage neck seal; machine
Oil leakage of neck 2. The connection is subject to external 2. The products must meet installation
1
part force during installation, causing single requirements when being connected
side abrasion of the seal to lead to oil and installed;
leakage. 3. Replace the seals.
Oil leakage at the Loosening of fastening bolt or damage and
2 Retighten the bolt, and replace the seal.
place of cover aging of seal at the place of cover.
Oil leakage of oil Hydraulic pipeline fitting connecting with
3 Replace with new hydraulic pipeline fitting.
port oil port is damaged
3-88
Explosion-proof valve
The pipeline explosion proof valve is optional.

Schematic diagram
LG950EIII03076
1. Check valve 3. Relief valve 5. Check valve

2. Throttle valve 4. Balanced valve 6. Strainer
For the optional, it is directly installed on the cylinder (large boom cylinder cavity and small boom
cylinder cavity) to prevent the control work implement from suddenly dropping without the action of
gravity after hose bursting to cause accidents. Generally, the C2 port is directly installed with the cylinder
port and the V2 port is connected with the pipeline.
During normal operation, the upward flow (V2-C2) flows into C2 port to enter the cylinder freely through
the two check valves and the reverse flow (C2-V2) is stopped by the balanced valve (4). The spool
provides accurate throttling during the original opening stroke and it keeps normally closed for its
adjustment of spring force; the spool is controlled remotely through the pilot pressure from the PiL port;
the pilot pressure for moving the spool has nothing to do with the load. The relief connector (3) can
detect the pressure of C2 port and open under the overload or impact condition to guide the balanced
valve (4) to open thoroughly; the hydraulic oil of the cylinder flows into the oil tank through the pipeline
and the main control valve from the V2 port.
After the hose bursts suddenly, hydraulic oil in the hydraulic cylinder cannot pass through the valve due
to the blocking of the balanced valve (4). When the system uses two identical cylinders, one small
balance line is used to balance the pressure between the cylinders.
3-89
The relief valve (3) is used for protecting cylinders from being damaged under the action of external
force. When external force impacts the cylinder, impact pressure passes through the (6) strainer and
outputs pressure signals to the balanced valve (4) through the relief valve (3) to open the balanced
valve. The pressure of the cylinder is released. The check valve at the lower right corner ensures
enough pressure to open the balanced valve (4) can be created after the impact pressure passes
through the relief valve (3).
The setting pressure of the relief valve (3) is the maximum pressure that the cylinder cannot be
damaged. When the impact pressure does not reach the relief pressure of the relief valve (3), the relief
valve (3) cannot overflow, and the bursting-proof valve cannot be opened in the reverse direction.
After the hose bursts, the cylinder can be slowly lowered by adjusting the relief valve (3). However, after
the cylinder is lowered to the safety position, the safety pressure of the relief valve (3) needs to be reset.
The safety pressure of the relief valve (3) for protecting the cylinder from being damaged has been set
while leaving the factory. After adjustment, the relief valve needs to be reloaded to the test bench to set
the safety opening pressure.
Exterior drawing
LG950EIII03077
3-90
Specification
Position 12C2490 (Boom) 12C5640 (Arm)

Maximum working pressure 42 MPa(6090psi) 42 MPa(6090psi)
Maximum flow 400 L/min(105.7US gpm) 500 L/min(132.1US gpm)
Valve 3 35MPa(5075psi) 35MPa(5075psi)
Setting pressure
Valve 4 0.75MPa(108.8psi) 0.75MPa(108.8psi)
35~46MPa(5075~6670psi) 35~46MPa(5075~6670psi)
Valve 3 (tighten by 1 cycle to increase (tighten by 1 cycle to increase
Pressure regulating 22.8MPa(3306psi)) 22.8MPa(3306psi))
range 0.6~1.5MPa(87~217.5psi) 0.6~1.5MPa(87~217.5psi)
Valve 4 (tighten by 1 cycle to increase (tighten by 1 cycle to increase
0.35MPa(50.8psi)) 0.35MPa(50.8psi))
Category Anti-wear hydraulic oil Anti-wear hydraulic oil
Hydraulic oil -30~100°C -30~100°C
Temperature range
(-22~212°F) (-22~212°F)
The relief valve (3) is used to keep safety pressure preventing the cylinder from damages. The
setting of the pressure regulating spring of the balanced valve 4 should be matched with the
main control valve spool spring. Do not adjust without permission. After adjustment for specific
reasons, please restore to the factory setting pressure.
3-91
Hand pilot valve
After modify the specification and maintenance reference in the text according to the below, quote the
corresponding chapters in 925E4f Service Manual
Specification
First side pressure Maximum pressure 6.9MPa (1000.5psi)

Secondary side pressure 0~4.4 (maximum control pressure) MPa (0~638psi)
Allowable backpressure Maximum 0.3MPa (43.5psi)
Rated flow rate 20 L/min(5.28US gpm)
Operating angle ±19°and ±25° (independently)
PV48K1: 1.9kg(4.19lb)
Mass
PV48KC1: 3.8kg(8.38lb)
In order to obtain well responsiveness, appropriate pipeline is the one with inner diameter
Pipeline as φ8 and length as about 3m (118.1In). In addition, return oil shall not be affected by other
backpressures and directly enter into tank.
(1) Hand pilot valve structure (2) Working principle of the hand pilot valve
Overall structure of hand pilot valve Schematic diagram of hand pilot valve
P T
3 1 4 2
LG922E930E03085 LG922E930E03086
1. Control lever 2. Pilot valve 1,2,3,4- Oil inlet and outlet P-Pilot pressure oil port
ports T-Pilot oil return port
The hand pilot control valve is composed of a
control lever (1) and a pilot valve (2). It can
control two working devices, the left pilot
controlling rotation and the arm, and the right
pilot controlling bucket and boom.
3-92
Therefore, the control lever generates one angle,

Schematic diagram of hand pilot valve the pressure adjusting spring (6) is compressed
and pretightened, the pressure adjusting spring
1 2 (6) will also make the valve rod (11) move
downwards, the oil inlet passage (10) is opened,
pilot pressure oil reaches one end of the main
3 valve control valve rod through the oil inlet
4 passage (10), and thus, the angle of the main
9 control valve rod corresponding to the control
8
5 lever generates a certain displacement.
6
14 When the pilot lever slightly swings to a small
15 angle under non-operative state, the pressure
7 adjusting spring (6) will also make the valve rod
(11) move downwards slightly, and the main
16 13 10
17 12 valve control valve rod also generates one small
LG922E930E03087 displacement. At the moment, the main valve will
output small-flow pressure oil, and this pressure
1. Pressure plate 9. Return passage oil will make the working cylinder or motor act
2. Push rod 10.Oil inlet passage slowly. However, when the pilot lever suddenly
3. Spring 11.valve rod
swings by a large angle, the pressure adjusting
4. Dowel bar 12.Oil port
5. Spring seat 13.Oil inlet cavity spring (6) will also make the valve rod (11) move
6. Regulating Spring 14.Return passage downwards quickly, the main control valve rod
7. Reset spring 15.Oil inlet passage will quickly generate one large displacement to
8. Return cavity 16.Oil port
output large-flow pressure oil, so that the working
When the control lever is pulled rightwards, the cylinder or motor quickly acts. Therefore, the
presser plate (1) tilts rightwards. The presser action speed of the cylinder or motor is related to
plate (1) pushes the push rod (2) downwards, it the control angle of the pilot control lever.
brings the spring holder (5) to overcome the The controllability depends on the action
pretightening forces of the pressure adjusting sensitivity of the cylinder and motor. The timely
spring (6) and return spring (7) to move action of the cylinder and motor needs pilot
downwards. The valve rod (11) also moves pressure oil to timely reach the main control
downwards under the action of force of the valve rod end and timely make the main control
spring (6). The oil inlet passage (10) is opened. valve rod act timely. The pilot lever swings in the
Pilot oil flows from the oil inlet cavity (13) to the non-operative state, and only the pressure
port of the main valve control valve rod through adjusting spring (6) makes the valve rod (11)
the passage (10) and via the oil port (12). Pilot move downwards. Actually, the downward
pressure oil makes the main control spool move, movement of the valve rod (11) firstly makes the
and corresponding actuating mechanism under push rod (2), the spring (3) and the force
control acts to operate or rotate. transmission rod (4) move downwards, and then,
Pilot oil at the another port of the main valve the spring (3) and the pressure adjusting spring
control valve rod returns to the oil port (17), and (6) act together to make the valve rod (11) move
the return passage (14) is opened and the oil downwards. Therefore, the conduction speed of
inlet passage (15) is closed because the push pilot pressure oil is closely related to these two
rod is not pressed by the presser plate. Pilot oil springs, i.e. the controllability is closely related to
returned to the oil port (17) enters the return these two springs.
cavity through the return passage (14) and When the lever is released, the return spring (7)
returns to the system oil tank via the hand pilot makes the control lever return to the natural non-
valve. operative state.
3-93
Maintenance references
Check items Maintenance limit Treatment Remarks

If one of them is
When the lever is at neutral
reached, the pilot Conditions:
position: more than1000 cc/min
Leakage volume valve needs to be Primary pressure 2.94 MPa (426.3psi)
When working: More than
replaced with a Oil viscosity 23mm²/s
2000cc/min
new one.
The sliding section is abraded by Replace the pilot In the aspect of leakage, the left condition
Slide valve 10 μm more than the non-sliding valve with a new is predicted to be roughly the same to the
section one. condition with the above leakage.
The head is abraded by more

Push rod Replace it
than 1 mm (0.04In)
The amount of clearance

Abrasion of
between the disk (302) of When shaking (clearance) is generated
operating section
operating section and the joint Replace it due to the looseness of the tightening
(amount of
section (301) is more than 2 mm section, etc., adjustment is needed.
clearance)
(0.08In)
Abnormal sounds, irregular
vibrations, too low primary Replace the pilot
Stability of action pressure, etc. are generated valve with a new
during working and cannot be one
restored after treatment
Note 1) Although seals such as O-rings are expected to be replaced after removal, it doesn't matter
to reuse them after being confirmed to be undamaged.
Foot pilot valve
(1) Specification
First side pressure Maximum pressure 6.9MPa (70 kgf/cm2) (1000.5psi)

Secondary side pressure Maximum control pressure 0~4.4 MPa (0~44.8 kgf/m2) (0~638psi)
Allowable backpressure Maximum pressure 0.3 MPa (3 kgf/ m2) (43.5psi)
Rated flow rate 10 L/min(2.64US gpm)
Operating angle ±12.4°
Mass 6.3kg(13.9lb)
To obtain good responsibility, a pipeline with about φ8 inner diameter and 3 m (118.1In)
Pipeline length is selected. Return oil shall not be affected by other backpressures and directly enter
into tank.
To prevent the slide valve from being jammed due to uncleanness, please set oil filter with
Oil filter
above 40 meshes at the entrance of port P.
3-94
(2) Structure of travel pilot valve

The overall structure of the travel pilot valve is Internal structure of travel pilot valve
shown in the figure below
External structure of travel pilot valve 13 1
11 2
3
12
4
6
1
5
7 T
8 14
2
T
9 P
10 15
P
LG922E930E03091
LG922E930E03089 1. Push rod 10.Oil port

2. Spring 11.Cam adjusting group
1. Pedal T- fuel return port 3. Spring 12.Push rod
P- Oil inlet 4. Spring cavity 13.Pedal
2. Pilot valve
14.Regulating Spring
5. Steel ball
15.Oil port
The travel pilot valve is composed of a pedal (1) 6. Damping piston T- Oil return port
and a pilot valve (2). Two control pedals 7. Spring seat P- Oil inlet
respectively control the left and right travel 8. Reset spring
motors and share return port T and oil inlet port 9. Spool
P. A hydraulic damping device is arranged inside
(3) Working principle of travel pilot valve this valve. When the machine is operated to
move forwards or backwards and the road is
The schematic diagram of the travel pilot valve is
bumpy, machine vibration is easily caused, so
as follows
the driver's operation must be affected, and the
External structure of travel pilot valve driver cannot operate well to make the machine
vibrate more severely to form a vicious circle.
The controllability of travel pilot valve without this
1 device is poor, and the driver always has no
choice but to stop the machine to eliminate
machine vibration.
2
P The hydraulic damper is composed of a spring
(2), a spring (3), a spring cavity (4), a steel ball
T (5) and a damping piston (6); and the pressure-
reducing valve is composed of a spring holder
(7), a spring (14) and a spool (9).
LG922E930E03090
1. Pedal T- fuel return port

2. Pilot valve P- Oil inlet
3-95
When the travel pedal presses leftwards as When the oil pressure of the oil inlet joint P rises,
shown in the figure, the cam adjusting gp (11) the pressure of the oil port (10) will also rise
tilts to press the push rod (12) downwards, the within a short period of time. Because the oil
push rod (12) moves downwards to drive the pressure of the oil port (10) rises, the force
damping piston (6) and the spring valve seat (7) making the spool (9) move upwards increases,
to overcome the resistance applied by the so the pressure adjusting spring pushes the
hydraulic damper and the elastic forces of the spool (9) upwards to reduce the communication
springs (8) and (14) to move downwards, and the amount between the port P and the oil port (10).
pressure adjusting spring (14) forces the spool Because the communication amount between
(9) to move downwards so the oil port (10) is the port P and the oil port (10) is reduced,
communicated with the oil inlet joint P. When the damping increases, i.e. the pressure drop from
oil port (10) is communicated with the oil inlet the port P to the oil port (10) increases, and the
joint P, pilot pressure oil enters along the oil inlet pressure of the oil port (10) is ensured to be
joint P, reaches the travel control valve rod unchanged, even when the pressure of the oil
control port through the oil port (10), and pushes inlet joint P has rised. When the pressure of the
the travel control valve rod so that high pressure oil inlet interface P decreases, the pressure of
oil from the main pump flows across the travel the oil port (10) will also decrease within a short
control valve rod to the travel motor. The travel period of time. Because the oil pressure of the oil
motor rotates to drive the mechanical travel to port (10) decreases, the force making the spool
move. (9) move upwards decreases, so the pressure
adjusting spring pushes the spool (9) downwards
The travel control valve rod makes low pressure
to increase the communication amount between
oil at the other end flow back the oil port of the
the port P and the oil port (10), i.e. damping of
travel pilot valve (15), the pressure adjusting
communication between the port P and the oil
spring is not stressed due to the action of the
port (10) decreases, the pressure drop from the
return spring, the spool is also in the upper
port P to the oil port (10) decreases, and the
position, and the oil port (15) is communicated
pressure of the oil port (10) is ensured to be
with the return interface T at the moment. Low
unchanged, even when the pressure of the oil
pressure oil enters to the oil port (15) enters the
inlet joint P has decreased.
return cavity along the oil port (15) and returns to
the system oil tank from the return interface T. (3) Fault cause and treatment of travel pilot valve
To make sure the mechanical travel moves The general phenomena are shown in the table
stably, pilot oil pressure reaching the travel below. Look for the cause and then remove the
control valve rod control port needs to be stable, trouble. However, a mechanical failure may not
i.e. oil pressure coming out of the oil port (10) be caused only by one poor part, but other
needs to be stable, which is realized by the associated parts. Be sure to bear in mind the
pressure-reducing valve composed of the spring treatment other than the matters described in the
holder (7), the spring (14) and the spool (9). table, if necessary.
The causes and countermeasures listed in the
following table are not all. If necessary, the
person in charge of repair must find out the
trouble and its cause
.
3-96
Symptom Reason Treatments

Insufficient primary pressure Ensure primary pressure
The elastic force of the spring (324) for setting
Replace with new product
secondary pressure has been weakened.
Secondary pressure
does not rise. The clearance between the slide valve and the
Replace slide valve and valve body group
valve body has been abnormally large.
Disassembling, assembling and replacing
The operating part becomes loose.
the operation parts
Sliding parts are jammed Repair stuck parts
Unstable secondary Variation in oil circuit pressure of oil tank Directly return the return oil to the oil tank
pressure Operate repeatedly for several times to
Air in the pipeline
exhaust air
Secondary pressure Too high oil tank oil circuit pressure Directly return the filling oil to the oil tank
is too high. Sliding parts are jammed Repair jammed section
Operate repeatedly for several times to
Air remained in the plunger chamber
exhaust air
Sliding parts are jammed Repair jammed section
The elastic force of the buffering spring (336 and
Replace with new product
337) has been weakened.
Ineffective buffering The clearance between the buffering plunger

Replace the buffering plunger and buffering
(224) and the buffering housing has been
hosing group
abnormally large.
Check the check valve section after
Poor action of check valve
disassembly.
The damping hole of the buffering plunger has
Replace the buffering plunger
been abnormally large.
The sliding part gets stuck. Repair stuck parts
Shuttle’s buffer torque
is heavier. The damping hole of the buffering plunger has
Replace or repair the buffering plunger
been blocked
The shuttle valve
Shuttle valve malfunction Dismantle and check the shuttle valve.
does not work.
3-97
Buffering valve (optional)
(1) Outline Diagram of Buffering Valve
LG922E930E03092
3-98
(2) Structure of Buffering Valve
1 2 3 4 5 6 7(2) 8 9 10 11 12 13 14 15
LG922E930E03093
1. Plug 6. One-way throttling valve 11. Spring

2. O-ring 7. Plug 12. Joint
3. Steel ball 8. Check valve 13. Orifice
4. Plug 9. Valve body 14. Strainer joint Spring
5. O-ring 10. spool
3-99
(3) Schematic Diagram of Buffering Valve

The buffering valve has two functions, and its working principle will be respectively described below.
Schematic Diagram
E F G H
2
P
1 3 6
4 7
A I B C D
LG922E930E03094
1. Strainer 4. Check valve and throttle valve 6. Check valve

2. Orifice 5. spool 7. One-way throttling valve
3. Check valve
1) Oil Replacement
When the outside working temperature is relatively low, the viscosity of hydraulic oil greatly increases, so
that the flowing property of the hydraulic medium becomes poor, and the property for transmitting
pressure energy greatly decreases. Therefore, the action of the whole machine lags. To improve the
flowing property, low temperature hydraulic medium in the pilot hose needs to be replaced.
The Specific Working Process is as Follows:
High temperature hydraulic oil (system return oil) of the whole machine enters the buffering valve
through the port P, and the strainer (1) preliminarily filters oil entering the buffering valve. The purpose of
preventing large-particle impurities in oil from entering the buffering valve is achieved. Filter high
temperature oil flows to check throttle valves (4), (7), etc. through check valves (3), (6), etc., flows out of
the pilot oil ports A, B, etc. through small damping holes of the check throttle valves, and flows back the
oil tank through the hand pilot valve. Therefore, the purpose of replacing low temperature hydraulic
medium in the pilot hose is achieved.
2) Buffering Function
When the hand pilot valve is operated, the port A of the buffering valve receives pilot pressure signal,
and the port B is communicated with return oil through the hand pilot valve. Pilot oil flows out from the
port F of the buffering valve through the port A and the check valve of the check throttle valve 4. It enters
the valve rod control port of the main control valve. It drives the main valve rod to act. Meanwhile, this
pressure signal drives the spool 5 of the buffering valve to move rightwards. The port F is communicated
with the port T.
3-100
Therefore, the action of the external cylinder represents quick starting. When the operation of the hand
pilot valve is suddenly stopped, the ports A and B are communicated with return oil through the hand
pilot valve. Hydraulic oil in the pilot hose as is subject to the action of the return spring of the main valve
rod. It flows back to the oil tank through port E to A and flows across the small orifice of the check throttle
valve (4). Therefore, this pressure signal will lag for a certain period of time, which is represented by the
stop of the cylinder after buffering.
Octuple solenoid valve
(1) Specifications
1. Maximum working 12. Electrical
7.0MPa(1015psi)
pressure specification
2. Allowable backpressure Less than 1.0MPa(145psi) (1) Solenoid valve type Oil immersed
3. Maximum flow Control valve – 16 L/min JIS C 3214 H class (180°C)
(2) Coil insulation type
(Equivalent to one spool) (4.23US gpm) (356°F)
Proportional valve – 10L/
min Tyok Electronics Japan
(3) Connector type
(2.64US gpm) Econoseal J series
4. Leakage volume Control valve -70cm2/min

(Equivalent to one spool) (0.018US gpm)
12-1 Solenoid control
Proportional valve – 125 Specification
valve
cm³/min
(0.033US gpm)
5. Waterproofness Equivalent to JIS D 0203 S2 (1) Rated voltage DC 24 V
6. Vibration resistance JIS D 1601-1995 Category (2) Allowable voltage
20.4~30 V
3 Class B Grade 70 fluctuation range
7. Operating oil (3) Rated power Less than 17W (at 24V and
Equivalent to ISO VG32~68
consumption 20°C (68°F))
8. Oil temperature range Diode (equivalent to Hitachi
-20~90°C(-4~194°F) (4) Overvoltage limiter
U05E)
9. Allowable pollution
Below NAS Level 10 (5) Continuous rating Below 29V
degree
10.Port specification 12-2 Electric proportional
JIS B 2351 G1/4 Specification
pressure-reducing valve
JIS B 2351 G3/8 (1) Rated power 700mA
(2) Coil resistance 17.5 Ω (at 20°C (68°F))
3-101
(2) Overall Structure

Structure of Octuple Solenoid Valve
LG922E930E03095
1. Valve body 3. Return port T1 5. Oil outlet A

2. Solenoid valve 4. Oil inlet P1
(3) Schematic Diagram of Octuple Solenoid Valve

Schematic Diagram of Octuple Solenoid Valve
A1 A2 A3 A4 A5 A6 A7 A8
T1
P2
P1
LG922E930E03096
This valve is composed of eight solenoid valves, including six switch type solenoid valves and two
proportional type solenoid valves. Solenoid valves A3-A8 share one return port T1, solenoid valves A3-
A7 share one oil inlet port P1, and the solenoid valve A8 independently uses oil inlet port P2. A3-A8
output pressure oil is connected with return oil T1 according to electronic control signals. In addition,
proportional solenoid valves A5, A6 can proportionally output 0-3.9 MPa pressure oil according to
signals of electronic control system.
3-102
(4) Fault Cause and Treatment of Octuple Solenoid Valve
S/N Symptom Reasons Treatment

1. Confirm that the voltage of the electrical
1. The supply voltage is too low
wiring reaches the specified value
2. Replace the reversing valve coil
Note: Whether the voltage is too high?
2. The solenoid valve is burnt
The spool of the Whether the polarity of the solenoid valve is
solenoid valve contrary?
1
can not be 3. Clean or replace the spool/valve bushing
changed 3. The spool is stuck of the reversing valve (confirm the
cleanliness of the operation oil)
4. Decrease the pressure to the correct
4. The pressure is too high
value
5. The flow is too large 5. Decrease the flow to the correct value
1. The wiring connection is poor 1. Check and repair the circuit
2. The solenoid coil is damaged 2. Replacement
3. Clean or replace the spool/valve bushing
3. The spool is stuck (confirm the cleanliness of the operation
oil)
4. Fault of driving amplifier 4. Repair or replace the amplifier
5. Adjustment of the high frequency
The pressure of disturbance is poor
the electric Frequency of the high frequency
proportional 5. Readjustment
disturbance is too high
2 pressure- Amplitude of the high frequency disturbance
reducing valve is too small
can not be
6. The spool is slightly stuck 6. Removal, check and cleaning
increased
7. Adjustment of the high frequency
disturbance is poor
Frequency of the high frequency
7. Readjustment
disturbance is too low
Amplitude of the high frequency disturbance
is too large
8. In according with the specified pressure
8. The supply pressure oil level is too low
application range.
Oil leaks out 1. The O-ring is damaged 1. Replace the O-ring
3 from the
solenoid coil 2. The gasket nut is damaged 2. Replace the damaged gasket nut
3-103
Travel Motor & Reduction Gear
The features of travel motor & reduction gear equipped by LiuGong are as follows:
1) Integrate the planetary gear reduction gear with the axial plunger motor brake valve
2) With small size, light weight, high performance and superb durability.
3) It can be directly installed with sprocket and can enter the track width completely.
4) The heavy load bearing can be internally installed to bear external heavy load well.
5) High and low speed switching mechanism is internally installed and the two modes of high speed/low
torque rotation and low speed/high torque rotation are available.
The travel motor & reduction gear is divided into travel reduction gear and travel hydraulic motor.
The travel reduction gear is a planetary differential combined mechanism combining planetary gear
mechanism and differential gear mechanism. It converts the high speed rotary movement of the
hydraulic motor into low speed high torque so as to rotate the reduction gear housing.
Functions of the travel hydraulic motor are as follows
1) Hydraulic motor function: The hydraulic motor is also called swashplate type axial plunger motor with
the function of converting the hydraulic oil pressure from the pump into rotary movement. Meanwhile, it
has the following functions:
2) Function of built-in valves
The hydraulic motor has several built-in valves inside with the three following functions.
(1) When stopping the motor, control the inertia force of keeping the motor rotating, which is caused by
the inertia of the motor body itself, to brake stably.
(2) With the check valve function of preventing the hydraulic motor cavitation.
(3) With the relief valve function of controlling the pressure and the function of preventing cavitation
when braking the hydraulic motor.
3) Dual-speed switching function
Through the function of change-over valve and control piston, change the tilt angle of the swashplate to
switch between the high speed/low torque rotation and the low speed/high torque rotation.
4) Function of parking brake
The parking brake valve has the function of preventing the excavator from sliding down automatically
when the excavator is parked on the slope, which is realized through the friction plate type brake
structure. It is integrated with the hydraulic motor.
1. Travel Motor Specifications
Item Unit TM40VD-A-96/165-1

Motor stroke volume (high volume / low volume) cm3/ rev. 95.9/165
Rated pressure kgf/ cm2 350
Dual-speed switching pressure kgf/ cm2 20-70
Parking brake torque kgf·m More than 40.6
3-104
Item Unit TM40VD-A-96/165-1

Parking brake release pressure kgf/ cm2 6
Common 0.14
Allowable oil discharge pressure MPa
Max. 0.2
Rated output torque kgf·m 2669.7 4593.3
Output rotate speed r.p.m 50.1 29.1
Reduction ratio 49.95
3-105
2. Structure of Travel Motor
Reduction gear
Hydraulic circuit
High speed range Low-speed range
Hydraulic motor
Brake valve
Stop braking
2-speed switching mechanism
Control valve
Hydraulic pump
LG925E4F03095
3-106
3. Working Principle of Travel Reduction Gear
Rotate the sun gear (S) at the power input side to drive the planetary gear (P) to revolve on its axis, and
then the planetary gear revolves around the sun gear due to meshing between the planetary gear (P)
with the fixed sun gear ring (R), finally, the revolution around the sun gear is transfered to the gear rack
(K) to generate torque.
i1 = 1 ＋ (R·P2 )/(S·P1)
(R)
(P1)
(P2)
(S) (K)
LG925E4F03096
The rotation of the gear rack (K) drives the planetary gears (P1,P2) to revolve around the sun gear. At
the moment, there are appropriate tooth number difference between (P1),(R) and (P1),(P2), and then
torque is generated from the rotation speed difference on the gear (D) because the gear (P1),(P2) are in-
line gears.
i2 ＝ 1/(1-(R·R2)/(D·P1))
3-107
(D)
(R)
(P1)
(P2)
(K)
LG925E4F03097
Rotate the sun gear (S) at the input side, and then planetary movement is generated among gears
(S,P1,R) and the revolution around the sun gear of the gear (P1) drives the gear rack (K) to rotate. The
rotation of the gear rack generates the differential motion among gears (R,P1,P2,D) to drive the gear ring
(D) to rotate. The connection between the gear ring (D) and the reduction gear housing of the TM motor
drives the TM motor to rotate.
i ＝ i1 × i2
＝ (1+(R·P2)/(S·P1))/(1-(R·P2)/(D·P1))
3-108
(D)
(R)
(P1)
(P2)
(S)
LG925E4F03098
3-109
4. Working principle of travel hydraulic motor
(1) Hydraulic motor function principle
301 109 104 103 102
F1
A
F3
F2
αȾ
(Y1)
F3
F3
ri
F3
F3
105
(Y2)
LG925E4F03099
The hydraulic oil from the hydraulic pump enters the motor valve cover [301], and then the oil flows into
the cylinder [104] via the thrust plate [109] through the balanced valve.
The hydraulic oil with pressure forms the up stroke point and down stroke point (Y1)-(Y2) of the piston
[105], which is a structure only flowing from single side.
The hydraulic oil entering the single side of the cylinder [104] pushes the plunger [105] (No.4 or No.5) to
form the pressure(F2(kgf) =P(kgf/cm2) x A(cm2)) in the vertical direction of the swashplate [3] and the
pressure acts on the swashplate [103]. The swashplate [103] and the axis of the drive shaft [102] form
the fixed angle (α), so the forces (F1, F3) are formed and the force (F3), which is vertical to the axis,
generates torque against (Y1)-(Y2) respectively. The torque resultant force is the gyroscopic moment (T
= (F3 x ri)) and it can rotate the piston cylinder [104] through the piston [105]. This piston cylinder [104] is
connected with the drive shaft [102] spline to rotate the drive shaft [102] and transfer torque.
3-110
(4) Working Principle of Brake Valve

(When stopping)- Release the brake-
112
D C
302
E
223 a
294
228
b
227
B A
LG925E4F03100
Supply the hydraulic oil from the A port and the oil will open the check valve [227] to enter the oil inlet (C)
of the hydraulic motor to rotate the motor.
At the moment, the high-pressure oil flows into the chamber (b) through the small hole oil passage (a) of
the spool [223] and then acts on the spool [223] end surface to move the spool [223] leftwards which is
kept neutral due to elastic force of the spring [228].
3-111
After moving the spool [223], because the closed side passage port (D) of the hydraulic motor is
connected with the (B) port led to the oil tank when the spool [223] keeps stable and so that the oil return
passage of the hydraulic motor is connected with the oil tank, the hydraulic motor can rotate.
Meanwhile, the high-pressure oil can enter the (P) port due to the movement of the spool [223], and then
the oil pushes the parking brake cylinder [112] to release the parking brake.
112
D C
302
E
223 a
294
228
227
B A
LG925E4F03101
3-112
During traveling, after the high-pressure oil supplied from the (A) port is cut off, for the disappearance of
the pressure, the spool [223] originally moving to the left generates the rightward force through the
spring seat [294] by virtue of the elastic force of the spring [228].
At the moment, the hydraulic oil in the (b) chamber flows out of the (A) port through the small hole oil
passage (a) in the spool [223]. But the reset speed of the spool [223] is reduced for the backpressure
from the oil passage throttling effect.
Meanwhile, the hydraulic oil tends to return to the (B) port from the (D) port through the gap between the
spool [223] and the valve cover [1].
The spool [223] returns to the neutral status completely and because the passage formed by the gap
closes completely, the hydraulic motor will stop. By this way, the hydraulic oil is controlled slowly through
the reset speed of the spool [223] and the spool size to brake the hydraulic motor stably.
But due to the inertia, the hydraulic motor still keeps rotating and the motor function changes into the
pump function to tend to suck in the hydraulic oil. However, because the high-pressure oil is cut off, the
hydraulic oil can not be supplied again and the motor has cavitation inside, which is harmful to the motor;
meanwhile, the spool [223] cuts the hydraulic oil return passage from the (D) port, so the internal
pressure increases.
The pressure plunger [223] moving leftwards makes the (D) port and the (C) port connected, so the
pressure increasing and cavitation are prevented. To prevent the above bad phenomena, adjust the
notch area of the spool [223], the throttling bore and the throttling bore of the spring seat [294] to prevent
the pressure increasing and cavitation. The check valve [227] can be opened even under minimal
pressure to open the (A) port return passage and the motor suction section (C) oil passage to prevent
the cavitation of the hydraulic motor.
(2) Working principle of parking brake
(When traveling)
The high-pressure oil acts on the balanced valve and the action of the balanced valve on the hydraulic
motor opens the oil passage of parking brake, then the oil enters the piston chamber (a) formed by the
motor housing of the reduction gear and the braking cylinder [112].
When the pressure oil is more than 11kgf/cm2, which is larger than the elastic force of the spring [113],
the braking cylinder [112] is boosted.
According to the movement of the braking cylinder [112], the compacted pressure of the braking cylinder
[112] to the relative plate [116] and the friction plate [115] disappears and the friction plate [115] stuck
onto the piston cylinder of the hydraulic motor moves freely so as to release the brake force of the motor.
In addition, if the hydraulic pressure is higher than 45kgf/cm2, the reduction gear starts to work to reduce
the pressure in the oil chamber to 45kgf/cm2.
3-113
113 112 116 115
A
LG925E4F03102
(When stopping)
The pressure in the cylinder chamber (a) reduces to below 11kgf/cm2, after the high-pressure oil from
the balanced valve is cut off, because the elastic braking cylinder [112] of the spring [113] tends to return
to the original position. For the elastic force of the spring [113], the braking cylinder [112] will be pressed
down and the relative plate [116] and the friction plate [115] both at free status are compacted onto the
motor housing, so the generated friction force makes the piston cylinder rotation force stop imposing
braking torque (49.3 kgf.m) to the hydraulic motor axis.
In addition, because the hydraulic oil in the oil passage is controlled appropriately, the action will be
performed stably.
3-114
113 112 116 115
A
LG925E4F03103
(3) Dual-speed switching mechanism

(When at low speed) - Pilot pressure is 15(kgf/cm2) below
When the (A) port is not supplied with pilot pressure (the pressure is 15 kgf/cm2 below), the pressure oil
of the (B) port will be cut off because the spring [166] elastic spool of the spool [163] is compacted
leftwards. Then, the pressure oil of (C) chamber is opened towards the oil return section through the
spool [163]. The tilt angle of the swashplate [3] becomes the maximum angle θ1,, the piston stroke of the
hydraulic motor becomes the maximum and the rotating speed is the minimum.
3-115
3
A 163
166
LG925E4F03104
When at high speed - Pilot pressure is above 15(kgf/cm2) below

When the (A) port is supplied with pilot pressure (the pressure is above15 kgf/cm2), the pressure oil
pushes the spool [163] rightwards with the pressure higher than the elastic force of the spring [166]. The
pressure oil of the (B) port enters the (C) chamber through the spool [163], and then the oil pushes the
piston [161] to stick the swashplate [103] onto the motor housing (b) surface, by this way, the tilt angle of
the swashplate [103] becomes the minimum angle θ2, the piston stroke of the hydraulic motor becomes
the minimum and the rotating speed is the high.
3-116
3
A 163
166
LG925E4F03105
5. Precautions for use
(1) Use the connection torque for bolts
Part Quantity Bolt size Connection torque

Frame installation part 30 M16(P2.0) 25.7±4.0 kgf.m
Sprocket installation part 22 M16(P2.0) 25.7±4.0 kgf.m
(Sprocket installation part) (30) (M16(P2.0)) (25.7±4.0 kgf.m)
When installing the TM motor, do not use hammer, etc. to knock and use the bolt hole for installation.
(2) Precautions for pipeline connection
① Please confirm the rear exhaust pipe in the rotary direction of the motor.
② When supplying, the exhaust pipe end port (braking valve port and motor oil return port) is installed
with isolation cover and insulation plug. Before operation, please don't remove the cover for preventing
dust and welding slags.
③ Fill the motor chamber with hydraulic oil before the motor operation.
④ Essential oil volume for the motor chamber: 1.2R
⑤ When choosing the exhaust pipe size, please note that the relief pressure at the motor oil return port
is below 2kgf/cm2. (The maximum is 7kgf/cm2)
⑥ The oil return pipe must be installed onto the port over the installation position.
(3) Hydraulic oil
Before operation, please fill the new hydraulic motor chamber with hydraulic oil
3-117
The following items should be paid attention to when choosing hydraulic oil for the TM motor.
① Please use the hydraulic oil equivalent to VG32-VG56.
② Please use the anti-wear hydraulic oil.
③ Please conduct consultation in advance if you want to use hydraulic oil not included in this table.
Viscosity (40°C) 32CST 46CST
GRADE
ISO VG VG32 VG46
HOUGHTON HYDRO DRIVE HP 32 HYDRO DRIVE HP 46
GULF HARMONY 32 AW HARMONY 46 AW
Company name CALTEX RANDO HD32 AZ RANDO HD 46
MOBLIL DTE 24 DTE 25
SHELL TELUS 32 TELUS 46
Although the replacement period of hydraulic oil is determined by the operation condition, you'd better
replace the oil according to the following period.
The table below indicates the replacement references for the hydraulic oil.
Test items Replacement references
Viscosity changes (40°C) ±10%
Oxidation (mgKQH/g) *
Water content,% 0.1%
Impurity 10mg/100ml
Non-complete decomposition substance 0.05%
Color Serious change
* Hydraulic oil is various from manufacturers to manufacturers, so please conduct consultation.

(4) Maintenance and check
Before operating the TM motor, please do confirm the following maintenance and check items.
① Check whether the oil leaks (hydraulic oil and gear oil)
② Check whether bolts are loose
③ Check whether there is any abnormal sound
④ Check whether the temperature of the housing is too high
⑤ Check whether the standard housing temperature is MAX.80°C during continuous operation)
⑥ Check whether the replacement period of the gear oil is appropriate. (refer to 6-4 Lubricant)
⑦ Check whether the normal oil drain quantity of hydraulic motor is: 4R/min (pressure of 50K and speed
of 25rpm)
6. Maintenance References of New Combined Motor & Reduction Gear
When discomposing and checking the TM motor, please conduct maintenance according to the following
references.
Be careful to take and place each part; especially, don't damage lubricating parts of each part.
3-118
1. Seal components
Replace the removed seal components (O-ring, shaft seal and floating oil seal) with new ones in any
case.
2. Replacement references of worn parts
(1) Please immediately replace the parts with obvious damaged marks on their appearances.
(2) Please replace the parts with the following abnormal phenomena.
Reference
dimension
Part number Part name Symptom Repair limit
(standard
dimension)
Motor housing assembly
Motor housing assembly parts
① There are major damages on the
[2] Motor housing
appearance. - -
Coupling band ② Abnormal wear
[8]
gear
[17] Pin
Gear rack assembly
[3] Gear rack
[6] Concentric gear ③ End surface of concentric gear [6]
Connecting is worn unevenly.
[9] - -
shaft ④ The concentric gear [6] can not be
[14] Bushing rotated smoothly.
[25] Needle bearing
[34] Dowel pin
There are uneven wear and damage
[4] Gear ring (A) - -
on the gear surface.
[5] Gear ring (B) - -
on the gear surface.
[7] Sun gear on the gear surface. - -
Spline is worn.
Coupling band There is abnormal wear on the gear
[8] - -
gear surface.
[19] Coupling band Spline is worn. - -
The axial clearance
between the
[20] Washer (R) Wear. coupling band gear Clearance of 0.8mm
[8] and the rear
cover is 0.3~0.6mm
① The sliding surface is damaged.
[12] Washer ② There is abnormal wear on the - -
gear surface.
3-119
① There is indentation.
② There are fish scale shape ex-
[24] Ball bearing - -
foliation
③ There is uneven wear.
① The part sliding with the spool is
damaged Clearance diameter Clearance diameter
Valve cap assembly
② The clearance with the spool is too 10~20μ 25μ
large
[201] Valve cap
① There is damage on the periphery
[223] spool ② There is uneven wear on the - -
periphery
① The installation part for the shaft
[102] Motor shaft seal is worn - -
② The spline is worn.
[103] Swashplate It is stuck and frozen - -
① The spline part is damaged
② The internal piston hole is worn
[104] Cylinder body ③ The part sliding with the thrust
plate[109] is worn unevenly or
damaged
Piston assembly ① There is axial clearance between
[105] Piston the piston [105] and the shoe [106]
② There is abnormal wear on the
[106] Shoe shoe Clearance: 0.05mm Clearance: 0.15mm
③ There is uneven wear on the shoe
There is uneven wear on the
[107] 9-hole plate
periphery end surface
Spherical ①The spherical sliding part
[108]
bushing contacting with the thrust plate[109] is
worn unevenly
② Wear
[109] Thrust plate
③ The sliding part is stuck and frozen
and is worn unevenly
[115] Friction plate ① There is uneven wear on the two
end surfaces
Braking torque Braking torque
② Specified torque can not be
49.3kgf.m 49.3kgf.m
[116] Relative plate generated
above below
③There is stuck and frozen
phenomenon
[149] Ball bearing ① There is indentation.
② There are fish scale shape ex-
[150] Ball bearing foliation
③ There is uneven wear.
3-120
3. Fault diagnosis
(1) Unable to start
The set adjust-

Unable to Without Set it to the
ment pressure is
start pressure correct position
excessively low
Check if there is
work other than
traveling and
The pump repair the pump
has failed if action of other
parts is abnormal
Steering control
Steering control valve has failed
valve has failed
Replace the
corresponding parts
The brake if the spool, valve,
With pressure valve fails etc. are damaged
due to burn.
Check the
hydraulic oil and
The hydraulic replace with new
motor has failed hydraulic oil or
motor if the oil
deteriorates.
Reduction gear Replace the

is damaged motor with
reduction gear
Overloading
appears Lighten the load
LG925E4F03106
3-121
(2) Oil leakage
At the The joint surface Correct with oil

Oil leakage joint surface is damaged stone, abrasive
cloth, etc.
The bolts Check after

are loose tightening
Whether the joint

At the housing pipe is loose Tightening
Damage resulting Replace the motor

from stone, etc. with reduction gear
At the Wear on Replace the motor

floating seal vibration surface with reduction gear
Shifting of Replace the motor

O-ring with reduction gear
From the The bolts

hydraulic motor are loose Tightening
The O-ring Replace

is damaged the O-ring
Damage on Correct with oil

seal surface stone, abrasive
cloth, etc.
LG925E4F03107
3-122
(3) Brake fails on a slope
Poor volume Replace the

Brake fails efficiency of motor with
on a slope hydraulic motor reduction gear
Replace the
Internal leakage brake valve
of brake valve (replace the rear
increases placed flange)
Parking brake
The spring Replace
valve is out of
is damaged the spring
work
Replace the
Brake friction
friction plate
plate is worn
and mesh plate
LG925E4F03108
(4) The temperature of the reduction gear housing surface is excessively high
The temperature of
the reduction gear Gear oil is Refill to the
housing surface is insufficient specified amount
excessively high
Replace the
The bearing
motor with
is worn
reduction gear
Hydraulic oil
leaks into the Replace the
reduction gear oil seal
LG925E4F03109
3-123
(5) Leftwards and rightwards snaking symptoms
Leftwards and Different oil inlet

Taking place
rightwards volume at the Repair the
snaking under low
left and right hydraulic pump
symptoms pressure status
sides
Different motor Replace the

displacement at motor with
the left and right reduction gear
sides
Taking place Repair the

Different oil inlet hydraulic pump
under high volume at the left and
pressure status and right sides the control valve
Different motor Replace the

displacement at motor with
the left and right reduction gear
sides
Different brake Replace the

valve actions at brake valve and
the left and right the rear placed
sides flange
The set adjustment Set correct

pressure of the left pressure or
or the right control
valve is excessively replace the relief
low valve
LG925E4F03110
3-124
(6) Low speed
Revise the
Small pump Pressure-reducing design value of
Low speed displacement valve action of pressure-reducing
pump is incorrect valve
External leakage Repair and

amount of hydraulic replace pumps
pump is large
External leakage Replace the

amount of motor with
hydraulic motor is reduction gear
LG925E4F03111
(7) Abnormal sound
Hydraulic motor Replace the motor

Abnormal
or reduction with reduction gear
sound gear is damaged
The oil supply Perform

pipe vibrates tightening
LG925E4F03112
3-125
Swing motor & reduction gear
The swing motor & reduction gear includes a rotary hydraulic motor (hereinafter referred to as swing
motor) and a reduction gear.
(1) Swing motor
1-1 Rotating motor parameters:
Model M5X130CHB
Displacement (cm3/rev) 129.2
Rated 32.4(4698psi)
Pressure (MPa)
Max. 39.2(5684psi)
Speed (r/min) Max. 1850
Output torque(N*m) 666(491.2lbf·ft)
Output power (KW) 129(173HP)
Maximum parking torque (N*m) 843(621.7lbf·ft)
Releasing parking pressure(Mpa) 3.4(493psi)
Weight (kg) 48(105.8lb)
3-126
1-2 Structure of swing motor
122 123 121 111 301 742 743 706 707 702 472 712
985 303
124 162
052
443
A 171
491 151
161
101
A
163
985
444
984
114
131
451
(031-2) (031-1) 033 031 (031-3)

LG950EIII03078
3-127
488 469 355 351
401 (051-1) 051
LG950EIII03079
3-128
400 (400-2) (400-1) 100

390
391
(052)
ᯣ䶘 A-A
SECTIONA-A
LG950EIII03080
Parts list of swing motor

10 plunger assembly 313 O-ring
20 Shell 351 Piston
31 Time delay valve 355 Spring
33 Hex screw 390 Nameplate
51 Safety valve 391 Pin
52 Valve 400 Valve
81 Tool set 401 Screw
100 Valve body 443 Bearing
101 Drive shaft 444 Ball bearing
111 Cylinder block 451 Pin
114 Spring holder 469 Plug
121 Piston 472 O-ring
123 Fixed plate 491 Oil seal
124 Swashplate 511 O-ring
131 Bracket 702 Braking block
151 Plug 706 O-ring
161 O-ring 707 O-ring
162 O-ring 712 Brake spring
163 O-ring 742 Friction block
171 Hex screw 743 Spacing block
301 Shell 984 Plug
303 Shell 985 Plug
311 Plug 4001 O-ring
312 O-ring 4002 Snap ring
3-129
1-3 Working principle of swing motor
Schematic diagram of hydraulic motor
F1 F2
Outlet Entrance
F
1
2
Drive shaft
4
5 LG950EIII03081
1. Sloping plate (3) 3. Plunger 5. Valve plate (1)

2. Brake shoe (2) 4. Cylinder body (4)
As shown in figure above, the high pressure oil flows in the oil cylinder through the inlet hole (a) of valve
block (1) and the hydraulic force generated is applied on the plunger to generate the force F in axial
direction. The force F separately generates the vertical force F1 and force F2 in shaft right angle
direction on the wobble plate (3) through brake shoe (2). The force F2 is transferred to cylinder block (4)
via the plunger, and generates rotation turning pair around the output shaft.
9 plungers are arranged in equal distance in oil cylinder block; these plunger connects with the high
pressure oil inlet hole, and transfers the rotation torque to the output shaft in sequence.
Change the inlet/outlet direction of oil into reverse direction, and the rotating direction of force output
shaft will be reversed.
The theoretical output torque T(Nm) is calculated according to following formula.
P: Effective differential pressure q: Capacity per turn [cm3]

3-130
1) Control valve
Air suction preventing check valve
Working principle of air suction preventing check valve
LG950EIII03083
1. Control valve 2. Oil filler pipe 3. Refilling 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.
3-131
3) Braking of swing motor

Braking process of swing motor
LG950EIII03084
1. Hydraulic oil cavity 301-Housing

2. Hydraulic oil acting force 702-Brake plunger
3. Spring action force 712-Brake spring
101-Drive shaft 742-Friction plate
111-Cylinder block 743-Release plate
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.
3-132
1-4 Maintenance references of swing motor
Replacement standards of friction parts

When the abrasion degree of each friction part exceeds the following standard, it shall be replaced or
readjusted. However, when the appearance of any part has obvious damages, it shall be replaced in
advanced without limitations of this standard.
Part replacement standard
Replacement
Standard size
Items recommended Handling method
(mm)
value (mm)
Clearance between plunger and cylinder Replace the plunger or
0.027(0.00106In) 0.052(0.00205In)
bore (D-d) cylinder.
Looseness (δ) between plunger and skid Replace the plunger and
0 0.3(0.0118In)
shoe riveting section skid shoe group.
Replace the plunger and
Thickness of skid shoe(t) 5.5(0.2165In) 5.3(0.2087In)
skid shoe group.
Thickness of friction plate 2.0(0.0787In) 1.8(0.0709In) Replace it.
Clearance (D-d) Looseness (δ) between plunger and skid shoe

D
d
LG950EIII03085 LG950EIII03086
Thickness of skid shoe(t)

3-133
LG950EIII03087
Maintenance standards of rotation meshing surfaces

When the roughness on the rotation meshing surface of each section exceeds the following standard, it
shall be trimmed or replaced.
Maintenance standards of rotation meshing surfaces
Part name Standard roughness Roughness requiring trimming

Skid shoes 0.8-Z(Ra=0.2)(abrading) 3-Z(Ra=0.8)
Piston shoe 0.4-Z(Ra=0.1)(abrading) 3-Z(Ra=0.8)
Cylinder 1.6-Z(Ra=0.4)(abrading) 12.5-Z(Ra=3.2)
Valve plate 0.8-Z(Ra=0.2)(abrading) 6.3-Z(Ra=1.6)
Remarks:
1. The roughness of each rotation meshing surface is controlled to be lower than the standard
roughness through abrading.
2. When the spherical meshing section between the plate spring and cylinder is rough, the complete set
of group shall be replaced.
7. Swing reduction gear
2-1 Specification and parameters of rotating reducer:
Model RG14D20E1-T
Reduction ratio 20.04
Output torque (KN*m) 11.5(8481lbf·ft)
Maximum speed (r/min) 73.4
Lubricant SAE#140(GL-4)
Quantity of lubricant(L) 5.3(1.4US gal)
Weight (kg) 223(491.7lb)
The reduction gear is composed of double planetary gears.

3-134
The total transmission ratio is 20.04. I.e. the rotating speed of the hydraulic motor is transmitted to the
output shaft in 1/20.04. The output shaft is consistent with the rotating direction of the output shaft.
The gear number and the transmission ratio of the reduction gear are as the following table:
Sun gear Planetary gear Ring gear Transmission ratio

First level 14 18 52 i1=4.714
Second level 16 17 52 i2=4.250
Total transmission ratio i1×i2=20.04
2-2 Structure of reduction gear
926 391
102 390
311
401
312
915
913
201 402
801 802
912
901
925
282
211 313
203
286 287
602
910 104
202
283
231
403
204 210
285
LG950EIII03088
230
3-135
Parts list of reduction gear

102 Valve body D2 601 Hex bolt
104 Rear shaft cover E 602 Hexagon socket head cap bolt
201 Drive shaft B 801 Oil seal
202 Gear ring E 802 O-ring
203 #2 planetary gear D 903 Plug
204 #2 sun gear D 904 Hexagon socket head cap bolt
210 #1 planetary gear D 905 O-ring
211 #1 sun gear D 909 Pin
230 #2 bracket D 910 Pin
231 #1 bracket D 912 Snap ring
282 #2 pin B 913 Snap ring
283 #1 pin B 915 Bearing seal
284 Push plate E 922 Plug
390 Nameplate 925 Exhaust valve
391 Pin 926 Grease fitting
402 Roller bearing 930 Hex screw
403 Plug
2-3 Maintenance references of reduction gear
Maintenance
Part Check Treatment
references
When the size of single
Sun gear
Pitting corrosion and dents on tooth pitting corrosion and dent
Planetary gear Replace it
surface is above φ1 mm or
Ring gear
occupied 5% of total area
Replace it
(Notice: Replace them
when the reduction gear is
Oil seal Lip surface is damaged or abraded Damaged or abraded
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. within the Replace it
Support bearing visible range. (Note: Do not reuse
(front side) of drive 2. Check whether dust caused by Abnormal condition
bearing extracted from the
shaft excessive abrasion exists in gear oil. shaft.)
3. Check whether excessive abrasion
dust is adhered between the roller
and the cage.
4. Check whether it can smoothly rotate
by hand.
3-136
Maintenance
Part Check Treatment
references
Check whether the race surface and
Drive shaft bearing
roller of the bearing have pitting Having pitting corrosion Replace it
(rear side)
corrosion
Slide bearing
Check whether planetary gear No.2 and
section of
pin No.2 of carrier group No.2 are loose Looseness is above 0.5 Replace it
planetary gear
in the peripheral direction.
No.2
Check whether the sliding face zone with
Side plate type Having obvious bruises Replace it
the sun gear No.2 has obvious bruises
Needle bearing set
and pin No.1 for
Check whether the rotation face has Having pitting corrosion
supporting Replace it
pitting 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.
3-137
List of parts to be replaced simultaneously
Parts to be replaced simultaneously

Part Number 201 401 402 203 230 282 286 910 210 231 283 284 285 287 403 909
Braking self-aligning roller bearing
Braking self-aligning roller bearing
No.2 Planetary gear
Planetary gear No.1

Thrust washer
Part
Lateral plate
Carrier No.1
No.2 Carrier
Thrust plate
Thrust plate
Drive shaft
Part name
Pin gauge
Spring pin
Spring pin
Pin No.1
No.2 Pin
Num
ber
201 Drive shaft — ○ ○

Braking
self-aligning
Parts to be replaced simultaneously
401
roller △ — △
bearing
Braking
self-aligning
402
roller △ △ —
bearing
No.2
203 Planetary — △ ○ △ ○
gear
230 No.2 Carrier △ — ○ △ ○
282 No.2 Pin △ △ — △ ○
Thrust
286
washer △ △ ○ — ○
910 Spring pin △ △ ○ △ —

Planetary
210
gear No.1
— △ ○ △ △ △ △ ○
231 Carrier No.1 △ — ○ △ △ △ △ ○

283 Pin No.1 △ △ — △ △ △ △ ○
284 Thrust plate △ △ ○ — △ △ △ ○
Lateral
285
plate △ △ ○ △ — △ △ ○
287 Thrust plate △ △ ○ △ △ — △ ○

403 Pin gauge △ △ ○ △ △ △ — ○
909 Spring pin △ △ ○ △ △ △ △ —
Parts marked by ○ indicate parts to be replaced simultaneously compulsorily.

Parts marked by △ indicate parts to be replaced simultaneously at best.
Note: Inner and outer races in the roller bearing must be replaced simultaneously.
2-4 Causes and handling of reducer failure

3-138
(1) The reduction gear doesn't rotate
Overload Lighten the load
Inlet pressure of Damage of Replace reduction

swing motor rises reduction gear gear
The reduction Confirm pressure

Parking brake of swing
gear doesn't relief and check the
motor is not released
rotate brake part
Confirm relief of
No rise of inlet pressure of command pressure
swing motor
Swing motor has Motor axle Replace swing motor

whirling motor damage
Damage of Replace reduction

reduction gear gear
Swing motor has no Abnormalities of Confirm abnormal

whirling pump, valve, etc. parts and dispose
LG950EIII03089
(2) Oil leakage
Forget to apply liquid

seal filling material Remove and apply again
Oil leakage from Joint surface is loosened

Remove, apply again and
junction surface because the bolt is not
assemble as specified
screwed with looseness, etc.
Oil
leakage The joint surface Replace parts and
is damaged components
Oil leakage Oil seal has Replace oil seal when

from the shaft been damaged removing reduction gear
LG950EIII03090
3-139
(3) Housing temperature of reduction gear is too high
Confirm the oil level

Housing temperature of Gear oil is not filled or oil
and fill to specified
reduction gear is too high level is too low
amount
The amount of
Fill the grease fully
grease is too little
The gear, bearing,

Replace reduction
etc. have been
gear
damaged
LG950EIII03091
Cylinder
Hydraulic cylinder is one kind of hydraulic actuating mechanism, and it converts hydraulic energy
supplied by hydraulic pump into huge linear motion force, and changes the direction of oil pressure
through valve operation to realize stretching of movement direction.
Its basic function is to convert the directions of huge linear motion and movement.
(1) Structure of cylinder Structural diagram of arm cylinder
The structural diagram of the cylinder is shown
below:
Structure figure of boom cylinder
1 2
8 9
LG925E4F03125
3 5 6 7
4
LG925E4F03124
3-140
Cylinder retraction: pressure oil enters the

Structure diagram of bucket cylinder small cavity, return oil enters the small cavity,
pressure oil acts on the rod end of the piston,
and the piston moves towards the no-rod cavity
so that the piston rod retracts.
Cushioning process:
Cushioning of boom and bucket cylinder
Cushion device of boom and bucket cylinder
10 1
LG925E4F03126
1. The oil port of small 6. Cushion collar

cavity 7. Piston
2. The oil port of large 8. Arm cylinder
cavity
9. Cushion collar
3. Boom cylinder
10. Bucket cylinder
4. Cylinder body
5. Piston rod 11 6
(2) Working principle of cylinder
LG925E4F03128
Working principle of cylinder
1. The oil port of small cavity 11. Passage
6. Cushion collar
8 10
When the boom and bucket cylinder stretches
out and the cushion collar (6) approaches to the
3 3 end of the extension stroke, the through-flow
area of the passage (11) decreases, so that the
displacement of the cylinder decreases, and the
running speed of the piston slows down and
reaches the stroke end slowly. There is the
cushion in the boom and bucket cylinder only
when stretching.
LG925E4F03127
Cylinder extension: pressure oil enters the

large cavity, return oil enters the small cavity,
pressure oil acts on the big end of the piston, and
the piston moves towards the rod cavity so that
the piston rod extends out.
3-141
Arm cylinder cushioning: 1) In order to guarantee hydraulic cylinder

Cushion device of boom and bucket cylinder operates normally, working medium in
hydraulic cylinder must be filled. The
cleanliness of the medium must meet NAS
2 level 8 as the minimum limit requirement. If
anti-rust oil needs to be mixed in working oil,
12 its oxidation or acidification degree must be
detected.
2) Because air is highly compressible, the
residual air in hydraulic cylinder can affect its
operating.
If the hydraulic cylinder with air not emptied
needs to be quickly operated or pressurized,
because high heat generated by adiabatic
9
LG925E4F03129 compression of air will cause seal burn-out,
leakage generated inside the hydraulic cylinder
2. The oil port of large cavity 12. Passage cannot maintain the load, etc., and there is a
9. Cushion collar possibility of major accidents.
The extension of the arm cylinder is same to the For air exhaust of hydraulic cylinder, please refer
boom and bucket cylinder, as described above. to "Air exhaust of each device" in "Test and
When the arm cylinder retracts and the cushion adjustment" chapter.
collar (9) approaches to the end of the extension (5) Maintenance
stroke, the through-flow area of the passage (12)
decreases, so that the displacement of the Lubricant shall be applied on hydraulic cylinder,
cylinder decreases, and the movement speed of such as swing shaft, articulated point, pin, etc.
the piston slows down and reaches the stroke periodically to prevent rust and stagnant
end slowly. The arm cylinder is cushioned during operation. After a new system is put into
extension and retraction. operation, periodic check is necessary,
(3) Precautions on loading and handling The following points must be noted during check:
1) Hydraulic cylinder must be transported a. Check oil port for leakage.

horizontally, and placed on wood block, and b. Check piston rod for damage.
it is better to use original packaging if
c. Frequently eliminate dirt, water, dust,
possible.
grease, etc. on piston rod. However, do not
2) Impact, collision, etc. are not allowed during clean dust ring and sealing parts with
the process of storage and transportation. water, and please use waste cotton yarn or
The surface of exposed piston rod and other cloth to wipe. Under the occasion of
assembly must be protected properly. placing more than one week, please apply
3) Use soft strap in case of damaging surface anti-rust oil on the surface of piston rod.
coating. d. Periodically check sealing performance of
hydraulic cylinder, especially the joint
4) Strap distribution shall make lifting stable.
between piston rod and cylinder head for
Use balance device if necessary. The center
leakage.
of gravity of cylinder can be confirmed by
test.
(4) Precautions for use
3-142
e. Periodically check and fasten the screws of important parts (such as flange and oil pipe). The
dynamic seal in the hydraulic cylinder is a quick-wear part. When internal leakage and external
leakage exceeds allowable values, please contact LG local service agency.
Hydraulic oil tank
Structure
Exterior drawing of hydraulic oil tank
1 2 3 4 5 6 7 8 9 (7) 20 (3)
10
11
(3) (2) 19 18 17 (7) 16 15 14 LG950EIII03092
1. Housing 7. O-ring 15.Cap

2. Bolt 8. Tank cover 16.O-ring
3. Washer 9. Breather valve 17.Cover
4. Return oil filter element 10.Dipstick 18.Plug
5. Magnet 11.Suction strainer 19.O-ring
6. Sealing end cover 14.Bolt 20.Bolt
3-143
Distribution diagram of oil ports in tank body
5 6 7
4
9
3
10
12 11 LG950EIII03093
1. Pilot pump oil return port 5. Oil filler 9. Center joint drainage port
2. Accessory oil return port 6. Main pump drainage port 10.Rotating motor drainage port
3. Back pressure oil return port 7. Fan pump oil return port 11.Oil suction port
4. Oil cooler oil return port 8. Pilot return port 12.Oil drain hole
3-144
1. Return oil filter following indicates there is insufficient oil for the
system.
Return oil filter is composed of a return oil filter
element 4 and a bypass valve, the return oil filter
element 4 can filter out particles with overall size
greater than 10 μm in oil so the oil keeps certain
cleanliness. The bypass valve plays the action of
protecting the return oil filter element 4. When Safe oil level:
the filter element works for a period of time and above red
line
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
will be opened during liquid resistance pressure
setting, oil directly returns to the oil tank without
filtering, so that the damage of the strainer of the
return oil filter element 4 by flushing can be
avoided, and it can be used after many times of
LG950EIII03094
cleaning. The system works in this state, the
back pressure of the system is too high, and
unsmooth oil return will cause slow and Working principle
powerless working. To avoid this problem, the Schematic diagram
return oil filter element shall be frequently
cleaned or replaced. 4 5
2. Magnet 1 2 3 6
The functions of a magnet are as follows: (1)
magnetizing the tank; (2) absorbing 7
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
9 8
The respiratory system of the hydraulic system is
mainly composed of a tank and an air filter, LG950EIII03095
wherein the air filter is the respiratory passage of
the system, and its function is mainly to prevent
1. Suction element
the air pressure in the hydraulic oil tank from 2. Pump
rising or dropping in the following case: 3. Relief valve
4. Actuator
An air pressure change in the hydraulic oil tank 5. Radiator
due to oil cylinder movement; 6. Bypass valve
7. Return oil filter element
An air pressure change in the hydraulic oil tank 8. Tank
due to a temperature change. 9. Air filter
Ch2-Check valve
4. Dipstick Ch1-counterbalance valve
T-Pilot oil return
Its function is mainly to reflect the oil level in the Dr1-Dr2-Dr3-Dr6- Dr7 oil return of main valve
tank and the oil range for the system. As shown DrS-Leakage return oil in travel motor
in the figure, a safety oil level refers to the DrS-Leakage return oil in swing motor
system oil level that is above the red line, and the Drp-Leakage return oil inside pump
3-145
Oil suction process: the oil is drawn from the oil

tank 8 oil suction port 11i through the oil suction Fan pump assembly structure
filter element to the pump 2.
Pump body
Oil return process: oil is transferred to the Adjuster
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 4 or passes through the back
pressure valve Ch1 and flows to oil port 3, and
returns to the tank 8, after being filtered by the
return oil 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 3 from the back pressure
valve Ch1, and returns to the tank 8 after being LG950EIII03096
filtered by the return oil filter element 7. Oil
passing across the back pressure valve indicates (3) Structure and working principles of fan pump
return oil pressure is too high, which is caused by
too high liquid resistance flowing across the The figure below shows the structural diagram of
radiator 5. the fan pump as, and the numbers in parenthesis
behind concerned parts in the figure below shall
Fan pump assembly structure prevail.
(1) Fan pump specification

Displacement cm3/rev 45
Continuous
28 (4060psi)
pressure
Pressure
Intermittent
MPa 32 (4640psi)
pressure
Peak pressure 35 (5075psi)
Rotate Rated 1800
speed
r/min Max. 2600
Weight kg 15 (33.1lb)
Anti-wear hydraulic
Category
oil,
Hydraulic oil Temperature range -40~+90°C
(-40~194°F)
Viscosity range 6~160cSt(mm2/s)
(2) Fan pump assembly structure

The fan pump assembly is of variable
displacement plunger double pump and driven
by the PTO unit externally connected by main
pump so as to provide hydraulic oil for fan motor
pipeline and activate the hydraulic unit.
3-146
3-1 Pump body
25
26
3
41
4
7 5
9
27
10 11 10
14
13
15
44 42
12
45 19
28
20
43
21
31 31
32 32 22
33 23
34 35
46 47
24
38
39
40
LG950EIII03097
3-147
Fan pump part list

1 Hex screw 25 Return plate
3 Oil port block 26 Plunger piston shoe assembly
4 Oil port block O-ring 27 Drive shaft
5 Sealing plug 28 Swashplate
7 Oil distribution disc pin 31 Screw
8 O-ring 32 Swashplate retainer pore plate
9 Oil distribution plate 33 Shell
10 Offset piston O-ring 34 Plug
11 Offset piston guide sleeve 35 O-ring
12 Offset piston 38 Shaft seal
13 Offset spring 39 Seal ring
14 Control piston guide sleeve 40 Adjuster
15 Control piston 41 End cover locating pin
19 Snap ring 42 Oil port block bush
20 Cylinder block retaining spring 43 cylindrical roller bearing
21 Cylinder block retaining washer 44 Snap ring (shaft)
22 Cylinder block fixing pin 45 Snap spring (housing)
23 Cylinder block 46 Plug
24 Spherical bush 47 O-ring
The pump is roughly divided into: main part rotating mechanism of pump for rotating movement, titling
plate mechanism changing the output flow, oil distribution cover mechanism for suction-drainage
switching of oil.
1) Rotating mechanism
The rotating mechanism consists of driving shaft (27), cylinder body (23), cylinder retaining spring (20),
cylinder body retaining washer (21), cylinder block retaining pin (22), plunger piston shoe assembly (26),
return disc (25) and spheric bushing (24). The piston shoe is rived with the plunger to form spheric
connection, and reduce the push force generated due to load pressure. On the other hand, to enable
smooth sliding of plunge - piston shoe assembly (26) mechanism on swashplate (28), it is pressed on
the swashplate (28) by the cylinder retaining spring (20) by help of the return disc (25) and spheric
surface bush (24). This end of cylinder block (23) is also pressed onto the oil distribution disc (9) by
cylinder block retaining spring (20).
2) Swash plate mechanism
The swashplate mechanism consists of swashplate (28), screw (31), swashplate retainer pore plate (32),
spheric bushing (24), offset piston mechanism (10, 11, 12, 13) and control piston mechanism (10, 14,
15). The swashplate (28) is supported on the swashplate retainer pore plate (32), and the pore plate is
mounted on the housing (33). Adjust the swashplate through offset piston mechanism (10, 11, 12, 13)
and control piston mechanism (10, 14, 15) so as to change the inclination angle (α) of swashplate.
3-148
3) Oil distribution cover mechanism

The oil distribution cover mechanism consists of oil port block (3), oil distribution disc (9) and oil
distribution disc pin (7). The oil distribution disc (8) is mounted on the oil port block (3) and the oil supply
and drainage of the cylinder block (23) must be implemented through it. The oil through oil distribution
disc (9) is connected to external pipeline through oil port block (3).
3-2 Regulator
Outside spring is only used

for type L0 and L2
Inner spring is used for
type L0，L1, L2 and L3.
LG950EIII03098
1. Regulator body 15.Load sensing regulator piston O-ring

2. Main regulator spool 16.Load sensing regulator seal piston
3. Main regulator spring seat 17.Load sensing regulator spring
4. Main regulator outer spring 18.Load sensing regulator spring seat
5. Main regulator inner spring 19.Load sensing regulator spool
6. Main regulator spring seat and piston 20.Setscrew
7. Regulator seal piston O-ring 21.Setscrew
8. Main regulator spring cover O-ring 22.O-ring seal plug
9. Main regulator spring cover 23.O-ring
10.Adjusting screw lock nut 24.Hardened O-ring seal plug
11.Adjusting screw 25.Teflon O-ring
12.Load sensing regulator spring cover 26.Cylindrical pin
13.Load sensing regulator spring cover O-ring 27.Hexagon mounting bolt
14.Load sensing regulator piston support ring
Unscrew the adjusting screw lock nut (10) to adjust the adjusting screw (11); as shown in the figure, the
upper adjusting screw is used to adjust the spring force of adjusting spring (17) so as to adjust the
minimum flow of pump, while the lower adjusting screw is used to adjust the spring force of adjusting
springs (4) and (5), and thus adjust the maximum flow of pump.
3-149
(4) Fault diagnosis
Faults Possible cause Failure point

Leak of oil suction pipe
Low level
Oil turbulence
The oil return pipe opening is higher than the level
Air in oil
Air leak of accumulator
Pressurized oil tank leads to too large pressure drop in oil
suction pipeline
Air accumulated in oil suction filter
Too low oil temperature
Too sticky oil
Too large oil density
Too high speed
Air cavity in rotating subassembly Too small oil suction pipe diameter
Pump noise
Too small size of oil suction filter
Suction strainer is too dirty
Too high working altitude
Too low oil suction pressure
Installation error
Deformation during installation
Poor mounting linearity of shaft Axial interference
Problem of coupler
Too large radial force
Loose or damage of plunger or piston shoes
Bearing damage
Mechanical failure
Direction error of oil distribution disc
Inner corrosion or wear of displacement controller
Corrosion of Air in oil Same as "Pump noise"
plunger hole
and oil Air cavity Same as "Pump noise"
distribution disc
Toothed load Mechanical problem
Overflow valve wear Maintenance required
Wear of regulator Replace it
Pressure shock
Slow response of check valve Replace or renew
Too large power drop Enhance the pressure drop control
Air leak of cylinder block Wear of rotor and too high housing pressure
Too large pipeline capacity (too Reduce the pipeline size or length
Instability of long pipeline and accumulator
regulator effect lead to too large circuit Do not use the hose
capacity)
3-150
Faults Possible cause Failure point

Decrease the pressure setting
Overload
Decrease the speed
No regular maintenance of filter element
Inadequate accuracy of filter element
Dirty oil mixed in
Particular foreign matter in oil
Open of oil tank
Improper oil tank air filter
Improper replacement of pipeline
Too large or small oil viscosity in working temperature range
Severe damage
Oil decomposition due to time/temperature/heating
of pump Improper oil
Improper additive added in new oil
Aging of chemical additive in oil
Mistaken use of part and component
Improper maintenance
Wrong maintenance method, size and surface treatment
Due to condensation
Improper air filter and oil filter
Water in oil Leak of heat exchanger
Improper cleaning
Water in oil make-up flow
Recheck the oil return of housing and repair if necessary
Excess leak of pump The oil viscosity is too weak
Improper assembly; no calibration for oil distribution disc timing
Too low pressure setting (compared to the load and regulator)
Relief valve
Working instability due to back pressure or part wear
Too high setting (compared to the relief valve)
Adjuster
Part wearing
Too large pump selection
Select the pump with less displacement
displacement
Overheat of oil Close of cooler water valve or less water volume
Too high water temperature
Rotation failure or limit of fan
Heat exchanger
Reduction of heat exchange efficiency due to foreign matters
such as slurry or debris
Intermittent flow of hydraulic oil
Too little oil
Improper baffle plate
Tank
Radiation blocking by the oil tank coverage
Heat suction from neighboring device
3-151
PTO Pump
PTO gear pump adopts the internationally-used floating shaft sleeve structure with features of high
pressure, low noise, high efficiency and flexible installation.
1. Performance parameters
Model PGP517 Displacement ml/rev 19

Rated pressure (bar) 250(3625psi) Maximum pressure (bar) 275(3625psi)
Minimum speed (r/min) 500 Maximum speed (r/min) 3200
Input power (kW) (Maximum pressure, rotate
29.7(39.83HP) Weight (kg) 8.5(18.74lb)
speed 3000r/min, total efficiency 0.8)
2. Structure
12
13
14
15
1 2 3 4 5 6 7 8 9 10 11
LG950EIII03099
1. Oil seal 6. Drive gear 11.Rear cover

2. Front housing 7. Driven gear 12. Bolt
3. Support part 8. Pin 13. Washer
4. Seal part 9. Intermediate part 14. Rivet
5. Shaft sleeve subassembly 10. O-ring 15. Sign
3-152
3. Maintenance references 4. Precautions for use
1. Intermediate part 1. Strictly ensure the oil cleanliness. The

hydraulic system involved the pump in should
When the pump efficiency decreases too much
have filter device with filter fineness of less
and the intermediate part chamber cleaning is
than 25μm.
more than 0.127mm, replace the intermediate
part. And check whether the set pressure of 2. 2. Anti-wear hydraulic oil is recommended. At
system safety valve is too high and whether 40°C, the oil kinematic viscosity is
there is abnormal hydraulic impact to confirm the 42~74mm2/s and when using the oil, keep
fault cause and then conduct troubleshooting. the oil temperature range of (-20~80)°C (-
4~176°F).
2. Gear
3. Elastic coupling is recommended to install
When the gear surface and end surface have
the pump drive shaft and the prime motor
obvious scratches, grooves and burrs which can
output shaft with coaxiality difference of less
not be repaired, replace the gear. Or the wear is
than 0.1mm; for the shaft sleeve coupling,
more than 0.051mm, replace the gear. And
the coaxiality difference should be less than
check the oil cleanliness, check whether the
0.05mm (0.00197In)
input connection is normal and whether there is
abnormal hydraulic impact. 4. The pump suction oil level is not more than
0.5m (0.0197In).
3. Drive gear
5. The pump rotation direction can not be
Replace the drive gear when the spline is worn
mistaken, that is, the pump oil inlet and outlet
or damaged. Replace the oil seal when the
can not be mistaken.
contacting part wear with the journal is more than
0.051mm. 6. Avoid start or stop with load.
4. Shaft sleeve assembly 7. If the pump is not used for a long time,
separate the pump with the prime motor to
When the shaft sleeve surface has obvious
stop the pump. When reusing the pump, do
scratches, cavitation, deformation, etc. or the it is
not apply the maximum load immediately and
worn too much, replace the shaft sleeve. And
run with no load at low rotating speed for not
check the oil cleanliness, check whether the
less than 2 minutes.
suction oil is sufficient, whether the input
connection is normal and whether there is 8. Inlet, outlet port shall be installed firmly and
abnormal hydraulic impact. sealing device is secured, otherwise it may
cause oil leak or air suction, which will affect
5. Dowel pin
the pump's performance.
When the positioning pin or pin hole is damaged
9. The highest pressure and maximum rotating
during removal and installation, or the matching
speed mean the allowable peak values in a
clearance is poor, replace the positioning pin or
short period during operation, which should
replace the parts matching with the positioning
be avoided for applying for a long time,
pin.
otherwise, the pump service life will be
6. Seal part influenced.
No matter when the pump is removed or 10. Before operation, run the new pump or
installed, replace the O-ring, seal components, repaired pump with no load and conduct
oil seal, etc. in the pump. impact running for a short time. Then check
the working condition of the pump and no
leakage, excessive heat and noise is
allowed.
3-153
5. Transportation and storage
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.
6. Fault diagnosis
1. Symptom: Abnormal noise.

Solution: Check the rotation direction and
whether the oil inlet and outlet are connected
firmly and correctly; check whether the input
shaft and the locating flange are connected firmly
and check whether there is sir suction.
2. Symptom: There is crawling in the cylinder.
Solution: Exhaust the system and loosen relative
connectors for exhaust if necessary.
3-154
3.3.3Hydraulic working principle
Main hydraulic circuit
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.
2 3
LG950EIII03100
1. Tank 3. Suction pipe

2. Suction rubber hose 4. Main pump
3-155
Drain passage
5 7 9 6 8
4 3 2 1
LG950EIII03101
1. P1 hose assembly 6. Bucket cylinder hose assembly

2. P2 hose assembly 7. Arm cylinder hose assembly
3. Main control valve 8. Swing motor hose assembly
4. Left travel motor hose assembly 9. Right Travel motor hose assembly
5. Boom cylinder 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.
3-156
Return passage
4 3 2 1 6 5
LG950EIII03102
1. Return passage 1 3. Check valve 5. Hydraulic oil tank

2. Return passage 2 4. Oil cooler 6. Check valve
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 2 return oil flows 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 backpressure 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.
3-157
Leakage passage
LG922E930E03138
1. Right travel motor 2. Left travel motor 3. Center connector

3-158
The leaked oil at the lower part, which is absorbed to the upper part through the center connector (3), is
mainly from the two travel motors.
1 2 2 3
3
2
1
LG950EIII03103
1. Center connector 2. Swing motor 3. Main pump
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 connector (1);
II. Swing motor (2) leakage; III. Main pump 3 leakage.
3-159
Pilot circuit
3
2
1
5 6 7 4 8 3 2 1
LG950EIII03104
1. Pilot pump 4. Octuple solenoid valve group 7. Travel pilot valve

2. Hydraulic oil tank 5. Left hand pilot valve 8. Main control valve
3. Pilot valve group 6. Right hand pilot valve
The pressure of the pilot circuit 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 port P1 of the eight-step solenoid
group (4). The return oil of all the solenoids in the eight-step solenoid group (4) flows back to the tank
through the port T1. A1 controls the pilot shutoff; A2 controls the travel shift; A3 controls the pressurizing;
A4 controls the grader mode.
The pilot oil which flows out from the eight-step solenoid 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 complete machine arm and the revolving action. Right-hand pilot
valve (6) controls the complete machine boom and the bucket action. Travel pilot valve (7) controls the
travel action of the complete machine.
3-160
Negative flow control circuit (with the control spool in the neutral)
Negative flow control system (neutral)
Negative flow control system (neutral)
4 5 5 6
3 8
12 11 10 LG950EIII03105
3-161
1. Center position passage 5. Orifice 9. Center position passage

2. Oil return passage 6. Relief valve 10.Hydraulic oil tank
3. Negative flow control oil 7. Negative flow control oil 11.Rear pump
4. Relief valve 8. Oil return passage 12.Front pump
The negative flow control system is an energy saving system. When the system does not work, the
pressure oil output from the front pump (12) and the rear pump (11) of the main pump (2) and (8) returns
to the hydraulic oil tank (10) through the orifice (5) respectively after passing through the neutral passage
(1) and (9), 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.
3-162
Negative flow control circuit (with the control of spool moving)
Negative flow control system (operation)

Negative flow control system (operation)
4 5 5 6
3 8
13
9
14
12 11 10 LG950EIII03106
3-163
1. Center position passage 8. Oil return passage

2. Oil return passage 9. Center position passage
3. Negative flow control oil 10.Hydraulic oil tank
4. Relief valve 11.Rear pump
5. Orifice 12.Front pump
6. Relief valve 13.Swing spool
7. Negative flow control oil 14.Check valve
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 rear 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 (3)
is minimized, and the front pump swashplate swing angle of the main pump increases to supply oil to the
swing motor; the rear pump of the main pump keeps in the smallest swing angle with the action of the
negative feedback control pressure (7).
3-164
Boom rising working circuit
Boom-up
Boom-up
LG950E4f03023
1. Boom cylinder 11.Solenoid valve

2. Boom cylinder big chamber oil pipe 12.Pilot valve group
3. Boom cylinder small chamber oil pipe 13.Tank
4. Boom lock valve 14.Left pump
5. Pressure passage 15.Right pump
6. Pilot control oil line 16.Pilot pump
7. Boom spool 1 17.Boom spool 2
8. Check valve 18.Check valve
9. Pilot control oil line 19.Load holding valve
10.Hand pilot valve 20.Pilot control oil line
3-165
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 left control ports of the boom spool 1 (7) and boom spool 2 (17)
respectively after passing through pilot line (6); 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 pilot control oil pipe
(20) 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 right pump (14) of main pump reaches the big chamber of boom
cylinder (1) after passing through the check valve (8), boom spool 1(7), boom locking valve (4), pressure
passage (5), boom cylinder big chamber oil pipe (2), load retaining valve (19); at the same time, the
pressure oil of the left pump (14) reaches the big chamber of boom cylinder (1) after passing through the
boom spool 2 (17), the check valve (18), merging into boom spool 1(7) and load remaining valve (19);
the oil in the boom cylinder (1) small chamber flows back to the oil 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.
3-166
Boom descending working circuit
Boom-down (regeneration of oil return)
Boom-down (regeneration of oil return)
LG950E4f03024
1. Boom cylinder 11.Solenoid valve

2. Boom cylinder big chamber oil pipe 12.Pilot valve group
3. Boom cylinder small chamber oil pipe 13.Tank
4. Boom lock valve 14.Front pump
5. Pressure passage 15.Rear pump
6. Pilot control oil line 16.Pilot pump
7. Boom spool 1 17.Boom spool 2
8. Check valve 18.Check valve
9. Pilot control oil line 19.Load holding valve
10.Hand pilot valve 20.Pilot control oil line
3-167
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) and load remaining valve (19) 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 (7) towards to left with the action of the pilot control
pressure, and the switching pools of the boom locking valve and load remaining valve move to the left;
The pressure oil in the rear pump (15) of the main pump 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 to the boom cylinder big chamber oil
pipe line (2) through load holding valve (19), 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 front pump (14), which minimizes the discharge capacity of the front
pump (14), and then the energy is saved.
3-168
Arm stretching working circuit
The arm stretches out
The arm stretches out
LG950E4f03025
1. Arm cylinder 11.Solenoid valve

2. Arm cylinder big chamber oil pipe 12.Pilot valve group
3. Arm cylinder small chamber oil pipe 13.Tank
4. Arm lock valve 14.Left pump
6. Arm spool 1 16.Pilot pump
7. Check valve 17.Arm spool 2
8. Pilot control oil line 18.Pressure passage
9. Regeneration valve 19.Load holding valve
10.Left hand pilot valve
3-169
When the left-hand pilot valve (10) 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 (6) and the arm spool 2 (17)
respectively after passing through the pilot control oil pipe (8); at the same time, the control oil in the left
control chamber of the arm spool 1 (6) and the right control chamber of the arm spool 2 (17) flows back
to the tank (13) after passing through the port 4 of the piping and left hand pilot valve (10); the arm spool
1 (6) and arm 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 the main pump reaches the small chamber of the arm
cylinder (1) after passing through the check valve (7), arm spool 1 (6), arm locking valve (4), arm cylinder
small chamber oil pipe (3) and load holding valve (19); at the same time, the pressure oil of the right
pump (15) reaches the arm spool 2 (17) and pressure passage (18) to joint after passing through the
check valve; the pressure oil of the arm spool 1 (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 (3) and load
remaining valve (19); 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 (6) and the arm spool 2 (17), thus, with
the action of the pressure oil, the piston rod of the arm cylinder withdraws to make the arm stretch out.
3-170
Arm withdrawing working circuit (with regeneration)
Arm retraction (light load, with regeneration)
Arm withdrawing (with regeneration)
LG950E4f03026
1. Arm cylinder 11.Solenoid valve
2. Arm cylinder big chamber oil pipe 12.Pilot valve group
3. Arm cylinder small chamber oil pipe 13.Tank
4. Arm lock valve 14.Left pump
6. Arm spool 1 16.Pilot pump
7. Check valve 17.Arm spool 2
8. Pilot control oil line 18.Pressure passage
9. Regeneration valve 19.Load holding valve
10.Left hand pilot valve
3-171
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 solenoid valve (11) of the pilot valve group (12) from
the pilot valve (16), and reaches the control ports of the arm spool 1 (6) and the arm spool 2 (17), arm
locking valve (4) and load remaining valve (19) respectively after passing through the pilot piping (8); at
the same time, oil in the right control chamber of arm spool 1 (6) and the left control chamber of arm
spool 2 (17) will flow back to the tank (13) via pilot control line and the port 2 of the left-hand pilot valve
(10); the arm spool 1 (6) and arm spool 2 (17) reverse to corresponding positions with the action of the
pilot control pressure, and 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, and meanwhile enters into the control oil port of the load
retaining valve (19) to open the load retaining valve (19);
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 1 (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 1 (6) after passing through the arm
spool 2 (17) 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 (6) after passing through the load remaining valve (19), 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 entering the pressure oil passage (2) through the internal check valve of the spool,
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.
3-172
Arm withdrawing working circuit (with no regeneration)
Arm retraction (heavy-load, no regeneration)

Arm In No Regenerative Circuit
Arm retraction (no regeneration)
LG950E4f03027
1. Arm cylinder 8. Pilot control oil line 14.Left pump

2. Arm cylinder big chamber oil pipe 9. Regeneration valve 15.Right pump
3. Arm cylinder small chamber oil pipe 10.Left hand pilot valve 16.Pilot pump
4. Arm lock valve 11.Solenoid valve 17.Arm spool 2
5. Pressure passage 12.Pilot valve group 18.Pressure passage
6. Arm spool 1 13.Tank 19.Load holding valve
7. Check valve
3-173
With the heavy load, when the oil inlet pressure of the arm cylinder big chamber exceeds the set
pressure of the regeneration valve (9) spring, the regeneration valve (9) 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 (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 valve (16), and reaches the control ports of the arm spool 1 (6) and the arm spool 2 (17)
respectively after passing through the pilot piping (8); at the same time, the control oil in the right control
chamber of arm spool 1 (6) and the left control chamber of arm spool 2 (17) will flow back to the tank (13)
via pilot control line and the port 2 of the left-hand pilot valve (10); the arm spool 1 (6) and arm spool 2
(17) reverse to corresponding positions with the action of the pilot control pressure, and 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, and meanwhile enters into the control oil port of the load retaining valve (19) to open the load
retaining valve (19);
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 1 (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 (2) jointing the pressure oil of the arm spool 1 (6) after passing through the arm spool 1 (17) 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 load holding valve (19), the arm cylinder small chamber oil
piping (3), arm locking valve (4) and the arm spool 1 (6), thus, with the action of the pressure oil, the
piston rod of the arm cylinder stretches out to make the arm withdraw.
3-174
Bucket withdrawing working circuit
Bucket withdrawing
Bucket withdrawing
17 19 18
4
2
11 10 9 12 13 16 14 15 LG950EIII03112
3-175
1. Bucket cylinder 11.Solenoid valve

2. Bucket cylinder big chamber oil pipe 12.Pilot valve group
3. Bucket cylinder small chamber oil pipe 13.Tank
4. Pilot control oil line 14.Left pump
6. Bucket spool 16.Pilot pump
7. Check valve 17.Center position passage
8. Pilot control oil line 18.Check valve
9. Shuttle valve 19.Shut-off valve
10.Right hand pilot valve
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 3 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.
3-176
Bucket stretching working circuit
The bucket stretches out
The bucket stretches out
LG950E4f03028
3-177
1. Bucket cylinder 11.Solenoid valve

2. Bucket cylinder big chamber oil pipe 12.Pilot valve group
3. Bucket cylinder small chamber oil pipe 13.Tank
4. Pilot control oil line 14.Left pump
6. Bucket spool 16.Pilot pump
7. Check valve 17.Center position passage
8. Pilot control oil line 18.Check valve
9. Shuttle valve 19.Shut-off valve
10.Right hand pilot valve
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.
3-178
Left swing working loop
Left swing
Left swing
LG950E4f03052
3-179
1. P1 Pump 13.Right swing motor & reduction gear

2. Pump P2 14.Left swing motor & reduction gear
3. Pilot pump 15.Swing motor A port piping
4. Fuel tank 16.Time delay valve
5. Pilot valve group 17.Motor unlock piping
6. Shuttle valve 18.Swing spool
7. Pilot valve (LH) 19.Swing logic valve
8. Solenoid valve 20.Neutral passage
9. Pilot control oil line 21.Shut-off valve
10.Pilot pipeline (middle), swing shuttle valve 22.Motor unlock control line
11.Pilot control oil line 23.Throttle valve
12.Swing motor B port piping 24.Valve-inner pilot oil passage
When the left hand pilot valve (7) handle is rotated to left, the pilot pressure reaches the port 1 of the
hand pilot valve (7) after passing through the pilot valve group (5) and solenoid valve (8) from the pilot
pump (3), and reaches the control port of the swing spool (18) after passing through the pilot line (9); at
the same time, the control oil in the left control chamber of the swing spool (18) flows back to the tank (4)
after passing through the line (11) and the oil port 3 of the left-hand pilot valve (7). With the action of the
pilot control pressure, the swing spool (18) switches to the corresponding position; at this moment, the
valve-inner pilot oil passage (24) is set with pressure due to the swing spool (18) position switched and
shut-off; one way of pilot pressure oil from the pilot valve group (5) reaches the throttle valve (23), and
then pushes and switches the delay valve (16) by the motor unlock control line (22) to the swing motor
unlock; the other pilot pressure oil way from the pilot valve group (5) enters the motor lock cylinder
through the motor unlock line (17) and realizes unlock;
The pressure oil of the P2 pump (2) reaches the swing motor and reduction gear (13)&(14) after passing
through the swing logic valve (19), swing spool (18), and the swing motor B port line (12); the oil of the
swing motor & reduction gear (13)&(14) A port flows back to the tank after passing through the swing
motor A port line (15) 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 P1 pump (1) reaches the regulator of the P1 pump (1) passing through
the neutral passage (20), shut-off valve (21), and the negative feedback hose to control and minimize the
outlet of P1 pump (1).
3-180
Right swing working loop
Right swing
Right swing
LG950E4f03053
3-181
1. P1 Pump 13.Right swing motor & reduction gear

2. Pump P2 14.Left swing motor & reduction gear
3. Pilot pump 15.Swing motor A port piping
4. Oil tank 16.Time delay valve
5. Pilot valve group 17.Motor unlock piping
6. Shuttle valve 18.Swing spool
7. Pilot valve (LH) 19.Swing logic valve
8. Solenoid valve 20.Neutral passage
9. Pilot control oil line 21.Shut-off valve
10.Pilot pipeline (middle), swing shuttle valve 22.Motor unlock control line
11.Pilot control oil line 23.Throttle valve
12.Swing motor B port piping 24.Valve-inner pilot oil passage
When the left hand pilot valve (7) handle is rotated to right, the pilot pressure reaches the port 3 of the
hand pilot valve (7) after passing through the pilot valve group (5) and solenoid valve (8) from the pilot
pump (3), and reaches the control port of the swing spool (18) after passing through the pilot line (11); at
the same time, the control oil in the right control chamber of the swing spool (18) flows back to the tank
(4) after passing through the line (9) and the oil port 1 of the left-hand pilot valve (7). With the action of
the pilot control pressure, the swing spool (18) switches to the corresponding position; at this moment,
the valve-inner pilot oil passage (24) is set with pressure due to the swing spool (18) position switched
and shut-off; one way of pilot pressure oil from the pilot valve group (5) reaches the throttle valve (23),
and then pushes and switches the delay valve (16) by the motor unlock control line (22) to the swing
motor unlock; the other pilot pressure oil way from the pilot valve group (5) enters the motor lock cylinder
through the motor unlock line (17) and realizes unlock;
The pressure oil of the P2 pump (2) reaches the swing motor and reduction gear (13)&(14) after passing
through the swing logic valve (19), swing spool (18), and the swing motor A port line (15); the oil of the
swing motor & reduction gear (13)&(14) B port flows back to the tank after passing through the swing
motor B port line (12) 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 P1 pump (1) reaches the regulator of the P1 pump (1) passing through
the neutral passage (20), shut-off valve (21), and the negative feedback hose to control and minimize the
outlet of P1 pump (1).
3-182
Rotating priority pipeline (rotating opposite arm priority function)
Priority function of slewing relative to arm
Arm withdrawing (with regeneration)
LG950E4f03054
3-183
1. P1 Pump 15.Swing motor A port piping

2. Pump P2 16.Time delay valve
3. Pilot pump 17.Motor unlock piping
4. Fuel tank 18.Swing spool
5. Pilot valve group 19.Swing logic valve
6. Shuttle valve 20.Neutral passage
7. Pilot valve (LH) 21.Shut-off valve
8. Solenoid valve 22.Motor unlock control line
9. Pilot control oil line 23.Throttle valve
10.Pilot pipeline (middle), swing shuttle valve 24.Valve-inner pilot oil passage
11.Pilot control oil line 25.Swing priority valve
12.Swing motor B port piping 26.Arm spool 1
13.Right swing motor & reduction gear 27.Arm spool 2
14.Left swing motor & reduction gear
The main function of the swing priority valve (25) is to distribute the pressure oil output to the swing spool
(18) and the arm spool 1 (26) by the P2 pump (2). As shown in the circuit diagram, the throttle passage
is at the left position of the swing priority (25).
When the right handle of the hand pilot valve (7) is operated at 45 degrees toward rear left, the pilot
pressure reaches the port 3 & port 4 of the left hand pilot valve from the pilot pump (3) through the pilot
valve group (5) & the solenoid valve (8), and reaches the corresponding control ports of the swing spool
(18) & the arm spool 1 (26), the arm spool 2 (27) through the pilot line. At this moment, the swing pilot
control oil reaches the pilot control port PSP of swing priority valve (25) through the swing shuttle valve
pilot line (10), and pushes the valve moving toward right.
The pressure oil output from the pump P1 (1) reaches the big chamber of the arm cylinder through the
arm spool 2 (27).
a part of the pressure oil of the pump P2 (2) reaches the swing motor (13)&(14) after passing through the
swing spool (18), and another part enters the arm cylinder big chamber after passing through the throttle
passage-lh of the swing priority valve (25) and the arm spool 1 (26); as the throttling action of the swing
priority valve (25), the flow entering the arm spool 1 (26) is restricted, and then the swing priority to the
arm is achieved.
3-184
Travel forward (fast)
LG950E4f03055
3-185
1. Left travel motor & reduction gear 24.Variable cylinder

2. Right travel motor & reduction gear 25.Motor brake
3. Motor brake 26.Control passage
4. Unlock pressure oil passage 27.Check valve
5. A port oil passage, left motor 28.Transmission reversing valve
6. Balanced valve 29.Variable cylinder
7. Travel motor A port piping-lh 30.Center Swivel Joint
8. Travel motor B port piping-lh 31.Pilot control oil line
9. Control passage 32.Pilot control oil line
10.B port passage, left motor 33.Solenoid valve
11.Pilot control oil line 34.Travel spool (left)
12.Pilot control oil line 35.Pressure oil passage
13.Travel pilot valve 36.Solenoid valve
14.Travel fast and slow gear control line 37.Pilot return lines
15.Travel motor B port piping-rh 38.Pilot oil supply line
16.Port A piping, right travel motor 39.Hydraulic oil tank
17.A port oil passage, right motor 40.Pilot pump
18.Control passage 41.P1 Pump
19.Balanced valve 42.Pump P2
20.Return passage 43.Pressure switch
21.Check valve 44.Pilot valve group
22.Transmission reversing valve 45.Travel spool (right)
23.Control passage 46.Pilot control oil passage
47.Pilot control oil passage
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 (44) and the solenoid valve (33) from the pilot pump (40), and
reaches the control ports of the left travel spool (34) and the right travel spool (45) after passing through
the pilot lines (31) and (11) respectively; at the same time, the control oil in the right control chamber of
the left travel spool (34) and the right travel spool (45) flows back to tank (39) after passing through the
piping (32) and (12), oil port 2 and 4 of the travel pilot valve (13) and the pilot return line (37); with the
action of the respective pilot control pressure, the left travel spool (34) and the right travel spool (45)
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 (36) to make it reverse; the
pilot control pressure reaches the transmission reverse valve (28) and (22) of the left travel motor and
the reducer (1) as well as the right travel motor 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 right motor enters the variable cylinder (24) of the right travel motor
after passing through the check valve (21) and transmission reverse valve (22), while the oil inlet
pressure of the left motor enters the variable cylinder (29) of the left travel motor 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;
3-186
The pressure oil output from the pump P2 (42) of the main pump reaches the port B of the left travel
motor & reduction gear (1) after passing through the pressure passage (35), left travel spool (34), 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 (39) 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 (34); at the same time, the pressure oil of the pump P1 (41) reaches
the port A of the right travel motor & reduction gear (2) after passing through the right travel spool (45),
center swivel joint (30) and the port A piping (16) of right travel motor; the pressure oil 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 motor after passing through the return passage (20)
and the balanced valve (19), and then connects with the hydraulic oil tank (39) after passing through the
port B piping (15) of right travel motor, center swivel joint (30) and the right travel spool (45); thus, with
the action of the pressure oil, the left and right motors and the reduction gear drive the machine to move
forward fast.
As the reversing of the right travel spool (45), the return passage of the control pressure outputting from
the pilot valve group (44) port B is suspended and the pressure is produced, and this pressure acts on
the pressure switch (43) after passing through the pilot control passage (46) and (47), and then the
pressure switch (43) transmits the electrical signal to realize the function of travel warning.
3-187
Travel backward (slow)
LG950E4f03056
3-188
1. Left travel motor & reduction gear 25.Motor brake

2. Right travel motor & reduction gear 26.Control passage
3. Motor brake 27.Check valve
4. Unlock pressure oil passage 28.Transmission reversing valve
5. B port passage, left motor 29.Variable cylinder
6. Balanced valve 30.Center Swivel Joint
7. Travel motor A port piping-lh 31.Pilot control oil line
8. Travel motor B port piping-lh 32.Pilot control oil line
9. Control passage 33.Solenoid valve
10.A port oil passage, left motor 34.Travel spool (left)
11.Pilot control oil line 35.Pressure oil passage
12.Pilot control oil line 36.Solenoid valve
13.Travel pilot valve 37.Pilot return lines
14.Travel fast and slow gear control line 38.Pilot oil supply line
15.Port A piping, right travel motor 39.Hydraulic oil tank
16.Travel motor B port piping-rh 40.Pilot pump
17.Port B passage, right motor 41.P1 Pump
18.Control passage 42.Pump P2
19.Balanced valve 43.Pressure switch
20.Return passage 44.Pilot valve group
21.Check valve 45.Travel spool (right)
22.Transmission reversing valve 46.Pilot control oil passage
23.Control passage 47.Pilot control oil passage
24.Variable 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 (34) and the right travel spool (45) after
passing through the pilot lines (31) and (11) respectively; at the same time, the control oil in the control
chamber-rh of the left travel spool (34) and the right travel spool (45) flows back to tank (39) after
passing through the piping (32) and (12), oil port 1 and 3 of the travel pilot valve (13) and the pilot return
line (37); with the action of the respective pilot control pressure, the left travel spool (34) and the right
travel spool (45) 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 (36) to
make it reset (as shown in the figure), and the travel fast-slow gear control line (14) pressure returns the
tank through the solenoid valve (36); 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 RDr and is 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;
3-189
The pressure oil output from the pump P2 (42) of the main pump reaches the port A of the left travel
motor & reduction gear (1) after passing through the pressure passage (35), travel spool-lh (34), 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 (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 (39) after passing through the return passage (5) and balanced
valve (6) to the B port of motor, and then passing through the travel motor B port piping-lh (8), the center
swivel joint (30) and the travel spool-lh (34); at the same time, the pressure oil of the pump P1 (41)
reaches the B port of the travel motor-rh & reduction gear (2) after passing through the travel spool-rh
(45), center swivel joint (30) and the travel motor B port piping-rh (16); the pressure oil enters the motor
by passing through the motor B port 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 A port of the motor after passing through the return passage
(20) and the balanced valve (19), and then connects with the hydraulic oil tank (39) after passing through
the travel motor A port piping-rh (15), center swivel joint (30) and the travel spool-rh (45); 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 (45), the return passage outputting the control pressure from the
pilot valve group (44) port B is stopped and the pressure is produced, this pressure acts on the pressure
switch (43) after passing through the control passage (46) and (47), and then the pressure switch (43)
transmits the electrical signal to realize the function of travel warning.
3-190
Bilateral travel and boom rising compound operation
Linear traveling (Traveling forward + Boom up)

Straight travel
LG950E4f03057
1. Pump P2 4. Controlling oil circuit

2. P1 Pump 5. Straight travel valve
3. Travel spool (left) 6. Travel spool (right)
3-191
Under normal travel state (namely without other actions), the pump P2 (1) supplies oil to the left travel
spool (3) and the pump P1 (2) supplies the oil to the right travel spool (6). With the both sides traveling,
when any actions of the swing or working device are operated synchronously, the oil-way control (4)
pressure of the straight travel valve (5) 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
(5) to reverse, at this moment, the output oils of the pump P2 are distributed again by passing through
the straight travel valve (5); the pressure oil output from the pump P2 (1) is supplied to the left and right
travel valve, and the pressure oil output from the pump P1 (2) 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.
3-192
Fan hydraulic system
Linear traveling (Traveling forward + Boom up)
17
16
15
14
13
12
11
10
18
19
LG950EIII03120
3-193
1. Plunger pump 11.Oil line

2. Variable cylinder 12.Electronic proportional relief valve
3. Servo valve 1 13.Check valve
4. Servo valve 2 14.Reversing valve
5. Reversing oil line 15.Hydraulic oil line
6. Oil line 16.Oil returning circuit
7. Controlling oil circuit 17.Gear pump
8. Oil line 18.Return lines
9. Oil line 19.Oil drain piping
10.Oil line
During normal operation, under the constant conditions of electronic proportional overflow valve (12), the
plunger pump (1) drains the oil under the running of engine through the reversing valve (14), hydraulic oil
circuit (15) to the gear motor (17). The oil flows back to the oil tank through return circuit (16), reversing
valve (14) and oil return pipeline (18), and the discharge oil working in gear motor flows back to the oil
tank through discharge pipeline (19).
When the hydraulic oil temperature, water temperature or ambient temperature rise, the controller cuts
down the current supplied to the electronic proportional overflow valve (12) by judgment (electric
system); the electronic proportional overflow valve is of inverse proportion overflow valve; when the
current reduces, the control pressure (11) increases and it is transferred via the control oil passage to the
plunger pump servo valve 1 (4) to make the servo valve 1 (4) switching to the left side; the oil in the
variable displacement cylinder (2) under the spring effect flows through the servo valve 2 (3) and servo
valve 1 (4) back to the oil tank; the displacement of plunger pump (1) increases and the gear motor (17)
speed increases; the fan speed increases to add the air supply volume, and therefore increase the
radiation volume so as to achieve heat balance
When the hydraulic oil temperature, water temperature or ambient temperature decreases, the controller
increases the current supplied to the electronic proportional overflow valve (12) by judgment (electric
system); the electronic proportional overflow valve is of inverse proportion overflow valve; when the
current rises, the control pressure (11) decreases and it is transferred via the control oil passage to the
plunger pump servo valve 1 (4) to reduce the reversing pressure of servo valve 1(4); the pressure oil
passage (5) makes the reversing valve switching to the right side; the pressure oil flows through the oil
circuit (6), servo valve 1 (4) and then servo valve 2 (3) to the variable displacement cylinder to compress
the spring and therefore reduce the pump displacement, thus the speed of gear motor (17) reduces
3-194
Single-way working circuit of breaking hammer
Working circuit of breaking hammer
Working circuit of breaking hammer
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
LG950EIII03121
3-195
1. Quartering hammer 10.Octuple solenoid valve

2. Stop valve 11.Breaking hammer pilot valve
3. Stop valve 12.Controlling oil circuit
4. Three-way ball valve 13.Pilot valve group
5. Oil tank oil pipeline 14.P2 pump
6. Piping 15.Pilot pump
7. Stop valve 16.Tank
8. Relief valve 17.P1 pump
9. Breaking hammer spool 18.Pressure oil line
When using the hydraulic hammer (1), firstly have the accessories pipeline unidirectional , that is, have
the Unidirectional and bi directional switching valve (4) unidirectional and switch on the stop valve (7).
After connecting the hydraulic hammer (1), switch on the stop valve (2) and (3) and adjust the relief valve
(8) until to satisfy the working pressure of the hydraulic hammer (1).
Operate the breaking hammer pilot valve (11) to make the pilot pump (15) oil flowing through pilot valve
bank (13), 8-joint solenoid valve (10), breaking hammer pilot valve (11) port 1 and the pipeline (12) to the
breaking hammer spool (9) to make the breaking hammer spool (9) reversing; P2 pump (14) outputs the
pressure oil and the left side of breaking hammer spool (9) gets into the hydraulic hammer (1)?
3-196
Attachment swing system (Left swing)
Attachment swing system
Attachment swing system circuit
LG950E4f03030
1. Hydraulic oil tank 8. Hydraulic crusher

2. Pilot pump 9. Hydraulic oil line
3. Pilot valve 10.Hydraulic oil line
4. Octuple solenoid valve 11.Reversing valve spool
5. Proportional solenoid valve 12.Oil line
6. Pilot control oil line 13.Gear pump
7. Pilot control oil line
3-197
When operate the attachment swing handle to the left, the oil of pilot pump (2) passing through the pilot
valve (3), octuple solenoid valve (4), and port b1 of the proportional solenoid valve (5), and it is applied to
the reversing spool (11) of the valve assembly through the pilot control oil line (6), the spool switches to
the left, and the hydraulic oil of the left chamber returns through the pilot control oil passage (7), port a1
of the proportional solenoid valve (5) and then the pilot oil return pipe.
The oil of the attachment swing gear pump (13) reaches the reversing spool (11) of the valve assembly
through the oil line (12), after the spool switches, the oil is applied to the hydraulic shear from the
hydraulic oil line (10) through the reversing spool (13) to drive the hydraulic shear to rotate to the left.
3-198
Attachment swing system (Right swing)
Attachment swing system
Attachment swing system circuit
LG950E4f03031
1. Hydraulic oil tank 8. Hydraulic crusher

2. Pilot pump 9. Hydraulic oil line
3. Pilot valve 10.Hydraulic oil line
4. Octuple solenoid valve 11.Reversing valve spool
5. Proportional solenoid valve 12.Oil line
6. Pilot control oil line 13.Gear pump
7. Pilot control oil line
3-199
When operate the attachment swing handle to the right, the oil of pilot pump (2) passing through the pilot
valve (3), octuple solenoid valve (4), and port a1 of the proportional solenoid valve (5), and it is applied to
the reversing spool (11) of the valve assembly through the pilot control oil line (7), the spool switches to
the right, and the hydraulic oil of the right chamber returns through the pilot control oil passage (6), port
b1 of the proportional solenoid valve (5) and then the pilot oil return pipe.
The oil of the attachment swing gear pump (13) reaches the reversing spool (11) of the valve assembly
through the oil line (12), after the spool switches, the oil is applied to the hydraulic shear from the
hydraulic oil line (9) through the reversing spool (13) to drive the hydraulic shear to rotate to the right.
3-200
3.4 Work Implement CLG950E
3.4Work Implement
3.4.1Maintenance references of main parts
C
G
F
H
Q
A
LG922E930E03156
3-201
CLG950E 3.4 Work Implement
A G
B H
C N
1
4
D E Q
F K
6
2
LG922E930E03157
3-202
Judgment standards
No. Items Tolerance Permissi Measures

Standard Standard
ble
clearance
Clearance between -0.036 +0.19
0.116~0.261 0.116~1.0
mounting pin and φ120 {-0.0014 In} {+0.0075 In}
1 {0.0046~0.0 {0.0046~0.0
bushing of swing {4.72 In} -0.071 +0.08
10 In} 39 In}
platform and boom {-0.0028 In} {+0.0031 In}
Clearance between -0.036 +0.19
0.116~0.261 0.116~1.0
mounting pin and φ120 {-0.0014 In} {+0.0075 In}
2 {0.0046~0.0 {0.0046~0.0
bushing of boom and {4.72 In} -0.071 +0.08
10 In} 39 In}
arm {-0.0028 In} {+0.0031 In}
Clearance between -0.036 0.166
0.119~0.237 0.119~1.0
mounting pin and {-0.0014 In} {0.0065 In}
3 {0.0047~0.0 {0.0047~0.0
bushing of arm and -0.071 0.083
093 In} 39 In}
bucket {-0.0028 In} {0.0033 In}
Replace it
-0.036 0.17 0.107~0.24
Clearance between 0.107~1.0
φ100 {-0.0014 In} {0.0067 In} 1
4 mounting pin and {0.0042~0.0
{3.937 In} -0.071 0.071 {0.0042~0.0
bushing of arm and lever 39 In}
{-0.0028 In} {0.0028 In} 095 In}
-0.036 0.17 0.107~0.24
Clearance between 0.107~1.0
φ100 {-0.0014 In} {0.0067 In} 1
5 mounting pin and {0.0042~0.0
{3.937 In} -0.071 0.071 {0.0042~0.0
bushing of link and lever 39 In}
{-0.0028 In} {0.0028 In} 095 In}
Clearance between -0.036 0.184 0.131~0.25
0.131~1.0
mounting pin and φ100 {-0.0014 In} {0.0072 In} 5
6 {0.0052~0.0
bushing of link and {3.937 In} -0.071 0.095 {0.0052~0.0
39 In}
bucket {-0.0028 In} {0.0037 In} 10 In}
3-203
3.4.2Maintenance references of arm part
9
19
11
6
12
A
D
D
5
10
13
14 7
A-A B-B
15
18
16
17
c-c D-D
4
2
3
LG922E930E03158
3-204
Position for Tolerance

No. Standard size
measurement Shaft Hole
-0.036 +0.054
φ110 {-0.0014 In} {+0.0021 In}
1 —
{4.33 In} -0.071 0
{-0.0028 In} {0 In}
+1.5
137 {+0.059 In}
Arm side
{5.39 In} 0
{0 In}
2
0
135 {0 In}
Cylinder side
{5.31 In} -0.5
{-0.020 In}
-0.036 +0.054
φ120 {-0.0014 In} {+0.0021 In}
3 —
{4.72 In} -0.071 0
{-0.0028 In} {0 In}
+1.5
407 {+0.059 In}
Boom side
{16.02 In} 0
{0 In}
4
0
403 {0 In}
Arm side
{15.87 In} -0.5
{-0.0197 In}
208.2 ±0.5
5 —
{8.197 In} {±0.0197 In}
583.6 ±1
6 —
{22.98 In} {±0.039 In}
1132.2 ±1
7 —
{45.57 In} {±0.039 In}
3374 ±4
8 —
{132.83 In} {±0.157}
3099.4 ±1.5
9 —
{122.02 In} {±0.059}
507.4 ±0.5
10 —
{19.98 In} {±0.0197 In}
720 ±0.5
11 —
{28.35 In} {±0.0197 In}
719 ±0.5
12 —
{28.31 In} {±0.0197 In}
537.1 ±0.5
13 —
{21.15 In} {±0.0197 In}
1836
14 — —
{72.28 In}
3-205
Position for Tolerance

No. Standard size
measurement Shaft Hole
-0.036
φ100 {-0.0014 In} +0.087
15 —
{3.937 In} -0.071 0
{-0.0028 In}
0
396 {0 In}
Link itself
{15.59 In} -0.5
{-0.0197 In }
16
0
Press fitting of 418 {0 In}
bushing {16.46 In} -0.7
{-0.028 In}
-0.036 +0.087
φ100 {-0.0014 In} {+0.0034 In}
17 —
{3.937 In} -0.071 0
{-0.0028 In} {0 In}
0
358 {0 In}
Arm itself
{14.09 In} -0.5
{-0.0197 In }
18
0
Press fitting of 388 {0 In}
bushing {15.28 In} -0.7
{-0.028 In}
1995 ±4
Min.
{78.54 In} {±0.157 In}
19
3255 ±7
Max.
{128.15 In} {±0.276}
3-206
3.4.3Maintenance references of bucket part
LG950E4f03032
Unit: mm
No. Standard size Tolerance

535.4 ±0.5
1
{21.08 In} {±0.0197 In}
42.2 ±0.5
2
{1.66 In} {±0.0197 In}
3 94.5° —
3-207
No. Standard size Tolerance

537.1 ±0.5
4
{21.15 In} {±0.0197 In}
1836
5 —
{72.28 In}
294.8
6 —
{11.61 In}
159
7 —
{6.26 In}
122
8 —
{4.8 In}
R140
9 —
{R5.51 In}
R130
10 —
{5.12 In}
R800
11 —
{31.5 In}
+0.5
389 {+0.0197 In}
12
{15.3 In} 0
{0 In}
63
13 —
{2.48 In}
113
14 —
{4.45 In}
542
15 —
{21.34 In}
+0.087
φ100 {+0.0034 In}
16
{φ3.937 In} 0
{0 In}
104
17 —
{4.09 In}
168
18 —
{6.61 In}
230
19 —
{9.06 In}
22
20 —
{0.87 In}
185
21 —
{7.28 In}
3-208
3.5 A/C System CLG950E
3.5A/C System
Layout diagram of A/C pipeline
3
4
2
1
7
C A
B
LG950E4f03033
1. A/C air duct 6. Air conditioning condenser

2. Evaporator assembly (HVAC) 7. Refrigerant pipeline
3. Thermal return pipeline A: Fresh air intake
4. Thermal inlet pipeline B: Internal circulation air
5. Compressor C: Cold and hot air
3-209
CLG950E 3.6 Electrical System
3.6Electrical System
3.6.1Engine control
Engine
Sensor signal
Control signal
Frequent power
Start power supply supply signal of
signal of starting motor starting motor
ECM control starting signal
Main controller
Engine controller
Control signal
of pilot lever
(Sensor signal) Starting relay
Starting signal of
supply
signal
Power
main controller
CAN bus Speed control
signal and
other signals
Power-on signal
of electric lock
Main controller
Electric lock start signal
Fuel level signal

Accelerator knob signal
Battery relay
Battery
LG950E4f03034
1. Start the engine

When the electric lock is turned to the "Start" position, the electric lock starting signal is detected by the
main controller, and then the main controller sends main controller control starting signal to transmit the
power supply signal to the power end of the start motor, then the engine is started.
(Note: The starting signal of the starter relay is controlled by the ECM, and the starter relay is driven
jointly by the main controller control starting signal and the pilot handle control signal. When the machine
is free of failure, and the excavator is started following the correct steps, the starting process of the
engine is described as above.)
3-210
3.6 Electrical System CLG950E
At the same time, the main controller detects the accelerator knob signal, and sets the corresponding
engine speed of the accelerator knob as the set speed, then sends the speed control signal to the
engine controller via the CAN bus, so as to control the oil feed pump and make the current speed
become the set speed steadily.
2. Engine speed control
Each gear of the accelerator knob corresponds 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.
3.6.2Display system
Engine controller
(Alarm signal and engine

state information)
CAN bus
(Alarm signal and hydraulic (Complete machine information

system information) and command signal)
Main controller Display
LG950E4f03035
The operator can obtain the operating condition of complete machine through the display system. The
display shares the data with the engine controller and the main controller via CAN bus, and the
information of the machine is displayed on the LCD screen.
The contents displayed on the screen can be divided into following categories:
1. Alarm information when the complete machine fails;
2. Working condition information of the machine (including the engine speed, hydraulic oil temperature,
etc.).
3. Maintenance information of the machine.
The buttons for special purposes on the control panel of the display are used to operate the control
system of the machine.
3-211
Display
LG925E4F03166
Performance
1) With LCD screen, the backlight brightness is adjustable.
2) Internal integrated microprocessor and storage unit.
3) A build-in buzzer is installed, the volume is adjustable and the mute is available.
4) Support CAN bus communication.
Tyco 1437209-7
1 7
20 26
LG925E4F03167
3-212
Definition of connector pin:
Number Input and output port

Signal name Description
of pin function
1 CAN Low CAN Low CAN Low
2 CAN Shield CAN Shield CAN Shield
3 NC - The pin is not adopted
5 Earthing Earthing Earthing
6 Battery power supply Battery voltage 24V, always connect with the battery
7 Battery power supply Battery voltage 24V, always connect with the battery
8 CAN High CAN High CAN High
10 Earthing Earthing Earthing
Input 24V when the ignition switch is
26 Electric lock ON Switch input
turned to "on" position
Note: NC indicates that the stitch is not adopted.

3-213
LCD part of display
LG925E4F03168
Indicate the
Icon Description
content
The working modes are separately of "P", "E", "F",
1 Working mode
"L", "B" and "ATT"
Accelerator has 12 gears in total from "1" to "12"
2 Accelerator gear
respectively
The illuminated icon indicates the engine is

3 Engine warming up
warming up
When the flattening function is enabled, the icon will
4 Flattening function
be displayed, otherwise, it will not be displayed
When the trenching function is enabled, the icon
5 Trenching function
will be displayed, otherwise, it will not be displayed.
1) When the automatic power boosting function is
valid, the icon is always displayed on the main
interface no matter whether the engine is operating.
2) Manual power boosting, when the manual
transient power boosting knob is pressed, the icon
Transient power
6 will be displayed; when the manual power boosting
boosting function
knob is released, the icon will disappear.
3) Under the L mode, the icon will be displayed all
the time unless the vehicle is in the travel state, and
the automatic power boosting cannot be canceled
under the L mode.
3-214
Indicate the
Icon Description
content
Automatic idling When the automatic idling function is enabled, the
7
function icon will be displayed
8 Travel speed Display when the travel speed is fast: , display

when the travel speed is slow:
The illuminated icon indicates the engine is
9 Preheating function
preheating and the preheating time is 30s at most.
When the engine is running, the hour meter reading
can increase even if the machine does not move.
Operating hours of
10 The least significant digit of the hour meter
engine
increases by one when the engine works for six
minutes.
It is normal when the indicator is within the green
range.
If the indicator enters the red range when the
Hydraulic oil hydraulic oil temperature alarms as high, very high
11 -
temperature gauge and extremely high during operation, it indicates the
oil temperature is 82°C(180°F) or above, run the
engine at low idling speed or shut the engine to wait
the oil temperature decreases to the normal range.
range.
If the indicator enters the red range when the
Temperature table of coolant temperature alarms as high, very high and
12 - cooling fluid of the extremely high during operation, it indicates the
engine coolant temperature is 102°C(216°F) or above, run
the engine at low idling speed or shut the engine to
wait the coolant temperature decreases to the
normal range.
Indicate the fuel quantity percent left in the fuel
tank.
range. If the indicator enters the red range when
13 - Fuel gauge the fuel quantity alarms as low level during
operation, it indicates the fuel quantity percent is
lower than10% and then the "time and alarm zone"
displays words and the buzzer sounds. Replenish
fuel in time.
It is illuminated to warn the operator that the set
time is exceeded since the latest maintenance.
After 30s, the monitor screen goes out and returns
Maintenance interval
14 to the standard status.
hint
If the maintenance items are not reset, the monitor
screen will go out after 30s every time the machine
is powered on.
3-215
Indicate the
Icon Description
content
The zone displays alarm word, fault code, hint
information when necessary, otherwise, it displays
Time and alarm
5 the current time. When there are several massages
indication
to be displayed, these massages will the displayed
cyclically.
Switch function It indicates the detailed functions of F1~F6 buttons
16
indication in the current interface.
Display button panel Indication icon Indicate the content
4 "Silence Already" indicator
"Video" indicator,
It will appear if the instrument is
5
mounted on the machine with a
video system
6 "Confirm" indicator
7 "Cancel/Return" indicator
8 "Up/Increase" indicator
9 "Down/Decrease" indicator
LG925E4F03166 10 "Rightwards" indicator
11 "Leftwards" indicator
The standard screen is displayed as the figure
above. 12 "Previous Page" indicator
There are 12 buttons (every button has backlight
to indicate its position), of which 6 are special 13 "Next Page" indicator
buttons and 6 function buttons.
There are 6 function switches from F1 to F6 on
the bottom of the display. According to the
display contents, every function switch has
different function; the function from F1 to F6
buttons can be confirmed through the indication
icons on the top every switch.
Indication icon Indicate the content
1 "Menu" indicator
2 "Maintenance" indicator
3 "Silence" indicator
3-216
1. Selector mode switch of video screen: 2. Maintenance selector switch:

For the machine with camera (if equipped), if When pressing down the button F5 on the
press down the button F3 on the standard standard screen, the monitor screen will switch
screen, the image screen will be displayed (see to the maintenance category screen.
the figure below).
For the machine without camera, no indication
image will be displayed on the top of the Maintenance items Period Remaining
button F3, and even pressing down the button Replace the return oil filter element of
hydraulic oil tank
F3, the screen will not switch to the camera Replace the return oil filter element of
hydraulic oil tank
screen to display. Lubricate the swing reduction gear
bearing (applying grease)
Please contact with the LiuGong dealer if you Replace the return oil filter element
of hydraulic oil tank
want to install camera. Replace the pilot oil filter
Replace hydraulic oil
Replace the suction oil filter element
of hydraulic oil
Replace the anti-freeze
LG925E4F03195
On the maintenance category screen, if the time

left for maintenance of any item (the indicator is
ON) is less than 30 hours, the left time will be
highlighted with yellow color. If the time left for
maintenance of any item is 0, the left time will be
highlighted with red color.
LG925E4F03194 If you want to change the setting of maintenance

interval, please contact with the LiuGong dealer.
On the image display screen, the standard
screen will be returned to if the button F6 is
pressed down.
3-217
The items displayed on the maintenance category screen are as follows:
Default maintenance interval

Maintenance item
(period)
Check instruments
Check engine oil level
Check coolant level
Check hydraulic oil level 8 hours (every day)
Fuel tank drainage
Oil-water separator drainage
Check the looseness of bolts and screws routinely
50 hours (once every day within the previous
Lubricate pins work implement (applying grease)
100 hours)
Check the leakage of A/C refrigerant
Check and adjust the travel track looseness
Clean the external filter parts of filter 100 hours
Check and adjust the fan belt looseness
Check and adjust the compressor belt looseness
Check the gear oil level of swing reduction gear
Check the gear oil level of travel reduction gear
Clean the strainer for internal and external air of air conditioner
250 hours
Replace engine oil
Replace engine oil filter element
Replace the fuel pre-filter element
Lubricate the swing bearing ball (applying grease)
Lubricate the swing bearing gear (applying grease)
Replace the fuel filter element 500 hours
Replace the fuel coarse filter element
Replace the air filter
Replace the gear oil of travel reduction gear
Replace the swing reduction gear oil
Lubricate the swing reduction gear bearing (applying grease) 1000 hours
Replace the return oil filter element of hydraulic oil tank
Replace the pilot oil filter
Replace the hydraulic oil
Replace the suction oil filter element of hydraulic oil 2000 hours
Replace the anti-freeze
3-218
On the maintenance category screen, use the ● Press the button F6 down to switch to the
button from F1 to F6 to do the following work: confirmation screen.
● F1: Display the next page. It displays the first When at the confirmation screen of resetting
page when at the last page. maintenance interval:
● F2: Display the previous page. It displays
the last page when at the first page.
● F3: Move to the next page (next line). It Maintenance time setting
moves to the first line of the next page when
at the last line. Reset displayed result change
● F4: Move the previous item (the previous times increased
line). It moves to the last line of the previous Confirm to reset?
page when at the first line.
● F5: Return to the standard screen. Cancel Yes
● F6: If you press and hold this button, the

screen will switch to the display screen used
for resetting left time of chosen item (the
highlighted item with yellow color). LG925E4F03197
Operation of maintenance interval resetting
On the maintenance category screen, pressing ● Press the switch F5 down to cancel the
down the button F6 can switch to the resetting resetting and the screen returns to the
screen of maintenance interval. On this screen, maintenance category screen.
the left time can be reset. ● Press down the switch F6, and setting the
When at the screen of resetting maintenance remaining time and change this screen to the
interval: maintenance directory screen.
3. The introduction to the special button
function:
1) Flattening function key
Replace the gear oil of travel reduction gear
Press this button to activate or cancel the
Maintenance time resetting flattening function. When the flattening function
Confirm whether resetting is needed? is enabled, the corresponding icon on the main
interface will be illuminated.
The trenching function and the land leveling
function are not mutually exclusive - namely the
Back Yes both functions can be enabled at the same time.
2) Trenching function key
Press this button to activate or cancel the
LG925E4F03196 trenching function. When the trenching function
is enabled, the corresponding icon on the main
interface will be illuminated.
● Press the switch F5 down to cancel the
resetting and the screen returns to the The trenching function and the land leveling
maintenance category screen. function are not mutually exclusive - namely the
both functions can be enabled at the same time.
3-219
3) Working mode selector button When the B mode or the ATT mode is selected,
the system will pop up the following information
Press the key to make the mode selection menu
prompt box:
pop up, and then the user can select the
expected working mode.
Working mode
Work mode selection
Overload mode Confirm the working mode is started
Economy mode
Fine mode ATT
Lifting mode Mode
Breaker mode 3 Volume
Hydraulic shear mode 1 Volume Cancel Yes
LG925E4F03202
LG925E4F03201
When starting to work and keep at the B mode,
press the function switch F6 (confirmation). If F5
P High speed mode: for operation with heavy
is pressed down (canceling), the system will
load
work with E mode.
E Economic mode: for operation of saving fuel
consumption
F Fine mode: for operation of accurate control
L Lifting mode: for operation of lifting control Working mode
B Breaking hammer mode: for operation of

Confirm the working mode is started
breaking hammer
ATT Hydraulic shear mode: for of double ATT
functional oil passage accessories , such as Mode
hydraulic caliper (machine can be installed with
accessories ) Cancel Yes
About the B and ATT mode
For the machine equipped with the attachment,
the B/ATT mode is invisible in the selecting menu
LG925E4F03203
unless the B/ATT is enabled.
When starting to work and keep at the ATT
mode, press the function switch F6
(confirmation). If F5 is pressed down (canceling),
the system will work with E mode.
If you want automatic setting of P, E, F, L, B, or
ATT (any default setting)at the beginning, please
contact with the LiuGong dealer to change the
setting.
3-220
If you want to keep the activated mode last time User menu
at the beginning, please contact with the
LiuGong dealer to change the setting. Set
4) Travel speed control button (rabbit/ On the main interface, press the button "F6" to
tortoise) enter the "User Menu", and then if no operation
Press the key to switch between the low speed of the menu is not conducted with15s, it will
state and high speed state, and the return to the main interface automatically.
corresponding icon (rabbit/tortoise) on the main Some corresponding menu options for the user
interface will switch synchronously. When to perform some basic settings are provided in
starting the engine, the speed will be set ti low this setting interface. Thereof, part of menu items
speed automatically. only appear under special conditions.
When pressing the button , the display will be
switched as the sequence of → → .
The travel icon on the display is only consistent Users' menu
with the state selected by the user, not the state Flow setting of attachments
of the travel solenoid valve. That is, indicating
icon is not affected by whether the vehicle is in Auto-boosting start'1 disable
the running state or whether the travel solenoid Clock setting
valve is failed.
Language setting
5) Automatic idling control button Brightness sett mg
Pressing this button down will activate or cancel Current faults
the automatic idling function and the
corresponding icon on the main interface will be
illuminated or go out simultaneously.
LG925E4F03212
6) Travel buzzer mute button (external
horn)
● Attachment flow setting
This button controls the status of the travel
● Automatic power boost activation/
buzzer.
deactivation
When the buzzer sounds, press this button to
● Monitor of over load lifting activation/
switch between the Mute Mode →Cancel
deactivation
Mute mode .
● Clock adjustment
If the buzzer always does not sound, pressing
this button is invalid. ● Language setting
● Brightness setting
● Current fault
● Machine information
● Instrument information
● Controller information
● Accelerator calibration
● Fan emergency control
● Fan control
3-221
● Forbidden regeneration When the machine is at the B mode, press the

button "Up/Down" to select the "Breaking
● Manual regeneration
Hammer Flow Setting" under the "User Menu",
1) Attachment flow setting and then press the button F6 "Confirmation" to
enter the interface of "Breaking Hammer Flow
When the machine is at the B or ATT mode,
Setting".
press the button "Up/Down" to select the
"Attachment Flow Setting" under the "User
Menu", and then press the button "Confirmation"
to enter the interface of "Attachment Flow
Setting". Accessory device flow setting
Hydraulic hammer flow setting
Breaking hammer flow setting and hydraulic
shear flow setting Flow setting of attachments
Accessory device flow setting

Flow setting of attachments
LG925E4F03215
Flow setting of attachments
LG925E4F03213
LG925E4F03216
When the machine is at the ATT mode, press the

button "Up/Down" to select the "Hydraulic Shear
Flow Setting" under the "User Menu", and then
press the button F6 "Confirmation" to enter the
interface of "Hydraulic Shear Flow Setting".
LG925E4F03214
It can be set only when the working mode is in
ATT mode, and the operation instruction is
similar to that of the breaking hammer.
3-222
User can adjust the flow setting from 1 to 4 level 3) Monitor of over load lifting activation/
through the left /right navigation key. deactivation
After that, press the F6 "√" key for confirmation. This interface only appears at L mode. Press the
Press the F5 "Return" key to cancel the current button "Up/Down" to select the "Monitor of Over
setting. Load Lifting Activation/Deactivation" under the
"User Menu", press the confirmation button to
2) Automatic power boost activation/
enter "Monitor of Over Load Lifting Activation/
deactivation
Deactivation" interface, press the button "Up/
Press the button "Up/Down" to select the Down" to select activation or deactivation and
"Automatic Boost Activation/Deactivation" under complete selection by pressing the
the "User Menu", press the confirmation button "confirmation" button. When choosing activation
to enter "Automatic Boost Activation/ or deactivation, the corresponding box is
Deactivation" interface, press the button "Up/ selected. After operation, press the "Return"
Down" to select activation or deactivation and button to return to the previous menu.
complete selection by pressing the
"Confirmation" button. When choosing activation
or deactivation, the corresponding box is
selected. After operation, press the "Return"
Lift overload monitor start/ disable
button to return to the previous menu.
Start
Auto-boostiiig start/ disable Disable
Start
Disable
LG925E4F03218
LG925E4F03217
3-223
4) Clock adjustment
"Clock adjustment" function is used for setting
the instrument clock. Enter the "Clock
Adjustment" interface through pressing "Up/
Down button" to select "Clock Adjustment" under Language setting
the "User Menu" and then pressing the Chinese
"Confirmation" button. Under the "Clock English
Adjustment" interface, firstly press the "Left/ Portuguese
Right" button to select the desired date, secondly Spanish
press the "Confirmation" button to enter the
Russian
setting status. And then press "Left/Right" button
French
to choose the desired focus; finally, press the
Arabic
"Up/Down" button to change the size and press
the "Confirmation" button to complete
modification and return to the previous step.
Press the Cancel button to return to the previous LG925E4F03220
menu.
6) Brightness setting
"Brightness setting" function is used for
adjustment of LED backlight brightness. Press
Clock setting
the "Up/Down" button to select "Brightness
Setting" under "User Menu" and press the
Confirmation button to enter the "Brightness
Date Setting" interface. And then press the "Up/Down"
button to choose the brightness setting of
Time daytime/nighttime, press the "Left/Right" button
to modify brightness and press Confirmation
button to complete and keep the setting to return
to the previous menu
LG925E4F03219
Brightness setting
5) Language setting
Different languages can be selected (Chinese,
English, etc.) by different customers.
Enter the "Language Setting" interface through
pressing "Up/Down" button to select "Language
Setting" under the "User Menu" and then
pressing the Confirmation button. Press the "Up/
Down" button to select desired language and
press Confirmation button to complete setting
and return to the previous menu.
LG925E4F03221
3-224
7) Current fault
It is used for checking the current faults of the
machine. Enter the "Current Fault" interface
through pressing "Up/Down" button to select
"Current Fault" under the "User Menu" and then Machine info
pressing the Confirmation button.
Machine model
CLG922E
Machine series NO.
DE888888
1) Low engine oil pressure
LG925E4F03223
9) Instrument information
It is used for check the instrument information.
Enter the "Instrument Information" interface
LG925E4F03222 through pressing "Up/Down" button to select
"Instrument Information" under the "User Menu"
8) Machine information and then pressing the Confirmation button. This
interface includes the information of instrument
It is used for checking the machine information.
model, ex-factory date, hardware version,
Enter the "Machine Information" interface
software version, instrument serial number and
through pressing "Up/Down" button to select
product name. The instrument information is kept
"Machine Information" under the "User Menu"
in the instrument and can not be modified. Press
and then pressing the Confirmation button. This
the "Return" button to return to the previous
interface includes the information of machine
menu.
model and machine serial number, etc. The
machine model and machine serial number are
kept in the instrument and can not be modified.
Press the "Return" button to return to the
previous menu. Monitor info
Monitor model
35B0286
Monitor hardware
V11
Monitor software
V17
Monitor series NO.
J06W555555
Product name
WDJLGEVDISP57-10
LG925E4F03224
3-225
10) Controller information 11) Accelerator calibration

It is used for checking the controller information. Accelerator calibration is only applicable to the
Enter the "Controller Information" interface model with mechanical accelerator. Enter the
through pressing "Up/Down button" to select "Accelerator Calibration" interface through
"Controller Information" under the "User Menu" pressing "Up/Down" button to select "Accelerator
and then pressing the Confirmation button. This Calibration" under the "User Menu" and then
interface includes the information of hardware pressing the Confirmation button.
version, software version, controller model.
Operate step by step according to the screen
Press the "Return" button to return to the
indication.
previous menu.
Throttle adjusting
Controller info
Software version
1.22
Hardware version
730 Press YES key to continue throttle setting and
Parameter list mark press RETURN key to go back quit setting!
9225200
Parameter list series No.
1
Parameter list version
122.98
LG925E4F03226
LG925E4F03225
3-226
12) Fan emergency control 13) Fan reverse

When the controller is equipped with fan logic When the controller is equipped with fan logic
control function, the function setting option will be control function, the function setting option will be
displayed for the user to cancel the fan rotation displayed for the user to set the fan reverse at
speed logic control and run at full speed. This full speed. This option is only available before
option is only available after the machine is the machine is equipped with fan control function
equipped with fan control function and the engine and the engine starts (that is, the machine is
starts. equipped with fan control system and the fan is
at static status). After starting the engine, this
Press the button "Up/Down" to select the "Fan
option is not available. If the user wants the fan
Emergency Control" under the "User Menu",
normal mode (forward operation), stop the
press the confirmation button to enter "Fan
engine firstly until the fan is static.
Emergency Control" interface, press the button
"Up/Down" to select activation or deactivation Press the button "Up/Down" to select the "Fan
and complete selection by pressing the Reverse" under the "User Menu", press the
"confirmation" button. When choosing activation confirmation button to enter "Fan Reverse"
or deactivation, the corresponding box is interface, press the button "Up/Down" to select
selected. After operation, press the "Return" activation or deactivation and complete selection
button to return to the previous menu. by pressing the "confirmation" button. When
choosing activation or deactivation, the
corresponding box is selected. After operation,
press the "Return" button to return to the
previous menu.
Fan emergency control
Starting
Fan reverse
Shutting
Starting
Shutting
LG925E4F03227
LG925E4F03228
3-227
User menu structure

1.1.1 Breaking hammer flow setting
1.1 Attachment flow setting
1.1.2 Hydraulic shear flow setting
1.2 Automatic boost activation/deactivation -
1.3 Monitor of over load lifting activation/
-
deactivation
1.4 Clock adjustment
1.5.1 Chinese
1.5.2 English
1.5.3 Portuguese
1.5 Language setting 1.5.4 Spanish
1.5.5 Russian
1 User menu 1.5.6 French
1.5.7 Arabic
1.6 Brightness setting -
1.7 Current fault -
1.8 Machine information -
1.9 Instrument information -
1.10 Controller information -
1.11Accelerator calibration -
1.12 Fan emergency control -
1.13 Fan reverse -
1.14 Forbidden regeneration -
1.15 Manual regeneration -
Appendix 1 - Comparison table of system unit

All system monitor vales are displayed as one of the two units: most of default units are metric system
except for the pressure unit of ISO or British system. The following table lists the units in the display; if
the table of British system is empty, it indicates that the unit is the same as the metric system:
Monitoring variable Default unit ISO British system

Temperature °C °F
Volume L gal
Flow L/h gal/h
Pressure kPa or MPa psi
Rotate speed RPM
Current mA
Voltage V
Percentage %
3-228
3.6.3 Electrical control system
CAN BUS
Sensor signal
Engine controller Control signal Engine
Display
Accelerator
Accelerator knob signal knob
Electric lock signal

Main controller Electric lock
Fuel level signal
Fuel level sensor
GPS Sensor signal
Hydraulic system
LG950E4f03036
Work mode
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.
3-229
Automatic idling function
Engine controller
CAN bus
(Automatic idling command

and working mode command)
Main controller Display

Accelerator knob signal
switch signal
pedal pilot pressure
signal for attachment

Handle pilot pressure
Switching signal of
Secondary pressure switch
LG950E4f03037
Function:
When you are not operating the lever, pedal or attachment control lever, the engine speed will drop to the
preset idle speed so as to achieve the purpose of reducing fuel consumption or noise.
No matter the lever or pedal, either or the control lever of attachment is operated, the engine speed will
restore to the corresponding speed of the current accelerator knob.
Operation:
1) When the handle, foot step and the control lever of the attachment are not handled (without
hydraulic request signal)
If the hydraulic request signal is unavailable within 1s, the engine speed will reduce about 100RPM
based on the current speed. If the hydraulic request signal is still unavailable after 3 minutes, the engine
speed will reduce to the idling speed (about 1000RPM).
2) When the handle, foot step or the control lever of the attachment are operated (with hydraulic
request signal)
When the engine is in idling speed, operate the handle, foot step or the control lever of the attachment,
then the hydraulic request signal is available, and the engine will resume to the speed which the
accelerator knob indicates.
3-230
Note: The hydraulic request signal includes the handle pilot pressure switch signal, foot pilot pressure
switch signal and the attachment secondary pressure switch signal.
Engine speed
(RPM) Level-1 deceleration
Level-2 deceleration
Current speed
Current speed
100RPM
Idling speed
No hydraulic Have hydraulic

Time (s)
request signal request signal
LG950E4f03038
Transient power boosting function
Display
(Automatic power command)

CAN bus
Transient power Control signal for transient

boosting button signal power boosting solenoid valve
Main controller
Transient power boost
solenoid valve
switch signal
P1 pump-pressure signal
Pedal pilot pressure
LG950E4f03039
3-231
Function:
Under the P, E and F mode, it will increase the digging force of the excavator within certain time. Under
the L mode, it will increase the digging force of the excavator continuously. Under the B and ATT mode,
this function is unavailable. When the vehicle is running, the transient power boosting function will be
unavailable.
The transient power boosting function is divided into manual power boosting and automatic power
boosting.
1) Manual power boosting
The operator presses the transient power boosting button to increase the digging force for 8s, then the
button will reset automatically. 10s later, whether the power boosting function being enabled depends on
if the transient power boosting button is pressed or not.
2) Automatic power boosting
The automatic power boosting function can be selected from the display menu. When the P1 pump
pressure signal is detected by the main controller or the P1 pump pressure signal is greater than or
equal to 34MPa (4930psi) and maintains for over 3 seconds, the main controller will output the power
boosting solenoid valve control signal to increase the digging force.
When the conditions of the automatic power boosting function are met, the machine will increase the
digging force for 8s, then the button will reset automatically. 10s later, whether the power boosting
function being enabled depends on if the conditions of the transient power boosting are met or not.
Overheating protection function
Engine controller
Hydraulic oil
temperature signal
and coolant
CAN bus temperature signal
Pump current signal

and engine speed control signal
Main controller
LG950E4f03040
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.
3-232
The overheating protection function is divided into level 1, level 2 and level 3.
Protection
Working conditions Measures Reset conditions
level
Hydraulic oil temperature is Work mode: P
Hydraulic oil temperature:
higher than 86°C (187°F) Engine speed: keep as original
Level 1 less than 82°C(180°F)
or Pump current: reduce the pump current
protection Coolant temperature: less
Coolant temperature is Display: Warning appears
than 100°C
higher than 102°C(216°F) Warning buzzer: Sound
Hydraulic oil temperature is Work mode: P, E, F, L, B and ATT
higher than 88°C(190°F) Engine speed: keep as original
Level 2 less than 82°C(180°F)
or Pump current: reduce the pump current
protection Coolant temperature: less
than 100°C
Hydraulic oil temperature is Work mode: P, E, F, L, B and ATT
less than 82°C(180°F)
higher than 95°C(203°F) Engine speed: speed in 1st gear
Level 3 Coolant temperature: less
or Pump current: pump current in 1st gear
protection than 100°C(212°F)
Accelerator knob: back to the
1st gear position for once
Traveling speed control function
Display
(Travel variable speed command)

CAN bus
Switching signal of pedal pilot pressure

Main controller
Travel shift speed solenoid valve control signal
Travel shift solenoid

LG950E4f03041
3-233
Function: Resistor type temp sensor

The machine travel speed can be changed
artificially and can also be changed automatically 1 2 3
based on the pump pressure during travel.
1) Control the travel speed control key on the
display to switch between the low speed and
high speed.
2) When the travel speed is high, the main
controller will change the travel speed
automatically based on the pressure output
by the pump. If the pump pressure is higher
than 28MPa(4060psi) for at least 1s, the travel LG922E930E03185
speed will be changed as slow speed
automatically. If the pump pressure is less 1. Seal ring
than or equal to 15MPa(2175psi) for at least 2. Sensor
3. Connector
1s, the traveling speed will automatically
recover to high speed. Refer to the following table for the corresponding
relation between the temp sensor resistance and
Travel speed the temperature
Resistance Temperature Temperature

High speed (Ω) (°C) (℉)
169 150 302
191 145 293
215 140 284
Low speed
244 135 275
15MPa 28MPa Pump output
277 130 266
pressure 316 125 257
LG950E4f03042 361 120 248
414 115 239
Various components
476 110 230
Pressure switch 549 105 221
637 100 212
1 2 741 95 203
865 90 194
1015 85 185
1195 80 176
1678 70 158
2401 60 140
P
3509 50 122
10000 25 77
LG922E930E03184 12000 20 68
14800 15 59
1. Switch
2. Connector 19300 10 50
3-234
Temperature The relation between the 500 bar pressure

Resistance Temperature
sensor output current and the pressure is as the
(Ω) (°C) (℉)
following figure.
25000 5 41
31400 0 32 Voltage
40000 -5 23
4.5
52000 -10 14
69000 -15 5
95000 -20 -4
138100 -25 -13
188500 -30 -22 0.5
261500 -35 -31

0 500 Pressure
361100 -40 -40
LG950E4f03044
Voltage type pressure transmitter
1 3
LG922E930E03186
1. COMBINATION CUSHION
2. Sensor
3. Connector
The relation between the 50 bar pressure sensor
output voltage and the pressure is as the
following figure.
Voltage
4.5
0.5
0 50 Pressure
LG950E4f03043
3-235
Fuel level sensor
A
CDNNETOR
B DTO4-2P
1 3
PVC TUBE(BLACK)
CDRRUGATE TUBE
A-direction
B-direction
LG922E930E03189
1. Block 2. Floater 3. Connector

3-236
105.5±4
20
67.75
143.25±4
L21 100％
181±4
218.75±4
L20
265.5±4
95％
294.25±4
L19 90％
332±4
369.75±4
L18 85％
407.5±4
445.25±4
L17 80％ 483±4
L16 75％ 520.75±4
558.5±4
596.25±4
L15 70％
634±4
671.75±4
L14
709.5±4
65％
747.25±4
L13 60％
785±4
L12
808±4
55％
820
L11 50％
L10 45％
L9 40％
L8 35％
L7 30％
L6 25％
L5 20％
L4 15％
L3 10％
L2 5％
L1 液面位置 0％
LG922E930E03190
Percentage Floater position Output resistance (Ω)

0% Below L1 1100±11
5% L1-L2 1050±10.5
10% L2-L3 1000±10
15% L3-L4 950±9.5
20% L4-L5 900±9
25% L5-L6 850±8.5
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
70% L14-L15 400±4
75% L15-L16 350±3.5
80% L16-L17 300±3
3-237
Percentage Floater position Output resistance (Ω)

85% L17-L18 250±2.5
90% L18-L19 200±2
95% L19-L20 150±1.5
100% L20-L21 100±1
Door controlled switch
1 2
LG922E930E03191
1. Switch 2. Connector
Accelerator knob
ʔ40
˄REF.˅
15.875
15°
˄REF.˅
150°=90% PWM 0°=10% PWM

˄REF.˅ ˄REF.˅
15°
150° ˄REF.˅ Guide line Pin
˄REF.˅ Power line $
Slot
Earthing cable %
Signal line &
200±25.4
10.3 Connector:DEUTSCH DT04-3P

˄REF.˅ LG922E930E03192
3-238
Working temperature: -40°C~+85°C.

Working voltage: 5V±0.25V
Output type: PWM
Output current (MAX): 20mA
Corresponding parameters and specifications of each gear
Accelerator gear Pulse width (±3.2%) Rotation angle (°) Voltage (V)
1 10.0 0 0.51~0.52
2 17.27 13.63 0.89~0.90
3 24.55 27.27 1.25~1.26
4 31.82 40.91 1.61~163
5 39.09 54.55 1.97~1.99
6 46.36 68.18 2.34~2.35
7 53.64 81.82 2.71~2.72
8 60.91 95.45 3.07~3.08
9 68.18 109.09 3.43~3.45
10 75.45 122.73 3.80~3.82
11 82.73 136.36 4.16~4.19
12 90.0 150 4.52~4.53
3-239
Controller
254
238
144
128
4× 8
47
29
LG922E930E03193
Black (J1) AMP 776164-1 White (J2) AMP 776164-2
1 12 1 12
24 35 24 35
LG922E930E03194 LG922E930E03195
3-240
J1
of pin function
1 Traveling alarm buzzer High level output Output 24V to the buzzer
2 Battery is always energized Battery voltage 24V, always connect with the battery
7 Fan pressure Analog input Input 0.5 ~ 4.5V
8 Handle pilot pressure switch Number input Low level is valid
9 Coolant level alarm switch Number input Low level is valid
High level is valid, and input 24V when the
10 Engine starting Number input
start switch is turned to "start" position
Input 24V when the start switch is turned
11 Power on Number input
to "on" position
13 Transient power boost solenoid valve High level output Output 24V to drive solenoid valve
14 Power earthing Earthing
18 Hoist overload pressure Analog input Input 0.5 ~ 4.5V
20 Hydraulic oil level warning switch Number input Low level is valid
22 Boom light signal input Number input High level is valid
23 CAN Shield CAN Shield
24 Power supply relay High level output Output 24V to drive the relay
Trenching function proportional
25 High level output Output 24V to drive solenoid valve
solenoid valve
26 Travel lifting solenoid valve High level output Output 24V to drive solenoid valve
27 Flattening solenoid valve High level output Output 24V to drive solenoid valve
28 5V power supply Sensor power supply Output 5V voltage
29 12-gear throttle potentiometer Frequency input PWM signal of variable duty ratio
30 Fan speed Frequency input Input 0-24V voltage signal
31 Hydraulic oil temperature Analog input Resistance signal
32 Rotation secondary pressure Analog input Input 0.5 ~ 4.5V
33 CAN Low CAN Low
34 CAN High CAN High
Form circuit with J2-7 and control the fan
35 Fan relief valve 2 Low level output
relief valve
3-241
J2
of pin function
Form circuit with J2-5 and control the
1 Pump solenoid current feedback Low level output
pump proportional solenoid valve
2 Engine oil pressure switch Number input Low level is valid
3 Power boosting switch Number input Low level is valid
It rotates forward when 0V is output, and it
4 Fan reversing solenoid valve High level output
reverses when 24V is output
Output PWM signal and control the pump
5 Pump solenoid current High level output
proportional solenoid valve
6 Fuel pump relay High level output Output 24V to drive the relay
Output PWM signal and control the fan
7 Fan relief valve 1 High level output
relief valve
Accessory adjusting proportional
8 High level output Output PWM signal
solenoid 2
9 High level output Output PWM signal
solenoid 1
It is low speed when 0V is output and high
10 Track switching solenoid High level output
speed when 24V is output
11 Counterweight unloading function High level output Output 24V to drive solenoid valve
12 ATT solenoid valve High level output Output 24V to drive solenoid valve
13 Foot pedal pressure switch Number input Low level is valid
17 Manual preheating switch Number input High level is valid
19 N1 Negative flow pressure Analog input Input 0.5 ~ 4.5V
Pressure of pump proportional
20 Analog input Input 0.5 ~ 4.5V
pressure-reducing valve
21 Oil water separation warning sensor Number input Low level is valid
22 Sensor to earthing Sensor to earthing
23 Start cut-off valve relay High level output Output 24V to drive the relay
Form circuit with J2-8 and J2-9 and control
Pq1 & Pq2 flow adjusting solenoid
24 Low level output the auxiliary adjustment proportional
valve
solenoid valve 1 and 2
25 Subsidiary secondary pressure switch Number input Low level is valid
26 Engine oil level switch Number input Low level is valid
27 Air filter blocked alert Number input Low level is valid
High level is valid, which is connected to
28 Battery charging indicator switch Number input
the P point of the engine
30 Fuel level Analog input 0.5 Voltmeter signal
3-242

of pin function
31 P1 left pump pressure Analog input Input 0.5 ~ 4.5V
32 P2 right pump pressure Analog input Input 0.5 ~ 4.5V
33 N2 Negative flow pressure Analog input Input 0.5 ~ 4.5V
Note: NC indicates that the stitch is not adopted.
3.6.4Descriptions of partial circuits
Travel 2-speed circuit
IPC Controller -
Track switching solenoid
(valve A2) - :+
A2Travel speed solenoid
$

*<
*1'
LG922E930E03196
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.
3-243
Transient pressure boosting circuit
Transient power boosting button (right)

:+
*<
IPC Controller -
Power boosting switch -
A7 Power boost solenoid valve
-
$
Instantaneous power solenoid
- :+
(valve A7)
*<
*1'
LG922E930E03197
When the transient power boosting button is pressed, the J1-13 pin of the main 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 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.
3-244
Start circuit
LG950E4f03045
● When the electric lock (also called as start 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 coil circuit is conducted, making
the starter relay 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 K11 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.
● When the electric lock is turned to Start position, J5-83 of the engine ECM outputs 0V voltage to
ECM control starter relay K9 coil, making the ECM control the starter relay K9 main contact always in
the closed state.
1) Starter motor circuit:
"Battery positive pole — battery relay main contact — starter motor 30 end—starter relay main con-
tact — starter motor 50 end— starter motor — GND"
2) Battery relay coil circuit
"Battery positive pole — 50A fuse — electric lock power supply 20A (fuse box) — ignition switch B1
end — start switch B2 end — diode — battery relay coil — groud"
3) Starter relay coil circuit:
3-245
"Battery positive pole — 50A fuse — electric lock power supply 20A fuse (fuse box) — ignition switch
B1 end — ignition switch S end — pilot control starter relay K7 main contact (fuse box) — controller
control starter relay K8 main contact (fuse box) — ECM control starter relay K9 main contact (fuse
box) — starter relay K1 coil — earthing"
4) Pilot control starter relay K7 coil circuit:
"Battery positive pole — battery relay main contact — 50A fuse — pilot shut off 10A (fuse box) —
safety relay K11 main contact (fuse box) — pilot shut-off valve switch main contact — pilot control
starter relay K7 coil (fuse box) — earthing"
5) Starter relay K11 coil circuit:
"Battery positive pole — 50A fuse — electric lock power supply 20A (fuse box) — ignition switch B1
end — ignition switch B2 end — safety relay K11 coil (fuse box) — earthing"
6) Controller control starter relay K8 coil circuit:
"J2-23 pin of controller — controller control starter relay K8 coil (fuse box) — earthing"
7) ECM control starter relay K9 coil circuit:
"the pin J5-83 of the engine ECM — ECM control starter relay K9 coil (fuse box) — the pin J5-76 of
the engine ECM"
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 B1 end and the B2 end of the
start switch are conducted with the S end.
3-246
Trenching function circuit
IPC Controller -
Digging function solenoid
Valve A8 - :+
A8 Digging function solenoid
$

*<
*1'
LG922E930E03198
When the trenching function key on the display is pressed, the J1-25 pin of the main 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
outputs 0V voltage to the trenching 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.
3-247
Flattening function circuit
IPC Controller -
Flattening solenoid valve :+
(valve A3) -
A3 arm speed 2-position solenoid valve
$

*<
*1'
LG922E930E03199
When the flattening function key on the display is pressed, the J1-27 pin of the main 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.
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.
3-248
Charge circuit
Battery charging indicator switch J2-28

Main power switch
Battery
Starting relay
Starting motor
Battery relay Engine ground
LG950E4f03046
J2-28 pin of the main controller will monitor the L end of the alternator.
The current output from the B end of the alternator charge the battery via the wire 120, fuse 100A, wire
105, main contact of battery relay.
Working circuit of pump proportional solenoid valve
Pump proportional solenoid
IPC Controller -
$
Pump solenoid current feedback - :+

-
Pump solenoid current
(Main pump PWM signal) - :+
LG922E930E03201
The main controller will output PWM signals to the pump proportional solenoid valve according to the
matching strategy of pump power and engine output power.
3-249
Wiper working circuit
Wiper and
washer 10A
LG950E4f03047
Wiper has 5 working states: wiper resetting position, wiper slow speed position, wiper fast speed
position, wiper intermittent position and wiper spraying position. Only when the front window of the cab is
closed and the door control wiper switch is closed, the wiper enters standby state.
Wiper resetting position: when the wiper is in "0" position, the wiper motor stops and it is reset to the
initial position.
Wiper slow speed position: when the wiper is in "1" position, the wiper motor works in slow speed
position.
Wiper fast speed position: when the wiper is in "2" position, the wiper motor works in fast speed position.
Wiper intermittent position: when the wiper switch is in "0" position, press the wiper intermittent position
switch, the wiper motor will work for a cycle, after 5 s, it works another cycle.
Wiper spraying: when the wiper switch is in "0" position, press the spraying switch, the washer motor
sprays once, and the wiper motor works forward and backward twice. When the wiper switch is in "1" or
"2" position, press the spraying switch, the washer motor sprays once, and the wiper motor works in
cycles according to the speed of the current position.
3-250
1) Wiper relay coil circuit: relay—end R of the wiper motor—wiper

motor—GND"
"Battery positive pole — battery relay main
contact — fuse 50A — wiper, washer 10A—
end 86 of wiper relay K6—wiper relay coil—
end 30 of wiper relay K6—end 87A of wiper
end 85 of wiper relay K6—door control wiper
relay K6—spraying switch 1#—spraying
switch—GND"
switch 5#—washer motor—GND"
2) Wiper fast speed position circuit:
relay K6—wiper switch 3#—wiper switch
1#—end H of wiper motor—wiper motor—
GND"
3) Wiper slow speed position circuit:
5#—end L of wiper motor—wiper motor—
GND"
4) Wiper resetting position circuit:
7#—end S of wiper intermittent relay—end
31b of the wiper intermittent relay—end R of
the wiper motor—wiper motor—GND"
5) Wiper intermittent position circuit:
relay K6—wiper intermittent position switch
1#—wiper intermittent position switch 5#—
end I of wiper intermittent relay—end 31b of
the wiper intermittent relay—end R of the
wiper motor—wiper motor—GND"
6) Wiper sraying position circuit:
relay K6—spraying switch 1#—spraying
switch 5#—end 86 of wiper intermittent
relay—end 31b of the wiper intermittent
3-251
Counterweight loading and unloading work circuit
Counterweight unloading function J2-11
Counterweight unloading
function solenoid valve J1-26
LG950E4f03048
When select the counterweight loading and unloading function on the display, the pin J2-11 of the main
controller outputs 24V voltage to the relay circuit of the counterweight loading and unloading function.
Disconnect the ground wire of the pilot shut-off solenoid valve, the pilot shut-off solenoid valve coil is
powered off, and the pilot oil line is shut off.
When select the counterweight loading and unloading function key on the display, the pin J1-26 of the
main controller outputs 24V voltage to travel lifting solenoid valve. Travel lifting solenoid valve is closed.
Note: After the counterweight loading and unloading function is started, the coil of the pilot shut-off
solenoid valve is powered off, the pilot shut-off solenoid valve is shut off, and the pilot oil line is shut off,
and the boom, arm, bucket, swing and travel function are locked.
3-252
Variable speed fan work circuit
Fan speed J1-30

Fan relief valve 2 J1-35
Fan reversing solenoid valve J2-4

Fan relief valve 1 J2-7
Sensor to earthing J2-22
LG950E4f03049
Main controller
receives the fan speed sensor signal via pin J1-30 and pin J2-22, and measures the speed of the
variable speed fan.
Based on the informations of hydraulic oil temperature, engine water temperature, fan speed etc., the
main controller makes logical operation,
and outputs PWM signal and controls the fan relief valve, accordingly the speed of the variable speed
fan is controlled.
When select the reversing function of the variable speed fan on the display, the pin J2-7 of the main
controller outputs 24V voltage to the variable fan reversing solenoid valve coil, and the variable speed
fan reversing solenoid valve is energized, and the fan rotates reversely.
3-253
Attachment swing work circuit
LG950E4f03050
When the the right swing button of the attachment on the hydraulic shear control switch (Left hydraulic
handle) is pressed, the pin 1# of the hydraulic shear control switch outputs 24V voltage to the right swing
solenoid valve of the attachment.
When the the left swing button of the attachment on the hydraulic shear control switch (Left hydraulic
handle) is pressed, the pin 2# of the hydraulic shear control switch outputs 24V voltage to the left swing
solenoid valve of the attachment.
3-254
Attachment opening and closing work circuit
LG950E4f03051
When the the attachment button on the hydraulic shear opening and closing switch (Right hydraulic
handle) is pressed, the pin 1# of the hydraulic shear opening and closing switch outputs 24V voltage to
the opening and closing solenoid valve of the attachment.
When the the attachment button on the hydraulic shear opening and closing switch (Right hydraulic
handle) is pressed, the pin 2# of the hydraulic shear opening and closing switch outputs 24V voltage to
the opening and closing solenoid valve of the attachment.
4-1
September 3, 2019 Parameters
CLG950E
4 Parameters
4.1 Basic Parameters.....................................................................................................4-4

4.2 Performance Parameters of Diesel Engine............................................................4-10
4.3 Performance Parameters of Complete Machine ....................................................4-11
4-2
Parameters September 3, 2019
CLG950E
4-3
CLG950E
The unit conversion involved in this paragraph please refer to the table below
Parameters Metric unit British unit Multiple

mm In 0.03937
Length
mm ft 0.003281
L US gal 0.2642
Capacity L US qt 1.057
m³ 3 1.308
Yd
Weight kg lb 2.205
N kgf 0.10197
Intensity
N lbf 0.2248
Nm kgf·m 0.10197
Torque
Nm lbf·ft 0.7375
MPa kgf/cm3 10.197
Pressure
MPa psi 145.0
kW PS 1.360
Power
kW HP 1.341
Temperature °C °F °C×1.8+32
km/h mph 0.6214
Speed
min-1 rpm 1.0
L/min US gpm 0.2642
Flow
mL/rev cc/rev 1.0
4-4
4.1 Basic Parameters CLG950E
4.1Basic Parameters
The machine is applicable for digging and loading the earth of I-IV level (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 the engineering operation, this machine can also be installed with
various work implements such as backacting shovel, crowd shovel, hydraulic breaker, plum claw, etc.
Altitude: ≤2438m*(7998'8")
Ambient temperature: -23°C~ 40 °C(-9.4~104°F)
Fording depth: no matter what kind of position (horizontal or slope) the machine is in, the fording depth is
not allowed to exceed the center of the carrier roller.
Main technical parameters
All rated operation of the machine are obtained when the machine operates on hard horizontal
supporting surface. If the working environment conditions of the machine are different from the above
reference conditions (for example, working on soft or uneven ground or slopes), then operator shall
consider these conditions.
Dimension drawing
LG950E4f04001
Complete vehicle parameters
Items Unit Parameters

Engine model Cummins QSG12/ X12
Operating weight kg 47000/48000(103635/105840 lb)
Standard bucket capacity m3 2.2(581.2 US gal)
Running speed (high/low) km/h 0~5.5,0~3.3(0~3.4mph,0~2.1mph)
Swing speed r/min 8.5(8.5rpm)
Gradeability 35° (70%)
Pressure to the ground (track width is 600mm) KPa 83.1(12psi)
4-5
CLG950E 4.1 Basic Parameters
Items Unit Parameters

J: Overall length mm 11515(37'9")
Overall width (track width is 600mm) mm 3340(10'11")
Overall height mm 3810(12'6")
D: Height of cab roof mm 3307(10'10")
E: Total width of the upper platform mm 3170(10'5")
*H: Counterweight ground clearance mm 1324(4'4")
*C: Minimum ground clearance mm 532(1'9")
I: Tail end length of the upper platform mm 3627(11'11")
End rotating radius mm 3640(11'11")
G: Frame axle base mm 4257(13'11")
F: Frame length mm 5256(17'3")
A: Frame track distance mm 2740(9'0")
B: Frame width (track width is 600mm) mm 3340(10'11")
Note: The sizes with * exclude track height.
Components parameters
Component Items Unit Parameters

Model Cummins QSG12 Cummins X12
Turbo charged and air to air intercooling/
Type
high pressure
Stage 4 of European and American off-
Emission
highway vehicle
Cooling mode Water cooling
Ignition order 1-5-3-6-2-4
Cylinder bore X stroke mm 132X144(5.2 In×5.6 In)
Cylinder displacement L 11.8(3.1 US gal)
Compression ratio 17:1
Engine Rated power 298kW(400HP)/2100r/min
Net power 303kW(407HP)/1900r/min
Maximum torque (1400 r/min) N.m 2034(1500 lbf-ft)
Engine oil level L 37.8(10 US gal)
Net weight of diesel engine kg 860(1896.3 lb)
Maximum no-load rotate speed r/min 2160 2130
Minimum no-load rotate speed r/min 800
Rated fuel consumption rate g/kW.h 226
Starter motor 24V-7.5kW
Alternator 24V-70A
4-6

Main pump Double axial variable plunger pump
Max. flow of system L/min 2X380(2×100.4 US gal)
Main relief valve Setting pressure MPa 32.3(4683.5 psi)
When instantaneously
MPa 35.3(5118.5 psi)
supercharging
Big chamber/small
Setting pressure MPa 37.2(5394 psi)
chamber of boom
of outlet safety
valve Big chamber/small
MPa 37.2(5394 psi)
chamber of arm
Big chamber/small
MPa 37.2(5394 psi)
chamber of bucket
Relief valve setting pressure of swing
MPa 28(4046 psi)
motor
Hydraulic system
Safety valve setting pressure of travel
MPa 32.3(4683.5 psi)
motor
Pilot pump Gear pump
Pilot circuit MPa 3.9(565.5 psi)
Quantity - bore × rod 2-φ165×φ115×1560
mm
Boom cylinder diameter × stroke (2-φ6.5 In×φ4.5 In×61.4 In)
Buffer When stretching out
mm
Arm cylinder diameter × stroke (1-φ7.5 In×φ5.1 In×78 In)
Buffer When stretching out and withdrawing
mm
Bucket cylinder diameter × stroke (1-φ6.7 In×φ4.7In×49.6 In)
Buffer When stretching out
Boom (standard configuration) mm 7060(23'2")
Work implement
Arm (standard configuration) mm 3900(12'9")
Track shoe width mm 900(35.4 In)
Track assembly Bar 2
Number of track shoe (each bar) 51
Track tension device Piece 2
Travel device
Sprocket Piece 2
Idler assembly Piece 2
Track roller 9 at each side
Carrier roller 2 at each side
System voltage V 24
Electrical system
Battery 2×12V
4-7

Refrigerating capacity W 5000
Cooling air output m3/h 550
Heating capacity W 5800
Heating air output 3 400
m /h
Voltage V.DC 24
Air conditioning
system Total power consumption W ≤310
Compressor shaft power kW 3.02
Refrigerant R134a
Refrigerant filling quantity g 950±50(2.09±0.11 lb)
Compressor 10S15C (Denso compressor)
Refrigeration oil ND-OIL8 (Denso special compressor oil)
4-8
Scope of work
LG950E4f04002
4-9
Items Parameters
Arm length 2900mm 9'6"
Boom length 7060mm 23'2"
*A: Maximum digging height 10618mm 34'10"
*B: Maximum unloading height 7578mm 24'10"
*C: Maximum digging depth 7380mm 24'3"
*E: Maximum vertical digging depth 6011mm 19'9"
H: Maximum digging radius 11585mm 38'0"
G: Maximum ground digging radius 11368mm 37'3"
*D: Maximum digging depth (2.5m horizontal plane) 7218mm 23'8"
F: Minimum swing radius 5052mm 16'7"
Maximum digging force of bucket (ISO) 287kN 94517.6lbf·ft
Maximum digging force of arm (ISO) 263kN 59122.4lbf·ft
Note: The sizes with * exclude track height.
4-10
4.2 Performance Parameters of Diesel Engine CLG950E
4.2Performance Parameters of Diesel Engine
Name Parameters
Engine model Cummins QSG12/X12
Turbo charging plus air-air inter-cooling/direct injection/water
Mode
cooling
Number of cylinder 6
Cylinder diameter x stroke 132mm×144mm(5.2 In×5.6 In)
Displacement 11.8 L(3.1 US gal)
Compression ratio 17: 1
Ignition order 1-5-3-6-2-4
Rated power 298kW(400 HP)/2100RPM
Maximum power 322kW(432 HP)/1600RPM
Maximum torque 2034N·m(1500 lbf-ft)/1400RPM
Engine oil volume 34L(9 US gal)
Fan 8—φ1050mm(8—φ41.3 In)
Starter motor 24V-7.5kW
Air intake heater 24V-142A
Alternator 24V-70A
Intake valve 0.36mm(0.014 In)
Valve lash
Exhaust valve 0.69mm(0.028 In)
Opening temperature 82°C-88°C(179.6°F—190.4°F)
Thermostat
Full open temperature 88°C(190.4°F)
4-11
CLG950E 4.3 Performance Parameters of Complete Machine
4.3Performance Parameters of Complete Machine
Performance
Items Unit
temperature
Minimum speed (idling) 1000±30
Engine speed (A/C OFF) r/min
Maximum speed (idling) 1950±30
Rabbit position/forward 12.9±1.5
Rabbit position/backward Sec/20m 12.9±1.5
Running speed (Sec/
Tortoise position/forward 65'7") 21.6±2.5
Tortoise position/backward 21.6±2.5
Tortoise position/
37.5±2.5
forward
Tortoise position/
37.5±2.5
backward
Track-lh
Rabbit position/
22.7±1.5
forward
Rabbit position/
22.7±1.5
Travel speed backward
Sec/3rev
(Idling speed) Tortoise position/
37.5±2.5
forward
Tortoise position/
37.5±2.5
backward
Track-rh
Rabbit position/
22.7±1.5
forward
Rabbit position/
22.7±1.5
backward
Tortoise position ≤100(3.9 In/65'7")
Travel deflection mm/20m
Rabbit position ≤100 (3.9 In/65'7")
Swing speed Sec/3rev 21±1.5
Counterclockwise ° ≤200
Swing service brake angle
Clockwise ° ≤200
Vertical direction mm ≤0.65(0.256in)
Swing bearing clearance
Horizontal direction mm ≤80(3.15in)
Boom cylinder stretches out 4.13±0.4
Hydraulic oil cylinder Boom cylinder retracts /
action time (with the air Extension of arm cylinder 4.69±0.4
conditioner closed and the sec
engine at the maximum Arm cylinder retracts 3.35±0.4
speed) Bucket cylinder stretches out 2.73±0.4
Bucket cylinder retracts 2.11±0.4
Retraction of boom cylinder (mm) ≤10(0.39 In)
Stretch of arm cylinder (mm) mm/ ≤10(0.39 In)
Cylinder settlement
Retraction of arm cylinder (mm) 10min ≤50(1.97 In)
Retraction of bucket cylinder (mm) ≤50(1.97 In)
4-12
4.3 Performance Parameters of Complete Machine CLG950E
Performance
Items Unit
temperature
Boom control lever 10±2(2.25±0.45lbf)
Arm control lever 10±2(2.25±0.45lbf)
Bucket control lever 10±2(2.25±0.45lbf)
Control force of control
Swing control lever N 10±2(2.25±0.45lbf)
lever
Travel control lever 17±1(3.82±0.22lbf)
Travel control pedal (forward) 60±5(13.49±1.12lbf)
Travel control pedal (backward) 70±10(13.49±1.12lbf)
Boom control lever 85±10(19.11±2.25lbf)
Arm control lever 85±10(19.11±2.25lbf)
Control lever stroke Bucket control lever mm 85±10(19.11±2.25lbf)
Swing control lever 85±10(19.11±2.25lbf)
Travel control lever 150±10(33.72±2.25lbf)
Bucket unloaded, boom lifting, upper frame
sec 4.0±0.1
revolving 90°
Check of boom lifting and
swing action Platform is rotated by 90°, and the tooth ground
clearance after the boom lifting action is mm 7460(23'2")
finished.
Adjustment of pilot Engine: high idle MPa 3.9~4.1(565.5~594.5 psi)
pressure Engine: low idle MPa 3.7~4.1(536.5~594.5 psi)
The boom is lifted MPa 3.9~4.1(565.5~594.5 psi)
The boom is lowered MPa 3.9~4.1(565.5~594.5 psi)
The arm retracts MPa 3.9~4.1(565.5~594.5 psi)
The arm stretches out MPa 3.9~4.1(565.5~594.5 psi)
Secondary pilot pressure Left swing MPa 3.9~4.1(565.5~594.5 psi)
(Handle full stroke) Right swing MPa 3.9~4.1(565.5~594.5 psi)
The bucket is rolled in MPa 3.9~4.1(565.5~594.5 psi)
The bucket stretches out MPa 3.9~4.1(565.5~594.5 psi)
Forward MPa 3.9~4.1(565.5~594.5 psi)
Backward MPa 3.9~4.1(565.5~594.5 psi)
Pressure of main relief valve MPa 34.3+1(4973.5±145psi)
Left swing MPa 26±0.5(3770±72.5psi)
Main circuit pressure
Right swing MPa 26±0.5(3770±72.5psi)
Drive (travel hold pressure) MPa 34.3+1(4973.5±145psi)
The boom is lifted MPa 39±0.5(5655±145psi)
The boom is lowered MPa 39±0.5(5655±145psi)
Pressure testing of oil port The arm retracts MPa 39±0.5(5655±145psi)
relief valve The arm stretches out MPa 39±0.5(5655±145psi)
Rolling in of bucket (large cavity) MPa 39±0.5(5655±145psi)
Stretch in of bucket (small cavity) MPa 39±0.5(5655±145psi)
Main pump flow L/min 380×2(100.4×2US gal/min)
4-13
CLG950E 4.3 Performance Parameters of Complete Machine
Performance
Items Unit
temperature
Swing motor oil unloading
Oil drainage pressure MPa ≤0.2(29psi)
(oil drainage)
Travel motor oil unloading
Oil drainage pressure MPa ≤0.2(29psi)
(oil drainage)
4-14
4.3 Performance Parameters of Complete Machine CLG950E
5-1
September 3, 2019 Testing and Adjustment
CLG950E
5 Testing and Adjustment
5.1 Performance Test of Complete Machine..................................................................5-3

5.1.1 Diesel engine speed....................................................................................................................5-4
5.1.2 Travel speed (idling speed) .........................................................................................................5-4
5.1.3 Measurement of running speed (actual measurement speed)....................................................5-5
5.1.4 Travel deflection ..........................................................................................................................5-6
5.1.5 Swing service brake angle ..........................................................................................................5-7
5.1.6 Swing speed................................................................................................................................5-9
5.1.7 Swing bearing clearance ...........................................................................................................5-10
5.1.8 Action time of cylinder ...............................................................................................................5-11
5.1.9 Cylinder settlement....................................................................................................................5-14
5.1.10 Operating force of control lever .................................................................................................5-15
5.1.11 Control lever stroke ...................................................................................................................5-15
5.1.12 Boom lifting and swing action....................................................................................................5-15
5.1.13 Pilot pressure ............................................................................................................................5-16
5.1.14 Secondary pilot pressure...........................................................................................................5-17
5.1.15 Output pressure of solenoid proportional valve.........................................................................5-19
5.1.16 Setting pressure for main relief valve ........................................................................................5-20
5.2 Other Tests ............................................................................................................5-25

5.2.1 Measurement of blow-by of crankcase......................................................................................5-27
5.2.2 Measurement and adjustment of track tension .........................................................................5-34
5.2.3 Inspection and adjustment of minus feedback pressure N1......................................................5-35
5.2.4 Inspection and adjustment of minus feedback pressure N2......................................................5-37
5.2.5 Release of remaining pressure in hydraulic oil lines .................................................................5-38
5.2.6 Exhaust of various devices........................................................................................................5-39
5.2.7 Inspection procedures of diode .................................................................................................5-41
5.2.8 Performance test of travel motors and reduction gears ............................................................5-42
5-2
Testing and Adjustment September 3, 2019
CLG950E
5-3
CLG950E 5.1 Performance Test of Complete Machine
5.1Performance Test of Complete Machine
The standard values of the tested data involved in the Chapter are as follows:
(1) Standard value list of diesel engine speed
Model CLG950E(TIER IV)

Gear Gear Gear
Gears Gear 1 Gear 2 Gear 3 Gear 4 Gear 5 Gear 6 Gear 7 Gear 8 Gear 9
10 11 12
Idling
1000± 1100± 1200± 1350± 1550± 1600± 1650± 1750± 1800± 1850± 1900± 1950±
speed (r/
50 30 30 30 30 30 30 30 30 30 30 30
Mode P
min)
Current
300±1 360±1 390±1 520±1 520±1 550±1 550±1 560±1 580±1 580±1 600±1
setting 0~20
0 0 0 0 0 0 0 0 0 0 0
(mA)
Idling
1000± 1100± 1200± 1350± 1450± 1500± 1550± 1650± 1700± 1750± 1800± 1850±
speed (r/
50 30 30 30 30 30 30 30 30 30 30 30
Mode E
min)
Current
280±1 350±1 390±1 420±1 500±1 510±1 520±1 530±2 550±1 570±1 580±1
setting 0~20
0 0 0 0 0 0 0 0 0 0 0
(mA)
(2) For the standard performance parameters of the complete machine, please see the section 4.3.
First test whether diesel engine speed reaches technical specification before all other tests,
because if diesel engine speed is not adjusted correctly, the data of all other performances are
not reliable.
5-4
5.1 Performance Test of Complete Machine CLG950E
5.1.1Diesel engine speed 5.1.2Travel speed (idling speed)
Tools and testing instrument Tools and testing instrument
1. Reflective sheeting 1. Stopwatch.

2. Tachometer 2. Tool used for marking starting point.
Preparations 3. Test is performed by two people.
Turn off the air conditioner and the automatic Machine state and parking site
idling, there is no load, and turn the gear to
1. Solid and flat parking site
the position to be tested.
2. Maintain hydraulic oil temperature between
Test method 45°C and 55°C(113~131°F)
1. Open the diesel engine hood. 3. Set the engine in 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 working current of the pump 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. Start the engine, shift the gear to the one to 6. The working pressure and the pilot pressure
be tested and shine the area attached with of the pump are within the normal range.
reflector paper using tachometer if it is safe to
do so and the diesel engine speed can be Travel speed test
obtained from the meter.
1. Park the machine at a solid and flat site.
4. Repeat measurement three times and
calculate average value. 2. Maintain hydraulic oil temperature between
45°C and 55°C(113~131°F)
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 as shown in
the Figure below
PP
LG922EIII05001
5-5
5. Lower the boom until the right track is raised 5.1.3Measurement of running
for about 100 ~ 200 mm(3.94~7.87In) from
the ground to keep the track away from the
speed (actual measurement
ground during operation as shown in Figure speed)
1. Mark on the appropriate position of the
track.
Tools and testing instrument
6. Set accelerator linkage or knob to the top
position of engine speed. 1. Stopwatch.
7. Turn the travel speed selection switch to gear 2. 50m(164’5’’) measuring tape.
"1" (tortoise ). 3. Test is performed by two people.
8. Push the right travel control lever to the front
Machine state and parking site
end, and then measure and record the time
for the right track swinging 3 circles. 1. Solid and flat parking site
9. Repeat the Step 7 and 8 to totally measure 2. Maintain hydraulic oil temperature between
three times. Calculate the average value of 45°C and 55°C(113~131°F).
the data based on the three measurements.
3. Set the engine in the maximum speed (turn
10. Measure the data of the right track "1" off A/C).
position (tortoise position) backwards using
the same method. 4. The working current of the pump is within the
normal range.
11. Turn the travel speed selector switch to "2"
position (rabbit position), repeat the Step 8 to 5. The complete machine works in the normal
10, and compare the average value of mode.
measured data with the standard values in 6. The working pressure and the pilot pressure
the Table below. of the pump are within the normal range.
12. Lift the boom till the bottom of the bucket off
the ground 300 mm(11.8In). Operate the left Travel speed test
swing and turn the upper mechanism by
1. Park the machine in a solid and flat site (the
180°.
flat site for straight travel about 30m(98'5").
13. Repeat the step 4 to 11, and measure the
2. Maintain the hydraulic oil temperature
travel speed of the left track in same way.
45°C~55°C(113~131°F).
14. Refer to attached table 1 for test table.
3. Operate the work implement and make it at
the transport status, as shown in Figure
below.
LG922EIII05002
5-6
4. Draw a 30m(98'5") line on the ground starting 5.1.4Travel deflection

from the track front end, and then draw
another line approx. 10m (32'10") away from
the starting point and make it paralleled with Tools and testing instrument
the machine. As shown in Figure below.
1. Tape (30m(98'5")).
2. Tool used for marking the location of the
machine.

At the start At the end 45°C and 55°C(113~131°F).
timing point
P P
LG950EIII05095 off A/C).
5. Set accelerator linkage or knob to the top 4. The working current of the pump is within the
position of engine speed. normal range.
6. Turn the travel speed selection switch to gear 5. The complete machine works in the normal
"1" (tortoise ). mode.
7. Driving into the test road, the front 6. The working pressure and the pilot pressure
10m(32'10") of which is for acceleration, at of the pump are within the normal range.
the steady speed. Starts timekeeping when 7. The maximum wind speed shall be no more
the front end of the track enters the timing than 6m/s during the test.
line and stop it when the front end of the track
reaches the finishing line. Record the time for Travel deflection test
the machine running through the test road.
As shown in the above Fig. 1. Park the machine at a solid and flat site.
8. Repeat step 7 to measure three times, and 2. Maintain hydraulic oil temperature between
calculate average value of measured data for 45°C and 55°C(113~131°F).
three times. 3. All work implements, such as boom, arm and
9. Rotate the upper mechanism by 180°, and bucket cylinder, all extend, as shown in
measure the data of the right track "1" Figure below.
position backwards (tortoise position) using
the same method.
10. Turn the travel speed selector switch to "2"
position (rabbit position) and repeat steps
6~9.
11. Refer to attached table 1 for test table.
LG926E5003
5-7
4. Draw a line of 25m(82'0") on the ground 11. Rotate the lower mechanism by 180°, repeat
starting from the track front end and make the Step 3 ~10, and measure the travel
the line paralleled to the machine. Draw a deflection values when the excavator
line at each position about 5m(16'5") and reverses and compare them with the
15m(49'3") away from the front end of standard values in the Table below.
excavator track and at the finishing point
12. Refer to attached table 2 for travel deflection
respectively.
test table.
position of engine speed.
5.1.5Swing service brake angle
6. Turn the travel speed selection switch to gear
"1" (tortoise ).
7. Push forward the left and right travel control
lever to the topmost at the same time. The
excavator reaches the position about 5m Please confirm that testing site allows 360°
(16'5") away from the starting point, where swing of the machine! Please confirm that
mark A on the track on the relative location of there are no other personnel or facilities
the ground. Similarly, mark B and C correctly within 3m scope of swing area!
when the excavator reaches the position
about 15m(49'3") away from the starting
point and to the finishing point. As shown in Tools and testing instrument
the Figure below
1. Tool used for marking starting point.
2. Measuring tape.
$ %
HG
&
3. Plumb.
4. Measurement is performed by three person.

P P P
LG922EIII05005 45°C and 55°C(113~131°F).
8. Measure the perpendicular distance "e" of off A/C).
point "B" to straight line AC on the track.
4. The working current of the pump is within the
9. Repeat the Step 7 and 8 to totally measure normal range.
three times. Calculate average value of
measured data for three times. 5. The complete machine works in the normal
mode (and the idling state).
10. Turn the travel speed selection switch to gear
"2" (rabbit), repeat steps 7~9 and measure 6. The working pressure and the pilot pressure
the travel deflection value at gear "2" of the pump are within the normal range.
(rabbit).
Swing service brake angle test

5-8
3. Extend the arm completely (retract cylinder) , 7. After operation is allowed by whistling,
as shown in Figure below. operate swing pilot valve to maximum stroke,
and swing one circle clockwise with fastest
speed. When the bucket arrives at starting
position, release pilot valve to make the
machine stop operating naturally, as shown
in the Figure below.
1.5m B
L2 L1
L1+L2
LG922EIII05006
A a
L1+L2
LG922EIII05007
8. Measure the distance between A and B with

the tape (chord length which swing angle
corresponds to).
LG950EIII05003 9. Repeat the steps 6 and 7, measure three
times in all and calculate the average value.
4. Retract the bucket completely (extend
cylinder), as shown in Figure below. 10. Measure the distance between A and B
during anticlockwise swing with the same
5. Adjust boom height till the distance reaches method.
1.5m(4'11") between bucket tooth and the
ground. 11. Refer to attached table 3 for swing service
brake angle test table.
6. Confirm the projection point of middle tooth
of bucket on the ground with plumb bob and
make corresponding mark A, measure the
distance L2 of the projection point to the track
front end, and get the distance L1 of swing
bearing center to track front end.
Please honk the horn before swing action!

5-9
5.1.6Swing speed 3. Extend the arm completely (retract cylinder) ,

as shown in Figure below.
Please confirm that testing site allows 360°

swing of the machine! Please confirm that
there are no other personnel or facilities
within 3m scope of swing area!

LG922EIII05008
1. Stopwatch.
2. Tool used for marking starting point. 4. Retract the bucket completely (extend
cylinder).
3. Two test personnel who are familiar with
operating the excavator. 5. Adjust the height to make the bottom of the
bucket at the height of boom hydraulic
Machine state and parking site cylinder articulated axle.
45°C and 55°C(113~131°F). Please honk the horn before swing action!
off A/C). 6. After operation is allowed by whistling,
operate swing right pilot valve to maximum
4. The working current of the pump is within the stroke, swing clockwise with fastest speed,
normal range. start timekeeping from third circle, record the
5. The complete machine works in the normal time for three circles in total, and then stop
mode. swing.
6. The working pressure and the pilot pressure 7. Repeat the Step 3 to 6 to totally measure
of the pump are within the normal range. three times. Calculate average value of the
measured clockwise swinging time for three
Swing speed test times.
8. Measure the time of anticlockwise swinging 3
circles with the same method.
9. Refer to attached table 4 for swing speed test
table.
5-10
5.1.7Swing bearing clearance 2. As shown in the Figure below, install magnet

base on swing bearing support, and the
probe of dial indicator contacts with mounting
Swing bearing clearance (vertical direction) bolt of swing bearing outer ring.
In front of machine
1. Dial indicator.
2. Dial gage bracket (can be rotated freely).
3. Tape measure.
4. Measurement is performed by two people.

Magnet base
Dial
2. Maintain hydraulic oil temperature between indicator
45°C and 55°C(113~131°F).
LG922E930E05014
off A/C). 3. Operate the arm to retract or stretch out to
4. The working current of the pump is within the make the included angle between it and
normal range. boom is about 90°, as shown in figure below.
5. The complete machine works in the normal 4. Operate the bucket to retract or stretch out to
mode. make bucket bottom parallel with the ground.
6. The working pressure and the pilot pressure 5. Lower the boom to make bucket bottom
of the pump are within the normal range. contact with the ground. Continue to lower
the boom, and jack up the machine at front
end to the height of 450mm(17.7In) from
track to the ground, as shown in Figure
below.
Pay close attention to the machine
conditions when reading the dial indicator!
During maintenance and test, the qualified
protective suit, safety shoes and helmet must
be worn. Make sure that there are no barriers 90o
within the maximum swing radius.
Measurement of swing bearing clearance 450mm

(vertical direction)

LG922E930E05015
6. Place the pointer of dial indicator to position

"0".
7. Lift boom and release arm till extend the arm
completely, as shown in Figure below.
5-11
8. Release the bucket completely, and lift or 5.1.8Action time of cylinder

lower boom to make the distance between
bucket tooth and ground is 450mm(17.7"), as
shown in Figure below.
Be sure to move the machine (standard

configuration) out of the route of other
machines before testing so that there are no
obstacles within maximum swing radius.
Other personnels can not approach the
450mm machine when starting the machine for
adjustment or test.
LG922E930E05016
Only the time of buffer stroke starting point is
9. Record readings of the dial indicator. required to be measured when measuring the
10. Repeat the Step 3 to 9 to totally measure action time of cylinder.
three times. Calculate average value of
measured data for three times.
11. Rotate the upper mechanism by 180°, repeat
the steps 2~10, and measure the vertical 1. Stopwatch.
clearance of swing bearing of other side. 2. Two test personnel who are familiar with
12. Refer to attached list 5 for swing bearing operating the excavator. (1 excavator
clearance (vertical direction) operator and 1 timekeeper/recorder)

45°C~55°C(113~131°F) (subject to the
temperature on the display, similarly
hereinafter).
off A/C).
normal range.
5. The complete machine works in the normal
mode.
6. The working pressure and the pilot pressure
of the pump are within the normal range.
5-12
Measurement of the boom cylinder action Measurement of the arm cylinder action time
time

This test method is for standard-
configuration excavator. If the tested
3. The height of bucket tooth is in accordance machine equipment has optional
with that of the front pin of the arm, as shown configuration, check and confirm that there is
in Figure below. no interferences between the frontal
attachments and the cab!

3. Lift the boom cylinder to certain height, as
shown in Figure below.
LG922EIII05009
4. The arm cylinder retracts completely.

5. Lower the boom till the bucket touching the
ground.
6. Operate pilot valve which controls the boom
lifting to the maximum stroke and lift the
boom at the fastest speed. The timekeeper LG922EIII05010
begins to time as soon as the boom is acting,
and records the time from action start to 4. The bucket cylinder must be retracted to
boom cylinder reaching the buffer stroke make sure the bucket can't bump against the
starting point. earthing with arm cylinder is forward and
7. Operate pilot valve which controls the boom back.
lowering to the maximum stroke and lower 5. Extend the arm completely (retract the
the boom at the fastest speed. The cylinder).
timekeeper begins to time as soon as the
boom is acting, and records the time from 6. Operate arm pilot valve to the maximum
action start to bucket touching the ground. stroke and retract the arm at the fastest
speed (extend the cylinder). The timekeeper
8. Repeat the Step 6 and 7 to totally measure begins to time as soon as the arm is acting,
three times. Respectively calculate average and records the time from action start to arm
values of the boom lifting & lowering time for cylinder reaching buffer stroke starting point.
three times.
7. Operate arm pilot valve to the maximum
9. Refer to attached table 7 for boom cylinder stroke and release the arm at the fastest
action time test table. 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.
5-13
8. Repeat the Step 6 and 7 to totally measure 8. Operate bucket pilot valve to the maximum
three times. Calculate the average values of stroke and retract the bucket at the fastest
time for arm retracting and stretching out for speed (extend the cylinder). The timekeeper
three times respectively and compare them begins to time as soon as the bucket is
with the standard values in the Table below. acting, and records the time from action start
to bucket cylinder reaching buffer stroke
9. Refer to attached table 7 for arm cylinder
starting point(if any).
action time test table.
9. Repeat the Step 7 and 8 to totally measure
Measurement of the bucket cylinder action three times. Calculate the average values of
time time for bucket stretching out and retracting
for three times respectively and compare
1. Park the machine at a solid and flat site. them with the standard values in the Table
2. Set accelerator linkage or knob to the top below.
position of engine speed. 10. Refer to the attached table 6 for the bucket
3. Lift the boom to highest position. cylinder action time test table.
4. Adjust the arm to make the angle between
the arm and its cylinder about 90 °, as shown
in Figure below.
Be careful for climbing operation.
LG922EIII05011
5. Lower the boom till the height of the front pin

of arm in accordance with that of rear pin of
the boom.
6. Retract the bucket completely (extend
cylinder).
7. Operate bucket pilot valve to the maximum
stroke and release the bucket at the fastest
speed (the cylinder retracts). The timekeeper
begins to time as soon as the bucket is
acting, and records the time from action start
to bucket cylinder reaching buffer stroke
starting point(if any).
5-14
5.1.9Cylinder settlement 3. Retract the bucket completely (extend

cylinder).
Tools and testing instrument 4. Adjust the boom height until the distance
reaches 1.5m(4'11") between bucket tooth
1. 30cm(11.8") steel ruler. and the ground.
2. Stopwatch. 5. Shut down the engine, keep 10 minutes, and
measure and record moving distances of
3. Tape used for marking staring point.
boom, arm, and bucket cylinder piston and
4. 3m(9'10") tape measure. settlement distance of tooth.
5. Plumb. 6. Repeat the Step 4 and 5 to totally measure
three times. Respectively calculate average
6. Two test personnel who are familiar with
values of the moving distances of boom, arm,
operating the excavator.
and bucket cylinder piston and settlement
Machine state and parking site distance of tooth for three times.
7. Bucket cylinder and arm cylinder is extended
1. Solid and flat parking site completely, and the boom is lowered to
2. Maintain hydraulic oil temperature between certain height to make articulated joint
45°C and 55°C(113~131°F). between link and bucket cylinder is
250~300mm(9.8In~11.8In) from the ground,
as shown in Figure below.
normal range.
mode.
6. Engine stop
Measurement of cylinder settlement
1. Park the machine in a solid and flat site and

maintain the hydraulic oil temperature LG922EIII05013
between 45°C and 55°C(113~131°F).
2. Extend the arm completely (retract cylinder) , 8. Shut down the engine, keep 10 minutes, and
as shown in Figure below. measure and record moving distance of arm
cylinder piston.
9. Repeat step 8 to totally measure three times.
Calculate the average value of moving
distances of arm cylinder piston rod.
10. Refer to attached table 7 for cylinder
settlement test table.
1.5M
LG922EIII05012
5-15
5.1.10Operating force of control 5.1.11Control lever stroke

lever
Steel ruler
Spring balance: range 200N(44.96lbf)
1. Solid and flat parking site 2. Shut down the diesel engine.
2. Shutdown the engine
Measure of control lever stroke
1. Measure control lever stroke from neutral

position to ending point respectively at the
tops of boom, arm, bucket, swing and travel
control levers.
calculate average value.
3. Record measurement value.
LG950EIII05005 5.1.12Boom lifting and swing

action
Measure of control lever operating force
1. Make spring balance hook on control lever as Tools and testing instrument
shown in Figure below and operate the
following functions: boom lifting and lowering, 1. Stopwatch
arm retracting and stretching out, bucket 2. Tape measure
retracting and stretching out, left and right
swing and travel Machine state and parking site
2. Measure the maximum operating force when 1. Solid and flat parking site
each actuating mechanism is in maximum
stroke. 2. Set accelerator linkage or knob to maximum
positions of engine speed. Lift the boom
3. Record measurement data. cylinder and make sure that the cylinder runs
4. Repeat measurement three times and smoothly without collision.
calculate average value. 3. Extend all the arms, retract all the buckets,
and lower the buckets to the ground, and the
buckets shall be at idle. As shown in the
Figure below
5-16
4. Keep the hydraulic oil temperature at 3. When upper mechanism swings by 90°,
(50±5)°C(113~131°F). release control lever to stop these two kinds
of actions, as shown in Figure below.
Measure the time of swinging by 90° and the
height of bucket tooth (H).
LG950EIII05006
Check of boom lifting and swing action

position of engine speed. Turn the air LG922E930E05029
conditioner and automatic idling off.
2. Conduct full-stroke operation while lifting
boom and conducting swing. As shown in the
Figure below
5.1.13Pilot pressure
If the cab display screen of your machine has

the setting of pressure display, you can use
the information on display screen to conduct
the following tests. If your machine does not
support the function, the following operation
steps will guide you to install pressure
gauge.
LG922E930E05028
Pressure gauge, range

0~10MPa(0~1450psi);

2. Keep the hydraulic oil temperature at 50±5°C
(113 °F ~131 °F)
5-17
Measurement of pilot pressure 3. Record the pressure value.
1. Install pressure gauge. Specific operations 4. Repeat measurement three times and
are as follows calculate average value.
1) Release the residual pressure in oil tank.

5.1.14Secondary pilot pressure
Shut down the engine, and unscrew the dust
cover on the breather valve as shown in Figure
below, and then press the exhaust valve stem on
the breather valve.

Secondary
pilot hose support the function, the following operation
gauge.
1. Pressure gauge, range

LG950E4f05002 0~10MPa(0~1450psi);
2. Tee (Material No.: 32c0621)
1. Dust cap
2. Press the exhaust valve stem 3. Pressure measurement joint (material No.:
2) Connect the pressure gauge at position (1) 12C1140)
of Figure below.

2. Keep the hydraulic oil temperature at
50±5°C (113 °F ~131 °F)
1
Measurement of secondary pilot pressure
1. Install pressure gauge. Specific operations

are as follows:
cover on the breather valve as shown in Fig-
LG950EIII05008
3) Start the engine, and confirm there is no

obvious oil leakage at the place of pressure
gauge.
position of engine speed. Turn the air
5-18
ure below, and then press the exhaust valve

stem on the breather valve. Pressure gauge
Pressure
measurement joint
Pressure tee
Secondary
pilot hose
LG950E4f05002 LG950EIII05010
1. Dust cap 2. Set accelerator linkage or knob to the top

2. Press the exhaust valve stem position of engine speed. Turn the air
2) Connect the pressure gauge; Connect the 3- conditioner and automatic idling off.
way joint (material No.: 32c0621), pressure
3. Full-stroke operation of corresponding
test joint (material No.: 12C1140) and
control lever and measurement of pilot
pressure meter in pilot pipeline. Start the
pressure, include:
engine, and confirm there is no obvious oil
leakage at the place of pressure gauge. 1) Boom lifting and lowering
2) Arm retraction and extension
3) Bucket retraction and extension
4) Left and right swing
Secondary
pilot hose 5) Forward and backward travel
4. Operate control lever and record average
value.
5. Repeat to measure three times and calculate
average value
LG950E4f05002
5-19
5.1.15Output pressure of solenoid

proportional valve
Secondary
pilot hose

gauge. LG950E4f05002
1. Dust cap
2. Press the exhaust valve stem
2) Remove the screw plug from the main pump
1. Pressure measurement joint (material No.: and the position is shown in Figure below;
12C1140) connect he O-ring (material No.: 12b0428)
2. O-ring (Material No.: 12b0428) and pressure measurement joint (material
No.: 12C1140), and then connect the
3. Pressure gauge, range 0~10MPa(0~1450psi) pressure meter.
Machine state and parking site 3) Start the engine, and confirm there is no
1. Solid and flat parking site gauge.
2. Keep the hydraulic oil temperature at 50±5°C
(113 °F ~131 °F)
Measurement of output pressure of solenoid Pressure

proportional valve measurement joint
and O-ring
1. Install pressure gauge. Specific operations Pressure

are as follows: gauge

cover on the breather valve as shown in Fig-
ure below, and then press the exhaust valve
stem on the breather valve.
LG950EIII05011

position of engine speed. Turn the air
3. Full-stroke operation of corresponding
control lever and measurement of the
pressure of the solenoid proportional valve,
include:
5-20
1) Boom lifting and lowering 2. Connect the pressure gauge (take the left
pump as an example):
2) Arm retraction and extension
1) Separately assemble the O-rings onto the
3) Bucket retraction and extension
reducer union and 3-way joint;
4) Left and right swing
2) Unscrew the screw plug at port a1 shown in
5) Forward and backward travel the figure;
4. Repeat measurement three times and 3) Mount the reducer union and 3-way joint;
4) Mount the pressure measuring connector;
5) Connect the pressure meter onto the
5.1.16Setting pressure for main pressure measurement joint;
relief valve
6) Connect the sensor of electrical system into
the other port of tee;
7) Start the engine, and confirm there is no
gauge.
gauge.
1. Tee (material No.: 32c0529)

2. O-ring (12b0428)
3. Transition joint (00a1964)
4. Pressure gauge, range 0~40MPa(0~5800psi)

2. Keep the hydraulic oil temperature at
(50±5)°C(113°F~131°F)
Measurement of setting pressure for main

relief valve
1. Install pressure gauge. Specific operations

are as follows:
The steps refer to the test procedure 1 of pilot
pressure
5-21
The method for connecting right pump with the pressure gauge is the same as that of left pump.
2
5
4
LG950E4f05002
1. Transition joint 3. Pressure connector 5. O-ring

2. Tee 4. Pressure gauge
3. Set accelerator linkage or knob to the top 7. Press the transient boost switch, operate the
position of engine speed. Turn the air bucket, arm and boom control lever slowly
conditioner and automatic idling off. within 8s to the maximum stroke to make the
hydraulic system overflow, and then measure
4. Slowly operate control levers of bucket, arm,
and record the pressure value.
and boom to maximum strokes, at the
moment, hydraulic system overflows, and
measure and record pressure value.
5. For swing function, make upper swing
platform fixed, and slowly operate swing
control lever in order to make swing function
overflow. Record measurement value.
6. For the travel function, fix the track on the
immobile object to make the travel function
overflow. Record measurement value.
5-22
Attached table 1
Traveling speed(idling speed/actual measurement speed) meter

Model of complete machine: Testing date:
Number of complete machine: Testing site:
Testing personnel:
Traveling Traveling time (s)
Speed(m/
Determination items distance( Average Remarks
1 2 3 s)
m) value
Forward gear i
Forward gear II Hydraulic oil
Idling
temperature at initial
speed Backup I measurement: °C
Backup II
Forward gear i
Forward gear II Hydraulic oil
Travel
temperature at initial
speed Backup I measurement: °C
Backup II
Attached table 2
Travel deviation measurement table

Testing personnel:
Deviation(mm)
Determination items Average Remarks
1 2 3
value
Forward gear i
Travel Forward gear II Hydraulic oil temperature at
deflection
Backup I initial measurement: °C
value
Backup II
5-23
Attached table 3
Swing service brake angle table

Testing personnel:
AB chord length (mm)
Determinati L1+ L2 Slewing brake
Average Remarks
on items (mm) 1 2 3 angle(°)
value
Hydraulic oil temperature at
initial measurement: °C
Attached table 4
Rotating speed meter

Testing personnel:
Rotation time(s) Swing speed
Determinati
回转圈数 Average (s/circle) Remarks
on items 1 2 3
value
顺时针 Hydraulic oil temperature at
逆时针 initial measurement: °C
Attached table 5
Measurement table of the swing bearing clearance

Testing personnel:
Determination Swing bearing clearance(mm)
Remarks
items 1 2 3 Average value
Hydraulic oil
Vertical temperature at initial
direction measurement
Temperature: °C
5-24
Attached table 6
Action time measurement table for excavator work implement

Testing personnel:
Measured value
Determination Working condition Standard
Average Remarks
items for measurement 1 2 3 requirements
value
Lifting
Boom
Lowering
Hydraulic oil
Action time of Retraction temperature at
Arm
the work Extension initial
implement(s) measurement:
Excavatio
°C
Bucket n
Unloading
Attached table 7
Fuel cylinder deflection meter

Testing personnel:
Determination Measure Fuel cylinder deflection (mm)
Remarks
items time(min) 1 2 3 Average value
The boom is
lowered
The arm
retracts Hydraulic oil
temperature at
The bucket
initial
stretches out
measurement:
Bucket °C
excavation
Bucket
unloading
5-25
CLG950E 5.2 Other Tests
5.2Other Tests
Adjustment of valve lash
Pictures Procedures
 Batteries can emit explosive gas, in order

to reduce the possibility of personal injury,
maintain ventilation before battery repair. In
order to reduce the possibility of arc
discharge, remove the negative (-) battery
cable first and install it last.
 For temperature that is of 30°C[86°F] or
lower than ambient atmosphere, engine
cooling for 1.5 hours is permitted before check
or set the valve clearance. When the
temperature of ambient atmosphere is higher
than 30°C[86°F], engine cooling for 2.5 hours
is permitted before check or set the valve
clearance.
1. Use the jigger tool, part No. 4919092, rotate
the crankshaft until the No.1 cylinder is at top
LG950E4f05003 dead center (TDC), the barring port can be
found at the bottom of flywheel housing.
2. The top dead center (TDC) of No.1 cylinder
can be found through the arrangement holes
on the vibration damper and on lubrication
pump housing. The lever of No.1 cylinder must
be able to move freely. If the rocker arm of
No.6 cylinder can move freely, the crankshaft
must be rotated by 360 degrees.
3. On these positions of engine, the valve lash
can be measured by the rocker arm lever
below:
1,3,5-cylinder exhaust valve
1,2,4-cylinder intake valve
LG950E4f05004
5-26
5.2 Other Tests CLG950E
Pictures Procedures
 Check the setting of the top-mounted

mechanism is usually performed as a part of
the troubleshooting procedure, no reset is
required during the check as long as the
clearance measurement is within the specified
range.
LG950E4f05005
 The clearance is correct if there is some

resistance when the feeler gauge slips
between the beam and the rocker socket.
4. The valve lash can be measured by insert the
feeler gauge between the valve and the rocker
seat. If the measurement clearance is out of
specification, unscrew the locknut and adjust
the clearance to meet the specification.
Measure the clearance by part No.3163172
and 3163171.
Adjusted value
mm in
Inlet valve
0.36 ± 0.08 0.014 ±0.003
lash (nominal)
Adjusted value
mm in
LG950E4f05006 Exhaust valve
0. 69 ± 0.08 0.027 ±0.003
lash (nominal)
5. After tighten the locknut, measure the

clearance again
 If the running clearance is not within the
specification, the engine will be damaged.
6. Tightening the torque: 28 n.m [248 in-lb]
5-27
Pictures Procedures
7. Use the jigger tool, part No. 4919092, rotate
the crankshaft by 360°
8. Measure the following rocker clearance
according to the same procedure and specified
value as previously mentioned:
Exhaust valve of cylinder No.2, No.4 and No.6
Inlet valve of cylinder No.3, No.5 and No.6
9. Please reset if it out of specification
LG950E4f05003
5.2.1Measurement of blow-by of 3) Conduct troubleshooting for probable diesel

engine internal damages, such as worn
crankcase piston rings, oil seals or tubes of valve rods,
turbochargers, air compressors, etc.
Overview These steps provide the general guideline about
The actual diesel engine configurations are measurement of gas blow-by related to above
not showed in some figures in this step. condition.
However, the steps are same.
If crankcase pressure and/or blow-by volume is

too much, it indicates that fault occurs in the
diesel engine or its related components, and Crank
case
consequently burning gas or air leaks into the Ventilating
crankcase. The result is that the generated device
hose
pressure exceeds normal crankcase pressure,
and therefore the blow-by level is increased. To
pressure
gauge
How to measure the crankcase pressure/blow-by
and how to determine the fault components are
described in this step.
LG922E930E05056
The general purpose of blow-by measurement
lies in:
1) Check the diesel engine running-in after re-
installation
2) For the open crankcase breather system,
conduct fault diagnosis and troubleshooting
when excess engine oil overflows from the
crankcase breather pipes (generally also
known as oil carry-out).
5-28
● The diesel engine internal components make

engine oil deviate to the breather cavity
(piston cooling nozzle, attachment drain pipe
of engine oil, etc.)
4. Confirm whether there is another breather
option for the diesel engine being repaired.
Other steps can be adopted to verify the

doubt that the internal faults of the diesel
engine cause excess blow-by.
Blow-by measurement shall be considered only

LG922E930E05057 when the running-in of diesel engine after re-
installation is confirmed or other symptoms
It is worth noticing that the two terms about appear. Emerging symptoms include:
“blow-by” and “carry-out (engine oil overflows
from the breather pipe)” are usually equivalent. 1. Excess engine oil carry-out (the engine oil is
carried-out from the crankcase breather
The engine oil quantity will directly affect the pipes)
measurement results of blow-by if excess engine
oil overflows from the breather pipes when 2. Over-high crankcase pressure (for the diesel
measuring blow-by. engine equipped with crankcase pressure
sensor)
The blow-by measurement results shall also be
affected by the engine oil collected on the 3. Low power
metering holes of blow-by measurement and 4. Engine oil consumption
maintenance tools. This reduces the sizes of
metering holes, and therefore, the measurement 5. Exhaust smoking
results always exceed the actual blow-by It is not necessary to measure the blow-by if
measurement values. there are no other symptoms.
If so, the following measures shall be taken: Other steps can be adopted to verify the doubt
1. Find different measuring positions on the that the internal faults of the diesel engine cause
diesel engine to measure the crankcase excess blow-by. These steps include:
pressure (engine oil filler, engine oil filler 1. Confirm the maintenance regulations for
cover, drainage position of unused crankcase.
turbocharger, etc.).
2. Cut the engine oil filter and check whether
2. Clean the residual engine oil on the breather there are chippings.
before measuring blow-by, and dry it
completely.
3. Confirm whether there are some factors
making the breather be full with engine oil, for
example:
● Engine oil level is incorrect
● Vehicle operation (excessive incline,
excessive all-round rotation of the diesel
engine)
5-29
4) Get an engine oil sample and check whether Pictures of blow-by tools
there are pollutions.
LG922E930E05058
LG922E930E05060
Connect the hydraulic gauge (the part number is
ST1111-3), pressure gauge or sensor on the
Measurement tools blow-by measurement and maintenance tools
when measuring the crankcase/blow-by
The tools used for measuring blow-by are
pressure.
generally similar in the structure. The sizes of
metering holes are their main distinctions. It is supposed to measure the water column for
Different sizes of metering holes are designed for the height of 944 mm at most by using the
accurately measuring blow-by, which can also hydraulic gauge (the part number: ST1111-3).
meet the needs for various diesel engine
configurations and rated power. Because the
diesel engine blow-by depends on the volume of
inlet air.
For example:
● If the measurement of blow-by is conducted
on two diesel engines with same
configurations and sizes, but with different
horsepowers and rated speeds, the
measured maximum blow-by values will be
different.
The air inflow of engine with high rated LG922E930E05059
horsepower and high rated speed is relative
high, so the blow-by value will be higher. That is
to say, if the small metering orifice blow-by tool is
used to measure the engine with high rated
horsepower and high rated speed, the
measurement will exceed the limit of pressure
measurement tool.
Part number of blow-by tool: 3822571
Size of metering hole: 8.99 mm[0.354 in]
5-30
The blow-by conversion table for the orifice

with 8.99 mm[0.354 in] diameters and blow-
by
Crank
case mm H2O [in H2O] Liter/min [cfm]
Ventilating
device 584.2 [23] 335 [11.830]
hose
609.6 [24] 341 [12.042]
To
pressure
gauge
LG922E930E05056
The relationship between measured pressure

value of orifice with 8.99 mm [0.354 in] diameters
and flow velocity is shown in the table below.
The blow-by conversion table for the orifice

with 8.99 mm[0.354 in] diameters and blow-
by
mm H2O [in H2O] Liter/min [cfm]
25.4[1] 70 [2.472]
50.8[2] 100 [3.531]
76.2[3] 120 [4.238]
101.6[4] 140 [4.944]
127[5] 158 [5.580]
152.4[6] 172 [6.074]
177.8[7] 185 [6.533]
203.2[8] 198 [6.992]
228.6[9] 210 [7.416]
254[10] 220 [7.769]
279.4[11] 231 [8.158]
304.8[12] 241 [8.511]
330.2[13] 252 [8.899]
355.6[14] 260 [9.182]
381[15] 270 [9.535]
406.4[16] 280 [9.888]
431.8[17] 289 [10.206]
457.2 [18] 298 [10.524]
482.6 [19] 305 [10.771]
508 [20] 312 [11.018]
533.4 [21] 320 [11.301]
558.8 [22] 328 [11.583]
5-31
Initial inspection
Pictures Procedures
Initial inspection
 The locations and types of crankcase

breathers will be different along with the
differences of engine configurations (front
gear power train or rear gear power train) and/
or engine applications.
1. Check whether the crankcase breather pipes
are blocked before measuring the blow-by
pressure.
2. When troubleshooting for excess engine oil
overflowing from the breather pipe is carried
out, the breather components shall be
LG950E4f05007 removed prior to blow-by measurement in
order to clean and clear all collected engine oil
away.
3. Check the engine oil level in the diesel engine.
If necessary, correctly calibrate the oil scale. If
the oil level is too high, the blow-by pressure
will exceed normal level and/or excess engine
oil will be carried out .
LG922E930E05062
5-32
Measurement
1. Connect the hydraulic gauge (the part number
is ST1111-3), pressure gauge or sensor on the
blow-by measurement and maintenance tools
when measuring the crankcase/blow-by
pressure.
 The locations of crankcase breather pipes
may change along with the diesel engine
configurations and/or its specific applications.
2. Installation of applicable blow-by maintenance
tools:
● For the open crankcase breather/ventilating
system, connect applicable blow-by
maintenance tools at the end of crankcase
LG950E4f05008
breather respirator pipes. Connect a hydraulic
gauge, pressure gauge or sensor on the blow-
by maintenance tools.
 The following methods for operating the

diesel engine with rated speed and load are
optional:
(1) Use chassis dynamometers or diesel
dynamometers for the diesel engine running-
in.
(2) Use chassis dynamometers or diesel
dynamometers for the diesel engine test.
(3) Stall test (for the diesel engine only equipped
LG922E930E05064 with an automatic transmission).
5-33
 Excess engine oil overflows from the

breather pipes during the blow-by
measurement. So the engine oil volume also
directly affects the blow-by measurement
results.
3. Operate the diesel engine with rated speed
and full load until stable values are obtained.
 During the blow-by measurement, a
"peak" will appear initially in the values when
the diesel engine achieves peak power and
rated speed. Start to read the readings after
the blow-by measured value is stable.
 For the diesel engine running-in, if blow-
by is increased suddenly or it exceeds the
maximum allow limit in any running-in steps,
return to the previous step to continue the
running-in. If the blow-by does not reach
acceptable level, interrupt the running-in and
LG922E930E05065 confirm the causes.
4. Record the blow-by measured values in
steady state.
Remove the diesel engine blow-by mainte-
nance tools and hydraulic gauges or pressure
gauges if blow-by is within the technical speci-
fications.
5-34
5.2.2Measurement and Standard value of the track tension

adjustment of track tension Track type Standard value A
Metal track 10-30mm(0.4"-1.2")
Measurement of the track tension
Adjustment of track tension
If the track tension is abnormal, adjust it
1. Steel ruler. according to the following procedures.
Machine state and parking site 1. Increase the tension
1) Fill the grease from the grease fitting 1 using
2. Maintain hydraulic oil temperature between grease gun. As shown in the Figure below
45°C and 55°C(113~131°F).
3. Set the diesel engine in the maximum speed
(with the air conditioning turned off).
normal range.
mode.
LG922E930E05077
Measurement of the track tension
1. After drive the machine forward (with idler in 2) To determine that the tension of the track
front) for 20m(65'7 "), park it in a solid and flat shoe is normal, operate the diesel engine in
site. low idle speed and drive the machine
forward for a distance which equals to the
2. Maintain hydraulic oil temperature between length of the track shoe on the ground and
45°C and 55°C(113~131°F). then stop the machine slowly.
3. Put the level gauge on the track between the 3) After adjustment, measure the tension again
sprocket and carrier roller, and measure the according to the procedures above to
sag quantity A at the maximum droop of level guarantee that the tension is normal.
gauge and track by steel ruler, as shown in
the Figure below.
LG950E4f05009
5-35
2. Reduce the tension 5.2.3Inspection and adjustment of

1) Loosen the filling valve 2, discharge the
minus feedback pressure N1
grease and then tighten it. As the figure
below: 1. Inspection and measurement steps
1. Directly read the minus feedback pressure

N1 on the display. Contact Liugong service
provider if it needs to read pressure.
2. Measure the minus feedback pressure N1 on
its port shown in the figure below.
Disconnect here
LG922E930E05078
The valve may fly off as a result of the

internal high-pressure grease, so do not
loosen the filling valve 2 more than two
circles.
2) To determine that the tension of the track

shoe is normal, operate the diesel engine in LG950E4f05010
low idle speed and drive the machine
forward for a distance which equals to the 3. Measurement steps:
length of the track shoe on the ground and
then stop the machine slowly. Tools and testing instrument
3) After adjustment, measure the tension again Pressure gauge, range 0~10MPa(0~1450psi);
according to the procedures above to Tee (Material No.: 32c0621)
guarantee that the tension is normal.
Pressure measurement joint (material No.:
12C1140)
(1) Disconnect the hose joint as shown in Figure
above;
5-36
(2) Assemble as shown in Figure below: firstly 2. Adjustment

assemble the pressure measurement 3-way
joint, and then assemble the pressure Change the minus feedback pressure values by
measurement joint changing the current values of octa-
electromagnet A6. The corresponding curve of
Pressure gauge current with output feedback pressure N1 is
shown in the figure below.
Tee union Pressure joint
LG922E930E05083
LG950E4f05011
(3) Insert the pressure gauge (10 MPa(1450psi)

measuring range) with pressure hoses into
the pressure measuring connector and
measure the pressure on the main pump
feedback pressure port N1.
5-37
5.2.4Inspection and adjustment of 2. Adjustment

minus feedback pressure N2 Change the minus feedback pressure values by
changing the current values of octa-
1. Inspection and measurement steps electromagnet A5. The corresponding curve of
current with output feedback pressure N2 is
1. Directly read the minus feedback pressure shown in the figure below.
N2 on the display. Contact Liugong service
provider if it needs to read pressure.
2. Measure the minus feedback pressure N2 on
its port shown in the figure below.
3. Measurement steps
The measurement stops are same as the
measurement method in N1
Disconnect here
LG922E930E05083
LG950E4f05012
5-38
5.2.5Release of remaining 6. Repeatedly turn the pilot lever or foot pilot

valve to the maximum angle, release high
pressure in hydraulic oil lines pressure oil in corresponding lines, and
meanwhile, release pressure in
corresponding pilot lines.
7. After releasing the pressure in lines, turn the
pilot shutoff lever to "OFF" position.
The high pressure liquid medium in the
hydraulic system and hot hydraulic medium 8. Turn the engine starting switch to "OFF"
upon operation may cause personnel injury. position.
There is still high pressure in the hydraulic 9. Turn the engine starting switch to "ON"
system after the engine is stopped. If the position, start the engine, operate it at low
pressure is not released before maintaining idling about 10 seconds for storage of the
any hydraulic system, serious personal injury pressure in the accumulator, and then stop
may be caused. Be sure that all the the engine.
accessories have been put on the ground, 10. Repeat the steps from the 3rd to the 10th
and the hydraulic oil has been cooled before above for several times.
removing any components or lines. Only
remove the oil filler cap when the engine has 11. Screw out the exhaust valve protective caps
been shut down, and the oil filler cap has of an air filter above the hydraulic oil tank,
been cooled enough to be touched by hands. press the exhaust valve and release air
pressure in the hydraulic oil tank until the gas
with pressure is released fully.
Release the pressure of the hydraulic system
according to the following procedures: 12. Tighten the exhaust valve protective caps on
the air filter.
1. Park the excavator on the flat ground.
13. When the pressure in the hydraulic system
2. Completely place the work implement on the pipeline has been released, the
horizontal ground. Make the bucket in corresponding lines or components can be
complete contact with the ground, as shown removed.
in the figure below:
Although the pressure in pipelines is

released to the most extent by the above
steps, a minority of pressure still cannot be
released fully. When removing the pipeline
connecting assemblies such as connectors,
properly do necessary protections to avoid
personnel injury.
LG922E930E05086
3. Shutdown the engine.

4. Rotate the engine starting switch to "ON"
position but do not start the engine.
5. Turn the pilot shutoff lever to "ON" position.
5-39
5.2.6Exhaust of various devices
Exhaust shall be carried out upon the following repair:
Exhaust project
Procedures 1 2 3 4 5 6
Hydraulic
Start the Oil cylinder Swing motor Travel motor
Work content pump Start work
engine exhaust exhaust exhaust
exhaust
• Replace the hydraulic oil
○ ○ ○ ○ ○ ○
• Cleaning of filter element
• Replacement of backflow
○ ○
filter element
• Repair or replacement of
hydraulic pump ○ ○ ○ ○
• Remove the suction tube
• Repair or replacement of
○ ○ ○
control valve
• Replacement of oil cylinder
○ ○ ○
• Remove the cylinder line
• Replacement of swing motor
○ ○ ○
• Remove the swing motor line
• Replacement of travel motor
○ ○ ○
• Remove the travel motor line
Exhaust the air in the pump
When maintaining the main pump or replacing the hydraulic oil lines, exhaust the air according to the
methods below:
The hydraulic oil pressure and the hot oil may cause personal injury.
When the engine is stopped, the hydraulic oil can still be in the hydraulic system. If the pressure
is not released before maintaining any hydraulic system, serious personal injury may be caused.
Be sure that all the accessories have been put on the ground, and the oil has been cooled before
removing any components or lines.
Only remove the oil filler cap when the engine has been shut down, and the oil filler cap has been
cooled enough to be touched by hands.
5-40
Do not telescope the cylinder to the stroke

end, or. The piston seal will be damaged by
the air in the cylinder.
3. Operate the cylinders to the stroke end for 3-

Refill hydraulic 4 times
oil via this port
4. Operate the cylinders to the stroke end for 4-
5 times to exhaust the air completely.
Exhaust the air in the travel motor
The air can be exhausted only after the

hydraulic oil in the travel motor housing was
discharged.
1. Before starting the engine, remove the

LG950E4f05013 discharge hose on the travel motor housing,
fill the hydraulic oil to the motor housing until
1. Park the machine on the flat ground, lower the level reaches the discharge port, and
the bucket to the ground and pull the pilot then connect the discharge hose, as shown
control level to the locked position. in the Figure below.
2. Shut down the engine and take the key out.
Secondary
3. Loosen the exhaustion plug and check for
pilot hose
overflowed oil.
4. If not, fill the hydraulic oil to the pump
housing body.
5. Make the engine operate in idle speed. If
there is no bubble appears any more, tighten
the exhaustion plug and the discharging is
over.
If the pump runs without full oil in the pump

body, the abnormal heat may be produced
resulting in the early damage for the pump.
LG950E4f05014
Exhaust the air in the cylinder
2. Make the motor operate in low idle speed,
1. Start the engine and make it operate in low loosen the discharge hose connector nut on
idle speed for 5 min. the motor housing, and tighten the connector
when the hydraulic oil overflows.
2. Operate the engine in low speed and
telescope the cylinder to the position about
100 mm(3.94In) away from the stroke end for
4-5 times.
5-41
3. Make the engine operate in low speed and Conduct the exhaust according to the
rotate the work implement for 90° to make it method specified by the manufacturer.
locate in the other side of the track.
2. After discharging the air, shut down the
engine and leave the machine alone for 5
min which will eliminate the bubble in the
hydraulic cylinder. After exhausting the air,
check the oil level. If it is low, fill the oil.
5.2.7Inspection procedures of
diode
LG950E4f05015 The diode, also called crystal diode, is an

electronic device capable of unidirectional
4. Jack up the machine with the work implement current conduction. There is one PN joint and
to make the track off the ground a little, and two lead terminals in the semiconductor diode.
operate the track in no-load condition for 2 According to the direction of the applied voltage,
min. the electronic device, which is popular, has the
transduction performance of the unidirectional
5. Repeat the operation above in the left and current.
right side. And rotate the track forward and
backward evenly.
1
Exhaust the air in the accessories (if any)
2
1. If the knapper or other accessories are
equipped, make the engine run in low speed,
and repeatedly operate the auxiliary pedal for
LG950E4f05016
about 10 times until the air is exhausted from
the oil line of the accessories.
1
2
LG950E4f05017
1. Use the diode grade of the digital multimeter

to measure the diode:
a. Connect the red probe (+) to the positive
LG922E930E05091 pole (P) of the diode, and the black probe
(-) to the negative pole (N) of the diode,
1. Auxiliary pedal
then the diode is in positive biased. If the
diode is normal, the multimeter will display
a certain value.
5-42
b. Connect the red probe (+) to the negative 5.2.8Performance test of travel
pole (N) of the diode, and the black probe
(-) to the positive pole (P) of the diode,
motors and reduction gears
then the diode is in reverse biased. If the
diode is normal, the multimeter will display Carry out the following performance tests upon
0L or a very large value. disassembly and maintenance of travel motors
c. During measuring, if the values measured and reduction gears.
in two times are very little, there is a short
Test method
circuit in the diode; if the values measured
in two times are very large or 0L, there is Test the pressure of the following points: left
an open circuit in the diode. motor is for MA, MB and D2; right motor is for
2. 2. Use the Ohm grade of the digital MA, MB and D2.
multimeter to measure the diode:
Pressure measuring side
a. Connect the red probe (+) to the positive
pole (P) of the diode, and the black probe
(-) to the negative pole (N) of the diode,
LH
then the diode is in positive biased. Read
the measured resistance value.
b. Connect the red probe (+) to the negative
pole (N) of the diode, and the black probe
(-) to the positive pole (P) of the diode,
then the diode is in reverse biased. Read RH
the measured resistance value. LG922E930E05096
c. If the two values measured are quite
different, it indicates that the performance
of the diode is good; if not, it indicates that
the performance of the diode is poor or the
diode is damaged---internal short or open
circuit.
LG950E4f05018
5-43
Test conditions:
1. Air is not allowed in the lines.

2. The hydraulic oil temperature about (50±5)°C (113°F~131°F)
Test items and standard values:
Operation status
Test Gea
S/N Contents Horizontal Vertical Operation Criteria
ground rs
direction direction
Left and right pumping
pressure difference < 3
MPa (435psi), without
Low dragging
Oil drainage
<0.2MPa(29psi),
Travel and stop Max<0.69MPa(100.1psi)
1 on flat ground
Flat ground Left and right pumping
MPa (435psi), without
High dragging
Oil drainage
<0.2MPa(29psi),
Max<0.69MPa(100.1psi)
Curve is flat, without
Slow operation Low dragging
2 Forward→Rever Oil drainage
se <0.2MPa(29psi),
High
Atmospheric pressure
<34.3MPa(4973.5psi);
3 Unilateral drive High Max<34.3MPa(4973.5psi)
Oil drainage Max < 0.69
Concrete MPa(100.1psi)
Atmospheric pressure
<34.3MPa(4973.5psi);
Unmovable
4 High Max<34.3MP(4973.5psi)
rotation
MPa(100.1psi)
Left and right pumping
MPa (435psi),
Rapid alternate Left and right pumping
5 High
(Forward) pressure Max< 34.3 MPa
(4973.5psi)
MPa(100.1psi)
Synchronous switching,
Switching
without dragging
between high Low
6 Oil drainage
and low velocity High
<0.2MPa(29psi),
Forward
Forward and
7 reversing Low
Slope
5-44
6-1
September 3, 2019 Fault diagnosis
CLG950E
6 Fault diagnosis
6.1 Precautions for Fault Diagnosis ...............................................................................6-5

6.2 Basic Fault Detection Before Maintenance ..............................................................6-5
6.3 Classification of Faults .............................................................................................6-8
6.4 Fault Code..............................................................................................................6-10
6.4.1 Fault code 101001 Extremely low battery voltage....................................................................6-10
6.4.2 Fault code 101003 High battery voltage...................................................................................6-18
6.4.3 Fault code 101017 Low battery voltage ...................................................................................6-22
6.4.4 DTC 111001 System charging fault .........................................................................................6-30
6.4.5 Fault code 121305 Hand pilot pressure switch OFF ................................................................6-33
6.4.6 DTC 121405 Foot pilot pressure switch OFF ...........................................................................6-38
6.4.7 Fault Code 121604 Air filter switch shorted to ground ............................................................6-43
6.4.8 Fault Code 121615 Air filter clogging .......................................................................................6-46
6.4.9 Fault Code 131200 Extremely high hydraulic oil temperature.................................................6-48
6.4.10 Fault Code 131203 Hydraulic oil temperature sensor voltage above the range value .............6-50
6.4.11 Fault Code 131204 Hydraulic oil temperature sensor voltage below the range value .............6-53
6.4.12 Fault Code 131215 High hydraulic oil temperature ..................................................................6-57
6.4.13 Fault Code 131216 Extremely high hydraulic oil temperature..................................................6-59
6.4.14 Fault Code 131303 Fuel level sensor voltage above the range value .....................................6-61
6.4.15 Fault Code 131304 Fuel level sensor shorted to ground .........................................................6-67
6.4.16 Fault code 131317 Low fuel level.............................................................................................6-73
6.4.17 Fault Code 131603 Water-in-fuel sensor voltage above the range value ...............................6-77
6.4.18 Fault Code 131604 Water-in-fuel sensor voltage below the range value................................6-80
6.4.19 Fault Code 131605 Water-in-fuel sensor open-circuit..............................................................6-83
6.4.20 Fault code 131615 Water-in-fuel ..............................................................................................6-86
6.4.21 Fault code 131703 Sensor power (5V) shorted to the power supply of the complete machine
.................................................................................................................................................6-88
6.4.22 Fault Code 131704 Sensor power (5V)shorted to ground........................................................6-91
6.4.23 Fault Code 141005 Pump proportional solenoid valve feedback open-circuit .........................6-95
6.4.24 Fault Code 141006 Pump proportional solenoid valve feedback overcurrent..........................6-98
6.4.25 Fault Code 141104 Pump proportional solenoid valve shorted to ground .............................6-101
6.4.26 Fault code 141105 Pump proportional solenoid valve open-circuit or shorted to the power supply
...............................................................................................................................................6-104
6-2
Fault diagnosis September 3, 2019
CLG950E
6.4.27 Fault Code 151004 Attachment confluence solenoid valve shorted to ground ......................6-107
6.4.28 Fault code 151005 attachment confluent solenoid valve open-circuit or shorted to the power
supply .....................................................................................................................................6-110
6.4.29 Fault Code 151204 A2 Travel shift solenoid shorted to ground .............................................6-113
6.4.30 Fault code 151205A2 Travel shift solenoid valve open-circuit or shorted to the power supply
...............................................................................................................................................6-117
6.4.31 Fault Code 151304 A3 Flattening solenoid valve shorted to ground.....................................6-121
6.4.32 Fault code 151305 A3 Flattening shift solenoid valve open-circuit or shorted to the power supply
...............................................................................................................................................6-125
6.4.33 Fault Code 151404 A8 Trenching solenoid valve shorted to the ground ...............................6-129
6.4.34 Fault code 151405 A8 Digging solenoid valve open-circuit or shorted to the power supply ..6-133
6.4.35 Fault Code 151504 A5 Flow adjusting solenoid shorted to ground .......................................6-137
6.4.36 Fault code 151505 A5 flow adjusting solenoid valve open-circuit or shorted to the power supply
...............................................................................................................................................6-140
6.4.37 Fault code 151605 A6 Flow adjusting solenoid valve open-circuit or shorted to the power supply
...............................................................................................................................................6-144
6.4.38 Fault Code 151704 A7 Power boosting solenoid valve shorted to the ground.......................6-148
6.4.39 Fault code 151705 A7 Transient power boosting solenoid valve open-circuit or shorted to the
power supply ..........................................................................................................................6-152
6.4.40 Fault Code 151804 A4 Travel lifting solenoid valve shorted to the ground ............................6-156
6.4.41 Fault code 151805A4 Travel lifting solenoid valve open-circuit or shorted to the power supply
...............................................................................................................................................6-160
6.4.42 Fault Code 151905 A5 or A6 solenoid valve feedback open-circuited ...................................6-164
6.4.43 Fault Code 151906 A5 or A6 solenoid valve feedback overcurrent .......................................6-167
6.4.44 DTC 171004 Short circuit to ground of battery relay ..............................................................6-170
6.4.45 Fault Code 171104 Auto preheating relay shorted to the ground .........................................6-173
6.4.46 Fault code 171105 Auto preheating relay open circuit or shorted to the power supply..........6-176
6.4.47 Fault Code 171204 Start cut-off relay shorted to ground .......................................................6-180
6.4.48 Fault code 171205 Start cut-off output open circuit or shorted to the power supply ..............6-184
6.4.49 Fault Code 201004 Traveling alarm shorted to ground .........................................................6-189
6.4.50 Fault Code 211003 P1 pump pressure sensor voltage above the range value ....................6-192
6.4.51 Fault code 211004 P1 pump pressure sensor voltage below the range value.......................6-196
6.4.52 Fault Code 211003 P2 pump pressure sensor voltage above the range value .....................6-200
6.4.53 Fault code 211104 P2 pump pressure sensor voltage below the range value.......................6-204
6.4.54 Fault Code 211203 N1 negative flow pressure sensor voltage above the range value .........6-208
6.4.55 Fault Code 211204 N1 negative flow pressure sensor voltage below the range value..........6-211
6-3
CLG950E
6.4.56 Fault Code 211303 N2 negative flow pressure sensor voltage above the range value .........6-215
6.4.57 Fault Code 211304 N2 negative flow pressure sensor voltage below the range value..........6-218
6.4.58 Fault Code 211316 High N2 negative flow pressure ..............................................................6-222
6.4.59 Fault Code 231012 Abnormal controller heartbeat ................................................................6-224
6.4.60 Fault Code 231014 CAN bus communication error................................................................6-227
6.4.61 Fault Code 241014 accelerator knob outside the measurement range .................................6-230
6.4.62 Fault Code 251004 Fuel pump relay shorted to ground.........................................................6-233
6.4.63 Fault code 251005 Fuel pump relay open circuit or shorted to the power supply ..................6-237
6.4.64 Fault code 261011GPS antenna fault ....................................................................................6-241
6.4.65 Fault Code 261111GPS module fault.....................................................................................6-243
6.4.66 Fault code 261211GSM signal fault .......................................................................................6-244
6.4.67 Fault Code 261311 GPRS connection fault ...........................................................................6-246
6.4.68 Fault Code 261411 SIM card read fault ................................................................................6-247
6.4.69 Fault code 261512 Abnormal GPS heartbeat ........................................................................6-249
6.4.70 Fault Code 261611 automatic locking level 1 GPS abnormal heartbeat, limited machine .....6-252
6.4.71 Fault Code 261614 command locking level 1 payment expired, limited machine ..................6-255
6.4.72 Fault Code 261711 automatic locking level 2 GPS abnormal heartbeat,limited machine ......6-256
6.4.73 Fault Code 261714 command locking level 2 payment expired, limited machine .................6-259
6.4.74 Fault Code 261814 Please pay the due loan timely ..............................................................6-260
6.4.75 Fault code 271304 Fan reversing solenoid valve shorted to ground......................................6-261
6.4.76 Fault Code 271305 Fan reversing solenoid valve open-circuited or short-circuited to the power
supply .....................................................................................................................................6-264
6.4.77 Fault Code 271404 Fan drive solenoid valve shorted to the ground......................................6-267
6.4.78 Fault code 271405 Fan drive solenoid valve open circuit or shorted to the power supply .....6-270
6.4.79 Fault Code 271505 Fan drive solenoid valve feedback open-circuited.................................6-273
6.4.80 Fault Code 271506 Fan drive solenoid valve feedback overcurrent .......................................6-276
6.5 Fault Diagnosis of the Electrical System..............................................................6-279

6.5.1E1 Troubleshooting solution for battery power loss ...................................................................6-279
6.5.2 E2 Troubleshooting solution for abnormal battery..................................................................6-281
6.5.3 E3 Automatic slowdown failed................................................................................................6-284
6.5.4 E4 Engine cannot be started ..................................................................................................6-288
6.5.5 E5 Engine cut-out during operation........................................................................................6-298
6.5.6 E6 Engine cannot be shut down.............................................................................................6-302
6.5.7 E7 Pre-heater does not work..................................................................................................6-305
6.5.8 E8 All the work implements, revolving and traveling cannot move ........................................6-311
6-4
CLG950E
6.5.9 E9 Display panel showing nothing .........................................................................................6-316

6.5.10 E10 Incorrectly displayed hydraulic oil temperature ...............................................................6-320
6.5.11 E11 Fuel gauge unable to display correct value ....................................................................6-323
6.5.12 E12 Windshield wiper fails .....................................................................................................6-330
6.5.13 E13 Travel alarm unable to sound .........................................................................................6-336
6.5.14 E14 A/C panel unable to display ............................................................................................6-340
6.5.15 E15-No wind or abnormal air volume of air conditioner .........................................................6-345
6.5.16 E16 Poor A/C refrigeration .....................................................................................................6-348
6.5.17 E17 air conditioning abnormal alarm E11--Inner gas sensor break line.................................6-351
6.5.18 E18 air conditioning abnormal alarm E12--Inner gas sensor short circuit ..............................6-353
6.5.19 E19 air conditioning abnormal alarm E15--water temperature sensor break line ..................6-355
6.5.20 E20 air conditioning abnormal alarm E16--water temperature sensor short circuit................6-357
6.5.21 E21 air conditioning abnormal alarm E18--solar sensor short circuit .....................................6-359
6.5.22 E22 air conditioning abnormal alarm E43--Air blowing valve abnormal .................................6-361
6.5.23 E23 Abnormal alarm of the A/C E44 – Abnormal air mixing door ..........................................6-363
6.6 Fault Diagnosis of the Hydraulic System and Mechanical System ......................6-365
6.6.1 System table of the hydraulic system and mechanical system ..............................................6-365
6.6.2 H1 Excessive barking angle for slewing stop .........................................................................6-366
6.6.3 Abnormal noise from H2 pump mounting position .................................................................6-367
6.6.4 H3 Start the engine, and all operations have no response ....................................................6-368
6.6.5 H4 Hydraulic oil emulsification ...............................................................................................6-369
6.6.6 H5 Abnormal hydraulic oil temperature rise ...........................................................................6-370
6.6.7 H6 Slewing abnormally to left and right directions .................................................................6-371
6.6.8 H7 No response for slewing single direction operation ..........................................................6-372
6.6.9 H8 Rotation unable to stop.....................................................................................................6-373
6.6.10 H9 Fail to actuate unilateral travel mechanism ......................................................................6-374
6.6.11 H10 Travel deviation ..............................................................................................................6-375
6.6.12 H11 Slow speed of the boom, arm or bucket .........................................................................6-376
6.6.13 H12 Weak actions of the boom, arm or bucket ......................................................................6-377
6.6.14 H13 Significantly reduced engine speed or engine stalling....................................................6-378
6.6.15 H14 Abnormal fan speed........................................................................................................6-378
6-5
CLG950E 6.1 Precautions for Fault Diagnosis
6.1Precautions for Fault Diagnosis
● Park the machine on the flat ground, check whether the locking pin, cushion block and parking brake
are fixed firmly.
● When two or more workers are operating, follow the agreed signal strictly, and any unauthorized
people are not allowed to get close.
● 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 do not be jammed by any rotating
components.
● When disconnecting the wire, be sure to disconnect the negative pole (-) of the battery first.
● Be sure to release the inner pressure 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.
6.2Basic Fault Detection Before Maintenance
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 operates in a closed space, be sure to discharge the exhaust gases before starting
the engine to maintain 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 require the appropriate hearing protection devices.

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.
6-6
6.2 Basic Fault Detection Before Maintenance CLG950E
S/N Test items Test requirements

1 Rotate the start switch to "ON" position but do not start the engine.
Hydraulic oil state

Shut down the engine, park the 1. Check whether the oil level is within the normal range.
machine on a firm and horizontal
ground, and make the machine in
 Notice: Check before the engine is started.
2 the hydraulic oil testing state (all 2. Check whether the engine oil level is between the MIN and MAX marks
the arms are stretched out, the of the dipstick.
bucket is withdrawn, and the work 3. Check whether the cold hydraulic oil level is between the maximum
attachment is lowered to ground). scale and the minimum scale of the dipstick.
4. Check the hydraulic oil lines or the connectors for damage or leakage.
5. Visually check the machine for wear or damage sign. Whether the
parts are damaged or lost. Whether the welding piece has cracks.
6. Check the parts for loss.
7. Check the track for obvious scratches or wear.
Horn Check whether the horn sounds. (Yes or No)
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,
revolving signal light, brake light, Check whether the outdoor light and dome light works normally.
3 dome light, etc.)
Check whether all the indicators come on?
Instrument, meter and indicator
If not, do not start the engine.
Operate all the switches and controls to check whether they can work
Switches and controls normally.
If not, do not start the engine.
Cab Check whether all the control levers are in the correct positions.
Check whether the safety warning labels on the machine can be seen
Safety warning label
clearly.
4 Check whether the cab windows and doors can be opened smoothly?
Whether the gate lock can be locked?
Gate lock and engine hood lock
Check whether the engine hood can be closed? Whether the engine
hood can be locked?
6-7
CLG950E 6.2 Basic Fault Detection Before Maintenance
S/N Test items Test requirements

Check the surrounding of the engine for obvious damage or oil leakage
sign?
Start the engine and listen to the engine for abnormal noise?
When the engine operates in idle speed, whether the oil pressure
indicator goes off?
5 Engine system Check whether the engine speed is normal. Whether the operation is
smooth?
After the engine operates 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 operates in idle speed
After the engine operates in idle speed for several minutes, check
whether the air conditioner refrigerates?
Start the engine and check the battery voltage on the display to
7 Charging of battery
guarantee that the voltage is not less than 24V.
6-8
6.3 Classification of Faults CLG950E
6.3Classification of Faults
The faults described in this chapter is only the troubleshooting thinking normally. Please contact the
LiuGong local service providers if the faults cannot be removed according to the thinking method in the
text.
The faults are divided into three categories.
(1) Fault code
If the machine display shows fault code, perform the fault diagnosis corresponding to the code according
to the displayed fault code.
(2) Electrical system faults
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 table below
Fault SN Fault phenomenon Consequence
E1 Battery power loss The battery is damaged.
E2 The battery is abnormal The battery is damaged.
E3 Automatic slowdown failed Increased fuel consumption and noise
Engine cannot be started (the engine does not
E4 Failed to work.
rotate)
E5 Engine shuts down during operation. System fault.
E6 The engine can not shut down System fault.
The machine is difficult to start or won’t
E7 Pre-heater does not work
start.
All the work implements, revolving and travel cannot
E8 No motion, failed to work.
move
E9 Display panel shows nothing It can not display the machine information.
Reducing the pump current and engine
speed can affect the working performance
E10 Incorrectly displayed hydraulic oil temperature
of the complete machine, or cause damage
to the engine and hydraulic components.
The fuel level display is inaccurate, and it
E11 Fuel gauge cannot display correct value
brings trouble to the work.
Foreign matters on glass cannot be
E12 Windshield wiper does not work.
removed; the sight for operator is poor.
Alarm system is faulty, causing potential
E13 Travel alarm does not sound
safety hazard.
E14 A/C panel unable to display Air conditioning system cannot work
Air conditioner blows no air or air volume is
E15 The service effect of air conditioner is poor
abnormal
The refrigeration effect of air conditioning
E16 Poor A/C refrigeration
system is poor
Abnormal A/C alarm E11 -- Internal air sensor open
circuit
6-9
CLG950E 6.3 Classification of Faults
Fault SN Fault phenomenon Consequence

Abnormal A/C alarm E12 -- Internal air sensor short
circuit
Abnormal A/C alarm E15 -- Water temperature
sensor open circuit
sensor short circuit
E21 Abnormal A/C alarm E18 -- solar sensor short circuit The service effect of air conditioner is poor
Abnormal A/C alarm E43 -- Air blowing valve
abnormal
Abnormal A/C alarm E44 -- Abnormal air mixing
doors
(3) Faults of hydraulic mechanical system

The Faults of Hydraulic System and Mechanical System mainly introduces the diagnosis methods for the
common faults in the hydraulic system. For the faults of components itself, please see the details in the
chapter of "3.3.3 Hydraulic Elements". Please conduct the removal and installation for the elements in
strict accordance with the chapter of "7.Removal and installation".
The faults introduced in this chapter are shown in the table below
S/N Fault phenomenon

H1 Excessive braking angle for slewing stop
H2 Abnormal noise from pump mounting position
H3 When the engine is started, all operations are unresponsive.
H4 Hydraulic oil emulsification
H5 Abnormal hydraulic oil temperature rise
H6 Normal slewing cannot be achieved either in the left direction or in the right direction
H7 Unidirectional slewing operation is unresponsive
H8 Rotation cannot be stopped
H9 Unilateral travel mechanism fails to move completely
H10 Travel deflection
H11 Boom, arm or bucket moves slowly
H12 Boom, arm or bucket is unable to move
H13 Significantly reduced engine speed or engine stalling
H14 Abnormal fan speed
6-10
6.4 Fault Code CLG950E
6.4Fault Code
6.4.1Fault code 101001 Extremely low battery voltage
Fault code Fault description Consequence

Extremely low battery voltage (The controller
101001 detects the battery voltage is extremely low—— It is difficult to start the engine.
below 16V.)
System description
When the alternator does not work or generates a low voltage, the battery supplies power to the
electrical equipment. When the engine starts, the battery supplies power to the starter motor. When the
engine is started, the battery is charged by the alternator. When the electrical equipment needs more
power simultaneously and the alternator is overloaded, the battery assists the alternator to supply power.
A single battery has a rated voltage of 12V. The complete machine is powered by two batteries in series.
;
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6-11
CLG950E 6.4 Fault Code
Component position
Front
Battery
LG925E4F06003
Fault diagnosis and troubleshooting steps
Step 1 Check the battery terminals for looseness or rust
 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
6-12
Step 2 Check whether the battery voltage is too low
Make sure the start switch is at the OFF position before removing and installing 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 or
the injury to person due to short-circuit spark.
During the detection period, turn the start switch to the OFF position
Inspection method
There are three possible causes for low battery voltage:

1. Long time uncharged battery
2. Battery damage
3. Feed
Check the battery in the following procedures:
1. Check the inspection window for the battery. If the inspection window becomes black, the battery
needs to be charged. If the inspection window becomes white, the battery has been damaged. If the
inspection window 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. See the schematic diagram for detection as follows:
Black probe
Red probe
LG925E4F06004
Is the battery voltage too low?

Yes No
Charge or replace the battery.
6-13
Step 3 Check the charging harness for open-circuit (check whether the coupling ends become
loose)
Pay special attention to the following when the engine running:

1. Hot engine block can scald you seriously.
2. Prevent the harnesses, clothing and others from being drawn into the belts and the
flywheel.
3. Do not let the excavator move.
Correctly tie up harness and wire:

1. Avoid folding or bending the harness forcibly.
2. It shall be kept away from moving components as far as possible to prevent tensile failure
and wear.
3. Avoid friction with sharp metal edges.
4. Keep away from oil and water as far as possible.
5. Keep away from high temperature parts (e.g. engine body) as far as possible.
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 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
00.9
Starting motor Alternator
Connect the multimeter probes to both

ends of the charging harness
LG925E4F06005
6-14
Method B: Turn the start 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).
Connect the red probe Connect the black

to the alternator B+ probe to ground
LG925E4F06006
Whether the charging harness is open-circuit or not (the coupling ends become loose)?
Yes No
Repair the harness or re-connect it.
6-15
Step 4 Check whether the alternator fails or the output voltage is low

flywheel.
Inspection method
After the complete machine is started, there are two possible causes for the alternator fault:
1. The belt is too loose.
2. Alternator is faulty
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. Tension or replace the drive belt
2. Contact your local LiuGong dealer or
authorized service station.
6-16
Step 5 Check whether the controller power voltage is too low
Inspection method
1. Check the controller power line for wear and the coupling ends for looseness
2. Turn the multimeter to its DC voltage function (200V), and measure the voltage between the
controller power terminal (J1-2, J1-3, J1-4, J1-5, J1-6) and the grounding, respectively.

Connect the black
probe to ground
To the red probe
LG925E4F06007
Whether the controller power voltage is too low?

Yes No
Step 6 Check whether this fault is eliminated
Inspection method
Turn the start switch to the ON position and re-check the fault code.
Has this fault been eliminated?
Yes No
Troubleshoot the faults according to the steps
Maintenance is over again or contact the local LiuGong dealers and
authorized service centers.
6-17
Attached drawing
Alternator
Starting motor
LG925E4F06008
6-18
6.4.2Fault code 101003 High battery voltage

Extremely high battery voltage (The controller
101003 detects the battery voltage is extremely high—— The engine may shut down
higher than 30V)
System description
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6-19
Component position
Front
Battery
LG925E4F06003
Step 1 Check the battery voltage for fault
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. See the schematic diagram for detection as follows:
Black probe
Red probe
LG925E4F06004
Normally, the battery (2 packs) voltage is about 25V.

Whether the battery voltage is correct or not?
Yes No
Repair or replace the battery
6-20
Step 2 Check the alternator for faults

1. Hot engine block can scald you seriously
2. Prevent the harnesses, clothing and others from being drawn into the belts and the flywheel
3. Do not let the excavator move
Inspection method:
Start the engine. Turn the multimeter to its DC voltage function (200V), and connect the red probe to
the alternator B+ terminal and the black probe to the grounding. Measure the voltage between the
alternator B+ terminal and the grounding (normally, no more than 30V). For the alternator location, see
the attached drawing

LG925E4F06006
Whether the alternator fails?

Yes No
Contact your local LiuGong dealer or authorized
service station.
Go to Step 3
Go to Step 3
6-21
Inspection method
Yes No
Attached drawing
Alternator
LG925E4F06013
6-22
6.4.3Fault code 101017 Low battery voltage

Low battery voltage (The controller detects the
101017 battery voltage is low ——lower than 16V higher It is difficult to start the engine.
than 18V.)
System description
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6-23
Component position
Front
Battery
LG925E4F06003
Step 1 Check the battery terminals for looseness or rust
 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
Step 2 Check whether the battery voltage is too low
Make sure the start switch is at the OFF position before removing and installing 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 or
the injury to person due to short-circuit spark.
6-24
Inspection method
There are three possible causes for low battery voltage:

1. Long time uncharged battery
2. Battery damage
3. Feed
1. Check the inspection window for the battery. If the inspection window becomes black, the battery
needs to be charged. If the inspection window becomes white, the battery has been damaged. If the
inspection window is in the green status, the battery is good.
Black probe
Red probe
LG925E4F06004
If the voltage below 18V, this indicates the battery voltage is too low.
Is the battery voltage too low?
Yes No
Charge or replace the battery.
6-25
Step 3 Check the charging harness for open-circuit (check whether the coupling ends become
loose)

flywheel.

1. Avoid folding or bending the harness forcibly.
2. It shall be kept away from moving components as far as possible to prevent tensile failure
and wear.
3. Avoid friction with sharp metal edges.
4. Keep away from oil and water as far as possible.
5. Keep away from high temperature parts (e.g. engine body) as far as possible.
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 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
00.9
Starting motor Alternator
Connect the multimeter probes to both

ends of the charging harness
LG925E4F06005
6-26
Method B: Turn the start 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).

LG925E4F06006
Whether the charging harness is open-circuit or not (the coupling ends become loose)?
Yes No
6-27
Step 4 Check whether the alternator fails or the output voltage is low

flywheel.
Inspection method
After the complete machine is started, there are two possible causes for the alternator fault:
1. The belt is too loose.
2. Alternator is faulty
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. Tension or replace the drive belt
2. Contact your local LiuGong dealer or
authorized service station.
6-28
Step 5 Check whether the controller power voltage is too low
Inspection method
1. Check the controller power line for wear and the coupling ends for looseness
2. Turn the multimeter to its DC voltage function (200V), and measure the voltage between the
controller power terminal (J1-2, J1-3, J1-4, J1-5, J1-6) and the grounding, respectively.

Connect the black
probe to ground
To the red probe
LG925E4F06007
If the voltage is below 18V, this indicates the battery voltage is too low.
Whether the controller power voltage is too low?
Yes No
6-29
Inspection method
Yes No
Attached drawing
Alternator
Starting motor
LG925E4F06008
6-30
6.4.4DTC 111001 System charging fault

System charging fault (The controller detects
111001 Battery power loss.
the J2-28 port has 0V).
System description
The engine is accompanied with the alternator, and the silicon rectifier circuit and voltage adjuster with
the frequency output are installed in the alternator. After the engine is started, the alternator driven by the
drive belt starts generating (nominal voltage 28V). The current from the generating terminal (B+) flows
through the # 120 and #108 wires and the battery relay to the battery to charge it. The charging indicator
signal terminal (L) is connected to the controller J2-28 via the wire (# 928). The controller checks
whether the alternator is working properly through the signal terminal.
Alretnator
B+
Controller J2 G1
Battery charging indicator switch J2-28 28 928AEXWH 1 P
GND
2 L
3
4
30
120AEXOR15.0
RD70.0 108AEXOR70.0
50
M
RD70.0
BK70.0
B Start Moter
Battery
Battery Relay
E
GND
BK70.0
GND
LG925E4F06021
6-31
Component position
Alternator
Front
LG925E4F06022
Step 1 Check the alternator P terminal for electrical signal output (whether the alternator fails.).
Inspection method
2. Starts the engine and turn the multimeter to its voltage function, and then measure the voltage
between the alternator L terminal and ground (Normally, 14±0.5V).
Whether the alternator P terminal has no electrical signal output (the alternator fails)?
Yes No
Tension or replace the belt.
Contact local LiuGong dealers and authorized
service centers.
Go to Step 2
Go to Step 3
6-32
Step 2 Check the harness for open-circuit

Avoid folding or bending the harness forcibly.
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 body) as far as possible.
Inspection method
1. Check the # 928 harness (between the alternator L terminal and the J2-28 port) for wear.
2. Disconnect the connectors from the L terminal 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 P terminal (normally, <10Ω).
Is the harness open-circuit?
Yes No
Connect the harness again and wrap the harness.
Inspection method
Turn the start switch to the ON position and re-check for fault.
Yes No
6-33
6.4.5Fault code 121305 Hand pilot pressure switch OFF

121305 Hand pilot pressure switch OFF. No automatic idling.
System description
The hand pilot pressure switch is used to detect the hand pilot pipeline pressure and the logic signal
input for the automatic idling function. After the engine is started, open the pilot shut-off valve. Then,
when the hand pilot control lever is not operated, the pressure switch contact should be closed. When
the hand pilot control lever is operated, the pressure switch contact should be open. The automatic idling
function can be achieved only when the controller detects simultaneously the hand pilot switch and foot
pilot switch signals, that is, when one or two pilot pressure switches are unplugged, the automatic idling
function will be invalid.
3
Controller - δBlackε
3 Pressure Switch
Handle pilot pressure switch - :+

- δWhiteε
3
Foot pedal pressure switch -
3
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LG925E4F06027
6-34
Component position
Front
Foot pilot pressure switch
Hand pilot pressure switch
LG925E4F06028
Step 1 Check the hand pilot pressure switch for fault
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).
00.9
Connect the multimeter probes to two pins of

the hand pilot pressure switch, respectively.
LG925E4F06029
Whether the hand pilot pressure switch fails?

Yes No
6-35
Repair or replace the hand pilot pressure switch.


wear.
Inspection method
1. Check the harness (# 808) between the controller (J1-8) and the hand pilot pressure switch and the
grounding wire for wear.
2. Disconnect the connectors from the hand pilot pressure switch and the controller, and check the
harness for open-circuit:
a. Turn the multimeter to its resistance function, and measure the resistance between the grounding
wire hand pilot pressure switch terminal and the grounding (normally, <10Ω).
Black probe
Gray wire
Red probe
LG925E4F06030
6-36
b. Turn the multimeter to its resistance function, and measure the resistance between the connector
ports J1-8 and hand pilot pressure switch harness (normally, <10Ω).
To the black probe
To the red probe
White wire

LG925E4F06031

Yes No
6-37
Step 3 Check the connector for fault

Inspection method
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
port J1-8 and the grounding (normally, <10Ω).
35 12
23
13
24 1
To the black probe
To the red probe
LG925E4F06032
When the resistance is abnormal, this indicates the connector is poorly contacted.
Whether the connector fails?
Yes No
Replace the connector.
Inspection method
Yes No
6-38
6.4.6DTC 121405 Foot pilot pressure switch OFF

121405 Foot pilot pressure switch OFF. No automatic idling.
System description
The foot pilot pressure switch is used for detecting the foot pilot line pressure and the logic signal input
for automatic idling function. After the engine is started, open the pilot shut-off valve. Then, when the foot
pilot control lever is not operated, the pressure switch contact should be closed. When the foot pilot
control lever is operated, the pressure switch contact should be open. The automatic idling function can
be achieved only when the controller detects simultaneously the foot pilot switch and hand pilot switch
signals, that is, when one or two pilot pressure switches are unplugged, the automatic idling function will
be invalid.
P
Controller J1 δBlackε
P9 Pressure Switch
Handle pilot pressure switch J1-8 8 808WH 1
240GY 2 ᢁ‫ݾ‬ሲু࣑ᔶީ
J2 δWhiteε
13 P
Foot pedal pressure switch J2-13
P10
913WH 1 Pressure Switch
240GY 2 㝐‫ݾ‬ሲু࣑ᔶީ
GND
LG922E930E06013
6-39
Component position
Front
Foot pilot pressure switch
Hand pilot pressure switch
LG925E4F06028
Step 1 Check the foot pilot pressure switch for fault

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 and damage.
2. Turn the multimeter to its resistance function, and measure the resistance between the hand foot
pilot pressure switch connector terminals 1 and 2 (normally, <10Ω).
00.9
Connect the multimeter probes

to two pins of the foot pilot
pressure switch, respectively.
LG925E4F06035
Whether the foot pilot pressure switch fails?

Yes No
Repair or replace the foot pilot pressure switch.
6-40

wear.
Inspection method
1. Check the harness (# 913) between the controller (J2-13) and the foot pilot pressure switch and the
2. Disconnect the connectors from foot pilot pressure switch and the controller and check the harness
is open-circuited.
wire foot pilot pressure switch terminal and the grounding (normally, <10Ω).
Black probe
Gray
wire
Red probe
LG925E4F06036
6-41
ports J2-13 and foot pilot pressure switch harness (normally, <10Ω).

White
wire

To the red probe
To the black probe
LG925E4F06037

Yes No
6-42

Inspection method
Connect the foot pilot pressure switch connector and disconnect the controller connector. Turn the
port J2-13 and the grounding (normally, <10Ω).

To the black probe

To the red probe
LG925E4F06038
Yes No
Inspection method
Yes No
6-43
6.4.7Fault Code 121604 Air filter switch shorted to ground
121604 If the machine is operated as usual, the engine

Air filter switch shorted to ground
can be damaged
System description
The air prefilter is used to filter the dust and large impurities in the air before entering the air filter. The air
filter mounted on the inside of the left door of the complete machine is used to filter further the air from
the prefilter, and keep the air clean and dry through the main filter element and safety filter element
before entering into the engine cylinders for combustion. When the airflow through the air filter is blocked
and the air filter is needed to work, then if the engine is running, a high vacuum between the air filter and
the engine will produce. The vacuum can activate the electronic indicator (air filter switch) to generate
ground which is transmitted to the controller. The display will show the current situation to alert the
operator.
δWhiteε
Controller J2 P
WK Filter alarm SW
Air filter blocked alert J2-27 27 927WH
LG925E4F06039
Component position
Front
Air filter switch
LG925E4F06040
6-44
Step 1 Check the air filter switch for fault

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.
Step 2 Check the harness for shorted to ground

wear.
Inspection method
1. Check the harness (# 927) between the controller (J2-27) and the air filter switch for wear.
2. Disconnect the connectors from the air filter switch and the controller. Turn the multimeter to its
resistance function, and measure the resistance between the harness (# 927) switch terminal and
the grounding (normally, >100kΩ).
Whether the harness is shorted to ground or not?
Yes No
6-45

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.
Yes No
Inspection method
Yes No
6-46
6.4.8Fault Code 121615 Air filter clogging

Air filter clogging- When the engine is running,
121615 the signal circuit of the air filter switch detects If the machine is operated as usual, the engine
the air filter is clogged (the sensor contact is can be damaged.
closed).
System description
The air prefilter is used to filter the dust and large impurities in the air before entering the air filter. The air
filter mounted on the inside of the left door of the complete machine is used to filter further the air from
the prefilter, and keep the air clean and dry through the main filter element and safety filter element
before entering into the engine cylinders for combustion. When the airflow through the air filter is blocked
and the air filter is needed to work, then if the engine is running, a high vacuum between the air filter and
the engine will produce. The vacuum can activate the electronic indicator (air filter switch) to generate
ground which is transmitted to the controller. The display will show the current situation to alert the
operator.
δWhiteε
Controller J2 P
WK Filter alarm SW
Air filter blocked alert J2-27 27 927WH
LG925E4F06039
Component position
Front
Air filter switch
LG925E4F06040
6-47
Step 1 Check the air filter for clogging
Inspection method
Check whether the air filter for clogging

Whether the air filter is clogging?
Yes No
Clean or replace the air filter.
Step 2 Check the air filter monitoring system for fault

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
Yes No
6-48
6.4.9Fault Code 131200 Extremely high hydraulic oil temperature

Extremely high hydraulic oil temperature- When the
131200 engine is running, the signal circuit of the hydraulic If the machine is operated as usual, the
oil temperature sensor detects the hydraulic oil tem- hydraulic components can be damaged.
perature is extremely high (95°C/203°F).
System description
The temperature sensor is made of NTC temperature sensing material and is used for detecting
hydraulic oil temperature. The temperature sensor is a negative temperature coefficient thermistor type,
i.e., the lower the temperature, the larger the resistance. Therefore, the temperature change is converted
into a resistance voltage signal output, and through connecting to the ECM controller the temperature of
the hydraulic oil is detected, and the signal is transmitted to the instrument via the bus, and the
temperature of the hydraulic oil appears on the display. When the temperature is higher than a certain
value, an alarm signal is sent.
Hyd temperature Sensor

ECM Controller -
3
Hydraulic oil - :+
temperature
*<
Sensor to earthing -
LG925E4F06043
Component position
Front
Hydraulic oil temp sensor
LG925E4F06044
6-49
Step 1 Check whether the hydraulic oil temperature is extremely high
Be careful! Hot engine block and hydraulic oil can scald you seriously
Inspection method
Check whether the hydraulic oil is overheating with a thermometer.

Whether the hydraulic oil temperature is extremely high or not?
Yes No
Troubleshoot the high hydraulic oil temperature.
Step 2 Check the hydraulic oil temperature monitoring system for fault

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 fault diagnosis of 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
Yes No
6-50
6.4.10Fault Code 131203 Hydraulic oil temperature sensor voltage above

the range value

The controller detects the coolant temperature If the excavator is operated as usual, this can
131203 sensor voltage is higher than the range value, cause pump power down and damage to the
that is, the detected voltage is above 4.9V. hydraulic components.
System description

ECM Controller -
3
Hydraulic oil - :+
temperature
*<
LG925E4F06043
Hydraulic oil temperature sensor parameter table

Coolant temperature
50 60 70 80 85 90 95 100 105 110 115
(centigrade)
Coolant temperature (°F) 122 140 158 176 185 194 203 212 221 230 239
Resistance (ohms) 3509 2401 1678 1195 1015 865.5 741.2 637 549.8 476 411
6-51
Component position
Front
LG925E4F06044
Step 1 Check the hydraulic oil temperature sensor for fault
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 hydraulic oil temperature
sensor.
Go to Step 2
Go to Step 4

wear.
6-52
Inspection method
1. Check the harnesses (# 756 and # 743) between the ECM controller (J5-56, J5-32) and the
hydraulic oil temperature sensor for wear.
2. Disconnect the connectors from the hydraulic oil temperature sensor and the ECM controller. Turn
the multimeter to its resistance function, and measure the resistance of the harness (# 756/# 743)
between the ECM controller (J5-56, J5-32) and the hydraulic oil temperature sensor, respectively
(normally, <10Ω)
Yes No

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 ECM controller port
J5-56 and J5-32, comparing the result with the parameter table (normally, <4kΩ).
An abnormal resistance indicates that there is poor contact in the connector
Yes No
Inspection method
Yes No
6-53
6.4.11Fault Code 131204 Hydraulic oil temperature sensor voltage below

the range value
131204 The hydraulic oil temperature sensor voltage is If the machine is operated as usual, the
below the range valve. hydraulic pipeline can be damaged.
System description

ECM Controller -
3
Hydraulic oil - :+
temperature
*<
LG925E4F06043
Coolant temperature (°C) 50 60 70 80 85 90 95 100 105 110 115

Coolant temperature (°F) 122 140 158 176 185 194 203 212 221 230 239
Resistance (Ω) 3509 2401 1678 1195 1015 865.5 741.2 637 549.8 476 414
6-54
Component position
Front
LG925E4F06044
Step 1 Check the hydraulic oil temperature sensor for fault

Inspection method
Turn the knob switch to the OFF position, and disconnect the sensor connector:
1. Check the connector for moisture, oil dirt and other
2. Turn the multimeter to its resistance function (20 kΩ), and measure the resistance between the
sensor connector terminals 1 and 2, comparing the result with the parameter table (normally,
>10Ω).
Whether the hydraulic oil temperature sensor fails?
Yes No
Repair or replace the sensor.
6-55

wear.
Inspection method
1. Check the harnesses (# 756 and # 743) between the ECM controller (J5-56, J5-32) 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 (# 756/#
743) sensor terminal and the grounding, respectively (normally, >100kΩ).
Yes No

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 ECM controller port
J5-56 and J5-32, comparing the result with the parameter table (normally, >10Ω).
When the resistance is abnormal, this indicates there is an insulation fault in the connector
Yes No
6-56
Inspection method
Yes No
6-57
6.4.12Fault Code 131215 High hydraulic oil temperature

High hydraulic oil temperature - When the engine
is running, the signal circuit of the hydraulic oil If the machine is operated as usual, the
131215
temperature sensor detects the hydraulic oil hydraulic components can be damaged.
temperature is high (86°C/186.8°F).
System description

ECM Controller -
3
Hydraulic oil - :+
temperature
*<
LG925E4F06043
Component position
Front
LG925E4F06044
6-58
Step 1 Check whether the hydraulic oil temperature is too high
Inspection method
Check whether the hydraulic oil temperature is high with a thermometer.

Whether the hydraulic oil temperature is too high or not?
Yes No

Inspection method
Temperature Sensor Voltage Above the Range Value.
Yes No
sensor. Go to Step 3
Go to Step 3
Inspection method
Yes No
6-59
6.4.13Fault Code 131216 Extremely high hydraulic oil temperature

Extremely high hydraulic oil temperature- When the
131216 engine is running, the signal circuit of the hydraulic If the machine is operated as usual, the
oil temperature sensor detects the hydraulic oil tem- hydraulic components can be damaged.
perature is extremely high (88°C/190.4°F).
System description

ECM Controller -
3
Hydraulic oil - :+
temperature
*<
LG925E4F06043
Component position
Front
LG925E4F06044
6-60
Step 1 Check whether the hydraulic oil temperature is extremely high
Inspection method
Check whether the hydraulic oil temperature is extremely high with a thermometer.
Whether the hydraulic oil temperature is extremely high or not?
Yes No

Inspection method
Temperature Sensor Voltage Outside the Range Value.
Yes No
sensor.
Inspection method
Yes No
6-61
6.4.14Fault Code 131303 Fuel level sensor voltage above the range value

If the machine is operated as usual, the engine
131303 Fuel level sensor voltage above the range value
will shut down.
System description
The fuel level sensor is a reed pipe type. The magnetic floater density is lower than the working medium
(diesel) density, so the fuel level sensor floats on the surface of the working medium and can slide up
and down on the reed pipe. When the floater moves on the reed pipe, the on-off of the internal circuit of
the reed pipe is controlled by a magnetic field to allow the resistance between the two output leads of the
connector to change. Therefore, the fuel level change is converted into a resistance signal output, and
through connecting to the controller the fuel level in the tank is detected, and through connecting to the
display instrument the fuel level is displayed.
Controller - δWhiteε (
Fuel level - :+
Fuellevel sensor

*1'
LG925E4F06053
Fuel level sensor parameter table (for the details, see the attached drawing)
Component position
Front
Fuel level sensor
LG925E4F06054
6-62
Step 1 Check the fuel level sensor for fault

High temperature and high pressure oil or water can cause personal injury! When replacing
the sensor, please shut down the engine first, wait until the engine and gearbox housing are
sufficiently cooled.
To install the fuel level sensor into the fuel tank, wipe off its water and keep it clean.
Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the fuel level sensor:
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.).
.453
LG925E4F06055
Whether the fuel level sensor fails?

Yes No
Repair or replace the fuel level sensor.
6-63

wear.
6-64
Inspection method
1. Check the harness (# 930) and the grounding wire between the controller (J2-30) and fuel level
sensor for wear.
2. Disconnect the connectors from the fuel level sensor and the controller. Check the harness for
open-circuit:
wire sensor terminal and the grounding (normally, <10Ω).
Gray wire
LG925E4F06056
ports J2-30 and sensor harness (normally, <10Ω).

White wire

To the black probe

To the red probe
LG925E4F06057

Yes No
6-65

Inspection method
Connect the water-in-fuel sensor connector and disconnect the controller connector. Turn the
port J2-30 and the grounding (normally, 2kΩ, for the specific resistance, see the attached drawing).
Connect the black
probe to ground

Connect the red

probe to Pin 30 LG925E4F06058
Yes No
Inspection method
Yes No
6-66
Attached drawing: Fuel level sensor parameter table
Floater position (be subject to 17.5mm) Output resistance

ȍ
/ԛс f
// f
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LG925E4F06059
6-67
6.4.15Fault Code 131304 Fuel level sensor shorted to ground
131304 If the machine is operated as usual, the engine

The fuel level sensor is shorted to ground
will shut down.
System description
Fuel level - :+
Fuellevel sensor

*1'
LG925E4F06053
Component position
Front
Fuel level sensor
LG925E4F06054

6-68

Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the fuel level sensor
2. Turn the multimeter to its resistance function (2kΩ), and measure the resistance between the fuel
level sensor terminals 1 and 2 (normally, >10Ω, for the details, see the figure).
.453
LG925E4F06055

Yes No
6-69

wear.
Inspection method
1. Check the harness (# 930) between the controller (J2-30) and fuel level sensor for wear.
2. Disconnect the connectors from the fuel level sensor and the controller. Turn the multimeter to its
resistance function, and measure the resistance between the harness (# 930) sensor terminal and
the grounding (normally, >100kΩ).
Gray wire
LG925E4F06056

Yes No
6-70

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).
Yes No
Inspection method
Yes No
6-71

ȍ
/ԛс f
// f
// f
// f
// f
// f
// f
// f
// f
// f
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// f
// f
// f
// f
// f
// f
// f
// f
// f
// f
LG925E4F06059
6-72

f
/
f

f
/
f

f
/
f

/
f
f

/ f
f

f
/
f

f
/
f

f
/
f

f
/
f

f
/
f

/

/

/

/

/

/

/

/

/

/
/
Oil level

LG925E4F06060
6-73
6.4.16Fault code 131317 Low fuel level

Low fuel level - When the start switch is turned
131317 to the ON position (without starting the engine), If the machine is operated as usual, the engine
the signal circuit of the fuel level sensor detects will shut down.
that the fuel level is low (below 10%).
System description
connector to change. Therefore, the fuel level change is converted into a resistance signal output , and
Fuel level - :+
Fuellevel sensor

*1'
LG925E4F06053
Component position
Front
Fuel level sensor
LG925E4F06054
6-74
Step 1 Check whether the fuel level is low
Inspection method
Check the fuel level.

Whether the fuel level is too low or not?
Yes No
Add fuel.
Step 2 Check the fuel level monitoring system for fault

Inspection method
If the fuel level is normal, check the fuel level monitoring system in accordance with the fault diagnosis
in the 131304- Fuel Level below the Lower Limit.
Whether the fuel level monitoring system fails?
Yes No
Inspection method
Yes No
6-75

ȍ
/ԛс f
// f
// f
// f
// f
// f
// f
// f
// f
// f
// f
// f
// f
// f
// f
// f
// f
// f
// f
// f
// f
LG925E4F06059
6-76

f
/
f

f
/
f

f
/
f

/
f
f

/ f
f

f
/
f

f
/
f

f
/
f

f
/
f

f
/
f

/

/

/

/

/

/

/

/

/

/
/
Oil level

LG925E4F06060
6-77
6.4.17Fault Code 131603 Water-in-fuel sensor voltage above the range

value

The water-in-fuel sensor voltage is higher than
131603 the range value. The signal circuit of the water-
The engine can not be started.
in-fuel sensor detects the voltage is too high
(more than 4.3V)
System description
The water-in-fuel sensor is used to detect water content in the fuel. The more the water in the fuel, the
smaller the resistance. Therefore, the change in water content is converted into the resistance voltage
signal output, and through connecting to the ECM controller the water in the fuel is detected, and an
alarm signal is sent.
Water in fuel sensor

ECM Controller J5 E1
Water in fuel sensor 13 350AEXWH 1
ECM Sensor switch 62 620AEXGY 2
grounding
LG925E4F06071
Component position
Front
Water in
fuel sensor
LG925E4F06072
6-78
Step 1 Check the water-in-fuel sensor for fault

Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the water-in-fuel sensor:
2. Turn the multimeter to its resistance function, and measure the resistance between the water-in-fuel
sensor connector terminals 1 and 2 (normally,2.62kΩ--4.6MΩ).
Whether the water-in-fuel sensor fails?
Yes No
Repair or replace the water-in-fuel sensor.

wear.
Inspection method
1. Check the harness (# 350) between the ECM controller (J5-13) and water-in-fuel level sensor and
the switch grounding wire for wear.
2. Disconnect the connectors from the water-in-fuel sensor and the ECM controller. Check the
a. Turn the multimeter to its resistance function, and measure the resistance between the ECM
sensor switch grounding (#620) and sensor connecting terminal (normally, <10Ω).
b. Turn the multimeter to its resistance function, and measure the resistance of harness between
the controller port J5-13 and sensor (normally, <10Ω).
Yes No
6-79

Inspection method
Connect the water-in-fuel sensor connector and disconnect the ECM controller connector. Turn the
multimeter to its resistance function, and measure the resistance between the harness at the ECM
controller port J5-13 and J5-62 (normally, 2.62kΩ--4.6MΩ).
Yes No
Inspection method
Yes No
6-80
6.4.18Fault Code 131604 Water-in-fuel sensor voltage below the range

value

The water-in-fuel sensor voltage is below the
131604 range value. The signal circuit of the water-in-
There is white smoke from the engine
fuel sensor detects the power voltage is too low
(below 0.25V)
System description
signal output, and through connecting to the ECM controller the water in the fuel is detected, and an

grounding
LG925E4F06071
Component position
Front
Water in
fuel sensor
LG925E4F06072
6-81

Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the water-in-fuel sensor
sensor connector terminals 1 and 2 (normally,>2.62kΩ).
Yes No

wear.
Inspection method
1. Check the harness (# 350) between the ECM controller (J5-13) and the water-in-fuel sensor for
wear.
2. Disconnect the connectors from the water-in-fuel sensor and the ECM controller, respectively. Turn
the multimeter to its resistance function, and measure the resistance between the harness (# 350)
sensor terminal and the grounding (normally, >100kΩ).
Yes No
6-82

Inspection method
multimeter to its resistance function, and measure the resistance between the controller port J2-21 and
the grounding (normally, >2.62kΩ).
Yes No
Inspection method
Yes No
6-83
6.4.19Fault Code 131605 Water-in-fuel sensor open-circuit

The water-in-fuel sensor is open-circuit (The
131605 signal circuit of the water-in-fuel sensor is open-
circuit)
System description
signal output, and through connecting to the controller the water content in the fuel is detected, and an

grounding
LG925E4F06071
Component position
Front
Water in
fuel sensor
LG925E4F06072
6-84

Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the water-in-fuel sensor:
sensor connector terminals 1 and 2 (normally, <4.6M).
Yes No

It shall be kept away from moving components as far as possible to prevent tensile failure and wear.
Inspection method
1. Check the harness (# 921) and the grounding wire (# 254) between the controller (J2-21) and the
water-in-fuel sensor for wear.
2. Disconnect the connectors from the water-in-fuel sensor and the controller. Check the harness for
open-circuit:
wire (#254) sensor terminal and the grounding (normally, <10Ω).
b. Turn the multimeter to its resistance function, and measure the resistance of harness between
the connector ports J2-21 and sensor (normally, <10Ω).
Yes No
6-85

Inspection method
port J2-21 and the grounding (normally, <4.6 MΩ).
Yes No
Inspection method
Yes No
6-86
6.4.20Fault code 131615 Water-in-fuel

Water-in-fuel——When the start switch is turned
131615 to the ON position (without starting the engine), If the machine is operated as usual, the engine
the signal circuit of the water-in-fuel sensor power will reduce.
detects there is water in the fuel.
System description
signal output, and through connecting to the controller the water content in the fuel is detected, and an
Oil water separation warning sensor

ECM Sensor switch grounding 62 620AEXGY 2
LG925E4F06077
Component position
Front
Water in
fuel sensor
LG925E4F06072
6-87
Step 1 Check the fuel for water.
Inspection method
Check the fuel-water separator for water.

Whether water in the fuel or not?
Yes No
Drain the water in the fuel.
Step 2 Check the water-in-fuel monitoring system for fault

Inspection method
If the fuel is normal, check the water-in-fuel detection circuit or the water-in-fuel sensor for fault in
accordance with the fault diagnosis in the 131604- Water-in-Fuel Sensor Voltage below the Range
Value or 131603- Water-in-Fuel Sensor Voltage above the Range Value.
Whether the water-in-fuel monitoring system fails?
Yes No
Repair the water-in-fuel detection circuit or replace
the water-in-fuel sensor.
Go to Step 3
Go to Step 3
Inspection method
Yes No
6-88
6.4.21Fault code 131703 Sensor power (5V) shorted to the power supply
of the complete machine
131703 Sensor power (5V) shorted to the power supply The working gear of the complete machine can
of the complete machine not work normally.
System description
The accelerator control system is mainly composed of accelerator potentiometer(accelerator knob) ,

controller and engine. Schematic: 828 is 5V power line, and 829 is accelerator position signal line, rotate
the accelerator knob clockwise and 829 outputs 0.5-4.5V power supply. The controller, depending on
the received voltage signal, controls the engine speed. The pressure sensor used to measure system
pressure also requires 5V power supply.
LG950E4f06001
Component position
Accelerator
potentiometer
Controller
LG925E4F06193
6-89
Front P2 pump pressure sensor
P1 pump pressure sensor
LG950E4f06002
Step 1 Check whether the sensor power (5V) is shorted to the power supply of the complete
machine

wear.
Inspection method
Turn the start switch to the ON position and disconnect the connector of controller to switch on the
switches of all electrical equipment, and then measure the voltage between the J1-28 port (# 828) and
ground (normally, 0V).
Whether the sensor power (5V) is shorted to the battery or not?
Yes No
Re-connect the harness and wrap it or replace the
connector.
Go to Step 2
Go to Step 2
6-90
Inspection method
Yes No
6-91
6.4.22Fault Code 131704 Sensor power (5V)shorted to ground
131704 The accelerator actuator cannot function

The sensor power (5V) is shorted to ground
properly.
System description

the accelerator knob clockwise and 829 outputs 0.5-4.5V power supply. The controller, depending on
the received voltage signal, controls the engine speed. The pressure sensor used to measure system
pressure also requires 5V power supply.
LG950E4f06001
Component position
Accelerator
potentiometer
Controller
LG925E4F06193
6-92
Front P2 pump pressure sensor
P1 pump pressure sensor
LG950E4f06002
Step 1 Check the accelerator knob or actuator for fault

Inspection method
Turn the start switch to the OFF position and disconnect the connectors from the accelerator knob and
each pressure transmitter:
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 connector (normally, >10Ω).
Whether the accelerator knob or actuator fails?
Yes No
Repair or replace the accelerator knob.
6-93

wear.
Inspection method
1. Check the harnesses (# 828 and # 922) between the controllers (J1-28 and J2-22) and the
accelerator knob for wear.
2. Disconnect the accelerator knob and the controller connectors, turn the multimeter to its resistance
function, and measure the resistance between the terminal opposite to the harness (# 828 and #
922) controller and the grounding, respectively (normally, >100kΩ).
Yes No

Inspection method
1. Connect the accelerator knob connector and the controller connector, turn the multimeter to its
resistance function, and measure the resistance between the controller ports J1-28 and J2-22
(normally, >10Ω).
2. Connect the 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 J2-22 (normally, >10Ω).
When the resistance in any step above is abnormal, this indicates an insulation fault develops in the
connector.
Yes No
6-94
Inspection method
Yes No
6-95
6.4.23Fault Code 141005 Pump proportional solenoid valve feedback

open-circuit
141005 Pump proportional solenoid valve feedback

The complete machine moves slowly.
open-circuit
System description
The pilot pump provides oil to the electromagnetic proportional pressure-reducing valve on the main
pump directly. The electromagnetic proportional pressure-reducing valve regulates the displacement of
the main pump based on various operating conditions.
Pump proprtional solenoid
Pump solenoid current Main A10

pump PWM signal J2-05 05 905WH1.25 1
Pump solenoid current feedback J2-01 01 901WH1.25 2
LG925E4F06083
Component position
Front
Pump proportional
solenoid valve
LG925E4F06084
6-96
Step 1 Check the pump proportional solenoid valve for fault

Inspection method
Turn the start switch to the OFF position and disconnect the pump proportional solenoid valve
connector:
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 2
Go to Step 4

wear.
Inspection method
1. Check the harness (No. 905/No. 901) between the controller and the pump proportional solenoid
valve for wear.
2. Disconnect the connectors from the pump proportional solenoid valve and the controller,
respectively. Turn the multimeter to its resistance function, and measure the resistance of the
harness (# 905/# 901) between the controller and the solenoid valve, respectively (normally, <10Ω).
Yes No
6-97

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).
Yes No
Inspection method
Yes No
6-98
6.4.24Fault Code 141006 Pump proportional solenoid valve feedback

overcurrent
141006 Pump proportional solenoid valve feedback The engine gets stuck or even shuts down in a
overcurrent low gear.
System description

LG925E4F06083
Component position
Front
Pump proportional
solenoid valve
LG925E4F06084
6-99

Inspection method
connector
Yes No
valve.
Go to Step 2
Go to Step 4
Step 2 Check the harness for short-circuit

wear.
Inspection method
1. Check the harnesses (# 901 and # 905) between the controller (J2-01 and J2-05 ) and the pump
proportional solenoid valve for wear. 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 (# 901 and # 905) between the solenoid valve terminals
3. Check whether the harness is shorted to the power supply: turn the start switch to the ON position
and switch on the switches of all electrical equipment, and then measure the voltage between the
harness (# 901 and # 905) solenoid valve terminal and the grounding (normally, 0V)
Is the harness short-circuit?
Yes No
6-100

Inspection method
Yes No
Inspection method
Yes No
6-101
6.4.25Fault Code 141104 Pump proportional solenoid valve shorted to

ground

Pump proportional solenoid valve shorted to
141104 Works slowly
ground
System description

LG925E4F06083
Component position
Front
Pump proportional
solenoid valve
LG925E4F06084
6-102

Inspection method
connector
Yes No
valve.
Go to Step 2
Go to Step 4

wear.
Inspection method
1. Check the harnesses (# 901 and # 905) between the controller (J2-01 and J2-05 ) and the pump
proportional solenoid valve for wear.
2. Disconnect the connectors from the pump proportional solenoid and the controller. Turn the
multimeter to its resistance function, and measure the resistance between the harnesses (No. 904
and No. 905) solenoid valve terminal and the grounding, respectively (normally, >100kΩ)
Yes No
6-103

Inspection method
the multimeter to its resistance function, and measure the resistance between the controller port J2-01
and the grounding (normally 16~40Ω).
Yes No
Inspection method
Yes No
6-104
6.4.26Fault code 141105 Pump proportional solenoid valve open-circuit

or shorted to the power supply

Pump proportional solenoid valve open-circuit
141105 The engine gets stuck
System description

LG925E4F06083
Component position
Front
Pump proportional
solenoid valve
LG925E4F06084
6-105

Inspection method
connector:
Yes No
valve.
Go to Step 2
Go to Step 4
Step 2 Check whether the harness is open-circuit or shorted to the power supply

wear.
Inspection method
1. Check the harness (No. 905/No. 901) between the controller and the pump proportional solenoid
valve for wear.
Disconnect the connectors from the pump proportional solenoid valve and the controller.
3. Check the harnesses for open-circuit. Turn the multimeter to its resistance function, and measure
the resistance of the harnesses (#905 and #901) between the controller and the solenoid valve,
respectively (normally,<10Ω).
Whether the harness open-circuit or shorted to the power supply or not?
6-106
Yes No

Inspection method
Yes No
Inspection method
Yes No
6-107
6.4.27Fault Code 151004 Attachment confluence solenoid valve shorted

to ground

Attachment confluent solenoid valve shorted to
151004 There is no hydraulic shear function
ground
System description
The attachment confluent solenoid valve (hydraulic shear function solenoid valve, ATT function solenoid
valve) (optional) is used to control realization of hydraulic shear function.
Shear function solenoid(option)

Controller J2
A12
ATT solenoid valve J2-12 12 912WH 1
2
GND
LG925E4F06091
Component position
Front
Attachment confluent
solenoid valve (position)
LG925E4F06092
6-108
Step 1 Check the attachment confluent solenoid valve for fault

Inspection method
Turn the start switch to the OFF position and disconnect the attachment confluent solenoid valve
connector
2. Turn the multimeter to its resistance function, and measure the resistance between the attachment
confluent solenoid connector terminals 1 and 2 (normally, 16~40Ω).
Whether the attachment confluent solenoid valve fails?
Yes No
Repair or replace the attachment confluent
solenoid valve.
Go to Step 2
Go to Step 4

wear.
Inspection method
1. Check the harness (No. 912) between the controller (J2-12) and the attachment confluent solenoid
valve for wear.
2. Disconnect the connectors from the attachment confluent solenoid valve and the controller. Turn
the multimeter to its resistance function, and measure the resistance between the harness (No.
912) solenoid valve terminal and the grounding (normally, >100kΩ)
Yes No
6-109

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 controller port
J2-12 and the grounding (normally, 16~40Ω).
Yes No
Inspection method
Yes No
6-110
6.4.28Fault code 151005 attachment confluent solenoid valve open-

circuit or shorted to the power supply

Attachment confluent solenoid valve open-
151005 There is no hydraulic shear function
circuit or shorted to the power supply
System description
The attachment confluent solenoid valve (hydraulic shear function solenoid valve, ATT function solenoid
valve) (optional) is used to control realization of hydraulic shear function.
Shear function solenoid(option)

Controller J2
A12
ATT solenoid valve J2-12 12 912WH 1
2
GND
LG925E4F06091
Component position
Front
Attachment confluent
solenoid valve (position)
LG925E4F06092
6-111
Step 1 Check the attachment confluent solenoid valve for fault

Inspection method
Turn the start switch to the OFF position and disconnect the attachment confluent solenoid valve
connector:
2. Turn the multimeter to its resistance function, and measure the resistance between the attachment
confluent solenoid connector terminals 1 and 2 (normally, 16~40Ω).
Whether the attachment confluent solenoid valve fails?
Yes No
Repair or replace the attachment confluent
solenoid valve.
Go to Step 2
Go to Step 4

wear.
Inspection method
1. Check the harness (# 912) between the controller and the attachment confluent solenoid valve or
the grounding wire for wear.
Disconnect the connectors from the attachment confluent solenoid valve and the controller.
and turn on all switches of the electrical equipment, and then measure the voltage between the
harness (#912) solenoid valve terminal and the grounding (normally, 0V).
3. Check the harness for open-circuit. Turn the multimeter to its resistance function, and measure the
resistance of the harness (#912) between the controller and the solenoid valve and that of the
harness between the solenoid valve and the grounding, respectively (normally, <10Ω).
6-112
Yes No

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).
Yes No
Inspection method
Yes No
6-113
6.4.29Fault Code 151204 A2 Travel shift solenoid shorted to ground

The travel shift solenoid valve is shorted to
151204 There is no travel shift function.
ground.
System description
The controller outputs a signal to the travel shift solenoid valve through the harness (# 910) to open the
valve port.
Controller
J2
J2-10 10 910WH A2 1
valve (valve A2) A2 Travel speed solenoid
2
LG925E4F06095
Component position
Front
A2-marked solenoid
valve can be located.
LG925E4F06096
6-114
Step 1 Check the travel shift solenoid valve for fault

Inspection method
Turn the start switch to the OFF position and disconnect the valve connector from the travel shift
solenoid valve.
1. Check the pins for moisture, oil dirt and other.
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 lifting solenoid valve.
Step 2 Check whether the power harness of the travel shift solenoid valve is shorted to ground
Shutdown operation is needed

Inspection method
1. Turn the start switch to the OFF position for fault diagnosis.
2. Disconnect the connectors from the controller (in the attached drawing) and travel speed solenoid
valve, and measure the resistance between the power line (No. 910) of travel speed solenoid valve
and the grounding, the resistance should be greater than 100kΩ.
Whether the power harness of the travel shift solenoid valve is shorted to ground or not?
Yes No
Re-connect the harness, and wrap it.
6-115
Step 3 Check the connectors for fault

Inspection method
Connect the travel shift solenoid valve connector and disconnect the controller connector. Turn the
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

LG925E4F06097

Yes No
Inspection method
Turn the start switch to the ON position and re-check the fault code
Yes No
6-116
Attached drawing
Controller
Controller connector
Front
LG925E4F06098
6-117
6.4.30Fault code 151205A2 Travel shift solenoid valve open-circuit or

shorted to the power supply

A2 travel shift solenoid valve is open-circuite or There is no travel shift function or the travel shift
151205
shorted to the power supply. solenoid valve is uncontrolled by the controller.
System description
The controller outputs a signal to the travel shift solenoid valve through the harness (# 910) to open the
valve port.
Controller
J2
J2-10 10 910WH A2 1
valve (valve A2) A2 Travel speed solenoid
2
LG925E4F06095
Component position
Front
A2-marked solenoid
LG925E4F06096
6-118
Step 1 Check the travel shift solenoid valve for fault

Inspection method
Turn the start switch to the OFF position and disconnect the connector from the travel shift solenoid
valve.
1. Check the pins for looseness, rust, bending and damage.
2. Measure the resistance between both ends of the travel speed solenoid valve. The resistance
should be 16~40Ω
Whether the travel shift solenoid valve fails?
Yes No

wear.
6-119
Inspection method
1. Check the harness (# 910) and the grounding wire between the controller (J2-10) (attached
drawing) and the travel shift solenoid valve for wear.
2. Disconnect the connectors between travel speed solenoid and controller and check whether the
harness is open-circuited:
a. Turn the multimeter to its resistance function, and measure the resistance between the controller
ports J2-10 and travel speed solenoid valve harness (normally, <10Ω).
b. Turn the multimeter to its resistance function, and measure the resistance between the grounding
wire travel shift solenoid valve connecting terminal and the grounding (normally, <10Ω).
Definition of
connector pin
serial number

LG925E4F06097

Yes No
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 (# 910) 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.
Yes No
Repair or replace the connector.
6-120
Step 4 Check whether the travel shift solenoid valve is shorted to the power supply
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 0V.
Whether the travel shift solenoid valve is shorted to the power supply 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
Yes No
Attached drawing
Controller
Front
LG925E4F06098
6-121
6.4.31Fault Code 151304 A3 Flattening solenoid valve shorted to ground

151304 Flattening solenoid valve shorted to ground. There is no flattening function.
System description
The controller outputs a signal to the flattening solenoid valve through the harness (# 827) to open the
valve port.
A3 Flattening function solenoid

A3
Controller J1
Flattening solenoid
valveδA3ε J1-27 27 827WH 1
2
CND
LG925E4F06103
Component position
Front
A3-marked solenoid
LG925E4F06107
6-122
Step 1 Check the flattening solenoid valve for fault

Inspection method
Turn the start switch to the OFF position and disconnect the connector from the travel shift solenoid
valve.
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.
Step 2 Check whether the power line of the flattening solenoid valve is shorted to ground

Inspection method
Turn the start switch to the OFF position for fault diagnosis
Disconnect the connectors from the controller (attached drawing) and the flattening solenoid valve, and
measure the resistance between the power line (# 827) of the flattening solenoid valve and the
grounding. The resistance should be greater than 100kΩ.
Whether the power line of the flattening solenoid valve is shorted to ground or not?
Yes No

6-123
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
Definition of
connector pin
serial number

LG925E4F06097

Yes No
Inspection method
Yes No
6-124
Attached drawing
Controller
Front
LG925E4F06098
6-125
6.4.32Fault code 151305 A3 Flattening shift solenoid valve open-circuit


A3 Flattening solenoid valve is open-circuit or There is no flattening function or the flattening
151305
shorted to the power supply. solenoid valve is uncontrolled by the controller.
System description
The controller outputs a signal to the flattening solenoid valve through the harness (# 827) to open the
valve port.
A3 Flattening function solenoid

A3
Controller J1
Flattening solenoid
valveδA3ε J1-27 27 827WH 1
2
CND
LG925E4F06103
Component position
Front
A3-marked solenoid
LG925E4F06107
6-126
Step 1 Check the flattening solenoid valve for fault

Inspection method
Turn the start switch to the OFF position, and disconnect the travel shift solenoid valve connector
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.

wear.
6-127
Inspection method
1. Check the harness (# 827) between the controller (J1-27) and the flattening solenoid valve and the
2. Disconnect the connectors from the flattening solenoid valve and the controller. Check the harness
for open-circuit:
a. Turn the multimeter to its resistance function, and measure the resistance between the connector
ports J1-27 and flattening solenoid valve harness (normally, <10Ω).
b. 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

LG925E4F06097

Yes No

Inspection method
Connect the flattening solenoid valve connector and disconnect the controller connector. Turn the
Yes No
6-128
Step 4 Check whether the flattening solenoid valve is shorted to the power supply
Inspection method

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
Whether the flattening solenoid valve is shorted to the power supply or not?
Yes No
Go to Step 5
Go to Step 5
Inspection method
Yes No
Attached drawing
Controller
Front
LG925E4F06098
6-129
6.4.33Fault Code 151404 A8 Trenching solenoid valve shorted to the

ground

151404 The digging solenoid valve is shorted to ground. There is no digging function.
System description
The controller outputs a signal to the digging solenoid valve A8 through the harness (# 825) to open the
valve port.

A8
Controller J1
Trenching solenoid valve
(Valve A8) J1-25 25 825WH 1
LG925E4F06110
Component position
Front A8-marked solenoid

valve can be located
LG925E4F06111
6-130
Step 1 Check the digging solenoid valve for fault

Inspection method
Turn the start switch to the OFF position and disconnect the connector from the digging solenoid valve.
2. Measure the resistance between both ends of the digging solenoid valve. The resistance should be
16~40Ω.
Whether the digging solenoid valve fails?
Yes No
Repair or replace the digging solenoid valve.
Step 2 Check whether the power harness of the digging solenoid valve is shorted to ground

Inspection method
1. Turn the start switch to the OFF position for fault diagnosis
2. Disconnect the connectors from the controller (attached drawing) and the digging solenoid valve,
and measure the resistance between the power line (# 825) of the trenching solenoid valve and the
grounding. The resistance should be infinite.
Whether the power harness of the digging solenoid valve is shorted to ground or not?
Yes No

6-131
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
Definition of
connector pin
serial number

LG925E4F06097

Yes No
Inspection method
Yes No
6-132
Attached drawing
Controller
Front
LG925E4F06098
6-133
6.4.34Fault code 151405 A8 Digging solenoid valve open-circuit or


The digging solenoid valve is open-circuit or There is no digging function or always in the
151405
shorted to the power supply. digging function state.
System description
The controller outputs a signal to the digging solenoid valve A8 through the harness (# 825) to open the
valve port.

A8
Controller J1
Trenching solenoid valve
(Valve A8) J1-25 25 825WH 1
LG925E4F06110
Component position

LG925E4F06111
6-134
Step 1 Check the digging solenoid valve for fault

Inspection method
Turn the start switch to the OFF position and disconnect the connector from the digging solenoid valve.
2. Measure the resistance between both ends of the digging solenoid valve. The resistance should be
16~40Ω.
Whether the digging solenoid valve fails?
Yes No
Repair or replace the digging solenoid valve.

wear.
6-135
Inspection method
1. Check the harness (# 825) between the controller port J1-25 (attached drawing) and the digging
solenoid valve and the grounding wire for wear.
2. Disconnect the connectors from the digging solenoid valve and the controller, and check the
port J1-25 and trenching solenoid valve harness (normally, <10Ω).
b. Turn the multimeter to its resistance function, and measure the resistance between the digging
solenoid valve connecting terminal and the grounding (normally, <10Ω).
Definition of
connector pin
serial number

LG925E4F06097

Yes No

Inspection method
Connect the digging solenoid valve connector and disconnect the controller connector. Turn the
Yes No
6-136
Step 4 Check whether the digging solenoid valve is shorted to the power supply
Inspection method

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 digging solenoid valve is shorted to the power supply or not?
Yes No
Go to Step 5
Go to Step 5
Step 5
Inspection method
Yes No
Attached drawing
Controller
Front
LG925E4F06098
6-137
6.4.35Fault Code 151504 A5 Flow adjusting solenoid shorted to ground

151504 A5 flow adjusting solenoid is shorted to ground. There is no flow adjusting function.
System description
The controller outputs current signals to A5 flow adjusting solenoid valve through wire #908 and then the
signal returns to the controller through wire #924. The port size of A5 flow adjusting solenoid valve is
controlled through outputting different current signal to solenoid valve.
Controller A5 Flow adjust solenoid 2

J2 A5
J2-8 8 908WH1.25 1
solenoid 2 Valve A5
Pq1 & PQ2 flow adjusting solenoid
J2-24 24 924WH1.25 2
valve (A6 & A5)
LG925E4F06118
Component position
Front
A5-marked solenoid
LG925E4F06119
6-138
Step 1 Check the flow adjusting solenoid valve for fault

Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the flow adjusting solenoid
valve.
2. Measure the resistance between both ends of the flow adjusting solenoid valve (normally16-40Ω).
Whether the flow adjusting valve fails?
Yes No
Repair or replace the flow adjusting solenoid valve.
Step 2 Check whether the harness of A5 flow adjusting solenoid valve is shorted to ground

Inspection method
2. Disconnect the connectors from the controller (attached drawing) and the A5 flow adjusting
solenoid valve, and measure the resistance between ports J2-8 and J2-24 of connector and the
grounding . The resistance should be greater than 100kΩ.
Definition of
connector pin
serial number

LG925E4F06097
Whether the harness of A5 flow adjusting solenoid valve is shorted to ground or not?
Yes No
6-139

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.
Yes No
Inspection method
Yes No
Attached drawing
Controller
Front
LG925E4F06098
6-140
6.4.36Fault code 151505 A5 flow adjusting solenoid valve open-circuit or


A5 flow adjusting solenoid valve is open-circuit
151505 There is no flow adjusting function.
or shorted to the power supply.
System description
Controller A5 Flow adjust solenoid 2

J2 A5
J2-8 8 908WH1.25 1
solenoid 2 Valve A5
J2-24 24 924WH1.25 2
valve (A6 & A5)
LG925E4F06118
Component position
Front
A5-marked solenoid
LG925E4F06119
6-141

Inspection method
valve.
Yes No

wear.
6-142
Inspection method
1. Check the harness (# 908 and #924)between the controller (J2-8) (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:
a. Turn the multimeter to its resistance function, and measure the resistance between the connector
ports J2-8 and flow adjusting solenoid valve port A5-1 (normally, <10Ω).
ports J2-24 and flow adjusting solenoid valve port A5-2 (normally, <10Ω).
Definition of
connector pin
serial number

LG925E4F06097

Yes No

Inspection method
of controller (normally, 16~40Ω). When the resistance is abnormal, this indicates there is a fault in the
connector.
Yes No
6-143
Step 4 Check whether the flow adjusting solenoid valve is shorted to the power supply
Inspection method

Disconnect the connectors from the controller and A5 flow adjusting solenoid valve to switch on the
switches of all electrical equipment, and then measure the voltage of the harness of A5 flow adjusting
Whether the flow adjusting solenoid valve is shorted to the power supply or not?
Yes No
Go to Step 5
Go to Step 5
Inspection method
Yes No
Attached drawing
Controller
Front
LG925E4F06098
6-144
6.4.37Fault code 151605 A6 Flow adjusting solenoid valve open-circuit or


A6 flow adjusting solenoid valve is open-circuit
151605 There is no flow adjusting function.
or shorted to the power supply.
System description
A6 Flow adjust solenoid 1

J2 A6
J2-9 9 909WH1.25 1
solenoid 1 Valve A6
J2-24 24 924WH1.25 2
valve (A6 & A5)
LG925E4F06126
Component position

LG925E4F06127
6-145

Inspection method
valve.
Yes No

wear.
6-146
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:
a. Turn the multimeter to its resistance function, and measure the resistance between the control
connector port J2-9 and flow adjusting solenoid valve port A6-1 (normally, <10Ω).
b. Turn the multimeter to its resistance function, and measure the resistance between the controller
connector port J2-24 and flow adjusting solenoid valve connecter port A6-2 (normally, <10Ω).
Definition of
connector pin
serial number

LG925E4F06097

Yes No
Go to Step5 Go to Step 3

Inspection method
of controller connector in the harness (normally, 16~40Ω). When the resistance is abnormal, this
Yes No
6-147
Step 4 Check whether the flow adjusting solenoid valve is shorted to the power supply
Inspection method

Disconnect the connectors from the controller and A6 flow adjusting solenoid valve to switch on the
switches of all electrical equipment, and then measure the voltage of the harness of A6 flow adjusting
Whether the flow adjusting solenoid valve is shorted to the power supply or not?
Yes No
Go to Step 5
Go to Step 5
Inspection method
Yes No
Attached drawing
Controller
Front
LG925E4F06098
6-148
6.4.38Fault Code 151704 A7 Power boosting solenoid valve shorted to

the ground

The transient power boosting solenoid valve is
151704 No transient power boosting function.
shorted to ground.
System description
Sends a power boosting signal automatically or manually to control on-off of the solenoid valve port to
achieve the power boosting.
Controller J1 A7
Transient power boosting
solenoid valve (Valve A7) J1-13 13 813WH 1
2
A7 Power boost solenoid
GND
LG925E4F06130
Component position

LG925E4F06131
6-149
Step 1 Check the transient power boosting solenoid valve for fault

Inspection method
Turn the start switch to the OFF position and disconnect the connector from the connector of the
transient power boosting solenoid valve.
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 2
Go to Step 4
Step 2 Check whether the power harness of the transient power boosting solenoid valve is
shorted to ground

Inspection method
2. Disconnect the connectors from the controller (in the figure) and transient power boosting solenoid
valve, and measure the resistance between the power line (# 813) of the transient power boosting
solenoid valve and the grounding. The resistance should be infinite.
Whether the power harness of the transient power boosting solenoid valve is shorted to ground
or not?
Yes No

6-150
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

LG925E4F06097

Yes No
Inspection method
Yes No
6-151
Attached drawing
Controller
Front
LG925E4F06098
6-152
6.4.39Fault code 151705 A7 Transient power boosting solenoid valve

open-circuit or shorted to the power supply

The transient power boosting solenoid valve is There is no transient power boosting or the
151705
open-circuited or shorted to the power supply. power boosting is kept.
System description
Sends a power boosting signal automatically or manually to control on-off of the solenoid valve port to
achieve the power boosting.
Controller J1 A7
Transient power boosting
solenoid valve (Valve A7) J1-13 13 813WH 1
2
A7 Power boost solenoid
GND
LG925E4F06130
Component position

LG925E4F06131
6-153
Step 1 Check the transient power boosting solenoid valve for fault

Inspection method
Turn the start switch to the OFF position and disconnect the connector from the connector of the
transient power boosting solenoid valve.
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 2
Go to Step 5

wear.
6-154
Inspection method
1. Check the harness (#813) between the controller (J1-13) (attached drawing) and the transient
power boosting solenoid valve and the grounding wire for wear.
2. Disconnect the connectors from the power boosting solenoid valve and the controller, and check
the harness for open-circuit:
port J1-13 and power boosting solenoid valve harness (normally, <10Ω).
wire transient power boosting solenoid valve terminal and the grounding (normally, <10Ω).
Definition of
connector pin
serial number

LG925E4F06097

Yes No

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.
Yes No
6-155
Step 4 Check whether the transient power boosting solenoid valve is shorted to the power
supply
Inspection method

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 transient power boosting solenoid valve is shorted to the power supply?
Yes No
Go to Step 5
Go to Step5
Inspection method
Yes No
Attached drawing
Controller
Front
LG925E4F06098
6-156
6.4.40Fault Code 151804 A4 Travel lifting solenoid valve shorted to the

ground

The travel lifting solenoid valve is shorted to
151804 There is no travel lifting function.
ground.
System description
The controller outputs an electric signal to the travel lifting solenoid valve A4 through the harness (# 826)
to open the valve port.
A4 Travel lift function solenoid

J2 A4
Travel lifting solenoid
valve (Valve A4 J2-26 26 826WH1.25 1
223WH1.25 2
LG925E4F06138
Component position

LG925E4F06139
6-157
Step 1 Check the travel lifting solenoid valve for fault

Inspection method
Turn the start switch to the OFF position and disconnect the connector from the travel lifting solenoid
valve.
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
Go to Step4 Go to Step 2
Step 2 Check whether the power harness of the travel lifting solenoid valve is shorted to ground

Inspection method
2. Disconnect the connectors from the controller (attached drawing) and the travel lifting solenoid
valve, and measure the resistance between the power line (No. 826) of the travel lifting solenoid
valve and the grounding. The resistance should be greater than 100kΩ.
Whether the power harness of the travel lifting solenoid valve is shorted to ground?
Yes No

6-158
Inspection method
Connect the travel lifting solenoid valve connector and disconnect the controller connector. Turn the
port J1-26 and the grounding (normally, <10Ω). When the resistance is abnormal, this indicates there is
a fault in the connector.
Definition of
connector pin
serial number

LG925E4F06097

Yes No
Inspection method
Yes No
6-159
Attached drawing
Controller
Front
LG925E4F06098
6-160
6.4.41Fault code 151805A4 Travel lifting solenoid valve open-circuit or


There is no travel lifting function or the travel
Travel lifting solenoid valve is open-circuit or
151805 lifting solenoid valve is uncontrolled by the
shorted to the power supply.
controller.
System description
The controller outputs an electric signal to the travel lifting solenoid valve A4 through the harness (# 826)
to open the valve port.
A4 Travel lift function solenoid

J2 A4
Travel lifting solenoid
valve (Valve A4 J2-26 26 826WH1.25 1
223WH1.25 2
LG925E4F06138
Component position

LG925E4F06139
6-161
Step 1 Check the travel lifting solenoid valve for fault

Inspection method
Turn the start switch to the OFF position and disconnect the connector from the travel lifting solenoid
valve.
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

wear.
6-162
Inspection method
1. Check the harness (No. 826) and the grounding wire (No. 429) between the controller (J1-26)
(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
port J1-26 and travel speed solenoid valve harness (normally, <10Ω).
wire (# 429) travel lifting solenoid valve terminal and the grounding (normally, <10Ω).
Definition of
connector pin
serial number

LG925E4F06097

Yes No

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 (No.826) at the
controller port J1-26 and the grounding (normally, <16~40Ω). When the resistance is abnormal, this
Yes No
6-163
Step 4 Check whether the travel lifting solenoid valve is shorted to the power supply.
Inspection method

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.
Whether the travel lifting solenoid valve is shorted to the power supply or not?
Yes No
Go to Step 5
Go to Step 5
Inspection method
Yes No
Attached drawing
Controller
Front
LG925E4F06098
6-164
6.4.42Fault Code 151905 A5 or A6 solenoid valve feedback open-

circuited

A5 or A6 flow adjusting solenoid valve is open
151905 The flow cannot be adjusted.
circuit.
System description
The controller sends a signal through which A5 or A6 adjusts the hydraulic flow.
Controller J2
Accesspry adjusting solenoid 2 valve A5 J2-8 8 908WH1.25
accesspry adjusting solenoid 1(valve A6) J2-9 9 909WH1.25
Pql & PQ2 flow adjusting(valve A6 & A5) J2-24 24 924WH1.25
A5
908WH1.25 1
924WH1.25 2
A6
909WH1.25 1
924WH1.25 2
LG925E4F06146
Component position
Solenoid valve
assembly. The
solenoid marked
with A5 and A6 can
be located
Front
LG925E4F06147
6-165

Correctly tie up harness and wire
Keep away from high temperature parts (e.g. engine body) as far as possible
Inspection method
Turn the start switch to the OFF position,

Disconnect the connectors from the controller (attached drawing), A5 and A6 flow adjusting solenoid
valves, and measure the resistance between the J2-24 wire and the A5, A6 flow adjusting solenoid
valve, normally the resistance should be less than 10Ω.
Definition of
connector pin
serial number

LG925E4F06097

Yes No
Re-connect the harness and wrap it.

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 flow adjusting solenoid valve,
and then measure the resistance between the controller connector ports J2-8 and J2-24. The
resistance should be 16-40Ω. Otherwise, there is a fault in the connector.
6-166

Yes No
Adjust or replace the connector.
Inspection method
Yes No
Attached drawing
Controller
Front
LG925E4F06098
6-167
6.4.43Fault Code 151906 A5 or A6 solenoid valve feedback overcurrent

151906 A5 or A6 solenoid valve feedback overcurrent. The flow cannot be adjusted.
System description
The controller sends a signal through which A5 or A6 adjusts the hydraulic flow.
Controller J2
Accesspry adjusting solenoid 2 valve A5 J2-8 8 908WH1.25
accesspry adjusting solenoid 1(valve A6) J2-9 9 909WH1.25
Pql & PQ2 flow adjusting(valve A6 & A5) J2-24 24 924WH1.25
A5
908WH1.25 1
924WH1.25 2
A6
909WH1.25 1
924WH1.25 2
LG925E4F06146
Component position
Solenoid valve
assembly. The
solenoid marked
with A5 and A6 can
be located
Front
LG925E4F06147
6-168

Inspection method
Turn the start switch to the OFF position, and check the pins for moisture, oil dirt and other.
Measure the resistance of A5 or A6 flow adjusting solenoid valve. The resistance should be 16-40Ω.
Yes No
Replace the solenoid valve.
Step 2 Check whether the harness is shorted to the power supply.

Inspection method
Disconnect the connectors from the controller, A5 and A6 solenoid valves, respectively
Measure the voltage between the controller (attached drawing) connector port J2-24 and the ground
with the voltmeter (200V). The voltage should be 0V.
Definition of
connector pin
serial number

LG925E4F06097
Whether the harness is shorted to the power supply or not?

Yes No
6-169

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.
Yes No
Repair or replace the connector
Inspection method
Yes No
Attached drawing
Controller
Front
LG925E4F06098
6-170
6.4.44DTC 171004 Short circuit to ground of battery relay

The alternator’s load dump may burn electronic
171004 Battery relay is shorted to ground
components and electrical equipment.
System description
When the B terminal is connected to the positive pole of the power (24V) and the E terminal to the
negative pole, the energized coil generates a magnetic field suction to move the armature to pull in the
contact, so that the controlled circuit is switched on.
Battery
GND BK70.0 RD70.0 RD70.0
IPC Controller J1
Power supply
relay J1-24 24 824
B
E
145
GND
Battery Relay
LG925E4F06154
6-171
Component position
Front
Battery relay
LG925E4F06155
Step 1 Check the battery relay for fault

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).
Whether the battery relay fails?
Yes No
Replace the battery relay.

wear.
6-172
Inspection method
1. Check the harness (# 824) between the controller (J1-24) and the battery relay for wear.
2. Disconnect the relay connector and the controller connector. Turn the multimeter to its resistance
function, and measure the resistance between the harness (No. 824) relay terminal and the ground
Yes No
Inspection method
Yes No
6-173
6.4.45Fault Code 171104 Auto preheating relay shorted to the ground

171104 The auto preheating relay is shorted to ground. The auto preheating function fails.
System description
After the ECM controller judges logically that preheating is needed, if the harness (#704) is energized,
the auto pre-heater K10 is energized and the harness (#123) is connected to the harness (#190), then
the harness (#190) is energized, as a result, the preheating relay K3 is energized, so that the harness
(#104) is connected to the harness (#185) which connects the heater for heating.
ECM Controller J5 lgnition Switch

Air intake preheating (+) 75 704AEXWH
B1 B2 G1 G2 S M
Earthing 75 713AEXGY
Heat
OFF
ON
704WH 7 704
ST
713WH 9 713
X2 S16
Auto prehest relay K10
3
1
2
5
86
704 Auto preheating 10A
110OR2.0
30
190WH
123 101OR3.0
145OR
87A
87 190
85 713
D1 Diode
100OR3.0
101OR3.0
103OR3.0
005OR3.0
260GY 2
X1 190WH 1
190WH1.25 20 190
FUSE50A
FUSE50A
Electric lock power 20A 110OR2.0 5 110OR2.0 RELAY K3
X2 190WH 185AEXOR15.0
110OR2.0 9 005
260GY 104OR15.0
004
102
Grid Heater
MAIN POWER SEITCH
Battery
BK70.0 BK70.0 RD70.0 RD70.0 105OR15.0 104OR15.0

FUSE 150A
GND
Diode D6
2 145OR B
+ 260GY2.0
1 155OR E
- 261GY
Battery Relay
GND
LG925E4F06156
6-174
Component position
Open the fuse box
K9 auto preheating relay.

It can be pulled out during detection
LG925E4F06157
Step 1 Check whether the harness connecting the ECM controller port J5-75 is shorted to ground

Inspection method
Turn the start switch to the OFF position for fault diagnosis.
Disconnect the connector from the ECM controller and pull out the auto preheating relay, and then
measure the resistance between the harness (# 704) at the J5-75 port and the grounding. The
resistance should be infinite.
Whether the harness connecting the ECM controller port J5-75 is shorted to ground?
Yes No
6-175

Inspection method
Check manually the connectors between the automatic preheating relay and the ECM controller one by
one for moisture, oil dirt and other which may cause electric leakage.
Yes No
Inspection method
Yes No
6-176
6.4.46Fault code 171105 Auto preheating relay open circuit or shorted to

the power supply

Auto preheating relay is open-circuit or shorted
171105 The auto preheating function fails.
to the power supply.
System description
After the ECM controller judges logically that preheating is needed, if the harness (#704) is energized,
the auto pre-heater K10 is energized and the harness (#123) is connected to the harness (#190), then
the harness (#190) is energized, as a result, the preheating relay K3 is energized, so that the harness
(#104) is connected to the harness (#185) which connects the heater for heating.
ECM Controller J5 lgnition Switch

Air intake preheating (+) 75 704AEXWH
B1 B2 G1 G2 S M
Earthing 75 713AEXGY
Heat
OFF
ON
704WH 7 704
ST
713WH 9 713
X2 S16
Auto prehest relay K10
3
1
2
5
86
704 Auto preheating 10A
110OR2.0
30
190WH
123 101OR3.0
145OR
87A
87 190
85 713
D1 Diode
100OR3.0
101OR3.0
103OR3.0
005OR3.0
260GY 2
X1 190WH 1
190WH1.25 20 190
FUSE50A
FUSE50A
Electric lock power 20A 110OR2.0 5 110OR2.0 RELAY K3
X2 190WH 185AEXOR15.0
110OR2.0 9 005
260GY 104OR15.0
004
102
Grid Heater
MAIN POWER SEITCH
Battery
BK70.0 BK70.0 RD70.0 RD70.0 105OR15.0 104OR15.0

FUSE 150A
GND
Diode D6
2 145OR B
+ 260GY2.0
1 155OR E
- 261GY
Battery Relay
GND
LG925E4F06156
6-177
Component position
Open the fuse box

LG925E4F06157
Step 1 Check the auto preheating relay for fault

Inspection method
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.
6-178

Avoid folding or bending the harness forcibly
Try to keep far way from oil and water
Inspection method
Disconnect the connector from the controller (attached drawing) and pull out the auto preheating relay,
and then measure the resistance between the harness (# 704) at the J5-75 port and the auto
preheating relay. Normally, the resistance should be less than 10Ω.
Measure the resistance between the ports 85 in the fuse box and J5-76 . Normally, the resistance
should be less than 10Ω.
Yes No

Inspection method
Insert the auto preheating relay into the fuse box properly and disconnect the ECM controller
connector, and then turn the multimeter to its resistance function and measure the resistance between
the harness at the controller port J5-75 and J5-76. The resistance should be between 345-360Ω. When
the resistance is abnormal, please check the auto preheating relay connector for looseness and
damage.
Yes No
6-179
Inspection method
Yes No
6-180
6.4.47Fault Code 171204 Start cut-off relay shorted to ground

The start cut-off relay is not controlled by the
171204 Start cut-off valve relay is shorted to ground.
controller.
System description
After the controller port 23 is energized, the harness (# 923) is energized, so that the ports 30 and 87A of
the start cut-off relay K8 are switched off.
Controller X2
Start cut-off valve relay J2-23 23 15
525
923
181
230
310
180
320
230
87A
87A
86
30
87
85
86
30
87
85
Pilot control start relay K7 controller control start relay K8
LG925E4F06160
6-181
Component position
Open the fuse box

LG925E4F06157
Step 1 Check whether there is a fault in the start cut-off relay

Inspection method
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
Whether the start cut-off relay fails.
Yes No
Replace the start cut-off relay.
6-182
Step 2 Check whether the power harness of the start cut-off relay is shorted to ground

Inspection method
2. Disconnect the connectors from the controller (Attached drawing) and the start cut-off relay, and
measure the resistance between the power line (No. 923) of the start cut-off relay and the
grounding, the resistance should be infinite
Whether the power harness of the start cut-off relay is shorted to ground or not?
Yes No

Inspection method
Connect the connector of the start cut-off relay and disconnect the controller connector, and measure
the resistance between the harness at the controller end J2-23 and the grounding (normally, <10Ω)
using resistance band of the multimeter. If the resistance is abnormal, this indicates that there is a fault
in the connector.
Definition of
connector pin
serial number

LG925E4F06097

Yes No
6-183
Inspection method
Yes No
Attached drawing
Controller
Front
LG925E4F06098
6-184
6.4.48Fault code 171205 Start cut-off output open circuit or shorted to

the power supply

The start cut-off relay is open-circuit or shorted The start cut-off relay is not controlled by the
171205
to the power supply. controller.
System description
After the controller port 23 is energized, the harness (# 911) is energized, so that the ports 30 and 87A of
the start cut-off relay K8 are switched off.
Controller X2
Start cut-off valve relay J2-23 23 15
525
923
181
230
310
180
320
230
87A
87A
86
30
87
85
86
30
87
85
Pilot control start relay K7 controller control start relay K8
LG925E4F06160
6-185
Component position
Open the fuse box

LG925E4F06157
Step 1 Check whether there is a fault in the start cut-off relay

Inspection method
Open the fuse box, and pull out the start cut-off relay.
Measure the resistance between the ports 85 and 86 of the start cut-off relay coil. The resistance
Whether the start cut-off relay fails.
Yes No
Replace the start cut-off relay.
6-186

Avoid folding or bending the harness forcibly
Try to keep far way from oil and water
Inspection method
Disconnect the connector from the controller (attached drawing) and pull out the start cut-off relay, and
then measure the resistance between the harness (# 923) at the J2-23 port and the start cut-off relay.
Normally, the resistance should be less than 10Ω.
Measure the resistance between the 85 port in the fuse box and the ground. Normally, the resistance
Definition of
connector pin
serial number

LG925E4F06097

Yes No
6-187

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:
a. Check the connector at the grounding of the start cut-off relay for poor contact
b. Check the connector of the start cut-off relay for looseness or damage.
Yes No
Step 4 Check whether the start cut-off relay is shorted to the power supply

Inspection method

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 0.
Whether the start cut-off relay is shorted to the power supply or not?
Yes No
Go to Step 5
Go to Step 5
Inspection method
Yes No
6-188
Attached drawing
Controller
Front
LG925E4F06098
6-189
6.4.49Fault Code 201004 Traveling alarm shorted to ground

201004 Travel alarm is shorted to ground Travel alarm fails to work
System description
The travel alarm is used to beep for warning when the machine is moving, as shown in the figure. One
pin of the travel alarm is connected to the controller directly and the other pin is grounded. When the
machine is moving, the controller receives the traveling signal and allows the travel alarm to be
energized through its internal logic program.
δBlackε
J1
N3
Traveling alarm buzzer J1-1 1 801WH1.25 1
255GY1.25 2
Controller
Traveling alarm (optional)
GND LG925E4F06167
Component position
Controller
Front
LG925E4F06098
6-190
Step 1 Check the travel alarm for fault

Inspection method
Turn the start switch to the OFF position, and disconnect the travel alarm connector:
2. Turn the multimeter to its resistance function, and measure the resistance between the alarm
connector terminals 1 and 2 (normally, >10Ω).
Whether the travel alarm fails?
Yes No
Repair or replace the sensor.

Inspection method
1. Check the harness (# 801) between the controller (J1-01) and the travel alarm for wear.
2. Disconnect the travel alarm connector and the controller connector. Turn the multimeter to its
resistance function, and measure the resistance between the harness (# 801) sensor terminal and
grounding (normally, >100kΩ).
Yes No
6-191

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).
Yes No
Inspection method
Yes No
6-192
6.4.50Fault Code 211003 P1 pump pressure sensor voltage above the

range value

The P1 pump pressure sensor voltage is out of
the range value. (When the left/right control
211003 level is operated, the voltage detected in the
will get stuck or even shut down.
signal circuit of the P1 pump pressure sensor is
higher than the normal 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.
3
Controller -
5V power supply - :+ :+ 3
:+
- *<
P1 pump pressure - :+ P1 pump pressure sensor
Sensor to earthing - *<
%$5
a
LG925E4F06169
Pressure sensor parameters:

Output voltage: 0.5-4.5V
Working voltage: 5Vdc
Pressure range: 0-500bar(7250psi)
6-193
Component position
P1 Pump
pressure
sensor
P2Pump
pressure
sensor
Front
LG925E4F06170

Inspection method
Check the connector for moisture, oil dirt or insulation fault.

Yes No
6-194
Step 2 Check the harness for shorted to power supply

wear.
Inspection method
1. Check the harness (# 931) between the controller (J2-31) and the pump pressure sensor for wear.
2. Turn the start switch to the ON position and disconnect the connectors from the pump pressure
sensor and the controller. Measure the voltage between the harness (# 931) sensor terminal and
the grounding using voltage band of the multimeter (normally, 0V).
Whether the harness is shorted to the power supply?
Yes No
Step 3 Check whether the sensor power supply is normal.

wear.
Inspection method
1. Check the harness (# 828) between the controller (J1-28) and the pump pressure sensor for wear.
2. Turn the start switch to the ON position and disconnect the pump pressure sensor connector. Turn
the multimeter to its voltage function and measure the voltage between the harness (# 828) sensor
power supply terminal and the grounding (normally, 5V).
Whether the sensor power supply is normal?
6-195
Yes No
Replace controller
Step 4 Check the pump pressure sensor for fault

Inspection method
Turn the start switch to the OFF position and connect the controller connector, and then disconnect the
pump pressure sensor connector and measure the voltage in the pump pressure sensor signal:
Start the engine, and with the boom lifted, turn the multimeter to its voltage function, and measure the
voltage between the sensor signal J2-31 (#931) and grounding (normally, 0.5-4.5V).
Whether the pump pressure sensor fails?
Yes No
Replace the pump pressure sensor.
Inspection method
Yes No
6-196
6.4.51Fault code 211004 P1 pump pressure sensor voltage below the

range value

The P1 pump pressure sensor voltage is lower
than the range value (When the left/right control
211004 level is operated, the voltage detected in the Some hydraulic actions cannot be achieved.
too low (<0.5V))
System description
the current signal, which is input to the controller, then the controller detects the hydraulic oil pressure
value which is displayed on the display instrument.
3
Controller -
5V power supply - :+ :+ 3
:+
- *<
P1 pump pressure - :+ P1 pump pressure sensor
Sensor to earthing - *<
%$5
a
LG925E4F06169

6-197
Component position
P1 Pump
pressure
sensor
P2Pump
pressure
sensor
Front
LG925E4F06170

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.
Yes No
Step 2 Check the harness for open-circuit or shorted to ground

wear.
6-198
Inspection method
1. Check the harness (# 931) between the controller (J2-31) and the pump pressure sensor and the
power line for wear.
Turn the start switch to the ON position, and disconnect the pump pressure sensor connector.
2. Check the harness for open-circuit:
a. Measure the voltage between the power line sensor connecting terminal and the sensor
grounding using voltage band of the multimeter (normally, 5V).
b. Turn the start switch to OFF position. Measure the resistance of the harness (# 931) between the
controller and the sensor using resistance band of the multimeter(normally, <10Ω)
3. Check whether the harness is shorted to ground:
Measure the resistance between the harness (# 931) sensor connecting terminal and the grounding
Whether the harness open-circuit or shorted to ground?
Yes No

Inspection method
Yes No
6-199
Inspection method
Yes No
6-200
6.4.52Fault Code 211003 P2 pump pressure sensor voltage above the

range value

The P2 pump pressure sensor voltage is higher
211103 level is operated, the voltage detected in the
will get stuck or even shut down.
too high (>4.5V))
System description
P2
Controller J1
5V power supply J1-28 28 828WH 828WH 2 P
932WH 4
J2 922GY 1
P2 pump pressure J2-32 32 932WH P2 pump pressure sensor
Sensor to earthing J2-22 22 922GY
0~500BAR
LG925E4F06173

6-201
Component position
P1 Pump
pressure
sensor
P2Pump
pressure
sensor
Front
LG925E4F06170

Inspection method

Yes No
6-202
Step 2 Check the harness for shorted to battery

wear.
Inspection method
1. Check the harness (wire NO. 932) between the controller (J2-32) and the pump pressure sensor for
wear.
2. Turn the start switch to the ON position and disconnect the connectors from the pump pressure
sensor and the controller. Measure the voltage between the harness (# 932) sensor terminal and
the grounding using voltage band of the multimeter (normally, 0V).
Whether the harness is shorted to the battery.
Yes No

Inspection method
Yes No
6-203
Inspection method
Yes No
6-204
6.4.53Fault code 211104 P2 pump pressure sensor voltage below the

range value

The P2 pump pressure sensor voltage is lower
211104 level is operated, the voltage detected in the No special response.
too low (<0.5V))
System description
P2
Controller J1
932WH 4
J2 922GY 1
P2 pump pressure J2-32 32 932WH P2 pump pressure sensor
Sensor to earthing J2-22 22 922GY
0~500BAR
LG925E4F06173

Pressure range:0-50bar(725psi)
6-205
Component position
P1 Pump
pressure
sensor
P2Pump
pressure
sensor
Front
LG925E4F06170

Inspection method

Yes No
6-206

wear.
Inspection method
1. Check the harness (wire No. 932) between the controller (J2-32) and the pump pressure sensor,
the power line (wire No. 121) for wear.
Turn the start switch to the ON position, and disconnect the connectors from the pump pressure
sensor and the controller, respectively.
a. Measure the voltage between sensor power line terminal and the grounding using voltage band
of the multimeter (normally, 5V).
b. Turn the start switch to OFF position. Turn the multimeter to its resistance band, and measure the
resistance of the harness (# 932) between the controller and the sensor (normally, <10Ω).
Yes No
6-207

Inspection method
Yes No
Inspection method
Yes No
6-208
6.4.54Fault Code 211203 N1 negative flow pressure sensor voltage above

the range value

The N1 negative flow pressure sensor voltage is
higher than the range value (The voltage in the
211203 The complete machine moves slowly.
signal circuit of the N1 negative flow pressure
sensor is too high (>4.5V)).
System description
P4
Controller J1
919WH 4
J2 922GY 1
N1 Negative flow
pressure J2-19 19 919WH
22 N1 Negative flow pressure sensing
Sensor to earthing J2-22 922GY
0~60BAR
LG925E4F06177

6-209
Component position
N1䍕⍷䠅ু࣑Ֆ᝕
N1 Negative flow pressure
sensor
ಞδփ㖤ε(position)
LG925E4F06178

Inspection method

Yes No

wear.
6-210
Inspection method
1. Check the harness (# 919) between the controller (J2-19) and the N1 negative flow pressure sensor
for wear.
2. Turn the start switch to the ON position and disconnect the connectors from N1 negative flow
pressure sensor and the controller, and measure the voltage between the harness (# 919) sensor
terminal and the grounding using voltage band of the multimeter (normally, 0V).
Yes No
Step 3 Check the N1 negative flow pressure sensor for fault

Inspection method
N1 negative flow pressure sensor connector and measure the voltage in the sensor signal circuit:
Whether the N1 negative flow pressure sensor fails?
Yes No
Replace the N1 negative flow pressure sensor.
Inspection method
Yes No
6-211
6.4.55Fault Code 211204 N1 negative flow pressure sensor voltage below

the range value

lower than the range value (The voltage in the Abnormal hydraulic oil temperature rise under
211204
signal circuit of the N1 negative flow pressure no load.
sensor is too low (<0.5V)).
System description
P4
Controller J1
919WH 4
J2 922GY 1
N1 Negative flow
22 N1 Negative flow pressure sensing
Sensor to earthing J2-22 922GY
0~60BAR
LG925E4F06177

6-212
Component position
sensor
LG925E4F06178

Inspection method

Yes No
6-213

wear.
Inspection method
and the power line (# 121) for wear.
Turn the start switch to the ON position, and disconnect the connectors from the N1 negative flow
pressure sensor and the controller.
a. Turn the multimeter to its voltage function, and measure the voltage between the power line (#
121) sensor terminal and the grounding (normally, 25±0.5V (battery voltage) ).
b. Turn the multimeter to its resistance function, and measure the resistance of the harness (# 919)
between the controller and the sensor (normally, <10Ω)
Yes No
6-214

Inspection method
Yes No
Inspection method
Yes No
6-215
6.4.56Fault Code 211303 N2 negative flow pressure sensor voltage above

the range value

higher than the range value (The voltage in the
211303 The complete machine moves slowly.
signal circuit of the N2 negative flow pressure
sensor is too high (>4.5V)).
System description
P3
Controller J1
933WH 4
J2 922GY 1
N2 Negative flow
Sensor to earthing J2-22 22 922GY N2 negative flow pressure sensor
0~60BAR
LG925E4F06181

6-216
Component position
sensor
LG925E4F06178

Inspection method

Yes No

wear.
6-217
Inspection method
for wear.
2. Turn the start switch to the ON position and disconnect the connectors from N2 negative flow
pressure sensor and the controller, and turn the multimeter to its voltage function, then measure the
voltage between the harness (# 933) sensor terminal and the grounding (normally, 0V).
Yes No

Inspection method
Yes No
Inspection method
Yes No
6-218
6.4.57Fault Code 211304 N2 negative flow pressure sensor voltage below

the range value

lower than the range value (The voltage in the Abnormal hydraulic oil temperature rise under
211304
signal circuit of the N2 negative flow pressure no load.
sensor is too low (<0.5V)).
System description
P3
Controller J1
933WH 4
J2 922GY 1
N2 Negative flow
0~60BAR
LG925E4F06181

Pressure range: 0-50bar
6-219
Component position
sensor
LG925E4F06178

Inspection method

Yes No
6-220

wear.
Inspection method
and the power line (# 121) for wear.
Turn the start switch to the ON position, and disconnect the connectors from the N2 negative flow
pressure sensor and the controller.
a. Measure the voltage between the sensor power terminal and the sensor grounding using voltage
band of the multimeter (normally, 5V).
b. Turn the start switch to OFF position. Turn the multimeter to its resistance band, and measure the
resistance of the harness (# 933) between the controller and the sensor (normally, <10Ω).
Yes No
6-221

Inspection method
Yes No
Go to Step 4
Go to Step 4
Inspection method
Yes No
6-222
6.4.58Fault Code 211316 High N2 negative flow pressure

High N2 negative flow pressure - When the
machine is operated, the pressure detected in
211216 the signal circuit of the N2 negative flow The complete machine moves slowly.
pressure sensor is high (more than 4.2MPa/
609psi).
System description
P3
Controller J1
933WH 4
J2 922GY 1
N2 Negative flow
0~60BAR
LG925E4F06181

Pressure range: 0-50bar
6-223
Component position
sensor
LG925E4F06178
Step 1 Check whether the N2 negative flow pressure is high
Inspection method
Using the manometer, check whether the N2 negative flow pressure is too high.
Whether the N2 negative flow pressure is high?
Yes No
Troubleshoot the high pump pressure.
Step 2 Check the N2 negative flow pressure monitoring system for fault

Inspection method
When the pressure is normal, check the N2 negative flow pressure detection circuit or pressure sensor
for fault in accordance with the fault diagnosis in the 211303-N2 Negative Flow Pressure Sensor
Voltage Above the Range Value.
Whether the N2 negative flow pressure monitoring system fails?
Yes No
Check and repair N2 negative flow pressure
detection circuit or replace the pressure sensor.
Go to Step 3
Go to Step 3
6-224
Inspection method
Yes No
6.4.59Fault Code 231012 Abnormal controller heartbeat

231012 Abnormal controller heartbeat. The machine fails to work.
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.
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8QVZLWFKHG3RZHU 8QVZLWFKHG3RZHU - 25 ⭫Ⓠ
Power
supply
8QVZLWFKHG3RZHU 8QVZLWFKHG3RZHU - 25
LG925E4F06187
6-225
Component position
Controller
Front
LG925E4F06098
Step 1 Check the controller connector J1 for looseness
Inspection method
Manually check whether the controller connector for looseness or fall-off.

Whether the controller connector J1 becomes loose or not?
Yes No
Tighten the connector J1.
6-226
Step 2 Check whether the controller has the power supply.
Inspection method
Dismantle the controller connector J1 (black)

Turn the multimeter to its voltage function, and measure the voltage between J1’s port 2, 3, 4, 5 and 6
and ground, respectively. The voltage should be about 24V. Otherwise, the controller is short of power.
Definition of
connector pin
serial number

LG925E4F06097
Whether there is no power to the controller?

Yes No
Check the harness (# 111) for open-circuit, and re-
connect it.
Go to Step 3
Go to Step 3
Inspection method
Yes No
6-227
6.4.60Fault Code 231014 CAN bus communication error

231014 CAN bus communication error. The machine cannot operate properly.
System description
The CAN bus can achieve real-time data exchange of various control units of the excavator.
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Battery
Battery
⭫⬬⭫Ⓠ
⭫⬬⭫Ⓠ
Earthing
supply
Earthing
supply
power
power
lock ON
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LG925E4F06190
6-228
Component position
GPS antenna
GPSཟ㓵
ᱴ⽰ಞ
Display
GPS
LG925E4F06191
Step 1 Check the display connector for fault
Inspection method
Manually check the controller connector for looseness or fall-off, and check the pins for bending.
Whether the display connector fails?
Yes No
Repair or tighten the connector.
Step 2 Check the harness of display for fault
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.
6-229
Inspection method
Yes No
6-230
6.4.61Fault Code 241014 accelerator knob outside the measurement

range

Accelerator knob outside the measurement
241014 The gear positions display abnormally.
range
System description

the accelerator knob clockwise and 829 outputs 0.5-4.5V power supply. Controller control engine
revolving speed according to received voltage signal.
12-gear throttle
potentiometer
5V power supply
Accelerator knob
Sensor to earthing
LG950E4f06003
Component position
Accelerator
potentiometer
Controller
LG925E4F06193
6-231
Step 1 Check for accelerator knob failure

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.
Step 2 Check the harness for short-circuit and open-circuit

wear.
Inspection method
1. Check the harness (No. 828/No. 829) between the controller (J1-28/J1-29) and the accelerator
actuator and the grounding wire (No. 922) for wear.
2. Check whether the harness is shorted to the battery:
Disconnect the connector R1 for the accelerator knob and the controller. Turn the multimeter to its
voltage function, and measure the voltage respectively between the harness No. 828/No. 829 and
the grounding (normally 0V).
Measure the resistance between the (#922) harness actuator connecting terminal and the ground with
multimeter resistance range (normally, 100kΩ).
6-232
Is the harness short-circuit or open-circuit?

Yes No

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.

Yes No
Inspection method
Yes No
6-233
6.4.62Fault Code 251004 Fuel pump relay shorted to ground
251004 The refueling pump automatically stops and

Fuel pump relay shorted to ground
refueling function fails
System description
Power on the electric lock to energize the battery relay, the harness (#133) and the harness (#320), so
that the refueling pump can operate. If the J2-6 port of the controller gives the signal and the harness
(#906) is energized, then the refueling pump relay is energized, so that the harnesses (#133 and #320)
are open-circuit and the refueling pump automatically stops.
Controller
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⭫䬷⭫Ⓠ lock
IXVH$ ⟹⋯ࣖ⋯⌫
Fuel IXVH$
refueling pump䘿䞃
power supply fuse 20A opentional
ࣖ⋯⌫㔝⭫ಞ.
IXHOSXPSUHOD\
%. 5' 5'

%DWWHU\㫺⭫⊖
:+
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LG925E4F06194
6-234
Component position
ᢉᔶؓ䲟ⴈ
Open the fuse box
K11⟹⋯⌫㔝⭫ಞθ
K11 Fuel pump relay can be
pulled Ỷ⎁ᰬθਥԛᤊ࠰
out when detected
LG925E4F06195
6-235
Step 1 Check whether the harness connecting the controller port J2-6 is shorted to ground

Inspection method
Disconnect the connector from the controller (in the figure ) and pull out the fuel refueling pump relay,
and then measure the resistance between the harness (#906) at the J2-6 port and the grounding. The
resistance should be infinite.
Definition of
connector pin
serial number

LG925E4F06097
Whether the harness connecting the controller end J2-6 is shorted to ground?
Yes No
6-236

Inspection method
Check manually the connectors between the automatic preheating relay and the controller one by one
for moisture, oil dirt and other failures which may cause electric leakage.
Yes No
Inspection method
Yes No
Attached drawing
Controller
Front
LG925E4F06098
6-237
6.4.63Fault code 251005 Fuel pump relay open circuit or shorted to the
power supply

Fuel refueling pump relay is open-circuit or The refueling pump automatically stops and
251005
shorted to the power supply. refueling function fails.
System description
Power on the electric lock to energize the battery relay, the harness (#133) and the harness (#320), so
that the refueling pump can operate. If the 6th port of the controller J2 gives the signal and the harness
(#906) is energized, then the refueling pump relay is energized, so that the harnesses (#133 and #320)
are open-circuit and the refueling pump automatically stops.
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fuse 20A opentional
Electric
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power supply
fuel pump relay
ࣖ⋯⌫㔝⭫ಞ.

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Battery 㫺⭫⊖
:+
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LG925E4F06198
6-238
Component position
ᢉᔶؓ䲟ⴈ
Open the fuse box
K11⟹⋯⌫㔝⭫ಞθ
K11 Fuel pump relay can be
pulled Ỷ⎁ᰬθਥԛᤊ࠰
out when detected
LG925E4F06195
Step 1 Check the fuel refueling pump relay for fault

Inspection method
Turn the multimeter to its resistance function and measure the resistance between the terminals 85
and 86 of the fuel refueling pump relay coil. The resistance should be between 320-360Ω.
Turn the multimeter to its on/off function, and measure the ports 30 and 87A of the relay. The relay
should switch on and sound.
Connect the ports 85 and 86 to the power supply (24V), and measure the ports 30 and 87A. The relay
should switch off and not sound.
Whether the fuel refueling pump relay fails?
Yes No
Replace the relay.
6-239

Inspection method
Turn the start switch to the OFF position for fault diagnosis.
Disconnect the connector from the controller (attached drawing) and pull out the fuel refueling pump
relay, and then measure the resistance between the harness (#906) at the J2-6 port and the fuel
refueling pump relay. Normally, the resistance should be less than 10Ω.
Measure the resistance between the 85 port in the fuse box and the ground. Normally, the resistance
Definition of
connector pin
serial number

LG925E4F06097

Yes No
6-240

Inspection method
Insert the fuel refueling pump 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
(# 906) at the controller port J2-6 and the grounding. The resistance should be between 320-360Ω.
Otherwise, check the connector:
a. Check the connector at the grounding of the auto preheating relay for poor contact
b. Check the connector of the auto preheating relay for looseness or damage.
Yes No
Inspection method
Yes No
Attached drawing
Controller
Front
LG925E4F06098
6-241
6.4.64Fault code 261011GPS antenna fault

The machine cannot be positioned and
261011 GPS antenna fails.
connected to the monitoring center.
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 position
GPS antenna
GPSཟ㓵
ᱴ⽰ಞ
Display
GPS
LG925E4F06191
Step 1 Check the antenna connector for looseness and fall-off

Inspection method
Manually check whether the antenna connector becomes loose or falls off.
Whether the antenna connector becomes loose or falls off?
Yes No
Tighten the antenna connector.
6-242
Step 2 Check the antenna for damage
Inspection method
Remove the antenna, and re-install a new one to determine whether the antenna is damaged.
Whether the antenna is damaged or not?
Yes No
Replace the antenna.
Inspection method
Yes No
6-243
6.4.65Fault Code 261111GPS module fault

261111 GPS module fault. GPS signals cannot be received.
System description
Component position
GPS antenna
GPSཟ㓵
ᱴ⽰ಞ
Display
GPS
LG925E4F06191
Step - Contact local LiuGong dealers and authorized service centers.

6-244
6.4.66Fault code 261211GSM signal fault

261211 GSM signal fault. GSM signal is weak.
System description
Component position
GPS antenna
GPSཟ㓵
ᱴ⽰ಞ
Display
GPS
LG925E4F06191
Step 1 Check the antenna connector for looseness and fall-off
Inspection method
Manually check whether the antenna connector becomes loose or falls off.
Whether the antenna connector becomes loose or falls off?
Yes No
Tighten the antenna connector.
6-245
Step 2 Check the antenna for damage
Inspection method
View the mobile signal strength. Compared with the GSM signal, if the mobile signal is stronger, the
antenna is faulty.
Whether the antenna is damaged or not?
Yes No
Replace the antenna.
Inspection method
Yes No
6-246
6.4.67Fault Code 261311 GPRS connection fault

261311 GPRS connection fault. GPS cannot operate properly.
System description
GPRS is used to transmit information between GPS and mobile server.
Steps - Contact local LiuGong dealers and authorized service centers

6-247
6.4.68Fault Code 261411 SIM card read fault

261411 SIM card read fault. GPS cannot operate properly.
System description
The GPS positioning information is transmitted to the monitoring center through the SIM card.
Component position
GPS antenna
GPSཟ㓵
ᱴ⽰ಞ
Display
GPS
LG925E4F06191
Step 1 Check whether the SIM card becomes loose
Inspection method
Turn the start switch to the OFF position, and manually check whether the SIM card becomes loose.
If the SIM card becomes loose?
Yes No
Fix the SIM card.
6-248
Inspection method
Yes No
6-249
6.4.69Fault code 261512 Abnormal GPS heartbeat

261512 Abnormal GPS heartbeat. Over time, the machine is limited to be used.
System description
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⛯⚡ᔶީ
% % * * 6 0
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21
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&$1B/ &$1/ </%8
32:(5 ⭫Ⓠ
32:(5 ⭫Ⓠ 25
&$1+ &$1+ 5'*1
$&& ⭫䬷൦
1& *<
1& *<
1&
LG925E4F06210
6-250
Component position
GPS antenna
GPSཟ㓵
ᱴ⽰ಞ
Display
GPS
LG925E4F06191
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.
Step 2 Check the harness (#149) for fault
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 port 4 and the grounding. The
voltage should be 24V. Otherwise, a fault develops in the harness (#149).
Is there a fault in the harness (#149)?
Yes No
Rewire.
6-251
Inspection method
Turn the start switch v to the ON position and re-check the fault code.
Yes No
6-252
6.4.70Fault Code 261611 automatic locking level 1 GPS abnormal

heartbeat, limited machine

Level-1 automatic locking, abnormal GPS
261611 The machine is limited to be used.
heartbeat, the machine is limited to be used.
System description
OJQLWLRQ6ZLWFK
⛯⚡ᔶީ
% % * * 6 0
+HDW
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21
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1&
*1'
$&& ⭫䬷21 25
&$1B/ &$1/ </%8
32:(5 ⭫Ⓠ
32:(5 ⭫Ⓠ 25
&$1+ &$1+ 5'*1
$&& ⭫䬷൦
1& *<
1& *<
1&
LG925E4F06210
6-253
Component position
GPS antenna
GPSཟ㓵
ᱴ⽰ಞ
Display
GPS
LG925E4F06191
Inspection method

Yes No
Inspection method

Yes No
Rewire.
6-254
Inspection method
Yes No
6-255
6.4.71Fault Code 261614 command locking level 1 payment expired,

limited machine

Level-1 forced locking, overdue payment, the
machine is limited to be used.
System description

6-256
6.4.72Fault Code 261711 automatic locking level 2 GPS abnormal

heartbeat,limited machine
Code Faults Consequence

Level-2 automatic locking, abnormal GPS
heartbeat, the machine is limited to be used.
System description
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⛯⚡ᔶީ
% % * * 6 0
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21
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$&& ⭫䬷21 25
&$1B/ &$1/ </%8
32:(5 ⭫Ⓠ
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1& *<
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LG925E4F06210
6-257
Component position
GPS antenna
GPSཟ㓵
ᱴ⽰ಞ
Display
GPS
LG925E4F06191
Inspection method

Yes No
Inspection method

Yes No
Rewire.
6-258
Inspection method
Yes No
6-259
6.4.73Fault Code 261714 command locking level 2 payment expired,

limited machine

Level-2 forced locking, overdue payment, the
machine is limited to be used.
System description

6-260
6.4.74Fault Code 261814 Please pay the due loan timely

The machine will be limited to be used if
261814 Please pay the due loan promptly.
overdue.
System description
Remind the owner of payment to avoid unnecessary faults.
Steps – Pay the loan on time

6-261
6.4.75Fault code 271304 Fan reversing solenoid valve shorted to ground

271304 Fan reversing solenoid valve shorted to ground The fan cannot reverse
System description
The fan reversing solenoid valve (variable speed fan reversing solenoid valve) is used to control the
fan’s positive and negative rotation. To achieve that end, the controller receives the operation signal for
the fan’s positive and negative rotation from the instrument and controls the solenoid valve through the
J2-4 port.
Direction changing solenoid

਎䙕伄᡽ᦘੇ⭫⻷䰶
᧝࡬ಞ
Controller J2
A16
਎䙕伄᡽ᦘੇ⭫⻷䰶 J2-04 04 904WH1.25 1
229GY1.25 2
LG925E4F06212
Component position
Front
ࢃ
Fan drive
伄᡽ᦘੇ⭫⻷䰶
solenoid valve
LG925E4F06213
6-262
Step 1 Check the fan reversing solenoid valve for fault

Inspection method
Turn the start switch to the OFF position, and disconnect the fan reversing solenoid valve connector
2. Turn the multimeter to its resistance function, and measure the resistance between the fan
reversing solenoid valve terminals 1 and 2 (normally, >10Ω).
Whether the fan reversing solenoid valve fails?
Yes No
Repair or replace the fan reversing solenoid valve.

wear.
Inspection method
1. Check the harness (# 904) between the controller (J2-04) and the fan reversing solenoid valve for
wear.
2. Disconnect the connectors from the fan reversing solenoid valve and the controller. Turn the
multimeter to its resistance function, and measure the resistance between the harness (#904)
solenoid valve terminal and the grounding (normally, >100kΩ).
Yes No
6-263

Inspection method
Connect the fan reversing solenoid valve connector and disconnect the controller connector. Turn the
the grounding (normally, >10Ω)
Yes No
Inspection method
Yes No
6-264
6.4.76Fault Code 271305 Fan reversing solenoid valve open-circuited or

short-circuited to the power supply

Fan reversing solenoid valve open circuit or
271305 The fan cannot reverse
short-circuited to the power supply
System description
The fan reversing solenoid valve (variable speed fan reversing solenoid valve) is used to control the
fan’s positive and negative rotation. To achieve that end, the controller receives the operation signal for
the fan’s positive and negative rotation from the instrument and controls the solenoid valve through the
J2-4 port.

᧝࡬ಞ
Controller J2
A16
਎䙕伄᡽ᦘੇ⭫⻷䰶 J2-04 04 904WH1.25 1
229GY1.25 2
LG925E4F06212
Component position
Front
ࢃ
Fan drive
solenoid valve
LG925E4F06213
6-265
Step 1 Check the fan reversing solenoid valve for fault

Inspection method
Turn the start switch to the OFF position and disconnect the fan reversing solenoid valve connector:
2. Measure the resistance between the fan reversing solenoid valve connector terminals 1 and 2 using
resistance range of the multimeter (normally, <100kΩ).
Whether the fan reversing solenoid valve fails?
Yes No
Repair or replace the fan reversing solenoid valve.

wear.
Inspection method
1. Check the harness (#904) or grounding wire (#229) between the controller and the fan reversing
solenoid valve for wear.
Disconnect the connectors from the fan reversing solenoid valve and the controller,
and turn on all switches of the electrical equipment, and then measure the voltage between the
harness (#904) solenoid valve terminal and the grounding (normally, 0V)
3. Check the harness for open-circuit. Turn the multimeter to its resistance function, and measure the
resistance of the harness (No.904) between the controller and the solenoid valve and that of the
harness (No. 229) between the solenoid valve and the grounding (normally, <10Ω).
Yes No
6-266


Inspection method
Connect the fan reversing solenoid valve connector and disconnect the controller connector. Turn the
the grounding (normally, <100kΩ).
Yes No
Inspection method
Yes No
6-267
6.4.77Fault Code 271404 Fan drive solenoid valve shorted to the ground

271404 Fan drive solenoid valve shorted to ground The fan speed cannot be controlled
System description
The fan drive solenoid valve (variable speed fan overflow solenoid valve) is used to control the fan
speed: the controller provides the current through Port J2-07 to control the relief valve which regulates
the hydraulic oil pressure to drive the fan, thereby changing the fan speed.
Controller
᧝࡬ಞ J2
A17
伄᡽ⓘ⍷⭫⻷䰶1
Fan solenoid relief valve 1 J2-07 07 907WH1.25 1 Relief solenoid
835WH1.25 2 ਎䙕伄᡽ⓘ⍷⭫⻷䰶
伄᡽ⓘ⍷⭫⻷䰶2
Fan solenoid relief valve 2 J1-35 35
J1
LG925E4F06216
Component position
Front
ࢃ
Fan drive
solenoid valve
LG925E4F06213
6-268
Step 1 Check the fan drive solenoid valve for fault

Inspection method
Turn the start switch to the OFF position and disconnect the fan drive solenoid valve connector
2. Turn the multimeter to its resistance function, and measure the resistance between the terminals 1
and 2 of the fan drive solenoid valve (normally, >10Ω).
Whether the fan drive solenoid valve fails?
Yes No
Repair or replace the fan drive solenoid valve.

Inspection method
1. Check the harnesses (#907 and #835) between the controllers (J2-07 and J1-35) and the fan drive
solenoid valve for wear, respectively.
2. Disconnect the connectors from the fan drive solenoid valve and the controller. Turn the multimeter
to its resistance function, and measure between the harnesses (#907 and #835) solenoid valve
terminal and the grounding, respectively (normally, >100kΩ)
Yes No
6-269

Inspection method
Connect the fan drive solenoid valve connector, disconnect the controller connector, and then turn the
multimeter to its resistance function, and measure the resistance between the controller port J2-07
(normally, >10Ω)
Yes No
Inspection method
Yes No
6-270
6.4.78Fault code 271405 Fan drive solenoid valve open circuit or shorted
to the power supply

271405 Fan drive solenoid valve shorted to ground The fan speed cannot be controlled
System description

᧝࡬ಞ
Controller J2
A16
਎䙕伄᡽ᦘੇ⭫⻷䰶 J2-04 04 904WH1.25 1
229GY1.25 2
LG925E4F06212
Component position
Front
ࢃ
Fan drive
solenoid valve
LG925E4F06213
6-271

Inspection method
Turn the start switch to the OFF position and disconnect the fan drive solenoid valve connector:
2. Measure the resistance between the fan drive solenoid valve connector terminals 1 and 2 using
Yes No

wear.
Inspection method
1. Check the harness (#904 and #835) between the controller and the fan drive solenoid valve for
wear.
Disconnect the connectors from the fan drive solenoid valve and controller.
3. Check the harnesses for open-circuit. Turn the multimeter to its resistance function, and measure
the resistance of the harnesses (#904 and #835) between the controller and the solenoid valve,
respectively (normally,<10Ω).
Yes No
6-272

Inspection method
Connect the fan drive solenoid valve connector and disconnect the controller connector, and then turn
and J1-35 (normally,<100kΩ).
Yes No
Inspection method
Yes No
6-273
6.4.79Fault Code 271505 Fan drive solenoid valve feedback open-

circuited

271505 Fan drive solenoid valve feedback open-circuit The fan speed cannot be controlled
System description

᧝࡬ಞ
Controller J2
A16
਎䙕伄᡽ᦘੇ⭫⻷䰶 J2-04 04 904WH1.25 1
229GY1.25 2
LG925E4F06212
Component position
Front
ࢃ
Fan drive
solenoid valve
LG925E4F06213
6-274

Inspection method
Turn the start switch to the OFF position and disconnect the fan drive solenoid valve connector:
2. Measure the resistance between the fan drive solenoid valve connector terminals 1 and 2 using
Yes No

wear.
Inspection method
1. Check the harness (#904 and #835) between the controller and the fan drive solenoid valve for
wear.
2. Disconnect the connectors from the fan drive solenoid valve and the controller. Turn the multimeter
to its resistance function, and measure the resistance of the harnesses (#904 and #935) between
controller and the solenoid valve (normally, <10Ω).
Yes No
6-275

Inspection method
Connect the fan drive solenoid valve connector and disconnect the controller connector, and then turn
and J1-35 (normally,<100kΩ).
Yes No
Inspection method
Yes No
6-276
6.4.80 Fault Code 271506 Fan drive solenoid valve feedback overcurrent

271506 Fan drive solenoid valve feedback open-circuit The fan speed cannot be controlled
System description

᧝࡬ಞ
Controller J2
A16
਎䙕伄᡽ᦘੇ⭫⻷䰶 J2-04 04 904WH1.25 1
229GY1.25 2
LG925E4F06212
Component position
Front
ࢃ
Fan drive
solenoid valve
LG925E4F06213
6-277

Inspection method
Turn the start switch to the OFF position and disconnect the fan drive solenoid valve connector
2. Turn the multimeter to its resistance function, and measure the resistance between the fan drive
solenoid valve terminals 1 and 2 (normally, >10Ω).
Yes No
Step 2 Check the harness for short-circuit

Inspection method
1. Check the harnesses (#904/#835) between the controllers (J2-04 and J1-35) and the fan drive
solenoid valve for wear.
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 (# 904 and # 835) between the solenoid valve terminals
harness (# 904/# 835) solenoid valve terminal and the grounding (normally, 0V).
Yes No
6-278

Inspection method
Connect the fan drive solenoid valve connector, disconnect the controller connector, and then turn the
multimeter to its resistance function, and measure the resistance between the controller ports J2-04
and J1-35 (normally, >10Ω).
Yes No
Inspection method
Yes No
6-279
CLG950E 6.5 Fault Diagnosis of the Electrical System
6.5Fault Diagnosis of the Electrical System
6.5.1E1 Troubleshooting solution for battery power loss
Fault SN Faults Consequence

E1 Battery power loss The battery is damaged.
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 motor does not generate
electricity or the voltage is low, the battery powers the electric equipment; when the motor is overloaded
because of too many electric equipment, the battery assists the motor to power; as the battery is
equivalent to a big capacitor, it will protect the components and parts in case of transient overvoltage.
Hydrometer
LG925E4F06224
LG925E4F06225
6-280
6.5 Fault Diagnosis of the Electrical System CLG950E
Step 1 The battery needs to be charged
Check the battery hydrometer color when the start 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
Step 2 The battery is aging and lack of power.

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.
Inspection method
After replacing a new battery, connect the battery firmly.

Yes No
again or contact the local LiuGong dealers and
Maintenance is over authorized service centers.
Back
6-281
6.5.2E2 Troubleshooting solution for abnormal battery

E2 The battery is abnormal The battery is damaged.
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 motor does not generate
electricity or the voltage is low, the battery powers the electric equipment; when the motor is overloaded
because of too many electric equipment, the battery assists the motor to power; as 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-Charge, White-Scrapped.
Hydrometer
⭫⵲ eye
Electric
LG925E4F06226
Component position
LG925E4F06225
6-282
Step 1 Normal battery level
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.
Step 2 The battery needs to be charged
Inspection method
Is the color of battery hydrometer black?
Yes No
Charge the battery
Step 3 The battery is scrapped
Inspection method
Is the color of battery hydrometer white?
Yes No
Repair or replace battery
6-283
Inspection method
Yes No
Back
6-284
6.5.3E3 Automatic slowdown failed

E3 Automatic slowdown failed Increased fuel consumption and noise
System description
When you are not operating the lever, pedal or attachment control lever, the engine speed will drop to the
preset idle speed so as to achieve the purpose of reducing fuel consumption or noise. No matter the
lever or pedal, either or the control lever of attachment is operated, the engine speed will restore to the
corresponding speed of the current accelerator knob.
Engine controller
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-
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CAN 1/2 shield -
&$1ኅ㭳 %. & ᱴ⽰ಞ
CAN 1 low -

&$1ք </%8 &$1B/
1 high -
&$1儎
CAN 5'*1 &$1B+
Handle pilot (QJLQH6SHHG'LDO
pressure switch - 5
9⭫Ⓠsupply- ⋯䰞ᰁ䫤
5V power
12-Gear accelerator -
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potentiometer
δ:KLWHε
- δⲳ㢨ε
Foot pedal
㝐䑅ᶵু࣑ᔶީ
pressure switch -
to earthing -
Ֆ᝕ಞ᧛൦
Sensor
3UHVVXUH6ZLWFK
ᢁ᧝࡬⋯䐥ু࣑ᔶީ
3
3

3
*1' 3

3UHVVXUH6ZLWFK
㝐᧝࡬⋯䐥ু࣑ᔶީ
LG925E4F06228
6-285
Component position
Handle pressure switch
Pedal pressure switch
Pressure switch of attachments
LG925E4F06229
Display
Accelerator knob
LG925E4F06230
ECM Controller
LG925E4F06231
6-286
Step 1 Operate the automatic idle speed control key to cancel the automatic idle speed function.
Whether the automatic idle speed function is canceled or not?

Yes No
Operate the control key of automatic idle speed on
the display to enable the automatic idle speed
function.
Step 2 Select mode L
Inspection method
Check the display for automatic idle speed icon and no icon means the automatic idle speed function is
canceled.
Whether the automatic idle speed function is canceled or not?
Yes No
Operate the control key of automatic idle speed on
the display to enable the automatic idle speed
function.
Step 3 121305, 121405, 231012, 231014 alarm appears on the display
Inspection method
Turn the start 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 fault code.
Go to Step 4
Go to Step 4
6-287
Inspection method
Operate the machine, and check whether each action is normal.

Yes No
Find out the engine system fault or contact the
local LiuGong dealers or authorized service
Maintenance is over centers.
Back
6-288
6.5.4E4 Engine cannot be started

Engine cannot be started (the engine does not
E4 Failed to work.
rotate)
System description
In the condition where there is no fault on the machine and the excavator is started in the correct steps,
and when the electric lock is switched to “Start” position, the starter relay is jointly driven by the actuating
signal controlled by ECM, main control start signal and handle control signal of pilot actuating. Send the
power supply signal to the start power end of the starter motor, so as to start the engine.
LG950E4f06004
6-289
Component position
Display
Accelerator knob
LG925E4F06230
Starting motor
LG925E4F06233
ECM Controller
LG925E4F06231
6-290
Step 1 Immobilization alarm appears on the display
Inspection method
Turn the start switch to ON state, and then check the alarm on the display.
Is the alarm with the fault code of 261711, 261714 appears on the display?
Yes No
corresponding fault diagnosis and troubleshooting
steps of the fault code.
Go to Step 2
Go to Step 15
Step 2 Fuel level is too low
Inspection method
Check the fuel level.

Whether the fuel level is too low or not?
Yes No
Refuel.
Step 3 Battery voltage is too low.

6-291
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.
Black probe
Red probe
LG925E4F06235
Voltage value is 24V in the normal condition.

Whether the battery voltage is too low or not?
Yes No
corresponding fault diagnosis and exclusion steps
of the DTC, or charge the battery or replace the
battery. Go to Step 4
Go to Step 15
Step 4 Fuse blows
The start switch is in OFF state.

Inspection method
1. Open the electrical control unit, remove the fuse, visibly check whether the fuse blows or check
whether both ends of the fuse are connected by the multimeter on the diode gear.
2. Open the fuse box, unplug the fuses 1 and 14 by a fuse clip, and observe by visual inspection
whether the fuse is blown or measure by the DIO position of multimeter whether both ends of fuse
are connected.
Note: There may be grounding fault, so please refer to step 14.
6-292
Is the fuse blown?

Yes No
Replace the fuse
Step 5 Start switch fault
Remove the battery cable (-).

Inspection method
Measure the resistance between the start switch B1 and S with multimeter.
1. When the start switch is turned to OFF state, the resistance between B1 and S is infinite.
2. When the start switch is turned to START state, the resistance between B1 and S is less than 10Ω.
Is there fault on the start switch?
Yes No
Replace the start switch
Step 6 Pilot shut-off valve switch fault

Inspection method
Measure the resistance between the pilot shut-off valve S13 (male 1) and S13 (male 3) with multimeter
1. When the pilot shut-off valve switch is turned to Locked state, the resistance between S13 (male 1)
and S13 (male 3) is less than 10Ω.
2. When the pilot shut-off valve is turned to Unlocked state, the resistance between S13 (male 1) and
S13 (male 3) is infinite.
Whether the pilot shut-off valve switch fails?
Yes No
Repair or replace the pilot shut-off valve switch
6-293
Step 7 Safety relay K11 fault

Inspection method
Measure the resistance between each two contacts of safety relay K11 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 about 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 K11 fails?
Yes No
Replace the safety relay.
Step 8 Pilot control starter relay K7 fault

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.
contacts.
Whether the starter relay K7 controlled by the pilot fails or not?
Yes No
Replace the pilot control starter relay.
6-294
Step 9 starter relay K8 controlled by controller fault

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.
contacts.
Whether starter relay K8 controlled by controller fails or not?
Yes No
Replace the starter relay controlled by a controller.
Step 10 ECM controller starter relay K9 fault

Inspection method
Measure the resistance among all contacts of ECM controller starter relay K9 with a multimeter.
1. Remove ECM controller starter relay K9, and then measure the resistance among all contacts.
contacts.
Whether ECM controller starter relay K9 fails?
Yes No
Replace the ECM controller starter relay.
6-295
Step 11 Starter relay K1 fault

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.
Whether starter relay K1 fails or not?
Yes No
Replace the starter relay.
Step 12 Internal fault of starter motor
Remove the wiring on the input end 50 and end 30 on the starter motor.
When replacing the starter motor, please be sure to use the 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 an
internal fault in the starter motor.
Whether the starter motor has internal fault or not?
Yes No
Replace the starter motor.
6-296
Step 13 Open circuit or poor contact of wire in harness or connector
Correctly tie up harness and wire.

wear.

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. Wire 137 on the main contact of battery relay - wire 136 of the main contact of starter relay K1
2. Wire 182 on the main contact of starter relay K1 - end 30 of starter motor
3. Wire 004 on the main contact of battery relay - X2(8) - X1(5) - end B1 of start switch
4. End S of start switch - X2(2) - end 30 of starter relay K7 controlled by the pilot
5. End 87 of the starter relay K7 controlled by the pilot - starter relay K8 (30-87A) controlled by
controller - ECM control starter relay K9 (30-87A) - X1(19) - wire 181 on the starter relay K1
6. Wire 260 on the starter relay K1 - frame ground (GND)
7. Wire 102 on the main contact of battery relay -X2 (12) - end 30 of the safety relay K11
8. End 87 of safety relay K11- X1(21) -switch of pilot shut -off valve (3-1) - X2(3) -end 86 of starter
relay K7 controlled by pilot
9. Wire 85 on the start relay K7 controlled by pilot - frame ground (GND)
10. End B2 of start switch - X1(28) - end 86 of safety relay K11
11. Wire 85 on the safety relay K11 - frame ground (GND)
12. J2(female 23) - X2(15) - end 86 of the starter relay K8 controlled by controller
13. End 85 on the start relay K8 controlled by controller - frame ground (GND)
14. J5 (female 83) -X2(11) -end 83 of the starter relay K12 controlled by ECM
15. End 85 of the starter relay K9 controlled by ECM - X2(9) - J5 (female 76)
16. End S of start switch - J1 (female 10)
17. End B2 of start switch - End B of battery relay
18. End E of battery relay - frame ground (GND)
Yes No
6-297
Connect the harness again and wrap the harness

Step 14 Wire in harness shorted to the grounding wire

Inspection method
Remove the battery cable (-), and turn the start switch to OFF position, check whether the following
circuits are shorted to ground, and normally the resistance between any check point and the ground
shall be greater than 1MΩ.
1. Wire 137 on the main contact of battery relay - main contact of starter relay K1 - end 30 of the
starter motor
2. Wire 004 on the main contact of battery relay - X2 (8) - X1 (5)- start switch (B1-S) - X2(2) - relay K7,
K8, K9 (main contact) -X1(19)- wire 181 on the coil contact of starter relay K1
3. Start switch (B1-B2) - X2 (28) - end 86 of safety relay K11
4. Wire 102 on the main contact of battery relay -X2 (12) - safety relay K11 (main contact) - X1(21) -
switch of pilot shut-off valve (3-1) - X2(3) - end 86 of starter relay K7 controlled by pilot
5. Ignition switch (B1-S)- J1 (female 10)
Yes No
Inspection method

Yes No
Back
6-298
6.5.5E5 Engine cut-out during operation

E5 Engine shuts down during operation. System fault.
System description
During the operation, the engine shut down may be caused by the engine stuck because of overload, or
because of open circuit in the power circuit of the engine controller. The power circuit of engine controller
is shown in the following figure.
lgnition Switch RD70.0 RD70.0 BK70.0
B1 B2 G1 G2 S M
Heat
OFF
ON FUSE 50A FUSE 50A
ST
144
005
GND
110
X1 X2
28
J5
5
2
8
1
Engine controller
Ignition switch ON
146 5
12 Engine controller 5A
49 Power-
13 Engine controller 30A 51 Power-
52 Power-
14 Electric lock power 20A 113 26 Power+
113 25 Power+
113 1 Power+
LG925E4F06236
6-299
Component position
Ignition switch
Fuse box
LG925E4F06237
ECM Controller
LG925E4F06231

Inspection method
Measure the resistance between the start switch B1 and B2 with multimeter.
1. When the start switch is turned to OFF state, the resistance between B1 and B2 is infinite.
2. When the start switch is turned to ON position, the resistance between B1 and S is less than 10Ω.
Is the start switch damaged?
Yes No
6-300

Step 2 Fuse blows

Inspection method
2. Open the fuse box, unplug the fuses 12, 13 and 14 by a fuse clip, and observe by visual inspection
whether the fuse is blown or measure by the DIO position of multimeter whether both ends of fuse
are connected.
Note: There may be grounding fault, so please refer to step 4
Is the fuse blown?
Yes No
Replace the fuse

wear.

Inspection method
1. No. 50 Fuse terminal - X2(8) - X1(5) - end B1 of start switch
2. X2(8) - X1(2) - J5 (1, 25, 26, 27 & 28)
3. End B2 of start switch - X1(28) - X2(1) - J5(5)
4. J5(73, 49, 50, 51,52) - Frame ground (GND)
Yes No
6-301


Inspection method
1. No. 50 Fuse terminal - X2(8) - X1(5) - end B1 of start switch
2. X2(Male 8) - X1(2) - J5(1, 25, 26, 27 & 28)
Yes No
Inspection method

Yes No
Back
6-302
6.5.6E6 Engine cannot be shut down

E6 The engine can not shut down System fault.
System description
While the machine is operating, start switch is turned from ON to OFF to shut off the start signal of
engine controller, so that the engine shuts down. The power circuit of engine controller is shown in the
following figure.
lgnition Switch RD70.0 RD70.0 BK70.0
B1 B2 G1 G2 S M
Heat
OFF
ON FUSE 50A FUSE 50A
ST
144
005
GND
110
X1 X2
28
J5
5
2
8
1
Engine controller
Ignition switch ON
146 5
12 Engine controller 5A
49 Power-
13 Engine controller 30A 51 Power-
52 Power-
14 Electric lock power 20A 113 26 Power+
113 25 Power+
113 1 Power+
LG925E4F06236
6-303
Component position
Ignition switch
Fuse box
LG925E4F06237
ECM Controller
LG925E4F06231
Step 1 Start switch fault (internal short circuit)

Inspection method
Measure the resistance between the start switch B1 and B2 with multimeter.
1. When the start switch is turned to OFF state, the resistance between B1 and B2 is infinite.
2. When the start switch is turned to ON position, the resistance between B1 and S is less than 10Ω.
Yes No
6-304

Step 2 Thermal short circuit of wire in harness

wear.

Inspection method
circuits are shorted to the battery (+), and normally the resistance between any check point and the
battery (+) shall be greater than 1MΩ.
Is there thermal short circuit in the harness?
Yes No
Inspection method

Yes No
Back
6-305
6.5.7E7 Pre-heater does not work

E7 Pre-heater does not work The machine is difficult to start or won’t start.
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 engine
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 J5-75 on
engine controller is 24V, which drives the automatic preheating relay K10 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.
FUSE 50A
RELAY K3
105 190 104
FUSE 50A
185
FUSE 50A
260
B 102
Grid Heater
E
GND
101
FUSE 50A
D1 Diode
Battery Relay
X1 2
190 20 190 1
2 Auto preheating 10A X2

101 12
704 7 704 J5 Engine controller
123
713 9 75 Air intake preheating (+)
713 76
87A
Preheating grounding wire

86
30
87
85
B1 B2 G1 G2 S M
lgnition Switch Heat
OFF
ON
ST
auto preheat relay K10
190 LG925E4F06242
6-306
Component position
Ignition switch
Fuse box
LG925E4F06237
PREHEATER
Engine controller
LG925E4F06244
6-307

Inspection method
Measure the resistance between the start switch B1 and G1 with multimeter.
1. When the start switch is turned to OFF state, the resistance between B1 and G1 is infinite.
2. When the start switch is turned to HEAT position, the resistance between B1 and G1 is less than
10Ω.
Yes No
Step 2 Preheating relay fault
When replacing the preheating relay, please make 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.
6-308
Step 3 Fuse blows

Inspection method
2. Open the fuse box, unplug the fuse 2 by a fuse clip, and observe by visual inspection whether the
fuse is blown or measure by the DIO position of multimeter whether both ends of fuse are
connected.
Note: There may be grounding fault, so please refer to step 5
Is the fuse blown?
Yes No
Replace the fuse

wear.

6-309
Inspection method
1. Wire 105 on the main contact of battery relay - wire 104 of the main contact of preheating relay K3
2. Wire 185 on the main contact of preheat relay K3 - terminal of the pre-heater.
3. End G1 of start switch - wire 190 on the coil of preheat relay K3
4. Wire 260 on the preheat relay K3 - frame ground (GND)
5. End 87 of automatic preheating relay K10 X1(20) - wire 190 on the coil of preheating relay K3
6. Wire 102 on the main contact of battery relay - X2(12) - end 30 of the automatic preheating relay
K10
7. End 86 of the automatic preheating relay K10 - X2(7) - J5(75)
8. End 85 of the automatic preheating relay K10 - X2(9) - J5(76)
Yes No

Inspection method
1. Wire 105 on the main contact of battery relay - main contact of preheating relay K3 - terminal of pre-
heater.
2. End G1 of start switch - wire 190 on the coil of preheat relay K3
3. Wire 102 on the main contact of battery relay - X2(12) - automatic preheating relay K10 (main
contact) - X1(20)- wire190 on the coil of preheating relay K3
Yes No
6-310
Step 6 Pre-heater fault
When replacing the preheater, 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.
Inspection method

Yes No
Back
6-311
6.5.8E8 All the work implements, revolving and traveling cannot move

All the work implements, revolving and travel
E8 No motion, failed to work.
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 0 6ZLWFKIRU3LORW6ROHQRLG
OJQLWLRQ6ZLWFK +HDW
6
2))
21

$3LORWFXWRIIVROHQRLG
67

$

;

*1'
; )86($
Pilot cut-off 10A

*1' )86($
$

%
(
VDWHW\UHOD\
%DWWHU\5HOD\
LG925E4F06246
6-312
Component position
Ignition switch
Fuse box
Pilot cut-off valve switch
LG925E4F06247
A1
A2
A3
A4
A5
A6
A7
A8
LG925E4F06248
Step 1 Check whether the fuses 1 are blown

Inspection method
Unplug the fuse 1 by a fuse clip, visibly check whether the fuse blows or check whether both ends of
the fuse are connected by the multimeter on the diode gear.
Is fuse 1 blown?
Yes No
Replace the fuse
6-313
Step 2 Pilot solenoid shut-off switch fault (switch closed)

Inspection method
1. 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 3
Go to Step 6
Step 3 Check whether the safety relay fails.

Inspection method
Measure the resistance between each two contacts of safety relay K11 with a multimeter.
1. Remove the safety relay K11, and then measure the resistance among all contacts.
contacts.
Is there a fault in the safety relay?
Yes No
Replace the safety relay.
6-314

wear.

Inspection method
2. End 87 of safety relay K11 - X1(21) - S13 (female 3) of pilot shutoff valve switch
3. S13 (female 2) of pilot shutoff valve switch - pilot shutoff solenoid valve A1 (female 1)
4. Pilot shutoff solenoid valve A1 (female 1)- frame ground (GND)
6. End 85 on the safety relay K11 -X2(16) - frame ground (GND)
Yes No
6-315
Step 5 Wire fault in harness--shorted to grounding wire.

Inspection method
2. End 87 of safety relay K11 - X1(21) - pilot shut off valve switch (3-2) - pilot shut off solenoid valve A1
(female 1)
Yes No
Inspection method

Yes No
Back
6-316
6.5.9E9 Display panel showing nothing

E9 Display panel shows nothing It can not display the machine information.
System description
Protect the constant power end by fuse 15, control the energy power in the display by start switch, and if
the power circuit is normal, turn on the display.
Monitor
lgnition Switch
Battery power supply
Battery power supply
Electric lock ON
CAN_H
CAN_L
B1 B2 G1 G2 S M
Earthing
Earthing
Heat
OFF
ON C4
ST
005
10
26
6
7
5
FUSE 50A FUSE 50A

111
111
270
148
270
X2
8
δGrayε
005
004
X3
15
Controller and display 30A
10
6
8
111
X1
148
111 1
B
GND
E
Battery Relay
LG925E4F06249
6-317
Component position
Ignition switch
Fuse box
Pilot cut-off valve switch
LG925E4F06247
Step 1 Blowing of fuse 15

Inspection method
Is fuse 15 blown?
Yes No
Replace the fuse.

wear.

6-318
Inspection method
1. Wire 004 on the main contact of battery relay -X2(8)-X1(1)-X3(6)- C4(female 6) of the display
2. X1 (female1)- X4 (7)- display C4 (femal7)
3. C4 (female 5) of the display-X4(5) - frame ground (GND)
4. C4 (female 10)-X3(10) of the display - frame ground (GND)
5. End S of start switch -X3(8)- C4(female 26) of the display
Yes No
Step 3 Wire grounding fault in harness---shorted to grounding wire
Shutdown operation is needed.

Inspection method
1. Wire 004 on the main contact of battery relay -X2(8)-X1(1)-X3(6)- C4(female 6) of the display
2. X1 (female1)- X4 (7)- display C4 (femal7)
3. End S of start switch -X3(8)- C4(female 26) of the display
Yes No
6-319
Step 4 Display fault

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
Is there a fault in the display?
Yes No
Replace the display.
Inspection method

Yes No
Maintenance is over service centers.
Back
6-320
6.5.10E10 Incorrectly displayed hydraulic oil temperature

Reducing the pump current and engine speed
can affect the working performance of the
E10 Incorrectly displayed hydraulic oil temperature
complete machine, or cause damage to the
engine and hydraulic components.
System description
The hydraulic oil temp sensor monitors the actual temperature, and outputs different resistance to the
engine controller; the engine controller sends the hydraulic oil temperature to the display through CAN
bus, so the hydraulic oil temperature can be displayed on the display.
ECM Controller
Hydraulic oil temperature
Sensor to earthing
LG950E4f06005
Coolant temperature
50 60 70 80 85 90 95 100 105 110 115
(centigrade)
Coolant temperature °F) 122 140 158 176 185 194 203 212 221 230 239
Resistance (ohms) 3509 2401 1678 1195 1015 865.5 741.2 637 549.8 476 414
Component position
Front
LG925E4F06252
6-321
Step 1 Hydraulic oil temperature sensor fault

Inspection method
Turn the knob start switch to OFF position and disconnect sensor connector:
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.

wear.

Inspection method
1. J5 (female 56) of engine controller - P7 (female 1) of hydraulic oil temp sensor
Yes No

6-322
Inspection method
Yes No
Inspection method

Yes No
Maintenance is over service centers.
Back
6.5.11E11 Fuel gauge unable to display correct value

The fuel level display is inaccurate, and it brings
E11 Fuel gauge cannot display correct value
trouble to the work.
System description
6-323
Controller J2 (White)
Fuel level sensor
Fuel level
LG925E4F06282
Component position
Front
Fuel level sensor
LG925E4F06253

6-324
Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the fuel level sensor:
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.).
.453
LG925E4F06254

Yes No

wear.
6-325
Inspection method
1. Check the harness (# 930) and the grounding wire between the controller (J2-30) and fuel level
sensor for wear.
2. Disconnect the connectors from the fuel level sensor and the controller. Check the harness for
open-circuit:
a. Turn the multimeter to its resistance function, and measure the resistance between the
grounding wire sensor terminal and the grounding (normally, <10Ω).
Gray wire
LG925E4F06255
b. Turn the multimeter to its resistance function, and measure the resistance between the
connector ports J2-30 and sensor harness (normally, <10Ω).
1 24
13
23 White wire
12 35
To the black probe
To the red probe
LG925E4F06256

Yes No
6-326

Inspection method
port J2-30 and the grounding (normally, 2kΩ, for the specific resistance, see the attached drawing).
Connect the black

probe to ground
1 24
13
23
12 35
Connect the red

probe to Pin 30 LG925E4F06257
Yes No
Inspection method
Yes No
6-327
Floater position (be subject to 17.5mm) 2XWSXWUHVLVWDQFH ȍ
LG925E4F06258
6-328

f
/
f

f
/
f

f
/
f

/
f
f

f
/ f

/ f
f

f
/
f

f
/
f

f
/
f

f
/
f

/

/

/

/

/

/

/

/

/

/
Oil level
/
LG925E4F06259
6-329
6.5.12E12 Windshield wiper fails

Foreign matters on glass cannot be removed;
E12 Windshield wiper does not work.
the sight for operator is poor.
System description
Wiper has 5 working states: wiper resetting position, wiper slow speed position, wiper fast speed
position, wiper intermittent position and wiper spraying position. Only when the front window of the cab is
closed and the door control wiper switch is closed, the wiper enters standby state.
Wiper resetting position: when the wiper is in "0" position, the wiper motor stops and it is reset to the
initial position.
Wiper slow speed position: when the wiper is in "1" position, the wiper motor works in slow speed
position.
Wiper fast speed position: when the wiper is in "2" position, the wiper motor works in fast speed position.
Wiper intermittent position: when the wiper switch is in "0" position, press the wiper intermittent position
switch, the wiper motor will work for a cycle, after 5 s, it works another cycle.
6-330
Wiper spraying: when the wiper switch is in "0" position, press the spraying switch, the washer motor
sprays once, and the wiper motor works forward and backward twice. When the wiper switch is in "1" or
"2" position, press the spraying switch, the washer motor sprays once, and the wiper motor works in
cycles according to the speed of the current position.
Wiper and washer 10A
LG950E4f06006
Component position
Wiper switch
Wiper motor
Fuse box
LG925E4F06261
6-331
Step 1 Check whether the fuses 9 are blown

Inspection method
Is fuse 9 blown?
Yes No
Replace the fuse
Step 2 Wiper switch fault

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 7 and pin 3 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.
is infinite.
is infinite.
Is the wiper switch damaged?
Yes No
Replace the wiper switch
6-332

wear.

Inspection method
1. Wiper switch S1 (female 1) - X3 (3) -wiper motor M4 (female 2)
3. Wiper switch S1 (female 7) - wiper intermittent relay S - wiper intermittent relay 31b - X3 (1)-wiper
motor M4 (female 1)
4. Wire 102 on the main contact of battery relay - X2(14) - end 30, end 86 -X1 (24) of wiper relay K6 -
wiper switch S1 (female 3) - wiper intermittent relay 15 - spraying switch S3 (1)- 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)
6. Spraying switch S3 (5) - wiper intermittent relay 86
7. Wiper intermittent position switch S17(5)- wiper intermittent relay I
Yes No
6-333
Step 4 Wire fault in harness--shorted to grounding wire.

Inspection method
3. Wiper switch S1 (female 7) - wiper intermittent relay S - wiper intermittent relay 31b - X3 (1)-wiper
motor M4 (female 1)
4. Wire 102 on the main contact of battery relay - X2(14) - end 30, end 86 -X1 (24) of wiper relay K6 -
wiper switch S1 (female 3) - wiper intermittent relay 15 - spraying switch S3 (1)- X3(4)- wiper motor
M4 (female 6)
5. Spraying switch S3 (5) - wiper intermittent relay 86
6. Wiper intermittent position switch S17(5)- wiper intermittent relay I
Yes No
Step 5 Wiper motor fault

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 motor
6-334
Inspection method
Operate the wiper system and check whether each action is normal.
Yes No
Back
6-335
6.5.13E13 Travel alarm unable to sound

Alarm system is faulty, causing potential safety
E13 Travel alarm does not sound
hazard.
System description
The figure below is the travel alarm electrical circuit diagram. Operators can cancel or enable the travel
alarm function by operating buttons on the display. The main controller judges whether the complete
machine is on travel status in accordance with the foot controlled oil circuit pressure switch. If it is in
travel status, J1-1 foot of the main controller outputs 24 V voltage to the travel alarm. If not, J1-1 foot of
the main controller outputs 0 V voltage to the travel alarm.
(Black)
IPC ControllerJ1 Monitor
C4
CAN 1/2 shield J1-23 23 750BK
CAN 1 low J1-33 33 751YL/BU 1 CAN_L
CAN 1 high J1-34 34 752RD/GN
8 CAN_H
Traveling alarm buzzer J1-1 1 801
N3
(White)
J2 1
Foot pedal pressure switch 12-13 13 913 2
GND
Travel Alarm(Option)
P
P10
1
2
Pressure Switch
GND
LG925E4F06262
6-336
Component position
Front
Travel alarm
LG925E4F06263
6-337

wear.

Inspection method
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
Yes No

Inspection method
1. Main controller J1 (female 1) – travel alarm N3 (female 1)
2. Main controller J2 (female 13) – foot controlled oil circuit pressure switch P10 (female 1)
Yes No
6-338
Step 3 Travel alarm fault

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 fails?
Yes No
Replace the travel alarm.
Inspection method

Yes No
Maintenance is over local LiuGong dealers or authorized service
centers.
6-339
6.5.14E14 A/C panel unable to display

E14 A/C panel unable to display Air conditioning system cannot work
System description
(1) Electrical schematic diagram of air conditioning system, see the attached drawing.
(2) The evaporator assembly arrangement schematic diagram
a. Front view
Air-mixing servo motor
Vent
Vent servo
motor
Foot vent
Water temp
sensor
Warm water Warm water

outlet inlet
LG922E930E06128
6-340
b. Bottom view
Internal air sensor
Expansion valve inlet
Internal-to-external air
switching motor
Fan speed control

resistance
Expansion valve
outlet
LG922E930E06129
6-341
c. Rear view
Air-mixing servo motor
Vent
Vent servo
motor
Foot vent
Water temp
sensor
Warm water Warm water

outlet inlet
LG922E930E06128
Step 1 Base machine power fault

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 if 128 wire has 24V voltage?
Yes No
Find out the reason according to Step 2. Check whether A/C 30A fuse is damaged.
6-342
Step 2 Wire grounding fault - failed to connect with the grounding wire.

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 3
Go to Step 6
Step 3 A/C 30A fuse is blown.
When replacing A/C fuse, please make sure to use LiuGong parts.
Inspection method
Check A/C 30A fuse, visibly check whether the fuse blows 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.
Step 4 5A fuse of the A/C panel is damaged.
When replacing A/C fuse, please make 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.
Is A/C panel fuse damaged?
Yes No
Replace 5A fuse of the A/C panel
6-343
Step 5 A/C panel fault (internal fault).
When replacing A/C panel, please make 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.
Is there a fault in the A/C panel?
Yes No
Replace the A/C panel
Inspection method

Yes No
Look for the electrical system fault or contact local
Maintenance is over
LiuGong dealers and authorized service centers.
6-344
6.5.15E15-No wind or abnormal air volume of air conditioner

Air conditioner blows no air or air volume is
abnormal
Step 1 Blower main relay fault (internal fault).
When replacing the A/C relay, please make 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.
Relay Two terminals code of wire (contact) Standard value

Unplug the relay, and measure the Measure 240±10Ω
resistance between each two
contacts of it Contact E-3 Infinite
Whether the blower main relay fails?

Yes No
Replace the blower main relay.
Step 2 Power transistor fault.

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
6-345
Step 3 Blower motor fault.

Inspection method
Unplug the blower plug of the evaporator as, and check whether there is short circuit or open circuit of
blower coil winding with a multimeter.
Whether the blower fails?
Yes No
Replace the blower. Find out the reason according to Step 4
Step 4 A/C circuit fault.
When replacing the blower, please make 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.
Step 5 A/C panel fault.

Inspection method
If the A/C panel is checked to be normal through step 1 to step 4, it may have been damaged.
Yes No
Replace the A/C panel.
6-346
Inspection method

Yes No
Look for the fault of air conditioning system or
Maintenance is over contact local LiuGong dealers and authorized
service centers.
6-347
6.5.16E16 Poor A/C refrigeration

The refrigeration effect of air conditioning
E16 Poor A/C refrigeration
system is poor
Step 1 Compressor relay fault

Inspection method
Check whether the electromagnetic coil of the compressor clutch relay is open with a multimeter.
Whether the compressor clutch relay fails?
Yes No
Replace the compressor clutch relay Troubleshoot according to Step 2.
Step 2 Internal air sensor fault.

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. Find out the reason according to Step 3
6-348
Step 3 High-low voltage protection switch fault.

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/28.42psi and less than 3.14 MPa/455.3psi, the
pressure switch shall be connected.
Whether the high and low voltage protection switch is damaged?
Yes No
Replace the high and low voltage protection
Find out the reason according to Step 4
switch.
Go to Step 4
Go to Step 8
Step 4 Compressor clutch fault.

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. Find out the reason according to Step 5
Step 5 Compressor fault.

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 fails?

Yes No
Replace the A/C compressor. Find out the reason according to Step 6
6-349
Step 6 A/C harness fault.

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. Find out the reason according to Step 7

Inspection method
If the A/C panel is checked to be normal through step 1 to step 7, it may have been damaged.
Yes No
Replace the A/C panel.
Inspection method

Yes No
Look for the refrigerating system fault or contact
Maintenance is over local LiuGong dealers and authorized service
centers.
6-350
6.5.17E17 air conditioning abnormal alarm E11--Inner gas sensor break

line

Abnormal A/C alarm E11 -- Internal air sensor
open circuit

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.
Step 2 Internal air sensor is open circuit.

Inspection method
Check whether the internal sensor to the A/C panel is open-circuited with a multimeter.
Whether the internal air sensor is open circuit?
Yes No
Check fault points and repair them
6-351

Inspection method
If open circuit is not found through checking by step 1 and 2, it may be internal fault of the A/C panel.
Is it internal fault of the A/C panel?
Yes No
Inspection method

Yes No
service centers.
6-352
6.5.18E18 air conditioning abnormal alarm E12--Inner gas sensor short

circuit

Abnormal A/C alarm E12 -- Internal air sensor
short circuit

Inspection method
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.
Step 2 Internal sensor short-circuited.

Inspection method
Check whether the internal sensor to the A/C panel is short-circuited with a multimeter.
Yes No
6-353

Inspection method
If short circuit is not found through checking by Step 1 and 2, it may be internal fault of the A/C panel.
Yes No
Inspection method

Yes No
service centers.
6-354
6.5.19E19 air conditioning abnormal alarm E15--water temperature

sensor break line

sensor open circuit
Step 1 Water temperature sensor fault.

Inspection method
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.
Step 2 Water temperature sensor open circuit.

Inspection method
Check whether the water temperature sensor to the A/C panel is open-circuited with a multimeter.
Whether the water temperature sensor is open circuit?
Yes No
6-355

Inspection method
If open circuit is not found through checking by step 1 and 2, it may be internal fault of the A/C panel.
Yes No
Inspection method

Yes No
service centers.
6-356
6.5.20E20 air conditioning abnormal alarm E16--water temperature


Step 1 Water temperature sensor fault.

Inspection method
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.
Step 2 Water temperature sensor short circuit.

Inspection method
Check whether the water temperature sensor to the A/C panel is short-circuited with a multimeter.
Whether the water temperature sensor is short circuit?
Yes No
6-357

Inspection method
Yes No
Inspection method

Yes No
service centers.
6-358
6.5.21E21 air conditioning abnormal alarm E18--solar sensor short

circuit

Abnormal A/C alarm E18 -- solar sensor short
circuit
Step 1 The solar sensor fault (internal fault).
Be sure to use LiuGong parts in replacing the solar sensor.

Inspection method
3. If E18 DTC occurs, check whether the circuit of the solar sensor is short with a multimeter?
Yes No
Replace the solar sensor
Step 2 The solar sensor short-circuited.

Inspection method
Check whether the solar sensor to the A/C panel is short-circuited with a multimeter.
Whether the solar sensor is short circuit?
Yes No
6-359

Inspection method
Yes No
Inspection method

Yes No
service centers.
6-360
6.5.22E22 air conditioning abnormal alarm E43--Air blowing valve

abnormal

Abnormal A/C alarm E43 -- Air blowing valve
abnormal
Step 1 Air-out servo motor fault (internal fault)

Inspection method
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 fails?
Yes No
Replace the air-out servo motor.
Step 2 Circuit fault of the air-out servo motor.

Inspection method
Check whether the circuit from the air-out servo motor harness to the A/C panel is short or open with a
multimeter.
Whether the air-out servo motor circuit fails?
Yes No
6-361

Inspection method
Yes No
Inspection method

Yes No
service centers.
6-362
6.5.23E23 Abnormal alarm of the A/C E44 – Abnormal air mixing door

Abnormal A/C alarm E44 -- Abnormal air mixing
doors
Step 1 Air mixing door (A/M) servo motor fault (internal fault).

Inspection method
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 air-out servo motor fails?
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 fault of the servo motor of the air mixing door (A/M).

Inspection method
Check whether the circuit from the servo motor harness 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 door (A/M) fails?
Yes No
6-363

Inspection method
Yes No

Yes No
service centers.
6-364
6.6 Fault Diagnosis of the Hydraulic System and Mechanical System CLG950E
6.6Fault Diagnosis of the Hydraulic System and Mechanical

System
6.6.1System table of the hydraulic system and mechanical system

Right travel motor
Bucket cylinder
Boom cylinder
Left travel Straight travel

Right travel
Boom 1
Arm 2
Bucket
Boom 2
Arm 1
Spare
Swing
Boom cylinder
Left travel motor

Arm cylinder
Swing motor
LG950E4f06007
6-365
CLG950E 6.6 Fault Diagnosis of the Hydraulic System and Mechanical System
6.6.2H1 Excessive barking angle for slewing stop
Excessive braking
angle for slewing stop
<HV
Check whether the

pressure of slewing 1R Slewing relief
overflow valve is normal. valve fault
<HV
Check whether the Anti-reversing
anti-reversing valve is 1R
functioning properly. valve fault
<HV
Check the slewing pilot Clean and replace
circle for clogging <HV
the pilot line
1R
Check whether the

pilot valve is 1R Pilot valve fault
functioning properly
<HV
Check whether the

slewing valve element 1R Spring fault
spring is normal
<HV
Swing motor fault

LG950E4f06008
6-366
6.6.3Abnormal noise from H2 pump mounting position
Abnormal noise from

pump mounting position
Yes
Check the flywheel Coupling components:

Yes
inside for foreign matters Removal and repair
No
Check the coupling hub spline

for wear and the adjusting Replace the hub or tighten
Yes
screw for fixing the hub for the adjusting screw.
looseness.
This abnormal sound may be

caused by the hydraulic pump
No or the engine itself. Refer to
the operating instructions of the
device and the engine
LG950E4f06009
6-367
6.6.4H3 Start the engine, and all operations have no response
When the engine

is started, all operations
are unresponsive.
Yes
Check whether the

No
Add oil to the specified
hydraulic
level as required
oil level is normal.
No
The hydraulic pump Hydraulic pump fault:
Yes sounds abnormally. Yes
Remove and repair it.
Check whether the
abnormal sound comes from
the hydraulic pump
or pump installation position.
Yes
The pump installation Troubleshoot by
No position sounds Yes
abnormally. referring to H2.
Check whether the Check whether any Pilot relief valve fault:
ੜ oil flows out from Yes
pilot pressure is normal. the pilot pump. Repair or replace it
Pilot pump fault:

No
Yes
Pilot valve or main

Check the pilot line for
No control valve fault:
clogging or leakage.
Yes Clean the pilot line or repair it.

LG950E4f06010
6-368
6.6.5H4 Hydraulic oil emulsification
Hydraulic oil
emulsification
Yes
Sample the oil and drop Let the hydraulic oil sit
This may be due to
the sample droplets onto for a period of time, and
Yes water in the
the hot iron plate, and remove the water
hydraulic oil.
then check for bubbles. or replace the oil.
Check the suction line

This may be due to
Yes and the return line,
air in the hydraulic oil.
and cut off the
air-mixed source.
LG950E4f06011
6-369
6.6.6H5 Abnormal hydraulic oil temperature rise
Abnormal hydraulic
oil temperature rise
Yes
Check whether the

Add oil to the specified
hydraulic oil level No
level as required
is nortmal
Yes
Check the oil radiator Clean the oil radiator to

Yes
for clogging keep the air ventilated
No
Check whether the fan

Abnormal noise from
belt tension is No
pump mounting position
appropriate or not
Yes
Check whether the

pressure of the main relief
Adjust the setting
valve, the port relief valve Yes
pressure again
and the motor relief valve is
lower than the standard value
No
Check whether the

Replace the failed
oil return check valve No
check valve
is normal LG950E4f06012
6-370
6.6.7H6 Slewing abnormally to left and right directions
Normal slewing cannot

be achieved either in
the left direction or in
the right direction
Yes
Whether other Troubleshoot it by referring to the method that for

operation is Yes Unidirectional Slewing Operation Is Unresponsive.
unresponsive or not?
No
Check whether the Check whether the The slewing valve

slewing pilot Yes slewing valve Yes element gets stuck:
pressure is normal. element gets stuck. Remove and repair it.
No
Check whether the

slewing relief valve No Repair or replace the
is functioning properly. slewing relief valve.
No
Yes
Slewing motor and reducer fault:

Repair or replace it.
Check whether the

slewing pilot valve is Slewing pilot valve fault: Remove,
No
functioning properly. repair or replace it.
Yes
Clogging or leakage
inside the pilot line Yes Clean or replace the pilot line.
LG950E4f06013
6-371
6.6.8H7 No response for slewing single direction operation
Unidirectional
slewing operation
is unresponsive
Yes
Check whether the left Check the pilot line

slewing pilot pressure is Pilot valve fault:
No inside for clogging No
the same as the right one. Remove and repair it.
or leakage.
Yes
Yes
Clogging or Clean or repair
leakage occurs. the pilot line.
Check whether the The slewing valve element gets

slewing valve Yes
element gets stuck. stuck: Remove it.
Slewing relief valve fault:

No
Remove, repair or replace it.
LG950E4f06014
6-372
6.6.9H8 Rotation unable to stop
Rotation cannot
be stopped
Yes
Check whether the Check whether the slewing

slewing valve element No No Spring fault: Remove
is in the neutral position. valve element spring is normal or replace it.
Yes
Check whether the slewing The slewing valve element gets

valve element gets stuck. Yes
stuck: remove or replace it.
No
Check whether the slewing No Slewing pilot valve fault:

pilot pressure is normal. Remove or replace it.
Yes
Yes
Check whether the pilot Pilot relief valve fault:

Yes
pump pressure is normal. Remove, repair or replace it.
Pilot pump fault:

No
Check whether the

slewing relief valve No Slewing relief valve fault:
pressure is normal. Repair or replacement
LG950E4f06015
6-373
6.6.10H9 Fail to actuate unilateral travel mechanism
Unilateral travel
mechanism fails to
move completely
Yes
Whether other Troubleshoot

operation is Yes according to H3
unresponsive or not?
No
Check whether the travel Travel valve element gets stuck:

valve element gets stuck. Yes
Removal and repair
No
Check whether the Travel pilot line Clean or replace the pilot line.
travel pilot pressure No and pilot valve fault Travel pilot valve fault: Remove,
is normal. repair or replace it.
Yes
Check whether the The travel motor balance valve gets

travel motor balance Yes stuck: remove, repair or replace it.
valve gets stuck.
Travel motor and reducer fault:

Yes Remove and repair it.
LG950E4f06016
6-374
6.6.11H10 Travel deviation
Travel deflection
Yes
Let both left and right sides of the Exchange the left pump output
excavator travel at the same time hose and negative feedback Hydraulic pump fault:
in the same direction+ any No hose with the right ones, and Yes Remove and repair it.
movement on the upper part, check whether the fault
whether pulling one side or not? phenomenon transfers.
Yes
No
Check whether the travel The travel valve element fault:
valve element gets stuck? Yes remove, repair or replace it.
No
Check whether the travel No Travel pilot line and pilot valve fault: clean,
pilot pressure is normal. repair and replace it.
Yes
Check whether the center No Center joint fault: Remove, repair or replace it.
joint is functioning properly.
Yes
Check whether the travel No Travel motor fault: Remove and repair it.
motor is functioning properly.
Yes Main control valve fault: remove, repair or replace it.

LG950E4f06017
6-375
6.6.12H11 Slow speed of the boom, arm or bucket
Boom, arm or
bucket moves slowly
Yes
Whether the engine

speed is normal
No Adjust the engine speed.
Yes
Check whether the left Check whether both the

and right traveling No left speed and the right Yes Main pump fault:
speeds are normal. speed are slow.
No
Check whether the boom,

arm or bucket pilot
pressure is normal.
No
Yes
Check the pilot line inside Yes Clean or repair the pilot line.
for clogging or leakage.
No
Check whether the pilot

valve is functioning properly No Pilot valve fault: Remove and repair it.
Check whether the confluence Check whether the pilot

is normal when the boom rising No pressure of the boom (2) No Check the pilot line and pilot valve
or the arm expanding. or the arm (2) is normal.
Check whether the above- The confluent valve element

mentioned valve element Yes is stuck:Removal and repair
gets stuck.
Yes
ੜ
Check whether the confluent

valve element spring is
functioning properly.
No Replace the spring
Check whether the boom, arm or No Check the pilot line for Pilot valve fault:
clogging or leakage. No Remove and repair it.
bucket pilot pressure is normal.
Yes Yes Clean or repair the pilot line.

Check whether the above-
mentioned valve Yes Spool is stuck:
element gets stuck. repair or replace
No
Check whether the main relief

valve and the port relief valve No Relief valve fault: Remove,
are functioning properly. repair or replace it.
Yes
Cylinder inside damage:
LG950E4f06018
6-376
6.6.13H12 Weak actions of the boom, arm or bucket
Boom, arm or
bucket is
unable to move
Yes
Check whether the

Main relief valve fault: Adjust the
main relief valve No
pressure, and repair or replace the valve.
pressure is normal.
Yes
Check whether the

port relief valve No Port relief valve fault: Adjust the pressure,
pressure is normal. and repair or replace the valve.
Yes
Check whether the cylinder

No Cylinder fault: Remove and repair it.
leakage rate is normal.
Troubleshoot according
Yes
to the H11 fault
LG950E4f06019
6-377
6.6.14H13 Significantly reduced engine speed or engine stalling
Precautions:
(1) Turn off the engine, make preparations, rotate the engine at high speed and then take fault diagnosis
(2) Check the harness connectors for looseness in advance.
Significantly reduced
Check whether the
engine speed or engine Yes No Main relief valve fault
system pressure is normal.
stalling, shutdown
Yes
Check whether the main

Pump proportional valve
pump proportional valve No
is functioning properly. fault: Repair or replace it.
Yes
Engine or electronic
control system fault
LG950E4f06020
6.6.15H14 Abnormal fan speed
Abnormal fan
speed—— too
low or no operation
Yes
Whether the electric Electric system fault

system No solve the electric
input current is normal system problem
Yes
Whether the PTO Replace or repair

No
connector is normal the PTO connector
Yes
Whether the fan

drive pump is normal LG950E4f06021
6-378
7-1
September 3, 2019 Removal and Installation
CLG950E
7 Removal and Installation
7.1 Overview ..................................................................................................................7-3

7.2 Power System ..........................................................................................................7-3
7.2.1 Removal and installation of diesel engine assembly...................................................................7-3
7.2.2 Removal and installation of the hydraulic oil cooler ..................................................................7-14
7.2.3 Removal and installation of the intercooler ...............................................................................7-18
7.2.4 Removal and installation of water radiator ................................................................................7-22
7.2.5 Removal and installation of the diesel tank assembly...............................................................7-26
7.2.6 Removal and installation of the fuel cooler................................................................................7-30
7.2.7 Removal and installation of the fuel injector..............................................................................7-31
7.2.8 Removal and installation of the engine front seal......................................................................7-34
7.2.9 Removal and installation of the engine rear seal ......................................................................7-36
7.2.10 Removal and installation of the cylinder head assembly...........................................................7-39
7.3 Undercarriage System ...........................................................................................7-43

7.3.1 Removal and installation of the track roller ...............................................................................7-43
7.3.2 Removal and installation of the carrier roller .............................................................................7-45
7.3.3 Removal and installation of the track assembly ........................................................................7-47
7.3.4 Removal and installation of the sprocket...................................................................................7-49
7.3.5 Removal and installation of the idler assembly and tensioner assembly ..................................7-50
7.3.6 Removal and installation of the revolving frame........................................................................7-52
7.3.7 Removal and installation of the swing bearing ..........................................................................7-54
7.4 Covering Parts .......................................................................................................7-55

7.4.1 Removal and installation of the engine hood ............................................................................7-55
7.4.2 Removal and installation of the counterweight..........................................................................7-60
7.5 Hydraulic System ...................................................................................................7-63

7.5.1 Removal and installation of center swivel joint..........................................................................7-63
7.5.2 Disassembly and assembly of center revolving joint.................................................................7-66
7.5.3 Removal and installation of hydraulic oil tank ...........................................................................7-70
7.5.4 Removal and installation of the main control valve assembly ...................................................7-74
7.5.5 Disassembly and assembly of the main control valve as ..........................................................7-78
7.5.6 Removal and installation of main pump assembly and fan pump assembly .............................7-96
7.5.7 Removal and Installation of main pump assembly ..................................................................7-101
7-2
Removal and Installation September 3, 2019
CLG950E
7.5.8 Disassembly and assembly of the fan pump as ......................................................................7-122

7.5.9 Removal and installation of the travel pilot valve assembly ....................................................7-134
7.5.10 Disassembly and assembly of the travel pilot valve assembly................................................7-137
7.5.11 Removal and installation of hand pilot valve assembly ...........................................................7-162
7.5.12 Disassembly and assembly of the hand pilot valve assembly.................................................7-164
7.5.13 Removal and installation of the travel motor & reduction gear................................................7-182
7.5.14 Disassembly and assembly of the travel motor & reduction gear ...........................................7-186
7.5.15 Removal and installation of the swing motor & reduction gear ...............................................7-228
7.5.16 Disassembly and assembly of the swing motor & reduction gear ...........................................7-232
7.5.17 Removal and installation of fan control valve ..........................................................................7-264
7.5.18 Removal and installation of fan motor .....................................................................................7-266
7.5.19 Removal and installation of the gear pump (attachment swing)..............................................7-268
7.5.20 Removal and installation of the valve block assembly (attachment swing).............................7-270
7.6 Work Implement ...................................................................................................7-273

7.6.1 Removal and installation of the bucket....................................................................................7-273
7.6.2 Removal and installation of link and lever ...............................................................................7-276
7.6.3 The removal and installation of arm ........................................................................................7-279
7.6.4 Removal and installation of the boom .....................................................................................7-282
7.6.5 Removal and installation of the work implement assembly.....................................................7-287
7.6.6 Removal and installation of the bucket cylinder ......................................................................7-291
7.6.7 Removal and installation of arm cylinder.................................................................................7-294
7.6.8 Removal and installation of boom cylinder..............................................................................7-297
7.6.9 Disassembly and assembly of cylinder ...................................................................................7-301
7.7 A/C system...........................................................................................................7-312

7.7.1 Removal and installation of A/C compressor assembly ..........................................................7-312
7.7.2 Removal and installation of A/C evaporator assembly............................................................7-316
7.8 Cab.......................................................................................................................7-322
7.8.1 Removal and installation of cab ..............................................................................................7-322
7.8.2 Removal and installation of floor plate assembly ....................................................................7-328
7-3
CLG950E 7.1 Overview
7.1Overview 7.2Power System
This chapter introduces the removal and 7.2.1Removal and installation of

installation methods for main parts of this
machine.
diesel engine assembly
The removal and installation of a component
introduce the methods for removing and Removal
installing the component from and on the
complete machine. The disassembly and
assembly of a component introduce the method
for disassembling the component into 1. Before removal, remove the negative (-)
subcomponents and the method of assembly. battery cable firstly in order to avoid
Partial figures may differ from the machine you electric arcs.
are using, but the procedures are the same. 2. When the machine is under operation,
anti-freeze is in the high-temperature
state. Make sure the diesel engine stops
working and antifreezing solution is
cooled before removing the water radiator
or opening the water radiator cap in order
to prevent possible personal injuries.
3. 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
7-4
Photograph Procedure
1. Remove the engine hood (1), (2), (3). Refer to
1 "Removal and Installation of Engine hood" in
this chapter for details.
 Precautions:
2
● Please disengage the mounting bracket and
pipe clamp of DEF pipeline during removal
of engine hood (1).
● Please disengage the mounting bracket of
inter-cooler steel pipe during removal of
engine hood (2).
3
LG950E4f07001
2. Remove the two bottom plates (4) and (5).
LG950E4f07002
7-5
3. Remove the angle block and attached sponge
(6) from the shroud.
4. Prepare a container for receiving anti-freeze,
open water drain valve (7), and discharge anti-
freeze in the water radiator.
Open water tank cover to accelerate water

discharge time.
6 The capacity of anti-freeze in the cooling

system is about 33 L. It is forbidden to
directly drain the anti-freeze to ground to
prevent from contaminating the environ-
ment.
LG950E4f07003
LG950E4f07004
7-6
To make safe operation, firstly make sure

9 the battery negative (-) cable is removed,
and then go to the next step.
5. Disconnect the positive (+) connecting harness
(9) and negative (-) grounding harness (10)
10 connecting the start relay harness(8), start
motor;
LG950E4f07005
6. Remove the bracket (11) and hydraulic pipes

12 (12)(13);
11
7. Remove the inter-cooler hose (14);
13 8. Remove the inter-cooler steel pipe (15);
14
 Precautions:
● The pipes must be sealed with plug to avoid
15 leakage of hydraulic oil or environmental
pollution when the hydraulic pipes (12),(13)
LG950E4f07006
are removed.
● The inlets and outlets of the engine, inter-
cooler hose (14) and inter-cooler steel pipe
(15) must be masked immediately after the
inter-cooler hose is removed,to prevent
dust and other foreign matters from
entering the intake system to cause engine
damage.
7-7
9. Disconnect the frame harness from the engine:
17 18
19
16 1) Disconnect the harness (16) for the A/C
compressor;
2) Disconnect the harness (17) from the engine;
20 3) Disconnect the engine ECM connected
connector (18);
21
4) Disconnect the air intake heater harness (19);
22 5) Disconnect the air flow sensor harness (20);
LG950E4f07007
6) Remove the grounding harness (21) of the
engine cylinder body;
7) Remove the harness fixing support (22).
10. Disconnect the connecting pipes (23), (24)
from the gear pump;
23
 Precautions:
24 ● The oil port of the gear pump and pipelines
must be masked immediately after the
pipelines (23), (24) are removed, to prevent
dust and other foreign matters from
entering the hydraulic system to cause
damage;
LG950E4f07008 ● Meanwhile, the line must be identified to
indicate its mounting ports.
7-8
11. Close the fuel shutoff valve (25) of the oil
circuit;
12. Disconnect the diesel pipes (26), (27), (28),
(29) connecting the engine;
Precautions:
● The oil ports of engine and diesel pipe must
25 be masked immediately after fuel pipes (26),
(27), (28), (29) are removed, to prevent dust
and other foreign matters from entering the
fuel system to cause engine damage.
LG950E4f07009
● Meanwhile, the line must be identified to
indicate its mounting ports.
26 27
28
29
LG950E4f07010
7-9
13. Disconnect the connecting pipe at the upper
32 part of the engine:
31 33
1) Disconnect the intake pipe (30), air outlet pipe
(31) from the turbocharger;
30 2) Disconnect the engine degassing pipe (32),
34 water outlet pipe (33);
3) Disconnect the inter-cooler steel pipe (34);
4) Disconnect the engine water inlet pipe (35);
35
After disconnecting the intake pipe and air
outlet pipe from the turbocharger, the air
LG950E4f07011 inlets of the line and the engine must be
masked to prevent dust and other foreign
bodies from entering the air intake system
to cause engine wear.
After disconnecting the line, the port must

be masked to prevent the foreign matters
from entering the line to cause contamina-
tion.
14. Disconnect the remaining connecting water
36 pipes from the engine:
1) Disconnect the A/C heater water intake hose
37
(36);
2) Disconnect the water inlet and outlet pipes
(37), (38) of the DEF pipeline;
38
3) Disconnect the A/C heater water return hose
39 (39);
4) Disconnect the engine lower water pipe (40);
40 After disconnecting the line, the port must

be masked to prevent the foreign matters
from entering the line to cause contamina-
LG950E4f07012 tion.
7-10
15. Remove the A/C compressor (41), and place it
on the main frame H-beam;
41
LG950E4f07013
16. Disconnect the DPF (Diesel Particle Filter)

43 harnesses (42), (43), (44), (45);
42
44
45
LG950E4f07014
17. Remove the DPF (Diesel Particle Filter)

connecting pipe clamp (47);
46
18. Remove the DPF (Diesel Particle Filter)
mounting bolt (48);
19. Check the components around the DPF, slowly
lift the DPF (46) after making sure lifting has no
effect on them, and place them in a safe place.
(The total weight of the DPF is about: 240kg)
47 After the DPF connecting pipe clamp

removed, the pipe port and DPF exhaust
pipe port must be masked to prevent the
foreign matters from entering the line to
48 cause contamination.
LG950E4f07015
7-11
20. Remove the main pump baffle(49);
 When removing the main pump baffle (49),

be careful not to damage the oil filter pipe
49 of the engine.
LG950E4f07016
21. Remove the oil filter mounting bolt (50), fixing

pipe clamps (51), (52) and fix the oil filter on
50 52
the engine body and then lift it together with
51 engine.
LG950E4f07017
7-12
22. Lift the main pump (54) with a lifting sling,
remove flange mounting bolt (53), and move
53 the main pump and the flange outwards
together so that the coupling bushing is
separated from the engine flywheel.
(the total weight of main pump is about: 260kg)
54
LG950E4f07018
23. Remove 4 shock absorber mounting boles (55)

on the engine bracket;
55
LG950E4f07019
24. Check the components around the engine,

slowly lift the diesel engine (56) after making
sure lifting has no effect on them, and put it in a
safe place. (Total weight of the engine,
mounting bracket and other components:
56 approx 980kg.)
LG950E4f07020
7-13
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 anti-freeze, 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 anti-freeze.
● Table for bolt tightening torques in specific positions:
Tightening torque
Position Grade
N•m lbf•ft
Engine cylinder body M8(8.8) 26±3 19.2±2.2
Engine cylinder body M14(10.9) 180±10 132.8±7.4

Mounting bolts connecting
the main pump flange and M10(10.9) 72±6 53.1±4.4
iron flywheel housing
Mounting bolt of diesel
M12(10.9) 120±10 88.5±7.4
particle filter shock absorber
Coupling bushing mounting
M16(12) 140±7 103.3±5.1
bolts
Mounting bolt of shock
M24(10.9) 900±80 663.8±59.0
absorber
Caution: when assembling, if remove the coupling sleeve (A) from the main pump, the spline
shaft of main pump must be pushed to align with the end surface of coupling sleeve (A) and then
tighten it.
When installing the main pump, please clean the original sealant from the main pump flange, and
reapply the flange sealant and install it with the seal code of ANF2.
7-14
7.2.2Removal and installation of the hydraulic oil cooler
Removal
1. Before removal, rotate the machine revolving platform to an angle suitable for removal, lower
the work implement to ground, shut down to park the machine, release accumulator pressure,
open the hydraulic oil tank cover to release pressure inside, and pump out the hydraulic oil
from tank.
2. Before removal, remove the negative (-) battery cable firstly in order to avoid electric arcs.
1. Seal 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.
2. Clean the area around the assembly ports before removing lines, connectors or hoses.
1. Remove the engine hood (1); and refer to
"Removal and Installation of Engine hood" in
LG950E4f07021
7-15
2. Remove the hydraulic oil radiator oil inlet pipe
(2) and oil outlet pipe (3);
After removing the oil inlet and outlet pipe

of the hydraulic oil cooler, check whether
2 the O-ring at the oil port is damaged. Imme-
diately make replacement in case of dam-
ages,so as to prevent oil leakages after
assembly is restored.
LG950E4f07022
3. Drain the hydraulic oil in hydraulic radiator.
Hold the hydraulic oil with an appropriate

container whose capacity is about 50 L.
LG950E4f07023
7-16
4. Remove the wind shield (4) between wind
scooper and radiator;
LG950E4f07024
5. Remove the 3 cushion mounting bolts and

cushion (5) at the side of the hydraulic oil
5
radiator;
LG950E4f07025
6. Hook the hydraulic oil cooler (9) with a steel

wire rope, and slowly lift it out of the cooler
9
frame.
Be careful not to scratch the hydraulic oil

cooler core during lifting.
 Be careful not to scratch the oil port flange

face during the lifting of the hydraulic oil
cooler to cause oil leakages after assembly
is restored.
LG950E4f07026
7-17
Installation
The installation sequence is just opposite to the removal sequence.
● Clean the components to be assembled properly before assembly.
● The tightening torque shall be in accordance with the general specifications;
● Refill hydraulic oil. Fill the hydraulic oil to the specified level via the filler. Restore the assembly of the
negative battery cable, operate the engine, make hydraulic oil circulate in the hydraulic system,
check the oil level once again and check the line for leakages.
7-18
7.2.3Removal and installation of the intercooler
Removal
1. Before removal, park the machine on flat and hard ground, and lower and shut down the work
implement.
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.
1. Rotate the machine revolving frame to an
angle suitable for removal, and remove the
engine hood (1). Refer to Removal and
installation of engine hood section in this
chapter for details.
LG950E4f07027
7-19
2. Remove the plate (2) under the platform;
LG950E4f07028

LG950E4f07029
7-20
4. Disconnect the air outlet hose (4) connected to
the inter-cooler.
4
LG950E4f07030
5. Disconnect the air inlet hose (5) connected to

the inter-cooler.
5
LG950E4f07031
7-21
cushion (6) at the side of the inter-cooler;
LG950E4f07032
7. Hook the hydraulic oil cooler (7) with a steel

wire rope, and slowly lift it out of the cooler
frame.
Be careful not to scratch the intercooler

core during lifting.
LG950E4f07033
Installation
● Properly clean the inner wall of the air intake pipe before assembly.
● Restore the assembly of the negative battery cable, and operate the engine to check the line for
leakages.
7-22
7.2.4Removal and installation of water radiator
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.
2. When the machine is under operation, anti-freeze is in the high-temperature state. Make sure
the diesel engine stops working and antifreezing solution is cooled before removing the water
radiator or opening the water radiator cap in order to prevent possible personal injuries.
1. Remove the engine hood (1); and refer to
"Removal and Installation of Engine hood" in
LG950E4f07034
7-23
2. Remove the bottom plate (2) under the cooler;
LG950E4f07035

LG950E4f07036
7-24
4. Prepare a container for receiving anti-freeze;
5
open the water drain valve (4), and discharge
4 anti-freeze in the water radiator (open the
water tank cover to accelerate water discharge
time);
The capacity of anti-freeze in the cooling

system is about 33 L. It is forbidden to
directly drain the anti-freeze to ground to
prevent from contaminating the environ-
ment.
5. Disconnect the lower water pipe (5) of the
water radiator;
LG950E4f07037
6. Disconnect the degassing pipe (6), the

7 overflow pipe (7), the upper water hose (8) and
the water inlet hose (9) from the water radiator;
7. Remove the upper cover plate (10) of the
6 8 shroud;
10
LG950E4f07038
7-25
cushion (11) at the side of the water radiator;
11
LG950E4f07039
9. Hook the water radiator (12) with a steel wire

12 rope, and lift it out of the radiator frame.
 Be careful not to scratch the water radiator

core during lifting.
LG950E4f07040
Installation
● Clean the components to be assembled properly before assembly.
● Refill anti-freeze, 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 anti-freeze.
7-26
7.2.5Removal and installation of the diesel tank assembly
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 firstly in order to avoid electric arcs.
Prepare two appropriate fuel drums for receiving fuel during disassembly which can be reused.
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.
Collect the diesel oil with suitable barrel,

and the capacity of reusable fuel tank is
about 650 L.
LG950E4f07041
2. Remove the handrail (2) and (3);
LG950E4f07042
7-27
3. Disconnect the harness (4) of the fuel level
sensor and its fixing harness clamp;
4 4. Remove the DEF pipeline and water pipe fixing
6 pipe clamps (5), (8);
5
5. Remove the hollow bolt, and disconnect the
7
fuel return tube of the diesel tank tube(6) and
its fixing pipe clamp;
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 bodies from entering the fuel
8 system to cause engine damages.
9 6. Remove the bolt (7) of the DEF pump
mounting bracket and its electrical harness:
LG950E4f07043
7. Remove the bolt (9) of the solenoid water
valve mounting bracket and its electrical
harness:
8. Remove the refueling pump filler pipe joint (10)
10 from the diesel fuel tank;
LG950E4f07044
7-28
9. Remove bottom plates (11), (12) and (13)
under the fuel tank;
11 12 13
LG950E4f07045
10. Disconnect the two pipes at the bottom of the

15 16 diesel tank: fuel suction pipe (14), fuel drain
pipe (15);
14
and the fuel port on the fuel tank must be
masked immediately to prevent dust and
other foreign bodies from entering the fuel
system to cause engine damages.
11. Remove the 8 mounting bolts (16) at the
bottom of fuel tank;
LG950E4f07046
7-29
12. After checked and confirmed the connecting
parts around the fuel tank have no influence on
the lifting of the fuel tank, lift the fuel tank (17)
17 with lifting rings welded at the top and sides of
the fuel tank, and place it in a safe place.
LG950E4f07047
Installation
● For the tightening torque of bolts, refer to the general tightening torque.
● Refill fuel, restore the assembly of the negative battery cable, operate the engine, check the line for
leakages and check whether the fuel level indication on the display is normal.
7-30
7.2.6Removal and installation of the fuel cooler
Removal
1. Rotate the machine to an appropriate angle,
open the right door, open the fuel drain valve
(1) and receive the fuel with a container.
Prepare a fuel holding container to receive

the fuel from the fuel tank. (The fuel capac-
1
ity is about 650L)
LG950E4f07048
2. Remove the assembly hollow bolts of the fuel

pipes (2) and (4);
2
3. Remove the assembly bolts of the fuel cooler
(3).

3 and the oil port of the fuel cooler must be
masked to prevent dust and other foreign
bodies from entering the fuel system to
4 cause damages.
LG950E4f07049
Installation
1. Restore the assembly of the fuel radiator first, and then reassemble the fuel pipes;
2. Refuel the fuel tank;
7-31
3. Operate the engine to check the fuel pipeline for leakages.
7.2.7Removal and installation of the fuel injector
Removal
Precautions:
● When removing the fuel injector, be careful
to take it out and not to damage the nozzle;
● If available, please provide a working area
without dust and debris, place slightly the
removed injector in a clean working bench
or container free from debris and oil,
meanwhile, cover the injectors to avoid
pollution, cover the engine and place it at a
area difficult to be found to avoid pollution;
1. Remove the injector actuation harness screw
and the harness;
2. Loosen and remove the injector holder screw;
3. It is possible to pry up the edge of injector
holder (injector body located at upper end of
cylinder head) using a pry bar with heelpiece to
pry up the injector;
LG950E4f07050 4. Remove the fixing clamp of injector;
5. Remove the injector from the cylinder body;
6. Cover the nozzle with a cap.
7. Insert a blind plug to prevent the dust or debris
entering into engine from the cylinder head;
8. The removed injector which will be reused
must be installed at the same cylinder body,
recorded with cylinder number or marked with
fuel injector to track the correct position of each
injector.
7-32
Installation
Precautions:
● When installing the injector, make sure that
all the injectors are not damaged;
● If a injector is not equipped with
electromagnet packing cap, the mounting
pressure should not act on the
electromagnet terminal, and if pushed in
force, the electromagnet terminal will crack;
1. Record well each injector trim code;
2. Record well each injector cylinder installing
position;
LG950E4f07051
The injector trim code is a nine-character
alphabetic numeric code located at the
electromagnet on the top of injector
3. Move away the dummy connector installed at
engine injector and used to stop dust and
debris;
4. Make sure that the injector mounting hole is
clean.
5. Make sure that O-ring and injector is correctly
sealed.
6. Use clean engine oil to lubricate injector O-
ring.
LG950E4f07052 7. The injector is installed with fixing clamp prior

to inserting into mounting hole;
8. Using the electromagnet cap of injector to
ensure that the injector and mounting hole is
sealed;
9. Install the injector fixing clamp screw during
which tighten the screw to a level not more
than that of by hand, so does the other five
injectors.
LG950E4f07053
7-33
10. Install the rocker cover without oil seal, tighten
the mounting bolt at both sides of cap, and for
the detailed operation, please refer to the
installation of rocker cover;
 The rocker cover must be installed without

oil seal, and if installed with oil seal, the
injector may be not aligned correctly result-
ing in leakage of diesel or fuel.
LG950E4f07054
11. Using the high pressure oil pipe to connect the

ends of injector and the end nut of injector to
guide the center ring of injector;
12. Remove the high pressure oil pipes from the
six injectors;
13. Remove the rocker cover and install oil seal
ring, for the detailed operation, please refer to
the installation of rocker cover;
LG950E4f07055
14. Tighten the injector fixing clamp bolt,
Tightening torque:
Injector fixing clamp bolt 65N.m[48ft-lb]
15. Install the injector actuation harness and nut
 Align the injector harness to make each

harness not interfere with rocker cover, and if
the rocker cover contacts with injector
harness, it will cause friction with harness
insulator and resulting in fault of injector
circuit.
16. Tighten the nut.
LG950E4f07056
Tightening torque:
2 N.m [18 in-lb] for injector actuation harness nut
17. Install the other five injectors by repeating the
same procedure.
7-34
7.2.8Removal and installation of the engine front seal
Removal
1. The engine front crankshaft seal has five pre-
drilled slots on the housing (1), and these slots
1 have formed rubber and are designed to be
removed from top of crankshaft seal, and thus
it is not necessary for the seal to drill holes on
the crankshaft seal.
LG950E4f07057
2. Clean the surface of front crankshaft seal.

3. The formed rubbers covering the pre-drilled
slots on the seal housing are dented and these
dents are visible from the front crankshaft seal
surface.
4. Push with proper pin through dents to further
determine the positions of pre-drilled slots.
LG950E4f07058
5. Install the 3.5×20mm tapping screws and

insert them into the pre-drilled slots on the seal
housing.
LG950E4f07059
7-35
6. Using the standard pry-pull tool with fork end to
clamp the screw to pull out the front crankshaft
seal.
7. Discard the seal.
LG950E4f07060
Installation
1. The new front crankshaft seal has a plastic
guide rail at its center which should not be
removed before installation, and should be
used to locate the hole of seal at crankshaft.
2. Lubricate the outer ring of seal to prevent it
from cracking during installation.
3. Install the oil seal in the front gear chamber
with the tool (part number: 5299870)
4. When the tool assembling the oil seal installs
the seal to a proper depth, it flushes the front
gear housing surface.
LG950E4f07061
5. Using plastic hammer to tap at 90°equal
interval until the seal goes in completely.
7-36
7.2.9Removal and installation of the engine rear seal
Removal
1. The engine rear crankshaft seal has five pre-
drilled slots on the housing (1), and these slots
have formed rubber and are designed to be
removed from top of crankshaft seal, and thus
1 it is not necessary for the seal to drill holes on
the crankshaft seal.
LG950E4f07062
2. Clean the surface of front crankshaft seal.

3. The formed rubbers covering the pre-drilled
slots on the seal housing are dented and these
dents are visible from the front crankshaft seal
surface.
4. Push with proper pin through dents to further
determine the positions of pre-drilled slots.
LG950E4f07063
5. Install the 3.5×20mm tapping screws and

insert them into the pre-drilled slots on the seal
housing.
LG950E4f07064
7-37
6. Using the standard pry-pull tool with fork end to
clamp the screw to pull out the front crankshaft
seal.
7. Discard the seal.
LG950E4f07065
Installation
1. Using two screws, p/n 5299479 from mounting
package 5299476 to install the crankshaft.
LG950E4f07066
2. The new front crankshaft seal has a plastic

guide at its center, using the part with part
number 5299478 from mounting package
5299476 to align the plastic guide and slide the
seal on the part with part number 5299478.
LG950E4f07067
7-38
3. Using driver p/n 5299477, from mounting
package 5299476 to install the seal, and a
hammer to tap at 90°equal interval until the tool
reaches its place.
LG950E4f07068
7-39
7.2.10Removal and installation of the cylinder head assembly
Removal
The weight of this component or assembly is more than 23 kg. Make sure to seek help or use
appropriate hoisting equipment to lift this component or assembly to prevent serious personal
injuries.
1. Remove the cylinder head bolts in the
sequences shown in the figure.
LG950E4f07069
2. Install the No. 3162871 engine lifting fixture to

the lifting eyelet, and fix the lifting eyelet to the
cylinder head with bolts.
LG950E4f07070
7-40
When removing the cylinder head, the plug

must be installed to all the oil holes at cylin-
der head and cylinder body, and the neces-
sary plug can prevent the debris from
entering into lubricating system during the
repair,and the plug failed in inserting into
oil passage will cause crankshaft accident.
3. Use crane or hydraulic arm to remove the
cylinder head.
4. Remove the cylinder gasket, and discard this
gasket.
5. The reusable plugs are included in the
protective plug group in the oil passage, part
LG950E4f07071 No. 4919403.
6. Install the plugs to the oil ports of the cylinder
block and cylinder head.
7. Place the cylinder head to the bracket, part No.
ST-583 or equivalent.
Installation
1. Remove all the package of the cylinder head, if
package exists.
LG950E4f07072
7-41
2. Install the No. 3162871 engine lifting fixture to
the lifting eyelet, and fix the lifting eyelet to the
cylinder head with bolts.
LG950E4f07073
 Before assembling the cylinder head to the

cylinder block, all the oil passage plugs
must be removed. If the plugs have not
been removed timely, large scale of engine
damage will be caused.
3. Remove the oil plug and/or belt from the
cylinder head and cylinder block.
LG950E4f07074
Precautions
● The weight of this component or as reaches
more than 23 kg[50 lb]. Make sure to seek
help or use appropriate hoisting equipment
to lift this component or assembly to
prevent serious personal injuries.
● Do not allow the cylinder head fall on the
cylinder gasket, otherwise the gasket
material will be damaged.
4. Install a new cylinder head gasket.
LG950E4f07075
5. Use crane or hydraulic arm to install the
cylinder head.
7-42
6. Remove the No. 3162871 engine lifting fixture,
and fix the lifting eyelet to the cylinder head
with bolts.
LG950E4f07076
7. Coat a thin layer of clean lubricating oil to the

head and bottom flanges of the cylinder bolt,
and make the unnecessary oil in the threads
flow out.
8. Install the cylinder cover bolts.
LG950E4f07077
9. Tighten all the bolts of the specified value as

shown in the illustration:
For bolt 1-26:
Tightening torque:
1.90 N.m [66 ft-lb]
2.150 N.m [118 ft-lb]
3. Rotating 120°
LG950E4f07078 For bolt 27:

Tightening torque:
46 N.m [34 ft-lb]
7-43
7.3Undercarriage System
7.3.1Removal and installation of the track roller
Removal
1. Support the complete machine so that the
platform forms 90° angle with the track frame,
and support one side track beam.
LG922E930E07085
2. Loosen the filling valve (1), discharge grease in

the tensioner, and reduce track tensioning
level.
1 Danger:
The valve has the risk of flying out due to high
pressure grease inside.
Therefore, do not loosen the filling valve 2 by
more than two turns.
LG922E930E07086
7-44
3. Remove the track roller mounting bolts.
LG922E930E07087
Installation
The installation procedures are just opposite to the removals.
● Adjust the track tension to the proper level, referring to the "Measurement and Adjustment of Track
Tension" in the Chapter of Test and Adjustment.
● Apply the anaerobic thread locker (TONSAN 1277) to the track roller mounting bolts with tightening
torque 800±50N.m (590±37 lbf·ft).
7-45
7.3.2Removal and installation of the carrier roller
Removal
1. Loosen the filling valve (1), discharge grease in
the tensioner, and reduce track tensioning
level.
1 Danger:
LG922E930E07086
2. Support the track beside the carrier roller (2)

with a hydraulic jack (or wooden block) to the
height suitable for the removal of the carrier
2
roller.
LG922E930E07088
7-46
3. Loosen carrier roller mounting bolts with a
wrench, and remove the carrier roller. Take out
the carrier roller from the mounting hole.
LG922E930E07089
Installation
Installation sequence is just reverse to the removal sequence.
● Apply the anaerobic thread locker (TONSAN 1277) to the carrier roller mounting bolts, with
tightening torque 415±35N.m (306±26 lbf•ft).
7-47
7.3.3Removal and installation of the track assembly
Removal
1. Move the complete machine forwards so that
the main pin (1) is located at the front section
of the sprocket.
LG922E930E07090
2. Loosen the filling valve (2) with a wrench,

discharge grease, and reduce track tensioning
level.
2 Danger:
LG922E930E07582
7-48
3. Squeeze out the main pin with a pin squeezing
machine (3).
LG922E930E07091
4. Move the complete machine forward to unfold

the track.
LG922E930E07092
Installation
7-49
7.3.4Removal and installation of the sprocket
Removal
1. Refer to "Removal of track as" section to
remove the track assembly Rotate the work
implement by 90°, and jack up the complete
machine with the work implement.
2. Rotate the track to the sprocket (1) side. Unfold
the track.
LG922E930E07093
3. Remove 30 sprocket mounting bolts, and

remove the sprocket.
LG922E930E07094
Installation
● Apply the anaerobic thread locker (TONSAN 1277) to the sprocket mounting bolts,
Tightening torque
1020±90N.m (752.25±66.38 lbf•ft).
7-50
7.3.5Removal and installation of the idler assembly and tensioner

assembly
Removal
1. Refer to "Removal of track as" section to
remove the track assembly
LG922E930E07095
2. Push out the idler and tensioner (1) out of the

idler bracket with a crowbar;
LG922E930E07096
7-51
3. Lift the idler and tensioner assembly (1) and
move it forwards for removal.
LG922E930E07097
4. Remove the tensioner from the idler assembly.
LG922E930E07098
Installation
● Apply the anaerobic thread locker (TONSAN 1277) to the tensioner and idler assembly connecting
bolt, with
tightening torque 600±55N.m (442.5±40.6lbf•ft).

7-52
7.3.6Removal and installation of the revolving frame
Removal
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 the hose(1) —(4) .
2 4
Label the disconnected hoses to prevent mistakes
during reinstallation.
1 3
5 4. Lift the boom cylinder assembly (5) temporarily.
LG950E4f07079
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.
LG950E4f07080
7-53
7. Remove bolts (8) from the center connector.
10 8. Disconnect hoses (9) (10) and tubes (11)-(14).
11 9 13
9. Label the disconnected hoses and tubes to
prevent mistakes during reinstallation.
10. Lift the platform as temporarily.
11. Remove 44 mounting bolts and remove the
revolving frame as.
12 14
8 LG950E4f07081
Installation
● Apply the anaerobic thread locker (TONSAN 1277) to the swing bearing mounting bolt, with
tightening torque 1020±100N.m (752±74lbf•ft).

● Pin axle captive bolt M12
Tightening torque: 120±10N.m(88.5±7.4 lbf•ft).

7-54
7.3.7Removal and installation of the swing bearing
Removal
1. Remove the revolving platform assembly For
details, see the Removal of Revolving Platform
2. Remove the 44 mounting bolts (1) for removing
the swing bearing.
LG922E930E07102
3. Lift the revolving support (2).

Weight of the revolving support: 660 Kg.
LG922E930E07103
Installation
● Apply the anaerobic thread locker (TONSAN 1277) to the swing bearing mounting bolt, with
tightening torque 1020±90N.M. (752±66 lbf•ft)

● When installing the swing bearing, the tape mark S on the swing bearing inner ring needs to face the
right side.
7-55
CLG950E 7.4 Covering Parts
7.4Covering Parts
7.4.1Removal and installation of the engine hood
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.
1. Lower and shut down the work implement.
1 2. Remove the 7 bolts (1) of the left engine hood.
LG950E4f07082
3. Remove the 4 bolts at the other side of left

engine hood(2).
2
LG950E4f07083
7-56
7.4 Covering Parts CLG950E
4. Lift down the left engine hood, and put it on the
flat ground covered with foam cardboard.
Weight ≈ 56kg (123.5Ib)
LG950E4f07084
5. Remove the 7 bolts (3) from the right engine

hood.
3
LG950E4f07085
6. Remove 4 bolts (4) installing the other side of

right engine hood.
LG950E4f07086
7-57
7. Lift down the right engine hood, and put it on
flat ground covered by foam cardboard.
LG950E4f07087
8. Open the middle engine hood.
LG950E4f07088
7-58
9. Remove 2 mounting bolts (5) of inter-cooler
5 steel pipe.
LG950E4f07089
10. Remove the 4 mounting bolts (6) of the DEF

pipe.
LG950E4f07090
11. Remove the 4 bolts (7) of the center engine

hood.
LG950E4f07091
7-59
12. Remove the 3 bolts (8) of the center engine
hood.
LG950E4f07092
13. Lift down the middle engine hood, and put it on

flat ground covered by foam cardboard.
LG950E4f07093
Installation
● Engine hood mounting bolt M12,
Tightening torque: 120±10N.m (88.5±7.4lbf•ft).

● Installation and adjustment of the engine hood:
Tighten the mounting bolts of engine hood, adjust the engine hood if the profile of the left engine hood
isn’t aligned with the right one, make sure the clearance between the left and right engine hoods is
adjusted within the range of 5±3mm(0.20±0.12In).
7-60
7.4.2Removal and installation of the counterweight
Removal
Before the removal of the counterweight, move the machine to the level ground to make sure no
heavy sway when lifting the counterweight in order to avoid of personal injury.
1. Lower and shut down the work implement;
2. Remove 12 bolts (1) fixing protective barrier
bracket.
1
LG950E4f07094
3. Remove the engine hood and rearview

instrument circuit.
LG950E4f07095
7-61
4. Stably lift the counterweight with a steel wire
rope and a hoisting equipment to prevent it
from falling down during removal.
LG922E930E07109
5. Remove the 4 counterweight mounting boles

M42 (1) and washers with a torque wrench.
1
LG936E4F07089
6. Lift and move away the counterweight, and put

it on a flat and safe location.
CAUTION: Do not knock the counterweight

against the engine or radiator.
The counterweight weighs 9000kg. (1984.5lb).
LG922E930E07111
7-62
Installation
● Counterweight mounting bolts M42: 4, tightening torque: 4600±15N.m (3392.5±110.6 lbf•ft). The bolt
thread shall be applied with anaerobic thread locker (TONSAN 1277).
● Install and adjust the counterweight:
1. Adjust the level error or clearance error between the counterweight and the revolving frame and the
covering part with shims.
2. Fix the counterweight, and make the longitudinal clearance among the counterweight, the revolving
frame and the door consistent, and the clearance should be in the range of 15±3mm (0.59±0.12 In).
3. The clearance between the outer profile planarea of the door and the outer profile planarea of the
counterweight in the transverse direction of the complete machine is within the range of 5±3 mm
(0.20±0.12In);
4. The outer profile of the revolving frame is aligned with the outer profile of the counterweight;
7-63
7.5Hydraulic System
7.5.1Removal and installation of center swivel joint
Removal
Before removing hydraulic lines, lower the work implement to the ground completely, shut down
the engine, turn the key to the KEY ON position, operate all hydraulic control levers several times
to release the residual pressure from the hydraulic system, and then press the air filter valve to
release the internal pressure from the hydraulic 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, in order
to prevent pollution source from entering the hydraulic system.
1. Remove the 4 travel pipes (1);
2. Remove the 2 return oil pipes (2),
3. Remove the 2 pilot pipes (3),
4. Remove the pilot pipe tee joint (4).
1 3
3
1 2
LG950EIII07097
7-64
5. Remove the 4 travel pipes (5);
6. Remove the oil return pipe (6);
6 7. Remove the pilot pipe (7).
7
LG950EIII07098
8. Remove the locating bolt (8) from the center

joint;
8
9. Remove 4 captive bolts (9);
LG950EIII07099
10. Move the center swivel joint out with the lifting
slings and the hoisting equipment.
Lifting weight: about 57kg(125.7lb)
LG950EIII07100
7-65
Installation
● Mounting bolt of the center joint
M16-10.9: 305±25 N.m(224±18.4lbf•ft)
Flange oil port screw M10-10.9: 73.5±3.5N.m(54±2.6lbf•ft)
● Tightening torque of angle-sealed connector with O -ring:
G1/4: 36±2N.m(27±1.5lbf•ft);
G3/4: 165±15 N.m(122±13lbf•ft)
● Tightening torque of 24° taper-sealed hose with O-ring:
M18×1.5: 37±2N.m(27±1.5lbf•ft);
M30×2: 116±5N.m(85.5±3.7lbf•ft);
M36×2: 137±6N.m(101±4.4lbf•ft).
7-66
7.5.2Disassembly and assembly of center revolving joint
Disassembly
Choose a clean location. Lay rubber plates or cloth, etc. during removal, and be careful not to
damage parts
1. Remove the four bolts (1) and shims (2).
1 Be careful to fix the center joint to prevent

2 hard objects from scratching the sealing
surface of each oil port.
LG950EIII07101
2. Remove the end cover (3).
3 Be careful not to damage the inner O-ring

while taking out the cover.
LG922E930E07118
7-67
3. Remove the sealing cover O-ring (4)
4
Be careful not to damage the O-ring.
LG922E930E07119
4. Remove the snap ring (5) from the spindle (6).

5
Be careful in operation and not to damage
6 the mounting surface.
LG922E930E07120
5. Remove the stop ring (7).

7
LG922E930E07121
7-68
6. Extract the spindle (6) out of the center joint
body (8) with a puller.
8 7. Remove the bushing (9) .
Hook the claw end of the puller to the flange

surface, and push the spindle out of the
cover.
6 While taking out the bushing, be careful not

to damage the sealing surface of the spin-
9 dle.
LG922E930E07122
8. Remove the seal ring (12) (14) dust ring (10)

and the upper center joint body.
12
Be careful not to damage the sealing sur-
face of the joint body.
When the seal rings cannot be taken out,

the seal rings can be taken out by destroy-
14 ing, and replace them with new seal rings
during re-installation.
10
LG922E930E07123
9. Remove the four plugs (11) at the end of the

11 spindle (6).
Be careful not to damage the O-ring (13).

13
LG922E930E07124
7-69
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 blow them 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 seal, 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.
Name Specification Tightening torque

Bolt M10X25-8.8-Zn.D 52±6N.m(38.4±4.4lbf•ft)
Plug G1/2 110±10N.m(81±7.4lbf•ft)
7-70
7.5.3Removal and installation of hydraulic oil tank
Removal
receive oil.
1. Rotate the revolving frame, and evacuate a
removal and installation space for fuel tank and
main control valve bottom plates.
LG922E930E07125
2. Remove the fuel tank bottom plates (1).

1
LG922E930E07126
7-71
3. Put the bucket under the oil drain port of the
tank,
4. Remove the drain plug (2), drain the oil
completely, and then reinstall the drain plug
back.
LG950EIII07102
5. Remove the dipstick (3);

6. Remove the pilot valve set 4 oil pipes (4),
5 6 7. Remove the main pump drain pipe (5);
3
8. Remove the fan pump oil drain hose (6).
9. Remove the oil drain pipe of the pilot gear
4 pump(7).
7
LG950EIII07103
10. Remove the front cover plate (8).
LG950EIII07104
7-72
11. Remove the 2 main valve oil return pipes (9),
12. Remove the 6 pilot oil return pipes (10),
13. Remove the travel motor oil drain pipe (11),
14. Remove the swing motor oil drain pipe (12),
9
15. Remove the fan motor oil drain pipe (13).
10
11
12
13
LG950EIII07105
16. Remove the pilot valve bank (14),

17. Remove the clamp (15).
14
15
LG950EIII07106
18. Remove 5 mounting bolts (16) from the oil

suction pipe flange,
19. Remove the 6 oil tank captive bolts (17).
16 17
×5
×6
LG950EIII07107
7-73
20. Penetrate through the lifting eyes, and lift and
move the fuel tank to a clean and safe place
with a sling and a hoisting equipment.
Lifting weight: 280kg (617.4 lb)
LG922E930E07133
Installation
● Tightening torque of mounting bolts:
M10-10.9: 72±6N.m(53±4.4lbf•ft),
M12-10.9: 120±10N.m(88.5±7.4lbf•ft),
M16-10.9: 305±25 N.m(224±18.4lbf•ft).
● The threads of mounting bolts shall be coated with thread locker (Tonsan 1277) before installation.
● Tightening torque of the joint bolt:
M18: 37±2N.m(27±1.5lbf•ft),
M22: 47±2N.m(34.6±1.5lbf•ft),
M36:137±6N.m(101±4.4lbf•ft).
● Tightening torque for installation of level meter: 10±1N.m (7.4±0.7lbf•ft).
● Refill hydraulic oil.
7-74
7.5.4Removal and installation of the main control valve assembly
Removal
receive oil.
removal and installation space for fuel tank and
main control valve bottom plates.
LG922E930E07125
2. Remove the fuel tank bottom plates (1).
LG922E930E07126
7-75
3. Place a barrel below the oil drain port of the
tank, remove the drain plug (2) and drain the oil
back.
2
LG950EIII07108
4. Remove the front cover (3).
LG950EIII07109
5. Remove the bottom plate (4) under the main

control valve.
LG922E930E07135
7-76
6. Remove 2 oil inlet hoses (5);
6 8 7. Remove the oil return steel pipe (6);
7
5 8. Remove the revolving motor oil refilling port
pipe (7);
9. Remove 38 pilot hoses (8) and their joint;
10. Remove the 8 steel pipes (9).
LG950EIII07110
11. Remove the 4 captive bolts (10) of the main

10 10 control valve from the bottom.
10 10
LG950EIII07111
12. Shift the main control valve out with lift

equipment such as a sling.
Lifting weight: about 337kg(743 lb)
LG922E930E07138
7-77
Installation
● Tightening torque of mounting bolt for main control valve assembly: M16-10.9:305±25 N.m
(224±18.4lbfoft);
● Clean the threaded hole before installing the bolts, and apply the anaerobic thread locker (TONSAN
1277) on the thread of bolt.
● The hex screw of the flange seal pipe joint:
M10-10.9: 73.5±3.5 N.m(54.2±2.6lbfoft);
M12-10.9:136±6 N.m (100±4.4lbfoft);
M14-10.9: 195±15 N.m (143.8±11lbfoft).
● Tightening torque of the hose:
M18×1.5:37±2 N.m (27±1.5lbfoft);
M36×2:179±8 N.m (132±5.9lbfoft);
M45×2:226±11N.m (166.7±8.1lbfoft).
● Tightening torque of the pipe joint:
G1/8:8.75±1.25N.m (6.45±0.92lbfoft),
G1/4:36±2N.m (26.6±1.5lbfoft),
G3/8:73.5±4.5N.m (54.2±3.3lbfoft),
G1:225±25N.m (165.9±18.4lbfoft).
7-78
7.5.5Disassembly and assembly of the main control valve as
For the main control valve part drawing, see Appendix 8 for details
Mounting Mounting
torque No . Part name Quantity torque No . Part name Quantity
(N.m) (N.m)
Straight
101 Valve body A 1 391 travel spool 1
assembly
Bypass stop
102 Valve body B 1 392 2
spool
7.8-9.8 Spool of
151 Oil plug 2 393 1
(5.75-7.23) boom 2
69-78 Spool of arm
155 Oil plug 14 394 1
(50.9-57.5) 2
Rotary
13-17
158 Oil plug 7 395 priority valve 1
(9.6-12.5)
spool
34-39
159 Oil plug 1 511 Cone valve 10
(25-28.7)
161 O-ring 11 512 Cone valve 2

Cone valve
165 O-ring 16 515 1
gp
168 O-ring 7 522 Spring 10
202 Spool cover 8 524 Spring 2
203 Cover 2 525 Spring 1
204 Cover 1 541 Steel ball 1

Boom priority
205 1 542 Spring holder 1
valve cover
25-29
208 Spool cover 1 550 Oil plug 1
(18.4-21.4)
34-39 370-410
211 Oil plug 1 551 Oil plug 8
(25-28.7) (272.9-302.4)
230-260
212 O-ring 2 552 Oil plug 2
(169.6-191.7)
78-98 370-410
251 Oil plug 2 553 Oil plug 2
(57.5-72.3) (272.9-302.4)
7-79
Mounting Mounting
(N.m) (N.m)
Lock valve
9.8-14 69-78
252 selection 2 554 Oil plug 2
(7.22-10.3) (50.9-57.2)
subassembly
200-250 Oil plug
262 O-ring 8 557 2
(147.5-184.4) subassembly
200-250
263 O-ring 12 558 Oil plug 2
(147.5-184.4)
264 O-ring 7 561 O-ring 12
265 O-ring 2 562 O-ring 7
267 O-ring 1 563 O-ring 2

52-62 Inner 120-140 Main relief
273 40 601 1
(38.4-45.7) hexagon bolt (88.5-103.3) valve
52-62 Inner 120-140 Port relief
274 12 603 8
(38.4-45.7) hexagon bolt (88.5-103.3) valve
Negative flow
52-62 Inner
275 5 611 control relief 2
(38.4-45.7) hexagon bolt
valve
120-140
301 Travel spool 2 652 Oil plug 2
(88.5-103.3)
Arm 1 spool
302 1 663 O-ring 2
subassembly
Boom 1
303 spool 1 664 O-ring 2
subassembly
Sealing ring
304 Bucket spool 1 665 protection 2
gasket
305 Swing spool 1 751 Flange 2
Cover plate
308 Backup spool 1 754 without pipe 1
opening
Cover plate
37-41
313 Oil plug 1 755 without pipe 2
(27.3-30.2)
opening
326 Spring 2 761 O-ring 2
140-160 Inner
327 Spring 2 762 8
(103.3-118) hexagon bolt
332 Spring holder 22 763 O-ring 1
83-110 Inner
335 Shim 3 764 4
37-41 Bolt with a 83-110 Inner
336 11 765 8
(27.3-30.2) liner (61.2-81.1) hexagon bolt
7-80
Mounting Mounting
(N.m) (N.m)
390-470 Inner
337 Rod 2 972 4
15-19 390-470 Inner
351 Orifice plug 2 973 3
(11-14) (287.6-346.6) hexagon bolt
15-19 390-470 Inner
352 Orifice plug 1 974 1
(11-14) (287.6-346.6) hexagon bolt
355 Piston 1 991 Nameplate 1
356 Piston 1 992 Rivet 2
371 Spring 7
372 Spring 1
373 Spring 1
374 Spring 1
375 Spring 1
General notes
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. In addition, the operation should be performed on an appropriate platform.
Before the operation, the platform should be covered with clean paper sheets or rubber plates, etc.
4. The force support in carrying and moving the control valve should act on the solid positions of the
body and should never act on the projecting positions such as the spool and spring cover. Be careful
of the operation.
5. In addition, 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.
6. In addition, prepare clean cleaning oil, working oil and lubricant,etc, in advance.
7-81
Tools
Before removing the control valve, prepare the tools in advance as follows.
Name Quantity Size (mm)

Bench vice 1 ―
22(0.87In), 27(1.06In), 32(1.26In),
Socket wrench Each for 1
36(1.42In), 46(1.81In)
5(0.20In), 8(0.32In), 12(0.47In),
Inner hexagon spanner Each for 1
17(0.67In)
Thread locker 1 JIS#262
10(0.39In), 22(0.87In), 24(0.94In),
Wrench 1 32(1.26In)(Main relief valve),
36(1.42In)
Disassembly
The number in the () after a part name represents a part number in the parts drawing.
1. Place the control valve on an operation
platform.
Perform removal in a clean place. Do not

damage the flange face.
2. Removal of main spool (travel, bucket, swing,
standby, arm 2, boom 2, swing priority):
1) Loosen inner hexagon bolt (273) and remove
the spring cove (201). (Inner hexagon spanner
8mm(0.32In)
Before removing bucket spring cover (206),
firstly remove the oil plug (558) and piston
(356).
(Inner hexagon spanner 17mm(0.67ln)
LG950EIII07112
7-82
2) Take the spool, spring, spring seat, bolt with
gasket, spacer (only for arm 2, boom 2 and
swing priority) out of the valve body in spool
group form.
When removing the spool group from the

valve body, be careful not to damage the
valve body.
LG950EIII07113
3) Fix the spool onto the bench vice with

protective hood on jaw. Then remove the bolt
with gasket (336) and then remove the spring,
spring seat, spacer (only for bucket rod 2,
movable arm 2 and rotation priority). (Inner
hexagon spanner 12mm(0.47In)
LG950EIII07114
3. Removal of the arm 1 spool:

1) Loosen inner hexagon bolt (273) and remove
the spring cove (201). (Inner hexagon spanner
8mm(0.32In)
2) Take the arm 1 spool (302), spring (371),
spring seat (332) and bolt with gasket (336),
out of the valve body in spool group form.
When removing the spool group from the

valve body.
LG950EIII07115
7-83
3) Fix the arm 1 spool (302) onto the bench vice
with protective hood on jaw. Then remove the
bolt with gasket (336), and then the spring
(371) and spring seat (332). (Inner hexagon
spanner 12mm(0.47In)
4) The arm 1 spool (302) can not be further
disassembled.
LG950EIII07116
4. Removal of straight travel spool:

1) Loosen the inner hexagon bolt (273) and
remove the spring cover (201); take the travel
spool (391), spring (373), spring seat (332)
and bolt with gasket (336) out of the valve
body in spool group form. (Inner hexagon
spanner 8mm(0.32In)
 When removing the spool group from the

valve body.
2) Fix the straight line travel spool (391) onto the
bench vice with protective hood on jaw. Then
remove the bolt with gasket (336), and then
the spring (373) and spring seat (332). (Inner
hexagon spanner 12mm(0.47In)
3) The straight travel spool (391) should not be
further disassembled.
7-84
5. Removal of boom 1 spool:
1) Before removing the boom 1 spring cover
(206), firstly remove the oil plug (558) and
piston (355). Loosen the inner hexagon bolt
(273) and remove the spring cover (206); take
the boom 1 spool (303), oil plug (313), spring
(371), spring seat (332) and bolt with gasket
(336) out of the valve body in spool group
form.
(Inner hexagon spanner 8mm(0.32In?
 When removing the spool group from the

LG950EIII07117
valve body.
2) Fix the boom 1 spool (303) onto the bench

vice with protective hood on jaw. Then remove
the bolt with gasket (336), and then the spring
(371) and spring seat (332). (Inner hexagon
spanner 12mm(0.47In)
3) The boom 1 spool (303) can not be further
disassembled.
6. Removal of spool cover:
Loosen THE hexagon socket bolt (273) and
remove the valve element cove (202, 208).
Inner hexagon spanner 8mm(0.32In)
When removing the boom 1 cover, firstly
remove the oil plug (211).
Socket wrench 22mm(0.87In)
LG950EIII07119
7-85
7. Removal of main relief valve and interface
relief valve:
Remove the main relief valve (601) and inter-
face relief valves ( 603) from the valve body.
Main relief valve: Wrench 32mm(1.26In) (inter-
face relief valve: Socket wrench
36mm(1.42In), wrench 36mm(1.42In)
LG950EIII07120
8. Removal of lock valve selection subassembly:

Loosen the inner hexagon bolt and remove the
lock valve selection subassembly (252).
(Inner hexagon spanner 5mm(0.20In)
LG950EIII07121
7-86
9. Removal of bypass stop spool:
Remove the oil plug (251), springs (326, 327),
(337), bypass stop valve element (392).
Socket wrench 27mm(1.06In)
LG950EIII07122
LG950EIII07123
10. Removal of negative flow relief valve:

1) Remove the oil plug (551).
LG950EIII07124
7-87
2) Remove the negative flow relief valve (611).
LG950EIII07125
11. Disassembly of the check valve:

1) Remove the oil plug (551), cone valve (511)
and spring (522). (Inner hexagon spanner
17mm(0.67In)
2) Loosen the inner hexagon bolt (275) and
remove the check valve cover (204), and then
take out the cone valve (511, 514), springs
(522, 525). Inner hexagon spanner
8mm(0.32In)
3) Loosen the hex bolt (274) and remove the
check valve cover (203), and then take out the
cone valve (511), spring (522). Inner hexagon
LG950EIII07126
spanner 8mm(0.32In)
4) Remove the oil plug (553), and then take out

the cone valve (513) and spring (524).
5) Remove the oil plug (552), and then take out
the cone valve (512) and spring (523).
(Inner hexagon spanner 12mm(0.47In)
LG950EIII07127
7-88
6) Remove the oil plug group (557), and then
take out the cone valve (511) and spring (522).
(Socket wrench 32mm(1.26In)
LG950EIII07128
12. Removal of boom priority valve:

1) Loosen the hex bolt (276, 277), and remove
the boom priority valve cover (205) and cone
valve subassembly (515).
2) Fix the boom priority valve cover (205) onto
the bench vice with protective hood on jaw,
and then remove the cone valve subassembly
(515).
LG950EIII07129
3) Boom priority valve cover (205):

Turn over the cover (205) of boom priority
valve, and fix on the bench vice with protective
hood on jaw; then remove the oil plug (559)
and take out the piston (356).
LG950EIII07130
7-89
See details in following figure 4) Cone valve group (515):
Take the cone valves (101 and 102), oil plug
(103) and spring (104) out of the valve sleeve
(106) in subassembly form.
5) And then take out the spring (105) and spool
(107).
6) The group in above 12.4 can not be further
disassembled.

*

*

LG950EIII07270
LG950EIII07270
7-90
13. Removal of the valve body:
1) Except special circumstances, do not
generally remove the anchor bolt of the valve
body A.
2) The oil plug not recorded in above sequences
will not be removed unless in exceptional case
due to it is the plug for process hole and
casting cleaning hole.
LG950EIII07131
14. Post-removal inspection

Thoroughly clean all the removed parts with
clean mineral oil, after they are dried by com-
pressed air, place all parts on clean paper or
cloth in order to inspect them.
1) Control valve:
(1) Inspect the entire surface of each part. No
burrs, rough edges, drag marks, galling,
scratches or other defects are allowed.
(2) Confirm that the seal groove faces of the valve
body and valve block are smooth. Defects such
as impurities, deformations, pits and corrosion
are not allowed.
(3) If there are deformations and pits on the valve
seat surface of the check valve body and valve
block, eliminate them in the abrading method.
7-91
15. Be careful not to keep abrasive paste remain
in the valve body and valve block.
(4) Confirm that sliding and mating parts are able
to flexibly rotate by hand and no impurities are
left in all grooves and passages.
(5) Replace the spring with a new one in case of a
break or deformation.
(6) When the relief valve acts ineffectively, repair it
according to the removal and assembly of the
relief valve.
(7) Replace all seals and O-rings with new ones.
8) Relief valve:
(1) Make sure the spool and valve seat head seal
surface of each valve have no defects and the
mating surfaces are in uniform contact.
(2) Make sure the spool and valve seat of the main
valve are easily and freely slid by hand.
(3) Make sure the main valve spool outer
circumferential surface and valve seat inner
circumferential surface have no drag marks
and galling.
(4) Make sure the springs have no breaks,
deformations or abrasion.
(5) Make sure the damping holes of the spool and
valve seat of the main valve are not blocked by
impurities.
(6) Replace all O-rings with new ones.
(7) When minor damage is found in the above
inspection, it can be eliminated in the abrading
method.
(8) When a defective part exists, replace the relief
valve by group.
7-92
Assembly 511: 10 position

1. The assembly process is only provided with 512: 2 position
descriptive texts. For relating figures and
513: 2 position
photos, refer to the relating disassembled
items. 514: 1 position
2. The figures in () following the component Mounting
Inner hexagon
name in descriptive text indicate the symbols No. torque
spanner
in part drawing. (N.m)
3. Precautions in assembling O-ring seals: 17mm 370~410(272.9-

(551)
(0.6693In) 302.4)
1) Note that the seals must have neither 8mm
forming defects nor the scars generated in (274) 52~62(38.4-45.7)
(0.3150In)
use.
17mm 370~410(272.9-
(553)
2) Apply grease or working oil in the positions (0.6693In) 302.4)
of the seals and similarly shaped seals to 12mm 230~260(169.6-
(552)
ensure sufficient lubrication. (0.47244In) 191.7)
(Socket wrench)
3) Do not stretch the seals to a permanent 200~250(147.5-
(557) 32mm
deformation that they cannot recover. (1.2598In)
184.4)
4) When installing an O-ring seal, do not install

it in a distorted way. A distorted O-ring seal 2. Installation of boom priority valve:
is difficult to naturally recover after being a. After mounting O-ring (108) into the valve
installed, which is the cause of oil leakage. sleeve (106), mount the spool (107) and
5) The mounting bolts of all parts are fixed with spring (105).
the torque wrench according to the mounting b. Mount the cone valve (101, 102), oil plug
torques in part list. (103), spring (104) group into the valve
sleeve (106).
1. Mounting of the check valve:
c. Mount the valve sleeve onto the cover
Mount in the cone valves (511, 512, 513, 514),
(205) of boom priority valve subassembly,
springs (522, 523, 524, 525). Mount the O-ring
and then mount the cover subassembly
(561) onto the oil plug (551, 553); then mount the
onto the valve body. Then tighten with
O-ring (563) onto the oil plug (552); mount the O-
hexagon socket bolts (276, 277).
ring (264) on cover (203), O-ring (264, 267) on
Inner hexagon spanner 8mm(0.3150In),
the cover (204), and tighten according to
mounting torque 52 ~ 62 N•m(38.4-
specified torque.
45.7lbf•ft)
Notice that the following is the used d. After mounting the piston (356) into the
combination of cone valve, spring and oil boom priority valve cover (205), mount and
plug. tighten the oil plug (559).
Cone valve Spring Oil plug or cover Socket wrench 24mm(0.9449In), mounting
torque 200~250 N•m(147.5-184.4lbf•ft)
203,204
511 522 3. Installation of negative control relief valve:
551,557
512 523 552 Mount the negative flow relief valve (611) onto
the valve body A (101) and B (102). Install the O-
513 524 553 ring seal (561) onto the oil plug (551), and tighten
514 525 204 it with specified torque.
7-93

mounting torque 370~410 N•m(272.9-302.4lbf•ft)
4. Installation of bypass stop valve:
Separately mount the bypass stop spool (392), Before installing the bolt with liner (336),
springs (326, 327), rod (337) into the valve body apply #262 thread seal on it.
A (101) and valve body B (102), and mount the
b. Upon the installation of item a, then install
O-ring (265) into the oil plug (251); tighten
the spool group onto the valve B (102).
according to specified torque. (Socket wrench
27mm(1.0629In), mounting torque 78~98
N•m(57.5-72.3lbf•ft))
5. Installation of lock valve selection
While installing the spool group onto the
subassembly:
valve body B (102), do it slowly and
Mount the O-ring (163) onto the lock valve prudently. Never push the spool into the
selection subassembly (252), and tighten with valve body forcibly.
specified torque.
8. Installation of the boom 1 spool (303):
mounting torque 10~14 N•m(7.4-10.3lbf•ft) a. Fix the boom 1 spool (303) with the bench
vice with protective hood on jaw. Mount the
6. Installation of main relief valve and interface spring seat (332), spring (371); tighten the
relief valve: bolt with gasket (336) with specified
Install the main relief valve (601) and interface torque. Tighten the oil plug (313) according
relief valve (603) onto the valve body, and fasten to specified torque.
it in the following specified torque.
Mounting
Tools
torque
Before installing the bolt with liner (336),
Main relief Wrench 120N.m~140N.m( apply #262 thread seal on it.
valve 32mm(1.2598In) 88.5-103.3lbf•ft)
Wrench ● bolt with liner (336): (Inner hexagon spanner
Port relief 36mm1.4173In) 120N.m~140N.m( 12mm(0.47244In), mounting torque 37~41
valve Socket wrench 88.5-103.3lbf•ft) N•m)(27.3-30.2lbf•ft)
36mm(1.4173In)
● Oil plug (313): (Wrench 30mm(22.1In),
7. Installation of straight travel spool: mounting torque 37~41 N•m) (27.3-30.2lbf•ft)
2) Upon the installation of item 1), then install
a. Fix the straight line travel spool (391) with
the spool group onto the valve body B(102).
the bench vice with protective hood on
vice, and mount the spring seat (332),
spring (373), and tighten the bolt with
gasket (336) with specified torque. (Inner
hexagon spanner 12mm(0.47244In), While installing the spool group onto the
mounting torque 37~41 N•m(27.3- valve body B (102), do it slowly and
30.2lbf•ft) prudently. Never push the spool into the
valve body forcibly.
9. Installation of arm 1 spool:

7-94
a. Fix the arm 1 spool (302) with the bench

vice with protective hood on vice, and
mount the spring seat (332), spring (371),
and tighten the bolt with gasket (336) with
specified torque. When installing the spool group onto the
valve body A (101) and valve body B (102), do
it slowly and prudently. Never push the spool
into the valve body forcibly.
Before installing the bolt with liner (336), 11. Installation of covers:
apply #262 thread seal on it.
a. Mount the spool cover (202, 208) at the
Inner hexagon spanner 12mm(0.47244In), side opposite to the spring subassembly of
mounting torque 37~41 N•m (27.3-30.2lbf•ft) valve element, and tighten the hex bolt
(273) with specified torque.
b. Upon the assembly of item a, install the
spool group onto the valve body A (101).
Confirming whether the O-ring (262) has been

mounted on the spool cover (202), and
When installing the spool group on valve whether the O-ring (263) has been mounted
body A (101), do it slowly and prudently. on the boom 1 spool cover (208).
Never push the spool into the valve body
forcibly. Inner hexagon spanner 8mm(0.3150In),
10. Installation of main spools: the travel (301),
bucket (304), swing (305), standby (308), b. Boom 1 spool cover:
arm 2 (394), boom 2 (393) and swing priority Mount the O-ring (212) onto the oil plug (211),
(395) and mount and tighten the boom 1 spool cover
a. Fix the spools with the bench vice with (208) with specified torque.
protective hood on jaw. Mount the spring Socket wrench 22mm(0.866In), mounting torque
seat and spring (mount the spacer (335) 34~39 N•m(25-28.8lbf•ft)
on arm 2, boom 2, swing priority valve),
and tighten the bolt with gasket (336) c. Install the spring covers (201, 206) to the
according to specified torque. spring side of spool and tighten the hex
bolt (273) with specified torque.
Before installing the bolt with liner (336),

apply #262 thread seal on it. Confirming whether the cover has been
mounted with O-ring (263).
(Inner hexagon spanner 12mm(0.47244In),
mounting torque 37~41 N•m (27.3-30.2lbf•ft)) Inner hexagon spanner 8mm(0.3150In),
b. Upon the assembly of item a, install the
spool group onto the valve body.
7-95
d. Installation of bucket spool cover:

Mount the piston (356) in the bucket spring cover
(206), and mount the O-ring (561) onto the oil
plug (558); mount and tighten with specified
torque.
e. Boom 1 spring cover:
Mount the piston (355) in the boom 1 spring
cover (206), and mount the O-ring (561) onto the
oil plug (558); mount and tighten with specified
torque.
(Inner hexagon spanner 17mm(0.6693In),
mounting torque 196~245 N•m(144.6-
180.7lbf•ft))
7-96
7.5.6Removal and installation of main pump assembly and fan pump

assembly
Removal
receive oil.
removal and installation space for hydraulic
fuel tank bottom plates.
LG922E930E07125
2. Remove the hydraulic fuel tank bottom plates

(1).
1
LG922E930E07126
7-97
3. Place a barrel below the oil drain port of the
tank, remove the drain plug (2) and drain the oil
back.
2
LG950EIII07132
4. Remove the engine hood (3).
LG950EIII07133
5. Remove the smoke eliminator (4) and door

frame (5).
LG950EIII07134
7-98
6. Remove the fan pump oil suction pipe (6);
13 13 14 7. Remove the fan pump oil outlet pipe (7);
9
8. Remove the fan pump oil return pipe (8);
9. Remove the fan pump feedback oil pipe (9)
and its joint;
10. Remove 2 pilot gear pump oil outlet pipes (10)
7 12 and their joint;
8 12
11. Remove the pilot gear pump oil drain pipe (11)
and its joint;
6 12. Remove 2 main pump oil outlet pipes (12);
10 10
13. Remove 2 main pump control oil pipes (13)
and their joint;
LG950EIII07135
14. Remove the main pump oil return pipe (14)
and its joint.
15. Remove the oil suction steel pipe (15).
15
LG950EIII07136
7-99
16. Stably hang the fan pump with slings and lifting
devices, and remove 2 bolts (16) of fan pump;
17. Lift out the fan pump (17).
17
16
LG950EIII07137
18. Lift up the main pump with sling and hoisting

equipment, and remove 12 bolts fixing the
flange (18).
×12
18
LG950EIII07138
19. Lift out the main pump (with PTO unit).

Lifting weight: 267.5kg (589.8lb)
LG950EIII07139
7-100
Installation
Install the main pump in the reverse sequence of removal.
Pay attention to the following technical requirements during installation:
● Main pump mounting screw M10-10.9 tightening torque: 72±6N.m (53±4.4lbf•ft);
● Apply thread locker on the screw thread before installation (Tonsan 1277).
● Tightening torque of the flange oil port bolt:
M10-10.9:72±6N.m(53±4.4lbf•ft);
M12-10.9:120±10N.m(88.5±7.4lbf•ft);
M16-10.9:305±25N.m(224±18.4lbf•ft);
● Tightening torque of angle-sealed joint with O-ring:
G1/4: 36±2N.m(27±1.5lbf•ft);
G3/8: 73.5±4.5N.m(54.2±3.3lbf•ft);
G3/4:165±15 N.m(122±13lbf•ft);
● Tightening torque of pilot gear pump joint:
G1/2: 55±5N.m(40.6±3.7lbf•ft);
G3/8: 49±3N.m(36.1±2.2lbf•ft).
● Tightening torque of 24° taper-sealed hose joint with sealing O-ring:
M16×1.5:26±2N.m(19.2±1.5lbf•ft);
M18×1.5:(37±2)N.m(27.3±2.2lbf•ft);
M20×1.5:(37±2)N.m(27.3±2.2lbf•ft);
M22×1.5:( 47±2)N.m(34.7±2.2lbf•ft);
M36×2: (137±6)N.m(101±4.4lbf•ft).
7-101
7.5.7Removal and Installation of main pump assembly
Disassembly and assembly of the pump body

Pump part drawing
For the part numbers involved in the pump body,refer to the Chapter 8.
Serial Serial
number in Part name number in Part name
the figure the figure
111 Drive shaft 497 Plug
113 Driven shaft 531 Pin
122 cylindrical roller bearing 532 Spool
123 cylindrical roller bearing 534 Limiting screw plug
124 Needle bearing 535 Block
125 Cone 536 Nut
126 Washer 541 Valve seat
127 Washer 543 Plug
128 Snap ring 545 Steel ball
129 Snap ring 548 Feedback pin
130 Assistor 702 O-ring
141 Cylinder block 709 O-ring
151 Plunger 711 O-ring
153 Pressure plate 724 Seal ring
156 Bushing 725 O-ring
157 Cylinder block spring 726 O-ring
192 Driven gear 731 O-ring
211 Swash plate 732 O-ring
212 Support plate 733 O-ring
214 Pin bushing 752 Lip type seal
251 Support 774 Oil seal

7-102
Serial Serial
261 Front housing 789 Snap ring
262 Cover 792 Snap ring
263 Cover 806 Nut
271 Pump body 807 Hex nut
312 Pump body 823 Snap ring
465 Plug 901 Screw
468 Plug 981 Nameplate
469 Plug 983 Pin

7-103
Tools
The tools necessary for removal and assembly of K5V200DPH pump are shown in the table below.
Name and specification of

Part name
tools
Recessed head RO oil plug/ROH
bolt oil plug
Name B Inner hexagon bolt Servo piston
(Taper thread for (straight thread for
pipe) pipe)
4 - NPTF1/16 -
5 M6 Rc1/8 -
6 M8 For Rc1/4 G1/4 -

Inner hexagon
8 M10 - G3/8
spanner
10 M12 - - -
12 - - G3/4 -
17 M22 - G11/4 M30
Monkey wrench / middle-sized, 1 pcs
Screwdriver / middle-sized, 2 straight screwdrivers
Hammer / 1 plastic hammer
Clamp / TSR-160, TSR-200 for stop ring
Steel bar / Steel bar for keys: about 10x8x200
Torque wrench / Select the torque wrench which can be used to tighten to the specified torque
Sealing tape / For Rc1/4
Resin cover / For needle bearing

7-104
Disassembly of pump body

During removal of pump, please operate according to following procedures after completely read the
removal key points.
1. Select the disassembly site.
Please select a clean site.

Please lay the rubber plate or cloth on the
special working bench to avoid collision of part
and component.
During removal, use the 2-M10-L18

threaded hole set under the pump housing
(271); it must be fixed before operation.
2. Remove the rubbish, rusting, etc. on the pump
surface with cleaning oil, etc.
3. Please remove the oil plug (469) of oil leak joint
LG950EIII07141
and drain out the oil in pump housing (271).
For ease of oil drainage, please remove the

iron oil plug (469) of oil filler.
4. After removal of hexagon socket bolt
(accessory on the regulator: 415) , please take
down the regulator (002). Please remove the
PTO (if applicable).
The removal related to regulator (002)

please refers to the operation instructions
of regulator.
5. After removing the hexagon socket bolt, please
take down the gear pump (04), boosting wheel
(130), electro-hydraulic proportional valve
block (080) and cover plate (262).
6. Please loosen the hexagon socket bolt
(410·411·412) connecting the oil distribution
LG950EIII07142 cover (312).
Conduct this operation after removed regu-

lator (002), gear pump (04) and PTO (05).
7-105
7. Place the pump horizontally and separate the
pump housing (271) from the oil distributor
cover (312).
 Since the oil distributor cover (312) is

heavy (approx. 60kg), please remove it with
a crane, etc.prudently.
 Please remove the oil distribution cover

(312) perpendicular to the driving shaft
(111) and driven shaft (113). (To avoid dam-
age of needle bearing) If the guide bolt is
used, it can keep stable pose of oil distribu-
tion cover. (Refer to the reference figure)
 When removing the oil distributor (312),

notice not knock the mating face of the
pump housing (271) and the oil distributor
(312) damaged.
LG950EIII07143  When removing the oil distribution cover

(312), the oil distribution disc (313•314),
check valve pair (541•543•545), O-ring
(724•725•726) and gasket (752) may attach
to the oil distribution cover (312). Since it is
apt to fall-off, please take care to remove it.
8. If necessary, please remove the needle
bearing (124) from the oil distribution cover
(312).
Except considering the service life of bear-

ing, do not remove the needle bearing (124)
as far as possible.
Do not loosen the hexagon long nut (807).

Otherwise the set flow may change.
7-106
9. Remove the cylinder body (141) perpendicular
to the driving shaft (111) and driven shaft (113)
in the pump housing (271); at this time, remove
the plunger pair (151, 152), return plate (153),
spherical bushing (156) and return spring
(157).
Do not knock the sliding surface of cylinder

body (141), spherical bushing (156), skid
shoes (152) and swashplate (212) to be
damaged.
LG950EIII07144
10. Remove the shoe plate (211) and swashplate

(212) from the pump housing (271).
Take the swash-plate and piston shoes disc

out of the pump housing (271); please
remove the piston shoe disc (211) from the
swash plate (212) with straight screwdriver.
LG950EIII07145
7-107
11. After removing the lock ring (827), move the
front cover (261).
The operation must be done only after prop-

erly fixed. In addition, the mating face must
not be damaged during fixing.
The slot is set at outer edge of front cover

(261). Please use straight screwdriver to
pry in this slot, and remove perpendicular
to the driving shaft (11)
Since there is oil seal (774) mounted on

front cover (261), do not damage the lip
edge of oil seal (774) when removal.
12. Please loosen the hexagon socket bolt (408)
LG950EIII07146
connecting front housing (171).
The operation must be done only after prop-

erly fixed. In addition, the mating face must
not be damaged during fixing.
13. Please separate the front housing (171) from
the pump housing (271).
Since the front housing (171) is heavy

(about 28kg), take care to remove it.
Please remove the front housing (171) per-

pendicular to the driving shaft (111). If the
guide bolt is used, it can keep stable pose
of front housing. (Refer to the reference
drawing); in addition, do not damage the oil
seal sliding surface of driving shaft (111).
When removing the front housing (171), the
gasket (752) may attach on the front hous-
ing (171). Please take care to remove it.
LG950EIII07147
Please take care to remove it without dam-
aging the mating face of front housing (171)
and pump housing (271).
7-108
14. Firstly remove the stop ring (823 ·825), and
then remove the bearing spacer ring
(126·127); take down the driving gear (191)
and driven gear (192).
LG950EIII07148
15. Remove the lock ring (828), bearing spacer

ring (128), slightly knock the rear ends of
driving shaft (111) and driven shaft (113) with
plastic hammer if necessary; pull the driving
shaft (111) and driven shaft (113) out of the
pump housing (271).
 Since there is pin (887) at the cylindrical

roller bearing (123) at the driven side which
can prevent the rotation, take care when
pulling out the driven shaft (113).
16. If necessary, please remove the stop ring
(824), bearing spacer ring (128) and cylindrical
roller bearing (122•123) from the driving shaft
(111) and driven shaft (113).
 Except considering the service life of bear-

ing, do not remove the cylindrical bearings
(122•123) as far as possible. If necessary to
LG950EIII07149 remove, please use a special clamp to pull
it out due to shrink fit.
17. Please loosen the hexagon socket bolt (405)
connecting the swash plate support stand
(251).
 The adhesive is applied at the thread part

of the hexagon socket bolt (405).
7-109
18. Take the swash plate support stand (251) out
of the pump housing (271).
19. If necessary, remove the bumping post (L)
(534), the bumping post (S)(535), servo piston
(532), inclined pin (531) and servo cover (536)
from the pump housing (271).
 When removing the inclined pin (531),

please operate with the clamp in case of the
inclined pin head is not being damaged.
 The adhesive is applied at fitting part of

inclined pin (531) and servo piston (532),
take care not to damage the servo piston.
LG950EIII07150
Do not loosen the hexagon nut (806) on

servo cover (536). Otherwise the flow set-
ting will change.
Assembly of pump body
The assembly processes are reverse to those for removal; please notice following points for assembly.
(1) The sections damaged during removal must be repaired, and prepare replacement parts in advance.
(2) Since the mixing of foreign matters is the cause for poor action, the part and component shall be
blown dry with compressed air after fully cleaned with clean oil, and assembled in a clean place.
(3) Assembly must be carried out after the slide part and bearing are applied with clean working oil.
(4) The sealing parts such as O-ring, oil seal and gasket shall be replaced with the new one in principle.
(5) The O-ring and gasket apt to fall-off shall be applied with right amount of grease during installation so
as to ensure it will not fall off and also make sure of better operation performance. The prepared
mounting bolts, oil plugs, torque wrenches for each part shall be tightened according to the specified
torque in the Maintenance Reference.
(6) For parallel pump, it will rotate rightward if viewed from the driving shaft end and leftward if from
driven side. Please notice that the parts and components of the parts must not be mixed. Especially
notice that the parts and components from driving side and driven side must not be mixed.
(7) When removing the driving side regulator and driven side regulator, please separately make the
marks so as to differentiate the two sides.
7-110
Disassembly and assembly of regulator

Regulator part drawing
The part numbers involved in the paragraph below please refer to this drawing.
Regulator part drawing
801
924
630
438
858
755
629
614
753
875
801
858
755
925
601
E
815
875
628
D
756
887
728
645
708
649
724
646
413 412
644
730 725
E
C
C
722 496
627 732
875
O
734
A
G
613
735
656
897
626
874
611
438
643
612
625
641
624
652
875
623
651
621
438
436
836
655
622
654
733
653
732
814
631
898
LG950EIII07151
7-111

413 Bolt 653 Spring holder
436 Bolt 654 Return spring
412 Bolt 655 Pressure regulating spring
438 Bolt 656 Cover
439 Screw 698 Cover
496 Plug 708 O-ring
611 Link 724 O-ring
612 Link 725 O-ring
613 Link 728 O-ring
614 Plug 730 O-ring
615 Adjusting plug 732 O-ring
621 Compensation piston 733 O-ring
622 Piston sleeve 734 O-ring
623 Intermediate extension rod 735 O-ring
624 Spring holder 753 O-ring
627 Adjustable lever 763 O-ring
628 Adjusting bolt 801 Nut
629 Cover 802 Nut
630 Locknut 814 Ring washer
631 Sleeve 836 Ring washer
641 Valve cap 874 Pin
643 Valve stem 875 Pin
644 Spring holder 876 Pin
645 Adjustable lever 887 Pin
646 Spring 897 Pin
651 Valve bushing 898 Pin
652 Spool 924 Bolt

7-112
Disassembly of adjuster
Photograph Precautions and inspection

1. Select one disassembly site.
 Select one cleaning site.

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).
LG922E930E07179  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).
 Never loosen these bolts or nuts. After they

are loosened, the pressure-flow set already
will change.
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.
 It is easy to remove the regulating ring (Q)

(645) by using M4 screw.
LG922E930E07180
7-113

5. Take down the hex screws (436, 438) and
remove the pilot cover plate (641).
After removing the 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.
LG922E930E07181
6. Remove the ring washer (814), spring holder

(653), reset spring (654), and bushing (651).
The backup ring (836) fixes bushing (651),

and while removing backup ring (814), reset
spring (654) can pop. Protect the reset
spring from losing.
LG922E930E07182
7. After removing lock ring (858), remove the

center plug (614) and adjusting plug (615).
It is easy to remove center plug (614) and

adjusting plug (615) with M6 bolt.
LG922E930E07183
7-114

8. Remove lever (2) (613), but do not pull out pin
(875)
It can make the operation easier to use a

pair of tweezers
LG922E930E07184
9. Push out the pin (874), and remove the

feedback rod (611).
Push the pin (874) (pin diameter φ4) off from
the top part with slimy steel bar, and mean-
while, avoid hitting rod (1) (612)
LG922E930E07185
10. Take out the lever (1)(612). But do not pull the
pin (875) out
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
 During removal of plunger bushing (622), it

can be extruded from the end of compensa-
tor rod (623) on the opposite side to
LG922E930E07186
plunger bushing (622).
7-115
Assembly of the regulator
Apply clean hydraulic oil on component surface to get lubrication effect before assembly.
1. Select the assembly site.
Select one cleaning site

In order to protect the parts from being
damaged, rubber plate or operation-used
cloth, etc. shall be laid on the operation
platform.
2. Install compensating rod (623) into
compensating hole of housing (601).
3. Snap the pin (875) installed on lever (1) (612)
into the slot of compensating rod (623), and
then snap lever (1) (612) into pin (876)
embedded on housing (601).
Please make sure that spool (652) and valve

bushing (651) can not get stuck in housing
(601), and they can slide neatly.
Pay attention to the installation direction of

spool (652).
4. During installation of feedback rod (611), insert
it after aligning pin (874) to the pin hole on
LG922E930E07194 feedback rod (611).
 It is easy to operate to insert a part of pin

(874) into feedback rod (611) in advance.
 Pay attention to the direction of feedback

rod (611) and do not make mistake.
5. Install pilot plunger (643) into the hole for pilot
plunger (643) of housing (601).
 Make sure that pilot plunger (643) can not

be stuck in housing (601), and it can slide
neatly.
7-116
6. Snap pin (875) pressed in lever (2) (613) into
the slot of pilot plunger (643), and then install
the lever (2) (613).
LG922E930E07195
7. Align pin (876) pressed into center plug (614)

to pin hole of lever (2) (613), install it into
center plug (614), and then install lock ring
(858).
LG922E930E07196
8. Install the adjusting bushing (615), and then

install lock ring (858).
Do not install adjusting plug (615) into the

hole of center plug(614), so as to replace
adjusting plug (615).
At this time, shake feedback rod (611) to

make sure there is no serious waggle and
no failure such as getting stuck.
LG922E930E07197
7-117
9. Install reset spring (654) and spring holder
(653) into the hole of spool (652), and then
install Snap ring (814) on spool (652).
LG922E930E07198
10. Install setting spring (655) in the hole of spool

(652), and install compensating plunger (621),
plunger bushing (622), Pf bushing (631) and
pin (898) in the compensating hole
respectively.
Make sure the compensating plunger (621)

and pin(898)are not stuck and they can
slide flexibly.
11. Upon installation of pilot valve (641), install and
fasten it with hex bolts (436), (438).
LG922E930E07199
12. Install spring holder (Q) (644), pilot spring

(646) and regulating wheel (Q) (645) in the
pilot hole, and install spring holder (C) (624),
internal spring (626) and external spring (625)
in the compensating hole.
Notice the direction of spring seat (Q) (644)
LG922E930E07200
7-118
13. Install adjusting screw (C) (629), regulating
wheel (C) (628), locknut (627), hex nut (801),
and hex positioning screw (924) installed on
cover (C) (924) together on housing (601), and
fasten them with hex bolts (438).
LG922E930E07201
7-119
Disassembly and assembly of pilot pump

Removal of pilot pump
Choose a clean location. Lay rubber plates or cloth, etc. for removal, and be careful not to
damage parts.
1. After removing pilot pump (1) from main pump,
find a clean site to disassemble it.
LG922E930E07187
2. Place the pilot pump shaft end (2) downwards.
Because input shaft of pump is more protu-

berant than fitting surface, it is best to pro-
vide supporting objects on the two ends of
the fitting surface.
LG922E930E07188
7-120
3. Remove four mounting screws (3) on the pump
cover from the upper end.
LG922E930E07189
4. Pull out the upper cover (4) of pilot pump

upwards slowly and gently.
Be careful in operation and not to damage

4 the mounting surface.
LG922E930E07190
5. Put the upper cover aside. Remove O-ring

carefully.
O-ring The damaged O-ring cannot be reused.
LG922E930E07191
7-121
6. Grasp one end of driven gear, and pull out the
driven gear (5) straight up slowly.
5
Mark the direction and make sure to pull it
out from the fitting direction of driven gear.
Protect supporting shaft on two ends of
gear and the fitting surface matched with it
from damage.
LG922E930E07192
7. Grasp one end of drive gear, and pull out the

driven gear (6) straight up slowly.
6 Mark the direction and make sure to pull it

out from the fitting direction of drive gear.
 Protect supporting shaft on two ends of
gear and the fitting surface matched with it
from damage.
LG922E930E07193
Assembly of pilot pump

The assembly sequence is opposite to that of disassembly.
Mounting torque:
S/N Name Specification Tightening torque

1 Bolt M8X60 17N.m(12.5lbf.ft)
2 Bolt M8X50 17N.m(12.5lbf.ft)

7-122
7.5.8Disassembly and assembly of the fan pump as

Fan pump part drawing
Part number involved in the chapter is based on the following drawing
25
26
3
41
4
7 5
9
27
10 11 10
14
13
15
44 42
12
45 19
28
20
43
21
31 31
32 32 22
33 23
34 35
46 47
24
38
39
40
LG950EIII07152
7-123
S/N ?Part name S/N ?Part name

1 Hex screw 25 Plate
3 Oil port block 26 Plunger piston shoe assembly
4 Oil port block O-ring 27 Drive shaft
5 Sealing plug 28 Swash plate
7 Oil distribution disc pin 31 Bearing retainer pore plate
8 O-ring 32 Swash plate bearing
9 Oil distribution plate 33 Shell
10 Offset piston O-ring 34 Plug
11 Offset piston guide sleeve 35 O-ring
12 Offset piston 38 Shaft seal
13 Offset spring 39 Seal ring
14 Control piston guide sleeve 40 Compensator
15 Control piston 41 End cover locating pin
19 Snap ring 42 Oil port block bush
20 Cylinder block retaining spring 43 cylindrical roller bearing
21 Cylinder block retaining washer 44 Snap ring (shaft)
22 Cylinder block fixing pin 45 Snap spring (shell)
23 Cylinder block 46 Plug
24 Spherical spacer 47 O-ring
7-124
Special tool
T1 seal mounting tool
133mm
(5.250 in)
33.3 mm
(1.312 in)
D
9.5 mm
(0.375 in) R3.0 mm
(0.12 in)
A B 3.0 mm
Ɏ
C
Ɏ
(0.12 in)
1.5 mm x 45° Typical value

Undercut (0.06 in X 45°)
LG950EIII07153
Specifications
Part Number A B C D
of pump
060&075 213-0-004194 69.9mm(2.750in) 50.3mm(1.980in) 34.9mm(1.375in) 20.3mm(0.800in)
100 213-0-004208 63.5mm(2.50in) 56.6mm(2.230in) 43.3mm(1.703in) 14.0mm(0.550in)
140 213-0-004199 85.7mm(3.375in) 70.6mm(2.780in) 53.4mm(2.10in) 19.1mm(0.750in)

7-125
T3 seal guide
B
C
e
D
+/- 0.05 mm F +0.05 / -0.00mm
Ɏ
E
Ɏ
(+/- 0.002 in) Bore diameter (+0.002 / -0.000 in)
Transition radius & Polishing outer diameter
LG950EIII07154
Specificati
Part
ons of A B C D E F
Number
pump
213-0- 108mm 57.1mm 25.4mm 34.90mm 31.75mm
060&075 10°
004195 (4.25in) (2.25in) (1.00in) (1.373in) (1.250in)
213-0- 108mm 70.6mm 25.4mm 43.26mm 38.1mm
100SAE 10°
004206 (4.25in) (2.78in) (1.00in) (1.703in) (1.500in)
213-0- 114mm 76.2mm 22.4mm 43.26mm 40.06mm
100ISO 15°
004207 (4.50in) (3.00in) (0.88in) (1.703in) (1.577in)
213-0- 108mm 70.6mm 25.4mm 53.04mm 44.48mm
140SAE 10°
004200 (4.25in) (2.78in) (1.00in) (2.088in) (1.751in)
213-0- 114mm( 76.2mm 22.4mm 53.04mm 50.04mm
140ISO 15°
004201 4.50in) (3.00in) (0.88in) (2.088in) (1.970in)
7-126
T2 Front bearing outer ring mounting tool
T2 Front bearing outer ring mounting tool
Typical value
LG950EIII07155
Specifications of
Part Number A B C
pump
66.0mm
060&075 213-0-004192 71.4mm(2.812in) 12°
(2.60in)
100 213-0-004204 92.1mm(3.623in) 86.1mm(3.390in) 15°
140 213-0-004197 93.7mm(3.687in) 89.3mm(3.515in) 15°

7-127
T5 Rear bearing outer ring mounting tool
T5 Rear bearing outer ring mounting tool
Typical value
LG950EIII07156
Specifications of
Part Number A B C
pump
060&075 213-0-004193 53.8mm(2.120in) 48.7mm(1.918in) 12°
100 213-0-004205 65.1mm(2.562in) 59.3mm(2.335in) 15°

71.1mm
140 213-0-004198 65.1mm(2.562in) 15°
(2.80in)
7-128
Disassembly 1. Identify the pump information from the

parameter nameplate in figure 1.
The pump can be disassembled and checked
only under following conditions:
a. Failure of pump, or the oil leak due to
pump damage or wearing.
b. The previous troubleshooting steps have
not solved the problem.
For turning direction change or shaft
changeover, the disassembly shall be limited to
the extent necessary to complete the
changeover.
The disassembly and re-assembly shall be done
in clean environment.
LG950EIII07157
2. Drain out the oil in housing. The oil drained

from the pump shall be properly handled.
The spring assembly in pump body is
normally set at high compression state, so 3. Fix the pump in the clamp to avoid pump
the inattention may lead to personal injury body movement when removing the main
during disassembly. housing screw.
Under normal conditions, it is no need to replace 4. Remove the screw fixing the compensator on
the spring (20) mounted in cylinder block. Unless pump housing. When the compensator is
absolute need, do not replace this spring. removed, the liquid may flow out of the port
passage. Place the compensator aside for
After disassembly, all internal parts and later removal and inspection.
components shall be applied with a lay of
cleaning oil to protect it from harm by the dust 5. Remove the screw mounting the oil port
and humid environment. block on main housing.
Recommend measuring the extension part of 6. Carefully take down the oil port block. Please
compensator adjusting screw on controller 40 take care to avoid the oil distribution plate
and making a mark before disassembly, which falling-off. Notice the positions of offset spring
will be used during assembly. - piston subassembly and control piston
subassembly. The control plunger, offset
The disassembly process must be careful to plunger and offset spring may be in the pump
avoid the damage or pollution of machining when removed the oil port block. Take 3
components and control valve due to part falling- white Teflon sealing parts on oil port block
off. and discard them. These sealing parts shall
For overhaul, all O-rings and sealing parts shall be replaced during each removal of pump.
be discarded and use new components to 7. Remove the control plunger and offset
replace. plunger-spring subassembly.
Only change the turning direction; do not

further disassemble and proceed the step 14.
7-129
8. Horizontally place the pump and remove the 14. In case of overhaul or change of burning
rotating subassembly. If possible, avoid the direction, remove the control piston and
separation of plunger and cylinder block. It offset piston guide bush. The control piston
will be helpful to find the damaged and offset plunger guide bush are fixed and
component between signal plunger and mounted with anaerobic thread. Place the oil
plunger sleeve when checking the part. port block in the heating furnace to heat at
163°C (325°F).
a. To replace with a sealing part or carry out
overhaul for the pump of 045 specs, turn
over the housing before step 9, and
remove the snap ring and shaft seal.
To avoid heat treatment superficial anneal, do
9. Remove the swash plate from the housing.
not use the fire to heat the piston guide bush.
See Fig. 2.
(Only limited to the pump of 45 specs)
10. Remove the swash plate bushing screw and
swash plate bushing from the pump. Disassembly of compensator
11. Remove the snap ring on housing and the

bearing subassembly on shaft.
12. To replace a sealing part or carry out the The plug at the end of compensator valve
overhaul, turn over the housing and remove element hole is of hardened plug. Do not
the snap ring and axle seal. change other plug in this controller. If
a. If your are maintaining the pump of 045 changing the turning direction, it is
specs, please neglect this step, due to it necessary to replace with complete
has been completed in the step 8a. compensator subassembly.
b. Please make sure using a new shaft seal. 1. Measure and record the extension length of
Do not repeatedly use a used shaft oil. two pressure adjusting screws.
2. Carefully remove the main compensator
spring cover. Remove two springs. Take
Big slot down the sealing piston and spring seat.
Remove the O-ring sealing plug at the other
side of compensator. Take out the
compensator valve element.
One side of pump The compensator valve element and inner

body pressure spring can not be interchanged with the load
controller
sensing compensator valve element and
LG950EIII07158 spring.
13. In case of excess wearing of oil port block

bushing, take out the bushing from the oil
port block.
7-130
3. Load sensing compensator: Carefully 4. Check the baffle surface contacting the
remove the load sensing compensator plunger skid shoe. Any mark severer than
spring catch cover and spring seat/sealing slight polishing indicates the need of
piston. Remove the spring Take out the replacement. Check the baffle spherical zone
spring seat. Remove the O-ring sealing plug surface and spherical guide ball surface.
at the other side of compensator. Remove Check the guide ball back contacting the load
the load sensing compensator valve element. pin. If any indentation, replace the guide ball.
Note: The load sensing compensator valve
5. Check the swashplate top and bottom
element and spring can not be interchanged
surfaces. If any scratch or drag mark
with the main compensator valve element
penetrates the surface treatment layer, the
and main compensator inner spring.
swash plate must be replaced.
4. Remove all SAE O-ring sealing plug.
6. If the wearing penetrates the Teflon surface,
Inspection steps of pump the swashplate bearing can not work; it shall
be timely replaced.
Carefully clean and dry all parts with air
before inspection. 7. The offset plunger and compensator piston
shall freely move in each cylinder block. The
1. Check whether there are scratched or
piston and cylinder block shall have no
strained marks on the plunger diameter. If
scratch or drag mark.
any plunger is severely damaged, notice
which plunger cylinder it fits; these cylinder 8. The sealing area of drive shaft shall be
body shall be additionally noticed in step 2. smooth without any mark generated due to
Check the axial clearance of plunger skid wear of sealing part. For flat key shaft, check
shoe assembly. Check whether the skid shoe whether there is indentation and damage
bottom surface is damaged, and the surface sign on flat key contact surface. The spline
of skid shoe shall be level. Measure the shaft may have the contact wearing, but
depth of the skid shoe notch. there shall have no excessive wearing in
spline contact area.
If the notch depth is within the allowable limit
range, grind the skid shoe to make them fit-
ting. Confirm the notch depth is still within the
limit range after grinding.
P1/PD-018, 028 and 045 shaft rotate, and the
2. Check whether there is scratch on cylinder
cylindrical bearing shall have no fracture,
block; check the cylinder block inner
indentation or discolor. The bearing shall
diameter at 4 different postilions, including
freely rotate without any resistance or
the position near the cylinder block bottom
jamming.
without plunger travel. If the dimension
variation exceeds 0.0102 mm (0.0004 inch) Inspection steps of compensator
or any dimension exceeds the allowable limit
value, replace the cylinder block if necessary.
Check whether there is scratch or drag mark
on cylinder block surface. If the dimension is
within the range listed in table 1, the cylinder The compensator shall be replaced as
block can be used again. assembly. If any part is severely damaged, it
is necessary to replace with one complete
3. If there is only slight scratch on oil distribution compensator.
disc surface, it can be ground; otherwise it
shall be timely replaced. 1. Check whether there is scratch or other
damage of main compensator valve element
and load sensing valve element.
7-131
2. Check whether the spring has proper free 1. Turn over the housing and use the mounting
extension length. tool T1 to press the shaft seal in sealing
cylinder block. Mount the snap ring at the
Free length of compensator spring groove of housing sealing hole.
Type S/N Part Tolerance
Inner spring of Free length:
C*/L* 5 main 25.9±0.5mm
compensator (1.020±0.020in) Mount the shaft and bearing on part 45 before
Outer spring of Free length: mounting the shaft seal. The part 45 does not
C0/L0/L2 4 main 39±0.7mm require the tool T1; use tool T3 to insert the
compensator (1.535±0.028in) shaft seal onto the input shaft.
Free length:
L* 17
Load sensing
14±0.4mm 2. Mount the cylindrical bearing on pump shaft
spring (transition fit). Mount the bearing outer ring to
(0.551±0.016in)
keep the bearing on the shaft. Insert the shaft
R* 6 Offset spring
assembly into the housing body; the bearing
slides to the bearing hole position of housing.
3. Check whether the valve element hole is
Mount the bearing inner ring on the housing
damaged. Apply a layer of oil film on valve
(shown in figure).
element and check the hole fitting. The valve
element shall be closely adhered without any
radial clearance. A
Assembly
For overhaul, remove all plug and replace all
sealing part. Before assembly, thoroughly clean
all parts. The assembly shall be done in clean
working environment.
Do not use bearing grease during installation.
The grease is insoluble in hydraulic oil and it may A A-A section view
block the orifice or filter in system. Vaseline is Roller bearing
preferential to lubricate the O-ring and sealing
part, and to adhere the part during assembly. LG950EIII07159
For non-petroleum base hydraulic oil, it shall

ensure the Vaseline is compatible with this
oil. If incompatible, use other product to
substitute.
Check all bearing surfaces and sealing zones,

and ensure they have no crack, bending ,scratch
or rusting.
7-132
3. If the cylinder block fixing spring is removed 6. For 045 specs pump, use Loctite Primer
during removal, it is necessary to mount 3 class-T adhesive to fix the thread and air dry
pins in cylinder block spline groove (only for it. Mount the O-ring without lubrication on the
pump of 45 specs). It is possible to use control piston guide sleeve and offset piston
Vaseline to keep the pin position, which will guide sleeve. Use Loctite 271 to tighten the
not change when mounting the remaining thread. The levorotation pump offset piston
parts. Place the cylinder block on the clamp guide sleeve is mounted at the position
with one end of the pin downward (figure 4). closest to the locating pin (figure 5A). The
Mount the support washer, fixing spring and dextrorotation pump control piston guide
the 2nd support washer. Compress the sleeve is mounted at the position closest to
spring to mount the snap ring. the locating pin (figure 5B). Tighten the
control piston and offset piston guide sleeve
with the torque indicated in table2.
For the pumps of 018 and 028 specs: the
Please ensure the snap ring has been guide sleeves are same; press fit them into
correctly mounted in the groove before the hole (not indicated in the figure below).
pressure relief.
Offset piston
guide sleeve Dowel pin
045 pump
Figure 5A Oil outlet Control piston Figure 5B Oil outlet plug

plug of left-handed guide sleeve
pump of right-handed pump
LG950EIII07161
LG950EIII07160
Specificatio Torque of control piston and
4. Apply a layer of oil film on the inner wall of ns of pump offset piston guide sleeve
the plunger cylinder block and carefully
018 Press fit
lubricate the guide ball spherical surface.
Mount the nine pistons on the fixing baffle 028 Press fit
into the plunger cylinder and install the guide
ball onto the fixing baffle. Use the fixing baffle 045 142N.m(104.7lbf•ft)
to hole the guide ball and mount the plunger
7. Apply a layer of oil film on control piston and
into the cylinder block.
mount it into control piston guide sleeve hole.
5. Mount the locating pin on oil port block.
8. Apply a layer of oil film on offset piston and
mount the offset spring and offset plunger
into the offset plunger guide sleeve.
7-133
9. Apply a layer of Vaseline on oil distribution 13. Mount the drive shaft into the housing and
disc back; mount the oil distribution disc onto place the pump horizontally; mount the
the oil port block; use the locating pin to align rotating subassembly on pump shaft. Rotate
with the triangular groove on oil distribution the cylinder block and ensure it has closely
disc (refer to figure 6). rested against the swash plate; the shaft is at
proper position of front bearing.
10. Mount the O-ring on oil port block oil trap and
mount 3 Teflon O-rings on pressure 14. Confirm the rotation direction indicated by
connection oil port. compensator, oil distribution disc rotation
direction, the rotation direction indicated by
control and offset piston position are same.
15. Carefully mount the assembled oil port block
Oil distribution disc
onto the pump housing. Press the oil port
for industrial pump block and mount the housing screw. After
Play attention
to the triangular installation, tighten the screw in interval and
groove length
and quantity crossing method according to the torque
Oil distribution disc
for walking
listed in table 3, and ensure the oil port block
machinery pump will not warp up.
16. Install O-ring and assembled compensator at
Oil distribution disc for
Oil distribution disc for counter
clockwise rotation pump
clockwise rotation pump the pump housing side. The rotation direction
of pump is same as that indicated by the
LG950EIII07162 arrow on compensator housing. The
tightening torque of compensator mounting
11. Install the swash plate bearing on housing screw is 5±0.25N.m(3.7±0.18lbf·ft) (refer to
support. The chamfer on bearing back must figure below).
face outer wall of housing. Apply Loctite Specificatio Tightening torque of housing
Primer "T" or other proper treating agent on ns of pump screw
the screw; use small amount of Loctite #242
as the adhesive; tighten the screw to fix the 018 51N.m(37.6lbf.ft)
bearing. Tightening torque of the screw: (3.4±
028 70N.m(51.6lbf.ft)
0.25)N.m(2.5±0.18lbf·ft).
12. Apply a thin layer of clean oil film on the 045 85N.m(62.7lbf.ft)
surface of swash plate bearing. Install the
swash plate onto the housing. For 045 specs Dowel pin
pump, the swash plate must be aslant
mounted before mounting into the housing. Compensator for counterclockwise Compensator for clockwise
rotation pump rotation pump
The large notch on the bottom surface of

swash plate and pressure connection holes
on main housing shall be at same side. The
rotation direction of pump shall not impair
the assembly of swash plate. Counterclockwise rotation Clockwise rotation pump
pump with compensator with compensator
LG950EIII07163
7-134
7.5.9Removal and installation of the travel pilot valve assembly
Removal
receive oil.
1. Remove the bottom plate (1) under the foot
pilot.
LG950EIII07164
2. Disconnect the 6 pilot lines (2).

2
LG950EIII07165
7-135
3. Remove the two connectors (3)
3
3
LG950EIII07166
4. Remove anti-slip pedal (4) with cross

screwdriver;
5. Remove floor mat (5) and rubber pedal (6).
6
4 5
LG950EIII07267
6. Remove the four bolts and take down the pedal

(7).
LG950EIII07167
7-136
7. Remove 4 captive bolts (8) and then remove
foot pilot valve upwards.
8
×4
LG950EIII07168
Installation
Install the travel pilot valve in the procedures opposite to that of removal.
● Tightening torque of joint: (36±2)N.m(26.6±1.5lbf·ft);
● Tightening torque of hose joint: (37±2)N.m(27.3±1.5lbf·ft);
7-137
7.5.10Disassembly and assembly of the travel pilot valve assembly
Part drawing of the travel pilot valve

The part number involved in the section shall be based on the following drawing.
212 212
521
202
202
210
210 203
203
522
522 213
213
501
521 215
215
311
423 214 311
420 335
522 224 335
522 501 214
520
271 337 324
423 471 471 224 324
313
217
313
472 337 336
420 472 301
301 134
520 271 412 213 102
211 163
522 336 211 131 153
522 471 471 225 103
201 213
220
225
431 421 151
413
522 201
522 412
112
220 151
412
431 413 131
103
134
102
163
153
LG922E930E07208
S/N Part Number S/N Part Number

101 Shell 301 Slide valve
102 Shell 311 Spring holder
153 Oil plug 313 Washer
191 Valve seat 324 Spring
194 Steel ball 335 Spring
201 Valve cap 336 Spring
202 Plug 337

Spring
203 Oil cup 412 Bushing
210 Oil cup 413 Cam shaft
211 O-ring 420 Cam

7-138
S/N Part Number S/N Part Number

212 O-ring 423 Positioning screw
213 O-ring 431 Seat
214 Push rod 471 Positioning screw
215 Washer 472 Locknut
217 Washer 473 Inner hexagon bolt
218 Spring seat 501 Rubber sleeve
220 Inner hexagon bolt 520 Step
224 Piston 521 Step bushing
225 Steel ball 522 Inner hexagon bolt
271 Hex screw
Disassembly 4. During disassembly, do not forcibly knock,

pry and cut out; otherwise it may lead to burr,
Special tool
deformation and damage, and therefore
For removing bushing assembly failure or oil leak and thus the
performance degradation.
&HQWHUKROHDOORZDEOH QHHGWREHEHORZɎ
5. The parts after removed shall be treated with
anti-rust and dustproof measures; otherwise
it may lead to rusting of part and component
due to moisture and foreign matters;
recommend the disassembly works shall be

Ó

Ó
continuously done.

e

LG950EIII07170
1. Require adequately wide disassembly/

assembly field; prepare stable working stand
without shaking, and ensure the part and
component will not fall or roll during
operation.
2. Prepare tools and related data.
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.
7-139
1. Clean the pilot valve with white kerosene,
 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 pedals
521 (520). Remove it from the upper side.
520
LG922E930E07210
3. Loosen the hex bolt (522) with the inner

hexagon spanner, and remove the pedal (520)
.
522
522
LG922E930E07211
7-140
hexagon spanner, and remove the seat (431).
473 431
LG922E930E07212
5. Remove rubber bushing (501) from the upper

side of valve cap (201).
501
201
LG922E930E07213
6. Unscrew the positioning screw (423) with inner

hexagon spanner.
423
423
 As it is coated with anaerobe #241, torque
to loosen is large.
LG922E930E07214
7-141
7. Align the round rods (below φ8) with the one
end of the cam shaft (413), and then beat it
413
413 with hammer to remove it.
LG922E930E07215
8. Unscrew locating screw (471) and locknut

(472) on the cam (420), and remove them in
pair.
420
420
 Record the position relationship between
472
472 the cam and valve cap 201).
471
471  During removal, please note the push rod
(214) may be ejected.
LG922E930E07216
9. Unscrew the hex screw (271) with the inner

hexagon spanner.
271
LG922E930E07217
7-142
10. Remove valve cap (201).

the valve cap and the buffer housing (102).
201
 During removal, please note the push rod
(214) and push rod bushing (202) may be
ejected because of the elastic forces of the
102 buffer springs (336), (337). (The push rod
bushing may not be ejected from buffer
housing because of the sliding resistance of
the O-ring (212) )
LG922E930E07218
11. Remove push rod (214) from plug (202).

214
214
202
202  Record the position relation between plug
and push rod.
 Be careful not to damage the surface of the
push rod.
 During removal, pay attention to the
occasion where the plug can pop up.
LG922E930E07219
12. Remove plug (202) together with lubricating oil

202 cup (203) and NHU oil cup (210).

203 the plug and the buffer housing.
 During removal, please note the plunger
210 may be ejected because of elasticity of the
buffer spring.
LG922E930E07220
7-143
13. Remove the plunger (224) from the buffer
224
224 housing.

the plungers and the buffer housing holes.
LG922E930E07221
14. Remove the buffer springs (336), (337) from

the buffer housing.
336
337
the buffer spring and the buffer housing hole.
LG922E930E07222
15. Remove the spring seat (218) from the buffer

housing.
218
the spring holder and the buffer housing hole.
LG922E930E07223
7-144
16. Take out the steel ball (225) with magnet, etc.
225
225
 Keep the steel balls well. Do not lose them.
LG922E930E07224

hexagon spanner.
220
LG922E930E07225
18. Remove the buffer housing (102).
102
102
the buffer housing and the housing (101).
 During removal, please note the pressure
335
335 reducing valve group can be ejected because
of the elastic force of the reset spring (335).
101
101
LG922E930E07226
7-145
19. Remove the O-ring (211) and the O-ring (213)
from the valve body.
211
213
LG922E930E07227
20. Remove the pressure reducing valve group

and reset spring (335) from the housing.
 Record the position relationship with the

housing hole.
335
335
LG922E930E07228
LG922E930E07229
7-146
21. Place the valve cap (201) on the platform
horizontally, then align the special tool 1 to the
bushing (412), knock at it gently with the
hammer, and remove the bushing.
201
201
LG922E930E07230
22. Fix the cam group on the bench vices, loosen

the locknut (472) with spanner, and remove the
locknut and locating screw (471).
471
471
 Neutral position must be adjusted to
assemble the locating screw. If it is not
472
472 necessary to replace the locating screw, keep
it in the cam group form in following process.
LG922E930E07231
23. Removal of Pressure Reducing Valve Group.

Please vertical upright the slide valve (301)
311 and place it on the flat operation table, depress
the spring holder (311), and then remove the 2
round washers (215) with the head of a small
straight screwdriver.
301
 Be careful not to damage the surface of the
slide valve.
 There is no depressing scope above 4 mm
for the spring holder.
LG922E930E07232
7-147
24. Separate the slide valve (301), spring holder
(311), spring (324) for secondary pressure
setting, washer (215) and washer (313).
 Keep it well in group form until assembling.

 Washer (215) is used for presetting and
215 adjustment of spring for secondary pressure
324
313 setting; the thickness of each slide valve is
different. It may also not be used.
LG922E930E07233
25. Remove lubricating oil cup (203) from plug

(202).
203
202
LG922E930E07234
26. Remove NHU oil cup (210) from plug (202).

Please remove with plastic sheet bars or other
tools.
 Never touch the inner face of plug.

202
LG922E930E07235
7-148
27. Remove (O) seal ring (212) from the plug
(202).
212
202
LG922E930E07236
28. Fix the housing (101) on the bench vice with

buffer plates (the copper soft plate, etc.), and
101 then loosen the oil plug (153) with inner
hexagon spanner. (Only for PVD8PC)
153
LG922E930E07237
29. Pull out the valve seat (191) from the housing
(101). (Only for PVD8PC)
101
191
LG922E930E07238
7-149
30. Take out the steel ball (194) from the
housing(101). (Only for PVD8PC)
101  Remove the steel ball with magnet.
194
LG922E930E07239
Cleaning of components and parts

1. Put all components and parts into a coarse cleaning container with white kerosene, and clean them.
(Coarse cleaning)
a. Cleaning all components and parts in dirty oil initially, this will damage the components. Clean the
components and parts after they are fully steeped, and the impurity and grease are floated.
b. Unclean kerosene will damage the part and component, and it will impair the performance after re-
assembly; thus it is necessary to ensure the cleanliness of white kerosene.
2. 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.
Do not use the compressed air; otherwise the garage, foreign matters and moisture in compressed
air will lead to damage and corrosion of part and component.
Rust protection of components and parts.
Apply anti-rust agent on components and parts.
The part will be corroded when placed if not subjected to the anti-rust treatment after cleaning.
Assembly
Precautions:
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)
7-150
6. When assembling the components and parts, please use the 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.
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
101 the housing (101). (Only for PVD8PC)
 Attract the steel balls to the weak magnets,

or install them with tweezers, etc.
194
LG922E930E07240
2. Install the valve holder (191) into housing

101
101 (101). (Only for PVD8PC)
191
191
LG922E930E07241
3. Install oil plug (153) according to the specified

torque. (Only for PVD8PC)
153
LG922E930E07242
7-151
4. Install the washer (313), washer (217), spring
(324) for secondary pressure setting, and
spring holder (311) to the slide valve (301) in
sequence.
 The washer 2 is used for presetting and

adjustment of spring for secondary pressure
301
301
313
313 324
324 setting. The thickness of each slide valve is
217
217 different. It may also not be used.
311
311
LG922E930E07243
5. Vertical upright the end of slide valve (301) and

place it on the flat operation table, depress the
spring holder (311), and then install half-round
washer (215) on the spring holder upside. Do
not make the washer overlap with two slices.
 Make the acute angle side (no arc side) of

311 washer 1 face upward. Be careful not to force
215 to install the slide valve head.
 There is no depressing scope above 4 mm
301 for the spring holder.
 Make the acute angle side (no arc side) of
LG922E930E07244
washer 1 face upward. Be careful not to force
to install the slide valve head.
 The room for further compression of the
spring holder is no more than 4 mm.
Acute
angle side
LG922E930E07245
7-152
6. Install the reset spring (335) into valve body.
335  Install it according to the position before

removal.
LG922E930E07246
7. According to above No.4 item, install the

pressure reducing valve assembly into the
valve body.
 Install it according to the position before

removal.
LG922E930E07247
8. When installing pressure reducing valve group,

note not let the lower end of slide valve to
excessive impact the valve angle.
Note the valve body corner
LG922E930E07248
7-153
9. Install the O-ring (211) and O-ring (213) on the
213
valve body.
211
LG922E930E07249
10. Install the buffer housing (102) and housing

(101) together with hex bolt (220), and fasten
them according to the specified torque.

removal.
220  The 2 hex bolts (220) shall be evenly
screwed in, and keep the buffer housing (102)
fastened in parallel.
102 101
LG922E930E07250
11. Attract the steel ball (225) to the weak magnet,

or install it into the buffer housing (102) with
225
225
tweezers, etc.
102
102
LG922E930E07251
7-154
12. Install the spring seat (218) into buffer housing.
218
218
removal.
LG922E930E07252
13. Install the buffer spring (336) into buffer

336 housing.

removal.
LG922E930E07253
14. Install the buffer spring (337) into buffer

337 housing.

removal.
 Note not to make it engage with the buffer
housing (336).
LG922E930E07254
7-155
15. Install piston (224).
224
removal.
LG922E930E07255
16. Install O-ring (212) onto the plug (202).
212
202
LG922E930E07256
17. Install NHU oil cup (210) into push rod bushing.
 When installing NHU seal ring, pay

210 attention to the direction.
 It is easier to install it when NHU seal ring
is applied with a layer of grease before
installing NHU seal ring.
LG922E930E07257
7-156
18. Install lubricating oil cup (203) into push rod
bushing.
203
LG922E930E07258
19. Install the push rod (214) into the push rod
bushing.
 The push rod surface shall be applied with

hydraulic oil before installing.
 Do not force to insert the NHU seal ring to
prevent damaging the lips.
214
LG922E930E07259
20. According to (15) (16) (17) (18) items, the push

rod group shall be installed into the buffer
housing in the group form.
LG922E930E07260
7-157
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.
 When compressing the bushing, note not

to knock out the inner side of cover.
201
412
LG922E930E07261
22. Install the cover to the buffer housing.

removal.
 Note the cover may be ejected because of
the elastic force of the buffer springs (336),
(337).
LG922E930E07262
7-158
23. Install and fasten the hex bolt (271) according
to the specific torque.
 The cover should be installed in the

horizontal state without deflection.
 Install the locating screw (471) to the cam
271 (420), and install the locknut (472) temporarily.
LG922E930E07263
471
472
LG922E930E07264
24. Install the cam (420) on the cover.

420 removal.
LG922E930E07265
7-159
25. Press the cam (420); meanwhile insert the
420 camshaft (413) into the cam from outside.
413
LG922E930E07266
26. The surface of the hex locating screw (423)

shall be applied with the thread rubber #241 or
other appropriate objects.
423
LG922E930E07267
27. Install and fasten the hex locating screw (423)

according to the specified torque.
423
LG922E930E07268
7-160
28. Adjust the height of the locating 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.
 Attach the 4 push rods (214) to appropriate

positions with the set screws. When over-
tightening the set 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.
LG922E930E07269
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.
 When applying and filling the grease,

please do not damage the cam and the surface
of the plug as well as the push rod bushing,
and conduct with soft material.
LG922E930E07270
30. After inserting the upper end of rubber cover

(501) into cam, insert the lower end into the
slot of cover.
501  Before the rubber bushing lower end is
inserted into the cover groove, spray the
injection-type antirust oil onto the components
and parts in the rubber bushing.
 If the rubber bushing is not inserted into
the groove properly or installed in the
distorting state, the dust tightness and
waterproofness shall be reduced.
LG922E930E07271
7-161
31. Install the seat (431), and install and fasten the
hex bolt (473) according to the specified
torque.
431
473
LG922E930E07272
32. Install the pedal (520), and install and fasten

the hex bolt (522) according to the specified
torque.
522
520
LG922E930E07273
33. At last, install the pedal cover (521) on the

pedal (520).
521
LG922E930E07274
7-162
7.5.11Removal and installation of hand pilot valve assembly
Removal of hand pilot valve assembly-LH
receive oil.
1. Pull out the rubber sheath (1) from the pilot
valve.
2. Disconnect the wire (2).
1
3. Remove the locknut (3) from the control lever,
and then remove the control lever.
3 2
LG922E930E07275
4. Remove the 4 mounting bolts (4) from the

handrail box, and move the handrail box cover
4
out.
LG922E930E07276
7-163
5. Remove the 4 captive bolts (5) from hand pilot.
LG922E930E07277
6. Pull out hand pilot slightly, and disconnect 6

pilot pipes (6).
7. Remove the hand pilot valve.
6
LG922E930E07278
Installation of left-hand pilot valve

● Install the hand pilot valve assembly according to opposite procedures of removal.
● Tightening torque of joint: 36±2N.m (26.6±1.5lbf·ft);
● Tightening torque of hose connector: M18×1.5: 37±2N.m(27.3±1.5lbf·ft).
Disassembly and assembly of the right-hand pilot valve
By referring to removal and installation of left-hand pilot valve, remove and install right-hand pilot valve.
7-164
7.5.12Disassembly and assembly of the hand pilot valve assembly
Part drawing of hand pilot valve

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.
The part number involved in the section shall be based on the following drawing.
PV48K1 model
4-221 4-221
501 4-241
4-241
4-217
4-217
4-201 4-201
302
301
101
151
4-213
4-213 4-211 122
4-211
4-214 131
4-214 4-212 126
4-212
312 4-216
4-216 111
121
121
125
125
LG922E930E07279
7-165
PV48KC1 model
4-221 4-221
501 4-241
4-241
4-217
4-217
4-201 4-201
302
301 101
151
4-213
4-211 122
4-213
4-211
131
4-214
4-214 136
4-212
4-212 293 291
312 4-216
4-216 111
294 292 121

121
125
125 LG922E930E07280
1. All components and parts have been processed precisely. Pay attention to handling with care and not
crashing or dropping components and parts.
2. 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.
3. Suggest continuous operating. If the operation is interrupted, please adopt the rust-proof and dust-
proof measures.
7-166
Disassembly
1. Clean the pilot valve with white kerosene.
501  Seal the connectors with plugs.

2. Fix the pilot valve on the bench vive.
3. Remove the ripple protection cover (501).
 Do not damage the ripple protection cover

(501).
LG922E930E07281
4. Clamp distance between the adjusting nut

(312) and the disk (302) with spanner. Remove
312 adjusting nut and disk.
302
LG922E930E07282
7-167
5. Rotate the connector (301) to the left with
clamp and then loosen it.
 When the elastic force of the reset spring

301
301
(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
212
212
connector, they may also be ejected out.
211
211
LG922E930E07283
LG922E930E07284
6. Remove the cover (151).
151
LG922E930E07285
7-168
7. The push rod bushing (211) may be blocked in
the valve body (101) because of the weak
reset spring (221) and the O-ring slide
resistance, and please remove it with a straight
101 screwdriver.
 Utilize the bushing peripheral groove under

the condition of the bushing (211) not being
damaged result from deflection.
 Note the push rod bushing (211) may be
ejected because of the elastic force of the reset
spring (221).
LG922E930E07286
8. Pull out the push rod (212), push rod bushing

(211), the pressure reducing valve group and
reset spring (221) from the valve body (101).
 Record the position relationship of the

valve body holes.
221
LG922E930E07287
9. Keep the interface plate (111) upward, and fix

the pilot valve on the bench vice with the
111 copper plate.
10. Loosen the oil plug (293) with inner hexagon
spanner. (Only for PV48KC1)
293
LG922E930E07288
7-169
11. Pull out the valve seat (291) from the interface
plate (111). (Only for PV48KC1)
291
LG922E930E07289
12. Remove the steel ball (292) with the magnet,

etc. from the interface plate (111). (Only for
PV48KC1)
292
LG922E930E07290
Hook the valve seat and pull it backward

as shown in the following figure. Do not
damage the junction surface of the steel ball.
Steel ball
Valve seat
LG922E930E07291
7-170
hexagon spanner.
125
LG922E930E07292
14. Remove the interface plate (111) O-ring (122)

from the valve body (101).
15. Pull out the bushing (131) from the valve body
(101).
LG922E930E07293
122
122
LG922E930E07294
7-171
16. For removal of the pressure reducing valve,
depressing the spring holder (216) to
131
131 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).
216
216 Then separate the slide valve (201), the spring
holder (216), the secondary pressure spring
(241) and the washer (217).
241
241
● Be careful not to damage the surface of the
slide valve (206).
● The room for further compressing of the spring
LG922E930E07295
holder (216) is no more than 6 mm.
● Keep it well in the group form until reassembly.
LG922E930E07296
17. When installing the spring (246) and spring

holder (218) of two segmented breaking,
remove it from the push rod (212).
206
217
LG922E930E07297
7-172
18. Pull out the push rod (212) from push rod
bushing (211).
211 212
LG922E930E07298
19. Remove the O seal ring (214) and seal ring

(213) from the push rod bushing (211) with
214 small straight screwdriver or other tools.
LG922E930E07299
213
LG922E930E07300
7-173
Precautions for cleaning the components:

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.
Rust prevention of components and parts
Apply antirust onto components and parts If they are placed without rust prevention after rinse, this may
cause rust and then affect their performances.
Assembly
Precautions:
1. 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.
2. O-rings and protective washers shall be replaced with new ones in principle.
3. 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)
4. When assembling components and parts, please use grease to prevent it dropping.
5. All connectors shall be sealed with plugs after installing to avoid impurities.
The figure below shows tightening torque value of mounting torque of bolts, etc. Measure mounting
torque value with torque wrench.
Thread Mounting torque

Tools Size (mm) Functional parts
specification (N.m)
Inner hexagon 20.6±1.5
6(0.2362in) Inner hexagon bolt M8
spanner (15.2±1.1lbf·ft)
Inner hexagon
spanner 11.8±1.0
5(0.1969in) ROH oil plug G1/8
Only (PV48KC1 (8.7±0.7lbf·ft)
specification)
22(0.8661in) Adjusting nut M14
68.6±4.9
Wrench
32 （1.2598in） Disk M14 (50.6±3.6lbf·ft)
47.1±2.9
Special clamp 24 （0.9449in） Joint M14
(34.7±2.1lbf·ft)
7-174
1. Place mounting surface of interface plate (111)
upward and fix the pilot valve with the copper
122 board.
2. Install bushing (131) and O-ring (122) on valve
body (101).
111
LG922E930E07301
3. Put the gasket (121) between interface board

(111) and valve body (101), and fix it with hex
bolt (125).
 Pay attention to the assembling position,

when assemble the spring pin (126) in the hole
126
126 of the valve body(101).
 The gasket(121) shall be replaced with a
new one.
LG922E930E07302
125
LG922E930E07303
7-175
4. Fix the hex bolts (125) with an inner hexagon
spanner according to specified torque.
 While installing, screw them in pairs

alternately and slowly.
LG922E930E07304
5. Install the steel ball (292) into the interface

plate (111) with magnet. (PV48KC1)
6. And then install the valve seat (291) into the
interface plate (111). (Only for PV48KC1)
292
LG922E930E07305
291
LG922E930E07306
7-176
7. Fix the oil plug (293) as per specified torque
with an inner hexagon spanner. (Only for
PV48KC1)
293
LG922E930E07307
8. Install washer 2(217), secondary pressure

spring (241), and spring holder (216) in
sequence into slide valve.
Then press in the spring holder (216) to com-
press the secondary pressure spring (241) as
stagger the spring holder (216) horizontally a
bit. And, put it through the hole and then install
it onto the slide valve (201).
 The room for further compressing of the

201 217 241 216 spring holder (216) is no more than 6 mm.
LG922E930E07308
LG922E930E07309
7-177
9. Install the reset spring (221) into the valve
body (101). Install pressure reducing valve gp
into the valve body (101).

removal.
221
101
LG922E930E07310
10. Install O-ring (214) onto the oil plug (221).
214
221
LG922E930E07311
11. Install the seal ring (213) onto the push rod
bushing (211).
211
213  Please install the seal ring (213) in lip
direction as shown in the figure below.
LG922E930E07312
7-178
12. Install the push rod (212) into the push rod
bushing (211).
Push rod If there is a spring (246) and a spring holder
bushing
Sealing (218) used for two segmented breaking, install
them onto the push rod (212).
 Apply working oil onto the surface of the

Push Apply push rod (212).
rod working oil
 Be careful not to leave the slide valve tilted
(201), otherwise, it will cause damage to the
hole of the valve body (101).
LG922E930E07315
211
212
LG922E930E07313
246
LG922E930E07314
7-179
13. Install the push rod group into the valve (101).
When elasticity of the reset spring (221) is
weak, the spring may not pop up because of
sliding resistance of the O-ring (214).
When the reset spring (221) is strong, the
cover (151) can be used to install 4 connectors
(301) temporarily at the same time.
 Pay attention to the pop out of the push rod

bushing group and the cover (6).
LG950EIII07171
LG950EIII07172
7-180
14. Install it on (151).
15. Install the connectors (301) onto the valve
body (101) according to specified torque with
clamp.
301
LG922E930E07318
25
LG922E930E07319
16. Install disk (302) on the connector (301).
 Adjust the 4 push rods (212) to an even

contacting position, and then install screws. If
the screws are over screwed, it may cause the
base machine malfunction because the control
lever placed in the neutral position may
produce secondary pressure. So pay special
attention to the adjustment of to screwing
302
position of disc (302) screws.
LG922E930E07320
7-181
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.
 While installing, do not move the disc (302).

312
302
LG922E930E07321
18. Apply grease onto swing parts of connectors

(301) and the top of the push rod (212).
301
LG922E930E07322
19. Install crease shield (501).
 Be careful not to break the ripple

protection cover (501).
20. Add antirust to each port, and then install the
plug.
501
501
LG922E930E07323
7-182
7.5.13Removal and installation of the travel motor & reduction gear
Removal
Attach the identification label to each pipe to prevent wrong installation in the subsequence
procedures.
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.
Corresponding figure Removal and installation steps

1. Refer to the method for the removal of the
track assembly to remove it.
2. Remove the five bolts (1) and remove the
blanking plate from the traveling motor.
×5
LG950EIII07173
7-183

3. Remove the oil return pipe (2) and elbow joint
(3);
2
3 4. Remove the 2 high pressure pipes (4) and their
4 joints;
5. Remove the pilot pipe (5) and its joint.
5
LG950EIII07174
6. Remove the 24 bolts (6), and then remove the

sprocket.
×24
LG950EIII07175
7. Bind travel motor with sling, adjust the rope to

the center-of-gravity position, and straining it
with hoisting equipment slowly.
LG922E930E07327
7-184

8. Remove 27 mounting bolts (7).
9. Remove travel motor.
10. Lifting weight: about 647kg (1426.6Ib).
×27
LG950EIII07176
Installation
1. Install the travel motor in track beam, and the
motor oil port shall orient the underframe side.
LG922E930E07327
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.
LG950EIII07177
7-185
3. 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.
LG950EIII07178
4. Tighten pilot pipe, oil return pipe and two high-

pressure pipes.
LG950EIII07179
5. Tighten the plate mounting bolts of the travel

motor.
LG950EIII07180
7-186
7.5.14Disassembly and assembly of the travel motor & reduction gear
Disassembly and assembly of the traveling motor

Relevant part drawing
The codes involved by the travel motor in this section shall refer to the code in the figure below.
47 48 46 45
45
35
24
23 C-C 36 30 32
5 2 B-B 52 43 56 31
2 7 33
54 44
B
41 42
51 C
6 C
34 35
8 50
58 53
57
41 42
4
37 38
3
55 40
9
12
10
39
49 59 28
11 13 17 19 22 26 25
1 20 60
15 14 16 18 21 29 27
LG950EIII07181
Parts lift of travel motor

1 Housing 31 The pin (MRC03)
2 NPT1/16 plug 32 Spring seat (MRC03)
3 Oil seal 33 Spring(MRCO3)
4 Locating ring IRTW68 34 the pilot valve screw plug G3/8
5 Tilt piston 35 O-ring 1B P11
6 Piston sealing 36 Connecting pipe (MRCO3)
7 Steel ball 25 37 G1 / 4 screw plug
8 Main shaft 38 O-ring 1B P11
9 Bearing HR33209J 39 Throttle valve (brake valve)
10 Pivot 40 Spring (brake valve)
7-187

11 Swash plate 41 G1 / 8 screw plug
12 Cylinder block 42 O-ring 1B P8
13 Cylinder block spring 43 Check valve
14 Spring holder 44 Check valve spring
15 Ball joint 45 M6 throttle valve φ
16 Shoe brake 46 O-ring 1B P12.5
17 Plunger group 47 M6 throttle valve (φ0.8)
18 Meshing plate 48 O-ring 1B P15
19 Friction plate 49 O-ring 215.57X2.62
20 Piston brake 50 Bearing HR32207C
21 D-ring (small diameter) 51 Shim
22 D-ring (large diameter) 52 Parallel valve pin M68x12
23 Motor rear cover 53 Oil distribution plate
24 NPT1 / 16 screw plug (red) 54 Brake spring
25 Spool group (M4V RBV) 55 Inner hexagon bolt M18×50
26 Spring seat (M4V290RBV) 56 Safety valve ORV-240L
27 Spring(M4V150RBV) 57 Connector
28 the M42 screw plug(M4V290RBV) 58 Snap ring
29 O-ring 1B G40 59 G1 / 2 screw plug
30 Pilot spool (M4V290) 60 O-ring 1B P18
Special tool
21
10
P . C. D. 2 5 1
280
195
215
Piston brake installer 2 M1 8 X 35
2 20 U
50
15
2 M I 8 X 50
52
LG930E922E07085
7-188
160
20
70
Compression mold (2 units) 100
37
LG930E922E07086
Inner hexagon bolt 2-M6X100 12

60
24
40
Piston brake drawer (2 units)
6.5
20
100
LG930E922E07087
100
Oil seal installer

10 ԛр
.5
R0
8.2
67.5
90
LG930E922E07088
7-189
25
10
R2
Guide pins for motor cover (2 units)

M18 32
100
LG930E922E07089
120
42
36
Bearing installer
LG930E922E07090
7-190
Disassembly
Precautions
1. Kerosene and other combustible materials are used for cleaning the parts.
Pay great attention to combustible materials. Failure to do so may cause a fire.
2. 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.
3. 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.
4. 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.
5. Before dismantling, study the figure above. Prepare the necessary components based on the part to
be dismantled.
6. 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.
7-191
23 29 28 56 56-3 31 30 32 33 34 35
Photograph
57
27 26 25 39 40 41 42
LG950EIII07182
1. Dismantling the affiliated valve
Before the motor is removed, remove its affiliated valve.
According to the purpose of dismantling, not removing the affiliated valve outside the
dismantling scope is the best.
However, to dismantle the motor, you have to remove the safety valve (56).
Do not dismantle the motor until its temperature drops to the room temperature. Oth-
erwise, you can be seriously scalded.
Disassembly steps
1) Remove the M42 screw plug (28) and O-ring (29).

2) Remove the spring (27), spring seat (26) and spool group (25)
Mark the spool group (25) and the rear cover (23). Failure to do so can cause reverse
installation.
3) Remove the plug (41), O-ring (42), throttle valve spring (40) and throttle valve (39).
4) Remove the safety valve (56).
During the removal of the safety valve (56), the valve seat (56-3) can easily slip off.
Make sure the valve seat does not fall into the rear cover (23) or is lost.
5) Loosen the pilot valve screw plug (34), and remove the O-ring (35), the spring (33), the
spring seat (32), the pilot spool (30) and the pin (31).
6) Remove the connector (57).
7-192
Hole for releasing ˁʹ˞˩̈

48
brake(left) Guide pin
46 54 23 51
A-A
A
A
Photograph
53 49 50 55
12
LG950EIII07183
7-193
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.
2. Disassemble the motor.
1) Place the motor shaft horizontally. Remove the hex bolts M18 × 50 (55), but leave two of
them diagonally.
Disassembly steps
2) Install two guide bars in the diagonal positions. (Purpose: They are used to prevent slipping
off when removing and to guide when assembling.)
3) Loosen the two reserved hex bolts M18 × 50 (55) gradually.
4) Remove the rear cover (23) and the brake spring (54). Make sure the cylinder (12) is
carefully taken away together with the rear cover (23).
Always prevent your hand from being clamped into the parts. Prevent your feet from
being hit by any lifted part.
Do not let the oil distribution disc (53), the brake spring (54), the bearing bush (50),
the gasket (51), the O-rings (49), (46) and (48) fall to the ground.
Notice: There is a gasket (51) in the bearing bush. Avoid its loss during removal.
Photograph
LG950EIII07184
5) Do not bring the cylinder (12) out when the oil distribution disc (53) is removed.
Mark the oil distribution disc (53) and the rear cover (23). Failure to do so can cause
Disassembly steps
reverse installation.
6) Press the cylinder block downward with tool and expose the bearing inner ring; notice not
bruise the cylinder block (12) surface; refer to above figure.
To protect the cylinder (12) surface, put a rubber pad between the cylinder surface
and the tool.
7) Hook the bearing (50) inner race with the puller to remove it.
7-194
Hole for
terminating brake
Photograph
LG950EIII07185
8) The piston brake can be pulled out with the tool. To remove the piston brake (20), install the
tool into the M6 screw hole on the surface of the piston brake (20). Roll the paper into a
Disassembly steps
barrel and insert it into the plunger hole, and then mark the outer surface of the cylinder
block.
9) Remove the rotating group (including the cylinder (12), the plunger (17), the shoe brake
(16), the ball joint (15), the spring seat (14) and the cylinder spring (13)).
17 18 19 20
Photograph
㍏˦ʹˬ
Paper pipe
ⴤদ
Matching mark
15 14 16 12 13
LG950EIII07186
7-195
10) Remove the mesh plate (18) and the friction plate (19).
11) Remove the plunger (17), the shoe brake (16) and the ball joint (15) from the rotating
group.
Disassembly steps
12) Remove the spring seat (14) and the cylinder spring (13) from the cylinder.
Install the plunger (17) into the cylinder (12) according to the marks. Make sure that
the plunger is installed into the hole which is the same as the one before dismantling.
Avoid damage to each contact surface. If damaged, do not use the plunger again.
The plunger and the shoe are pressed together. They cannot be dismantled.
Oil hole
Photograph
LG930E922E07096
13) Remove the swashplate (11);

14) 1, 2-speed piston does not need to be removed. If necessary, hold the piston by hand, and
Disassembly steps
then push it out from the via hole with air pressure.
The air pressure may blow the 1-2-speed piston away. Be careful! It is very danger-
ous.
15) Pull out the main shaft (8).
16) If the bearing (9) needs to be replaced, pull out its inner race with the puller, and then
replace the bearing with a new one.
7-196
4 3 9 1 6 5
7
Photograph
10 11
8
LG950EIII07187
When the parts associated with the bearing, such as bearings (9) (50), main shaft (8),
housing (1), rear cover (23) or the like, need to be replaced, adjust the gasket (51).
Determine the gasket gap accurately, and then replace the gasket with the corre-
Disassembly steps
sponding one. Adjust the bearing clearance to the range of 0-0.1mm (0-0.003937In).
 Generally, the pivot (10) does not need to be removed. If necessary, mark the corre-
sponding swashplate (11).
 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).
7-197
E S
Photograph
F
8 9 1 50 51 23
LG950EIII07188
17) Calculation of tapered bearing gasket (51) thickness
This operation can be implemented only any of bearing (9) (50), main shaft (8), motor
housing (1) and rear cover (23) is to be replaced.
a. Under the assembly state shown in the figure above, measure the size E.
Disassembly steps
Make sure the main shaft (8) is not inclined.

b. Measure the size F on the side of the rear cover (23).
Be sure to measure four points on the circumference in a crisscross pattern and take
their average.
c. If the gasket (51) thickness is defined as S, the gap Y may be calculated as follows:mm
d. Make sure the gap Y is within 0-0.01mm (0-0.0003937In), and select one or two gaskets
(51).
7-198
Photograph
56-3 56-2 56-1 56-12 56-13 56-4 56-9 56-8 56-12 56-10 56-11 56-6 56-7 56-5
LG950EIII07189
3. Dismantling the safety valve

Disassembly steps
The safety valve (56) is an important part in performance and safety. It is very difficult to re-set
its pressure. If a malfunction happens, do not dismantle it but replace the valve (56) assembly.
Grease
Photograph
LG930E922E07100
The valve seat (56-3) is fitted in the gap of the inner hole of the sleeve (56-1). Do not
Disassembly steps
let the valve seat (56 -3) fall off when removing the safety valve (56) from the motor
cover (23).
Further, when the safety valve (56) is assembled into the motor cover, to prevent the
valve seat (56 -3) from falling off, grease the joint surface.
7-199
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.
any lifted part.
Oil seal installer

Photograph
LG930E922E07101
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.
Assembly steps
2. Fix the oil seal (3) with the locating ring (4).
3. Install the outer race of the front bearing (9) into the housing (1) (clearance fit). Press the
inner race in the main shaft (8) (interference fit).
To press in the inner race easily, you can heat it to 100°(or below).
Avoid scalding.
7-200
6
4 3 9 1 5
7
Photograph
8 10 11
LG950EIII07190
4. Fix the main shaft (8) to the housing (1). Be sure to grease the seal contact surface.
5. Assemble the obliquely-rotating plungers (5), (6) and (7).
Be sure to set the obliquely-rotating plunger right and then insert it.
Assembly steps
When inserting the obliquely-rotating plunger, grease its sealed portion. Avoid dam-
age to the plunger.
6. When assembling the pivot (10) into the housing (1), be sure to install it on the side which is
consistent with the matching mark of the swashplate (11). 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 (11).
7-201
16 17 14 12
Photograph
8 11 15 13
LG950EIII07191
7. Grease the three spherical surfaces of the swashplate (11) fully before assembling.
8. Install the plunger group (17), shoe brake (16), ball joint (15), spring holder(14), cylinder
spring (13) and cylinder (12) into an assembly, and then insert the assembly into the main
shaft (8).
Assembly steps
Be sure to insert the plunger group (17) into the same hole as that before dismantling
the cylinder.
9. Insert the front bearing (50) inner race into the main shaft (8) using the special tools (A1,
A2).
7-202
ງᯏ䭚
Plastic hammer
A2
1 17 18 19 21 22 20
50
Photograph
┐⨖䖪䳅‫׵‬㻻‫ޭ཯ޛ‬
A1 Jig for inserting
rear beaning 55
࡬ࣞ⍱ດ㻻‫ޭ཯ޛ‬
B Jig for inserting
brake piston
10- ᒩ෡
10- Plain washer
LG950EIII07192
10. Assemble the mesh plates (18) and the friction plates (19) alternately. The first one and the
last one should be the mesh plate (18).
11. Insert the piston brake (20) with D-rings (21) and (22) in the housing (1) with the special
tools.
Assembly steps
Grease the D-rings (21) and (22).

Insert the piston brake (20) evenly with the special tools. The piston brake is
equipped with D-rings (21) and (22). Install the large-diameter D-ring (22) first, and
then install the small-diameter D-ring (21). The installation state of the small-diameter
D-ring (21) cannot be visually confirmed. Do not force to install it. The hole on the
housing (1) can be cut sometimes.
7-203
ሲੇ䬶
Guide pin 48
54
57 46
23
Photograph
51
55
1 12 53 49 50
LG950EIII07193
Adjustment of gaskets When the related parts need to be replaced, adjust the gas-
kets.
Determine the gasket thickness according to the Dismantling Essentials 4-2-2, 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 oil distribution disc into
the motor cover, and then install the gasket (51), the front bearing (50) outer race, the brake
Assembly steps
spring (54) and the O-rings (49), (46) and (48).

14. Insert the motor cover (23) into the housing (1) along the guide pin. To allow the motor cover
to be installed parallel to the diagonal position (2), tighten it with the M18 × 50 (55) 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.
When the front bearing (50) outer race is removed, remember to install the gasket
(51). Make sure the motor cover (23) is equipped with the O-rings (46), (48) and (49).
Caution: Tighten the hex bolt M18 × 50 (56) to 324±32.4N·m (239±23.9lbf·ft).
15. Install the connector (57).
7-204

Photograph

LG950EIII07194
16. Install the spring (33), the spring holder(32), the pilot spool (30) and the pin (31) in the motor
cover (23), and then tighten the pilot valve screw plug (34) with O-ring (35).
 Tighten the pilot valve screw plug (35 ) to 49.0-58.8N·m (36.1-43.4lbf·ft).

17. Install safety valve (56)
 The valve seat (56-3) is installed at the position with clearance fit. During installation,
to prevent it from slipping off or falling off, grease the joint surface.
 Tighten the safety valve (56) to 98.1-118N·m (72.3-87lbf·ft).

Assembly steps
18. Install the check valve (39) and its spring (40) in the motor cover (23), and then tighten the
pilot valve screw plug (41) with O-ring (42).
 Tighten the plug (41) to 14.7N·m (10.8lbf·ft).

 When the new check valve (39)is needed, grease the sealing portion.
19. According to the matching marks made when dismantling, install the spool assembly (25)
into the motor cover (23), and then install the spring holder(26) and the spring (27)
sequentially.
 The spool assembly (25) is directional. Insert the spool assembly with care.
20. M43 screw plug (28) assembly O-ring (29).
Tighten the M42 screw plug (28) to 441~461N·m (325.2-339.9lbf·ft).
7-205
Initial operation
1. Drain and add oil
After dismantling and assembling, fill the hydraulic oil in the motor housing.
There is 2 (G1/2) oil drain ports on M4V290/170 motor. Bleed the air using the port on the side without
piping.
Perform the initial operation.

Please operate the motor for 5 minutes in low speed mode; confirm there is no any abnormality
such as noise and external exposure.
2. Disassembly and assembly of the reduction gear

7-206
Structure diagram of reduction gear

The serial numbers behind the names of the parts relevant to reduction gear below should be based on
the following drawings:

LG950EIII07195
7-207
S/N Part name S/N ?Part name

1 Housing 16 Spring pin (10x63)
2 Bearing(280BA40GS) 17 Shim
3 Gear ring 18 Sun gear 2
4 Inner hexagon bolt (M20X120) 19 Support 1
5 Cover 20 Planetary gear 1
6 Inner hexagon bolt (M10X25) 21 Thrust shim 1
7 Float seal ring 368 22 Needle bearing FBNP-406040
8 Shim 23 Gear pin 1
9 Lock shim 24 Spring pin 6X36
10 Supporting ring 25 Sun gear 1
11 Support 2 26 Thrust plate
12 Planetary gear 2 27 Rear cover
13 C-type retaining ring 28 Inner hexagon bolt (M12X30)
14 Bearing (22213EAE4) 29 Plug G(PF)3/4
15 Gear pin 2 30 O-ring 1B P24
Disassembly
Precautions
1. 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.
2. Unscrew and remove the drain plug and the fill plug G3 / 4 (29), 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.
3. To re-install the parts easily, be sure to mark the outside of each corresponding surface.
7-208
1. Remove the reduction gear from the traveling
motor and reduction gear.
Mating Mark
2. Lift the reduction gear onto the work bench.
a. Remove three hex bolts
M12×30(28)installed in the rear cover (27)
equally. Then install the lift rings.
 Always prevent your hand from being

clamped into the parts. Prevent your feet from
 Be sure to lift the reduction gear up
LG930E922E07108 horizontally.
3. Remove the rear cover of the reduction gear.

a. Remove the remaining hexagon socket bolt
M12x30 (28).
LG950EIII07196
b. The joint surface between the rear cover

(27) and the ring gear (3) is glued. Be sure to
tap the rear cover upward and obliquely
using a metal liner to withstand the rear
cover.

LG930E922E07110
7-209
4. Remove the bracket 1.
a. Remove the thrust plate (26).
b. Install three M10 eyebolts on the bracket 1
(19). Lift up the brackets (19, 20, 21, 22, 23,
24) overall.

being hit by any lifted part. Warning: Be sure to
lift up the brackets horizontally.
c. Remove the sun gear 1 (25).
LG950EIII07197  Do not put your hands between the gears.
Doing so can cause hand injury.
LG950EIII07198

a. Remove the sun gear 2 (18).
 Do not put your hands between the gears.

Doing so can cause hand injury.
LG950EIII07199
7-210
b. Install three M10 eyebolts on the bracket 2
(11). Lift up the brackets 2 (11, 12, 13, 14,
15, 16, 17) overall.

 Be sure to lift up the brackets horizontally.
LG950EIII07200
6. Outer housing disassmelby

a. Remove the support ring (10).
LG950EIII07201
b. Put a screwdriver against the opening of the

lock washer (9) and knock it out with a
hammer.
LG950EIII07202
7-211
c. Install three M12 eyebolts into the ring gear
equally and lift out the housing assembly
(including ring gear (3), housing (1), bearing
(2), seal end cover (5),floating seal ring (7),
hex bolts M20 × 120 (4)) horizontally

being hit by any lifted part. Warning: Be sure to
lift up the brackets horizontally.
LG950EIII07203
7. Outer housing disassmelby
7 6 a. Install three eyebolts M24 into the housing

5 4 (1) equally. Let the ring gear (3) face down
2 1 and the housing (1) face upward, and then
lift them onto the work bench. Mark the
outside of the housing and ring gear (3).

over 300
3 clamped into the parts. Prevent your feet from

 Be sure to lift up the brackets horizontally.
LG950EIII07204
7-212
b. Remove the floating sealing ring (7) from the
end cover (5).
c. Remove the hexagon socket bolt M10x25
(6) and remove the end cover (5) from the
housing.
d. Remove the hex bolts M20 × 120 (4), but
leave two on the diagonal positions.
e. 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.
LG950EIII07205  Always prevent your hand from being

 Notice: Avoid damage to the sliding metal
surface of the floating seal ring (7) and the O-
ring.
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.
LG950EIII07206
a. Remove the floating seal ring (7) on the side
of the motor head.
LG950EIII07207
7-213
 If the gear pin 1 (23) 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.
a. Tap the spring pin 6 × 36 (24) into the gear
pin 1 (23).
b. Remove the gear pin 1 (23) from the bracket
1 (19).
c. Remove the thrust shim 1 (21), the planetary
gear 1 (20) and the needle bearing (22) from
LG930E922E07118
the bracket 1 (19).
 Do not put your hands between the gear

and the bracket. Doing so can cause hand
injury.
d. During re-assembly, knock the spring pin
6x36 (24) from the gear pin 1 (23).
 If the gear pin 1 (23) or the planetary gear 1

(20) needs to be replaced, replace all the three
ones.
LG930E922E07119
LG930E922E07120
7-214
LG930E922E07121
 If the gear pin 2 (15) needs to be re-used,

before removing, make the same mark on both
the gear pin 2 (15) and the mounting hole. For
follow-up matching.
a. Tap the spring pin 10 × 63 (16) into the gear
pin 2 (15).
b. Remove the gear pin 2 (15) from the bracket
2 (11).
c. Remove the planet gear 2 (12), bearing (14)
and C-type retaining ring out of the support 2
LG930E922E07122
(11).
 Notice: Do not put your hands between the

gear and the bracket. Doing so can cause hand
injury.
d. Remove the spacer (17) from the support 2
(11).
e. Remove the spring pin 10×63(16)from the
gear pin 2(15).
 If the gear pin 2 (15) or the planetary gear 2

(12) needs to be replaced, replace all the three
ones.
LG930E922E07123
7-215
LG930E922E07124
LG930E922E07125
7-216
Assembly
Precautions
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 each part for abnormity.
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.
any lifted part.
6. Be sure to use a torque wrench for tightening operation.

Table 3 Tightening Torques
Part symbol Part name Dimension Tightening torque (N·m)
461±44.1N·m(340±32.5lbf·ft)
4 Hex bolt M20X120
# 242 sealant coating
98.1±9.8N·m(72.3±7.2lbf·ft)
28 Hex bolt M12X30
# 242 sealant coating
29 Plug G3/4 147±14.7N·m(108.4±10.8lbf·ft)
7-217
1. Assembly of bracket 2 Ass’y.
a. Insert the spacer (17), planet gear 2 (12),
bearing (14) and C-type retaining ring into
the support 2 (11).

injury.
b. Insert the gear pin 2 (15) into the bracket 2
(11) toward the direction of the spring pin
hole.
c. Insert the spring pin 10 × 63 (16) into the
LG930E922E07126
bracket 2 (11) and the gear pin 2. (spring pin
surface recess: 1-2mm) 1.4 Caulk the two
positions which are symmetrical in 180°.
LG930E922E07127
LG930E922E07128
7-218
Based on the caulking,

the spring pin is hidden by 0.5.
Opening part of spring pin is Two caulking positions
as shown in the figure which are symmetrical
in 180°, as shown
in the figure.  For the direction of inserting the spring pin
and the caulking method, refer to the left
figure.
Front end settlement
1.0~2.0 of spring pin
Gear side LG950EIII07208

a. Insert the planetary gear 1 (20), needle
bearing (22) and thrust shim 1 (21) into the
bracket 1 (19).

injury.
b. Insert the gear pin 1 (23) into the bracket 1
(19) toward the direction of the spring pin
hole.
c. Insert the spring pin 6 × 36 (24) into the
LG930E922E07130
bracket 1(19) and the gear pin (23).
d. Caulk the two positions which are
symmetrical in 180°.
 For the direction of inserting the spring pin

and the caulking method, refer to the upper left
figure.
LG930E922E07131
7-219
LG930E922E07132
3. Installation of bearings and floating seals

a. Mount the housing (1) into the bearing (2).
b. Install the floating seals (7) on one side of
the motor and one side of the housing,
respectively.
 Remove the oil, impurities, paint and

foreign matters from the floating seal
installation positions.
 Apply a thin layer of gear oil to the sliding
part of the floating seal (7). (Do not apply gear
LG930E922E07133
oil to the O-ring.)
c. Apply the sealant #515 on fitting surface of
housing (1) and sealing end cover (50
without clearance.
correct incorrect incorrect
d. Install the M20 eyebolts on the housing (1)
and lift it with the hoist. Install the ring gear
(3) based on the matching marks.
Assemble the sealing end cover onto the
housing (1).
Apply #242 sealant on 16 M10x25(6)
hexagon bolts; do not remove the anti-rust
agent and tighten with the torque wrench.
 Please refer to the figure blow "Apply #242

sealant on front end of bolt".
LG930E922E07134
7-220
4. Assembly of housing Ass’y
a. Apply the sealant #515 to the joint surfaces
Sealant #515 between the housing (1) and the ring gear
(3).
b. Install the M24 eyebolts on the housing (1)
and lift it with the hoist. Install the ring gear
(3) based on the matching marks.

LG930E922E07135
 Be sure to lift up the component
horizontally.
c. Apply #242 sealant on 26 hexagon socket

bolts M20x120(4); do not remove the anti-
5 4
rust agent and tighten with torque wrench;
2 1 tightening torque: 461±44.1N·m
(342.2±32.5lbf·ft).
LG930E922E07136

 For coating the bolts with sealant #242,

refer to the sealant #242 coating method in the
left figure.
Apply the #242 sealant to the

front end of the bolt
LG930E922E07137
7-221
5. Angular contact bearing’s gasket thickness
requirements.
 This must be done when any one of the

motor (case), the housing (1), the (angular
contact) bearing (2) and the lock washer (9)
needs to be replaced. If not the above
conditions, the gasket can be used as usual.
a. Install the two bearing (2) outer races in the
housing.
b. Install the two bearing (2) outer races evenly
and measure the inner race’s assembly size.
 When measuring the inner race’s assembly

size, rotate the bearing for more than 5 times
before measuring.
c. Measure the motor housing’s bearing size
(B).
S d. Measure the motor housing’s lock washer
D A
C B groove size (C).
LG930E922E07138 e. Measure the thickness (D) of lock washer

(9).
 Be sure to measure four points on the

circumference in a crisscross pattern and take
their average. Dimensional accuracy: 0.01mm.
f. When the gasket (8) to be used is S thick, the
gap X is as follows. X=(B+C)?(A+D+S)
g. In this case, the gasket with a gap X
(0.08~+0.02mm, -0.0031496~-0.0007874) is
selected.
7-222
6. Assembly of housing Ass’y
a. Let the main shaft of the motor face upward
and put it onto the work bench. Select the
gasket (8) 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.

horizontally.
b. Install the three eyebolts (M12) 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.
LG950E4f07096
horizontally.
c. When pressing the bearing 2 inner ring,
mount the lock spacer (9) into the groove.
LG930E922E07140
7-223
d. Fix the support ring (10) to the outside of the
lock washer (9).
LG930E922E07141

a. Install the M10 eyebolts on the housing
2(11) and lift it with the hoist. Install the ring
gear (3) based on the matching marks.
Put the three planetary gears 2 (12) onto the
bracket 2Ass'y shown in the left figure and
put the 2Ass'y into the ring gear (3), and
then let it engage with the housing spline.

LG950EIII07210  Be sure to lift up the component
horizontally.
LG950EIII07211
7-224
b. Insert the sun gear 2 (18)
 Do not put your hands between the sun

gear and the other gear. Doing so can cause
hand injury.
 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.
LG950EIII07212

a. Lift up the bracket 1Ass’y using 3 bolts
(M10) and put it into the ring gear (3), and
then turn the matching position of the
planetary gear 1 (20) to engage with the sun
gear 2 (18).

horizontally.
b. Make sure the connector is behind the main
shaft of the motor. Insert the sun gear 1 (25).
LG930E922E07145
 Do not put your hands between the sun
gear and the other gear. Doing so can cause
hand injury.
LG930E922E07146
7-225
c. Insert the thrust plate (26) into the bracket
1(19).
 Let the sharp corner point toward the side

of the rear cover (27).
LG930E922E07147
Rear cover for

reduction gear
Sharp corner R
Thrust shim
LG930E922E07148
7-226
9. 9. Assembly of rear cover
 You fill the gear oil before assembling the

rear cover (27).
a. Coat the matching surfaces of the rear cover
(27) and the ring gear (3) with sealant # 515,
and then fix the rear cover (27) to the ring
gear (3).

LG950EIII07213 b. Coat the 18 hexagonal bolts M12 × 30 (28)
with sealant # 242, and tighten them to 98.1
± 9.8N·m (72.3±7.2lbf·ft).
 For coating the bolts with sealant #242,

refer to the #242 coating method in the left
figure.
LG950EIII07214
20 20
Apply the #242 sealant to the

front end of the bolt
LG930E922E07151
7-227
10. Filling of gear oil
a. Pour the gear oil (SAE90, API classification
GL-4 or GL-5, 15 L) into the port G3/4.
a. Install the hexagonal plug G3 / 4 (29) in the
rear cover and tighten it to 147.1 ± 14.7N·m
(108.5±10.8lbf·ft).
Inspection after assembling

1. Thrust washer and spacer
a. Check whether any one is damaged, or with abnormal wearing or uneven wearing.
b. Check whether the wear exceeds the allowable value
2. Gear
a. Check whether there is pitting or damage on tooth surface
b. Check whether the tooth root has any sound with mold
3. Gear
Manually rotate to see whether there is abnormal sound or uneven rotation during rotation.
4. Check the defect of sliding surface or O-ring
7-228
7.5.15Removal and installation of the swing motor & reduction gear
Removal
receive oil.
1. Remove the front cover (1).
LG950EIII07215
7-229
2. Remove the oil filler pipe (2);
3 7 3. Remove the oil filler pipe (3);
4 4. Remove the 3-way joint (4);
5. Remove the 4 high-pressure hoses (5);
6 6. Remove the 2 oil return hoses (6);

7. Remove the 3-way joint (7).
5
2
LG950EIII07216
8. Remove the 2 brake valve control oil pipes (7);

9. Remove the 2 brake valve pilot pipes (8).
7
LG950EIII07217
10. Remove the bottom plate (9).
LG950EIII07218
7-230
11. Remove the 2 oil pipes (10).
12. Remove block (11).
11
10
LG950EIII07219
13. Remove the 2 grease hoses (12) on the bottom

of swing motor reduction gear.
13
15. Apply lubricant on 2 pins (14), and then
remove it.
14
12
LG950EIII07220
16. Lift the motors with rope and hoisting

equipment one by one, and place them on a
clean and safe position.
Lifting weight: about 100kg (220.5lb).
17. Cover the installing port of the motor with
paperboard after it is lifted, so as to avoid
foreign matters falling into the port.
LG950EIII07221
7-231
Installation
Installation is in the reverse order of removal.
● Mounting bolt M20-10.9, tightening torque: 600±50Nm (442.5±36.9lbf·ft).
● Clean the threaded hole before the installation, and apply thread locker (Tonsan 1277) on the thread
of bolt.
● Check whether the hydraulic oil is enough.
● M18 pilot hose tightening torque: 37±2N.m (27±1.5lbf·ft)
● Tightening torque of M22 oil return pipe: 47±2Nm (34.6±1.5lbf·ft)
● Tightening torque of M30 high pressure pipe: 89±4Nm (65.6±2.95lbf·ft)
● Tightening torque for M36 oil drain pipe: 179 ± 8Nm (132±5.9lbf·ft)
● Tightening torque for M45 oil filler pipe: 226±11Nm (166.7±8.1lbf·ft)
● Joint G1/4 tightening torque: 37.5±2.5N.m (27.7±1.8lbf·ft);
● Tightening torque for connector G3/8: 75±5N.m (55.3±3.7lbf·ft);
● Tightening torque for connector G3/4: 165±15N.m (121.7±11lbf·ft);
7-232
7.5.16Disassembly and assembly of the swing motor & reduction gear
Cross-section view of swing motor & reduction gear
122 123 121 111 301 742 743 706 707 702 472 712 985 303
124 652
162
443
171
491
151
161
101
163
985
444
984
114
131
451
031-2 031-1 033 031 031-3

LG950EIII07222
7-233
488 469 355 351
401 051-1 051
LG950EIII07223
400 400-2 400-1

100 390
391
052
断面 A-A
SECTION A-A
LG950EIII07224
7-234
926 391 391 230 231 602
930
104
204
287 601
912
211
201
802
915
401
903
102 801 910 910 402 913 910 286 202 285 282 285 210 403 283
LG950EIII07225
7-235
926 391
102 390
311
401
312
915
913
201 402 802
801 912
901
925
282 211
203 287 313
286
602
104
910
202
283
231 403
204
210
285
230 LG950EIII07268
7-236
Serial Serial
102 Valve body D2 601 Hex bolt
104 Rear shaft cover E 602 Hexagon socket head cap bolt
201 Drive shaft B 801 Oil seal
202 Gear ring E 802 O-ring
203 #2 planetary gear D 903 Plug
204 #2 sun gear D 904 Hexagon socket head cap bolt
210 #1 planetary gear D 905 O-ring
211 #1 sun gear D 909 Pin
230 #2 bracket D 910 Pin
231 #1 bracket D 912 Snap ring
282 #2 pin B 913 Snap ring
283 #1 pin B 915 Bearing seal
284 Push plate E 922 Plug
390 Nameplate 925 Exhaust valve
391 Pin 926 Grease fitting
402 Roller bearing 930 Hex screw
403 Plug
7-237
1. Bolt specs and tightening torque 3. Special clamp

Inner 1. Remove the clamp used for bearing (401)
hexagon Tighteni
Part Part Specifica
spanner ng
number name tion 250
dimensi torque
on 220
Length of 235N.m(
24mm(0.
601 Hex bolt M16: 40 173.3lbf·f
94In)
(1.57In) t
Inner Length of 235N.m(
14mm(0. 173.3lbf·f
210
230
602 hexagon M16: 160
bolt (6.30In) 55In) t
14mm(0. 98N.m(7
903 Oil plug PT3/4
55In) 2.3lbf·ft)
10mm(0. 65N.m(4
901 Oil plug PT31/2 LG950EIII07226
39In) 7.9lbf·ft)
2. Tools 2. Install the clamp used for bearing (402)
S/N Name Remarks

Counter edge width:
1 Hex. wrench 14mm(0.55In).10mm(0.40 125
In) 105
2 Socket wrench
Monkey
3
55
spanner
75
Double end
4
solid wrench
5 Hammer
6 Plastic hammer LG950EIII07227
7 Screwdriver
3. Install the clamp used for oil seal (801)
8 Torque wrench
Special clamp
9
for spline
Liquid sealing
10 Three Bond No.1217
filler 135
Oil groove for shrink fit with 80°C-100°C
11
10
heating (176°F~212°F)
LG950EIII07228
7-238
4. Special tool used to remove brake plunger
14
85
75
30
15
35
2.5
R1
100
30
14
M16
44
8
M16
贯通
Perforation
4
8
LG922E930E07425
7-239
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.
1. Disassembly of swing motor

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.
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.
 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
LG922E930E07426
this time, make the mark at the junction
position between motor body (301) and valve
body (303).
7-240
4. Loosen pressure-reducing valve (051) and
remove it from valve body (303).
 O-ring may be destroyed while loosening

pressure-reducing valve, therefore, be sure to
replace the O-ring.
LG922E930E07427
5. Remove ROMH oil drain plug (469) from valve

body (303), and then remove spring (355) and
plunger (351).
 Protect the plunger valve seat from being

damaged.
LG922E930E07428
6. Unscrew hex bolt (401), and then remove valve

body (303) from motor body (301).
(Because of the elastic force of brake spring
(712), valve body (303) may pop from motor
body (301) after the removal of bolt.
Remove the valve block (131) from valve body
(303).
 Conduct the operation carefully so as to

protect valve block from falling off from valve
body.
(For some motor, valve block is installed on a
LG922E930E07429 side of cylinder.) When prying the junction
surface with screwdriver, protect the junction
surface from being damaged.
7-241
7. Remove the brake spring (712) from the brake
plunger.
LG922E930E07430
8. Pull out the brake plunger (702) from motor

body (301) with remover.
 Hook the slot of brake plunger using the

remover paw end, and then lift it vertically.
LG922E930E07431
9. Level the motor again, and then pull out the

cylinder (111) from drive shaft (101). Pull out
the plunger (121), plate (123), plate spring and
plunger (124) in sequence.
 Protect the revolving mating surface of

cylinder and plunger, etc. from being damaged.
When it is not available to move the plunger
out, do it in the 12th operation step.
LG922E930E07432
7-242
10. Remove friction plate (742) and metal plate
(743) of separator from motor body (301).
LG922E930E07433
11. Remove drive shaft (101) and plunger (124).
 The spline may destroy oil seal during the

removal of drive shaft, so twine the spline part
of drive shaft with plastic adhesive tape before
the removal.
LG922E930E07434
LG922E930E07435
7-243
12. Carry out the following operation steps in
accordance with the requirements.
Drive out the inner ring of cylindrical roller
Punch bearing from drive shaft with press machine.
 The inner ring of cylindrical roller bearing

Drive shaft can also be knocked by hammer and steel bar,
but it is needed to knock the inner ring
uniformly and protect the bearing from being
damaged.
The removed bearing cannot be reused.
LG922E930E07436
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).
 The removed bearing cannot be reused.

14. Remove the cylindrical roller bearing (444)
from valve body (303) with sliding weight
bearing detacher.
 The removed bearing cannot be reused.
LG922E930E07437
2. Disassembly of reduction gear

Precautions
1. Take care during disassembly and do not damage the part and component;
2. Before installation, please check the parts and components according to the maintenance reference
introduced in 3.3.3 Hydraulic Units;
3. Each part and component shall be cleaned with cleaning oil and blow dry with compressed air;
4. During disassembly, the liquid sealing filler shall be cleanly removed on surface with knife, and then
degrease after treated the surface with oil stone;
7-244
Disassembly steps
1. Remove the hydraulic motor from the reduction
gear, and remove the oil plug (901) of oil drain
port, and drain out the gear oil. Then place on
proper working bench.
 Collect the gear oil with clean container,

and check the oil for wear powder.
2. Unscrew the hexagon socket bolt (601) and
remove the hydraulic motor.
3. Unscrew the hexagon socket bolt (602) and
remove rear housing (104).
LG950EIII07229
4. Remove No.1 sun gear (211);
LG922E930E07438
5. When taking out No.1 support subassembly,

please take out the subassembly for No.1
planet wheel A (210) and other part;
LG922E930E07439
7-245
6. Removal of the No.1 support subassembly
 The No.1 support subassembly needs no

further disassembly till now; please check the
part and component according to the critical
points provided in the maintenance reference
7. Remove the inner gear ring (202)
There are two slots for removal on the joint sur-
face of housing (102) and inner gear ring (202),
and pry open with straight screwdriver.
 Notice not damaging the joint surface.
LG922E930E07440
8. Remove No.2 sun gear (204);

9. Remove No.2 support subassembly
10. Remove No.2 support subassembly
If no special conditions, the No.2 support sub-
assembly needs no removal in this state.
Please inspect according to related mainte-
nance reference; if replacement required, we
recommend replacement of subassembly. If
necessary to replace part of component,
please conduct as follows.
 Make the marks on each planet gear and

pin; ensure the fitting and assembly method
unchanged during assembly.
1) Pull out the spring pin (910) and the innermost
No.2 spring pin (282);
 No.2 spring pin (282) can not be used after

removed.
2) Take out No.2 planet gear (203) and thrust
washer (286) from the side.
7-246
11. Remove the stop ring (913) from the driving
shaft (201).
LG922E930E07443
12. Adjust the shaft end to downward; the shaft

shoulder will be placed on the supporting
bench. Knock the shaft center with plastic
hammer to knock the shaft downward out.
 Leave the automatically centering roller

bearing (402) into the housing. Due to the
driving shaft will fall if facing downward,
please take care not to bruise it.
If no abnormal conditions, do not further disas-
semble. In this state, please refer to related
maintenance reference for inspection. Recom-
mend replacing the driving shaft subassembly
in subassembly form. If necessary to replace
part of components, please operate according
to step 13.
 If there is no abnormality of inspection at

this stage, please do not further disassemble!
7-247
13. As shown in figure, support the driving shaft
subassembly and remove the bearing sealing
cover (915) and the automatically centering
bearing (401) with press.
LG950EIII07230
14. Remove the oil seal (801) from the housing

(102).
 If the bearing seal (915) and oil seal (801)

are removed, never reuse them.
7-248
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
Precautions:
The assembly sequence is opposite to that of disassembly, so please pay attention to the following
points.
1. Protect the components from being damaged
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.
5. Seals such as O-ring and oil seal shall be replaced in principle.
6. Tighten the captive bolts and oil drain plug, etc. with torque wrench according to the tightening torque
shown in the following table.
7. If the liquid filling material is used. Peel the surface of the component with knife or similar objects.
and grind the surface with oilstone.
Table of specification and tightening torque of bolt
Tightening torque Applicable part

Bolt size Name
(N.m) number
M20 Inner hexagon bolt 431(317.86lbf·ft) 401
M33xP1.5 Pressure reducing valve 177(130.53lbf·ft) 051
M30xP1.5 ROMH oil drain plug 334(246.325lbf·ft) 469
PF1/4 ROM oil drain plug 36(26.55lbf·ft) 467
12mm Inner hexagon bolt 102(75.23lbf·ft) 602
10mm Plug 65(47.94lbf·ft) 901
If it does not conform to the above part number, please refer to the assembly profile view.
7-249
1. Assembly of swing motor
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.
 Pay attention to the direction of dowel pin

of cylindrical roller bearing.
LG922E930E07445
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.
 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.
One side of the output shaft

 Knock it uniformly to protect the periphery
from being damaged.
LG922E930E07446
5. Knock it gently with hammer and steel bar to

install the cylindrical roller bearing (443) on the
motor body (301).
LG922E930E07447
7-250
6. Install the drive shaft on the motor body (301).
 Install it carefully to protect the sealing part

of oil seal from being damaged.
 Twine the spline of shaft with plastic
adhesive tape.
LG922E930E07448
7. Place the motor body (301) flatly, and then

insert the plunger (124).
 Revolve the side with big chamfer of

plunger into the motor body.
 Apply a layer of grease on it in order to
avoid it falling off from the junction surface.
LG922E930E07449
8. Assemble the plate (123) and plate spring, and

then assemble them and piston group (121,
122).
LG922E930E07450
7-251
9. Install the plunger group (121, 122) assembled
on plate (123) on the cylinder (111), and install
it together with drive shaft (101) cooperatively.
LG922E930E07451
LG922E930E07452
7-252
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.
LG922E930E07453
LG922E930E07454
11. Install O-ring (706) (707) in the motor body

(301).
 The O-ring is uneasy to be broken off when

it is installed on the brake plunger if it is
applied a layer of grease.
LG922E930E07455
7-253
12. Install the brake plunger (702) in the motor
body (301).
LG922E930E07456
13. Install brake spring (712) in brake plunger

(702).
LG922E930E07457
14. (This step can be implemented only when

removing cylindrical roller bearing (444).
Install the outer ring of the cylindrical roller
bearing (444) into valve body (303) while knock
it gently with hammer and steel bar.
 Knock on the periphery of outer ring evenly

till it is completely installed into clamp slot of
valve body.
LG922E930E07458
7-254
15. Install valve plate (131) into valve body (303),
and then into O-ring.
 Apply a thin layer of grease on joint surface

of valve plate. (Prevent falling off)
LG922E930E07459
LG922E930E07460
16. Install valve body (303) on motor body (301),

and then tighten it with hex bolt.
 Pay attention to installation direction of

valve body. (Refer to external dimension figure)
Pay attention to avoiding falling-off of valve
plate.
Pay attention to avoiding falling-down of brake
spring.
Hex bolt shall be tightened evenly.
LG922E930E07461
7-255
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).
 Check whether the plunger moves

smoothly.
LG922E930E07462
18. Install pressure-reducing valve (051) into valve

body (303).
LG922E930E07463
7-256
2. Assembly of reduction gear
1. Assembly of driving shaft assembly
a. Install bearing seal (915) into drive shaft
(201).
LG922E930E07464
b. Add the grease inside the bearing (401) and

correctly press in with press machine. Knock
the inner ring till there is bouncing feeling of
hammer, and correctly mount it in.
 Since the automatic centering roller

bearing (401) center is of partition type, add the
grease in from both sides of bearing before
assembly of shaft.
LG922E930E07465
7-257
c. Apply and pile up the grease as the shape
indicated in the figure.
LG922E930E07466
Grease
LG922E930E07467
2. Place the housing (102) on horizontal

operation platform
3. Install oil seal (801) into the housing (102) with
the clamp.
LG922E930E07468
7-258
4. Lift up drive shaft assembly with threaded hole
in front end of drive shaft, and then install it into
housing.
The outer ring of bearing shall be of horizontal
shape and slightly knocked in.
 When the outer ring is of inclined shape,

the slight knocking can not make it in. Do no
forcibly mount in; please pull out once again;
adjust the outer ring as horizontal shape again.
Use the special clamp mentioned in above text
to mount in horizontal mode while not
LG922E930E07469 damaged the oil seal lip.
5. Lift the reduction gear erectly, and make drive

shaft downward. Properly support the housing
with boss.
6. Mount the bearing (402) with clamp and press
it into at same time.
 It is necessary to use the special tool

mentioned in above paragraph to fit according
to the dimensions of shaft end inner ring end
surface.
LG922E930E07470
7. Install the circlip (913).
LG922E930E07443
8. Add the grease into the housing from grease

filler and fill it.
7-259
9. Assembly of No.2 support subassembly
a. Align the thrust washer (286) with the pin
hole and place it in.
b. Install the No.2 planet gear (203).
LG922E930E07471
c. Align No.2 pin (282) spring pin with the

spring pin hole of No.2 support; slightly
knock No.2 pin (282) edge with plastic
hammer and then mount it into the support.
LG922E930E07472
7-260
d. Knock the spring pin (910) in and then seal
two ribs of No.2 support with punch.
LG922E930E07473
LG922E930E07474
10. Apply liquid seal on the joint surface of housing

(102).
LG922E930E07475
7-261
11. Mount No.2 sun gear (204) and No.2 support
subassembly together into the housing (102).
LG922E930E07476
12. Install the gear ring (202) into the housing

(102) while confirming the fitting mark position.
Temporarily use four screws to fix the gear
ring.
Notice using the washer while screwing in the
screw to avoid damage of housing
LG922E930E07440
13. Install the No.1 support subassembly (231).

Insert the center thrust plate (287) into the
recessed part of No.1 support subassembly
(231).
LG922E930E07439
7-262
14. Install the No.1 sun gear (211).
LG922E930E07438
15. Temporarily remove the bolt, and apply liquid

seal on the installation surface of housing
(102).
LG922E930E07477
7-263
16. Notice the mounting direction of rear housing
(104) and mount onto the inner gear ring (202),
and then tighten and fix with hexagon socket
bolt (602).
17. Install the snap ring (912) and O-ring (802) on
hydraulic motor driving shaft. Then vertically lift
down; while adjusting the position of spline
shaft, mount in the hydraulic motor, and tighten
and fix with hexagon socket bolt (601).
18. Wrap the oil plug (922) of oil drain port with
sealant and mount it onto the guide pipe (920).
19. Add the gear oil into the reduction gear through
the gear oil filler.
Temporarily mount the oil gauge test rod and
guide pipe and confirm the oil capacity of gear
oil. Please mount PT1/4 oil plug on the port
LG922E930E07478 with the guide pipe part during transportation;
after the reduction gear hydraulic motor is
mounted on this machine, please formally
mount the guide pipe and oil capacity test rod.
(Completely remove the sealing tape of bolt,
and degrease; then wrap with new sealing tap
and mount in)
7-264
7.5.17Removal and installation of fan control valve
Removal
receive oil.
Use lifting points as many as possible. Lifting ring is not allowed to bear shear force, and if there
is no appropriate lifting point, wide lifting rope that is able to bear enough weight shall be used.
LG950EIII07231
7-265
2. Remove the oil inlet pipe (2);
3. Remove the oil outlet pipe (3);
2 3 4. Remove the oil drain pipe (4);
5. Remove the feedback oil pipe (5).
LG950EIII07232

7. Lift the control valve with rope and hoisting
equipment, and then place it on a clean and
safe position.
Lifting weight: about 13kg (28.665Ib).
LG950EIII07233
Installation
● Tightening torque of mounting bolt M8-10.9: (33±3) N.m (24.3±2.2lbf·ft).
of bolt.
● M16 feedback hose tightening torque: (26±2)N.m (19.1±1.48lbf·ft);
● Tightening torque of M30 hose: (126±6)N.m (92.9±4.43lbf·ft);
● Tightening torque of G1/4 connector: (36±2)N.m (26.6±1.48lbf·ft)
● Tightening torque of G3/4 connector: (165±15)N.m (121.7±11.06lbf·ft).
7-266
7.5.18Removal and installation of fan motor
Removal
receive oil.
LG950EIII07234
7-267
2. Remove the 2 high-pressure pipe (2);
3. Remove the oil return pipe (3).
2
LG950EIII07235

5. Lift the fan motor with rope and hoisting
equipment, and then place it on a clean and
safe position.
4
LG950EIII07236
Installation
● Mounting bolt M14-10.9; tightening torque: (195±15)N.m (143.8±11.06lbf·ft).
of bolt.
● Flange oil port screw M8-10.9, tightening torque: (33±3) N.m (24.3±2.21lbf·ft).
● Tightening torque of M18 oil return hose: (37±2)N.m (27.3±1.48lbf·ft);
● Tightening torque of G1/4 connector: (36±2)N.m (26.6±1.48lbf·ft).
7-268
7.5.19Removal and installation of the gear pump (attachment swing)
Removal
receive oil.
1
LG950E4f07097
2. Remove the gear pump oil outlet pipe (2);

3. Remove the gear pump oil inlet pipe (3).
2 LG950E4f07098
7-269
4. Remove 2 captive screws and washer (4).
Remove the lower screw with a long round-
head inner hexagon spanner.
4
5. Lift the gear pump with rope and hoisting
equipment, and then place them on a clean
and safe position.
Lifting weight: about 8.5 kg (18.7Ib).
LG950E4f07099
Installation
of bolt.
● Mounting screw M12-10.9 tightening torque: (120±10)N.m (88.5±7.38lbf·ft);
● Gear pump oil inlet hose tightening torque: M24×1.5: (84±4)N.m (61.95±2.95lbf·ft)
● Gear pump oil outlet hose tightening torque: M36×2: (137±6)N.m (101±11.06lbf·ft)
● connector tightening torque:G3/4: (165±15)N.m; G1:(225±25)N.m (165.93±18.43lbf·ft);
7-270
7.5.20Removal and installation of the valve block assembly (attachment

swing)
Removal
receive oil.
1. Remove the bottom plate (1);
1
LG950E4f07100
7-271
2. Remove the valve oil inlet hose (2);
3. Remove the 2 pilot control hoses (3);
4. Remove the 2 working hoses and an oil return
3 hose (4).
4
2
LG950E4f07101
5. Remove 3 captive bolts and washer (5);

6. Lift the valve block with rope and hoisting
equipment, and then place them on a clean
and safe position.
5
Lifting weight: about 10 kg(22.05lb)
LG950E4f07102
7. Remove the 3 screws fit with mounting plate

6 and the washer (6);
LG950E4f07103
7-272
Installation
of bolt.
● Tightening torque of the bolt & screw M10-10.9: (72±6)N.m(53±4.4lbf·ft).
● Tightening torque of the valve block oil inlet hose & working hose: M24×1.5:
(84±4)N.m(61.9±2.95lbf·ft)
● Tightening torque of the valve block oil return hose: M30×2: (116±5)N.m(85.6±3.7lbf·ft);
● Tightening torque of the pilot control hose: M18×1.5: (37±2)N.m(27.3±1.5lbf·ft)
● Tightening torque of joint: G1/4:(36±2)N.m(26.6±1.5lbf·ft);
● G1/2:(110±10)N.m(81.1±7.38lbf·ft);
7-273
7.6Work Implement
7.6.1Removal and installation of the bucket
Removal
1. Start the engine, operate the machine to make
bucket back lie on the ground, and then
shutdown the engine;
 Put the pad between the bucket and

ground.
LG922E930E07479
2. Remove captive bolt and nut (1);
1 3. Remove captive bolt and nut (2);

2
LG922E930E07480
7-274
4. Remove the pin shaft (3) with copper hammer
3 and raping bar;
 It needs the coordination 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.
 The pin shaft weighs 36Kg?79.4 lb?.
 O-ring, which is installed between front
bracket of arm and the bucket, needs to be
removed and put at a safe place.
LG922E930E07481

and raping bar
 It needs the coordination 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.
 The pin shaft weighs 36 Kg 36Kg?79.4 lb?.
4
 O-ring, which is installed between front
bracket of arm and the bucket, needs to be
removed and put at a safe place.
LG922E930E07482
6. Start the engine, lift and swing the boom, and

then remove the bucket (5).
LG922E930E07483
7-275
Installation
Installation steps:
● Tightening torque for pin shaft captive bolt (2) (4): M20: 600±55N.m (442.5±41 lbf·ft); distance from
the nut close to the locating sleeve to the locating sleeve: 1-1.5mm (0.04-0.06In).
● Clean thread part of bolt and nut before assembling bolt, and apply thread locker Tianshan 1277 on
thread surface.
● Clean the pin hole and pin shaft surface before installation.
● If it is difficult to knock the pin shaft, adjust the installation position of the bucket and knock it again.
● Do not damage or lose O-ring and dust ring during installation.
● Fill the grease after the installation.
7-276
7.6.2Removal and installation of link and lever
Removal
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 (1) and arm as well as between bucket
cylinder body and arm during the process.
LG922E930E07147
3. Remove captive bolt and nut (1).

4. Remove captive bolt and nut (2).
2
LG922E930E07485
7-277
5. Install the rapping bar into axle hole of the link,
hook two ends of rapping rod with the sling,
and lift the link to vertical state with hoisting
equipment and sling.
6. Remove left lever (3).
 There are adjusting washers between the

3 lever and link, and between the lever and
middle bracket of the arm, and it is necessary
to remove and put them at a safe place.
LG922E930E07486
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).
 There are adjusting washers between

bucket cylinder and link, and between the link
4 and lever, and it is necessary to remove and
put them at a safe place.
8. Tighten the piston rod and the cylinder body
with wire rope.
LG922E930E07487
9. Rotate right lever (5) and drop its end on the

ground, and take off the sleeper. Knock small
end of the pin shaft (6) with cooper hammer
and rapping rod, push the pin shaft (6) to the
6 direction of right lever, and remove the pin
shaft (6) and right lever (5) at the same time.
 There are adjusting washers between the

lever and middle bracket of the arm, and it is
necessary to remove and put them at a safe
place.
5
LG922E930E07488
7-278
10. Remove the link (7), and convey it to safe
place for storage.
LG922E930E07489
Installation
● Tightening torque for pin shaft captive bolt (1) (4): M20: 600±55N.m (442.5±41 lbf·ft); distance from
the nut close to the locating sleeve to the locating sleeve: 1-1.5mm (0.04-0.06In).
thread surface.
● If it's difficult to knock the pin shaft, adjust the installation position of the lever and link, and knock it
again.
● Do not damage or lose dust ring and adjusting washer during the installation.
7-279
7.6.3The removal and installation of arm
Removal
Before removal of oil pipe, open the arm and bucket completely, keep the distance between the
bucket and the ground about 300~400mm (11.8~15.7ln) , 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.
Installation of Bucket for details in this chapter
2. Remove link and lever. See Removal and
Installation of Link and Lever for details in this
chapter.
3. Remove the bucket cylinder. See Removal and
Installation of Bucket Cylinder for details.
4. 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.
LG922E930E07490
 The pad needs to be placed between the
arm and ground.
7-280
5. Lift up arm cylinder with lifting rope and
hoisting equipment.
6. Remove the bolt, nut and plate (1) with
spanner.
2
and rapping rod.
 There is adjusting washer between arm

cylinder and arm, and it needs to take it down
and place it at a safe place.
1 8. Start the engine, retract arm cylinder piston
LG922E930E07491
rod, and fasten piston rod with wire rope in
case of stretching out.
 Do not release the pressure

9. 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.
10. Remove lifting rope on the cylinder.
11. Install the pin shaft (2) into pin hole, and lift the
arm (5) with lifting rope and hoisting equipment
through the pin shaft (2).
5 12. Remove the captive bolt, nut and plate (3) from
2
3 the boom front bracket hinge pin shaft.
13. Remove hinge pin shaft (4) with copper
hammer and rapping rod.
14. Slowly put the arm on the ground with the
sling.
4
LG922E930E07492  The sleeper needs to be placed between
the arm and ground.
15. Start the engine, and lift and swing the boom to
remove the arm.
7-281
Installation
● The tightening torque of captive bolts of the shaft pin:
M12 : (120±10)N.m {88.5±7.4 lbf·ft }
M20: (600±55)N.m {442.5±41 lbf·ft}
thread surface.
again.
7-282
7.6.4Removal and installation of the boom
Removal
Before removal of oil pipe, open the arm and bucket completely, keep the distance between the
bucket and the ground about 300~400mm {11.8~15.7In }, 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 pipelines and connectors.
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 release of residual pressure in hydraulic
oil line in "test and adjustment")
LG922E930E07493
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
 Hold hydraulic oil leaked from the line with

oil bucket to prevent contaminating the
ground.
LG922E930E07494
7-283
4. Refer to "removal and installation of the arm" in
this chapter for removal of arm assembly (2),
(arm assembly includes arm, bucket, link, lever
and pin shaft)
 The sleeper needs to be placed between

arm and ground.
LG922E930E07495
5. Start the engine, and swing the machine till

there is enough space for removing the boom.
LG922E930E07496
6. Operate the machine to place the boom on the

ground.
 The pad needs to be placed between front

bracket of the boom and ground.
LG922E930E07497
7-284
7. Disconnect the connection of grease line (3)
and boom cylinder.
8. Remove fixed sleeve (4) between boom
cylinder and boom hinge pin and its accessory
bolt and pin shaft.
3
4
 There is adjusting washer between locating
sleeve and cylinder, and it needs to take it
down and place it at a safe place.
9. Remove the fixed sleeve, bolt and nut on the
right side of boom cylinder with the method in
article 8.
LG922E930E07498
10. Lift the left boom cylinder (5) with lifting rope
and equipment.
6 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
LG922E930E07499
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
7 same method.
14. Lift the stretching part on both ends of boom
middle bracket pin shaft with lifting rope and
equipment.
LG922E930E07500
7-285
16. Disconnect the harness (8) and fix it on the
boom with strap.
17. Disconnect the connection between hose (9)
9 9
8 and boom tube.
9
 Wrap the connector with towel or cloth to
prevent oil splashing.
LG922E930E07501 oil-holding equipment to prevent the
contamination.
18. Remove fixed plate (10) of boom and frame
hinge pin and its accessory bolt and washer.
10
LG922E930E07502
19. Remove boom and frame hinge pin (11) with

special tools.
20. Operate hoisting equipment to remove the
boom.
11
LG922E930E07503
7-286
Installation
M12 :120±10 N.m (88.5±7.4 lbf·ft )
M20:600±55 N.m (442.5±41 lbf·ft)
The distance between the locating sleeve and its nearest nut is 1-1.5mm (0.04-0.06 In).
thread surface.
● The distance between the locating sleeve and its nearest nut is 1-1.5mm (0.04-0.06 In).
again.
7-287
7.6.5Removal and installation of the work implement assembly
Main components of working device assembly: movable arm, bucket rod, bucket, connecting rod, rocker
rod, pin shaft, grease pipeline system.
Removal
Installation of Bucket for details in this chapter;
2. Start 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.
LG922E930E07504
3. Remove fixed sleeve (1) between boom

cylinder and boom hinge pin and its accessory
bolt and pin shaft.
 There is adjusting washer between locating

sleeve and cylinder, and it needs to take it
1 down and place it at a safe place.
4. Remove the fixed sleeve, bolt and nut on the
right side of boom cylinder with the method in
article 2.
LG922E930E07505
7-288
5. Lift the left boom cylinder (2) with lifting rope
and equipment.
3 6. Push boom cylinder and hinge pin shaft (3) of
boom to the position that does not affect the
moving of left boom cylinder (2) with copper
7. Start the engine, retract piston rod of left boom
2 cylinder, and fasten piston rod with wire rope to
prevent it stretching out. Lower left boom
4 cylinder to revolving frame, and place the
sleeper between the cylinder and frame.
8. Lower the right boom cylinder (4) with the
LG922E930E07506
same method

10. Disconnect the harness (8) and fix it on the
boom with strap.
11. Disconnect the connection between hose (9)
6 6 and boom tube.
5
6
 Wrap the connector with towel or cloth to
prevent oil splashing.
LG922E930E07507 oil-holding equipment to prevent the
contamination.
LG922E930E07508
7-289
12. Remove fixed plate (7) of boom and frame
hinge pin and its accessory bolt and washer.
LG922E930E07509
13. Remove the boom and frame hinge pin (8) with
special tools (9).
LG922E930E07510
14. Install arm front bracket pin shaft back into arm
front bracket.
15. Use two sets of hoisting equipment for
coordination, one lifts stretching part on both
ends of boom bracket pin, the other lifts
stretching part of arm bracket pin, and operate
two sets of hoisting equipment to remove work
implement assembly (10).
10
10
LG922E930E07511
7-290
Installation
M12 :120±10N.m (88.5±7.4 lbf·ft )
M20:600±55 N.m (442.5±41 lbf·ft)
The distance between the locating sleeve and its nearest nut is 1-1.5mm (0.04-0.06 In).
thread surface.
● The distance between the locating sleeve and its nearest nut is 1-1.5mm (0.04-0.06 In).
again.
7-291
7.6.6Removal and installation of the bucket cylinder
Removal
receive oil.
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.
 Separate the cylinder from the arm with tie,

and prevent causing appearance worn from
direct touch and bump.
LG922E930E07512
7-292
3. Retract bucket cylinder, and fix piston rod with
wire rope to prevent it from stretching out.
LG950EIII07237
4. Remove the hydraulic hose (1) on both sides of

bucket cylinder, and pay attention to wrap the
connector with towel or cloth to prevent oil
splashing.
1
5. Remove the captive bolt (2) of bucket cylinder
pin plate, and take down the plate (3).
3
LG950EIII07238
6. Lift bucket cylinder with strap and hoisting

equipment.
 Be sure to fix piston rod in the shortest and

safe state, and then lift it.
LG950EIII07239
7-293
7. Knock the small end of pin shaft (4) with
copper bar and take it out.
 Do not stand at receding side of the pin

shaft, otherwise, the sudden falling of the pin
4 shaft will cause personal injury.
8. Take down bucket cylinder and horizontally
place it on the sleeper.
LG950EIII07240
Installation
Welding is not allowed on the cylinder, and the cylinder can not be ground wire for welding, in
case of electric arcs between piston rod and cylinder head, and piston and cylinder body
damaging parts.
Installation sequence is just reverse to the removal sequence,

● Tightening torque of pin shaft captive bolt: M12-10.9: 120±10N.m (88.5±7.4lbf·ft);
● Clean the threaded hole before installation, and apply oxygen-weary type thread locker (Tonsan
1277)on thread surface.
● Tightening torque of the oil pipe flange captive bolt: M14: 195±15 N.m (143.8±11.06lbf·ft).
Precautions:
1. Clean 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.
4. Fill the grease after 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 the installation of hydraulic cylinder. Oil
port shall be sealed in 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 it will affect service life of cylinder.
7-294
7.6.7Removal and installation of arm cylinder
Removal
receive oil.
1. Lift the arm cylinder steadily with nylon strap
and hoisting equipment.
LG922E930E07517
7-295
2. Remove the captive bolt of piston rod pin shaft,
and remove the plate (1)
1 2 3. Knock the small end of pin shaft (2) with
copper bar and take it out.

shaft will cause personal injury.
LG950EIII07241
4. Operate the machine to retract the arm bucket

piston rod completely, and fix piston rod with
wire rope to prevent it stretching out.

LG950EIII07242
5. Remove two hydraulic hoses (3) of bucket rod

cylinder and remove the grease hose (4) with
19mm (0.75In) wrench.
3
4
LG950EIII07243
7-296
6. Remove captive bolt of piston rod pin shaft,
and remove the plate (5).
6 7. Knock the small end of pin shaft (6) with
5 copper bar and take it out.

8. Slowly lift arm cylinder and place it on the
sleeper.
LG950EIII07244
Installation
Welding is not allowed on the cylinder, and the cylinder can not be ground wire for welding, in
case of electric arcs between piston rod and cylinder head, and piston and cylinder body
damaging parts.
Installation sequence is just reverse to the removal

● Tightening torque of pin shaft captive bolt: M12: 120±10N.m (88.5±7.4 lbf·ft );
● Clean bolt hole before installation, and apply the thread locker Tonsan 1277 on thread surface;
● Tightening torque of the oil pipe flange captive bolt: M14: 195±15 N.m(143.8±11.1 lbf·ft ).
Precautions:
6. Any dirt is not allowed to enter into hydraulic system during removal and installation of hydraulic
cylinder. Oil port shall be sealed in reliable method. Such as rubber cap or sealing plug
7-297
7.6.8Removal and installation of boom cylinder
Removal
receive oil.
1. Fix boom cylinder (1) with nylon sling and
travel crane.
LG922E930E07522
7-298
2. Remove the captive bolt from the piston rod pin
shaft and remove the locating sleeve (2), and
then remove the grease tube (3) with the
19mm (0.75In) wrench.
LG950EIII07245
3. Tie the boom cylinder with lifting ropes; knock

the small end of pin shaft with copper bar and
take it out.

LG922E930E07524
4. Operate the excavator to retract boom cylinder

piston rod completely. Fix piston rod with wire
rope to prevent it from stretching out. Place a
wood block under the boom cylinder to lower
the cylinder gently.
LG950EIII07246
7-299
5. Remove the boom cylinder hydraulic hose (4).
LG950EIII07247
6. Remove the captive bolt of the left and right

boom cylinder body pin shaft, and take pin
shaft plate (5) out.
7. Knock the small ends of the 2 pins (6) on the
left and right with copper bar and take them
out.
LG950EIII07248
8. Lift boom cylinder assembly out and place it

horizontally on sleeper

LG950EIII07249
7-300
Installation
Welding is not allowed on the cylinder, and the cylinder can not be ground wire for welding, in case of
electric arcs between piston rod and cylinder head, and piston and cylinder body damaging parts.
Installation sequence is just reverse to the removal
● Tightening torque of pin shaft captive bolt: M12: 120±10N.m (88.5±7.4 lbf·ft );
● Clean bolt hole before installation, and apply the thread locker Tonsan 1277 on thread surface;
● Tightening torque of oil pipe flange captive bolt: M12: 120±10N.m (88.5±7.4 lbf·ft ).
Precautions:
6. Any dirt is not allowed to enter into hydraulic system during the operation of hydraulic cylinder. Oil
port shall be sealed in reliable method. Such as rubber cap or sealing plug
7-301
7.6.9Disassembly and assembly of cylinder
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.
2529
28 26 7 30
1 4 24 26 5 27 25 6 8
31
32
13
32 33
31 10
34
40
15 16 20 23 39
41
31
32
3
13
32 37
14 17 18 21 22 36 38
19 2 35 31
12
34 12
35
36 11
9
39
33
LG922E930E07529
S/N Name S/N Name

1 Piston rod 22 O-ring
2 Cover 23 O-ring backup ring
3 Cylinder components 24 Buffering ring
4 Cushion collar 25 Wiper ring
5 Piston 26 Molding guide ring
6 Clip 27 Seal ring for hole
7 Rear cushion collar 28 Flat end set screw
8 Check ring 29 Steel ball
9 Oil pipe group A 30 Buffering ring

7-302
S/N Name S/N Name

10 Oil pipe group B 31 Dust ring
11 Clamp group 32 C-bushing
12 Plate 33 Hex screw
13 Oil ring 34 O-ring
14 Snap ring 35 Bolt
15 Dust ring 36 Spring washer
16 Seal ring for shaft 37 Bolt
17 Split washer 38 Spring washer
18 Buffer ring 39 Oil port cover
19 Hex screw 40 Rubber gasket
20 Slide bushing 41 Inner hexagon bolt
21 Steel wire snap ring
Disassembly
Preparations
1. Keep the operation area clean and tidy.
2. Estimate the total weight of the hydraulic cylinder and accessories, prepare appropriate lift
equipment, and the hook distribution shall keep the lifting stable.
The hydraulic cylinder oil ports shall be sealed with the rubber plugs or seal plugs to prevent the
hydraulic cylinder from being polluted by the foreign matter.
Protect the hydraulic cylinder assembly (piston rod in particular) from damage.
7-303
1. Drain the oil from cylinder
2. Fix the hydraulic cylinder.
a. Remove the pipes and other interferences
before the fixation.
b. Fix the hydraulic cylinder on the vertical or
horizontal position.
c. Locate with the pin shaft hole at the cylinder
bottom.
Fixed device
3. Remove the cover.

The thread type: remove it with hook wrench.
4. Pull out the piston rod
a. Confirm that the pipes and so on have been
removed.
b. Prepare the appliance to collect the
LG922E930E07530 hydraulic oil from the hole of telescope side
(the end cover side).
c. Pull out the piston rod to the longest
position, loosen and pull out the end cover
slowly.
d. Pull out the piston rod with the end cover
together, and place them on the tie.
5. Fix the piston rod with the pin hole and the flat
part of piston rod lifting eye.
6. Remove the piston nut.
a. Remove the setscrew.
There are two chisel seams at the outside of
setscrew; they’re used for riveting on the cush-
ion head. Remove the riveting parts with hand
drill, and then remove the setscrew.
b. Remove the steel ball from setscrew.
c. Remove the piston nut.
LG922E930E07531
7-304
7. Remove the parts such as piston, etc.
Remove components according to the
sequence: Nuts→ Pistons → Cushion Collars
→ Covers.
8. Remove the cushion collars of telescope side
a. Remove the piston nut.
b. Knock the elastic snap ring with plastic
Thread hammer or other tools to remove it without
damaging piston rod and cushion collar.
Piston rod c. Slide the cushion collar to the piston rod
screw, and then the baffle rings (double-slice
type) fall off.
Snap Buffering ring Cushion Baffle ring

d. Remove the cushion collar. There is a gap
ring with one notch collar (two-piece) on the cushion ring, then remove the
cushion ring by using the gap.
9. Removal of piston seal.
LG922E930E07532
a. The guide rings and wiper rings shall be
removed simply by hands.
b. Make the screw driver up-right with the seal
ring and knock it with hammer, then cut off
and remove it.
c. Take out the O-ring with iron needle.
7-305
10. Remove the cover seal.
a. 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 turn over and pry the
whole sealing element to take it out.
b. Remove the buffer ring: first remove the
buffer ring (black), and the following removal
is the same as the removal of primary seal.
11. Remove the dust ring and circlip
a. When removing the dust ring, put the screw
driver against the opening of the dust ring
circlip, knock it to the bottom of circlip, and
Press then pry the circlip to take it out.
b. Continue to knock the screw driver until it
running through the whole dust ring, then
Mounting clamp
turn over and pry the entire dust ring to
Bushing
remove it.
12. Remove the slide bushing
a. Find the juncture of the slide bushing.
b. Support the upper end of the slide bushing
LG922E930E07533 opening with screw driver, and then knock
on the screw driver with the hammer until it
pass through the whole slide bushing.
c. Remove the entire slide bushing with screw
driver.
13. Remove the lifting eye dust ring and the
bushing.
a. 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.
b. Remove the bushing with the heel plate, as
shown in figure.
7-306
Installation
1. Install the lifting eye dust ring and bushing.
a. Press it into the piston rod axle hole with the
mounting clamp.
Press
b. Install dust ring with the heel plate.
Mounting clamp
Bushing
LG922E930E07533
Heel block
Piston rod
Dust ring
Bushing
LG922E930E07534
7-307
2. The assembly of the cover units.
a. Press the slide bushing with the press-in
clamp.
b. Install the round wire snap ring into the slide
bushing snap ring slot.
Recheck the slide bushing for the scratch.
Dust ring and snap ring  Do not scratch the slide bushing during the
assembly.
Main sealing ring c. Take out the O-ring backup ring from the
Buffering ring heating box and assemble it, press the
and snap ring
backup ring with iron needle, and rotate it for
Slide bushing one revolution around the ring recess to
O-ring retainer (white) transform it. Place the relevant O-ring into
the groove, install it with iron needle and
O-ring (Black) rotate it for one revolution to ensure that the
assembly is complete without turn-up.
LG922E930E07535
d. Overturn the cover by 180°.
e. Install the buffer ring into its groove.
 Pay attention to the direction. Install the

small backup ring into the buffer ring, and keep
the circular side of the small snap ring at the
inner side.
Clamp
f. Install the primary seal ring into the seal ring
Cover groove.
 Pay attention to the direction of the primary

seal ring, and install the snap ring firstly if
there’s primary seal snap ring.
Slide bushing g. Apply adhesive to the outside area of the
LG922E930E07536 dust ring, place it on the dust ring groove,
and then place the guide sleeve under the
pressure head and press it.
h. Erase redundant adhesive around the dust
ring with wiping paper, and then install the
snap ring of dust ring into its groove.
i. Precautions about the installation of cover
sealing elements.
7-308
1. Forget to assemble or not

2. Whether the mounting position
is correct
3. Are there parts installed in wrong
direction?
Be careful not to install the Install the buffering ring

main sealing ring at the and then the snap ring
position where the check (pay attention to the No damage on the
should be installed or vice direction) internal surface
versa
Dust ring Snap ring

Install it to the bottom Install it in the groove. O-ring and snap ring
Piston rod may be
scratched if it slides out Snap
ring
from the groove.
No damage
O-ring Qualified Unqualified Remove the

O-ring upper unqualified
convex check ring
LG950E4f07104
7-309
3. Install the piston sealing elements.
a. Install the black lining ring into the seal ring
groove of the piston with iron needle
(prevent the sealing elements from being
scratched).
Please compress
b. Put the guide jig onto the piston.
Please compress Heel block
using a compressor
using a compressor c. Take out the primary seal ring from the
Jig heating box and install it to the interior guide
Correcting jig, and then place the exterior pressing
clamp
sleeve.
Jig d. Press the external sleeve by the
compressor. Press the seal ring into the
Piston
groove, then remove the sleeve and guide
Seal ring jig.
Seal ring
e. Install snap ring of the seal ring for hole
Snap ring
LG922E930E07538  The chamfering side faces outward and the
two gaps of the snap ring are not on the same
direction.
f. Both guide rings and wiper rings have
openings, open the openings in the
minimum limit, and then install them from the
axial direction.
4. Install the piston rod assembly
a. Fix the piston rod side.
b. When installing the guide sleeve and piston
rod, the lip of the dust ring and the shaft ring
shall not be hooked by the shoulder parts.
According to the right figure to install the
guide sleeve and piston rod.
LG950E4f07105
7-310
c. For the piston rod with the front cushion
collar, install the plane machining parts of
Flat wire direction Cushion collar Piston
the cushion collar according to the right
figure.
Front buffer
LG922E930E07540
d. For the piston rod with rear cushion collar,

install relevant components and parts
according to the following orders:
1) Install the gap direction of the buffer ring into
Thread
the ring recess towards the thread side.
Piston rod 2) Install the facing process parts of the cushion
collar according to the following figure.
3) Put the baffle ring (double-slice) into the slip
groove.
Clip Buffering ring Buffer bearing Baffle ring
with notch bushing (two-piece)
4) Press the cushion collar towards the baffle
ring sufficiently, and then install the clip. Knock
LG922E930E07541 it into the slip groove with hammer without
damaging the piston rod and cushion collar.
7-311
5) Tighten the piston nut
6) Install the setscrew and steel ball on nut.
After fastening piston nut, put in steel ball and
tighten setscrew. Rivet two parts of the periphery
with the cushion head.
5. Install the piston rod into the cylinder body.
Riveting Punch
a. Fix the cylinder body vertically or
horizontally.
Setscrew b. The vertical situation: install piston rod into
the cylinder body according to its dead-
Steel ball weight.
c. When the piston rod entering into the
cylinder body, protect the wiper ring and
guide ring from falling off.
LG922E930E07542 6. Tighten the cover
Tighten it according to the required tightening
torque on the assembling drawing.
a. The thread type: tighten it with the hook
wrench.
7. 7 Install the tubing
a. Confirm whether the O-ring is installed into
the groove correctly.
b. Insert the oil tube into the connector and
tighten the nut.
c. Referring to the requirements of assembling
drawing, adjust the position of the oil tube
and tighten the clamp.
d. Tighten the fastening nut.
8. Test run.
Note the O-ring a. Conduct full-stroke movement more than six

times slowly after the machine body is
installed to keep the hydraulic cylinder full of
oil.
LG922E930E07543
b. If the oil cylinder is filled with exhaust vents,
try to pressurize the exhaust vent side
(return side) to release the air.
c. Apply the grease or engine oil to the bushing
at both ends of the lifting eye.
7-312
7.7 A/C system CLG950E
7.7A/C system
7.7.1Removal and installation of A/C compressor assembly
Removal
Before the removal of the air compressor assembly, recycle the refrigerant in the A/C system by
using the refrigerant auto filling and recovery device, 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 the installation, it is prohibited to use 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.
1. Open the engine hood (1) at the middle part
rear side.
LG950E4f07106
7-313
CLG950E 7.7 A/C system
2. Unscrew the automatic tensioning mechanism
(2) with tools, and take out the diesel engine
belt (3) from the A/C compressor pulley.
LG950E4f07107
3. Remove the 10 captive bolts (4) of bottom

5 plate on lower part of diesel engine with a
6
wrench; take down the bottom plates (5)(6) by
the cooperation of two people.
Weight of bottom plate: 18Kg(40 lb)
LG950E4f07108
7-314
4. In the position of diesel engine bottom plate,
pull out the A/C compressor harness connector
(7) by hand to separate it from the base
machine harness.
LG950E4f07109
5. Separately remove the two captive bolt (8) of

A/C refrigerating tube on the side of A/C
compressor, and move A/C refrigerating tubes
(9) and (10) out.
9
8
10
LG950E4f07110
7-315
6. Remove the four captive bolts (11) of A/C
compressor with a wrench, and take down the
A/C compressor (12) by two persons.
Weight of compressor assembly: 6Kg (13lb)
11
12
LG950E4f07111
Installation
● Adjust the pre-tightening force of the A/C compressor belt to 441±88.2N(99.1±19.8lbf).
● Torque for pipeline joint M6 bolt: 10±2N.m(7.4±1.5lbf·ft).
● Upon the assembly of the A/C compressor, it needs to use the refrigerant filling equipment to
vacuumize the A/C system and fill it with refrigerant, and the filling quantity of the refrigerant is
950±50g(2.1±0.1lb).
7-316
7.7.2Removal and installation of A/C evaporator assembly
Removal
Before the removal of the A/C evaporator assembly, recycle the refrigerant in the A/C system by
using the refrigerant auto filling and recovery device, 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 the installation, it is prohibited to use 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.
1. Remove six captive bolts (1) of bottom plate on
lower part of floor plate, and take down bottom
plate (2).
LG922E930E07550
7-317
2. Disconnect the connector (3) connecting with
A/C high-low pressure switch.
3
LG922E930E07551
3. Remove captive bolt (4) of A/C refrigerating

tube with spanner, and take down the fixed
plate (5). Move A/C refrigerating tubes (6) and
(7) out at the same time.
4 5
6
7
LG922E930E07552
4. Remove fixed clamp (8) of A/C water pipe.

5. Pull the water pipes (9) and (10) out.
8
10
LG922E930E07553
7-318
6. Open access door on driving side with the key,
and take out air filter (11) outside air
conditioner.
11
LG922E930E07554
7. Remove the fridge (12) and storage grid (13)

on the upper part of A/C hood in the cab.
12
13
LG922E930E07555
8. Remove two captive bolts (14) and three

fastening screws (15) of A/C hood upper cover
and take down the upper cover (16).
14
16
15
LG922E930E07556
7-319
9. Remove three bolts (17) from the lower cover
plate, and remove that plate (18).
18
17
LG922E930E07557
10. Remove setscrew (19) of new air duct that has

butt joint with new vent of evaporator assembly
to extract new air duct (20) upward.
20
19
LG922E930E07558
11. Remove rear air ducts (21) and (22) on upper

part of evaporator assembly.
21
22
LG922E930E07559
7-320
12. Remove the four air ducts (23)(24)(25) at the
side of evaporator assembly.
23
24 25
LG922E930E07560
13. Remove two captive bolts (26) of air duct guard

plate on front lower part of evaporator
assembly, and take down air duct guard plate
(27).
27
26
LG922E930E07561
14. Push feet blow air duct (28) forward to

separate it from feet blow air duct of evaporator
assembly.
LG922E930E07562
7-321
15. Remove the connectors (29) and (30)
connected with A/C harness and located on
rear part of evaporator assembly.
LG922E930E07563
16. Remove seven captive bolts (31) of evaporator

assembly.
17. Move A/C evaporator assembly (32) from the
floor.
32
31
LG922E930E07564
Installation
● The torque requirements of the A/C cooling pipe connectors on the side of the evaporator assembly:
M6, 10±2N.m(7.4±1.5lbf·ft)
● After the installation of the A/C evaporator as, it needs to use the refrigerant filling equipment to
vacuumize the A/C system and fill it with refrigerant, and the refrigerant filling quantity is
950±50g(2.1±0.1lb).
● Pay attention to the orientation when installing air filter outside the air conditioner, suede side of
evaporator should face inward.
7-322
7.8 Cab CLG950E
7.8Cab
7.8.1Removal and installation of cab
Removal
1. Open the hood left front door (1), turn off the
negative switch (2), remove the buttery guard
(3), and remove the negative cable (4) from the
battery.
4
1 3
LG950E4f07112
2. Remove the fridge (5), sundries box (6), upper

cover (7) and lower cover (8) behind the cab
9 and move them out;
Unlock two locks on rear cover (9), and take
down the cover.
6
LG950E4f07113
7-323
CLG950E 7.8 Cab
3. Remove 4 air ducts (11) connected with A/C
11 evaporator (10);
11
11
10
11
LG950E4f07114
4. Disconnect the connector (12) on right rear

pillar of the cab.
15 5. Disconnect the connector (13);
12 13
6. Disconnect nine-pin plug (14), and pull its
harness out, and place on the floor;
14
16 7. Disconnect two connectors connected with
controller (15);
8. Unplug two relays (16) on A/C harness from
stop plate of the cab;
9. Disconnect two connectors (17) connected
18 with fuse box;
19 17 10
10. Remove two fixed clips (18);
11. Disconnect the connector (19) connecting
frame harness and A/C harness and located
LG950E4f07115 on right side of evaporator (10);
7-324
7.8 Cab CLG950E
12. Disconnect the 3 connectors (20) at the
evaporator (10) right side and rear connecting
the driver’s harness, pull the harness out and
place it onto the floor;
20
10
LG950E4f07116
13. Remove the antislip step (21);

14. Move floor mat out (22);
22
21
LG950E4f07117
15. Remove decoration plate (23) installed on the

floor;
24 16. Remove the decoration (24);
23
LG950E4f07118
7-325
CLG950E 7.8 Cab
17. Remove captive bolt of the cover(25);
18. Disconnect the connector connected on sun
26 sensor (26), and pull out the harness
connecting the connector from the rear of the
25 cab, and place it on the evaporator.
LG950E4f07119
19. Remove the 4 shock absorber bolts (27) on the

4 corners of the cab;
20. Remove the 6 bolts (28) connecting the cab
and floor plate and located on cab bottom
27 frame.
28
LG950E4f07120
21. Remove the blanking plate (29) under the

driver cab.
29
LG950E4f07121
7-326
7.8 Cab CLG950E
31 22. Remove the pin (30) under front end of driver

32 cab and the nut (31), and take down the
30 backing plate (32).
LG950E4f07122
23. Remove the pin (33) under rear end of driver

cab and the nut (34), and take down the
34 backing plate (35).
33
35
LG950E4f07123
24. Disconnect water pipe (36) on washing end of

wiper washer reservoir in the rear of the cab
from washer reservoir (37);
25. Remove the clamp (38) from fixed water pipe
(36);
36 26. Tidy water pipe (38) and fix on outer wall of the
37 cab, located at water pipe outlet on right rear
side of the cabin outside the cabin.
38
LG950E4f07124
7-327
CLG950E 7.8 Cab
27. If the cab is not equipped with falling-object
protective structure, install the 4 of M16 lifting
41 eye bolts (39) to the lifting hole (40) located at
40
top of cab, hook the two diagonal bolts with
sling (41) to remove the cab from the complete
machine.
28. Start hoisting equipment, and slowly lift the
cabin.
 The weight of standard cab is 390kg(860lb)

39 and the weight of cab with roll over protection
structure is 580kg(1279lb), please choose the
proper sling
 Please be careful about the operation, and
during the lift, the water pipes and harness
LG950E4f07125
shall not drag other components
29. If the cab is equipped with falling-object

43 42 protective structure, hook the circular tube
beam (43) of protective cover using sling (42);
30. Start hoisting equipment, and slowly lift the
cabin.
 The cab weight is 680kg (1499lb), so

please select applicable sling
during the lift, the water pipes and harness
shall not drag other components
LG950E4f07126
Installation
● Tightening torque of mounting bolt M12-10.9 of the cab: 120±10 N·m(88.5±7.4lbf·ft),
● Tightening torque of mounting nut M20- of shock absorber is: 600±50 N·m(442.5±36.9lbf·ft),
● The bolt thread shall be applied with anaerobic thread locker (Tonsan 1277).
● Clean the thread hole before applying tread locker.
7-328
7.8 Cab CLG950E
7.8.2Removal and installation of floor plate assembly
Removal
When removing the hose, mark on the hose and connectors to facilitate the matching when
assembling;
Seal the removed connectors and hoses with covers or plugs to prevent water and dust, etc.;
Clean the periphery of the assembled oil port.
Corresponding figure Operation step

1. Remove the cab. For specific operations, refer
to 7.8.1 Removal and Installation of Cab
1
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
2 remove its internal electrical connectors;
3 2 5. Pull the harness out of left console;
LG950E4f07127 6. By referring to above steps, pull the harness
out of right console.
7. Remove four clips (4) fixed on the floor;
5
8. Slide grommet (5) to the right off floor plate,
and move the harness (6) out of floor plate.
4 6
 Wire harness (6) includes A/C harness.
LG950E4f07128
7-329
CLG950E 7.8 Cab

9. Remove the plate (7) and plate (8) on lower
part of the cab.
7 LG950E4f07129
10. Disconnect two A/C water pipes (9) and

refrigerating tubes (10) located on lower part of
A/C evaporator assembly.
10
9
LG950E4f07130
11. Disconnect 10 pilot lines connectors (11)

located on the rear part of the cab.
11
11 11
LG950E4f07131
7-330
7.8 Cab CLG950E

12. Disconnect pilot clamp (12), clamp (13), clamp
(14), and clamp (15) at the bottom of floor
plate;
18 13. Disconnect 2 pilot pipelines (17) connecting

16 with the support (16).
14. Disconnect the 4 pilot lines (19) connecting
with the foot pilot valve (18).
15. Arrange all the 6 pilot tubes (17) and (19), and
pull them to the rear part of the cab to ensure
14 15 there is no pulling phenomenon during the
17
19 12 13 process of lifting cab.
LG950E4f07132
16. Arrange 10 pilot hydraulic lines (11) and ensure
there is no pulling phenomenon with other
parts during lifting process.
17. Install the 4 M12 lifting eye bolts (20) to the
lifting holes at 4 corners on the floor.
18. Hook the lifting eye bolts (20) with 4 hooks of
21
the sling (21).
19. Start lifting device, and slowly hang from floor
plate.
20
 The bearing capacity of the sling shall not
be less than 300 (662lb)KG.
LG950E4f07133
the pilot pipes shall not drag other
components during the hang process,.
Installation
● Tightening torque of mounting nut of cab shock absorber is 600±50N.m (442.5±36.9lbf·ft), and apply
the anaerobic thread locker (Tonsan 1277) on the thread before installing to prevent the looseness of
nut.
8-1
September 3, 2019 Attached drawing
CLG950E
8 Attached drawing
8.1 Pump Part Drawing ..................................................................................................8-3

8.2 Main Control Valve Part Drawing .............................................................................8-4
8.3 Hydraulic System Schematic Diagram.....................................................................8-7
8.4 Electrical Schematic Diagram ..................................................................................8-8
8.5 A/C System Schematic Diagram..............................................................................8-9
8-2
Attached drawing September 3, 2019
CLG950E
8-3
CLG950E 8.1 Pump Part Drawing
8.1Pump Part Drawing

8-4
CLG950E 8.2 Main Control Valve Part Drawing
8.2Main Control Valve Part Drawing

8-5
8-6
8-7
CLG950E 8.3 Hydraulic System Schematic Diagram
8.3Hydraulic System Schematic Diagram

8-8
CLG950E 8.4 Electrical Schematic Diagram
8.4Electrical Schematic Diagram
MC ECM DEF LINE1 LINE2 LINE3
50Y2183
8-9
CLG950E 8.5 A/C System Schematic Diagram
8.5A/C System Schematic Diagram

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8-10
CLG950E 8.5 A/C System Schematic Diagram
Part of copyrights are reserved by Cummins Co., Ltd.
Any reprodution shall be used for specific purpose
with permission of Cummins.
It is forbidden to use and/or repoduce the document
without permission of Cummins.

950C Manual de Operacion

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950C Manual de Operacion

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201909001

Applicable type and model: CLG950E

Safety Tips .............................................................. 1-1

1.1 Safety Precautions ...................................................................................................1-4

Important Safety Information

The meaning of this safety alert symbol is as follows:

1.1Safety Precautions Do not wear casual clothes, jewelries or keep a

LG950E4f01001 Only trained and qualified persons are permitted

Make sure all guard plates and covers of the

When using detergent, be careful. Do not use

Compressed air may cause personal injury.

Safe disposal of waste liquid

Please wear safety glasses and leather gloves

Precautions for accumulator application Asbestos

At working temperature, the hydraulic oil tank is

● The hose reinforcement steel has embedded Preventing injury by thunder

1. Top guard devices

Inspect and maintain the fire extinguisher

Measures in emergency Precautions for accessories

● It is forbidden to stand under lifted load.

Heavy objects of above 25kg must be lifted by

15) After the operation is finished, place the

1) By referring to following table, select most

Note: Allowable load value is 1/6 of breaking

2.1 How to Read the Manual..........................................................................................2-3

2.1How to Read the Manual

Composition of service manual

Fault Hydraulic System

Other reference manuals

Suggestions on the use and reading ideas of this manual

Hydraulic fault Work implenment and

Maintenance Fault code

Learn about abnormal components

2.2Marking of Revised Version

The meaning of version number for service manual of LiuGong is as follows:

2.3General Torque Specifications

Tightening torque of 24°Cone with O-ring sealed hose connector

Hose inner Tightening torque

Tightening torque of flange-type sealed hose connector bolt

Bolt performance Tightening torque

Bolt performance Tightening torque

Tightening torque of thread angle type sealed hose connector

Connector tightening torque

Thread size Tightening torque

2.4Unit Conversion Table

Parameters Metric unit British unit Multiple

2.5Cable Identification Methods

Color abbreviation code

S/N Wire type Wire name Description Heat resistance

Color abbreviation codes

Color English Abbreviation Color English Abbreviation

Color English Abbreviation Color English Abbreviation

Remarks: The code composed of 2 colors indicates double-color wire

Circuit type and color abbreviation code

Circuit type Color abbreviation codes

Name Specification Main features and purposes

Component Weight (kg) Weight (lb)

2.8Oils Use Specifications

Time interval of oil change and approximate filling volume

Oil change interval

Technical specification for oil

0# ★ Above 4°C (above 39.2°F)

3 Structure Function and Maintenance